CARRY STAINLESS STEEL AXIAL-FLOW SUBMERSIBLE PUMP

Transcription

1 CARRY STAINLESS STEEL AXIAL-FLOW SUBMERSIBLE PUMP HIGH VOLUME (CP08) THREE PHASE OWNER S MANUAL CARRY MANUFACTURING, INC Prospect Avenue Caro, MI CARRY or FAX: or

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3 ATTENTION! IMPORTANT INFORMATION FOR INSTALLERS OF THIS EQUIPMENT! THIS EQUIPMENT IS INTENDED FOR INSTALLATION BY TECHNICALLY QUALIFIED PERSONNEL. FAILURE TO INSTALL IT IN COMPLIANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES AND WITH CARRY MANUFACTURING RECOMMENDATIONS MAY RESULT IN ELECTRICAL SHOCK OR FIRE HAZARD, UNSATISFACTORY PERFORMANCE, AND EQUIPMENT FAILURE. INSTALLATION INFORMATION IS AVAILABLE FROM CARRY MANUFACTURING. CALL TOLL FREE WARNING! SERIOUS OR FATAL ELECTRICAL SHOCK MAY RESULT FROM FAILURE TO CONNECT THE MOTOR, CONTROL ENCLOSURES, METAL PLUMBING, AND ALL OTHER METAL NEAR THE MOTOR OR CABLE, TO THE POWER SUPPLY GROUND TERMINAL USING WIRE NO SMALLER THAN THE MOTOR CABLE WIRES. TO REDUCE THE RISK OF ELECTRICAL SHOCK, DISCONNECT POWER BEFORE WORKING ON OR AROUND ALL ELECTRICAL COMPONENTS. DO NOT USE MOTOR IN SWIMMING AREAS. CARRY MANUFACTURING, INC Prospect Avenue Caro, MI CARRY or Fax: or i Effective 02/2016

4 MODEL NUMBER EXPLANATION Example No. CP X CP08 = Pump Size: (CP08) = 8" Pump Discharge 0200 = Horsepower: (0200) = 20 Horsepower (0250) = 25 Horsepower 3 = Phase: (3) = Three Phase 23 = Voltage: (20) = 200 Volt (23) = 230 Volt (46) = 460 Volt (57) = 575 Volt X = Impeller No.: (10) = 10E Impeller (13) = 13E Impeller (16) = 16E Impeller (specified at time of order) = Orientation: ( ) = Blank is Vertical Please Note: All Carry High Volume (CP08) 8" Pumps come standard with a 30 power lead. Other lengths are available upon request. ii Effective 02/2016

5 TABLE OF CONTENTS ATTENTION... I MODEL NUMBER EXPLANATION... ii TABLE OF CONTENTS... iii STANDARD WARRANTY AND CONDITIONS OF SALE...1 GENERAL PUMP INSTALLATION...5 Pump Installation...5 Variable Speed Pump Installation...6 Variable Frequency Drive Package...11 Single Phase Input VFD Wiring Diagram...13 Three Phase Input VFD Wiring Diagram...14 Pressure Transducer/Flow Sensor Hook-up Diagram...15 Adjusting Level Parameters in Pump Controller...16 GENERAL INFORMATION...17 Product Use & Safety Information...18 Franklin Submersible Motors...19 Vertical Stainless Steel Pumps...20 Pump Performance Information...23 Maintenance Procedures...27 OPTIONAL EQUIPMENT...29 Lift Chains, Quick Links and Wire Rope Assemblies...29 Motor Leads...30 Pump Discharge Pipe Options...31 PVC Pipe and Accessories...32 Swing Check Valves...34 Flap Valves...35 Flap Gates...35 Quick Disconnects...36 Wil-loc Ball and Socket Couplings...37 Flexible Couplers...38 iii Effective 02/2016

6 TABLE OF CONTENTS GRAPHS 20 HP Performance Curve HP Performance Curve...25 ILLUSTRATIONS Sample Installation of a Variable Speed Pumping Application...6 Lifting Chain...7 Single Phase Input Wiring Diagram...13 Three Phase Input Wiring Diagram...14 Pressure Transducer/Flow Sensor Wiring Diagram...15 Vertical Stainless Steel Pumps - 8" Discharge Exploded View " Vertical Pump...22 Discharge Piping Example...31 PVC Threaded Fittings...33 Wil-loc Ball and Socket Couplings...37 TABLES Standard Variable Frequency Drive Package Components " Vertical Pump Dimensions...22 iv Effective 02/2016

7 STANDARD WARRANTY AND CONDITIONS OF SALE PRELIMINARY INFORMATION: Any preliminary drawings and illustrative materials used in the specification build-up process show general arrangement and approximate dimensions only. Certified drawings will be submitted after receipt of an order, if required. PRICES: Any listed price is subject to change without notice. Orders are accepted with the understanding that the product will be billed at the price in effect at the time of shipment, unless otherwise specified by Carry Manufacturing, Inc. QUOTATIONS: Any quotation 60 days old is subject to change without notice. The price of each order is subject to the resource availability and costs incurred by Carry Manufacturing, Inc. at the time of manufacture. FREIGHT: F.O.B. Carry's factory in Caro, Michigan. Catalog weights are careful estimates, but they are not guaranteed. No allowance will be made for cartage at destination. TAXES AND OTHER CHARGES: The prices do not include any Federal, State or Local sales, use or other taxes, or brokerage fees that may be applicable. The amount of any such applicable taxes or fees will be added to the invoice at the rate in effect at the time of shipment. ACCEPTANCE: No order shall be binding upon Carry Manufacturing, Inc. until accepted in writing by an authorized official at its home office in Caro, Michigan. Any contract for the sale of product and these Conditions of Sale, shall be governed by and construed according to the Uniform Commercial Code as adopted in the State of Michigan. If the product quoted is not approved by the Consulting Engineer, Carry Manufacturing, Inc. assumes no responsibility to furnish any item manufactured by others. CREDIT: Credit worthiness of a Purchaser will be determined upon receipt of the contract. Credit terms, if authorized, are subject to change during the life of the contract if the financial condition of the Purchaser changes. CANCELLATION: Cancellation of orders will be accepted with the understanding that Carry Manufacturing, Inc. will be entitled to reimbursement for expenses incurred at the time of cancellation, including any and all special engineering, design, tooling, manufacturing, storage or transportation costs. TERMS, PAYMENT & INVOICING: Standard payment terms are COD. Payment is due prior to shipment. For Open Accounts (with approved credit), payment terms are NET 30 days from the date of invoice. Retaining a percentage of the contract sale amount is prohibited without prior, written agreement. Payment must be made in U.S. Funds. An invoice will be rendered as of the date product is ready for shipment. A service fee of 1-1/2% per month on all invoices over 30 days past due will be imposed. In the event of any default by the Purchaser, Carry Manufacturing, Inc. shall have the right to repossess the product as well as all other rights afforded to a conditional seller under the provisions of the Uniform Conditional Sales Act and any other applicable laws. 1 Effective 02/2016

