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HomeMy WebLinkAboutKrugerr I reit,• eI 111 I .. O ak:y .:i: . z - ark _ eighth s Lift Station :, 1 :.' M Operations and Maintenance Manual M M • I s III March 1992 i • • ji I . .•_� File No. 5594 4. i\ t e - i . Bonestroo 1 AidAl Rosene Anderlik & Associates IIEngineers & Architects • St.Paul • Milwaukee 11 I ICITY OF OAK PARK HEIGHTS LIFT STATIONS 1 O1ERATION AND MAINTENANCE MANUAL 1 1.0 General: The City sewer system includes three prefabricated steel type lift stations and Ione submersible type lift station. The lift stations pump wastewater from low areas to higher gravity sewers where it is conveyed to wastewater treatment facilities. This manual provides Ioperation and maintenance procedures for these facilities. IThe manual consists of two sections; the first covering prefabricated steel stations and the second covering submersible type stations. The stations differ in operation and Imaintenance depending on the type of pumps and motors and the electric control system at each facility. This manual provides a general guideline for operation and maintenance with specific instructions provided in the manufacturer's operation and maintenance manuals Ifurnished with each station. 1 I I I 1 I I 55-GEN.OM - 1 - I I I I2.0 Prefabricated Steel Lift Station 2.1. Equipment: The lift station consists of a concrete wet well and a prefabricated Isteel pump chamber with two centrifugal pumps and a control panel. The station piping Icontains suction and discharge isolation gate valves and a check valve for each pump. Information on each pump is included on the equipment data sheets. IAuxiliary equipment a ui ment is provided for environmental control as ventilation, Idehumidification and lighting systems. Drainage within the station is removed by a sump pump. I Electrical control consists of an air bubbler system with mercury switches for pump Ioperation and alarm functions. Control panel devices include HOA switches, elapsed time meters, indicating lights for status and alarm functions, control devices for environmental I equipment, and an exterior alarm light. Control and alarm functions vary at each station Iand the manufacturer's operation and maintenance instructions should be reviewed for Ifeatures included at each facility. 2.2. Initial Startup. Before putting the lift station into service or returning to service, the 1 following checks should be made: IWARNING: Prior to entering a lift station for any reason, be sure that it has been adequately ventilated. An air tester and a self-contained breathing unit is recommended. 1 1. Check pipe connections for tightness. 2. Check gate and check valves for proper operation. 1 3. Check to make sure all of the equipment is lubricated properly according to the Imanufacturer's instructions. I 55-GEN.OM _ 2 _ I I I 1 4. Check rotation of pumps to be sure rotation is in correct direction. First rotate Iimpeller by hand to be sure it doesn't bind. 5. See that current characteristics of voltage and frequency or motor nameplate IIcoincide with service provided. I6. See that all thermal units are set. 7. See that valves on the discharge lines are open. 1 S. Check for proper cleanliness of wet well. The pumps will not handle large rocks, Ibricks, sticks and other heavy materials of a similar nature. They must be removed. 1 9. Check that wet well is filled with sewage or water. 1 With these checks completed, place the lift station into operation. To start up the lift station: 111 1. Energize the station's control center. 2. Start lift station pumps. Ia. Open gate valves. Ib. Select lead-lag pump sequence. c. Energize pump. d. Check operation of each pump. 111 e. Check operation of bubbler system. I I 55-GEN.OM - 3 - I I I Once the lift station has been put into operation, check the following: 1. Observe complete pumping cycle to insure that the level control system and automatic pump alternator are operating properly. I2. Check all pipe connections to be sure that they are tight. The lift station is ready to be put into service with these checks completed. I' 2.3. Normal Operation. The pump control shall operate the two pumps based on the Ioperation of the liquid level in the wet well. As the level rises the lead pump shall start followed by the lag pump on a continuing level rise. If the level continues to rise, the high IIlevel alarm shall be activated along with the exterior alarm. All pumps shall stop at a Icommon low level. If the Level continues to drop, a low level alarm will be activated if provided along with the external light. IWhen check valve limit switches are provided a failure to open the check valve after 1 pump is called to run will result in a pump failure activation on the panel and the external alarm light. I2.4. Alternate Operation. The pumps can be controlled manually if the bubbler Icontrol system is not working properly. If the pumps must be manually controlled, the operator should monitor their operation to maintain a relatively constant water level in the 111 wet well. If a pump needs to be removed for service repair work, automatic operation will 111 not be interrupted. The operator should select the pump sequence position that would put the pump to be serviced in the standby position. The HOA switch should be in the off iposition before efore removing the pump and the motor disconnect pulled off. 111 2.5. Alarms: The following is a list of alarms that may be included ateach facility. IThe alarm functions included at each facility are listed on the equipment data sheets. 55-GEN.OM - 4 - I I I Ia. High Water alarm: activated by mercury switch if wet well level exceeds setting. Ib. Low Water Alarm: activated by pressure switch if wet well level falls below common pump off level. Ic. Pump Failure: activated by tripping of motor starter overloads or by failure of Icheck valve to open if limit switches are provided on check valve. d. Phase Faulures: activated by tripping of phase failure device monitoring incoming Ipower. Ie. Bubbler System Failure: activated by low of air pressure in control air compressor system. If. Station Flood: activated by high water in the pump chamber. I 2.6. Emergency Operation. Breakdown of a pumping unit is an emergency situation which may occur. If one of the pumps breaks down, it should be taken out of service. The Ioperator should assess the damage to the unit and determine if s(he) can repair it or if a trained serviceman is needed. In any case, the inoperative pump should be repaired and put Iback into operation as soon as possible. IA high wet well level is also an emergency situation which may occur. Upon discovering the emergency, the operator should deactivate the alarm and immediately Iinvestigate the basic reason for the alarm condition. For example, a malfunction in the Iautomatic controls would require that the pumps be operated manually by the operator. After the alarm situation is corrected, a complete investigation should be conducted as to II I 55-GEN.OM - 5 - I I I Ithe cause of the alarm condition. For example, a malfunction of the control system or 1 mechanical equipment problems may have caused it. 2.7. Maintenance. To insure efficient operation of the pumps, an inspection of the Iautomatic controls should be made at least weekly. Check to see that: II1) Controls respond to a rising level in wet well. 2) Units start and stop at proper levels. 1 3) Constant speed motors start up and shut down smoothly. 1 4) No excess noise, heat, or vibration in motor or pump. For additional preventative Maintenance Tasks, refer to the Preventative Maintenance ISchedule at the end of this section. 2.8. Troubleshooting Guide. The following list identifies most problems experienced with pumps although some of them should be dealt with only by a trained electrician. The Iremedy for the problem is either obvious or can be inferred from the description of the Icause. ITROUBLESHOOTING GUIDE PROBLEM PROBABLE CAUSE AND CURE I1. Pumpwill not start 1. No power to the motor. Check for Vblown fuse or open circuit breaker. 2. Selector switch may be in the off Iposition. 3. Control circuit transformer breaker Imay be tripped. Push to reset. 4. Overload heater on starter may be Itripped. Push to reset. 55-GEN.OM - 6 - I i ITROUBLESHOOTING GUIDE (CONT'D' 2. Pump will not start and 1. Turn off power and check motor illoverload heaters trip. leads for possible ground. 2. Check resistance of motor windings. I All three phases should show same reading. 3. Check for clogged or blocked impeller. 3. Pump operates with 1. This indicates trouble in the control selector switch in or the alternator relay. Consult Ihand position, but manufacturer. will not operate in auto position. I 4. Pump runs but will not 1. Pump may be air locked. Open I shut off. volute air vent until water appears, then restart. Repeat as necessary. I2. Check pump off switch operation. 3. Selector switch may be in the Hand IPosition. 5. Pump does not deliver 1. Suction or discharge gate valve may I proper capacity. be partially closed or partially clogged. I2. Check valve may be partially clogged. Raise lever up and down to clear. Ili 3. Pump may be running in wrong direction. Low speed pumps can Ioperate in reverse direction without much noise or vibration. 1 I 55-GEN.OM - 7 - V I , 1 ft4. If pump has been in service for some time and capacity falls off, I remove pump and check for wear or clogged impeller. I 6. Motor stops and then restarts after short 1. Pump may be operating on a short cycle due to water returning to period, but overload manhole from a leaking check valve. I heaters in starter do not trip. I 7. Pump requires too 1. Shutoff level of pump too low causing much power cavation or air to enter pump. Raise shutoff level. 1 2. Mechanical failure of critical pump parts. Check impeller and bearings Ifor damage. 3. Voltage of electrical current lower I than that for which motor was built. Contact power company for low service voltage. 111 4. Defect in motor bearings or windings. I I I I 1 I 1 55-GEN.OM _ 8 - I I I EQUIPMENT DATA SHEET - LIFT STATION #1 Station Identification Number: 07-4492 Pump Quantity: 2 Manufacturer: Smith & Loveless Type: Centrifugal Non-Clog Model: 4B2A Capacity: 110 GPM @ 70.3 TDH Motor: 7.5 Hp, 1760 RPM, 3/60/220 Station Supplier: Smith & Loveless, Inc. Address: 14040 Santa Fe Trail Drive City, State: Lenexa, Kansas 66215 I Representative: Fadden Pump Co. Address: 855-3rd St. S.W. City, State: New Brighton, MN 55112 Phone: 612/636-7060 CONTROL FUNCTIONS High Water Level Alarm 1 I I I' 55-GEN.OM - 9 - I I I EQUIPMENT DATA SHEET - LIFT STATION #2 Station Identification Number: 07-7097F Pump Quantity: 2 Manufacturer: Smith & Loveless Type: Centrifugal Non-Clog Model: 4B2A Capacity: 115 GPM @ 53 TDH Motor: 7.5 Hp, 1760 RPM, 3/60/230 Station Supplier: Smith & Loveless, Inc. Address: 14040 Santa Fe Trail Drive City, State: Lenexa, Kansas 66215 Representative: Fadden Pump Co. Address: 855-3rd St. S.W. City, State: New Brighton, MN 55112 Phone: 612/636-7060 CONTROL FUNCTIONS High Water Level Alarm Low Water Level Alarm 55-GEN.OM - 10 - I I I EQUIPMENT DATA SHEET - LIFT STATION #3 Station Identification Number: 07-7991 Pump Quantity: 2 Manufacturer: Smith & Loveless Type: Centrifugal Non-Clog Model: 4B2A Capacity: 200 GPM @ 65 TDH Motor: 7.5 Hp, 1760 RPM, 3/60/230 IStation Supplier: Smith & Loveless, Inc. Address: 14040 Santa Fe Trail Drive City, State: Lenexa, Kansas 66215 Representative: Fadden Pump Co. Address: 855-3rd St. S.W. City, State: New Brighton, MN 55112 Phone: 612/636-7060 CONTROL FUNCTIONS High Water Level Alarm Pump failure by limit switches Station flood alarm Phase failure alarm Power factor correction, fused Time delay to prevent simultaneous starting of pumps Loss of air in bubbler system alarm I I 55-GEN.OM - 11 - II I I PREVENTIVE MAINTENANCE SCHEDULE UNIT NAME LIFT STATION UNIT NO. 07-4492. 07-7097F, 07-7991 I DESCRIPTION DWMS A OTHER I Inspect: 1) Bubbler line air flow and moisture. X Drain bubbler line as necessary. 2) Sewage pump operation for noise X vibration and pump down. 3) Leakage of sewage pump X mechanical seal. 4) Sump pump operation. X 5) Ventilating blower operation, check X for coil icing during winter. 1 6) Dehumidifier operation, check for X icing during winter. 11 7) Station lights. X 8) Station control lights including X exterior alarm light. 1 9) Station cleanliness. X 10) Control alarms for proper operation X 111 11) Pump alternation X 12) Pressure switch settings and X operation. Reset as necessary. 1 13) Check pump seal filters X 14) Clean pump seal filters. 2 mo. 15) Check operation of check valve, X is listen for leaking. Repair as necessary. 55-GEN.OM - 12 _ I I PREVENTIVE MAINTENANCE SCHEDULE UNIT NAME LIFT STATION UNIT NO. 07-4492, 07-7097F. 07-7991 DESCRIPTION D W BVI S A OTHER 16) Check and operate gate valves. X 17) Touchup scratches in paint or X bare metal. 18) Check impeller and volute and clean. As required Lubricate: 1) Motor Bearings X 2) Ventilation motor bearing X Clean: 1) Dehumidifier and coil X 2) Clean station. X As req'd. 3) Clean debris from sump. X P 4) Wet well of solids accumulation X and floating grease and debris I I I . D-DAILY W-WEEKLY M-MONTHLY S-SEMI-ANNUALLY A-ANNUALLY I 55-GEN.OM - 13 - I ISECTION 3 SUBMERSIBLE LIFT STATION I3.0 SUBMERSIBLE LIFT STATION "KRUEGERS" LIFT STATION 3.1 Purpose: To pump wastewater approximately 1/2 mile east to a gravity sanitary sewer. 1 3.2 Equipment: The lift station consist of a wet well and a valve manhole. The valve Imanhole houses two 8" check valves and two 8" gate valves. The two (2) ABS submersible raw sewage pumps are located in the raw sewage wet well shown in Figure 3-2. Each pump Iis an ABS pump Model AF150-4-6 capable of pumping 700 GPM against a total dynamic Ihead of 47 feet. Electrical controls consist of"Hand-Off-Auto"switches, running lights and running time Imeters on the station's control panel. Also, running lights and pump failure alarm lights are Ilocated at the control panel. The pumps operate on 3 phase 460 volt 60 Hz current. The pumps are controlled using an electrogage duplex pump controller. The Ielectrogage manometer, in conjunction with the air bubbler system, is used to control the 111 operation of the submersible pumps. The mercury filled manometer has one common contact and 40 set points which are used to control the pump starting and stopping in 3 inch Iincrements. IFigures 3-1, 3-2, and 3-3 show the site plan,wet well&valve manhole plan and section of the lift station. i t 55-gen.sec3. 3-1 I I t • • L {{k t'x y�y/x 'i`Et } z^ { L 'k Y 3t#x ms' x 3 ~x x s. z .41kk . '3>s aR,I 3 r,`, ,§ of HAW# — G z ,,,, Sn. , 1 „„i„„„,,,,„,„,„„ t „:„.0.4,,i40:040,:„:„„„ ,,,,t4..„.0„:„,,,,..„.„,„ 4„„„„cg.,:,4,,,,,„ I ................. .„i c::::::: {A f ,„,,4,,:...„.:.:,:„:„.,,,,,,,t,:. ,..:.,:::„...„,,,..„.,.. ..„,.:,„„t,„,,,,,,mow„iwiR.„ . .. .. ...........,,. ..."...,.........., ... 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FF'F: :i x.4§,2, `,airy .., $:.....f,'a '''^s, "'` i: : ilihi<' PUMP AND MOTOR (TYP) I 1 in 1 1 I PLAN eo:: '°° st I Rne • 1 1 OAK PARK HIEGHTS, MINNESOTA FIGURE 3-3 Ander ssoci ates LIFT STATION NO. Enpin.•Associn s Archlt•cist. I St. Paul•Mllwauk . 5594R02.DWG COMM. 5594 MARCH 1992 I 1 3.3. Initial Startup. Before putting the lift station into service, the following checks Ishould be made: WARNING: Prior to entering a lift station for any reason, be sure that it has been Iadequately ventilated. An air tester and a self-contained breathing unit is recommended. I 1. Check pipe connections for tightness. 2. Check gate and check valves for proper operation. 3. Check to make sure all of the equipment is lubricated properly according to the I 4. manufacturer's instructions. Check rotation of pumps to be sure rotation is in correct direction. First rotate impeller by hand to be sure it doesn't bind. 5. See that current characteristics of voltage and frequency or motor nameplate 111 coincide with service provided. 6. See that all thermal units are set. 7. See that valves on the discharge lines are open. 8. Check for proper cleanliness of wet well. TheP umps will not handle large rocks, bricks, sticks and other heavy materials of a similar nature. They must be removed. 9. Check that wet well is filled with sewage or water. With these checks completed, place the lift station into operation. To start up the lift II station: 1 1. Energize the station's control center. 2. Start lift station pumps. I a. Open gate valves. b. Select lead-lag pump sequence. c. Energize pump. 111 d. Check operation of each pump. e. Check operation of bubbler system. . IOnce the lift station has been put into operation, check the following: 1. Observe complete pumping cycle to insure that the level control system and 1 automatic pump alternator are operating properly. 2. Check all pipe connections to be sure that they are tight. IThe lift station is ready to be put into service with these checks completed. I 55-gen.sec3. 3-2 I I I 1 3.4. Normal Operation. The pump control shall operate the two pumps based on the Iliquid level in the wet well. As the level rises the lead pump shall start followed by the lag pump on a continuing level rise. If the level continues to rise, the high level alarm shall be Iactivated. There is a redundant high level float which will start pumps if the bubbler system 111 fails. A bubbler air monitoring system has been provided which is connected to two air Icompressors. The bubbler system provides continuous pressure on the electrogage Imanometer which is used to control the submersible pumps. As the mercury in the manometer moves with changing water levels in the wet well, the pumps come on and off as the various set points make contact with the mercury. The air compressor operation may be adjusted so that the compressors alternate evenly or on a four hour to one hour operation sequence or manually. 3.5. Alternate Operation. The pumps can be controlled manually if the bubbler system is not working properly. If the pumps must be manually controlled, the operator should monitor their operation to maintain a relatively constant water level in the wet well. If a pump needs to be removed for servicerepair work, automatic operation will not be Iinterrupted. The operator should select the pump sequence position that would put the pump to be serviced in the standby position. The HOA switch should be in the off position Ibefore removingthe pumpand the motor disconnectplaced in the off position. I3.6 Alarms: The following is a list of alarm functions. Ia) If the wet well level rises to the high level setting, a red panel light is lit. A manual reset is required to turn off the alarm light. I 55-gen.sec3. 3-3 I 1 ' b) All pumps stop at a common low level. If the level continues to drop, light will be lit. A manual reset is required to turn off the alarm light. c) Pump failure alarms may be caused by one of the following conditions: 1) Pump over temperature alarm. 2) Pump overload alarm. 3) Pump seal leak alarm. 4) Pump phase failure alarm. ' Each of these conditions is explained in the O&M manual supplied with the pump equipment. 3.7. Emergency Operation. Breakdown of a pumping unit is an emergency situation ' which may occur. If one of the pumps breaks down, it should be taken out of service. The operator should assess the damage to the unit and determine if s(he) can repair it or if a ' trained serviceman is needed. In any case, the inoperative pump should be repaired and put back into operation as soon as possible. A high wet well level is also an emergency situation which may occur. Upon discovering the emergency, the operator should deactivate the alarm and immediately investigate the basic reason for the alarm condition. For example, a malfunction in the automatic controls would require that the pumps be operated manually by the operator. ' After the alarm situation is corrected, a complete investigation should be conducted as to P g the cause of the alarm condition. For example, a malfunction of the control system or mechanical equipment problems may have caused it. 55-gen.sec3. 3-4 I 1 3.8. Maintenance. To insure efficient operation of the pumps, an inspection of the I automatic controls should be made at least weekly. Check to see that: 1) Controls respond to a rising level in wet well. 1 2) Units start and stop at proper levels. I3) Constant speed motors start up and shut down smoothly. 4) No excess noise, heat, or vibration in motor or pump. I5) The elapsed time meter reading is monitored to insure that both pumps are Ioperating approximately the same amount of hours. For additional preventative Maintenance Tasks, refer to the Preventative Maintenance I Schedule at the end of this section. 1 3.10. Troubleshooting Guide. The following list identifies most problems experienced with pumps although some of them should be dealt with only by a trained Ielectrician. The remedy for the problem is either obvious or can be inferred from the I description of the cause. ITROUBLESHOOTING GUIDE FOR SUBMERSIBLE PUMPS PROBLEM PROBABLE CAUSE AND CURE I1. Pump will not start 1. NoP ower to the motor. Check for blown fuse or open circuit breaker. ' 2. Selector switch may be in the off position. III 1 3. Control circuit transformer breaker may be tripped. Push to reset. 1 4. Overload heater on starter may be tripped. Push to reset. I 55-gen.sec3. 3-5 1 I III2. Pump will not start and 1. Turn off power and check motor leads for overload heaters trip. possible ground. 1 2. Check resistance of motor windings. All three phases should show same reading. I3. Remove pump from MH and check for clogged or blocked impeller. I 3. Pump operates with 1. This indicates trouble in the float control I selector switch in hand position, but or the alternator relay. Consult manufac- turer. will not operate in I auto position. 4. Pump runs but will not 1. Pump may be air locked. Turn pump off and I • shut off. let set for several minutes, then restart. Repeat as necessary. ' 2. Verify that the bubbler system is operating and maintaining proper pressure to the man- ometer. ' 3. Selector switch may be in the Hand Position. I 5. Pump does not deliver 1. Discharge gate valve may be partially closed proper capacity. or partially clogged. 112. Check valve may be partially clogged. Raise level P and down to clear. u I 3. Pump may be running in wrong direction. 4. If pump has been in service for some time and I capacity falls off, remove pump and check for wear or clogged impeller. I I I I55-gen.sec3.g 3-6 I 6. Motor stops and then 1. This indicates heat sensors in the motor are restarts after short tripping due to excessive heat impeller may I period, but overload heaters in starter do be partially clogged giving a sustained over- load, but not high enough to trip overload not trip. heater switch. 1 2. Motor may be operating out of liquid due to a failed level control. Submersible motors can I . operate for extended periods out of water without burning up the winding, but the heat sensors give motor prolonged life by controlling winding Itemperature. 3. Pump may be operating on a short cycle due to Iwater returning to MH from a leaking check valve. 7. Pump requires too 1. Shutoff level of pump too low causing I much power. cavation or air to enter pump. Raise shutoff level. I 2. Mechanical failure of critical pump parts. Check impeller and bearings for damage. I3. Voltage of electrical current lower than that for which motor was built. I Contact power company for low service voltage. I4. Defect in motor bearings or windings. 8. Bubbler air flow 1. Air flow should read approximately 2 Varies Significantly. to 3 SCFM. Purge the bubbler tube I if air flow s.drops below normal readings. g Consult the manufacturer's O&M manual Ifor instructions on purging the bubbler tubing. I I .. 55- ensec3 g 3-7 I IEQUIPMENT DATA SHEET - LIFT STATION PUMPS Quantity: 2 IManufacturer: ABS Pumps Type: Submersible I Model: AF 150-4-6 Capacity: 700 GPM @ 47 TDH Motor: 20.0 Hp, 1750 RPM, 3/60/460 volts Accessories: 1. ABS Guide Rail Base. I 2. Halliday W1R3660 Aluminum Hatch. 3. Strand Plastic Cable Rack. 4. E.G. Pump Controls. I5. Anchor Model S30NO Float Switch. Representative: Mr. Bob Morgan, Techniflow Corporation I . Address: 2700 East 33rd Street City, State: Minneapolis, MN 55406 Phone: 612/722-2203 ISPARE PARTS I QUANTITY ITEM 2 Mechanical Seal Assemblies I 2 Impellers 2 Wear Plates il 1 Set Control Components I DESCRIPTION SUPPLIER PART # OTY. I FUSE, 5 AMP LittleF FLQ5 2 FUSE, 1/8 AMP LITTLEF FLQ1/8 3 FUSE, 10 AMP LITTLEF FLM 10 1 I RELAY, PLUG-IN, 120 VAC EATON D5PR3A 5 RELAY, PLUG-IN, 24 VDC EATON D5PR3T1 2 RELAY, INTRINSICALLY SAFE GEMS 22445 1 I TIMER, ON-DELAY SYRELEC PAR2B 110 1 TIMER, ON-DELAY, 24V SYRELEC PAR2B24 1 TIMER, OFF-DELAY SYRELEC LCR2B 110 1 IPILOT LIGHT, GREEN EATON 1025OT181N-C2N 1 PILOT LIGHT, RED EATON 10250T181N-C1N 4 AIR COMPRESSOR INGRAM HR10WB 1 ILAMP 40W, APPLIANCE SYL 40A19W1 PHASE MONITOR RELAY SYRELEC PR.U440 1 I I .. 55- ensec3 g 3-8 r ' • PREVENTIVE MAINTENANCE SCHEDULE UNIT NAME LIFT STATION PUMPS ' DESCRIPTION D W M S A Other rInspect: 1) Check control alarms for proper operation X 2) Open hatch and check pump operation for noise, vibration, drain down of rlevel, etc. X 3) Inspect check valves and seats X ' 4) Check that lead pump alternates X 5) Check Impeller and casing and clean X 6) Inspect pump electrical control cables for cracks X 111 Lubricate: 1) Change oil in pumps yearly or as required by inspection of con- taminated oil. Clean: 1) Wet well walls of solids accumulation accumulations of grease and scum X 2) Floats of accumulation When necessary D-DAILY W-WEEKLY M-MONTHLY S-SEMI-ANNUALLY A-ANNUALLY 55-gen.sec3. 3-9 1 1 1 II II t 1 tchniflow corporation Operation and Maintenance Manual Project: Highway 36 and Washington Avenue Utility Extensions Oak Park Heights, MN Contractor: Richard Knutson, Inc. 12585 Rhode Island Avenue So. Savage, MN 55378 (890-8811 ) Contact: Mr. Tyler Enright Engineer: Bonestroo, Rosene, Anderlik and Associates • 2335 West Trunk Highway 36 St. Paul, MN 55113 (636-4600) Contact: Mr. Dick Foster, P.E. Supplier: Techniflow Corporation 2700 East 33rd Street Minneapolis, MN 565406 (722-2203) Contact: Mr. Bob Morgan 2700 East 33rd Street • Minneapolis, MN 55406 • (612) 722-2203 • Fax (612) 722-0003 • Scope„ quipment Provided Two (2) ABS Model AF 150-4-6” submersible sewage pumps, 460 volt, 3 phase, 1750 RPM, 6" discharge, 45' electrical power and control cable, 622,13 impeller for a design condition point of 700 GPM @ 47' TDH. Two (2) ABS guide rail base and upper bracket asemblies. One ( 1 ) Halliday Model W 1 R3660 aluminum access frame and cover 36" x 60" clear opening, waterproof design, with spring opening assist, hold open bar, bituminous coating on exterior surfaces that come in contact with concrete, recessed padlock hasp. Two (2) 5/16" x 40' galvanized lifting chains with shackles. • One ( 1 ) Strand plastic coated cable rack. One ( 1 ) E.G. Pump Controls Electrogage duplex pump control panel U.L. Listed, Nema 3R enclosure, 460 volt, 60 HZ, 3 phase, 3 wire power to control 2 x 20 HP pumps with 25.3 FLA. E.G. Bubbler Air Monitor System included with a redundant high level intrinsically safe float circuit included. One ( 1 ) Anchor Scientific Model 530N0 mercury float switch with normally open contact and 30' cord. One ( 1 ) Thern Model T-4 base socket (only) for casting into concrete slab for future *5334 crane. • 011.11111111101111111117- techniflow corporation FOR LIFT STATION SERVICE PLEASE CONTACT TECHNIFLOW CORPORATION 612-722-2203 2700 EAST 33RD STREET MINNEAPOLIS, MINNESOTA 55406 FOR EMERGENCY SERVICE AFTER NORMAL BUSINESS HOURS PLEASE CONTACT PETE REARDON 612-485-3850 OR ROB DOWELL 612-774-9500 ip 27001 pct 3•tc! Start • Mu►nr;gx►h',. MN 1,1,10() • (617) 777 770.E • Fax (( 1?) 722.0004 I/ SECT. 200 TAB 6" 1750 RPM 30 PG. 131 ( 0 ' uM . . DATE April 1 , 1988 ,fir► TANDI RD C MODEL AF 125 150 180 -4-6" RATED HP 17 20 24 SOLID SIZE 3 • 'LADE 1 SPEED 1750 tow DISCHARGE SIZE 6 • VOLTAGE 230d2,600 ; 60 Mt 3 PN 140 . - _ - 120 •' I . L LL ..4..,. 11111111111114w. 45% . Z100 11' ,NCD th '•i' - W 1 . NNIIIIIii.' 55% . '_ 60% . . O , s3% NN-wiiii (.. 5% , I 1Nt4%14%.: /16Nkb, . . 40 - �. ���`► 45% 700e 7 , 6,o Tot/ - 0 200 400 600 800 1000 1200 1400 USGPM 23 - - , _. _ , _ „Ap..„„, 1 i _ _ 322.1 .e!"1..