A Crane Co. Company

INSTALLATION MANUAL

IMPORTANT! Read all instructions in this manual before operating pump. As a result of Crane Pumps & Systems, Inc., constant product improvement program, product changes may occur. As such Crane Pumps & Systems reserves the right to changeproductwithoutpriorwrittennotification.

420 Third Street 83 West Drive, BramtonPiqua, Ohio 45356 Ontario, Canada L6T 2J6Phone: (937) 778-8947 Phone: (905) 457-6223Fax: (937) 773-7157 Fax: (905) 457-2650www.cranepumps.com Form No. 116953-Rev. R

ENVIRONMENTALLY SEALED PRESSURE SWITCH

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Other brand and product names are trademarks or registered trademarks of their respective holders.® Barnes is a registered trademark of Crane Pumps & Systems, Inc© Crane Pumps & Systems, Inc. 2003, 2/2006, 9/06, 10/06 Alteration Rights Reserved

TABLE OF CONTENT

SAFETY FIRST ................................................................................................3

INTRODUCTION ..............................................................................................4 SWITCH WIRING SCHEMATIC .......................................................................5 SIMPLEX SCHEMATIC ....................................................................................5 DUPLEX SCHEMATIC .....................................................................................5

ESPS-100 WIRING DIAGRAM JUNTION BOX TO CONTROL PANEL ............................................................6 ESPS-100 WIRING DIAGRAM SWITCH TO CONTROL PANEL (UltraCAP2) ..................................................7

IDENTIFICATION OF STEALTH CONTROL PANELS ....................................8

STEALTH-R & -O “E” SERIES PANELS JUNCTION BOX TO CONTROL PANEL ..........................................................9

DUPLEX STEALTH R & O, G and C SERIES PANELS 1 HP & 2 HP 200/240 VOLT - 1 PHASE ..........................................................10

DUPLEX STEALTH UGP, UCP SERIES PANELS ALL UGP/UCP HP, VOLTAGE & PHASE STEALTH -R, -O, -G and -C Except 200 or 240 Volt, 1Ph ...............................11

ELECTRICAL CORD CONNECTION ..............................................................12

RAIL MOUNTING ASSEMBLY .........................................................................13

NON-RAILED MOUNTING ASSEMBLY .......................................................... 14

ATTACHED ROPE TO SWITCH ......................................................................15

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Please Read This Before Installing Or Operating Pump. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols:

IMPORTANT! Warns about hazards that can result in personal injury orIndicates factors concerned with assembly, installation, operation, or maintenance which could result in damage to the machine or equipment if

ignored.

CAUTION ! Warns about hazards that can or will cause minor personal injury or property damage if ignored. Used with symbols below.

WARNING ! Warns about hazards that can or will cause serious personal injury, death, or major property damage if ignored. Used with symbols below.

Only qualified personnel should install, operate and repair pump. Any wiring of pumps should be performed by a qualified electrician.

WARNING ! - To reduce risk of electrical shock, pumps and control panels must be properly grounded in accordance with the National Electric Code (NEC) or the Canadian Electrical Code (CEC) and all applicable state, province, local codes and ordinances.

WARNING! - To reduce risk of electrical shock, always disconnect the pump from the power source before handling or servicing. Lock out power and tag.

Prevent large articles of clothing, large amounts of chemicals, other materials or substances such as are uncommon in domestic sewage from entering the system.

During power black-outs, minimize water consumption at the home(s) to prevent sewage from backing up into the house.

Always keep the shut-off valve completely open when system is in operation (unless advised otherwise by the proper authorities). Before removing the pump from the basin, be sure to close the shut-off valve. (This prevents backflow from the pressure sewer.)

Keep the control panel locked or confined to prevent unauthorized access to it.

If the pump is idle for long periods of time, it is advisable to start the pump occasionally by adding water to the basin.

CAUTION! Pumps build up heat and pressure during operation-allow time for pumps to cool before handling or servicing.

WARNING! - DO NOT pump hazardous materials (flammable, caustic, etc.) unless the pump is specifically designed and designated to handle them.

