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HomeMy WebLinkAboutSWP2703693_1 CST' Page 16 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A 4.4 Power Carle Connections IMPROPER POWER CABLE CONNECTIONS CAN CAUSE EXCESSIVE HEAT AND SUBSEQUENT EQUIPMENT FAILURE. WARNING to the cable lugs to the torque identified on the label affixed to the door of the unit. POWER CONDUCTORS MAY HAVE VOLTAGE PRESENT THAT CAN 4.5 Wiring CAUSE SEVERE PERSONAL INJURY OR DEATH. DE-ENERGIZE ALL g POWER OR CONTROL CIRCUIT CONDUCTORS TO BE CONNECTED TO THE ATS EQUIPMENT BEFORE BEGINNING TO WORK WITH THE ® WARNING CONDUCTORS AND!OR TERMINATING THEM TO THE EQUIPMENT. POWER CONDUCTORS AND CONTROL WIRING MAY HAVE VOLT- AGE PRESENT THAT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. DEENERGIZE ALL POWER OR CONTROL CIRCUIT CON- ® CAUTION DUCTORS BEFORE BEGINNING TO PERFORM ANY WIRING ACTIV- ITY TO OR WITHIN THE ATS EQUIPMENT. USE OF CABLE LUGS NOT DESIGNED FOR THE ATS MAY CAUSE HEATING PROBLEMS. Power sources, load conductors, and control wiring should be connected to locations as indicated in the Customer Wiring Book- let supplied with the ATS equipment. ® CAUTION ® CAUTION TO HELP PREVENT COMPONENT DAMAGE OR FUTURE MALFUNC- TIONS,USE EXTREME CARE TO KEEP CONTAMINANTS OUT OF ENSURE THE ATS VOLTAGE IS SET CORRECTLY. IT SHOULD BE THE ATS EQUIPMENT WHEN MAKING POWER CABLE CONNEC- THE SAME AS THE SOURCE 1 AND SOURCE 2 LINE VOLTAGES. TIONS. OPERATING THE EQUIPMENT ON IMPROPER VOLTAGE CAN -- CAUSE EQUIPMENT DAMAGE. ---- Once the ATS equipment has been installed and wired, perform CAUTION the initial mechanical and electrical procedures as outlined in Sec- RUN THE POWER CABLE THROUGH THE GUTTER SPACE PROVIDED tion 6 to verify that the equipment is installed and operating prop TO THE RIGHT OR LEFT OF POWER PANEL. erly. Test all power cables prior to connection to the unit to ensure 4.6 Engine Start Connection • that the conductors or cable insulation have not been damaged The engine control contact connections are located on the logic while being pulled into position. panel of the ATS. Connect the engine start wires to the terminals Power cables are to be connected to solderless screw type lugs marked 13 and 14 on J-5 connector on the ATC-300+ Controller located on the ATS switching devices. Refer to the separate Cus- (see Figure 12). A contact closes between these terminal when tomer Wiring Booklet supplied with the ATS equipment for power an engine start signal is provided by the ATS logic. The wiring termination. Verify that the lugs supplied will accommodate the diagram provides additional engine start connection information. power cables being used. Also verify that the cables comply with Use the proper wire size as listed by the generator set (Genset) local electrical codes. Standard ATS equipment, as supplied from manufacturer. the factory, will accommodate the wire sizes shown in Table 4. Carefully strip the insulation from the power cables to avoid nick- ing or ringing of the conductor strands. Prepare the stripped con- NOTICE ductor termination end by cleaning it with a wire brush. If aluminum conductors are used, apply an appropriate joint com- PRIOR TO MAKING THE ENGINE START CONNECTION TO THE pound to the clean conductor surface area. SWITCH, SET THE ENGINE GENERATOR CONTROLS SELECTOR SWITCH IN THE OFF POSITION TO PREVENT AN UNWANTED ENGINE START. CONTROL WIRING,SUCH AS THE ENGINE START WIRES, MUST BE RUN IN A SEPARATE CONDUIT FROM THE AWARNING POWER CABLES. Fable 4. Transfer Switch Equipment Wire Sizes TRANSFER SWITCH AMPERE RATING WIRE SIZE RANGES NUMBER OF CABLES PER PHASE TERMINAL TEMPERATURE RATING°C 1°FP 100 #14 210 1 75(157) 200 k6-250 KCMIL 1 75(167) 320 #4-600 KCMIL or(2)110-250 KCMIL 1 or 2-depending on wire size used 75(167) 400 y4-600 KCMIL or M 110 250 KCMIL 1 or 2-depending on wire size used 75(167) • For more information visit: www.cat.com CI-AEOM-00074-01-E Cff O&M Manual for the ATC-300+, 3-Postion Effective: July 2011 Page 17 Contactor Based Transfer Switch 40-400A O Oil RS485 ON } Termination a SHD �S1-Line J10 3 Corn MODBUS Control S1-Neut J7 2 B Power S2-Line 1 A S2-Neut 7 Tx 6 Rx J3 5 Gnd Programming Phase C 4 5V Port Source 1 Phase B J1 3 Out Phase 2 in 8.0 in. 1 Clk Phase C J8 8 Emergency Source 2 Phase B J2 7 Inhibit Control . Phase Manual 5 Inputs 5 Re-Transfer 4 K4 NO 3 K4 ComCl. Output 2 K3 NO� Relays TERMINALS 13& 14 1 �Com c� Fol -01 J5 J4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 U c?a Z U > Oz z > j ,Z 8 �Nj U Ny () N O N O N Y Y + + N + -j + in + 9 - g? o @ a a a Lu o mcD �o o a a a C7 � J 1� Output Relays Control Inputs 6.5 in. Figure 12. Location of Terminals 13 and 14 on the J-5 Connector of ATC-300+ Controller. • CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 18 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A 4.7 Voltage Selection Adjustments Certain devices, such as the Voltage Selection Panel, sensing relays, and timers, need to be set and/or calibrated prior to plac- ing the ATS equipment in service. Adjustments for logic devices are described in the separate instructional document dedicated to the specific logic being used. Voltage selection adjustments are described in this section. A CAUTION , BE SURE THAT THE CORRECT VOLTAGE IS SELECTED TO MATCH THE SYSTEM VOLTAGE. AN IMPROPER SELECTION AND/OR CON- NECTION COULD RESULT IN EQUIPMENT DAMAGE. ax 4.7.1 Voltage Selection Panels (208, 240, 480, a }H 600 V, - 60 Hz & 220, 380, 415 V, -50 Hz) � The optional voltage selection panel consists of multi-tap trans- formers, contained in a steel case mounted in the enclosure. To change the voltage from the factory default 600 Vac, follow theaw steps detailed below. 3 Step1: Loosen the six screws securing the cover of the Voltage Selection Transformer case. Slide the cover up, thenV away from the case. Step 2: Remove the wires from the primary taps of both trans- formers and installed them on the taps for the desired Figure 13A. Voltage Selection Panel. voltage (Figure 13B). Note that only one wire per trans former is moved since the second wire is the zero refer ANIL - n ence. •4 f i A CAUTION a �S WHEN CHANGING THE VOLTAGE, ONE WIRE MUST BE MOVED ON >.W . THE PRIMARY TAPS OF BOTH TRANSFORMERS. IN RAN F. ems_ Step 3:Reinstall the cover and tighten the four screws �x 4 ` y j y ke Figure 13B. Voltage Selection Panel. 0 For more information visit: www.cat.com CI-AEOM-00074-01-E CAT O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 19 Contactor Based Transfer Switch 40-400A • 4.8 Terminal Block Wire Installation and Removal Proceed with the following steps and associated figures to install or remove terminal block wiring. Step 1: Figure 14 shows two tension clamp terminal blocks. There is a large one and small one, but the operation is the same for both. A small tool, such as a screwdriver, will be pushed into the square hole next to the wire hole and a wire will be inserted into the larger circular hole on the outer edge. x TOOL HOLE WIRE HOLE Figure 16. Wire Inserted in the Wire Hole. Step 4: While holding the wire in place, pull the screwdriver out. The wire will now be held securely in the terminal block. Pull on the wire to insure that it is correctly inserted into a the clamp. w. Figure 14. Tension Clamp Terminal Blocks. Step 2: Begin by inserting a small, flathead screwdriver into the square (tool) hole with the flat surface of the screw- driver against the back wall of the hole. With a little bit of force, push the screwdriver in on a slight angle toward the center of the clamp. Be sure to slide it in until it clicks. You will then see the clamp open in theR �n m a wire hole. Figure 17. Wire Securely Installed in the Terminal Block. i< Q' 6. L Figure 15. Screwdriver Inserted in the Tool Hole. Step 3: Once the screwdriver is in place, obtain a stripped wire • (strip about 1/4 in.) and insert it into the larger circular wire hole. Push the wire in until it can go no further. CI-AEOM-00074-01-E For more information visit: www.cat.com CA" Page 20 Effective: July 2011 O&M Manual for the ATC-300+, 3-Postion Contactor Based Transfer Switch 40-400A Section 5: Operation 5.1 General ..t An ATS provides a power contactor to connect and disconnect . the load to and from the Source 1 and Source 2 power sources �Y = (Section 3.2.1). 5.2 Manual Operation $ ;nrtzc� tecr f F„ 3, A WARNING DO NOT ATTEMPT TO MANUALLY OPERATE THE ATS WITH ; SOURCE 1 OR SOURCE 2 AVAILABLE. A WARNING HIGH VOLTAGES ARE PRESENT IN AND AROUND TRANSFER �,1 , SWITCH EQUIPMENT. BEFORE ATTEMPTING TO MANUALLY TRANSFER, DISCONNECT THE LINE POWER FROM THE EQUIP- ` MENT BEING SERVICED BY OPENING AND LOCKING OUT,IF POSSI- Figure 18. ATS Manual Operating Handle in Use, BLE,THE NEXT HIGHEST DISCONNECT DEVICE. FAILURE TO FOLLOW THIS PROCEDURE COULD CAUSE SEVERE PERSONAL 10. Once the manual operation is complete and automatic opera- INJURY AND/OR DEATH. tion is desired, connect the sources of power. ALWAYS TURN THE SOURCE 1 POWER OFF AND TURN THE 11. Check for 120 Vac at J7-2 to J7-1 if Source 1 is available. SOURCE 2(IF A GENERATOR)CONTROL SELECTOR SWITCH TO THE"OFF" POSITION BEFORE ATTEMPTING A MANUAL TRANS- 12. Check for 120 Vac at J7-4 to J7-3 if Source 2 is available. FER. See the Troubleshooting Guide (Table 3, Section 6 of ATC- 800 Controller Q&M manual if values are above 130 Vac or To manually operate: below 110 Vac. 1. Disconnect all sources of power. 13. Insert the J7 connector into the controller. 2. Disconnect the J7 connector from the ATC-300+ controller. 14. Follow the testing procedure in Section 6 to ensure proper 3. Locate the manual lever on the left side of the contactor. automatic operation. 4. Locate the handle used to manually transfer the switch. 5. Attach the handle to the manual lever (See Figure 18). 6. Rotate the lever down to go to open or trip the unit. 7. Depress the close button located on the operating mecha- nism of the contactor to bring the contactor to the Source-1 position. 8. Rotate the lever down to open or trip the unit. 9. Depress the source select button on the operating mecha- nism of the contactor and depress the close button while keeping the source select button depressed to go to Source-2. • For more information visit: www.cat.com CI-AEOM-00074-01-E CAT' 0&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 21 Contactor Based Transfer Switch 40-400A • 5.3 Automatic Transfer Section 6: Testing and Troubleshooting The operating sequence of an ATS is dictated by the switch's 6.1 Testing standard features and selected options. Operation of an ATS during Source 1 power source failure and Source 1 power source After the ATS equipment is initially installed or during planned restoration will be described here with only standard options outages, the installation should be tested to ensure that all equip- included on the switch. Additional options, as described in Sec- ment operates properly. This attention to detail will help avoid tion 3, can change sequences and timing, depending upon the unexpected malfunctions. Mechanical and/or electrical tests options selected. It is strongly suggested that you become famil- should be performed as described in this section. iar with additional options selected with the particular ATS and their effect on the normal operation of an ATS. The frequency of subsequent testing should be based on recom- mendations of the Genset manufacturer. Use the test pushbut- 5.3.1 Source 1 Power Source Failure ton to check the electrical operation of the switch. Standard Source 1 power source failure is defined as a reduction or loss of voltage. If this occurs, the sequence of operation is as follows. A WARNING 1. Failure of Source 1 is detected by the controller intelligence. HIGH VOLTAGES ASSOCIATED WITH OPERATIONAL TRANSFER 2. When the controller detects a failure, the engine contacts SWITCH EQUIPMENT PRESENT A SHOCK HAZARD THAT CAN close (after delay if programmed) and start the engine driven CAUSE SEVERE PERSONAL INJURY OR DEATH. USE EXTREME CAUTION TO AVOID TOUCHING ELECTRICAL CONNECTIONS generator. WHENEVER INSPECTING OR TESTING THE EQUIPMENT. 3. When the Source 2 voltage reaches its operation rating, the IN ADDITION, IMPROPER OPERATION OF THE GENERATOR SET K2 and K4 relays inside ATC 300 controller operate to start PRESENTS A HAZARD THAT CAN CAUSE SEVERE PERSONAL transfer operation to Source 2. This operating sequence INJURY OR DEATH. OBSERVE ALL SAFETY PRECAUTIONS IN YOUR causes the contactor to open Source 1 and close on GENERATOR SET OPERATIONS AND INSTALLATION MANUALS. Source 2. 4. The load is now transferred to the Source 2 power source. 6.1.1 Mechanical and/or Electrical Testing 5.3.2 Source 1 Power Source Restoration • 1. A return to the Source 1 power source begins when the volt- NOTICE age in all phases of a 3-phase sensing unit, or phase-to- SINCE FEATURE 4(TIME DELAY ENGINE COOL-OFF). AS phase in a single sensing unit, is restored to a preset value. DESCRIBED IN SECTION 3,IS A STANDARD FEATURE,AN ENGINE 2. At the preset voltage, K1 and K3 relays inside ATC 300 con START SIGNAL WILL BE PRESENT FOR A PERIOD OF TIME WHEN THE SWITCH IS FIRST ENERGIZED. THE PERIOD OF TIME IS EQUAL troller operate to start transfer operation to Source 1. TO THE TIMER SETTING. TO AVOID STARTING THE ENGINE DUR- this sequence, the contactor opens Source 2 and ING THIS TIME PERIOD,TURN THE GENERATOR CONTROLS TO 3. During q THE OFF POSITION. closes on Source 1. 4. Simultaneously,the engine cool-down timer initiates the shut Energize the ATS equipment as described in Sections 6.1.2 down of the engine driven generator. through 6.1.6. Insure that all safety precautions are taken and that all WARNINGS and CAUTIONS are observed. 5. Transfer of the load back to the Source 1 power source is 6.1.2 No Voltage Steps now complete. With no voltage available on either power source, proceed as fol- lows. Step 1: The generator engine start controls should be in the OFF position to prevent an undesired start. Step 2: Ensure that the ATS has been set to the proper applied system voltage (See Section 4.7). Step 3: Check all ATS loads to ensure that they are ready to be energized. 6.1.3 Connecting the Power Sources Step 1: Close the Source 1 power source upstream protection device. Step 2:Connect the engine start battery cable. Step 3:With the emergency generator in the OFF position, close the Source 2 power source upstream protective device, . assuming such a device used. CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 22 Effective: July 2011 0&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A --- W NOTICE A WARNING AT THIS POINT, AND PRIOR TO MAKING ANY ATTEMPT TO ENER- DO NOT ATTEMPT TO MANUALLY OPERATE THE ATS WITH THE GIZE THE ATS EQUIPMENT, THE ENGINE-DRIVEN GENERATOR SOURCE 1 POWER SOURCE CONNECTED AND AVAILABLE. SHOULD BE OPERATED. IF NECESSARY, THE VOLTAGE REGULA- TOR ON THE GENERATOR SHOULD BE ADJUSTED ACCORDING TO DO NOT ATTEMPT TO MANUALLY OPERATE THE ATS WITH THE THE MANUFACTURER'S RECOMMENDATIONS. THE ATS EQUIP- SOURCE 2 POWER SOURCE CONNECTED AND AVAILABLE. MENT WILL RESPOND ONLY TO THE RATED VOLTAGE AND FRE- QUENCY PROGRAMMED INTO THE CONTROLLER. Step 4: Close any generator engine-start controls opened as a 6.2 Troubleshooting result of actions taken in Step 1, Section 6.1.2. 9 Step 5:Where required, use an accurate voltmeter to check phase-to-phase and phase-to-neutral voltages present at ® WARNING the transfer switch Source 1, Source 2, and/or load termi nals. HAZARDOUS VOLTAGES IN AND AROUND ATS EQUIPMENT DUR 6.1.4 Operational Checks ING THE PROBLEM SOLVING PROCESS CAN CAUSE SEVERE PER- SONAL INJURY AND/OR DEATH. AVOID CONTACT WITH ANY Step 1: Check to ensure that Source 1 switching device is in the VOLTAGE SOURCE WHILE TROUBLESHOOTING. CLOSED position. This should have been done in Section 6.1.3, Step 1. Step 2: Initiate an automatic transfer operation from the Source 1 ® WARNING to the Source 2 power source by pressing the <Engine ONLY PROPERLY TRAINED PERSONNEL, FAMILIAR WITH THE ATS Test> pushbutton two times. EQUIPMENT AND ITS ASSOCIATED EQUIPMENT,SHOULD BE PER- Note:The ATC-300+ Logic Controller provides the capability to set the MITTED TO PERFORM THE PROBLEM SOLVING FUNCTION. IF AN Engine Test function to: INDIVIDUAL IS NOT QUALIFIED TO PERFORM THE PROBLEM SOLV- ING FUNCTION,THE INDIVIDUAL SHOULD NOT ATTEMPT ANY OF 0. No Load Engine Test; THESE PROCEDURES. 1. Load Engine Test; or A basic troubleshooting effort is the first step to take prior to call- 2. Disabled. ing for assistance. Frequently, the effort will successfully The factory default is set to 0-No Load Engine Test: address most problems encountered. The problem solving proce- dure is presented in the Troubleshooting Guide of the ATC 300+ 1. Load Engine Test Controller O&M Manual. Remember, only qualified individuals a. After the Time Delay Engine Starting (TOES)has timed out, familiar with the ATS equipment and the system in which it is the engine should start,run, and build up to normal voltage applied should attempt these problem solving procedures. and frequency. b. The transfer switch will transfer to the Source 2 power If a problem persists after having completed the problem solving source after the Time Delay Normal to Emergency(TDNE) procedure, contact your Cat dealer for further assistance. When times out. calling for assistance, the following is the minimum information Step 3: Initiate an automatic transfer operation back to the required to properly address the need: Source 1 power source by pressing the <Engine Test> 1. Serial number of ATS, if applicable; pushbutton one time. 2. Catalog number of ATS; 1. After the Time Delay Emergency to Normal timer(TDEN)has timed out, the transfer switch will transfer back to 3. Actual location of the ATS (type of facility, address, etc.); the Source 1 power source. 4. Company name and name and position of individual repre- 2. The Time Delay for Engine Cool-Down (TDEC- Feature senting company; 4) will allow the engine to run unloaded for a preset time 5. Basic description of the situation as it exists; and after transfer to the Source 1 power source is com- pleted. 6. Any results of the troubleshooting steps taken and/or read- 6.1.5 Alternate Tests ings taken. 1. Alternate operational tests may be possible depending upon the options provided with any given ATS. Refer to the sche- matic diagram provided with the ATS equipment, along with the specification nameplate, to determine the exact options provided. • For more information visit: www.cat.com CI-AEOM-000 74-0 1-E CAT' O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 23 Contactor Based Transfer Switch 40-400A • Section 7: Adjustments Section 8: Maintenance 7.1 General 8.1 Introduction Refer to the Controller O&M Manual, supplied with the ATS for — ATC-300+ Controller adjustments and programming. A WARNING HIGH VOLTAGES ARE PRESENT IN AND AROUND ATS EQUIPMENT. BEFORE INSPECTING OR MAINTAINING THIS EQUIPMENT, DISCON- NECT THE LINE POWER FROM,THEN LOCK OUT,IF POSSIBLE,THE NEXT HIGHEST DISCONNECT DEVICE. FAILURE TO FOLLOW THIS PROCEDURE COULD CAUSE SEVERE PERSONAL INJURY AND/OR DEATH. In general, ATS switch equipment is designed to be relatively maintenance free under normal usage. However, because of the variability of application conditions and the importance placed on dependable operation by this type of equipment, inspection and maintenance checks should be made on a regularly scheduled basis. Since equipment maintenance will consist mainly of keep- ing the equipment clean, the frequency of maintenance will depend to a large extent on the cleanliness of the equipment s surroundings. If a significant amount of dust or foreign matter is present, a more frequent maintenance schedule should be fol- lowed. It is suggested that visual inspections of the equipment be made on a regular basis, not just during scheduled periods. Always be alert for an accumulation of dirt in and around the structure; loose parts; and/or hardware, cracks, and/or discoloration to insulation; and damaged or discolored components. • 8.2 Procedures A suggested maintenance procedure is outlined in Table 5. Table 5. Periodic Maintenance Procedures STEP ACTION a.Make the ATS equipment safe for inspection and/or maintenance. Disconnect the line power from equipment being serviced by opening the next highest disconnect device. Make certain that any accessory control power is switched off by disconnecting all control plugs. b.Inspect the structure area for safety hazards or potential maintenance problems. Inspect the area,especially where switching device is installed,for any safety hazards,including personnel safety and fire hazards. Exposure to certain chemical vapors can cause deterioration of electrical connections. Inspect for accumulated dirt,loose hardware,or physical damage. Examine the primary insulation for evidence of cracking or overheating. Overheating will show as discoloration, melting,or blistering of conductor insulation,or as pitting or melting of conductor surfaces due to arcing. Inspect the secondary control connections for damage and the control wiring for insulation integrity. c.Inspect the power contactor for dust,dirt,soot,grease,moisture,or corrosion. Remove dust,dirt,soot,grease,moisture,and corrosion contamination from the surface of the switching device using a dry soft lint-free cloth,dry soft bristle brush,and vacuum cleaner. Do not blow debris into the power contactor. If contamination is found,look for the source and fix the problem. d.Check for material integrity,unever.wear,discoloration,or loose hardware. Severe material cracking will require replacement and loose hardware will need to be tightened. e.Check the terminals and connectors for looseness or signs of overheating. Overheating will show as discoloration,melting,or blistering of the conductor insulation. Connections that do not have signs of looseness or overheating should not be disturbed. f.Contact Inspection Procedure Carefully remove the arc chute clips using needle nose pliers.Remove the arc chutes to inspect the contacts. Contact your Cat dealer if the contacts have excessive wear.Reinstall the arc chutes and arc chute clips,mak- ing sure the ends of the clips are fully seated in the grooves on the barriers. g.Exercise the power contactor if it is not often exercised while in operation. If the power contactor is used fer frequent switching during normal operation,this step can be disregarded. This will permit a'wiping'action by the contacts. h.Return the ATS equipment to service. Make certain all barriers are in place and doors closed. Reapply secondary and primary power. • CI-AEOM-00074-01-E For more information visit: www.cat.com CAT. Page 24 Effective: July 2011 0&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A Section 9: Renewal Parts Guide 9.1 General Example:To order the ATC-300+ Controller for an ATC3C3X30400WRU transfer switch, order Catalog Number as shown in Figure 19, below. e Y � _ x ATC•300+Controller•3 Position Contactor type(In-Phase)-EP8160AOOG27 Transformer Pack 400A,2-Pole,3-Pole,4-Pole•EP68C82291302 Contactors(400A) 400A,480VAC,2-Pole•EP9C2990G01 400A,480VAC,3-Pole-EP69C29901302 400A,480VAC,4-Pole-EP691329901303 200A,600VAC,2-Pole-EP69C2990G01 200A,600VAC,3-Pole•EP691329901302 200A,600VAC,4-Pole•EP69C2990G03 Wire Harness 1400A AG Switch,up to 240VAC,2-Pole-EP68C8189G05+EP68138189G06 Contactor) AG Switch,up to 240VAC,3-Pole,1-Phase-EP68C8189G05+EP68C8189G09 AG Switch,up to 240VAC,3-Pole,3-Phase-EP68C8189G05+EP68C8189G07 AG Switch,up to 240VAC,4-Pole•EP68C8189G05+EP68C8189G08 Domestic Switch,up to 600VAC,2-Pole•EP6908301 G02+EP68C8189G35 Domestic Switch,up to 600VAC,3-Pole•EP6908301 G02+EP68C8189G35 Domestic Switch,up to 600VAC,4-Pole•EP69DB301G02+EP681381891335 Lugs(400A Contactor) Up to 400A-EPAB-750-4 100W Space Heater Domestic Switch,up to 600VAC-EP8160A41 G54 Figure 19. Typical ATC-300+ Controlled Contactor Based ATS. For more information visit: www.cat.com CI-AEOM-00074-01-E CST' 0&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 25 Contactor Based Transfer Switch 40-400A 0- Section 10: ATC-300+ Controlled ATS _ Quick Start Instructions I A WARNING _ THESE QUICK START INSTRUCTIONS ARE NOT A COMPLETEf, SOURCE OF INFORMATION ON THE ATC-300+ CONTROLLED ATS EQUIPMENT. INSTALLATION SHOULD NOT BE STARTED UNTIL THE ENTIRE INSTRUCTION BOOK HAS BEEN REVIEWED AND UNDERSTOOD. FAILURE TO FOLLOW THE FULL INSTRUCTIONS ` t CAN RESULT IN DEATH,SEVERE PERSONAL INJURY,OR PROP- ERTY DAMAGE. WARNING THESE QUICK START INSTRUCTIONS ARE PROVIDED FOR USE ONLY BY TECHNICIANS HIGHLY FAMILIAR AND EXPERIENCED WITH ATC-300+ CONTROLLED ATS EQUIPMENT INSTALLATION, SET UP,AND TESTING. IT IS STRONGLY SUGGESTED THAT THE FULL INSTRUCTIONS BE FOLLOWED FOR ALL INSTALLATIONS, SET UP,AND TESTING. Step 1: Mount the ATS on a flat rigid surface(Figure 20). Shim if necessary. Step 2: Install the power cables. Cables must be sized and installed per National Electrical Code, refer to NFPA70. The cables must be sized within the specified cable size range on the side of the cable connectors. Connect the cables and torque to the correct value indi- cated on the label on the door in the following order: 11oad Cables* (T1, T2, T3); 2.Source 1 or Utility Supply (N1, N2, N3); and 3.Source 2 or Generator Supply (E1, E2, E3). , For 4 pole transfer switches, connect the load cables (TN), Source 1 or utility supply (NN), and Source 2 or generator supply (EN). Refer to Figure 21 for the loca- tion of all parts discussed in this document. Shim if Necessary *Load cables MUST be connected and torqued BEFORE installing the SUPPLY cables (Figures 21). Figure 20. Mounting Details. CI-AEOM-00074-01-E For more information visit: www.cat.com CAT Page 26 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A • VOLTAGE SELECTION AND TRANSFORMER PANEL Y � Is LOGIC PANEL GROUND �' NORMAL LUGS CONNECTION Y �y TRANSFER MECHANISMy � k Y NEUTRAL # �' CONNECTION LOAD LUGS EMERGENCY LUGS Figure 21. 400A, 3-Pole, ATS Interior Components. For more information visit: www.cat.com CI-AEOM-00074-01-E CAT' O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 27 Contactor Based Transfer Switch 40-400A i Step 3: Turn the generator OFF at the generator control panel. the engine generator is needed, and should be con- This will prevent unexpected activation of the generator. nected to a generator controller. NEVER connect directly to a starter solenoid or ignition system. See the Step 4: Connect the Engine Generator Start wires to terminals Genset manufacturer instruction leaflet for recom- 13 and 14 on the J-5 connector on the ATC-300+ Con- mended wire sizes and location procedures. troller (Figure 22). This contact is CLOSED whenever ON 1 RS485 } Termination a D r-S., t-Line J1 SH RS-485 0 3 Corn MODBUS Control -Neut J7 2 B Power S2-Line 1 A S2-Neut ? Tx 6 Rx J3 5 Gnd Programming Thase C 4 5V Port Source 1hase B A3 Out haseA 2 In 8.0 in. 1 Clk Thase hase C J8 8 Emergency Source 2 B J2 ? Inhibit . haseA Control 6 Manual Inputs 5 Re-Transfer 4 K4 NO 2 TERMINALS 13 & 14 3 K4Can case output 2 K3 NO1 Relays 1 K3 Can Close Q J5 J4 1 1 2 3 4 1 5 6 ? 8 9 10 11 12 13 1 14 1 1 1 2 3 1 4 1 5 1 6 1 7 1 8 1 9 10 E O F O U pU 2 �] Bi � Bi � � - 8 , 0 z z z z Z z g > g > g > > W > o U i U N U S V N U N g Y Y N € € + + N + J + CO+ 9 N b b a a Q lL � C ~ " a b d co U 0 ino �o a a a co � J 1� Output Relays Control Inputs 6.5 in. Figure 22. Engine Generator Control Connection. Step 5: Apply Utility (Source 1) power. If the switch is properly applied for the system voltage ordered, the display should work and the Source 1 Available LED should light (Figure 23). Using a voltmeter, check for proper system voltage on Source 1 and load terminals. Check all phases on a 3-phase switch. Voltage measurements should be taken phase to phase and phase to neutral. CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 28 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A IMP . Figure 23. ATC-300+ Logic (Utility Supplying Load). Step 6: To view the setpoints, press the <Step/Enter> pushbut- ton and enter the Password. Note: The factory default Password is 0300. Once all installation and testing is complete,the Password should be changed by authorized personnel to a unique Password for the equipment. After entering the password, press the <Step/Enter> pushbutton until the VIEW SETPOINTS menu appears. Select YES. Press the <Step/Enter> pushbutton to scroll through the setpoints (Figures 24 through 26 and Table 6). is For more information visit: www.cat.com CI-AEOM-00074-01-E CST' O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 29 Contactor Based Transfer Switch 40-400A 16 Utility- Generator Transfer Switch Source 1 is available Close Source 1 (Energize K1) Source 1 is powering the load No Source 1 becomes unavailable (or Engine Test, Plant Exercise,Go To Emergency) <is TIDES timer times out TDEN timer times out Send"Engine Start"signal (Energize Gen Start relay) Sends pretransfer signal TPRE timer times out . No Open Source 2 Is Source 2 (Energize K1) Available? Yes Close Source 1 (Energize K1) TDNE timer times out Source 1 is powering the load Sends pretransfer signal TPRE timer times out (If Source 1 is Available) TDEC timer times out Open Source 1 Remove"Engine Start"signal (Energize K2) (De-energize Gen Start relay) Close Source 2 (Energize K2) Source 2 is powering the load Figure 24. Utility -Generator Transfer Switch. CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 30 Effective: July 2011 O&M Manual for the ATC-300+ , 3-Postion Contactor Based Transfer Switch 40-400A r Dual Utility Transfer Switch Source 1 is available Close Source 1 (Energize K1) Source 1 is powering the load Source 1 becomes unavailable (or Go To Emergency) No No Is Source 1 Is Source 2 Available? Available? Yes Yes TDEN timer times out TDNE timer times out [::ends pretransfer signal Sends pretransfer signal PRE timer times out TPRE timer timSource 1 is Available) Open Source 2 Open Source 1 (Energize K1) (Energize K2) Close Source 1 Close Source 2 (Energize K1) (Energize K2) Source 1 is powering the load Source 2 is powering the load Figure 25. Dual Utility Transfer Switch. For more information visit: www.cat.com CI-AEOM-00074-01-E Cm' O&M Manual_for the ATC-300+, 3-Postion Effective: July 2011 Page 31 Contactor Based Transfer Switch 40-400A Table 6. Setpoint Possibilities SETPOINT SETPOINT UNITS DESCRIPTION RANGE FACTORY DEFAULT New Password Four Digits Set New Password 0000 to 9999 0300 TOES Minutes:Seconds Time Delay Engine Start 0 to 120 seconds 0:03 TONE Minutes:Seconds Time Delay Normal to Emergency 0 to 1800 seconds 0:00 TDEN Minutes:Seconds Time Delay Emergency to Normal 0 to 1800 seconds 5:00 TDEC Minutes:Seconds Time Delay Engine Cool-off 0 to 1800 seconds 5:00 NOM FRED Hertz Nominal Frequency 50 or 60 Hz As ordered NOM VOLTS Volts Nominal Voltage 120 to 600 volts As ordered S1 UV DROP Volts Source 1 Undervoltage Dropout Range: Contactor Style ATS(2-position/3-position) 78 to 97%of Nominal System Voltage 85% S2 UV DROP Volts Source 2 Undervoltage Dropout Range: Contactor Style ATS(2-position/3-position) 78 to 97%of Nominal System Voltage 85% St UV PICK Volts Source 1 Undervoltage Pickup Range: Contactor Style ATS(2-positionl3-position) (Dropout+2%)to 99%of Nominal System Voltage 90% S2 UV PICK Volts Source 2 Undervoltage Pickup Range: Contactor Style ATS(2-position/3-position) (Dropout+2%)to 99%of Nominal System Voltage 90% S1 OV DROP Volts Source 1 Overvoltage Dropout Range: Contactor Style ATS(2-positionl3-position) 105 to 110%of Nominal System Voltage 110% S2 OV DROP Volts Source 2 Overvoltage Dropout Range: Contactor Style ATS(2-positionl3-position) 105 to 110%of Nominal System Voltage 110% S1 OV PICK Volts Source 1 Overvoltage Pickup Range: _ Contactor Style ATS(2-positionl3-position) 103%to(Dropout-2%)of Nominal System Voltage 105% S2 OV PICK Volts Source 2 Overvoltage Pickup Range: Contactor Style ATS 12-positionl3-position) 103%to(Dropout-2%)of Nominal System Voltage 105% . S1 OF DROP Hertz Source 1 Underfrequency Dropout Range: Contactor Style ATS(2-position/3-position) 90 to 97%of Nominal System Frequency 90% S2 OF DROP Hertz Source 2 Underfrequency Dropout Range: Contactor Style ATS(2-positionl3-position) 90 to 97%of Nominal System Frequency 90% S1 OF PICK Hertz Source 1 Underfrequency Pickup Range: Contactor Style ATS(2-position/3-position) (Dropout+1 Hz)to 99%of Nominal System Frequency 95% S2 OF PICK Hertz Source 2 Underfrequency Pickup Range: Contactor Style ATS(2-position/3-position) (Dropout+1 Hz)to 99%of Nominal System Frequency 95% Sl OF DROP Hertz Source 1 Overfrequency Dropout Range: Contactor Style ATS(2-position/3-position) i 03 to 105%of Nominal System Frequency 105% S2 OF DROP Hertz Source 2 Overfrequency Dropout Range: Contactor Style ATS(2-position/3-position) 103 to 105%of Nominal System Frequency 105% S1 OF PICK Hertz Source 1 Overfrequency Pickup Range: Contactor Style ATS(2-position/3-position) 101%to(Dropout-1 Hz)of Nominal System Frequency 102% S2 OF PICK Hertz Source 2 Overfrequency Pickup Range: Contactor Style ATS(2-position/3-position) 101%to(Dropout-1 Hz)of Nominal System Frequency 102% TDN Minutes:Seconds Time Delay Neutral 0 to 120 seconds 0:00 BAUD RATE Modbus Baud Rate 9600 or 19200 9600 ADDRESS Modbus Address 1 to 247 1 PLANT EXER Days Plant Exerciser Programming OFF,DAILY,7-DRY,14-DAY or 28 DAY OFF PE LOAD XFR Plant Exerciser Load Transfer 0 or 1(1 -yes) 0 r CI-AEOM-00074-01-E For more information visit: www.cat.com CAT Page 32 Effective: July 2011 0&M Manual for the ATC-300+, 3-Postion Contactor Based Transfer Switch 40-400A Table 6. Setpoint Possibilities Icont') SETPOINT SETPOINT UNITS DESCRIPTION RANGE FACTORY DEFAULT PE DAY Days Plant Exerciser Day of the Week 1 SUN,2 MON,3 TUE,4 WED,5 THU,6 FRI or 7 SAT PE HOUR Hours Plant Exerciser Hour 0 to 23 0 PE MINUTE Minutes Plant Exerciser Minute 0 to 59 0 TEST MODE Test Mode 0,1 or 2(0- No Load Engine Test,1 -Load Engine Test,2- 0 Disabled) TER Hours:Minutes Engine run test time 0 min to 600 min 5:00 TPRE Minutes:Seconds Pretransfer delay timer O sec to 120 sec 0:00 PHASES Three phase or single phase 1 or 3 AS ORDERED VOLT UNBAL Volts Voltage Unbalanced 0 or 111 -Enabled) 1 UNBAL DROP% Percent Percent for Unbalanced Voltage Dropout 5 to 20%of Phase to Phase Voltage Unbalance 20% UNBAL PICK% Percent Percent for Unbalanced Voltage Pickup Dropout minus(UNBAL DROP% 2)to 3% 10% UNBAL DELAY Seconds Unbalanced Delay Timer 10 to 30 0:20 TOEF Seconds Time Calay Emergency Fail Timer 0 sec to 6 sac 6 IN-PHASE Hertz In-Phase Transition. 0 or 1 11-Enabled) 1 IP FRED DIFF Hertz In-phase Transition Frequency0ifference 0.0 Hz to 3.0 Hz SYNC TIME Minutes In-phase Transition Synchronization Timer 1 min to 60 min 5 PHASE REV Phase Reversal OFF,ABC,or CBA OFF DST ADJUST Day Light Savings Oat 1(1-Enabled) 1 MAN RETRAN Manual Retransfer 0 or 1(1-Enabled', 0 LANGUAGE Selected Language English,French,or Spanish English CHANGE TIMEIDATE? Set Time and Date Hours Set Hour 0 to 23 Eastern Standard Time -4 MINUTES Set Minute 0 to 59 Eastern Standard Time WEEKDAY Set Weekday SUN,MON,TUE,WED,THU,FRI or SAT Eastern Standard Time MONTH Set Month JAN or Gi Eastern Standard Time DAY Set Day 1 to 31 Eastern Standard Time YEAR Set Year Current Year Eastern Standard Time RESET Yes or No Ne SYSTEM COUNTERS? RESET ALL? Resets all System Counters Yes or No No RESET Hours Resets ENGINE RUN Counter 0 to 9999 XXXX ENGINE RUN? RESET Hours Resets S1 CONN Counter 0 to 9999 XXXX S1 CONN RESET Hours Resets S_ 0 to 9999 XXXX S2 CONN RESET Hours Resets S1 AVAIL Counter 0 to 9999 XXXX S1 AVAIL RESET Hours Resets S2 AVAIL Counter 0 to 9999 XXXX S2 AVAIL RESET Hours Resets LOAD ENERG Counter 0 to 9999 XXXX LOAD ENERG RESET Cycles(Counts) Resets TRANSFERS Counter 0109999 XXXX TRANSFERS SAVE Save Changed Setooints Yes or No Yes SETPOINTS? See tables in the appendix for Voltage and Frequency Pickup and Dropout settings. For more information visit: www.cat.com CI-AEOM-00074-01-E CAT' O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 33 Contactor Based Transfer Switch 40-400A Alft - VW Step 7: To change or add a setpoint, select Yes when the the load terminals of the ATS. Check all phases on a 3- "Change Setpoints" message appears on the screen. phase system. Voltage measurements should be taken Use the <Step/Enter> pushbutton to step through the phase to phase and phase to neutral. A load test will setpoints. cause a momentary power outage during transfer. Use the <Increase> and <Decrease> pushbuttons to change the setpoint. When finished scrolling through and changing the desired setpoints, answer Yes when the "Save Setpoints?"ques- tion appears on the screen. The display will return to the default screen. HELP �► sir ENGINE STEP TEST t. INCREASE +� r. 1 DECREASE ® Figure 27. ATC-300+ Logic. LAMP TEST BYPASS ENTER ALARM RESET Step 10:ATC-300+ Controlled ATS Power Failure Test- Initiate TDNE/TDEN a Load Test by simulating an actual power failure. Figure 26. ATC-300+ Pushbuttons. 