Barmesa Pumps BPSTEP Series Submersible Effluent Pumps Instruction Manual

Barmesa Pumps BPSTEP Series Submersible Effluent Pumps

General Safety Information

IMPORTANT! Read all instructions in this manual before operating or servicing a pump.
Before installation, read the following instructions carefully. Failure to follow instruction and safety information could cause serious bodily injury, death and/or property damage. Each Barmesa product is carefully inspected to insure proper performance. Closely following these instructions will eliminate potential operating problems, assuring years of trouble-free service.
“Danger” indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
“Warning” indicates an imminenty hazardous situation which, if not avoided, MAY result in death or serious injury.
“Caution” indicates a potentially hazardous situation which, if not avoided, MAY result in minor ormoderate injury.
IMPORTANT Barmesa Pumps is not responsible for losses, injury or death resulting from failure to observe these safety precautions, misuse, abuse or misapplication of pumps or equipment.

ALL RETURNED PRODUCTS MUST BE CLEANED, SANITIZED, OR DECONTAMIN AT EDPRIOR TO SHIPMENT, TO INSURE EMPLOYEES WILL NOT BE EXPOSED TO HEALTH HAZARDS IN HANDLING SAID MATERIAL. ALL APPLICABLE LAWS AND REGULATIONS SHALL APPLY.
WARNING Installation, wiring, and j un c t i on conn e c t i on s mu s t b e i n accordance with the National Electric Code and all applicable state and local codes. Requirements may vary depending on usage and location.
WARNING Installation and servicing is to be conducted by qualified personnel only.
Keep clear of suction and discharge openings. Do not insert fingers in pump with power connected; the impeller can cause serious injury.
Always wear eye protection when working on pumps. Do not wear loose clothing that may become entangled in moving parts.
DANGER Pumps build up heat and pressure during operation. Allow time for pumps to  cool before handling or servicing the pump  r any accessory items associated with or near the pump.
DANGER This pump is not intended for use in swimming pools or water installations where there is human contact with pumped fluid.
DANGER Risk ofelectric shock. To reduce risk of electric shock, always disconnect pump from power source before handling any aspect of the pumping system.Lock outpower and tag.
WARNING Do not use these pumps in water over 104 F. Do not exceed manufacturers recommended maximum performance, as this could cause the motor to overheat.
DANGER Do not lift, carry or hang pump by the electrical cables. Damage to the electrical cables can cause shock, burns or death. Never handle connected power cords with wet hands. Use appropriate lifting device.
WARNING Sump and sewage pumps often handle materials which could cause illness or disease. Wear adequate protective clothing when Working on a used pump or piping.
Never enter a basin after it has been used.
DANGER Failure to permanently ground the pump, motor and controls before connecting to power can cause shock, burns or death.
DANGER These pumps are not to be installed in locations classified as hazardous in accordance with the National
Electric Code, ANSI/NFPA 70.

WARNING The Uniform Plumbing Code (UPC) states that sewage systems shall have an audio and visual alarm that signals a malfunction of the systems, that are required to reduce the potencial for property damage.
IMPORTANT! Prior to installation, record Model Number, Serial, Amps, Voltage, Phase and HP from pump name plate for the future reference. Also record the Voltage and Current

Readings at Startup:

• Model Number: ____
• Serial: ____
• Amps: Voltage:
• Phase: HP:

Specifications & Dimensions

• DISCHARGE: 2″ NPT, vertical.
• SPHERICAL SLD HNDLG: 3/4″
• LIQUID TEMPERATURE: 104° F (40° C) continuous.
• VOLUTE: Cast iron ASTM A-48 class 30.
• MOTOR HOUSING: Cast iron ASTM A-48 class 30.
• SEAL PLATE: Cast iron ASTM A-48 class 30.
• IMPELLER: Single vane enclosed. Polypropylene with stainless steel insert.
• SHAFT: Stainless steel.
• O-RINGS: Square shaped Buna-N.
• PAINT: Air dry enamel, water based.
• SEAL: Outboard single mechanical, oil filled chamber. carbon / ceramic / Buna-N, with stainless steel hardware.
• HARDWARE: 300 series stainless steel.
• CORD ENTRY: 20 ft of neoprene cord, sealed against moisture.
• BEARINGS: Ball, single row, oil lubricated.
• MOTOR: NEMA L, single phase, permanent split capacitor, oil filled, with overload protection in motor.
• OPTIONAL EQUIPMENT: Additional cord, seal material, impeller trims, slide rail coupling (SRC-2).

