Easy-Lift. Package Lift Stations. Sewage Stormwater Industrial Waste Process Waste

Convenient Economical Easy to install Integrated design High capacity Large solids handling Sewage Stormwater Industrial Waste Process Waste

INTRODUCTION Thank you for selecting Easy-Lift! In today's competitive market, discerning customers will appreciate the many features and benefits provided by the Easy-Lift systems. Whether your goal is simplicity of design, ease of installation, quality construction or long service life, we believe that our systems will exceed your expectations. This catalog provides the basic tools needed for product selection and sizing of our standard systems. If you require a larger or more highly customized system, please do not hesitate to contact us. Our staff of experienced applications engineers is ready to assist you with your specific needs. TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. FEATURES... BASIC CONFIGURATIONS... CONTROL PANEL IMAGES... STANDARD SIZES... TYPICAL BILL-OF-MATERIAL... RANGE CHARTS AND PUMP CURVES... SUGGESTED SPECIFICATIONS... BASIN SIZING - MINIMUM DIAMETER REQUIREMENTS... INSTALLATION DRAWINGS... MOTOR DATA... PUMP CONTROLLER... TYPICAL WIRING SCHEMATICS... BASIN INSTALLATION GUIDELINES... QUOTATION REQUEST FORM... PAGE 1 2 2 3 3 4 23 31 32 36 37 39 44 45

Features... 1 - Rugged fiberglass basin assembly for durability and corrosion resistance; simplex and duplex systems standard 2 - Integral bottom plate / anti-flotation flange 3 - Solids-handling submersible pump (IP68); FM listing available for Class 1, Groups C & D; 3"and 4" discharge sizes rated for capacities to 1300 GPM; Heads to 150 ft. 4 - Stainless steel pump lifting chain 5 - Rugged cast-iron guiderail base elbow 6 - Stainless steel guiderail(s) 7 - Direct-acting, sealed polypropylene-encapsulated level control switches 8 - Discharge pipe; available in PVC, ductile iron, stainless steel or galvanized steel 9 - Outside valve box (optional); includes drain and check valve assembly (not illustrated) 10 - Cast iron check valve, full-port design, includes external lever and adjustable weight; provides indication of "open" or "closed" position 11- Cast iron plug valve, full-port design, 1/4-turn type for quick and easy operation 12 - Wet-well vent (optional) 13 - Rugged stainless steel upper guiderail bracket; intermediate brackets supplied as required for deep basins 14 - Access covers; available in fiberglass, steel or aluminum 15 - Pump control panel; available with NEMA 3R or NEMA 4X enclosure; U.L. 508 listed; includes a wide variety of standard and optional features 16 - NEMA 4X junction box (not illustrated) 1 2 12 4 3 13 Quality construction throughout! 6 7 8 5 14 9 15 10 11 1

Basic configurations... Standard design Optional valve box design Compact control panel systems packed with the features operators want! 2

Standard size charts... Main Basin Basin Diameter Basin Depth 36" 48" 60" 72" 84" 96" Simplex Only Simplex or Duplex 48" X X X 60" X X X X 72" X X X X 84" X X X X X 96" X X X X X X 108" X X X X X X 120" X X X X X X 132" X X X X X X 144" X X X X X X 156" X X X X X X 168" X X X X X X 180" X X X X X X Optional Valve Box Width Depth 48" 48" 48" 60" 48" 72" Typical Bill of Material for Duplex system with optional Valve Box... QTY DESCRIPTION 2 Submersible Solids-Handling Pumps* 1 Fiberglass Basin with "D" type attached Valve Box; including Lifting Lugs (4) and Anti-Flotation Flange 1 Basin Cover* 1 2" Electrical Fitting* 1 NEMA 4X Junction Box and fittings* 1 Level Control Bracket (SS)* 4 Level Control Switch* 1 Inlet Fitting (Adapt-A-Flex)* 2 Guiderail Base Elbow QTY DESCRIPTION 2 Upper Guiderail Mounting Bracket 2 Guiderails 2 Pump Lifting Chain* 2 Discharge Pipe 2 Check Valve 2 Plug Valve 3 Link Seal 1 Vent (Mushroom Type)* 1 Valve Box Drain & Check Valve Assembly 1 Duplex Pump Control Panel* * Shipped loose for field installation 3

SOLIDS-HANDLING SUBMERSIBLE PUMP PERFORMANCE RANGE CHART 1750 RPM 4

SOLIDS-HANDLING SUBMERSIBLE PUMP PERFORMANCE RANGE CHART 1160 RPM 5

SOLIDS-HANDLING SUBMERSIBLE PUMP PERFORMANCE RANGE CHART 875 RPM 6

SOLIDS-HANDLING SUBMERSIBLE PUMP CURVES 1750 RPM "SWPA Data Categories Presented -- Data on this sheet supply design information as the minimum recommended by the Submersible Wastewater Pump Association (SWPA) and is defined in accordance with SWPA's Standardized Definitions for Pump and Motor Characteristics. The accuracy of the data is the responsibility of YEOMANS CHICAGO CORP." 7

SOLIDS-HANDLING SUBMERSIBLE PUMP CURVES 1160 RPM "SWPA Data Categories Presented -- Data on this sheet supply design information as the minimum recommended by the Submersible Wastewater Pump Association (SWPA) and is defined in accordance with SWPA's Standardized Definitions for Pump and Motor Characteristics. The accuracy of the data is the responsibility of YEOMANS CHICAGO CORP." 14

SOLIDS-HANDLING SUBMERSIBLE PUMP CURVES 875 RPM "SWPA Data Categories Presented -- Data on this sheet supply design information as the minimum recommended by the Submersible Wastewater Pump Association (SWPA) and is defined in accordance with SWPA's Standardized Definitions for Pump and Motor Characteristics. The accuracy of the data is the responsibility of YEOMANS CHICAGO CORP." 20

