污水泵安装操作指南

Wastewater PumpsWastewater P umps

Installation and Operation Manual

Dewatering, Effluent and Sewage

Owner’s Information

Pump Model Number:Pump Serial Number:Control Model Number:Dealer:

Dealer Phone No.Date of Purchase:

Current Readings at Startup: 1ØAmps:Volts:

3ØAmps:Volts:

L1-2

L2-3

L3-1

Installation:

Table of Contents

SUBJECT PAGE

Safety Instructions........................................................... 2Pre-Installation Checks.....................................................2Lifting of Pump...............................................................2Optional Guide Rail or Lift-Out System............................. 2Piping ............................................................................ 3Wiring and Grounding.................................................... 3Selecting and Wiring Pump Control Panels and Switches...3-4Installation ..................................................................... 4Operation ................................................................... 4-5Float Switch and Panel Chart............................................5Three Phase Power Unbalance.......................................... 6Insulation Resistance Readings..........................................6Engineering Data............................................................ 7Typical Installations.........................................................8Trouble Shooting............................................................ 9Limited Warranty..........................................................10

IM107R02

www.goulds.com

SAFETY INSTRUCTIONS

All electrical work must be performed by a

qualified technician. Always follow the

National Electrical Code (NEC), or the Canadian ElectricalCode, as well as all local, state and provincial codes. Codequestions should be directed to your local electricalinspector. Failure to follow electrical codes and OSHAsafety standards may result in personal injury or equipmentdamage. Failure to follow manufacturer’s installationinstructions may result in electrical shock, fire hazard,personal injury or death, damaged equipment, provideunsatisfactory performance, and may void manufacturer’swarranty.

Standard units are not designed for use in

swimming pools, open bodies of water,

hazardous liquids, or where flammable gases exist. Thesefluids and gases may be present in containment areas. Tankor wetwell must be vented per local codes.

Only pumps specifically Listed for Class 1, Division 1 areallowable in hazardous liquids and where flammable gasesmay exist. See specific pump catalog bulletins or pumpnameplate for all agency Listings.

Disconnect and lockout electrical power

before installing or servicing any electrical

equipment. Many pumps are equipped with automaticthermal overload protection which may allow anoverheated pump to restart unexpectedly.

All three phase (3Ø) control panels for

submersible pumps must provide

Class 10, quick-trip, overload protection.

2

PRE-INSTALLATION CHECKS

Open all cartons and inspect for shipping damage. Reportany damage to your supplier or shipping carrierimmediately.

Important: Always verify that the pump nameplate Amps,Voltage, Phase, and HP ratings match your control paneland power supply.

Many of our sewage pumps are oil-filled. If there are anysigns of oil leakage or if the unit has been stored for an

extended period check the oil level in the motor dome andthe seal housing, if so equipped.

Check the motor cover oil level through the pipe plug ontop of the unit. The motor chamber oil should just coverthe motor. Do not overfill, leave room for expansion!To check the seal housing oil level, where used, lay the uniton its side with the fill plug at 12 o’clock. Remove the plug.The oil should be within 1⁄

2” (13mm) of the top. If low,refill with an ASTM 150 turbine oil. Replace the plug.Oil is available in 5 gallon cans through our distributors.You can also source oil locally at motor repair shops.

Typical oil brands are: Shell Turbo 32, Sunoco Sunvis 932,Texaco Regal R&O 32, Exxon Nuto 32 and Mobil DTELight.

Check the strain relief nut on power cable strain

assemblies. Power cables should be torqued to 75 in. lbs.for #16 cables and 80 in. lbs. for all other cable assemblies.Seal/heat sensor cables, where used, should be torqued to75 in. lbs.

Warranty does not cover damage caused by connectingpumps and controls to an incorrect power source (voltage/phase supply).

Record the model numbers and serial numbers from thepumps and control panel on the front of this instructionmanual for future reference. Give it to the owner or affix itto the control panel when finished with the installation.

