PUMP STATION START-UP and
Contents
1. Runs in Hand Does not run in Auto Float Switch Page 12 PROBLEM LT 2 Seal Failure iG Page 13 PROBLEM I 1 3 Pump shuts off and turns on independent of switch trips thermal overload Page 14 PROBLEM I 1 4 Pump runs but does not pump down in Hand or Auto Electrical seeeeeeeeeeeesssss Page 15 PROBLEM 1 1 5 Pump runs but does not pump down in Hand or Auto Mechanical Page 16 PROBLEM ET Pump noise Excessive vibration E Page 17 PROBLEM 1 7 Pump will not Shut E Page 18 PROBLEM 1 1 8 Circuit breaker trips or fuse blows pumps do not start Page 19 PROBLEM 1 1 9 Pump cycles Treouenihy nennen nnn nnne nnn nnn nnns narrar nn nnns nna nnn nen Page 20 PROBLEM i 1 10 Failed start capacitor when pump turns on Page 21 ELECTRICAL SAFETY POINTS Before attempting any repair be sure incoming power is OFF double check with a volt meter 1 Visually check power cable for signs of deterioration Visually check for water intrusion in control panel Check for low resistance between control panel and ground Make sure ground green in control panel is properly secure Pull fuses and keep in safe place Tag control panel with CAUTION tag Secure control panel with padlock ALWAYS disconnect the pump from the power source before handling or servicing oO O N O Ci A C bh NEVER handle connected power co2. Voltage Phase Hertz Horsepower Full Load Amps Service Factor Amps Motor Manufacturer Controls Control panel manufacturer Model Part number Number of pumps operated by control panel Short circuit protection YES NO Type Number and size of short circuit device s Amp rating Overload Type Size Amp rating Do protection devices comply with pump and motor Amp rating YES NO Are all electrical and panel entry connections tight YES Is the interior of the panel dry YES NO Liquid level Control Brand and Model Pre Startup All Pumps Type of equipment NEW REBUILT USED _ Condition of equipment at Start Up DRY WET MUDDY Was Equipment Stored YES NO Length of Storage Liquid being pumped Liquid Temperature Supply Voltage Phase Frequency matches nameplate YES NO Shaft turns freely YES NO Direction of rotation verified for 30 motors YES Debris in piping or wet well YES Debris removed in your presence YES NO Pump case wet well filled with liquid before startup YES NO Is piping properly supported YES NO Non Submersible Pumps Is base plate properly installed grouted YES N A Coupling Alignment Verified per I amp O Manual YES NO N A Grease Cup Oil Reservoir Level checked YES NO NA Submersible Pumps Resistance of cable and pump motor measured at pump control Red Black Ohms O Red White Ohms O White Black Ohms Q Resistance of Ground Circuit bet
3. 15 CUTTER IMPELLER PLUGGED PULL PUMP YES FOR GOOD SERVICE 1 2 19 CHECK VALVE STUCK BAD YES DISCHARGE FROM PUMP TO MAIN PLUGGED 1 2 19 CHECK VALVE STUCK ves DISCHARGE FROM PUMP MAIN PLUGGED 1 2 24 CONSULT NO DISCHARGE HEAD YES NO FACTORY TO HIGH Problem 1 6 Pump Noise Excessive Vibration 1 2 25 DISCHARGE PLUMBING OR RAIL ASSEMBLY LOOSE TIGHTEN YES ALL PLUMBING 1 2 17 PULL PUMP CHECK ROTATION ROTATION CORRECT NO 1 2 17 PUMP RUNNING BACKWARDS 3 PHASE ONLY 1 2 15 CLEAN CLOGGED BAD IMPELLER CUTTER GOOD GOOD PUMP WAS RUNNING TIGHTEN REPLACE ALL PLUMBING BAD BACKWARDS GOOD REMOVE PUMP FOR SERVICE 17 Problem 1 1 7 Pump Will Not Shut Off EN CHECK FOR CORRECT WIRING CORRECT PUMP CYCLES LOOSE WIRES CONTROL BAD WIRING GOOD CORRECTLY PANEL JUNCTION BOX GOOD BAD SWITCH IN HAND TURN SWITCH TO POSITION YES AUTO GOOD I 2 21 CONSULT EXCESSIVE YES FACTORY INFLOW Ken CORRECT FOR PUMP AIRLOCK YES AIRLOCK GOOD BAD 12 3 amp 1 2 34 1 2 4 1 25 OFF SWITCH YES CONTINUITY TEST GOOD STUCK FLOAT SWITCH BAD 1 2 4 amp 1 25 CONTINUITY TEST GOOD FLOAT SWITCH BAD 227 REPLACE CONTACT YES CONTACTOR GOOD STICKING BAD CONSULT 2 24 PUMP IMPROPERLY YES FACTORY SIZED NO 18 1 2 10 MOISTURE IN CONTROL PANEL DRY PANEL WITH BLOW DRYER PUMP STARTS DOES NOT TRIP CIRCU
4. 3 IIg Purchased From _ BARNES PUMPS Z Suevi Nameplate Data Pump Model 4SHYA3004 2Z Serial 5 25 E Jp a Pad 42740052 _ Impel ler Diameter Noua A Voltage GO Phase Hertz 20 Hor power SSL HL Full Load Amps _ e 7 Service Factor Apps iid Motor Manufacturer ERAI AES PONEN Z Contr Control panel manufacturer 2 7 HAE Model Part number VE CSATROL ip BA Number of pumps operated by control panel 2N Short circuit protection YESs lt Number and size of short circuit device Overload ie Lz MATE Si 6 Is the interior of the panel dry YES Liquid level Control Brand and All Pumps Type of equipment Condition of equipment at StarN MUDDY Was Equipment edd YES Length of Storage Liquid being pumped 2 Liquid Temperature 75 y matches nameplate YES gt lt um NOX Y presence YES gt lt NO well fled with i ade before startup YES X NO NAX NAX NO NAX Submersible Pumps Resistance of cable and pump motor measured at pump control Red Black 2 35 Ohms Q Red White _0 3 4 Ohms Q White Black Resistance of Ground Circuit between Control Panel and outside of pump MEG Ohms check of insulation Red to Ground 24500 White to Ground gt Soo Black to Grounc Operational Checks Is there noise or vibration present YES 2X Source of noise vibration Does check valve operate prop
5. CLEAN TIGHTEN NEUTRAL WIRE REPAIR OR REPLACE REPAIR OR REPLACE REPOSITION FLOAT REPLACES SWITCH REMOVE DEBRIS INSTALL LARGER PUMP 20 GOOD GOOD GOOD GOOD GOOD GOOD PUMP CYCLES CORRECTLY 1 2 1 CHECK FOR CORRECT PUMP POWER LEADS AT TERMINAL STRIP GOOD 1 2 1 CHECK FOR CORRECT PUMP POWER CONNECTION AT JUNCTION BOX GOOD 1 2 25 MEGGER CONTROL PANEL TO JUNCTION BOX GOOD REPLACE START CAPACITOR Problem 1 1 10 Failed Start Capacitor Single Phase Units With Start Circuit in Panel When Pump Turns On 1 2 33 REPLACE REPLACE CAPACITOR BAD CORRECT WIRING OK CONSULT FACTORY CORRECT WIRING BAD GOOD 1 2 30 PULL PUMP BAD MEGGER JUNCTION BAD FOR SERVICE BOX TO PUMP GOOD REPLACE DIRECT BURIAL CABLE 21 UGP 101 PANEL SECTION I TROUBLE SHOOTING 2 1 Check for Correct Wiring Check all switch control leads for correct color coding or number marking Trace all leads through junction box to correct terminal in the control panel Refer to appropriate wiring diagrams in service manual control panel and junction box NOTE Pump power leads at control panel terminal strip must be red to R black to B and white to W When checking for correct wiring look for moisture in the control panel or junction box corrosion at wire connections loose wire connections and poorly stripped wires of the above can