SUGGESTED SPECIFICATIONS PART 1 GENERAL 1.1 DESCRIPTION Work Included: Under this section, the contractor shall provide all labor, equipment and material necessary to furnish, install, test and place in operation the pre-fabricated Package Lift Station as shown in the plans and as specified herein. To assure proper design, operation and system responsibility, the pre-fabricated Package Lift Station system, Pumps, and Control Panel shall be supplied by the pump manufacturer. Other Project Specific Work 1.2 Related Work Described Elsewhere: Project Specific 1.3 GENERAL Furnish and install a pre-fabricated Easy-Lift Package Lift Station complete with all accessories, controls and appurtenances as shown in the plans and specified herein and as required for a complete operating system. The Package Lift Station shall be rated for handling unscreened sewage wastewater in accordance with the operating conditions defined in Table 1 of these specifications. The design shall be such that the pumping units will be automatically connected to the discharge piping when lowered into place on the discharge connection. The pump shall be easily removable for inspection or service without the need for removal of nuts, bolts or other fasteners and without the need for personnel to enter the wet-well. Each pump shall be fitted with a stainless steel lifting chain of adequate strength and length to permit raising the pump for inspection and removal. 1.4 QUALITY ASSURANCE Qualifications of Manufacturers: The pre-fabricated Easy-Lift Package Lift Station shown and specified is based on the products manufactured by Yeomans Chicago Corporation, Aurora, Illinois. Catalog numbers and references are given only as an indication of the quality of materials and workmanship to be used. 1.5 QUALITY CONTROL The Submersible Pumping Units shall conform to all applicable requirements of NEMA, IEEE, NEC, SWPA and Hydraulic Institute. For purposes of this specification, the revision and/or version of the referenced standards in effect on the date of public bid opening shall apply. The Submersible Pumping Units shall be the products of reputable manufacturers who have been regularly engaged in the design, manufacture and furnishing of Waste Water Pumping Equipment for a minimum of ten (10) years. The manufacturer of the pump shall assume full responsibility for the compatibility of the supplied components with the application. The motor and pump shall be manufactured by one company providing sole source responsibility for the warranty of the unit. Manufacturers who do not manufacture the submersible motor and who limit their warranty to that of the motor manufacturer shall not be acceptable. 23

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS PART 2 PRODUCTS 2.1 PUMPS The Submersible Pumping Units shall be self contained, integral pump/motor units designed to operate at continuous full load in a partially or completely submerged condition without the need for any external cooling devices such as water jackets. The air filled motor shall be cooled by an adequately sized motor frame, which shall conform to the latest applicable requirements of NEMA, IEEE, ANSI and NEC standards and shall meet the latest design standards of a Totally Enclosed Non-Ventilated NEMA frame motor. Heat transfer shall be accomplished by convection through the stator-housing wall to the surrounding media. Designs which incorporate cooling jackets and in particular, designs which rely on circulation of the pumped sewage or externally sourced water for cooling, are not considered equal to the equipment described in this specification and shall not be acceptable. The nameplate ratings of the motor shall be based on 40 C ambient environment. The pump motors and all associated sealing devices shall be designed to operate submerged at a depth of 150 feet of water. All motors shall be furnished and certified per IEEE 117 with Class H rated insulation materials (Class F on 140 frame). All motors not having IEEE 117 certified insulation systems shall be considered not acceptable. Insulation materials rated lower than Class F (i.e. Class B or A) are specifically prohibited. Pumps shall be of the submersible solids-handling type, Model, as manufactured by Yeomans Chicago Corporation, Aurora, Illinois. 2.1.1 BEARINGS AND LUBRICATION Bearings shall be specifically selected to carry all radial and axial loads imposed by the pump and motor. Bearings shall be rated to provide a minimum L10 Bearing Life of 25,000 hours at any design operating point within the allowable operating region (limit lines). Bearing selection shall limit the bearing temperature rise to a maximum of 60 C under full load operation. All bearings shall be permanently lubricated with a premium moisture resistant grease containing rust inhibitors and shall be suitable for operation over a temperature range of -25 C to +120 C. The bearings shall not require any additional or periodic lubrication. All bearings shall be commercially available from third party sources other than the pump/motor manufacturer. 2.1.2 SHAFT SEALS Two independent, tandem mounted, mechanical seals shall be provided in the oil filled housing to isolate and protect the air-filled motor from the pumped media. The oil level shall not require constant monitoring and shall be suitable for a minimum of two (2) years service under specified operating conditions before requiring replacement for normal maintenance. The oil reservoir shall act as a barrier to trap moisture and provide sufficient time for a planned shutdown in the event of an outer seal failure. The inner mechanical seal shall be constructed with a solid block carbon rotating seal face and a solid block silicon carbide stationary seal face. The outer mechanical seal shall be constructed with a solid block silicon carbide rotating seal face and a solid block silicon carbide stationary face. All other metal components of the inner and outer seals shall be AISI 316 stainless steel. All elastomers of both inner and outer seals shall be of Viton material. The outer mechanical seal shall be located in a recessed housing outside the main flow path of the pump to avoid damage. Mechanical seals that employ sprayed or laminated seal faces shall neither be considered equal, nor shall they be acceptable. Mechanical seals shall be readily and commercially available from third party sources other than the pump and motor manufacturer, their agents, dealers and/or distributors. Mechanical Seals shall be Type 21 or approved equivalent. 24

