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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. 6/05, 7/05, 1/06, 5/06, 7/06, 9/06, 10/06, 2/07   

 

 

Alteration Rights Reserved

TABLE OF CONTENTS 

  

 

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

 

 

USER GUIDE ...................................................................................................4

 

 

Step 1. UNPACK INSTRUCTIONS ..................................................................5

 

 

PACKAGED PARTS AS RECIEVED ................................................................6

 

 

Step 2. COMPONENT OVERVIEW .................................................................7 

 

 

Step 3. BEFORE YOU BEGIN .........................................................................8

 

 

SYSTEM INSTALLATION:

 

 

 

Step 4. SETTING THE BASIN - Location Overview ........................................9 - 10

 

 

Step 5. RISER TANK PARTS ASSEMBLY .......................................................11

 

 

Step 6. HOLE DEPTH AND HANDLING BASIN ..............................................12

 

 

Step 7. ADAPTER / CONDUIT LAYOUT ..........................................................13

 

 

Step 8. BALLASTING REQUIREMENTS .........................................................14

 

 

Step 9. DISCHARGE CONNECTIONS ............................................................15

 

 

Step 10A & B. INLET LOCATION: Installing Flexible Inlet Flange ...................16

 

 

Step 10C. BACKFILLING .................................................................................17

 

 

Step 11. INSTALLING DIRECT BURIAL CABLE & Mounting alarm box .........18

 

 

Step 12. BACKFILLING  and FINAL GRADING ..............................................19

 

SYSTEM ELECTRICAL WIRING:

 

 

Step 13. WIRING THE STATION TO ELECTRICAL PANEL ............................20

 

 

Step 14. WIRING THE SERVICE POWER TO THE ELECTRICAL PANEL ....21

 

FINALIZING INSTALLATION:

 

 

Step 15. INSTALL PUMP HARNESS ...............................................................22

 

 

Step 16. INSTALLING THE PUMP & LEVEL CONTROL CORDS ...................22

 

 

Step 17. ASSEMBLING THE CORD CONNECTOR ........................................22

 

 

Step 18. RECORDING PUMP NAMEPLATE INFORMATION .........................23

 

 

Step 19. INSTALLING THE PUMP ..................................................................23

 

 

Step 20. INSTALLING THE LEVEL CONTROL ...............................................23

 

 

Step 21. TIDY-UP & STD. VENTED ROCK COVER INSTALLATION .............24

 

 

Step 22. SYSTEM START-UP PRE-CHECKLIST  ...........................................25

 

 

Step 23. START-UP CHECK LIST ...................................................................25

 

 

 

TROUBLE SHOOTING ....................................................................................26

 

 

Appendix 1: CORD CONNECTOR - Assembly / Wiring Instructions ...............27

 

 

Appendix 2: POD REMOVAL  ..........................................................................28

 

 

Appendix 3: WINTERIZATION .........................................................................28

 

 

Appendix 4: OPTIONAL FLOOD PLAIN ROCK COVER INSTALLATION .......29 - 30

 

 

Appendix 5: OPTIONAL FLAT COVER INSTALLATION ..................................31

 

 

EXPLODED VIEW DRAWING .........................................................................32

 

 

PARTS LIST   ...................................................................................................33

 

WARRANTY TERMS .................................................................................................35

 

START-UP FORM (Mail in) ........................................................................................37 - 38

Summary of Contents for Barnes EcoTRAN

Page 1: ...provement program product changes may occur As such Crane Pumps Systems reserves the right to change product without prior written notification 420 Third Street 83 West Drive Bramton Piqua Ohio 45356 Ontario Canada L6T 2J6 Phone 937 778 8947 Phone 905 457 6223 Fax 937 773 7157 Fax 905 457 2650 www cranepumps com Form No 119061A Rev R EcoTRAN System Optional Rock Cover and ESPS Shown ...

Page 2: ... INSTALLING DIRECT BURIAL CABLE Mounting alarm box 18 Step 12 BACKFILLING and FINAL GRADING 19 SYSTEM ELECTRICAL WIRING Step 13 WIRING THE STATION TO ELECTRICAL PANEL 20 Step 14 WIRING THE SERVICE POWER TO THE ELECTRICAL PANEL 21 FINALIZING INSTALLATION Step 15 INSTALL PUMP HARNESS 22 Step 16 INSTALLING THE PUMP LEVEL CONTROL CORDS 22 Step 17 ASSEMBLING THE CORD CONNECTOR 22 Step 18 RECORDING PUMP...

Page 3: ...eration 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 WARNING Do not pum...

Page 4: ...ectly or through a drain or waste disposal Glass metal or plastic Diapers Sanitary napkins or tampons Socks rags or cloth In addition you must NEVER introduce into any sewer Explosives or Flammable material Lubricating oils or Grease Strong Chemicals or Gasoline POWER FAILURE Your grinder pump station cannot dispose of wastewater or provide an alarm signal without electrical power If an electrical...