6. pump will be under load and turn pump on Record amperage readings on all necessary leads Compare your recorded amperage with the nameplate rating and the amperage recorded on the system start up sheets See Figures 12 and 13 Amps will drop as motor becomes warm NOTE Must not exceed 10 nameplate amps at nominal voltage 1 PHASE CONTROL PANE 1 PHASE READING TAKEN ON LINE SIDE OF CONTROL BREAKER THREE PHASE CONTROL PANEL THREE PHASE READING TAKEN TO PUMP Figure 13 2 12 Jammed Cutter Impeller With the power off and the control panel locked check the cutter impeller for freedom of movement you should be able to move the cutter by hand If clogged clear the cutter impeller cavity of any obstruction If all the debris cannot be removed it may be necessary to remove the volute to clean around the impeller refer to pump Installation Operation Manual 24 2 19 Check Application Check for undersized pump or incorrect impeller installed for conditions Recheck performance curve It is possible the original pump selection is at fault or system head has changed 2 14 Correct Pump Rotation All Barnes Submersible Grinder Pumps rotate clockwise looking down at the pump To check rotation suspend the pump freely momentarily apply power and observe the kickback Kickback should always be in a counterclockwise direction as viewed from the top of the pump motor housing Incorr
7. remains at infinity 00 capacitor is open e f the pointer remains at zero 0 capacitor is shorted A shorted or open capacitor must be replaced NOTE The above test builds up a small charge in the capacitor which it will store Before repeating test or reconnecting capacitors discharge capacitor by shortening terminals with an insulated screwdriver A good capacitor will discharge a small spark Check each metal Run Capacitor for grounds by clipping one ohmmeter lead to capacitor case and the other ohmmeter lead in turn to each of the two capacitor terminals With ohmmeter set at R x 100K pointer should remains at infinity OO on extreme left of scale Start Capacitors often have backlight case and cannot be checked by this method for ground BARNES BARNES MA Burks WEINMAN DEMING PROSSER Limited 24 Month Warranty Crane Pumps amp Systems warrants that products of our manufacture will be free of defects in material and workmanship under normal use and service for twenty four 24 months after manufacture date when installed and maintained in accordance with our instructions This warranty gives you specific legal rights and there may also be other rights which vary from state to state In the event the product is covered by the Federal Consumer Product Warranties Law 1 the duration of any implied warranties associated with the product by virtue of said law is limited to the same duration as stated he
8. taken at Black White the control panel terminal strip between red ground black ground and white ground with the power off record your NOTE readings in meg ohms see Figure 5 Readings of 5 meg If OHMS reading are not within range disconnect ohm and higher are acceptable Note 0 readings indicate wires at terminal strip and check again a dead short Correct the problem before proceeding THIS TEST MUST BE PERFORMED AFTER THE GROUND RESISTANCE CHECK IN SECTION F 4 SECTION G PERFORMANCE CHECK G 1 With discharge valve s closed pull pump and rotate impeller by hand replace pump X IMPORTANT All power must be off NOTE With the pump power off circuit breaker fill the wetwell with enough water to trip the high water alarm float Open discharge valve in the wetwell and if necessary the discharge valve at the force main G 2 Is the High Water Alarm On Check YES or NO Turn power on is the high water alarm on red light on top of control panel NOTE If your control panel is equipped with an alarm horn push the button on the panel cover to silence Let the pump run until the alarm light turns off and manually turn power off at the control panel circuit breaker G 3 Alarm Shut Off at Appropriate Level Check YES or NO Measure the water depth with pump off when the alarm shuts off and record if desired G 4 Amperage Load at Line Connection Single Phase Using a clamp on amp
9. 2 21 alpin Ib 29 WARRANTY REGISTRATION E 30 ES 30 HARPUR REFOR Mi ee 31 32 SPECIAL TOOLS AND EQUIPMENT INSULATION TESTER MEGGER DIELECTRIC TESTER SEAL TOOL KIT see parts list PRESSURE GAUGE KIT see parts list Other brand and product names are trademarks or registered trademarks of their respective holders Barnes is a registered trademark of Crane Pumps amp Systems Inc 1994 2002 2003 1 2004 8 2004 4 05 3 06 8 06 1 07 2 07 Alteration Rights Reserved P 41 SAFETY FIRST PLEASE READ THIS BEFORE INSTALLING OR OPERATING PUMP GENERAL Most accidents can be avoided by using COMMON SENSE Read this operation and maintenance instruction manual Do not wear loose clothing that may become entangled in the impeller or other moving parts Always wear appropriate safety gear such as safety glasses when working on the pump or piping Bronze brass and bronze brass fitted pumps may contain lead levels higher than considered safe for potable water systems Vari ous 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 Minimize the amount of cooking grease entering the system Do Not leave pump cover off the basin except while servicing to prevent entrance of foreign materials such as rocks metal soil anim
10. BARNES PUMP STATION START UP and TROUBLESHOOTING MANUAL Crown PO6 IMPORTANT Read all instructions in this manual before operating pump As a result of Crane Pumps amp Systems Inc constant product improvement program product changes may occur As such Crane Pumps amp Systems reserves the right to change product without prior written notification CRANE Pumps amp SYSTEMS am A Crane Co Company 420 Third Street 83 West Drive Brampton Piqua Ohio 45356 Ontario Canada L6T 2J6 Phone 937 778 8947 Phone 905 457 6223 Fax 937 773 7157 Fax 905 457 2650 Www cranepumps com Form No 101686 Rev B TABLE OF CONTENTS SAFELY eg sen cig tents 3 A GENERAL INFORMATION aaa eee 4 B START UP WARRANTY 4 C NECESSARY GENERAL INFORMATION iisecccesencoetonuteceucesougsguiaustienocstarteennans 4 D E 5 E TION BOX INFORMATION 5 F E 5 6 G PERFORMANCE CHECK Oe nr ene ee eee ene ee ee ee 7 H MINAL CHECK 8 l TROUBLE SHOOTING E 11 28 PROBLEM FLOW CHARTS 1
