Barnes BARNES 4DSE-HL Series, Installation And Operation Manual

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SECTION: D START-UP OPERATION
D-1) Check Voltage and Phase:
Before operating pump, compare the voltage and phase
information stamped on the pump identifi cation plate to the
available power.
D-2) Check Pump Rotation:
Before putting pump into service for the fi rst time, the motor
rotation must be checked. Improper motor rotation can result
in poor pump performance and can damage the motor and/or
pump. To check the rotation, suspend the pump freely, mo-
mentarily apply power and observe the “kickback”. “Kickback”
should always be in a counter-clockwise direction as viewed
from the top of the pump motor housing.
D-2.1) Incorrect Rotation for Three-Phase Pumps:
In the event that the rotation is incorrect for a three-phase
installation, interchange any two power cable leads at the
control box.
DO NOT change leads in the cable housing in
the motor. Recheck the “kickback” rotation again by momen-
tarily applying power.
D-2.2) Incorrect Rotation for Single-Phase Pumps:
In the unlikely event that the rotation is incorrect for a single
phase pump, contact a Barnes Service Center.
D-3) Start-Up Report:
Included at the end of this manual is a start-up report sheet,
this sheet is to be completed as applicable. Return one copy
to Barnes and store the second in the control panel or with
the pump manual if no control panel is used. 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.
D-3.1) Identifi cation Plate:
Record the numbers from the pump identifi cation plate on
both START-UP REPORTS provided at the end of the manual
for future reference.
D-3.2) Insulation Test:
Before the pump is put into service, an insulation (megger)
test should be performed on the motor. The resistance values
(ohms) as well as the voltage (volts) and current (amps)
should be recorded on the start-up report.
D-3.3) Pump-Down Test :
After the pump has been properly wired and lowered into the
basin, sump or lift station, it is advisable to check the system
by fi lling with liquid and allowing the pump to operate through
its pumping cycle. The time needed to empty the system, or
pump-down time along with the volume of water, should be
recorded on the start-up report.
SECTION E: PREVENTATIVE MAINTENANCE
As the motor is oil fi lled, no lubrication or other maintenance
is required, and generally Crane Pumps & Systems will give
very reliable service and can be expected to operate for years
on normal sewage pumping without failing. However as with
any mechanical piece of equipment a preventive mainte-
nance program is recommended and suggested to include
the following checks:
1) Inspect motor and seal chambers for oil level and
contamination and repair as required per section F-1.
2) Inspect impeller and body for excessive build-up or
clogging and repair as required per section F-2.
3) Inspect motor and bearings and replace as required per
section F-3.
4) Inspect seal and diaphragm for wear or leakage and
repair as required per section F-4.
5) Inspect suction elbow cleanout for excessive build-up or
clogging, service per section F-5.
SECTION F: SERVICE AND REPAIR
NOTE: All item numbers in ( ) refer to Figures 10 thru 12,
4DSE-L Pumps; Figures 13 thru 15, 4DSE-HL.
CAUTION ! - Before servicing and/or
removing pump from system, verify that the pip-
ing system has no pressure.
F-1) Lubrication:
Anytime the pump is removed from operation the cooling oil
in the motor housing (1) and seal chamber, must be checked
visually for oil level and contamination.
F-1.1) Checking Oil:
Motor Housing -
To check oil, set unit upright. Remove cap
screws (23), lift conduit box assembly (49) from motor hous-
ing (1) but
DO NOT disconnect conduit box wiring from motor
leads. With a fl ashlight, visually inspect the oil in the motor
housing (1) to make sure it is clean, clear and that oil level is
above all internal componentry.
Seal Chamber - Place pump on its side with pipe plug (8)
downward, remove pipe plug (8) and drain oil from the seal
chamber. If the oil is found to contain considerable water
or other contamination or little oil drains out, the shaft seal
(12) and diaphragm (14) should be inspected and replaced if
required.
F-1.2) Testing Oil:
1. Place pump on it’s side, remove cap screws (23), lift
conduit box assembly (49) from motor housing (1) and
drain oil into a clean, dry container. In separate container
drain seal chamber by removing pipe plug (8).
2. Check oil for contamination using an oil tester with a
range to 30 Kilovolts breakdown.
3. If oil is found to be clean and uncontaminated (measure
above 15 KV. breakdown), refi ll the motor housing and
seal chamber as per section F-1.3.
4. If oil is found to be dirty or contaminated (or measures
below 15 KV. breakdown), the the pump must be
carefully inspected for leaks at the shaft seal (12),
conduit box assembly (49), diaphragm (14), O-ring (3),
pipe plug (8) and pressure valve (26) before refi lling with
oil. To locate the leak, perform a pressure test as per
section F-1.4. After leak is repaired, refi ll with new oil as
per section F-1.3.
F-1.3) Replacing Oil:
Motor Housing -
Drain all oil from motor housing and dis-
pose of properly. Refi ll with (see parts list for amount) new
cooling oil as per Table 1. An air space must remain in the top
of the motor housing to compensate for oil expansion (see
Fig. 10 or 13).