1. This should be done by opening the upstream breaker or fused disconnect switch. AWARNING 2. The generator should start and the ATS should transfer to Source 2. THE GENERATOR SHOULD BE MANUALLY STARTED AND THE OUTPUT CHECKED AND VERIFIED BEFORE PROCEEDING TO STEP 3. After transfer, close the upstream breaker, or close 8. IF IMPROPER VOLTAGE/FREQUENCY IS APPLIED TO THE LOAD, the Source 1 Control Circuit Fused Disconnect. The THE ATS MAY BE DAMAGED. TDEN timer should begin counting, and, when com- Step 8: Manually start the engine generator at the generator plete, the ATS should transfer to Source 1. The controller. Check that the generator is running and the TDEC should time out and shut the Source 2 power Source 2 Available LED is lit. Press the <Step/Enter> unit down. pushbutton, step through the phase voltages, frequency, and message display. If the source message indicates that the source is Good, shut down the generator and NOTICE place the Genset controller in the Auto-operating posi- tion. If the message indicates a problem with the WHILE PERFORMING TESTING, IF AN UNDESIRED OR UNDOCU- source, the setpoints should be reviewed and the gener- MENTED RESULT OCCURS,FIRST CONTACT THE LOCAL GENSET ator checked for proper voltage and frequency output. DEALER. IF THE RESULT IS NOT CORRECTED, CONTACT YOUR CAT DEALER. Step 9: Initiate a Load Test from the front panel of the ATC- 300+ (Figure 28). This may be done by setting the engine test setpoint to: 1 Load Test then saving the setpoints. Once the engine test setpoint has been changed and saved, press the <Engine Test> pushbutton twice. The generator should start, the ATS should transfer and run on the generator for the set test interval, then proceed to a TDEN countdown and return to Source 1. While the ATS is connected to Source 2, use a voltmeter to check for correct system voltage on CI-AEOM-00074-01-E For more information visit: www.cat.com CAT' Page 34 Effective: July 2011 O&M Manual for the ATC-300 + , 3-Postion Contactor Based Transfer Switch 40-400A Appendix A: Pickup / Dropout Tables UNDERVOLTAGE PICKUP/DROPOUT TABLE PERCENTAGE VOLTAGE 120 20B 220 240 380 415 480 600 97 116 202 213 233 369 403 466 582 96 115 200 211 230 365 398 461 576 95 114 198 209 228 361 394 456 570 94 113 196 207 226 357 390 451 564 93 112 193 205 223 353 386 446 558 92 110 191 202 221 350 382 442 552 91 109 189 200 218 346 378 437 546 90 108 187 198 216 342 374 432 540 Pickup 89 107 185 196 214 338 369 427 534 88 106 183 194 211 334 365 422 528 87 104 181 191 209 331 361 418 522 86 103 179 189 206 327 357 413 516 85 102 177 187 204 323 353 408 510 Dropout 84 101 175 185 202 319 349 403 504 83 100 173 183 199 315 344 398 498 82 98 171 180 197 312 340 394 492 81 97 168 178 194 308 336 389 486 80 96 166 176 192 304 332 384 480 79 95 164 174 190 300 328 379 474 78 94 162 172 187 296 324 374 468 77 92 160 169 185 293 320 370 462 76 91 158 167 182 289 315 365 456 75 90 156 165 180 285 311 360 450 74 89 154 163 178 281 307 355 444 73 88 152 161 175 277 303 350 438 72 86 150 158 173 274 299 346 432 71 85 148 156 170 270 295 341 426 70 84 146 154 168 266 291 336 420 69 83 144 152 166 262 286 331 414 68 82 141 150 163 258 282 326 408 67 80 139 147 161 255 278 322 402 66 79 137 145 158 251 274 317 396 65 78 135 143 156 247 270 312 390 64 77 133 141 154 243 266 307 384 63 76 131 139 151 239 261 302 378 62 74 129 136 149 236 257 298 372 61 73 127 134 146 232 253 293 366 60 72 125 132 144 228 249 288 360 59 71 123 130 142 224 245 283 354 58 70 121 128 139 220 241 278 348 57 68 119 125 137 217 237 274 342 56 67 116 123 134 213 232 269 336 55 66 114 121 132 209 228 264 330 54 65 112 119 130 205 224 259 324 53 64 110 117 127 201 220 254 318 52 62 108 114 125 198 216 250 312 51 61 106 112 122 194 212 245 306 50 60 104 110 120 190 208 240 300 For more information visit: www.cat.com CI-AEOM-00074-01-E C O&M Manual for the ATC-300+ , 3-Postion Effective: July 2011 Page 35 Contactor Based Transfer Switch 40-400A OVERVOLTAGE PICKUP I DROPOUT TABLE PERCENTAGE VOLTAGE 120 208 220 240 380 415 480 600 120 144 250 264 288 456 498 576 720 119 143 248 262 286 452 494 571 714 118 142 245 260 283 448 490 566 708 117 140 243 257 281 445 486 562 702 116 139 241 255 278 441 481 557 696 115 138 239 253 276 437 477 552 690 114 137 237 251 274 433 473 547 684 113 136 235 249 271 429 469 542 678 112 134 233 246 269 426 465 538 672 111 133 231 244 266 422 461 533 666 110 132 229 242 264 418 457 528 660 Dropout 109 131 227 240 262 414 452 523 654 108 130 225 238 259 410 448 518 648 107 128 223 235 257 407 444 514 642 106 127 220 233 254 403 440 509 636 105 126 218 231 252 399 436 504 630 Pickup UNDERFREQUENCY PICKUP i DROPOUT TABLE PERCENTAGE FREQUENCY 50 60 97 49 58 96 48 58 95 48 57 Pickup 94 47 56 93 47 56 92 46 55 91 46 55 90 45 54 Dropout OVERFREQUENCY PICKUP I DROPOUT TABLE PERCENTAGE FREQUENCY 50 60 110 55 66 109 55 65 108 54 65 107 54 64 106 53 64 105 53 63 Dropout . 104 52 62 103 52 62 102 51 61 Pickup CI-AEOM-00074-01-E For more information visit: www.cat.com O&M Manual for the ATC-300+ , 3-Postion Page 36 Effective: July 2011 Contactor Based Transfer Switch 40-40� This instruction booklet is published solely for information pur- poses and should not be considered all-inclusive. If further infor- mation is required, you should consul Caterpillar. Sale of the product(s) shown in this literature is subject to terms and conditions outlined in appropriate Caterpillar selling policies or other contractual agreements between the parties. This literature is not intended to and does not enlarge or add to any such con- tract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the pur- chaser and Caterpillar. NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WAR- RANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MER- CHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Caterpillar be responsible to the purchaser or user in contract,in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not lim- ited to damage or loss of use of equipment, plant or power sys- tem, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and description contained herein. i CSA is a registered trademark of the Canadian Standards Associ- ation. National Electrical Code and NEC are registered trademarks of the National Fire Protection Association, Quincy, Mass. NEMA is the registered trademark and service mark of the National Elec- trical Manufacturers Association. Uniform Building Code (UBC) is a trademark of the International Conference of Building Officials (ICBO). UL is a federally registered trademark of the Underwriters Laboratories Inc. C i fi e, Generator Switchgear Products Automatic Transfer Switches 4955 Marconi Drive Alpharetta, GA 30005 (770) 442-9442 8 7 6 5 4 3 2 1 1 1 ATC3C3X30400XSU AUTOMATIC OPEN TRANSFER CONTACTOR SWITCH ATC-3DO+ CONTROL, 3 POSITION CONTACTOR F FIXED MOUNTED F 3 POLE, 400 AMPS 6.89 [175] TYPE 1 ENCLOSURE, UHLS1008 LIRSTED ------ --------------------------------------------- FEATURES INCLUDED: 1A TIME DELAY NORMAL TO EMERGENCY ADJ D-1000 sec 2A TIME DELAY ENGINE START ADJ 0-120 sec 3A TIME DELAY EMERGENCY TO NORMAL ADJ D-18M sec 4A TIME DELAY ENGINE ODOL—OFF ADJ 0-1800 sec 5H EMERGENCY(S2) SENSING PHASE REVERSAL 5J EMERGENCY(((S2) SENSING ALL PHASE UNDERVOLTAGE/UNDER FREQ 5K EMERGENCY S2)) SENSING ALL PHASE OVERVOLTAGE/OVER FREQ 5L EMERGENCY S2 SENSING ALL PHASE VOLTAGE UNBALANCE 6B ENGINE TEST PUSHBUTTON 7A TIME DELAY ENGINE FAIL ADJ 0-6 sec 8C TIME DELAY BYPASS EMERGENCY TO NORMAL 82 MEDICONNA1TCNNECE �E 1C LED INDICATION ORL(S) ONNECrD E 12D LED INDICATION EMERGENCY (S2) CONNECTED 12G LED INDICATION NORMAL (S1)AVAILABLE 12H LED INDICATION EMERGENCY(S2)AVAILABLE 3484 [8a5] 15E POSITION INDICATION CONTACT NORMAL(S1)AVAILABLE 1 FORM C 15F POSITION INDICATION CONTACT EMERGENCY(S2)AVAILABLE 1 FORM C TOP VIEW 18DL 10130MA6510 ON LOAD 23K PLANT EXERCISER 7/14 28 DAY LOAD/NO LOAD 0-6DO min 26D GO TO EMERGENCY(S2) INPUT 26H NORMAL IS11 SENSING PHASE REVERSAL 26J NORMAL Si SENSING ALL PHASE UNDERVOLTAGE/UNDER FREQ 26K NORMAL S1 SENSING ALL PHASE OVERVOLTAGE/OVER FREQ 26L NORMAL S1 SENSING ALL PHASE VOLTAGE UNBALANCE 32A TIME DELAY NEUTRAL ADJUSTABLE 0 — 120 sec 35A PRETRANSFER SIGNAL CONTACTS 1 FORM C 19.81 [503] 42 IBC/CBC SEJSMK: QUALIFIED ---------------------------------------------------- D 13 DO [330] REQUIRED FOR SEISMIC, RECOMMENDED FOR ALL APPLICATIONS: D 9.80 (249] THESE BOLTS USE 4, IARE TO BE3 LING ETTORQUED TO755 FT. LBS. (102 NM).E 5 OR BETTER HEX HEAD BOLTS WASHERS. 16.75 [425]�I ---------------------------------------------------- SEE NOTE 4 I NOTES: 1 APPROXIMATE SHIPPING WEIGHT= 250 LBS [113 KG] 2 DIMENSIONS SHOWN IN INCHES [MILLIMETERS] 3 DEVICE CUTOUTS 3 AUTOMATIC do NON—AIITO►AATIC CONTROLS PROVIDED BASED ON CUSTOMER SEE NOTE 3 ORDER INFORMATION. 4 TRANSFORMER PACK IS NOT INCLUDED WITH 240/12OV, 1 PHASE OR 208/120V SYSTEMS. NORMAL POWER 5 FOR SWITCHED NEUTRAL APPLICATIONS, CONNECT TO TERMINALS MARKED CABLE CONNECTIONS 'NN', 'EN',AND 'LN'. NEUTRAL ASSEMBLY WILL NOT BE PROVIDED. 0 C ° ° CA CONNECTIONS C _ � o N n LOAD POWER $ CABLE CONNECTIONS 0 O O O N STANDARD NEUTRAL CONNECTIONS SEE NOTE 5 n 5.48[139] x 105 v; 7.92 [201] 4.13 [ ] N 10.36 [263] " u � N N B 14.40 [366] 0.72 [18] B 6.10(155] ONE LANE DIAGRAM 8.46 [215] FRONT VIEW SIDE VIEW(WITH RIGHT SIDE REMOVED) � SOURCE 1 SOURCE 2 — A �ECWYNICAL INTERLOCK u l PREVENTS PARALLELING OF CENTER OF GRAVITY LOAD SOURCES •1-' DTHET�Nd Im TM�N DFTR DANIEL QUIROZ �2/20,2 COTERPII.LAR® N- CONSTITUTE NFIDENTIAL FVRYATION AND APPD DATE TITLE A PRO AUTOMATIC OPEN TRANSFER CONTACTOR SWITCH c WHCH IS THE PROPERLY of CATERPILLAR,INC.,AND IS NOT 480V 3 POSITION 1 40-400 AMP I ATC-300+ CONTROLLER TO BE USED OR REPRODUCED BY ANY PART EXCEPT AND TD FEDERAL ID NO. S.O. TYPE THE WENT IN THE MAKER 88725 OOFE92 ATC3C3X30400XSU OUTLINE AUTHOR®BY CATERPILLAR, INC. PRODUCT CODE REVISION DESIGNATION G.O. DWG SHEET AT 1 RTS0001450-001 IWOOFE92-000111 OF 4 8 7 6 5 4 3 2 1 1 �R SOURCE 2 SOURCE 1 ----------------------- �S2-A0) r---------------------- T1 a(Sl-NO) I E2 S2-B4) I T2 P 480/277V E3 S2-CO) I SOURCE 2OURCE 1 T3 CO) 80/277V • EN S2-NO) TN v v v v CTLA pp N Qmxl v CUSTOMER E oo v LOAD E CABLES a z1 KV-9 3 AMP T 1 1 .25 ANP 600 VAC SBL 600 VAC 14 e u ID : 1 1 t { ATC_300 NS1-1 7 1 _ 71 F 1 INPUT J4-1 Nc C ET1 /120V NT1 /120V I J4-2 I ES1-1 10 a, 121 10 121 N to v J _ — N J V v J4-3 INC C INPUT N I o L N GND MC Fa HN VR VC VB �VA1BDL — _x LOB LOB MA65 p I 1 D I I I V I I I I I I " - - J4-5 SENSING SENSING SOURCE 21 - I N w SOURCE 11 LOCKOUT I ATC-300+I I S S ATC-300+I I INPUT I I CNTL PWR " CML PWR J4-6 � � • J4 7 REMOVE TO 6 12 4 GO TO TRANSFER I S2 TO S2 J4-8 5 9 1 MONITOR J4-9 13 MODE � ATC-300 OUTPUTS J4 101 C C I I 14 �K1 S21 I J5 ' J5-2 1 1 1 9 9 CONTACTOR = ! I K2 st I RLY1 RLY2 i S1-6 Pl-6 ATt t AT2 Sl-2 I ( J5-3 J5-4 4 12 4 12�� I P1-2 MANUAL J8-6 3� st 14 RE-TRANSFER. S-1 -pi-1 IAt51A2I J JB-1' 8-5 1 J8-2 I RLY2 K4 ss --I3 u S2 J8-7 I __ -3- -4 S1-3 P1-3 Bt a2 INHIBIT _ J8-8 I I I B NT1 - NORMAL TRANSFORMER B 1 ETA - EMERGENCY TRANSFORMER CONNECT TO JS-13 REMOTE START ERA - EMERGENCY AUXILIARY RELAY __CONTACT FROM TB CUSTOMER CONTACTS I I NSx - NORMAL AUXILIARY SWITCH ENGINE -+ ESx - EMERGENCY AUXILIARY SWITCH J5-14 GENERATOR SHOWN DE-ENGERGIZED START D NPRR - NORMAL PHASE SEROTROTATION RELAY CONNECTED TO NORMAL JS-8 NS1-2 ES1-2 NT1 ET1 EPRR - EMERGENCY PHASE ROTATION RELAY Nx - CUSTOMER NORMAL CONNECTION 7 18a Tx - CUSTOMER LOAD CONNECTION - CUSTOMER EMERGENCY ECI'K)N ALARM JS-9 9 12a Px - FEMALE CONNECTOR J5-12 i5E 15F 10 300VA Sx - MALE CONNECTOR — — _ FSx - FUSE HOLDER _ tt tea KV -VOTING RELAY POSITION INDICATION TXx - TRANSFORMER 12 25VA THIS DOCUMENT AND THE DFM DATE CATERPILLAR® DETAILS EMBODIED THEREIN DANIEL QUIROZ 10 2 2012 CONSTITUTE CONFIDENTIAL A AND PROPRIETARY APPD FATE TmE AUTOMATIC OPEN TRANSFER I CONTACTOR SWITCH G INFORMATION WHICH IS THE PROPERTY OF CATERPILLAR, 480V 3 POSITION 1 40-400 AMP I ATC-300+ CONTROLLER INC..AND IS NOT TO BE USED OR REPRODUCED BY FEDERAL ID NO. S.O. TYPE ANY PART EXCEPT AND TO 88725 DOFE92 ATC3C3X30400XSU SCHEMATIC THE EXTENT IN THE MANNER AUTHORIZED BY PRODUCT CODE REVISION DESIGNATION G.O. DWG CATERP LUIR, INC. AT 1 RTS0001450-001 WOOFE92-S001 2 0 4 8 7 6 5 4 3 2 1 � 8 7 6 5 4 I 3 I 2 I 1 ENCLOSURE XFMR PANEL W/COVER REMOVED MOUNTED ON LEFT HAND SIDE OF ENCLOSURE S7-5 9 1 57-1 57-7 7 12 S7-10 S7-6 10NT1 ETIIt S7-9 I 57-3 it to 57-12 I S7-4 12 7 S7-2 S7-8 1 9 S7-11 El - e - J POWER PANEL I J , N1 a N2 1 2 3 J7-4 KV_1 (0(9 a s E J7-3 4 5 8 GND 4 t 4 t E1 1 L OPM A2 E E2 7 8 9 J7-2 ,S Z ,-� OPM Al 1 2 a OPM 81 E3 KV_5 5 I _lRLY1J+ -lRLY2'+ I N3 1 a RLY1-1 J7-1 1 t t GND 4 P7 I 1 9 1 9 I OOO Nil-7 NTI-11 3 2 1 NT1-1 f ®�© NT1-9 i P1 NT1-10 8 5 1 NT1-12 $ GND ET1-7 J8-4 a 2 I J8-2 ET1-11 9 8 7 ET1-1 _�' g J2-3 ETt-9 a ii I I I I J5-2 a s 1 J1-3 t Ell -10 1 1 1 Eft-12 I G1�1 el I S7 a s 000 4 1 I 00� D T sl D _�KV�+ TB 3 4 5 6 7 8 9 IL i 15E 15F Yj CUSTOMER CONNECTIONS • I I J4-2 NS1CAN TB-4 J4-1 TB-3 NC w 7-, N I I ONO TB-5 I ES1 I O O i Nb&M ONO TB-B ON1 O 3 J4_3 NO TB_6C 18DL-N J4-4 (%)II TB-7 OPTION PANEL(MOUNTED BELOW POWER PANEL) 18DL-GND At A2 f$8-12 1 2 _Ir o xtx2 o ill SBL SBL-1 SBL-3 I� 18DL-HIA 2 t CTL1 -xl 0 0 RLY2-14 S1-2 01 a CTL1 -X2 RLYl-14 KV-14 P7-6 OPM 18DL-HIB e a M-X1 ISJ57-12-12 (OPERATING MECHANISM) I oe 7 CTT2-X2 18DL-HIC o u CTL3-X1 l 18DL-LOG z t CTL3-X2 o xt X2 o SGND TUD Wi� I I CND SBL-5 SBL-7 I i 0 0 x B B O OE1 E2 OE3 t t t t ���21 °D T1 r-0T2 3 O %1 XZ O 2 2 2 2I I SBL-9 SBL-11 o TN w— — — — — 55 ONNO oao ;���, n��� � � .--I THIS DOCUMENT AND THE OFTR DATE Yr ER PILLAR® DETAILS EMBODIED THEREIN DANIEL OUIROZ 10 2/2012 CONSTITUTE CONFIDENTIAL z AND PROPRIETARY APPD DATE TITLE AUTOMATIC OPEN TRANSFER I CONTACTOR SWITCH A PROPERTY AT O WHICH I I THE 480V 3 POSITION 140-400 AMP I ATC-300+ CONTROLLER � PROPERTY OF CATERPILLAR INC., AND IS NOT TO BE USED OR REPRODUCED BY FEDERAL ID NO. S.O. TYPE ANY PART EXCEPT AND TO 88725 OOFE92 ATC3C3X30400XSU DIAGRAM THE E7XTENT IN THE MANNER AUTHORIZED BY PRODUCT CODE REVISION DESIGNATION G.0_ DWG CATERPILLAR, INC. AT 1 RTS0001450-001 WOOFE92-WOO J SHE 3 0F 4 4 3 2 1 axis 8 I 7 I 6 I 5 I 4 3 2 1 HINGE SIDE F ENCLOSURE DOOR (REAR VIEW) F FlG 1 E AG 2 E HG 1 FIG ATC-300+ CONTROLLER R5-485 ON 1 18DL TERI&ATION T IQ1301o1A6510 J10 4-Shd 4 GND GND RS-485 3-CO11 SBL-2 Hl J7 YODBIS 2-A J I(/� ILL-1 L(+) 1-B LO P7-3 4 St CNTL PWR NPUT J3 GND N(-) P7-4 3 1� SBL--6 H P7-9 2 2-M KB) TN Vref S2 CNR PWR NPUT LO P7-10 1 4-� FLA-1 V. S_c SBL-10 H O—Rc 6 KC) FlB—t w SBL-12 Lo E) 51-4 J C) J1 7-Tx JB RC-1— vc E) N2 2 B 3 St SENSINGN1 1 A INPUT S2 NHfIT MANLLAL 51-5 3 C RE-TRMSFER J2 4 S1-3 E2 2 B 52 Sa6NG K4 S2 CLOSE RLY2-13 Et 1 A INPUT st cxDSE 51-1 J5-3 9 9 8 RLY1-13 �r >>I 1 =VZV Z W C c B B .--I THIS DOCUMENT AND THE DFTR DETAILS BABODIED THEREIN DANIEL QUIROZ ;ai2/2012 CHERPILLAR° CONSTITUTE CONFIDENTIAL z AND PROPRIETARY APPD DATE TTTU AUTOMATIC OPEN TRANSFER I CONTACTOR SWITCH A p INFORMATION WHICH IS THE PROPERTY OF CATERPILLAR• 480V 3 POSITION 1 40-400 AMP I ATC-300+ CONTROLLER INC.,AND IS NOT TO BE USED OR REPRODUCED BY FEDERAL ID NO. S.O. TYPE ANY PART EXCEPT AND TO 88725 OOFE92 ATC3C3X30400XSU DIAGRAM THE EXTENT IN THE MANNER AUTHORIZED BY PRODUCT CODE REVISION DESIGNATION G.O. DWG CATERPILLAR, INC. SHEET AT 1 RTS0001450-001 WOOFE92-W002 4 OF 4 8 7 6 5 � 4 3 2 1 caDiBL ItLV 02 -- 6 5 4 3 2 META I C 282-3241 ABBREVIATIONS SYMBOLS A.V.R. AUTOMATIC VOLTAGE REGULATOR III FUSE I� CUSTOMER TERMINAL AC ALTERNATING CURRENT EMERGENCY STOP PUSHBUTTON o INTERNAL PANEL TERMINAL 10 1: DC DIRECT CURRENT R RELAY COIL 2 0 OUTGOING/INCOMING PANEL TERMINAL SRN SCREEN FROM SCREEN CABLE SCREEN CABLE CONTROLLER 70-WAY CONNECTOR Y RLY RELAY DIODE ENGINE SOCKET 1 I/P INPUT R/1 1\I3 RELAY CONTACT N/0 : O POWER TERMINAL ALR ALARM RELAY ' EARTH -,VIr a INTERNAL AC TERMINAL BLOCK GRR GENERATOR RUN RELAY -x CANOPY E-STOP SOCKET FCS FUEL CONTROL SOLENOID -X CIRCUIT BREAKER m ECM SOCKET -- 51— RESISTOR PI P2 sir CURRENT TRANSFORMER « BUZZER / SIREN " I A T FCs SOLENOID NT i TR 1 E0013Y CONFIDENTIALITY 1E2733 DRAWING — AUTOCAD o 1E0011 INTPR & TOIL T SPEC NO. I NAME DRN A CUPPLES CHK J MOORE APPDM SPITZNAGLE T Ef ,oD PROD. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN DIMENSIONS W/O TOL ARE BASIC SCALE NONE 0 16APR07 SHEET 1 OF 2 TPRODIECTONE CHG DAZE CATERPILLAR INC. IK i-TIM KKM I5 rK YROP(Ilir d CA—ILLM iW AD/W ITS .rear.rtmM rcnursvM,Ax sMnu ro mKn uu c W v n a�-D IS DIAGRAM-WIRING C6 6 EMCP 3.2 CSA 282-3241 p,- `OtL 72 D 6 5 4 3 6 5 4 3 2 —I METRIC 282-3241 NOTE, IF 4 POLE BREAKER FITTED CHANGE NI y N 4 POLE BREAKER OPTIONAL (SEE NOTE REF.A01) LI P1 P2 L4 5pp � X • L2 o1 P2 LS - G l3 _K L6 • s s2 N1 N1 • �I E E -_EARTH STUD I 104 103 102 101 CIO C30 C50 C90 i F1 F2 F3 (GA) (aA) (64) u REP BO6 MAGNETIC PICK-LIP REF ELECTRONIC SERVICE TOOL LINK B06 A B D E G F C 7 5 371 37 61 11 D- R COS BDS 63 61 SC fi5 66 C ® ® �BO6 REF B06 �806 120nuc 120n 1�-- 09110 10, C10 C70 C50616342 41 INTERENGINACE E MODULE NOOUIE 13 11 9 7 31 17 57 39 50 34 42 62 64 63 5 3 4 67 66 .22 3i EMCP3.2 We IA IB IC I RETURN CANI A939 CAN2 J1 9N i �iiVB RS 485 NAG PICKUP p VA I-—— 806 EARTH(MOUNTING SCREW) 53A 3(25A)B JA - 3A REF. Oaf"]C05 56 i2 15A 41 10 ® 10]R`F PROG LCD DISPLAY @� ooq —t�-1904 o(��o 5 7 8 a 0 1 REf. 69 SINK O/P I p��—B05 51 I 1 (_2g 5) ♦ I --J Efl�II CONI © + F10 7 I . REF 5 D06 86 65 BATTERY(12/24Vtic) (6A) L RLYI RLY2 RLY3 RLY4 RLYS RLY6 RLY7RLrB REF. ENG FUEL GLOW AUDIBLE COMMON GENSETD03 CRANK CONTROL PLUG ALARM ALARM RUNNINGSEE 51 + ENERG REMOTE LOW COOLENT PRpG PrypG PRpG PROG PROG OIL ENGINE PROD OIL ENGINE PgoG 5B NOTE 2 STOP START LEVEL I/r' I/P I/P I/O I/P PRESSURI. TEMP I/P PRESSURE TEMP 1/P+ 7 IIr I1Ir IIr Ir I/P 1 I/P 2 I/P 3 I/P 4 I/P 5 I/P fi I/P 7 I/P B PASSIVE PASSIVE PASSIVEPASSIVE PASSIVE PASSIVE 67 I —IIM —��—�� I �� I ANALOG 1* ANALOG 2i ANALOG 3+ANALOG 1- ANALOG 2- ANALOG 3- SS APR/1D+ fill 4B 35 4J 33 all 32 40 26 27 2 2 15 1 21 1a 70+ 55+ 54+ 53+ 45' HI 36I 2B+ 56 38� 30+ 461 37i 29+ 12V t2v 30 SBA - CHARGING 78 18 7 27 7 10 7 87 7 BB 7 90 7 I67 7 I69 I70 7 72 17 24 16 SPO SP1 SP2 SP3 SP4 Y r SAI Y Y 30 ALTERNATOR SEE NOTE I $IIyO XIly1 XII(1, A REF. M GLow T B03 P UGS �SA — 19 SA BBOB.I. 5A HT , ® © 510 5 7 WATTS ——————6­4 1——————————— REF. COS ® 60 STOP 5 1.1 S 17 iB03 _ El 1 AMP 1 AMP 005 R . 0 IT 2a REF RE1 REF. 80% REF 3 r S CUSTOMER B03 E01 D01 DOOR 1E06 EVER.STOP ON JI\ CHASSIS AE03 OTHRWISE ADO LN1K O I 5 10 IE0013Y CONFIDENTIALITY REF. REF, R06 oos. cEoe-[ 1E2733 DRAWING — AUTOCAD E02 ED2 i — o tE0011 INTPR & TOL J 16 SPO SPl SP2 SP3 SP4 SA7 70 T I SPEC NO NAME 61 62 371 372 REF REF I DRN A CU P P LE S 606 BOB CHK J MOOR E SCHANNELSLT APPDM SPITZNAGLE ,1 L153A IS 16 PT E%P R PROD 15.3IA53A53A 5 5 5 5 5 61 f62 I— 371 372 III TO LOW COOLENT IEVEI - -1— —�—� -1 SWITCH IF FITTED UNLESS OTHERWISE SPECIFIED I T DIMENSIONS ARE IN FO ® ® L� O m ® ® ® ® ® ® ® ® DIMENSIONS W 0 TOL ARE BASIC NOTE 1: LINK TERMINALS 7 & 3B FOR NORMAL OPERATION SCALE NONE A4:E2 ECM @)� 0716APRO7 LINK TERMINALS 7 & 3A FOR COMMUNICATION WITH THE SERVICE TOOL SHEET z or PROJECTIOON CHG DATE GENSET MUST NOT BE STARTED WITH 7 AND 3A LINKED CATERPILLAR INC. NOTE 2: FIT SECOND BATTERY IN PARALLEL ONLY FOR C6.6 TAG4 WLNawna Ku[a is lff rnoFEAlY or c•rznuW 1.AwroA ns SUR9NMIFS W1NOUl MRn%1 H:MNZL011..w.CWNN6 m.Ms— ro oTMAs A« z.¢r,,N.,raA Imcrl o.Nco�:nrto,. DIAGRAM—WIRING C&6 EMCP 3.2 CSA 282-3241 DK wa `�ws72 D 6 5 4 3 1 - -- 6 3 METRIC 284-2442 F F E w E L1 L4 LZ I L5 ti L3 I L3 ^y� L��- Nl - Nl C I E I EARTH STUD F7T SHTiR C) ST I IF REWIRED lI :14 1:11 // - - I3 I � 72- i AUX I I IFBKR TR AU EOUIREDT TO FAULT CHANNEL W I IN CONTROL PANEL[ :9!-1 ALT I • D LI ILs -.;.- L] 0 N1 1 NI E E I EARTH STUD �- - 1 1 FIT SH(2) CZ ST 1 IF REOU7IRTD 14 1 11 :12 AU% I FTR AU EW%fREDT TO FAULT CHANNEL 23 :9p 1:95 IN CONTROL P,WEL[ � I 5 DUAL BREAKER CBR%%%2 L - - - -- - -F REQUIRED - J T HT TR B B 1E0013Y CONFIDENTIALITY 1 2733 DRAWING — AUTOCAD 0 1 011 N PR & TOL T SPEC NO. NAME DRN N WATSON CHK J MOORE APPOM SPITZNAGLE C - I E%P I I ppRED.1 I PROD. UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN DIMENSIONS W O TOIL ARE BASIC scALE NONE 03 09 C T 88 SHEET 1 OF 1 PRODIECPoo-N CHG DATE A A CATERPILLAR INC. OF 41FY11M NC AM) SUBSGARXs.r E-1 R.MS90x N11 COrs�c,iI1NNYTIAL Nn 0 "I UY �Cepl MAi V'M MII'N iT i5 LOAM R RION DIAGRAM—WIRING j BREAKER 284-2442 ER we D�ws72 D 6 S 4 3 I METRIC 284-2441 OVER VOLTAGE SHUTDOWN PPV!FOR EMCP3.I ONLY AUpOLE ALARM PAAI NOTE: ONLY APPLICABLE RAISE LOW NEL LEVEL SWITCH FS2 FUEL IF REWIRED IF SEPARATE PROBE L T11 I LOW FUEL LEVEL SWITCH FS2 k HIGH FUEL LEVEL SWITCH FS5 SPEED ADJUST STI LEAKAGE SWITCH FCUL IF RE RED FlrtLD ON 4-WIRE SWITCH. DC ENGINE FKI/2/41F REQUIRED IF REQUIRED PO17:NRp1ETER 87TER �N LO0^M P551 FAULT CHANNEL POI IF REQUIRED PSVI PRE TO CONTROL PANEL TO CONTROL PANEL TO CONTROL PANEL E REIXIIRm RAINATOR F TO ELECTRONIC r 67 �I REOE 53A r � t F GOVERNOR LOWER 1�-,�.O. �I Fig __ I ST2 I 7 21 5 _ FOR IP2WI VT2 21 5 8 5 -5T1 STZ 1roCONTRaFni; 22 21 24 FORCONNECT P3W:115 TO 109 BLACK5 PANEL CONNECT 110 TO 101 B ENGINE LOW HIGH FOR 3P4W: SIREN VOLTS ADJUST 1 TEMP LOW HIGH FUEL FUEL L1 L2 U N DO NOT CONNECT 115 (FlTTED) POTENTIOMETER 5 I SWITCH �LVEL TO ELECTRONIC LEVEL LEAK _ _ _ FOR FOLlOIMNG VOLTAGE. LOW WATER LEVEL SWITCH W51 1 SWITCH SWITCH SWITCH SWITCH - COVERNOR GE1 P551 FOR GES V506 230/1 to - 1 10 110 115 VIS 220/110 DC ENGINE V6 7 240/120 LOOM V609 230/I10 S OVER VOLTAGE V609 220/110 PROTECTION UNIT PAA2 IS SUPPUED LOOSE VFC FOR COMMON VFC FOR GENERATOR ALARM PACI IF REWIRED RUNNING PGR1 IF REWIRED CAR/1 GRR/1 EL REQUICTRRE C GOVERNOR GET .3 .4 '3 4 IF REQUIRED GOVERNOR GES LOW FUEL LEVEL SWITCH FS2 LOW WATER TEMPERATURE SWITCH WCI LOW LOW FUEL LEVEL SWITCH FSI HIGH OIL TEMPERATURE SWITCH LS1 1 2 O 5 DC LCS IF REQUIRED IF REQUIRED IF REQUIRED IF REWIRED OIL TEMPERATURE 1 ENGINE ELECTRONIC FUEL TO CONTROL PANEL 81 B2 B3 84 85 88 SENDER MILT FUEL LEVEL ELECTRONIC 1 O-SM�l00M GOVERNOR TO GONE TO CONTROL PANEL TO CONTROL PANEL E B1 u BS �85 os I IF REWIRED F REWIRED EMER.STOP Q. RLTNOUS) 7 IOTUNK MAGNETIC O 5 �� �� E REMOTE CONTACTS IFOR REMOTE CONTACTS FOR ro CONTROL C W KEY PSBS 1 I PIA(UP GENERATOR RUNNING PANEL TO CONTROL / B SEE NOTE 1 �� ��1 OC GENERAL ALARM PANEL IF REQUIRED ENGINE 27 5 20A 5 5 OT FL �0-03 9 I I I 53A LOOM 20 5 26 C^O ACTUATOR O—�4 106'UNKLOW r' IT 1PII 4 FUEL LOW LOW LOW OIL 53 53 MAGNERC�—' 1I -8 120-'UNK MPUt� 5T1�IF P551 REWIRED SWITCH B TEMP LEVEL lu_ B TEMP. PICK UP ?I.pLJ MPU- �3�']}-pl I ®ST2 RAI+SEE/LOWER SWITCH SWITCH SWITCH NOTE 1: SWITCH IN PANEL IF PSS1 REQUIRED LJ TO 70-WAY TO 70-WAY REMOVE LINK d CONNECTOR AT CONTROLLER CONNECTOR AT CONTROLLER CONNECT 10 SPEED POT IN PANEL r1 r1 BB 90 2 2 CAR GRR 10 10 s s D OIL TEMPERATURE SENDER FUEL FILL PREV SOLENOID FS6 R OVERLOAD RELAY(3 PHASE)PP02 FOR EMCP3.1 ONLY IF REWIRED 108 109 110 101 CIO C30 C50 OVERLOAD RELAY(I PHASE)PP02 FOR EMCP3.1 ONLY IF REQUIRED 109 109 110 101 CIO C30 C50 CAN2 SERVICE CONNECTOR IF REQUIRED ML1 FOR EMCP3.1 ONLY HIGH FUEL LEVEL SWITCH FS5 IF REWIRED IF REQUIRED A B G F C t F22 71 TO SPARE �) FAULT CHANNEL 5 S HIGH 68 F EL LEVEL FUEL '6 ;} i t SWITCH HFLR/2 HFLR/I IC1 C11 ] C31 CSI 1 C14-Iff 51 TEMP OIL 7 73 :G :2 4 AMPS AMP AMPS 108 AMPS 100 HFLR 79 5 'OCR' L NOTE: 'OCR' V2�2P�N I 6] fia C :H - OVERCURRENT I 115 FOR 400V OVERCURRENT PROTECTON CONNECT PROTECTION 14 11 12t15 14 11 1207UNIT _ I75 TO 107 UNIT _5 3 PHASE 35 FOR 200V 1 PHASE 63A 5ECT c 5 115 TO 110 53 5 79 TO SPARE TO SHUNT TO SPARE TO SHUNT :MC FAULT CHANNEL TRIP FAULT CHANNEL TRIP i gMT MOTORISED VALVE 100 tog "0 101 CI1 C31 C5t 108 109 ,I10 101 C11 C31 CSI A IN i IT I Ht 13 11 9 7 7 31 47 57 13 it 7 .31 47 57 VC IA to IC VC IA IB IC VB J VB VA VA CONTROLLER AC SENSING TERMINALS CONTROLLER AC SENSING TERMINALS B 1E01 88R LETTERS B lEO013Y CONFIDENTIALITY 33 RAWING — AU CAD 0 lEO011 INTPR & L OPTION OPTION CODE WIRE NUMBER PRIORITY IN FAULT CHANNEL SELECTION T SPEC NO. NAME ORN LGOWDY HIGH OIL TEMP.SHUTDOWN LSI 26 1 CHK C.McILROY LOW COOLANT TEMP.ALARM WC1 20A 2 APPD W.SMYTH LOW FUEL LEVEL ALARM FS2 21 3 p-I I EKP I I PROD. LOW FUEL LEVEL SHUTDOWN FS1 20 4 UNLESS OTHERWISE SPECIFIED HIGH FUEL LEVEL ALARM F55 68 5 DIMENSIONS ARE IN DIMENSIONS WIG TOl ARE BASIC OVERLOAD ALARM PP01 23 8 SCALE NONE 04—Gyju109 OVERVOLTAGE SHUTDOWN PPV7 67 7 THIRD pNGIE SHEET 1 Oi 1 PROJECTION CMG DATE ^ A OVERCURRENT SHUTDOWN PP02 63p B CATERPILLAR INC. I"V d Noanl Is 1N[PIIaPW1Y GTuwJAll PLC.Alo vesaWLKs.WIHwr WmrrtJl PExMssla.A�iIY IZPrINc.1RAxfYrtAl 10� O1HIA NIY VSE E r 11Mi Fq WFCR OWIFi)IS DIAGRAM—WIRING (PANEL/ENGINE) �6 s 4s 4 3 284-2441 pKB GDNw972 D 6 -- — 5 -- - — 4 — 3 2 — BATTERY CHARGER PBC5/PMBCUL3/PMBCUL5 BATTERY CHARGER PBCUL3/PBCULI0 # FOR PSVA 120V, F9 MUST BE 4A METRIC 284-2440 IF REQUIRED IF REQUIRED AUXILIARY AUXILIARY HEATER CIRCUITRY WH/AH1/EBH A.C. SUPPLY A.C. SUPPLY IF REQUIRED *SEE FUSE (ENGINE HEATER) TABLE F 132 F6 132 AUXILIARY F (6A) (6A) 136 _ _ _ _ _ _ A.C. SUPPLY 131 F r 132 156 131 CR 2 F6 F9 F8* I F12 I I F11 I 132 FUSE (ENGINE HEATER) CR/2 :6 / (2A) (2A (2A) (2A) 131 131 SET DESCRIPTION FUSE DESCRIPTION :6 137 131 136 BOOST PS63� 137 131 .5 GAS 3.OL - 110V AND 240V 10A BATTERY CR/2 133 134 I 140 I 171 GAS 4.2L - 110V AND 240V 10A IF REQUIRED I � - rINTERNAL � .6 I 1 I I GAS 6.8L - 110V 20A B62 � F- B/ B1 11 \?�BATTERY I AC FUSE I 137 I I I GAS 6.8L - 240V 10A �O _ CHARGER :Al :1 :5 :3 :1 GAS 8.1L - 110V 20A OPEN -BOOST I` 31 I 1 1 BATTERY I HC — — — — t- I I CR/1 I GAS 8.1L - 240V 10A E L CLOSED -NORMAL-j I +\ CHARGER I :A2 41 38 I 142 I I 72 ( C4.4 - 110V 16A E rr (INTERNAL I I I I I HEUI 13060V 110V 20A ItRICKLE CHARGE DC FUSE - - AMMETER PMA4 �-- — — — — ALTER- ENGINE I BATTERY I _ I HEUI 1306 - 240V 10A IF REQUIRED TCA I I HEADER I HEATER THEATER SUMP HEATER CSA GAS 3.OL - 110V AND 240V 10A L — — — — 77 1 f- — — — — 77� 131 — — — — I — — I I I I CSA GAS 4.2L - 110V AND 240V 10A L'— — — �L= — — J CSA GAS 6.8L - 110V 20A ITRICKLE CHARGEAMMETER PMA4 TCA I CSA GAS 6.8L - 240V 10A FIT EBH FIT EOS (6A) IIF REQUIRED I IF REQUIRED IF REQUIRED CSA GAS 8.1L - 110V 20A CSA GAS 8.1L - 240V 10A + 5 L — — — — + J 5 BATTERY CHARGER PBCUL3/PBCUL10 CSA C4.4 - 110V 15A & HEATER CIRCUITRY WH/AH1/EBH/EOS IF REQUIRED CSA C6.6 - 110V 20A D *SEE FUSE (ENGING HEATER) TABLE CSA HEUI 1306 - 110V 20A BATTERY CHARGER PBC5/PMBCUL3/PMBCUL5 # FOR PSVA 120V, F9 MUST BE 4A CSA HEU11306 - 240V 10A & HEATER CIRCUITRY WH/AH1/EBH IF REQUIRED *SEE FUSE (ENGING HEATER) TABLE NOTE: IF SECOND ENGINE AUXILIARY HEATER IS USED F12 IS 20A. A.C. SUPPLY # FOR PSVA 120V, F9 MUST BE 4A AUXILIARY 132 A.C. SUPPLY 132 F6 F7 F9 F8* F1 I F11 I �- — — — 1 F— — — 132 (2A) (6A) (2A (2A2} (2A) F6 F7 F9# F8* I(2A� I I(2A) I 132 136 I I 131 (2A) (6A) (2A 136 I I I I CR/2 131 135 133 134 140 171 131 :6 C CR/2 31 135 133 134 140 171 137 6 I I I I :Al 13 :1 :5 :3 I CR 1 137 13 �1 :5 I :3 I 1 �1 I HC -- --- 14----- 2------- -6 ------ :4 Al I I GR/1 HC 14 :2 :6 :4 :3 A2 39 141 138 142 I 172 IF REQUIRED 'A2 39 141 138 142 I I 172 I ALTER- ENGINE ;BATTERY I ;SUMP NATOR HEATER .HEATER I IHEATERI 31 ALTER- ENGINE I BATTERY SUMP I THEATER I TOR SECOND LTTE 1HEATER I HEATER I I �HEATERI - -,ENGINE HEATER J HEATER 131_1---------- IFOR 4012/16----I B 1E0198R LETTERS B 1 0013Y CON I EN IALtTY FIT EBH FIT EOS INTERNAL 1 33 RAWING - AUTO AD FIT PSB3 IF REQUIRED AC FUSE IF REQUIRED IF REQUIRED I O 1 E 11 IN NA & TOL T SPEC NO. NAME BATTERY ?�IB62 I I r l BATTERY( DRN LGOWDC.McILY CHARGER +�IIB -1 I + CHARGERI 3 APPDC.SMYTHY �I�' I W.SM YTH OPEN-BOOST - ExP PRE PROD. CLOSED-NORMAL J I INTERNAL I UNLESS oTHERw15E sPEanEo 1 LDC FUSE — — J 2 DIMENSIONS ARE IN mm _ CR OMENSIONs w O TOL ARE BASIC SCALE N ONE TRICKLE CHARGES :10 TCA AMMETER PMA4 26APR10 IF REQUIRED I SHEET 1 �1 PROJECT OJ CHG DATE ^ A 1 77 — — — — _I [TRICKLE CHARGE 771 5 CATERPILLAR INC. F20 AMMETER PMA4 n1E Mrab.nw.slSon i5 M[nMOPflliv Of G1FAPxUx iw:.Aw/p1 iR IF REQUIRED TCA FIT IF PBC5/WH/AH1/EBH/PMBCUL3/5/PBCUL3/10 v���Es..111.1 ,a�.wsga.wr m onEAs v use sxcar nwr roll sHIOI iris ioNlm a PxasN (6A) I REQD DIAGRAM—WIRING + L— — — — — — I BATT CHARGER HEATERS + 5 284—2440 DK s,Ea c'7.72 D 6 5 4 3 21 6 5 4 3 2 1 BATTERY CHARGER PBC5/PMBCUL3/PMBCUL5 BATTERY CHARGER PBCUL3/PBCUL1O FOR PSVA 120V, F9 MUST BE 4A METRIC 284-2440 IF REQUIRED IF REQUIRED # AUXILIARY AUXILIARY HEATER CIRCUITRY WH/AH1/EBH A.C. SUPPLY A.C. SUPPLY IF REQUIRED 132 F6 132 *SEE FUSE (ENGINE HEATER) TABLE F6 AUXILIARY F (6A) (6A) 136 A.C. SUPPLY 136 131 — — — _j F — — — 1 132 132 131 :C F6 F9 F8* I F12 I I F11 I FUSE (ENGINE HEATER) CR/2 :6R/2 (2A) (2A (2A) (2A) 131 137 131 6 136 131 SET DESCRIPTION FUSE DESCRIPTION _ _ _ _ _ F-BATTERY BOOST PS63� 137 131 I I I GAS 3.OL - 110V AND 240V 10A CR/2 133 134 I 140 _ 171 GAS 4.2L - 110V AND 240V 10A IF REQUIRED I — — :6 BB2 �1_ 2 rINTERNAL I I I I GAS 6.8L - 110V 20A f-i B \�BATTERY I AC FUSE I 137 I I I I GAS 6.8L - 240V 10A — CHARGER El b :Al :1 ;5 :3 :1 GAS 8.1 L - 110V 20A OPEN -BOOST I 31 I — CR/1 I GAS 8.1L - 240V 10A CLOSED -NORMAL BATTERY :2 :6 :4 4E L - - - - - J CHARGER I :A2 141 138 I 142 I I 172 I C4.4 - 110V 16A E (INTERNAL I I I HEUI 1306Ov 110V 20A IIRICKLE CHARGE DC FUSE - - HEUI 1306 - 240V 10A AMMETER PMA4 TCA — — — — ALTER- ENGINE I BATTERY IIF REQUIRED I _ _ _ _ IHEATER IHEATER IHEATER SUMP HEATER CSA GAS 3.OL - 110V AND 240V 10A L — — — — 77 I 77� 131 — — — — I — I I I I CSA GAS 4.2L - 110V AND 240V 10A J ITRICKLE CHARGE I C- - _�L-J- - J CSA GAS 6.8L - 110V 20A AMMETER PMA4 TCA FIT EBH FIT EOS CSA GAS 6.8L - 240V 10A (6A) IIF REQUIRED I IF REQUIRED IF REQUIRED CSA GAS 8.1L - 110V 20A + 5 L — — — — J CSA GAS 8.1L - 240V 10A + 5 BATTERY CHARGER PBCUL3/PBCULIO CSA C4.4 - 110V 15A & HEATER CIRCUITRY WH/AH1/EBH/EOS IF REQUIRED CSA C6.6 - 110V 20A D *SEE FUSE (ENGING HEATER) TABLE CSA HEUI 1306 - 110V 20A BATTERY CHARGER PBC5/PMBCUL3/PMBCUL5 # FOR PSVA 120V, F9 MUST BE 4A CSA HEUI 1306 - 240V 10A & HEATER CIRCUITRY WH/AH1/EBH IF REQUIRED *SEE FUSE (ENGING HEATER) TABLE NOTE: IF SECOND ENGINE AUXILIARY # FOR PSVA 120V, F9 MUST BE 4A AUXILIARY HEATER IS USED F12 IS 20A. A.C. SUPPLY A.C. SUPPLY F 132 132 F6 F7 F9 F8* F1 I Fll r — — — -1 F — — 132 13 (2A) 136 (6A) (2A� (2A� I (2A) (2A) (6A) 11 (2A� F8* I(2A) I 1Fll 2A (2A)11 136 I I I I :5 R/2 131 135 133 134 140 I 171 I 131 C :5 131 135 133 134 140 171 131 137 :6 16 I I I I :Al :13 :1 :5 :3 CR/1 :Al :13 :1 ;5 I •3 I I :1 I H C -- --- :14-----ilALTER- :2------- :6 ------ :4 I :4 LA2 14 :2 :6 :4 II :3R/1 I A2 139 41 138 142 I 172 IIFITREQUIREDT HT 139 141 138 I 142 I I 172 I I I TR ENGINE ;BATTERY I ; UMP _ NNATOR NHEATER THEATER I IHEATERI 131 ALTER- ENGINE I BATTERY I I SUMP I THEATER I TOR SECOND NATOR ENGINE HE TER 1HEATER HEATER I LATER I I �HEATERI 131 i i ffOR 4012 16 I 1 I — -----1----------L---------L—-------- -------------J 1 0198R ILETTERS B 1E0013Y CONFIDENTIALITY FIT PS83 FIT EBH FIT EOS FNTERNAL 1E DRAWING - AU OCAD IF REQUIRED IF REQUIRED AC FUSE IF REQUIRED I I o 1 011 INTPR & OL T SPEC NO. NAME CHARGER l TT,I ATTERY - -i I I +�j CHARGERATTERY( APPo W OMYp H q1K C.McILROY — OPEN-BOOST I — I 3 CLOSED-NORMAL ExP —. INTERNAL I UNLESS oTHEMASE SPECIRED 5 31 LDC FUSE — — J :2 ONMEN"S ARE N — CR DIMENSMS W/O TOL ARE BASH; TRICKLE CHARGE( SrJUE NONE &Q I TCA AMMETER PMA4 i — — 10 SHEET 1 OF 1 THIRD ANGLE x+c 6 DATE A IF REQUIRED 7AL 77 — — — _ TRICKLE CHARGE 5 CATERPILLAR INC. AMMETER PMA4 F20 IIF REQUIRED TCA I FIT IF PBC5/WH/AH1/EBH/PMBCUL3/5/PBCUL3/10 - �« IT�mmzm_m 5 +6A) — — — — REQD DIAGRAM—WIRING ..a BATT CHARGER HEATERS + ej FeR ma 284-2440 pK � coN w972 p 6 5 4 2 1 METRIC 267-8808 F r-------------------------------------------------------------------------I 3 I I 1 7 4 12 ❑ ❑ ® c,rnzxcr s,oP I I xst I I I I ❑ ❑ i Y �o.coa.n*a"rE".n� j 11 E I i I E ❑ ❑ $x con w.a.c".n"rc I 5 I I I 1 ❑ ❑ .py or a"Mss 6 I I I I 9 1 I J1 ❑ ❑ — BATT I I 700 2 I NBC t + BATT 1 ❑ ❑ I I —3 NC I ❑ ❑ 0 ms o.o i""c —6 CAN HI I 5 CAN LOW n ® -C I co"mowno sr,a I —4 NC I ❑ ❑ "or w w,o I 1 I I 6 PIN DEUTSCH ❑ ❑ w�,�i�"' I CONNECTOR I � II i I I El ❑ : ,w,. p" I I I I -ctI I . ❑ ❑ I I II II I I Y----- y NOTE A: STANDARD GEN PANEL TERMINALS 1 I / I I I I I I I I I I I I I I B B F 1 AWIN_— A_U_ A 1 0011 INTPRV- TOL .w o". J. NG AND o« G.SCANDRETT A ICK M-m [n Is o A —s[nm A u NONE 01 6—ri�b 0 M CATERPILLAR MC.o.R WIRING DIAGRAM m ANNUNCIATOR 267-8808 DK K w972 E 8 7 6 5 4 3 2 METRIC 282-3239 F F E E ABBREVIATIONS SYMBOLS A.V.R. AUTOMATIC VOLTAGE REGULATOR FUSE 11 CUSTOMER TERMINAL AC ALTERNATING CURRENT EMERGENCY STOP PUSHBUTTON c INTERNAL PANEL TERMINAL 10 DC DIRECT CURRENT ']0 RELAY COIL Y QJ OUTGOING/INCOMING PANEL TERMINAL D SRN SCREEN FROM SCREEN CABLE _==r--' SCREEN CABLE 58 CONTROLLER 70-WAY CONNECTOR D IY - DIODE RLv RELAY ENGINE SOCKET 1 l\ RELAY CONTACT N/O I/P INPUT R/1 3 Q POWER TERMINAL • ALR ALARM RELAY �- EARTH INTERNAL AC TERMINAL BLOCK V GRR GENERATOR RUN RELAY FCS FUEL CONTROL SOLENOID is'X- CIRCUIT BREAKER GENERATOR SOCKET FCR FUEL CONTROL RELAY O CANOPY E-STOP SOCKET ECR ENGINE CRANK RELAY RESISTOR C C Q4 ECM SOCKET Pi P2 CURRENT TRANSFORMER GPR GLOW PLUG RELAY S""1��I S2 <[ BUZZER /SIREN SOLENOID B B LTTERS N3 . AW AP & L C.A ..m. A Q lYJ'�I 1 1 rc 2 CATERPILLAR INC.e rz 57GAM EMCP .2 e6-3239 pK 06 W972 E 8 7 6 5 4 3 2 -1 8 7 6 5 4 3 2 METRIC 9 F NO F 1 14 ALM��---Q ALM SON C_� tr4 OSDN GRR P-OGRR NOTE: IF 4 POLE BREAKER FITTED 4 POLE BREAKER OPTIONAL LFL a__� 1_O LFL CHANGE N1 y N (SEE NOTE REF.AO1) Pi P9 L4 GRR = GEN RUN SiS2 LFL = LOW FUEL LEVEL L L5 ALM = COMMON ALARM G S1 52 6 SON = COMMON SHUTDOWN S1 S2 N1 N1 E E E DEARTH STUD E ® 104 103 1D2 101 F1 F2 F3 II (6.3A) (6.3A) (6.3A) C10 C30 C50 C90 C0� MAGNETIC ® ® ® ® ® ® O PICK-UP 3A 1D0. ELECTRONIC SERVICE TOOL LINK 108 109 110 101 C10 C30 C50 C90 ® 10 IREF. R F. A B D E G F C 4 1C06 7 5 371 33�Ty'61 62 63 64 SC1 65 66 C 1REF 3A + 10 + 4 + 6 `"'"' ,BSF COB F30 F32 � ® 1C07 (25A) (20A) 1200 120 53 :2:2 1-87 GPR/1 51A } 61 62 63 64 65 66 2 41 I I I I I I I 1 I I I I I I I I I I D D :10:10 :30 13 11 9 7 31 47 57 39 50 34 S42 62 64 SCR + 3 SCRN 67 66 :2:2 :2:2 EMCP 3.2 -- � - + '87 '67 V IA IB IC RETURN REL FCR/1 REL ECR/1 R F CANT J1939 CAN2 J1939 RS 485 PMAC ICKUP :10:10 :30 :10:10 :30 C071 EARTH (MOUNTING SCREW) VA gg SIINK O/P 1 LCD DISPLAY ® r- 53A 5B SBA 51 + OG REF. EQ7 _ jm ® ® ® D o • ® + F10 7,5�65 BATTERY(12/24Vdc) (6 A) 2 RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8 OIL ENGINE PROG OIL ENGINE P OG SEE 6�1 3A p0' ENG FU L LOW AUDIBLE COMMON GENSET PRQQG PRpoG EMERG REMOTE LOW COOLANT FROG PROG FROG PROG PROG PRESSURE TEMP P PRESSURE TEMP I/qP NOTE 2 CRANK CONTROL PLUG ALARM ALARM RUNNING 0/P 0/P STOP START LEVEL I/P I/P I/P I/P I/P PASSIVE PASSIVE PASSIVE PASSIVE PASSIVE PASSIVE 1 r r r r 1 I P 2 P 3 P 4 P 5 P 6 I/P 7 I/P 8 ANALOG 1+ ANALOG 2+ ANALOG 3+ ANALOG 1- ANALOG 2- ANALOG 3- 2V 12V REL 19I Y 1r tl 4 -0 35 43 3 41 32 40 26I 27 2I25 1 1r2_4 14yyyy 701 551 541 531 451 441 361 28) 561 38Y 301 46Y 37Y 291 I CHARGING 16 7 27 7 10 7 87 7 8 7 90 7 67 7 69 �70 k2 17 24 16 SPO SP1 P2 SP3 SP4 SA 1 30 4 5B �M� ALTERNATORSEE t NOTE 1 R0F 0 C B T C I�_h PLUGS ® 7 C O COS A ST10P 5 17 �A ® 1 AMP 0 ® ® CUSTOMER ®I �Rr,'4- R F.RAF. 3 = - _ START SIGNAL REF. D 1 D01 COMM 0 0 C06 REF 4 10 EMER. STOP ON SHUTDOWN REF BOX 7D06 07 E 7 TH RWI E A ONLY N INK L C08T� DOOR 7RE08 5 16 ISPO SPt JSP2 SP3 JSP4 JSA1 130 CHASSIS 7RE0y. D,7 C,B I+ 5 �i6 SPARE ARE FAULT REF. TO LOW COOLANT LEVEL DOS D03 SWITCH IF FITTED LEAK 34 LFL AUX 61 W 62 Q 371 Z 372 T31 B 3A 53A 53A 53A 53A 5 5 5 5 5 61 62 ?371 372 1_ B � I I O®®®C4IDm®®®® ® ®® ® ®� A4:E2 ECM 019 R L NFIULNIIALIIT JT jr1527533 DRAWIN - AU A N IUL w 11 �12 mm A NOTE 1: LINK TERMINALS 7 & 38 FOR NORMAL OPERATION A LINK TERMINALS 7 & 3A FOR COMMUNICATION 4 WITH THE SERVICE TOOL >10 I NA° CATERPILLAR INC. GENSET MUST NOT BE STARTED WITH 7 &3A LINKED NOTE 2: FIT SECOND BATTERY IN PARALLEL ONLY FOR C6.6 TAG4 sioa/�oio� 13 2 E 8 7 6 5 4 3 2 110 POWER SYSTEMS GENERATOR SET TEST DATA CUSTOMER PURCHASE ORDER NO 0 PROJECT ENGINEER A.Main .JOB NAME Sbd119 BIM PACKAGE SN NODU1BI1 PACKAGE M% Cd-ft TEST LATE 5/14/14 ENGINE SN ESMMM ENGINEM/NMODEL DIT 2 PRE TEST CHECKOUT TESTED BY GENERATOR SN G I00 GENERATOR MN 0 RATED KVA.._......2I0.n RATED PF...........SA RATED LINE AMPS..........263.1 RATED FULL LOAD EXCITER VOLTS........3A21 RATED KW..........