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS 2.1.3 MOISTURE DETECTION SYSTEM A dual (2) probe moisture sensing system shall detect the entrance of moisture and provide an alarm. The moisture detection system shall be designed to detect the entrance of moisture in the stator and lower oil seal housing. The use of single probe or float switch type sensor systems shall not be acceptable. The moisture sensing probe leads shall terminate at a conductance relay located in the control panel, which shall provide an alarm in the event of moisture intrusion. The sensing relay (if not specifically ordered from the pump manufacturer) shall be approved by the pump/motor manufacturer. 2.1.4 CABLE ENTRY SYSTEM The power and control cable entry system shall be designed to provide a positive, leak-free seal to prevent liquid from entering the air filled motor housing. The design shall incorporate provisions that prevent moisture from wicking through the cable assembly even in the event the cable jacket has been punctured. All cable shall be type SEOW-A or better and U.L. Listed for the intended submersible service. Units above 1-1/2 HP shall be designed with separate power and control cables to prevent false sensor warnings. The power and control cable entry into the lead connection chamber shall be epoxy encapsulated for positive moisture sealing. For frame size 180 and above, the power and control cables shall be unitized modular assemblies permitting individual repair or replacement. Each modular cable unit shall include a cast iron connector body with flared inlet to protect against cable damage due to bending or flexing at the entry point. Each cable unit shall include both epoxy seal and a Buna-N sealing grommet. A sleeve/spacer shall be provided to isolate the epoxy from the connector body and facilitate easy removal and replacement of the sealing compound. Assembly of cable components and grommet tensioning shall be accomplished by a precision snap-ring connection to prevent cable damage or leakage due to under or over compression. The system shall permit the use of factory supplied epoxy or other commercial sealants for field repair without voiding the rating of explosion proof units. Cable strain relief shall be independent of the epoxy seal. Individual cable units shall be designed to permit repair or rebuilding independent of the motor. Each cap & cable assembly shall include a modular design rail-mounted terminal block system with individual terminal units for connection of each power and control lead. The terminal block system shall utilize standard non-proprietary commercial components. 2.1.5 MATERIALS OF CONSTRUCTION - MOTOR The submersible motor enclosure including frame, end brackets, flanges and cap assembly shall be constructed of close-grained cast iron, ASTM A-48, Class 30 or better. The top end bracket shall be fitted with a lifting bail and shall be capable of supporting four (4) times the combined weight of the pump and motor. All mating fits on the motor frame shall have rabbet joints with large overlap as well as o-ring seals to provide for a watertight seal. O-rings shall be Buna-N. The one-piece motor/pump shaft shall be constructed of stainless steel and shall be precision machined to ensure proper tolerances at all contact points. The entire rotating assembly shall be designed with sufficient rigidity and balanced for a minimal shaft deflection at extreme pump operating conditions. The motor rotor shall be of squirrel-cage design and constructed of die cast aluminum, fabricated copper or their respective alloys. The rotor shall have an interference fit to the shaft and the rotating assembly shall be dynamically balanced to ISO 1940, G.6.3. Balance weights, if required, shall be secured to the rotor resistance ring or rotor fins. Machine screws or nuts and bolts used to attach balance weights are specifically prohibited. 25

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS 2.1.6 ELECTRICAL The submersible motors shall successfully operate under power supply variations per NEMA MG1-14.30. Motors shall be NEMA Design B with torque and starting current in accordance with NEMA MG1-12. The submersible motors shall be of an air-filled, high efficiency design and shall be rated for continuous full load operation. The motor construction shall be of explosion proof, TENV-TEXP design and capable of being certified for use in Class I, Division 1, Groups C & D hazardous locations by Factory Mutual Research Corp. (F.M.). Motors shall be capable of withstanding up to 15 starts per hour and shall have a minimum 1.15 Service Factor at 40 C ambient. Stators shall be solid copper wound and shall be press fitted into the stator housing for true positive alignment and efficient heat transfer. The motor insulation system shall be Class F minimum, utilizing materials and insulation systems evaluated and certified with IEEE 117 classification tests. The entire wound stator assembly shall receive a minimum of two (2) coats of insulating varnish utilizing a dip and bake process. Three (3) normally closed, automatic reset thermostats connected in series shall be embedded in adjoining phases of the stator windings. The thermostats shall be connected to safely shut down the motor upon opening. 2.1.7 MATERIALS OF CONSTRUCTION - PUMP The pump casing, impeller, motor housing and stationary base elbow shall be manufactured of closegrained cast iron, ASTM A48, Class 30. The pump casing shall be of the semi-concentric volute design, of one piece construction, having centerline discharge to minimize clogging or flow interference, and to provide the proper weight distribution for use with the Easy-Lift disconnect system. The impeller shall be of a multi or single-vaned, fully shrouded enclosed design and shall have large passages to provide smooth flow transition and unimpeded passage of large spherical solids. All impellers shall be statically and dynamically balanced to ISO 1940, G.6.3. Solids passing capability of the impeller offered shall be clearly indicated on the manufacturer s performance curve. The volute suction shall be fitted with a replaceable hard polyurethane, radial/axial clearance, corrosion and abrasion resistant wearing ring system a minimum of 3/8 inch thick, securely fastened and replaceable. (Not applicable to Models 4153 and 4153L.) Wearing Rings- Optional: A replaceable 400 Series stainless steel wear ring shall be provided on the impeller inlet to reduce the effects of abrasive wear and provide the ability to renew the running clearance. The volute suction shall contain a replaceable 400 Series stainless steel wear ring to match the impeller wear ring. All external casting surfaces of the pump/motor coming into contact with the pumped liquid shall have a surface cleanliness equal to that of a SSPC-SP6 process prior to being factory protected by one (1) coat of an environmentally-safe machinery enamel coating with a high solids content. All external hardware including nameplates on the pump/motor shall be 300 Series stainless steel. 26