11. IT BREAKER OR BLOWN FUSE PROBLEM DUE TO MOISTURE IN CONTROL PANEL JUNCTION BOX REPLACE DIRECT BURIAL CABLE CONTROL CABLE TO JUNCTION BOX Problem 1 1 8 Circuit Breaker Trips or Fuse Blows Pumps Do Not Start 1 2 10 MOISTURE IN JUNCTION BOX DRY JUNCTION BOX WITH BLOW DRYER 1 2 29 MEGGER CONTROL PANEL TO PUMP BAD 1 2 30 MEGGER JUNCTION BOX TO PUMP BAD PULL PUMP FOR SERVICE BAD 19 1 2 28 CHECK BREAKER FUSE RATING 1 2 18 CHECK INCOMING VOLTAGE 1 2 15 PULL PUMP RESET CIRCUIT BREAKER CHECK FOR CLOGGED IMPELLER CUTTER YES CLEAN IMPELLER 1 2 33 FAULTY RELAY OR START CAPACITOR 1 PHASE ONLY GOOD CONSULT FACTORY NO YES REPLACE WITH CORRECT RATING CORRECT POWER SUPPLY GOOD PULL PUMP FOR SERVICE PUMPS OK BAD REPLACE DISCHARGE VALVE S NOT OPEN ALL THE WAY YES 1 2 1 CHECK FOR CORRECT WIRING LOOSE WIRES CONTROL PANEL JUNCTION BOX GOOD POOR CONTROL CIRCUIT NEUTRAL 1 2 21 LEAKING DISCHARGE WATER INFILTRATION NO BAD BAD YES BAD YES moo BAD 1 2 32 DEFECTIVE CHECK VALVE NO YES BAD 1 2 26 FLOATS SET TOO CLOSE DEFECTIVE SWITCH YES BAD 1 2 15 PUMP CLOGGED NO YES BAD 1 2 24 PUMP SIZED INCORRECTLY CONSULT FACTORY YES Problem 1 9 Pump Cycles Frequently OPEN VALVES CORRECT WIRING
12. LIED WARRANTY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No rights extended under this warranty shall be assigned to any other person whether by operation of law or otherwise without our prior written approval CRANE Pumps amp SYSTEMS r SYSTEMS A Crane Co Company 420 Third Street 83 West Drive Brampton Piqua Ohio 45356 Ontario Canada L6T 2J6 Phone 937 778 8947 Phone 905 457 6223 Fax 937 773 7157 Fax 905 457 2650 www cranepumps com IMPORTANT WARRANTY REGISTRATION Your product is covered by the enclosed Warranty To complete the Warranty Registration Form go to http www cranepumps com ProductHegistration If you have a claim under the provision of the warranty contact your local Crane Pumps amp Systems Inc Distributor RETURNED GOODS RETURN OF MERCHANDISE REQUIRES A RETURNED GOODS AUTHORIZATION CONTACT YOUR LOCAL CRANE PUMPS amp 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 CRANE PUMPS amp SYSTEMS A Crane Co Compan uM START UP REPORT General Information Pump Owner s Name Address Location of Installation Contact Person Phone Purchased From Nameplate Data Pump Model Serial Part Impeller Diameter
13. N HOT OIL UNDER PRESSURE ALLOW MOTOR TO COOL BEFORE OPENING 5 THIS PUMP IS NOT INTENDED FOR USE IN SWIMMING POOLS DECORATIVE FOUNTAINS OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH THE PUMPED MEDIA IS A COMMON OCCURENCE 6 DO NOT PUMP FLAMMABLE LIQUIDS O 7 DO NOT REMOVE CORD AND STRAIN RELIEF C 8 DO NOT CONNECT CONDUIT TO PUMP L Ge wm C Us LR16567 SECTION D CONTROLS D 1 Panel Model Number The panel model number will tell Barnes whether your control panel is a Simplex or Duplex and what options you may have The panel model number can be usually found inside the control panel cover Control Panel Model Number UGP 101 21 UGP Pump Series 101 Panel Options 2 Horsepower 1 Voltage amp Phase D 2 Is Interior Dry Check YES or NO The interior of the control panel must be clean and dry at startup If moisture is present determine cause and correct Check to make sure that all conduit entries in the panel are sealed D 3 Are All Connections Tight Check YES or NO It is recommended that all wire connections be checked for tightness in addition to the pump power control wires level sensor and service wires Check factory connections in the panel to assure that no connections were loosened during shipping SECTION E J UNCTION BOX INFORMATION CAUTION Check to be certain that all power is off E 1 Debris in Piping or Wet Well Indicate by checking YES or NO Inspect the basin for any
14. ROONA o a In the event of a moisture detect check the moisture sensor leads for continuity Refer to wiring diagram supplied with panel If resistance is detected check for continuity in junction box see Figure 10 2 9 Continuity Check Moisture Sensor Junction Box NOTE The moisture sensor is a N O normally open detector SH Series and explosion proof pumps have a 330K Ohm test resistor across the probes If a 330K reading is obtained this should be considered Open OO RESISTANCE INDICATES JUNCTION BOX MOISTURE If checking moisture sensor leads at the control panel for continuity indicates the presence of moisture disconnect the moisture sensor leads in the junction box and check for continuity from junction box to pump see Figure 11 2 10 Excessive Water Temperature Continuous water temperatures above 100 F 88 C may cause the pump temperature sensor to open and trip the thermal overload To determine if this is happening turn power off and fill the basin with cold water allowing time for the pump to dissipate heat Turn power on and check for normal pump cycle Continuous operation with the pump unsubmerged may result in the same symptoms Consult pump manual for minimum submergence requirements NOTE Water temperature not to exceed 160 F 71 C intermittent 23 2 11 Check Motor Amperage With the power off clamp the amp robe around the appropriate lead Fill basin so
15. YSES AND EVALUATIONS WE CONDUCT WILL BE BASED ON OUR BEST AVAILABLE EXPERIENCE AND PUBLISHED INDUSTRY INFORMATION SUCH RECOMMENDATIONS DO NOT CONSTITUTE A WARRANTY OF SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS GIVEN This warranty shall not apply when damage is caused by a improper installation b improper voltage c lightning d excessive sand or other abrasive material e scale or corrosion build up due to excessive chemical content Any modification of the original equipment will also void the warranty We will not be responsible for loss damage or labor cost due to interruption of service caused by defective parts Neither will we accept charges incurred by others without Our prior written approval This warranty is void if our inspection reveals the product was used in a manner inconsistent with normal industry practice and or our specific recommendations The purchaser is responsible for communication of all necessary information regarding the application and use of the product UNDER NO CIRCUMSTANCES WILL WE BE RESPONSIBLE FOR ANY OTHER DIRECT OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO TRAVEL EXPENSES RENTED EQUIPMENT OUTSIDE CONTRACTOR FEES UNAUTHORIZED REPAIR SHOP EXPENSES LOST PROFITS LOST INCOME LABOR CHARGES DELAYS IN PRODUCTION IDLE PRODUCTION WHICH DAMAGES ARE CAUSED BY ANY DEFECTS IN MATERIAL AND OR WORKMANSHIP AND OR DAMAGE OR DELAYS IN SHIPMENT THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER EXPRESS OR IMP