8 STANDARD WARRANTY AND CONDITIONS OF SALE MANUALS: One (1) owner's/service manual will be provided with each purchase of a single pump, included with the pump, control panel or variable frequency drive. Additional owner's/service manuals are available for $15.00 each. Standard Owner s Manuals are also be available for download from our website: Specialty Owner s Manuals for custom products will be available upon request. DELIVERY: Standard lead times for Storm Water products is 7-10 business days. 316 Stainless Steel and custom designed products have an 8-10 week lead time. The estimated shipping date is based on the production time required to process the order commencing with the date the order is accepted by Carry Manufacturing, Inc. In the event it is necessary to revise the design, specifications, or Conditions of Sale, the shipping date shall be automatically extended by the period of time required to achieve the mutually agreed upon correction or adjustments of the design, specifications or Conditions of Sale. Carry Manufacturing, Inc. reserves the right to make shipment of completed segments of an order and pro rate the invoice for those segments as shipments are made. DELAYS IN DELIVERY: Carry Manufacturing, Inc. shall not be responsible for any delay or for any damages suffered by the Purchaser by reason of any delay due to fires, strikes, riots, Acts of God, priorities, Government orders or restriction, delays in transportation, delays of suppliers of materials or parts, inability to obtain necessary labor, or other causes beyond the control of Carry Manufacturing, Inc. In the event of such a delay, the shipping date shall be extended for a period of time equal to the time lost by reason of such a delay. Any product held more than three (3) weeks after the estimated shipping date at the Purchaser's request will be stored at the Purchaser's expense unless otherwise agreed upon. DAMAGE OR LOSS IN TRANSIT: Delivery of the product to a carrier at Carry Manufacturing's plant or other shipping point selected by Carry Manufacturing shall constitute delivery to the Purchaser. Regardless of freight payment, all risk, loss or damage in transit shall pass to the Purchaser at that time. The Purchaser shall make claims for loss or damage to product while in transit, against the carrier and not against Carry Manufacturing, Inc. Carry Manufacturing, Inc. will assist the Purchaser in securing satisfactory adjustment of such claims. BETWEEN SHIPMENT AND PAYMENT: The Purchaser shall be responsible for the care, maintenance and protection of the material or product after delivery. The Purchaser agrees to provide and maintain adequate insurance for the product or materials shipped to the Purchaser against loss or damage by fire, explosion or other causes during the time between shipment and final payment in an amount fully protecting Carry Manufacturing, Inc. The title and right of possession to the machinery shall remain with Carry Manufacturing, Inc. and the machinery shall remain personal property irrespective of attachment to, or location on, any foundation or in any structure, until all payments shall have been made in cash. The Purchaser will do all acts necessary to protect the above title and right. 2 Effective 02/2016

9 STANDARD WARRANTY AND CONDITIONS OF SALE INSTALLATION: Unless specifically stated otherwise, all material or product shall be installed and placed in service by, at the expense of, and under the exclusive responsibility of the Purchaser. RETURNED PRODUCT: Authorization and shipping instructions for the return of any product must first be obtained by the Purchaser from Carry. Otherwise shipment will be refused. Contact Carry Manufacturing to be issued an RGA form. Complete the form and include a copy with the product to be returned freight pre-paid. Only unused standard product or materials of current design by Carry will be considered for return. Custom products cannot be returned for credit. If the returned product is in sellable condition, a credit memorandum will be issued minus a minimum restocking charge of 15% and minus any and all transportation charges paid by Carry. PUMP WARRANTY REGISTRATION CARD AND PROOF OF PURCHASE: Within 30 days of the purchase of the pump, Purchaser shall mail to Carry by certified mail, return receipt requested, the pump warranty registration card accompanied by proof of purchase from the retail seller indicating the date and purchase price of the pump at issue. This warranty is void unless the warranty registration card and proof of purchase are provided to Carry as set out above and are on file with Carry. LIMITED WARRANTY: Carry warrants the product sold by it to be free from defects in materials and workmanship for a period of one (1) year from the date of purchase of the pump as verified by the product warranty registration card and proof of purchase provided to Carry by purchaser. WARRANTY DISCLAIMER: This warranty does not apply to the product if used in an aquacultural application or to pumps that have been subject to misuse (including use in a manner inconsistent with the design of the pump), abuse, neglect, accident or improper installation or maintenance, or to pumps that have been altered or repaired by anyone other than Carry. The warranties in this agreement are in lieu of all other warranties, express or implied, including without limitation, any warranties of merchantability or fitness for a particular purpose, said warranties being expressly disclaimed. WARRANTY AMENDMENTS: Prior or subsequent courses of dealing, trade usage and verbal agreements not reduced to a writing signed by Carry, to the extent they differ from, modify, add to or detract from this warranty shall not be binding upon Carry. There are no agreements, promises or understandings, either verbal or written, that are not fully expressed in this warranty. No statements, recommendations or assistance by either party have been relied upon by either party nor shall they be relied upon and shall not constitute a waiver by either party of any of the provisions hereof. This warranty may be amended or altered only if agreed to in writing signed by Carry. 3 Effective 02/2016

10 STANDARD WARRANTY AND CONDITIONS OF SALE LIMITED REMEDY: Carry and Purchaser agree the repair or replacement of the pump at issue is a commercially reasonable allocation of risk and, therefore, Purchaser agrees that its sole and exclusive remedy against Carry shall be limited to the repair or replacement of the pump at issue. This exclusive remedy shall not be deemed to have failed of its essential purpose so long as Carry is willing and able to repair or replace the pump at issue. In the event Carry is unable to repair or replace the pump at issue in a manner acceptable to purchaser, or in the event it shall be determined by a court having jurisdiction thereof that any provisions of this warranty are unconscionable or fail in its essential purpose, then the maximum liability of Carry shall be that as set forth in the paragraph next following entitled Limitation on Liability. LIMITATION ON LIABILITY: Carry shall not be liable for any loss, damage or injury resulting from delay in delivery or installation of the pump or for any failure to perform which is due to circumstances beyond its control. Carry and Purchaser agree it is a commercially reasonable allocation of risk that the maximum liability, if any, of Carry for all damages, including without limitation contract damages and damages for injuries to persons or property, whether arising from Carry s breach of this agreement, breach of warranty, negligence, strict liability or other tort, is limited to an amount not to exceed the purchase price of the pump at issue in the dispute and said liability is so limited. In no event shall Carry be liable to Purchaser for any incidental, consequential or special damages, including without limitation, lost revenues and profits, even if it has been advised of the possibility of such damages. WARRANTY CLAIM PROCEDURE: This warranty is valid only if the following conditions are complied with by the Purchaser: Purchaser shall notify Carry in writing of the defect in the pump at issue within 30 days of discovery of the defect. The notice shall include with it copies of the warranty card, proof of purchase and the return receipt signed by a representative of Carry as provided above. In the event repair or replacement of the pump at issue is approved by Carry, Purchaser shall, upon written notice by Carry of the approval (RGA), return the pump to Carry, freight prepaid. Carry will return the repaired or replaced pump to Purchaser, freight prepaid. The repair or replacement of the pump shall not extend the duration of the one-year warranty term. GOVERNING LAW: This warranty shall be governed and controlled by and enforced in accordance with the laws of the State of Michigan, U.S.A., in all respects. FORUM: The parties agree they are of equal bargaining power and irrevocably submit to the jurisdiction and venue of the Circuit Court for the County of Tuscola, State of Michigan or, if original jurisdiction can be established, the United States District Court for the Eastern District of Michigan, Northern Division, with respect to any performance or breach of this agreement. The parties hereby stipulate that the venues referenced in this agreement are convenient to each of them. REMINDER: Mail in your WARRANTY REGISTRATION CARD today!! 4 Effective 02/2016

11 GENERAL PUMP INSTALLATION In this section, information has been provided on the installation of the Carry pump and its components. The installation will include: the Carry Pump, VFD, standard transducer, lightning arrestor and flow sensor for variable speed pumping applications. Optional equipment, like Quick Disconnects, Swing Check Valves, etc. are covered under OPTIONAL EQUIPMENT on page 29. Carry's Stainless Steel Axial-Flow Submersible Pump was designed to pump high volumes of water at low heads. The Franklin Electric motor was specifically developed to live under water. The variable frequency drive package is designed to allow for small capacity wet wells to be used with large capacity pumps and allows you to match the pump speed and discharge flow rate to the ever-changing drainage flow rates. The pump must be installed and operated correctly to keep it working at its utmost efficiency. This owner's manual has been developed to provide the owner and installer with as much information as possible to ensure satisfactory installation and operation. The following pages detail the specific instructions for each component of the installation. Following the installation information are several general information tips. CAUTION: THIS EQUIPMENT STOPS AND STARTS AUTOMATICALLY! USE EXTREME CARE WHEN WORKING AROUND PUMPS AND ELECTRICAL CONTROLS! 5 Effective 02/2016