- ' CL --__ 322.11 . _ /, '`� 322,12----- .,0 /__," 1�-322.1I3 ,/ a 1 022.14 C 15 t 0...0. r... 11 Supersedes Rev. 5-1-87 „ ;SECT. 300 TABsAFW 6" through 10" pumps PG 111 14T:rw"'°'"' PUMP SPECIFICATIONS €94'..t-Airr-0- gib AF SECT. '200 - TAB 6" 1750 RPM 30 PGi,_.121 MODEL: AF125, 150, 180, 290, 360-4-6" (. GENERAL C ` Furnish and Install l Model AF _/5 0 • Lz. 3 G ABS Submersible Pumps) to deliver UBGPM against a total head 447 feet.The motor shall be 20 _HP /750 RPM connected for operation on a volt 60 HZ phase service.The motor shall be an integral part of the pumping unit.The pump discharge size shall be PUMP DESIGN The pump(s)shall be capable of handling raw unscreened sewage,storm water,and other similar solids-laden fluids without clogging.There shall be no need for personnel to enter the wet well in order to remove or reinstall the pumps. PUMP CONSTRUCTION Impeller:The impeller shall be made of gray cast iron and shall be of closed,non-clogging,dynamically balanced, S • vane design capable of passing a minimum of " .diameter spherical solids.The impeller shall have a slip fit onto the motor shaft and drive key and shall be fastened to the shaft by an impeller nut having a cover for protection from the pumped fluid.The impeller shall be totally enclosed with upper and lower shrouds. Wear Ring: Rubber wear ring shall be fitted into the volute.This wear ring shall be replaceable. Pump Volute:The pump volute shall be made of gray cast iron with smooth internal surfaces tree of rough spots or flashings. The volute shall have a centerline discharge for guide rail installations. Rotating Assembly:The rotating assembly(impeller,shaft and rotor)shall be statically and dynamically balanced such that undue vibration or other unsatisfactory characteristics will not result when the pump is in operation. Shaft: Each pump shaft and motor shaft shall be an Integral unit. Each shaft shall be 420 stainless steel material and ade- quately designed to meet the maximum torque required at any start-up condition or operating point in the system. Maximum shaft deflection shall not exceed .005" at shaft end. Each pump shaft shall have a polished finish and have accurately ma- chined shoulders to accommodate bearings,seals and impeller. Mechanical Seals:Each pump shall be equipped with a tandem mechanical seal running in an oil reservoir.The lower seal faces are silicone carbide.The upper stationary seal face shall be made of carbon and the rotating seal face of tool steel.The two faces shall be held in contact by two independent separately mounted springs. Each seal shall require neither routine maintenance nor adjustment and shall not be damaged when the pump is run dry. When required,seal oil inspection shall be achieved without disassembly of the pump.The seal shall not require the pumped liquid as a lubricant. Seal Failure Warning System:An electrical probe shall be provided in the oil chamber for detecting the presence of water.A solid-state device mounted in the pump control panel or in separate enclosure shall send a low voltage,low amperage signal to the probe. If water enters the oil chamber,the probe shall close an electrical circuit and energize a warning light on the face of the control panel. Bearings: Each pump shaft shall rotate on two (2)permanently lubricated bearings.The upper bearing shall be a single row grooved ball bearing and the lower bearing shall consist of a heavy duty double row angular contact ball bearing. Bearings shall be of sufficient size and properly spaced to transfer all radial and axial loads to the pump housing and minimize shaft deflection. B-10 bearing life shall be a minimum of 70,000 hours at design conditions. Motor:The pump motor shall be housed in an airfilled watertight housing of gray cast iron.The motor shall be NEMA design B suitable for continuous duty with moisture resistant Class F insulation rated for 155°C.Oil filled motors shall not be considered equal to the dry airfilled type nor acceptable. Additional cooling of the motor shall be provided by a circulating flow of water from the upper side of the impeller through the water jacket and back to the volute. Each phase of motor shall contain a bimetallic electromechanical temperature monitor embedded in the motor windings.The monitors shall be connected in series and coupled to the control circuit of the pump control panel so as to shut the pump down should any one of the monitors detect high temperature.The temperature setting of the temperature monitors shall be 140°C f 5°C and shall automatically reset once the stator temperature returns to normal. Cable Entry: The pump cable shall enter the connection housing by means of strain relief entry locked to the junction chamber and provided with anti-kink cable gland. Junction Chamber:The pump shall have a separate junction chamber containing a terminal board.The junction board shall contain threaded studs for making all connections between the motor leads and the cable. The junction chamber shall be sealed from the motor. Installation:The pump(s)shall automatically connect to discharge connection(s)when lowered into place on a single guide rail system,requiring no bolts,nuts or fasteners to effect proper sealing. Each system shall consist of no more than one guide rail supported at the top by an upper guide bracket and at the bottom by the discharge connection.The guide call base shall be calequipped with a vertical straightening vane which properly aligns the slot in the pump bracket and centers the pump just prior to final seating.Ease and quick removal of pumps from other than the vertical direction over the center of the pump shall be a requirement of the system. Rev. iw Pomp.Int • . 4/1/8 8 140 Pond vl.w Drive . .�-11"./ Supersedes New Issue 1/1/86 Meriden,ConnoodoutOM60 » SECT. 200 TAB sATV 6" through 10" pumps PG 141 11°311 $ 70° TECHNICAL DATA AF SECT. 200 TAB 6" 1750 RPM 3g PG......M......._ ( (�MODEL: AF125, 150, 180,290,360-4-6" APPLICATION DATA _ i MODEL 125 150 _ 180 Z20 340 SOLID SIZE - IN 3 3 3 , 3 3k 3/31/2 , , MINIMUM HEAD - FT. .. _ MINIMUM FLOW- BPM 300 300 300 3Q0 300 MAXIMUM SUBMERGENCE - FT, 90 90 90 90 90 PUMP WEIGHT- lbs. l 1505 1540 1 545 1 890 1 _965 I 1 1 1 PHYSICAL DATA POWER CABLE•TYPE HO7RN, Ozoflex or Type SO CONTROL CABLE-TYPE HO7RN, Ozoflex or Type SO CABLE,STANDARD LENGTH 3 — MOTOR HOUSING Cast Iron - ASTM A-48, Class 30 COOLING JACKET Cast Iron - ASTM A-48, Class 30 H OIL CHAMBER Cast Iron - ASTM A-48, Class 30 � VOLUTE Cast Iron - ASTM A-48, Class 30 c IMPELLER Cast Iron - ASTM A-48, Class 30 BOTTOM PLATE N/A a MOTOR SHAFT 420 S S EXTERNAL HARDWARE 304 SS -- "0" RINGS Buna N MECHANICAL SEAL•TYPE Tandem Seal, Silicon Carbide, Lower; Tool Steel/Carbon, Upper UPPER BEARING Single Row Ball LOWER BEARING Double Row Angular Contact Ball - Heavy Duty DISCHARGE SIZE 6" IMPELLER TYPE Closed Single Vane COOLING MEDIUM Pumped Medium PUMP PROTECTION TEMPERATURE MONITORING SYSTEM Bimetallic switches in winding. Installer must conform to N.E.C. Stds. , 1984 Ed. Article 430. WATER DETECTION SYSTEM Sealminder in Oil Chamber. Rev. 4-1-86 1140 MShogs sba VIew ^ I • • Supersedes Rev. 5-1-87 Meriden,CennestloutMAO "'a" ' SECT. 200 TABsAFW G" through 10" pumps PG 151 NWI»Bd700 TECHNICAL DATA SECT. 200' TAB 6" 1750 RPM 30 pa, `182 AF MODEL: AF125, 150, 180, 290, 360-4-G" (10, ) ELECTRICAL DATA MOTOR DESIGN NEMA TYPE B MOTOR TYPE Enclosed Submersible INSULATION CLASS F MAXIMUM STATOR TEMP. 1550 C RPM 1750 VOLTAGE TOLERANCE t 10% COOLANT CIRCULATION PUMP N/A S CP �.4V4çV fq,230 17 42 . 8 242 G 1. 1 0. 86 0 .83 0 . 73 84 . 9 84 .882.6 125 460 17 21. 4 121 G 1. 1 0. 86 0 . 83 0 . 73 84 . 9 84 . 8 82.6 600 17 16. 4 93 G 1. 1 0. 86 0. 83 0 . 73 84 . 9 84 .8 82 .6 230 20 , 50 .6 306 G 1. 2 0 . 85 0. 79 0 .68 87. 5 87.4 86 .0 41106. 460 20 25. 3 153 G 1. 2 0. 85 0. 79 0.68 87. 5 87.4 86.02) 600 20 19.4 117 G 1.2 0. 85 0.79 0.68 87 .5 87.4 86.0 230 24 60 . 4 310 F 1. 1 0. 86 0 . 84 0 . 74 86 .6, 87 .4 86 . 3 180 460 24 30 . 2 155 F 1. 1 0. 86 0 . 84 0 . 74 86 .6 87.4 86 . 3 , 600 24 23. 2 119 F 1. 1 0 . 86 0 . 84. 0 .74 86 .6 , 87.4 86 .3 , 230 39102 . 4 458 E 1. 1 0 . 80 0 .81 0 .76 ' 88 . 5 89.4 88 .4 290 460 39 51. 2 229 E 1. 1 0 . 80 0 . 81 0 .76 88 . 5 89.4 88 .4 600 39 39. 3 176 E 1. 1 0. 80 0 .81 0 .76 88 .5 89.4 88 .4 230 ' 48 123.4 562 E 1. 1 0. 82 0 . 84 0 .80 89. 4 90 .2 89.3 360 460 48 61. 7 281 E 1. 1 0 . 82 0 . 84 0 .80 89.4 90 . 2 89. 3 600 48 47. 3 215 E 1. 1 0 . 82 0. 84 0 . 80 89. 4 90 .2 89. 3 III ) Rev. 4-1-88 Supersedes Rev. 5-1-87 AU PumpsIns ii. SECT. 200 TAB: AFW 6" through 10" pumps PG 152 M Id;,°=int0I410 .r ; , (203)2311d700 ,qr .e 1 A j 4.11 •_' 3 • GUIDE RAIL INSTALLATION SECT. 200 TAB 6" 1750 RPM 30 pQ. 191 (. 0 DIMENSIONS MODEL: AF125, 50 180, 230, 290, 360-4-S" ` TYPICAL DRAWING ONLY,NOT FOR CONSTRUCTION PURPOSES.CONTACT FACTORY FOR CERTIFIED DRAWINGS. lI MINIMUM CLEAR OPENING LxW -►r0 .0- 4 "ii 1111 D V • , � 9 I' � -i- �-2 125N ASA i FLANGE •_ a A \ � it til N -I--- l -----1 L-1.41 I _ IIU a _1 1.75 J V ir/r Ai 4 R IE F Mil P rAilkial, ° isik- 4% -10 S 1PAI; • Mit, cm.,--ffs.41 N....._ H T ' e •WET END A C D E F GHJNOPR S T V L x W 022 26.50 15.66 27.16 13.00 6.66 7.95 9.41 9.88 21.39 3.63 .71 2.68 5.69 5.50 S 64 814 4 025 15.79 20.28 31.110 17.72 10.47 8.84 11.02 6.68 21.38 3.63 .71 2.68 6.68 6.60 0 40 NV 026 $5.78 20.28 31.80 17.72 10.47 6.64 11.02 8.88 21.38 3.63 .71 2.56 6.69 6.50 6 40II17 11110 OlmeMions In Inches. Revision 4-148 MS My.b. 140 Pond v DrIw ^ 41. II I ' • Supersedes Rev.5-147 Meriden.Connecticut 0460 •A"I•A IF Seel 100,TAB:AFW a"through 10"pumps page 171 (203)181.1700 NAI RUM Pe • Installation Operation & Maintenance Manual • Submersible Pumps AF-2 Models: AF 115-6 AF 125-4 AF 150-4 AF 180-4 1 ABS Pumps inc. +ems Section 200 140 Pond View Drive - Page 1 Menden.Connecticut 06450 P u M P • i July 1, 1982 (203)238-2700 III 1CI III'1'I rirQg /!4 (((1cUM G °Walrtal+ ...., ...Z. FIVE-...., YEAR WARRANTY - STANDARD & EXPLOSION PROOF AFP & AF SERIES PUMPS PERMANENT TYPE INSTALLATION ABS Pumps Inc.warrants its AFP&AF Serie .- sof Submersible Pumps to be free from defects _ in workmanship and materials for a period of five (5) years after date of shipment to end customer, with approval of installation and start-up of the equipment by the Company's • - - authorized on-site representative and, upon payment of the applicable percentage of the list - - price of the following parts in effect at time of replacement. - Part Description Months After Shipment ' - 0-18 19-31 32-45 46-60 - Rotor& Stator 0% 25% 50% 75% • Mechanical Seal 0% 25% 50% 75% - -= Impeller 0% 25% 50% 75% : - Cutter Disc 0% 25% 50% 75% • - Pump Housing , 0% 25% 50% 75% ' - Ball Bearings 0% 40% 80% 90% -_ SStator guarantee etfectrve only if Company's authorized control panels are used. • All other ABS manufactured equipment or other uses of AFP or AF series pumps will carry a one (1)year warranty from date of shipment to end customer, but in no event. longer than M eighteen(18) months from date of shipment from the Company. Start-up reports and electrical hem system y schematics may be required to support Warranty me:=:, claims and will be required for claims on pumps of 30 horsepower and greater. The Company's sole obligation under this warranty shall be to make repairs and replace _ parts when necessary on products that have been returned to it or to an authorized service - facility and found to be defective by the Company. Explosion Proof pumps (EX) must be �'_ serviced at a facility approved by ABS Pumps Inc. The Company shall not be liable for any ' - -•' special, indirect, or consequential damages of any kind. Major components not manu- - • factured by the Company are covered by the original manufacturer's warranty in lieu of this -- _. warranty. The Company will not be held responsible for travel expenses, rented equipment, - outside contractors fees, or unauthorized repair shop expenses. The Company neither :: assumes nor authorizes any person or other company to assume for it, any other obligation - in connection with the sale of its equipment. Any enlargement or modification of this _ Warranty by a Representative or other Sales Agent is their exclusive responsibility. Trans- - portation charges shall be borne by the Buyer. Labor charges for warranty repairs shall not , 1 be assumed by the Company for repairs made after one (1) year from date of shipment to end customer. Returns must have prior written authorization from the Company. This warranty shall extend only to the original Owner,and shall not apply to any products that — _ have been repaired or altered without the Company's consent or have been subject to misuse,accident or neglect,or have been used for pumping other than raw sewage or similar • - non•corrosive liquids. NO OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING IMPLIED WARRANTIES OF - MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WILL APPLY. I I 1'1 TIT 1'1 t1'1'1f1 1 1 11'1�•1'•I'1i1s'Ifillt•l'•I'I''IsI'��1 I'•I •I$I'Ifl1lf!1$t1i��$1$111$11$11'1$ 't/ !$ , 410 Supersedes Section 200 Page 1,Dated April 1, 1080 • Table of Contents WARRANTY SECTION 1 INSTALLATION 1 1-1 INTRODUCTION 1 1-2 DESIGN OF PUMP 1 1-3 INSPECTION UPON RECEIPT 1 1-4 STORAGE BEFORE USE 1 Long Term Storage 2 1-5 PUMP INSTALLATION 3 1-6 PUMP INSTALLATION-DRY PIT 3 FIGURE 1-1 GUIDE RAIL INSTALLATION 3 FIGURE 1-2 DRY PIT INSTALLATION 3 SECTION 2 ELECTRICAL CONNECTIONS 4 2-1 PUMP CONNECTIONS 4 2-2 PUMP CONTROLS 4 2-3 ENERGIZING THE PUMP 4 FIGURE 2-1 PUMP WIRING DIAGRAM 230 VOLT 3 PHASE 5 FIGURE 2-2 PUMP WIRING DIAGRAM 460 VOLT 3 PHASE 5 FIGURE 2-3 ABS SEALMINDER WIRING DIAGRAM-LAMP OUTPUT 6 FIGURE 2-4 ABS SEALMINDER WIRING DIAGRAM-RELAY OUTPUT 6 110 SECTION 3 START-UP 7 3-1 IMPELLER ROTATION 7 3-2 INITIAL CURRENT CHECK 7 3-3 CURRENT UNBALANCE 8 3-4 VOLTAGE UNBALANCE 8 3-5 PRODUCT START-UP REPORT 8 SECTION 4 OPERATION&MAINTENANCE 9 4-1 OPERATION 9 42 PREVENTIVE MAINTENANCE 9 Cable Inspection 9 Seal Oil Check 9 4-3 LUBRICATION 9 4-4 SEAL OIL CHECK 9 4-5 DRAINING THE SEAL OIL 9 (cont'd) P it • Table of Contents (coM'd) SECTION 5 MAINTENANCE PROCEDURES 10 5-1 VOLUTE REMOVAL 10 5-2 WEAR RING REMOVAL 10 5-3 IMPELLER REMOVAL 10 5-4 COOLING JACKET REMOVAL 10 5-5 MOTOR HOUSING REMOVAL 10 5-6 TERMINAL CHAMBER REMOVAL 10 5-7 CABLE REMOVAL 11 5-8 LOWER MECHANICAL SEAL REMOVAL 11 5-9 UPPER MECHANICAL SEAL REMOVAL 12 5-10 ROTOR&BEARING REMOVAL 12 5-11 STATOR REMOVAL 12 5-12 STATOR INSTALLATION 12 5-13 ROTOR&BEARING INSTALLATION 13 5-14 UPPER MECHANICAL SEAL INSTALLATION 13 5-15 LOWER MECHANICAL SEAL INSTALLATION 13 5-16 CABLE INSTALLATION 14 5-17 TERMINAL CHAMBER INSTALLATION 14 • 5-18 MOTOR HOUSING INSTALLATION 14 5-19 COOLING JACKET INSTALLATION 15 5-20 IMPELLER INSTALLATION 15 5-21 WEAR RING INSTALLATION 15 5-22 VOLUTE INSTALLATION 15 5-23 LEAK TESTING 15 PARTS LEGEND 16 FIGURE 5-1 CROSS SECTION VIEW 17 FIGURE 5-2 UPPER MECHANICAL SEAL DETAIL 18 FIGURE 5-3 LOWER MECHANICAL SEAL DETAIL 18 TROUBLESHOOTING CHART t9 • ii "'SECTION 1 INSTALLATION 1-1 INTRODUCTION 1.3 INSPECTION UPON RECEIPT This manual was prepared to assist you in the Inspect the shipping container immediately for correct installation,operation,and maintenance of damage that may have occurred in shipment. Ex- your ABS pump. Please read it completely before ercise care in opening the shipping container to installing the pump. Make certain that you are avoid damage to the pump. Remove any blocking familiar with the contents.and that the chapters on and packing from within the container. Check all installation and start-up are fully understood before packing for spare parts before discarding.Visually running the pump. check the pump and any spare parts for damage. Check for damaged electrical wires, especially ABS pumps are designed for minimal main- where they exit the motor housing. Report any tenance. However, regular checks will ensure damage or shortage of parts to your supervisor or longer life and greater operating reliability. directly to the carrier. WARRANTY:The ABS warranty is contingent on proper pump start-up.In orderto validate warranty, 14 STORAGE BEFORE USE the PRODUCT START-UP REPORT must be com- p�eted and returned to ABS Pumps, Inc. ABS pumps are shipped from the factory ready for installation and use.They should be held in storage No repair work should be carried out during the if the pump station is not complete. If storage is warranty period without prior factory approval. To necessary,the pump should remain in its shipping do so will render the warranty void. container. It should be stored in a warehouse or NO.: In all correspondence and reports, storage shed that has a clean, dry, temperature- SERIALstable area where the pump and its container make certain that the pump serial number is given. should be covered to protect it from water,dirt,dust, etc. 1-2 DESIGN OF PUMP 4) LABS submersible pumps are designed for con- THE ENDS OF THE CABLES MUST BE 9 PROTECTED AGAINST MOISTURE. KEEP tinuous underwater operation. The motor and THEM SEALED AND DRY. pump form a close coupled,watertight unit capable of operating while submerged to a maximum depth of 65 feet. The squirrel cage induction motor is insulated against heat and moisture in accordance CAUTION I with Class"F"(155°C)regulations. AT NO TIME SHALL THE PUMP BE 2.Thermal overload protectors (one per phase) are STORED WITHIN AN INCOMPLETE WET imbedded in the stator windings. These are con- PIT.THE PUMP SHALL NOT BE PLACED nected in series and wired to the control panel to INTO THE PIT UNTIL IT CAN BE FULLY shut down the pump if overheating occurs. INSTALLED AND OPERATED. 3.The motor is protected against damage from water entry by an oil chamber and mechanical seal lo- cated at the impeller drive. A moisture probe is Prior to installation,the impeller should be rotated located in the oil chamber. When coupled to the by hand to ensure the mechanical seals are free- ABS Sealminder Module, the probe provides a spinning. signal which gives a warning that water is in the oil chamber and an inspection is necessary. Long Term Storage 4.The impeller is designed for efficient flow charac- 1.If It is necessary to store a pump for a long period teristics and clog-tree operation. of time, it should be stored indoors in a clean,dry 5temperature-stable environment.The pump should S.The pump motor is cooled by the pumped media, be covered to protect it from dust, dirt and water. circulated by vanes on the back of the impeller.The The ends of the cable must be protected against media flows through a cooling jacket surrounding moisture. the motor housing. 4110 2.Do not allow the pump to freeze. Water trapped during quality testing may expand and cause damage.if the pump must be stored In a sub-freez- Ing environment, consult the factory for specific recommendations and precautions. 1 • • • 3.During storage,the motor should be rotated a few 2.As the pump nears its final position,the straighten- turns once a month. This can be accomplished by ing vane squares the pump bracket with the guide turning the impeller by hand.Rotating the motor will bracket ears.The chain will slacken when the pump lubricate the mechanical seals and prevent their bracket ears have fully engaged the guide bracket seizing. ears. 4.Prior to installation, the pump motor should be 3.Grasp the lifting chain and shake the pump to rotated by hand to ensure the mechanical seals are ensure a good seat with the gasket. free-spinning. 4.The lifting chain may be removed from the hoist and 5.Installed pumps which are idle for long periods of hooked near the upper guide rail bracket. time should be started and run for a few seconds once a month to lubricate the mechanical seals. 5.Do not leave any slack in the lifting chain or cables which would allow them to be caught up in the 6.Installed pumps which have been idle for longer impeller. than one month should be lifted from the wet well before being started. The impeller should be rotated by hand to ensure the mechanical seals are free-spinning.The pump should then be reinstalled and started. CAUTION I i� BE CERTAIN THE CONTROL PANEL HAS BEEN TESTED AND OPERATES CORRECTLY BEFORE APPLYING � • • -r� • POWER TO THE PUMP. 1 , •%lio 1-5 PUMP INSTALLATION rr •+ CAUTION ! NEVER LIFT THE PUMP BY PULLING ON THE CABLE. USE THE LIFTING CHAIN ONLY. AC•] 1.Using the lifting chain, slip the pump bracket over the upper guide rail bracket.Lowerthe pump angle down the guide rail into the wet well. CAUTION! PRIOR TO PLACING THE PUMP INTO OPERATION, A PRODUCT START-UP U i PROCEDURE SHALL BE COMPLETED BY AUTHORIZED PERSONNEL.FAILURE TO 1 COMPLETE THE PRODUCT START-UP N\\ REPORT REPORT WILL VOID THE WARRANTY.A • COPY OF THIS REPORT IS FURNISHED WITH EACH PUMP. FIGURE 1-1 GUIDE RAIL INSTALLATION 2 • NOTE 3.When re-installingthe pump into the volute,keep The pumped media temperature must not the motor plumb. Guide the impeller into the wear exceed 104°F. The major material of ABS ring. Refer to SECTION 5-22. pumps is cast iron.They should not be used to pump corrosive liquids. CAUTION 1.6 PUMP INSTALLATION-DRY PIT TO AVOID EXCESSIVE TEMPERATURES, 1.The pump is shipped installed on the pedestal with DRY-PIT PUMPS MUST NOT BE bolts and spring washers.Connect the inlet piping EXPOSED TO DIRECT SUNLIGHT to the elbow using a flat gasket. Connect the dis- DURING OPERATION. THE MAXIMUM charge piping to the volute discharge flange using AMBIENT TEMPERATURE MUST NOT a flat gasket. Do not allow the pump to carry any EXCEED 40°C. weight of the piping. 2.When performing maintenance,the pump may be lifted from the volute, leaving the volute mounted and connected to the piping. Close all valves and drain the cooling jacket into the discharge piping before removing the pump.Refer to SECTION 5-1. CAUTION I THE INSTALLATION MUST NOT ALLOW THE PUMP TO CARRY ANY WEIGHT OF • THE PIPING. fes-" r41 /Nu • FIGURE 1-2 DRY PIT INSTALLATION 3 •SECTION 2 ELECTRICAL CONNECTIONS • CAUTION CAUTION ! ELECTRICAL CONTROL PANELS UNDER NO CIRCUMSTANCES SHALL SHOULD BE SERVICED ONLY BY A ANY MOTOR OR CONTROL LEAD BE LICENSED ELECTRICIAN. SPLICED AT A SUBMERGED POINT OR IN ANY WET LOCATION THAT WILL ALLOW WATER TO ENTER THE CABLE. Refer to the wiring diagrams supplied with the control panel for connection and location of actual 2.2 PUMP CONTROLS components. Follow the current edition of the Na- tional Electrical Code, as well as local electrical 1.There are too many variations of control systems codes and ordinances. to describe in this manual. Pumps may be used in single or multiple pump installations,in wet wells or dry pits.Typical installations start and stop pumps CAUTION ! with float switches.Other automatic control devices TURN OFF POWER AHEAD OF CONTROL may also be used.Manual control switches may be PANEL BEFORE PERFORMING ANY used in place of or to over-ride automatic systems. MAINTENANCE IN THE PANEL. CHECK Refer to the control panel wiring diagrams supplied INCOMING LINE TERMINALS WITH A with the control panel for pump connections,instal- VOLTMETER TO BE POSITIVELY SURE lotion and troubleshooting. THAT THE EQUIPMENT IS TOTALLY DE-ENERGIZED. MAIN SWITCHES CAUTION SHOULD BE LOCKED OFF AND TAGGED • FOR SAFETY. NO PUMP STATION SHOULD BE DESIGNED TO EXCEED 10 EVENLY- SPACED STARTS PER HOUR PER PUMP. 2-1 PUMP CONNECTIONS 1.The motor voltage rating of the pump is shown on the nameplate of the pump. Check that it is the 2-3 ENERGIZING THE PUMP same as the supply voltage.The connection of the 1.Energizing electrical equipment for the first time is pump cable leads should be carried out by a potentially dangerous.The control panel should be licensed electrician in accordance with the iden- fully tested before applying power to the pump. tification on the individual leads and the cor- responding connections in the control panel. Refer 2.Licensed electrical personnel should be present to the Pump Wiring Diagram. when the pump is energized for the first time. If faults caused by damage or poor installation prac- 2.The thermal overload protectors must be wired in tices have not been detected,serious damage can series with the motor starter to interrupt the starter result when power is applied. circuit if the pump motor temperature exceeds safe limits. 3.The moisture probe lead must be connected to the CAUTION ! ABS Sealminder Module at the control panel.Refer BE CERTAIN THE CONTROL PANEL HAS to the Sealminder Wiring Diagram. BEEN TESTED AND OPERATES CORRECTLY BEFORE APPLYING POWER TO THE PUMP. CAUTION I IF THE ABS SEALMINDER RELAY AND • THERMAL PROTECTION FEATURES ARE NOT PROPERLY CONNECTED,THE WARRANTY WILL BE VOID. 4 0 rN- �N O — N n 1 • a W < V) mCi _ , f_p 0 2 8�' n c cn p Oa Q a. Z< N o I Q Q s UV + i & Wi f 2- J c W� Z Q W O s 0 S O z m 0_ N 2 Q - �`' Ucr • a a ce N CD O>' Z a o N Q Z \ 1 I 0 = 0 cr o aixoN 3 i,2> _ � z a Lu 2 o JI Q N am ' � >� J W< J 2 m 0 L 51 J U • c ____0, — N n 0 cc Ii O W n N Q aI 1 I f� z 4 i N v o r �� Q O 2 a r, CD I w cc J o FE > 2 z` m a v 8 cc < .-1et N 4 I r.'. �Ni Z• Q 1 I i g ' _6 i Er. a mon. g F• .- -T g" o N cv1 i g , L.. .1 _I 0 5 • FROM POWER SOURCE CUSTOMER BLACK SUPPLIED BLACK //COMPONENT ABS M WHITE r------( I SIGNALLAMP SEALMINDER YELLOW I 0 I 24V 2-5W MODULE + L---J GREEN 3 BLUE GROUND MOISTURE PROBE - WWP NOTE: THE SEALMINDER MODULE MUST BE RATED FOR THE POWER SUPPLY VOLTAGE • FIGURE 2-3 ABS SEALMINDER WIRING DIAGRAM-LAMP OUTPUT FROM POWER SOURCE CUSTOMER BLACK SUPPLIED BLACK /COMPONENTS ABS M WHITE SEALMINDER Cl I Cl: 10-100uf 63V YELLOWI 1CR: 24VDC MODULE + I 1-8KOHM ♦ GREEN L J 5VA MAX. 3 BLUE GROUND MOISTURE PROBE - WWP • NOTE: THE SEALMINDER MODULE MUST BE RATED FOR THE POWER SUPPLY VOLTAGE FIGURE 2.4 ABS SEALMINDER WIRING DIAGRAM-RELAY OUTPUT 8 SECTION 3 START-UP 03-1 IMPELLER ROTATION 3-2 INITIAL CURRENT CHECK 1.After the electrical connections are completed,and After ensuring that the pump is rotating in the fully tested, the motor rotation must be checked. correct direction,the amount of current draw must Incorrect rotation will result in low flow and can be measured for each phase.Run the pump under damage the motor. water.simulating normal operating load conditions. 2.Suspend the pump Take current readings on the motor leads of each from a lifting chain. phase at the control panel terminal strip. Record Withm power applied n. the readings on the Product Start-up Report. If the R 7--1� ,� 2 the control pnel,start measured value is higher than the rated F.L. Y the pump for only a AMPS" value, notify the ABS Product Service Q second. The rotation Department immediately. z arrow and start reac- tion arrow are cast into the top of the motor CAUTION I sl ,\o� housing. The rotation CURRENT UNBALANCE BETWEEN SRT REPS is correct if the start PHASES SHALL NOT EXCEED 4%. reaction is in the same CONSULT THE FACTORY WHEN direction as the arrow. CURRENT UNBALANCE EXCEEDS 4%. THE PERCENT OF CURRENT UNBALANCE IS DEFINED AND CAUTION! CALCULATED IN THE CURRENT UNBALANCE EQUATION. WHEN APPLYING POWER TO PUMP. STAND CLEAR OF THE UNIT SINCE INJURY CAN BE SUBSTAINED BY • ROTATING THE PUMP. 3.1f the rotation is incorrect, disconnect power AHEAD of the control panel.Interchange two pump power leads at the terminal strip.Apply power and re-check the rotation. Do not switch incoming power supply line leads as this will affect all pumps in multiple installations. CAUTION ! PRIOR TO PLACING THE PUMP INTO OPERATION, A PRODUCT START-UP PROCEDURE SHALL BE COMPLETED BY AUTHORIZED PERSONNEL.FAILURE TO COMPLETE THE PRODUCT START-UP REPORT WILL VOID THE WARRANTY. A COPY OF THIS REPORT IS FURNISHED WITH EACH PUMP. 110 7 • 3-3 CURRENT UNBALANCE VOLTAGE UNBALANCE EQUATION After ensuring that the pump is rotating in the % MAX.VOLTAGE correct direction, and the current draw is within VOLTAGE = DIFFERENCE X100 specifications, the amount of current unbalance UNBALANCE FROM AVERAGE between phases must be calculated.Run the pump AVERAGE VOLTAGE underwater,simulating normal operating load con- ditions. Perform the measurements and calcula- EXAMPLE tions of the current unbalance equation. Enter the results of the current unbalance calculation on the 1• MEASURE THE VOLTAGE(IN VOLTS)BETWEEN PHASES Product Start-up Report. AT THE POWER SUPPLY INPUTS: CURRENT UNBALANCE EQUATION L1-L2=231 V L2-L3=230 V L1-L3 in 228 V %OF MAX.CURRENT 2. AVERAGE = 231+230+228 = 229.7 VOLTS CURRENT = DIFFERENCE X100 VOLTAGE 3 UNBALANCE FROM AVERAGE AVERAGE CURRENT 3. MAXIMUM VOLTAGE DIFFERENCE = 229.7-228 = 1.7 VOLTS EXAMPLE FROM AVERAGE 1. MEASURE THE CURRENT(IN AMPS)OF EACH PHASE 4. ACTUAL AT THE CONTROL PANEL TERMINAL STRIP: VOLTAGE = 1,7 X 100 = 0.7% T1 =10.0 AMPS T2=10.5 AMPS T3= 10.5 AMPS UNBALANCE 229.7 2. AVERAGE Is 10.0+10.5+10.4 = 10.33 AMPS The voltage unbalance for this installation is 0.7%, CURRENT 3 1110 within limits. If the unbalance between phases exceeds 1.0%, notify the power company. If the 3. MAXIMUM CURRENT voltage unbalance cannot be corrected to within DIFFERENCE or 10.33-10.0 is .33 AMPS 1.0% and the current unbalance exceeds 4.0%, FROM AVERAGE consult the factory immediately. Do not operate 4. ACTUAL the pump. CURRENT = ,33 X 100 = 3.2% UNBALANCE 10.33 3-5 PRODUCT START-UP REPORT The current unbalance for this installation is 3.2%, The ABS Product Start-Up Report contains space within specifications. If the unbalance between for information relating to the pump in the specific phases exceeds 4.0%,consult the factory imme- installation. diately.Do not operate the pump.Enterthe results of the current unbalance equation on the Product The Product Start-Up Report also provides the user Start-Up Report. of a record of the initial conditions of the pump and control system at the time of installation. 34 VOLTAGE UNBALANCE If there are ever any questions or problems relating If the current unbalance exceeds 4%, a possible to the pump,The ABS Product Service Department cause could be unbalanced voltage between will use the information provided in the Product phases. Perform the measurements and calcula- Start-Up Report to trouble-shoot the installation tions of the voltage unbalance equation. If voltage and assist the user. unbalance exceeds 1%, the power company A complete Product Start-Up Report will enable should be notified. ABS to evaluate the entire installation and provide the best assistance to the user. • The Product Start-Up Report is also required to support warranty claims. It Is important that the Product Start-Up Report be filled out completely by authorized personnel and returned to ABS Pumps. Be sure to keep a copy for your records. e • SECTION 4 OPERATION & MAINTENANCE 4-1 OPERATION 4-4 SEAL OIL CHECK After the electrical and mechanical installations 1.With the pump upright, remove the oil plug (2000) have been performed, and the Product Start-up and sealing ring(4600)on the side of the oil cham- Report completed,the pump is ready for operatbn. ber(0040). The oil level should be approximately No operational procedures are required except to even with the oil plug threads. apply rated power to the pump. There are no 2.Drain off a small quantity of oil.If the oil is clean,no specific shutdown procedures beyond disconnect- ing the power supply. further checks are necessary. Replenish the oil. Apply a non-hardening thread sealer to the oil plug. 4-2 PREVENTIVE MAINTENANCE Using a new sealing ring, replace the oil plug. ABS pumps are designed for long lasting,efficient 3.If the seal oil has become discolored or appears and reliable service with a minimum number of milky, drain off all the oil and refill with the correct preventive maintenance checks.These checks are quantity of new seal oil. few but will add years of satisfactory service to the 4.A further check should be made after an interval of life of the pump. Maintenance checks should be three weeks. If the oil has again become dis- performed at the intervals stated.Severe operating colored,the motor housing(0010)should be check- environments will require more frequent checks. ed for water entry. 