16. als or humans 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 discontinue water consumption at the home s to prevent sewage from backing up into the house Prevent infiltration or direct flow of rain or run off water into the pump basin to minimize pump cycling This will prevent overloading the treatment facility and will facilitate swift transportation of sewage Always keep the shut off valve completely open when system is in operation unless advised otherwise by the proper authorities 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 Before removing the pump from the basin be sure to close the shut off valve This prevents back flow from the pressure sewer Make sure level controls are provided at time of installation This basin system is intended for use with water sewage and effluent applications This basin must be vented in accordance with local codes This basin system is not to be installed in locations in which the basin interior would be classified as a hazardous loca tion in accordance with NEC ANSI NPFA 70 PUMPS Recommended no more than 10 starts per hour Pumps build up heat and pressure during operation allow time for pumps to c
17. contribute to control problems 2 2 Check Water Level Hemove wetwell cover and check water level If the water level is above the On float this should be sufficient to close all switches 2 9 Float Hang Up Visually check float movement while filling basin If floats get hung up on pump or rail system reposition floats and check again Inspect floats for build up of solids clean and check operation 2 4 Continuity Check of Controls Turn off Main Circuit Breaker at control panel Fill basin to a level above the discharge elbow this will allow all switches to be closed Referring to the wiring diagram supplied with panel check for continuity at the control panel terminal strip Off On and alarm switches should be closed continuity see Figure 8 TS AMPROBE PUMP ON SET ON OHMS 22 Turn on the Main Circuit Breaker and manually pump the basin down to the bottom of the pump volute Turn off the Main Breaker and repeat the continuity check Off On alarm switch should be open no continuity If these conditions are not met go to L 2 5 l 2 5 Continuity Check of Controls AT JUNCTION BOX Fill wetwell to a level above the discharge elbow this will allow all switches to be closed Refer to the wiring diagram supplied with the basin turn off the main breaker disconnect all switch control leads at the junction box check for continuity from switch controls to junction box Off On and alarm switch
18. ding SES this should be considered Open Problem 1 1 3 Pump Shuts Off and Turns on Independent of Switch Trips Thermal Overload 1 2 13 EXCESSIVE WATER ADD COLD WATER YES OR PURCHASE HI TEMP PUMP TEMPERATURE YES 1 2 1 CHECK FOR CORRECT WIRING CORRECT WIRING PUMP CYCLES ON BAD HAND AUTO AT CORRECT LEVEL LOOSE WIRED CONTROL PANEL JUNCTION BOX GOOD 1 2 15 PULL PUMP CHECK FOR JAMMED CUTTER IMPELLER 1 2 14 CHECK MOTOR AMPS 10 RATED AMPS BAD GOOD CORRECT WIRING GOOD WILL CAUSE HIGH AMPS BY RUNNING ON 1 2 16 CHECK APPLICATION DISCHARGE HEAD MAY BE LESS THAN MINIMAL RIGHT HAND SIDE OF CURVE GOOD CONSULT FACTORY 14 Problem 1 4 Pump Runs but Does Not Pump Down in Hand or Auto Electrical IF PROBLEM IS ELECTRICAL A 1 2 17 CORRECT ROTATION 3 PHASE ONLY REVERSE ANY 2 PUMP DOWN IN POWER LEADS HAND AUTO YES 1 2 18 CHECK FOR CORRECT INCOMING VOLTAGE REF B GOOD MECHANICAL BAD 1 2 18 CORRECT INCOMING POWER SUPPLY GOOD PUMP DOWN IN HAND AUTO 15 Problem 1 1 5 Pump Runs but Does Not Pump Down in Hand or Auto Mechanical IF PROBLEM IS MECHANICAL B 1 2 19 DISCHARGE VALVE HANDIAUTO NOT OPEN WETWELL amp MAIN YES 1 2 20 CORRECT FOR PUMP AIRLOCK YES AIRLOCK 1 2 21 CONSULT EXCESSIVE INFLOW YES FACTORY CORRECT LEAK EE DISCHARGE LEAK YES LEAK 1 2
19. ect rotation three phase In the event that the rotation is incorrect for a three phase pump interchange any two power cable leads at the control panel Do not change power cable leads in the pump Recheck the kickback rotation again by momentarily applying power Incorrect rotation single phase In the unlikely event that the rotation is incorrect for a single phase pump contact a Barnes Pump s Service Center 2 15 Check for correct incoming voltage Single Phase Check incoming voltage on the line side of the control panel circuit breaker Readings of 10 of published voltage nameplate are acceptable A true check of the voltage supply to the motor must be taken with the pump operating under load see Figure 14 Take voltage readings with the pump off and readings with the pump on compare the two readings and note any difference SINGLE PHASE MEASURING AC VOLTS t PHASE SUPPLY POWER OVERLOAD BREAKER If incorrect power supply readings are recorded contact local power source THREE PHASE CONTROL PANEL BREAKER Three Phase Check incoming voltage on the pump side of the control panel circuit breaker Readings of 10 of the published voltage nameplate are acceptable A true check of the voltage supply to the motor must be taken with the pump operating under load see Figure 15 Take voltage readings between all three legs with the pump off and reading