12 SAMPLE INSTALLATION OF VARIABLE SPEED PUMPING APPLICATION VARIABLE FREQUENCY DRIVE FLOW SENSOR (EITHER LOCATION) DISCHARGE PIPE LEVEL TRANSDUCER WET WELL 1.5" PVC PIPE INLET PIPE (MAIN) FULL SPEED PARM. #207 ON LEVEL PARM. #206/741 OFF LEVEL PARM #742 4" BELOW OFF LEVEL FOR THE PUMP. CARRY PUMP #1 Illustration 1 REQUIRED STORAGE VOLUME OF WATER IS 25% OF THE FULL FLOW GPM OF THE PUMP IN THE AREA BETWEEN THE ON LEVEL & OFF LEVEL OF THE TRANSDUCER. 6 Effective 02/2016

13 VARIABLE SPEED PUMP INSTALLATION Illustration 1 shows a sample installation of the intake pipe, pump, VFD, standard transducer and flow sensor in a variable speed pumping application. Before installation, check the bottom of the wet well for debris, sand or muck. Remove as much as possible. The presence of debris in the wet well could damage your submersible pump. Ideally, your sump site should be designed to prevent the accumulation of debris and sand. Unpack the pump and controls. Make sure to check all packaging against your packing slip to be sure that you have all the parts. Refer to Illustration 1 during your installation. Connect a lifting chain, rope or cable to the pump eyelets. Tip: Stainless Steel chain or cable is the best and longest lasting material, but also the most expensive. Galvanized chain will usually deteriorate after a few years. A good poly or nylon rope is an acceptable choice with a minimal cost. See Illustration 2. DO NOT lower the pump into the wet well by the power cord. This could damage the cord and cause an electrical hazard in the future. WARNING - Do not lift the pump using the power lead. Electrical shorts can occur and could damage the pump s motor and control panel. Connect a threaded PVC adapter to the pump discharge at the recuperator. Carry Stainless Steel Axial-Flow Submersible Pumps with a 8" discharge have 8" male NPT threads on the recuperator for connecting to the discharge piping. Carry recommends using 8" Schedule 40 PVC female adapters to connect the 8" discharge pipe to the Carry pump. Attach a riser pipe section to the threaded adapter. If up-sizing to 10" discharge pipe, then we recommend the use of a 8" cleanout and an 8"x10" increaser coupling (sometimes referred to as a 10"x8" reducer coupling). In applications where a check valve is to be installed in the discharge piping, we recommend that it be installed at this point before adding the riser pipe. Other recommendations include: a long radius (90E) elbow and a discharge pipe that should not exceed 20 feet in length unless otherwise indicated. Lower the pump with the riser pipe into the pump tank. Position the pump in the center of the wet well so the discharge elbow may be installed easier. Use nylon cord or electrical tape to attach the power cord vertically along the pump and the discharge pipe to avoid breakage. Connect the lifting chain, cable or rope to the top of the tank. Cut the riser pipe Illustration 2 off at the desired height to allow the attachment of a 90E elbow and the horizontal discharge pipe section. Tip: Try to avoid using short radius elbows. Instead of gluing the elbow to the pipe, it may be helpful to use bolts to secure the pipe. We usually apply a bit of dish soap to the pipe and elbow to ease the installation. Once the elbow is in place, we drill tap holes for stainless steel bolts (three 5/16"-18 x 3/4" are our preference.) 7 Effective 02/2016

14 VARIABLE SPEED PUMP INSTALLATION (continued) Attach the VFD controller to a post or nearby structure. The VFD has a NEMA 4X rating, meaning it is approved for outdoor applications. Tip: We do recommend a snow and ice shield be installed above the VFD to avoid build up on the controller or cooling fans. An insulated VFD winter cover is included for use during cold weather to protect the electronic components. Make sure that the electrical power is off at the main disconnect before starting to connect the electrical wiring. Severe electrical shock can occur if the power is not turned off before handling the electrical components. Remove the cover to the VFD controller. Bring all the electrical wires/cables into the bottom of the VFD controller through the cord connectors. Pull enough wire to make connections easy but avoid having too much excess wire in the controller itself. Connect the electrical wires from the power source and the pump per Illustration 3 or Illustration 4. Install the Lightning Arrestor into the breaker or fuse panel. There are two types of Lightning Arrestors depending on your power source, you may have either a Single Phase or Three Phase Lightning Arrestor. Single Phase Lightning Arrestors are used for Single Phase, 230 Volt incoming power. This Lightning Arrestor is wired as follows: connect the black wires of the Lightning Arrestor to the load wires on the breaker or fuses. Connect the White wire to the ground. The Lightning Arrestor has a green light on it to indicate that the unit is operations. If the power is on and the light is not lit, then the unit is bad and needs to be replaced. Three Phase Lightning Arrestors are used for Three Phase, 230 Volt; Single Phase, 460 Volt or Three Phase, 460 Volt incoming power. This Lightning Arrestor is wired as follows: connect the three black wires to the wires in the breaker or fuses, connect the white wire to ground. If you are using Single Phase, 460 Volt incoming power, you will not use one of the black wires. Use a wire nut or electrical tape to safely protect this wire from accidentally touching the other wires. Both Lightning Arrestors have a threaded mounting stud. This stud can be placed in a ½" knockout in the breaker panel. Mount the unit so you may view the green light on a regular basis. Install the Level Transducer. This is mounted on top of the tank lid. A 1-1/2" PVC pipe needs to be glued to the transducer box. It should extend down into the pump tank to a point 4" below the minimum submergence (OFF) level of the pump. The preset ON position of the Transducer is 15" above the bottom of the pipe. The preset FULL SPEED position of the Transducer is 23" above the bottom of the pipe. The preset OFF position of the Transducer is 4" above the bottom of the pipe. The preset positions may be changed in the Parameters of the VFD. See the VFD manual for more instructions. See Illustration 1. Make sure all connections on the 1-1/2" PVC pipe are glued and air tight. Leaks in the fittings may result in incorrect water level readings, which can result in slower than normal pump speeds. DO NOT mount the Transducer using the tabs on the box. Secure the PVC pipe with a clamp. Mounting the Transducer with the box tabs may cause stress on the fittings and create an air leak. If the box is the sole support, flexing may occur from the water currents in the tank causing air leaks in the fittings. Connect the Level Transducer wires to the VFD controller. See Illustration 5. Note: the Black wire has no connection. Use a wire nut or electrical tape to safely protect this wire. 8 Effective 02/2016

15 VARIABLE SPEED PUMP INSTALLATION (continued) Try to avoid running or winding the Level Transducer cable around the pump wires or the power wires. Sometimes, this can cause interference that will effect the level signal. The Level Transducer box has a breather hole in the bottom of it. This hole allows atmospheric air to enter the box and give a proper reference for the Transducer. Please make sure mounting of this box does not seal off this breather hole. Doing so, may effect the proper operation of the sensor. Install the Flow Sensor. The Flow Sensor is meant to be installed in the discharge pipe on the vertical riser just below the 90E elbow. This Flow Sensor detects the water in the pipe and helps prevent dry running of the pump. If the Flow Sensor doesn t sense water after a pre-determined amount of time during pump running, the VFD controller will fault out as Dry Pump. The Flow Sensor comes with a PVC mounting saddle. There are three sizes of mounting saddles - Blue is designed to fit 4" PVC pipe, Green is designed to fit 6" PVC pipe and Orange is designed to fit 8" PVC pipe. Use the correct Flow Sensor for your PVC pipe size. Drill a 1" hole in the discharge pipe and using PVC Primer, prime both the PVC saddle and mounting area in the vertical pipe. Glue the saddle to the pipe using standard PVC cement. Hook up the sensor wires according to the wiring diagram. Verify that the sensor is operational. After the pump is in operation, verify that the indicator light on the sensor changes state once the water is flowing in the discharge pipe. Tip: If the Flow Sensor does not activate when water passes by it, then adjustment is necessary. Adjustments can be made by loosening the compression nut and moving the sensor in or out of the water flow. The Sensor also has a sensitivity adjustment screw in the rear of the sensor. A plastic screw protects the adjustment screw. Remove this screw prior to making adjustments. Turn the sensitivity adjustment screw clockwise for increased sensitivity and counter-clockwise to decrease the sensitivity. Be sure to replace the plastic screw after making your adjustments. Connect the Flow Sensor wires to the VFD controller. See Illustration 5. Make sure all electrical connections to the VFD controller are tight and secure. Make sure all cord connectors are tight and secure. This helps prevent the wires from being pulled out of the VFD and keep it water tight. If water is able to enter the VFD then failure may occur. Replace the VFD controller cover. Once you have all the components in place, we recommend that you test the system through several cycles to ensure that everything is working properly. Turn the main power on at the breaker or fuse panel. Check the Lightning Arrestor green light for power. Wait for the VFD controller to become active. On the VFD LCD screen you will see REM (Remote) or LOC (Local). In the Remote mode, the VFD controller will operate the pump system with the Level Transducer (automatic mode). In the Local mode, the VFD controller will operate from the keypad. The LOC/REM setting may be changed with the operation of the toggle switch, located underneath the VFD, near the cooling fans and electrical connectors. It is somewhat hidden. 9 Effective 02/2016