5.Remove the plug (2000) and sealing ring (4600) CAUTION I from the side of the cooling jacket. Turn the pump to drain off any water from the motor housing.If no UNDER NO CIRCUMSTANCES SHOULD water is present, apply a non-hardening thread TOOLS BE APPLIED TO THE PUMP AND sealer to the oil plug. Using a new sealing ring, MOTOR WITHOUT THE POWER TO THE replace the oil plug. CONTROL BOX BEING DISCONNECTED 6.If water is present, the motor housing should be AND LOCKED OFF. removed to inspect for evidence of water damage. The mechanical seals(3800)and(3900)should be Cableinspected for evidence of damage and possible buipectIon replacement. The cable should be inspected for evidence of chafing, cuts or abrasion whenever the pump is 4-5 DRAINING THE SEAL OIL removed from the wet well. The area where the 1.Lay the pump on Its side with an oil plug (2000) cable enters the terminal chamber should be ex- amined carefully. If damage is found, the cable facing down. should be replaced. 2.Remove an oil plug and sealing ring(4600). Drain off the seal oil.The other oil plug and sealing ring Seal 011 Check should be removed to vent the oil chamber. The seal oil in the oil chamber should be checked 3.Replace with 3.7 Quarts of new seal oil. DO NOT at twelve (12) month intervals or when the seal OVERFILL alarm signal is given. Change the seal oil when contaminated by water. 4-3 LUBRICATION BALL BEARINGS: Permanently Lubricated MECHANICAL SEAL: Lubricated by the seal oil. SEAL OIL: 10W High Detergent Oil Oty: 3.7 Quarts(3.5 liters) • 9 SECTION 5 MAINTENANCE PROCEDURES • 5-5 MOTOR HOUSING REMOVAL NOTE CAUTION! Drain the seal oil from the oil chamber before NO REPAIRS SHALL BE MADE TO PUMP disassembling the pump. DURING WARRANTY PERIOD WITHOUT PRIOR FACTORY APPROVAL.TO DO SO 1.Remove the screws (1003) and span WILL VOID THE WARRANTY. ANY 9 washers REPAIRS SHALL BE MADE BY AN (3300)securing the motor housing(0010)to the oil AUTHORIZED ABS SERVICE chamber(0040). REPRESENTATIVE. 2.Remove the motor housing by prying or tapping away from the oil chamber. 5-1 VOLUTE REMOVAL 3.Pull the motor housing away from the bearing cover 1.Use the hoist to set the pump vertically on a solid (0760). surface.Keep the hoist attached to the lifting eye. 4.Disconnect the lead from the moisture probe as- 2.Remove the screws (1000) and spring washers sembly(0510)using long-nosed pliers. (3330) securing the volute (0200) to the motor 5.Remove the 0-Ring(4430)from the bearing cover housing(0010). perimeter. 3.Litt the motor housing from the volute with the hoist. 6.Remove the 0-Ring(4460)from the upper bearing 4.Remove the 0-Ring(4400). bore in the motor housing. 7.Remove the sealing rings (4480) from the cooling 5-2 WEAR RING REMOVAL system ports in the oil chamber. 1.The wear ring (0220) is a press-fit into the volute 8.If removal of the moisture probe assembly is re- (0200).It is not necessary to replace the wear ring quired,push it downward out of the bearing cover. unless it is severely worn or damaged. 9.It is not necessary to remove the groove pin(6100) 2.Pry the wear ring out of the volute. from the bearing cover unless replacement is re- quired. 5-3 IMPELLER REMOVAL 5.6 TERMINAL CHAMBER REMOVAL 1.Remove the impeller screw, right hand thread, (1200) and spring washers (3331). Remove the 1.Remove plug(2010)to provide a vent. impeller washer(0480). 2.Remove the screws (1002) and spring washers 2.Pull the impeller(0160)from the rotor shaft(0030). (3310) securing the terminal chamber lid(0410)to Remove the impeller key(4800)from the shaft. the terminal chamber(0350). 3.Pry the terminal chamber lid from the terminal 5-4 COOUNG JACKET REMOVAL chamber.Remove the 0-Ring(4450)from the lid. 1.Remove the screw (1004) and sealing washer 4.Disconnect all of the cable leads and jumpers (4610) at the top of the cooling jacket (0280) to (9102)from the terminal board(9030)by removing provide a vent for draining the cooling jacket.Drain hex nuts(2520)and washers(3000). the cooling jacket. Remove the circlip(5420) from the top of the cooling jacket. 2.Pry or tap the cooling jacket(0280)upwards to free CAUTION I the 0-Rings (4440) and (4410). Lift the cooling BEFORE DISCONNECTING ANY LEADS, jacket up from the motor housing(0010). MAKE SURE THEY ARE IDENTIFIED AND 3.Remove the 0-Rings(4440)and(4410). MARKED. • 10 3.With the cable leadsi d sconnected from the ter- 5.Remove the screws (10 70) and spring washers minal boards, pull the cable (9120) or(9121) and (3210) securing the terminal board to the bracket the cable seal(0400)and(0401)from the terminal (0470). Remove the terminal board. chamber. 6.Remove the screws (1070) and spring washers 5-8 LOWER MECHANICAL SEAL REMOVAL (3210)securing the terminal board bracket(0470) to the housing. The mechanical seal (3800) may be reused it un- 7.Remove the screws(1820),spring washers(3395) damaged. The seals must be replaced as a and clamp(9060)securing the ground leads to the matched set. Be careful not to scratch the seal housing, faces or the rubber seal parts during disassembly. Handle the seals with clean hands.Never touch the 8.Disconnect all of the leads from the small terminal seal faces as oils and acids in the skin can etch the strip(9020). surface. Refer to Figure 5-3, Lower Mechanical 9.Remove the screws (1820) and spring washers Seal Detail. (3395) securing the small terminal strip. Remove the small terminal strip. CAUTION ! 10.Remove the screws (1002) and spring washers WHEN REMOVING THE MECHANICAL (3310)securing the terminal chamber to the motor housing(0010). SEAL, BE CAREFUL NOT TO TOUCH OR SCRATCH THE SEAL FACES. 11.Loosen the screw(1250)compressing the stator- lead seal (0860). Loosen the covers (0870) and push the assembly out of the terminal chamber. 1.Drain the oil from the oil chamber(0040). 12.Pull the terminal chamber(0350) out of the motor housing, leaving the stator-lead seal attached to 2.Remove the support washer (5610) below the the stator leads. mechanical seal. Remove the rubber cup and the compression spring. In the case where the spring 13.Clip the wire lugs(9070)and(9071)from the stator is integral with the seal it should be removed as a leads. Pull the leads through the stator-lead seal unit. assembly. 3.Coat the shaft with seal oil. Pull the rotating as- 14.Remove the hex nut (2520) and spring washer sembly of the mechanical seal away from the sta- (3000)from the screw(1250). Remove the covers tionary seal face. If it will not release, pry with two (0870)from the stator-lead seal(4610). screwdrivers 180'apart.With a continuous twisting t 5.Remove the 0-Ring(4470). motion, slide the rotating part of the seal off the shaft. 5-7 CABLE REMOVAL 4.Tap the oil chamber away from the bearing cover The steps for servicing the cables apply to the (0760). Remove the oil chamber carefully to avoid control cable and the power cables. damage to the stationary mechanical seal. 1.Loosen the two triangular head screws on the cable 5.Press the stationary face of the mechanical seal out of the oil chamber. Remove the rubber boot from inlet (0380) or (0381). Loosen the strain relief the oil chamber. clamp. 2.Unscrew the cable inlet from the terminal chamber (0350). CAUTION! BEFORE DISCONNECTING ANY LEADS MAKE SURE THEY ARE IDENTIFIED AND • MARKED. 11 UPPER MECHANICAL SEAL 4,-9REMOVAL 2.M easure the depth the stator securing ecuri Refer to Figure 5-2,Upper Mechanical a screw l9ppe Seal Detail. holes. This measurement will be needed for reinstallation. CAUTION ! 3.Disconnect stator leads from terminal block as WHEN REMOVING CIRCLIPS, BE described in Section 5-6. CAREFUL NOT TO SCRATCH THE 4.Using a torch with a wide flame,apply heat quickly SHAFT. THIS IS ESPECIALLY and evenly to the motor housing,in order to expand IMPORTANT WHERE THE LIP SEALS the motor housing but not the stator(0020). if the MAKE CONTACT. stator does not drop freely from the motor housing, it may be freed by grasping the motor housing with insulated gloves, picking it up and ramming it 1.Remove the circlip(5420)from the shaft. STRAIGHT down with the edges of the housing striking wooden blocks. DO NOT STRIKE THE 2.Coat the shaft with seal oil. Pull the rotating face of HOUSING ON A HARD SURFACE. If the heating the mechanical seal away from the stationary seal procedure is not performed quickly,it is necessary face. If it will not release,pry with two screwdrivers to allow the assembly to cool to room temperature 180'apart.With a continuous twisting motion,slide before repeating. the rotating part of the seal off the shaft. 3.Remove the screws (1001) and spring washers CAUTION I (3310) securing the transition piece (0050) to the TAKE PRECAUTIONS TO ALLOW NO bearing cover(0760). DAMAGE TO STATOR WINDINGS OR 4.Remove the transition piece carefully to avoid LEADS. damage to the stationary mechanical seal. 41)5.Remove the 0-Ring (4460) from the transition piece. 5-12 STATOR INSTALLATION 6.Press the stationary mechanical seal assembly as a unit out of the transition piece. NOTE 5-10 ROTOR& BEARING REMOVAL Clean all parts thoroughly before assembly. Special attention should be paid to 0-Ring 1.Full the upper bearing (5000) from the rotor shaft grooves, mating surfaces and seal contact (0030). areas.Inspect these areas carefully for burrs or dents which may cause leakage. 2.Remove the circlip(5400)from the shaft. Remove the lower support washer(5600). 1.Coat the 0-Ring (4440) with seal oil. Install the 3.Support the bearing cover(0760)on a press table. 0-Ring into the groove in the upper bearing bore at Press the rotor and shaft out of the lower bearing the top of the motor housing(0010). (5100). 4.Turn the bearing cover over.Press the lower bear- NOTE ing with the upper support washer (5600) and safety ring(5210)out of the bearing cover. Use new seals and 0-Rings during assemb- 5.Remove the 0-Ring(4460)from the bearing cover. ly to safeguard against leaks. 5.11 STATOR REMOVAL 2.Heat the motor housing as described for stator 1.Remove the silicone sealant(0400)from the stator removal. Orient wires and check for grooves then drop in stator(0020)Into the motor housing(0010). screw bores. Remove the stator securing screws Apply force.to the ;,fetor frame only. DO NOT (1050)and sealing washers(4610). PRESS ON THE WINDINGS. 411 12 ill 3.Drill the stator screw pilot holes to the depth pre- 1.Thoroughly clean the shaft (0030) and the transi- t viously measured.Tap threads using a bottoming tion piece(0050) bore. tap. Apply a non-hardening thread sealer to the stator securing screws (1050). Install screws and 2.Coat the seal faces with seal oil.With a clean piece new sealing washers(4610). of paper between the seal face and fingers,press the seal assembly firmly into the seat on the tran- 4.Fill the screw counter bore with silicone sealant. sition piece with finger pressure. Once the unit has been freon checked. 3.Coat the 0-Ring (4460) with seal oil. Install the 5-13 ROTOR&BEARING INSTALLATION 0-Ring onto the transition piece. 1.Support the bearing cover(0760),upside down,on 4.Place the transition piece carefully to avoid damage to the stationarymechanical seal.Install the transi- a press table.Place the safetyring(5200)first,and then the upper support washer(5600)in the bear- tion piece (0050) to the bearing cover(0760)with ing cover. screws(1001)and spring washers(3310). 2.Centralize the support washer and safety ring in the 5.The rotating seal part is installed with the three bearing cover. Check the bearings are properly holes facing away from the stationary seal face. greased. Press the lower bearing (5100) into the Coat the mechanical seal rotating part and the shaft bearing Dover. with soapy water. With a continuous, twisting mo- tion, slide the seal along the shaft until the seal 3.Tum the bearing cover over. Support the bearing faces contact.If the rubber boot rolls out from under on the press table. the seal, it must be restarted. Take care not to cut 4.Press the rotor and shaft into the lower bearing.The the boot on the shaft shoulders and grooves. upper support washer must be fully seated against 6.Compress the seal spring and install the circip the shoulder on the shaft and the lower q•bearing. onto the shaft. (5400) • 5.Place the lower support washer(5600)on the shaft againstthe bearing. 5-15 LOWER MECHANICAL SEAL INSTALLATION 6.Install the crclip(5400)onto the shaft. NOTE Press the upper bearing(5000)onto the rotor shaft Do not install the mechanical seal until ready (0030). The bearing must be fully seated against to completely assemble the pump. the shoulder. 5-14 UPPER MECHANICAL SEAL INSTALLATION Refer to Figure 5-3,Lower Mechanical Seal Detail. Refer to Figure 5-2,Upper Mechanical Seal Detail. 1.Thoroughly clean the shaft(0030)and the oil cham- ber(0040)bore. The mechanical seal, along with the seal oil, 2.Coat the seal faces with seal oil. Press the rubber protects the motor from the intrusion of water.The boot into the oil chamber 0040 seal faces are made of silicon carbide which are ( ) with finger pros- and polishedsur- sure. The rubber boot must have lapped to form perfect mating no bumps or faces. Cleanliness of the seat faces is critical for ripples. long life. Blow dust off, or wipe with a clean, soft 3.Coat the mechanical seal stationary partwith soapy tissue. Handle the seals with clean hands. Never water.With a clean piece of paper between the seal touch the seal faces as oils and acids in the skin face and fingers, press the seal firmly Into the can etch the surface. rubber boot. 4.Coat the 0-Ring (4430) with seal oil. Fit it to the groove in the bearing cover(0760). CAUTION I 5.Push the oil chamber onto the bearing cover.Place INSPECT SEAL FACES CAREFULLY. the oil chamber carefully to avoid damage to the SCRATCHES, CHIPS OR CRACKS ARE stationary mechanical seal.The oil chamber must . CAUSE FOR REJECTION. be seated against the shoulder of the bearing Dover. 13 1 6.Coat the mechanical seal rotating part and the shaft 4.Insert the terminal chamber to the motor housing with seal oil. With a twisting, continuous motion, (0010). Secure with screws (1002) and spring slide the seal along the shaft until the seal faces washers(3310). contact. If the rubber skirt rolls out from under the seal, it must be restarted.Take care not to cut the 5.Tighten the screw (1250) to compress the stator- skirt on the circlip grooves. lead seal assembly in position.Do not over tighten. 7.Install the compression spring and rubber cup (if 6.Install the small terminal strip (9020) with screws used)to the rotating seal part. (1800) and spring washers(3395). 8.Compress the spring and install the support washer 7.Refer to the cable lead identification diagram.Con- (5610)below the mechanical seal. nect the thermal protection and moisture probe leads to the terminal strip. 9.Install the shaft key to hold the spring in place. 8.Connect the control cable leads to the terminal 5-16 CABLE INSTALLATION strip. 9.Install the terminal board bracket (0470) to the The steps for servicing the cables apply to the control cable and the power cables. housing with screws (1070) and spring washers (3395). 1.Coat the cable seal(0400)and(0401)with seal oil. 10.Connect the ground leads from the power cables Feed the cable(9120)or(9121)through the cable to the housing with screws(1800),spring washers inlet(0380)or(0381)and the cable seal. (3395)and clamp(9060). 2.Thread the cable inlet into the terminal chamber 11.Install the terminal board (9030) to the bracket (0350). Tighten securely, compressing the cable seal. (0470) with screws (1070) and spring washers (3395). • 3.Tighten the two triangular head screws on the strain 12.Refer to the cable lead identification dia ram.Con- relief clamp,compressing the cable. nett the stator leads and the power cable ble leads to NOTE the terminal board with the jumpers(9102).Secure the leads with hex nuts(2520)and washers(3000). When a cable is reinstalled,the cable seals 13.Coat the 0-Ring (4450) with seal oil. Fit it to the should squeeze a fresh area of the cable to groove in the terminal chamber lid 0410 obtain a water-tight seal. ( )• 14.Install the terminal chamber lid to the terminal 4.Cable connections are made after the terminal chamber (0350). Secure with screws (1002) and chamber is installed. spring washers(3310). 5-17 TERMINAL CHAMBER INSTALLATION 548 MOTOR HOUSING INSTALLATION The terminal chamber is assembled to the motor 1.Ensure that the groove pin(6100)Is installed in the housing.Then the motor housing is assembled to bearing cover(0760). the oil chambedbearing cover assembly. 2.Coat the sealing rings(4480)with seal oil. Fit them 1.Assemble the covers(0870)to the stator-lead seal to the oil chamber(0040). (0860)with the screw(1080),spring washer(3200) 3.Coat the 0-Ring (4490) with seal oil. Fit It to the and hex nut(2520).Leave the screw loose. groove in the upper bearing bore. 2.Feed the stator leads through the holes of the 4.Coat the 0-Ring (4420) with seal oil. Fit It to the stator-lead seal.Crimp wire lugs(9070)and(9071) bearing cover perimeter against the oil chamber. onto the stator leads.Insert the stator-lead seal into the terminal chamber. 3.Coat the 0-Ring (4470) with seal oil. Fit it to the groove in the terminal chamber. 14 upright,• 5-21 WEAR RING INSTALLATION 5.With the rotor shaft lower the motor hous- ing part way over the rotor. Ensure that the forked 1.The wear ring (0220) is a press fit into the volute recess in the motor housing Is aligned with the (0200). groove pin in the bearing cover. Ensure that the 2.Tap into place with a block of wood as a cushion. motor housing will cover the cooling ports in the oil The wear ring must be fully seated against the chamber. Leave room for plugging in the moisture probe wire. lower shoulder in the volute.It must not be cocked. 6.Plug Moisture probe wire in probe. 5.22 VOLUTE INSTALLATION 1.Coat the 0-Ring (4400) with seal oil. Fit It to the CAUTION i shoulder on the lower side of the oil chamber (0040). BE CERTAIN THAT ALL WIRES IN THE 2.Litt the motor assembly over the volute(0200). MOTOR HOUSING WILL BE CLEAR OF THE ROTOR AND WILL NOT BE PINCHED 3.Lower the motor assembly into the volute.Keep the AFTER ASSEMBLY. motor plumb.Guide the impeller into the wear ring. 4.Secure the volute to the motor housing with screws (1000) and spring washers(3330). 7.Lower the motor housing completely. Ensure that the groove pin in the bearing cover fits into forked 5-23 LEAK TESTING recess in the motor housing.Ensure that the upper bearing fits into the bore. 1.The pump may be tested for leaks by pressurizing with compressed air.The pump may be submerged 8.Secure the motor housing to the oil chamber with in a water tank and checked for bubbles of escaping the screws(1003)and spring washers(3300). air. A soap solution may be used to find leaks at 410 0-Rings,plugs and cable entries.The pump may 5.19 COOLING JACKET INSTALLATION be pressurized with Freon gas if a Freon Detector 1.Coat the 0-Ring (4410) with seal oil. Fit ft to the is available. lower groove in the motor housing(0010). 2.Coat the 0-Ring (4440) with seal oil. Fit ft to the CAUTION 1 upper groove in the motor housing. DO NOT EXCEED 10 PSI 3.Push the cooling jacket(0280)down overthe motor housing. 4.Press the cooling jacket down and insert the circiip 2.It is advisable to check for leaks as the pump is built 5420 in thegroove in the h u ,section bysection. motor housing,( ) , above P the cooling jacket. 3.To check the motor housing upper u er mechanical 5.Install the vent screw (1004) and sealing washer seal,apply pressure at the drain plug(2000)on the (4610)at the top of the cooling jacket(0280). cooling jacket side. 4.To check the terminal chamber, apply pressure at 5-20 IMPELLER INSTALLATION the plug(2010)above the terminal chamber lid. 1.Install the impeller key(4800)onto the shaft(0030). 5.To check the oil chanter and lower mechanical Coat the shaft and impeller bore with grease. seal,apply pressure at the oil plug(2010)on the oil 2.Push the impeller(0160)onto the rotor shaft.Make chamber side. sure that the support washer is seated against the 6.After all testing is completed, make certain the oil rubber cup and compression spring of the lower chamber has the correctantic of seal oil. New mechanical seal. �N Y sealing rings(4600)should be installed.AnyPs which have been removed 3.Install the impeller washer(0480)with thei should be coated with a • mpe impeller non-hardening thread sealer and screw (1200) and lock washers (3331). Tighten tightened. g securely securely. 15 PARTS LEGEND AF115-6 AF125-4 AF150-4 AF180-4 • REF. REF. NO. DUAN. DESCRIPTION NO. DUAN. DESCRIPTION 0010 1 Motor Housing 3331 2 Spring Washer 12MM 0020 1 Stator Assembly 3800 1 Mechanical Sea 0030 1 Rotor Assembly 3900 1 Mechanical Sealt 0040 1 Oil Chamber 4400 1 0-Ring 310X5MMt 0050 1 Transition Piece 4410 1 0-Ring 290X5MMt 0160 1 Impeller 4420 1 0-Ring 220X5MMt 0200 1 Volute 4430 1 0-Ring 205X5MMt 0220 1 Wear Ring!' 4440 1 0-Ring 94X5MMt 0280 1 Cooling Jacket 4450 1 0-Ring 110X4MMt 0350 1 Connection Box 4460 1 0-Ring 106X4MMt 0410 1 Terminal Box Cover 4470 1 0-Ring 57X4MMt 0480 1 Washer!. 4480 2 0-Ring 30X5MMt 0510 1 Seal-Probe Assembly 4490 1 0-Ring 89X3MMt 0760 1 Bearing Cover 4600 6 Sealing Washer 13x18x2.0MMt 0870 4 Cover 4610 5 Sealing Washer 8X12X1.5MMt 1000 6 Allen Screw M12X75 4800 1 Key 10x8x50t 1001 4 Allen Screw M8X30 5000 1 Grooved Ball Bearingt 1002 8 Alen Screw M8X25 5100 1 Ang.Cont.Ball Bearingt 1003 3 Allen Screw M6X35 5200 1 Safety Ring 1004 1 Alen Screw M8X15 5400 2 Cirdip 50X2MM 1050 4 Allen Screw M8x16 5420 1 Cirdip SB 200 S 1200 1 Hexagon Head Screw 12X25MM 5600 3 Support Washer 50X62X3.OMMt 2000 3 Plug Screw R 1/4• 5610 1 Support Washer 38X52X2.5MMt 2010 3 Plug Screw R 1/4' 6100 1 Grooved Pin 5x20 3300 3 Hexagon Nut 6MM 7200 4 Rivet 3310 12 Hexagon Nut 8MM 7400 3.5L Oil Fill 3330 6 Spring Washer 12MM CONNECTION BOX DETAIL 0350 1 Connection Box 2521 6 Hex.Nut M6 0380 2 Cable Inlet 3030 18 Washer 6.4 0381 1 Cable Inlet 3030 1 Washer 6.4 0400 1 fit' 3200 1 Spring Washer A-5 0401 2 Seat 3210 6 Spring Washer A-6 0470 1 Terminal Bracket 3395 2 Spring Washer A-3 0860 1 Pipe Connection 9020 1 Terminal Strip 0870 2 Cover 9030 1 Terminal Board 1070 4 Men Screw M8x16 9070 12 Wire Lug 1250 1 Hex.Heed Screw M6x50 9070 1 Wire Lug 1800 2 Alen Screw M8x12 9070 8 Wire Lug 1810 1 Men Screw M5x12' 9071 6 Wire Lug 1820 2 Allen screw M3x10 9102 3 Connection 2520 6 Hex.Nut M6 9120 m Cable 2520 1 Hex.Nut M6 9121 m Cable' • 'USED ONLY ON AF115.6,AF150.4,AF180.4. tRECOMMENDED SPARE PARTS .0-' 10-1 0020-1, f1004-1 0030-1,, - - --3.i ------------------ 4.610-1 9120 _ \ - 0360 4. / ` - LLLO-1 �� ,''_N�'i�kttb 5000-1 3900 a. �, IISQJ;PMy0%/ lin• Q _= - - 0250-1 0350 4, ` $ -:::ii:._ —__ \` ` • . . . �� -_,''I- # k .1050-6 3312-4. \ -..��� �r/,i -_4 ''��01 0 4610-4 1002-L. _ x.600.t. • _ \/ ` .0760-1 2010 a.'. t P i .�i. • a.\.. % / ; ` ,--v../5600-1 903094'71'-1 ; �� .5200-1 tolo- sm1� ` �� ` , 4.4.10-1 3210- '=% N 1250-1. r ` ' yi�r ` ' � /5100-t 2520 t.' 3000�, i ` / 5600-1 .54.00-1 1820-2, ' ' t All % - 4.600-1 3395-2.y `�, ; `` ...1000.1 _ . .0050-1 3200-1. - .��� 3310- 1010- ` JJ ---- 7-r: i r �► / 1.---:-.‘.‘"-------61°°-1 9061_ ,����:-� /.�LLT�U` �� �� ,2oo0-z � iIlle t�1 C--:&e: 1•/ -_ ■'1 5 % i - 600-2 4. 1 Ar`� :_,we,/ % ��� I imi,al; % 4.4.60-1 411:2 ......_ . `,` \'`'_riga,\.. % , `046/, ,�r4`'���-0°I: 420-1 �`I ONO- an an C '` '� �=� 1� eqe \ IA 4'I% •-t"1/•�l 1IV uao-, %10- `�s�\�__ •�� _,#-�►:- Ir' 'FP �n� ^x4.^3'0.2 �- 16. 7200- ' �` '1..x\`1\\\\\\\��`��/���'�.ri��� ;���/iu� 3WAF3 1Sli Ili 402-L -' �;:? < '"`#�•. •..;..-+ f'•_".??+.•JI)rr-� ♦. . 3500-1 1010-4. �� :r= TRANSITION SHAFT • PIECE Ir= -, ROTATING SEAL STATIONARY SEAL FACE ASSEMBLY RUBBER SUPPORT WASHER BOOT 11M11CIRCLIP FIGURE 5-2 UPPER MECHANICAL SEAL DETAIL ' • OIL CHAMBER --\ '<-"-----> SHAFT , s,. /7, / 1 , Alas A Aft. `c--RUBBER BOOT „ STATIONARY ROTATING '; � � ;�, SEAL FACE SEAL FACE RUBBER SKIRT SPRING ezSUPPORT WASHER IMPELLER //z<zz4.... ' 0 FIGURE 5.3 LOWER MECHANICAL SEAL DETAIL 18 111111 TROUBLESHOOTING CHART SYMPTOM POSSIBLE CAUSE ACTION 1. PUMP WILL A. Power supply failure A. Check power supply NOT START Check out electrical system for loose connections Check operating voltage B. Burned out fuse or B. Check circuit protectors tripped circuit Reset circuit breakers breaker C. Damaged power cable C. Check external cable for damage-repair E. Jammed impeller E. Inspect and remove jamming object F. Water inside motor F. Refer to Symptom 5 and 6 2. REPEATED A. Circuit protection A. Check rating and TRIPPING underrated replace with proper size B. Current unbalance B. Check current draw C. Pump connected to C. Venfy connections.See incorrect voltage wiring diagram D. Wet or damaged wiring D. Inspect external cable.and seal replace if worn or damaged E. Obstruction in pump E. Remove obstruction F. Incorrect motor rotation F. Check rotation G. Foreign matter build-up G. Clean motor housing 3. PUMP WILL A. Control panel failure A. Check control panel NOT SHUT OFF B. Obstructed float B.Check all floats 4. LOW FLOW A. Incorrect'-ump rotation A. Check rotation B. Low liquid level B. Check liquid level C. Obstruction in Pump or piping C. Remove obstruction D. Patton),dosed valve(s) D. Check and adjust valve 5. WATER IN A. Loose or damaged oil plug A. Check plug and sealing washer OIL CHAMBER 8. Mechanical seal failure B. Replace mechanical seal 6. WATER INSIDE A. Damaged upper I A. Replace seal MOTOR CASING mecnanical seal B. Damaged 0-Ring between B. Replace 0-Ring oil chamber and motor casing C. Damaged Cable C. Replace Cable and Cable Seal IF SYMPTOMS CONTINUE,CONSULT THE ABS PRODUCT SERVICE DEPT. 19 ro "'' "Its., Spare parts list 1/88 AF 150 - 4 USA .ice$ ni. Issue 07/88 AF 180 - w G 21 G 22 All/ Page i of 2 Ref-No. Part-No. Description -Quantity 0010-1 3100181 Motorhousing MK (Standard) -1 3100182 Motorhousing MK + FK 0020-1 6100437 Stator assembly 230/460/3/60Hz 0030-1 6101604 Rotor assembly 0040-1 3104538 Oil chamber 0050-1 3140021 Transition piece 0160-1 3107739 Impeller G 21.2 -1 3107740 Impeller G 21.3 -1 3107742 Impeller G 22.1 -1 3107093 Impeller G 22.11 -1 3107092 Impeller G 22.12 -1 3107091 Impeller G 22.13 0160-1 3107090 Impeller G 22.14 0200-1 3105619 Volute G 21 S -1 3105620 Volute G 22 S 0220-1 5134130 Wear ring G 21 -1 5134131 Wear ring G 22 0280-1 3101123 Cooling jacket 0350-1 4302196 Connection box 2K.4x10+IK.4x1,5 s. sep. Blatt 0410-1 3139507 Terminal box cover 0480-1 4201022 Washer 0510-1 eetb4-y-y!v/o3na 0760-1 3115208 Bearing cover 1000-6 1121132 Allen screw M 12x75 DIN 912 1001-4. 1121108 Allen screw M 8x30 DIN 912 1002-8 1121109 Allen screw M 8x25 DIN 912 1003-3 1121101 Allen screw M 6x35 DIN 912 1004-1 1121118 Allen Screw M 8x15 DIN 912 1050-4 1122030 Allen screw M 8x16 DIN 7984 1200-1 1121113 Hexagon head screw M 12x25 DIN 912 2000-2 1156024 Plug screw R 1/4" DIN 910 2010-4 1156024 Plug screw R 1/4" DIN 910 3300-3 1153016 Spring washer 6 DIN 7980 3310-12 1153017 Spring washer 8 DIN 7980 3330-6 1153019 Spring washer 12 DIN 7980 3331-2 1149028 Spring washer M 12 "JO AO • eitoi • DANIA I twiu*Ill ♦ .es AM MO Iola • • ••. . . . eeo 3�tid sdwnd set+ woa d eb r e t 6 . E I no►a Spare parts list 1/88 AF 150 - 4 USA 11.13 Issue 07/88 AV 180 - a G + '• G 21 G 22 411 Page 2 of 2 Ref-No. Part-No. Description -Quantity 3800-1 1111093 Mechanical seal 3900-1 1110056 Mechanical seal 4400-1 1112132 0-ring 310x5 DIN 3770 4410-1 1112143 0-ring 290x5 DIN 3770 4420-1 1112066 0-ring 220x5 DIN 3770 4430-1 1112063 0-ring 205x5 DIN 3770 4440-1 1112094 0-ring 194x5 DIN 3770 4450-1 1112089 0-ring 110x4 DIN 3770 4460-1 1112042 0-ring 106x4 DIN 3770 4470-1 1112198 0-ring 57x4 DIN 3770 4480-2 1112119 0-ring 30x5 DIN 3770 4490-1 1112192 0-ring 89x3 DIN 3770 4600-6 1113014 Sealing washer 13x18x2,0 4610-5 1113004 Sealing washer 8x12x1.5 DIN 7603 4800-1 1163013 Key 10x8x50 DIN 6885 5000-1 1101031 Grooved ball bearing DIN 625 4111 5100-1 1102020 Angular cont. ball bearing DIN 628 5200-1 1114032 Safety ring 5400-2 1107012 Circlip 50x2 DIN 471 6100444.9.-1 1108041 Circlip S8 200 5600-3 1106011 Support washer 50x62x3,0 DIN 988 5610-1 4247018 Support washer 38x52x2,5 6100-1 1155054 Grooved pin 5x20 DIN 1470 7400- 1103021 Oil fill 2.3 1 0 AIN OVIIIIPON AG • Rlr • maw s IWsisd . . Alli aY 11•ww • ` 00 ' 3Vd sdwnd sad 1408.i aid IPIe 16 , 61 AON ** S00 ' 39tid 11:1101 ** • Spare parts list 1/88 Cable inlet AM 11 Issue 07/88 2K.4x10+1K.4x1.5 Part-No. 4 302 196 4r. ac-o,„ /Sb'y /r4-q Ref-No. Part-No. Description -Quantity 0350-1 3130573 Connection box 0380-2 1294090 Cable inlet 0381-1 1294066 Cable inlet 0400-1 1294079 Seal 0401-2 4307026 Seal 0470-1 4407108 Terminal bracket 0860-1 4307208 Pipe connection 0870-2 4161005 Cover 1007-4 1125118 Allen screw M 6x16 DIN 912 1250-1 1119020 Hexagon head screw M 6x50 DIN 931 1800-2 1125119 Allen screw M 6x12 DIN 84 1810-1 1125115 Allen screw M 5x12 DIN 84 1820-2 1125100 Allen screw M 3x10 DIN 84 2520-6 1140031 Hexagon nut M 6 DIN 934 -1 1140004 Hexagon nut M 6 DIN 934 2521-6 1140052 Hexagon nut M 6 DIN 985 3030-18 1147031 Washer 6,4 DIN 125 U -1 1147035 Washer 6,4 DIN 7349 3200-1 1152003 Spring washer A 5 DIN 127 3210-6 1152004 Spring washer A 6 DIN 127 3395-2 1153001 Spring washer 3 DIN 7980 9020-1 1213101 Terminal strip C.0,1*K 1JtRF'. 