— RATED L{VOLTS..........,Bo RATED TEMP RISE.........Jos RATED FULL LOAD EXCITER AMPS........3.30 ENGINE PRE START CHECK LIST PRIOR TO OPERATING THE UNIT,THE FOLLOWING PRE-START INSPECTIONS ARE TO BE PERFORMED TO VERIFY THE UNIT IS IN COMPLETE OPERATING CONDITION. COOLING SYSTEM ENGINE ROOM VENTILATION COOLING SYSTEM IS FULL X LOUVERS FUNCTIONAL_CAT Enclosure ANTI FREEZEIWATER% 50% INTAKE/OUTLET FREE OF OBSTRUCTION Ok ELC or DEAC ELC ENGINE ROOM TEMPERATURE ACCEPTABLE COOLING WATER CONNECTIONS ARE SECURE Ok DRAIN VALVES ARE SECURE Ok STARTING SYSTEM VENT LINES ARE IN PLACE AND SECURE Ok BATTERY CABLES ARE TIGHT ON RADIATOR CAP IS IN PLACE Ok ELECTROLYTE LEVEL Ok JACKET WATER TEMPERATURE PRIOR TO START 115 Degree F BATTERY CHARGER OPERATING CORRECTLY Ok JACKET WATER HEATER OPERATING CORRECTLY Ok FUEL SYSTEM FUEL CONNECTIONS ARE TIGHT&LEAK FREE Ok GENERATOR FUEL FILTERS ARE SECURE Ok GENERATOR HEATERS ON FOR 48 HOURS Ok GOVERNOR LINKAGE IS FREE FROM BINDING NIA PRIOR TO STARTING? FUEL SYSTEM IS FREE OF AIR Ok GENERATOR ALIGNMENT PERFORMED(ATTACH Ok DAY TANK FULL OF FUEL 20%Fuel WORK SHEETS) FUEL TYPE/API #2 Demel GENERATOR SET PROPERLY GROUNDED Ok INTAKE SYSTEM REMOTE ANNUNCIATOR AIR CLEANERS ARE SECURE Ok VERIFY WIRING TERMINATIONS TO REMOTE N/A HUMP HOSE CONNECTIONS ARE TIGHT Ok ANNUNCIATOR PANEL LOAD BANK EXHAUST SYSTEM CONNECT LOAD BANKS AND VERIFY ON EXHAUST FREE OF OBSTRUCTIONS Ok PROPER OPERATION EXHAUST CONNECTIONS ARE SECURE Ok AUTOMATIC TRANSFER SWITCH LUBE OIL SYSTEM CAT ATC TAT02871 MANUFACTURER ENGINE CRANKCASE IS FULL OF OIL Ok ATS 1 ATS 2 ATS 3 OIL FILTERS ARE SECURE Ok OIL DRAIN VALVE IS SECURE Ok MODEL# ATC 300 ENGINE IS FREE FROM LEAKS ON SERIAL# TAT02271 MECHANICAL INSPECTION FOR LOOSE BELTS Ok TIME DELAYS INSPECT FAN AND DUCTWORK Ok ENGINE START 15 Sec INSPECT SUPPORTS Ok ATTACHMENTS SECURE Ok XFER TO EVER 30 Sec LUBRICATION POINTS Ok Neutral 1 Min PROPER ADJUSTMENT OF VIBRATION ISOLATORS N/A XFER TO NORM 5 Min VIBRATION MEASUREMENTS RECORDED N/A ENGINE COOLDOWN 5 Min COMMENTS • • • • N C POWER SYSTEMS GENERATOR BET TEST DATA CUSTOMER Mwntenananwn PURCHASE ORDER NO o PROJECT ENGINEER n JOB NAME src.�5a�GHa PACKAGE SIN NSoo+o17 PACKAGE MIN CAN1wMl TEST DATE ENGINE:IN EeM02378 ENGINE M/NMODEL D1752 PRE TESTCHECK OUT TESTED BY GENERATOR S/N GOA04100 GENERATOR MIN 0 WdT...d by RATED KVA..........21e.75 RATED PF.......o e RATED LINE AMPS..........263.1 RATED FULL LOAD EXCITER VOLTS........0e 21 RATED KW..........175 RATED L.L VOLTS.....4e0 RATED TEMP RISE.........105 RATED FULL LOAD EXCITER AMPS....,...130 WITNESSED TIME ENGINE GENERATOR GENERATOR GENERATOR GENERATOR GENERATOR GENERATOR GENERATOR POWER GENERATOR GENERATOR EXCITER EXCITER GENERATOR GENERATOR GENERATOR GENERATOR GENERATOR GENERATOR HOURS HOUR FREOUENCY VOLTAGE VOLTAGE VOLTAGE AMPS AMPS AMPS FACTORI LOAD LOAD FIELD FIELD INLET AIR INLET AIR OUTLET AIR OUTLET AIR AIR TEMP AIR TEMP METER HERTZ — SS AG C KVAR MY • VOLTS AMPS TEMP LH TEMPw RH TEMP LN TEMP-RN 0111-LH DIFF RH 1 2 3 4 5 e 7 5 9 10 11 12 13 14 15 to 11 19 19 20 9:50 1.7 80 477 478 477 217 217 217 1 179 103 10:05 2 80 477 478 477 217 217 217 1 179 103 10:20 2.2 60 477 476 477 217 217 217 1 179 102 10:35 2.5 60 477 478 477 217 217 217 1 179 102 10:50 2.7 60 477 477 477 217 217 217 1 179 102 11:05 3 60 477 477 477 217 217 217 1 179 102 11:20 3.2 60 477 477 477 217 217 217 1 179 102 11:35 3.5 60 477 477 477 217 217 217 1 179 102 11:50 3.7 60 477 477 477 217 217 217 1 179 102 GENERAL 1.CHECKALL FLUID LEVELS.START GENERATOR SETANDWARM UPAT IDLE.CHECK FOR LEAKS,EXCESSIVE VIBRATION,ETC. COMMENTS 2.BRING GENERATOR SET TO RATED SPEED AND VOLTAGE AND WARM UP WITH A PARTIAL LOAD. 3.RECORD READINGS EVERY...............................................HOURS 4.TURNOFF LOAD BANKS.COOL DOWN GENERATOR SET,SHUTDOWN ENGINE. i • • N C POWER SYSTEMS GENERATOR SET TEST DATA CUSTOMER An�aao�co�av��loa PURCHASE ORDER NO 0 PROJECT ENGINEER A.NBfNMN JOB NAME sv,aa.rema. PACKAGE SIN MM1917 PACKAGE MIN CAM N", TEST DATE ENGINE SIN EBM02570 ENGINE MINMODEL D17S-2 PRE TEST CHECK OUT TESTED BY GENERATOR SIN GSA0000 GENERATOR MIN 0Witnessed by RATED KVA_.._ :1s.75 RATED PF...........0.8 RATED LINE AMPS......__263.1 RATED FULL LOAD EXCITER VOLTS........U21 RATED KW.....,._ n5 RATED L-L VOLTS......... 00 RATED TEMP RISE. ..105 RATED FULL LOAD EXCITER AMPS........339 TIME ENGINE GENERATOR ENGINE ENGINE ENGINE BATTERY ENGINE ENGINE LEFT RIGHT IAT MANIFOLD LEFT RIGHT HOURS HOUR FREQUENCY OIL DIFF OIL WATER OC FUEL FUEL AIR CLEANER AIR CLEANER TEMPERATURE BOOST AIR CLEANER AIR CLEANER EXHAUST FUEL METER RPM PRESSURE PRESSURE TEMPI lA F METE"DC CONS GPM PRESSURE TEMPERATURE TEM RATURE E F PREBSUREIPSI DIFF PRESS DIFF PRESS SACKPRE88URE TEMP 1 3 S 4 5 0 7 0 0 10 11 10 18 14 to 13 17 IS 9:50 1.7 1800 82 180 13.8 13.7 10:05 2 1800 80 183 13.8 13.7 10:20 2.2 1800 80 183 13.8 13.7 10:35 2.5 1800 80 185 13.8 13.7 10:50 2.7 1 1800 80 185 13.8 13.7 11:05 3 1800 80 185 13.8 13.7 11:20 3.2 1800 80 185 13.8 13.7 11:35 3.5 1800 80 185 13.8 13.7 11:50 3.7 1800 59 185 13.8 13.7 GENERAL 1.CHECK ALL FLUID LEVELS.START GENERATOR SET AND WARM UP AT IDLE.CHECK FOR LEAKS,EXCESSIVE VIBRATION,ETC. COMMENTS 2,BRING GENERATOR SET TO RATED SPEED AND VOLTAGE AND WARM UP WITH A PARTIAL LOAD. 3.RECORD READINGS EVERY................................................HOURS t.TURN OFF LOAD BANKS,COOL DOWN GENERATOR SET,SHUT DOWN ENGINE. N C POWER SYSTEMS m PACKAGING SLIP 17900 West Valley Highway DATE March 31,2014 Tukwila,WA 98188 CUSTOMER NAME Guy F Atkinson Construe PH:(425)251-5877 FY:(425)251-6423 SHIP TO Guy F Atkinson Construction Strander Blvd Tukwila WA CUSTOMER PO NC ORDER NT"JIBER SERIAL NUMBER PROJECT/JOB NAME 150127-211 1:l r€112cr G gnu r' r ITEM# DESCRIPTION ORDERED SHIPPED B/O Ate. Below items in ship loose crate 0 301 96-18 \IDiA19 P.ANFI, 2 0 rFB 916 1,OC1' 1'"FY P A\I I, 2 251 MAN l,l'BI.FNGINH' ALL CXI I 1 3 0 44U \I \\ \\.AItK\\Il C.At,I1:AG 0 ISERP4548 \1.AN 19CD FNG C6.6 1 0 SEBU8139 AI A\ O\1\I I" (:6.6 0 1428240 K1,A' MOULDED PL;ASCIC 1 IE.AD LOGO 3 0 84?1-11) D1 AGR.A\f \V'1R1\C: 1�A 1"II:R(:I I_AR(d 1t 1 n 2842441 �l)l AGR.V\t\V lR1NG 2842442 [AAG1ZAM\V IR1\G tiltl:AIiER u 267/8808 IAAGR.A�1\\1RI\G_A\\t'NCIA"TOR 1 0 823241 DI.AGR.A\t\V'IRI\G 0 Il 0 , u 0 U 1 _ 0 0 II � Q 1 ' 0 ------------- _ _... . _ Please contact us with any questions or concerns. THANK YOU FOR YOUR BUSINESS! • • • Effective with sales to the first user on or after February 1,2008 CATERPILLAR LIMITED WARRANTY Industrial, Petroleum, Locomotive, Agriculture Engine Products and Electric Power Generation Products Worldwide Caterpillar Inc. or any of its subsidiaries ("Caterpillar") Caterpillar Responsibilities User Responsibilities warrants new and Remanufactured engines and electric If a defect in material or workmanship is found during the The user is responsible for: power generation products sold by it (including any warranty period, Caterpillar will, during normal working •Providing proof of the delivery date to the first user. products of other manufacturers packaged and sold by hours and through a place of business of a Caterpillar Caterpillar), to be free from defects in material and dealer or other source approved by Caterpillar: •Labor costs, except as stated under "Caterpillar workmanship. Responsibilities", including costs beyond those •Provide(at Caterpillar's choice)new,Remanufactured or required to disconnect the product from and reconnect This warranty does not apply to Caterpillar Motoren(CM) Caterpillar-approved repaired parts or assembled the product to its attached equipment, mounting and product, engines sold for use in on-highway vehicle or components needed to correct the defect. marine applications, engines in machines manufactured support systems. Note: Items replaced under this warranty become the by or for Caterpillar,3500 and 3600 Family engines used .Travel expenses not covered under "Caterpillar in locomotive applications, 3000 Family engines, C0.5 property of Caterpillar. Responsibilities". through C4.4 and ACERT(C6.6,C7,C9,C11,C13,C15, •Replace lubricating oil,filters,coolant and other service •All costs associated with transporting the product to - C18, C27, and C32) engines used in industrial items made unusable by the defect. and from the place of business of a Caterpillar dealer or applications, or Caterpillar brand batteries. These •Provide reasonable or customary labor needed to other source approved by Caterpillar. products are covered by other Caterpillar warranties. correct the defect, including labor to disconnect the •Premium or overtime labor costs. This warranty is subject to the following: product from and reconnect the product to its attached equipment,mounting,and support systems,if required. •Parts shipping charges in excess of those which a Warranty Period usual and customary. For new 3114,3116 and 3126 engines and electric power •For new industrial engines, engines in a Petroleum generation products (including any new products of the •Local taxes,if applicable. application or Petroleum Power Systems,or engines in other manufacturers packaged and sold by Caterpillar): •Costs to investigate complaints, unless the problem is a Locomotive application, or Uninterruptible Power caused by a defect in Caterpillar material or Supply (UPS) systems, the warranty period is •Provide travel labor,up to four hours round trip if,in the workmanship.12 months after date of delivery to the first user. opinion of Caterpillar,the product cannot reasonably be transported to a place of business of a Caterpillar dealer •Giving timely notice of a warrantable failure an •For Mobile Agricultural applications and Automatic or other source approved by Caterpillar(travel labor in promptly making the product available for repair. Transfer Switch(ATS)products the warranty period is 24 excess of four hours round trip,and any meals,mileage, •Performance of the required maintenance(including u months after date of delivery to the first user. lodging,etc. is the user's responsibility). of proper fuel, oil, lubricants and coolant) and item •For electric power generation products in prime or For all other products: replaced due to normal wear and tear. continuous applications the warranty period is .12 months.For standby applications the warranty period Provide reasonable travel expenses for authorized •Allowing Caterpillar access to all electronically stored is 24 months/1000 hours. For emergency standby mechanics, including meals, mileage, and lodging, data. applications the warranty period is 24months/400 hours. when Caterpillar chooses to make the repair on-site. All terms begin after date of delivery to the first user. (continued on reverse side...) •For all Remanufactured engines,the warranty period is 6 months (12 months for mobile agricultural and standby electric power generation applications) after date of delivery to the first user. E,A,O, D SELF5419 Limitations •Failures resulting from user's delay in making the •Repair of components sold by Caterpillar that is Caterpillar is not responsible for: product available after being notified of a potential warranted directly to the user by their respective •Failures resulting from any use or installation which product problem. manufacturer. Depending on type of application, certain Caterpillar judges improper, •Failures resulting from unauthorized repair or exclusions may apply.Consult your Caterpillar dealer for •Failures resulting from attachments, accessory items adjustments, and unauthorized fuel-setting changes. more information. and parts not sold or approved by Caterpillar. •Damage to parts, fixtures, housings, attachments, and •Failures resulting from abuse, neglect and/or improper accessory items that are not part of the engine or electric power generation product (including any repair. products of other manufacturers packaged and sold by Caterpillar). For products operating outside of Australia. Fiji, Nauru, New Caledonia, New Zealand, For products operating in Australia. Fiji, Nauru. New Caledonia, New Zealand, Papua New Guinea, the Solomon Islands and Tahiti, the following is applicable: Papua New Guinea, the Solomon islands and Tahiti, the following is applicable: NEITHER THE FOREGOING EXPRESS WARRANTY NOR ANY OTHER WARRANTY THIS WARRANTY IS IN ADDITION TO WARRANTIES AND CONDITIONS IMPLIED BY BY CATERPILLAR, EXPRESS OR IMPLIED, IS APPLICABLE TO ANY ITEM STATUTE AND OTHER STATUTORY RIGHTS AND OBLIGATIONS THAT BY ANY CATERPILLAR SELLS WHICH IS WARRANTED DIRECTLY 1'0 THE USER BY ITS APPLICABLE LAW CANNOT BE EXCLUDED, RESTRICTED OR MODIFIED MANUFACTURER. ("MANDATORY RIGHTS"). ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED(BY STATUTE OR OTHERWISE),ARE EXCLUDED. OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS NEITHER THIS WARRANTY NOR ANY OTHER CONDITION OR WARRANTY BY FOR A PARTICULAR PURPOSE, EXCEPT CATERPILLAR EMISSION-RELATED CATERPILLAR, EXPRESS OR IMPLIED (SUBJECT ONLY TO THE MANDATORY COMPONENTS WARRANTIES FOR NEW ENGINES, WHERE APPLICABLE. RIGHTS), IS APPLICABLE TO ANY ITEM CATERPILLAR SELLS WHICH IS REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF WARRANTED DIRECTLY TO THE USER BY ITS MANUFACTURER. MATERIAL AND SERVICES,AS SPECIFIED HEREIN. TO THE EXTERd r PERMITTED UNDER THE MANDATORY RIGHTS, IF CATERPILLAR CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL IS THE SUPPLIER TO THE USER,CATERPILLAR'S LIABILITY SHALL BE LIMITED AT DAMAGES. ITS OPTION TO (a) IN THE CASE OF SERVICES, THE SUPPLY OF THE SERVICES CATERPILLAR EXCLUDES ALL LIABILITY FOR OR ARISING FROM ANY AGAIN OR THE PAYMENT OF THE COST OF HAVING THE SERVICES SUPPLIED NEGLIGENCE ON ITS PART OR ON THE PART OF ANY OF ITS EMPLOYEES, AGAIN,AND(b)IN THE CASE OF GOODS,THE REPAIR OR REPLACEMENT OF THE AGENTS OR REPRESENTATIVES IN RESPECT OF THE MANUFACTURE OR SUPPLY GOODS, THE SUPPLY OF EQUIVALENT GOODS, THE PAYMENT OF THE COST OF OF GOODS OR THE PROVISION OF SERVICES RELATING TO THE GOODS. SUCH REPAIR OR REPLACEMENT OR THE ACQUISITION OF EQUIVALENT GOODS. IF OTHERWISE APPLICABLE, THE VIENNA CONVENTION (CONTRACTS FOR THE CATERPILLAR EXCLUDES ALL LIABILITY FOR OR ARISING FROM ANY INTERNATIONAL SALE OF GOODS) IS EXCLUDED IN ITS ENTIRETY. NEGLIGENCE ON ITS PART OR ON THE PART OF ANY OF ITS EMPLOYEES, AGENTS OR REPRESENTATIVES IN RESPECT OF THE MANUFACTURE OR SUPPLY For personal or family use engines or electric power generation products,operating in the OF GOODS OR THE PROVISION OF SERVICES RELATING TO THE GOODS. USA, its territories and possessions,some states do not allow limitations on how long an implied warranty may last nor allow the exclusion or limitation of incidental or CATERPILLAR IS NOT LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES consequential damages.Therefore,the previously expressed exclusion may not apply to UNLESS IMPOSED UNDER MANDATORY RIGHTS. you. This warranty gives you specific legal rights and you may also have other rights, IF OTHERWISE APPLICABLE, THE VIENNA CONVENTION (CONTRACTS FOR THE whi(,h vary by jurisdiction. To find the location of the nearest Caterpillar dealer or other INTERNATIONAL SALE OF GOODS) IS EXCLUDED IN ITS ENTIRETY. authorized repair facility, call (800) 447-4986. If you have questions concerning this This warranty covers every major component of the products.Claims under this warranty warranty or its applications,call or write: should be submitted to a place of business of a Caterpillar dealer or other source In USA and Canada: Caterpillar Inc.. Engine Division, P. O. Box 610, Mossville, IL approved by Caterpillar. For further information concerning either the location to 61552-0610, Attention: Customer Service Manager, Telephone (800) 447-4986. Outside submit claims or Caterpillar as the issuer of this warranty, write Caterpillar Inc., the USA and Canada:Contact your Caterpillar dealer. 100 N. E.Adams St.,Peoria, IL USA 61629. SELF5419 is 0 0 0 r a' w Level r a ti KPSIO u a sor's -. Man I Jar'Uary 2�) r t� t r, L� Pressure Systems, Inc. KPSIT" Level and Pressure Transducers User's Manual • Table of Contents 1.0 Product Description.......................................................... 2 General Characteristics....................................................... 2 Care and Handling............................................................... 2 Calibration........................................................................... 2 Approvals ............................................................................ 3 2.0 Product Accessories and Options................................... 4 NoseCaps........................................................................... 4 810 SuperDryM Vent Filter or 815 Aneroid Bellows............ 5 Sacrificial Anode.................................................................. 5 Absolute/Sealed Gage Transducer...................................... 6 Polyurethane& ETFE Jacketed Cable................................ 6 Lightning Protection............................................................. 8 '/2' Male NPT Conduit Fitting............................................... 9 Electrical Outputs................................................................ 9 Reverse Signal Output........................................................10 Temperature Output ...........................................................10 CableHanger......................................................................10 Submersible Cable Splicing Kit............................................12 3.0 Installation&Maintenance Tips.......................................13 General Installation Procedures..........................................13 Transducer Anchors............................................................13 Transducer Submersion......................................................14 SuperDryTM Vent Filter or 815 Aneroid Bellows ..................14 Cable Protection..................................................................15 Bendingof Cable.................................................................15 CableCompression.............................................................15 4-20 mA Output Wiring........................................................15 • VDC Output Wiring..............................................................16 Model750............................................................................16 Sealed-Gage Transducer Above Sea Level........................16 Transducer Position Sensitivity............................................17 General Maintenance Tips ..................................................18 Desiccant Maintenance.......................................................18 Clogged Nose Piece or Dirty Diaphragm.............................18 Cleaning Your Transducer...................................................19 4.0 Warranty and Product Return Procedures......................22 Restocking Policy ........................................................... 23 Appendix A Drawings and Diagrams............................................25 Appendix B Frequently Asked Questions ...................................29 Appendix C Field Checkout&Troubleshooting Techniques......34 Appendix D Calibration Calculations............................................50 Page 1 Pressure Systems, Inc. KPSIT" Level and Pressure Transducers User's Manual 1.0 Product Description General Characteristics KPSITm Level and Pressure Transducers use isolated- diaphragm sensors that are specifically designed for use with hostile fluids and gases. These sensors utilize a silicon pressure cell that has been fitted into a stainless steel or titanium package with an integral, compliant stainless steel or titanium barrier diaphragm. This sensor assembly is housed in a rugged 316 stainless steel or titanium case which provides for a variety of level ranges from 2.3 ft (0.75 m) H2O through 4614 ft (1408 m) H2O and pressure inputs from 0-1 (7 kPa) through 0-15000 psi (103 mPa). Our devices feature internal signal conditioning. Standard outputs are 4-20 mA and VDC. All units containing active electronic components have surge and reverse polarity protection. For ease of use in the field, our transducers are permanently laser engraved with our logo and name, wiring information, part number (P/N), serial number (S/N), date of manufacture (DOM), range, excitation and output. Transducers are offered in • diameters of 1.0 (25 mm) and 0.75 inches (19 mm). Care and Handling Our transducers are designed for rugged use. However, they need protection from over pressure and sharp impact. When lowering them into a liquid, penetrate the surface slowly and only to the depth necessary. Avoid dropping the unit from above the surface. Clean all transducers by rinsing them in a mild detergent. Direct probing of the diaphragm or attempts to remove Page 2 Pressure Systems, Inc. KPSIT°" Level and Pressure Transducers User's Manual • protective screens will damage the sensor, voiding the warranty. Calibration All transducers are shipped with calibration information unique to each transducer. Make sure you keep each calibration report. However, should you misplace your calibration sheet, you can contact the factory and request a duplicate. All KIPS ITm Transducer calibrations are traceable to the National Institute of Standards and Technology (NIST). Approvals Most of our products have UL and FM certification for intrinsic safety. Their respective installation control drawings can be downloaded from our website. Several of our product lines also carry ABS approval. Most products are CE compliant to EN 61326-1:2006 and EN 61326-2-3:2006. CE compliant units are labeled accordingly. These units are designed for installation in a Class I, Division 1, Groups A, B, C, and D, Class II, Division 1, Groups E, F and G, Class III, Division 1 hazardous location when connected to appropriate apparatus such as those manufactured by R. G. Stahl, Inc., and others. Page 3 I Pressure Systems, Inc. KPSIT" Level and Pressure Transducers User's Manual 2.0 Product Accessories and Options . WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD In hazardous locations: • Avoid building up static charge on case of data protector and plastic accessories. • Use damp rag to wipe data protector and plastic accessories to avoid static build up. Nose Caps There are several different user-installable nose caps for the 700, 710, 720, 730, 735 submersible level transducers. The ported nose cap (Delrin) with #8- 32UNC-2B threaded hole is best used where weights are required and for those installations where users may encounter sharp, protruding objects. The open-face nose cap which allows maximum contact with the liquid media is ideal for wastewater and "greasy" applications where clogging of the sensor is a concern. The piezometer nose cap allows the unit to be buried in saturated soil without damage to the sensor diaphragm. The 1/4" • male NPT pressure nose cap is not only useful for calibration purposes but also allows the device to be used as a submersible or above ground pressure transducer. WARNING: Caution must be exercised when inserting a screw into the nose cap as the maximum insertion length should not exceed 0.175". Page 4 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual 810 SuperDryTM Vent Filter or 815 Aneroid Bellows All submersible transducers with vented gauge format are supplied with a protective barrier that guards against moisture buildup in the cable vent tube. The 810 SuperDryTM vent filter is installed free of charge and is guaranteed to operate maintenance free for one year. We also offer the 815 Aneroid Bellows as a maintenance free option that can be used on submersibles with accuracies of: ±1%, ±0.5%, or±0.25% FSO. These barriers ensure reliable operation and long life as they protect sensitive electronic components from mildew and prevent the formation of a liquid column in the vent tube. Any such liquid column directly affects calibration of the transducer. Sacrificial Anodes Our sacrificial anodes are made from a special zinc alloy formulated to guarantee continued effectiveness over long periods. Because the anodes are 95% galvanic, they will not corrode unless there is an electrolytic demand. The anode maintains a high driving potential throughout its 12 month life, is self-sluffing and always exposes new zinc for the best possible protection. For • those applications where cable buoyancy is a problem, the sacrificial anode can be substituted for hanging weights. Sacrificial Anodes provide cathodic protection against galvanic corrosion for our submersible pressure transducers. Galvanic corrosion occurs when dissimilar metals are placed in contact with an electrolyte. This condition causes a potential difference to exist between the two metals, causing electron flow between them. Corrosion of the less corrosion-resistant metal is increased and attack of the more resistant metal is decreased. The 820 Sacrificial Anode is clamped to the Page 5 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual exterior of a one-inch bore submersible transducer. We • also offer a 1" diameter pencil anode, the 825, that attaches to the nose cap of either a 3/4" or 1" bore submersible transducer. Absolute/Sealed Gage Transducer The sealed gage option for submersible transducers eliminates the need for a vent filter. The standard output of a sealed gauge transducer is 4 mA at 14.70 psia. Before ordering a sealed gauge transducer, the customer should determine the altitude (above sea level) of the installation and inform PSI's Customer Service of this value before order entry. During manufacture, the output of the transducer will be adjusted to compensate for the altitude difference, if applicable. Polyurethane & ETFE Jacketed Cable Most installations of our submersible level transducers connect our polyurethane or ETFE cable to a junction box. From this junction box (P/N 840), users typically run their own cable to the required instrumentation. Polyurethane-jacketed cable is used for most applications while ETFE material is recommended for • more aggressive environments. Page 6 Pressure Systems, Inc. KPSlTm Level and Pressure Transducers User's Manual • Specifications for our standard polyurethane and ETFE jacketed cable are as follows: Specifications Standard Standard Submersible Cable Non-Submersible Cable Weight 0.05 Ibs/ft(0.07 kg/m) 0.025 Ibs/ft(0.035 kg/m) Min.OD 0.28"(7.10 mm) 0.189" (4.8 mm) Max OD 0.31"(7.87 mm) 0.19"(4.9 mm) Conductors 4-22 AWG 22 AWG Insulation PVC Conductors Polyurethane or ETFE Color coded PVC Outer jacket Shield 36 gauge spiral tinned Aluminum/polyester foil copper wire foil shield with facing outward drain wire Vent Tube Polyethylene, .060" ID Drain wire (1.52 mm) 7/32 tinned copper • Chemical resistance of polyurethane: Potable Water, Wastewater, Borax, Butane, Animal Fat, Carbonic Acid, Citric Acid, Cod Liver Oil, Corn Oil, • Glycerin, Glycol, Mineral Oils, Potassium Nitrate, Potassium Sulfate, Silicone Oils, Stoddard Solvent, Tannic Acid (10), Tartaric Acid, Turbine Oil. • Chemical resistance of ETFE: Acetic Acid (Glacial), Acetic Anhydride, Acetone, Aluminum Chloride, Anti- Freeze, Bromine, Calcium Chloride, Calcium Hydroxide, Chlorine, Copper Chloride, Ferrous Chloride, Hydrochloric Acid, Ketones, Lacquer Thinners, Sulfuric Acid. Page 7 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual The vented cable termination end is specially prepared at • the factory to eliminate the potential for moisture migration. Where the lead wires emerge from under the jacket, there's-potting material and a shrink tube "boot", every effort should be made to leave this feature intact. Should the cable be longer than needed for the installation, it is recommended that the excess length be accommodated in a service loop and that the potted end of the cable NOT be shortened. The cable attached to this instrument is specifically engineered for submersible applications. The polyurethane outer jacket provides long term reliability under most conditions. The cable should be handled carefully, however, as the jacket may be subject to cutting should it be "raked" over extremely sharp edges. To guard against water incursion should an inadvertent minor cut occur, we have incorporated an exclusive "water block" feature immediately beneath the jacket. The cable is fully shielded, with the shield connected to the metal housing at the transducer end and terminated in a drain wire at the termination or user end. The shield should always be terminated to a good earth ground, unless the transducer is installed in an area where galvanic corrosion is known to be a serious problem. • Lightning Protection Lightning and surge protection for VDC, SDI-12 and 4-20 mA output are available. This is achieved through the use of 2 protectors, one is integral to the transducer housing and one is provided for the outside line located at the surface and grounded to a DIN-Rail. Please remember this option must be factory installed at the time of order entry or as a factory upgrade. This option cannot be installed in the field. Lightning protection is Page 8 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • also available for unit only. Contact customer service for details. Featuring quick response and low clamping voltages, these devices protect against fast rising voltage transients as well as severe current surges associated with lightning discharges up to 20,000 amperes. Following a surge, the protector automatically restores the line to normal operation and awaits the next surge without having to reset a breaker or replace a fuse. The power supply needs to be limited to 150 mA to avoid lock up of the gas tube after a suppression event. Transducers installed with this option have a lifetime warranty against damage due to voltage surge. Please note: When using the lightning protection option on 4-20 mA products, users should take into account the additional series resistance of this option when selecting the loop power supply. This option will increase total loop resistance by 88 Ohms. 1/2" Male NPT Conduit Fitting Submersible level transducers can be attached to a rigid • conduit and the cable run through the conduit. To achieve this, all of our submersible transducers can be fitted with an optional '/2" NPT male conduit fitting (specify "Electrical Connection Option 4" when ordering) where the cable exits the transducer. This fitting can be mated to a standard rigid conduit. Electrical Outputs We offer the industry standard 0-5 VDC and 4-20 mA outputs. In addition we also offer a variety of voltage output ranges. Page 9 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual Reverse Signal Output , For some applications, it is important to know how far the water is from the top of the tank or the surface of the ground. If specified by the customer, our factory can set the transducer so that zero pressure reads full scale electrical output and maximum pressure reads zero electrical output. Temperature Output A temperature output option is available for most transducers having 4-20 mA pressure output. The temperature sensor requires an excitation of 9-28 VDC and is calibrated for a temperature range of-20 to 600C with an accuracy of±4°C. Output Option 6 (4-20mA output for-20 to 60°C) (mA Reading x 5) -40 = Temperature °C Example: Reading is 20mA (20 x 5) - 40 = 600C Reading is 12mA (12 x 5) - 40 = 20°C Reading is 4mA (4 x 5) - 40 = -20°C Cable Hanger • We can supply an optional cable hanger (P/N 12-90- 0931) to help end users secure the cable. The cable hanger can be positioned anywhere on the cable by pushing the ends together. Once positioned, the cable hanger expands and provides a snug grip on the cable. When mounting the transducer in a well casing, the cable hanger can be secured to a hook on the well plate or an eye bolt may be attached to the side of the well casing. The cable hanger loop is then secured to the eye bolt by Page 10 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • using any number of types of fasteners. A similar technique can be used when working in stilling wells for surface water level measurement. In this case, the loop- end of the cable hanger can be attached directly to a screw or bolt bored into the still well shelf. Submersible Cable Splicing Kit Our field-installable cable splice kit (P/N 830) allows you to splice polyurethane and ETFE submersible cable. It is most commonly used for well applications where the more expensive ETFE cable is required for suspension in corrosive media where the liquid level is fairly shallow, but the well is hundreds of feet in depth. It is also used in emergency situations where cable must be spliced together to get an application up and running. • Page 11 Pressure Systems, Inc. KPSIT" Level and Pressure Transducers User's Manual 3.0 Installation & Maintenance Tips WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD In hazardous locations: • Avoid building up static charge on case of data protector and plastic accessories. • Use damp rag to wipe data protector and plastic accessories to avoid static build up. General Installation Procedures The following is important installation and preventive maintenance information. Our Customer Service or Applications Engineering Support staff can provide additional instruction. 1. Transducer Anchors: Most users either suspend our submersible transducers in stilling wells or attach them to rigid conduit. This is done to prevent damage to the transducer from shock caused by water turbulence. It is not advisable to tie your transducer to a pump or to piping, as any • problem with the transducer could require that the pump be pulled from the installation. This could prove to be very expensive. (Please refer to the Cable Anchoring Schemes drawing in Appendix A.) Some applications use our optional bracket (P/N 49-06-OOPC) to clamp the transducer to a fixed object (i.e., wall, ladder, step) or require the unit to be suspended without any protective still well or attachment device. In all installations, Page 12 Pressure Systems, Inc. KPSI'm Level and Pressure Transducers User's Manual care should be taken to ensure no damage occurs to the cable. 2. Transducer Submersion: Damage to submersible cable is one of the most frequent causes of transducer failure. Lower your transducer into the liquid slowly, making sure the cable does not drag over sharp edges and only to the depth necessary. Avoid dropping the unit from the surface. This does not apply to Series 27, 28, and 30 transducers. 3. SuperDryTM Vent Filter (Desiccant) or Aneroid Bellows Installation (For submersible transducers vented gage pressure format only) Always install a desiccant vent filter or aneroid bellows immediately after transducer installation. Failure to use one or the other could result in premature failure of the transducer; which would not be covered by warranty. If you use a desiccant filter, you should establish a regular maintenance schedule. You should change your vent filter when it is 75% spent (pink color). Replacement filters are available at a nominal • cost from the factory. Do not remove the old vent filter until a new one is available. The most common failure mode of our transducers is moisture and corrosion damage due to lack of use or maintenance of the vent filter. This will allow air into the desiccant filter and allows the transducer to properly vent with changes in barometric pressure. To install/replace either the aneroid bellows or the vent filter, simply unplug the old unit from the vent tube and plug the 0.062" x 1" stainless steel connector tube (supplied with each filter or Page 13 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual bellows) into the vent tube. (Installation and mounting instructions are supplied with each aneroid bellows and vent filter.) The diagram on page 16 shows typical vent filter and aneroid bellows hookups. 