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS 2.2 PREFABRICATED FIBERGLASS BASIN ASSEMBLY The pump basin shall be of the laminated fiberglass type constructed of commercial grade resin and glass fiber reinforcing material. The reinforcing material shall have a coupling agent that will provide a secure bond between the glass reinforcement and the resin. The laminate shall consist of an inner surface, an interior layer and an exterior layer of laminate body. The inner surface shall have a smooth finish and shall be free of cracks and crazing. A minimum 0.100-inch of the laminate next to the inner surface shall be reinforced with not less than 20 percent nor more than 30 percent by weight of non-continuous glass strands having fiber lengths from 0.5 to 2.0 inches. The exterior layer of body of laminate shall be of construction suitable for the service intended and shall contain sufficient glass by weight to provide the aggregate strength necessary to meet the tensile and flexural requirements. The exterior surface shall have no sharp projections and shall contain adequate resin to prevent exposure of the fibers. The basin wall shall be designed to withstand collapse based on the assumption that saturated soil exerts hydrostatic pressure of 120 pounds per cubic foot. The basin wall laminate shall be constructed to withstand a minimum of two (2) times the actual imposed loading on any depth of basin. The basin shall be reinforced with a fiberglass bottom plate extending beyond the basin diameter. The bottom plate shall serve as an anti-flotation ring and shall be suitable for mounting to a concrete pad. Mounting studs shall be provided on the interior floor surface for factory assembly and mounting of the pump guiderail base elbows. (Optional: Valve Box) The fiberglass basin assembly shall include an attached exterior valve box as shown on the drawings. The valve box shall be of the same laminated fiberglass construction as the main basin. The valve box shall be integrally attached to the main basin at the factory utilizing reinforced fiberglass assembly. The valve box shall be furnished with a drain and integral check valve assembly to provide drainage from the valve box to the main basin. Systems with separate valve box modules requiring field assembly or external field attachment are not acceptable. (Cover Options) Solid Fiberglass - for basins up to 72 diameter without optional Valve Box : The basin shall be supplied with a solid fiberglass cover. Hinged fiberglass - for basins up to 48 diameter without optional Valve Box : The basin shall be supplied with a hinged fiberglass cover. Hinged Steel for all basin sizes, including those with optional Valve Box: The basin (and Valve Box) shall be supplied with a hinged steel cover. Hinged Aluminum for all basin sizes, including those with optional Valve Box: The basin (and Valve Box) shall be supplied with a hinged aluminum cover. 2.2.1 SLIDING GUIDE BRACKET & RAIL SYSTEM The pump slide bracket shall be of heavy-duty construction and shall be of a molded instant set polymer material. The slide bracket shall be sparkless design and shall be corrosion, abrasion and chemically resistant. The base discharge elbow shall meet the slide bracket by method of a three point, wedged engagement that is uniquely designed to match the volute flange to the stationary elbow to eliminate head losses. The discharge elbow shall be manufactured of close-grained cast iron, ASTM A48, Class 30, and shall be designed to carry the full weight of the pump, motor and discharge piping. Guide rail mounting brackets and guiderails shall be manufactured of stainless steel and shall be factory installed in the basin system. 27

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS 2.2.2 PIPING & VALVES The prefabricated fiberglass basin system shall be furnished complete with discharge pipes, fittings, check valves and shut-off valves. Discharge pipes shall be manufactured of (PVC, Ductile Iron, Galvanized Steel, Stainless Steel). The check valves shall be CLOW/Kennedy/M&H Swing Check type, cast iron ANSI Class 125 flanged, full-port type with external lever and weight, and shall conform to AWWA C-508 standards. The shut-off valves shall be ¼ turn eccentric plug type, cast iron ANSI Class 125 flanged, with 100% port area, and shall conform to AWWA C-504 standards. Valves that are not of the 100% port area design are not acceptable for the intended service. 2.2.3 ELECTRICAL & CONTROL ACCESSORIES The prefabricated fiberglass basin system shall be furnished with a NEMA 4X Junction Box and fittings for connection of the pump power/control and level control wiring. Suspension type tilt level control switches, stainless steel mounting bracket and a 2 electrical conduit fitting shall be included. All electrical and control accessories shall be shipped loose for field installation. 2.3 PUMP CONTROL PANEL The package lift station shall be furnished with an automatic pump control system housed in a NEMA (3R painted steel, 4X fiberglass, 4X stainless steel) enclosure. The control system shall include the following primary features: Main disconnect Motor starter/protector for each pump Start/run capacitor(s) - for single phase systems only Top mounted flashing alarm light Audible alarm with silence switch Pump run indicator INTELLIPUMP (duplex systems only) microprocessor based pump controller, including automatic alternation, pump run LED s, float activation LED s, alarm code blinker, pump fail LED and control power LED. To provide float loss indication and to maintain control even with the loss of up to three floats. Hand-Off-Automatic selector switch for each pump 24VAC float circuit Pump seal failure alarm indication Motor thermal overload circuit Aux. Contact for high-level alarm Terminals for all field connections U.L. 508 Listing 2.4 TESTING (Control Panel Options) Elapsed Time Meter for each pump Anti-condensation heater with thermostat Lightning Suppressor Pedestal Mount (painted steel) Intrinsically safe (UL 913) Dead Front with interior swing door (w/main fused disconnect) Additional Aux. Alarm Dry contact(s) Phase Monitor Each completed and assembled motor shall receive a routine factory test. Optional: The pumps shall be performance tested at the manufacturer s plant prior to shipment. The performance shall be within the limits set forth by the Hydraulic Institute. Certified curves shall be submitted to the design engineer upon request. 28

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS As a minimum, each finished pump shall be performance tested for total dynamic head, capacity, efficiency and power requirements at six (6) operating points plus shut-off head for the selected impeller diameter, of which, the design capacity operating point shall be included. After installation, a Field Test shall be performed by the installing contractor on each completed Submersible Pump and easy lift assembly under the supervision of the manufacture s authorized representative. The test shall demonstrate to the satisfaction of the Owner that the equipment meets all specified performance criteria, is properly installed and anchored, and operates smoothly without exceeding the full load amperage rating of the motor or excessive motor heating. 2.5 WARRANTY The Pump Manufacturer shall Warrant to the Owner the EASY-LIFT Package Lift Station components against defects in material and workmanship for a period of 1 year from date of acceptance or 18 months from date of shipment, whichever is sooner. This warranty shall cover the cost of labor and materials, excluding removal and reinstallation costs, required to correct any warrantable defect, FOB, Manufacturer s authorized Warranty Service Center. 2.6 FIELD SERVICE Days of Field Service shall be provided by an authorized, factory trained representative of the Pump Manufacturer. Services shall include, but not necessarily be limited to, inspection of the completed installation to ensure that it has been performed in accordance with the manufacturer s instructions and recommendations, supervision of all field-testing and activation of the Manufacturer s Prescribed Warranty. The Contractor shall be responsible for coordinating the required field services with the Pump Manufacturer. END OF SECTION 29