Do not block or restrict discharge hose, as discharge hose may whip under pressure.

WARNING! - DO NOT wear loose clothing that may become entangled in the impeller or other moving parts.

WARNING! - Keep clear of suction and discharge openings. DO NOT insert fingers in pump with power connected.

Make sure lifting handles are securely fastened each time before lifting. Do not operate pump without safety devices in place. Always replace safety devices that have been removed during service or repair.

Do not exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat.

Secure the pump in its operating position so it can not tip over, fall or slide.

Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently.

Never handle connected power cords with wet hands.

To reduce risk of electrical shock, all wiring and junction connections should be made per the NEC or CEC and applicable state or province and local codes. Requirements may vary depending on usage and location.

Submersible Pumps are not approved for use in swimming pools, recreational water installations, decorative fountains or any installation where human contact with the pumped fluid is common.

Do not remove cord and strain relief. Do not connect conduit to pump.

Products Returned Must Be Cleaned, Sanitized, Or Decontaminated As Necessary Prior To Shipment, To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material. All Applicable Laws And Regulations Shall Apply. Bronze/brass and bronze/brass fitted pumps may contain lead levels higher than considered safe for potable water systems. Lead is known to cause cancer and birth defects or other reproductive harm. Various government agencies have determined that leaded copper alloys should not be used in potable water applications. For non-leaded copper alloy materials of construction, please contact factory.

IMPORTANT! - Crane Pumps & Systems, Inc. is not responsible for losses, injury, or death resulting from a failure to observe these safety precautions, misuse or abuse of pumps or equipment.

SAFETY FIRST!

Hazardous fluids can cause fire or explo-sions, burnes or death could result.

Extremely hot - Severe burnes can occur on contact.

Biohazard can cause serious personal injury.

Hazardous fluids can Hazard-ous pressure, eruptions or ex-plosions could cause personal injury or property damage.

Rotating machineryAmputation or severe laceration can result.

Hazardous voltage can shock, burn or cause death.

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INTRODUCTION

Thank you for purchasing your new Barnes brand level control. The ESPS series of level control switches have been designed to provide years of reliable service when properly used with Barnes brand pumps and packages. Please completely read this manual and follow all installation instructions to insure your level control provides the best service possible.

When attempting to use this product in stations made by other manufacturers, care should be taken to ensure the application is compatible with the characteristics of the Barnes brand ESPS level control being used. Misapplication of this product will void the warranty.

This switch is designed to be a “Non-Serviceable” item. If a switch is suspected to be inoperative, contact your local service center for service replacement options.

The level control contains pressure sensitive components and diaphragms. Care should be taken when handling the unit to insure damage does not occur. Damage may result in improper function or undesirable performance. All actuation points are factory set and cannot be changed. Any attempt to change the actuation points will void the warranty.

Before placing switch into service, switch should be brought to operational temperature range. Excessive or direct heating or cooling should NOT be used.

OPERATION TEMPERATURE RANGE: +35°F (2°C) to +120°F (49°C)SHIPPING / STORAGE TEMPERATURE: -20°F (-29°C) to +150F (66°C)

SWITCH COMPONENT DESCRIPTION

FUNDAMENTALS OF OPERATIONSThe ESPS-100 Level control is designed to be used in conjunction with a simplex pump control panel identical to those used with conventional floats. It will signal the panel to turn the pump “On” at a point below the alarm bell as the liquid level rises in the basin. The pump will then run until the liquid level drops to a point above the lower switch housing where the panel will be signaled to turn the pump “Off”. In the event the pump does not turn on or the pump cannot keep up with the inflow, the alarm circuit will be activated once the liquid level submerges the Alarm Air Bell Tube. It will stay activated until the condition is corrected and the liquid level drops below the Alarm Air Bell Tube. The ESPS-200 Level control is designed to be used in conjunction with a duplex pump control panel identical to those used with conventional floats. It will signal the panel to turn the lead pump “On” at a point below the alarm bell as the liquid level rises in the basin. The pump will then run until the liquid level drops to a point above the lower switch housing where the panel will be signaled to turn the pump “Off”. During periods of high inflow where the lead pump cannot keep up with the inflow, the level control will signal the panel to turn the lag pump on at a point between the lead point and the alarm bell. In the event the pump does not turn on or both pumps cannot keep up with the inflow, the alarm circuit will be activated once the liquid level submerges the Alarm Air Bell Tube. It will stay activated until the condition is corrected and the liquid level drops below the Alarm Air Bell Tube.