9030-1 1220020 Terminal board MK 230/6-pol . 9070-12 1218016 Wire lug 4-6/M 6 9070-1 1218030 Wire lug 0,5-1,5/M 5 9070-8 1218033 Wire lug 6x5,4/102 9071-6 1216012 Wire lug 1,5 9102-3 1220029 Connection 9120- m 1210062 Cable HO7RN-F4G10 9121- m 1210057 Cable HO7RN-F4G1,5 ID) limmmliMililimmW MS MOM AD •illf l & 4bH , • MINIMA 1 ware at! • A►........ . as . ...T _ _ , , EP- ggggg4 p rip N404 I . • a ' s „„ N = i g `w ,ill 14/0 Z U f f f� f O gWo N iii f�i °.� z f.m � � ai O N N N N N'. EiqrS � - \ \ \co W V 6 { li v .15E5s k t M� '� .c < zc � �p � Z �'`' N� E'� 1�! U Q N 1 c� FO �` v si F l Q `oma oio .p tn8tiro tidi /Igh.lilliit Z y Q Z=�pJ ZZOZ `� � �� J N O 5 w , Q F� <{�I�O{nt dci a 3< p O N eo Io n Z N 'iV)=Ox[V < 4 • 3: = ' 0D O z a: NY 40 O` A Iki op Cn 5 J . i tErileYgt .l ffi wxrK� w 4 . r44 - W g _ ao< WOx6dEi3 r `l `W� .-U 1 . , !t I 's ,,. 1 v z Nov, (7-) ~ V . .›.4t t TIVIIIA0 0 ..ACI". ONNN3d03 `..t/t t -,T- 9., .Z'vi-Si lil .t n ,ter r—r--t�----E-A- 11 At t 1; $5 I I 4 I iiifi 1 1 1.0 I I H PzIL_Lf li F x LL--61 xIII e 1 Pk. IW___ ,�, F li „gi 0 WI techniflow corporation 1700 East 33►a$I:e+ei•M•rseapoles.MN SS101. CABLE RACK 4614 717.2203•fax)611)71/0003 , (4) PURPOSE: -general housecleaning suport for pump end loat cords CONSTRUCTION: -welded steel -1/16" (min.) PVC coating (black) -attaches to sliding-nut rail of access cover and frame 6. F-- ..: . uhl �s Noisj II . L11 . 1 • Q • • • ♦ ♦ 0006Q . • • • • (►MotrettsMctol =°'The. PVC COATED III A$lE MOLDER, ft.:ire li 5. • $LX WAD Rat • ',mum. NUT W$TM a/ANG • ' ,, t anchor scientific inc. ioto•Eloat Types - Suspended Box 378, Long Lake, MN 55356 /612-473-7115 Form 2700-A TYPE S vim. i. q ,'.MSR -F 7 ,,.. .' � 9s�i r I� 1.s . • ,. +�t like ,♦* + . !' .*• • H .--. ....z• .1� �T`,�C .�* , i:i • ' .tts• Yk. dr�r ' •OV•AOU 'VA Gil 'F,4'•.A 1 • ;'1 ria i:» e.:: !......‘..-,„i.,-..,,, f 031111 I�• ,i• it,:m 4 1 . .A.....->..:‘,:t4i..-.. . ..: Idle of loollt AO..,' . '...*1 I ;.‘, ,, . ! • ' .,�2:et.�l T<. - .>A •�:R-.f J'• 'r *:14: ".• fir• 7,,50 `.. :�, • 1, 1 S >r�t.' . w ,..•'.4.,., =,.:.., . . • .; i .,, ' . ' •)•t-'s: .1,:,4.4, ria i-I ' -.- w•ik:a-Liti�... :d 441.,•..• W.:.......4., :+_-. .•r •1}i 4i SO,'sl The ROTO-FLOAT is a direct acting float switch. Each ROTO-FLOAT contains a single pole mercury switch which actuates when the longitudinal axis of the float is horizontal,and deactuateswhen the liquid level falls 1" below the actuation elevation. IThe float is a chemical resistant polypropylene casing with a firmly bonded electrical cable protruding. One end of the cable is permanently connected to the enclosed mercury switch and the entire assembly is encapsulated to form a completely water tight 4 and impact resistant unit. Type S — Suspended has built in weight. ROTO-FLOATS can be mounted on a support pipe (type P) or suspended from above (type S).Advantages of the ROTO-FLOAT are low cost,simplicit y and reliability. II ® Listed • Pilot Duty • Industrial Control Equipment II BLE &wu+h C•I+lu Suspended Ship. V.C. type STO #18 conductors (41 strand) A"•"v''" '11 Le1v"+ iypeSMudelNoWI. 1111 rated 600 volts • Various lengths available 41111.4. 2 $20N0 Ir • 30 Sae table of models I Non-standard NOim•Ily Open S3ON0 11 lengths also available on special order. 40 610N0 $1140 111 a0 S7ONC 44 414,1 molly 30 s)ONG 11140 Clcr►e l 40 s10NC 011611 GENERAL DESCRIPTION. I THE ROTO-FLOAT ISA DIRECT ACTING FLOAT SWITCH: EACH ROTO-FLOAT CONTAINS A SINGLE POLE MERCURY SWITCH WHICH ACTUATES WHEN THE LONGITUDINAL AXIS OF THE FLOAT IS HORIZONTAL,AND DEACTUATES WHEN THE LIQUID FALLS 1"BELOW THE ACTUATION ELEVATION. IHFItTSA0M1ItRITANTPLPNTNE :INOYITNtF1"k ELIHEESSOLELYBONDEDELRICALCASLEPROTRUDING. ONEENOOFTHE CABLEKE MECURSWICH AND THE ENTIRE ASSEMBLY IS ENCAPSULATED TO FORM A COMPLETELY WATER( RMANTLY NND TO THE GLASS ENOS 0 UHT AND IMPACT RESISTANT UNIT. ROTO-FLOATS CAN BE MOUNTED ON A SUPPORT PIPE,(TYPE PI;OR SUSPENDED FROM ABOVE,(TYPE SI. ADVANTAGES OF THE ROTO-FLOAT ARE LOW COST, SIMPLICITY AND RELIABILITY. VARIOUS CIRCUIT CONFIGURATIONS,OTHER THAN THE ONES LISTED BELOW,ARE AVAILABLE. SPECIFICATIONS: PVC TYPE STO,2. • IS AWG 41 STRAND 1100V,On • UL LISTED,IND.CONT.EQ. Iii .. - CONDUCTORS 20,30',40' LENGTHS STANDARD. PILOT DUTY OTHER LENGTHS AVAILABLE. 4.5 AMPS 120 VAC UL&CSA LISTED. 2.25 AMPS 240 VAC TEMP LIMIT 50°C • FLOAT COLOR I N.O.,BLACK • CASING CONTAINS N.C.,RED HERMETICALLY SEALED MERCURY SWITCH. • MOUNTING ARRANGEMENT I— TYPE P.PIPE MOUNTED MODEL INCLUDES I ÔP0LYPROPYLENE POLYPROPYLENE CLAMP 41 —'1 USE;N.O.FOR PUMP OUT N.C.FOR PUMP IN TYPE S-SUSPENDED MODEL WITH STABILIZING WEIGHT. MODELS: SUSPENDED TYPE S PIPE MOUNTED TYPE P ' SWITCH CABLE ARRANGEMENT LENGTH MODEL NO. 1 SHIP WT. MODEL NO. 1 SHIP WT. I 520N0 4• P2ONO 2• NORMALLY 14) S3ONO 4'ti• P3ONO 21<• OPEN 1 S4ONO 5'.L• P4ONO 3v,• 20 S2ONC 4' P2ONC 2• NORMALLY 30 S3ONC 4 X• P3ONC 2 K• CLOSED 40 S4ONC S'%• P4ONC 3%• ' ,S4PPLICA�TIOINNSS. USE IN CONTROLLING PUMPS OR OTHER MACHINES AND MEASURING ALARM LEVELS IN WATER,SEWAGE AND MANY OTHER LIQUIDS. ROTO-FLOATS MAY BE USED FOR PUMP IN OR PUMP OUT CONTROL,FOR LOW LEVEL CUTOUT,OR FOR LOW AND HIGH LEVEL ALARMS. TYPICAL 2 PUMP CIRCUITS TYPICAL MOUNTING TYPE P TYPE S .—UNI 1IOVPI0I — ----ILMI tOLiN/ - PUMP IN PUMP OUT -11M. III IIIIIIIIIIIjl Oro!NMI" In NI 4116" I 470 .IMaI i KMO J 410 G at till 1 �i *LAT COMT.Ci �'� NIOi CpITKT fig if, , i A "'L__.. IPPON VAMP ® "'L� ro+o. T UM i 4i0111�� P11.0?CONTACT r'-"~ .KOT cONiai Up / cOONON1.11—.-4, T 4 A tiY.MIT POP �, ~' ,._. OCTOPI t7.OTU PLOW t—.—.0 MOTOR POMC '`f IAA* v MULilnl IMO SUBMITTAL ►i o' 11110 raom APPROVAL Pain46 '0M'� 4' SEE ACCESSORY .•.PINT r SHEET FOR . PINI YOITMI NAME VI:°"1110 HARDWARE MOM II winoDATE lila. 1 ..11.11 1 /I.NT - _ o "N" "T'PQ scientific Inc. .•.O. ' 1.9.]! anchor w.. Box 37$,Long Lake,MN 1131$ JA 1.9.74 S131473.7111 IMPORTANT NOTE:UM In occordona with ,O,P*IP WS Nal*atrial soda and authority hiving OS 440 7$ SPECIFICATION DATA SUBMITTAL 1 alio $tlrIadictIon.Do not two Roto Floats in ... AND INSTRUCTION SHEET N © wen rams pooII o,WolinWolinw NN a httw►uIII INr.. ROTO•FLOAT . JMAILAJUUL rpi1,.i. e.». N.. 174 4 a. a r . Controls :i*iti:i:1:1: 11790 Phillips Highway,Jacksonville Florida,32224USA Ph.(904)-292-0110 Fax;(904)292-0119 DUPLEX ELECTROGAGE CONTROLLER Operating and Maintenance Manual City ©f Oik 1Ark i hth 0 (11_1° nn:eel:AA EG JOB # 248038 REP: TECHNIFLOW CORPORATION, 2700 EAST 33RD STREET, MINNEAPOLIS, MN. 55405 (612) 722-2203 PO # LBM284 CUSTOMER: CITY OF OAK PARK HEIGHTS, MINNESOTA February, 1992 Jacksonville, Florida REVISIONS: i 0 Original 2/92 Operating&Maintenance Manual:Electrogage Duplex Pump Controller Oak Park Heights,Mn. DRAWINGS (In packet) 1 SAFETY WARNINGS, Cautions 1 3. DEFINITIONS 2 4. ABBREVIATIONS 2 5. COLOR CODE 3 SCR 6. DESCRIPTION 3 7. ELECTRICAL INSTALLATION 3 7.1. LINE POWER 3 7.2. WIRING 4 7.3. GROUNDING 4 8. PNEUMATIC INSTALLATION 4 9. START-UP PROCEDURE 6 9.1. FIRST-TIME START-UP 6 9.1.1. SETTING THE BUBBLER TUBE 6 9.1.2. RECORD THE CONTROL LEVELS OF THE WELL 6 9.1.3. ADJUSTING LEVELS ON THE ELECTROGAGE 6 9.1.4. MECHANICAL STARTUP 6 9.1.5. ELECTRICAL STARTUP 7 9.1.6. PUMP ROTATION CHECKS 7 9.2. NORMAL START-UP 8 10. PRINCIPLES OF OPERATION 9 10.1. ALARM LIGHTS, Principles of Operation 9 10.2. PANEL CONTROLS, Principles of Operation 9 11. FRONT PANEL CONTROLS EXPLAINED 10 11.1. OVERTEMPERATURE Light 10 11.2. RESET Button 10 C•11.3. OVERLOAD TRIPPED Light 10 11.4. HIGH LEVEL Light 10 11.5. HIGH HIGH LEVEL Light 10 11.6. HIGH HIGH LEVEL AUTO TEST Switch 10 11.7. LOW LEVEL Light 10 11.8. SEAL LEAK Light ll 11.9. PHASE FAILURE Light 11 11.10. LAMP TEST Pushbutton 11 11.11. RUNNING TIME Meters ll 11.12. HAND/OFF/AUTO Selector 11 11.13. LEVEL GAUGE 12 11.14. CONTROL POWER ON/OFF 12 11.15. MISCELLANEOUS 12 12. AUTOMATIC OPERATION 13 13. SHUTDOWN PROCEDURE 13 14. ADJUSTMENTS AND PROGRAMMING 13 14.1. WETWELL LEVELS 13 15. MAINTENANCE 14 15.1. AIR SUPPLY MAINTENANCE 14 15.2. BUBBLER MAINTENANCE 14 15.3. CONTROLLER MAINTENANCE 14 16. TROUBLESHOOTING GUIDE 14 16.1. BUBBLER AIR FLOW GOES UP AND DOWN 15 16.2. ALARM 15 16.3. HIGH LEVEL Light 16 • 16.4. LEVEL GAUGE DOES NOT GO TO ZERO WHEN WELL IS LOW 16 16.5. LEVEL GAUGE DOES NOT READ 17 16.6. LEVEL GAUGE IS AT THE TOP ALL THE TIME 18 Operating&Maintenance Manual:Electrogage Duplex Pump Controller Oak Park Heights,Mn. 016.7. LEVEL GAUGE TOO HIGH 18 16.8. LEVEL GAUGE TOO LOW 18 16.9. LOW LEVEL Light 19 16.10. PUMP MOTOR DOES NOT RUN 19 17. SPARE PARTS LIST 20 18. INDEX 21 19. APPENDICES 23 (• Operating&Maintenance Manual:Electrogage Duplex Pump Controller 1 Oak Park Heights,Mn. 1 . DRAWINGS (In packet) The following EG drawings apply to this installation; TITLE NUMBER sir REV DATE Schematic Diagram 248038D 1 1317/91 Enclosure and Pneumatic Diagram 248038D 2 1117/91 a. SAFETY WARNINGS. Cautions 2.1. WARNING; Every effort has been made to provide equipment which will both function correctly and provide proper safety to operators and equipment. However, no engineering design can render a system entirely safe from all hazards, therefore operators are urged to follow the procedures given in these operating instructions at all times. 2.2. WARNING; Disconnect all power and lock out main disconnects before servicing or handling pumps, motors and controls. 2.3. WARNING; The Pump enclosure door is equipped with a MAIN disconnect switch . The enclosure contains equipment powered from a MAIN disconnect. It is necessary to turn off the MAIN disconnect whenever the enclosure door is to be opened for service, r� adjustment, or maintenance \' 2.4. WARNING; Do not smoke, do not use electrical tools or devices, or ignite flames in or around septic sumps 2.5. WARNING; Pumps, motors and other devices powered by this controller may start at any time without warning. Personnel are strongly advised to either stand clear of moving equipment at all times, or secure their safety by locking OFF the appropriate service disconnect. 2.6. CAUTION; Be sure all guards are in place and secured before running equipment. Repair broken guards promptly, so that proper personal safety is maintained. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 2 Oak Park Heights,Mn. (4110 Danger Hazard of Burn or Electrical Shock! Turn OFF power supplying this equipment before working inside 3. DEFINITIONS Caution Advice to minimize risk of trouble. Danger Advice concerning possible personal injury or permanent equipment damage or destruction. Down A condition of the motor and pump set that would stop its use by the controller; the use of which would cause irreparable damage. This \\ could be due to a number of conditions including motor overload, moisture sensor trip, or overload failed. Failed Equipment that is no longer functional; a condition of the controller whereby it has tripped and has not restarted. Tripped The action of the control system when it goes off-line due to its internal circuits or programming detecting an out-of-range condition; e.g. overcurrent, overvoltage, or any other failed internal condition. Warning Advice of a safety, or procedural matter not necessarily concerned with the equipment. 4. ABBREVIATIONS The following abbreviations may be used throughout the text; A/C Air Compressor ALT Alternator BAMS Bubbler Air Monitor System CB Circuit Breaker CPT Control Power Transformer EG Electrogage ETM Elapsed Time Meter GFI Ground Fault Interuppter (Ili HHL High High Level HL High Level Operating&Maintenance Manual:Electrogage Duplex Pump Controller 3 Oak Park Heights,Mn. HOA Hand Off Auto ISR Intriscally Safe Relay LL Low Level LT Lamp Test MSR Moisture Sensing Relay OL Overload OT Overtemperature PMR Power Monitor Relay R Relay T R Timer Relay UV Undervoltage 5. COLOR CODE The annunciators and signal lights on this equipment are colored using the following principles; GREEN lights; "GO"or "Running" RED lights; Danger or alarm 6. DESCRIPTION (•.1. This Operating and Maintenance (O&M) manual applies to the following equipment supplied under the purchase order and job number referenced on the title page: 6.2. One Electrogage Duplex Pump Controller. Including bubbler level control system, two starters in one enclosure, level gauge and controls in one enclosure. 6.3. This system is designed to be connected to and integrated with existing equipment at site. 7. ELECTRICAL INSTALLATION 7.1 . LINE POWER 7.1.1. This equipment is designed to be operated on the following incoming line power; 480 volts AC,three phase,four wire 60 Hertz. 7.1.2. The above power should be supplied(by others)to the equipment in accordance with the electrical schematics provided with this Manual. Refer to Section 1 "Drawings". 7.1.3. Before starting equipment this a ui ment for the first time,ensure that the above power has been properly connected by physically checking it at the incoming line terminals of the disconnect switch in each enclosure. This should be done by a qualified electrician, with appropriate test equipment. Also a similar test should be done again before restarting after any changes in electrical service. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 4 Oak Park Heights,Mn. S C 7.2. WIRING 7.2.1. All wiring should be done in strict compliance with applicable sections of the National Electric Code and all local and state codes, if any. 7.3. GROUNDING 7.3.1. All electrical equipment must be provided with a bonded and tested grounding system. Electrical contractors should connect all electrical enclosures, cabinets, controllers, conduit, also pumps and motors to a proper earth ground. The provisions of the National Electrical Code is very clear with respect to bonding and grounding and should be adhered to as a minimum requirement. Contractors are strongly urged to install a network of bonded ground rods to provide the lowest practical impedance to ground. This design should then be integrated with a system of lightning conductors for full protection of the electronic equipment supplied herewith. 8. PNEUMATIC INSTALLATION 8.1. The controller contains its own air pumps and level sensors and associated pneumatic controls. (p2. Install the bubbler tube in the wetwell. Provide proper support for the tube so that it does not move under the pressure of currents in the well. The elevation of the bottom end of the tube should be carefully positioned with due consideration to the following: (Refer to Fig. 1, overleaf) 8.3. Position the end so that the operating range (controlled levels)are all within the 10 ft range of the gauge: The higher the tube,the lower the levels on the gauge. 8.4. The last 3 to 6 inches on the bottom of the gauge is not reliable for pump control use due to the small pressure differentials involved and also the dynamic losses in the bubbler tube. 8.5. The bottom of the tube should be between 9"(23 cm)and 2 ft(61 cm)below the STOP PUMPS level. Under NO circumstances should it contact the bottom of the well. 8.6. The tube bottom end should also be positioned away from any turbulence in the well. This means that any position near inlets to the well or outlets to pumps(pump inlet ports)should be strictly avoided, as this will upset the gauge and cause incorrect or fluctuating readings. 8.7. Connect the bubbler tube to the connection called"Bubbler Outlet"seen on sheet 2 of the as-built drawings. 8.8. Check all tube joints with leak detector and repair leaks where indicated. ._....4,a.La.x.aeeus:.*:mM..-.......:.:....... .... .... =uv—.s.ma.,w,, ...wv.u. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 5 Oak Park Heights,Mn. OBUBBLER AIR IN , BUBBLER OUTLET , FEET z. :m � — 10 INFLOW'`� HIGH q ALARM 8ft ,,o 0. ...►' NORMAL ' PUMP :x.:::::: LEVEL :1. :.Q :1. :l: . r' � :1. 1 : woo II(- DISCHARGE III_ \1 \s„....iI .. '=1-=:::::. ... :.:.: ... _ _ STOP 2 ( _ ,.... . PUMPS J. :0: WETWELL,TyP. ELECTROGAGE THE BOTTOM OF THE BUBBLER TUBE IS ALWAYS ZERO ON THE ELECTROGAGE DO NOT USE REAL WORLD CONTROLLER FIGURE 1: BUBBLER POSITION I Operating&Maintenance Manual:Electrogage Duplex Pump Controller 6 Oak Park Heights,Mn. 4111 START-UP PROCEDURE 9.1 . FIRST-TIME START-UP 9.1.1. SETTING THE BUBBLER TUBE 9.1.1.1. The instructions for the installation of the bubbler tube and the rules that control its positioning are detailed in a previous section titled PNEUMATIC INSTALLATION. It is important to obey the rules given there. Once set,there should be no more adjustment necessary to the tube. 9.1.1.2. The exception to this may be where the tube is found to be at the wrong elevation by later requirements. Or there may be a need to move all the levels at once and by the same amount;this would be simple if the bubbler tube was moved. Or if it found that the tube is in turbulence at certain levels that were not tested before. 9.1.2. RECORD THE CONTROL LEVELS OF THE WELL 9.1.2.1. Normally, the information about the control levels is available from the Project Engineer,or Station Supervisor as to where the water levels are to be. Obtain an approved copy of these dimensions. 9.1.2.2. Record the distance that the bubbler tube is above the bottom of the well. 1.2.3. Subtract this value from each of the levels Engineering desires in the well. 9.1.2.4. These levels are the levels that are to be programmed into the Electrogage for controlling the pumping speeds of the pumps. 9.1.3. ADJUSTING LEVELS ON THE ELECTROGAGE 9.1.3.1. The levels where the pumps start or stop may be changed by moving the connections on the back of the Electrogage.A tool is provided on the back of the panel for this purpose. The wires are marked to facilitate quick identification. Simply loosen the nut where the wire is now located and move it to the new desired level. DO NOT OVERTIGHTEN THE NUT as this may strip the screw. Be sure to keep the sequence the same;do not start the LAG pump before the LEAD pump,do not locate the LOW LEVEL ALARM above the STOP PUMPS,etc. It is suggested that the person making the changes write down the existing levels before making any changes. This will give him a "baseline" to work from. Refer to Electrogage Bulletin EG-791 in the Appendix for further information. 9.1.4. MECHANICAL STARTUP 9.1.4.1. Check that all motors are properly supported and mounted in position, and that all driveshafts, couplings, motor mounts, pumps and valves are correctly installed and bolted firmly into place. ( .1.4.2. Get approval from the Site Manager,or Project Manager to start the equipment. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 7 Oak Park Heights,Mn. ( • for anyservice activitywhich maybe r�.1.4.3. Do a final visual check of the pumping system o present. Check for persons present, warning tags, barricades or locked-out breakers. These must be cleared before proceeding. 9.1.4.4. Ensure all guards are firmly in place. 9.1.4.5. If the pumps require seal water,check that the seal water pump is on and the correct pressure is available at the pump seals. 9.1.4.6. Warn all persons present that testing is about to start. 9.1.5. P RCTRICAL STARTUP 9.1.5.1. Check that all electrical enclosures, conduit and terminal boxes are installed correctly. 9.1.5.2. Close all protective covers on pull boxes,junction boxes, motor terminal boxes and all raceways and secure them properly. 9.1.5.3. Inside the Pump Control Panel,locate all the circuit breakers in it and check that they are in the up, or ON position. 9.1.5.4. Close all controller doors. WARNING; Do not attempt to start-up for the first time with (9 interlocks defeated or doors open, since this is the time of greatest possibility of shorting, explosion, or fire hazard. 9.1.5.5. Wear protective glasses and appropriate clothing. 9.1.5.6. Ensure that all the HAND/OFF/AUTO switches for each pump are set to the OFF position. 9.1.5.7. Check that all disconnect switches are in the OFF position. 9.1.5.8. Turn on the main power disconnect switch on the power distribution panel that feeds this panel. 9.1.5.9. Turn on the MAIN control breaker or circuit breaker switch on the Pump Control Panel. 9.1.5.10. Turn on the circuit breakers for Pump number 1 and Pump number 2. 9.1.5.11. Then carry out the Phase Rotation Checks,below,to correctly install the three phase power to the pumps 4 Operating&Maintenance Manual:Electrogage Duplex Pump Controller 8 Oak Park Heights,Mn. C 01.6. PUMP ROTATION CHECKS I 9.1.6.1. WARNING; Pumps may be seriously damaged if started and run with the rotation in the wrong direction. Impellers on some pumps may loosen from their driveshafts if run across-the-line in the wrong direction. This may cause serious damage to the pump,the impeller,housing, and shaft. With those pumps where the impeller is keyed to the shaft and does not loosen,running the pump the wrong way is to be strictly avoided. 9.1.6.2. All first-time motor/pump starting should be donefor a minimum amount of time initially so a brief jog of the motor should be used to first test rotation before normal full speed operation is used. 9.1.6.3. Position yourself, or have an assistant move into a position which allows viewing of the motor or pumpshaft of No.1 pumpand also to be able to shout or signal to you. 9.1.6.4. With the controls set as in ELECTRICAL STARTUP above the pump controls should be set with their HAND/OFF/AUTO switches in the OFF position. 9.1.6.5. "Bump" the pump by setting the HAND/OFF/AUTO switch to the HAND position and then immediately back to the OFF position. 9.1.6.6. Pump number one will come on, as signified by the PUMP RUN light. The shaft should be turning. If it does not,check to ensure that there are no lockouts energized,no overloads tripped, etc. (01.6.7. Compare this direction with the pump manufacturer's installation specifications for the correct rotation. 9.1.6.8. If the rotation is wrong,then turn off and lock out all power to the panels and change over two of the three motor leads at the load side of the overload relay of pump No.1. Turn on power and retest. 9.1.6.9. If everything is okay with PUMP No.1,then go to PUMP No.2 controls and do the same check, this time observe pump No.2. If necessary, change over leads on the load side of pump No.2 overload relay. 9.1.6.10. Check that all the HAND/OFF/AUTO switches are set to the OFF position. NOTE: The following conditions will prevent a pump from coming on line in the AUTOMATIC or HAND mode; OVERTEMPERATURE OVERLOAD OVERVOLTAGE UNDERVOLTAGE PHASE LOSS PHASE REVERSAL If any of these conditions are present it will be necessary for maintenance personnel to find and correct the condition locking the pumps out. Failure to do so will prevent the pump(s) from running. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 9 Oak Park Heights,Mn. (12. NORMAL START-UP 9.2.1. On the Pump Control Panel,ensure that all the circuit breakers on it are in the up,or ON position. 9.2.2. All front doors should be closed. 9.2.3. Set the HAND/OFF/AUTO selectors to AUTO. 9.2.4. With all power on, and the switches positioned as above, the air compressors will pressurize the bubbler system and the controller will automatically start sensing the wetwell level and will bring on pumps in AUTO mode normally. 10. PRINCIPLES OF OPERATION 10.1 . ALARM LIGHTS, Principles of Operation 10.1.1. FLASHING ALARM BEACON Light; Indicates that there is an alarm condition that is on and presently active. 10.1.2. STEADY ALARM Light; Indicates that the alarm condition is presently active and "on". C41 10.1.3. The list below shows which lights obey the above FLASHING convention, above, and the others which do not (NON-FLASHING): HASHING NON-FLASHING ALARM BEACON HIGH LEVEL HIGH HIGH LEVEL RUN PHASE FAILURE OVERLOAD TRIPPED OVERTEMP SEAL LEAK NOTE: The following alarms will cause the ALARM BEACON to flash: Overtemperature, Seal Leak, Low Level, High High Level, Phase Loss, Phase Reversal, Under Voltage, or Over Voltage. 10.2. PANEL CONTROLS, Principles of Operation 10.2.1. The front panel controls are designed to be as simple as possible. 10.2.2. The emphasis is on the panel to do most of the'running' of the station and needing the least amount of operator intervention. 10.2.3. There is no front panel on/off switch or start control,as it is important that the Operating&Maintenance Manual:Electrogage Duplex Pump Controller 10 Oak Park Heights,Mn. controller should always start up by itself and be ready to look at levels and call for pumps at any time that power is available. It does not require operator assistance to do this. 11 . FRONT PANEL CONTROLS EXPLAINED This chapter gives a separate explanation for each and every front panel control,its use,what it controls and its purpose. 11 .1 . OVERTEMPERATURE Light 11.1.1. This is an indication that the overtemperature control circuitry has detected a overtemperature condition in the respective pump/motor. Maintenance personnel should investigate the cause of failure as soon as possible. 11 .2. RESET Button 11.2.1. This button is used to reset the overtemperature light,provided the overtemperature condition has been cleared. If the overtemperature condition still exists after the button has been pushed,the light will come back on. 11 .3. OVERLOAD TRIPPED Light 11.3.1. This is an indication that the overload control circuitry has detected a overload condition in the respective pump/motor. Maintenance personnel should investigate the cause of failure as soon as possible. 11 .4. HIGH LEVEL Light 11.4.1. This is an indication that the HIGH connection on the Electrogage has detected a high water level. The indication will flash if active. Light 11 .5. HIGH HIGH LEVEL Li 11.5.1. This is an indication that the HIGH HIGH LEVEL float, FS1,has been energized. A high water level condition exists. There is also a HIGH HIGH LEVEL Auto/Test switch available for testing the HIGH HIGH LEVEL circuitry and lamp. (• Operating&Maintenance Manual:Electrogage Duplex Pump Controller 11 Oak Park Heights,Mn. {` 40.6. HIGH HIGH LEVEL AUTO TEST Switch 11.6.1. This switch is used to simulate closure of float switch FS1. Placing the switch in the TEST position will energize relay R2 which in turn will light the HIGH HIGH LEVEL light and will energize relay HHLR. 11 .7. LOW LEVEL Light 11.7.1. This is an indication that the wetwell level has fallen below the low water level as detected by the LOW position on the Electrogage.At this point all motors are stopped when in the automatic mode regardless of any other activity, to prevent them from 'snoring' or running dry. 11 .8. SEAL LEAK Light 11.8.1. This is an indication that there is a seal leak in one of the respective motors/pumps. Service personnel should investigate and resolve the problem as soon as possible. In addition to the light there is a ALARM OFF ON switch which may be used to disable relays SLR1A and SLR2A. These relays provide dry contacts for telemetry. 1 .9. PHASE FAILURE Light ( 11.9.1. This is an indication that one or both of the Phase Control Relays (PMR-1 or PMR 2) has detected a loss of phase,under voltage, over voltage or phase reversal.The pumps) will not run until the particular fault is corrected. 11 .10. LAMP TEST Pushbutton 11.10.1. Pressing this button will test the lamps by lighting them and also turn on the alarm beacons and horns for testing. 11.10.2. Remote alarms or telemetering circuits monitoring the alarm contacts in the controller can also be tested by energizing them with the LAMP TEST pushbutton.. 11.10.3. CAUTION: Operators should be aware of whether they are connected to a remote alarm receiver, or security service before using this pushbutton., as these remote alarms will sound if connected. Connected services should be warned of testing. 11 .11 . RUNNING TIME Meters 11.11.1. The Run Time Meters provide a permanent record of the amount of time that each pump has been ON, as directed from the controller in either HAND or AUTO. (.1.11.2. Run time is generally of interest fox proper scheduling of maintenance of mechanical Operating&Maintenance Manual:Electrogage Duplex Pump Controller ]2 Oak Park Heights,Mn. 410 components. Please refer to the manufacturer's literature for the motor,pump, bearing, driveshaft and ventilation equipment for the correct scheduling of maintenance. 11 .12. HAND/OFF/AUTO Selector 11.12.1. This switch has three positions described below; 11.12.2. "HAND" position turns the pump on immediately, provided there is not a low level cutout condition.The following conditions will also prevent a pump from coming on line in the AUTOMATIC or HAND mode; OVERTEMPERATURE PHASE LOSS PHASE REVERSAL UNDERVOLTAGE OVERVOLTAGE OVERLOAD If any of these conditions are present it will be necessary for maintenance personnel to find and correct the condition locking the pumps out. Failure to do so will prevent the pump(s) from running. 11.12.3. OFF means that the pump motor is turned off from all power sources.Note that this control is not lockable and does not satisfy the requirements of a safety disconnect. Service personnel must must assure themselves that they have locked and tagged off (110 main power or other local service disconnect before servicing motors. 11.12.4. AUTO transfers control of the pump motor over to the Electrogage. All HAND controls on the pump panel will be ignored. 11 .13. LEVEL GAUGE 11.13.1. The level gauge,EG part number 10FW3I, shows the level of the water above the bottom of the bubbler tube.The gauge controls the pumps start and stop levels and also energizes the HIGH LEVEL and LOW LEVEL circuitry. 11 .14. CONTROL POWER ON/OFF 11.14.1. This control switches on and off control power to the bubbler panel. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 13 Oak Park Heights,Mn. Ali .15. MISCELLANEOUS 11.15.1. There are several circuit breakers utilized in the control panel which are used to provide voltage to various components. The following breakers are provided and they are named after the function they control: GFI DUPLEX(5CB) ALARM (7CB) HEAT (4CB) SPARE (6CB) 11.15.2. The Pump Control Panel also utilizes a Bubbler Air Monitor System (BAMS-20). The BAMS is used to provide air for the bubbler system. A complete detailed explanation of the Bubbler Air Monitor System is contained in the Appendix. 12. AUTOMATIC OPERATION 12.1. When all the HAND/OFF/AUTO selector switch is placed in AUTO, the controller will start to call for pumps in response to wetwell level sensed by the bubbler system and Electrogage. No separate "START" is required; it is always assumed that pumping is the first priority,and pumps will be started by the controller at any opportunity that presents itself and without needing operator approval. (v.2. The following conditions will prevent a pump from coming on line in the AUTOMATIC or HAND mode; OVERTEMPERATURE PHASE LOSS PHASE REVERSAL UNDERVOLTAGE OVERVOLTAGE OVERLOAD If any of these conditions are present it will be necessary for maintenance personnel to find and correct the condition locking the pumps out. Failure to do so will prevent the pump(s) from running. 12.3. In order for the station to carry out its designed function,operators are urged to check that the controls are correctly set and that all system are functioning perfectly before leaving the station unattended. 13. SHUTDOWN PROCEDURE 13.1. There is no special shutdown procedure, as the controller may be shutdown at any time either deliberately by switching the disconnect switches to OFF,or by unexpected power failure. 3.2. In any case, when power is lost, the controller is designed to abandon its then-current pumping situation so that when it comes back on line it takes a fresh look at the wetwell levels and then can rapidly assign pumps to account for the new conditions. L_ Operating&Maintenance Manual:Electrogage Duplex Pump Controller 14 Oak Park Heights,Mn. 1111 13.3. The controller may save any alarm situation that it is on its alarm annunciators for later viewing when power is restored. This function is determined by whether or not the MEMORY option has been provided for. 14. ADJUSTMENTS AND PROGRAMMING 14.1. WETWELL LEVELS 14.1.1. Wetwell levels at which the controller responds is a combination of the elevation of the bubbler tube in the well and the programmed stop and start levels on the Electrogage. Please refer to the relevant passages contained in "PNEUMATIC INSTALLATION" for setting the bubbler tube in the wetwell. 14.1.2. Refer to the passage above titled ADJUSTING LEVELS for details on how the levels are programmed into the Electrogage. 15. MAINTENANCE It is recommended that the following maintenance be done on this equipment on a routine basis: 110 15.1 . AIR SUPPLY MAINTENANCE 15.1.1. The air compressors require no maintenance. They are to be replaced when they fail. They are oilless, so there are no oil sumps to maintain. Contact EG Pump Controls for the correct replacement unit. 15.2. BUBBLER MAINTENANCE 15.2.1. Periodically make a visual check to be sure that the bubbler tube is properly secured by means of its mounting inside the wetwell. . 15.2.2. PURGE; If the level gauge appears to give unusually high or erratic readings it may be fouled. In this event it is recommended that the first step is to blow out the tube by using the purge provisions built into the Bubbler Panel. 15.2.3. On the ELECTROGAGE CONTROL plate place the NORMAL TEST/BLOWDOWN knob to the TEST/BLOWDOWN position. 16.2.4. Insert a air source(60-76 psi)in the BLOWDOWN PORT fixture and make an attempt to clear the bubbler tube.Watch for bubbles in the wet well. .2.5. The above sequence may be repeated as many times as required to clear the bubbler, however if the trouble remains,the bubbler tube may have to be removed from the well for repairs. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 15 Oak Park Heights,Mn. (1) 15.3. CONTROLLER MAINTENANCE 15.3.1. Lightly dust the controls if ever they accumulate dirt and dust. 15.3.2. Open the door every six months to check for dust, corrosion and any possible damp that has entered the enclosure. Correct the source of the problem as required. Check the seals on the front door to make sure that they are good; repair or replace as necessary. 16. TROUBLESHOOTING GUIDE We provide here a basic troubleshooting guide. Refer to the title that most closely fits the situation observed. Then follow the suggested possible causes associated with that failure and carry out the repair action suggested. Some headings have an explanation below them to aid in understanding some of the normal operation, or to give information. It is not possible to completely anticipate all possible failure modes of equipment of this complexity,therefore there may be situations which will not be covered here. If this occurs, it is recommended that qualified site personnel be contacted for assistance as a 011 first step. If site personnel cannot locate the cause of the problem and are unable to correct it,then it is recommended that E G Pump Controls be contacted for technical assistance. These notes below assume that main power is available in the normal way to each enclosure. If not,then the power feed to all enclosures should be checked and corrected by qualified individuals before proceeding. Problems associated with power will therefore not be covered here. 16.1 . BUBBLER AIR FLOW GOES UP AND DOWN EXPLANATION The air flow in a normal bubbler system will rise and fall as the wetwell rises and falls. When the level rises, the air flow will reduce somewhat and vice versa. This is normal and operators should not attempt to maintain a perfectly constant reading on the flowmeter, or they will be forever adjusting it for no good purpose. The ball in the flow meter should read 2 SCFH at a bubbler level of 10 feet. The ball may rise to indicate 3 SCFH when the wetwell is at low level. For other levels in between,the ball will settle at corresponding positions. What we would call trouble is any variation of the flow meter outside this range and particularly in an irregular fashion,i.e up one day and down the next, or the meter wandering up down down irregularly while you are looking at it. (i Operating&Maintenance Manual:Electrogage Duplex Pump Controller 16 Oak Park Heights,Mn. POSSIBLE CAUSE REPAIR ACTION 1 r The bubbler tube is fouled. Blowdown the bubbler tube. Carry out the procedure called PURGE under the section titled BUBBLER MAINTENANCE. 16.2. ALARM EXPLANATION An alarm indicates that there is a situation that requires immediate attention. Operators and staff should take Alarm very seriously as this is quite possibly an emergency condition arising. INDICATION The station large red globe light will flash. Telemetry will be indicating Alarm to remote stations. POSSIBLE CAUSE REPAIR ACTION Lamp test None High Level Investigate flow and pumping action. Low Level Investigate flow and pumping action. Overtemperature, any pump. OD Review other fail lights to determine which pump. Investigate cause. Overload, any pump Review other fail lights to determine which pump. Investigate cause. 16.3. HIGH LEVEL Light EXPLANATION The action of the controller is to call for correct and sufficient pumping to maintain a moderate level in the wetwell. A tripping of the HIGH LEVEL light shows that somehow this has not been the case,or there is a sensor problem. INDICATION Too few, or no pumps running, wetwell water level is really too high. POSSIBLE CAUSE REPAIR ACTION Failure of one or more pumps and/or their drives. Review other alarm and status indications and determine cause. Check that circuit breaker(s) are ON to f the controller. Check that the service disconnects are ON. Check fuses, where required. Hydraulic problem, closed vstuck valve, obstruction in impeller. valve, gate Check drywell gate valves and ball valves are open. Measure or estimate flow of each pump and its influence on the wetwell level. One that seems to pump slower than normal, also if it vibrates, should be opened for inspection. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 17 Oak Park Heights,Mn. (4) 16.4. LEVEL GAUGE DOES NOT GO TO ZERO WHEN WELL IS LOW EXPLANATION The level gauge reads pressure at the control panel and is therefor susceptible to problems in the bubbler tube and the pipe that connects it to the control panel. Frictional losses such as these cause the gauge to read higher than the true wetwell level by a constant amount. If this amount is not large and there is no known defect in the tube,it may be accounted for by adjusting the control setpoints(contacts on the gage)to be higher by the same amount. If full use must be made of the entire gage down to zero,or the gage error is objectionably high, then follow the troubleshooting below. PROBLEM Gage reads 3"to 9"with no water on the bubbler tube. POSSIBLE CAUSE REPAIR ACTION Air flow too high Check that the flow as indicated by the button on the flow meter is between 1.5 and 3 SCFH on the scale.This varies slightly as the water rises in the wetwell. Adjust by means of the control knob installed in the gauge. If these indications cannot be achieved, then service the air system accordingly. Air flow too low and due to bubbler tube fouled Blowdown the bubbler tube. Carry out the procedure called BLOWDOWN under the section titled BUBBLER MAINTENANCE Air flow too low because of restriction in bubbler tube or connecting tube. Insect the tube for dents,kinks, sharp bends(on a new installation look for improperly applied pipe tape, water, dirt etc.) and obstructions of any kind and repair as necessary. Air flow is normal; Partial restriction of the bubbler tube or its connecting pipe. Physically inspect the entire length of the connecting pipe or hose to find possible places of restriction. Remove obstructions. Air flow is normal; Connecting tube may be too small for the distance to the wetwell. For lengths 0-50 feet;use 3/8 in dia tube. For lengths 51-100 feet;use 1/2"dia tube For lengths 101-200 feet;use 3/4"dia pipe. For lengths 201-400 feet;use 1"dia pipe. Install the connecting tube sized per the above for proper zeroing of the Gage. PROBLEM Gage reads greater than 9"with no water on the bubbler tube. POSSIBLE .A TSE REPAIR ACTION 110 Improperly set NORMAL/TEST/BLOWDOWN control. Check the control is in the NORMAL position. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 18 Oak Park Heights,Mn. ( • Bubbler tube fouled Blowdown the bubbler tube. Carry out the procedure called BLOWDOWN under the section titled BUBBLER MAINTENANCE. Restriction in bubbler tube or connecting tube. Insect the tube for dents,kinks, sharp bends(on a new installation look for improperly applied pipe tape, water, dirt, trash etc.)and obstructions of any kind and repair as necessary. 16.5. LEVEL GAUGE DOES NOT READ (with water In the wetwell and no other fail indications) POSSIBLE CAUSE REPAIR ACTION Improperly set NORMAL/TEST/BLOWDOWN control. Open the Bubbler Panel and check the control is in the NORMAL position. Disconnected,cut or broken bubbler tube. or connecting tube. Inspect the entire bubbler tube and connections all the way from the control panel to the top of the bubbler tube in the wetwell. No air flow Check the air supply pressures and setting of the Flow Meter. • 16.6. LEVEL GAUGE IS AT THE TOP ALL THE TIME POSSIBLE CAUSE $EPAIR ACTION Improperly set NORMAL/TEST/BLOWDOWN control. Check the control is in the NORMAL position. Improperly adjusted Flow Meter Check the control on the Flow Meter inside the controller and use this to correct too great a flow to the bubbler. If this control does not respond,then there must be a problem with the piping and hoses inside the controller. Bubbler tube blocked If there are proper pressure readings in all the air system gauges, turn the NORMAL/TEST/BLOWDOWN control to the TEST position. Without anything connected to the Test Port adjacent,the gage should drop to zero. If this is so,then inspect the bubbler tube and connecting pipes for complete blockage. If the gage does not drop to zero,then there is a blockage in the tubing in the controller itself, or some improper connections have been made inside the controller. (! Operating&Maintenance Manual:Electrogage Duplex Pump Controller 19 Oak Park Heights,Mn. 16.7. LEVEL GAUGE TOO HIGH POSSIBLE CAUSE REPAIR ACTION Too high an air flow Check the reading on the Flow Meter and adjust to 2-3 SCFH. Obstruction in bubbler tube Refer to the section above titled"LEVEL GAUGE DOES NOT GO TO ZERO WHEN WELL IS LOW" for ideas on what may be the cause of this problem. 16.8. LEVEL GAUGE TOO LOW POSSIBLE CAUSE REPAIR ACTION Improperly set NORMAL/TEST/BLOWDOWN control. Check the control is in the NORMAL position. Leakage in the bubbler tube,or the connecting tubes and pipes Test and inspect the bubbler tube and check the entire length from the controller to the wetwell for leaks. 6.9. LOW LEVEL Light EXPLANATION Low level in the wetwell is dangerous because if the level drops below a certain point, a working pump may ingest air. A small proportion of air has a disastrous effect on the pumping power of the pump. Pumps may be seriously damaged if they are operated for long periods with air. Besides, it is also a waste of energy. Engineers always establish a LOW LEVEL in the wetwell which is designed to avoid this. Specifications therefore are typically written where if the low level is reached, all pumps must be automatically turned off. Difficulty comes if some pumps are left to run in the HAND position. INDICATION Actual wetwell level is very low, pumps are running and may be 'snoring'. POSSIBLE CAUSE IMPAIR ACTION Pumps in MANUAL. Turn HAND-OFF-AUTO switches to OFF or AUTO. If pumps do not appear to stop in OFF, starters have stuck,or welded contacts. If necessary,stop the pump by turning disconnect switches to the OFF position. INDICATION Actual wetwell level is about normal and some pumps are running but appear normal. Operating&Maintenance Manual:Electrogage Duplex Pump Controller 20 Oak Park Heights,Mn. l • DOES NOT RUN 16.10. PUMP MOTOR0 S POSSIBLE CAUSE REPAIR ACTION Service disconnect OFF or removed? Replace disconnect link plate, or switch ON disconnect switch. If motor emits a load hum,but does not turn it may be due to a jammed pump impeller. or single-phasing on the power line. Turn off the motor service disconnect and attempt to turn the motor shaft by hand. It should be possible to move the shaft by hand. If not,you may have an obstruction in the impeller, or a bad bearing on the driveshaft. Uncouple the motor from the driveshaft and test the motor by itself Find out whether the pump or the motor has the problem. `41° t410 � . . . � . Operating&Maintenance Manual:Electrogage Duplex Pump Controller 21 Oak Park Heights,Mn. t7. SPARE PARTS LIST The following Spare Parts List is a list of repair parts recommended to have on hand for the local service of one one controller at one location for 1-5 years. DESCRIFIION SUPPLIER PART# Q TY FUSE, 5AMP LITTLEF FLQ 5 2 FUSE, 1/8 AMP LITTLEF FLQ 1/8 3 FUSE, 10AMP LITTLEF FLM 10 1 RELAY, PLUG-IN, 120 VAC EATON D5PR3A 5 RELAY, PLUG-IN, 24 VDC EATON D5PR3T1 2 RELAY, INTRINSICALLY SAFE GEMS 22445 1 TIMER, ON-DELAY SYRELEC PAR2B110 1 TIMER, ON-DELAY, 24V SYRELEC PAR2B24 1 TIMER, OFF-DELAY SYRELEC LCR2B110 1 PILOT LIGHT, GREEN EATON 10250T181N-C2N 1 PILOT LIGHT, RED EATON 10250T181N-C1N 4 AIR COMPRESSOR INGRAM HR1OWB 1 LAMP 40W, APPLIANCE SYL 40A19 1 PHASE MONITOR RELAY SYRELEC PWR.U440 1 (-6• Operating&Maintenance Manual:Electrogage Duplex Pump Controller 22 Oak Park Heights,Mn. 8. INDEX 18.1. 2 ABBREVIATIONS 2 ADJUSTING LEVELS ON THE ELECTROGAGE 6 ADJUSTMENTS AND PROGRAMMING 14 Air Compressor 2 air pumps 4 AIR SUPPLY MAINTENANCE 15 ALARM 16 ALARM (7CB) 13 ALARM LIGHTS, Principles of Operation 9 ALT2 APPENDICES 25 AUTOMATIC OPERATION 14 BAMS 2 bonding and grounding 4 bottom of the gauge 4 bottom of the tube 4 BUBBLER AIR FLOW GOES UP AND DOWN 16 Bubbler Air Monitor System (BAMS-20). 13 bubbler level control system 3 BUBBLER MAINTENANCE 15 Bubbler Outlet 5 bubbler tube 4 (0 Bulletin EG-791 6 CAUTION 1,2 CB 2 COLOR CODE 3 CONTROL POWER ON/OFF 13 Controller 3 CONTROLLER MAINTENANCE 15 couplings 7 CPT 2 Danger 2 DEFINITIONS 2 DESCRIPTION 3 Down 2 DRAWINGS (In packet) 1 driveshafts 7 EG2 Elapsed Time Meter 2 electrical enclosures 7 ELECTRICAL INSTALLATION 3 ELECTRICAL STARTUP 7 ETM 2 Failed 2 first-time motor/pump starting 8 FIRST-TIME START-UP 6 FLASHING ALARM BEACON Light 9 (. fluctuating readings 5 FRONT PANEL CONTROLS EXPLAINED 10 Operating&Maintenance Manual:Electrogage Duplex Pump Controller 23 Oak Park Heights,Mn. GFI 2 \ • GFI DUPLEX(5CB) 13 GREEN lights 3 ground rods 4 GROUNDING 4 HAND/OFF/AUTO Selector 12 hazards 1 HEAT(4CB) 13 HHL3 HIGH HIGH LEVEL 9 HIGH HIGH LEVEL AUTO TEST Switch 11 HIGH HIGH LEVEL Light 11 HIGH LEVEL 9 HIGH LEVEL Light 10, 17 HL 3 HOA 3 ISR 3 LAMP TEST Pushbutton 12 LEVEL GAUGE 13 LEVEL GAUGE DOES NOT GO TO ZERO WHEN WELL IS LOW 17 LEVEL GAUGE DOES NOT READ 19 LEVEL GAUGE IS AT THE TOP ALL THE TIME 19 LEVEL GAUGE TOO HIGH 19 LEVEL GAUGE TOO LOW 20 level sensors 4 1111 LINE POWER 3 LL3 LOW LEVEL Light 11,20 LT 3 MAINTENANCE 15 HANICAL STARTUP 7 MISCELLANEOUS 13 motor mounts 7 motors 7 MSR 3 National Electric Code 4 NORMAL START-UP 9 OL 3 OT 3 OVERLOAD 8 OVERLOAD TRIPPED Light 10 OVERLOAD TRIPPED 9 OVERTEMP 9 OVERTEMPERATURE 8 OVERTEMPERATURE Light 10 OVERVOLTAGE 8 PANEL CONTROLS, Principles of Operation 10 PHASE FAILURE 9 PHASE FAILURE Light 11 PHASE LOSS 8 PHASE REVERSAL 8 410 PMR3 PNEUMATIC INSTALLATION 4 PRINCIPLES OF OPERATION 9 ' .. a's..F:..a '. '..r:. :: ' .r ii.Vsar..:L::«r ...4�Y. :E,a.•_...:wiiA.J/YwXJ.adw+YFb*a%dYa.i>..r. >>`,f`-S: 'W:+: ,. .. yw«-aww.r Operating&Maintenance Manual:Electrogage Duplex Pump Controller 24 Oak Park Heights,Mn. f PUMP MOTOR DOES NOT RUN 20 ( PUMP ROTATION CHECKS 8 PURGE 15 R3 RECORD THE CONTROL LEVELS OF THE WELL 6 RED lights 3 RESET Button 10 rotation in the wrong direction 8 RUN 9 RUNNING TIME Meters 12 SAFETY WARNINGS, Cautions 1 SEAL LEAK 9 SEAL LEAK Light 11 seal water 7 SETTING THE BUBBLER TUBE 6 SHUTDOWN PROCEDURE 14 SPARE(6CB) 13 SPARE PARTS LIST 21 START-UP PROCEDURE 6 STEADY ALARM Light 9 TR 3 Tripped 2 TROUBLESHOOTING GUIDE 16 turbulence 4 UNDERVOLTAGE 8 UV3 1110 WARNING 1, 2 WETWELL LEVELS 14 WIRING 4 !• Operating&Maintenance Manual:Electrogage Duplex Pump Controller 25 Oak Park Heights,Mn. ( . APPENDICES Appendix Title I Magnetic Starter Information(EATON, AE16) II Thermal Overload Information (EATON C306) III Lightning Arrestor Information(HULK) IV Phase Control Relay Information(SYREELEC) V Alternating Relay Informtion (SYRELEC) VI Relay Information (EATON, Model D5) VII Relay, intrisically safe Information (GEMS) VIII Timer Relay Information (SYRELEC) IX Flasher Information (SSAC) X Hour Meter Information(IVO) XI Transformer Information(BASLER) XII Transformer Information (GE) XIII Electric Heat Thermostat Information (WWG) XIV Capacitor Specifications(ASEA BROWN BOVERI) XV Alarm Panel Light Information (INGRAM) XVI Bubbler Air Monitor System Information (EG PUMP) XVII Electrogage Bulletin Information(EG-791) XVIII Enclosure Information (ELECTROMATE) XIX Circuit Breaker Information (EATON CUTLER/HAMMER) XX Circuit Breaker Information (GE) XXI Oiltight Pushbutton Information (EATON CUTLER,/HAMMER) • (11b CUTLER-HAMMER FREEDOM SERIES 45 711190 :.._.,..�_.�... ........:. . . .. ". ;;v I.E.C. Style 3 Phase Starters — Magnetic �'AE16 I7Full Voltage Non-Reversing -- 600 Volt Max. VTYPE AE16 I.E.C. STARTERS -- MANUAL OR AUTOMATIC RESET OVERLOAD RELAY MAXIMUM HORSEPOWER 0 OPEN TYPE--3 POLE . Magnet With Side Mounted Without Holding SIZE Coil HoldingCircuit Contact 0 Circuit Contact Motor 1 3 Voltagge • Voltage Phase Phase (60 IQ) Cat.No. Price Cat.No. • Price 115 1/4 --- 120 0 AEI6ANSOA AEI6ANOA �-• -� --- 1-1/2 208 ANSOE ANOE !''�'i'e�!'yJ A 230 1/2 1-1/2 240 ANSOB 5142. AMOK $129. s 460 3 480 ANSOC ANOC Y 1 / 575 --- 5 600 ANSOD AN00 • 115 1/2 --- 120© AE16BNSOA AE1BBNOA j����� 200 --- 2 208 BNSOE SHOE r: B 230 1 2 240 DIM 156. SNOB 138: : 460 --- 5 480 BNSOC BMX r.-!....1•%,--,e, - 575 --- 7-1/2 600 BNSOD 81100 115 1/2 --- 120 0 AEI6CNSOA . AEI6CNOA 200 3 208 • CNSOE CNOE 230 2 3 240 MOB186. CNOB 168. 45 mm Frame Width C 460 --- 7-1/2 480 CNSOC ' CNOC • 3 Power Poles 575 --- 10 600 CNS00 CNOD • 115 1 --- 120© AEI6DNSOA AEI6ONOA - i 1'7'3 200 --- 5 208 ONSOE DNOE Zt';}T D 230 _3 5 240 ONSOB 207. ONOB 189. 10 480 UNSOC ONOC •■ • 575 --- 15 600 IMOD IMOD - 115 2 --- 120 0 AEI6ENSOA • AE16ENOA • II ` - 200 --- 5 208 ENSOE (NOE E 230 3 7-1/2 240. ENSOB 219 (NOB 201. t : 460 --- 15 460 ENSOC ENOC •4.•• • 575 --- 20 600 (MOD ENOD e*M" 'P/ L 1150 -2 7-1/2 igi AEI6FNSOA AEI6fj1DA 230 5 10 240 FNSOB 270. MB 252. 45 mm F q6p SS 480 FNSOC ROC Frame Width 5755 600 INSOD FNOD -3 120 0 AEI66NSDA ." 200 7-1/2 208 6NSDE • SHOE ct�' r tG 230 5 10 240 6NS08AEI66NOA 6NSOC 348. • SNOB NH . • 330. 460 --- 25 480 lll° f4 -. 575 --- 30 600 6NSOD GNUi; ,. ' 115 , :- 115 3 --- 120 0 AE1SHNSOA AE16HNDA . 1 -;Aim ---20010 208 HNSOE • HNOE - "t+~t,. H230 460 30 7-1/2 15 240 480 HNS08 HNSOC 366. HNOB HOC348. r-44,f 575 --- 40 600 HNS00 IMOD (� 115 -5 --- 120 0 AEI6JNSOA AE16JNOA 200 15 208 JNSDE JNOE li e J 230 10 20 240 JNSOB 420. JNOB 402. 460 --- 40 480 JNSOC JNOC • • e 575 --- 40 600 JNSOD JNOD 65 mm 115 5 --- 120 0 AEi6KNSOA AEI6KNOA Frame Width 200 --- 20 208 KNSOE KNOE K 230 10 25 240 KNSOB 453. KNOB 435. 460 --- 50 480 KNSOC KNOC i s+ . 575 `-- -50 600 KNSOD KNOD 115 7.112 120© AE16LNOA _ —�, ."•,••!.• ,ri 200 25 208 LNOE ___ ___ 230 15 30 240 LNOB • 585. ~ �' 460 --- --- 75 600 LNOC _-.1 .A 575 115 10 --- 120 0 AEI6MNOA LtL4 200 --- 30 208 MNOE M 230 15 40 240 MNOB 753. 460 --- 75 480 MNOC ee _�, 575 --- 100 600 MNOC 1te 714'4:V.;:?... 1i 1<:��'+r 115 10 --- 120© AE16NNOA 200 --- 40 208 NNOE __ ___ !'� N 230 15 50 240 NNOB 1110. 90 mm i$inii' 460 --- 100 480 NNOC - Frame Width 575 --- 125 600 NNOD Prices of starters do not Include hater pecks.Select 1 carton of 3 heater packs at$27.total. Heater pack selection.Pape 63. ' 0 On I.E.C.Sizes A through C,the 4th power pole position is used as the side mounted 0 For separate 120 V control circuit.For maximum hp at fisted motor voltages.use the auxiliary contact and adds no additional width to the standard device.Size A-K rating of Other starters of same size. starters may be supplied with a top mounted holding circuit contact Instead of a ®Maximum horsepower retina of starters for 380 V 50 Hz applications: 0 side mounted contact.To order,changye the 7th digit of the listed catalog number 40 from I.E.C.Size A 8 C 0, E F OHJK L M N "S"to"T".Example AE1OAN rOA. Horsepower 3 8 714 10 15 20 25 30 40 60 80 78 100 DISCOUNT SCHEDULE 160-1 DIMENSIONS, Pape 46 ACCESSORIES,Pages 58.62 Pnnletf in U S A. F:Tial i GG 45 CUTLER-HAMMER FREEDOM SERIES w 63' 7/1/90 ciks k..t ' ?'• Thermal Overload Relays 'C 0•'1 Manual or Automatic Reset I . DESCRIPTION ~ - ; t Type C306 Manual or Automatic Reset overload relays are r WM designed for use with Type CE or CN non-reversing and ; ' r '✓ 2.43reversing contactors.Four sizes are available for overload � � I ! • 1. l 0. . protection up to 144 amperes. The 32 and 75 A overload - 1 J relays can be directly attached to contactors.Alternately, ` c.?g+V • - � r these relays can be DIN rail mounted-see adapter listed 1.,. 4 1 t � below. The 100 and 144 A overload relays are panel .. •7: 1 mounted only. Features include: 32 Ampere Overload 75 Ampere Overload Cat. • • Selectable Manual or Automatic Reset operation. cat.No.C306DN3 No.C306GN3 • Interchangeable Heater Packs adjustable±24%to match H EATER PACKS motor FLA and calibrated for 1.0 and 1.15 service factor MANUAL OR AUTOMATIC RESET motors. Heater packs for 32 A overload relay will mount in 75 A NOTE: Heater packs are shipped 3 to a carton. Catalog overload relay-useful in derating applications such as Numbers and prices listed below are for 3 heater packs. jogging. Motor Full Load Ampere Rating 0 Catalog Number Price • Bimetallic, ambient compensated operation. Trip free Dial Position (Includes 3 Heater Packs) (Includes mechanism. Fast Trip Std.Trip 3 Heater A B C D Class 10 Class 20 Packs) • Electrically isolated NO - NC contacts (pull RESET FOR USE WITH NEMA SIZES 00-2,I.E.C.SIZES A-K ONLY button to test). .283 .328 .374 .420 N2101.3 $2001.3 • Shrouded or"finger proof"terminals to reduce possibility .421 .488 .556 .623 $2102.3 $2002.3. of electrical shock. .624 .724 .824 .924 $2103.3 $2003.3' .925 1.07 1.22 1.37 $2104.3 $2004-3 • Single phase protection. 1.38 1.60 1.82 2.04 $2105.3 $2005-3 TYPE C306 THERMAL OVERLOAD RELAYS 2.05 2.38 2.713.03 112107.3 $2007-3 . $27 2.53 2.93 3.34 3.74 112107-3 112007.3. 3.70 4.29 4.88 5.48 H1122110898:33 2108-3 $2008-3' MAXIMUM Number OPEN TYPE NEMA 1 ENCLOSED 5.39 6.25 7.11 7.98 $2109 3 $2009 3 AMPERE of is Catalog;;, Price Catalog' `' 7.83 9.08 10.3 11.6 H2110-3 H2010-3„ RATING Poles y Price •,,Number:,=. ..Num , 10.8 12.4 14.1 16.0 112111-3 H2011-3;• 32 3 i, C306DN3; $ 63. C306063 ; S 87. 16.1 18.7 21.3 23.8 H2112-3 $2012.3: 75 3 '-'.?.--;.1,''. 6N3'' 108. `.•Z,;t? .663V" 156. 21.6 25.1 28.5 32.0 $2113 3 $2013 3 105 3 KN3 ' 156. '.= ;1 �E,, --- FOR USE WITH NEMA SIZE 2, I.E.C. SIZES G-K ONLY 144 3 ,$$3 216. -,-.7. -::,;:.4... : --- --- . ,._.. 27.0 31.3 35.6 40.0 112014.3. 27.4 30.7 34.0 37.3 $2114.3 --- DIN RAIL AND PANEL MOUNTING ADAPTER 35.32.5 39.0 37.7 42.5 46.0 $2115.3 H2015-3 These adapters are required 42.1 48.8 55.6 62.3 --- 112016-3 27. when component overload 44.5 49.6 54.8 60.0 $2116.3 --- '.�'r 50.6 58.7 66.8 74.9 - - H2017.3 relays are to be separately , , .- --- mounted. The terminal base e 58.0 63.6 69.3 74.9 $2117.3 adapter includes line ter- ' FOR USE WITH NEMA SIZES 3-4,I.E.C.SIZES L-N ONLY minals and connects with the 18.0 20.2 22.3 24.5 --- $2018.3 overload relays listed above. Cat.No. 24.6 27.6 30.5 33.4 _ $2019.3 33.5 37.5 41.5 45.6 $2020.3 C306Ta1 1 , ,_ 45.7 51.2 56.7 62.1 --- $2021.3 Z7. Description Catalog Number: Price 62.2 69.7 77.1 84.6 `-- 112022.3 84.7 95.0 105.0 115.0 H2023.3 For 32 Ampere Overload Relay C3061111:-U: $ 9. 106.0 118.0 131.0 144.0 --- $2024.3 • For 75 Ampere Overload Relay TB2!V18. FOR USE WITH SIZE 5 STARTERS ONLY 55.5 64.2 73.2 82.2 --- $2004.3 CONTACT RATINGS (Amperes) 82.8 96.0 109. 122. --- $2005.3 . Ac Volts 123. 143. 163. 182. --- 112006.3 • 27. Current 152. 176. 200. 224. --- $2007.3 120 V 240 V 480 V 600 V 222. 257. 293. --- --- H2008.3 - NC CONTACT(8600) FOR USE WITH SIZE 6 STARTERS ONLY Make& Interrupting 30 15 7.5 6 165. 192. 218. 245. I --- 112005.3. . Break 3 1.5 0.75 0.6 246. 286. 325. 364. --- 62006.3 . 27. 0 Continuous _ 5 5 5 5 304. 352. 401. 449. 1 --- 412007.8 qt." NO CONTACT(C600) 444. 515. 585. 62008-3' Make Interni tin 15 7.5 3.375 3 0 For motor full load amperes between listed values,adjust dial clockwise for higher p g or counterclockwise for lower motor currents.The currents listed are for 1.0 and Break 1.5 0.75 0.375 0.3 1.15 service factor motors.A position adjustment is provided for 1.0 service lactor Continuous 2.5 2.5 2.5 2.5 motors. DISCOUNT SCHEDULE 1C0.1 7rmted,n U 5 A I .t•N °G 63 .. . • , . HULK ILI..4 A THE COMPLETE FAMILY OF ELECTRONIC SYSTEMS SECONDARY SURGE ARRESTERS A DIVISION OF 11/1DC INDOOR OR OUTDOOR USE Designed to protect complete computer systems as well as electrical systems and solid state electronics for industry and home. a Hulk is a solid state,heavy duty lightning arrester and transient surge suppressor that is installed at the indoor service entrance panel or on the weatherhead where the utility permits. When a destructive lightning surge enters the wiring, Hulk clamps the voltage to a safe level in nanoseconds,absorbing the potentially _ dangerous pulse and dissipating it harmlessly to ground. Hay- ing protected your valuable electronic circuitry,Hulk immediately , self-restores, ready to protect against the next surge. Hulk also protects against power switching surges and induced ^ - AC surges that are proven to be extremely destructive to corn- , puter and other electronic and electrical equipment. It is far , superior to air-gap devices which typically allow over 2000v to .• pass through and damage electronic equipment. I Hulk is completely encapsulated,weatherproof and built to with- 9 0 0 1 stand great impact without imparing its ability to protect against kly surges. Hulk, guardian of Computer Systems, , Industrial, Home and Farm Equipment For industry Computers, motor controllers, testing laboratory equipment, motors, metering, security, traffic control, fire alarm and com- munication equipment. In the home SPECIFICATIONS Computers,video games,color television,fire and burglar alarm Peak Surge Current 25KA systems, citizens band radios, microwave ovens, hi-fi stereo Surge Life: (Calculated) 10,000 occurances a200 amps systems, digital clocks, air conditioning and heating systems, ENERGY: HE500S 270) major appliances and many other items. HE1203 270J On the farm HE4803550J Electric motors,submersible pumps,milking equipment,incub- Response Time ...< 5NS ators,coolers,freezers,refrigerators and other electrical and elec- CLAMP VOLTAGE: HE500S HE12 HE48D3 Ironic equipment. (let through) es !KA 385V 385V 1400V Note:Hulk only protects against damage due to lightning and AC @ 5KA 600V 600V 1600V power surges. a 10KA 825V 825V 2000V MAX. ALLOWABLE VOLTAGE: (L-N or L-G) HE500S 175 VAC _._ zn fi HE1203 175 VAC �M-, � = z T HE4B03 550 VAC '} `,� "• r Current Drain <100 micro amps Y".. 