EASY-LIFT PACKAGE LIFT STATIONS SUGGESTED SPECIFICATIONS TABLE 1 - PERFORMANCE DATA Pump Item Number... System Type (Simplex or Duplex)... Pump Primary Rated Condition Capacity (Flow)... GPM Head... Feet (TDH) Minimum Efficiency... % (Alternate) Condition "B" Capacity (Flow)... GPM Head Feet (TDH) Minimum Efficiency... % (Alternate) Condition "C" Capacity (Flow)... GPM Head Feet (TDH) Minimum Efficiency... % Shutoff Head... Feet Minimum motor horsepower required... HP Electrical Characteristics Required... Volt Hz. Ph. Maximum pump operating speed... RPM Minimum Suction Size... inches Minimum Discharge Size... inches Minimum Solid Size required to pass through Impeller... inches diameter Liquid to be Pumped... Pumping Temperature... F Specific Gravity @ Pumping Temperature... 30

BASIN SIZING MINIMUM DIAMETER REQUIREMENTS Recommended Minimum Basin PUMP MODEL Dia. Simplex Duplex 3062 36" 48" 4072 4072.5 4073 36" 60" 4083 4092.5 4103S 48" 60" 4103L 4103SV 4113SV 4123SV 4133SV 4123 48" 48" 60" 60" 4153 4153L 48" 72" 31

SIMPLEX - SUBMERSIBLE SOLIDS-HANDLING Inlet Discharge Vent Electrical Fitting Junction Box Level Control Bracket Access Cover Lifting Chain Power & Control Cables Lifting Lug Elbow Link Seal Fiberglass Basin Inlet Fitting Level Control Switches Anti-Flotation Flange Plug Valve Check Valve Companion Flange Discharge Pipe Guiderail(s) Guiderail Base Elbow OTY DESCRIPTION OTY DESCRIPTION 1 Model Submersible Solids-Handling Pump* 1 Guiderail Base Elbow (cast iron) Rated Capacity: GPM at Feet TDH 1 Upper Guiderail Mounting Bracket (SS) RPM, HP, HZ, VOLTS 1 Guiderail(s) (SS) (Single "V" bar for 3" pumps / Dual guide 1 Fiberglass Basin w! Lifting Lugs (4) and Anti-Flotation Flange pipes for 4" pumps) 1 Basin Cover (3) 1 Pump Lifting Chain* (SS) 1 2" Electrical Fitting* 1 Discharge Pipe: PVC Dl SS Galv. StI. 1 Duplex NEMA 4X Junction Box and fittings* 1 Check Valve (cast iron) 1 Level Control Bracket (SS)* 1 Plug Valve (cast iron) 3 Level Control Switch* 1 Link Seal 1 Inlet Fitting (Adapt-A-Flex)* Size: 4" 6" 1 Vent (Mushroom Type)* Notes and Clarifications: 1- Fill in all blanks and mark desired Inlet Fitting size. 2- Items marked with asterisk (*) are shipped loose for field installation. 3- Hinged type cover illustrated. Solid fiberglass type optional on basins 72" diameter and smaller. 32

SIMPLEX - SUBMERSIBLE SOLIDS-HANDLING with VALVE BOX Inlet Discharge Vent Access Cover Lifting Lug Electrical Fitting Junction Box Level Control Bracket Lifting Chain Power & Control Cables Elbow Link Seal Valve Box Fiberglass Basin Drain & Check Valve Plug Valve Check Valve Inlet Fitting Level Control Switches Companion Flange Discharge Pipe Guiderail(s) Anti-Flotation Flange Guiderail Base Elbow OTY DESCRIPTION OTY DESCRIPTION 1 Model Submersible Solids-Handling Pump* 1 Guiderail Base Elbow (cast iron) Rated Capacity: GPM at Feet TDH 1 Upper Guiderail Mounting Bracket (SS) RPM, HP, HZ, VOLTS 1 Guiderail(s) (SS) (Single "V" bar for 3" pumps / Dual guide 1 Fiberglass Basin w! "D" type attached Valve Box; including pipes for 4" pumps) Lifting Lugs (4) and Anti-Flotation Flange 1 Pump Lifting Chain* (SS) 1 Basin Cover (3) 1 Discharge Pipe: PVC Dl SS Galv. StI. 1 2" Electrical Fitting* 1 Check Valve (cast iron) 1 NEMA 4X Junction Box and fittings* 1 Plug Valve (cast iron) 1 Level Control Bracket (SS)* 2 Link Seal 3 Level Control Switch* 1 Vent (Mushroom Type)* 1 Inlet Fitting (Adapt-A-Flex)* Size: 4" 6" 1 Valve Box Drain & Check Valve Assembly Notes and Clarifications: 1- Fill in all blanks and mark desired Inlet Fitting size. 2- Items marked with asterisk (*) are shipped loose for field installation. 3- Hinged type cover illustrated. Solid fiberglass type optional on basins 72" diameter and smaller. 33

DUPLEX - SUBMERSIBLE SOLIDS-HANDLING Inlet Discharge Vent Electrical Fitting Junction Box Level Control Bracket Access Cover Lifting Chain Power & Control Cables Lifting Lug Tee Elbow Link Seal Fiberglass Basin Inlet Fitting Level Control Switches Anti-Flotation Flange Plug Valve Check Valve Companion Flange Discharge Pipe Guiderail(s) Guiderail Base Elbow OTY DESCRIPTION OTY DESCRIPTION 2 Model Submersible Solids-Handling Pump* 2 Guiderail Base Elbow (cast iron) Rated Capacity: GPM at Feet TDH 2 Upper Guiderail Mounting Bracket (SS) RPM, HP, HZ, VOLTS 2 Guiderail(s) (SS) (Single "V" bar for 3" pumps / Dual guide 1 Fiberglass Basin w! Lifting Lugs (4) and Anti-Flotation Flange pipes for 4" pumps) 1 Basin Cover (3) 2 Pump Lifting Chain* (SS) 1 2" Electrical Fitting* 2 Discharge Pipe: PVC Dl SS Galv. StI. 1 NEMA 4X Junction Box and fittings* 2 Check Valve (cast iron) 1 Level Control Bracket (SS)* 2 Plug Valve (cast iron) 4 Level Control Switch* 1 Link Seal 1 Inlet Fitting (Adapt-A-Flex)* Size: 4" 6" 1 Vent (Mushroom Type)* Notes and Clarifications: 1- Fill in all blanks and mark desired Inlet Fitting size. 2- Items marked with asterisk (*) are shipped loose for field installation. 3- Hinged type cover illustrated. Solid fiberglass type optional on basins 72" diameter and smaller. 34

