ENVIRONMENTALLY SEALED PRESSURE SWITCH

Transcription

1 INSTALLATION MANUAL ENVIRONMENTALLY SEALED PRESSURE SWITCH ESPS 200 SHOWN IMPORTANT! 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. A Crane Co. Company 420 Third Street 83 West Drive, Bramton Piqua, Ohio Ontario, Canada L6T 2J6 Phone: (937) Phone: (905) Fax: (937) Fax: (905) Form No Rev. H

2 TABLE OF CONTENT SAFETY FIRST... 3 INTRODUCTION... 4 SWITCH WIRING SCHEMATIC... 5 SIMPLEX SCHEMATIC... 5 DUPLEX SCHEMATIC... 5 ESPS-100 WIRING DIAGRAM JUNTION BOX TO CONTROL PANEL... 6 ESPS-100 WIRING DIAGRAM SWITCH TO CONTROL PANEL (UltraCAP2)... 7 IDENTIFICATION OF STEALTH CONTROL PANELS... 8 STEALTH-R & -O E SERIES PANELS JUNCTION BOX TO CONTROL PANEL... 9 DUPLEX STEALTH R & O, G and C SERIES PANELS 1 HP & 2 HP 200/240 VOLT - 1 PHASE DUPLEX STEALTH UGP, UCP SERIES PANELS ALL UGP/UCP HP, VOLTAGE & PHASE STEALTH -R, -O, -G and -C Except 200 or 240 Volt, 1Ph ELECTRICAL CORD CONNECTION RAIL MOUNTING ASSEMBLY NON-RAILED MOUNTING ASSEMBLY ATTACHED ROPE TO SWITCH Other brand and product names are trademarks or registered trademarks of their respective holders. Barnes is a registered trademark of Crane Pumps & Systems, Inc Crane Pumps & Systems, Inc. 2003, 2/2006, 9/06, 10/06 Alteration Rights Reserved 2

3 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: IMPORTANT! Warns about hazards that can result in personal injury orindicates 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 fl uids can cause fi re or explosions, burnes or death could result. Biohazard can cause serious personal injury. Rotating machinery Amputation or severe laceration can result. Extremely hot - Severe burnes can occur on contact. 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. Prevent large articles of clothing, large amounts of chemicals, other materials or substances such as are uncommon in domestic sewage from entering the system. During power black-outs, minimize water consumption at the home(s) to prevent sewage from backing up into the house. Always keep the shut-off valve completely open when system is in operation (unless advised otherwise by the proper authorities). Before removing the pump from the basin, be sure to close the shut-off valve. (This prevents backflow from the pressure sewer.) Keep the control panel locked or confined to prevent unauthorized access to it. Hazardous fl uids can Hazardous pressure, eruptions or explosions could cause personal injury or property damage. Hazardous voltage can shock, burn or cause death. If the pump is idle for long periods of time, it is advisable to start the pump occasionally by adding water to the basin. 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. Do not block or restrict discharge hose, as discharge hose may whip under pressure. 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. 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. Do not exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat. Secure the pump in its operating position so it can not tip over, fall or slide. Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently. Never handle connected power cords with wet hands. 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. 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. Do not remove cord and strain relief. Do not connect conduit to pump. 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. 3

