BARNES ® INSTALLATION and OPERATION MANUAL Submersible Non-Clog Pump Explosion Proof, Class I, Groups C & D, Division 1 Series: 8XSE-HA 20 - 30HP, 870RPM, 60Hz 30 - 75HP, 1150RPM, 60Hz 100 - 150HP, 1750RPM, 60Hz IMPORTANT! A Crane Co. Company Read all instructions in this manual before operating pump. As a result of Crane Pumps & Systems, Inc., constant product improvement program, product changes may occur. As such Crane Pumps & Systems reserves the right to change product without prior written notification. 420 Third Street Piqua, Ohio 45356 Phone: (937) 778-8947 Fax: (937) 773-7157 www.cranepumps.com 83 West Drive, Bramton Ontario, Canada L6T 2J6 Phone: (905) 457-6223 Fax: (905) 457-2650 Form No. 084841-Rev. H TABLE OF CONTENTS SAFETY FIRST ............................................................................................... 3 A. PUMP SPECIFICATIONS ................................................................................4 B. GENERAL INFORMATION ..............................................................................5 C. INSTALLATION ................................................................................................5 - 8 ELECTRICAL DATA .........................................................................................7 D. START-UP OPERATION ..................................................................................8 - 10 E. PREVENTATIVE MAINTENANCE ...................................................................10 F. SERVICE and REPAIR ....................................................................................10 - 11 G. REPLACEMENT PARTS..................................................................................11 TROUBLE SHOOTING ....................................................................................12 CROSS-SECTION, (Fig. 7) ..............................................................................13 EXPLODED VIEW, (Fig. 8) ..............................................................................14 PARTS LIST ..................................................................................................15 - 16 RETURNED GOODS POLICY.........................................................................17 WARRANTY ...................................................................................................18 START-UP REPORT ........................................................................................21 - 22 WARRANTY REGISTRATION SPECIAL TOOLS AND EQUIPMENT INSULATION TESTER (MEGGER) Other brand and product names are trademarks or registered trademarks of their respective holders. ® WARRICK Controls is a registered trademark of Charles F. WARRICK Co. ® Reliance is a registered trademark of Rockwell Automation ® Barnes is a registered trademark of Crane Pumps & Systems, Inc 1996, 1997, 1998, 2002, 01/04, 3/06, 9/06 2 Alteration Rights Reserved SAFETY FIRST! Please Read This Before Installing Or Operating Pump. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols: Do not block or restrict discharge hose, as discharge hose may whip under pressure. IMPORTANT! Warns about hazards that can result in personal injury or Indicates factors concerned with assembly, installation, operation, or maintenance which could result in damage to the machine or equipment if ignored. CAUTION ! Warns about hazards that can or will cause minor personal injury or property damage if ignored. Used with symbols below. WARNING ! Warns about hazards that can or will cause serious personal injury, death, or major property damage if ignored. Used with symbols below. Hazardous fluids can cause fire or explosions, burnes or death could result. Extremely hot - Severe burnes can occur on contact. Biohazard can cause serious personal injury. Hazardous fluids can Hazardous pressure, eruptions or explosions could cause personal injury or property damage. Rotating machinery Amputation or severe laceration can result. Hazardous voltage can shock, burn or cause death. WARNING! - DO NOT wear loose clothing that may become entangled in the impeller or other moving parts. WARNING! - Keep clear of suction and discharge openings. DO NOT insert fingers in pump with power connected. Always wear eye protection when working on pumps. Make sure lifting handles are securely fastened each time before lifting. DO NOT operate pump without safety devices in place. Always replace safety devices that have been removed during service or repair. Secure the pump in its operating position so it can not tip over, fall or slide. DO NOT exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat. DO NOT remove cord and strain relief. Do not connect conduit to pump. WARNING! Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently. Never handle connected power cords with wet hands. Only qualified personnel should install, operate and repair pump. Any wiring of pumps should be performed by a qualified electrician. WARNING ! - To reduce risk of electrical shock, pumps and control panels must be properly grounded in accordance with the National Electric Code (NEC) or the Canadian Electrical Code (CEC) and all applicable state, province, local codes and ordinances. WARNING! - To reduce risk of electrical shock, always disconnect the pump from the power source before handling or servicing. Lock out power and tag. WARNING! Operation against a closed discharge valve will cause premature bearing and seal failure on any pump, and on end suction and self priming pump the heat build may cause the generation of steam with resulting dangerous pressures. It is recommended that a high case temperature switch or pressure relief valve be installed on the pump body. CAUTION ! Never operate a pump with a plug-in type power cord without a ground fault circuit interrupter. CAUTION! Pumps build up heat and pressure during operation-allow time for pumps to cool before handling or servicing. WARNING! - DO NOT pump hazardous materials (flammable, caustic, etc.) unless the pump is specifically designed and designated to handle them. 3 WARNING! To reduce risk of electrical shock, all wiring and junction connections should be made per the NEC or CEC and applicable state or province and local codes. Requirements may vary depending on usage and location. WARNING! Submersible Pumps are not approved for use in swimming pools, recreational water installations, decorative fountains or any installation where human contact with the pumped fluid is common. WARNING! Products Returned Must Be Cleaned, Sanitized, Or Decontaminated As Necessary Prior To Shipment, To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material. All Applicable Laws And Regulations Shall Apply. Bronze/brass and bronze/brass fitted pumps may contain lead levels higher than considered safe for potable water systems. Lead is known to cause cancer and birth defects or other reproductive harm. Various government agencies have determined that leaded copper alloys should not be used in potable water applications. For non-leaded copper alloy materials of construction, please contact factory. IMPORTANT! - Crane Pumps & Systems, Inc. is not responsible for losses, injury, or death resulting from a failure to observe these safety precautions, misuse or abuse of pumps or equipment. SECTION: A - PUMP SPECIFICATIONS DISCHARGE ...................... 