1 *cInsulation to GND over 10KV sec. 4i:'. -. : _1_._ irk : LISTED L. "a 1' ' ' ..L 2E03 Mounting through panel 1Leads 12 AWG, 18" long ' Dimensions 2" L x 2" W x 1.5k 0 1060 E. INDUSTRIAL DR. ORANGE CITY, FL 32763 (904) 774-4551 (FAX) 774-5520 TYPICAL WIRING DIAGRAM WARNING • HULK should be installed only by a qualified electrician.Unqualified per. HE 500S sonnet may install the arrester incorrectly, making it inoperative or in- lit H' effective.Such persons are also In danger of working with high voltages • BLK and not having enough experience to prevent injuries to themselves from 2 ; . at BLK electrical shock,DO NOT ATTEMPT TO INSTALL THE HULK ON LIVE to �/"'" WHT WIRES. ui Cc • LINE TO NEUTRAL ANSI C62.11 OSCILLOGRAMS • VOLTAGE CANNOT EXCEED 175 VAC-RMS HE 500S — — — — HOT HE 1203 '..,_ BLK { 4 w• HOTI. BLK • > t ? '— _ HOT E, BLK• • o o _ i cc _ -'._ )- NEUTRAL f WHT $ .n . - -i '- wi • LINE TO NEUTRAL N • VOLTAGE CANNOT d _ _ EXCEED 175 VAC-RMS HE 1203 Y . , A.r j - HE 4803 BLK °'•' ` ' .. ar..ea� i--. . _. ��,s • HOT 4 1 Clamp Voltage-385V. w e HOT BLK �✓ 1.5 KA(8x20 us)(HE 500S) w • • HOT ,0 ELK -- x NEUTRAL WHT I/` _ V - LINE TO NEUTRAL >1 1- ' �.4 a VOLTAGE CANNOT a 5 i .i' , k 1 • EXCEED 550 VAC-RMS HE 4803 > = ; .:a I -i ---! .moi i6 C • i w te� •u Nj Installation on > _ v .� Outsides of 111111 0 Service Entrance Clamp Voltage- 600V Panel 5KA(8x20 us)(HE 500S) (Connect to wiring on load side i i T of main breaker or fuse box.) F + i Push out' " knockout in side of the panel. Slip threaded nipple sec- -__' �' i ' tion with three conductors through KO from outside the panel or fuse ij p 1 i �_ _ r box.Place 1/2"locknut over wires and tighten down on the threads from5 tel.. t, ,� inside. Make sure the locknut is securely tightened. Check the length 8 N _ Wank t _ 7 of the lead to make a secure,reliable connection to the service cables. N ' i _ Then cut the leads to the desired length.(The shorter the leads the bet- c I _ ' r N ter the protection.)First connect the white(ground)lead;then connect 1 ' the black (line)leads, all leads are No. 12 AWG tin plated, 18" long. j c Installation Inside the Service Entrance Panel Clamp Voltage-825V. 10KA(4X10 us)(HE 500S) Where it is impractical to mount HULK on the outside of the panel box, it may be installed on the inside.It can be placed safely in any position. The above oscillograms were taken using a Pierson,model 1025 cur- Find the most accessible area,in the wire raceway or on the wires.Mea- rent transformer, and a Tektronix model 466,dual trace,storage oscil- - sure and connect the leads as noted.Remember,the shorter leads give loscope.The significance of these oscillograms show that the outstanding greater protection, characteristic of the HE500S surge arrester does not allow any danger- Grounding ous or damaging high voltage condition to exist at any time,during or after the surge. -r the most effective installation,HULK should be connected to a low- Comparative testing of competitive products reveal that a danger- resistance angerresistance ground.Where the 1990 National Electric Code applies,see ous high voltage holdover condition exists during and after the surge Article 280.All Instructions above are subject to approvals by local elec- has ended. All surge testing was witnessed by Underwriters Labors- trical inspectors and utility requirements. tories, Inc. Controls piyrelec Controls WRU SERIES _ . , , ... . 4 IIhase Control Relay i - i-"I` U L•E80750 CSA•56339 ",,,.. z.. • Monitors _-. —'- — Phase Sequence -r� a tit 4m € { — Loss of Any Phase Even if _ _ Induced Voltage Reaches 95�Io f t of Nominal Voltage t �� �''hi; — Under and Over Voltage • LED Relay Status Indicator • SPOT IOA Relay Output MODE OF OPERATION WIRING DIAGRAM Vn.1056 ASI vn 111.5.111111111k Set Point M iIVn-1056 R = Ll 1 I I I I s S = L2 11 TaL3 R i 1 H If the phase sequence and the symetry of the 3 phases power __- °' supply is correct,the output relay is energized.The relay will iim�OOOMI- toalso stay energized if the value of the three phase voltages remains within t 100/0 of the value displayed by the top mm��I 1111111 mounted potentiometer. SPECIFICATION: STOP 1. _ OM Power Directly 3 x 220 VAC 60 Hz from Controlled Voltages 15% 3 x 380 VAC 60 Hz 3 x 440 VAC 60 Hz 11* Power Consumption 20 VA at 220V START 1. �'___j Output SPDT relay Contact Material AQCdo Maximum Loadih10 AC resistive IA DC inductive0 VD Maximum Switching Voltage 250 VAC 250 vDC Relay Max.Power Rating 2200 VA 30W 0 Mechanical Life of Relay 30 x 10'operations Electrical Life of Relay 2 x 10'operations a1 2200VA resistive load Operating Temperature ... .... .+14'F to *140'F -10"C to *80'C D W R U 11 12 14 R S T Weight ............ . 7 oz.(200 grams) Response Time 100 to 600 ms LW R U 1 4 3 5 6 7 (depends on the setting of the controlled voltage) PWRU 1 2 8 3 4 5 Fixed Thresholds =10%of displayed value ORDERING INFORMATION: L WRU 380 MOUNTING SERIES INPUT POWER / I \ .re MOUNTING SERIES U INPUT POWER D a DIN•fill or pine)mounting 220 a 3X 220 VAC I. a 11 pin plug-in 360 a 3X 380 VAC P a I pin plug-In 440 a 3X 4151440 VAC 63 Controls iyrelec Controls (110 . =JRSSERIES ..4. , t:,..7-----....,:„Alternating Relay with , t . > *l�: rSelector Switch t � r ' '~ - UL-E80750 • Duplex Alternating Control • SPOT or OPOT Control Relay ,, • 10 Amp Rated • Externally Controlled , • Selection of lead or lag load `V` The electronic alternating relay is designed to replace of the control circuit). When the control initiate switch is mechanical style devices used in control applications actuated and released or opened,the relay will change state. requiring a duplexing or alternating action of the control circuit The next time the initiate switch is actuated, it will change to operate pumps, compressors, etc. This is achieved by back to its original state.Two red LED's located on the top of activating a control switch which is common to one side of the the dust resistant enclosure provide the status of the relay.A input control voltage. The output contact of the relay(s) 3 Position Selector switch is installed for selection of normal change state when this switch is opened(on de-energization operation (alternating) or selection of lead or lag load. 611° SPECIFICATIONS: WIRING DIAGRAM Input Power 24 VAC/DC. 110. 220 VAC. :15%. 150/60 Hz) Power Consumption 24 VAC: 1 5V 24VDC: .8W 110 VAC: SVA 220 VAC1IVA PJRS PJRXS LJRS2 : Output SPDT 10A resistive wn Ali wnutt OPOT 10A resistive ,qt.wx■ "��,1t swnc- DPDT 10A crosswired ''� VQ © (�y VOi Minimum Pulse .. 30ms V © —.Q © Q Contact Material.. AgCdo © O t ,.0 Maximum Loading 10A AC Resistive BA DC inductive {j}.��Q z,� Maximum Switching Voltage... . 250 VAC 250 VDC t s 02:110.1 V m Maximum Power Rating 2200 VA BOW 4.-/- Mechanical ,mMechanical Life of Relay 30 x 10'operation wnu,(SWITCH • Electrical Life of Relay 2 x 10'at 2200 VA resistive load Operating Temperature 14'F to 140'F -10'C to +60'C Weight 2.8 oz.1100 grams) ORDERING INFORMATION: L JRS 2 110 MOUNTING SERIES INPUT POWER / . MOUNTING SERIES INPUT POWER I. e 11 pin plug•in ' JRII 2•DPDT 24 r 21 VACIDC P • S Din Dlug•rn PAS •SPOT lip . 110 VAC PJRX$•DPDT(cross wired) U0 . 220 VAC Not*: DPDT relay avaliable only wkh 11 pin plug4n(y. CUTLER-HAMMER RELAYS AND TIMERS 205 7/1190 General Purpose Plug-In Relays FILE r( " DESCRIPTION MOUNTING ACCESSORIES l These compact,industrially rated D5 300 Volt 10 Ampere Order in Standard Package Quantity noted below or in mul- Plug-In Relays have a transparent, polycarbonate dust tiples of these quantities.For quantity pricing,contact your cover to protect the contact surfaces from airborne dust nearest Eaton Corp.,Cutler-Hammer Distributor or call our and other contaminants. They can be supplied with an Customer Service Center 1-800-833-3927. Indicating Light-light ON when power is applied to relay Min. Ordering Catalog Price coil;and/or with a Push-To-Test button to manually actu- Description Quantity Number Per Unit ate contacts for circuit testing. PANEL OR CHANNEL MOUNTING These relays can either be channel mounted using acces- Screw Terminal Socket --- ` 05PA1 $ 8.00 sory relay Socketandchannel; or, the D5PA1 C381MC -=> Y Hold Down Spring -for applica = , can be snap mounted on standard 35 mm DIN rail using tions subject to shock or severe n.= Socket D5PA2. Accessory 11-Blade vibration-use with either . `'" Sockets have captive, self-lifting D5PA1 or D5PA2 Sockets 100 05P81 , .50 ....i_..-„. ., clamps,plus/minus screw heads and �t'* 1' Channel Clamps-used to terminal identification numbers a mount D5PA1 Socket to chan molded into the socket for ease of J` nel. Total number required is wiring. When used with D5PA1 or k socketsrto be mounted or.of D5PA2 screw terminal sockets, the P"t -. ` gether 100 D5PC1 .50 D5 Plug-In relayis UL Listed-Files ;, b` 10 6' 9- Aluminum Mounting Channel- E65675, E1491 and CSA Approved t 6' Lengths 10 C381MC 18 70 -Class 3211-04. - -- PANEL OR DIN RAIL MOUNTING Cat No.05Pa3A Screw Terminal Socket --- 05PA2 10.70 TWO AND THREE POLE - Double Throw End Clamp with Mounting Screw -used with track below,one . . Coil Features Catalog Price menacof end to prevent move 10 D5PC2. .70 Voltage Number Each relays TWO POLE-DOUBLE THROW 35 mm x 7.5 mm Aluminum DIN Mounting Track- 1"mount- 24 V.50/60 Hz --- '05PR2T.'t''' $14.00 ing centers-3'Lengths10 05P02 7.70 120 V,50/60 Hz --- ; PR 2A 14.00 120 V.50/60 Hz With Indicating Light 4 PR2IA 16.40 PUSH TO TEST BUTTON HOLD DOWN 110 120 V. 50/60 Hz With Push-To-Test Button PR22A 15.40 NOLO DOWN , * SPRING- _. 240 V.50/60 Hz --` OSI'R28 15.40 ,� 12 V dc --- 7 PR2R1 12.30 05PA2 SOCKET D5PA1 SOCKET I 24 V do '. PR2T1 12.30 .' DIN RAIL CHANNEL 110 Vdo --- ` ,PR2A1 14.00 END CLIAMP THREE POLE-DOUBLE THROW CLAMP / �r- ��- �: 24 V.50/60 Hz --- 05PR3T 15.40 ---"\' ilia120 V,50/60 Hz --- 4',PR3A 15.40 _._._ _ 120 V,50/60 Hz With Indicating Light ,},PR31A 17.70 120 V, 50/60 Hz With Push-To-Test Button 1 PR32A 16.70 DIN Rail Mounting Channel Mounting 120 V,50/60 Hz With Indicating Buttoned ``}PR33A 20.00 APPROXIMATE DIMENSIONS - Inches[mm] 240 V,50/60 Hz --- 05PR3B 16.70 D 12 V do --- r;PR3R1 14.00 1 24 110 V do -- - "PR3A 1 17.70 70 222 (;0 80 ,0 ----f (561 04 80 1 CONTACT RATINGS I 0 156 DIA p I eitpit17r III MTS HOLES j : ... 8 Ac-UL6300 Dc - - -- Volts Continuous Make, Break, Motor Volts Amperes '0 20 10I Ac Thermal Rating Amperes Amperes Load, Hp Dc _ _ 120 10 30 3.0 1/4 28 10L 240 10 15 1.5 1/2 125 0.5 .e._®_= [361 1 41 f`•1'38� .iiim } - �C C SPECIFICATIONS 1. 153 , ` - _�_i • Operating Times- 1391 L.- A Pick-Up-4- 15 milliseconds Dimensions in Inches[mm] Drop Out-6- 15 milliseconds Catalog Number Wide High OeCep Mounting I NI' • Nominal Coil Power- A B Ac-2.5 VA maximum D5PA1 1,89[48] 3.16[80] 1.20[311 1.64[42] Dc- 1,5 watts maximum 05PA2 1.71 [43] 3.15[80] 1.03[26] 1.56[40 DISCOUNT SCHEDULE 1C0-S8 Printed in U.S.A. E:T•N 00 205 DELAVA GEMS® C SWITCHING UNITS NO. 632 THD. vs? DIA. y .t / The GEMS SAFE-PAK is completely encapsu- @ O 0 ,(5.6 mm) :4. de ' -,..,,, lated,impervious to dust and foreign material, / -4h; 't ..; 2W and is shock- and vibration-resistant. Stan- p D •". - (57.1 mm) dard No. 6.32 binding posts are provided for ease of wiringand two tabs permit - . . . mounting on any surface, in any position. I @ O I 31/4' 21/4' ---3W (19.3 mm)V '(66.6 mm) (76.2 mm) OPERATING P/N P/N "'' VOLTAGE FOR NORMALLY FOR NORMALLY OPEN OPERATION CLOSED OPERATION When ordering SAFE-PAK Switching Units, please specify the correct P/L (Parts list) 95-135 22445 25872 number for operation required. 200.250 1 25873 — 1 I L E.:i, ; 2' l ,-.1 , . ] WIRING DIAGRAM . . . 11, MAX. RMS LOAD CURRENT 5 amps —1 MAX. ON VOLTAGE 2 V. LOAD MAX. SWITCH CURRENT • .1 ma VAC TURN-ON TIME 1 msec MIN. & MAX. AMBIENT TEMP 0°- 120°F. 0 0 0 OPERATING FREQUENCY 50— 60 Hz SAFE-PAK LEAKAGE CURRENT 12 ma Max. NON HAZARDouS LOCATION CASE MATERIAL Polysulfone O o , : SAFE-PAK Surge Time • • Load Rating .010 Sec. 1.0 Sec. 10 Sec. , 5 Amps. 50 20 10 HAZARDOUSLOCATION SENSOR SWITCH i "Intrinsically safe equipment and wiring is equipment and wiring which is incapable of releasing sufficient electrical or thermal energy under normal or abnormal conditions to cause INTRINSICALLY SAFE EQUIPMENT FOR CLASS I, DIVISIONS 1 AND 2 . . . ignition of a specific hazardous atmospheric mixture in its most from paragraphs 5.1 and 5.2 of Instrument ignited concentration. Intrinsically safe electrical equipment Society of America Specification ISA-R P12.2, and wiring may be installed in any hazardous location of any .ted 1965 . . . Group classification for which it is accepted without requiring explosion-proof housings or other means of protection." Gems products Include SWITCHES .. .Now,level,and solid-state; DELAVA SYSTEMS...tank level gauping,position indicating,and solid-state control. OELAVAL TURBINE INC, Technical Bulletins are available on all unite. GEMS SENSORS DIVISION Farmington,Connecticut 06032, USA rr M.a ill U.S.A. . -,.... aw a»m .. .:..-, ...,.. M. .«S.404,P.W4.-.r.us.1i w..., '. tL.i:.,...- - ' _;www;. Timers t yrelec Timers sC R2 SERIESY ti �. �-:,. DELAY ON BREAK TIMING. � .c...,.....,_ "'' ��` RELAY WITH SOA DPDTzi- -a 1y �..z. OUTPUT = s • UL•ES0750 .I. "� t,- Z rye. • • Multiple AC/DC Voltages `k "'4.„ :••• • 0• ,.. • 10 Amp DPDT Output Relay .. ; 'a:: I • Two Time Ranges • Initiate Switch Controlled Function C: Delay on Break Function C: Input power (Si) is continuously supplied to Input Power SI 1... the timer. When an external initiate switch (S2) is closed, the output relay is energized. Timing begins when the S2 Initiate Switch S2 f switch opens.At the end of the delay time(T),the output is .e de-energized and the timer is ready for another cycle. Relay ''�4► J s isolate the initiate switch (S2) from other circuits. tr•--may ( • • SPECIFICATIONS: WIRING DIAGRAM Input power 12 VDC.24 VACrDC,48 VAC/DC DCR2 LCR2 _ KCR2 110 VAC,220 VAC, x 15•/.,50/60 Hz '*"T "' ♦ S�_ 111.0 3 2 1 Maximum power consumption 24 VAC: 1.5 VA 12 VDC: 0.5W 82 48 VAC 2 VA 24 VDC: 0.8W S2 4.-o o— el} 110 VAC: 5 VA 48 VDC: 1.8W 220 VAC: 11 VA Ill Output SPOT Relay COCIE0�l�� y 1)0 9 8 7 Contact material Ag Cdo O O Maximum loading 10A AC resistive 1A DC inductiveFAIIII Q + ‹ Maximum switching voltage 240 VAC 30VDC 0 B LT A Relay maximum power rating 2400 VA 30W 0m®®1111® t O 0Transient protection 2500 volts r------ Mechanical life of relay 30 x 10'operation Input Electrical life of relay 2 x 10'et 2400 VA Power Repetition Accuracy s 0,5%at a constant ambient S1 Reset time Function C: 200ms during timing. Minimum contact closure time 50ms. NOTE: When start switch is closed and Operating temp -4•F to+ 140'F -20'C to+so'C power is applied,relay energizes. Weight 3 5 oz.(100 grams) The command contacts should be isolated from other circuits.The contact will operate on the same supply as the timer and will have maximum load of , Sma. ORDERING INFORMATION: D CR2 8 24 MOUNTING SERIES TIME NGE INPUT POWERDIMENSIONS: tine pogo 2 (Ilk MOUNTING SERIES TIM[RANG[ INPUT POWER II 0 • DIN•rall or panel mounting CR2 •Rage in 9.011 Immo•180 sees M Range • 11 seas•$40 min. 12 • 12 VDC 1. is 11 pin eluQ•in • 0.05 secs•b.e sacs- • 16 secs•160 secs 24 • 24 VAC/DC R • 11 pin spade • 0.26 soca•2.6 secs • 00 secs•000 secs 4$ • 41 VAC/DC • 2 secs•20 secs 't • 8 min•1O min 110 a 1101148 • 16 secs•10.0 secs • $4 min•$40 min 220 a 220 4 AC LOW COST SOLID STATE FLASHER FS100 Series ( . D Totally Solid State—No Moving Parts O Two Wire Leads Series Connection with Load , O Small Size-15/16"Dia.x 11/2"Long os`►.*" D Completely Encapsulated Circuitry i O High Inrush Capability _.-- O Low Cost O UL Recognized DESCRIPTION CONNECTION This line of AC Solid State Flashers is designed for low • INPUT • cost, high reliability, and to handle loads up to 200 watts. A direct replacement for thermal types. Operate inductive, incandescent or resistive loads. A first • —I LOAD I----• choice when low cost is required without sacrificing life. SPECIFICATIONS ( O FLASHER 1. Mode of Operation: ON/OFF recycling solid state flasher(continuous duty) II2. Operating Voltage: 24,120 volts AC, #15% i 50/60 Hertz t 3. Flash Rate: Factory fixed at 75 flashes per minute MECHANICAL #20% at nominal operating voltage 4. ON/OFF Ratio: Approximately 50% 1 5"14- ---Ho• 5. Load Type: Incandescent, resistive, or°inductive (°Specify RC types for inductive loads.) RE 6. Output: Fullwave AC or halfwave rectified AC .40e 'o nb • 7. Max. Load Rating Fullwave: 1 ampere steady state ' ; Halfwave:2 amperes steady state BLACK ,,,6' /: Eo 8. Inrush: 10 amperes maximum CT PA : BLACK 9. Operating Temperature: -20° to +60°C — ` 10. Custom Flash Rates Available: From 45 to 150 0 y'} NOTEBRACKET RE movADLE FPM±20% (Consult Factory) wins B•LONG fMINJ•zoA»c ORDERING INFORMATION Part Number Operating Voltage Rating Type FS126 •FS126RC 120VAC 1 ampere Fullwave FS127 2 amperes Hallways • FS146 1 ampere Fullwave •FS146RC 24VAC FS147 2 amperes Halfwave AR'Specify RC tor Inductive loads. CZ=Aft 11", --_ n A d.... 4nnn a..t.a...t----ttt. kl‘P assAAUP 1014e%efte aAAA • ( 4110 - hour meter B 148 series • * :. r;4 , will totalize the running time of AC operated machinery and 'iii-.4-1%Y.:,..:::::'-.---3.181.. r ' " equipment to indicate warranty periods, maintenance and ,--r , servicing intervals, facilitate the calculation of operating costs, etc. • - ...,-..f." ,~ standard models Q U M Q P it- - i -� B 148.1 : front 1.90 x 1.90 for square cutout 1.80 x 1.80 B 148.2 : front 2.16 x 2.16 for round cutout 2.00 x 2.00 au:.- rtsma. B 148.6 . base mounting standard specifications (UL and CSA approved) operation highly accurate time keeping is insured by a synchronous motor which drives the counter and a running indicator (III ..... `_ voltage ±10% : ., _ 115V 60Hz standard -24V-220V and 50Hz are optional 4• time range -99999,9H- 11 years- resolution 1/10H color- case black- hours : white on black- 1/10H : red on black 4nnnnnt* h connections .us .77.161—;-....' -- screw-pins on which can also be plug-on 0.25" tabs "' temperature +15° to +125° F standard tip:4._ - -.- mounting mounting spring clip or screws for base mounting ordering information - model -voltage and frequency dimensions B 148.1 B 148.2 B 148.6 base mounting 1.10 1 Deb ,.....tµ ri 1.4t .25— , C4a r 1-__ 1 7 111101117 18 ti, iii t IMF -, ; , ?I mit i - . 7' Om* 1 • 1 .........11. i h.... .II..... ' OA.* , moi.' $ .11 i.)0.-- squsrs cutout round cutout r .004 1.11O nCt.1114 4:e.00- - .. ..... —.....;,... ..4.„... t ti..k .� 47i4.......,%-', '�_•,. 'it -4w .q .cam';..' .Uw'....F•5+aw«i.a.e;iX:w,o.;ums*A aa:.an..a.'eWse.&wLti;;;#.ri%.`.:2_ ':Y+t.:.tm•:. ..w+ SLIT CS U APPLICATION WICK(UIP1(ILle I'N1►.NAI4Y 1."UU1fUIN WUt. .W 1..1."4: :c I o1+o4;,r•U1lMc►1 UL ANL►tr �.r • • •A.S. No. s 2 0 '0111.2 .4.4.52.E ::;%.:1.',.RAW'. ' r'r: DWG. No. REV _._._...� P/N.• ,; ' • • :�. SEP NAME =. QTY DATE . • QUOTE NO ...1•1:1:7 •,'' ', •..,, .' . ... 3A$uEN C 1•' '`BE i'D 013 2' , 4 0 0 . mm.k._93.j3. Ii . PRI..(P)'4 D : ':,,'SEC: (w....1 AbEI• bIAHK1t�Ci� ION I Jai l l CHECK INDICATES COMPONENT RECOGN ION. • CI:)ENTIFY APPROPRIATE Lora: ' c 1 ATiIN UL&C8A LISTED '• war 8E 1 2 1 61 0 0./i.1 I.D.NO..4.Q..I. 06A ; UL 8 CSA RECOCNIZEO taC*6 X , • PRI, 120 V 50160 HZ. Blk/Wht PRIMARY,TERMINATION UL USTED 104} SEC. 24 v off VA Yel/Yel SECONDARY TERMINATION UL RECOGNIZED 13806 • +• L . J CUSTOMER PART. NO. RAT'L REQ. DATE )UTLINE DRAWING Nor TO SCALE—DO NOT COPY—FOR REFERENCE ONLY jp.wvotdo off owoEiiED: 7/6/IA_ 2K2M FLAY •WELDED•'PLATE, WITHOUT END 'BELLS, 2 HOLE: HORIZONTAL ' •MOUNTIN••G•. . •,,,.;,, 9 1i" 9 • rig- 2 32 : 16 16 .'• I r_ ... , . tD up wort - <t . I!!ILLUh(4° l • ---------- • .in 4 3/4 T sloe . 1 1�4'-�— �. 6_: .. 2M ..:, . , 32 • .: • • • • 's.' i.. "ri'' 3 2 • • • of-ra-~ .tel INA. ' 2/• StRE'W TLLM. HOLE a/Ib/I`" MALI ta.C.' • 2 w„ACEII :.,;J . . TOLERANCES(Unless otherwise specified) 174 MAL a.c. � � •. 'RACTIONS t'hM •DECIMALS4A05"- • . . L•lAO TRRM$NAL S . •+- '•a►NeR Team.TERMIN • . '• ' NO. 1i•AWO LEADS` ' ' • ' •• • COLOR UNGTN ,STRIP. PM O••CRIPTI M MN •. '?1?OL'l.'A.C. SCREW 'RI.NO. 1 •'B1k. . . •6;".. . :. .3/4" . 01245 ' . , • )RLNQZ • . . N t �6 "' '" ...3)4/i• 012 • ' •, • ` '•.. ... '‘..1 — II 'SECONDARY Na Yel ,¢4„ . _2(4" 012 SECONDARY.N0.A _ •Jei , 6p. , 1/4" ,•1a&7 _ 1r ..; SEC.LINE CORD • ' . ' . - - - • 'LEAD TOLERANCE: LENGTH *W STRIP * '/a' (LENGTH INCLUDES ANY LEAD TERMINALS OR STRIP) . 40 "'SPECIAL MATERIALS,NOTES.OA INSTRUCTIONS"' •• Ey►N< !Nita* f1,1�Iry,f�.+RK'+'� )REPAREO ...�..J ,' • :NECKED Silt, r•vP • . We.. 1 �. ;..r: _.>, .. ._.:. - ......,w. ...,..... • ,,,rcniriaer2>.,a+..w.::.w_ .: ra: _h..;-,a ,. ...0..a (.0 GE Specialty Transformers ( Type General Purpose Transformers For General Lighting and Power Service Types QB,QMS,and Qj.. 600 Volts and Belot,'-UL Listed through )67 kVA Limited CSA Certification Single-Phase Data (Cont. next page.) Note: Refer to page 8-7 for maximum dimensions and weights. 240 X 480 Volts Primary 480 Vons Primary 600 Volts Primary Secondary 120/240 Vons Secondary 120/240 Volts Secondary 120/240 Volts - Trade Wiring ' Trade Wiring Trade Wiring Net Diagram Net Diagram Net Diagram 0 Price, No. 0 Price, No. 0 Price, No. t kVA Hertz Catalog Number Taps 90.90 (Page 8-14) Hertz Catalog Number Taps 00.90 (Page 8.14) Hertz Catalog Number Taps 00-50 (Page 8.14( .050-3 kVA Indoor/Outdoor,Type 08 .050 60 975162 N $ 31.60 1 60 975182 N $ 31.50 1 60 9151862 N $ 32.50 6 50/60 91518502 N 33.00 1 - - - - - 50/60 97516582 N 34.60 8 .075 60 975183 N 34.50 1 60 915163 N 34.50 1 - - - - 50/60 9T518503 N 35.50 1 - - - _. -- - - - - ._ .100 60 9751164 N 37.50 1 60 915104 N 37.50 1 60 9151864 N 39.00 6 50/60 97518504 N 39.50 1 - - - - - 50/60 97518564 N 41.00 6 .150 60 975195 N 45.00 1 60 975185 N 45.00 1 60 9751985 N 45.50 6 50/60 97518505 N 47.50 1 - - - - - 50/60 91518585 N • .4950 6 .250 60 975187 N 54.00 1 60 915187 N 64.00 1 60 9751887 N 55.50 8 50/60 91518507 N 67.00 1 50;60 97518547 2 57.00 2 50/60 91516587 N $2.00 6 - - - - - - - - • - - 50/60 91518567 2 55.00 2 .500 60 975188 N 74.50 1 60 975108 N 74.50 1 60 9151088 N 77.50 6 50/60 97516508 N 79.00 1 50.60 97518548 2 • 79.00 2 50/60 97518588 N $3.00 6 - - - - - - - - - - 50/60 97518568 2 33.50 2 .750 60 915189 N 95.50 1 60 975184 N 06 50 1 60 9751889 N '100.00 6 siar' 50/60 91518509 N 102.00 1 50;60 91518549 2 102.00N 119.00 2 50/60 97518589 N 105.00 6 't llio om_ $j5 g-Q N- - - - - - - 50/60 91510569 2 112.00 Z 50/60 91518510 ' N / 127 00 1 60 9751810 60 9751850 2 126 00 2 0 60 9751860 70 2 1 00 2 - - - - 50/60 91518550 2 127.00 2 50/60 91518590 N 132.00 6 - - - . -- - - - - - - 50/60 91518570 2 133.00 2 ffF" 1.5 60 9751811 N 146.00 1 60 9751811 N 145.00 1 60 9751891 N 156.00 6 1111 50/60 97518511 N 165.00 1 60 9151851 2 151.00 2 60 9751071 2 '1590.00 2 - - - - 50/60 91518551 2 155.00 2 50/60 97518591 N 155.00 6 - - - - - - - - - - 50/60 91518571 2 -.169.00 2 2 60 9751812 N 179.00 1 60 9151812 N 179.00 1 60 9151692 N .166.00 6 50/60 91518512 N 190.00 1 60 9751852 2 166.00 2 60 9751872 2 7 195.00 2 - - - - 50i60 91518552 2 190.00 2 50/60 91519592 N 200.00 6 - - - - - - - - - 50/60 97510572 2 207.00 2 3 60 9751013 N 221.00 1 60 9151913 N 221.00 1 60 4751993N • 227.00 6 50/60 91519513 N 234.00 1 60 9151953 2 227.00 2 60 9151873 1 • 249.00 2 - - - - 60 91518135 4 265.00 3 50/60 91518593 N 255.00 6 - - - - - 50;60 91519553 2 234.00 2 50/60 91518573 _ 2 264.00 2 5-25 kVA, Indoor/Outdoor,Type OMS 5 60 91218100402 N $05.00 1 60 97210100762 2 313.00 2 60 97218101602 N 327.00 6 50/60 97218105562 N • 339.00 1 60 97219101362 4 $45.00 3 60 97218101902 2 339.00 2 - - - - - 50/60 91210105502 N 339.00 1 - - - - 7.5 60 91216100502 N 423.00 1 60 97218100802 2 429.00 2 60 91218101702 N 452.00 6 50/60 97210105662 N 472.00 1 60 91218101402 4 473.00 3 60 97218102002 2 466.00 2 - - - - - 50/60 97218105602 N 472.00 1 - - - - 10 60 97219100662 N 543.00 1 60 97219100902 2 551.00 2 60 97218101862 N 675.00 6 50/60 97218105762 N 595.00 1 60 97218101502 4 ' 502.00 3 60 97218102162 2 540.00 2 - - - - - 50/60 91218105702 N 596.00 1 - - - - 15 60 912169103 N . 730.00 1 60 912189105 2 740.00 2 60 972189111 N 762.00 8 50/60 972189133 N $21.00 1 60 972189109 4 321.00 3 60 972189113 2 $10.00 2 • - - - - - 50/60 972189133 N $21.00 1 - - ' j., 25 60 972189104 N 1100.00 1 60 97218g � 2 1106 00 2 60 972189112 N = 1171.00 6 , 50/60 912189134 N 1211.00 1 60 _9111 e rrriso 310 4 . 1211.00 3 60 972189114 2 1215.00 2 - - - - 50/60 912189134 N 1211.00 1 - - - .- - 25.167 kVA, Indoor,Type OL-For Outdoor NEMA 3R Enclosure,Type OL-WP, add suffix G62 to Catalog Number _rriba• Trod* : Net = 1Ne Net • 25 60 972382671 6 )1009.00 9 60 912382671 8 $1009.00 9 60 972382681 6 $1005.00 7 .. 37.5 60 972382672 6 1305.00 9 60 912382672 6 ^t•1306.00 9 60 972362682 6 >,1404.00 7 . 50 00 912382673 0 1863.00 4 80 972382673 6 °'1563.00 1 60 912382683 81702.00 7 . 00 972392674 6 . !055.00 4 60 972382674 0 . 1101.00 4 60 012382684 6 ' 10.00 7 ( 00 072382675 057500 1 60 972382675 0 117500 4 60 972382655 I 0199 00 7 , 00 971382670 8 4444 00 4 60 972382676 6 444L00 4 60 072382696 5 iN0 00 7 (;) Tap Arrangements: 4-(4)21/2% taps: 2 above 6-(6)21/a% taps: 2 above N-No Taps. and 2 below rated and 4 below ratedtit' 2-(2)5%taps below rated primary volts. Iprimary volts. primary volts. 6'4 Mrs MI Rate syeet a chap wiriest HIM$ ('• ! • ' ELECTRIC HEAT THERMOSTATS "• . • Heavy-Duty,Self•Cleaninp Contacts. , �•' • Control non-inductive electric beating loads up to 5000 watts at 240V.or 2500 • : . watts att 120V.22 amps—heat cable,electric baseboard.glass paneL Control knob is an extra-sensitive element that senses radiant beat or room tempera- .,,,..:,, '= tures to provide superior control of room comfort. Silent switch has large. • self-cleaning slide-action contacts • that assure noiseless operation. Type hock : ` • dill'. No. � ;� -:-:-.1.; Range: 40' to $5 F.. 1 switch ,. 2E174 has "off" position and dou- ,��,.r� ble line disconnect.Gold/beige fin- SPST rt'lltt..as�' IM.zrn ish. 434H x 21/4W x 14VD on wall SPS surface; overall 2 deep. UL Listed. (t)With double line disconnect in oiL C. . Principal Components of a 3-Phase Capacitor The principal components of a 3-Phase ASEA Capacitor 4. Nonflammable Dry Vermiculite Filler ( � include: Vermiculite is a dry. granular insulating material that is 1. Self-Healing Capacitor Elements solid, inertand fire proof. This material tills all open One or more self-healing capacitor elements are installed spaces in the housing enclosure to insulate the capacitor for each phase. These units are connected in parallel with elements and exclude free oxygen. (Most designs use each phase, and the three phases are then normally liquid for this purpose, but ASEA uses dry, nonflammable connected in delta. In case of dielectric breakdown, the vermiculite.) fault is cleared by evaporation of the metallized layer 5. Terminal Studs around the breakdown . . . with negligible loss of Large terminal studs are located inside the enclosure capacitance and continued operation of the capacitor! at the top of the capacitor for quick and easy cable 2. A Sequential Protection System connections. A unique Sequential Protection System including the IPE 6. Enclosure design (IPE- internally protected elements) ensures that All ASEA enclosures are made of rugged, welded heavy each individual element can be disconnected from the gauge steel. Available enclosure types include Indoor circuit at the end of the element's life. NEMA 1, Outdoor Raintight, and indoor Dusttight. 3. Discharge Resistors Discharge resistors (one for each phase) are sized to ensure safe discharge of the capacitor to less than 50 volts under one minute as required by the NEC. What is a Metallized-Film Element? Metallized-film is a microscopically thin layer of some conducting material (called an electrode), usually wlre a f,--Electrode aluminum or zinc, on an underlying layer of insulating film. MI „��,�,�.m.� ., The electrode averages only .01 microns thick while the insulating (polypropylene) film ranges from 5 to 10 ll ,��,,,,,,, ���� microns in thickness depending upon the design voltage 2 I II of the capacitor (the higher the voltage rating, the thicker . ! v 4 — y,,—,,,,,,-,,,,,-,,,,,,,,,,,,,,,-m the insulating film). w I, u 110 There are two electrode layers separated by one layer of p ' d 0) insulating film. Thousands of these layers are tightly !, E, o wound around a core in such a manner that the edge of Ili one electrode is exposed on one side of the element and 1 1 0 MYYZKIZFACIZIM,!,#M7ZIV.r/2,77,19 the edge of the other electrode is exposed on the other side of the element. See Fig. 10. Wires are then fusedDielectric „� onto each side of the element. The element is then put 0fe Partial cutaway View of into a container with the two wires coming out the top and wins a Copocitive Element Loyers then filled with a hardening protective sealant. FIG.10 Advantages of Metallized-Film Elements 1. Self-Healing Design 3. Small Element Size Self-healing refers to a process where a short circuit Due to the microscopically thin electrode and dielectric, between electrodes vaporizes the electrode around the metallized-film elements are small and compact in size fault until the fault is eliminated. The element continues to resulting in smaller, more powerful capacitors. function with negligible loss of performance. More on this The capacitive output of any element design is on page 17. proportional to the surface area of the electrodes and 2. Low Internal Losses inversely proportional to the separation between Due to the high dielectric efficiency of the metallized-film, electrodes. In other words, if the separation between the internal losses are extremely low. Compared to a conducting surfaces is cut in half, the effective conventional non-metallized design 3-phase capacitor capacitance is doubled in addition to reducing the which will average 2.5 watts per kvar in losses, the ASEA physical size of the element by half. metallized-film design only totals about .5 watts per kvar including the losses across the discharge resistors. 