LIFTING OF PUMP

DO NOT LIFT, CARRY OR HANG

PUMP BY THE ELECTRICALCABLES. DAMAGE TO THE

ELECTRICAL CABLES CAN CAUSESHOCK, BURNS OR DEATH.

Lift the pump with an adequately sized chain or cable attachedto the lifting eye bolt. DO NOT damage electrical and sensorcables while raising and lowering unit.

OPTIONAL GUIDE RAILOR LIFT-OUT SYSTEM

In many effluent and sewage basins or lift stations it is

advisable to install the pump on a guide rail system or on alift-out adapter to facilitate installation and removal forinspection and/or service. Most codes do not allow

personnel to enter a wetwell without the correct protectiveequipment and training. Guide rails are designed to alloweasy removal of the pump without the need for entry intothe wetwell or need to disturb piping. The guide rail or lift-out adapter should locate the pump opposite the influent

opening preventing stagnate areas where solids can settle.The basin or pit must be capable of supporting the weightof the pump and guide rail. The pit floor must be flat.NOTICE: FOLLOW THE INSTRUCTIONS THAT ARE

PROVIDED WITH THE GUIDE RAILASSEMBLY.

PIPING

Discharge piping should be no smaller than the pump dis-charge diameter and kept as short as possible, avoidingunnecessary fittings to minimize friction losses.

Install an adequately sized check valve matched to thesolids handling capability of the pump to prevent fluidbackflow. Backflow can allow the pump to “turbine”backwards and may cause premature seal and/or bearingwear. If the pump is turning backwards when it is called onto start the increased torque may cause damage to thepump motor and/or motor shaft and some single-phasepumps may actually run backwards.

Install an adequately sized gate valve AFTER the check valvefor pump, plumbing and check valve maintenance.

Important – Before pump installation. Drill a 3⁄16” (4.8mm)relief hole in the discharge pipe. It should be located withinthe wetwell, 2” (51mm) above the pump discharge butbelow the check valve. The relief hole allows any air toescape from the casing. Allowing liquid into the casing willinsure that the pump can start when the liquid level rises.Unless a relief hole is provided, a bottom intake pumpcould “air lock” and will not pump water even though theimpeller turns.

All piping must be adequately supported, so as not to impartany piping strain or loads on the pump.

The pit access cover must be of sufficient size to allow forinspection, maintenance and crane or hoist service.

WIRING AND GROUNDING

Important notice: Read Safety Instructions beforeproceeding with any wiring.

Use only stranded copper wire to pump/motor andground. The ground wire must be at least as large asthe power supply wires. Wires should be color codedfor ease of maintenance and troubleshooting.Install wire and ground according to the NationalElectrical Code (NEC), or the Canadian ElectricalCode, as well as all local, state and provincial codes.Install an all leg disconnect switch where required bycode.

Disconnect and lockout electrical power beforeperforming any service or installation.

The electrical supply voltage and phase must matchall equipment requirements. Incorrect voltage orphase can cause fire, motor and control damage, andvoids the warranty.

All splices must be waterproof. If using splice kitsfollow manufacturer’s instructions.

Select the correct type and NEMA grade

junction box for the application andlocation. The junction box must insuredry, safe wiring connections.

Seal all controls from gases present which

may damage electrical components.

FAILURE TO PERMANENTLY

GROUND THE PUMP, MOTOR AND

CONTROLS BEFORE CONNECTING

TO POWER CAN CAUSE SHOCK,BURNS OR DEATH.

SELECTING AND WIRING

PUMP CONTROL PANELS AND SWITCHES

FLOAT SWITCH TYPES

There are two basic float switch designs; single-action andwide-angle. Single-action switches operate over a range of15º so they open and close quickly. Wide-angle floatsoperate over a 90º swing with the tether length betweenthe float body and the pivot point controlling the On-Offrange. The design determines how many floats are requiredwith different systems or controls.