8” NPT, 125 lb. Flange Horizontal LIQUID TEMPERATURE ... 104°F (40°C) Continuous VOLUTE ............................. Cast Iron ASTM A-48, Class 30 with Cast Iron Wear Ring MOTOR HOUSING ............. Cast Iron ASTM A-48, Class 30 SEAL PLATE ...................... Cast Iron ASTM A-48, Class 30 IMPELLER: Design.................... 3 Vane, Enclosed with Bronze wear ring and pump out vanes on back side. Dynamically Balanced ISO G6.3 Material ................. Cast Iron ASTM A-48, Class 30 SHAFT ............................... 416 Stainless Steel SQUARE RINGS................. Buna-N HARDWARE ....................... 300 Series Stainless Steel LIFTING CHAIN .................. Yoke, Galvanized PAINT ............................... Air Dry Enamel. SEAL: Design ................... Tandem Mechanical, Oil Filled Reservoir. Material .................. Rotating Faces - Carbone Stationary Faces - Ceramic Elastomer - Buna-N Hardware -300 Series Stainless CORD ENTRY ..................... 25 ft. (7.6 m) Std. Cord. Epoxy Sealed Housing with Secondary Pressure Grommet for Sealing and Strain Relief SPEED ............................... 870, 1150, 1750 RPM (Nominal) UPPER BEARING: Design ....................Single Row, Ball, Grease Lubricated Load ...................... Radial LOWER BEARING: Design .....................Double Row, Ball, Grease Lubricated Load ....................... Radial & Thrust MOTOR: Design ................. NEMA B, Three Phase Torque Curve Air-Filled, Squirrel Cage Induction “UL” Listed for Class I, Groups C & D, Division 1, Explosion Proof Insulation ..............Class F. SINGLE PHASE ................Capacitor Start/Induction Run. Start Capacitors included with pump assembly. Controls require external overload protection. THREE PHASE .................Dual Voltage 230/460; Requires Overload Protection to be Included in control panel. MOISTURE SENSOR .......Normally Open (N/O), Requires Relay in Control Panel TEMP SENSOR ................Normally Closed (N/C), Requires Relay in Control Panel OPTIONAL EQUIPMENT: Seal Material, Impeller Trims, Additional Cord inches (mm) 8XSE20048HA - 49.06 (1246) 8XSE20058HA - 49.06 (1246) 8XSE25048HA - 49.06 (1246) 8XSE25058HA - 49.06 (1246) 8XSE30048HA - 49.06 (1246) 8XSE30058HA - 49.06 (1246) 8XSE30046HA - 49.06 (1246) 8XSE30056HA - 49.06 (1246) 8XSE40046HA - 49.06 (1246) 8XSE40056HA - 49.06 (1246) 8XSE50046HA - 49.06 (1246) 8XSE50056HA - 49.06 (1246) 8XSE60046HA - 49.06 (1246) 8XSE60056HA - 49.06 (1246) 8XSE75046HA - 54.50 (1384) 8XSE75056HA - 54.50 (1384) 8XSE100044HA - 54.50 (1384) 8XSE100054HA - 54.50 (1384) 8XSE125044HA - 54.50 (1384) 8XSE125054HA - 54.50 (1384) 8XSE150044HA - 54.50 (1384) 8XSE150054HA - 54.50 (1384) IMPORTANT ! 1.) MOISTURE AND TEMPERATURE SENSORS MUST BE CONNECTED TO VALIDATE THE UL LISTING. 2.) A NON-SPARKING BREAK AWAY FITTING MUST BE USED TO VALIDATE THE UL LISTING. 3.) A SPECIAL MOISTURE SENSOR RELAY IS REQUIRED IN THE CONTROL PANEL FOR PROPER OPERATION OF THE MOISTURE SENSORS. CONTACT BARNES PUMPS FOR INFORMATION CONCERNING MOISTURE SENSING RELAYS FOR CUSTOMER SUPPLIED CONTROL PANELS. 4.) THESE PUMPS ARE UL LISTED FOR PUMPING WATER AND WASTEWATER. DO NOT USE TO PUMP FLAMMABLE LIQUIDS. 5.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIDED FOR VISUAL ENJOYMENT MUST BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSI/NFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION. THIS PUMP IS NOT INTENDED FOR USE IN SWIMMING POOLS, RECREATIONAL WATER PARKS, OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH PUMPED MEDIA IS A COMMON OCCURRENCE. 4 SECTION B: GENERAL INFORMATION C-1.1) Submergence: It is recommended that the pump be operated in the submerged condition and the sump liquid level should never be less than dimension “A” in Figure 1. The time required to draw the well down from top of motor to the minimum submergence level should not be greater than 15 minutes. NOTE: Outer shaft seal must be in liquid when motor is operated, whether motor is submerged or in air. B-1) To the Purchaser: Congratulations! You are the owner of one of the finest pumps on the market today. CP&S pumps are products engineered and manufactured of high quality components. Over one hundred years of pump building experience along with a continuing quality assurance program combine to produce a pump which will stand up to the toughest applications. This manual will provide helpful information concerning installation, maintenance, and proper service guidelines. B-2) Receiving: Upon receiving the pump, it should be inspected for damage or shortages. If damage has occurred, file a claim immediately with the company that delivered the pump. If the manual is removed from the packaging, do not lose or misplace. Recommended Submergence Level B-3) Storage: Short Term- CP&S Pumps are manufactured for efficient performance following short inoperative periods in storage. For best results, pumps can be retained in storage, as factory assembled, in a dry atmosphere with constant temperatures for up to six (6) months. Minimum Submergence Level A = 12” Long Term - Any length of time exceeding six (6) months, but not more than twenty-four (24) months. The unit should be stored in a temperature controlled area, a roofed over walled enclosure that provides protection from the elements (rain, snow, wind-blown dust, etc.), and whose temperature can be maintained between +40 deg. F and +120 deg. F. (4.4 - 49°C). Pump should be stored in its original shipping container. On initial start up, rotate impeller by hand to assure seal and impeller rotate freely. If it is required that the pump be installed and tested before the long term storage begins, such installation will be allowed provided: Bottom of Feet FIGURE 1 C-2) Discharge: Discharge piping should be as short as possible. Both a check valve and a shut-off valve are recommended for each pump being used. The check valve is used to prevent backflow into the sump. Excessive backflow can cause flooding and/or damage to the pump. The shut-off valve is used to stop system flow during pump or check valve servicing. 