20. erly YES X NO NA Is system free of leaks YES gt lt Leaks at Does system appear to operate at design flow rate YES X Nominal Voltage ZO Phase Voltage Reading at panel connection Pump OFF L1 L2 7 Voltage Reading at panel connection Pump ON L1 L2 S3 oS A3 _ 57 Amperage Draw Pump ON L1 Z9 Sf x Submersible Pumps Are BAF and guide rails level plumb YES Additional Comments e En Es VZS Date 57 3 0 G9 Operator SAH Other ies daten a copy of this report for future trouble shooting reference IMPS amp SYSTEMS J0 Third Street 83 West Drive Brampton Piqua Ohio 45356 Ontario Canada L6T 2J6 Phone 937 778 8947 Phone 905 457 6223 Fax 937 773 7157 Fax 905 457 2650 www cranepumps com SECTION I TROUBLE SHOOTING 3 The Reference Number can be found in Section 1 2 see pages 26 32 Corrective Action 1 Trouble Shooting Flow Charts How to read flow charts 4 Corrective Action instructions Section 1 2 1 through I 2 34 will give details on trouble shooting your problem 1 Based on your observations and initial inspection of the system select a Flow Chart 1 1 1 through 1 10 CAUTION Shut off power unless otherwise noted before 2 All flow charts start at the top left hand corner follow making electrical mechanical checks the chart in the direction of the arrows Note the reference number at the top of each block TROUBLE SHOOTING PROBLEM I 1 1
21. es should be closed continuity See Figure 9 JUNCTION BOX Turn on breaker and manually pump the basin down to the bottom of the pump volute Off On alarm switch should be open lack of continuity If these conditions are not met replace switch CAUTION Wu When the breaker is turned on the control leads may be energized with 120 V Make sure they are safely tied off and isolated 2 6 Replace Cable between Panel amp Junction Box If it is necessary to replace the direct burial cable note the following 1 Is the cable the same size type 2 Reseal conduit entering control panel 3 Are the cord grip grommets in the junction box the correct size 4 Use NEW wire nuts in the junction box 5 How did the cable get damaged 2 7 Moisture in Control Panel Junction Box The accumulation of moisture in the controls can lead to a number of electrical problems If moisture is evident turn power to the control panel off and thoroughly dry with a blow dryer After drying check for loose or corroded connections determine cause of moisture and correct 2 8 Continuity Check Moisture Sensor Control Panel NOTE The moisture sensor is a N O normally open detector SH Series and explosion proof pumps have a 330K Ohm test resistor across the probes If a 330K reading is obtained this should be considered Open OO RESISTANCE INDICATES ND MOISTURE SEAL PROBE N O CHECK LEADS 8 AND 9 TO G
22. ground water entering the basin around the inlet pipe or cord entries G 8 Equipment Difficulties List any difficulties encountered during start up and note what if any corrective action was taken NOTE If you encounter any problems during start up refer to the trouble shooting section of this manual SECTION H FINAL CHECK H 1 Has the End User Received All Manuals After completion of a successful start up the end user homeowner should receive the Installation Manual Control Panel Installation Operation Manual Pump Installation Operation Manual User Guide if applicable and this Start Up Manual H 2 Has the End User been Briefed on Warranty A copy of the warranty is in the back of all manuals and should be pointed out to the end user H 3 Are the Operation Maintenance Manuals Saved Advise end user to save all Installation Operation Manuals and keep for future reference H 4 Received Above Information If possible have those present at start up sign and date the start up form if the system is operating properly NOTE If duplex system is being started fill out duplicate forms mark first set PUMP 1 or LEAD mark second set PUMP 2 or LAG CRAN E PUMPS amp SYSTEMS A Crane Co Company START UP REPORT General Information Pump Owner s Name SOHN oF E Address 125 FEST St Location of Installation 4 7 ST Contact Person SMITH Phone 33
23. igher than pump full load amps but no more than 3 times the full load amps Current overloads should be sized in accordance with pump nameplate amps A new motor without Drop Cable 20 000 000 or More 20 0 A used motor which can be reinstalled in the well 10 000 000 or More 10 0 Motor in well Ohm readings are for drop cable plus motor A new motor in well 2 000 000 or More 5 0 A motor in the well in reasonably good condition 500 000 2 000 000 0 5 5 0 A motor which may have been damaged by lighting or with damaged leads 20 000 500 000 0 02 0 5 DO NOT pull the pump for this reason A motor which definitely has been damaged or with damaged cable The pump 10 000 20 000 0 01 0 02 should be pulled and repairs made to the cable or the motor replaced The mo tor will not fail for this reason alone but it will probably not operate for long A motor which has failed or with completely destroyed cable insulation The Less Than 10 000 0 0 01 pump must be pulled and the cable repaired or the motor replaced 26 2 26 Megger Control Panel to Pump With power off at the control panel disconnect the pump power cable leads from the control panel DISCONMMECT AT d SSES PANEL MEGOHMMETER Connect one lead to ground green and check red black white power cord leads see Figure 16 A minimum insulation resistance readings of 5MQ is considered acceptable Readings of less than indicates a bad circu
24. it between control panel and pump See Resistance Values on Page 30 2 27 Megger Junction Box to Pump With power off at the control panel disconnect the pump power cable leads at the junction box ISCONNECT AT e JUNCTION BOX MECOHMME TER Connect one lead to ground green and check red black white power cord leads see Figure 17 A minimum insulation resistance reading of 5MO is considered acceptable Readings of less than 5MO indicate a bad circuit between the junction box and pump pull the pump for service 2 28 Poor Neutral With power off check for clean tight neutral connection on control panel terminal strip also check neutral connection at power supply Refer to appropriate wiring diagram in service manual 2 29 Defective Check Valve If the check valve is not installed properly or is defective this will allow back flow at the end of the pump cycle Remove and examine check valve for proper installation and freedom of movement repair or replace 2 30 Faulty Relay or Start Capacitor Checking the start relay see Figure 18 CAUTION Be sure to short out start capacitor and remove wires from relay terminals before making any resistance checks with ohmmeter Always remove all power from circuits before making resistance measurements OHMME TER Measure Between Terminals 1 and 2 Zero Ohms Measure Between Terminals 2 and 5 Actual coil resistance Relay Check The te