16 VARIABLE SPEED PUMP INSTALLATION (continued) Place the toggle switch in the LOC mode. Flip the switch until the LCD screen reads LOC. Press the FORWARD button to test the pump operation. Once the pump is started, the INC (increase) and DEC (decrease) keys can be used to adjust the speed of the pump. Press the STOP key to stop the pump. Do not leave a pump running un-attended in the LOC mode to prevent dry running. Place the toggle switch in the REM mode by flipping the switch until the LCD screen reads REM. This will set the operation of the pump based on the water levels and the parameter settings. Adjustments to the parameters can be made to start and stop at different water levels. See the back of this manual for details on making adjustments to the parameters. Caution should be used to ensure any parameter changes do not cause short cycling. Installation is complete. 10 Effective 02/2016

17 VARIABLE FREQUENCY DRIVE PACKAGES Carry Manufacturing has put together a VFD package for use with our stainless steel axial flow submersible pumps. These VFD units can be used for pump down applications. The use of the VFD in conjunction with our pump allows the user to vary the flow rate of the pump to match the incoming water flow rate. The benefits of a system of this type include: Higher GPM with lower Horsepower than conventional fixed speed pumps. Additional No/Low Flow shutdown safety features. Matching the pump s flow rate to the inlet water flow rate. Soft starting to reduce motor starts and increase the available cycles per hour. Decrease wet well storage requirements by 75%. Lower minimum pumping depths. Simple field adjustable parameters for start, stop and full speed ratios. VFD UNIT VFD s may be used on Carry Three Phase Pumps only. Incoming voltage may be either single or three phase. In addition, the following rules need to apply: Minimum speed is 30 Hertz. Maximum accel and decel times are one (1) second. Requires adequate flow for motor cooling. Filters or reactors are required if the motor power cord is longer than 50 feet and the voltage is above 380 volts. The VFD package includes the following: WINTER COVER Variable Frequency Drive unit which controls the pump. The drive unit has a NEMA 4X Outdoor Enclosure constructed of Aluminum and Fiberglass with adjustable parameters for Stop, Start, Full Speed, Ramp Rate, Minimum Speed, Maximum Speed and many more. Parameters in the VFD may be adjusted to fine tune the pumping system for a particular application. Level transducer which determines the water level and transmits that information to the drive unit to control speed and starting and stopping. Lightning Arrestor is field installed and is used in between the main disconnect and the VFD to prevent damage to the controls from power surges and lightning strikes. Insulated Winter Cover is used during the colder temperatures to protect the VFD s electronic components from freezing. TRANSDUCER Flow Sensors are optional and are not included in the VFD package. They can be attached to the discharge piping and used to determine when the pump is not pushing water and is a safety feature to prevent the pump from running dry. FLOW SENSOR LIGHTNING ARRESTOR 11 Effective 02/2016

18 VARIABLE FREQUENCY DRIVE PACKAGES Table 1: Standard Variable Frequency Drive Package Components: VFD Package Part #: Description: Drive Unit #: Lightning Arrestor #: Flow Sensor #: (optional) Cover Part #: 620-VFD-123* 20 HP - 1PH/230V in - 3PH out Consult Factory " Flow Sensor N/A 620-VFD HP - 3PH/230V in - 3PH out X5C20250C " Flow Sensor XXLarge 620-VFD-323* 20 HP - 3PH/230V in - 3PH out Consult Factory " Flow Sensor N/A 620-VFD HP - 1PH/460V in - 3PH out X5C40500C " Flow Sensor XXLarge 620-VFD-146* 20 HP - 1PH/460V in - 3PH out Consult Factory " Flow Sensor N/A 620-VFD HP - 3PH/460V in - 3PH out X5C40250C " Flow Sensor XLarge 620-VFD-346* 20 HP - 3PH/460V in - 3PH out Consult Factory " Flow Sensor N/A 625-VFD-123* 25 HP - 1PH/230V in - 3PH out Consult Factory " Flow Sensor N/A 625-VFD-323* 25 HP - 3PH/230V in - 3PH out Consult Factory " Flow Sensor N/A 625-VFD HP - 1PH/460V in - 3PH out X5C40600C " Flow Sensor N/A 625-VFD-146* 25 HP - 1PH/460V in - 3PH out Consult Factory " Flow Sensor N/A 625-VFD HP - 3PH/460V in - 3PH out X5C40300C " Flow Sensor Large 625-VFD-346* 25 HP - 3PH/460V in - 3PH out Consult Factory " Flow Sensor N/A * Due to Horsepower restrictions, a Vacon Drive is not available for this package. Carry has designed a custom control panel that includes an enclosure, deadfront, variable frequency drive, potentiometer, and terminal strip for use in these applications. Consult factory for details and available options. 12 Effective 02/2016

19 SINGLE PHASE INPUT POWER TO THREE PHASE OUTPUT GND L1/R L2/S L3/T B+ DB T1/U T2/V T3/W GND SINGLE PHASE POWER CMI PUMP 3 PHASE CMI PUMP LIGHTNING ARRESTOR RECOMMENDED TO BE INSTALLED IN BREAKER PANEL Illustration 3 WARNING!! The wiring must be hooked up according to the drawing and all connections must be tight. Failure to do so, could result in damage to your system. Incoming Power Source - Single Phase, 230 or 460 volts The incoming power is connected to L1/R, L3/T and GND on the terminal strip. Pump Connections - Pump leads are connected as follows: Black lead to T1/U on the terminal strip, White lead to T2/V on the terminal strip, Red lead to T3/W on the terminal strip and Green lead to the GND on the terminal strip. Exact placement of Black, Red and White wires will be determined by testing the pump and using the connection that runs the pump in the proper direction. See the Franklin Electric Motor Manual, page33 for more information. CAUTION: Failure to ground the control frame can result in a serious electrical shock hazard if a circuit fault occurs. 13 Effective 02/2016

20 THREE PHASE INPUT POWER TO THREE PHASE OUTPUT GND L1/R L2/S L3/T B+ DB T1/U T2/V T3/W GND THREE PHASE POWER CMI PUMP 3 PHASE CMI PUMP LIGHTNING ARRESTOR RECOMMENDED TO BE INSTALLED IN BREAKER PANEL Illustration 4 WARNING!! The wiring must be hooked up according to the drawing and all connections must be tight. Failure to do so, could result in damage to your system. Incoming Power Source - Three Phase, 230 or 460 volts The incoming power is connected to L1/R, L2/S, L3/T and GND on the terminal strip. Pump Connections - Pump leads are connected as follows: Black lead to T1/U on the terminal strip, White lead to T2/V on the terminal strip, Red lead to T3/W on the terminal strip and Green lead to the GND on the terminal strip. Exact placement of Black, Red and White wires will be determined by testing the pump and using the connection that runs the pump in the proper direction. See the Franklin Electric Motor Manual, page33 for more information. CAUTION: Failure to ground the control frame can result in a serious electrical shock hazard if a circuit fault occurs. 14 Effective 02/2016