4 INTRODUCTION Thank you for purchasing your new Barnes brand level control. The ESPS series of level control switches have been designed to provide years of reliable service when properly used with Barnes brand pumps and packages. Please completely read this manual and follow all installation instructions to insure your level control provides the best service possible. When attempting to use this product in stations made by other manufacturers, care should be taken to ensure the application is compatible with the characteristics of the Barnes brand ESPS level control being used. Misapplication of this product will void the warranty. This switch is designed to be a Non-Serviceable item. If a switch is suspected to be inoperative, contact your local service center for service replacement options. The level control contains pressure sensitive components and diaphragms. Care should be taken when handling the unit to insure damage does not occur. Damage may result in improper function or undesirable performance. All actuation points are factory set and cannot be changed. Any attempt to change the actuation points will void the warranty. Before placing switch into service, switch should be brought to operational temperature range. Excessive or direct heating or cooling should NOT be used. OPERATION TEMPERATURE RANGE: SHIPPING / STORAGE TEMPERATURE: +35 F (2 C) to +120 F (49 C) -20 F (-29 C) to +150F (66 C) SWITCH COMPONENT DESCRIPTION LEVEL CONTROL CORD UPPER DIAPHRAGM LOWER DIAPHRAGM ALARM AIR BELL TUBE LOWER SWITCH HOUSING UPPER SWITCH HOUSING FUNDAMENTALS OF OPERATIONS The ESPS-100 Level control is designed to be used in conjunction with a simplex pump control panel identical to those used with conventional fl oats. It will signal the panel to turn the pump On at a point below the alarm bell as the liquid level rises in the basin. The pump will then run until the liquid level drops to a point above the lower switch housing where the panel will be signaled to turn the pump Off. In the event the pump does not turn on or the pump cannot keep up with the infl ow, the alarm circuit will be activated once the liquid level submerges the Alarm Air Bell Tube. It will stay activated until the condition is corrected and the liquid level drops below the Alarm Air Bell Tube. The ESPS-200 Level control is designed to be used in conjunction with a duplex pump control panel identical to those used with conventional fl oats. It will signal the panel to turn the lead pump On at a point below the alarm bell as the liquid level rises in the basin. The pump will then run until the liquid level drops to a point above the lower switch housing where the panel will be signaled to turn the pump Off. During periods of high infl ow where the lead pump cannot keep up with the infl ow, the level control will signal the panel to turn the lag pump on at a point between the lead point and the alarm bell. In the event the pump does not turn on or both pumps cannot keep up with the infl ow, the alarm circuit will be activated once the liquid level submerges the Alarm Air Bell Tube. It will stay activated until the condition is corrected and the liquid level drops below the Alarm Air Bell Tube. 4

5 SWITCH WIRING SCHEMATIC 5

6 ESPS-100 WIRING DIAGRAM JUNCTION BOX TO CONTROL PANEL (Where Applicable) IF J-BOX IS NOT USED, WIRE ACCORDING TO CHART HEADING ESPS CONTROL CORD AND TERMINAL NUMBER TERMINAL NUMBER DIRECT BURIAL CABLE* ESPS CONTROL CORD 1 RED RED 2 BLACK BLACK 3 YELLOW WHITE 4 ORANGE ORANGE 5 BLUE GREEN NOT USED BROWN NOT USED *Colors may vary on DBC NOTES: 1. Check for nicks and defects in cable. 2. Cord jacket should be slightly visible inside cord grips. Approximatelt 1/4 to 1/2 3. Tighten cord grips 1/4 turn past hand tight. 6

7 ESPS-100 WIRING DIAGRAM SWITCH TO CONTROL PANEL (UltraCAP2) TERMINAL NUMBER 1 RED 2 BLACK 3 WHITE 4 ORANGE 5 GREEN LEAD COLOR LEAD LENGTH LEAD STRIP LENGTH TERMINAL STRIP TORQUE 7.00 in.50 in 18 in lbs NOTES: 1. Check for nicks and defects in cable. 2. Cord jacket should be slightly visible inside cord grips. Approximately 1/4 to 1/2 3. Strip wire lengths and tighten per chart 4. Tighten gland nut 3 turns past hand tight 5. Tighten control panel cord grip 1/4 turn past hand tight 7