1 11111. 0 Page 16 ...:..r:.. ,!_..• ....3.esreYr.h ,r.;.'vf a.+n.4W cliY.Pi a More About Self-Healing Elements "Self-healing" is a characteristic which is unique to metallized-film capacitors. All capacitors normally FL. , experience insulation breakdown as a result of the DIE l ECT RIC accumulated effect of temperature, voltage stress, •1ie1eI impurities in the insulating medium, etc. When this DIELECTRIC happens in a nonmetallized design, the electrodes are 12 short-circuited and the capacitor ceases its production of 14•11:1•144-_ reactive power. In an ASEA metallized-film unit, however, DIELECTRIC these individual insulation breakdowns do not mean the shutdown of the capacitor. The faults self heal themselves Fig. 11-A illustrates two electrodes short circuiting through and the capacitor continues operation. a fault in a dielectric layer. FIG.11•A The conducting electrode is so thin, that should a short circuit develop as a result of a fault in the insulating dielectric, this very thin electrode vaporizes around the DIELECTRIC area of the fault. This vaporization continues until sufficient1•111101J.z -- separation exists between the faulted electrodes to DIELECTRIC overcome the voltage level causing the fault. Fig. 11-8 illustrates the process of self-healing. 3,04401111:1.11= — —= The entire process of self-healing takes only fractions of a DIELECTRIC second, and the amount of electrode which is lost is negligible in comparison to the total surface area of the Fig. 11-8 illustrates "self-healing" The electrode layers in the element.The result is that the metallized-film unit may area where they were short circuiting have been vaporized, self-heal hundreds of times during its long life and still thereby eliminating the short circuit. FIG.11.8 retain virtually all of its rated capacitance. The IPE Sequential Protection System At the end of the element's life, the dielectric deteriorates ASEA's metallized-film self-healing design capacitor so that self-healing becomes somewhat a continous elements will far outlive their conventional foil design process progressing outward from the middle of the counterparts for reasons described above. However, element. Every element in an ASEA capacitor is provided accumulated effects of time, temperature, voltage stress, with its own fuse link which works together with a nonself- (4. etc., eventually take their toll. healing outer winding to reliably and selectively r The unique Sequential Protection System provides the disconnect the element at the end of its fife. ultimate system for safety and protection including: • Dry, self-healing design • IPE(internally protected elements) • Dry, nonflammable vermiculite filler What Are Discharge Resistors? As all the capacitor elements store electrical power like a battery, the capacitor will maintain a near full charge even when not energized. As this is obviously a potentially very dangerous condition to unsuspecting plant personnel that might be inspecting.the capacitor terminals and wiring, discharge resistors are connected between all of the terminals. When the capacitor is shut off, these discharge resistors drain the capacitor elements of their stored electrical charges. It is recommended, however,that capacitor terminals should ALWAYS be short-circuited before touching the terminals. What Is the Significance of Dry Type Design? ASEA low voltage capacitors contain no free liquids end are filled with a unique nonflammable granular material called vermiculite. Environmental and personnel concerns associated with leakage or flammability of conventional 40 oil-filled units are eliminated; and kvar for kvarvermiculite sip filled units weigh 30%to 60%less than their oil-filled counterparts. Vermiculite Is routinely used In the United States as an Insulating material In the walls and ceilings of new buildings. Its properties have been extensively documented and it is an ideal material from the standpoint of safety and environmental acceptability. Page t7 ASIA BROWN BOVERI ( • Chapter 6 Appendix General ASEA Capacitor Specifications Capacitor Technology Cable Termination Metallized polypropylene film, self-healing for internal Each capacitor is provided with 2 knockouts for conduit faults. entry (1.25" and 1.5") and a terminal stud in each phase for power cable termination. Overcurrent Protection Internal fuse link on each capacitor element. Grounding An internal grounding lug is provided. Internal Insulating Material Nontoxic, nonflammable, dry vermiculite. Enclosure Options Available enclosures include Indoor NEMA 1, Outdoor Discharge Mechanism Raintight, and Indoor Dusltight. Carbon filament or wire-wound resistors sized to Enclosure Steel automatically discharge the capacitor to less than 50 volts in under one minute. All enclosures are fabricated of 16 gauge galvanized steel. Voltage and kvar Ranges soIndividual Units: Fixed Capacitor Banks Finish • 208V,2.0 to 73 kvar • 208V,60 to 225 kvar Light gray, applied over galvanized steel. • 240V,2.5 to 73 kvar • 240V,80 to 300 kvar • 480V, 1.5 to 100 kvar • 480V, 120 to 600 kvar Internal Cables and Insulation • 600V, 2 to 100 kvar • 600V, 120 to 600 kvar All internal conductors utilize stranded, tinplated copper. Automatic Capacitor Banks Insulation is fire-retardant, rated 105°C (220°F). • 208V, 19 to 116 kvar • 240V,25 to 155 kvar No Hazardous Materials • 480V,50 to 300 kvar No PCB's are used as filler. • 600V,50 to 300 kvar Rated Frequency Safety Standards UL approved for the United States;CSA approval is Standard units are rated for 60 Hertz;other designs at 25 available for Canadian applications. Complies with and 50 Hz are available. applicable requirements of IEC and the National Electric Code. Losses Less than 0.5 watts per kvar. Ratings and Tolerances Tolerance on Capacitance Power factor correction capacitors will provide at least the p rated amount of kilovar power at the rated voltage and 0%, +15% frequency. Due to manufacturing tolerances, however, they may provide up to 15%more. In other words, a 20 Overcurrent Tolerance kvar capacitor will not provide less than 20 kvar, but may 135%x rated current, continuously, provide up to 3 kvar more. Overvoltage Tolerance Internal Fusing 110% x rated voltage, continuously. Power factor correction capacitors are provided with Internal protection to disconnect a shorted capacitor Ambient Temperature Range element from the circuit. Refer to"The IPE Sequential Protection System"on page 17. 1, -40°C through +40°C • Mounting Restrictions Must be mounted upright or sideways . . , not upside down. A minimum of 2 inches clear space must be main- tained around the capacitor for ventilation. Page 18 W.A.Vuxfaelin Typical Recommended Ratings of Cables and Protective Devices Plwe Minimum Copper Minimum Copper Recommended • C�eeMa Retell Current Cable Size For Cable Size is Fuss Amps RecommendedSwitchmRecommerbW kvar Par PNse(amps} 95 C Insulation 90 C Insulation (Time Delay) Disc Switch Amps MCCB Trip Amps rt; 240 VOLT 2.5 6 14 GA 14 GA 10 30 15 . 3.5 8.4 14 GA 14 GA 15 30 15 5 12 14 GA 14 GA 20 30 20 7.5 18 12 GA 14 GA 30 30 30 10 24 10 GA 10 GA 40 60 40 15 36 6GA 8GA 60 60 60 20 48 4 GA 6GA 80 100 80 25 60 4 GA 4 GA 100 100 90 30 72 2 GA 4 GA 125 200 110 40 96 1 GA 2 GA 175 200 150 50 120 00 0 200 200 200 60 144 000 00 250 400 225 75 180 250 MCM 0000 300 400 300 100 241 350 MCM 300 MCM 400 400 400 125 301 500 MCM 400 MCM 500 600 500 150 361 2-250 MCM 2-0000 600 600 600 200 481 2-350 MCM 2-300 MCM 800 800 750 250 601 2-500 MCM 2-400 MCM 1000 1000 900 300 722 3-350 MCM 3-300 MCM 1200 1200 1100 480 VOLT 1.5 1.8 14 GA 14 GA 3 30 15 2 2.4 14 GA 14 GA 6 30 15 2.5 3 14 GA 14 GA 6 30 15 3 3.6 14 GA 14 GA 6 30 15 3.5 4.2 14 GA 14 GA 10 30 15 4 4.8 14 GA 14 GA 10 30 15 5 6 14 GA , 14 GA 10 30 15 6 7.2 14 GA 14 ZaA 15 30 15 6.5 7.8 14 GA 14 GA 15 30 15 7.5 9 14 GA 14 GA 15 30 15 10 12 14 GA 14 GA 20 30 20 Alli 15 18 12 GA 14 GA 30 30 30 20 24 10 GA 10 GA 40 60 40 1"clillir 25 30 8GA 10 GA 50 60 50 30 36 6 GA 8 GA 60 60 60 35 42 6GA 6GA 70 100 70 40 48 4 GA 6 GA 80 100 80 45 54 4 GA 6 GA 90 100 90 50 60 4 GA 4 GA 100 100 90 60 72 2 GA 2 GA 125 200 110 70 84 1 GA 2 GA 150 200 150 75 90 1 GA 2 GA 150 200 150 80 96 1 GA 2 GA 175 200 150 90 108 0 1 GA 200 200 175 100 120 00 0 200 200 200 150 180 250 MCM 0000 300 400 300 200 241 350 MCM 300 MCM 400 400 400 250 301 500 MCM 400 MCM 500 600 500 300 361 2-250 MCM 2-0000 600 600 600 350 421 2-300 MCM 2-250 MCM 700 800 650 400 481 2-350 MCM 2-300 MCM 800 800 750 500 601 2-500 MCM 2-400 MCM 1000 1000 902 600 VOLT _ 2 2 14 GA 14 GA 3 30 15 3 3 14 GA 14 GA 6 30 15 4 4 14 GA 14 GA 6 30 15 5 5 14 GA 14 GA 10 30 15 7.5 7 14 GA 14 GA 15 30 15 10 10 14 GA 14 GA 20 30 15 15 14 14 GA 14 GA 25 30 25 20 19 12 GA 12 GA 35 60 30 25 24 10 GA 12 GA 40 60 40 • 30 29 8 GA 10 GA 50 60 50 35 34 8GA 8GA 60 60 60 40 38 6 GA 8 GA 70 100 60 .40 45 43 6GA 6GA 80 100 70 50 48 4 GA 6 GA 80 100 80 80 58 4 GA 4 GA 100 100 90 70 . 67 2 GA 4 GA 125 200 110 80 77 2 GA 2 GA 150 200 125 90 87 1 GA 2 GA 150 200 150 100 96 1 GA 2 GA 175 200 150 CONTINUED NEXT PAGE < NOTE:Cable sizes are derived from Article 310,Table 310-23 of the 1987 NEC. Page 19 a ,Bulli Capacitors AMA BROWNEIOVERI Type CLMD Individual Dry Type Power3-Phase � . Factor Correction Capacitor s 480 VOLT,60 Hz-3-Phase RATED RATED APPROX ENCLOS)RE TYPE ENOL MC CURRENT P TAE SHIPPING INOOR-REV':.I OUTDOOR-RLrt�pht INDOOR-Dusliyls SIZE RATING PER PHASE PER PHASE WEIGHT (AMPS) MICROFARADSi BSS 1 CATALOG NURSER UST PRICE CATALOG NUMBER :UST,PRICE- CATALOG NUMBER ! e••:x�i; 1.5 1.8 5.8 8.0 C48431.5 6;'125 C484R1.5 S 135^ C48401.5 2 2.4 7.7 8.2 C484G2 ;•;-,130_, C484R2 140 - C484D2 'FT: 2.5 3.0 9.6 8.2 C484G2.5 135 C484R2 5 --':•,i,..„.145; C48402.5 ;j;1-3 _ 3 3.6 11.5 8.2 C484G3 140 C484R3 . 150 C484D3 3.5 4.2 13.4 8.2 C484G3.5 145 C484R3.5 '°155., C48403.5 - r. 4 4.8 15.4 8.5 C484G4 , 150 C484R4 160` C484D4 5 6.0 19.2 8.5 C484G5 .,.:170 C484R5 •-'.;180 C484D5 1) 6 7.2 23.0 8.5 C484G6 ,x.180 C484R6 1 • 90 C484D6 ' X1�r 6.5 7.8 24,9 8.5 C484G6.5 ,,^190- C484R6 5 200 • C48406.5 : .-a!,.+ 7 8.4 26.9 8.5 C48467 ' 210 C484R7 -.- 220 C484D7 7.5 9.0 28.$ 8.5 C48437.5 220 C484R7.5 . 230 C48407.5 89.6 30.7 8.5 C484G8 225 C484R8 .. 235 C484D8 - 9 10.8 34.5 8.5 C484G9 "'230 C484R9 240- C484D9 10 12.0 38.4 8.5 C484G10 235 C484R10 245 C484D10 ' 43' 11 13.2 42.2 13 C484G1177 240 ` C484R11 .• 250 : C484D11 , -"IR.!) 12 14.4 46.0 13 C484G12 250" C484R12 260: C484012 �• 12.5 15.0 48.0 13 C484G12.5 "'255 C484R12.5 `- 265 C484012.5 1 i 13 15.6 50.0 13 C484G13 260 C484R13 270 C484013 -X270; 43 13.5 16.2 52.0 13 C484G13.5 ' 265 C484R13.5 275 C484013.5 '-'•2 ,1. 14 16.8 54.0 8.5 C484G14 270 C484R14 280 C484D14 280 S 15 18.0 57.6 8.5 C484G15 260 C484R15 290 C4840015 •4- "290 16 19.2 61.4 13 C484G16 290 C484R16 300 C484D16 .•" 300`. 17 20.4 65.2 13 C484017 300 C484R17 310 C484017 ';:'..3 0.. 17.5 21.0 67.2 13 C484G17.5 305 C484R17.5 315 C484017.5 •-:.:•. 15- c it 18 21.7 69.1 13 C464G18 310 C484R18 320 C484016 r 32' 19 22.8 73.0 13 C464G19 315 C484R19 325 0484019 ,: 20 24.1 76.8 13 C484G20 320 C484R20 330 C484020 21 25.3 80.6 13 C484G21 330 C484R21 340 C484021 '. 22 26.5 84.4 13 C484G22 340 C484R22 350 C484022 = =`3 22.5 27.1 86.4 13 C484G22.5 345 C484R22.5 355 C484022.5 ':'.355 24 28.9 92.1 13 C484G24 350 C484R24 360 C484024 . 3360= 25 30.1 95.9 13 C484G25 360 C484R25 370 0484025 -1.370; 27 32.5 103.6 13 C484G27 380 C484R27 390 C484027 .°'A'3'.':: 30 36.1 115.1 13 C484G30 395 C484R30 405 C484D30 .405 32.5 39.1 124.7 13 C485G32.5 420 C485R32.5 430 C485032.5 ,--/r415__0 35 42.1 134.3 22 C485G35 435 C485R35 445 C485035 445' 37.5 45.1 143.9 22 C485G37.5 ..450 C485R37.5 ' 460 C485D37.5 460 40 48.1 153.5 22 C485G40 475 C485R40 485 C485040 ;485' 53 42.5 51.1 163.1 22 C485G42.5 495 C485R42.5 495 C485042.5 4,495: 45 54.1 172.7 24.2 C485G45 -, 510 C485R45 520 C485D45 520: 47.5 57.1 182.3 24.2 C465G47.5 535 C485R47.5 545 C485047.5 r541. 50 60.1 191.9 24.2 C485G50 550 C485R50 560 C485D50 560-- , 52.5 63.1 201.5 36 C486G52.5 575 C486R52.5 585 C486052.5 1:" 55 66.2 211.1 36 C486G55 650 C486R55 660 C486055 {t :660 57.5 69.2 220.7 36 C486G57.5 700 C486R57.5 710 C486D57.5 •,x`;7 16,� 63 60 72.2 230.3 36 C486G60 750 C486R60 760 C486D60 --.r 60.. 65 78.2 249.4 36 C486G65 880 C486R65 890 C486065 890' 70 84,2 268.6 37.5 C486G70 1015 C486R70 1030., C486D70 ' 0.0 75 90.2 287.8 39.8 C486G75 1060 C486R75 1075 C486075 ; • 4 77.5 93.2 297.4 39.8 C486G77.5 1095 C486R77.5 1105 C486D77.5 ' ' 80 96.2 307.0 52.8 C488G80 1125! C488R80 1140 C488D80 :1 i 85 102.2 326.2 55 C488G85 1175 C488R85 1190 C488D85 '.. ,e 83 87.5 105.2 335.8 52.8 C488G87.5 1200 C488R87.5 1215 C488D87.5 ,;..121- • 90 108.3 345.4 52.8 C488G90 1225 C488R90 1240 C488D90 • 95 114.3 364.6 52.8 C488G95 . 1275 C488R95 1290 C488D95 1210." 100 120.3 383.8 55.0 C488G100 1325 C488R100 1340 C488D1001 ILill SPECIAL MOUNTING OPTIONS For special mounting options, see page 31. II Floor mounting Is standard. DISCOUNT SCHEDULE DS•10 Page 25 . ASEA CLMB Capacitors ( • Detail Specifications Dimensions & Data CLMB 53,63,83 I • t •I _.22..2 it. CLMB 43 $ A, 2.2 7-1 Height 10.9 1.75 1 i n 1 n l.I,—OS_ X+ ,..6 ..., i i I+ 6 — 9.315.9 Height 5 37 5 3 CLMB 53 12.3 _____t _L CLMB 63 19.2 CLMB 83 26.6 'Note:Alt enclosures available as either NEMA 1.3R or 12. (410 Standard Ratings 240V, 30, 60 Hz 480V, 30, 60 Hz 600V, 30, 60 Hz ENCLOSURE WEIGHT ENCLOSURE WEIGHT ENCLOSURE WEIGHT STYLE KVAR (LBS) STYLE KVAR KVAR (LBS) STYLE (LBS) 43 2.5 8 43 1.5 8 43 2 8 43 3.5 8 43 2 8 43 3 8 43 5 8 43 2.5 8 43 4 8 43 7.5 8 43 3 8 43 5 8 43 10 8.5 43 3.5 8 43 7.5 8 43 15 13 43 4 8.5 43 10 8.5 43 20 13 43 5 8.5 43 15 8.5 53 25 22 43 6 8.5 43 20 13 53 30 22 43 6.5 8.5 43 25 13 63 40 32 43 7.5 8.5 43 30 13 63 50 33 43 10 8.5 53 35 24 63 60 36 43 15 8.5 53 40 24 43 20 13 53 45 24 43 25 13 53 50 30 43 30 13 63 60 36 53 35 22 63 70 38 53 40 22 63 80 38 53 45 24 83 90 53 53 50 30 83 100 55 63 60 36 63 70 38 63 75 40 • 63 80 40 83 90 53 83 100 55 (, • L • s Pi 8 lit04 N N O O O 0) 0) N N N N N M M 0 N N it III N N N O O O O N M R V N 8 n 8 R 8 8 O N T T T T m C y M N RI N N N 10 N N N 10 U) N) M N r r r T C •8 a so W z 1 N N N ^ O O o R R R $ t $ g n n 8 `. c3 8 8 r 0 r r r I ii N N N N N r 0 0 O CO to 0 CO CO 0 O 0 1 Ii°`SQ tt) r N N < N N N N O O N N N 8 8 o t0 o n 00 8 8 8 ( • § n P. j i 1 . N. N N N N N N •••- r T 0) 0) 01 O) 0) O) CO 0 CO CO CO 1• tO 'b at fa I L 1% ....,.U y T r N M Y to N N N O O O N N O O N O O O O N O y W ^ r r r N M M •1 1q f� P P h to Z T J 47i 1 0 0p9i.0 I i . N tD tD M M M 0 O) n 0 /� n ^ ►� n tp 0 0 to coN coN N N 0 i<� 8 N 75 p pp y� p p p p p o 8 ILI WI ¢ ,( T N N OJ ♦ N N N ti 0 e Or N N N S S 8 8 8 g 8 .2 a m V SC 0 a1 i C a ~ as Q 2 ... w O 0 0 O) 0 N in 1D to in in 0 to in N N N N in N , ti. 1 1 . . VI Qp �f} po po pp pp p l is le 4q T ; ; • N r N N co N ^ ^ � N.. N (V f Yi N 0 tD R V R .11 hi ... , ,.. N R !C 8 $ 8 S �i g , t( . L____ INGRAM (• ODUCTS , INC , PANEL ALARM LIGHT (MODEL LRX-40) 43j ►..1 • r a ••♦� 101a Nema 4X Redr Amber mber / shatter resistant G.E. / _/''�� Type 143 Lexan. Flame � Retardant and UV Stabilized. /l Enclosure Wall Gasket 1:7 _: /.7.ir i; ./ . - - a�i> >1 tZt�Z iZZz C:.. ��\�,\\r� raV\\0V\l . T1♦ . viii !ii iii i.. JOne piece heavy duty itiln procelain lamp holder • Low profile, top mounted gives 360'Visibility • Supplied with 40 watt clear rough service • Easy To Install - appliance bulb to withstand temperature changes. • NEMA 4X Rating . _ • Universal Mouting with hardware & instructions. (W• Weather Proof Gasket • Globe height is 31/4" . • Shatter Resistant Globe • Flanged Base of 43 • Colon: Red or Amber The entire assembly has Underwriters Laboratories, Inc.% recognition. • 6823.4 Phillips Parkway North • Jacksonville. Florida 32256 • (904) 268-5353 .e 2..„.._.t.:�::x •m .. a. Q...-ra II�a�lsrid- ,x ,.�...9'4w*:ei"Cv:.:�):u'uwca..veb - ... Panel Alarm Light Model LRX-40 1 (410 0 "0"..iij aiim. al 1 4.4iudip.04 ftbs 1 1 0 1 1 t #8-32 Tapped Hole T 11 0 T (2 Req.) • Enclo0 sure t yr;a Hole (4 Req.) 44 4 . , : l t i • 1 ' / 1 1 CO t1 I i 1 II, I 1 ID f t W t 1 1 1 i mss, I t 0..--.1 - t \...r.4411 .1.11:Z/ : 0 t - 1 1 , s t 4 CDI 4 • T i i 1 g ITEM DESCRIPTION 1 LEXAN ALARM GLOBE - TYPE #143 (RED OR AMBER) 2 . , CLOSED CELL NEOPRENE GASKET 3 HEX. HD. (WSHR. TYPE) SELF TAPPING SC. 8-32X1/2" (4 REQ'D) • C110 4 LIGHT BULB 130 V, 40W 5 LAMP SOCKET, SNAP-IN TYPE H.D. PROCELAIN 6 SOCKET MTG. PLATE . 7 HEX. HD. (WSHR. TYPE) SELF TAPPING SC. 8-32X1/2" (2 REQ'D) . BUBBLER AIR MONITOR SYSTEM (BAMS) ( • JNFORMATION / SPECIFICATION SHEET T1 Purpose of the PAM$ A "bubbler" level sensing and control system is only as reliable as its air supply. Historically, in order to achieve a higher degree of reliability than is offered by a single air compressor system, many Users have opted to utilize an air storage tank system with two fractional horsepower air compressors. Unfortunately, this type of configuration introduces additional problems into the system: 1. Constant adjustmepts / maintenance: this air system requires the use of pressure switch(es), pressure regulators, and flow regulators, all of which require constant adjustment due to inherent mechanical drift. Z. Condensate drainage I maintenance: condensation build-up must be manually and continually drained from the bottom of the air storage tank. This can be particularly troublesome and bothersome in outdoor applications in a cold environment. 3. Vibration: even with good shock mounting, over years the vibration associated Amk with the running of these large air compressors can vibrate equipment and Mr fittings loose. 4, Noise: the required fractional horsepower air compressors are relatively noisy when operating. S. Enclosure size and cost: the relatively large size of this compressor and tank arrangement can increase the cost of the required enclosure up to hundreds of dollars, depending on the enclosure material type. In addition, increased enclosure size requires more space, thus peripheral costs increase such as building space, concrete pad size, etc. t . •' l I I I ' : • 1 , ' ' 11 7. Back-up compressor unreliability: most of these systems typically do not alternate the air compressors, thus when the standby compressor is finally called for it may not operate due to years of not being used. 8. No self-resting capabilities: these systems do not have the capability to continually test their critical components for proper operation. Thus, a critical component such as a pressure switch, flow regulator, pressure regulator, alternator, etc., could fail and the nobody would know about the failure until it was too late and an overflow occurred. ** • 1 ' I cl , • 11 • . 1 • 1 • 1 . • , 11 1 lle1 • 1 . 1 • 11 . : 11 I / ' 1 1 1 1 • 1 • 1 , . . 1 • _ ! • ! ' / 1 i • J t . • 1St EG Pump Controls has solved all of the referenced problems of the air storage frk system with our Bubbler Air Monitor System (RAMS). The BAMS performs the following functions that are critical in maintaining the highest degree of reliability availability today in an . air supply system. 1. Two highly reliable, compact, quiet, and relatively inexpensive compressors are used for the air supply. No air storage tank is required. No maintenance is required. 2. The air compressors are alternated: either manual alternation, even alternation of 4 hours run time each or uneven alternation of 4 hours to 1 hour. This is User selectable by a dip-switch. EG recommends uneven alternation so that when one compressor fails there is plenty of life left in the standby, thus giving you time to install a new compressor. 3. Extensive annunciation. testing. and indication is built into the BAMS. A. LED lights are used to indicate the presence of air flow, no air flow, flow switch failure, compressor number 1 running, compressor number 2 running, compressor number 1 failed, compressor number 2 failed. B. Warning and failure contacts are supplied to indicate the failure of one ("warning") or both ("failure") compressors. The failure of the internal flow switch can energize either of these contacts (User adjustable by a dip-switch). C. A "Test I Alternate" switch allows the User to manually alternate the compressors as well as do a complete BAMS system check when this alternation occurs. A "Reset" button is utilized to reset the complete system after the problem which is annunciated has been corrected. 4. Individual contacts and visual indication for an "Air Supply Warning", which typically indicates that one compressor has failed, and an "Air Supply Failed", which typically indicates that both air compressors have failed. These signals can be telemetered to remote sites if required. EG recommends that these contacts be used to control "Air Supply Warning" and "Air Supply Failed" lights to be mounted on the exterior of the enclosure or on the deadfront. 5. Jnternal checking of_Da system components is constantly occurring. Upon each automatic alternation of the air compressors, or when the "Test/Alternate" switch is depressed, the BAMS does a self check of not only the compressors but the flow switch and the BAMS Iogic as well. A flow switch failure is User adjustable to close the "Air Supply Warning" or the "Air Supply Failure" contact. 6. Fail-safe operation: in the event that both air compressors or the flow switch indicates a failure, power is supplied to both air compressors in an attempt to establish air flow. At the same time, the "Air Supply Failed" contact is energized. 7. For cold environments, the BAMS will output a calibrated DC voltage to the coil of s • • • 1 • - • • . . • . .. • - . .'n This system only works properly with the HR10WB and SR10 air compressors and should be disabled by removing the black plastic jumper on the circuit board when other compressors are utilized or as desired by the User. ** Operation Note: time delays are built into the system as follows: (11. 1. 45-60 seconds delay after a no-flow condition is sensed before an air compressor is indicated to have failed. 2. 12 seconds (maximum) are allowed for the flow switch to open or close during compressor alternation and/or system test before a flow switch failure is indicated. ,Specifis�linn for the RAMS with 2 air compr.Sssnrs (normal and standby) 411? Bubbler Air Monitor System (BAMS) shall be supplied with two (2) air compressors. 1. Method of Construction A. Surge protection - input isolation transformer and secondary MOV's. B. The BAMS connection diagram and all annunciation nomenclature shall be silk screened on a brushed aluminum faceplate. C. All components including the check valves, logic, and flow switch shall be mounted inside of a phenolic housing. D. Flow sensing must be accomplished with a differential pressure switch. 2. The BAMS unit shall perform the following functions: A. Alternation - air compressor alternation shall be User adjustable to be automatic even alternation (4 Hrs/4 Hrs), automatic uneven alternation (4 Hrs/1 Hr), or manual alternation. The logic controller, standby compressor, and flow switch must be automatically tested for proper operation after each alternation sequence. B. Operation visual indication - lights must be supplied to indicate the following: Location 1) Air Supply #1 Run BAMS 2) Air Supply #2 Run BAMS 3) Air Supply #1 Failed BAMS 4) Air Supply #2 Failed BAMS 5) Air Flow BAMS 6) No Air Flow BAMS 7) Flow Switch Failed BAMS 8) Air Supply Warning Deadfront or outer door 9) Air Supply Failure Deadfront or outer door C. Operation contact indication - Normally open dry contacts must be supplied as follows: 1) Air Supply Warning - this contact shall close when one air compressor has failed. A flow switch failure can cause this contact to close (User selectable). 2) Air Supply Failed - this contact shall close when both air compressors have failed. A flow switch failure can cause this contact to close (User selectable). D. A flowmeter calibrated in $CFH of air shall be mounted on the faceplate. E. Pushbutton operation - pushbuttons shall be supplied to perform the following functions: 1) Test / Alternate - depressing this button causes a manual alternation of the air compressors. In addition, a complete system check of the BAMS logic, air compressor, and flow switch shall occur during each alternation sequence. 2) Reset - depressing this button returns the system to normal operation and clears the alarms only if the indicated problems have been corrected. F. Standby Air Compressor Heating - a calibrated DC voltage shall be supplied to the coil of the standby compressor in order to maintain its temperature above the freezing point. G. Fail-safe Operation - if both air compressors and the flow switch indicate a failure. both air compressors shall be supplied power. (• area 'oN 40(' O O a % • N ` � .fiT ' Ili ��y v � .. .....„„.,:, .,.....iini:.....,Li.„...,„...„:?.„,ii:,::„.00:1,...,.:±±,..„,..„,,. ......„ .,..:::,:„..,z.,...i;:„:, .„,:,,,,:.:„„:„:„„i..14,,Lx.......,..i:,*::?„,..,:::::.::...::::1:K::„::::....:._ Cao ev l y ^� x CC • : tv •:.vR::r ::y:yyr>.. r �.y °74i• x i :kYyx5e .Yrr., . : y }vi9n ia Owy f!> sY xr Y k vs t �(W �h • { • r pp,:-::::-....,..:101.31 s:-. T • CD R - w� w x•., W 1'f R 4 f4 Ly r { .Y r { 1eL Yh. y h 4 .F'* ,„ f 7$s h R } � a•v • y ' ��. •dl►„ _.' ..n ' ;r„ +>Duj,'y : tom. WO .....•....-....v.... �`,'� "y'A �;�4 -,;i6,::.:'..::-.,.} +�elpi {e .T� v.. r5{:`,---.- r "rs ,�Y < 7 y L :. S r s } ,� { A�111 a' ,; y : a,it.*::S:.!ww��4r� ";S ,''f• y�y,/r,'. '�'s i :; �S.;.x.( R f k f ".f} iii?:`..f�.t:5•.4 r: y ,r Yy'i, ei. - $ C:•r':YYiy •} $9:R f t�iY r./ r....,,,i;,..:•>:4:V,46e,:w.e•::;:$,:::::::-::::,,:.:•'..:,fd } s '•�< ¢}Y.• "i•9 , `• {•:(`s` i : 0t fi :.f . f. Y 2- 6 f/r `y?,-�:*i::: s<. r;it .y r xrv�rn7ii a ..# e;� q o}£• `a•':�••r� •'- ..Sri . .,:.+.:: r.,,V::) kv.:. #.• f �l`Y �• �>.?%�•:: !.#:;!;ki,::; ,.1 •C. ;>;4.:*,..s .•• . .�..4'!aY;;:.. •s.:;i yc:S: ::i: BULLETIN EG-791 Electrogage e/ N / ( fb The Liquid Level FEET AND INCHES OF WATER Indicator/Controller FEET �,INClit S Electrogage is a patented instrument designed for 10 '-`11 ►1_ 120 use as a liquid level indicator/controller. It is SIMPLE, — 0= RELIABLE, ►— RELIABLE, ACCURATE, VERSATILE and 9 =741110 11= ECONOMICAL. U— 100 THEORY OF OPERATION 8 _:":2,41 41` _90 Electrogage is a combination of two well-known and 7 +—Y► 11- time-proven principles: A well-type liquid manometer, —a`il► 80 and electrical conductivity. 6 =4111- II— 70 These are illustrated in the diagram, Fig 1, below. �—Y.1 - When pressure is applied to the well side of a 5 —`O 0=/1 x=--60 manometer at"P"it causes the mercury in the indicating —NI — column at"A" to rise in direct proportion to the amount m 4 —II /1— 50$ of pressure applied. As the mercury rises in the —1.1 41= column, it touches a series of contacts (1-5) that are �► 41— 40 built into the column. The number of contacts it 3 ` 0= touches will be proportional to the pressure applied. -41 0----30 The electrical conductivity of the mercury is used to 2 =A 141= complete each contact circuit. These contacts are then -y1 20 used by the control circuitry to control an almost 1 —,V'1 11= 10 faunlimited number of pumps,valves,alarms, etc. =1.1 t► P Ell eB i A p Electrogage 1 © MODEL lormi ........1 = ©� EG Pump Controls, Inc. � — ' l ® Jacksonville,Florida CID �l� ' / • FIG.1 FRONT VIEW ELECTRICAL CONTROL Electrogage has one common electrical contact(C, above) which maintains electrical connection with the mercury at all times. There are a series of 40 control contacts located in the indicating column. These control contacts are precisely located so as to produce an electrical output for every 3" of water pressure applied to the instrument*. Each contact is clearly labelled as to the level at which it will be activated. The control contacts can be used to directly energise conventional electromechanical relays or PLC inputs, as desired, without any other interface devices needed. Contacts are rated at 24V DC or AC, 5 VA max., UL Class II power supply. ADJUSTMENT Level control adjustments are simple and straightfoward using the clearly labelled terminals. Select (40 the control contact for the level desired and wire to it. This will produce an electrical output at that precise liquid level. There are no other adjustments or calibrations needed on the gage. *This refers to the 10 ft'gage. This will be 6"on the 20 ft'gage. LOW P1 URF 141611140 H >URi S RELIABILITY � � 141 Electrogage, due to its inherent simplicity, is totallyreliable. It has 9'J—�•; no moving parts such as gears, levers, cams, springs, bearings or diaphragms. Only the liquid mercury column moves. Since there are ° LI 9 no moving parts to wear or get out of calibration, the Electrogage should last indefinitely. °.,— —Fl.°.. r9'— ACCURACY 7,3.. Liquid manometers are considered a primarystandard and are q 6.3..—,r,,, frequently used in laboratories to calibrate other instruments. 59 -4''—`0 Electrogage is precision machined from a solid block of acrylic to a —56.. tolerence that guarantees accuracy better than plus or minus 1/2% of S3— ' full scale. Repeat accuracy is 100%,with zero dead band when making 4.9 ,f,—4.6.. and breaking electrical contacts. 4 3 -_4.°.. 3'9 Electrogage is carefully calibrated at the factory by the critical fill 33--'r., r''-36" method. The mercury is then sealed in with microporous filters that 79'—.r.. r;-31) .. pass air and gases,but not mercury. Electrogage is always accurate and can not get out of calibration. -1.6.. 