Page 5: ...STEP 1 Cut the banding and discard STEP 2 Roll the tank to its right side up position and remove the level control STEP 3 Open the PARTS BOX and remove enclosed contents STEP 4 Open the pump box and remove the enclosed pump NOTE Optional rock cover shown ...

Page 6: ...6 PACKAGED PARTS AS RECEIVED ...

Page 7: ...nd adapt from ball valve Material Bronze POD Pump Orientation Device Orient and support pump and level control Material HDPP FLEXIBLE DISCHARGE FITTING Provide some flexibility for settling Material 300 series stainless steel TANK Reservoir for pump and sewage Material HDPP PUMP Remove sewage from tank Material Cast iron body LEVEL CONTROL Controls pump and alarm to set heights Material CPVC body ...

Page 8: ... sure you have the necessary equipment and supplies before starting your installation see lists below EQUIPMENT REQUIRED LIST NOT INCLUDED 3 8 WRENCH LARGE NYLON LIFTING STRAP S REGULAR AND PHILLIPS SCREWDRIVERS HOLESAW 5 FOR INLET PAGE 16 1 8 FLAT TIP ELECTRICIAN SCREWDRIVER WIRE STRIPPERS 10 AWG TO 18AWG BOX KNIFE AND CUTTERS PIPE WRENCH S ELECTRICAL MULTI METER CORDED OR CORDLESS DRILL ELECTRIC...

Page 9: ...t One Call information http www call811 com The location of your basin should meet the following conditions Not placed in low lying or frequently flooded areas Ground slopes away from the basin Have well draining soil Removed from normal traffic routes Close proximity to the structure sewage is originating from to minimize bends and overall inlet line length Does not damage foundations of structur...

Page 10: ...10 STEP 4 SETTING THE BASIN Location Overview ...

Page 11: ...11 STEP 5 RISER TANK PARTS ASSEMBLY ...

Page 12: ...ructural damage Handle the tank in a vertical manner whenever possible Never place a chain around the basin when moving the tank Only use a nylon lifting strap or similar device around the tank Never lift the package by the riser or the cover Never drag drop or roll package Do not install pump until basin assembly has been backfilled around Once the package is installed in the hole place a level o...

Page 13: ...e Thread and tighten the fitting into the adapter STEP 7 ADAPTER CONDUIT LAYOUT 7A Cut drain tile to proper elevation at bottom of corrugation Optional Methods Miter Saw or Sawzall IF EXTENSION IS REQUIRED TO BRING DRAIN TILE ABOVE GRADE LEVEL USE CRANE PUMPS SYSTEMS DRAIN TILE EXTENSION KIT P N 123510 ...

Page 14: ...but must have a minimum of 1 3 cubic yard of concrete and the specified minimum s shown below STEP 8 BALLASTING REQUIREMENTS IMPORTANT FAILURE TO BALLAST STATION WILL VOID WARRANTY AND MAY RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE AVOID ANY DIRT SPILLAGE INTO TANK DURING BALLAST BACKFILL CONCRETE BAGS Per Bag Weight Dry Number Bags Required 40 lb 50 lb 60 lb 80 lb 90 lb 30 25 20 15 14 IMPORTAN...

Page 15: ...force main connection for station isolation from main This valve is to be placed between the force main and redundant check valve Pipe of proper size and strength for rated conditions supplied by others Important Notes about the discharge All discharge components should be below frost depth If above frost depth all components must be properly insulated to prevent freezing Pressure checking of disc...

Page 16: ...entially overwork the treatment facilities WHAT TO DO Verify pipe O D The inlet fitting is sized for 4 inch Schedule 40 80 and SDR 35 MUST have a minimum of 1 8 per foot drop If required only use 45 degree elbows INSTALLATION NOTES The hole MUST be cut with a 5 inch HOLE SAW to ensure proper sealing around inlet flange See Fig 10A Use of any other tool or method is prohibited The end of the pipe c...

Page 17: ...e pipe bottom and ensure there are no voids The material in the haunching area supports the vertical load applied to the pipe Not compacting the embedment material will allow excessive deflection of the pipe and potential failure Compact to 70 STANDARD PROCTOR DENSITY or a 700PSI SOIL MODULUS Note 6 pipefittings are not to be used with basins SEE PAGE 19 FOR BACKFILL DESCRIPTION STEP 10C INLET INS...

Page 18: ...nicked insulation or conductors All cable is ran inside of conduit when going from the Alarm Box to 24 below grade All connections made are utilizing Third party listed devices MOUNTING ALARM BOX Make sure bottom of Alarm Box is a minimum of 36 above grade and level All penetrations through the enclosure should be made on the bottom and utilize NEMA 4 fittings to maintain the enclosure rating Two ...

Page 19: ...als offer high stiffness and strength and depending on the amount of fines may be relatively free draining Examples of material types Angular crushed stone or other Class 1A materials and stone sand mixtures with gradations selected to minimize migration of adjacent soils contain little or no fines Gravel and Soils Class II Materials Class II materials when compacted provide a relatively high leve...