4. Cable Protection An inexpensive way to protect the cable from damage is to order the submersible pressure transducer with a '/2" conduit attachment. Connect an inexpensive flexible 5/8" garden hose to the '/2" conduit fitting with an equally inexpensive female PVC '/2" NPT x 3/4" NHT swivel fitting, available at your local hardware store 5. Bending of Cable Our polyurethane and ETFE jacketed cables are quite flexible. Care needs to be taken to ensure that when bending the cable to suit your installation you do not crimp the vent tube inside the cable. Consequently, do not bend the cable more than a radius of 1 inch. 6. Cable Compression Many users require a compression fitting to secure our ETFE and polyurethane jacketed cable as it enters a junction • box. Care needs to be taken that you do not over-tighten the fitting so as to damage the cable. 7. 4-20 mA Wiring When connecting a 2-wire 4-20 mA transducer to a typical power supply and mA meter, verify that the meter has an input impedance of at least 10 Ohms. If you are unsure of the input impedance, then a 10 Ohm resistor may be placed in series with the meter and transducer. Connect the + (red) lead of the transducer to the + terminal of the power supply. If the 10 Ohm resistor is required, connect it to the Page 14 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • - (black) lead of the transducer. Use a short length of 22 AWG or heavier wire to connect the + terminal of the meter to the resistor (if it is required) or the - (black) wire of the transducer. Connect the - terminal of the meter to the - terminal of the power supply with a length of 22 AWG or heavier wire. Connect the drain wire from the transducer to a good earth ground. (See Appendix, page 14 for wiring diagram.) Please refer to "Maximum Cable Lengths and Minimum Supply Voltage" in Appendix C, page 22 to verify minimum loop supply voltage requirements. 8. VDC Wiring To connect a 3 wire VDC output transducer to a typical power supply and the voltmeter, connect the -terminal of the power supply to the - input terminal of the meter with a length of 22 AWG or heavier wire. Connect the - excitation (black) lead of the transducer to the - input terminal of the meter. Connect the + input terminal of the meter to the signal lead (white) of the transducer. Connect the + terminal of the power supply to the + lead (red) of the transducer. • Connect the drain wire to a good earth ground. (See Appendix A, page 14.) 9. The Model 750 comes standard with a field removable diaphragm protector (one-inch or 25 mm standoff). The diaphragm protector can easily be taken off by removing six (6) fasteners located on the bottom of the unit. 10. Sealed-Gage Transducer Configured For Altitude Above Sea Level Since sealed-gauge transducers are normally calibrated at sea level, there may be considerable error induced when Page 15 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual used at a higher elevation. If the transducer was , calibrated without taking into consideration the difference in atmospheric pressure at sea level and the higher elevation, an offset error will occur. In order to eliminate error due to this difference, the customer must identify the elevation where the transducer will be installed. The nominal atmospheric pressure at the location is calculated and the transducer will be ranged accordingly. Not all KPSI Transducers are available in a sealed pressure format. Please refer to the appropriate datasheet for availability. 11. Position Sensitivity The transducer should be installed so that the diaphragm located behind the nose cap is oriented in a vertical position, otherwise the unit could exhibit an offset. • Page 16 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • General Maintenance Tips for Submersible Transducers 1. Desiccant Maintenance WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD In hazardous locations: • Avoid building up static charge on case of data protector and plastic accessories. • Use damp rag to wipe data protector and plastic accessories to avoid static build up. If you use a desiccant vent filter, you should establish a regular maintenance schedule. You should change your vent filter when it is 75% spent (pink color). Replacement filters are available at a nominal cost from the factory. Do not remove the old vent filter until a new one is available. Remember that Pressure Systems' improved 810 SuperDryTM Vent Filter are designed to be effective for at least one year before requiring replacement. 2. Clogged Nose Piece or Dirty Diaphragm Either of these conditions could result in erroneous readings from your transducer. WARNING: NEVER attempt to clean your transducer's nose piece or diaphragm with any object. This will dent the sensor diaphragm and cause permanent damage to the transducer. Page 17 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual Your transducer may be cleaned in accordance with • the procedures listed in step 4, below. 3. Cleaning your transducer Materials required: • Plastic bowls 8-12 inches (200-300 mm) in diameter and 4-6 inches (100 - 150 mm) deep • Supply of clean, lint-free cleaning rags • 32 ounce bottle of"The Works-Tub and Shower Cleaner" (a mild detergent) manufactured by Lime-O-Sol Company in Ashley, IN 46705 and available locally through Wal-Mart, K-Mart, Target, and Ace Hardware stores at $2 to $4 per bottle Preparation: Prior to cleaning your pressure transducer, ensure that all procedures have been followed in the proper cleaning of the cable and transducer to remove any hazardous materials. The vent filter (or bellows) must be properly attached. The cable should be coiled to ensure ease of handling and it must be protected against the possibility of accidental abrasion and/or penetration of the cable jacket by sharp objects. A lead length of 1 to 1 '/2 feet (0.3 - 0.45 m) of cable from the transducer should be allowed to facilitate handling during cleaning. The protective covering (or similar protective device) that is shipped with each transducer should be attached to the transducer at all times. It should only be removed prior to installation or cleaning. Your work surface needs to be clean and free of clutter and large enough to accommodate all materials required in addition to the transducer Page 18 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • and cable. Fill one of the bowls with fresh water, one with a mild detergent mixed with water and the last with 16 ounces (0.45 kg) of"The Works". Cleaning: Step 1: Holding the cable 6 inches (150 mm)from the transducer, immerse the unit in the bowl containing the mild detergent and stir for 20-30 seconds. Remove and rinse in the bowl containing the fresh water, using the same stirring motion used in the mild detergent. Rinse and wipe dry. Step 2: Holding the body of the transducer with one hand so that you are looking at the retaining screen protecting the sensor, carefully remove the sensor nose piece by simply unscrewing it from the transducer body. Do not touch the sensor diaphragm with your finger or any other object. Also, do not try to dry the inside portion of the transducer, as you risk damaging the pressure sensor. Step 3: Place the transducer in a vertical position with the sensing end facing downward in the bowl containing "The Works" solution for approximately 15-20 seconds. Rinse in the bowl containing clean water and wipe dry the external Page 19 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual casing only. Place the protective • screen in the same solution for 15- 20 seconds, rinse and wipe dry. Step 4: Holding the transducer in a vertical position so that you can see the face of the sensor, screw the protective nose piece back into place. 4. Cleaning the Lightning Protection Data Line Protector WARNING: POTENTIAL ELECTROSTATIC CHARGING HAZARD In hazardous locations: • Avoid building up static charge on case of data protector and plastic accessories. • Use damp rag to wipe data protector and plastic accessories to avoid static build up. • Page 20 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual i 4.0 Warranty and Product Return Procedure Any transducer/transmitter that is less than 2 years old (see DOM) which does not meet the product's specifications and exhibits no obvious physical damage to the housing, sensor, or cable (cuts), will be replaced under warranty. Units 2-3 years old: Units that fall within this age group and exhibit no obvious physical damage to the housing, sensor, or cable (cuts), may be replaced at a discounted list price. Units greater than 3 years old: Units that fall within this age group are not replaced under warranty. Merchandise Return Procedures Contact the Applications Support Group or the Customer Service Department at Pressure Systems if your transducer is not operating properly. Our staff is available for troubleshooting at (757) 865-1243 or toll free at 1-800-328-3665 during normal working hours, Eastern time. If your transducer or accessory needs to be returned to Pressure Systems, obtain a Returned Merchandise Authorization (RMA) from the Customer Service Department prior to shipment. Be prepared to supply the following information when requesting the RMA: • Part number • Serial number • Complete description of problems/symptoms • Bill To and Ship To address Page 21 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • Purchase order number (not required for warranty • repairs) • Customer contact and telephone number The above information, including the RMA number, must be on the customer's shipping documents that accompany the equipment to be repaired. Pressure Systems also requests that the outside of the shipping container be labeled with the RMA number to assist in tracking the repairs. All equipment should be sent to the following address: ATTN: KPSI TRANSDUCER REPAIR DEPARTMENT (7-digit RMA number) Pressure Systems, Inc. 34 Research Drive Hampton, Virginia 23666 Prior to returning to Pressure Systems, the transducer and cable must be cleaned per instructions provided on the cleaning certificate supplied when the transducer was delivered. The certificate can also be found on Pressure Systems website: www.PressureSystems.com/cleaning.html • The completed certificate must accompany the transducer when shipped to Pressure Systems. If the transducer has been used in media other than potable water, PSI customer service must be notified at the same time an RMA number is requested. PSI reserves the right to reject any shipment deemed to be unsanitary or environmentally unsafe to handle. If these guidelines are not met, the package will be sent back unopened and at the customer's expense. Please include the attached Page 22 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual vent filter or aneroid bellow with each returned vented gage submersible transducer. Pressure Systems will return warranty items prepaid via UPS GROUND. If the customer desires another method of return shipment, Pressure Systems will prepay and add the shipping charges to the repair bill. Incoming freight charges are the customer's responsibility. The customer is also responsible for shipping charges to and from Pressure Systems for all equipment not under warranty. Once the return is received, it typically takes 5-10 working days for the technician to make a fault determination. A cable reconnect fee will be charged when the customer requests a different length of cable. Restocking Policy Pressure Systems does allow standard products to be returned for credit in the event it is no longer required, providing the products are in new and unused condition. A restocking fee will be assessed depending on the model type and variety. A 25% restocking fee applies to the following models, providing they are vented-gage reference format and [pressure ranges above 3 psig (20 kPa) and below 100 psig (690 kPa)]. 27 320 700 710 750 28 342 705 720 Display Meters-all models Page 23 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual A 50% restocking fee applies to the following models. This also applies to all other models with sealed-gage and absolute pressure formats as well as vented-gage reference formats with [pressure ranges below 3 psig (20 kPa) and above 100 psig (690 kPa)]. 30 335 30ODS 730 330 735 NOTE: Expedite premiums and shipping charges are non-refundable. Please consult the individual manuals for the Series 500 and Series 550 (waterMONITOR) for the restocking policy. Page 24 Pressure Systems, Inc. KPSIT"' Level and Pressure Transducers User's Manual Appendix A Drawings and Diagrams Wiring Diagram VDC, mA, and Temp Output............................ 26 Cable Anchoring Schemes ....................................................... 27 Reference Connection Schemes ...............................................28 Submersible Cable Termination.................................................28 Page 25 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual Wiring Diagram VDC, mA, and Temp Output • + EXCITATION POWER SUPPLY - EXCITATION Y C) VDC m Configuration COMMON VOLTAGE METER + SIGNAL WHITE DRAIN WIRE RED m y m aEi E. _ + + _ a a a + d Z z Z RED t3LK Y W w U ~ W C m 7i Lt — DRAIN WIRE W POWER mA SUPPLY z METER a� a 4-20 mA - Temperature output Configuration Option Notes: 1. These diagrams depict typical installations. Refer to your power supply and instrumentation Manufacturer for the specifics of your application. Page 26 Pressure Systems, Inc. KPSITM Level and Pressure Transducers User's Manual • Cable Anchoring Schemes CLOSED TOP Page 27 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual t Reference Connection Schemes TRANSDUCER CABLE VENTED VENT FILTER TANKS OR — )ANEROID BELLOWS (option) NON-VENTED VENT FILTER :7"Rd", TANKS TOP OF TANK b w Submersible Cable Termination to d ANEROID O O BELLOWS SHIELD y OR w U 0 rr� D EARTH VENT FILTER z GROUND O F Page 28 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • Appendix B 1. Question: What installation ideas do you have to help me get rid of electrical noise interfering with the signal? Answer: An ounce of prevention goes a long way. Either try to eliminate the source of noise or move the transducer as far away from it as possible. We strongly encourage you to secure our cable shield to a good earth ground and that you use a 4-20 mA signal output. Armed with these precautions and the fact that many of our transducers are CE approved for electromagnetic interference, you should have few problems. 2. Question: The cable on the submersible transducer always seems to get cut and damaged. What am I doing wrong? Answer: This is the most common problem that our users encounter. Make sure that all of your colleagues and staff understand the importance of handling the cable with care. The cable should not be bent around rough or sharp edges. Always use a cable reel during transport. Where possible, suspend the unit in a perforated 2" (50 mm) PVC pipe and thread the cable through protective conduit to the nearest junction box. Page 29 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual 3. Question: I have an application where the • transducer is frequently damaged by voltage spikes. What can be done to prevent this? Answer: At a minimum, make sure the cable shield is connected to an earth ground as near as possible to the transducer. We can provide a surge protection kit for both our submersible and non- submersible transducers. See page 4. These kits will handle typical spikes that might come in through the power lines as well as surges that travel through the ground due to nearby lightning strikes 4. Question: How much impact shock can your submersible transducers withstand? Answer: Our transducers are not shock tested and the lower pressure ranges can be damaged if dropped from several feet onto an unforgiving surface like concrete. We recommend that the protective shipping foam remain in place until the unit is installed. 5. Question: What is the response time of your transducer? Answer: From initial power up, the transducer output will stabilize within a fraction of a second. The frequency response is rather low, probably less than 1 kHz, but it depends on the application, the media, plumbing, etc. Call our factory for application assistance if frequency response is critical in your application. Page 30 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual 6. Question: How do I attach your vent filter or aneroid bellows to my cable vent tube? Answer: The vent filter can be mounted anywhere convenient, preferably out of the weather. It can be mounted in any position and connects to the cable vent tube via the extension tube with metal connector tube provided. The aneroid bellows must be mounted in a way that its movement is not encumbered. It is provided with a mounting base. 7. Question: What is the best way to mark my cable? Answer: Use white vinyl marking tape available from your local hardware or electronic stores. These same stores may also sell cable marking kits. 8. Question: Any ideas for preventing marine growth on your submersible transducers? Answer: You might want to try waterproof grease. Remove the threaded nose cap to facilitate applying the grease. Take care not to damage the diaphragm when applying the grease and not to trap air bubbles against the sensing diaphragm. 9. Question: How many measurements can you make before the diaphragm on the sensor fails? Answer: In normal operation - millions of cycles. We find that sensor failure is rarely due to diaphragm fatigue. Page 31 Pressure Systems, Inc. KPSIT"" Level and Pressure Transducers User's Manual 10. Question: What is the turnaround time on r, repairs? Answer: Once we receive a unit into our facility it takes less than 10 working days to complete an evaluation. 11. Question: What is the longest length of cable you have attached to a submersible transducer? Answer: Two thousand feet (610 meters). 12. Question: Why do you use 316 SS housings and sensors for your standard transducers? Answer: It offers a good combination of corrosion resistance and reasonable cost. As an option, we do offer titanium for more aggressive environments. 13. Question: What wire gauge should I limit myself to when connecting to your 22 AWG wire? Answer: Use 22 AWG or heavier. 14. Question: Does it make any difference if I mount the transducer in a vertical or horizontal position? Answer: Yes. Our units will experience a certain amount of position sensitivity. You should mount it in a vertical position throughout the measurement cycle. If you lay the transducer down, the user must realize than an offset will occur. Page 32 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual 15. Question: What happens when you freeze your transducer in a column of water? Answer: We have frozen our transducers in a container of water in a home freezer, with no resulting damage. However, depending on the level range of the unit, over pressure of the unit is possible. In harsh environments where debris is common and ice shifts, you might expect damage to both the transducer and cable. 16. Question: Why would I choose a KPSI Transducer versus a competitor? Answer: Reliable, long lasting products Rapid delivery Lightning protection lifetime warranty Excellent pre & post sales/application support No hassle service Page 33 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual • Appendix C Troubleshooting Techniques Quick Check Procedure The following is a quick field checkout procedure for KPSI Level and Pressure Transducers. It will be referred to throughout the troubleshooting section. Should a problem be encountered with a transducer or transmitter, it is sometimes helpful to test the transducer independently from the rest of the system, thereby establishing where to concentrate the troubleshooting effort. On the next page is a simple hookup diagram for the most common types of electrical output, a 0-5 VDC transducer and a 4-20 mA transmitter. In either case, the "power supply" can be a common 12 volt lantern battery, or even a 9 volt transistor radio battery, although the lifetime of a 9 volt battery will be limited. The meter should be a digital type capable of reading at least 2 digits to the right of the decimal point. Use 22 gage or heavier hookup wire or clip leads for jumpers. If your unit has other than a 0-5 VDC or 4-20 mA output, please call Applications Support at (800) 328-3665 for assistance. Once your transducer is correctly configured per one of the diagrams below, orient the transducer in a vertical position with the pressure port down and then read the zero output on your meter. For a 0-5 VDC output, the zero should be between 0 and 0.10 volts, and for a 4-20 mA output, between 3.80 and 4.20 mA. For Series 300, Page 34 Pressure Systems, Inc. KPSITM Level and Pressure Transducers User's Manual • the values do not change for VDC output but the values for mA are between 3.80 and 4.20 mA. If the output is outside of these limits, you may, at your option, choose to troubleshoot the transducer per the suggested measurements shown below. Otherwise, contact our Customer Service Department at (800) 328-3665 for a Return Material Authorization number (RMA). If the zero output is within these limits, the problem will more than likely be found elsewhere in your system. YOU MUST ADD 0-5 VDC THESE JUMPERS--,, 4-20 mA BLACK m f BLUE c = m - 0 m om 3 v �D � x < Ow m� D 0 Am 3 m En;a M 1 zm c< m 1 '0< �� z m p < r A <A m When an error is observed at a customer's installation, it is important to determine if the fault lies in the transducer or the instrument reading the transducer signal, ie. digital panel meter, programmable logic controller, etc. . To do this, a second instrument should be used to confirm the observations. The second instrument may be a handheld DMM (Digital Multi-Meter) or a dedicated milliammeter capable of reading 4-20 mA of current to a resolution of at least 0.1 mA. The diagram above illustrates the attachment of the meter in series with the black (negative signal) wire of the transducer using a 9-28 VDC power Page 35 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual supply for transducer excitation. Some suggested power • supplies are: • 1 - 12 VDC automotive battery. • 2 - 6 VDC lantern batteries connected in series (for a total of 12 VDC). • 2 - 9 VDC transistor batteries connected in series (for a total of 18 VDC). Batteries are suggested to power the transducer during testing to eliminate the possibility that line noise is passing through an improperly filtered, grounded, or damaged power supply. All measurements should be recorded and sent to Pressure Systems along with the transducer to assist in the evaluation process. Further Measurements: 0-5 VDC Should read: 4-20 mA Should read: +Excitation >2.5 Mohms +Excitation(red) >2.5 Mohms (white)to Shield to Shield(drain) (drain) -Excitation >2.5 Mohms -Excitation(black) >2.5 Mohms (black)to Shield to Shield(drain) (drain) +Output(red)to >2.5 Mohms Shield(drain)to <2 ohms Shield(drain) Housing Shield(blue)to <2 ohms Housing Page 36 Pressure Systems, Inc. KIDS ITm Level and Pressure Transducers User's Manual • Maximum Cable Lengths and Minimum Supply Voltage The maximum length of cable to be used with our submersible transducers is largely dependent upon the type of electrical output of the transducer. For a 0-5 VDC output, a maximum cable length of 100 feet (30 m) is recommended. A voltage output is more susceptible to electrical interference than a 4-20 mA signal. A 4-20 mA signal can be transmitted much longer distances, depending upon such factors as temperature, wire size, length of the wire, power supply, and voltage requirements of any devices to be powered. At 250C the 22 AWG conducting copper wire used in our polyurethane jacketed cable has a resistance of 16.45 ohms per 1000 feet (304 m). Using Ohms Law (E=1R)where E=voltage, l=current and R =resistance, one finds that a 20 mA signal requires .329 volts to drive it along 1000 feet (304 m) of 22 AWG copper wire (E=16.45 x .020). This drop is seen on both the supply and return wire for a total loop voltage drop of 0.658 volts • To find out how much voltage is required to drive our Series 700 submersible level transducer's 4-20 mA signal 10,000 feet, just add the minimum power requirement of the 700 (9 VDC)to the resistance offered by 10,000 feet (3048 m) of our polyurethane jacketed cable (10,000-1000 x .658=6.58). The resulting power requirement is 15.58 VDC (9 + 6.58). Connect the cable shield (drain wire) to a good earth ground. This will protect the transducer from relatively minor transient voltages. The only exception to this rule is if high rates of electrolytic corrosion have been previously experienced with grounded submersible Page 37 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual devices. In this case it may be better to leave the shield disconnected. Please note: When using products with the lightning protection option on 4-20 mA products, users should take into account the additional series resistance of this option when selecting the loop power supply. This option will increase total loop resistance by 88 Ohms. Troubleshooting Techniques 1. Symptom: Transducer fails to give output of any kind. Procedure: Isolate the problem to either the transducer or the power supply/readout. See the Quick Check Procedures (above)for this check. If it can be determined that the transducer is no longer operable, remove it from service for further analysis. If the transducer output falls within the limits described above, the fault lies somewhere else in your system. 2. Symptom: Transducer has failed and has been removed for analysis. Procedure: Inspect the cable for physical damage. Cuts in the cable jacket can result in liquid incursion into the transducer housing, which can cause permanent damage. If operational, the cable can be repaired by using a splice kit (P/N 830) supplied by Pressure Systems. Page 38 Pressure Systems, Inc. KPSIT" Level and Pressure Transducers User's Manual Inspect the transducer housing. It should be intact and free of corrosion. If the outer surface of the transducer is pitted, this could be an indication of galvanic corrosion caused by stray ground currents. If this is the case, the transducer will probably require replacement. If the external case exhibits none of these characteristics, carefully unscrew the nosepiece and look into the pressure sensing end of the transducer. The concentric rings of the sensing diaphragm should be visible. If they are not, it could be that residue has accumulated on the diaphragm, preventing it from responding properly to pressure changes. The transducer can be cleaned by gently swishing the transducer back and forth in a bucket of warm, soapy water until the residue softens and washes off. (See Cleaning Your Transducer, page 8.) Under no circumstances should any object or tool be used to remove residue from the sensing diaphragm or else permanent damage will be done. If cleaning the diaphragm does not solve the problem, the transducer should be returned to the factory for repair or replacement. Page 39 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual 3. Symptom: Transducer develops a negative offset and gets worse over time (actual level exceeds specified level). Procedure: This may be a sign that moisture has entered the reference (vent) tube in the cable and is inside the transducer housing. This is usually the result of not maintaining the desiccant vent filter or of operating the transducer without a desiccant filter or aneroid bellows. If caught early enough, the transducer can be saved by coiling the cable and transducer in a pan and baking it in an oven at 50'C (122'F) for a minimum of 2 hours. Be careful that the oven temperature does not exceed 500C (122'F) or both the transducer and the cable can be damaged. Alternatively, suspend both the cable and transducer in a vertical position (with vent tube down), overnight to allow water to drain from the transducer and vent tube. 91 4. Symptom: Transducer suddenly fails during or just after a nearby lightning event. Procedure: This failure is usually caused by overvoltage due to ground transients resulting from a direct or indirect lightning event. These transients can travel distances of a mile or more. The transducer may be returned to Page 40 Pressure Systems, Inc. KPSITA4 Level and Pressure Transducers User's Manual • the factory for repair and optional retrofit of our lightning protection system. This system carries a lifetime warranty against transducer damage due to lightning. 5. Symptom: Transducer response to pressure/level input changes becomes sluggish. Procedure: This is usually a sign that the sensing end of the transducer has become fouled with residue. The transducer must be removed from service and the sensing diaphragm cleaned as described in Item 2, (warm, soapy water). If fouling persists, the transducer may be replaced with a Series 705 or Series 750 (non- fouling) transducer, which is specifically designed for trouble-free operation in a high residue environment. 6. Symptom: Output reading is within limits but • "freezes"at one point. Procedure: In certain environments "crust' may form over the sensing diaphragm, preventing the sensor from identifying change in level. Removing the transducer from service and cleaning it (as described in Item 2) will generally solve the problem. To combat marine growth, you might try wrapping the transducer with copper wire similar to that found in wire scouring pads for cleaning dishes. Marine growth occurs on the copper Page 41 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual and eventually erodes the copper and drops off or the copper is manually removed during routine maintenance. Alternatively, there are various companies that will impregnate/coat the 316 stainless steel with anti- fouling chemicals of coatings. Level transducers temporarily removed from the well or sump should not be stored dry, but should be stored in a bucket of fresh water in order to prevent "crust" formation. 7. Symptom: Readings increase very slowly over time. Procedure: Our cable is shipped coiled and consequently takes time to straighten when installed. Attaching a weight to the transducer (e.g., one of our sacrificial anodes) will help. To prevent cable stretch with lengths greater than 200 feet (60 m), secure the Kevlar fibers (just under the cable jacket) to your junction box or other secure object. 8. Symptom: No electrical output from your transducer. Procedure: Check all electrical connections to ensure they are correct and secure. Double check your power supply or use a battery (as described previously) to ensure the transducer is getting power. If all checks OK, the problem could be a circuit board or the sensor in your transducer. The unit must be returned to the factory Page 42 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual for evaluation. The most probable cause of this type of failure is damage to the submersible cable jacket allowing water to leak down the cable and into the transducer housing or lightning damage. 9. Symptom: Formation of marine growth on a submersible transducer. Procedure: Certain transducer construction materials, for example, 316 stainless steel, attract marine life (snails) and algae. Clean the transducer diaphragm by soaking it in a bucket of warm water with a non-aggressive cleaning solution. You can also coat the transducer with marine grease. This may be the most effective and inexpensive way to protect your transducer. 10. Symptom: Submersible transducer exhibits corrosion or pitting on body or diaphragm Procedure: Dissimilar metals (for example, your transducer housing and your pump housing) in an electrolytic environment (fluid in your well) can lead to galvanic corrosion of the metal that is nearer the anodic end of the galvanic series. Likewise, a voltage potential between the ground wire of the transducer and the ground of other equipment in the well can lead to galvanic corrosion. Installation of a P/N 820 or 825 sacrificial anode will Page 43 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual help protect your transducer from galvanic corrosion. Our sacrificial anodes are made of a zinc alloy that, being nearer the anodic end of the galvanic series than the 316 stainless steel or titanium housing of the transducer, will corrode before the transducer. 11. Symptom: The transducer is buried in dirt or silt and the readings seem to be erroneous. Procedure: Use of a piezometer nosepiece in this application would help. This nosepiece can be easily installed in the field and features a very fine screen to keep dirt from fouling the diaphragm, but allows the diaphragm to sense moisture levels. 12. Symptom: Transducer has an offset error. Procedure: Our submersible transducers perform best when the sensing end is pointing in a downward manner. Keep in mind that you can experience offset error due to the position sensitivity or orientation change of the sensor. Offset errors are more prominent in low pressure applications with the sensing end of the transducer lying flat or pointing upward. Page 44 Pressure Systems, Inc. KIDS ITm Level and Pressure Transducers User's Manual 13. Symptom: I am testing a Series 700 4-20mA sensor for use with our data logger. On page A-2 of the KPSI Level and Pressure Transducers User's Manual, I see the standard 4-20mA configuration. Does the recording channel of my data logger become the mA meter? Procedure: Most data loggers cannot measure current (mA) directly. When this is the case a load resistor must be used to convert the current (mA) output into an appropriate voltage. If the User's Manual for your particular instrument does not illustrate a preferred method for recording current (mA) data then you should attach your transducer signal wires to your data logger in the following manner. Transducer red wire - Data Logger Excitation Terminal (The minimum excitation for a Series 700 Transducer is 9VDC) Transducer black wire — Data Logger signal input (+) terminal Attach a Load resistor between the Data Logger signal input (+) terminal and the Data Logger signal input (-) terminal. Attach a separate piece of wire between the Data Logger signal input (-) and analog ground. Page 45 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual In this configuration you will turn your data logger into a milliammeter. The size of your load resistor can be calculated in the following manner. D/0.02=R Where: Data logger input range = D Full scale output of transducer = 0.02 A (20 mA) Load Resistor Value = R Pick an appropriate standard value 250 Ohms results in 1 to 5 VDC at 4 and 20 mADC 125 Ohms results in 0.5 to 2.5 VDC (500 to 2500 mVDC) at 4 and 20 mADC At this point the discussion needs to address IR loss (voltage drop) in series circuits. Note that Series 700 transducers need a minimum of 9 VDC to operate correctly. When the transducer is operating correctly it will output a current which, when driven through a resistor, will generate some amount of voltage drop. If the resistor value is 250 Ohms then the voltage measured across that resistor will be 0.004 A * 250 Ohms = 1.000 VDC and 0.020 A * 250 Ohms = 5 VDC. Notice that, if the available voltage from the data logger is12 VDC then Page 46 Pressure Systems, Inc. KPSlTm Level and Pressure Transducers User's Manual 12 VDC - 5 VDC = 7 VDC which is less than the voltage required by the transducer to operate. If this scenario were to occur the transducer would actually stop functioning correctly when its output reached 12 mADC (50% of transducer full scale range). In this case the appropriate choice for a load resistor value is 125 Ohms. 14. Symptom: I have a Series 700 4-20mA transducer rated for 7.5 PSIG attached to a pressure source that is outputting 7.5 PSIG. With 20VDC being supplied I am getting 19.94 mA. I can't find the upper range allowance for the sensor, but this seems low to me. Does this mA reading fall into the acceptable range for the transducer with the settings I've specified? Procedure: When evaluating a transducer it is sometimes convenient to make some broad generalizations in order to rapidly determine the condition of the unit. In general, transducers that output a 4-20 mADC signal have a 16 mADC span (4 - 20 = 16). If the transducers accuracy is reported as being some percentage of its full- scale range then the following table could be used in conjunction with the instructional notations to determine whether a more detailed analysis of Page 47 Pressure Systems, Inc. KPSIT"' Level and Pressure Transducers User's Manual data quality is required. Model Accuracy Accuracy in mADC 700 1.00%FS ±0.16 ma 710 0.50%FS ±0.08 ma 720 0.25%FS ±0.05 ma 730 0.10%FS ±0.016 ma 735 0.05%FS ±0.008 ma In order to approximately determine how many milliamps a transducer should output at a given depth. 