1.) The pump is not installed under water for more than one (1) month. 2.) Immediately upon satisfactory completion of the test, the pump is removed, thoroughly dried, repacked in the original shipping container, and placed in a temperature controlled storage area. WARNING ! - These pumps are suitable for application in CLASS I, GROUPS C & D, HAZARDOUS LOCATIONS and require a nonsparking break away fitting. Failure to use the non-sparking BAF voids warranty. B-4) Service Centers: For the location of the nearest Barnes Service Center, check your Barnes representative or Crane Pumps & Systems, Inc., Service Department in Piqua, Ohio, telephone (937) 778-8947 or Crane Pumps & Systems Canada, in Brampton, Ontario, (905) 457-6223. Barnes Pumps, Inc. supplies a Non-Sparking break away fitting discharge system designed to allow the submersible wastewater pump to be installed or removed without requiring personnel to enter the wet well. Place the Break Away Fitting (BAF) in position. Temporarily secure the guide rails in the upper mounting brackets and locate the base elbow on the bottom of the wet well. Level the base elbow with grout and/or shims. Install the intermediate support brackets, if required. Make sure the rails are in a true vertical position so the pump will clear the access opening and will slide freely down the rails into place on the discharge base elbow. once the rails are in proper alignment, bolt the base elbow into the floor of the station and connect the discharge pipe to the elbow. Connect the movable portion and other supplied fittings of the BAF onto the pump and lower into wet well. See the Break Away Fitting manual for more information. SECTION C: INSTALLATION C-1) Location: These self-contained pumping units are Listed for Class I, Groups C & D, Division 1 locations and are recommended for use in a sump, lift station or basin. This pump is designed for submerged continuous duty (15 minutes duty in air at nameplate horsepower), pumping sewage, effluent, wastewater or other nonexplosive or noncorrosive liquids not above 104°F (40°C). Never install the pump in a trench, ditch or hole with a dirt bottom; the legs will sink into the dirt and the suction will become plugged. 5 If a rigid conduit is used to install the pump it must meet Class I, Division 1 requirements of the National Electrical Code. Conduit must be stainless steel or coated metal, resistant to sewage water. C-4.2) Control Cable: The cord assembly mounted to the pump must not be modified in any way except for shortening to a specific application. Any splice between the pump and the control panel must be made in accordance with all applicable electric codes. It is recommended that a junction box (if used) with seal fittings be mounted outside the sump or be of at least Nema 7 (EEMAC-7) explosion proof construction if located within the wet well. A UL listed seal fitting MUST be used in conduit leaving the hazardous location. DO NOT USE THE CONTROL CABLE TO LIFT PUMP. C-3) Liquid Level Controls: Intrinsically Safe WARNING ! - Level control floats used within the hazardous location, must be in an intrinsically safe control circuit suitable for use in CLASS I, GROUPS C & D, HAZARDOUS LOCATIONS. The level controls are to be supported by a mounting bracket that is attached to the sump wall, cover or junction box. Cord grips are used to hold the cords in place on the mounting bracket. The control level can be changed by loosening the grip and adjusting the cord length as per the plans and specifications. Be certain that the level controls cannot hang up or foul in it’s swing and that the entire pump is still submerged when the level control is in the “Off” mode. C-4.3) Wire Size: If additional cable is required consult a qualified electrician for proper wire size. See table for further electrical information. A Warrick Control® intrinsically safe relay, Series 27, is an acceptable panel mounted relay, providing the relay is properly installed and maintained. The primary (A.C. supply line) circuit is not intrinsically safe, therefore the relay must be located in a “SAFE” location (a place that is not classified as a hazardous location). The secondary circuit is intrinsically safe, however, any splice must be made in a “SAFE” location and any control cord that is cut or damaged must be replaced immediately. C-3.1) Level Control Float System: It is recommended to use a two float, on and off, level control system. An additional float, incorporated with an alternator switching system will be required for a duplex system. A high level alarm may be required to alert maintenance personnel. A low level cut off may be required to provide system shutdown if the main level control system malfunctions. The off or low level float should be positioned so that the liquid level never drops below the minimum submergence level. THREE PHASE, 200-230 VOLT AC Power Cable Motor Lead Number Green (Ground) Green White 2&8 Red 3&9 Black 1&7 4, 5 & 6 Together C-4) Electrical Connections: WARNING! - All model pumps and control panels must be properly grounded per the National Electric Code or Canadian Electric Code, state, province and local codes. Improper grounding voids warranty. All electrical controls and motor starting equipment must be installed outside the hazardous area unless approved explosion proof controls are used. C-4.1) Power Cable: The cord assembly mounted to the pump must not be modified in any way except for shortening to a specific application. Any splice between the pump and the control panel must be made in accordance with all applicable electric codes. It is recommended that a junction box (if used) with seal fittings be mounted outside the sump or be of at least Nema 7 (EEMAC-7) explosion proof construction if located within the wet well. A UL listed seal fitting MUST be used in conduit leaving the hazardous location. DO NOT USE THE POWER CABLE TO LIFT PUMP. 6 MODEL NO "A" DIM HP VOLT/ Ph Hz 8XSE20048HA 8XSE20058HA 8XSE25048HA 8XSE25058HA 8XSE30048HA 8XSE30058HA 8XSE30046HA 8XSE30056HA 8XSE40046HA 8XSE40056HA 8XSE50046HA 8XSE50056HA 8XSE60046HA 8XSE60056HA 8XSE75046HA 8XSE75056HA 8XSE100044HA 8XSE100054HA 8XSE125044HA 8XSE125054HA 8XSE150044HA 8XSE150054HA 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 49.06 54.50 54.50 54.50 54.50 54.50 54.50 54.50 54.50 20 20 25 25 30 30 30 30 40 40 50 50 60 60 75 75 100 100 125 125 150 150 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 460/3 575/3 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 RPM NEMA (Nom) START