21 PRESSURE TRANSDUCER/FLOW SENSOR HOOK-UP LEVEL TRANSDUCER 24V POWER SOURCE 0-10 V INPUT SIGNAL BLUE WHITE BLACK NO CONNECTION BROWN/RED FWD REV R/J DI1 DI2 DI3 DI4 DI5 MOL +24V +10V VIN1 ACOM VIN2 ACOM CIN+ CIN- IMET ACOM VMET BROWN BLACK BLUE FLOW SENSOR (PROX) 24V POWER SOURCE NO/NC CONTACTS (NPN) NO1 RC1 NC1 NO2 RC2 NC2 DCOM EN +24V +24V DCOM DO1 DO2 DOP LOCAL/REMOTE SWITCH *DI1 IS THE LOCAL/REMOTE INPUT *DI2 IS THE USER FAULT INPUT. DRY PUMP SIGNAL FROM THE FLOW SENSOR OR LOW CURRENT THRESHOLD. TIMER 2 IS ALSO IN SERIES WITH THESE. *DI3 IS THE INPUT TO START TIMER 2 WITH THE FLOW SENSOR AND LOW CURRENT THRESHOLD. *RC1 AND NO1 ARE A RELAY CONTACT THAT IS ACTIVE WHEN THE DRIVE IS RUNNING. TIMER 1 IS IN SERIES WITH THIS CONTACT. *RC2 AND NO2 ARE A RELAY CONTACT THAT IS ACTIVE WHEN THE LOW CURRENT IS TRIPPED. *DO1 IS A DIGITAL OUTPUT USED TO START THE PUMP IN REMOTE MODE. *DO2 IS A DIGITAL OUTPUT THAT IS ACTIVE WHEN THE LOW CURRENT THRESHOLD OR FLOW SENSOR ARE TRIPPED AND TIMER 2 IS TIMED OUT. Illustration 5 DIRECTIONS: Pressure Transducer Connections - Transducer leads are connected as follows: Brown lead to +24V on the terminal strip, White lead to VIN1 on the terminal strip, and Blue lead to ACOM on the terminal strip. Black lead - no connection. Flow Sensor Connections - Flow Sensor leads are connected as follows: Black lead to D13 on terminal strip, Brown lead to +24 on terminal strip and Blue lead to DCOM on terminal strip. Verify that the sensor is operational: After the pump is in operation, verify that the indicator light on the sensor changes state once the water is flowing in the discharge pipe. 15 Effective 02/2016

22 ADJUSTING LEVEL PARAMETERS IN PUMP CONTROLLER Use the following steps to adjust the On/Off level parameters in your Pump Down Variable Frequency Drive. 1. Turn the VFD controller on. 2. Switch the LOC/REM toggle switch (located underneath the drive unit) in the LOC (local or manual) position. The display should read LOC. 3. Press the PROG and SHIFT keys at the same time. This will display the access code screen - Parameter #811. These must be pressed at the same time. We suggest using two thumbs. That seems to work the best. 4. The access code is 88. This can be input by using the INC and DEC keys Toggle Switch until 88 is displayed. After 88 is displayed, press the ENTER key. The display will flash Stored before returning to the Access Code display. 5. Press the PROG key. This will return the display back to the default screen. 6. Press the PROG and SHIFT keys at the same time to get into the parameter list. Again, use two thumbs. It seems to work the best. 7. Using the INC and DEC keys, move up and down through the parameters. Parameters #206 and #741 are the parameters that start the pump. They are Access Code scaled in percentages. One percent equals one inch of water above the level transducer pipe. Theoretically, the top of the pump location is the zero percent level. Parameter #207 is the parameter for full speed operation of the pump. It is also scaled in percentages. 8. Once a parameter is displayed on the screen, it can be adjusted to fit the pump system. Pressing the SHIFT key will make the parameter flash. Use the INC and DEC keys to adjust the value of the parameter. Once the correct value is displayed, press the ENTER key to save the value. You can move to another Parameter #206 parameter by using the INC and DEC keys. Follow the above instructions for changing the desired parameters. 9. Parameters #206 and #741 should be set to the same value. The value of # 207 should be greater that the value of Parameters #206 and #741. Decreasing Parameters #206 and #741 will result in the pump starting at a lower water level. Increasing Parameters #206 and #741 will result in the pump starting at a higher water level. Decreasing the differential between #206/#741 and Parameter #741 #207 will make the pump ramp up faster. Increasing the differential between #206/#741 and #207 will make the pump ramp up slower. 10. After all parameters have been adjusted to meet the needs of the pump station, the Parameters need to be saved. To save the Parameters, use the INC and DEC keys to scroll to Parameter #801. Press SHIFT to edit this Parameter. Use the INC and DEC keys to change the value to 2 (Store). Press ENTER to initiate the store function. Switch the LOC/REM toggle switch to the REM (remote or automatic) position to put the pump in automatic mode. Parameter # This procedure can be repeated as many times as necessary to get the pump operating to suit the needs of the application. 16 Effective 02/2016

23 GENERAL INFORMATION The following topics were included to provide general information and tips on installing, running, testing and repairing your Carry Stainless Steel Axial-Flow Submersible Pump. 17 Effective 02/2016

24 PRODUCT USE & SAFETY INFORMATION C Do not use a Carry Stainless Steel Axial-Flow Submersible Pump in a swimming area. C The electrical controls must be installed observing all applicable national, state and local codes as per the latest revision of the National Electric Code. C A service entrance rated disconnect may need to be fused depending on the distance it is from the controls and the presence of the primary power circuit breaker in the control panel. Consult the National Electric Code. C A good earth ground must be provided at the electrical service entrance by means of a metal grounding stake. The true ground must also be connected to the ground terminal in the electrical controls. C The pump must be properly grounded to protect personnel from a serious or fatal electrical shock hazard and the pump motor from lightning induced voltage surges. The ground wire in the motor lead must be connected to the ground terminal in the electrical controls. C A three-phase Carry Stainless Steel Axial-Flow Submersible Pump must be connected to the correct Carry, or equivalent, pump motor controls to validate the warranty. Per Franklin Electric specifications, the control panel must be protected by a magnetic starter with extra quick trip overload relays in all legs to validate the warranty. C The liquid level control wiring must be encapsulated or low voltage for safety. C Running a Carry Stainless Steel Axial-Flow Submersible Pump dry (i.e., without water going by the motor as a coolant) will ruin the motor. Running the pump dry will create a "no-load" situation that will not increase the amperage-draw and will not activate any protective devices in the electrical control panel (unless your electrical control panel is specifically designed to protect the pump with a low-amperagedraw monitor). C Show caution when operating a pump on manual control. It is important not to let the pump run dry. (See warning above.) C Remove the construction debris, muck and sludge from the sump bottom before the initial start up. These obstructions can starve the pump of water and ruin the motor. C Carry pumps can accept up to ½" solids. If your application has the potential for matter larger than ½", it is recommended that you screen the inlet if possible. C Do not let water freeze in and around the pump. Severe damage will result to the pump and motor if water freezes around them. 18 Effective 02/2016