1. Determine the depth (in feet) at which the transducer is sited. 2. Divide the depth value (from step 1) by the transducer full-scale range (in feet). - Record the value. 3. Multiply the value calculated in step 2 by 16 (the transducer span in milliamps). 4. Add 4 to the product of step 3. This is the approximate value in milliamps that should be output by the transducer at its current depth. In order to approximately determine the depth of a transducer (in feet) using a given value of milliamps. 1. Divide the full-scale range of the transducer (in feet) by 16. Record this value. Page 48 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual 2. Subtract 4 from the milliamp output of the transducer. Record this value 3. Multiply the result of step one by the result of step 2. This is the approximate depth at which the transducer is sited. If the resulting numbers are reasonably close to some verified value for current water depth, then the unit is functioning. In order to determine the quality of measurement, additional steps need to be performed. i Page 49 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual Appendix D Calibration Calculations Pressure Systems ships a calibration sheet with every KPSITm Transducer. This sheet lists the actual values that were output by the transducer, when it was being manufactured, at several different pressures. In addition, two coefficients are provided that can be used to calculate the actual depth from any given mA output value. These coefficients are derived from a Least Squares Best Fit Straight Line (BFSL) calibration using the data listed on the datasheet. Our accuracy specification is referenced to the line described by the BFSL coefficients and so the transducer may not output exactly 4 mADC at zero pressure and 20 mADC at full- scale. As an example here is an example of data for a typical transducer. • Page 50 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual Calibration Report Tw Dab 02%t76 Tw T—130257 Mo(W No 320T14SOA006670000000B100308 Tw Ton ROOM.263 D"C Saul No OW200 P1—.R.—OOO to 867 PSK3 Ero M-9.26 VDC Oupw a20,IA PCusonlo o TRFW6 Run 01— .._._._F—82......_.._ BFSL 1.,ga fin Tale Rm Tarp Eltpt Rm Tarp Ena Tw F owV. W ws Ou%%ts %FSO CX W% %F$O 000 40017 39M -00134 3998t 40222 1 73 72050 7 2 -0.0295 72066 0 009e 317 1O4 10.4111 00091 1041 N 0D297 520 313 36182 003M 136 DWI 6 1 1 6 2.e1 665e -00I14 68174 -0OO14 67 60219 2002 .00290 200190 -00184 594 166,62 -00057 60,72 00006 20 13e127 t36,76 00305 t36t75 00299 347 104063 0431 002W 04110 00167 173 72049 72067 001t5 72059 00065 a00 40=0 40001 -0We 40000 -00124 Man— StaaoEna 00523%FSO Max— Nun+epoa "y -00M%FSO Ebancal tatnmaoan RED.SUPPLY SKpa1 05411 PSIG BUCK SUPPLY Zao Oewfl 00000 PSIG BLUE SHELD Skpo2 +NM rnAT1fPG Zao O1-2 40017 nW Carve ,Fa 10000 NOlas CatwPalons M."I Cmkmpro9aulomOs6noO—uam0 aaHda.%P"A Al InO1paIWa9 vabpb PSIG.05411MA 40017).00000 MaNaO 2 Cakuuto proaaa0 salty.00,9 p O—d uMa uo^91Kostwo M 1M 14s W4-va7labb mA.1$4794 PSK3 0000CI.400,7 Page 51 Pressure Systems, Inc. KPSITm Level and Pressure Transducers User's Manual In this case, even though the offset or 0 PSIG output was 4.0017 mADC and the full-scale point was 20.0219 mADC the unit actually performed better than its specified accuracy of±0.25% of full-scale range as indicated in the Error % FS column. The calculation for pressure is illustrated below: PSIG = (Span*Output (in mA)) + Offset And, to convert to feet of water Feet HZO = PSIG * 2.3073 • Page 52 1 r measurementze SPECIALTIES so* 0 1000 Lucas Way, Hampton, VA 23666 USA • 0 757-865-1243, Toll Free 800-328-3665 • Fax 757-865-8744 E-maii sales@PressureSystems.com www.PressureSystems.com online orders www.LevelandPressure.com BARNES'�' INSTALLATION and OPERATION MANUAL Submersible Non-Clog Pump _j Explosion Proof, Class 1, Groups C & D, Division 1 ® Series: 8XSE-HA 20 - 30HP, 870RPM, 60Hz 30 - 75HP, 1150RPM, 60Hz 100 - 150HP, 1750RPM, 6ui-Pz DISCONTINUED ® Parts may NOT be available e • e • e • • • 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. LCRAN E PUMPS & SYSTEMS A Crane Co. Company 420 Third Street 83 West Drive, Bramton Piqua, Ohio 45356 Ontario, Canada L6T 2J6 Phone: (937)778-8947 Phone: (905)457-6223 Fax: (937) 773-7157 Fax: (905)457-2650 Form No. 084841-Rev. K www.cranepumps.com 1 TABLE OF CONTENTS SAFETYFIRST...............................................................................................3 • A. PUMP SPECIFICATIONS................................................................................4 B. GENERAL INFORMATION..............................................................................5 C. INSTALLATION 5-8-8 ELECTRICALDATA.........................................................................................7 D. START-UP OPERATION..................................................................................8- 10 E. PREVENTATIVE MAINTENANCE...................................................................10 F. SERVICE and REPAIR....................................................................................10- 11 G. REPLACEMENT PARTS..................................................................................11 TROUBLESHOOTING....................................................................................12 CROSS-SECTION, (Fig. 7)..............................................................................13 EXPLODED VIEW, (Fig. 8)..............................................................................14 PARTSLIST ..................................................................................................15- 16 RETURNED GOODS POLICY.........................................................................17 WARRANTY ...................................................................................................18 START-UP REPORT........................................................................................21 -22 WARRANTY REGISTRATION SPECIAL TOOLS AND EQUIPMENT INSULATION TESTER (MEGGER) Other brand and product names are trademarks or registered trademarks of their respective holders. ®WARRICK Controls is a registered trademark of Charles F.WARRICK Co. ®Reliance is a registered trademark of Rockwell Automation ®Barnes is a registered trademark of Crane Pumps&Systems, Inc 1996, 1997, 1998,2002,01/04,3/06,9/06 Alteration Rights Reserved 2 SAFETY FIRST! . lease Read This Before Installing Or Operating Pump. This information is provided for SAFETY and to PREVENT Do not block or restrict discharge hose,as discharge EQUIPMENT PROBLEMS.To help recognize this information, ! hose may whip under pressure. observe the following symbols: IMPORTANT!Warns about hazards that can result WARNING!-DO NOT wear loose clothing that may A! in personal injury or Indicates factors concerned with become entangled in the impeller or other moving parts. * assembly, installation,operation,or maintenance which could result in damage to the machine or equipment if WARNING!-Keep clear of suction and discharge ignored. openings. DO NOT insert fingers in pump with power connected. CAUTION I Warns about hazards that can or will cause minor personal injury or property damage if ignored. Used with symbols below. Always wear eye protection when working on pumps. WARNING ! Warns about hazards that can or will cause serious personal injury,death,or major property damage if ignored. Used Make sure lifting handles are securely fastened each with symbols below. time before lifting. DO NOT operate pump without safety devices in place.Always replace safety devices that have been removed during service or repair. Hazardous fluids can Extremely hot-Severe cause fire or explo- 6urnes can occur on contact. Secure the pump in its operating position so it can not sions,burnes or death tip over,fall or slide.i could result. , 4 Hazardous fluids can Hazard- • DO NOT exceed manufacturers recommendation for Biohazard can cause Add'' r>, ous pressure,eruptions or ex- maximum performance,as this could cause the motor serious personal injury. plosions could cause personal to overheat. injury or property damage. LL'11 - Rotating machinery DO NOT remove cord and strain relief. Do not connect Amputation orsevere Hazardous voltage can conduit to pump. z�- laceration can result. 4 shock,burn or cause death. Only qualified personnel should install,operate and repair WARNING! Cable should be protected at all times to pump.Any wiring of pumps should be performed by a qualified avoid punctures,cut, bruises and abrasions-inspect electrician. frequently. Never handle connected power cords with wet hands. WARNING !-To reduce risk of electrical shock, pumps and control panels must be properly grounded in WARNING!To reduce risk of electrical shock,all wiring accordance with the National Electric Code(NEC)or the and junction connections should be made per the NEC Canadian Electrical Code(CEC)and all applicable state, or CEC and applicable state or province and local province, local codes and ordinances. codes. Requirements may vary depending on usage and location. WARNING! -To reduce risk of electrical shock,always disconnect the pump from the power source before WARNING! Submersible Pumps are not approved for handling or servicing.Lock out power and tag. use in swimming pools, recreational water installations, decorative fountains or any installation where human e WARNING!Operation against a closed contact with the pumped fluid is common. discharge valve will cause premature bearing and seal failure on any pump,and on end WARNING! Products Returned Must Be Cleaned, suction and self priming pump the heat build Sanitized,Or Decontaminated As Necessary Prior may cause the generation of steam with resulting dangerous To Shipment,To Insure That Employees Will Not Be pressures. It is recommended that a high case temperature Exposed To Health Hazards In Handling Said Material. switch or pressure relief valve be installed on the pump body. All Applicable Laws And Regulations Shall Apply. CAUTION I Never operate a pump with a plug-in type Bronze/brass and bronze/brass fitted pumps may `ram power cord without a ground fault circuit interrupter. 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 r rf CAUTION!Pumps build up heat and pressure government agencies have determined that leaded during operation-allow time for pumps to cool copper alloys should not be used in potable water before handling or servicing. applications. For non-leaded copper alloy materials of construction, please contact factory. ®WARNING!-DO NOT pump hazardous materials (flammable,caustic,etc.)unless the pump is specifically IMPORTANT!-Crane Pumps&Systems, Inc.is not designed and designated to handle them. responsible for losses,injury,or death resulting from a • . failure to observe these safety precautions, misuse or abuse of pumps or equipment. 3 SECTION: A- PUMP SPECIFICATIONS DISCHARGE ......................8"NPT, 125 lb. Flange Horizontal SPEED ...............................870, 1150, 1750 RPM (Nominal) ' LIQUID TEMPERATURE...104°F(40°C)Continuous UPPER BEARING: VOLUTE .............................Cast Iron ASTM A-48, Class 30 Design ....................Single Row,Ball,Grease Lubricated with Cast Iron Wear Ring Load ......................Radial MOTOR HOUSING.............Cast Iron ASTM A-48, Class 30 LOWER BEARING: SEAL PLATE......................Cast Iron ASTM A-48, Class 30 Design .....................Double Row,Ball,Grease Lubricated IMPELLER: Load.......................Radial&Thrust Design....................3 Vane, Enclosed with Bronze wear MOTOR: Design .................NEMA B,Three Phase Torque Curve ring and pump out vanes on back Air-Filled,Squirrel Cage Induction side. Dynamically Balanced ISO "UL"Listed for Class I,Groups C& G6.3 D, Division 1, Explosion Proof Material .................Cast Iron ASTM A-48,Class 30 Insulation..............Class F. SHAFT ...............................416 Stainless Steel SINGLE PHASE................Capacitor Start/induction Run. SQUARE RINGS.................Buna-N Start Capacitors included with HARDWARE.......................300 Series Stainless Steel pump assembly. Controls require LIFTING CHAIN..................Yoke,Galvanized external overload protection. PAINT ...............................Air Dry Enamel. THREE PHASE.................Dual Voltage 230/460; Requires SEAL: Design ...................Tandem Mechanical,Oil Filled Overload Protection to be Included Reservoir. in control panel. Material..................Rotating Faces-Carbone MOISTURE SENSOR.......Normally Open (N/O), Requires Stationary Faces-Ceramic Relay in Control Panel Elastomer-Buna-N TEMP SENSOR................Normally Closed (N/C), Requires Hardware-300 Series Stainless Relay in Control Panel CORD ENTRY.....................25 ft. (7.6 m)Std.Cord. Epoxy OPTIONAL EQUIPMENT: Seal Material, Impeller Trims, Sealed Housing with Secondary Additional Cord Pressure Grommet for Sealing and Strain Relief inches (mm) 34.62 (879) 20.00 _ BXSE20048HA-49.06(1246) (508) 8XSE20058HA-49.06(1246) BXSE25048HA-49.06(1246) 8XSE25058HA-49.06(1246) 8XSE30048HA-49.06(1246) BXSE30058HA-49.06(1246) 8XSE30046HA-49.06(1246) 8XSE30056HA-49.06(1246) 16.50 8XSE40046HA-49.06(1246) (419) 8XSE40056HA-49.06(1246) 8XSE50046HA-49.06(1246) 8XSE50056HA-49.06(1246) 0 28.12 8XSE60046HA-49.06(1246) (714) 8XSE60056HA-49.06(1246) + 8XSE75046HA-54.50(1384) 8XSE75056HA-54.50(1384) 8XSE100044HA-54.50(1384) Q 8XSE100054HA-54.50(1384) 8XSE125044HA-54.50(1384) 8XSE125054HA-54.50(1384) 8XSE150044HA-54.50(1384) 8XSE150054HA-54.50(1384) -------- ----------------- ----r 7.68 (195) IMPORTANT ! 1.) MOISTURE AND TEMPERATURE SENSORS MUST BE CONNECTED TO VALIDATE THE UL LISTING. 2.) A NON-SPARKING BREAKAWAY FITTING MUST BE USED TO VALIDATE THE UL LISTING. 3.) A SPECIAL MOISTURE SENSOR RELAY IS REQUIRED IN THE CONTROL PANEL FOR PROPER OPERATION OF THE MOISTURE SENSORS. CONTACT BARNES PUMPS FOR INFORMATION CONCERNING MOISTURE SENSING RELAYS FOR CUSTOMER SUPPLIED CONTROL PANELS. • 4.) THESE PUMPS ARE UL LISTED FOR PUMPING WATER AND WASTEWATER.DO NOT USE TO PUMP FLAMMABLE LIQUIDS. 5.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIDED FOR VISUAL ENJOYMENT MUST BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSI/NFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION.THIS PUMP IS NOT INTENDED FOR USE IN SWIMMING POOLS,RECREATIONAL WATER PARKS,OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH PUMPED MEDIA IS A COMMON OCCURRENCE. 4 OW SECTION B: GENERAL INFORMATION C-1.1)Submergence: It is recommended that the pump be operated in the B-1)To the Purchaser: submerged condition and the sump liquid level should never . Congratulations!You are the owner of one of the finest pumps be less than dimension"A" in Figure 1.The time required on the market today. CP&S pumps are products engineered to draw the well down from top of motor to the minimum and manufactured of high quality components. Over one submergence level should not be greater than 15 minutes. hundred years of pump building experience along with a NOTE: Outer shaft seal must be in liquid when motor is continuing quality assurance program combine to produce a operated,whether motor is submerged or in air. pump which will stand up to the toughest applications. This manual will provide helpful information concerning installation, maintenance, and proper service guidelines. B-2)Receiving: Recommended Submergence Upon receiving the pump, it should be inspected for damage or shortages. If damage has occurred,file a claim immediately eve with the company that delivered the pump. If the manual is removed from the packaging, do not lose or misplace. B-3)Storage: Short Term- CP&S Pumps are manufactured for efficient performance following short inoperative periods in storage. Minimum Submergence Level For best results, pumps can be retained in storage, as factory assembled, in a dry atmosphere with constant temperatures for up to six (6) months. A= 12" Long Term - Any length of time exceeding six (6) months, • • but not more than twenty-four (24) months. The unit should ' • be stored in a temperature controlled area, a roofed over • • Bottom of Feet walled enclosure that provides protection from the elements • • (rain, snow, wind-blown dust, etc.), and whose temperature FIGURE 1 can be maintained between +40 deg. F and +120 deg. F. • (4.4 - 49°C). Pump should be stored in its original shipping C-2) Discharge: container. On initial start up, rotate impeller by hand to Discharge piping should be as short as possible. Both a assure seal and impeller rotate freely. If it is required that check valve and a shut-off valve are recommended for the pump be installed and tested before the long term each pump being used.The check valve is used to prevent storage begins, such installation will be allowed provided: backflow into the sump. Excessive backflow can cause flooding and/or damage to the pump.The shut-off valve 1.) The pump is not installed under water for more than is used to stop system flow during pump or check valve one (1) month. servicing. 2.) Immediately upon satisfactory completion of the test, the pump is removed,thoroughly dried, repacked in the WARNING!- These pumps are suitable for original shipping container, and placed in a temperature application in CLASS 1, GROUPS C&D, controlled storage area. � HAZARDOUS LOCATIONS and require a non- sparking break away fitting. Failure to use the B-4)Service Centers: non-sparking BAF voids warranty. For the location of the nearest Barnes Service Center, check your Barnes representative or Crane Pumps & Systems, Inc., Barnes Pumps, Inc. supplies a Non-Sparking break away Service Department in Piqua, Ohio,telephone(937)778-8947 fitting discharge system designed to allow the submersible or Crane Pumps & Systems Canada, in Brampton, Ontario, wastewater pump to be installed or removed without requiring (905)457-6223. personnel to enter the wet well. Place the Break Away Fitting (BAF) in position.Temporarily SECTION C: INSTALLATION secure the guide rails in the upper mounting brackets and locate the base elbow on the bottom of the wet well. Level the C-1) Location: base elbow with grout and/or shims. Install the intermediate These self-contained pumping units are Listed for Class I, support brackets, if required. Make sure the rails are in a true Groups C & D, Division 1 locations and are recommended vertical position so the pump will clear the access opening for use in a sump, lift station or basin. This pump is designed and will slide freely down the rails into place on the discharge for submerged continuous duty (15 minutes duty in air base elbow. once the rails are in proper alignment, bolt the at nameplate horsepower), pumping sewage, effluent, base elbow into the floor of the station and connect the • wastewater or other nonexplosive or noncorrosive liquids not discharge pipe to the elbow. Connect the movable portion above 104°F (40°C). Never install the pump in a trench, ditch and other supplied fittings of the BAF onto the pump and or hole with a dirt bottom; the legs will sink into the dirt and lower into wet well. See the Break Away Fitting manual for the suction will become plugged. more information. 5 If a rigid conduit is used to install the pump it must meet C-4.2)Control Cable: Class I, Division 1 requirements of the National Electrical The cord assembly mounted to the pump must not be Code. Conduit must be stainless steel or coated metal, modified in any way except for shortening to a specific resistant to sewage water. application.Any splice between the pump and the control panel must be made in accordance with all applicable electric C-3) Liquid Level Controls: Intrinsically Safe codes. It is recommended that a junction box(if used)with seal fittings be mounted outside the sump or be of at least WARNING!-Level control floats used within the Nema 7(EEMAC-7)explosion proof construction if located t hazardous location, must be in an intrinsically within the wet well.A UL listed seal fitting MUST be used in safe control circuit suitable for use in CLASS 1, conduit leaving the hazardous location. DO NOT USE THE GROUPS C&D, HAZARDOUS LOCATIONS. CONTROL CABLE TO LIFT PUMP. The level controls are to be supported by a mounting bracket C-4.3)Wire Size: that is attached to the sump wall, cover or junction box. Cord If additional cable is required consult a qualified electrician for grips are used to hold the cords in place on the mounting proper wire size. See table for further electrical information. bracket.The control level can be changed by loosening the grip and adjusting the cord length as per the plans and specifications. Be certain that the level controls cannot hang up or foul in it's swing and that the entire pump is still submerged when the level control is in the"Off'mode. A Warrick Control@ intrinsically safe relay, Series 27, is G L1 L L3 2 an acceptable panel mounted relay, providing the relay is properly installed and maintained. Z Y = p W J W The primary (A.C. supply line) circuit is not intrinsically safe, L9 0° therefore the relay must be located in a"SAFE" location (a place that is not classified as a hazardous location).The secondary circuit is intrinsically safe, however, any splice must be made in a "SAFE"location and any control cord that is cut or damaged must be replaced immediately. C-3.1) Level Control Float System: G T1 T7 T2 T8 T3 T9 T4 T5 T6 . It is recommended to use a two float, on and off, level control system.An additional float, incorporated with an alternator switching system will be required for a duplex system.A high MOTOR LEADS level alarm may be required to alert maintenance personnel. A low level cut off may be required to provide system THREE PHASE, 200-230 VOLT AC shutdown if the main level control system malfunctions.The Power Cable Motor Lead Number off or low level float should be positioned so that the liquid Green (Ground) Green level never drops below the minimum submergence level. White 2 &8 Red 3&9 C-4) Electrical Connections: Black 1 & 7 4, 5&6 Together WARNING!-All model pumps and control panels must be properly grounded per the National AElectric Code or Canadian Electric Code,state, !* province and local codes. Improper grounding voids warranty. All electrical controls and motor starting equipment must be installed outside the hazardous area unless approved explosion proof controls are used. C-4.1) Power Cable: The cord assembly mounted to the pump must not be modified in any way except for shortening to a specific application.Any splice between the pump and the control panel must be made in accordance with all applicable electric codes. It is recommended that a junction box(if used)with seal fittings be mounted outside the sump or be of at least • Nema 7(EEMAC-7)explosion proof construction if located within the wet well.A UL listed seal fitting MUST be used in conduit leaving the hazardous location. DO NOT USE THE POWER CABLE TO LIFT PUMP. 6 MODEL NO "A" HP VOLT/ Hz RPM NEMA FULL LOCKED CORD CORD CORD O.D. WINDING DIM Ph (Nom) START LOAD ROTOR SIZE TYPE # .02 (.5) RESISTANCE CODE AMPS AMPS in(mm) MAIN . 8XSE20048HA 49.06 20 460/3 60 870 G 27.8 141.0 8/4 SOW 0.985(25) .76 8XSE20058HA 49.06 20 575/3 60 870 G 22.0 109.0 8/4 SOW 0.985(25) 1.21 8XSE25048HA 49.06 25 460/3 60 870 G 36.5 174.0 8/4 SOW 0.985(25) .52 8XSE25058HA 49.06 25 575/3 60 870 G 28.8 139.2 8/4 SOW 0.985(25) 8XSE30048HA 49.06 30 460/3 60 870 F 43.0 199.0 8/4 SOW 0.985(25) .42 8XSE30058HA 49.06 30 575/3 60 870 F 34.4 159.0 8/4 SOW 0.985(25) .66 8XSE30046HA 49.06 30 460/3 60 1150 G 40.0 210.0 8/4 SOW 0.985(25) .36 8XSE30056HA 49.06 30 575/3 60 1150 G 32.0 168.0 8/4 SOW 0.985(25) .58 8XSE40046HA 49.06 40 460/3 60 1150 G 52.0 282.0 6/4 SOW 1.125(29) .30 8XSE40056HA 49.06 40 575/3 60 1150 G 42.6 226.0 6/4 SOW 1.125(29) .47 8XSE50046HA 49.06 50 460/3 60 1150 F 67.0 322.0 4/4 SOW 1.350(34) .25 8XSE50056HA 49.06 50 575/3 60 1150 F 53.6 258.0 4/4 SOW 1.350(34) .38 8XSE60046HA 49.06 60 460/3 60 1150 F 76.9 409.0 2/4 SOW 1.550(39) .17 8XSE60056HA 49.06 60 575/3 60 1150 F 61.4 315.0 2/4 SOW 1.550(39) .27 8XSE75046HA 54.50 75 460/3 60 1150 G 92.0 534.0 2/4 SOW 1.550(39) .13 8XSE75056HA 54.50 75 575/3 60 1150 G 73.6 427.0 2/4 SOW 1.550(39) .23 8XSE100044HA 54.50 100 460/3 60 1750 G 123.0 703.0 1/4 SOW 1.680(43) .08 8XSE100054HA 54.50 100 575/3 60 1750 G 98.4 1 562.0 1/4 SOW 1.680(43) .12 8XSE125044HA 54.50 125 460/3 60 1750 F 153.0 864.0 2/0/4 SOW 1.930(49) .05 8XSE125054HA 54.50 125 575/3 60 1750 F 122.0 691.0 2/0/4 SOW 1.930(49) .08 8XSE150044HA 54.50 150 460/3 60 1750 E 182.0 1080.0 3/0/4 SOW 2.070(53) .05 8XSE150054HA 54.50 150 575/3 60 1750 E 145.0 864.0 3/0/4 SOW 2.070(53) .07 Moisture and Temperature sensor cord for all models is 18/5 SOW,0.485(12.3mm)1.02(.51 mm)O.D. Winding Resistance t 5%.Winding resistance measured in OHMS @ 25°C.(Between Lines) Pump rated for operation at t 10%voltage at motor. ' CONTROL Small Cable Temperature Moisture Sensor Sensor Leads Leads G L1 L2 L3 S1 S2 W1 W2 G Y O Q :) 0 u.l w m m Of U Uj Z W Q = W w of m O U' 11`1 P2 ) W1 W2 G G T1 T2 T3 T4 T7 T5 T8 T6 T9 w z d. � f. Resistor MOTOR LEADS v ! iY � �0 a-;;_ Co THREE PHASE,460 VOLT AC THERMOSTAT a' Power Cable Motor Lead Number MOISTURE AND TEMPERATURE SENSORS Green(Ground) Green Control Cable Lead Number Black 1 Black P1 (Temperature Sensor) White 2 White P2 (Temperature Sensor) Red 3 Red W1 (Moisture Sensor) • 4 & 7 Together Orange W2 (Moisture Sensor) 5 &8 Together Green Ground 6&9 Together 7 WARRANTY NOTE:Both the temperature a. Proper grounding per NEC. sensor and moisture detection system must b.A temperature sensing circuit(see Fig. 2A& B) be connected to the motor circuitry such that c.A moisture detection circuit with continuity test Athe motor will be de-energized or sound alarm circuit(see Fig. 3) if excessive motor temperatures are reached d.An intrinsically safe level control system. • and/or if water is detected in the seal chamber e.A main power manual disconnect and lock out. and/or motor chamber. Failure to have the above f. A motor starter and overload system. mentioned systems installed and operative, g. Single phase only, requires a capacitor power nullifies warranty. pack (see Fig.2B). C-4.4) Overload Protection: Control panels for single phase pumps MUST be purchased The normally closed (N/C)thermal sensor is embedded in the from the factory and it is advisable that all three phase control motor windings and will detect excessive heat in the event panels are also purchased from the factory. an overload condition occurs which will then trip and stop the pump.The thermal sensor leads marked P1 and P2 MUST be connected in series with the stop button of the pilot circuit SECTION: D START-UP OPERATION of the magnetic motor controller located in the control panel D-1)Check Voltage and Phase: so that the thermostat will open the circuit before dangerous Before operating pump, compare the voltage and phase temperatures are reached.A manual momentary start switch information stamped on the pump's identification plate to the is required to prevent the automatic restarting of the motor available power. when the thermostat resets. For a typical wiring diagram, refer to Fig. 2. In the event of an overload,the source of this D-2)Check Pump Rotation: condition should be determined and rectified before the pump Before putting pump into service for the first time,the motor is put back into normal operation. DO NOT LET THE PUMP rotation must be checked. Improper motor rotation can CYCLE OR RUN IF AN OVERLOAD CONDITION OCCURS! result in poor pump performance and can damage the motor and/or pump.To check the rotation, suspend the pump If current through the temperature sensor exceeds the values freely, momentarily apply power and observe the"kickback". listed, an intermediate control circuit relay must be used to "Kickback"should always be in a counter-clockwise direction reduce the current or the sensor will not work properly. as viewed from the top of the pump motor housing. TEMPERATURE SENSOR ELECTRICAL RATING D-2.1) Incorrect Rotation for Three-Phase Pumps: In the event that the rotation is incorrect for a three-phase VOLTS CONTINUOUS INRUSH installation, interchange any two power cable leads at the . AMPERES AMPERES control box. DO NOT change leads in the cable housing 110-120 3.00 30.0 in the motor. Recheck the"kickback" rotation again by 220-240 1.50 15.0 momentarily applying power. 440-480 0.75 7.5 D-2.3)Test Procedure For Moisture Sensor Control: With a Warrick moisture detection control,type 2800, a normally closed push button and neon indicating lamp is C-4.5 Moisture Sensors: provided as a means of checking the moisture sensing A normally open (N/O)detector is installed in the pump seal components.When the push button is depressed,the chamber,which will detect any moisture present, and a indicating lamp will be illuminated to indicate(A) power is continuity test resistor built into the motor.The test resistor supplied to the control, (B)the control is operative, and (C) is rated 1 watt at 330K ohms.The moisture sensors MUST wiring to the moisture sensing probes in the motor is intact. be connected to moisture detector control,which includes a This procedure should be performed periodically to confirm continuity test circuit, see Fig. 3 for typical wiring diagram. integrity of the circuit. The normally closed (N/C) contact of the moisture detector MUST be connected in series with the stop button of the D-3)Start-Up Report: pilot circuit of the magnetic motor controller.A Warrick Included at the end of this manual are two start-up report moisture detection control,Type 2800 is an acceptable sheets, these sheets are to be completed as applicable. control if properly installed and maintained.Wiring must be Return one copy to Barnes Pumps, Inc. and store the second provided from the moisture detector sensor probe leads of in the control panel or with the pump manual if no control the motor designated W1 and W2 to terminals 9 and 10 of panel is used. It is important to record this data at initial start- the 2800-XXX control.Terminal pair 1-2 must be continuously up since it will be useful to refer to should servicing the pump energized from an A-C supply line of electrical characteristics be required in the future. shown on the data table. In the event of moisture detection, the pump should be pulled and the source of the failure D-3.1) Identification Plate: located and repaired. IF MOISTURE DETECTION HAS Record the numbers from the pump's identification plate on OCCURRED, SCHEDULE MAINTENANCE AS SOON AS both START-UP REPORTS provided at the end of the manual POSSIBLE! for future reference. C-4.6)Control Panel and Electrical System: The control panel and the electrical system MUST be properly designed and wired to include at least, but not limited to the following; 8 TYPICAL THERMAL PROTECTION WIRING DIAGRAM 115 VAC 1 PH _ 115 VAC 1 PH FUSED FUSED STAKE STAKE X1 X2 L1 L2 L3 GROUND X1 X2 L1 L2 GROUND I I i i M M M JM MOTOR STARTER M M M� M � M i I i i I OL OL OL OL CONTROL OL O OL PANEL i i .1.. Zsc STOP START i STOP START SC MOMENTARY MOMENTARY L WHITE WHITE g W R L H E BLACK P1 P2 T1 T2 T3 G BLACK P1 P2 K T D START T1 4 TA G SWITCHES THERMO SENSORTHERMOS 4 1 ENSOR NC CONTACT PUMP&MOTOR j NC CONTACT PUMP&MOTOR THREE PHASE SINGLE PHASE THREE PHASE SINGLE PHASE A FIGURE 2 B • TYPICAL WIRING DIAGRAM FOR MOISTURE SENSOR RELAY A.C. SUPPLY STANDARD LINE WIRING BY MFG WIRING BY OTHERS _ 3 a LOAD r — CONTROL ENCLOSURE ____ ❑ �❑ CONTACT I 1 2 ❑ ❑ I — 3 a l COLOANTACT I J I I 5 }� LOAD CONTACTS I � � s TO MOTOR STARTER D s 10 I CONTROL CONTACT CONFIGUATION i Y I I / I I I L --- J SENSOR PROBE CONTINUITY TEST PUSHBUTTON AND INDICATOR LIGHT Wi W2 • MOTOR FIGURE 3 9 i D-3.2)Insulation Test: NOTE: If impeller(7) is replaced, also replace impeller ring Before the pump is put into service, an insulation (megger) (8). If only the impeller ring (8) requires replacing, split the test should be performed on the motor.The resistance values ring and remove, be careful not to damage impeller. (ohms)as well as the voltage (volts) and current(amps) ' should be recorded on the start-up report. To remove Impeller(7), removing cap screw(10) (or nut) and washer(9) (and spring washer(11) if so equipped).The D-3.3) Pump-Down Test: impeller is keyed onto the shaft with a square key(6) and After the pump has been properly wired and lowered into the to remove, pull impeller straight off the shaft using a wheel basin, sump or lift station, it is advisable to check the system puller if required. Inspect gasket(1 H) if suction cover(1 E) by filling with liquid and allowing the pump to operate through has been removed, and replace if cut or damaged. Before it's pumping cycle. The time needed to empty the system,or reinstallation, check the motor shaft and impeller bore for pump-down time along with the volume of water, should be damage. recorded on the start-up report. F-1.2) Reassembly: To install wear ring (1 F)first apply retaining compound to the SECTION E: PREVENTATIVE MAINTENANCE bore of suction cover(1 E)and then press wear ring (1 F) into As the motor is Air-filled, no lubrication or other maintenance bore of suction cover(1 E) until seated. Position gasket(1 H) is required, and generally Barnes Pumps will give very on volute, and locate suction cover(1 E) on volute (1), apply reliable service and can be expected to operate for years of thread locking compound to socket head screws (1 D)j and normal sewage pumping without failing. However, as with any tighten into volute (1).To install impeller(7),first apply mechanical piece of equipment a preventive maintenance retaining compound to groove at bottom of impeller and press program is recommended and suggested to include the impeller ring (8) on impeller(7),then apply a thin film of oil following checks: to motor shaft and slide impeller straight onto shaft, keeping keyways lined up. Drive key(6) into keyway. Locate spacer 1) Test moisture detector control"Test Switch"for (9), and Lock-spring washer(11) on shaft, apply thread continuity of circuit.Water in the seal chamber will locking compound to cap screw(10)threads, thread cap energize a seal leak warning light at the control panel. screw(10) into shaft and torque to 35 ft. lbs. Rotate impeller This is a warning light only and does not stop the motor. to check for binding. It indicates the seal has leaked and must be repaired. This should be done within 2 or 3 weeks to prevent Install impeller and motor assembly over studs and onto further damage. See section D-2.3. volute (1).Apply thread locking compound to threads of each 2) Inspect impeller and body for excessive build-up or stud (3). Position lockwasher(5)on studs (3) and thread . clogging and repair as required per section F-1. nut(4) onto stud (3)and torque to 24 ft. lbs. Check for free 3) Inspect outer shaft sealyand replace as required per rotation of motor and impeller. section F-2. 