Floats may be normally open (NO) for pump downapplications or to empty a tank. Normally closed (NC)switches are used to pump up or to fill a tank.A single-action control switch may be used only with acontrol panel, never direct connected to a pump.The wide-angle, pump down switches may be used asdirect connected pump switches or as control switches.SETTING THE FLOAT SWITCHES

There are no absolute rules for where to set the floatswitches, it varies from job to job.

Suggested Rules to Follow:

All floats should be set below the Inlet pipe!

Off Float: Best: set so the water level is always above thetop of the pump (motor dome). Next Best: set so the waterlevel is not more than 6" below the top of the pump.On Float: set so the volume of water between the On andOff floats allows pumps of 11⁄2 HP and under to operate for1 minute minimum. Two (2) HP and larger pumps shouldrun a minimum of 2 minutes. Basin literature states thegallons of storage per inch of basin height.

Lag/Alarm Float(s): should be staggered above the Off andOn floats. Try to use most of the available storage providedby the basin, save some space for reserve storage capacity.See Diagrams and Charts in Float Switch Chart Section.PANEL WIRING DIAGRAMS

Our control panels are shipped with instructions and

wiring diagrams. Use those instructions in conjunction withthis IOM. Electrical installation should be performed onlyby qualified technicians. Any problem or questionspertaining to another brand control must be referred tothat control supplier or manufacturer. Our technical peoplehave no technical schematics or trouble shootinginformation for other companies' controls.

ALARMS

We recommend the installation of an alarm on all

Wastewater pump installations. Many standard controlpanels come equipped with alarm circuits. If a controlpanel is not used, a stand alone high liquid level alarm isavailable. The alarm alerts the owner of a high liquid levelin the system so they can contact the appropriate servicepersonnel to investigate the situation.

3

SINGLE PHASE PUMPS

Single phase (1Ø) pumps may be operated using apiggyback or hard wired float switch, a contactor, or aSimplex or Duplex control panel. See Figures 1, 2 and 5.All 1/3 and 1/2 HP, 115 or 230 volt pumps, and some 3/4and 1 HP pumps, are supplied with plug style power cords.They may be plugged into piggyback float switches forsimple installations. It is allowable to remove the plugs inorder to hardwire or connect to a Simplex or Duplexcontroller. Removing the plug neither voids the warrantynor violates the agency Listings. See Figure 5.

PLUG-CONNECTED UNITS MUST BE

CONNECTED TO A PROPERLYGROUNDED, GROUNDING TYPERECEPTACLE.

ON NON-PLUG UNITS, DO NOT

REMOVE CORD AND STRAIN RELIEF.DO NOT CONNECT CONDUIT TOPUMP.

Pumps with bare lead power cords can be hard-wired to afloat switch, wired to a 1Ø contactor, a Simplex controlleror a Duplex controller. Always verify that the float switchis rated for the maximum run amperage, maximum startingamperage, and the HP rating on the pump. Single-phasewastewater pumps contain on-winding overloads, unlessnoted on the pump nameplate. See Figures 1 and 2.THREE PHASE PUMPS:

As a Minimum a 3Ø pump requires a 3 pole circuitbreaker/fused circuit, an across the line magnetic starterrated for the pump HP, and ambient compensated QuickTrip Class 10 overloads.

SINGLE AND THREE PHASE CONTROL PANELS:Control panels are available as Simplex (controls 1 pump)or Duplex (controls 2 pumps). Our standard SES SeriesPanels are available with many standard features and can bebuilt with our most popular options. We also custom buildpanels which offer many more design options than the SESpanels. Custom control panels are available in many

different configurations. Custom panel quote requests maybe forwarded to Customer Service through any authorizeddistributor.

Our “SES” Duplex panels feature a solid-state printed

circuit board design with standard high level alarm circuits.Other standard features are: an auxiliary dry alarm contactfor signaling a remote alarm and float switch positionindicator lights. Our 3Ø panels have built-in, adjustable,Class 10 overloads. The adjustable overloads on all our 3Øpanels mean less labor for the installer and no need toorder specific overloads. Most SES panels are in stock forimmediate delivery.