DUPLEX - SUBMERSIBLE SOLIDS-HANDLING with VALVE BOX Inlet Discharge Vent Access Cover Lifting Lug Electrical Fitting Junction Box Level Control Bracket Lifting Chain Power & Control Cables Elbow Link Seal Valve Box Fiberglass Basin Drain & Check Valve Plug Valve Check Valve Inlet Fitting Level Control Switches Companion Flange Discharge Pipe Guiderail(s) Anti-Flotation Flange Guiderail Base Elbow OTY DESCRIPTION OTY DESCRIPTION 2 Model Submersible Solids-Handling Pump* 2 Guiderail Base Elbow (cast iron) Rated Capacity: GPM at Feet TDH 2 Upper Guiderail Mounting Bracket (SS) RPM, HP, HZ, VOLTS 2 Guiderail(s) (SS) (Single "V" bar for 3" pumps / Dual guide 1 Fiberglass Basin w! "D" type attached Valve Box; including pipes for 4" pumps) Lifting Lugs (4) and Anti-Flotation Flange 2 Pump Lifting Chain* (SS) 1 Basin Cover (3) 2 Discharge Pipe: PVC Dl SS Galv. StI. 1 2" Electrical Fitting* 2 Check Valve (cast iron) 1 NEMA 4X Junction Box and fittings* 2 Plug Valve (cast iron) 1 Level Control Bracket (SS)* 3 Link Seal 4 Level Control Switch* 1 Vent (Mushroom Type)* 1 Inlet Fitting (Adapt-A-Flex)* Size: 4" 6" 1 Valve Box Drain & Check Valve Assembly Notes and Clarifications: 1- Fill in all blanks and mark desired Inlet Fitting size. 2- Items marked with asterisk (*) are shipped loose for field installation. 3- Hinged type cover illustrated. Solid fiberglass type optional on basins 72" diameter and smaller. 35

