INSTALLATION, OPERATION AND MAINTENANCE MANUAL For SEWER CHEWER Wastewater / Sludge Grinder Submersible Gearmotor Yeomans Chicago Corporation 3905 Enterprise Court P.O. Box 6620 Aurora, IL 60598-0620 Phone: 630-236-5500 Fax: 630-236-5511 www.yccpump.com (THIS INSTRUCTION TO BE USED WITH GRINDER MANUAL 7671 AND DIGITAL CONTROLLER MANUAL 820) Important: Save this Manual for future reference. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 1
Table of Contents Title Page A. GENERAL DESCRIPTION AND INFORMATION 1. Acceptance of Shipment... 3 B. SAFETY PRECAUTIONS... 3 C. GENERAL NOTES 1. Long Term Storage Instructions... 4 2. Installation Notes... 4 D. START-UP... 5 E. MAINTENANCE... 5 F. THERMAL PROTECTION SYSTEM 1. Operation... 6 G. DISASSEMBLY INSTRUCTIONS 1. For Electrical Repairs... 7 2. For Mechanical Repairs... 7 H. REASSEMBLY INSTRUCTIONS... 8 I. ELECTRICAL DATA... 8 J. GEARMOTOR CROSS-SECTION DRAWING... 9 Motor Nameplate 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 2
A. GENERAL DESCRIPTION AND INFORMATION 1. Acceptance of Shipment Thoroughly inspect this equipment before accepting shipment from the transportation company. If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept them until the freight or express agent makes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight or express agent at once and request him to make an inspection. We will assist you in collecting claims for loss or damage in shipment; however, this willingness on our part does not remove the transportation company s responsibility in reimbursing you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the Yeomans Chicago Corporation invoice, nor should payment of the Yeomans Chicago Corporation invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safe delivery. If considerable damage has been incurred and the situation is urgent, contact the nearest Yeomans Chicago Corporation Representative or the factory for assistance. Please keep a written record of all such communications. B. SAFETY PRECAUTIONS IMPORTANT THOROUGHLY READ ALL INSTRUCTIONS BEFORE SERVICING YEOMANS CHICAGO CORPORATION GEARMOTORS. Yeomans Chicago Corporation cannot be responsible for any damage resulting from failure to comply with these instructions. This gearmotor is not to be operated at conditions, nor with liquids other than those stated in the original order acknowledgment or Sewer Chewer Typical Specifications without written permission from Yeomans Chicago Corporation. Keep this manual handy for ready reference. Extra sets of gearmotor nameplates are furnished for future reference. These should be retained in a safe place. Information shown on the nameplate is required for ordering replacement parts. CAUTION Surface temperature of the motor enclosure may reach temperatures that can cause discomfort or injury to personnel making accidental contact. The user should provide protection against accidental contact with hot surfaces. WARNING MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION. DISASSEMBLY MAY CAUSE BODILY INJURY. CARE MUST BE TAKEN IN DISASSEMBLY. CONTACT YEOMANS CHICAGO CORPORATION FOR ASSISTANCE. DANGER DISCONNECT POWER TO GRINDER CONTROLLER AND USE PROPER LOCKOUT DEVICE BEFORE MAINTENANCE OR OPERATOR ADJUSTMENT TO MACHINE. DISCONNECT MAIN MACHINE WINDINGS AND ALL ACCESSORY DEVICES FROM THE POWER SOURCE BEFORE DISASSEMBLY OF GEARMOTOR. INSTALL ALL GUARDS PRIOR TO ENERGIZING UNIT. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 3
C. GENERAL NOTES 1) Motor - YEOMANS CHICAGO CORPORATION Submersible gearmotors are T.E.N.V., of an explosion-proof design. To insure the integrity of sealing surfaces and explosion-proof fits when servicing these motors, all parts should be handled with utmost care. 2) Wound Stators - YEOMANS CHICAGO CORPORATION Submersible gearmotors have stator insulation systems specifically designed for the temperature and electrical ratings involved. If motor failure is analyzed to encompass a winding failure, it is required that a replacement wound stator be ordered from YEOMANS CHICAGO CORPORATION. 3) Epoxy Seal Cap Assembly - The leads have been specially encapsulated to insure integrity of the motor. The cap assembly can be removed from the motor in order to perform normal repairs. Should the power cables or cap assembly be damaged or the integrity of the encapsulation be in question, it is required that a replacement seal cap assembly be ordered from YEOMANS CHICAGO CORPORATION. 