MODEL| PART No.| HP| VOLTS| PHASE| RPM

(Nominal)

| MAX AMPS| LOCKED ROTOR AMPS| NEMA CODE| CORD SIZE| CORD TYPE| WEIGHT

(pounds)

---|---|---|---|---|---|---|---|---|---|---|---
BPSTEP512| 62180203| 0.5| 115| 1| 3500| 13.1| 26.2| G| 14/3| SOW| 80
BPSTEP512A| 62180204| 0.5| 115| 1| 3500| 13.1| 26.2| G| 14/3| SOW| 80
BPSTEP522| 62180205| 0.5| 230| 1| 3500| 5.6| 13.2| E| 14/3| SOW| 80
BPSTEP1022| 62180206| 1| 230| 1| 3500| 9.1| 23.5| f| 14/3| SOW| 80

Recommendations and Warnings

Receiving inspection
Upon receiving the pump, it should be inspected for damage or shortages. If damage has occurred, file a claim immediately with the company that delivered the pump. If the manual is removed from the packaging, do not lose or misplace.

Storage
Any product that is stored for a period longer than six (6) months from the date of purchase should be bench tested prior to installation. A bench test consists of, checking the impeller to assure it is free turning and a run test to assure the motor (and switch if provided) operate properly.

Controls
Manual models require a separate approved pump control device or panel for automatic operation. Be sure the electrical specification of the control selected properly match the electrical specifications of the pump.

Submergence
The pump should always be operated in the submerged condition. The minimum sump liquid level should never be less than above the pump’s volute (See Figure 1).

Installation

There are two methods of installing effluent pumps:

1. In a Flex-Hose system, most commonly used in interceptor tanks, and
2. A slide rail in a package system or concrete wet well, which allows the pump(s) to be installed or removed without requiring personnel to enter the wet well.

The sump, basin or lift station shall be sealed and vented in accordance with local plumbing codes. This pump is designed to pump sewage, effluent or wastewater, non-explosive and non-corrosive liquids and shall NOT be installed in locations classified as hazardous in accordance with the National Electrical Code (NEC) ANSI/NFPA 70 or Canadian Electric Code (CEC).The pump is designed to pump sewage, effluent or wastewater, non-explosive and non- corrosive liquids and shall NOT be installed in locations classified as hazardous in accordance with the National

Electrical Code (NEC) ANSI/NFPA 70 or Canadian Electric Code (CEC). The pump should never be installed in a trench, ditch, or hole with a dirt bottom. The legs will sink into the dirt and the suction will become plugged.
The installation should be at a sufficient depth to ensure that all plumbing is below the frost line.If this is not feasible, remove the check valve and size the basin to accommodate the additional back flow volume.

Discharge Piping
Discharge piping should be as short as possible and sized no smaller than the pump discharge. Do not reduce the discharge pipe size below that which is provided on the pump. Both a check valve and a shut-off valve are recommended for each pump. The check valve is used to prevent backflow into the sump. The shut-off valve is used to manually stop system low during pump servicing.

Liquid Level Controls
Typical Discharge Pipe Mounted: Refer to Figure 2 below which shows a typical installation of a 1 phase 120 or 240 volt pump using a level control mounted to the discharge piping with a piggy-back plug. The level control should have adequate clearance so it cannot hang up in it’s swing and that the pump is completely submerged when the level control is in the “Off” mode. By adjusting the cord tether the control level can be changed.