4) Check motor for ground leakage and proper amp draw. Motor and inner seal repair per section F-3. F-2) Outer Shaft Seal Service: SECTION F: SERVICE AND REPAIR A!* CAUTION!-Handle seal parts with extreme care. NOTE:All item numbers in () refer to Figures 7&8. DO NOT scratch or mar lapped surfaces. WARNING!-Electrical power to the pump motors must be disconnected and locked out to prevent any dangerous electrical hazards or personnel MOTOR END danger before any service work is done to the (Inboard End) pump. CAUTION 1- Operating pump builds up Mounti heat and pressure;allow time for pump to (M' cool to room temperature before handling f or servicing. Statio F-1) Impeller and Volute Service: Seal Assembly F-1.1)Disassembly and Inspection: (11 3) Rotatir To clean out the pump body(1), or clean out or replace 1 61;J r�� impeller(7),or replace wear ring (1 F)and impeller ring (8), Spring (13( disconnect power, remove hex nuts(5)and vertically lift motor Retaining Ri assembly from the pump body(1), and then lift out back plate (12). Clean out the pump body, if necessary, examine wear ring (1 F)and replace if worn. If the wear ring (1 F)requires • replacing, split the wear ring (1 F)and remove, be careful not to damage the suction cover(1 E). Clean and examine impeller FIGURE 4 (7)for pitting or wear, also check impeller ring (8)for scaring or + excessive wear, replace if required. 10 F-2.1) Disassembly and Inspection: F-3) Motor & Inner Shaft Seal Service To expose outer shaft seal (13)for examination, remove The XSE Submersible Pump motor is manufactured by Impeller and Volute per Section F-1.1. Set motor assembly Reliance Electric Co. and must be serviced and repaired by . (2) in the up position to prevent loss of oil. Remove snap Reliance approved service centers only. ring from motor shaft, then retaining ring (13D), spring (13C) For lead reconnection information, contact Reliance Electric and rotating member(13B)from shaft, See Fig.4. Examine Co., giving motor serial number. all seal parts and especially contact faces. Inspect seal for signs of wear such as uneven wear pattern on stationary WARNING!- These motors are U/L Listed members, chips and scratches on either seal face. DO NOT for application in CLASS 1, GROUPS C&D interchange seal components, replace the entire shaft seal EXPLOSION PROOF Environments.All repairs, (13). If replacing seal, remove stationary (13A)from mounting other than lead reconnects and outer seal plate by prying out with flat screw driver. Q replacement,shall be performed by an authorized reliance service facility.Any other repairs F-2.2)Reassembly: performed by the customer or NON-RELIANCE Lightly oil (DO NOT use grease)outer surface of stationary SERVICE Facilities negates the U/L Listing and member(13A). Press stationary member(13A)firmly into motor warranty. mounting plate using a seal pusher, nothing but the seal pusher is to come in contact with seal face (see Fig. 5). SECTION: G REPLACEMENT PARTS AIMPORTANT!-DO NOT hammer on the seal G-1 ORDERING REPLACEMENT PARTS: pusher-it will damage the seal face. When ordering replacement parts,ALWAYS furnish the following information: Stationary Member(13A) Polished Face Out 1. Pump serial number and date code. (Paragraph G-4) 2. Pump model number. (Paragraph G-3) / 3. Pump part number. (Paragraph G-2) 4. Part description. e — — 5. Item part number. 6. Quantity required. 7. Shipping instructions. Motor Mounting Plate Seal Pusher 8. Billing Instructions. • FIGURE 5 O HP. Volts Code Ph. Ht. 0 �Make sure the stationary member is in straight and that RPM FlA Model No. 2 the rubber ring is not out of it's groove. Lightly oil (DO NOT Part No. Serial No. 1 use grease) shaft and inner surface of bellows on rotating Z 3 member(13B) see Fig. 6.With lapped surface of rotating Impeller Dia. Tern iq• oC Ins. lass member(13B)facing inward toward stationary member (13A), slide rotating member(13B)onto shaft using a seal WARNING TO REDUCE RISK DF ELECTRICAL SHOCK DISCONNECT THE pusher, until lapped faces of(13A)and (13B)are together. PUMP HNDLING NG OR SESERVICING. EE HE POWER SSEE BEFORE (see Fig. 4). INSTRUCTION MANUAL FOR PROPER O INSTALLATION. SEE WARNING PLATE FOR O ADDITICNAL CAUTIONS. Reliance Mot Rotating Member(13B) G-2 PART NUMBER: Stationary The part number consists of a six(6)digit number,which r� appears in the catalog.A one or two letter suffix may follow this number to designate the design configuration.This number is used for ordering and obtaining information. G-3 MODEL NUMBER: Seal Pusher This designation consists of numbers and letters which Bullet represent the discharge size, series, horsepower, motor phase FIGURE s and voltage, speed and pump design.This number is used for ordering and obtaining information. IMPORTANT!-It is extremely important to keep G-4 SERIAL NUMBER: A!0 seal faces clean during assembly. Dirt particles The serial number block will consist of a six digit number, lodged between these faces will cause the seal to which is specific to each pump and may be preceded by leak. a alpha character,which indicates the plant location.This number will also be suffixed with a four digit number,which member(13B)),, making sure it is seated on retainer and not • Place spring over shaft and in place rotating indicates the date the unit was built(Date Code). EXAMPLE: ae A012345 0490. cocked or resting on bellows tail. Slide retaining ring (13B) Reference the six digit portion (Serial Number)of this number over shaft and let rest on spring (13C).Assemble impeller when referring to the product. and volute as outlined in paragraph F-1.2. 11 TROUBLE SHOOTING CAUTION I Always disconnect the pump from the electrical power source before handling. ' If the system fails to operate properly, carefully read instructions and perform maintenance recommendations. If operating problems persist,the following chart may be of assistance in identifying and correcting them: MATCH i°CAUSE" NUMBER WITH CORRELATING "CORRECTION" NUMBER. NOTE: Not all problems and corrections will apply to each pump model. PROBLEM CAUSE CORRECTION Pump will not run 1.Poor electrical connection, blown fuse, 1.Check all electrical connections for tripped breaker or other interruption of power, security.Have electrician measure current improper power supply. in motor leads, if current is within±20% 2.Motor or switch inoperative(to isolate of locked rotorAmps, impeller is probably cause,go to manual operation of pump). locked. If current is 0,overload may be 2a.Float movement restricted. tripped. Remove power, allow pump to cool, 2b.Switch will not activate pump or is defective. then recheck current. 2c.Defective motor 2a. Reposition pump or clean basin as 3. Insufficient liquid level. required to provide adequate clearance for Pump will not turn off 2a. Float movement restricted. float. 2b. Switch will not activate pump or is defective. Disconnect level control.Set ohmmeter for 4. Excessive inflow or pump not properly sized for a low range,such for application. and connect to level coo 1ntrooll leads.Actuate ohms full scale 9. Pump may be airlocked level control manually and check to see that 14. um A switch ai panel is in"HAND"position ohmmeter shows zero ohms for closed switch and full scale for open switch.(Float Switch). Pump hums but does not run 1. Incorrect voltage 2c.Check winding insulation(Megger Test) 8. Impeller jammed or loose on shaft,worn or and winding resistance. If check is outside damaged, impeller cavity or inlet plugged. of range,dry and recheck. If still defective, Pump delivers insufficient capacity 1. Incorrect voltage. replace per service instructions. 4. Excessive inflow or pump not properly sized 3. Make sure liquid level is at least equal to for application. suggested turn-on point. 5. Discharge restricted. 4. Recheck all sizing calculations to 6.Check valve stuck closed or installed backwards. determine proper pump size. 7.Shut-off valve closed. 5.Check discharge line for restrictions, . 8. Impeller jammed or loose on shaft,worn or including ice if line passes through or into damaged,impeller cavity or inlet plugged. cold areas. 9. Pump may be airlocked. 6. Remove and examine check valve for 10. Pump running backwards proper installation and freedom of operation. 7.Open valve. Pump cycles too frequently or runs 6.Check valve stuck closed or installed 8.Check impeller for freedom of operation, periodically when fixtures are not in use backwards. security and condition.Clean impeller and 11. Fixtures are leaking. inlet of any obstruction. 15.Ground water entering basin. 9. Loosen union slightly to allow trapped air Pump shuts off and turns on indepen- 1. Incorrect voltage. to escape.Verify that turn-off level of switch dent of switch,(trips thermal overload 4. Excessive inflow or pump not properly sized is set so that the suction is always flooded. protector). CAUTION! Pump may start for application. Clean vent hole. unexpectedly. Disconnect power supply. 8. Impeller jammed, loose on shaft,worn or 10. Check rotation. If power supply is three damaged,impeller cavity or inlet plugged. phase, reverse any two of three power supply 12. Excessive water temperature. leads to ensure proper impeller rotation.. (internal protection only) 11. Repair fixtures as required to eliminate leakage. Pump operates noisily or vibrates 2c.Worn bearings,motor shaft bent. 12.Check pump temperature limits&fluid excessively 5. Debris in impeller cavity or broken impeller temperature. 10. Pump running backwards 13. Replace portion of discharge pipe with 13. Piping attachments to buiding structure too flexible connector. rigid or too loose. 14.Turn to automatic position. 15.Check for leaks around basin inlet and outlets. 12 • 15 14 125 TO 200 HP PUMPS 2 13 3 9 4 12 10 5 6 7 1H 1E 1D 1F 8 10 9 1C 1B • 11 FIGURE 7 13 14 ' 15 �. �i i 7 5 8 I / I � 9 0 0 4 1 6 10 I 16 o (USE WITH 360 FRAME/ 0 1A 320 FLANGE MOTOR) 00 A I ° 1B �j o O F1 C 13 I o o O 1 C D 1F I SNAP RING SUPPLIED Qol I 1 H WITH MOTOR. 1E b o 12 1D • FIGURE 8 14 PARTS LIST ITEM QTY PART NO. DESCRIPTION . 1 1 084851 Volute Assembly 1A 1 079698 Volute 1 B 4 005810 Nipple 1C 4 014256 Nipple Cap 1D 8 079380 Soc. Hd. Screw 5/8-11 x 1" Lg Stainless 1 E 1 079190 Suction Cover 1 F 1 079369 Wear Ring Bronze 1 G 2 078994 Dowel Pin 1 H 1 079587 Gasket 2 1 See Table 1 Motor(See Note: 1) 3 8 079379 Stud 5/8 x 3" Lg Stainless 20HP-60HP 16 079379 Stud 5/8 x 3" Lg Stainless 75HP- 150HP 4 8 038519 Lockwasher 5/8 Stainless 20HP-60HP 16 038519 Lockwasher 5/8 Stainless 75HP- 150HP 5 8 15-21-1 Hex Nut 5/8-11 Stainless 20HP-60HP 16 15-21-1 Hex Nut 5/8-11 Stainless 75HP- 150HP 6 1 079381 Key 1/2 Sq x 3" Lg Stainless 7 1 Impeller, Cast Iron 083723 14.50" Dia. 75HP-1150 083723TA 14.38" Dia. 083723TB 14.25" Dia. 083723TC 14.12" Dia. 083723TD 14.00" Dia. 60HP-1150 083723TE 13.88" Dia. 083723TF 13.75" Dia. 083723TG 13.62" Dia. 083723TH 13.50" Dia. 50HP-1150 083723TJ 13.38" Dia. 083723TK 13.25" Dia. 083723TL 13.12" Dia. 083723TM 13.00" Dia. • 083723TN 12.88" Dia. 083723TP 12.75" Dia. 150HP-1750 083723TQ 12.62" Dia. 083723TR 12.50" Dia. 30HP-870,40HP-1150, 125HP-1750 083723TS 12.38" Dia. 083723TT 12.25" Dia. 083723TU 12.12" Dia. 083723TV 12.00" Dia. 083723TW 11.88" Dia. 083723TX 11.75" Dia. 083723TY 11.62" Dia. 083723TZ 11.50" Dia. 25HP-870, 30HP-1150 083723UA 11.38" Dia. 083723UB 11.25"Dia. 083723UC 11.12"Dia. 083723UD 11.00"Dia. 100HP-1750 083723UE 10.88" Dia. 083723UF 10.75" Dia. 083723UG 10.62" Dia. 083723UH 10.50" Dia. 20HP-870 8 1 079377 Impeller Ring Bronze 9 1 079588 Impeller Washer, 20 to 60 HP Stainless 1 079376 75 to 135 HP Stainless 10 1 1-111-1 Hex Hd. Cap Screw, 20 to 60HP 3/4-10 x 2" Lg Stainless 1 (Supplied with Motor) Nut, 75 to 135HP 1-1/2-12 Stainless 11 1 052699 Lock-Spring Washer, 20 to 60HP 3/4 Steel (Not Used) 75 to 135HP 12 1 079191 Back Plate 13 1 085980 Outer Seal (See Note: 2) Carbon/Ceramic/Buna-N (STD) 20HP-60HP 084259 Outer Seal (See Note: 2) Carbon/Ceramic/Buna-N (STD) 75HP- 150HP • 085981 (OPTIONAL, Pump End) Tungsten/Carbide/Buna-N 20HP-60HP 085982 (OPTIONAL, Pump End) Tungsten/Carbide/Buna-N 75HP- 150HP 14 5Ft. 625-01583 Chain .375 Steel 15 3 625-00826 Cold Shut .437 16 1 124823 Adapter(Used with 360 Frame/320 Flange Motor) 15 TABLE 1 -MOTOR WITH VARIOUS CORD LENGTHS PUMP MODEL 25FT 30FT 40FT 50FT 75FT 100FT 8XSE20048HA 079688 079688XC 079688XE 079688XF 079688X H 079688XL ' 8XSE20058HA 095171 095171XC 095171XE 095171XF 095171X H 095171XL 8XSE25048HA 079689 079689XC 079689XE 079689XF 079689X H 079689XL 8XSE25058HA 095172 095172XC 095172XE 095172XF 095172X H 095172XL 8XSE30048HA 079690 079690XC 079690XE 079690XF 079690X H 079690XL 8XSE30058HA 095173 095173XC 095173XE 095173XF 095173X H 095173XL 8XSE30046HA 083725 083725XC 083725XE 083725XF 083725X H 083725XL 8XSE30056HA 092836 092836XC 092836XE 092836XF 092836X H 092836XL 8XSE40046HA 079691 079691XC 079691X E 079691XF 079691X H 079691XL 8XSE40056HA 092835 092835XC 092835X E 092835XF 092835X H 092835XL 8XSE50046HA 079692 079692XC 079692XE 079692XF 079692X H 079692XL 8XSE50056HA 092834 092834XC 092834XE 092834XF 092834X H 092834XL 8XSE60046HA 079591 079591XC 079591X E 079591XF 079591XH 079591XL 8XSE60056HA 093644 093644XC 093644XE 093644XF 093644X H 093644XL 8XSE75046HA 079693 079693XC 079693XE 079693XF 079693X H 079693XL 8XSE75056HA 092833 092833XC 092833XE 092833XF 092833X H 092833XL 8XSE100044HA 079378 079378X C 079378XE 079378XF 079378X H 079378XL 8XSE100054HA 092831 092831X C 092831XE 092831XF 092831XH 092831XL 8XSE125044HA 079694 079694X C 079694XE 079694XF 079694X H 079694XL 8XSE125054HA 092832 092832X C 092832XE 092832XF 092832X H 092832XL 8XSE150044HA 079874 079874X C 079874X E 079874XF 079874X H 079874XL 8XSE150054HA 092830 092830X C 092830XE 092830XF 092830X H 092830XL NOTE: 1 Standard motor includes, 25 foot power and control cables, moisture&temperature sensors and carbon/ceramic/buna-n Inner& Outer shaft seals. NOTE: 2 When ordering motor(item 2), Outer seal is supplied. Item 13 is for Outer seal replacement ONLY. When ordering outer seal,furnish Reliance motor serial number. • 16 BARNES' ARNES ARNES PRESSURE SYSTEMS _- burKS WEINMAN DEMING PROSSER Limited 24 Month Warranty Crane Pumps&Systems warrants that products of our manufacture will be free of defects in material and workmanship under normal use and service for twenty-four (24) months after manufacture date, when installed and maintained in accordance with our instructions.This warranty gives you specific legal rights, and there may also be other rights which vary from state to state. In the event the product is covered by the Federal Consumer Product Warranties Law (1) the duration of any implied warranties associated with the product by virtue of said law is limited to the same duration as stated herein, (2) this warranty is a LIMITED WARRANTY, and (3) no claims of any nature whatsoever shall be made against us, until the ultimate consumer, his successor, or assigns, notifies us in writing of the defect, and delivers the product and/or defective part(s) freight prepaid to our factory or nearest authorized service station. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY PRODUCT SHALL BE TO REPLACE OR REPAIR AT OUR ELECTION, F.O.B. POINT OF MANUFACTURE OR AUTHORIZED REPAIR STATION,SUCH PRODUCTS AND/OR PARTS AS PROVEN DEFECTIVE.THERE SHALL BE NO FURTHER LIABILITY,WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE. Unless expressly stated otherwise, guarantees in the nature of performance specifications furnished in addition to the foregoing material and workmanship warranties on a product manufactured by us, if any, are subject to laboratory tests corrected for field performance.Any additional guarantees, in the nature of performance specifications must be in writing and such writing must be signed by our authorized representative. Due to inaccuracies in field testing if a conflict arises between the results of field testing conducted by or for user, and laboratory tests corrected for field performance, the latter shall control. RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS ANALYSES AND EVALUATIONS WE CONDUCT WILL BE BASED ON OUR BEST AVAILABLE EXPERIENCE AND PUBLISHED INDUSTRY INFORMATION. SUCH RECOMMENDATIONS DO NOT CONSTITUTE A WARRANTY OF SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS GIVEN. This warranty shall not apply when damage is caused by (a) improper installation, (b) improper voltage (c) lightning (d) excessive sand or other abrasive material (e) scale or corrosion build-up due to excessive chemical content. Any modification of the original equipment will also void the warranty. We will not be responsible for loss, damage or labor cost due to interruption of service caused by defective parts. Neither will we accept charges incurred by others without our prior written approval. This warranty is void if our inspection reveals the product was used in a manner inconsistent with normal industry practice and\or our specific recommendations. The purchaser is responsible for communication of all necessary information regarding the application and use of the product. UNDER NO CIRCUMSTANCES WILL WE BE RESPONSIBLE FOR ANY OTHER DIRECT OR CONSEQUENTIAL DAMAGES,INCLUDING BUT NOT LIMITED TO TRAVEL EXPENSES, RENTED EQUIPMENT, OUTSIDE CONTRACTOR FEES, UNAUTHORIZED REPAIR SHOP EXPENSES, LOST PROFITS,LOST INCOME,LABOR CHARGES,DELAYS IN PRODUCTION,IDLE PRODUCTION,WHICH DAMAGES ARE CAUSED BY ANY DEFECTS IN MATERIAL AND\OR WORKMANSHIP AND\OR DAMAGE OR DELAYS IN SHIPMENT. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No rights extended under this warranty shall be assigned to any other person,whether by operation of law or otherwise, without our prior written approval. CRANE PUMPS & SYSTEMS A Crane Co. Company 420 Third Street 83 West Drive,Brampton Piqua,Ohio 45356 Ontario,Canada L6T 2J6 Phone:(937)778-8947 Phone:(905)457-6223 Fax:(937)773-7157 Fax:(905)457-2650 www.cranepumps.com i 17 IMPORTANT! WARRANTY REGISTRATION Your product is covered by the enclosed Warranty. To complete the Warranty Registration Form go to- http-//www.cranepumps.com/ProductRegistration/ If you have a claim under the provision of the warranty, contact your local Crane Pumps & Systems, Inc. Distributor. RETURNED GOODS RETURN OF MERCHANDISE REQUIRES A "RETURNED GOODS AUTHORIZATION". CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR. Products Returned Must Be Cleaned, Sanitized, Or Decontaminated As Necessary Prior To Shipment, To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material. All Applicable Laws And Regulations Shall Apply. 18 CRAN E PUMPS & SYSTEMS . A Crane Co. Company START-UP REPORT General Information Pump Owner's Name: Address: Location of Installation: Contact Person: Phone: " Purchased From: Nameplate Data Pump Model #: Serial #: Part#: Impeller Diameter: Voltage: Phase: 0 Hertz: Horsepower: Full Load Amps: Service Factor Amps: Motor Manufacturer: Controls Control panel manufacturer: Model/Part number: Number of pumps operated by control panel: Short circuit protection? YES_ NO Type: Number and size of short circuit device(s): Amp rating: • Overload Type: Size: Amp rating: Do protection devices comply with pump and motor Amp rating? YES_ NO Are all electrical and panel entry connections tight? YES_ NO Is the interior of the panel dry? YES_ NO Liquid level Control Brand and Model: Pre-Startup All Pumps Type of equipment: NEW REBUILT_ USED Condition of equipment at Start-Up: DRY_ WET_ MUDDY_ Was Equipment Stored? YES_ NO_ Length of Storage: Liquid being pumped: Liquid Temperature: Supply Voltage/Phase/Frequency matches nameplate? YES_ NO Shaft turns freely? YES_ NO Direction of rotation verified for 30 motors? YES_ NO Debris in piping or wet well? YES_ NO Debris removed in your presence? YES_ NO Pump case/wet well filled with liquid before startup? YES_ NO Is piping properly supported? YES_ NO Non-Submersible Pumps Is base plate properly installed /grouted? YES_ NO_ N/A_ • Coupling Alignment Verified per 1&0 Manual? YES_ NO N/A_ Grease Cup/Oil Reservoir Level checked? YES_ NO_ N/A_ 19 Submersible Pumps Resistance of cable and pump motor (measured at pump control): Red-Black: Ohms(Q) Red-White: Ohms(Q) White-Black: Ohms(Q) Resistance of Ground Circuit between Control Panel and outside of pump: Ohms(0) MEG Ohms check of insulation: Red to Ground: White to Ground: Black to Ground: Operational Checks Is there noise or vibration present? YES_ NO Source of noise/vibration: Does check valve operate properly? YES_ NO N/A_ " Is system free of leaks? YES_ NO Leaks at: Does system appear to operate at design flow rate? YES_ NO , Nominal Voltage: Phase: 10 30 (select one) Voltage Reading at panel connection, Pump OFF: L1, L2 L2, L3 L1, L3 Voltage Reading at panel connection, Pump ON: L1, L2 L2, L3 L1, L3 Amperage Draw, Pump ON: L1 L2 L3 Submersible Pumps Are BAF and guide rails level / plumb? YES_ NO Is pump seated on discharge properly? YES_ NO Are level controls installed away from turbulence? YES_ NO Is level control operating properly? YES_ NO Is pump fully submerged during operation? YES_ NO Follow up/Corrective Action Required . YES_ NO Additional Comments: Startup performed by: Date: Present at Start-Up ( ) Engineer: ( ) Operator: ( ) Contactor: ( ) Other: All parties should retain a copy of this report for future trouble shooting/reference CRAN E PUMPS & SYSTEMS • A Crane Co. Company 420 Third Street 83 West Drive, Brampton Piqua,Ohio 45356 Ontario,Canada L6T 2J6 Phone: (937)778-8947 Phone:(905)457-6223 Fax:(937)773-7157 Fax: (905)457-2650 www.cranepumps.com 20 JP francis Submittal Cover Sheet Owner: City of Renton Project: Strander Blvd. Ext. PH 1 Owner Project#: Contractor: J.P. Francis & Associates Inc. Specification Section and Paragraph: Submittal No: 1 Submittal Title: Barnes Pump Material Cate: 1/27/11 Engineer's Comments: Contractor Comments: 10013 MLK Jr Way S. ♦ Seattle,WA 98178 206.722.4800 ♦ 206.725.5932 Fax BARNES Series 8XSE-HA 3" Spherical Solids Handling www.cranepumps.com Class I, Groups C & D, Division 1 8"Horizontal Discharge XP- Submersible Non-Clog Pumps Specifications: M- DISCHARGE ..............................8'NPT, 125 lb.Flange Horizootal LIQUID TEMPERATURE............104°F(40°C)Continuous VOLUTE .....................................Cast Iron ASTM A-48,Class, with Bronze wear ring MOTOR HOUSING.....................Cast Iron ASTM A-48,Class 30 SEAL PLATE .............................Cast Iron ASTM A-48,Class 30 IMPELLER: Design...................3 Vane, Enclosed With Pump%hut Vanes on Back Side.Dynamically Balanced ISO G6.3 Material .................Cast Iron ASTM A-48,Class 30 SHAFT .......................................416 Stainless Steel SQUARE RINGS ........................Buna-N LIFTING CHAIN..........................Yoke,Galvanized HARDWARE...............................300 Series Stainless Steel PAINT .........................................Air Dry Enamel. SEAL: Design ...................Tandem Mechanical,Oil Fiilec"Pressure e Equalized Reservoir • • , Material..................Rotating Faces-Carbon AD:Stationary Faces-Ceramic Elastomer-Buna-N Hardware-300 Series Stainless • • CORD ENTRY.............................25 ft.(7.6m)Std.Cord.Epox!:sealed Housing with Secondary Pressure Series: 8XSE^HA Grommet for Sealing and Stain Relief SPEED........................................1150 or 1750 RPM(Norrirail 30 - 75HP, 1150RPM, 50HZ UPPEF BEARING: Series: 8XSE-HA Design...................Single Row, Ball,Grease Lubricated Load......................Radial 100-150HP, 1750RPMp 50HZ LOWER BEARING: Design...................Double Row,Ball,Grease Lubricated Lead.......................Radial&Thrust MOTOR: Design...................NEMA B-Three Phase Torque Curve. Air-Filled,Squirrel Cage Induction Insulation ..............Class F. THREE PHASE...................... Dual Voltage 230/460;Requires Overload Protectico to b:in.:auded in control panel. MOISTURE SENSOR.................Normally Open(N/O),Rerj;;;:•es Relay in s itt; Canadlan Standards AssoclatJor. Control Panel File No.LR16567-26 TEMPERATURE SENSOR.........Normally Closed(N/C),Req::ires Relay in Control Panel OPTIONAL EQUIPMENT............Seal Material,Impeller Trims, �� Underwriters Laboratories Inc 0 Cord Length File No.E73942 Sample Specifications:Section 1 Page 21. DESCRIPTION: SUBMERSIBLE NON-CLOG SE`.JVAGE PUMP DESIGNED FOR HAZARDOUS RAW SEWAGE APPLICATIONS. CRANE PUMP:a & SYSTEMS SECTION 11 4 PAGE• � �� DATE 2 /06 A Crane Co.Company USA: (937)778-8947 Canada:(905)457-6223 International: (937)615-3598 10 r ' Series 8XSE-HA 3 Spherical Solids Handling BARNE9 Class I, Groups C & D, Division 1 www.cranepumps.com 8" Horizontal Discharge XP- Submersible Non-(,'log Pumps ndlea (mm) i 34.62 - (879) 20.00 16.50 (419) A' 08 50 28.12 49. (1246) (714) 54. (1384) + JJ - � U 7. MODE1.140 1 PART NO "A" HP VOLT/Ph Hz RPM NE,.A FULL LOCKED CORD CORD CORD O.D, t DIM (Nom) 1:START LOAD ROTOR SIZE � TYPE .02(.5) CODE AMPS AMPS In(mm) eXSE30046HA 084781 49.06 30 46013 60 1150 G 40.0 210.0 814 SOW 0.985(25 I 8XSE30056HA 089361 49.06 30 57513 60 1150 ( 32.0 188.0 _8/�i SOW 0.985 251 BXSE40046HA 084782 49.06 40 460/3 60 1150 (: 52.0 282.0 6/4 SOW 1.125(29 BXSC40056HA 089382 49.06 40 57513 60 1150 G 42.6 226.0 6/4 SOW 1.1?�29) - 8.XSE':0046HA 084783 49.06 50 460/3 60 1150 i 67.0 322.0 4/4 I sow 1.550 34) 8XSF.i50_0_56HA 889363 49.06 50 57513 60 1150 ' 53.6 258.0 4/4 _ SO_W 1.350 34 8XSE60046HA 084784 49.06 60 460/3 60 1150 _ 5.3 409.0 2/4 -sow_ _1 550(39 8XSF60056H.:_ 08064 49.06 60 575/3 80 1150 _ 61.4 315.0 214 sow 1.5u0(39 8XSE75046HA 084785 54.50 75 460/3 60 1150 C! 92.0 534.0 2/4 sow 1.550(39) 8XSE75056HAy 1 089365 54.50 75 575/3 60 1150 (=' 73.6 !27. 2/4 31-AN 1.550(39) BXSE100044HA 084786 54.50 100 460/3 60 1750 123.0 703.0 114 sow 1.680 4'3) 8XSE100054HA 089366 54.50 100 57513 60 1750 C 98.4 562.0 1/4 SOW 1.680 43 BXSE125044HA 084787 54.50 125 46013 60 1750 1- 153.0 864.0 2/014 SOW 1.930 49 8XSE125054HA 089367 54.50 125 575/3 60 1750 I 122.0 691.0 2/014 1 SOW 1.930 49 8XSE150044HA 084788 54.50 150 460/3 60 1750 L 182.0 1080.0 3/0/4 SOW 2.070 53 8XSE150054HA 089368 54.50 150 575/3 60 1750 E 145.0 1 864.0 3/0/4 1 SOW 2.070 53 Moisture and Temperature sensor cord for all models is 18/5 SOW.0.485(12.3mm)t 02(.51mm)O.D. IMPORTANTI -1.) MOISTURE AND TEMPERATURE SENSORS MUST BE CONNECTED TO VALIDATE THE UL LISTING. 2) A NON-SPARKING BREAKAWAY FITI iNG MUST BE USED TO VALIDATE THE UL.LISTING. 3.) A SPECIAL MOTS,URE SENSOR RELAY IS REQUIRED IN THE CONTROL PANEL FOR RC PER OPERATION OF THE MOISTURE SENSORS. CONTACT BARNES PUMPS FOR INFORMATION CONCERNING MOISTURE SENSIN,.,RELAYS FOR CUSTOMER SUPPLIED CONTROL PANEL':. 4.) THESE PUMPS ARE UL LISTED FOR PUMPING WATER AND WASTEWATER.DO NO1 JSE TO PUMP FLAMMABLE UQUIDS. 5.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIL'iir)FOR VISUAL ENJOYMENT MUST BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSI/NFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION.THIS PUMP IS NOT INTENDED FOR USE IN WIMMING PCOLS,RECREATIONAL WATER PARKS.OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH PUMPED MEDIA ISA COMMON OCCURRENCE. -� SECTION 5 CRANE PUMPS & SYSTEMS PAGE DATE 2/05 J ' ACrane Co.Company USA: (937)778-8947 • Canada: (905)457-6223 • International: (937)615-3598 -• • � 1 ' 1 1 • i ' 1" ' •1 MEMO am 0 in 0 will IN 0 IN 0 am UFO IZES N_ 'Pill! N■■■■Ml■■ ■no 0� . . ....__..Mai Pump HP Impeller. . 0 SOME swim MEN .. . ■ ■asommo ®;.. OM= i ■oom solo a of ■:Iring NEON. , ,MOM M ■.Emn ■■ ■ MEMOO N: : �. ■ .mom'I,�i:■now a NO NNE :MEMO: ••■■:Inn •0 00(356) 0 Mai I mom Boom j ' „ �_!\■■ N`m J■1 a l\ml■'�a/s onsassomm:��:�'.:■■E■.NN N■■E:■■E N:EMEN soon N'� ' a:i :7i is iini Is mMM '11Em1 CmMME MMEmo names CMmm::Em:0 ON 0 # 71!'rI ..R'10■■L:10■Ngo mass r.■!r■..!■.■..r..■!■■NEON r!!.r ::="C:l :; l ::M1 � NONE" EMOm :■t:Cn:■CEC■:N a:■:■:o:t:■:■:N:O:N:t:N:E:■ :: : 1 : : : : EMLtaf ■■■■.■■ lmo= tS:gl!nob q mi RA .■t.=. sO■M so=M.*NEWS BCLOH snong.man nm■Fh.'�■■ I. mI.aN■■■o aEsomm■om r■■mNnsum■�0 NNE WOMEN 0 ME MEMO swoon ENRON " •ai 'k :t In M bt 1a'' �i'4]:ia MEMO Oim:Main no::'::: mom -�..■.■:..:..I.gas\: : .I lama■■ won Omni aM■M■N..■:Hann.toms. mnNH.,m is IN:tm■F` mi \Room . rs imam ■SEEN smog 0"80 NEME. Erlfa imhoo, ►..►'4m t mk\Tlvm ■ msE ■E■a■MEM■ ■ mn:NOES � 11, I r.bf,i■ \o►t V.m// ■E LOR■NO HOME■Mason SEMEN:■=on ■nam■■ 11111 1\iolk.'. �►'kq■o.'n I■E■■■M■nNsmago sM. ■MEMEMOS■ �■a : l 1 mm\Rw ►N:\mm.'1■EEN■m►�Ef .E■ gin■■:sons■N■ENN ::IV I 11�v misMI6►` \►* !'"em ONION E::Li WOMEN rasa•N:'::AMEN Nam a`1�i �!�':�� Li Mil QEi�i: No mom �:aMIowns NES�i'M ass 'E:aEmO NMI .art JH SL VE . ►fir m■.�■�■.�mn�►��.i■r■N Na■N%NENP%&EMENE IN■Hn on tmom our l■.d_7•■� ►\R'■m►`.O '�.\Sno\"4 s\•.PP:•:\N Nmma■�m■■ �.a tO■NI .mrm d 1 Mm►.�.J.m.\H ►�►\r�MmaC 'M• •HORN t MNM1 moon ■ soma • m.N�N■E �■mo►.`ar.\I r ■s.■mm■m mono■ ' N.Nm ii.m:14ma V&Nbdma m '%E.L•.m►vr■falSLdF ■■■■ ■■EanI nom1/N \:Ik a :1% 'on Hl•�Ea 1n1M.7 n■►• n■NI ■sssS■ son r.���. �r. �. .r• r M\ s� M.M M.M�MEMOS■ oN FAMI Haig-7 iaiai►'.�iii:'?�5iai.:°:i.4■i••-.�G 4WE m►E■N�E■■■N■■■a■ E■ LMONE "N■Ema■lsoll 'RMEN 11n:n '�N.lN... �l6.i N" \r NEE! EEa ■ m Eamon ONINN ►14bi 0 �_� `► -0Mm�/ �s r\N=ono. ' .� amo N■asEN■■■ r■..., ■i.■.7■EIS a■rn mom ■. mamas.NE■N.ME _ El;\■t ,&jnib 6.7111 mo•dN qF M.F ' M mall!■■loss son mass. Emoll man on l 1 NM■M■nnmos N N■ ■ ZED��.�:�►•a r!Ho■nH ton■M.ENm■NNM:Nman■ ■mEE.amMl go"mom mom mNr rEmm■■E■ ■.r■ ►NE■��BEN E■moo NNE.■■■IS .ESE. ,MM6Il::::III:aa ::;: � :o:EE:8:m m :;;:; ;Noel : Lomas: �E■■■.lrIn����iEOE■■Faso■Nam■O.mm■m�on�mmmo Nnnnn .Er� . 1000 2000 3000 SECTION 11 .• 2105 BARNESO 8" Break Away fitting . Standard and Non-Sparking Models: BAF-8 & BAF-E8 www.cranepumps.com Break Away Fittings Specifications: BA><,e tandard 3"(76dule 4 should be for guides.An intermediate guide et should b pipe lengths of 20 feet(6),')or more. The stlbow is desi anchored to the floor of the wet well. A stainsealing on the el ates with a cast Iron flange. The pua moveable bracket ani Is the to rid4 up and down tails which are attached to the base elbo ne end and the anthe wet well cover at the other end.The guide 41s serve only to guide,they carry none of the pump weight. � I BAF-E8! Non-Sparking 1 3'(76mm)Schedule 40 pipe should be used for guides.An Intermediate guide pipe bracket should be used for pipe lengths of 20 feet W14)or%�.re. The stationary elbow is designed to be anchored to the floor of:hf:wte,w911. A brass sealing face on the elbow mates with a cast iron flange.A brass sheet is used on the stationary coupling at the moveable bracket stop. The pump bolts to the moveable bracket,which has brass ins?;r's that \ r I provide t'rie Non-Sparking feature,and is then free to ride up and down the guide rails which are attached to the base elbow at one end and the underside of the wet well cover at the other end.The guide rails serve only � to guide,they cant'none of the pump weight. Model: BAF-8 P/N: 082110 Model: BAF-E8 P/N: 082110D For OPTIONAL information see Intermediate Rail Suppori. DESCRIPTION: THE BREAK AWAY FITTING IS DESIGNED TO ALLOW THE SUBMERSIf±LE PUMP TO BE INSTALLED OR REMOVED WITHOUT REQUIRING PERSONNEL TO ENTER THE WET WELL. lCRAN E PUMPS tip SYSTEMS SECTION B -- s PAGE 33 DATE 6110 ACrane Co.Company USA:(937)778-8947 • Canada:(905)457-6223 • International:(937)615-3598 8" Break Away Fitting Standard and Non-Sparking BARNES Models: BAF-8 & BAF-E8 www.cranepumps.com ' Break Away Fittings I 11'00 ,- 7.50 4.56 (191) (116) � 42.00 4 I (1067) 9.60 I- 0 36.00 (246) T ti —T (914) I 18.00 I (457) I 18.00(457) 48.00(1219)OPENING -54.00(1372)REF. -----. GUIDE RAILS UPPER GUIDE BRACKET -3"(76) ;f7H.40 PIPE 2 REO'D 5.31 {t35J I I 12.06 L WET'.:`EI..L ( 06) _5 1.62 _- (1311)I +- i 37.00 (940) i I I i 8"(203)CLASS 125 8.81 O � f �(224 DISCHARGE FLANGE )` I I I 17.75 - 25.00(635) (451) MIN.WATER 11.00 6.0+1 (279) 12. QRb:p t I I a D p 5.Q 30' a,Da SQ ��� f (2 9) 0.50 (z79) (267 G a PAGE 34 CRANE PUMPS & SYSTEMS PA DATE 4105 ACrane Co.Company USA:(937)778-8947 • Canada:(905)457-6223 International:(937)615-3598 Specifications • BARNES"' 3 , 4", 6" & 8" Horizontal Discharge www.cranepumps.com XSE - Class I, Groups C & D, Division 1 Submersible Non-Clog Pumps FILE:SPEC:19 SCOPE:Furnish and install submersible non-dog sew3ge A secondary rubber pressure grommet shall be provided as an trump (s). Each pump shall be capable of delivering the following additional sealing point and strain relief at the point of cable entry. performance points, U.S.GPM at TDH; U.S.GPM at TDH; U.S. GPM PUMP TEST:The pump manufacturer shall perform the following at TDH,with a shut off head of TDH(minimum:) inspections and tests in accordance with Hydraulic Institute type B and %minimum efficiency at U.S.GFw. standards before shipment from the factory: at TDH (operating point).The pump motor speed shall be RPM, HP(maximum), Phase, 1. A check of the motor voltage and frequency shall be made as 60 Hertz, Volts.The pump(s)shall be manufactured in shown on the name plate. North America by a company regularly engaged In the manufacture and 2. A motor and cable insulation test for moisture content or assembly of similar units for a minimum of five(5)years.The pump(s) insulation defects shall be made per UL criteria. shall be Bames®Pumps model _, _ 3. The pump shall be completely submerged and run to determine that the unit meets three pre-determined hydraulic performance PUMP DESIGN: Each pump s'rlall be capable of handling raw, points. unscreened domestic sewage consisting of water, fibrous materials, 4. A written report shall be available showing the aforementioned anti inch diameter spherical solids. The pump (s) shall i,e tests have been performed In accordance with the specifications. capable of handling liqulris with temperatures to 1 G4 degrees F ronlinuous,and shall be capable of running dry for extended penow. START-UP:The pump(s)shall be tested at s'art-up by a qualified representative of the manufacturer.A start-up report as provided by PUMP CONSTRUCTION:The volute,seal plates, impeller and motor the manufacturer shall be completed before final acceptance of the housing shall be constructed ofh;gh qualityAST MA-48 class 30 cast iron. pump(s). Pump(s)shall be painted with a water based air dry enamel of 2.0 ma minimum thickness.All exposed hardware shall be 300 series stainless DOCUMENTATION:The manufacturer,if requested,will supply a steel.The pump construction shall contain no points of critical clearance minimum of sets of standard submittal data; nor require periodic r ijustment or replacement to maintain reasonable Standard submittal data consist of: ' operating efficiency. Discharge connection shall be a standard 125 e pound,_ inch flange.All gaskets shall be of the o-ring tvc. a Pump catalog data; b. Pump performance curve; The Impeller shall be of the non-clog design with pump out vanes on C. Non-Sparking Break Away Fitting(BAF E)data; the back side.'rhe impeller shall be dynamically balanced to ISO G6., d Access cover data; specifications. e. Typical installation dewing; f. Control panel data The motor shall be designed to be non-overloading throughout the entire g. Panel wiring schematic; ,pump curve. The pump and motor shall be listed with Undeewhtt:rs h. Accessory data; Laboratonea as Class I,Groups C&0,Division 1,explosion-proof,: r i. Installation&Operatior.IJlanuals with Parts List installation in water or sewage.All electrical parts shall be housed ir, i an air-filled, cast iron, water-tight enclosure. The enclosure shall b. sealed by the use of o-rings and shall have rabbit joints with a lar2.