25. lts and should be balanced within 1 Pump rated volts can be found on the pump nameplate If your pump is single phase mark N A THREE PHASE THREE PHASE MEASLIRIMG AC VOLTS SUPPLY POWER OVERLOAD BREAKER BAK POWER RED TO PUMP Figure 2 If incorrect power supply readings are recorded contact local power source F 3 Resistance of Pump Power Connections F 4 Resistance Between Ground Lug and outside Pump Record the ohms resistance reading of the motor windings Case Rail at the pump power connections on the control panel terminal Record the ohms resistance reading between the control strip with power off Readings should be taken between red panel ground lug and the pump case or the stainless black black white red white see Figure 3 Compare your steel rail if your basin has the rail system see Figure 4 ohms readings to the electrical chart in the pump operations Resistance readings of less than 1 ohm indicate a good safe manual you should be within 5 of resistance listed on the ground If basin is not located next to the panel a temporary chart extension wire from the basin to the meter may be required to take this reading UGF CONTROL PANEL OHM METER UGP CONTROL PANEL CHECK RED GROUND BLACK GROUND WHITE GROUND l POWER All Three Resistance readings should be the F 5 Insulation Check at Control Panel MEG OHM same The insulation check of the pump power leads is
26. meter clamp amp meter to the L1 wire between the service drop and control panel circuit breaker Turn pump power on at the control panel circuit breaker see Figure 6 IN COMING UGP CONTROL POWER PANEL L1 L2 AMPME TER SINGLE PHASE AMP READING OM LINE SDE OF CONTROL WITH PUMP RUNNING BREAKER NOTE If pump does not come on push the start button in the control panel Record the amperage readings of L1 and L2 they should not exceed more than 10 over the pump nameplate amps If your pump is a three phase mark N A G 5 Amperage Load at Line Connection Three Phase Using a clamp on amp meter clamp the amp meter to the L1 wire between the service drop and control panel circuit breaker 566 Figure 7 UCP INCOMING CONTROL POWER THREE PHASE AMP READING OVERLOAD ON LINE SIDE OF CONTROL BREAKER WITH PUMP RUNNING Figure 7 NOTE If pump does not come on push the start button in the control panel Record the amperage readings on L1 L2 and L3 they should not exceed 1096 over the pump nameplate amps If your pump is a single phase mark N A G 6 Did the Pump Shut Off at the Normal Off Point Check YES or NO The pump should have pumped the water level down to the predetermined Off point and shut off automatically G 7 Visible Leaks Check YES or NO Did you notice any visible leaks when pump was running You should look for leaks around discharge fitting within the basin and possible
27. of pumps should be performed by a qualified electrician Never operate a pump with a power cord that has frayed or brittle insulation Cable should be protected at all times to avoid punctures cut bruises and abrasions inspect frequently Never handle connected power cords with wet hands Do not remove cord and strain relief Do not connect conduit to pump To reduce risk of electrical shock all wiring and junction connections should be made per the NEC and applicable state and local codes Requirements may vary depending on usage and location See wiring diagrams in manual Do Not operate the pump in the HAND control position and leave the pump unattended CAUTION This unit may have more than one connection to the source of supply To reduce the risk of electric shock disconnect all such connections before servicing All connections inside this tank and or junction box must be made with listed watertight connectors IMPORTANT BARNES PUMPS 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 SECTION A GENERAL INFORMATION A 1 To the Purchaser Within the manual you will find the necessary information to verify correct start up and registration of your Barnes Pump system This manual will also provide helpful information concerning proper maintenance and troubleshooting procedures A 2 Service Centers For
28. ool before handling or servicing Only qualified personnel should install operate and repair pump Keep clear of suction and discharge openings DO NOT insert fingers in pump with power connected 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 Make sure lifting handles are securely fastened each time before lifting Do not lift pump by the power cord 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 Keep hands and feet away from impeller when power is connected Submersible Pumps are not approved for use in swimming pools recreational water installations decorative fountains or any instal lation where human contact with the pumped fluid is common Do not operate pump without safety devices in place Always replace safety devices that have been removed during service or repair ELECTRICAL To reduce risk of electrical shock pump must be properly grounded in accordance with the National Electric Code NEC and all ap plicable state and local codes and ordinances To reduce risk of electrical shock always disconnect the pump from the power source before handling or servicing Lock out power and tag Any wiring
29. rds with wet hands 10 NEVER operate a pump with power cord that is split frayed or has brittle insulation 11 L2 CHECK FOR CORRECT WIRING LOOSE WIRES CONTROL PANEL JUNCTION BOX GOOD EK IS THERE WATER TO TRIP FLOAT YES 1 2 3 FLOAT HUNG UP 1 2 4 CONTINUITY CHECK AT CONTROL PANEL OPEN 2 9 CONTINUITY CHECK AT JUNCTION BOX CLOSED 1 2 6 REPLACE DIRECT BURIAL CABLE FROM JUNCTION BOX TO CONTROL PANEL Problem 1 1 Runs in Hand Does Not Run in Auto Float Switch CORRECT BAD WIRING GOOD BAD ADD WATER REPOSITION AND BAD CONSULT CLOSED FACTORY REPLACE OPEN FLOAT SWITCH 12 OK RUNS IN HAND AUTO YES CLEAN FLOATS GOOD GOOD 1 2 10 MOISTURE IN CONTROL PANEL YES DRY PANEL WITH BLOW DRYER YES FALSE LIGHT DUE TO MOISTURE NOTE Problem 1 1 2 Seal Failure Light 1 2 10 MOISTURE IN JUNCTION BOX YES DRY JUNCTION BOX WITH BLOW DRYER YES FALSE LIGHT DUE TO MOISTURE 1 2 11 CONTINUITY CHECK SEAL PROBE LEADS AT CONTROL PANEL CLOSED 1 2 12 CONTINUITY CHECK MOISUTRE SENSOR LEADS AT JUNCTION BOX CLOSED SCHEDULE PUMP FOR SERVICE 1 2 6 REPLACE CABLE FROM JUNCTION BOX TO CONTROL PANEL The Seal Probe Moisture Sensor is a Normally Open N O Detector SH Series and explosion proof pumps have a 330K Ohm test resistor across the probes If a 330K rea