25 FRANKLIN SUBMERSIBLE MOTORS Carry Stainless Steel Axial-Flow Submersible Pumps come complete with the Franklin Submersible Motor installed inside a stainless steel casing. This motor was "Designed to Live Underwater." All Franklin Submersible motors were developed to live indefinitely in water. Why can this motor stay under water indefinitely? The motor was designed to protect its electrical windings from water while allowing the entire motor to be submerged and cooled by water. Other reasons include the following: 1. Its windings are completely hermetically sealed in a steel enclosure with both the outer and inner casings of stainless steel. The enclosure is surrounded and cooled by water. 2. Its rotor, consisting only of laminations and a copper or aluminum cage, runs in water with no ill effect but with the most effective cooling possible, a direct immersion in water. 3. Its bearings, both radial and thrust, are completely submerged in clean water. They require no other lubrication and therefore have an everlasting source of lubricant water. These features make the Franklin Submersible Motor highly efficient while reducing the possibilities of rust and wear on components. To assist in the pump installation, refer to the Franklin Electric Submersible Motor Application, Installation and Maintenance manual for more information. 6" SUPER STAINLESS SUBMERSIBLE MOTOR 19 Effective 02/2016

26 VERTICAL STAINLESS STEEL PUMPS HIGH VOLUME (CP08) 8" DISCHARGE PUMP EXPLODED VIEW Illustration 6 20 Effective 02/2016

27 Refer to Illustration 6 Item #: Description: 3/8"-16 x 7/8" Socket Cap Bolt 3/8"-16 x 1" Socket Cap Bolt Lifting Lug Recuperator O-Ring 5/16"-18 x 1" Hex Head Bolt 5/16" Lock Washer BILL OF MATERIALS Qty Part Number: T51 CP OR-270BN Construction Materials: 304 SS 304 SS 304 SS 303 SS Casting Buna Neoprene 304 SS 304 SS Impeller - 10E Impeller - 13E Impeller - 16E CP CP CP SS Casting 303 SS Casting 303 SS Casting 8 1/2"-20 x 1" Socket Cap Bolt SS HP Pump Shell: Storm 25HP Pump Shell: Storm /304 SS 303/304 SS Motor - See Sales Invoice SS Cord Guard Clamp Franklin Electric 304 SS Lead - 30' SEOW 2 AWG/3-Wire w/ Ground Lead - 30' SEOW 4 AWG/3-Wire w/ Ground Lead - 30' SEOW 8 AWG/3-Wire w/ Ground Lead - 30' SEOW 10 AWG/3-Wire w/ Ground SEOW 2/4 SEOW 4/4 SEOW 8/4 SEOW 10/ Cable Tie Strap Spacer Block: 2-1/8" Urethane Base Pad 5/16"-18 x 4-3/4" Hex Head Bolt A Plastic UHMW Buna Urethane 304 SS 21 Effective 02/2016

28 8"VERTICAL PUMP DIMENSIONS Table 2: 6" Vertical Pump Dimensions Illustration 7 CP08 Vertical Pump Dimensions (in inches) Weight (pounds) A- Height B-Minimum Submergence 20HP/3PH HP/3PH Effective 02/2016

29 20 HORSEPOWER W/ 10E IMPELLER PERFORMANCE CURVE 20 HORSEPOWER W/ 13E IMPELLER PERFORMANCE CURVE 23 Effective 02/2016

30 20 HORSEPOWER W/ 16E IMPELLER PERFORMANCE CURVE PUMP: < Axial-Flow/Lift < Stainless Steel construction < Stainless Steel impeller, investment casting, dynamically balanced DISCHARGE: < 8" Diameter < NPT standard threading, male IMPELLER: < 10E, 13E, 16E Impeller CYCLE CAPACITY: < 200 times per 24 hour period maximum in a variable speed application MOTOR: < Franklin Electric Super-6" Submersible < Thrust Capacity: 3500 pounds < 3450 RPM (2875 for 50 Hz) < Corrosion-Resistant Construction < Double Flange Design < Stainless Steel Shell < Epoxy Coated End Frames < Stainless Steel Splined Shaft < Hermetically-Sealed Windings < Anti-Track Self-Healing Resin System < Filter Check Valve < Kingsbury-type Water Lubricated Thrust Bearing < Pressure-Equalized Diaphragm < Sand Fighter Slinger < Copper Bar Rotor < Available with or without Subtrol protection 24 Effective 02/2016

31 25 HORSEPOWER W/ 13E IMPELLER PERFORMANCE CURVE 25 Effective 02/2016

32 25 HORSEPOWER W/ 16E IMPELLER PERFORMANCE CURVE PUMP: < Axial-Flow/Lift < Stainless Steel construction < Stainless Steel impeller, investment casting, dynamically balanced DISCHARGE: < 8" Diameter < NPT standard threading, male IMPELLER: < 13E or 16E Impeller CYCLE CAPACITY: < 200 times per 24 hour period maximum in a variable speed application MOTOR: < Franklin Electric Super-6" Submersible < Thrust Capacity: 3500 pounds < 3450 RPM (2875 for 50 Hz) < Corrosion-Resistant Construction < Double Flange Design < Stainless Steel Shell < Epoxy Coated End Frames < Stainless Steel Splined Shaft < Hermetically-Sealed Windings < Anti-Track Self-Healing Resin System < Filter Check Valve < Kingsbury-type Water Lubricated Thrust Bearing < Pressure-Equalized Diaphragm < Sand Fighter Slinger < Copper Bar Rotor < Available with or without Subtrol protection 26 Effective 02/2016

33 MAINTENANCE PROCEDURES C C C C C C C C Your Carry Stainless Steel Axial-Flow Submersible Pump was designed to require very little maintenance. In addition to implementing the procedures below, check the General Information section of the manual for more information pertaining to maintenance procedures that should be followed for any specialty components. See also the Optional Equipment section for more information about accessories like sensor floats, strainer screens and quick disconnects. Protect or remove the pump during periods when water might freeze directly around it. Do not let water freeze around the pump. Severe damage will result to the pump if water freezes around it. Debris management is critical to the effective operation of your pump. It is preferable that the design of the site keep debris, muck and sludge from entering the sump. If this is not the case, inspect and clean the inside base of the sump and the pump's strainer screen (if your pump is equipped with a strainer screen) at a safe time after a major storm event or series of storm events to minimize the debris and muck-pack build-up. Check that the ground wire is making a clean connection to the ground lug in the controls and that the ground rod is properly installed. Check that the pump is ready to work by test running it at intervals of no less than once a year. Check that any automatic, liquid-level control is adjusted and operating properly. The pump-on control for the pump must be set at the minimum submergence level or higher (i.e., top of the pump) or the pump will not prime when started, and the motor will not cool when running. This will cause damage to your motor. The pump-off control for the pump must be set above the mid-point of the pump or the risk of forming vortexes substantially increases. The risk of running the pump dry also increases. For Sales & Service - Call your Local Distributor or Carry Manufacturing at (800) Effective 02/2016

34 WINTERIZING TIPS MAINTENANCE PROCEDURES (continued) The Franklin Electric motors used in Carry submersible pumps are water lubricated; the solution inside is a mixture of de-ionized water and Propylene Glycol (a non-toxic antifreeze). This solution will prevent freezing in temperatures to 40EF (partial freezing will occur below 27EF, but no damage will occur). It should be noted that over time this solution can become diluted, so older motors are not as protected as new motors. Pumps with Sumoto motors are lubricated with a special food grade lubricant and are not susceptible to freezing. It is advised that pumps be stored in their wells during shut-down periods if the water surrounding the pump (below minimum submergence level) is not subject to freezing. Water above this level that freezes will not harm a pump that is shut-down. If it is necessary to remove the pump, storage in clean well water (not subject to freezing) above the minimum submergence level is recommended. If this is not an option, store the pump in an area where it will not be subject to freezing temperatures. A small amount of motor liquid may be lost with no damage, as an excess is provided. No other special care is needed. For Variable Speed applications that use a variable frequency drive, it is very important during cold winter months, to keep your variable frequency drives powered up. Vacon drives have a special ARCTIC operating mode that tries to maintains a safe operating temperature for the electronic components inside the drive. This ARCTIC mode can also help keep out condensation or frost that could form on the inside of the drive. This moisture can lead to problems with the electronics in the spring. The ARCTIC mode monitors the inside temperature of the drive. If the temperature drops below -7 C then the DB Resistor (Dynamic Brake) is activated to generate internal heat. Once this becomes active, the screen will display a warning. If the internal temperature drops below -10 C, then the drive will become inactive. Once the temperature gets above -10 C, and a period of time has elapsed, then the drive will become active again. If extreme cold weather operation is necessary, possible shielding of the drive may help keep it warmer. The VFD can be placed in the LOC mode (Local) by flipping the toggle switch. This will allow your drive to stay powered up for the winter, without pumping water. For additional protection, please install the vinyl winter cover that was included as part of your drive package. This cover uses Velcro straps to attach to the drive itself and provides insulation during cold temperatures. When all danger of freezing is past, your Carry pump will be ready to perform again. Make sure that the sump is cleared of any debris that may have accumulated over the winter. Check that the water is above the minimum submergence level of the pump. For variable speed applications, remove the winter cover and place the VFD back to REM mode (remote) by flipping the toggle switch. In addition, it may be necessary to purge the transducer pipe to ensure accurate operation. We recommend that you monitor the first couple of pump cycles to ensure that everything is working correctly. 28 Effective 02/2016