8 IDENTIFICATION OF BARNES STEALTH SERIES DUPLEX CONTROL PANEL FOR ESPS-200 LEVEL CONTROL WIRING To determine the proper wiring schematic you will need to fi rst determine the panel type you have using the information listed below. The information can be located inside the control panel door on the panel schematic. For STEALTH -R & -O E Series Panels: - Carries an E designation on the end of the model callout - This control panel identifi ed with a build date of March, 2006 or later - All horsepower, voltage, and phase combination will use this wiring type - Example is a STEALTH-R E or STEALTH-O E For STEALTH, R & O Series Panels or 240 Volt, 1 Phase, 1 & 2 HP: - 1 or 2 Horsepower, 200 or 240 Volt, 1-Phase ratings - This control panel identifi ed with a build date prior to March, 2006 or earlier - Carries one of the following designations STEALTH-R or STEALTH-O For STEALTH G, C, R, O, UGP and UCP Series Panels - All Voltage/Phase & HP: Horsepower, 200, 240, 480, or 600 Volt, 3-Phase ratings, 200 or 240 volt, 1 phase (Except STEALTH -R & -O), 200/240V 1Ph - 3.0, 5.0, or 7.5 Horsepower, 200 or 240 Volt, 1-Phase or 200, 240, 480, or 600 Volt, 3-Phase ratings - This control panel identifi ed with a build date prior to March, 2006 or earlier - Carries one of the following designations: STEALTH-R or STEALTH-O STEALTH-G or STEALTH-C UGP or UCP PUMP SERIES: UGP = SGV Grinders UCP = SGPC Grinders G = SGV Grinders C = SGPC Grinders R = SGV Grinders O = OGP, OGVF/OGVH & SGPC Grinders PANEL MODEL: 101 thru 116, Simplex 201 thru 216, Duplex HORSEPOWER: 1 = 1HP 2 = 2HP 3 = 3HP 5 = 5HP 7 = 7.5HP STEALTH -R E -P 0* = 200 Volt, 1 Phase, 60Hz 1* = 120 Volt, 1 Phase, 60Hz 2* = 240 Volt, 1 Phase, 60Hz 3* = 240 Volt, 3 Phase, 60Hz 4* = 480 Volt, 3 Phase, 60Hz 5* = 600 Volt, 3 Phase, 60Hz 6* = 200 Volt, 3 Phase, 60Hz VOLTAGE: MOUNTING: * = Wall Mount (STD) P = Poly Drywell Mount (*) Left Blank (*) If "E" - ESPS-200 Compliant. If Blank - Requires ESPS-200 wiring modification and/or kit. 8

9 DUPLEX STEALTH-R & -O E SERIES PANELS JUNCTION BOX TO CONTROL PANEL TERMINAL NUMBER DIRECT BURIAL CABLE ESPS CONTROL CORD 1 RED RED 2 YELLOW WHITE 3 (*) NONE FACTORY INSTALLED JUMPER PLACED BETWEEN TERMINAL 3 & 4 4 (*) NONE FACTORY INSTALLED JUMPER PLACED BETWEEN TERMINAL 3 & 4 5 BLACK BLACK 6 NONE N/A 7 NONE N/A 8 ORANGE ORANGE 9 BLUE GREEN NOTES: 1. Check for nicks and defects in cable. 2. Cord jacket should be slightly visible inside cord grips. Approximately 1/4 to 1/2 3. Tighten cord grips 1/4 turn past hand tight 9

10 DUPLEX STEALTH R & O SERIES PANELS 1 HP & 2 HP 200/240 VOLT - 1 PHASE TERMINAL NUMBER DIRECT BURIAL CABLE LEVEL CONTROL CORD 1 RED RED 4 YELLOW WHITE L3 on MS2 BLACK BLACK 7 ORANGE ORANGE 8 BLUE GREEN BROWN NOT USED RED/BLACK NOT USED BLUE/BLACK NOT USED NOTES: 1. Wire used for the jumpers is not supplied. Wire size must be #18 to #14 AWG, standed copper 2. To test functionallity of changes, the ESPS-200 switch should be ran through two complete cycles from off to alarm, making sure the lead and lag pumps change between each cycle identifi es the wiring change has been properly performed. 10

11 DUPLEX STEALTH UGP, UCP SERIES PANELS ALL UGP/UCP HP, VOLTAGE & PHASE, STEALTH -R, -O, -G and -C Except STEALTH -R & -O, 200 or 240 Volt, 1 Ph TERMINAL DIRECT BURIAL CABLE LEVEL CONTROL CORD NUMBER 1 RED RED 4 YELLOW WHITE 53 on MS2 BLACK BLACK 7 ORANGE ORANGE 8 BLUE GREEN BROWN NOT USED RED/BLACK NOT USED BLUE/BLACK NOT USED NOTES: 1. Wire used for the jumpers is not supplied. Wire size must be #18 to #14 AWG, standed copper 2. To test functionallity of changes, the ESPS-200 switch should be ran through two complete cycles from off to alarm, making sure the lead and lag pumps change between each cycle identifi es the wiring change has been properly performed. 11