�. overlap.The motor shaft extension and all external hardware shall bra stainless steel. The motor windings shall have a Class F insulativ,, system minimum and a 1.15 service factor. Shaft seals shall be cf e tandem design and operate in an oil filled enclosure.The seal materw s ;:hall be carbon for the rotating faces and ceramic for the stationar,, 1 faces,lapped and polished to a tolerance of one light band,300 sene!: stainless steel hardware, and all elastomer parts to be of Buna-1 . Two moisture sensing probes shall be used to detect any influx of liquid past the outer seal and provide ample warning to the first seal failun•. Thermal sensors shall be used to monitor stator temperatures. The stator shall he equipped with a thermal switch embedded in the end coil of the stator winding. This shall be used in conjunction with and supplemental to external motor overload protection and wired to tha control panel. The pump shall be equipped with__ft.of type power cable,and _ fit.of sensor cable type .All incomini; lead wires shall be spli;;ed in the motor terminal housing.After splicing. the terminal housing sha!1 be filled with epoxy to seal the outer cable jacket and the individual strands to prevent water from entering 6v. motor housing. PUMPS & SYSTEMS SECTION 1 CRANE PAGE 21 DATE 02/O5 ACrane Co.Company USA. (937)776-8947 • Canada: (905)457-6223 International: (937)615-3598 MCertification of 'vlateriaiS Origin Washington State Department of Transportation (Required for Acceptance of Steel Materials) Contract SR CAG-11-133 Section Contractor Atkinson Construction Subcontractor t Supplier JP Francis & Assoc. i Materials: Bid Item Ouantlty 33 2 bescription Sewage Pump Breakaway Fitting The following Certification of Materials Origin is made for tWt purposes of establishing materials acceptance under Contract Provisions entitled"Buy America." Materials as described above are furnished for use in compliance with the nertification as noted in f or 2 below. Manufacturing processes for the materials are defined on the back of this form. XX 1. The materials covered by this certification are AF,erican-Made with all manufacturing processes entirely within the United State of America. 2. The materials furnished for this project under this certification contain steel or iron manufactured, all or in part, outside _ the United States of America. -- — . The lDescription and Country of Origin of these materials is a toflcrrrs: The Invoice Cost for the above described foreign-made materi,s is: l I l declare under penalty of perjury under?he laws of the State of Washington that the foregoing is true and correct. John Box' i nge it c r/ 'ubco actor/Supplier Name f -v � -- 5/21/12 Kent, WA C poste Official Signature Dale Place DOT Farm 350.109 EF Side 1 of 2 i Revised 7iO7 13.5 in 13.125 in 50 80 60 70 60 R 10.5 in 2 - 40 -_----- 70 60 50 \ 20 \. 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 1.5 1 2 d 0.5 Z 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 50 tZ s 25 L 3 0 IL 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 US gpm Temp.104°F(40°C)Continous. Company: Crane/Barnes Size:8XSE500'6HA Name: Catalog:Crane Barnes.60,Vers 4-12 Speed: 1150 rpm 7/26/2012 Non-Clog 8"XP-11-1200 Dia:13.125 in BARNES" Design Point:3280 US gpm,32.3 ft • Atkinson Construction is Submittal 055.1 Response Narrative BCH 9/20/12 RH2 noted in their review of submittal 055.1 that JP Francis has submitted pumps with a higher horsepower than that specified in the plans. They are recommending supplying 50 horsepower pumps in lieu of the specified 45 horsepower pumps. JP Francis and their suppliers have been unable to secure 45 hp pumps that meet the project's "Buy America" clause- project special provision section 1-06. This includes the Flygt pumps suggested on sheet PS-1 which do not qualify. Attached is the pump curve for the proposed 50 hp pumps with trimmed impellers to meet the design duty point. The supplier has suggested that the only adaptation related to the larger pump motor is to provide a motor control with a 50 hp capacity. The Contractor has reviewed submittal 049.1- Motor Control Center One-line Diagrams. It appears that the proposed and approved Rockwell Automation motor control has 50 hp capacity(see sheets 3 of 6 and diagram sheet CS70727838.) • The Contractor requests that RH2 reconsider submittals 055.1 and 049.1, in conjunction with the • information provided here to confirm that this is an acceptable solution. k Order By Job Number C A S C A D E Site Contact MACHINERY & Date one AtL ELECTRIC, INC. Dispatch Time echnician Name Arrival Time 24 Hour Service 800.289.0500 • www.cascade-machinery.com WORKMAN'S VERIFICATION RECEIPT Miles 1-Way X2 ❑ 4600 East Marginal Way S. ❑ East 5711 Sharp Ave. Seattle,WA 98134 Spokane,WA 99212 Ph:206.762.0500 • Fx:206.767.5122 Ph:509.534.3559 • Fx:509.534.3768 CUSTOMER MODEL SERIAL NUMBER HOURS SERVICE CALL Site Information Equipment: Model: Serial: Hours: Last Service: rr+ Qty Material J THE ABOVE MAY NOT INCLUDE TIME AND MATERIAL EXPENDED AT CASCADE'S SHOP FACILITY. PLEASE NOTE CONDITIONS ON REVERSE. CUSTOMER SIGNATURE: X TERMS&CONDITIONS OF SALE ACCEPTANCE OF ORDERS: Cascade Machinery&Electric,Inc.(hereafter known as Cascade) hereby gives notice that it objects to any additional o/different terms which may be contained in any order 6vPurchaser. Any acceptance 6v Cascade is expressly conditioned un assent bv Purchaser to Cascade's terms. PRICING: Due to current material shortages and price adjustments,all prices quoted by Cascade for goods or services either orally or in writing,are subject to change without notice and will be those prices and discounts in effect at time of shipmentCascade to Purchaser, Unless otherwise noted in writing by a duly authorized representative of Cascade,all quotations are FOB factory. Wherever possible, price protection and firm delivery commitments will be secured. TAXES: Taxes on any sale of goods or services b Federal,State,County or Municipal Law are not included in any Cascade quotation. Said taxes,where applicable,will be added to the appropriate invoice. ROUTING: Routing of all goods sold by Cascade is subject to Cascade's sole discretion unless otherwise agreed upon in writing by Cascade. ORDERCHANGES: No order changes will be accepted unless expressly permitted in writing by a duly authorized representative of Cascade. CANCELLATIONS: The Purchaser may cancel his order only upon written notice and payment to Cascade of reasonable cancellation charges specified by Cascade. RETJURNED GOODS: Written permissionnnustbeohtainedbefomeneturninganymaterialforanyneasun. Materia| returned6orcred|tvvi|| besubjectto Cascade inspection. |n warranty product,original cartons of current design will be su t to a restocking charge of not less than 1S96of the price of such goods at the time of original shipment. All material must be shipped with transportation charges prepaid. Products which are obsolete or of special order are not returnable, WARRANTY. All goods sold as new are warranted to be of good quality as to workmanship and material used in their manufacture. Any goods that provedefective within one year from the date o[shipment will, if returned freight prepaid to Cascade's wanehuus* be replaced orrepaired atCascade's election,free ofcharge. Goods not ufCascade's manufacture are warranted only tnthe extent of the original noanufartunen'swarranty. Repair warranty on motors is one year from date ofshipment. All other repairs are warranted for 90 days from date ofshipment. LIMITATION OF LIABILITY: Cascade shall not,inan event,be liable for special,indirect, incidental,o/consequential damages. Cascade's liability onany claim of any kind,including negligence,for any loss or damage arising out of,connected with,or resulting from this contract,or the performanceorbpeach,thereof,o/thedeyign'mnanufactue\sa|ede|ivery,vesa|e,instaUadon,technica|di,ectionmr installation inspection,repeir,operationnruseofanyequipnoentorservicescovenedbvorfurnishedunderthiscont/actshaUin no case exceed the price paid bv the Purchaser for the equipment. Cascade also disclaims all liability,whether in contract,tort, warranty,or otherwise,to any party other than Purchaser. TERMS OF PAYMENT: Unless otherwise noted in writing by a duly authorized officer of Cascade,payment in full on all orders is due within 70days following shipment of goods or notification Cascade is ready toship. |f payment is not received onor before due date,interest will accrue at the rate nfl 1/296 per month on any unpaid balance. ATTORNEYS FEES: In the event it becomes necessary to institute legal action to enforce collection of any amount due Cascade, Purchaser agrees tu pay all necessary costs and attorney'sfees. TITLE: U goods sold by Cascade shall remain the property of Cascade until payment for such goods is received in full unless otherwise noted in writing by a duly authorized officer of Cascade. Notwithstanding the above,all risk of loss or damage on goods sold by Cascade is assumed by the Purchaser of such goods subsequent to their original shipment. It is expressly understood that any repossession of such goods hereunder will not preclude Cascade from recovering a deficiency from the Purchaser of such goods in the event the price is received is not sufficient to pay the unpaid balance then due and payable at the time of sale of such repossessed goods plus the cost of repossession and sale. Notwithstanding,any ifi delivery date set forth i otati provision therein ndi delivery,Cascade inmo event will be responsible for the loss,damage,or expense of whatever kind or nature suffered or incurred by Purchaser,or by any person or persons,whomsoever,by reason of any delay or delays in the delivery of goods or in delivery of replacement parts, regardless n[the cause ofsuch. Order By CASCADE Job Number;� f 0 Site Contact MACHINERY & Date Phone ELECTRIC, INC. Dispatch Time ;J c. TechniCi4n Name Arrival Time 24 Hour Service 800.289.0500 • www.cascade-machinery.com - WORKMAN'S VERIFICATION RECEIPT M Iles l-W?yX2 ❑ 4600 East Marginal Way S. ❑ East 5711 Sharp Ave. Seattle,WA 98134 Spokane,WA 99212 Ph:206.762.0500• Fx:206.767.5122 Ph:509.534.3559 • Fx:509,534.3768 CUSTOMER MODEL SERIAL NUMBER HOURS SERVICE CALL Site Information Equipment: Model: Serial: k Hours: Last Service: r_ l Qty Material THE ABOVE MAY NOT INCLUDE TIME ND MATERIAL EXPEND D AT CASCADE'S SHOP FACILITY. PLEASE NOTE CONDITIONS ON REVERSE. CUSTOMER SIGNATURE: X �- BARNE o Series 8XSE-HA S 3" Spherical Solids Handling 9 www.cranepumps.com Class I, Groups C & D, Division 1 8"Horizontal Discharge XP- Submersible Non-Clog Pumps Specifications: DISCHARGE ..............................8"NPT, 125 lb. Flange Horizontal LIQUID TEMPERATURE............ 104°F(40°C)Continuous VOLUTE .....................................Cast Iron ASTM A-48,Class 30,with Bronze wear ring MOTOR HOUSING.....................Cast Iron ASTM A-48,Class 30 SEAL PLATE .............................Cast Iron ASTM A-48,Class 30 IMPELLER: Design...................3 Vane, Enclosed With Pump Out Vanes on Back Side. Dynamically Balanced ISO G6.3 Material .................Cast Iron ASTM A-48,Class 30 SHAFT .......................................416 Stainless Steel SQUARE RINGS ........................ Buna-N LIFTING CHAIN..........................Yoke,Galvanized HARDWARE...............................300 Series Stainless Steel PAINT .........................................Air Dry Enamel. SEAL: Design ...................Tandem Mechanical,Oil Filled Pressure Equalized Reservoir Matefial..................Rotating Faces-Carbon ' Stationary Faces-Ceramic e Elastomer-Buna-N ADHardware-300 Series Stainless CORD ENTRY.............................25 ft. (7.6m)Std.Cord. Epoxy Sealed • Housing with Secondary Pressure Series: 8XSE-HA Grommet for Sealing and Strain Relief SPEED........................................ 1150 or 1750 RPM(Nominal) 30 - 75HP, 1150RPM9 60HZ UPPER BEARING: Series: 8XSE-HA Design...................Single Row, Ball,Grease Lubricated Load...................... Radial 100-150HP, 1750RPM, 60HZ LOWER BEARING: Design...................Double Row, Ball, Grease Lubricated Load.......................Radial&Thrust MOTOR: Design ...................NEMA B-Three Phase Torque Curve. Air-Filled,Squirrel Cage Induction Insulation ..............Class F. THREE PHASE...........................Dual Voltage 2301460;Require, Overload Protection to be Included in control panel. MOISTURE SENSOR.................Normally Open(N/O), Requires Relay in a Canadian Standards Association Control Panel File No.LR16557-25 TEMPERATURE SENSOR.........Normally Closed(N/C), Requires Relay in Control Panel OPTIONAL EQUIPMENT............Seal Material, Impeller Trims, �� Underwriters Laboratories Inc Cord Length File No.E73842 Sample Specifications:Section 1 Page 21. DESCRIPTION: SUBMERSIBLE NON-CLOG SEWAGE PUMP DESIGNED FOR HAZARDOUS RAW SEWAGE APPLICATIONS. CRAM E 11 4 PUMPS & SYSTEMS SECTION PAGE 4 ® DATE 2/05 A Crane Co.Company USA: (937)778-8947 • Canada: (905)457-6223 International: (937)615-3598 0Series 8XSE-HA 13ARNES .- Spherical Solids Handling Class I, Groups C & D, Division 1 www.cranepumps.com 8" Horizontal Discharge XP- Submersible Non-Clog Pumps (mm) 3C62 (879) 20.00 (508)FF I } li 16.5C (419) A' 28.12 49.08(1246) (714) 54.50(1384) t 7.68 (195) • MODEL NO PART NO "A" HP VOLT/Ph Nz RPM NEMA FULL LOCKED CORD CORD CORD O.D. DIM (Nom) START LOAD ROTOR SIZE TYPE t.02(.5) CODE AMPS AMPS In(mm) 8XSE30046HA 084781 49.06 30 460/3 60 1150 G 40.0 210.0 8/4 SOW 0.985(25) 8XSE30056HA 089361 49.06 30 575/3 60 1150 G 32.0 168.0 8/4 SOW 0.985 25 8XSE40046HA 084782 49,06 40 460/3 60 1150 G 52.0 282.0 614 SOW 1.125(29 BXSE40056HA 089362 49.06 40 57" 60 1150 G 42.6 226.0 6/4 SOW 1.125 29 BXSE50046HA 084783 49,06 50 460/3 60 1150 F 67.0 322.0 4/4 SOW 1.350(34) BXSE50056HA 089363 49.06 50 575/3 60 1150 F 53.6 258.0 4/4 SOW 1.350 34 8XSE60046HA 084784 49.06 60 460/3 60 1150 F 76.9 409.0 214 SOW 1.550(39 8XSE60056HA 089364 49.06 60 57513 60 1150 F 61.4 315.0 214 SOW 1,550 39 8XSE75046HA 084785 54.50 75 46013 60 1150 G 92.0 534.0 2/4 SOW 1.550(39 8XSE75056HA 089365 54.50 75 575/3 60 1150 G 73.6 427.0 2/4 SOW 1.550 39 8XSE100044HA 084786 54.50 100 460/3 60 1750 G 123.0 703.0 114 SOW 1.680 43 8XSE100054HA 089366 54.50 100 575/3 60 1750 G 98.4 562.0 1/4 SOW 1.680 43 BXSE125044HA 084787 54.50 125 460/3 60 1750 F 153.0 864.0 21014 SOW 1.930(49 8XSE125054HA 089367 54.50 125 575/3 60 1750 F 122.0 691.0 2/0/4 SOW 1.930 49 BXSE150044HA 084788 54.50 150 460/3 60 1750 E 182.0 1080.0 310/4 SOW 2.070 53 8XSE150054HA 089368 54.50 150 57513 1 60 1 1750 1 E 145.0 864.0 3/0/4 SOW 2.070 53 Moisture and Temperature sensor cord for all models is 18/5 SOW,0.485(12.3mm)t.02(.51mm)O.D. IMPORTANT I 1.) MOISTURE AND TEMPERATURE SENSORS MUST BE CONNECTED TO VALIDATE THE UL LISTING. 2) A NONSPARMNG BREAKAWAY FITTING MUST BE USED TO VALIDATE THE UL LISTING 3.) A SPECIAL MOISTURE SENSOR RELAY IS REQUIRED IN THE CONTROL PANEL FOR PROPER OPERATION OF THE MOISTURE SENSORS. CONTACT BARNES PUMPS FOR INFORMATION CONCERNING MOISTURE SENSING RELAYS FOR CUSTOMER SUPPLIED CONTROL PANELS 4.) THESE PUMPS ARE UL LISTED FOR PUMPING WATER AND WASTEWATER.DO NOT USE TO PUMP FLAMMABLE LIQUIDS. 5.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIDED FOR VISUAL ENJOYMENT MUST BE INSTALLED IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSIINFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION,THIS PUMP IS NOT INTENDED FOR USE IN WIMMING POOLS,RECREATIONAL WATER PARKS,OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH PUMPED MEDIA IS A COMMON OCCURRENCE. • SECTION 11 5 PAGE 6 CRANE PUMPS & SYSTEMS DATE 2105 ACrane Co.Company USA: (937) 778-8947 • Canada: (905)457-6223 • International: (937)615-3598 13.5 in 13.125 in — - 50 80 60 70 60 10.5 in — 80 50 20 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 1.5 � 1 2 rn 0.5 IL z 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 50 Q = 25 N 3 O IL 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 US gpm Temp.104°F(40°C)Continous. Company: Crane/Barnes Size:8XSE500'6HA Name: Non-Cli Catalog:Crane Barnes.60,Vers 4-12 Speed:115 rpm Non-Clo g g 8"XP-11-1200 Dia:13.125 n Design Point:3280 US gpm,32.3 It BARNES _ • NOON■■■NOON NOON■■■■nE■�■■■m■■n■■oNME NMMM■: STANDAR Pump HP Impeller• . 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ME M. .L S NEa' BEEN■NOUNS SWOON m■omm Ess■ all■E■■;\EMb%l E■RO■S.`m r1 riMCI ME ■m MENEM MEMOS m■mmE sommo som►�m�■>..nn►,g rims■ER:aiw•,d■m■i�on nmm ann■m mRm■m s■mm■mommE mom■■ RE►gym■►,%bj■m■m■■or roomr,r■.::�■Em s■mE■■■NE■ uaMB■■EBB BmE • _ \:Ms\\■\■Near/s.]MM11 mMM■■mmumm■NON■ MOMON EEMEN ORS ■O►.\■\.•%J ERE'iE M■r■L` ONIMON■ moa saw"' Ens■■m■s■E s■ �■R■►�■_:�► Ass on� '- .:■n_iammm■momm■mm■s Eommm/somm Ens■■■ ■ ■ bNOM■\-A ■►•.m rm mmm■m mamma s■om■■mmoO■■■■■ An =EENENEMEMEENNEEENNENumm iiiii ii il iMiRm B�iEm ii=ii�E IIii iii NE NEN iiiii iiiii MOO OMENS Emmons Ms■■E B■■aE m=■ HIM MamRE mo\�/a mum no MENEM■moss NONE m moons OMEN NRSN■SEMEN H ■ Rmum\Some■MM M■MENEM MESON MENEM somas • 111 2000 3000111 �SECTI • PAGE DATE V05 Specifications • BARNES 3", 4", 6" & 8" Horizontal Discharge www.cranepumps.com XSE - Class I, Groups C & D, Division 1 FILE:SPEC19 Submersible Non-Clog Pumps SCOPE:Furnish and install submersible non-dog sewage A secondary rubber pressure grommet shall be provided as an pump Is). Each pump shall be capable of delivering the following additional sealing point and strain relief at the point of cable entry. performance points, U.S.GPM at TDH; U.S.GPM at TDH; U.S. GPM PUMP TEST:The pump manufacturer shall perform the following at TDH,with a shut off head of TDH(minimum) inspections and tests in accordance with Hydraulic Institute type B and %minimum efficiency at U.S.GPM standards before shipment from the factory: at TDH (operating point).The pump motor speed shall be RPM, HP(maximum), Phase, 1. A check of the motor voltage and frequency shall be made as 60 Hertz, Votts.The pump(s)shall be manufactured in shown on the name plate. North America by a company regularly engaged in the manufacture and 2. A motor and cable insulation test for moisture content or assembly of similar units for a minimum of five(5)years.The pump(s) insulation defects shall be made per UL criteria. shall be Barnes®Pumps model 3. The pump shall be completely submerged and run to determine that the unit meets three pre-determined hydraulic performance PUMP DESIGN: Each pump shall be capable of handling raw, points. unscreened domestic sewage consisting of water, fibrous materials, 4. A written report shall be available showing the aforementioned and inch diameter spherical solids. The pump (s) shall be tests have been performed in accordance with the specifications. capable of handling liquids with temperatures to 104 degrees F continuous,and shall be capable of running dry for extended periods. START-UP:The pump(s)shall be tested at start-up by a qualified representative of the manufacturer.A start-up report as provided by PUMP CONSTRUCTION:The volute, seal plates, impeller and motor the manufacturer shall be completed before final acceptance of the housing shall be constructed ofhighqualityASTMA-48 class 30 cast iron. pump(s). Pump(s)shall be painted with a water based air dry enamel of 2.0 mil minimum thickness.All exposed hardware shall be 300 series stainless DOCUMENTATION:The manufacturer,if requested,will supply a steel.The pump construction shall contain no points of critical clearance minimum of sets of standard submittal data; nor require periodic adjustment or replacement to maintain reasonable Standard submittal data consist of: operating efficiency. Discharge connection shall be a standard 125 • pound, inch flange.All gaskets shall be of the o-ring type. a Pump catalog data; b, Pump performance curve: The impeller shall be of the non-clog design with pump out vanes on c Non-Sparking Break Away Fitting(BAF-E)data; the back side.The impeller shall be dynamically balanced to ISO G6.3 d Access cover data; specifications. e. Typical installation drawing, f, Control panel data The motor shall be designed to be non-overloading throughout the entire g. Panel wiring schematic; pump curve. The pump and motor shall be listed with Underwriters h. Accessory data; Laboratories as Class I,Groups C&D,Division 1,explosion-proof,for I. Installation&Operation Manuals with Parts List installation in water or sewage.All electrical parts shall be housed in an air-filled, cast iron, water- tight enclosure The enclosure shall be sealed by the use of o-nngs and shall have rabbit joints with a large overlap.The motor shaft extension and all external hardware shall be stainless steel. The motor windings shall have a Class F insulation system minimum and a 1.15 service factor. Shaft seals shall be of a tandem design and operate in an oil filled enclosure.The seal materials shall be carbon for the rotating faces and ceramic for the stationary faces,lapped and polished to a tolerance of one light band,300 senes stainless steel hardware, and all elastomer parts to be of Buna-N. Two moisture sensing probes shall be used to detect any influx of liquid past the outer seal and provide ample warning to the first seal failure. Thermal sensors shall be used to monitor stator temperatures. The stator shall be equipped with a thermal switch embedded in the end Coil of the stator winding. This shall be used in conjunction with and supplemental to external motor overload protection and wired to the control panel. The pump shall be equipped with ft,of type power cable,and ft.of sensor cable type .All incoming lead wires shall be spliced in the motor terminal housing,After splicing, the terminal housing shall be filled with epoxy to seal the outer cable jacket and the individual strands to prevent water from entering the motor housing. CRANE PUMPS & SYSTEMS SECTION , PAGE 21 s DATE 02105 A Crane Co.Company USA: (937)778-8947 • Canada: (905)457-6223 International: (937)615-3598 iBARNES° INSTALLATION and OPERATION MANUAL Submersible Non-Clog Pump Explosion Proof, Class I, Groups C & D, Division 1 Series: 8XSE-HA 20 - 30HP, 870RPM, 60Hz 30 - 75HP, 1150RPM, 60Hz 100 - 150HP, 1750RPM, 60Hz DISCONTINUED ® Parts may NOT be available e • e • • e 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. CRAN E PUMPS & SYSTEMS • A Crane Co. Company 420 Third Street 83 West Drive, Bramton Piqua,Ohio 45356 Ontario, Canada L6T 2J6 Phone: (937)778-8947 Phone: (905)457-6223 Fax: (937)773-7157 Fax: (905)457-2650 Form No. 084841-Rev. K www.cranepumps.com BARNES BARNES CRESS UHE SYSTEMS -• burks WEINMAN DEMING PROSSER Limited 24 Month Warranty Crane Pumps&Systems warrants that products of our manufacture will be free of defects in material and workmanship under normal use and service for twenty-four (24) months after manufacture date, when installed and maintained in accordance with our instructions.This warranty gives you specific legal rights, and there may also be other rights which vary from state to state. In the event the product is covered by the Federal Consumer Product Warranties Law (1) the duration of any implied warranties associated with the product by virtue of said law is limited to the same duration as stated herein, (2) this warranty is a LIMITED WARRANTY, and (3) no claims of any nature whatsoever shall be made against us, until the ultimate consumer, his successor, or assigns, notifies us in writing of the defect, and delivers the product and/or defective part(s) freight prepaid to our factory or nearest authorized service station. Some states do not allow limitations on how long an implied warranty lasts. so the above limitation may not apply. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY PRODUCT SHALL BE TO REPLACE OR REPAIR AT OUR ELECTION, F.O.B. POINT OF MANUFACTURE OR AUTHORIZED REPAIR STATION,SUCH PRODUCTS AND/OR PARTS AS PROVEN DEFECTIVE.THERE SHALL BE NO FURTHER LIABILITY, WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE. Unless expressly stated otherwise,guarantees in the nature of performance specifications furnished in addition to the foregoing material and workmanship warranties on a product manufactured by us, if any, are subject to laboratory tests corrected for field performance.Any additional guarantees, in the nature of performance specifications must be in writing and such writing must be signed by our authorized representative. Due to inaccuracies in field testing if a conflict arises between the results of field testing conducted by or for user, and laboratory tests corrected for field performance, the latter shall control. RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS ANALYSES AND EVALUATIONS WE CONDUCT WILL BE BASED ON OUR BEST AVAILABLE EXPERIENCE AND • PUBLISHED INDUSTRY INFORMATION. SUCH RECOMMENDATIONS DO NOT CONSTITUTE A WARRANTY OF SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS GIVEN. This warranty shall not apply when damage is caused by (a) improper installation, (b) improper voltage (c) lightning (d)excessive sand or other abrasive material (e) scale or corrosion build-up due to excessive chemical content.Any modification of the original equipment will also void the warranty. We will not be responsible for loss,damage or labor cost due to interruption of service caused by defective parts. Neither will we accept charges incurred by others without our prior written approval. This warranty is void if our inspection reveals the product was used in a manner inconsistent with normal industry practice and\or our specific recommendations. The purchaser is responsible for communication of all necessary information regarding the application and use of the product. UNDER NO CIRCUMSTANCES WILL WE BE RESPONSIBLE FOR ANY OTHER DIRECT OR CONSEQUENTIAL DAMAGES,INCLUDING BUT NOT LIMITED TO TRAVEL EXPENSES, RENTED EQUIPMENT, OUTSIDE CONTRACTOR FEES, UNAUTHORIZED REPAIR SHOP EXPENSES, LOST PROFITS,LOST INCOME,LABOR CHARGES,DELAYS IN PRODUCTION,IDLE PRODUCTION,WHICH DAMAGES ARE CAUSED BY ANY DEFECTS IN MATERIAL AND10R WORKMANSHIP AND\OR DAMAGE OR DELAYS IN SHIPMENT. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMPLIED WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. No rights extended under this warranty shall be assigned to any other person;whether by operation of law or otherwise, without our prior written approval. CRANE PUMPS & SYSTEMS A Crane Co.Company 420 Third Street 83 West Drive,Brampton Piqua,Ohio 45356 Ontario,Canada L6T 2J6 Phone:(937)778-8947 Phone:(905)457-6223 Fax:(937)773-7157 Fax:(905)457-2650 www.cranepumps.com • 17 • • F • FLEXGATE SLURRY KNIFE GATE VALVE Red Valve Company,Inc. Installation, Operation and Maintenance Manual The Red Valve Flexgate Slurry Knife Gate Valve is a 100%full bore, truly bi-directional valve designed for tough slurry applications. The Flexgate features heavy-duty elastomer seat cartridges which provide droptight clo- sure and are replaced WITHOUT ANY VALVE DISASSEMBLY, for ease of maintenance. The Flexgate is designed to meet MSS-SP81 face-to-face dimensions, so that it can be readily placed in service replacing convention- , al knife-gate products. Flush ports are provided to allow the valve to I be flushed with water and/or air. With a variety of actuators available, limit switches, and other • options, the Red Valve Flexgate can be built to fit your special applications. IMPORTANT Please take a moment to review this manual. Before performing any maintenance on the valve be sure the pipeline has been de-pressurized.The improper installation or use of this • product may result in personal injury, product failure, or reduced product life. Red Valve Co., Inc. can accept NO liability resulting from the improper use or installation of this product. If you have any questions or problems,please call the customer service department at(412)279-0044. We appreciate your comments.And thank you for choosing Red Valve. *When your Red Valve order arrives,check the contents INSTALLATION carefully to assure no damage or loss occured in transit. 1. Check flange faces of pipe for rough/damaged areas.Pipeline flanges 100%of 100%of tabulated values. If greater torque is Ia must be flat, properly spaced, and parallel to achieve proper seal. QQ required, continue retorquing in increments of 50%of 4 ° ° ° a NOT mate flexate valves directly to expansion joints or other flexible con- tabulated values.Improper or uneven torquing of flange ° , nections. bolts can cause premature seat cartridge failure and a a-0 .° a leak between the mating flange and valve.Use of high o 'o 2. The rubber seat acts as a gasket and seperate flange gaskets are normally quality anti-sieze compound on all bolt and/orstud thread 2 a not required. Installations where the mating flange has a"slick"surface is recommended. Figure 1 may require a metal serrated or combination metal gasket serrated gasket and contractor supplied standard gasket materials to assist in creating a 6. Apply grease liberally to stem. seal.All gaskets used on"LOW TORQUE"flange material such as FRP and PVC should be approved by the pipe manufacturer for compatibility. 7• Some leakage may occur at packing when line is pressurized.The factory (Often the torque rating of the composite mating flange may be less than does not tighten packing to overcome such leakage,as this can shorten the minimum torque required to install the valve packing life when valve is in storage.Simplytighten the packing nuts until the leakage ends. 3. Actuate valve to the full CLOSED position for installation. Lubricate seat cartridges and gate liberally with a grease compatible with the seat mate- 8. Over tightening flange bolts to stop a leak can fracture or distort a com- rial.Silicone grease is recommended for all seat materials. posite flange such as a FRP or PVC flange. Steel back-up rings should be considered to try to seal a flange against a leak.Caution should be 4. Insert seat cartridges. Flange gaskets are not required.Make sure that used to not over-torque FRP or PVC flanges when using steel back-up cartridges are of the correct size and properly centered on valve flange. rings.Consult with the pipe and/or flange manufacturer. 5. Installing Flange Bolts: 9. Fill out and attach the enclosed VALVE MAINTENANCE CARD to the CAUTION: Only use flange bolts of the correct length in such manner valve.This has been provided for maintenance convenience. that the BOLTS CAN NOT BOTTOM OUT IN TAPPED HOLES The use of bolts which are too long and bottom out in tapped holes can distort CAUTION: VALVES EQUIPPED WITH THE FLUSHPORT DESIGN body,create a leak path and cause permanent valve damage.Red Valve CAN BE PLUGGED OR PIPED TO A SUITABLE DRAIN. REMOVAL OF recommends the use of studs in the chest area of the flexgate in lieu of PLUG(S)WILL CAUSE LEAKAGE OF LINE MATERIALS. CONSULT bolts. YOUR SYSTEMS ENGINEER FOR PROPER PLUMBING OF FLUSH- PORT FOR YOUR INSTALLATION. Tighten each bolt uniformly on both sides of the valve (upstream and NOTE: It is recommended that valves with actuators be installed in the downstream side of the valve).This will distribute compression evenly vertical position. If actuated knife gates must be installed horizontally,it on seat ring. Torque all the flange bolts and/or studs in a star pattern is recommended that the actuator be supported with a hanger or bracket. (as shown in Figure 1),first to 50%of tabulated values,then retorque to NEVER... NEVER... DO... DO... • Install with gate up. Use bolts which bottom out in body. Lubricate seats and gate. Tighten bolts evenly. OPERATION ACTUATORS: FAIL-SAFE CLOSED: All actuators are furnished completely assembled and fully operational.All A large diameter spring on the top of the cylinder piston provides the force to valve accessories and instrumentation are properly set and calibrated at the close this type of cylinder configuration.Air is only supplied to the BOTTOM Red Valve factory. cylinder head for valve opening.The top cylinder head must remain vented at all times.When the bottom of the cylinder is pressurized with plant air,the MANUAL ACTUATORS: valve opens.The valve will close automatically when the pressure is vented All handwheel,chainwheel,and bevel gear operators turn clockwise to close. out of the bottom of the cylinder. The gate stops moving when the valve is fully opened or closed. FAIL-SAFE OPEN: BEVEL GEAR: A large diameter spring on the bottom of the cylinder piston provides the force Bevel gears operate the same as the standard handwheel.The handwheel to open this type of cylinder configuration.Air is only supplied to the top cylinder is turned clockwise to close and counter clockwise to open. head for valve closing.The bottom cylinder head must remain vented at all times. When top of cylinder is pressurized with plant air,valve closes.Valve CHAINWHEEL: will open automatically when pressure is vented out through top of cylinder. Chainwheels can be furnished on both standard valves and valves with bevel gears.The chain must be fed through the guides and over the spokes around CAUTION: the outside diameter of the rim.The ends of the chain are then joined with Fail Safe cylinders contain large diameter springs in a compressed state.To a connecting link. avoid risk of serious injury,never attempt to disassemble fail-safe cylinders, NEVER cut,bend, or alter the protruding threads at the top of the cylinder. ELECTRIC ACTUATORS: Fail-safe cylinders will actuate AUTOMATICALLY with an interruption of supply Electric Actuators come completely operational,with limit and torque switches air.To avoid risk of injury from unexpected actuation,always close cylinder set. Please refer to the individual actuator manuals for additional operation supply air prior to inspecting,lubricating,or servicing valve. or maintenance information. WATER HAMMER EFFECT: CYLINDER ACTUATORS: Too rapid of closure of any valve can create a forceful and potentially dam- Red Valve Cylinder Actuators operatefrom clean lubricated plantair.Cylinder aging water hammer effect. To minimize the risk of water hammer related Actuators are available in three basic configurations.Air-To-Open/Air-To- damage,Red Valve Co., Inc.recommends that the closure rate of the valve Close,Fail-Safe Open,and Fail-Safe Closed. be controlled by restricting the exhaust rate of cylinder pressure.The addition • of a needle valve in cylinder head ports will enable you to control closure rate ATO/ATC: for your service condition. A single 4-way valve is used to operate this standard cylinder style.The open air supply is connected to the lower cylinder head, and close air source is attached to the upper cylinder.Each side of the cylinder must be vented when the other side of the cylinder is pressurized,in orderforthe cylinderto function. MAINTENANCE INSPECTION: PACKING REPLACEMENT: Valves should occasionally be inspected for damage and wear. 1. Be sure that there is no pressure in the valve. The inspection period should be determined by the severity 2. Close the valve. Disconnect the stem from the gate by of the service and environment. Valves should be inspected removing the pin or bolts from the gate. every 90 days for normal applications, or more frequently for 3. Raise the stem or piston rod.Open pressure must be severe applications. If valves are periodically inspected and maintained on fail close cylinders. preventive maintenance done, the valve will last longer and 4. Remove the bolts from the packing stuffer. Remove the operate better. packing stuffer. Remove the old packing. NOTE: Be very careful not to damage the gate or lining. CAUTION: 5. Insert one ring of packing around the gate. Packing Do not remove any valve parts or bolting with pressure in should be scarf cut(on a 452 angle),to make the pack the line. It is easy to inspect the valve for obvious problems. ing seal better.Great care must be taken to make sure Several items should be checked: that the gate is flush against the seat. NOTE: If the packing is cut straight across, be sure that the ends of • Check the stem for wear and any damaged threads. If the packing butt together and do not overlap. Alternate threads are damaged, use a small file to remove small burrs the cut ends of the packing. on the thread. 6.Tamp the packing to the bottom of the gland. Use a wood, plastic or brass rod and be sure not to scratch • Check the stem bushing for small pieces of bronze which the gate or wall of the gland. NOTE: Be sure that the may have worn away. If excess material is noticed the stem gate is against the seat,and that packing contacts wall bushing should be replaced. of the gland and the gate all the way around. 