On pumps equipped with seal fail and/or heat (high

temperature) sensors it is recommended that you use ourcontrol panel with the appropriate options. The pumpsensors do not function without a seal fail relay or terminalconnection in the control panel and a warning device suchas a bell, horn or light.

Seal Failure Circuit - Some dual seal pumps are equippedwith a standard, built-in seal failure circuit, which may alsobe called a moisture detection circuit. This circuit must beconnected to a control panel with an optional seal failrelay. The panel must be special ordered with the seal failrelay and alarm. There are also stand alone seal fail panels4

such as the A4-3 or A4-4 available as standard items. Thepumps can be identified by an extra control cable exitingthe motor cover. The cable contains two wires, a blackwire, connects to panel "terminal" going to "probe"; and awhite wire, connects to the panel "terminal" going to therelay ground. Do not connect to the panel ground screw.Follow the wiring instructions supplied with the panel.Heat Sensor and Seal Failure Circuit - Some pumps areequipped with a seal fail and normally closed, on-windinghigh temperature thermostats (heat sensors). The pumpshave a control cable with four (4) leads, black (probe) andgreen (relay ground) for the seal fail circuit and red andwhite for the high temperature circuit. Connect the hightemperature (heat sensor) circuit to the panel terminal stripas indicated on the panel drawing using the red and whitewires. The high temperature panel circuit is also an

optional item which you must specifically order when youorder your control panel. The high temperature circuit isdifferent from the Class 10 overloads which are alwaysrequired on three phase pumps. Follow the wiringinstructions supplied with the panel.

INSTALLATION

Connect the pump(s) to the guide rail pump adapters or tothe discharge piping. Slide rail bases should be anchored tothe wetwell floor.

Complete all wiring per the control panel wiring diagramsand NEC, Canadian, state, provincial and/or local codes.This a good time to check for proper rotation of themotors/impellers.

DO NOT PLACE HANDS IN PUMPSUCTION WHILE CHECKINGMOTOR ROTATION. TO DO SOWILL CAUSE SEVERE PERSONALINJURY.

Always verify correct rotation. Correctrotation is indicated on the pump casing.Three phase motors are reversible. It isallowable to bump or jog the motor for afew seconds to check impeller rotation. Itis easier to check rotation before installingthe pump. Switch any two power leads toreverse rotation.

Lower the pump(s) into the wetwell.

Check to insure that the floats will operate freely and notcontact the piping.

OPERATION

Once the piping connections are made and checked youcan run the pumps.

Piggyback Switch Operation – Plug the piggyback switchinto a dedicated grounded outlet and then plug the pumpinto the switch. Test the pump by filling the wetwell untilthe pump goes On. If the pumps run but fail to pump,they are probably air locked, drill the relief holes per theinstructions in the Piping Section.

Check the operating range to insure a minimum oneminute run time and that the pump goes Off in thecorrect position.

Control Panel Operation – Fill the wetwell with clearwater.

Use the pump H-O-A (Hand-Off-Automatic) switches inHand to test the pumps. If they operate well in Handproceed to test Automatic operation. If the pumps runbut fail to pump, they are probably air locked, drill therelief holes per the instructions in the Piping Section.Place Control Panel switch(es) in Automatic position andthoroughly test the operation of the ON, OFF, andAlarm floats by filling the wetwell with clear water.

Important: Failure to provide a Neutral from the powersupply to a 1Ø, 230 volt Control Panel will not allow thepanel control circuit to operate. The Neutral is necessaryto complete the 115 volt control circuit.

Check voltage and amperage and record the data on thefront of this manual for future reference. Compare theamperage readings to the pump nameplate maximumamperage. If higher than nameplate amperage investigate

cause. Operating the pump off the curve, i.e. with toolittle head or with high or low voltage will increase

amperage. The motor will operate properly with voltagenot more than 10% above or below pump nameplateratings. Performance within this range will not

necessarily be the same as the published performance atthe exact rated nameplate frequency and voltage. Correctthe problem before proceeding. Three phase unbalance isalso a possible cause. See Three Phase Power Unbalanceand follow the instructions.