MOTOR DATA Three Phase - Typical Performance Data Totally enclosed, non-ventilated, hermetically sealed submersible type. Features include 416 stainless steel shaft, tandem mechanical seals (one inside an oil chamber and one outside); automatic reset N.C. series connected thermal overload protection, two moisture sensing probes, prelubricated shaft bearings and class F insulation. *Efficiencies include all mechanical losses including mechanical seals. H.P. Full Load RPM Frame Size Full Load Nominal Eff %@ * 3/4 Load 1/2 Load Nominal Power Factor % @ Full Load 3/4 Load 1/2 Load Amps @ 460V Full Load 1732 140 55.7 50.1 41.1 75.6 69.3 61.2 1.1 6.1 L 1.5 313 368 #16 0.57 0.5 1150 140 61.7 46.7 48.1 65.0 58.0 49.0 1.2 5.2 K 2.3 254 310 #16 0.57 864 140 58.7 53.2 44.1 51.0 44.0 36.0 1.6 5.6 K 3.0 265 320 #16 0.57 1733 140 63.9 58.9 50.3 76.8 70.4 61.8 1.4 8.5 K 2.3 302 356 #16 0.57 0.75 1151 140 67.2 62.9 54.9 65.0 58.0 48.0 1.6 7.3 J 3.4 234 295 #16 0.57 Not Applicable - 862 140 64.1 59.3 50.7 52.0 45.0 36.0 2.1 7.6 K 4.5 239 295 #16 0.57 Single Cable Used 1739 140 68.3 63.7 55.4 75.6 68.8 59.5 1.8 11.5 L 3.0 308 371 #16 0.57 1 1152 140 70.8 67.0 59.5 65.0 57.0 47.0 2.0 9.4 J 4.5 229 293 #16 0.57 863 140 68.4 64.2 56.2 53.0 45.0 36.0 2.6 9.7 J 6.0 229 288 #16 0.57 1737 140 72.3 68.5 61.1 76.7 69.8 58.9 2.5 15.4 K 4.5 268 332 #16 0.57 1.5 1154 140 73.9 70.6 63.7 64.0 56.0 45.0 3.0 13.9 J 6.8 220 290 #12 0.65 #18 0.45 861 140 72.1 68.6 61.3 54.0 45.0 36.0 3.6 13.8 J 9.0 221 278 #12 0.65 #18 0.45 1744 140 74.9 72.7 66.6 75.7 67.4 55.2 3.3 19.8 J 6.0 267 319 #12 0.65 #18 0.45 2 1160 140 76.2 72.8 65.9 60.0 52.0 41.0 4.1 20.2 K 9.0 241 323 #12 0.65 #18 0.45 862 140 74.8 71.6 64.7 52.0 44.0 34.0 4.8 18.5 J 12.0 226 285 #12 0.65 #18 0.45 1733 140 77.7 76.2 71.0 79.9 73.1 61.6 4.5 26.8 J 9.0 199 288 #12 0.65 #18 0.45 3 1153 140 79.0 76.8 71.2 65.0 56.0 44.0 5.5 25.7 H 13.5 205 277 #12 0.65 #18 0.45 874 210 83.9 83.1 79.7 62.2 53.5 41.4 5.4 31.6 K 18.0 203 360 #12 0.65 #18 0.45 1733 140 80.6 79.4 74.6 81.1 74.7 63.6 7.1 45.1 J 15.0 244 301 #12 0.65 #18 0.45 5 1147 180 79.5 81.2 80.0 67.0 58.0 45.4 8.8 35.2 G 22.9 161 228 #12 0.65 #14 0.59 869 210 83.4 83.0 79.9 59.3 50.6 38.7 9.5 46.3 J 30.2 193 318 #12 0.65 #14 0.59 1736 180 85.6 87.2 86.9 84.3 78.8 68.0 9.7 63.3 H 22.7 225 304 #8 0.99 #14 0.59 7.5 1133 180 79.8 81.9 81.2 73.3 64.6 50.9 12.0 51.1 F 34.8 149 224 #8 0.99 #14 0.59 858 210 82.8 83.8 82.2 65.4 56.9 44.6 13.0 57.2 G 45.9 160 260 #12 0.65 #14 0.59 1735 180 85.3 86.8 86.1 80.6 73.3 60.4 13.6 83.7 H 30.3 229 302 #8 0.99 #14 0.59 10 1156 210 84.0 85.8 85.4 70.7 63.3 51.0 15.8 75.3 G 45.4 212 237 #8 0.99 #14 0.59 878 250 86.2 86.6 85.0 68.1 60.0 47.9 15.9 72.5 G 59.8 177 244 #4 1.27 #14 0.59 1747 210 86.7 88.6 88.6 81.4 76.4 66.1 19.9 104.8 F 45.1 192 239 #8 0.99 #14 0.59 15 1158 250 85.8 87.5 87.2 77.6 71.1 58.9 21.1 89.1 E 68.0 150 210 #4 1.27 #14 0.59 870 250 85.6 87.4 87.0 72.3 66.3 54.6 22.7 85.2 E 90.5 137 191 #4 1.27 #14 0.59 1741 210 86.4 88.9 89.6 82.4 78.6 69.6 26.3 131.1 F 60.3 183 223 #4 1.27 #14 0.59 20 1164 250 87.2 89.0 89.0 80.8 75.8 65.0 26.6 124.6 E 90.3 160 220 #4 1.27 #14 0.59 863 250 85.1 87.0 86.8 73.9 67.0 54.9 29.8 145.5 G 121.7 137 248 #4 1.27 #14 0.59 25 1761 250 88.8 90.3 90.2 83.8 80.6 72.2 31.4 172.1 F 74.6 192 236 #4 1.27 #14 0.59 1162 250 87.7 89.6 89.8 80.8 76.1 65.8 33.0 152.8 E 113.0 162 217 #4 1.27 #14 0.59 30 1763 250 89.5 90.8 90.8 84.1 80.9 72.7 37.3 217.2 G 89.4 206 248 #4 1.27 #14 0.59 40 1757 250 89.2 91.1 91.5 84.7 82.2 75.0 49.6 273.0 F 119.6 197 234 #2 1.48 #14 0.59 Locked Rotor Full Load Torque (Ft- Lbs) %Full Load Torque Locked Rotor Power Cable Typical motor data for Submersible 3 phase, 60 hertz, Nema design B, 40 C ambient, normal torque motors. Amperes shown for 460 volt connection. If other connections are available, the amperes will vary inversely with rated voltage. All values nominal. All motors have 1.15 S.F. at 40 C ambient temperature. ** Above cable data for standard motors only, with cable length of 25'. Data applicable through lengths of 100'. 140 frame motors with #16 AWG cord utilize single cable, (8) conductor, with power and control leads. KVA Code Letter AWG Size O.D. ** (in.) Control Cable AWG Size O.D. ** (in.) Single Phase - Typical Performance Data Totally enclosed, non-ventilated, hermetically sealed submersible type. Features include 416 stainless steel shaft, tandem mechanical seals (one inside an oil chamber and one outside); automatic reset N.C. series connected thermal overload protection, two moisture sensing probes, prelubricated shaft bearings class F insulation. *Efficiencies include all mechanical losses including mechanical seals. H.P. Full Load RPM Frame Size Full Load Nominal Eff %@ * 3/4 Load 1/2 Load Nominal Power Factor % @ Full Load 3/4 Load 1/2 Load Amps @ 230V/1/60 Full Load 0.5 1735 REFER TO FACTORY 1735 0.75 1146 140 55.1 50.1 41.5 59.0 52.0 44.0 7.4 27.1 K 3.4 353 239 #10 0.8 #18 0.45 1 1.5 2 3 1735 1729 1730 1734 140 140 140 140 62.1 66.8 69.8 76.7 57.8 63.7 67.2 72.7 49.7 56.7 60.7 64.4 76.0 79.0 79.0 100.0 70.0 73.0 73.0 100.0 61.0 63.0 63.0 100.0 6.9 9.2 11.7 12.7 31.3 38.6 48.4 58.8 J G F E 3.0 4.5 6.0 9.0 289 235 217 227 251 223 220 229 #10 #10 #10 #10 0.8 0.8 0.8 0.8 #18 #18 #18 #18 0.45 0.45 0.45 0.45 1149 1149 1152 1146 140 140 140 140 58.5 61.0 73.5 75.0 53.7 56.6 68.8 71.7 45.3 48.3 59.8 64.0 59.0 59.0 95.0 88.0 52.0 51.0 94.0 85.0 43.0 42.0 91.0 78.0 9.4 13.6 9.3 14.7 35.4 43.8 43.1 53.5 K H E D 4.5 6.8 9.0 13.5 335 254 270 197 242 233 230 205 #10 #10 #10 #10 0.8 0.8 0.8 0.8 #18 #18 #18 #18 0.45 0.45 0.45 0.45 5 1725 140 79.0 77.0 70.8 97.0 97.0 96.0 21.1 83.7 C 15.0 147 201 #10 0.8 #18 0.45 Locked Rotor KVA Code Letter Full Load Torque (Ft-Lbs) %Full Load Torque Power Cable Control Cable Locked Rotor Breakdown Breakdown AWG Size O.D. ** (in.) AWG Size O.D. ** (in.) Typical motor data for Submersible 1 phase, 60 hertz, Nema design B, 40 C ambient, normal torque motors. Amperes shown for 230 volt connection. If other connections are available, the amperes will vary inversely with rated voltage. All values nominal. All motors have 1.15 S.F. at 40 C ambient temperature. ** Above cable data for standard motors only, with cable length of 25'. Data applicable through lengths of 100'. 36