30. reet C 3 Pump Model Number Pump model number will give Barnes information on your pump size and performance rating it can be found on the pump nameplate attached to the pump Pump Model Number 4SHVA30042 C 4 Pump Serial Number Like the basin serial number the pump serial number will tell Barnes the plant location of where the pump was built information specific to the pump and date pump was built This can also be found on the pump nameplate Pump Serial Number C575824 0897 C Covington Avenue Plant T Third Street Plant 575824 Specific pump information 0897 Built in August 1997 Date Code BARRES 5 Ambient Duty Code Weight Part No 40 C CONT CONNECT THERMAL CONTACTS SUBMERSIBLE TO 66 FEET SUBMERSIBLE SEWAGE PUMP WARNING 1 TO REDUCE RISK OF ELECTRICAL SHOCK A SEE INSTRUCTION MANUAL FOR PROPER INSTALLATION B PUMP MUST BE PROPERLY GROUNDED IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND ALL LOCAL CODES C DISCONNECT THE PUMP FROM THE POWER SOURCE BEFORE HANDLING OR SERVICING D INSTALLATION AND SERVICE SHALL BE CONDUCTED BY A QUALIFIED PERSON 2 USE WITH APPROVED MOTOR CONTROL THAT MATCHES MOTOR INPUT IN FULL LOAD AMPERES WITH UTILISER UN DEMARREUR APPROUVE DONT LES ELEMENTS THERMIQUES SONT REGLES OU CHOISIS CONFORMEMENT AUX INSTRUCTION QUI LACCOMPAGNENT 3 KEEP CLEAR OF SUCTION AND DISCHARGE OPENING AT ALL TIMES WHERE POWER IS CONNECTED 4 MOTOR HOUSING WILL CONTAI
31. rein 2 this warranty is a LIMITED WARRANTY and 3 no claims of any nature whatsoever shall be made against us until the ultimate consumer his successor or assigns notifies us in writing of the defect and delivers the product and or defective part s freight prepaid to our factory or nearest authorized service station Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY PRODUCT SHALL BE TO REPLACE OR REPAIR AT OUR ELECTION F O B POINT OF MANUFACTURE OR AUTHORIZED REPAIR STATION SUCH PRODUCTS AND OR PARTS AS PROVEN DEFECTIVE THERE SHALL BE NO FURTHER LIABILITY WHETHER BASED ON WARRANTY NEGLIGENCE OR OTHERWISE Unless expressly stated otherwise guarantees in the nature of performance specifications furnished in addition to the foregoing material and workmanship warranties on a product manufactured by us if any are subject to laboratory tests corrected for field performance Any additional guarantees in the nature of performance specifications must be in writing and such writing must be signed by our authorized representative Due to inaccuracies in field testing if a conflict arises between the results of field testing conducted by or for user and laboratory tests corrected for field performance the latter shall control RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS ANAL
32. rminals on the relay used in this check are numbered The numbers are stamped on the backlight housing next to the terminals With Ohmmeter set on the R x1 scale the reading between Terminals number 1 and number 2 should be all the way to the right of the scale or zero On some occasions due to higher than expected amp draws through the relay the contact may permanently weld together A relay with welded contacts will cause start capacitors to overheat and become defective A relay with welded contacts will often measure good with an ohmmeter O even though it is defective 2 If start capacitor is found faulty it is suggested that the relay cover be removed two screws and the contact points physically checked for contact surface condition as well as freedom of movement The reading between Terminal number 2 and number 5 should show the resistance in the relay holding coil If it shows open then the coil has burned up If it shows no resistance it may have shorted out Either way replace the relay 2 91 Checking Run and Start Capacitors CAUTION IF CAPACITORS ARE BEING CHECKED WHILE STILL IN THE CONTROL PROCEED WITH STEPS 1 4 1 Remove and lock off all power to control 2 Using a screwdriver with an insulated handle short circuit each capacitor by placing the blade of the screwdriver across the two terminals of each capacitor This will discharge the capacitor 3 Remove all leads connected to capaci
33. s with the pump on compare the two readings and note any difference Also note whether or not the voltages between all three legs are similar balanced THREE PHASE NEASURING AC VOLTS SUPPLY POWER If incorrect power supply readings are recorded contact local power source 2 16 Discharge Valve Open Inspect discharge and check valves for correct installation Are they installed backwards check valve Is the valve at the basin and main open Is the check valve stuck Is discharge line from pump to main plugged 2 17 Pump Air Locked If the pump has become air locked it will not pump the basin down air locked pumps may be corrected in one of the following manners e Shake pump up and down by the lifting rope do not pull on the power or control cables Close and open discharge valve a few times in quick succession e Start and stop pump a few times allowing 2 or 3 minutes between stop and restart 2 18 Excessive Inflow Inflow may be at a rate greater than pumping rate compare inflow with pump curve Excessive inflow may also be due to ground water infiltration With wetwell level pumped down as low as possible check for ground water leaks around inlet and discharge lines Check for leaks through damaged or cracked basin wall Note the wetwell installation if the top of the basin is below grade level ground water may be entering around the lid or vent 2 19 Discharge Leak Pump wet