CODE 870 870 870 870 870 870 1150 1150 1150 1150 1150 1150 1150 1150 1150 1150 1750 1750 1750 1750 1750 1750 FULL LOCKED CORD CORD CORD O.D. WINDING LOAD ROTOR SIZE TYPE ± .02 (.5) RESISTANCE AMPS AMPS in (mm) MAIN G G G G F F G G G G F F F F G G G G F F E E 27.8 22.0 36.5 28.8 43.0 34.4 40.0 32.0 52.0 42.6 67.0 53.6 76.9 61.4 92.0 73.6 123.0 98.4 153.0 122.0 182.0 145.0 141.0 109.0 174.0 139.2 199.0 159.0 210.0 168.0 282.0 226.0 322.0 258.0 409.0 315.0 534.0 427.0 703.0 562.0 864.0 691.0 1080.0 864.0 8/4 8/4 8/4 8/4 8/4 8/4 8/4 8/4 6/4 6/4 4/4 4/4 2/4 2/4 2/4 2/4 1/4 1/4 2/0/4 2/0/4 3/0/4 3/0/4 SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW SOW 0.985 (25) 0.985 (25) 0.985 (25) 0.985 (25) 0.985 (25) 0.985 (25) 0.985 (25) 0.985 (25) 1.125 (29) 1.125 (29) 1.350 (34) 1.350 (34) 1.550 (39) 1.550 (39) 1.550 (39) 1.550 (39) 1.680 (43) 1.680 (43) 1.930 (49) 1.930 (49) 2.070 (53) 2.070 (53) Moisture and Temperature sensor cord for all models is 18/5 SOW, 0.485 (12.3mm) ± .02 (.51mm) O.D. Winding Resistance ± 5%. Winding resistance measured in OHMS @ 25°C. (Between Lines) Pump rated for operation at ± 10% voltage at motor. THREE PHASE, 460 VOLT AC Power Cable Motor Lead Number Green(Ground) Green Black 1 White 2 Red 3 4 & 7 Together 5 & 8 Together 6 & 9 Together MOISTURE AND TEMPERATURE SENSORS Control Cable Lead Number Black P1 (Temperature Sensor) White P2 (Temperature Sensor) Red W1 (Moisture Sensor) Orange W2 (Moisture Sensor) Green Ground 7 .76 1.21 .52 .42 .66 .36 .58 .30 .47 .25 .38 .17 .27 .13 .23 .08 .12 .05 .08 .05 .07 WARRANTY NOTE: Both the temperature sensor and moisture detection system must be connected to the motor circuitry such that the motor will be de-energized or sound alarm if excessive motor temperatures are reached and/or if water is detected in the seal chamber and/or motor chamber. Failure to have the above mentioned systems installed and operative, nullifies warranty. a. Proper grounding per NEC. b. A temperature sensing circuit (see Fig. 2A & B) c. A moisture detection circuit with continuity test circuit (see Fig. 3) d. An intrinsically safe level control system. e. A main power manual disconnect and lock out. f. A motor starter and overload system. g. Single phase only, requires a capacitor power pack (see Fig. 2B). C-4.4) Overload Protection: The normally closed (N/C) thermal sensor is embedded in the motor windings and will detect excessive heat in the event an overload condition occurs which will then trip and stop the pump. The thermal sensor leads marked P1 and P2 MUST be connected in series with the stop button of the pilot circuit of the magnetic motor controller located in the control panel so that the thermostat will open the circuit before dangerous temperatures are reached. A manual momentary start switch is required to prevent the automatic restarting of the motor when the thermostat resets. For a typical wiring diagram, refer to Fig. 2. In the event of an overload, the source of this condition should be determined and rectified before the pump is put back into normal operation. DO NOT LET THE PUMP CYCLE OR RUN IF AN OVERLOAD CONDITION OCCURS! Control panels for single phase pumps MUST be purchased from the factory and it is advisable that all three phase control panels are also purchased from the factory. SECTION: D START-UP OPERATION D-1) Check Voltage and Phase: Before operating pump, compare the voltage and phase information stamped on the pump’s identification plate to the available power. D-2) Check Pump Rotation: Before putting pump into service for the first time, the motor rotation must be checked. Improper motor rotation can result in poor pump performance and can damage the motor and/or pump. To check the rotation, suspend the pump freely, momentarily apply power and observe the “kickback”. “Kickback” should always be in a counter-clockwise direction as viewed from the top of the pump motor housing. If current through the temperature sensor exceeds the values listed, an intermediate control circuit relay must be used to reduce the current or the sensor will not work properly. D-2.1) Incorrect Rotation for Three-Phase Pumps: In the event that the rotation is incorrect for a three-phase installation, interchange any two power cable leads at the control box. DO NOT change leads in the cable housing in the motor. Recheck the “kickback” rotation again by momentarily applying power. TEMPERATURE SENSOR ELECTRICAL RATING VOLTS CONTINUOUS AMPERES INRUSH AMPERES 110-120 3.00 30.0 220-240 1.50 15.0 440-480 0.75 7.5 D-2.3) Test Procedure For Moisture Sensor Control: With a Warrick moisture detection control, type 2800, a normally closed push button and neon indicating lamp is provided as a means of checking the moisture sensing components. When the push button is depressed, the indicating lamp will be illuminated to indicate (A) power is supplied to the control, (B) the control is operative, and (C) wiring to the moisture sensing probes in the motor is intact. This procedure should be performed periodically to confirm integrity of the circuit. C-4.5 Moisture Sensors: A normally open (N/O) detector is installed in the pump seal chamber, which will detect any moisture present, and a continuity test resistor built into the motor. The test resistor is rated 1 watt at 330K ohms. The moisture sensors MUST be connected to moisture detector control, which includes a continuity test circuit, see Fig. 3 for typical wiring diagram. The normally closed (N/C) contact of the moisture detector MUST be connected in series with the stop button of the pilot circuit of the magnetic motor controller. A Warrick moisture detection control, Type 2800 is an acceptable control if properly installed and maintained. Wiring must be provided from the moisture detector sensor probe leads of the motor designated W1 and W2 to terminals 9 and 10 of the 2800-XXX control. Terminal pair 1-2 must be continuously energized from an A-C supply line of electrical characteristics shown on the data table. In the event of moisture detection, the pump should be pulled and the source of the failure located and repaired. IF MOISTURE DETECTION HAS OCCURRED, SCHEDULE MAINTENANCE AS SOON AS POSSIBLE! D-3) Start-Up Report: Included at the end of this manual are two start-up report sheets, these sheets are to be completed as applicable. Return one copy to Barnes Pumps, Inc. and store the second in the control panel or with the pump manual if no control panel is used. It is important to record this data at initial startup since it will be useful to refer to should servicing the pump be required in the future. D-3.1) Identification Plate: Record the numbers from the