35 OPTIONAL EQUIPMENT The following pages highlight some of the optional equipment that may have come with your pump system or that you may want to add to your pump system in the future. OTHER PUMP ACCESSORIES LIFT CHAINS, QUICK LINKS & WIRE ROPE ASSEMBLIES These items are attached to the lifting lugs of the pump to assisting in the raising and lowering of the pump into the sump. Any of these items or common rope and chain can be used. CAUTION: Pumps should not be lifted by the power lead. This can cause a short in the lines and premature failure of the pump. 29 Effective 02/2016

36 MOTOR LEADS OTHER PUMP ACCESSORIES Carry Stainless Steel Axial-Flow Submersible Pumps are manufactured with a standard 30' power lead. The lead is used to connect the pump motor to the control panel. Longer lengths of power leads can be ordered to fit your application. Use Table 16 on page 16 of the Franklin Electric Submersible Motor Application, Installation and Maintenance manual to determine the maximum lengths of cable applicable to your pump application. In some instances it may be necessary to splice the power lead to suit the application. Carry Stainless Steel Axial-Flow Submersible Pump leads are generally 3 wire with a ground. When connecting to the control panel, use the wiring diagram to determine the connections for each color wire. 3-wire with ground leads have one each of a black, white, red and green wire. Some of the control panel diagrams indicate the use of a yellow lead. Carry 3-wire with ground leads use the white wire for connections to the yellow lead. FEATURES: < UL listed < C.S.A. certified < OSHA acceptable < Flame retardant (passes MSHA Flame Test) < Exceptional durability < Excellent resistance to oils, acids, chemicals, water, ozone, extreme temperatures, cuts, tears and abrasion < Sunlight resistant < UL and C.S.A. listed for continuous submersion in water CONSTRUCTION: Conductors: Bare, annealed copper per ASTM B-3, flexible, bunch stranded per UL-62 Separator: A paper tape is applied between the conductor and insulation to facilitate stripping Insulation: Color coded synthetic oil, ozone and water resistant rubber (EPDM) UL-62 Cabling: Conductors are assembled round with non-wicking fillers as needed and a cotton sleeve Jacket: Oil resistant thermoset, CPE (black) UL-62 Temperature Range UL 105 o C (221 o F) to -55 o C (-67 o F) Color Coding: 3/C: Black, White, Green 4/C: Black, White, Red, Green 30 Effective 02/2016

37 PUMP DISCHARGE OPTIONS Illustration 8 31 Effective 02/2016

38 PUMP DISCHARGE OPTIONS SCHEDULE 40 PVC PIPE AND FITTINGS Carry recommends the use of Schedule 40 PVC pipe and fittings for use with its pump systems. Schedule 40 PVC piping systems have been successfully used for pressure and drainage systems in industrial, residential, commercial and agricultural installations. PVC Schedule 40 is ideal for applications where transmission of liquids or materials does not exceed 140 o F. The physical and chemical properties of PVC Schedule 40 makes it ideal for the transmission of potable water and many chemical solutions. PVC Schedule 40 has a smooth interior surface that minimizes head pressure loss through friction, minimizes rust and oxidation, and is generally impervious to scaling or contaminant buildups. Systems are not adversely affected by environmental agents and buried systems are not adversely affected by normal soil contaminants. The life expectancy of plastic systems far exceeds that of metal systems and required maintenance is simpler and less costly. PVC Schedule 40 fittings are not recommended for use in compressed air or compressed gas systems. PIPE: This pipe is used for the discharge pipe connecting from the pump to the discharge location. It is available in a variety of lengths and diameters. Standard Carry pump systems use PVC pipe and fittings in diameters of 4", 6" or 8". ELBOWS: Elbows are used to create a directional change in the discharge pipe. Carry recommends the use of Long Radius elbows for better water flow. Elbows are available in either 45 o or 90 o angles. ADAPTERS: Female adapters can be used to connect the Carry Submersible pump to the discharge pipe system. (Carry Stainless Steel Axial-Flow Submersible Pumps are fitted with standard thread Male NPT.) These adapters may also be used as connectors between Schedule 40 PVC pipe and quick disconnect assemblies or other fittings. See discharge piping example on page 31. Both Female and Male Thread to Hub models are available. CLEAN-OUTS: These clean-out fittings without the plug can also be used for connecting the Carry Stainless Steel Axial-Flow Submersible Pumps to the discharge pipe system or as connectors between the pipe and quick disconnect assemblies or other fittings. These fittings are specifically recommended for use with increaser couplings. INCREASER COUPLING: These couplings are used to adapt a 4" discharge pipe to a 6" discharge pipe or a 6" discharge pipe to an 8" discharge pipe. They can also be used to adapt a new pumping system to an existing discharge pipe system, etc. The socket ends allow the fitting to slip over PVC pipe or spigot fittings. COUPLINGS: These are connectors to fit two pieces of pipe together to a make a longer length of pipe. 32 Effective 02/2016

39 PUMP DISCHARGE OPTIONS PVC PIPE AND FITTINGS INSTALLATION PROCEDURES Cemented Fittings and Joints: 1. Cut the pipe square using a miter box, mechanical cut off saw or plastic pipe cutting tool which does not flare up diameter end of pipe. 2. Remove all burrs from the end of the pipe with a knife, file or plastic de-burring tool. 3. Clean and dry the pipe and fitting of any dirt, moisture, or grease with a clean dry cloth. 4. Check the dry fit of the pipe and fitting by inserting the pipe into the fitting. By applying light pressure the pipe should easily go at least one third of the socket depth. If it bottoms, it should be snug. 5. Using the correct applicator, apply primer freely to fitting socket while keeping the surface and the applicator wet until the surface has been softened. Next, apply the primer to the end of the pipe equal to the depth of the fitting socket. When the surface is primed, remove any puddles of primer from socket. 6. Apply a full even layer of cement to the pipe and the fittings, while the surfaces are still wet with primer. Do not let the cement puddle or allow the cement to run down the inside of the pipe. 7. Assemble the parts quickly. Parts must be assembled while the cement is still fluid. If assembly is interrupted, re-coat parts and assemble. Then push the pipe fully into the fitting, using a turning motion of 1/8 to 1/4 turn, until it bottoms in the socket. Then hold them together for 15 to 30 seconds to offset any tendency of the pipe to move out of the fitting. Plastic cements set up very rapidly; consult cement manufacturer's instructions for curing time and other details. 8. After assembly, wipe excess cement from the pipe at the end of the fitting. A properly made joint will normally show a bead around its entire perimeter. Do not disturb the joint until initial setup of cement occurs. Allow the joints to adequately cure before testing. The exact curing time varies with temperature, humidity and pipe size. Threaded Fittings and Nipples 1. Brush the threads clean with a stiff bristle brush. 2. Wrap Teflon tape on the threads beginning with the No. 2 thread and continue wrapping with a slight overlap until the threads are covered. You should wrap in the direction of the threads. (See Illustration A to the right.) 3. Screw the fitting on the pipe, using care to start threads correctly, and tighten finger tight. Using strap wrenches, tighten an additional 1/2 to 1 turn. Over tightening will cause fracture or distortion of threads, pipe or fittings. (See Illustration B to the right.) Illustration 9 33 Effective 02/2016