Reset the Alarm circuit, place pump switch(es) in theAutomatic position and Control Switch in ON position.The system is now ready for automatic operation.Explain the operation of the pumps, controls and alarmsto the end user. Leave the paperwork with the owner orat the control panel if in a dry, secure location.

FLOAT SWITCH AND PANEL CHART

The purpose of this chart is to show the required switchquantities and the function of each switch in a typical

wastewater system. The quantities required vary dependingon the switch type, single-action or wide-angle. Switchquantities also vary by panel type: simplex with andwithout alarms, and duplex with alarms.Duplex Panels using single-action switches:SW1SW2SW3

Bottom Middle Top

Pumps Off1st Pump On

2nd Pump & Alarm On

Inlet

Simplex Panel using wide-angle switches:SW1Bottom Pump On/OffSW2Top Alarm On/OffSW1

SW1SW2SW3SW4

Bottom 2nd 3rd Top

Pumps Off1st Pump On2nd Pump OnAlarm On

Duplex Panels using wide-angle switches:SW1SW2

Bottom Top

1st Pump On/Both Off2nd Pump & Alarm On

SW1SW2SW3

Bottom Middle Top

1st Pump On/Both Off2nd Pump OnAlarm On

Simplex Panel using single-action switches:SW1Bottom Pump OffSW2Middle Pump OnSW3Top Alarm On/OffSW1SW2

Bottom Top

Pump OffPump On

Inlet

SW3SW2

SW1

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THREE PHASE POWER UNBALANCE

A full three phase supply consisting of three individualtransformers or one three phase transformer is recom-mended. “Open” delta or wye connections using only twotransformers can be used, but are more likely to cause poorperformance, overload tripping or early motor failure dueto current unbalance.

Check the current in each of the three motor leads andcalculate the current unbalance as explained below.

If the current unbalance is 2% or less, leave the leads asconnected.

If the current unbalance is more than 2%, current

readings should be checked on each leg using each of thethree possible hook-ups. Roll the motor leads across thestarter in the same direction to prevent motor reversal.To calculate percent of current unbalance:A. Add the three line amp values together.

B. Divide the sum by three, yielding average current.C. Pick the amp value which is furthest from the averagecurrent (either high or low).

D. Determine the difference between this amp value(furthest from average) and the average.

E. Divide the difference by the average. Multiply the resultby 100 to determine percent of unbalance.Current unbalance should not exceed 5% at servicefactor load or 10% at rated input load. If the unbalancecannot be corrected by rolling leads, the source of theunbalance must be located and corrected. If, on the threepossible hookups, the leg farthest from the average stays onthe same power lead, most of the unbalance is coming fromthe power source.

Contact your local power company to resolve theimbalance.

Hookup 1

Starter Terminals

L1

L2

L3

L1

Hookup 2L2

L3

L1

Hookup 3L2

L3

Motor LeadsExample:

R T3B T1W T2W T2R T3B T1B T1W T2R T3

T3-R = 51 ampsT1-B = 46 ampsT2-W = 53 ampsTotal = 150 amps÷ 3 = 50 amps— 46 = 4 amps4 ÷ 50 = .08 or 8%T2-W = 50 ampsT3-R = 48 amps

T1-B = 52 ampsTotal = 150 amps÷ 3 = 50 amps— 48 = 2 amps2 ÷ 50 = .04 or 4%T1-B = 50 ampsT2-W = 49 ampsT3-R = 51 ampsTotal = 150 amps÷ 3 = 50 amps— 49 = 1 amps1 ÷ 50 = .02 or 2%

INSULATION RESISTANCE READINGS

Normal Ohm and Megohm Values between all leads and ground

Insulation resistance varies very little with rating. Motors of all HP, voltage and phase ratings have similar valuesof insulation resistance.

Insulation resistance values above are based on readings taken with a megohmmeter with a 500V DC output.Readings may vary using a lower voltage ohmmeter, consult factory if readings are in question.

