Barmesa Pumps BPEV512 Submersible Effluent Pumps Instruction Manual

Barmesa Pumps BPEV512 Submersible Effluent Pumps

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  “Danger” indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
• WARNING  “Warning” indicates an imminenty hazardous situation which, if not avoided, MAY result in death or serious injury.

DECONTAMINAT ED PRIOR 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 junction connections must be in accordance with the National Electric Code and all applicable state and local codes. Requirements may vary depending on usage and location.
• WARNING  Keep clear of suction and discharge openings. Do not insert fingers in pump with power connected; the rotating 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 before handling or servicing the Risk of electric shock. To reduce risk of electric shock, always disconnect pump from power source before handling any aspect of the pumping system. Lock out power and tag.
• WARNING Do not use these pumps in water over 77º 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.
• 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

Specifications & Dimensions

• DISCHARGE: 2″ NPT, female, vertical.
• SPHERICAL SLD HNDLG: 3/4″
• LIQUID TEMPERATURE: 104 °F (40 °C) max.
• VOLUTE: Cast iron ASTM A-48 class 30.
• MOTOR HOUSING: Cast iron ASTM A-48 class 30.
• IMPELLER: Vortex. Cast iron ASTM A-48 class 30, dynamically balanced, ISO G6.3.
• SHAFT: 416 series stainless steel.
• O-RINGS: Square shaped Buna-N.
• PAINT: Air dry enamel, water based.
• SEAL: Single mechanical, oil filled chamber. Carbon / ceramic / Buna-N, with stainless steel hardware.
• HARDWARE: 300 series stainless steel.
• CORD ENTRY: 30 ft of neoprene cord SJTOW 16/3, sealed against moisture.
• UPPER BEARING: Ball, single row, oil lubricated, for radial load.
• LOWER BEARING: Ball, single row, oil lubricated, for radial and axial loads.
• MOTOR: NEMA L, single phase, permanent split capacitor, 115 volts, 60 Hz, 3500 RPM, oil
• filled, with overload protection in motor.
• OPTIONAL EQUIPMENT: Additional cord, slide rail coupling (SRC-200).

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

(Nominal)

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

(pounds)

---|---|---|---|---|---|---|---|---|---|---
BPEV512| 62180201| 0.5| 115| 1| 3450| 8| 16| 16/3| SJTOW| 50
BPEV512A| 62180202| 0.5| 115| 1| 3450| 8| 16| 16/3| SJTOW| 49

A = Automatic Float Switch

Receiving & Installation

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. Do not pump out of liquid.

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).

Liquid Level Control
Typical Discharge Pipe Mounted: Refer to Figure 2 below which shows a typical installation of a 1 phase 115 volt pump using a level control mounted to the discharge piping with a piggyback 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 Discharge Pipe Mounted 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.

Installation
These pumps are recommended for use in a sump or basin. The sump or basin shall be sealed and vented in 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 backflow 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 flow during pump servicing.

Electrical Connections Power cable
The power cable mounted to the pump must not be modified in any way. This pump is provided with a 3 wire cord and 3 prong grounded plug that must be connected into a 3 wire grounded Ground Fault receptacle. Do not bypass grounding wires or remove ground prongs from plug. This pump requires separate, properly fused and grounded branch circuit. Use of a ground fault circuit interrupter (GFCI) is strongly

IF USED with Control Panel – 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. If current through the temperature sensor exceeds the values listed, an

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. Incorrect rotation for Single-Phase pumps is unlikely. If the rotation is incorrect contact factory.
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

Maintenance

No lubrication or maintenance is required. Perform the following checks when pump is removed from 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, from housing.
• Check oil for contamination using an oil tester with a range to 30 kilovolts breakdown.
• If oil is found to be clean and uncontaminated (measuring above 15 kV breakdown), refill
• After leak is repaired, dispose of old oil properly, and refill with new oil.
• 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 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 Impeller and Volute

1. Disconnect power.

2. Remove cap screws, volute and gasket.

3. 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.

4. Check v-ring and remove if damaged.
   Power Cord and Motor:

5. Remove pipe plug and drain oil from housing.

6. Remove gland nut, washer and nylon housing from motor housing. Pull cord through and disconnect the wires from the terminals on power cord.

7. Remove screws and washers and lift motor housing and stator from seal plate.

8. Remove o-ring, replace if damaged.

9. 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 (∞) then drifts back, the capacitor is good. If needle does not move or moves to infinity (∞) and does not drift back, replace capacitor.

10. 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.
    Shaft Seal:

11. Remove snap ring from seal plate. Remove shaft and motor rotor from seal plate.

12. Remove seal’s rotating member, spring and retaining ring from seal plate. Examine all seal parts, if seal faces show signs of wear, uneven wear pattern, chips or scratches replace entire seal. DO NOT interchange seal components, replace the entire shaft seal. If replacing seal, remove stationary by prying out with flat screwdrive.
    Bearings:

13. Examine lower bearing, and upper bearing, if replacement is required, remove by using a wheel puller.

Reassembly

IMPORTANT  – All parts must be clean before reassembly. Handle seal parts with extreme care. DO NOT damage lapped surfaces.
Bearings:

1. Press bearings and onto shaft.
   Shaft Seal:

2. Clean seal cavity in seal plate and oil. Press seal’s 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.

3. Place seal’s retaining ring, spring onto shaft. Lightly oil (Do not use grease) shaft and inner surface of bellows.

4. With lapped surface of seal’s rotating member facing outward, slide over shaft using a seal tool, being carefull not to damage seal face. Make sure spring is seated in retaining ring and spring is lined up on rotating member and not cocked or resting on bellows tail.
   Motor:

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

6. Lower housing while stringing motor leads through the cord entry bore, with motor stator onto seal plate.

7. Place screws with washers through housing into seal plate and torque to 60 in/lbs.
   Power Cord:

8. Check power cord for cracks or damage and replace if required. Reconnect motor leads.

9. Place power cord with nylon housing, ring, washer and gland nut into housing and tighten gland nut to 17.5 ft/lbs.
   Impeller, V-ring and Volute:

10. Position v-ring into seal plate until seated.

11. 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.

12. Position gasket on volute flange and position impeller and motor housing assembly on volute.

13. Place screws into volute and torque to 11 ft/lbs. Check for free rotation of impeller.

14. Refill with cooling oil.

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.

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

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 supply2.    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 defective4. 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 voltage8. Impeller jammed or loose on shaft, or inlet plugged
Pump deliv a ers insufficient r capacity     m| 1. Incorrect low voltage4.    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 backwards11. 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 voltage4. 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 bent5. Debris in impeller cavity or broken impeller

10. Pump running backwards

13. Piping attachments to building structure too loose or rigid

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 1 2 months from installation date whichever occurs first. This warranty gives you specific legal rights, which vary
from state to state. This w arranty 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 FURTHER LIABILITY, 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 testing 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 ( l) 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, damage 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
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