pump’s identification plate on both START-UP REPORTS provided at the end of the manual for future reference. C-4.6) Control Panel and Electrical System: The control panel and the electrical system MUST be properly designed and wired to include at least, but not limited to the following; 8 TYPICAL THERMAL PROTECTION WIRING DIAGRAM FIGURE 2 FIGURE 3 9 D-3.2) Insulation Test: Before the pump is put into service, an insulation (megger) test should be performed on the motor. The resistance values (ohms) as well as the voltage (volts) and current (amps) should be recorded on the start-up report. D-3.3) Pump-Down Test: After the pump has been properly wired and lowered into the basin, sump or lift station, it is advisable to check the system by filling with liquid and allowing the pump to operate through it’s pumping cycle. The time needed to empty the system, or pump-down time along with the volume of water, should be recorded on the start-up report. SECTION E: PREVENTATIVE MAINTENANCE As the motor is Air-filled, no lubrication or other maintenance is required, and generally Barnes Pumps will give very reliable service and can be expected to operate for years of normal sewage pumping without failing. However, as with any mechanical piece of equipment a preventive maintenance program is recommended and suggested to include the following checks: 1) 2) 3) 4) Test moisture detector control “Test Switch” for continuity of circuit. Water in the seal chamber will energize a seal leak warning light at the control panel. This is a warning light only and does not stop the motor. It indicates the seal has leaked and must be repaired. This should be done within 2 or 3 weeks to prevent further damage. See section D-2.3. Inspect impeller and body for excessive build-up or clogging and repair as required per section F-1. Inspect outer shaft sealÿand replace as required per section F-2. Check motor for ground leakage and proper amp draw. Motor and inner seal repair per section F-3. NOTE: If impeller (7) is replaced, also replace impeller ring (8). If only the impeller ring (8) requires replacing, split the ring and remove, be careful not to damage impeller. To remove Impeller (7), removing cap screw (10) (or nut) and washer (9) (and spring washer (11) if so equipped). The impeller is keyed onto the shaft with a square key (6) and to remove, pull impeller straight off the shaft using a wheel puller if required. Inspect gasket (1H) if suction cover (1E) has been removed, and replace if cut or damaged. Before reinstallation, check the motor shaft and impeller bore for damage. F-1.2) Reassembly: To install wear ring (1F) first apply retaining compound to the bore of suction cover (1E) and then press wear ring (1F) into bore of suction cover (1E) until seated. Position gasket (1H) on volute, and locate suction cover (1E) on volute (1), apply thread locking compound to socket head screws (1D)ÿand tighten into volute (1). To install impeller (7), first apply retaining compound to groove at bottom of impeller and press impeller ring (8) on impeller (7), then apply a thin film of oil to motor shaft and slide impeller straight onto shaft, keeping keyways lined up. Drive key (6) into keyway. Locate spacer (9), and Lock-spring washer (11) on shaft, apply thread locking compound to cap screw (10) threads, thread cap screw (10) into shaft and torque to 35 ft. lbs. Rotate impeller to check for binding. Install impeller and motor assembly over studs and onto volute (1). Apply thread locking compound to threads of each stud (3). Position lockwasher (5) on studs (3) and thread nut (4) onto stud (3) and torque to 24 ft. lbs. Check for free rotation of motor and impeller. F-2) Outer Shaft Seal Service: SECTION F: SERVICE AND REPAIR NOTE: All item numbers in ( ) refer to Figures 7 & 8. CAUTION! - Handle seal parts with extreme care. DO NOT scratch or mar lapped surfaces. WARNING ! - Electrical power to the pump motors must be disconnected and locked out to prevent any dangerous electrical hazards or personnel danger before any service work is done to the pump. CAUTION ! - Operating pump builds up heat and pressure; allow time for pump to cool to room temperature before handling or servicing. F-1) Impeller and Volute Service: F-1.1) Disassembly and Inspection: To clean out the pump body (1), or clean out or replace impeller (7), or replace wear ring (1F) and impeller ring (8), disconnect power, remove hex nuts (5) and vertically lift motor assembly from the pump body (1), and then lift out back plate (12). Clean out the pump body, if necessary, examine wear ring (1F) and replace if worn. If the wear ring (1F) requires replacing, split the wear ring (1F) and remove, be careful not to damage the suction cover (1E). Clean and examine impeller (7) for pitting or wear, also check impeller ring (8) for scaring or excessive wear, replace if required. FIGURE 4 10 F-2.1) Disassembly and Inspection: To expose outer shaft seal (13) for examination, remove Impeller and Volute per Section F-1.1. Set motor assembly (2) in the up position to prevent loss of oil. Remove snap ring from motor shaft, then retaining ring (13D), spring (13C) and rotating member (13B) from shaft, See Fig. 4. Examine all seal parts and especially contact faces. Inspect seal for signs of wear such as uneven wear pattern on stationary members, chips and scratches on either seal face. DO NOT interchange seal components, replace the entire shaft seal (13). If replacing seal, remove stationary (13A) from mounting plate by prying out with flat screw driver. F-3) Motor & Inner Shaft Seal Service The XSE Submersible Pump motor is manufactured by Reliance Electric Co. and must be serviced and repaired by Reliance approved service centers only. For lead reconnection information, contact Reliance Electric Co., giving motor serial number. WARNING ! - These motors are U/L Listed for application in CLASS I, GROUPS C & D EXPLOSION PROOF Environments. All repairs, other than lead reconnects and outer seal replacement, shall be performed by an authorized reliance service facility. Any other repairs performed by the customer or NON-RELIANCE SERVICE Facilities negates the U/L Listing and motor warranty. F-2.2) Reassembly: Lightly oil (DO NOT use grease) outer surface of stationary member (13A). Press stationary member (13A) firmly into mounting plate using a seal pusher, nothing but the seal pusher is to come in contact with seal face (see Fig. 5). SECTION: G REPLACEMENT PARTS G-1 ORDERING REPLACEMENT PARTS: When ordering replacement parts, ALWAYS furnish the following information: IMPORTANT ! - DO NOT hammer on the seal pusher- it will damage the seal face. Stationary Member (13A) Polished Face Out Motor Mounting Plate 1. Pump serial number and date code. (Paragraph G-4) 2. Pump model number. (Paragraph G-3) 3. Pump part number. (Paragraph G-2) 4. Part description. 