INTELLIPUMP MICROPROCESSOR BASED PUMP CONTROLLER Float Logic Operation If one or more floats are left out of the normal float sequence, the Intellipump will compensate for the inoperable float, and produce an alarm code indicating which float is not operating. The code is indicated by an LED on the control board. The number of flashes followed by a pause will be your code. This code is repeated until the inoperable float or floats are shown to be good by returning to a normal float operation sequence. The alarm codes are noted on the controller board front label, and are as follows: 1 = Float #1 2 = Float #2 3 = Float #3 4 = Float #1 & 2 5 = Float #1 & 3 6 = Float #2 & 3 7 = Float #1 &2&3 If only the High Level float is made, both pumps will be called for, the high level alarm light will flash, and the buzzer will sound. Both pumps will enter a timer sequence, which prohibits short cycling of the pump motors. If all floats are shown to be good, the controller will return back to normal operation. Panel Operation For normal panel operation, the Overload connection must be set to ON or must be bypassed with a wire jumper. The Pump Thermal connections must also be connected or bypassed with a wire jumper. The HOA switches (front panel or board mounted) must be set to the Auto position for the float logic to function. Normal Float Operation If the Off and Lead floats are made, a single pump will be called for. If this condition is repeated, the controller will cycle one pump at a time, alternating between the two pumps. If the Off, Lead, and Lag floats are made, both pumps will be called for. If the Off, Lead, Lag, and High floats are made, both pumps will be called for, and the high level alarm light will flash, and the buzzer will sound. To silence the buzzer, press the silence switch, which is located on the front of the panel or the controller. Pump Fail Operation The Intellipump can be configured to signal a Pump Fail condition. A Fail condition can occur if the overload, pump thermal or auxiliary connection opens. If a pump is called for, but a Pump Fail condition occurs, the controller will automatically call for the other pump. The Pump Fail Alarm is a time delayed operation; this is done to allow the controller to verify pump operation via a check valve limit switch or auxiliary starter contact. A Pump Fail condition is indicated by an LED on the controller, an optional front panel light, and also activates a set of Normally Open contacts. Seal Fail Operation The seal fail connections on the Intellipump monitors the resistance of the pump motor Seal Fail probe. If the resistance of the probe drops below a preset point, a Seal Fail condition occurs. This is indicated by an LED on the control board, an optional light on the front of the enclosure. A Seal Fail condition will also activate a set of Normally Open contacts that can be used in conjunction with additional control equipment. 37

INTELLIPUMP MICROPROCESSOR BASED PUMP CONTROLLER FEATURES OPTIONS Utilizes Microprocessor Technology Alternates pumps Provides start delays to eliminate premature start-ups due to turbulence Detects High Level Conditions Generates Alarms Self-Diagnostic operation recognizes inoperable float switches and pumps then compensates for them to ensure continued reliable operation Fault code message informs user of problem for ease of trouble-shooting system Optional remote HOAs and silence switches Optional front panel indicator lights for pump run, pump fail, and seal fail Separate Dry Contacts for High Level Alarm, individual Pump Fails and each Seal Fail condition for use with additional monitoring and control equipment Available Pump Fail circuitry to allow verification of pump operation with the use of a check valve limit switch or auxiliary starter contact Available with selectable pump sequence Optional 24 VAC input version available Built-in dual Seal Fail Module with isolated UL Class 2 AC sensing voltage Seal Fails features high noise rejection, including induced voltage on sense lines Seal Fail is suitable for use on single probe, dual probe, and dual probe with resistor configurations Built-in 115W High Level Alarm light flasher On-board Float status indicators Low voltage 24VAC float control voltage Separate fuses for each contactor circuit and alarm circuit High Power UL B300 rated pilot circuits capable of 3600VA inrush and a sealed rating of 360VA Integrated transient protection and on-board pilot contact protection circuits Flexible 115VAC input voltage with on-board power supplies and control transformer High quality unplugging terminal blocks ease wiring and maintenance 38

SIMPLEX CONTROL CIRCUIT SINGLE PHASE - CAPACITOR START CAUTION ENCLOSURE TO BE CONNECTED TO A GOOD GROUND MAIN DISCONNECT INCOMING POWER BY OTHERS L1 L2 MSP1 M1 T1 T2 T3 CAPACITOR, POTENTIAL RELAY AND MOTOR CONNECTION BOARD 1 CRS 2 R B W START COMMON MAIN PUMP 1 FUSE 1-1A 5 FUSE 2-1A 208 VAC CAUTION Nonmetallic enclosure does not provide grounding between conduit connections. Use grounding bushings and jumper wires FS-3 = ALARM FLOAT FS-2=ONFLOAT FS-1 = OFF FLOAT BUZZER HIGH LEVEL ALARM R WHITE 24 25 26 WHITE 27 GRND J11 4A 125V FU1 POWER G HAND 200MA 250V FU2 HIGH LEVEL R PUMP RUN G H1 X1 X1 AUTO H3 120 VAC 11 12 SEAL FAIL A N H2 13 TORQUE TO 4.5"lb 14 H4 X2 100VA SEAL FAIL OPTION JUMPER REMOVE JUMPER FOR FIELD MOTOR THERMAL CONNECTIONS 20 MSP 21 13 14 SILENCE 28 29 TORQUE TO 4.5"lb 1 OFF 2 3 4 5 6 OPT. ALARM CONT. 22 23 WHITE A2 M1 A1 WHITE FS-3 BLACK WHITE FS-2 BLACK WHITE FS-1 BLACK 5 15 = TERMINAL NUMBER = WIRE NUMBER DASHED LINES INDICATE EXTERNALLY LOCATED ITEMS Typical Information Only - Not Certified Please refer to factory for certified diagrams 39