4) Hardware - All hardware is stainless steel, and if necessary, should be replaced with the same type. 1. Long Term Storage Instructions The equipment is shipped from the factory with adequate protection for transportation in covered trucks, and for indoor storage at the job site for a limited time between receipt and installation. If the equipment is not put into immediate use, it should be stored in a cool, clean, and dry indoor location. To help prevent rusting, any paint scratches or chips incurred during handling should be touched up prior to storage. Store in the vertical position. Electrical cables must be properly supported and protected from moisture. Exposed pipe flange connections should also be covered. 2. Installation Notes Maximum submergence of gearmotor is not to exceed 20 feet in depth. Thermal Protectors (Leads marked P1 and P2) must be connected. Leads marked W1 and W2 in the control cable are not used. (The unused wires are colors Red and Orange) Check power supply against final nameplate connection voltage. When the submersible gearmotor leaves the factory it is ready for installation, however, during shipping and handling, fasteners may loosen. Verify tightness before installation. No further adjusting, venting or lubricating is required. The motor will operate successfully when the following conditions are met: Voltage variation: 10% above or below nameplate data. Frequency variation: 5% above or below nameplate data. Voltage unbalance: 1% maximum between any two (2) incoming power legs. Performance within these ranges will not necessarily be the same as the established performance at exact rated voltage and frequency. The submersible gearmotor will operate in either direction of rotation. To reverse direction of a 3-phase motor, interchange any two motor leads at the starter. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 4
A lifting bail or lifting eyebolts are supplied for the purpose of installation and servicing. DO NOT USE MOTOR CABLES FOR LIFTING WHICH MAY RESULT IN PERMANENT DAMAGE TO THE CAP AND CABLE ASSEMBLY. Normal care should be exercised to prevent mechanical damage to the seal, the frame, and the insulated cable. CAUTION Control leads should not be installed in the same conduit as power leads. Additionally, junction boxes installed inside wet wells are subject to moisture and condensation. NEMA 4, 6 or 7 junction boxes should be used for this application. D. START-UP On initial start-up, prior to installation, the grinder should be rechecked for proper rotation. An arrow on the outside of the grinder housing shows the proper direction of rotation. Refer to Sewer Chewer Manual for procedure. The unit is designed to protect all power connections against moisture. All Yeomans Chicago Corporation submersible gearmotors have a lead connection chamber. Three phase, dual voltage motors have 9 stator leads. In addition, all submersible gearmotors have 2 thermal protector leads in this chamber. Leads are tagged for easy identification. Appropriate connection diagram can be found in the controller manual 820. 9-lead dual-voltage motors can be connected for either high or low voltages. (Some motor ratings are built as single voltage units and as such are not re-connectable.) The epoxy cap assembly is supplied with terminals for connecting power leads, control leads, and ground. The leads are brought through an epoxy sealed cap providing a mechanically strong, water tight, non-wicking seal. The cap and cable assembly is available from YEOMANS CHICAGO CORPORATION as a replacement part. When replacing the epoxy seal cap assembly, care should be taken not to nick or damage the O ring seal. Replace any damaged or nicked O rings. WHEN A REPLACEMENT CAP ASSEMBLY IS REQUIRED, BE SURE TO ORDER FROM YEOMANS CHICAGO CORPORATION USING GRINDER AND/OR MOTOR NAMEPLATE IDENTIFICATION NUMBERS. E. MAINTENANCE The motor and gear reducer are supplied with sufficient lubrication for five years of continuous use, and no routine maintenance is required during this time. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 5
F. THERMAL PROTECTION SYSTEM WARNING MOTOR CONTROLLER HAS AUTOMATIC OVERLOAD RESET. DISCONNECT ALL POWER LEADS TO MOTOR WHEN PERFORMING ANY WORK ON MOTOR OR GRINDER. FAILURE TO PROPERLY CONNECT OR UTILIZE THIS SYSTEM ON YOUR SUBMERSIBLE MOTOR OR ANY OTHER MOTOR FURNISHED WITH THERMAL PROTECTION VOIDS THE MOTOR WARRANTY. If current through the thermostats will exceed the values listed in Table 1, an intermediate control circuit relay must be used to reduce the current or the thermostats will not work properly. TABLE 1 Alternating Current Volts Continuous Amps Inrush Amps 200-240 1.5 15 380-480 0.75 7.5 1. Operation For proper operation, the thermostats located within the motor must be connected to the SEWER CHEWER control panel. Your submersible motor control cable is furnished with four leads: Thermostat leads are P1 (Black) and P2 (White). Leads W1 (Red) and W2 (Orange) are