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SWITCH WIRING SCHEMATIC

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ESPS-100 WIRING DIAGRAMJUNCTION BOX TO CONTROL PANEL (Where Applicable)

IF J-BOX IS NOT USED, WIRE ACCORDING TO CHART HEADING “ESPS CONTROL CORD” AND “TERMINAL NUMBER”

TERMINALNUMBER

DIRECT BURIALCABLE*

ESPS CONTROLCORD

1 RED RED2 BLACK BLACK3 YELLOW WHITE4 ORANGE ORANGE5 BLUE GREEN

NOT USED BROWN NOT USED

NOTES:1. Check for nicks and defects in cable.2. Cord jacket should be slightly visible inside cord grips. Approximatelt 1/4” to 1/2”3. Tighten cord grips 1/4 turn past hand tight.

*Colors may vary on DBC

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ESPS-100 WIRING DIAGRAMSWITCH TO CONTROL PANEL (UltraCAP2)

TERMINALNUMBER

LEAD COLOR LEAD LENGTH LEADSTRIP LENGTH

TERMINAL STRIPTORQUE

1 RED

7.00 in .50 in 18 in lbs2 BLACK3 WHITE4 ORANGE5 GREEN

NOTES:1. Check for nicks and defects in cable.2. Cord jacket should be slightly visible inside cord grips. Approximately 1/4” to 1/2”3. Strip wire lengths and tighten per chart4. Tighten gland nut 3 turns past hand tight5. Tighten control panel cord grip 1/4 turn past hand tight

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IDENTIFICATION OF BARNES STEALTH SERIES DUPLEX CONTROL PANEL FOR ESPS-200 LEVEL CONTROL WIRING

To determine the proper wiring schematic you will need to first determine the panel type you have using the information listed below. The information can be located inside the control panel door on the panel schematic.

For STEALTH -R & -O “E” Series Panels: - Carries an “E” designation on the end of the model callout - This control panel identified with a build date of March, 2006 or later - All horsepower, voltage, and phase combination will use this wiring type - Example is a STEALTH-R-204-26E or STEALTH-O-202-22E

For STEALTH, R & O Series Panels - 200 or 240 Volt, 1 Phase, 1 & 2 HP: - 1 or 2 Horsepower, 200 or 240 Volt, 1-Phase ratings - This control panel identified with a build date prior to March, 2006 or earlier - Carries one of the following designations STEALTH-R or STEALTH-O

For STEALTH G, C, R, O, UGP and UCP Series Panels - All Voltage/Phase & HP: - 2.0 Horsepower, 200, 240, 480, or 600 Volt, 3-Phase ratings, 200 or 240 volt, 1 phase (Except STEALTH -R & -O), 200/240V 1Ph - 3.0, 5.0, or 7.5 Horsepower, 200 or 240 Volt, 1-Phase or 200, 240, 480, or 600 Volt, 3-Phase ratings - This control panel identified with a build date prior to March, 2006 or earlier - Carries one of the following designations: STEALTH-R or STEALTH-O STEALTH-G or STEALTH-C UGP or UCP

STEALTH -R -101 -2 1E -P

PUMP SERIES:UGP = SGV GrindersUCP = SGPC GrindersG = SGV GrindersC = SGPC GrindersR = SGV GrindersO = OGP, OGVF/OGVH & SGPC Grinders

PANEL MODEL:101 thru 116, Simplex201 thru 216, Duplex

HORSEPOWER:1 = 1HP2 = 2HP3 = 3HP5 = 5HP7 = 7.5HP

VOLTAGE:0* = 200 Volt, 1 Phase, 60Hz1* = 120 Volt, 1 Phase, 60Hz2* = 240 Volt, 1 Phase, 60Hz3* = 240 Volt, 3 Phase, 60Hz4* = 480 Volt, 3 Phase, 60Hz5* = 600 Volt, 3 Phase, 60Hz6* = 200 Volt, 3 Phase, 60Hz

(*) If "E" - ESPS-200 Compliant. If Blank - Requires ESPS-200 wiring modification and/or kit.