Typical Installation with Wide Angle Level Control

Level Control Basic Instructions: Plug the level control plug into the GFI receptacle, then plug the pump into the piggy-back plug (See Figure 3). One cycle of operation should be observed, so that any potential problems can be corrected.
It is recommended that the level control float should be set to insure that the liquid in the sump never drops below the top of the motor housing or a minimum level of 6 inches above the basin floor.

Electrical Connections Power cable:
The power cable mounted to the pump must not be modified in any way except for shortening to a specific application. Any splice between the pump and the control panel must be made in accordance with the electric codes. It is recommended that a junction box, if used, be mounted outside the sump or be of at a minimum Nema 4 construction if located within the wet well. DO NOT USE THE POWER CABLE TO LIFT PUMP.
Always rely upon a Certified Electrician for installation.

Overload Protection

Single Phase  The stator in-winding overload protector used is referred to as an inherent overheating protector and operates on the combined effect of temperature and current. This means that the overload protector will trip out and shut the pump off if the windings become too hot, or the load current passing through them becomes too high.
IMPORTANT! The overload will then automatically reset and start the pump up after the motor cools to a safe temperature. In the event of an overload, the source of this condition should be determined and corrected immediately.
WARNING DO NOT ALLOW THHE PUMP TO CYCLE OR RUN IF AN OVERLOAD CONDITION OCCURS.
If current through the temperature sensor exceeds the values listed, an intermediate control circuit relay must be used to reduce the current or the sensor will not work properly.

TEMPERATURE SENSOR ELECTRICAL RATINGS

Volts| Continuous Amperes| Inrush Amperes
110-120| 3.00| 30.0
220-240| 1.50| 15.0

Wire Size: If longer power cable is required consult a qualified electrician for proper wire size.

Pre-Operation

1. Check Voltage and Phase: Compare the voltage and phase information stamped on the pump name plate.
2. Check Pump Rotation – Improper motor rotation can result in poor pump performance and can damage the motor and/or pump. Check rotation on three phase units by momentarily applying power and observe the “kickback”.
3. Name Plate   Record the information from the pump name plate to drawing in front of manual for future reference.
4. Insulation Test An insulation (megger) test should be performed on the motor. Before the pump is put into service. The resistance values (ohms) as well as the voltage (volts) and current (amps) should be recorded.
5. Pump-Down Test Be sure pump has been properly wired, lowered into the basin, sump or lift station, check the system by filling 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.

Maintenance

No lubrication or maintenance is required. Perform the following checks when pump is removed from operation or when pump performance deteriorates:

• Inspect motor chamber for oil level and contamination.
• Inspect impeller and body for excessive build-up or clogging.
• Inspect motor, bearings and shaft seal for wear or leakage.

Servicing

Cooling Oil – Anytime the pump is removed from operation, the cooling oil in the motor housing should be checked visually for oil level and contamination. To check oil, set unit upright. Remove pipe plug from housing. With a flashlight, visually inspect the oil in the housing to make sure it is clean and clear, light amber in color and free from suspended particles. Milky white oil indicates the presence of water. Oil level should be just above the motor when pump is in vertical position.

Oil Testing

• Drain oil into a clean, dry container by placing pump on it’s side, remove pipe plug (20), from housing (10).
• Check oil for contamination using an oil tester with a range to 30 kV breakdown.
• If oil is found to be clean and uncontaminated (measuring above 15 kV breakdown), refill the housing.
• If oil is found to be dirty or contaminated (or measures below 15 kV breakdown), the be carefully pump inspected for leaks at the shaft seal, conduit box, o-rings, pipe plug and pressure valve, before refilling with oil. To locate the leak, perform a pressure test.
• After leak is repaired, dispose of old oil properly, and re ill with new oil.

Pressure Test (If oil has been drained) Remove pipe plug from housing. Apply pipe sealant to pressure gauge assembly and tighten into hole. Pressurize motor housing to 10 PSI. Use soap solution around the sealed areas and inspect joints for “air bubbles”.