12 ELECTRICAL CORD CONNECTIONS CORD CABLES - The cord assembly mounted to the switch must NOT be modified in any way except for shortening to a specific application. Any modifications to the switch cord will void the warranty. OVER-TEMPERATURE PROTECTION - The type of in-line over-temperature protector used in this level control is referred to as an inherent overheating protector and operates on the affect of temperature rise. This means that the over-temperature protector will trip out and shut the pump off if the switch becomes too hot. It will then automatically reset after the switch cools to a safe temperature. In the event of an over-temperature, the source of this condition should be determined and rectified immediately. DO NOT LET THE PUMP CYCLE OR RUN IF AN OVER-TEMPERATURE CONDITION OCCURS! CORD CONNECTION - Insert female end of cord plug into housing bore aligning alignment mark with detent in terminal block, See Figure Below. Tighten bolts until the corners of the compression flange are drawn down to the top of the level control. DO NOT OVER TORQUE. 12

13 C CHANNEL RAIL MOUNTING ASSEMBLY NOTES: 1. Bracket may be reversed to allow switch mounting on either side of the guid rail to avoid obstructions and inlets in basin 2. Secure cord to avoid possible hazards 3. Install the pump before sliding the level control down the C channel ITEM QTY DESCRIPTION PART NUMBER MATERIAL 1 1 SWITCH, ESPS N/A 2 1 MOUNTING, BRKT, SLIDE Cast Iron 3 3 WASHER, FLAT, 1/ Stainless Steel 4 5 WASHER, LOCK, 1/ Stainless Steel 5 3 SCREW, BHCS, 1/4-20 x Stainless Steel 6 2 SCREW, HXHD, 1/4-20 x Stainless Steel 7 1 CORD, 18/5, SOW, 8 Ft. CORD, 18/5, SOW, 15 Ft. CORD, 18/5, SOW, 30 Ft. CORD, 18/5, SOW, 50 Ft. CORD, 18/5, SOW, 75 Ft. CORD, 18/5, SOW, 100 Ft A XC XF XJ XL 8 VARIES ROPE, 1/4 DIA. 3 STRAND Polypropylene 13

14 NON-RAIL MOUNTING ASSEMBLY NOTES: 1. Position level control in basin in a level loction and not in direct fl ow of inlets 2. Secure cord to avoid possible hazards 3. On ESPS-200 installation, remove ring from adapter boot ITEM QTY DESCRIPTION PART NUMBER MATERIAL 1 1 SWITCH, ESPS N/A 2 1 MOUNTING, NON-RAIL A Buna/Stainless Steel 3 1 CORD, 18/5, SOW, 8 Ft. CORD, 18/5, SOW, 15 Ft. CORD, 18/5, SOW, 30 Ft. CORD, 18/5, SOW, 50 Ft. CORD, 18/5, SOW, 75 Ft. CORD, 18/5, SOW, 100 Ft A XC XF XJ XL 4 3 WASHER, LOCK, 1/ Stainless Steel 5 3 SCREW, HXHD, 1/4-20 x Stainless Steel 6 1 HOOK, S, 13 GA, Stainless Steel 7 1 WASHER, FLAT, 1/ Stainless Steel 8 VARIES ROPE, 1/4 DIA. 3 STRAND Polypropylene 14

15 ATTACH ROPE TO SWITCH STEPS & TIPS: Attach lifting device to pump. 1. Make a small overhand loop in the rope. 2. Bring the short end through the overhand loop. 3. Place short end behind the fi xed part of the rope. 4. Bring end around and back into the loop. 5. Pull on the fi xed end of the rope away from the loop to tighten the knot. NEVER LOWER OR RAISE PUMP BY THE CORD! 15

16 CRANE PUMPS & SYSTEMS, INC. WARRANTY SERVICE GROUP 420 THIRD STREET PIQUA, OHIO U.S.A.