40 SWING CHECK VALVES Swing Check Valves are commonly used in discharge systems to prevent the rush of water back down to the pump during shut off and in capsule pump stations when more than one pump is operating using a single manifolded discharge pipe. The Waterman Model PC-30 in-line Swing Check Valve is designed to offer a dependable low pressure swing check valve for the pumping industry. The basic unit can be supplied with a variety of optional features to fit particular applications, including qualification as back-flow prevention against flooding the wet well or recycling water in the wet well. PUMP DISCHARGE OPTIONS This valve is constructed with a high strength castaluminum body and features a tight-sealing, nitrile rubber seal. Hinge pins are stainless steel and operate in non-metallic hinge bushings with lubrication fittings. All models (4", 6" and 8") are fitted with torsion springs on the covers for extra quick closing to prevent water hammer. Mechanical joint compression couplings are provided on each end to allow the unit to provide the additional function of a flexible coupler in many installations. Flanges are also available. Units may be fusion epoxy coated inside, including hinge arm and disc for total corrosion protection. "Open" Position flow of water from pump to discharge For PVC pipe use I.D. Gasketed Swing Check Valves. For Steel pipe use O.D. Gasketed Swing Check Valves. INSTALLATION: Installation of a swing check valve is fairly easy. Schedule 40 PVC pipe slips into the socket on either side of the valve. Using a wrench tighten the tension bolts on the flanges to create a tight seal. Removal is just a matter of loosening the tension bolts and removing the pipe from the socket. Closed Position prevents back-flow of water to pump 34 Effective 02/2016

41 FLAP VALVES PUMP DISCHARGE OPTIONS These flap valves are designed for use on pump discharge lines and other pipe end closures to prevent entrance of back water. These valves are furnished with a variety of frame styles to fit most installation needs. A 7-1/2 o inclined seating plane is used to ensure that the valve will not hang open from slight pipe sagging or off grade. A positive stop prevents over opening. The compression model uses time proven wedge type seals to install quickly and easily on plain end standard steel pipe. This model is standard with a cast iron frame with machined seat face and a cast iron cover with a resilient neoprene rubber seat face. Follow ring is cast iron with rubber wedge gasket and plated steel draw bolts. Model PF25W Valves are available with aluminum covers and neoprene seat faces where extra sensitivity is desired. Taper setting collars can be provided as an aid for installation on concrete pipe. FEATURES: < Cast Iron Body < Flange or Compression Mounted < Cast Iron Cover < Aluminum Cover Optional < Cast Iron, Bronze or Resilient Seat Faces < Bronze Hinge Pins < 7-1/2 o Seating Plane STANDARD FLAP GATES These gates are used to prevent back-flow of water into the drainage system, keeping the drainage system from flooding. They are constructed with quality materials and have a special finish for longer life. Standard Flap Gate Corrugated Flap Gate Standard flap gates fit all PVC, CMP and other similar types of pipe. Corrugated flap gates are designed with an extra wide band that catches several corrugations on corrugated plastic tubing. Heavy duty flap gates have rugged 3/16" steel construction. They close against its own collar for a more precise seal and are dual hinged for better performance. Heavy Duty Flap Gate 35 Effective 02/2016

42 QUICK DISCONNECTS PUMP DISCHARGE OPTIONS Quick Disconnects are used for quick and easy pump removal from wet wells and Capsule Pump Stations. The disconnects are attached to the discharge plumbing and may include cams for easy disconnection of the discharge plumbing. There are two styles available and both come with female or male threads. Type A - Adapter Type D - Coupling Type F - Adapter Type B - Coupling All aluminum couplings are furnished with bronze cams and Buna gaskets as standard. All Stainless Steel couplings are furnished with stainless steel cams and Buna gaskets as standard. 4" Quick Disconnect couplings are designed for working pressures of 150 psi. 6" Quick Disconnect couplings are designed for working pressures of 75 psi. Burst or failure can occur if this pressure is exceeded. INSTALLATION: These fittings are installed in-line with the discharge piping. One each of the adapter and coupling is required for a complete fitting. Standard configurations are Type A Adapters with Type D Couplings and Type F Adapters with Type B Couplings. Installation in the discharge piping requires PVC adapters. Use two female adapters with each set of Type F and Type B fittings and two male adapters with each set of Type A and Type D fittings. Attach the adapters to the discharge pipe using the methods described on page 33. Screw one end of the disconnect adapter to the PVC adapter, using care not to strip the threads. Connect the disconnect coupling to the disconnect adapter by opening the cams and slipping the fittings together. Close the cams on the disconnect coupling. Screw the second PVC adapter onto the end of the disconnect coupling. Connect the PVC adapter to the remaining discharge piping using the methods described on page 33. To disconnect the discharge piping at the disconnect fittings, open the cams of the disconnect coupling and gently slip the fittings apart. Use care not to crack or damage the remaining discharge piping by jerking or yanking on the fittings. 36 Effective 02/2016

43 PUMP DISCHARGE OPTIONS WIL-LOC BALL & SOCKET COUPLINGS These couplings can be used to replace standard PVC fittings and other types of quick disconnect couplings. The ball and socket couplings are designed to make connections quickly and easily even in conditions such as mud, sand and snow. The fittings can be used in applications without straight or exact alignment of the discharge piping. There are no threads in the connection to clean. Other features include: < Secured pivot points prevent binding of clamping jaws. < O-rings seated securely in socket with no leakage. This increases pump performance by providing excellent vacuum sealing. < 30 o socket flexibility in all directions allows easy set up. Pipes do not have to be perfectly in line. < Ball and socket decreases wear, kinking and binding of hoses and pipes. < Double pin design results in fast, smooth closing. INSTALLATION: Installation is similar to that of other types of disconnect fittings. Connect a PVC female adapter to the discharge piping using the methods described on page 33. Screw one section of the Wil-loc ball or socket to the PVC female adapter. Open the cams and connect the ball to the socket. Perfect alignment is not required. Close the cams. Screw a second PVC female adapter to the ball and socket fitting. Connect the remaining discharge piping the PVC female adapter using the methods described on page 33. To disconnect the fitting, open the cams and gently pull the fittings apart. Illustration 10 < Wide handle for a firm grip and better leverage. < 4" & 6" pipe has 175 PSI working pressure. < 8" pipe has 175 PSI working pressure. < Variety of fittings and pipe available. 37 Effective 02/2016

44 FLEXIBLE COUPLERS These flexible couplers are manufactured of specially formulated elastomeric PVC. They are used as highly effective PVC pipe couplers. This material is highly resistant to caustic chemicals, ultraviolet rays, fungus growth and normal sewer gases. They are leakproof, rootproof and seal against infiltration and exfiltration. They also flex with earth movement, maintaining the integrity of the seal. They feature rustproof Series 300 stainless steel bands including screw and housing to assure easy installation and a positive seal. PUMP DISCHARGE OPTIONS These couplers produce a strong, reliable connection every time. And no special tools or fittings are required. Because of their quality and ease of installation, these couplings have found wide acceptance among sewer and plumbing contractors and municipalities. INSTALLATION: Slip the flexible coupler over both ends of the discharge pipe to be connected. Tighten the set screws on both ends of the flexible coupler for a tight seal. To remove, loosen the set screws on the hose clamps and remove the fitting. BE WISE! When installing this equipment use extreme caution. Follow the installation instructions included in this and the Franklin Electric Submersible Motor Application, Installation and Maintenance manual. Call CARRY for assistance if needed. 38 Effective 02/2016