If, after five minutes, the pressure is still holding constant, and no “bubbles” are observed, slowly bleed the pressure and remove the gauge assembly. Replace oil. Leek must be located and repaired if pressure does not hold.

Pressure Test (If oil has NOT been drained)

Oil should be at normal level. Remove pipe plug from housing. Apply pipe sealant to pressure gauge assembly and tighten into hole. Pressurize motor housing to 10 PSI. Use soap solution around the sealed areas above the oil level and inspect joints for “air bubbles”. For sealed areas below oil level, leeks will seep oil. If, after five minutes, the pressure is still holding constant, and no “bubbles”/oil seepage is observed, slowly bleed the pressure and remove the gauge assembly. Replace oil. Leek must be located and repaired if pressure does not hold.

• Pressure builds up extremely fast, increase pressure by “TAPPING” air nozzle. Too much pressure will damage seal. DO NOT exceed 10 PSI.

Oil Replacement – Set unit upright and refill with new cooling oil as per table below . Fill to just above motor, but below capacitor as an air space must remain in the top of the housing to compensate for oil expansion. Apply pipe thread compound to threads of pipe plug then assemble to housing.

• DO NOT overfill oil. Overfilling of housing with oil can create excessive and dangerous hydraulic pressure which can destroy the pump and create a hazard.

Overfilling oil voids warranty

Cooling Oil Recommended Supplier/Grade

BP| Enerpar SE100
Conoco| Pale Parafin 22
Mobile| D.T.E. Oil Light
Shell Canada| Transformer-10
Texaco| Diala-Oil-AX

Disassembly & Assembly Impeller U-cup, V-ring and Volute:
Disconnect power. Remove cap screws and lock washers vertically lift motor, housing and seal plate assembly from volute. Clean out volute if necessary. Inspect gasket and replace if cut or damaged. Check U-cup for damage. If replacement is needed, cut the U-cup from the volute and clean surface of bore. Clean and examine impeller, for cracks or breakage and replace if required. To remove impeller, place a flat screwdriver in the slot of the end of the shaft to hold the shaft stationary while unscrewing the impeller.
To reassemble, clean the threads with thread locking compound cleaner. Apply removable Loctite® 242 or equivalent to shaft threads. Screw impeller onto the shaft hand tight while using a screwdriver in the slot at the end of the shaft to hold it stationary. Rotate impeller to check for binding. Install U-cup by applying adhesive to bore of volute. Be sure not to get adhesive on inside diameter of U-cup.
Position gasket on volute flange and position impeller and motor housing assembly on volute.
CAUTION Be sure the inside lip of the U-cup is not pushed out of place when assembling volute to rest of the pump.

Shaft Seal:
To examine or replace shaft seal, disassemble volute and impeller as stated. Remove retaining ring, spring and rotating member from shaft.
Inspect seal for signs of uneven wear pattern on stationary members, chips and scratches on either seal face. DO NOT interchange seal components, replace the entire shaft seal. If replacing seal, remove stationary by prying out with flat screwdriver.

Note: Handle seal parts with extreme care. Do NOT damage lapped surfaces.
To reassemble, clean seal cavity in seal plate and oil. Press seals stationary member firmly into seal plate, use a seal tool or pipe.
Nothing should come in contact with the seal face except the seal tool. Be sure the stationary is in straight. Lightly oil (Do not use grease) shaft and inner surface of bellows. Slide rotating member onto stationary using a seal tool. Place spring and retaining ring onto rotating member. Assemble impeller and volute as described.
Motor, Capacitor and Bearings: Remove volute and impeller as previously stated and drain oil from housing. Remove shaft seal. Position unit upright, using blocks to avoid resting unit on shaft. Unscrew cable cap screws and remove compression flange and power cord. Remove snap ring with a flat head screwdriver. Pull the terminal block out of the housing using a T-bolt or a pair of pliers and a .25-20 screw in the threads of the terminal block. Leave slack on the motor leads connected underneath. Use needle nose pliers to pull each female connector off of the pins on the underside of the terminal block. The voltage should be noted.