5. Item part number. 6. Quantity required. 7. Shipping instructions. 8. Billing Instructions. Seal Pusher FIGURE 5 Make sure the stationary member is in straight and that the rubber ring is not out of it’s groove. Lightly oil (DO NOT use grease) shaft and inner surface of bellows on rotating member (13B) see Fig. 6. With lapped surface of rotating member (13B) facing inward toward stationary member (13A), slide rotating member (13B) onto shaft using a seal pusher, until lapped faces of (13A) and (13B) are together. (see Fig. 4). Reliance Motor Rotating Member (13B) G-2 PART NUMBER: The part number consists of a six (6) digit number, which appears in the catalog. A one or two letter suffix may follow this number to designate the design configuration. This number is used for ordering and obtaining information. Stationary Bullet G-3 MODEL NUMBER: This designation consists of numbers and letters which represent the discharge size, series, horsepower, motor phase and voltage, speed and pump design. This number is used for ordering and obtaining information. Seal Pusher FIGURE 6 IMPORTANT! - It is extremely important to keep seal faces clean during assembly. Dirt particles lodged between these faces will cause the seal to leak. G-4 SERIAL NUMBER: The serial number block will consist of a six digit number, which is specific to each pump and may be preceded by a alpha character, which indicates the plant location. This number will also be suffixed with a four digit number, which indicates the date the unit was built (Date Code). EXAMPLE: A012345 0490. Reference the six digit portion (Serial Number) of this number when referring to the product. Place spring (13C) over shaft and in place on rotating member (13B), making sure it is seated on retainer and not cocked or resting on bellows tail. Slide retaining ring (13B) over shaft and let rest on spring (13C). Assemble impeller and volute as outlined in paragraph F-1.2. 11 TROUBLE SHOOTING CAUTION ! Always disconnect the pump from the electrical power source before handling. If the system fails to operate properly, carefully read instructions and perform maintenance recommendations. If operating problems persist, the following chart may be of assistance in identifying and correcting them: MATCH “CAUSE” NUMBER WITH CORRELATING “CORRECTION” NUMBER. NOTE: Not all problems and corrections will apply to each pump model. CAUSE CORRECTION Pump will not run PROBLEM 1. Poor electrical connection, blown fuse, tripped breaker or other interruption of power, improper power supply. 2. Motor or switch inoperative (to isolate cause, go to manual operation of pump). 2a. Float movement restricted. 2b. Switch will not activate pump or is defective. 2c. Defective motor 3. Insufficient liquid level. Pump will not turn off 2a. Float movement restricted. 2b. Switch will not activate pump or is defective. 4. Excessive inflow or pump not properly sized for application. 9. Pump may be airlocked 14. H-O-A switch on panel is in “HAND” position Pump hums but does not run 1. Incorrect voltage 8. Impeller jammed or loose on shaft, worn or damaged, impeller cavity or inlet plugged. Pump delivers insufficient capacity 1. Incorrect voltage. 4. Excessive inflow or pump not properly sized for application. 5. Discharge restricted. 6. Check valve stuck closed or installed backwards. 7. Shut-off valve closed. 8. Impeller jammed or loose on shaft, worn or damaged, impeller cavity or inlet plugged. 9. Pump may be airlocked. 10. Pump running backwards Pump cycles too frequently or runs periodically when fixtures are not in use 6. Check valve stuck closed or installed backwards. 11. Fixtures are leaking. 15. Ground water entering basin. Pump shuts off and turns on independent of switch, (trips thermal overload protector). CAUTION! Pump may start unexpectedly. Disconnect power supply. 1. Incorrect voltage. 4. Excessive inflow or pump not properly sized for application. 8. Impeller jammed, loose on shaft, worn or damaged, impeller cavity or inlet plugged. 12. Excessive water temperature. (internal protection only) Pump operates noisily or vibrates excessively 2c. Worn bearings, motor shaft bent. 5. Debris in impeller cavity or broken impeller 10. Pump running backwards 13. Piping attachments to buiding structure too rigid or too loose. 1. Check all electrical connections for security. Have electrician measure current in motor leads, if current is within ±20% of locked rotor Amps, impeller is probably locked. If current is 0, overload may be tripped. Remove power, allow pump to cool, then recheck current. 2a. Reposition pump or clean basin as required to provide adequate clearance for float. 2b. Disconnect level control. Set ohmmeter for a low range, such as 100 ohms full scale and connect to level control leads. Actuate level control manually and check to see that ohmmeter shows zero ohms for closed switch and full scale for open switch. (Float Switch). 2c. Check winding insulation (Megger Test) and winding resistance. If check is outside of range, dry and recheck. If still defective, replace per service instructions. 3. Make sure liquid level is at least equal to suggested turn-on point. 4. Recheck all sizing calculations to determine proper pump size. 5. Check discharge line for restrictions, including ice if line passes through or into cold areas. 6. Remove and examine check valve for proper installation and freedom of operation. 7. Open valve. 8. Check impeller for freedom of operation, security and condition. Clean impeller and inlet of any obstruction. 9. Loosen union slightly to allow trapped air to escape.Verify that turn-off level of switch is set so that the suction is always flooded. Clean vent hole. 10. Check rotation. If power supply is three phase, reverse any two of three power supply leads to ensure proper impeller rotation.. 11. Repair fixtures as required to eliminate leakage. 12. Check pump temperature limits & fluid temperature. 13. Replace portion of discharge pipe with flexible connector. 14. Turn to automatic position. 15. Check for leaks around basin inlet and outlets. 