MOUNTING:* = Wall Mount (STD)P = Poly Drywell Mount

(*) Left Blank

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DUPLEX STEALTH-R & -O “E” SERIES PANELSJUNCTION BOX TO CONTROL PANEL

TERMINALNUMBER

DIRECT BURIAL CABLE

ESPS CONTROL CORD

1 RED RED2 YELLOW WHITE3 (*) NONE FACTORY INSTALLED JUMPER PLACED BETWEEN TERMINAL 3 & 44 (*) NONE FACTORY INSTALLED JUMPER PLACED BETWEEN TERMINAL 3 & 45 ORANGE BLACK6 NONE N/A7 NONE N/A8 RED/BLACK ORANGE9 BLUE/BLACK GREEN

NOTES:1. Check for nicks and defects in cable.2. Cord jacket should be slightly visible inside cord grips. Approximately 1/4” to 1/2”3. Tighten cord grips 1/4 turn past hand tight

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DUPLEX STEALTH R & O SERIES PANELS1 HP & 2 HP 200/240 VOLT - 1 PHASE

TERMINALNUMBER

DIRECT BURIAL CABLE LEVEL CONTROL CORD

1 RED RED4 YELLOW WHITE

L3 on MS2 BLACK BLACK7 ORANGE ORANGE8 BLUE GREEN

BROWN NOT USEDRED/BLACK NOT USEDBLUE/BLACK NOT USED

NOTES:1. Wire used for the jumpers is not supplied. Wire size must be #18 to #14 AWG, standed copper2. To test functionallity of changes, the ESPS-200 switch should be ran through two complete cycles from off to alarm, making sure the lead and lag pumps change between each cycle identifies the wiring change has been properly performed.

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DUPLEX STEALTH UGP, UCP SERIES PANELSALL UGP/UCP HP, VOLTAGE & PHASE, STEALTH -R, -O, -G and -C Except STEALTH -R & -O, 200 or 240 Volt, 1 Ph

TERMINALNUMBER

DIRECT BURIAL CABLE LEVEL CONTROL CORD

1 RED RED4 YELLOW WHITE

53 on MS2 BLACK BLACK7 ORANGE ORANGE8 BLUE GREEN

BROWN NOT USEDRED/BLACK NOT USEDBLUE/BLACK NOT USED

NOTES:1. Wire used for the jumpers is not supplied. Wire size must be #18 to #14 AWG, standed copper2. To test functionallity of changes, the ESPS-200 switch should be ran through two complete cycles from off to alarm, making sure the lead and lag pumps change between each cycle identifies the wiring change has been properly performed.

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ELECTRICAL CORD CONNECTIONSCORD CABLES - The cord assembly mounted to the switch must NOT be modified in any way except for shortening to a specific application. Any modifications to the switch cord will void the warranty.

OVER-TEMPERATURE PROTECTION - The type of in-line over-temperature protector used in this level control is referred to as an inherent overheating protector and operates on the affect of temperature rise. This means that the over-temperature protector will trip out and shut the pump off if the switch becomes too hot. It will then automatically reset after the switch cools to a safe temperature. In the event of an over-temperature, the source of this condition should be determined and rectified immediately.DO NOT LET THE PUMP CYCLE OR RUN IF AN OVER-TEMPERATURE CONDITION OCCURS!

CORD CONNECTION - Insert female end of cord plug into housing bore aligning alignment mark with detent in terminal block, See Figure Below.Tighten bolts until the corners of the compression flange are drawn down to the top of the level control.DO NOT OVER TORQUE.