• Remove cap screws from seal plate and lift housing from seal plate.

• Remove square ring, replace if cut or damaged. Disconnect capacitor leads from capacitor. Remove motor bolts, lift cover, body and stator assembly from seal plate. Remove snap ring to
  remove rotor assembly. Remove bearings and with a wheel pulle.

• Check motor capacitor with an Ohm meter by first grounding the capacitor by placing a screwdriver across both terminals and then removing screwdriver. Connect Ohm meter (set on high scale) to terminals.

• If needle moves to infinity (oo) then drifts back, the capacitor is good.

• If needle does not move or moves to infinity (∞) and does not drift back, replace capacitor. Inspect motor winding for shorts and check resistance values. Check rotor for wear. If rotor or the stator windings are defective, the complete motor must be replaced.

• Slide rotor/shaft with bearings and into seal plate until bearing seats into seal plate. Install snap ring into seal plate.

• Place stator over rotor, lining up motor bolts with holes in seal plate.

• Place spring washer on bearing and cover onto rotor/stator assembly.

• Position capacitor so that it will lay on the opposite side of the cable entry boss of the housing. Install bracket and reconnect capacitor leads.

• Torque motor bolts to in/lbs. Set square ring in grove on seal plate.

• Lower housing down onto seal plate while aligning holes and stringing motor leads through the cord entry bore. Place cap screws through seal plate into housing and torque to 60 in/lbs. Reconnect motor leads to the underside of the terminal block.

• Place o-ring into groove in terminal block and lubricate with dielectric oil.

• Press the terminal block into the housing so it seats completely below the snap ring groove. Place snap ring into groove in cord entry bore of housing.

Power Cable Connection: Check power cord for cracks or damage and replace if required. Refill the cooling oil. Insert female end of cord plug into housing bore aligning
timing markwith hole in terminal block. Compress cord plug with compression flange by tightening cap screws with lock washers into the housing. Torque to 132 in/lbs.

Repair Parts

For Repair Part Please supply: Model Number and Serial as shown on Name Plate, and Part Description and Part Number as shown on Parts List.

Troubleshooting Chart

Risk of electric shock. Always disconnect the pump from the power source before handling inspections or repairs.

Risk of electric shock. Always disconnect the pump from the power source before handling inspections or repairs.

Symptom| Possible Cause(s)| Corrective Action

Pump will not run

| 1.   Poor electrical connection, blown fuse, tripped breaker or other interruption of power; improper power supply

2.    Motor or switch inoperative (go to manual operation)

2a.  Float  movement  restricted 2b. Switch will not activate pump or is defective 2c. Defective motor

3.    Insufficient liquid level

| 1. Check all electrical connections for security. Have electrician measure current in motor leads, if current is within ± 20% of locked rotor Amps, impeller is probably locked. If current is 0, overload may be tripped. Remove power, allow pump to cool, then re-check current.

2a. Reposition pump or clean basin as required to provide adaquate clearance for float

2b. Disconnect level control. Set ohmmeter for a low rang, such as 100 ohms full scale and connect to level control leads. Actuate level control manually and check to see that ohmmeter shows zero ohms for closed switch and full scale for open switch. (Float Switch)

2c. Check winding insulation (Megger Test) and winding resistance. If check is outside of range, dry and re-check. If still defective, replace per service instructions.

3.    Make sure liquid level is above the pump

4.    Re-check all sizing calculations to determine proper pump size.

5.    Check discharge line for restrictions, including ice if line passes through or into cold areas.

6.   Remove and examine check valve for proper

. in c stallation an o d freedom of op m eration

7.    Open valve

8.    Check impeller for freedom of operation, security and condition. Clean impeller cavity and inlet of any obstruction

9.    Loosen union slightly to allow trapped air to escape. Verify that turn- off level of switch is set so that the suction is always flooded. Clean vent hole

10.  Check rotation. If power supply is three phase, reverse any two of three power supply leads to ensure proper impeller rotation