1'3"--'G CONSTRUCTION °.9.. -0.6.. °'3 Electrogage is 12 inches(350 mm)high,5 1/2 inches (140 mm)wide [—D°.. and 1 1/2 inches (38 mm)deep. The transparent front lens is a single plate of unbreakable plastic. The faceplate is graduated in both feet n,—corArtoN and inches of water. All materials of construction are high quality and E G Pump Controls, Inc., corrosion resistant. The unit is designed to be impact resistant. E Jacksonville,FloridaModel 10FW31 LIQUID LEVEL APPLICATIONS BACK VIEW Electrogage is designed for use with purge bubbler systems. As the liquid level increases above the bottom of the bubbler tube, the pressure increases in the purge system. Electrogage senses this pressure and shows it clearly on its indicating column. Electrogage can be used in any system where the liquid level is to be displayed and also electrically controlled. The wide indicating column is easy to read in the viewing window. Both high and low pressure pneumatic connections are provided for applications which require differential pressure mesurement. It is in use daily, controlling sewage lift stations,pumping stations, intermediate process sumps, drainage control systems, storm water control and wetwells, sumps and ponds of all shapes and sizes. INSTALLATION Electrogage can be remotely located up to 1000 feet from the liquid being measured without affecting accuracy. It is designed to be mounted on a vertical surface. This means that, in most applications, Electrogage may be mounted directly in the front panel of the control enclosure. E G Pump Controls, Inc. supplies complete control systems incorporating Electrogage as its level sensor. These may be relay systems or programmable controller systems and may use constant speed or variable frequency drives as needed to drive any type or size of pumping installation. Please contact us for a free quotation. MANUFACTURED BY; REPRESENTED BY; (11111Controls, E G PumpInc., 11790 Phillips Highway, Jacksonville, Florida, 32224, USA. Pb; (904) 292-0110, (800) 874-4252. Fax (904) 292-0119 EG-791 Wall mount enclosures Page E-5 904.298.9270 FAX(9041)295•8804 NEMA 12 DOUBLE DOOR ENCLOSURES -�� 'ply ENC t (4110 vy ) fr. . _ . _ .„ ., . . , �__ .mss. . .� .... „.....„,..„,,,,, ---_______ . t ri; . _ ti M „.... . . . ....4. „..,,,.,., . . . , . .. ...,.. .-,..„ ,- _. ,,..-„........,..-:-.- - - ' z . :-.„-..,. .,,, ., . „7-,,,.4 .. ,.,.. ,..., . ..,-.. „ ,,..._,..-, - ,...-, , ., . . .. , .u , ., ; .. . ,,-,- ....„.„- . . ..„........._ : Application pins can be removed by snapping them off from the surface Electromate NEMA Type 12 double door wall mounted of the door. enclosures are designed to house electrical and electronic 3/8-16 collar studs with zinc dichromate finished nuts and equipment.These enclosures are intended for use indoors washers are welded to the rear interior of the enclosure to to protect the enclosed equipment against fibers,flyings, provide a means for mounting the optional panels.Panels lint,dust and dirt,and light splashing,seepage,dripping must be ordered separately.3/16 inch steel mounting feet and external condensation of noncorrosive liquids. are welded to outside rear of the enclosure for wall Construction mounting. To insure a strong and rigid construction,the doors and Panels body of the enclosure are made from 14 gauge cold rolled Optional back panels are available for equipment mounting steel.All seams are continuously welded and the welds are within the enclosure.ALL panels for the double door wall ground to present an attractive appearance.A rolled lip is mounted NEMA Type 12 enclosure are fabricated from 12 formed on all sides of the enclosure opening.This feature gauge cold rolled steel,except the E-60WFP42 and the E- not only provides additional strength,but prevents dirt and 48WFP48 which are 10 gauge steel.Panels must be ordered I liquids from dropping into the enclosure,when the doors separately. �,► are opened.Door and body stiffeners are welded into the Finish large enclosures,to further insure a rigid construction. The standard finish is white baked enamel inside and dark 'there are no holes or knockouts in the doors or body. The integrity of the door seal is assured by the use of a gray primer outside over phosphatized surfaces.The panels i closed cell neoprene gasket bonded to the inside of the are finished with white baked enamel over a phosphatized door with oil resistant adhesive and held in place with steel surface. retaining strips.The unique design of the overlapping Accessories I doors eliminates the need for a center post.The doors are There are many accessories that are available to adapt I attached to the body of the enclosure by means of heavy these enclosures to specific and unique uses.Among these duty continuous hinges,which are welded in place. are floor mounting kits,drip shield kits,latch&lock kits, 1 Removal of the doors can be accomplished by pulling the terminal kit assemblies,and louver plates. brass,self-lubricating hinge pins. A three point latching mechanism,operated by an oil Industry Standards N tight key locking handle,holds the doors securely closed. All of these enclosures conform to the National Electrical Solid aluminum bar latching rods feature rollers to facilitate Manufacturers'Association(NEMA)standard for Type 12 nu Cl) smoother latching action.Attached to the interior of the (industrial use)enclosures.They also conform to Joint Q m right hand door is a removable and reversible print pocket Industrial Council(JIC)standard EGP-1-1967,and are all Q m which is held in place by two small weld pins.These listed by Underwriters'Laboratories,Inc.and Canadian U Z a) Standards Association. L1.l W ENGINEERING DATA General Doors Panels 8ti1• Print Print Uuble Enclosure Body toner Usable Door Pocket Pocket Panel Pan- Panel Space Use- Wales Mounting Slit. Lou- Enclosure Door Slit- Size Lece. Catalog Penal Panel el Between bit Number Height Width Depth Centers loner anon Opening Space' tenor ”' lion Number Size Typo Holes Studs Depth A B C (H z W) E (H x W) (H z W) F G A-3 8-3 A-5% 8-5% C E•244208WF 24 42 8 25%x 18 — 21'8x39'8 1.-19'h x t8a1n _ S 9% 8'% N2P24 21 39 Form 6 18% 36% 8 36 — R•191hx14vr • 21 _ L•19%x2Phr ` E•244B08WF 24 48 6 25'ti x 21'/r x 15'ti S 9'h 8% E 1SP21 21 45 Form 6 18% 42% S Cle36 42 — R.19,4 x 17% — E401210WF 3D 42 10 31`i x 3 9% 27'ti x 39'A R•25%x t4�% L 13% 124 E•42P30 27 39 Form 6 24% 36% 10t.,0-0, E•3041110WF 30 48 10 31%x 21 3 11% 27%x 45% 1•25%z 21►he — L 131/4 12% E48P30 27 45 Form 6 24% 42% 10 42 11•251/2 z 17% E406010WF 30 60 10 31%x54 3 14% 27%x57'% R•25%x23' — l 131/4 12% E.10P30 27 57 Form 6 24% 54% 10 Wall mount enclosures Page E-6 904-296-9270 FAX:(904)296-8804 NEMA 12 DOUBLE DOOR ENCLOSURES /CirrM EENCLOSURES I i ENGINEERING DATA(Continued) general Doors Panels Stet- Print Print Usable Enclosure Body tenor Usable Door Pocket Pocket Panel Pan- Panel Space Use- Catalog Mounting Stlf- Lace. Enclosure Door Mit- Size Lacs- Wtalog Penal Panel el Between Me Number Height Width Depth Centers toner alien Opening Space tenor P•A tion Number Size Type Holes Studs Depth A 8 C (H x W) E (H x W) (H x W) F G A-3 B-3 A-5% 8.5% C E-364212WF 36 42 12 37%x 18 3 W4 33%x 39'4 L-311/2 x 189/32 — L 13'h 12% E-42P36 33 39 Form 8 30% 36% 12 36 R-311 x 141 E-364812WF 36 48 12 37%x 21 3 11% 33%x 45'4 L 31'h x 21ahr — L 13'h 12'4 E-48P36 33 45 Form 8 30% 42% 12 42 R-311 x 17% E-366012WF 36 60 12 37'4 x 27 3 14% 33'4 x 57'4 1-31%x 2711 — L 13'h 12% E-80P36 33 57 Form 8 30% 54% 12 54 R•31'h x 231/2 ' 181.37%x 189/32 E-424212WF 42 42 12 43%x 36 3 9% 39%x 39'4 R-37h x 14'h — L 13'h 12% E-42P42 39 39 Form 8 36% 36% 12 y ' E-424812WF 42 48 12 43'4 x 21 3 11% 39'4 x 45'4 L-37%x 219/32 — L 13'/ 12% E•48P42 39 45 Form 8 36% 42% 12 .4 42 R-371 x 177E '' 12T/T[" 27 1-371/2 x 11% yes L 131/2 12% E-60WFP42 38$ 56$ Form 8 35%4 531/24 12t E-426012WFA 42 60 12 43%x ca 3 14% 39%x 57% A-371/2 x 9'4 1-431/2 x 219172 E-484812WFA 48 48 12 49'4 x 2 3 11% 451/4 x 45'4 R-431/2 x 17% — 1 13% 12% E-48WFP48 44$ 44$ Form 8 41%$ 41%* 12t 'Usable space with print pocket removed tSubtract f4'from panel depth for door stiffener clearance **These dimensions represent the door space on each side of the door stiffener $Panel Size is A-4 and B-4 "'S—Small Print Pocket(6 x 6) L—Large Print Pocket(10 x 10) B ---C-- ..cr_ „.,1, 1._.-11,. : -fs,t---i; * ill rf , _ ...t.F----- ., -- .-' UP'1 1, �'. '1 EL E NII SPACE ~ I! �•„J T 3T ti 1j ,I 11 11 011IL 00ABLE I I C ' 11 11 II 11 ON DOOR, i AR I •-E: ;1111 17 11 11 OPENING Yf II 11 11 '1 z 5 Ii II A-2 LA NTNG 11 11 All 11 r.� -1 11 11 A W I I 4, 1 r 1: 11, PMNT POCNE7♦ ', W f T 1 _ __ I rl , , ' II �1 '1 C\\ 1 _.,..._,4"--"" a-►ANCL 11 11 1' 11 ,t FII A f,T 1 sem++.,-,-i-.+ I I I I I i I I I I I 1 1' T -+I 1 '„ ' I' 11 t 11 It I4—G OW ■■■ I � �q� ....mss:'p' P i __ t1 11 I I ..__.___ l___ 1 I II LL-- Gi[e1 ■ I i —i1—A-n'•r'.-___ - -- ? ai� �� - a stcr,06 V-Y t 1 1n ,-/— x rrl ..?.:;„,,,:,,,..,(.1,., OOR STIFF E1,C'LlN$ON A•Azf Itw'ALP ONLY • ►NNCLIONDEN = rn �'ITY►ALL HOCA) + [�+(TYP.) ItH&N CCLYI B O " S�STrP.I U O CS R�GM10008 FONT MUOUf 0 {_.. .._ rr-11, na .. LLfT DOOF IA 4NU4C ` MIN4C L� I / ' re'r ,C T— �N�Ftrn�Nr.rt�. �', 'N�Ittl�6 1 1._i I I I I •Lc Lata T WO MO 11 i t MST Two Mip U) co �ii1��t.F ..we 1'j1r 1 II tMAN el t 1 �a�A���;�, ,was■ ��.. , I. , {TUOS P a•LEC[ 1'�..1.41107i...1 /p '.�:�•..�. "'i I 11 I t I t 11 I. ?MAN SI {iueLNEN \.. ' 'I '1 1I II 11 N L6 SK[T"t 000R 1 ' Y4.411.AI 1Y STKrcNER 6007 CTIIFENCN$Omit If 14 9.1•101 • ON6f ON OP LESS I an 7-3\I 'I '1 I) 1I a `'0 f. . I I j1 RN 11 II 1I it C I I 6TIPIL9EN4•ANLL 12 N000 bet, I is I 8'3 it N P6441 t TiPPENER 1 1j 11 11 1t II it IIIII j r ��, II 1' I I 1 6 6 4 I( , E • .-1..TUDLLAR I • .LLJJ • U._a •' _ I I Jae''{�L'^^a�� —+- n alt Ili .. ;11. ,6 Fehr. W'W MOUNTING ICI? 1001/0•124i4 MT EFTION X X i 0W t-4IOM:100 i INON? TMt[f6[OIME"CION[ ON t•6l601tr/A • t•�6NItrPA. OW AR[MUkI?.6% •4N011OPA I t-N/9121/111 Page G-3 904-296.6270 g FAX (904)296.8804 ACCESSORIES (W) ENCLOSURES • u) ln ID c.› Drip Shield Kits for The stainless steel dripshield is fabricated from 14 gauge v Nema T e 12 Type 304 stainless steel,and is finished with a#3 Enclosures -4__ `, (brushed)polish. Electromate Drip Shield Steel Stainless Sleel Fr Use With Kits protect door hardware Drip:hleld Kit Drlpshield Kit Enclosure from dripping water and Catalog Number Catalog Number Width settling dust.These kits are i EDK12 EDK12SS 12 easily and quickly installed t. EDK16 EDKI6SS 16 to the enclosure by usingEDK20 EDK205S 20 stainless steel screws and EDK24 EDK24SS 24 sealing washers(provided). II. EDK30 EDK30SS 30 A stainless steel hinge pin EDK36 10K36SS 36 and stainless steel door clamping assemblies are furnished EDK42 EDK42SS 42 to replace the standard pin and door clamping assemblies. EDK48 EDK48SS 48 A tube of sealing compound is also supplied with each kit. E0K60 EDK80SS 60 The dripshield is fabricated from 14 gauge steel and is EDK72 EDK72S5 72 finished with dark gray primer over phosphatized surfaces. Floor Stand Kits for Steel Floor Stainless Steel Nema Type 4/4X and Stand Kit Floor Stand Kit For Use With Nema Type 12 r Catalog Number Catalog Number Height Enclosure Depth Enclosures -' EFK0608 EFK0608S5 6 8 EFK0610 EfK0610SS 6 10 EFK0612 EFK0612SS 6 12 Electromate Floor Stand ''Y' EFK061B EFK06l8SS 6 18 Kits for Nema Type 4/4X 'N EFK1208 EFK1208SS 12 8 and Nema Type 12 enclo- ' `,.EFK 1210 EFK1210SS 12 10 sures are designed to pro- EFK1212 EFK1212SS 12 12 • vide a suitable method for EFK1216 EFK1116SS 12 --t—" floor mounting enclosures • EFK1218 EFK1218SS 12 18 which would otherwise be EFK1110 EFK1220SS 12 20 suspended.Each kit con- EFKIB08 EFK1808SS 18 8 sists of two legs,which are fabricated from 10 gauge steel, EFK1810 EFK1810SS 18 10 and finished with dark gray primer over phosphatized EFK1812 EFK1812SS 18 12 surfaces. EFK2408 EFK2408SS 24 8 NOTE:Additional finishing required if used in a Nema EFK2410 EFK2410SS 24 10 4/4X application. EFK2412 EFK2412SS 24 12 Each leg has a flange along the top and is pre-punched EFK2416 EfK2416SS 24 16 for mounting to the enclosure.For extra stability,each leg has a pad,which is welded in place and pre-punched for securing to the floor.Stainless steel legs are fabricated from 10 gauge Type 304 stainless steel,and feature a#3(brushed) polish on all exterior surfaces.All hardware for mounting to enclosure is supplied with floor stand kits. Louver Plate Kits Note:A cutout in the enclosure is required to accommo- '',,_ . - date louver plate.See table for recommended sizes. Electromate louver plate tr , kits are used to provide •, a �r . +k Steel louver Stainless Steel ventilation for enclosures _ . _ +' Plate Kit Lauver Piste Kit Number at Sscemmsnded which require interior air f -------- ' Catalog Number Catalog Number Plate Size Louvers Cwut Slat flow.Louver plate kits i J, , (H x W) (Mx w) consist of a 14 gauge plate, 4. .. repunched with ventilation .,erg„ , ELYS EU/188 5x 5 3 4x4 Pouversanamounting .. &'r`"` EU/2 EMS 5x10 8 4x9 holes.An oil-resistant gasket is attached to the `. rear of the plate and mount- ing hardware is furnished.Standard finish is gray primer 411 over phosphatized surfaces.Stainless steel louver plates are fabricated from 14 gauge stainless steel,and Is provided with a#3(brushed)finish. .... ... .,..a.. ,..-.;_ ' - MI ' - . ' ' , ' . . , VERSATILITY PERFORMANCE OFF THE SHELF ULDED CASE CIRCUIT BREAKERS rULL LINE FROM 15 AMPERE TO 1200 AMPERE CONTINUOUS RATING • TWO POLE THREE POLE 240V MAXIMUM 480V 240V MAXIMUM 480V AIC 240V 22K 10K 25K 100K 65K 22K 22K 10K 25K 100K 65K 22K /- 480V --- --- --- --- 14K --- --- --- --- --- 14K --- VOLTS 600V --- --- --- --- --- --- --- --- --- --- --- CS TYPE--s FS 0 CC CCH CHH KS FS FS CC CCH CHH KS FS 15 FS220015A IFS240015A FS320015A FS340015A 20 220020A 240020A 320020A 340020A 25 --- --- 320025A 340025A 30 220030A 240030A 320030A 340030A 35 - --= 320035A 340035A 40 • 220040A 240040A 320040A : - • 340040A • ' - 45 . --- --- 320045A340045A • 50 220050A 240050A 320050A 340050A co 60 220060A 240060A 320060A 340060A z 70 220070A 240070A 320070A 340070A Kt 80 220080A 240080A 320080A 340080A 90 220090A 240090A 320090A 340090A w • 100 220100A ,CC2100 CHH2100 240100A .._ • _ . _ _._... . s: 320100A CC313100 • CHH3100 340100A cc. 125. 2125. CCH2125 21253125 CCH3125 3125 3401258 ( _It •.150 2150 2150 ; 2150 3150 3150 3150 3401508 175 2175 2175 2175 3175.: _ 3175 3175 0 200 2200 2200 2200 3200 3200 3200 z 225 2225 2225 2225 3225 3225 3225 1'- 250 KS220250D KS320250D 0 300 2203000 320300D v • _: 350 • ': - 220350D L• . 3203500 400 2204000 320400D 500 . . j 600. 700 _ • - . .... 800 900 1000 1200 ' o Single pole type FS SINGLE POLE 277V MAXIMUM Amp 65,000 AIC at 120V Rating 22,000 AIC at 277V TYPE FS 1SA FS130015A 20A 130020A 30A 130030A (41" • E:1•N L r . L r J h 1 I L. r a 1 W r a- i i a V a f a•r ,. 1• a.. �. s.. r../ 1 , . ,a 6— J a I a- 4. a ai• • 116. !► w et a I L a a a OS a V a► 1 V a l 1 = r= ` = 5" HELFC3VERSATILI T YCPERFORMAU' CECOFF THE SHELF EVERSAT1Lt -.: 7, ;i "r. ' OPPt.', ANCECOi- F THE St-1ELF :>: VERSATILITYi PERFORMANCE DOFF - :. ‘" '::: ::7r ,"-. TtLlTYL3FERFORMAttCEF' OFF THE SHELF ® VERSATILITYEPERFO7 FHELFL'• VERSATILITYECPERFORiMA. PtCECOFF THE SHELF CVERSATIL : 1L1 T '�" _, _ ., FORMANCErOFF THE SHELF : VEFSATILITYF.2PERFORMANCEMOFF - MOLDED CASE CIRCUIT BREAKERS —Also Rated for Two-Pole Applications 600 VOLT MAXIMUM—AIC Ratings at 240/480/600V 22K 100K 25K 100K 200K 42K 65K 42K 65K 42K 65K 42K 65K 14K 30K 22K 30K 100K 30K 35K 30K 35K 30K 35K 30K 35K 14K 18K 14K 18K 25K 22K 25K 20K 25K 22K 25K 22K 25K fS FH JS JH JL KS _ KH LS LN MS MH NS NH . FS360015A FH360015A 360020A 360020A 360025A 360025A 360030A 360030A 4 +'3600354 w . 360040A 360045A,j.360045A 360050A 360050A . - ,. 360060A 360060A 360070A 360070A 360080A 360080A 360090A 360090A PRI111114r-ikNor=.2 360100A JS360100A JH360100A JL360100A KS3601000 K113601000 '360125A 0 360125A 360125A •360125A " 360125A 3601250 3601250 360150A 0 360150A -360150A 360150A 360150A 3601500 3601500 • - • 360175A 360175A 360175A 3601750 3601750 (41° . . •'-' -- - - -360200A 360200A 360200A •9 360200D 9 3602000 360225A 360225A 360225A 360225D 360225D 3602500 360250D LS360250A 1113602504 360300D 3603000 360300A 360300A 360350D 3603500 --- . --- MS360350A M H360350A 360400D 3604000 360400A . 360400A 3604004 3604004 0 0 360500A 360500A 360500A 360500A - 360600A 360600A 360600A 3606004 3607004 360700A NS360700A NH360700A 360800A 360800A 3608004 360800A 3609004 360900A 361000A 361000A 361200A 3612004 9 High magnetic(Or instantaneous)trip breakers are also available in Type FH,125A,150A.480V maximum.with B suffix Magnetic trip setting is 1875A maximum for FH3401258 and 1950A maximum for FH3401508 ©Type KS and KH are available with thelmal•magnetic trip as shown,or with 200A-400A Sol d•State Rating Plugs in a K5350400R or 10H380400R Circuit Breaker Frame • oil Ea:T•N GE Molded Case Circuit Breakers o Line Circuit Breakers t t Types TOL, THQL, TQB, THQB, TQC, THQC 5-125 Amps • 10,000 Amps IC TOL,THOL Ptug•in TOC,THOC Lug-tug0 109,THOB Bon-on Net Trade Net Trade Net Ampere Price, Price, " ' Rating Catalog Number GO- Catalog Number 00-1358 Catalog Number 00.1359 . Single-pole, 120/240 Volts ac® }` 100 1011110 5 6.80 01110w1 $ 8.70 1091110 1 7.50 150 TH01.1115 5.50 ' THOss1115W 8.70 TH081115 7.50 200 THOL,120 6.80 t� TH11201t 8.70 1H081120 7.60 I 25 711011125 8.50 THOC11251Y1 8J0 111081125 7.50 30 711011130 550 THOC t 130lv1 8.10 711091130 7.60 35 THOL1135 5.50 THOC1135WL 6.70 TH001135 7.60 THQL1120 40 TH011140 5.80 THOC1140WL 5.70 TH001140 7.50 45 TH0L1145 6.80 THOC1145WL 8.70 TH081145 7.60 50 TH011150 5.50 THOC 1 150W 5.70 111081150 7.50 60 111011160 5.60 THOC 1160W1 6.70 TH081160 7.50 • 70 THOL1170 14.00 THOC1170W1 17.25 TH081170 14.75 r- Two-pole, 120/240 Volts ac® 100 TOL2110 15.25 TOC21101'VL 19.00 1092110 16.25 r-'. 15 TNOL2115 14.25 THOC2115WL 19.00 TH002115 1625 20 TH012120 14.25 THOC2120WL 19.00 THOB2120 16.25 25 TH012125 15.25 TH0C2125wL 19.00 TH092125 16.25 1, _ 30 711012130 13.25 1H0C2130w1 19.00 1//082130 1625 35 THOL2135 15.25 THOC2135WL 19.00 TH092135 16.25 0801 40 TH012140 14.25 1H0C2140W1 19.00 TH092140 15.25 45 111012145 15.25 1110C2145W1 19.00 TH082145 15.25 50 TH01.2150 14.25 THOC2150WL 19.00 TH082150 15.25 THHQB2115 60 TH012160 14.25 THOC2160WL 19.00 TH092160 1625 70 THOL2170 29.00 TH0C2170wL 37.00 711062170 31.50 80 71101,2180 4350 THOC2180WL 50.00 TH092180 43.00 (4° • 90 7110 2190 40.50 TH0C2190WL 50.00 711092190 43.00 100 7110121100 40.50 THOC21100WL 50.00 7110921700 • 43.00 r ,`t, 110 THOL21110 95.00 - - - .� 125 71101211250 5050 - - - - i'' Two-pole,240 Volts acC 1 100 70122010 42500 TOC220'OWL 50.00 10922010 43.00 15 1110L22015 42.500 THOC22075wL 50.00 TH01322015 43.00 Y"_Y 20 TH01.22020 42.500 THOC22020WL 50.00 TH0922020 43.00 25 TH0122025 42500 THOC22025WL 60.00 7110922025 43.00 30 11101.22030 42.500 11-40022030W1 50.00 TH0922030 . 43.00 ' THQC22020WL 35 1110L22035 . 42.500 14-40022035W1 50.00 1110822035 43.00 40 THOL22040 42.600 THOC22040WL 50,00 TH0022040 43.00 45 1110122045 42.500 THOC22045WL 60.00 TH01322045 43.00 50. THOL22050 42.600 THOC22050WL 50.00 T110822050 43.00 60 THOL22060 42.600 TH0C22060W1. 60.00 1110822060 43.00 70 THOL22070 _ $0.500 THOC22070WL 66.60 TH0922070 56.60 - 80 1110122080 71.000 THOC22080WL 75.50 TH0622080 $4.50 ' 90 THOL22090 ' 71.000 THOC22090WL 75.50 1110822020 $4.50 100 11101.22100 . 71.000 THOC22100WL 75.60 TH0822100 54.50 !)' Three-pole, 240 Volts Sc® 100 10132010 62.500 TOC32010WL 51.50 10832010 62.50 CS 15 TH0132015 52.600 THOC32015w1 51.50 TH0032015 12.50 20 71101.32020 46.000 THOC32020WL 61.60 TH0832020 52.50 THQL32015 25 1110132025 52.600 TH3C32025WL $1.50 1110832025 52.50 30 1110132030 . 45.600 1H0C32030W1 $1.50 TH0B32030 52.60 35 1110132035 52.500 THOC32035WL $150 TH0832035 52.50 40 1140132040 48.500 THOC32040WL 51.60 TH0832040 - 52.50 45 THOL32045 52.500 TH0C32045WL 61.50 TH0832045 . 12.50 50 1110132050 48.600 THOC32050WL 51.50 TH0932050 . 52.60 80 1410132060 '" 45.500 1110C32060WL 51.50 TH0832060 52.50 70 THOL32070 $9.000 THOC32070WL 77.50 TH0932070 _ 55.00 80 TH0132080 79.00•Q 1110032080WL 88.50 7110832080 75.50 90 TH0132090 79.000 TH0C32090WL $0.50 7110932090 76.60 100 TH0132100 78.00® THOC32100WL $5.60 7110832100 75.60 ' 0 Requires mounting plate. See 0 Recommended for use as 0 GO-138. • page 4-38. main or sub-main breaker Q 5000 AIC,not UL Listed. only. 0 Us 15-60 amp are UL Listed as UL Listed as SWD(Switching ole:See Product Index HACK. Duty)rated. Suitable for cdditional stock og Numbers. switching 120-volt ac fluorescent lighting loads. 4-6 hien std iota subject to swap 1tkuf stain T , 7/1/90 30.5 mm HEAVY DUTY OILTIGHT PUSHBUTTONS 281 Pushbutton Units FILE Components 10250T ORDERING COMPLETE, UNASSEMBLED OPERATORS USING SINGLE COMPOSITE CATALOG NUMBER For convenience— when ordering from the components Combined into a single catalog number(Any component • listings—the individual component catalog numbers may may be omitted by merely collapsing the number to be combined into a single catalog number. Individual eliminate the space). components will be packed in a single box labeled with the Basic Lens or Contact Legend combined identification number. No Operator Button Hyphen Block(a) Plate Example: .___—.____` Component numbers for an illuminated pushbutton with Order Cat. No.: 102507 411 C21 - 153 S33 red lens,a NO-NC contact block,a NO contact block and \.....1 (10250TS33"START" legend plate. (102501411) START )102507411 illuminated ushbutton— a e 284 Illuminated LegendPlate ( p p 9 ) Pushbutton10250TC21 (red lens—page 284) (10250153) 10250T1 (NO-NC contact block— page 283) (10250TC21) 7/ Hyphen must NO 10250T53 (NO contact block— page 283) Red Lens appear before (1025071) 10250TS33 ("START" legend plate— page 300) contact blocks NO-NC 10250T411C21-153S33 0 When not included with operator ORDERING EXAMPLES: ,.r s --' START (4 • For complete 10250T operators using ri single composite catalog number @ - (Example: 10250T101-151S33), See Instruction Above. Contact Block Contact Block Legend Plate Operator 1025071 10250751 10250TS33 OP102507101 (Page 283) (Page 283) (Page 300-301) PUSHBUTTON OPERATORS—Vertical or Horizontal Mounting — UL(NEMA)4,4X and 13 . Color Cat. No. Price Color Cat. No. Price Color Cat. No. l Price 'A _ Standard Button Extended Button Half Shrouded Button !it 10250T 10250T Vert. Horiz. . Black 101 Red 112 r =-1.,- ed R102 .. Black 111 �' 10250T 102501 - Green 103 r �- Green 113 Black 501 511 I ` + Red 502• 512- m normal position Yellow 104 L4.� Yellow 120 $16.20 p Gra 105 516.20 White 116 \ Green 503 513:.. button surface is it N., ' Yellow 504 514:. 516.20 hush with guard White 106 Blue 118 0 Blue 108 Orange 119 Whitehy 506- 516, Orange ' 109 • le •5 8 518 • . 1, Mushroom Head Jumbo Mushroom Head Orange 509 519. .;:,, i `jr' Black 121 i ' Black 171 $40.20 Red 122 / Red 172 40.20 0 it operators are to be mounted in a vertical row,specify t Green 123 $34.20 ' ( Red f•7, 17213 45.00 VERT,for correct orientation of contact block terminals, Yellow 124 >>L Green 173 40.20 See page 309 for mounting instructions. ''' L Blue 129 - Yellow 174 40.20 GROUNDING KITS 16tGROUNDING OF 10250T COMPONENTS GROUNDING screconsisto0 ntngrcO ector too rear of con- NIBS tact block mounting screw. 10250T line operators have new "grounding nibs" — four Application Catalog Price metal points on the operator casting designed to bite pp Number through most paints and other coatings on metal panels to ,: All components 102507 enhance the ground connection when the operator is except standard • $015 securely tightened. indicating lights Each ' and PresTest est Minimum For grounding of operators mounted to non-metal panels or rhaN" , Indicating Lights KG.1. Order for extreme applications where the grounding nibs may not • . Standard Indicating KG2 ©.; Quantity be effective due to excessively hard or thick coating mate- Lights 50 rials on the panel,the grounding kits at right can be used. PresTest Indicating •'•G3.-•0,,:- Lights These kits permit installation of a separate daisy chain Includesreptac•m•ntmounting•cr•wstoNlgfltunit ground wire between components and ground. 4•ad of r.pfac.mlnt screw is drifted and tapped to accept ring connector. DISCOUNT SCHEDULE 100.1 DIMENSIONS, Pages 307.909 Printed m U.S.A. E�� GG281 . Ammiro 288 30.5 mm HEAVY DUTY OILTIGHT PUSHBUTTONS _ 7n/90 FILE _ Indicating Lights 102507 j Components k C.)0 ORDERING EXAMPLE *M^ ^ ' For complete 10250T operators using it, single composite catalog number f, - 0 (Example: 10250T181 NC1 NS81),See '1.' Page 281. Legend Plate Standard Transformer Type Lens 102507581 Cat.No.10250T181N 10250TC1N (Page 300-301) BASIC UNIT— UL(NEMA) 4,4X, 13 Vertical or Horizontal Mounting Type Lamp Volts STANDARD UNIT PRES-TEST MASTER TEST Cat. No. Price Cat. No. Price Cat. No. Price 10250T 10250T 102501 �- —5 120 0 181N 221N 187N ,. Transformer Type Volt 208-240 1822rN. •I .' 222N --- - 1, e.; 50 or 60 Hertz Lam 277 198N S60.00 578.00 S90.00 .- ac only p 380 183N 223N --- k -. 0 480 184N• 224N --- 600 185N 225N --- Standard Trans- Full Voltage former Type For use w/LED None 0 19714 46.50 Cat.No. Bayonet Base 0 10250T181N Type Lamp (10 755 6 203N 233N --- --- Full Voltage Type 756 12-14 204N 233N i ac or dc 757 24 206N 48.00 235N 66.00 41:1 } (Direct Connected) 1828 32 207N 238N / it 1835 48 208N 239N 1, _ , i ....:...1,71 Resistor 120MB 120 201N . ' 48.00 231N 66.00 --- --- ,� ..? 1 ac or dc 120MB 240 202N 240N Neon Type ac or dc #B2A 120 ac. dc 226N 0 48.00 --- --- --- --- i PresTest Trans- (Resistant to (NE51 H) 240 ac,dc 227N 0 • former Type— Shock&Vibration) Cat.No Solid State 7 e . 1o2soT22,N 120 V ac only 120 MB 120 - --- --- . --- ' --- 189N 78.00 50or60Hz . 0 For flashing lamp,add letter••F"to listed catalog number and add 56.00 to price.Example: 10250T181NF,Price 566.00. o For Master Test(dual input)or Flasher add-on modules.see Page 305.Modules can only be used with 24 or 120 V ac/dc standard indicating lights. ©Relay lest circuit. o These units do not include lamp.Order LEO lamp separately from Page 305. • ©For best illumination use amber,yellow or clear lens. o Additional voltages available,contact your nearest Eaton Corp.Cutler-Hammer Distributor or call our Customer Service Center 1-800.833-3927. LENS ' FOR STANDARD AND MASTER FOR PRES-TEST TEST INDICATING LIGHTS _ INDICATING LIGHTS Color Plastic Glass f Color Plastic Glass �;Cat .N6. Price Cat. No: Price 11,-::,•:,L, Cat. No.. Price Cat. No. Price Plastic r'.10250T,' i.• 10250T • Plastic • 102501 102501 Red r:5 C1 N C7N. Red C21 .. . C13N Green t 2N C8N Green C22. . C14N 'r Amber ya t9N'#. 64,20 ;.C9N 87.50 Amber43 $4.20 C15N 57.50 Yellow . 3N;_vi-:-. --- Yellow C23" t Blue `, 4N " C10N • � Blue 24 16N • Clear rt 5N1,-4;,' , C11 N Clear c25.. 17N r( Glass White ,; 6NP.�'r:.; C12N Glass White 26 • _ 18N \� DIMENSIONS,Pspfs 807.309 DISCOUNT SCHEDULE 1CD-1 . F=T•N Primal in USA 288 OG : ------------------------------------ s 30.5 mm HEAVY DUTY OILTIGHT PUSHBUTTONS 291 Selector Switch Components FILE OPERATORS WITH CAM AND CAP 10250T OTE: See Pages 290 and 292 for Cam and Contact Block Selection r DEGREES OF KNOB LEVERet'"` THROW- OPER- i!( OPER �,,,, KEY (.4 Between ATOR !Iy ATOR A I OPER- ✓ , / selectoren witch 1\ (Black) ATOR l i `.. positions ons Description 2 Position-60° Catalog and Code No. Catalog and Code No. Catalog and Code No. : . 3 Position-60° 4 Position-40° Vert. Vert. Key Vert. Horiz. Mtg. Cam Mtg. Cam Cam Removal ", O Code Price Code Price Mtg Mt . Code Positions Price KEY REMOVAL • _ ',� NEMA 0 NEMA A 4E 3A 4-13 A Code POSITIONS 0.. 4-13 4-13 No. 2 Position4102507 1D250T 102507 Select One Code Maintained MINI-1 522.20 301 'f 1 522.20 151 161 + 1 1,2,3 558.20 No. onlyc w- 2 Pos.Spr. V 137 + 1 34.20 307 4. 1 34.20 157 158 + 1 2 70.20 eR *et.Fr.Right Position 132 i or 22.20 302 or 22.20 152 162 + or 1,2'3,4 58.20 Maintained 3 33 5,6 or 7 Code 3 Pos.Spr. No. Positions Ret.Fr.Left �i 133 + or 34.20 303 + or 34.20 153 163 + or 1,4 or 5 70.20 • 1 Right Maint.in 2 Left Right Pos. l . 3 Right&Lett 3 Pos.Spr. 12 12 2 4 Center Ret.Fr.Right`s 134 + or 34.20 304 + or 34.20 154 164 + or .4 70.20 5 Right&Center and Left 3 3 3 6 left&Center 7 All Positions 3 Pos.Spr. Ret.Fr.Right 135 or 34.20 305 or 34.20 165 166 or 2,4 or 6 70.20 Key removal in"spring ° *Maint.in �I� _ return from"positions eft Pos. I 3I 3 3 • not recommended. Position 136© ♦ 7 22.20 306 ♦ 7 22.20 167 168 4. 7 ' 7 70.20 Maintained t I t CONTACT REPLACEMENT KEYS or DISSIMILAR LOCKS For Above Key Operators BLOCKS o Listed operators have identical locks and keys(Key Code H661)Cat.No.10250ED824. ' For dissimilar lock and key combinations,see listing on Page 293. LEGEND Replacement Keys(Code H661) Cat.No.10250E0824 S6.00 Per Pair PLATES 0 ', OPERATOR ONLY WITHOUT CAP OPERATING CAPS (COLORED) -;'..g_ OPERATORCat.and Code No. Knob Lever Lever Lever ONLY .- Uni NEMA 4-13 NEMA 4.13 NEMA 3-4-13 NEMA 4-13 WITHOUT AP versa) Cam Price �� MM Code ` ; r111/4 ��- NEMA A Color • 2 Position Maintained 102507 1 $18 401 + Cat.& Cat.& Cat.& Cat.& 2 Pos.Spc f Code Price Code Price Code Price Code Price Ret.Fr.Right V 408 4. 1 30. No. No. No. No. . 3 Position Maintained 402 ) 10250T 10250T 10250T 10250T �`2 or 3 18. Black KB LB SB • CB ": 3 Pos.Spr.Ret. Red KR LR SR ' CR Fr.Left Maint. v,,- 403 +2 or 3 30. Green KG LG SG • CG in Right Pos. Yellow KY $4.20 LY $4.20 SY $16.20 CY $16.20 White KW LW SW CW;:• 3 Pos.Spr,Ret. Gray KA LA SA CA - � Fr.Right&Left V - 1 404 2 or 3 - 30. Blue KL LL SL ' CL A 3 Pos.Spr.Ret. Orange KO LO SO CO Fr.Right Maint. - 2 405 4,2 or 3 30. 0 Field convertible to Horizontal Mounting or order operator only and separate operator ill"In Left Pos. cap. +8 For selection of the proper cam and contact block to obtain the proper dreult sequence. 4 Position Maintained 406 4- 7 18. see selection Instructions and chart on Pages 290 and 202. Cannot use early closing or late opening contacts on 4 poskion selector switches. For selection and allowable number of contact blocks per operator,see Pape 289. Legend Plates,see table Pages 200.301. DISCOUNT SCHEDULE 1CD-1 EIte111 Primed m U.S A 291 •CM 1)305 1