not used in this application and should be capped. For all other motors, refer to the motor manufacturer s wiring diagram, usually located inside motor conduit box. Connect control cable wire P1 to terminal block #50 and wire P2 to terminal block #65 located in control panel (refer to electrical schematic in manual 820). If the grinder is running and the temperature of the motor exceeds the thermostat setting, relay will de-energize. This will de-energize the motor contactors not allowing the grinder motor to run. After five seconds, the operator interface display (OID) will flash an alarm message on the screen and the alarm horn will sound every 10 seconds. This will continue until the alarm is cleared (the motor temperature cools). Once the alarm is cleared, the SEWER CHEWER will automatically begin a restart sequence with a continuous horn for 10 seconds followed by a beeping horn for 5 seconds to provide a warning that the grinder will automatically restart. Upon completion of the horn sequence the controller resumes the exact grinder status as before. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 6
G. DISASSEMBLY INSTRUCTIONS WARNING MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM ABNORMAL OPERATION. DISASSEMBLY MAY CAUSE BODILY INJURY. 1. For Electrical Repairs Electrical repairs such as stator repair and/or replacement, or servicing of thermal protectors may be accomplished without disturbing the rotating assembly (i.e. rotor, thrust bearing housing, lower seal housing). Refer to Cross Section Drawing (Page 9) 1) Remove cap screws securing epoxy seal cap (9A). 2) Disconnect all leads and grounding wire. Remove epoxy seal cap assembly. 3) Remove bolts securing thrust bearing housing (5) to stator housing (7). Using top lifting bail (29), lift stator assembly. 4) Remove lifting bail (29) and lifting bail hardware, along with all hardware connecting the radial bearing housing (8) to the stator housing (7). NOTE: Pay particular attention to the location of lifting bail so that it is reassembled in the same position. 5) Remove radial bearing housing (8) if necessary. 2. For Mechanical Repairs This unit is not field serviceable for mechanical repairs and must be returned to the factory for the following: 1. Bearing replacement. 2. Shaft and rotor replacement. 3. Seal replacement. 4. Cycloidal gear repairs. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 7
H. REASSEMBLY INSTRUCTIONS Place O rings on register fits. Lightly coat all fits with a suitable lubricant. Alternately, grease may be substituted (not excessive). Lower stator housing (7) over rotating assembly. Bolt stator housing (7) to thrust bearing housing (5) with cap screws, making sure the O ring is not damaged and is properly seated. Pre-pack radial bearing (11) 3/4 full with #2 lithium based grease unless it is a sealed type bearing which requires no additional lubrication). Do not over-grease. Assemble radial bearing housing (8) to stator housing (7) by pulling all lead wires through one of the cored openings in bearing housing (8). Make sure O ring is seated properly before tightening all hardware previously removed. Replace lifting bail (29) to original position and secure with fastening hardware. Cable Cap Assembly-- A) Place O ring on radial bearing housing (8) and lightly coat with grease (not excessive). B) Reconnect power and control wires using applicable connection diagram shown below. C) Secure epoxy seal cap (9A) to radial bearing housing (8) using screws, making sure O ring is properly seated. LEAD COLOR CODING BLACK WHITE RED GREEN ORANGE POLYPHASE POWER CABLE T1 T2 T3 GROUND --------------- CONTROL CABLE P1 P2 --------------- --------------- --------------- Note: The Red and Orange control wires are unused in this application. I. ELECTRICAL DATA The submersible gearmotor is totally enclosed, non-ventilated (TENV), hermetically sealed submersible type. Automatic reset normally closed thermal overload protection, pre-lubricated shaft bearings, Class H winding insulation. The power cable provided is sized for the specified electrical service. See the Digital Controller Manual 820 for additional details and the electrical schematic. 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 8
J. GEARMOTOR CROSS-SECTION DRAWING 29 9B 9A 11 9C 1 2 3 5 PARTS LIST ROTOR STATOR MOTOR SHAFT THRUST BEARING HOUSING 8 6 7 8 THRUST BEARING CAP STATOR HOUSING RADIAL BEARING HOUSING 1 9A 9B CAP CABLE CONNECTOR MODULE 2 9C 10 MODULAR TERMINAL BLOCK THRUST BEARING 6 7 3 11 15 17 RADIAL BEARING SEAL SHAFT SLEEVE 5 10 39 17 29 39 40 43 LIFTING BAIL THRUST BEARING SNAP RING "HEAVY SHOCK" CYCLOIDAL TYPE SPEED REDUCER OUTPUT SHAFT 15 40 43 840 Sub Gearmotor Swr Chwr.doc 8/11/2010 9