11.  Repair fixtures as required to eliminate leakage

12.  Check pump temperature limits and fluid temperature

13.  Replace portion of discharge pipe with flexible connector or tighten existing piping.

14.  Turn to automatic position

15.  Check for leaks around basin inlet and outlets

Pump will not turn off

| 2a.  Float  movement  restricted 2b. Switch will not activate pump or is defective

4. Excessive inflow or pump not properly sized for application

9. Pump may be air locked causing pump not to flow

14. H-O-A switch on panel is in “HAND” position

Pump hums but doesn’t run

| 1. Incorrect low voltage

8. Impeller jammed or loose on shaft, or inlet plugged

Pump deliv a ers insufficient r capacity m| 1. Incorrect low voltage

4.    Excessive inflow or pump not properly sized for application

5.    Discharge restricted

6.    Check valve partially closed or installed backwards

7.    Shut e -off valve closed sa

8.    Impeller jammed or loose on shaft, or inlet

plugged

9.    Pump may be air locked causing pump not to flow

10.  Piping fixtures leaking or discharge before the nozzle

Pump cycles too frequently or runs periodically when fixtures are not in use| 6. Check valve partially closed or installed backwards

11. Fixtures are leaking

15. Ground water entering basin

Pump shuts off and turns on independent of switch, (trips thermal overload protector). CAUTION! Pump may start unexpectedly. Disconnect power supply.

| 1. Incorrect low voltage

4. Excessive inflow or pump not properly sized for application

8. Impeller jammed or loose on shaft, or inlet plugged

12. Excessive water temperature (internal

protection only)

Pump operates noisily or vibrates excessively

| 2c. Worn bearings, motor shaft bent

5. Debris in impeller cavity or broken impeller

10. Pump running backwards

13. Piping attachments to building structure too loose or rigid

NOTE: Barmesa Pumps assumes no responsibility for damage or injury due to disassembly in the field. Disassembly of the pumps or supplied accessories other than at Barmesa Pumps or its authorized service centers, automatically voids warranty.

BARMESA PUMPS FACTORY WARRANTY

Barmesa Pumps warrants that products of our manufacture will be free of defects in material and workmanship under normal use and service for 18 months from date of manufacture or 12 months from installation date whichever occurs first. This warranty gives you specific legal rights, which vary from state to state.
This warranty is a limited warranty, and no warranty related claims of any nature whatsoever shall be made against Barmesa Pumps, until the ultimate consumer or his/her successor 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 as instructed by Barmesa Pumps. THERE SHALL BE NO FUIUHER UABILITY, WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE. PRODUCT SHALL BE EITHER REPLACED OR REPAIRED AT THE ELECTION OF BARMESA PUMPS. Guarantees relating to performance specifications provided in addition to the foregoing material and workmanship warranties on a product manufactured by Barmesa Pumps, if any, are subject to possible factory testing. Any additional guarantees, in the nature of certified performance specifications or time frame must be in writing and such writing must be signed by our authorized factory manager at time of order placement and/or at time of quotation. Due to inaccuracies in field resting and should a conflict arises between the results of field testing conducted by or for the user, Barmesa Pumps reserves the right to have the product returned to our factory for additional testing.

This warranty shall not apply when damage is caused by [ 1) improper installation, (2) improper voltage, (3) lightning, (4) excessive sand or other abrasive material, (5) corrosion build-up due to excessive chemical content or (6) uncontrollable acts of god. Any modification of the original equipment will also void the warranty. We will not be responsible for loss, damaqe or labor cost due to interruption of service caused by defective pumps, parts or systems. Barmesa Pumps will not 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, 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 IMPLIED WARRANTY. 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.

IMPORTANT!
If you have a claim under the provision of the warranty, contact Barmesa Pumps or your authorized Barmesa Pumps Distributor:
warranty@barmesapumps.com
www.barmesapumps.com

References

• Barmesa Pumps USA | Quality Pumps Since 1953
• Barmesa Pumps México | Bombas de Calidad desde 1953

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