7. Repeat steps 5 and 6 with another strip of packing.The • Check the exposed portion of the gate when it is in the full end joints of the packing should be alternated to reduce open position for excessive wear. If the gate is excessively the possibility of leakage. worn,the gate should be replaced.Always keep the valve well 8. Install the rubber secondary seal and push it to the bot lubricated and the gate free of excess buildup. tom of the gland. 9. Repeat steps 5 and 6 with the third and final layer of RESILIENT SEAT REPLACEMENT: packing. 1. Make sure there is no pressure in the pipeline. 10. Install the packing stuffer and tighten the bolts evenly. •2. Remove the valve or remove all bolting except one bolt The bolts should not be completely tightened. Recon nearest the horizontal centerline and swing the valve out nett the gate to the actuator. of the line. 11. Operate the valve several times to break in the packing. Be sure that the gate is against the seat. Fully tighten the packing bolts. TROUBLESHOOTING GUIDE STORAGE If your Flexgate Slurry Knife Gate Valve is to be stored for SYMPTOM: a period of time prior to installation, the following storage VALVE BINDS or DIFFICULTY TURNING HANDWHEEL guidelines will help preserve your valve and assure a trouble free installation. • Examine stem & bushing for burrs or wear. • Clean build-up on gate, flush body 1. Store resilient seat cartridges in a clean, cool and dry location. Avoid exposure to light, electric motors, dirt or • Lubricate stem &gate chemicals. • Remove seat cartridges&inspect for damage • Make certain no in-line obstructions exist 2. Store valve in a clean,dry location.Make certain that valve and actuator are well supported. Do not stack other items on valve. SYMPTOM: 3. Grease stem,gate,and flange holes liberally to inhibit VALVE LEAKS AT PACKING corrosion. •Tighten packing gland • Replace packing as needed MAKE CERTAIN THAT SEAT CARTRIDGES, AND THIS P P 9 MANUAL ARE STORED AND READILY AVAILABLE AT • Inspect gate and seat cartridges for wear or damage TIME OF INSTALLATION. SYMPTOM: SYMPTOM: • VALVE DOES NOT CHECK FLOW WHEN CLOSED RESILIENT SEAT CARTRIDGES ARE SOFTENED OR • Check for obstruction in line DETERIORATED •Inspectgate and seat cartridges for build-up,wear,ordamage • Consult Red Valve for chemical compatability of resilient seat cartridges. INSTALLATION, OPERATION & MAINTENANCE SUPPLEMENT NOMINAL FLANGE BOLT MINIMUM VALVE BOLT LENGTH BOLT SIZE SIZE TO USE TORQUE (INCHES) (INCHES) (FT. POUNDS) 3 5/8-11 1.63 20 4 5/8-11 1.63 20 6 3/4-10 1.63 20 8 3/4-10 2.00 30 10 7/8-9 2.00 35 12 7/8-9 2.00 50 14 1-8 2.25 65 16 1-8 2.50 35 18 1 1/8-7 2.50 45 20 1 1/8-7 3.00 55 24 1 1/4-7 3.25 60 30 1 1/4-7 3.50 60 36 1 1/2-6 3.75 60 Torque values are suggested minimum values. Torque all flange bolts in a star pattern. First to 50% of tabulated values, then retorque to 100% of tabulated values. If greater torque Is required, continue retorquing in increments of 50% of tabulated values. Variables such as surface finish on bolt threads, type of anti-sieze compound used, and surface finish of the mating flanges all have an effect on the minimum torque required to obtain a leak • tight flange seal. Use of a high quality anti-sieze compound on all bolt threads is recommended. PART NOMENCLATURE RED VALVE WARRANTY F L EXG AT E WARRANTIES-REMEDIES-DISCLAIMERS-LIMITATION OF LIABILITY Unless otherwise agreed to in writing signed by Red Valve,all Products supplied by Red Valve will be described in the specifications set forth on the face hereof. 304 SS STEM THE WARRANTIES SET FORTH INTHIS PROVISIONARE EXCLUSIVEAND IN LIEU OF ALL OTHER WARRANTIES WHETHER STATUTORY, EXPRESS OR IMPLIED (INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FORAPAR- CAST IRON HANDWHEEL TICULAR PURPOSE AND ALL WARRANTIES ARISING FROM COURSE OFDEALING _ OR USAGE OR TRADE). BRONZE OILITE Red Valve Products are guaranteed for a period of one year from date of shipment, BEARING against defective workmanship and material only,when properly installed,operated and serviced in accordance with Red Valve's recommendations. Replacement for items of GREASE FITTING Red Valve's manufacture will be made free of charge if proved to be defective within such year;but not claim for transportation,labor or consequential damages shall be allowed. We shall have the option of requiring the return of the defective product to our CARBON STEEL YOKE factory,with transportation charges prepaid,to establish the claim and our liability shall be limited to the repair or replacement of the defective product,F.O.B.our factory. Red Valve will not assume costs incurred to remove or install defective products nor shall 316 STAINLESS we incur backcharges or liquidated damages as a result of warranty work. Red Valve STEEL GATE does not guarantee resistance to corrosion erosion,abrasion or other sources of failure, \\ nor does Red Valve guarantee a minimum length of service,or that the product shall be fit for any particular service. Failure of purchaser to give prompt written notice of any PACKING FOLLOWER alleged defect under this guarantee forthwith upon its discovery,or use,and possession thereof after an attempt has been made and completed to remedy defects therein,or BODY failure to return product or part for replacement as herein provided,or failure to install and operate said products and parts according to instructions furnished by Red Valve,or failure to pay entire contract price when due,shall be a waiver by purchaser of all rights FLUSH PORTS/ under these representations. All orders accepted shall be deemed accepted subject to this warranty which shall be exclusive of any other or previous warranty,and shall be NPT PLUG the only effective guarantee or warranty binding on Red Valve,anything on the contrary • contained in purchaser's order,or represented by any agent or employee of Red Valve REINFORCED in writing or otherwise,not withstanding implied warranties. RED VALVE MAKES NO WARRANTY THAT THE PRODUCTS,AUXILIARIES AND PARTS ARE MERCHANT- CARTRIDGE SEAT ABLE OR FIT FOR ANY PARTICULAR PURPOSE. ONYX VALVE 835 Industrial Hwy,Cinnaminson, NJ 0:0 0:0 The Onyx Isolator Ring provides a simple, accurate method to measure pressure of slurries ' and corrosive fluids. The PSR series is compatible with flanged pipe connections. The full face thru bolt holes match the bolt circle of mating flanges for accurate alignment making it the ideal choice for use with non-metallic flanges. , The inside diameter of the PSR precisely matches standard pipe for smooth, unobstructed flow, self-cleaning operation, and minimum turbulence and friction. Onyx ultra-deep vacuum filling • insures the highest accuracy in the industry. The patented "Module Seal" - standard on all ! Onyx Isolator Rings - allows instruments to be or replaced or calibrated without interrupting the process. Materials of Construction Center Section: Carbon Steel- PVC-C 316 Stainless Steel End Plates: Acetal(Standard) Kynor UHMW-PE 316 Stainless Steel Titanium Carpenter-20 Teflon PVC Elastomer: Nitrile(Bunn-N) -30°F->220°F Benefits Listed: ('Available with EPDM-(Nordel-) -40°F->300°F •Absolute immunity to clogging optional Teflon Neoprene -20°F->220°F •Available with either 150#or 300# • coatings) y -15°F->315°F Hpolypaon •10°F->250°F •Integral snubber eliminates gauge fluctuations at no additional cost Fill Fluid: Silicone Fluid -40°F->400°F •Instruments can be replaced without vacuum filling Food Grade Silicone -20°F->400°F •Immune to errors caused by ambient temperature Module Seal Stinger Bross 316 Stainless Steel fluctuations Fitting: •No tools required to change pressure instruments Pipe Fittings: (arbon Steel 316 Stainless Steel Pressure Range: Vacuum to+1,000 psi The Onyx Isolator ring has been tested by an independent lab to 1,500 psi. 1 4.25 1.87 1/z 5.00 1.87 2 6.00 I V 2/2 7.00 1.87 3 7.50 1.87 4 9.00 2.12 5 10.00 2.25 6 11.00 2.25 8 13.50 2.25 3.37 10 16.00 2.81 12 19.00 3.12 14 21.00 3.12 O 11 16 1 23.50 3.12 0 18 25.00 3.12 OA 20 27.50 3.12 24 32.00 3.12 30 38.75 3.12 LBJ 36 41.12 4.00 42 53.00 4.00 WINTERS GAUGE CENTER MATERIAL: CARBON STEEL ❑ 316 STAINLESS STEEL ❑ CARPENTER 20 STAINLESS STEEL ❑ OTHER END PLATE MATERIAL: E ACETAL 8.62 ❑ 316 STAINLESS STEEL MODULE SEAL W/INTERNAL (MAX.) ❑ CARPENTER 20 STAINLESS STEEL SNUBBER/PULSATION DAMPENER. [I TEFLON SENSOR MATCHES 150 LB. ANSI BOLT PATTERN OF ❑ OTHER MATING FLANGES SLEEVE ELASTOMER: BUNA—N MODULE SEAL MATERIAL: CARBON STEEL/BRASS ❑ CARBON STEEL/316 S.S. ❑ 316 S.S./316 S.S. O ❑ 316 S.S./BRASS ❑ OTHER FILL FLUID: SILICONE (STD) (-40' F TO 400° F) 0 19.00 ❑ FDA SILICONE (-20' F TO 400' F) Cl OTHER PRESSURE RATING: 1,000 PSI MAXIMUM WINTERS Q SERIES GAUGE Y� SPECIFICATIONS: GAUGE SIZE: 3.1< METRIC - 100R (4") TUBE I.D. MATCHES SCH. 40 CARBON STEEL PIPE CASE: 304 STAINLESS STEEL RING: 304 STAINLESS STEEL WINDOW: ALL DIMENSIONS ARE IN INCHES. PLEXIGLASS LIQUID FILL: CUSTOMER HD SUPPLY ONYX VALVE GLYCERINE (STD) TUBE/SOCKET MATERIALS: FOR 12" PSR W/WINTERS GAUGE PHOSPHOR BRONZE/BRASS CUSTOMER NO. PDX 5601435 NONE RJD A6-15-12ACCURACY:ANSI GRADE 1A TAG NO. 24e7oHD SUPPLYRANGE: CUS R TO SPECIFY ORDER R 24870 '°° °"' "PC-4259 • ONYX VALVE CO ISOLATOR RING Installation & Maintenance Operation: (02-2010) Obtaining accurate pressure readings on slurry lines is difficult because slurries, abrasives and solids clog pressure elements such as gauges, switches and transmitters. THE ONYX ISOLATOR RING IS NOT SLURRY CLOGS AFFECTED BY SLURRY DIAPHRAGM SEAL Iola Onyx Isolator rings consist of rubber"inner tube"captured in a steel ring. The assembly is installed between flanges in the process pipe. Clear instrument oil behind the rubber membrane transmits pressure to the gauge Onyx Isolator ring are vacuum filled at the factory with high viscosity silicone fluid. (Other fluids available on special order.) After vacuum filling, the Isolator Ring is permanently sealed with our patented"Module Seal". The Module Seal enables the users to remove or replace the gauges and other pressure instruments while the Isolator Ring remains in the process pipe without having • to vacuum fill the rings. • 0.250" Allen Wrench i► Module Seal i Set Screw Module Seal Lock Ring Isolator Onyx Isolator rings are usually supplied with instrumentation such as gauges, transducers, and pressure switches;refers to specific manufacturer's literature concerning maintenance for these accessories. If you detect instrument oil weeping from under the Lock Ring,the Module seal may require minor adjustment. To adjust the Module Seal: a) Loosen the Lock Ring,and then carefully remove the pressure measuring instruments. b) Insert a 0.250 inch Allen key into the Module Seal Set Screw and turn clockwise 1/8 revolution. c) Reinstall the pressure measuring instruments and tighten Lock Ring. • • Turning the Module Seal Set Screw clockwise eliminates weeping but makes the fit around the needle tighter. If the Module Seal is too tight to reinstall the pressure measuring instrument, do not force the needle in or you will risk bending or breaking the needle. Instead, loosen the Set Screw until the needle can be inserted easily. If fluid weeping persists, it may be necessary to tighten the Set Screw further. When tightening the Set Screw, turn clockwise 1/8 revolution at a time. PRESSURE RATING: Onyx isolator rings are rated for operation up to 1,000 psi. STORAGE: Correct storage extends service life. Rubber is perishable. Ideal storage conditions are 50°F/60%relative humidity. We recommend the following precautions for Isolators and spare parts stored for any length of time prior to installation. 1. Keep Isolators cool. They can be stored in an unheated area, but allow maximum ventilation in storage areas subject to high ambient temperatures. Trailers and storage sheds become incredibly hot during summer months. Avoid such locations. • 2. Avoid sunlight. Ultra-violet light deteriorates rubber. Leave the Isolator in its box. 3. Avoid ozone. DO NOT STORE Isolator near active electrical equipment. 4. The Isolator may be supplied with sensitive instrumentation. Refer to specific manufacturer's literature concerning proper storage. 5. Separate instruments may be supplied with a stinger fitting attached. DO NOT REMOVE RUBBER TIP PROTECTOR FROM THE STINGER FITTING NEEDLE UNTIL ATTACHING THE FITTING TO THE ISOLATOR RING. INSTALLATION: 1. Safety Considerations: a) Isolators rings frequently handle chemically reactive and abrasive fluids; it is reasonable to expect the elastomer sleeve to eventually wear out. Instrument fill fluid must be compatible with the process liquid. Mixing incompatible fluids may cause a violent chemical reaction resulting in equipment damage or personal injury. b) Make certain that instruments such as gauges, pressure switches, etc, have pressure and temperature rating suitable for actual operating conditions. Exceeding manufacturer's design limits may result in equipment damage or • personal injury. • c) The rubber sleeve elastomer must be compatible with the chemistry and temperature of the process fluid. d) Do not use Onyx Isolator rings for oxygen service. 2. Inspect prior to installation. Onyx Isolator rings should not show any indication of leakage, and rubber sleeve should be free from cuts or punctures. 3. Onyx Isolator rings can be installed in any attitude with flow in either direction. Install in straight pipe run as far from tees and elbows as possible. 4. Onyx Isolator rings may be installed without pressure instruments attached. This minimizes damage to gauges and sensitive pressure instruments during pipe fitting and construction. 5. Onyx Isolator rings are vacuum filled at the factory to insure high accuracy in operation. DO NOT DISASSEMBLE UNLESS NECESSARY FOR REPAIRS. 6. To install, sandwich the Isolator between two flanges in the process pipe line. Center as carefully as possible. Install gaskets on both sides of Isolator ring. Insert flange bolts. Tighten flange bolts in criss cross pattern. • OPERATING INSTRUCTIONS: l. Onyx Isolator Rings and pressure instruments are vacuum filled at the factory. They may be shipped assembled or shipped separately for field assembly. a) Do not disassemble the ring except to replace the rubber membrane. b) Do not break connections between the stinger fitting and pressure instruments. c) Do not remove the rubber seal (#5) from the stinger. 2. To attach a pressure instrument to the Isolator Ring: Pressure measuring element and stinger fitting must be pre-assembled and vacuum filled prior to attaching to the Isolator ring!!! a) Instruments can be attached to an Isolator Ring installed in the pipe line while the system is pressurized. b) Hold the pressure instrument and stinger fitting assembly upright above the Isolator Ring. c) Remove the rubber tip protector from the stinger needle (#5F). (Save the rubber tip protector.) • • d) Gently push the needle(#5F)through the rubber seal(#5)until it hits bottom. e) Thread the lock ring(#5C)onto the stinger fitting(#5E). HAND TIGHTENED. f) Gauges can be rotated to face any direction by loosening the coupling ring, turning the gauge, and re-tightening the ring. 3. To attach instruments which did not come with a stinger fitting, refer to instructions on attaching stinger fitting to instruments at the end of this booklet. 4. To remove pressure instruments from the Isolator Ring: A) It is NOT necessary to remove the Isolator Ring from the process pipe. B) In order to minimize fluid loss, reduce process pressure as low as possible before removing gauges or other instruments from the Isolator Ring. Turn off pump prior to removing instrument from the Isolator Ring (The interruption will be brief. Instruments can be removed from the Isolator in about 10 seconds.) B) Loosen knurled lock ring(#5C). C) Gently lift the gauge and stinger assembly out of the module seal. • D) Immediately attach a rubber tip protector to the end of the stinger needle. E) Now your process can be re-pressurized without loosing fluid from the Isolator Ring. SLEEVE AND MODULE SEAL REPLACEMENT: 1. Remove Isolator Ring from process line. 2. Remove gauge or auxiliary instrument. 3. Remove end plate screws(#4A). 4. Remove end plates(#4). 5. Remove old sleeve(#1). 6. Use a 0.250 inch hex key to remove the module seal set screw(013). 7. Use a packing extractor to remove the old rubber seal(0). 8. Clean all components thoroughly. 9. Press new rubber seal (#5) into the module seal tube (#5A). Drive all the way to bottom of bore. Replace module seal set screw(013). Do not over tighten. 10. Collapse new sleeve (#1), push through center housing (0) and work sleeve lips into • housing grooves. , ITEM DESCRIPTION I SLEEVE 3 CENTER HOUSING 3A SENSING LIQUID,CENTER 6 4 END PLATE 5E 4A SCREW,END PLATE 5F 5 RUBBER SEAL 56 5D 5A TUBE, MODULE SEAL 5 SC 5B SETSCREW,MODULE SEAL SC LOCK RING,MODULE SEAL 3A 5A 5D SEAL WASHER , 5E STINGER FITTING • 3 5F NEEDLE,STINGER FITTING 4A 6 GAUGE +34 - i 11. Reinstall end plates(#4). 12. Replace end plate screws(#4A). 13. Connect a separate stinger fitting (#5E), to vacuum filling system, evacuate air from the ring assembly,and refill with fresh instrument fluid. Use Onyx silicone fluid. 14. The Isolator Ring can now be returned to service. TO ATTACH STINGER FITTING TO INSTRUMENTS: 1. Attach gauge or other instrument to the stinger fitting(#5E). • • 2. Connect an Onyx Vacuum Fill Tool Adapter, P/N#T75132-01-00,to your vacuum filling system. 3. Attach the instrument assembly to the adapter fitting. 4. Evacuate all the air from the instrument, and fill with silicone fluid. 5. Detach the instrument from the filling system. 6. The instrument can now be attached to an Isolator Ring, or stored for future use. INSTRUMENT ASSEMBLY VACUUM FILL TOOL ADAPTER tVACUUM FILLING SYSTE M Questions? Contact Onyx Valve Company Tel: 856-829-2888 Fax: 856-829-3080 E—mail: david@onyxvalve.com • Quick Start Instructions • Changing Instruments on an Onyx Isolator Ring Start by making sure that you have the new gauge(or other pressure instrument)on hand,and that the new instrument is the correct range. New Gauge Defective Make sure the new instrument Gauge enclosure is appropriate for the environment. A gauge for outdoor service should be sealed construction;an electrical device such as a switch or transmitter must Stinger Fitting have an explosion proof enclosure if with Tip Protector the area is classified as a hazardous environment. The only tools you might need are a Isolator Ring pair of channel lock pliers and a %" Allen key. Before removing the old gauge, reduce the line pressure as close to zero as practical. Turn off the pump if there is one connected to the process line. CAUTION: This assembly is vacuum filled with instrument oil. Do NOT loosen or • separate any of the pipefittings,or the instrument will not function properly and the warranty is void. After the line pressure is down,start by New Gauge loosening the knurled lock ring on the Module Seal post(see diagram at the Defective right). Gauge s If you can't loosen the ring by hand,a pair of channel lock pliers should persuade it to cooperate. When the knurled lock ring is completely free from the brass stinger, Stinger Fitting pull straight up on the gauge with a with Tip Protector firm,gentle pressure until the stinger Setp 2: Pull gauge and needle pulls free from rubber stinger fitting straight up P Isolator Ring diaphragm in the Module Seal. Step 1: Loosen knurled ring. At this point,check to see if there is any weeping in the Module Seal. If any oil seeps out,insert an Allen key into the top of the Module Seal post and snug down(1/8 turn should do it) on the diaphragm. • • On the new gauge,remove the Old gauge rubber tip protector. (Don't tang: You have 3 to 4 minutes until the New Gauge oil drips out.) E You can replace the tip protector onto the old gauge to keep it from dribbling oil. Take the new gauge,position the stinger needle right over the rubber Stinger Fitting diaphragm in the Module Seal and applying firm steady pressure Step 4: Insert stinger fitting insert the needle through the on new gauge through rubber Step 3:Remove tip diaphragm in Module Seal. protector from new original hole into the Module Seal gauge and apply to old until the bottom of the brass gauge. stinger fitting hits home. Isolator Ring Step 5: hten Don't force it. If it doesn't go in knurled ig ring. readily,use an Allen key and loosen the module seal about 1/8 tun and try again. — — - - - - Replace the knurled lock ring and thread it back onto the new stinger fitting. Turn the gauge into any position convenient for viewing. • Use a channel lock to snug it up so it doesn't vibrate loose. The"Pressure Instrument"can be New Gauge a complete assembly consisting New Switch of a gauge and switch,or any other combination of pressure instruments. In this case,the same procedure applies. 0 0 You extract and replace the entire manifold assembly as one piece. CAUTION: This assembly is vacuum filled with Do NOT break or loosen Stinger fitting instrument oil. Do NOT any of these fittings!!! loosen or separate any pipe Stinger Needle fittings,or the instrument Isolator Ring will not function properly Knurled Lock Ring and the warranty is void. • If you notice fill fluid weeping from the module seal: • Occasionally the module seal will weep a few drops of the fill fluid. If this happens, temporarily remove the gauge assembly from the isolator ring. Insert a '/" Allen hex key into the module seal as shown in the picture on the right and turn 1/8 of a turn clockwise to tighten the seal. Then replace the gauge. a If the module seal is too tight to insert the stinger fitting,loosen the adjustment a little bit by rotating the hex key anti-clockwise. Just a few degrees of rotation with the hex key should be sufficient to reinsert the stinger. How to Turn the Gauge to Face a New Direction • Onyx Isolator Rings are usually assembled with the gauge axis parallel to the axis of the process pipe. This allows for the most compact configuration for shipping purposes. However,if you wish, it is possible rotate the gauge to face any desired direction without compromising the '9 integrity of the vacuum fill. DO NOT LOOSEN THE CONNECTION BETWEEN THE STINGER FITTING AND THE GAUGE. Failure to observe this precaution could cause the fill fluid to leak, compromising the integrity of the vacuum fill. To rotate the gauge, loosen the knurled lock ring on the module seal. This can usually be loosened by hand,but if it is too tight,you can use channel lock pliers. • • ° , Use an open-end wrench to keep the stinger fitting from rotating,and use the channel lock pliers to loosen the knurled ring as shown in the picture. Rotate the knurled ring clockwise as viewed from above to loosen it. You just have to break the lock ` ring free, 1/8 turn is more than adequate. Don't remove it completely. The gauge will now rotate freely to face any desired direction. Turn the gauge as desired,and use the channel lock pliers to re-tighten the lock ring. { Questions? Call Onyx Valve Co. P: 856-829-2888 www.onyxvalve.com • W, Limitations of Fire Alarm Systems Manufacquer recommends that smoke and/or heat detectors be • Heat detectors do not sense particles of combugtion and located throughout a protected premise following the recom- are designed to alarm only when heat on their sensors in- mendations of the current edition of the National Fire Protec- crease at a predetermined rate or reaches a predetermined tion Association Standard 72,National Fire Alarm Code fNFPA level.Heat detectors are designed to protect property.not 72,manufacturer's recommendations,state and local codes, life. and the recommendations contained in Guide for the Proffer • Warning devices(including horns,sirens,and bells)may Use of System Smoke Detectors,which is made available at no not alert people or wake up sleepers who are located on charge to all installing dealers.A study by the Federal Emer- the other side of closed or partially open doors.A warn- gency Management Agency(an agency of the United States ing device that activates on a different floor or level of government)indicated that smoke detectors may not go off or a dwelling or structure is less likely to awaken or alert give early warning in as many as 35%of all fires.While fire people.Even persons who are awake may not notice the alarm systems are designed to provide warning against fire, warning if the alarm is muffled by noise from a stereo, they do not guarantee warning or protection against fine.AM radio,air conditioner or other appliance,or by passing alarm system is subject to compromise or failure to warn for traffic.Audible warning devices may not alert the hearing- a variety of reasons.For example: impaired(strobes or other devices should be provided to • Particles of combustion or"smoke"from a developing fire warn these people).Any warning device may fail to alert may not reach the sensing chambers of the smoke detector people with a disability,deep sleepers,people who have recently used alcohol or drugs,or people on medication because: or sleeping pills. - Barriers such as closed or partially closed doors,walls, Please note that: or chimneys may inhibit flow. Smoke particles may become"cold"and stratify,and i)strobes can, under certain circumstances, cause seizures in people with conditions such as epilepsy. may not reach the ceiling or upper walls where detec- tors are located. ii)Studies have shown that certain people,even when Smoke particles may be blown away from detectors by they hear a fire alarm signal,do not respond or air outlets. comprehend the meaning of the signal. It is the Smoke particles may be drawn into air returns before property owner's responsibility to conduct fire drills reaching the detector. and other training exercises to make people aware of fire alarm signals and instruct on the proper In general,smoke detectors on one level of a structure cannot reaction to alarm signals. be expected to sense fires developing on another level. ili)In rare instances,the sounding of a warning device • The amount of"smoke"present may be insufficient to alarm can cause temporary or permanent hearing loss. smoke detectors.Smoke detectors are designed to alarm at . Telephone lines needed to transmit alarm signals from various levels of smoke density.If such density levels are not created by a developing fire at the location of detectors, a premises to a central station may be out of service or the detectors will not go into alarm. temporarily out of service.For added protection against • Smoke detectors,even when working properly,have sens- telephone line failure,backup radio transmission systems ing limitations.Detectors that have photoelectronic sensing • are recommended. chambers tend to detect smoldering fires better than flaming System components,though designed to last many years, fires,which have little visible smoke.Detectors that have can fail at any time.As a precautionary measure,it is rec- ionizing-type sensing chambers tend to detect fast flaming ommended that smoke detectors be checked,maintained, fires better than smoldering fires.Because fires develop in and replaced per manufacturer's recommendations. different ways and are often unpredictable in their growth, • System components will not work without electrical neither type of detector is necessarily best and a given type power.If system batteries are not serviced or replaced of detector may not provide adequate wanting of a fire. regularly,they may not provide battery backup when AC • Smoke detectors are subject to false alarms and nuisance power fails. alarms.For example,a smoke detector located in or near a • Environments with high air velocity or that are dusty or kitchen may go into nuisance alarm during normal operation dirty require more frequent maintenance. of kitchen appliances.In addition,dusty or steamy environ- ments may cause a smoke detector to falsely alarm.If the In general,fire alarm systems and devices will not work location of a smoke detector causes an abundance of false without power and will not f properly unless h alarms or nuisance alarms,do not disconnect the smoke are maintained and tested re 1 detector:call a professional to analyze the situation and While installing a fire alarm system may make the owner recommend a solution. eligible for a lower insurance rate, p,alarm system is not a • Smoke detectors cannot be expected to provide adequate substitute for insurance.Propert,;Zers should continue warning of fires caused by arson,children playing with to act prudently in protecting the premises and the people matches(especially within bedrooms),smoking in bed, in the premises and should properly insure life and property violent explosions(caused by escaping gas,improper storage and buy sufficient amounts of Ability insurance to meet of flammable materials,etc.). their needs. t Requirements and recommendations • All fire alarm systems require notification devices,includ- ing sirens,bells, horns, and/or strobes. In residential for proper use of fire alarm systems applications,each automatic alarm initiating device when including smoke detectors and other fire activated shall cause the operation of an alarm notification alarm devices: device that shall be clearly audible in all bedrooms over ambient or background noise levels(at least 1Sd13 above Early firh detection is best achieved by the installation noise)with all intervening doors closed. ■ and maintenance of fire detection equipment in all rooms • It is recommended that a smoke detector with an integral and areas of the house or building in accordance with the sounder(smoke alarm)be located in every bedroom and requirements and recommendations of the current edition an additional notification device be located on each level of the National Fire Protection Association Standard 72, of a residence. National Fire Alarm Code(NFPA 72),the manufacturer's • To keep your fire alarm system in excellent working order, recommendations, State and local codes and the recom- ongoing maintenance is required per the manufacturer's mendations contained in Guide for the Proper Use of System recommendations and UL and NFPA standards. At a Smoke Detectors,which is made available at no charge to minimum the requirements of Chapter 7 of NFPA 72 all installing dealers.For specific requirements,check with shall be followed.A maintenance agreement should be the local Authority Having Jurisdiction(ex.Fire Chief)for arranged through the local manufacturer's representative. fire protection systems. Maintenance should be performed annually by authorized personnel only. Requirements and Recommendations include: • The most common cause of an alarm system not func- • For residential applications, smoke detectors shall be coning when a fire occurs is inadequate maintenance.As installed outside of each separate sleeping area in the im- such,the alarm system should be tested weekly to make mediate vicinity of the bedrooms and on each additional sure all sensors and transmitters are working properly. story of the family living unit,including basements and • Wireless smoke detectors that are used in one- and excluding crawl spaces and unfinished attics. two-unit family dwellings may be used as long as the • Smoke detectors shall be installed in sleeping moms in new detectors are being monitored,tested,and maintained. construction and it is recommended that they shall also be Once the detector is no longer part of a listed fire alarm installed in sleeping rooms in existing construction. system monitoring program,it is recommended that it be • It is recommended that more than one smoke detector shall replaced prior to 10 years from the date of manufacture be installed in a hallway if it is more than 30 feet long. • per recommended practice of NFPA 72. • It is recommended that there shall never be less then two Any smoke detector,fire alarm system or any component smoke detectors per apartment or residence. of that system which fails shall be repaired or replaced •It is recommended that smoke detectors be located in any immediately. room where an alarm control is located,or in any room where alarm control connections to an AC source or phone lines are made.If detectors are not so located,a fire within the room could prevent the control from reporting a fire. Typical System Installations per NFPA 72 ♦ ❑ ■o DINING KITCHEN BEDROOM BED OOM T 0 no ❑V ROOM KITCHEN DINING BDRM ■O ♦ O ■ BEDROOM p ■ LIVING ROOM O■ ■ BDRM ■O ■O TO ii BEDROOM BR No ❑ ■O HOUSE TYPE"B" O ■ D LIVING ROOM BEDROOM BEDROOM KRGHEN GARAGE ■� CLOSED HOUSE TYPE"A^ LIVING DOOR ROOM ■ ■-Smoke Detectors required BASEMENT ■O-Smoke Detectors required with integral sounders recommended HOUSE TYPE"C" ♦ -Heat Activated Detectors required ❑-Smoke Detectors for additional protection Q-Notification Devices As of March 2012,this document supersedes any previous liability information enclosed with this product. 156-1558-00 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO.913 ATLANTA GA POSTAGE WILL BE PAID BY ADDRESSEE 3G/4G Upgrade Incentive Claim Dept Telular Corporation 2727 Paces Ferry Rd SE Ste 1-800 Atlanta GA 30339-9860 IV t;l TELGUARD 3G/4G Upgrade Incentive Program With the upcoming 2G Sunset, all 2G cellular alarm communicators will have to be replaced. That's all GSM and GPRS based devices. So be proactive and start replacing them now with Telguard and get paid to do it. Telguard offers a $25* incentive to security dealerst who replace their existing 2G hardware with Telguard products for 3G/4G networks. Simply complete and return this form to receive your incentive credit on your next cellular service invoice. What are you waiting for? Upgrade your customers today. Step 1 Step 2 Step 3 Step 4 Receive $25* Q Alarm.com Telguard Monthly Invoice Q Honeywell Amount Description gUplink -$25.00' 3G/4G Upgrade 0 Telguard Remove the old Mark the replaced Replace it with an Seal this form using For valid submissions, 2G unit,then remove manufacturer in the eligible Telguard unit the adhesive strips a$25 credit will appear its SIM Card and space provided for 3G/4G networks. and drop it in any on the next service invoice attach it to the below. mailbox. after the submission is space provided Write the 10-digit serial processed. below. number in the space It's already provided below. addressed with prepaid postage so just drop it in the customer's mailbox as you leave. This is a limited time offer. •Telguard dealers NOT paying rates specified on Telguard's Dealer Cellular Service Rate Plans For complete terms and conditions visit www.Teiguard.com/Upgrade. sheet will receive$12.50 instead of$25.Check with Telguard to verify your incentive amount. +Telguard dealers billed through their central station must verify their central station's eligibility. m F m m o m Cn Clearly write the 10-digit serial number of the Telguard device 11 W o o for 3G/4G Networks replacing the 2G device: LLI 0 m m m Ul ¢ i D m Q Z Z p Z Q J Z7 N > (n El EIEI [1 [1 [1 [] El O t y m w n Lu c m ? One digit per box. o ¢ Eligible products include the TG-1 Express, TG-1B, TG-4, TG-7, TG-7A and y TG-7FS for 3G/4G networks. o = LU x m aC m a r LLJ x Lu v 9 ¢ W O Oa i w = w , a a > = O 0 o o Place the 2G SIM Check the box of thecn o `. a Q o removed from the replaced manufacturer of the m x unit onto the adhesive. 2G product being replaced: o 0 Cl) Ch ; D = o � > 1 o K'p ` S 0 Alarm.com 0 NAPCO o m 0 (n T G Ln Ti W g N DMP Q Uplink Z 9 r m v a � � 3 :0 16 0 DSC O Telguard o 7i ° o m m 0 oa '^ w Honeywell Other CCm L 'n M m Other W a:z o z u , hi t=INI I dAUVV:Id LAr-/ nCJIrC r CMUrC L114cn 70UUAy Ul I tA1"UJt AUntWVt ntrV1UVt1' 38 3AIS3HG'd 3SOdX3 Ol TO EXPOSE ADHESIVE REMOVE LINER d3Nll 3AON13H 3AIS3HOV 3SOdX3 Ol TO EXPOSE ADHESIVE REMOVE LINER 83Nll 3A R 89Nn 9AOV43H SAIS3HGV 3SOdX3 01 TO EXPOSE ADHESIVE REMOVE LINER E13Nll 3AOW3H 3AIS3HGV 3SOdX3 01 TO EXPOSE ADHESIVE REMOVE 1 Important Product Advisory: Style D initiating Devices Circuits and 2-wire i3 Smoke Detectors Refer to installation manual for required wiring of 2-wire 13 smoke detector (2W-B, 2WT-B, 2WTA-B, or 2WTR-B) in the style D initiating device circuit configuration. 156-2719-00