This table was reprinted through the courtesy of Franklin Electric.

6

ENGINEERING DATA

Engineering data for specific models may be found in your catalog and on our website (address is on the cover).

Control panel wiring diagrams are shipped with the control panels. Please use the control panel drawings in conjunction with thisinstruction manual to complete the wiring.

PUMP CONSTRUCTION

Minimum Submergence

Continuous Duty Fully SubmergedIntermittent Duty

6" Below Top of Motor

Pumpmaster and Pumpmaster Plus -Hard Wired

Fig. 1

Double Float - Hard Wired

Fig. 2

Determining Pumping Range

Fig. 3

Maximum Fluid Temperature

Continuous Operation 104º F 40º CIntermittent Operation

140º F 60º C

Wide-Angle Float Switch

Piggyback Pump plug

switch plug

Pumping range

Fig. 5

Three Phase Connection Diagram

S1

L1Red L2Black PUMP

L3White GRD

Green

Fig. 6

7

TYPICAL INSTALLATIONS

Typical Effluent, Sewage andDewatering Pump Installations

8

TROUBLE SHOOTING

FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL

POWER BEFORE ATTEMPTING ANY SERVICE CAN CAUSESHOCK, BURNS OR DEATH.

PROBABLE CAUSE

Motor thermal protector tripped.Open circuit breaker or blown fuse.Pump impeller binding or jammed.Power cable is damaged.

Inadequate electrical connectionin control panel.

No neutral wire

connected to control panel.Inadequate electrical connectionin control panel.

Defective liquid level switch.

RECOMMENDED ACTION

Allow motor to cool. Insure minimum pump

submergence. Clear debris from casing and impeller.Determine cause, call a qualified electrician.

Check motor amp draw. If two or more times higherthan listed on pump nameplate, impeller is locked,motor bearings or shaft is damaged. Clear

debris from casing and impeller, consult with dealer.Resistance between power leads and ground shouldread infinity. If any reading is incorrect, call aqualified electrician.

Inspect control panel wiring. Call a qualifiedelectrician.

With switch disconnected, check continuity whileactivating liquid level switch. Replace switch, asrequired.

Allow liquid level to rise 3" to 4" (76 mm - 101 mm)above turn-on level.

Untangle cords and insure free operation.Untangle cords and insure free operation.

Shut off pump for approximately one minute, thenrestart. Repeat until air lock clears. If air locking

persists in a system with a check valve, a 3⁄16" (4.8 mm)hole may be drilled in the discharge pipe approximately2" (51 mm) above the discharge connection.Larger pump may be required.

Check flow arrow on valve and check valveoperation.

Consult with dealer.

Inspect and clear as required.

Check pump rotation, voltage and wiring.Consult with qualified electrician.See recommended action, above.Inspect impeller, replace as required.Inspect, readjust or replace as required.Inspect, repair or replace as required.Consult with dealer.

Inspect, readjust or replace as required.Consult with dealer.

SYMPTOM

MOTOR NOT RUNNINGNOTE: If circuit breaker“OPENS” repeatedly,DO NOT reset. Callqualified electrician.a) Manual operation

b) Automatic operation

NOTE: Check the pump inmanual mode first to confirmoperation. If pump operates,the automatic control orwiring is at fault. If pumpdoes not operate, see above.PUMP WILL NOTTURN OFF

Insufficient liquid level toactivate controls.

Liquid level cords tangled.Liquid level cords tangled.Pump is air locked.

Influent flow is matching pump’sdischarge capacity.

LITTLE OR NO LIQUIDDELIVERED BY PUMP

Check valve installed backwards,plugged or stuck closed.Excessive system head.Pump inlet plugged.

Improper voltage or wiredincorrectly.

Pump is air locked.

Impeller is worn or damaged.Liquid level controls defectiveor improperly positioned.Discharge check valve inoperative.Sewage containment area too small.Liquid level controls defective orimproperly positioned.

Influent excessive for this sizepump.

PUMP CYCLESCONSTANTLY

9