Page 20: ...ION TO ALARM BOX Strip the outer jacket of the cord or cable back about six inches making sure not to damage the individual leads Strip about of the insulation off the ends of the individual leads Wire per the illustration below ...

Page 21: ...le Options for running cable from the service supply to the alarm panel A 1 10AWG cable with four conductors plus a ground 5 separate leads OR B 1 10AWG two conductor with ground and 1 14AWG two conductor with ground properly sized for the rated loads to be used between the service supply panel and station electrical panel 6 leads total with two being ground leads STEP 14 WIRING SERVICE DROP TO AL...

Page 22: ... on compression flange until it touches the housing Pump Power Large pin Level Control Small pin Level control cord has molded fitting at both ends of the cord Install one end to the Pump and the other end to the Level Control Step 15 INSTALL PUMP HARNESS Tie the bowline knot where shown per the directions provided Tie one bowline knot on the handle of the moveable fitting and one bowline knot in ...

Page 23: ...valve upper moveable and support flange This will guide the pump down the guide rail and rest on the stop built into the POD Pump Orienting Device Check to make sure the check valve is aligned as shown before lowering into the guide rail When lowering or lifting the pumps always use the lifting device and appropriate lifting equipment NEVER MOVE THE PUMP BY THE POWER CORD ALWAYS INSTALL PUMP BEFOR...

Page 24: ...N The cover gasket is a large soft O ring that is factory installed Lube the O ring lightly with the provided lube Then install the cover The rock cover is secured with a twist lock mechanism Rotate the rock cover clockwise while looking at top of cover Insert lock thru the adapter lock hub and cover lock eye and lock To remove unlock rock cover and turn counter clockwise See APPENDIX 4 for OPTION...

Page 25: ...s been installed in the service disconnect panel Proper gauge and conductor wire installed from service disconnect to house panel All terminal connections are secure Circuit breakers in the Alarm Box are turned to the OFF position Circuit breaker in the service disconnect turned to ON Pump is properly seated on the discharge opening in the rail Level control is installed properly Final grade slope...

Page 26: ...izing calculations to determine pump type 6 Check discharge line for restrictions including ice if line passes through or is into cold areas 7 Remove and examine check valve for freedom of operation 8 Open valve 9 Check impeller for freedom of operation security and condition Clean impeller cavity and inlet of any obstruction 10 Check and clean anti siphon 11 Repair fixtures as required to elimina...

Page 27: ...y during colder months proper steps should be taken to ensure uninterrupted use upon restarting the basin Remove the basin cover and check the liquid level Fill the station with water until the pump turns ON The Level Control switch will pump the station level down to the normal OFF level With the liquid level at the normal OFF level add fresh water until the pump turns ON by itself and liquid lev...

Page 28: ... on page 13 D Push the adapter onto the riser making sure the station power cable and conduit is positioned correctly for wiring back to the control panel E Install the six retaining fasteners supplied The fasteners should fall inside the riser valley per Section View below STEP 2 FLOOD PLAIN VENT Supplied by Others A When ready to install vent plumbing remove the 1 NPT thread protector B Plumb as...

Page 29: ...over o ring is seated in the adapter groove See Section View on page 29 D Apply supplied pipe lube to the cover o ring E Orient the Pie Shaped cut out in the rock cover with the station power cord grip F Orient the adapter ears with the cut outs in the rock cover G Push the rock cover down onto the adapter See ARROW PUSH DOWN Appendix 4 OPTIONAL FLOOD PLAIN ROCK COVER INSTALLATION Continued Contin...

Page 30: ...wn on top of rock until the cover eyebolt aligns with the adapter locking tab See View A B Make sure the small ear on the adapter is engaged under a cover locking washer See View B C Make sure the two side ears on the adapter are each engaged under a cover locking washer See View C D To secure station place lock through eyebolt and adapter locking tab hole See View A ...

Page 31: ...ining fasteners supplied The fasteners should fall inside the riser valley per Section View below STEP 2 FLOOD PLAIN VENT Supplied by others A Insert male threaded 1 pipe coupling adapter into vent port B Plumb as required per Local Codes Use thread sealant compatible with plastic threads in the adapter vent port Thread 1 locknut onto male NPT side adapter STEP 3 POSITIONING ENGAGING FLAT COVER A ...

Page 32: ...32 ...

Page 33: ...0034 Conduit with Adapter 1 inch 21 1 141207 Conduit 22 1 141206 Adapter 23 1 119069 EcoTRAN Tank Assembly 24 1 118239A Adapter 24A 24B 1 140591 140591A Adapter Flat Cover Vent 24 Adapter Flat Cover No Vent 24 25 1 094270 Cord Grip 26 1 123049 123049A 123049C 30 Ft Electrical Connection 12 5 DBC 50 Ft 100 Ft 27 2 119088 Cord Hook 28 2 118249 PH PanHd Screw 1 4 10 x 75 Lg 29 1 111666 116742 Panel A...

Page 34: ...Notes ...

Page 35: ...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 ...

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