12 FIGURE 7 13 FIGURE 8 14 PARTS LIST ITEM 1 1A 1B 1C 1D 1E 1F 1G 1H 2 3 4 5 6 7 QTY 1 1 4 4 8 1 1 2 1 1 8 16 8 16 8 16 1 1 PART NO. 084851 079698 005810 014256 079380 079190 079369 078994 079587 See Table 1 079379 079379 038519 038519 15-21-1 15-21-1 079381 * * * * * * * * 083723 083723TA 083723TB 083723TC 083723TD 083723TE 083723TF 083723TG 083723TH 083723TJ 083723TK 083723TL 083723TM 083723TN 083723TP 083723TQ 083723TR 083723TS 083723TT 083723TU 083723TV 083723TW 083723TX 083723TY 083723TZ 083723UA 083723UB 083723UC 083723UD 083723UE 083723UF 083723UG 083723UH 8 9 11 1 1 1 1 1 1 12 13 1 1 14 15 5Ft. 3 079377 079588 079376 1-111-1 (Supplied with Motor) 052699 (Not Used) 079191 085980 084259 085981 085982 625-01583 625-00826 16 1 124823 10 DESCRIPTION Volute Assembly Volute Nipple Nipple Cap Soc. Hd. Screw Suction Cover Wear Ring Dowel Pin Gasket Motor (See Note: 1) Stud Stud Lockwasher Lockwasher Hex Nut Hex Nut Key Impeller, Cast Iron 14.50” Dia. 14.38” Dia. 14.25” Dia. 14.12” Dia. 14.00” Dia. 13.88” Dia. 13.75” Dia. 13.62” Dia. 13.50” Dia. 13.38” Dia. 13.25” Dia. 13.12” Dia. 13.00” Dia. 12.88” Dia. 12.75” Dia. 12.62” Dia. 12.50” Dia. 12.38” Dia. 12.25” Dia. 12.12” Dia. 12.00” Dia. 11.88” Dia. 11.75” Dia. 11.62” Dia. 11.50” Dia. 11.38” Dia. 11.25” Dia. 11.12” Dia. 11.00” Dia. 10.88” Dia. 10.75” Dia. 10.62” Dia. 10.50” Dia. 5/8-11 x 1” Lg Stainless Bronze 5/8 x 3” Lg Stainless 5/8 x 3” Lg Stainless 5/8 Stainless 5/8 Stainless 5/8-11 Stainless 5/8-11 Stainless 1/2 Sq x 3” Lg Stainless 20HP - 60HP 75HP - 150HP 20HP - 60HP 75HP - 150HP 20HP - 60HP 75HP - 150HP 75HP-1150 60HP-1150 50HP-1150 150HP-1750 30HP-870, 40HP-1150, 125HP-1750 25HP-870, 30HP-1150 100HP-1750 20HP-870 Impeller Ring Impeller Washer, Bronze 20 to 60 HP Stainless 75 to 135 HP Stainless Hex Hd. Cap Screw, 20 to 60HP 3/4-10 x 2” Lg Stainless Nut, 75 to 135HP 1-1/2-12 Stainless Lock-Spring Washer , 20 to 60HP 3/4 Steel 75 to 135HP Back Plate Outer Seal (See Note: 2) Carbon/Ceramic/Buna-N (STD) Outer Seal (See Note: 2) Carbon/Ceramic/Buna-N (STD) (OPTIONAL, Pump End) Tungsten/Carbide/Buna-N (OPTIONAL, Pump End) Tungsten/Carbide/Buna-N Chain .375 Steel Cold Shut .437 Adapter (Used with 360 Frame/320 Flange Motor) 15 20HP - 60HP 75HP - 150HP 20HP - 60HP 75HP - 150HP PUMP MODEL TABLE 1 - MOTOR WITH VARIOUS CORD LENGTHS 25FT 30FT 40FT 50FT 75FT 100FT 8XSE20048HA 079688 079688XC 079688XE 079688XF 079688XH 079688XL 8XSE20058HA 095171 095171XC 095171XE 095171XF 095171XH 095171XL 8XSE25048HA 079689 079689XC 079689XE 079689XF 079689XH 079689XL 8XSE25058HA 095172 095172XC 095172XE 095172XF 095172XH 095172XL 8XSE30048HA 079690 079690XC 079690XE 079690XF 079690XH 079690XL 8XSE30058HA 095173 095173XC 095173XE 095173XF 095173XH 095173XL 8XSE30046HA 083725 083725XC 083725XE 083725XF 083725XH 083725XL 8XSE30056HA 092836 092836XC 092836XE 092836XF 092836XH 092836XL 8XSE40046HA 079691 079691XC 079691XE 079691XF 079691XH 079691XL 8XSE40056HA 092835 092835XC 092835XE 092835XF 092835XH 092835XL 8XSE50046HA 079692 079692XC 079692XE 079692XF 079692XH 079692XL 8XSE50056HA 092834 092834XC 092834XE 092834XF 092834XH 092834XL 8XSE60046HA 079591 079591XC 079591XE 079591XF 079591XH 079591XL 8XSE60056HA 093644 093644XC 093644XE 093644XF 093644XH 093644XL 8XSE75046HA 079693 079693XC 079693XE 079693XF 079693XH 079693XL 8XSE75056HA 092833 092833XC 092833XE 092833XF 092833XH 092833XL 8XSE100044HA 079378 079378XC 079378XE 079378XF 079378XH 079378XL 8XSE100054HA 092831 092831XC 092831XE 092831XF 092831XH 092831XL 8XSE125044HA 079694 079694XC 079694XE 079694XF 079694XH 079694XL 8XSE125054HA 092832 092832XC 092832XE 092832XF 092832XH 092832XL 8XSE150044HA 079874 079874XC 079874XE 079874XF 079874XH 079874XL 8XSE150054HA 092830 092830XC 092830XE 092830XF 092830XH 092830XL NOTE: 1 Standard motor includes, 25 foot power and control cables, moisture & temperature sensors and carbon/ceramic/buna-n Inner & Outer shaft seals. NOTE: 2 When ordering motor (item 2), Outer seal is supplied. Item 13 is for Outer seal replacement ONLY. When ordering outer seal, furnish Reliance motor serial number. 16 IMPORTANT! WARRANTY REGISTRATION Your product is covered by the enclosed Warranty. Complete the Warranty Registration Form and return to Crane Pumps & Systems, Inc. Warranty Service Group If you have a claim under the provision of the warranty, contact your local Crane Pumps & Systems, Inc. Distributor. RETURNED GOODS RETURN OF MERCHANDISE REQUIRES A “RETURNED GOODS AUTHORIZATION”. CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR. Products Returned Must Be Cleaned, Sanitized, Or Decontaminated As Necessary Prior To Shipment, To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material. All Applicable Laws And Regulations Shall Apply. 17 BARNES ® Limited Warranty We warrant to our immediate customer and to the ultimate consumer that products of our manufacture will be free of defects in material and workmanship under normal use and service for the following time periods, when installed and maintained in accordance with our instructions. Pump Products: One (1) year from date of installation or (24) twenty-four months from date of shipment, whichever occurs first. Cleaning Products: Twelve (12) months from date of installation or eighteen (18) months from date of shipment, whichever occurs first. As used herein, “the ultimate consumer” is defined as the purchaser who first uses the product after its initial installation or, in the case of product designed for non permanent installation, the first owner who used the product. It is the purchaser’s or any sub-vendee’s obligation to make known to the ultimate consumer the terms and conditions of this warranty. This warranty gives you specific legal rights, and there may also be other rights which vary from state to state. In the event the product is covered by the Federal Consumer Product Warranties Law (1) the duration of any implied warranties associated with the product by virtue of said law is limited to the same duration as stated herein, (2) this warranty is a LIMITED WARRANTY, and (3) no claims of any nature whatsoever shall be made against us, until the ultimate consumer, his successor, or assigns, notifies us in writing of the defect, and delivers the product and/or defective part(s) freight prepaid to our factory or nearest authorized service station. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY PRODUCT SHALL BE TO REPLACE OR REPAIR AT OUR ELECTION, F.O.B. POINT OF MANUFACTURE OR AUTHORIZED REPAIR STATION, SUCH PRODUCTS AND/OR PARTS AS PROVEN DEFECTIVE. THERE SHALL BE NO FURTHER LIABILITY, WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE. Unless expressly stated otherwise, guarantees in the nature of performance specifications furnished in addition to the foregoing material and workmanship warranties on a product manufactured by us, if any, are subject to laboratory tests corrected for field performance. Any additional guarantees, in the nature of performance specifications must be in writing and such writing must be signed by our authorized representative. Due to inaccuracies in field testing if a conflict arises between the results of field testing conducted by or for user, and laboratory tests corrected for field performance, the latter shall control. Components or accessories supplied by us but manufactured by others are warranted only to the extent of and by the terms and conditions of the original manufacturer’s warranty. RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS ANALYSES AND EVALUATIONS WE CONDUCT WILL BE BASED ON OUR BEST AVAILABLE EXPERIENCE AND PUBLISHED INDUSTRY INFORMATION. SUCH RECOMMENDATIONS DO NOT CONSTITUTE A WARRANTY OF SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS GIVEN. This warranty shall not apply when damage is caused by (a) improper installation, (b) improper voltage (c) lightning (d) sand or other abrasive material (e) scale or corrosion build-up due to excessive chemical content. Any modification of the original equipment will also void the warranty. We will not be responsible for loss, damage or labor cost due to interruption of service caused by defective parts. Neither will we accept charges incurred by others without our prior written approval. This warranty is void if our inspection reveals the product was used in a manner inconsistent with normal industry practice and\or our specific recommendations. The purchaser is responsible for communication of all necessary information regarding the application and use of the product. UNDER NO CIRCUMSTANCES WILL WE BE RESPONSIBLE FOR ANY OTHER DIRECT OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOST PROFITS, LOST INCOME, LABOR CHARGES, DELAYS IN PRODUCTION, IDLE PRODUCTION, WHICH DAMAGES ARE CAUSED BY ANY DEFECTS IN MATERIAL AND\OR WORKMANSHIP AND\OR DAMAGE OR DELAYS IN SHIPMENT. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No rights extended under this warranty shall be assigned to any other person, whether by operation of law or otherwise, without our prior written approval. A Crane Co. Company 420 Third Street Piqua, Ohio 45356 Phone: (937) 778-8947 Fax: (937) 773-7157 www.cranepumps.com 83 West Drive, Bramton Ontario, Canada L6T 2J6 Phone: (905) 457-6223 Fax: (905) 457-2650 18 Notes 19 Notes 20 START-UP REPORT FOR SUBMERSIBLE PUMPS This form is designed to provide assurance that customer service and a quality product are the number one priority with Crane Pumps & Systems, Inc (CP&S). Please fill out the following questions as completely and accurate as possible. When complete, mail this form to: In U.S.A Send To: Crane Pumps & Systems, Inc Attn: Warranty Service Group 420 Third Street Piqua, Ohio 45356 In Canada Send To: Crane Pumps & Systems, Inc. Attn: Service Manager 83 West Drive, Brampton Ontario, Canada L6T 2J6 REPORTS THAT ARE NOT RETURNED CAN DELAY OR VOID WARRANTY. Pump Owner’s Name: Address: Location of Installation Person in Charge Phone Purchased From (Crane Pumps & Systems Representative/Distributor Pump Model Serial No. Part Number Voltage Phase Hertz Horespower Rotation: Direction of impeller rotation (Use C/W for clockwise, CC/W for counter-clockwise) Method used to check rotation (viewed from bottom) Does impeller turn freely by hand: Yes No Condition of equipment Good Fair Poor Condition of cable jacket Good Fair Poor Resistance of cable jacket Good Fair Poor Resistance of cable and pump motor (measured at pump control) Red-Black Ohms, Red-White Ohms, White-Black Ohms Resistance of Ground Circuit between Control Panel and outside of pump Ohms MEG Ohms check of insulation: Red to Ground White to Ground Black to Ground Condition of equipment at Start-Up: Dry Was Equipment Stored? Describe station layout Wet Length of Storage Liquid being pumped Debris in bottom of station? Was debris removed in your presence? Are guide rails exactly vertical? Is BAF stationary installed level? Liquid level controls: Model Are level controls installed away from turbulence? Operation Check: Tip lowest float (Stop Float), All pumps should remain off. Tip second float (and Stop Float), one pump comes On. Tip third float (and Stop Float), both pumps on (alarm on simplex). Tip fourth float (and Stop Float), high level alarm on (omit on simplex). If not CP&S level controls, describe type of controls Does liquid level ever drop below volute top? 21 Muddy CP&S control panel part no. and brand Number of pumps operated by control panel NOTE: At no time should holes be made in top of control panel, unless proper sealing devices are utilized. Control panel manufactured by others Company name Model number Short circuit protection Type Number and size of short circuit device(s) Amp rating Overload type Size Amp rating Do protection devices comply with pump and motor Amp rating? Are all connections tight? Is the interior of the panel dry? ELECTRICAL READINGS: Single Phase: Voltage supply at panel line connection, Pump Off, L1, L2 Voltage supply at panel line connection, Pump On, L1, L2 Amperage: Load connection, Pump On L1 L2 Three Phase: Voltage supply at panel line connection, Pump Off, L1 - L2 Voltage supply at panel line connection, Pump On, L1 - L2 Amperage: Load connection, Pump On L1 L2 - L3 L2 - L3 L2 FINAL CHECK: Is pump seated on discharge properly? Does check valve(s) operate properly? Flow, Does station appear to operate at proper rate? Noise level: High Medium Comments: L3 - L1 L3 - L1 L3 Check for leaks? Pump down time Low Equipment difficulties during start-up: MANUALS: Has operator received pump instructions and parts manual? Has operator received electrical control panel diagram? Has operator been briefed on Warranty? Address of local CP&S Representative/Distributor: I have received the above information (Name of Operator) Name of Company Date: I Certify this report to be accurate (Name of Start-Up person) Employed By: Date: Date and time of Start-Up Present at Start-Up ( ) Engineer: ( ) Operator: ( ) Contactor: ( ) Other: To be filled out by factory: Start-Up form checked by: Date warranty registration mailed: 22 IMPORTANT! WARRANTY REGISTRATION Your product is covered by the enclosed Warranty. Complete the Warranty Registration Form and return to Crane Pumps & Systems, Inc. Warranty Service Group If you have a claim under the provision of the warranty, contact your local Crane Pumps & Systems, Inc. Distributor. FOLD HERE AND TAPE, DO NOT STAPLE **IMPORTANT!** WARRANTY REGISTRATION CUSTOMER’S NAME DATE INSTALLED ADDRESS CITY STATE PHONE # ZIP FAX # DEALER’S NAME CITY STATE MODEL NO. SERIAL NO. PART NO. BRAND ZIP FOLD HERE AND TAPE, DO NOT STAPLE PLACE STAMP HERE CRANE PUMPS & SYSTEMS, INC. WARRANTY SERVICE GROUP 420 THIRD STREET PIQUA, OHIO 45356 - U.S.A.