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“C” CHANNEL RAIL MOUNTING ASSEMBLY

ITEM QTY DESCRIPTION PART NUMBER MATERIAL1 1 SWITCH, ESPS N/A2 1 MOUNTING, BRKT, SLIDE 114580-SS Stainless Steel3 3 WASHER, FLAT, 1/4 20-5-1 Stainless Steel4 5 WASHER, LOCK, 1/4 20-13-1 Stainless Steel5 3 SCREW, BHCS, 1/4-20 x .75 26-80-1 Stainless Steel6 2 SCREW, HXHD, 1/4-20 x .63 1-4-1 Stainless Steel

7 1

CORD, 18/5, SOW, 8 Ft.CORD, 18/5, SOW, 15 Ft.CORD, 18/5, SOW, 30 Ft.CORD, 18/5, SOW, 50 Ft.CORD, 18/5, SOW, 75 Ft.CORD, 18/5, SOW, 100 Ft.

113288A113288

113288XC113288XF113288XJ113288XL

8 VARIES ROPE, 1/4” DIA. 3 STRAND 115664 Polypropylene

NOTES:1. Bracket may be reversed to allow switch mounting on either side of the guid rail to avoid obstructions and inlets in basin

2. Secure cord to avoid possible hazards

3. Install the pump before sliding the level control down the “C” channel

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NON-RAIL MOUNTING ASSEMBLY

ITEM QTY DESCRIPTION PART NUMBER MATERIAL1 1 SWITCH, ESPS N/A2 1 ESPS 100/150 BASE

ESPS 200 BASE (ESPS 200 includes Hose Clamp)

130979P116876A

Cast IronBuna/Stainless Steel

3 1

CORD, 18/5, SOW, 8 Ft.CORD, 18/5, SOW, 15 Ft.CORD, 18/5, SOW, 30 Ft.CORD, 18/5, SOW, 50 Ft.CORD, 18/5, SOW, 75 Ft.CORD, 18/5, SOW, 100 Ft.

113288A113288

113288XC113288XF113288XJ113288XL

4 3 WASHER, LOCK, 1/4 20-13-1 Stainless Steel5 6 SCREW, HXHD, 1/4-20 x .63 1-4-1 Stainless Steel6 1 HOOK, S, 13 GA, 1.01” 109489 Stainless Steel7 1 WASHER, FLAT, 1/4” 20-5-1 Stainless Steel8 VARIES ROPE, 1/4” DIA. 3 STRAND 115664 Polypropylene9 3 Washer, Flat 131836 Stainless Steel

NOTES:1. Position level control in basin in a level loction and not in direct flow of inlets

2. Secure cord to avoid possible hazards

3. On ESPS-200 installation, remove ring from adapter boot

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ATTACH ROPE TO SWITCH

STEPS & TIPS: • Attach lifting device to pump.

1. Make a small overhand loop in the rope.2. Bring the short end through the overhand loop.3. Place short end behind the fixed part of the rope.4. Bring end around and back into the loop.5. Pull on the fixed end of the rope away from the loop to tighten the knot. NEVER LOWER OR RAISE PUMP BY THE CORD!

ESPS-200

ESPS-100

IMPORTANT!WARRANTY REGISTRATION

Your product is covered by a warranty: www.cranepumps.com/downloadables/CATALOGS_OIPMs/Warranty/24MonthWarranty.pdf

If you have a claim under the provisions of the warranty, contact your local Crane Pumps & Systems, Inc. Distributor.

RETURNED GOODSRETURN OF MERCHANDISE REQUIRES A “RETURNED GOODS AUTHORIZATION”.

CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR.

Products Returned Must Be Cleaned, Sanitized, Or Decontaminated As Necessary Prior To Shipment, To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material. All Applicable Laws And Regulations Shall Apply.

IMPORTANT!WARRANTY REGISTRATION

Your product is covered by the enclosed Warranty.

If you have a claim under the provision of the warranty, contact your local Crane Pumps & Systems, Inc. Distributor.