34. the location of the nearest Barnes Pumps Service Center check your catalog your Barnes Pumps Inc representative or Barnes Pumps Inc Service Department in Piqua Ohio telephone 937 778 8947 or go to www cranepumps com SECTION B START UP WARRANTY REGISTRATION FORM B 1 Start Up Form Included at the end of this manual is a start up report sheet which should be completed as applicable Return one copy to Barnes and store the second in the control panel or with the pump manual It is important to record this data at initial start up since it will be useful to refer to should servicing the pump be required in the future B 2 Sample Form We have also included a sample form see Pages 11 12 that has been filled out to help you better understand some of the information Barnes is asking for Refer to the sample form as each section of the start up warranty registration is explained eh CRANE Pues a syst Piqua Ohio SECTION C NECESSARY GENERAL INFORMATION C 1 Owner Name amp Address In most cases this will be the party that will pay for and be responsible for service of the unit This may be a municipal water or sewer district or it may be individual home owners C 2 Location of Installation amp Contact The address of where the basin is physically located and who is main contact As shown on the sample form the owner if City of Piqua but they have installed the basin at a house located at 234 Second St
35. thing that may have been inadvertently left in the bottom or rocks and excessive amounts of dirt that may have been dropped in the basin during installation E 2 Is Junction Box Control Panel Dry Check YES or NO The junction box must be dry to avoid power control problems If any moisture is present wipe dry or use a blow dryer if necessary E 3 Are all Wire Connections Tight Check YES or NO All wire nut connections in the junction box should be tight In addition look for wires that may be exposed beyond the end of the wire nut E 4 Are Pump Cords away from Pump Check YES or NO Do not allow excess pump or control cords to hang any lower than the top of the pump SECTION F ELECTRICAL CHECK F 1 Single Phase Check and record incoming voltage to the control panel circuit breaker with the pump off the reading is taken across L1 and L2 of the circuit breaker on the incoming side see Figure 1 The voltage reading should be within 10 of pump rated volts pump rated volts can be found on the pump nameplate If your pump is three phase mark N A SINGLE PHASE MEASURING AC VOLTS SUPPLY POWER OVERLOAD BREAKER F 2 Three Phase Check and record incoming voltage to the control panel circuit breaker with the pump off Readings should be taken across L1 L2 L2 L3 and L3 L1 on the incoming side of the circuit breaker see Figure 2 The voltage reading should be within 1096 of pump rated vo
36. tor terminals It is most important to make note of the position of leads so that they will be properly reconnected after testing 4 Remove any resistors found across the capacitor terminals usually found on start capacitors CHECKING CAPACITORS The following checks made with a Simpson Ohmmeter Model Number 372 or equivalent apply to both RUN and START CAPACITORS except for the range setting or scale used If a digital meter with a capable of measuring capacitance is used verify the reading obtained matches the capacitance on the capacitor case Use scale R x 100K for Run Capacitors and R x 10K for Start Capacitors The following check can be taken with capacitors on the bench or in the control 28 Check each capacitor by clipping an ohmmeter lead to one of the capacitor terminals and touching the other ohmmeter lead to the other terminal for a few seconds NOTE Results as follows e Agood Run Capacitor is indicated by pointer of ohmmeter moving towards zero the figure 0 on right hand side of scale and then slowly drifting back towards the left e When checking a Start Capacitor you will note depending on MFD rating that some of them will not move the ohmmeter needle to complete zero before it is on its way back and that unlike the Run Capacitors the needle will not always move all the way to the left side of the scale The reason for this is the much higher rating of Start Capacitors e f the pointer
37. ween Control Panel and outside of pump Ohms Q MEG Ohms check of insulation Red to Ground White to Ground Black to Ground Operational Checks Is there noise or vibration present YES V9 Source of noise vibration Does check valve operate properly YES N A Is system free of leaks YES NO Leaks at Does system appear to operate at design flowrate YES NO Nominal Voltage Phase 10 90 select one Voltage Reading at panel connection Pump OFF L1 L2 Lo Lo Voltage Reading at panel connection Pump ON L1 L2 l2 13 _ L1 L3 Amperage Draw Pump ON L1 L2 L3 Submersible Pumps Are BAF and guide rails level pllumb YES NO Is pump seated on discharge properly YES NO Are level controls installed away from turbulence YES NO Is level control operating properly YES NO Is pump fully submerged during operation YES NO Follow up Corrective Action Required YES Additional Comments Startup performed by Date Present at Start Up Engineer Operator Contactor Other All parties should retain a copy of this report for future trouble shooting reference CRANE PUMPS amp SYSTEMS A Crane Co Company 420 Third Street 83 West Drive Brampton Piqua Ohio 45356 Ontario Canada L6T 2J6 Phone 937 778 8947 Phone 905 457 6223 Fax 937 773 7157 Fax 905 457 2650 www cranepumps com
38. well down below discharge plumbing observing discharge line check for plumbing leaks while line is under pressure repair fixtures or discharge gasket as required 2 20 Impeller Cutter Damage If the impeller and or cutter is damaged or excessively worn it must be replaced see appropriate disassembly assembly section in this Pump manual NOTE If the cutter on grinder pumps is excessively worn the shredding ring may be reversed 2 21 Discharge Head Too High Check total head and pump performance curve and that the correct impeller has been installed or consult factory I 2 22 Discharge Plumbing or Rail Assembly Loose With pump running check for loose pipe attachments and or loose rail assembly Make any necessary adjustments 2 29 Adjust Float or Replace Switch If floats are used you may have to reposition on float to get a longer pump down cycle You may also have a float stuck in the open position 2 24 Connector Sticking The connector used in many control panels can be tripped on off manually With the liquid level above the on float turn pump on this will close the connector Allow the system to pump down to the off level If the pump does not shut off manually turn it off If the connector is still closed it is sticking and should be replaced 25 2 25 Check Circuit Breaker and Fuse Rating NOTE Control Panel Circuit Breaker short circuit protection should be rated at least 20 h
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