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STATION INSTALLATION & OPERATION MANUAL
IMPORTANT!
Read all instructions in this manual before operating pump.
As a result of Crane Pumps & Systems, Inc., constant product improvement program,
product changes may occur. As such Crane Pumps & Systems reserves the right to
change product without prior written notifi cation.
A Crane Co. Company
420 Third Street
Piqua, Ohio 45356
Phone: (937) 778-8947
Fax: (937) 773-7157
www.cranepumps.com
Manual Index
EcoTRAN System
83 West Drive, Bramton
Ontario, Canada L6T 2J6
Phone: (905) 457-6223
Fax: (905) 457-2650
Form No. 133887-Rev. C
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Summary of Contents for Barnes EcoTRAN
- Page 1 Manual Index STATION INSTALLATION & OPERATION MANUAL EcoTRAN System IMPORTANT! Read all instructions in this manual before operating pump. As a result of Crane Pumps & Systems, Inc., constant product improvement program, product changes may occur. As such Crane Pumps & Systems reserves the right to change product without prior written notifi...
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Page 2: Table Of Contents
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... -
Page 3: Safety First
SAFETY FIRST! Please Read This Before Installing Or Operating Pump. This information is provided for SAFETY and to PREVENT If the pump is idle for long periods of time, it is advisable to start EQUIPMENT PROBLEMS. To help recognize this information, the pump occasionally by adding water to the basin. -
Page 4: User Guide
The key element in this • Explosives or Flammable material system is the Barnes grinder station. The station • Lubricating oils or Grease collects all wastewater from your house or facility. •... -
Page 5: Step 1. Unpack Instructions
STEP 1: UNPACK INSTRUCTION STEP 1: Received EcoTRAN Package Cut outer cardboard at the designated cut line and remove cover. STEP 2: Cut the banding that retains the STEP 3: Roll the tank to its right side up tank and discard. Cut the banding position and remove the level together. -
Page 6: Packaged Parts As Recieved
PACKAGED PARTS AS RECEIVED LEVEL CONTROL CORD PUMP HARNESS RISER EcoTRAN GRINDER PUMP ESPS LEVEL CONTROL DRAIN TILE O-RING PARTS BOX ALARM BOX 6" TO 4" FLEXIBLE FITTING BASIN TANK ASSEMBLY FLEXIBLE DISCHARGE FITTING TANK 2 PAD LOCKS RECEIVER PIPE LUBE... -
Page 7: Step 2. Component Overview
STEP 2: COMPONENT OVERVIEW ROCK COVER (ACTUAL COVER MAY VARY) RISER ADAPTER FLEXIBLE INLET FITTING BALL VALVE FEMALE RECEIVER PUMP ORIENTATION DEVICE FLEXIBLE (POD) DISCHARGE FITTING TANK PUMP LEVEL CONTROL REBAR (FACTORY INSTALLED) ROCK COVER ... Cover basin assembly. POD (Pump Orientation Device) Load rating of 150 lbs per sq. -
Page 8: Step 3. Before You Begin
STEP 3: BEFORE YOU BEGIN • Read This Manual Completely Before Starting Your Installation. • Consult local offi cials for any applicable codes and regulations. Obtain all necessary permits. Call your local utilities committee before digging to locate all underground lines and cables (page 9). •... -
Page 9: Step 4: Setting The Basin: Location Overview
STEP 4: SETTING THE BASIN: Location Overview You should have your local utilities committee mark all utility lines to help determine the proper location. You may also call 888-258-0808 which is a national directory to identify your local utility authority. On the Internet you can go to the following website to fi... - Page 10 STEP 4: SETTING THE BASIN: Location Overview...
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Page 11: Step 5. Riser Tank Parts Assembly
STEP 5: RISER TANK PARTS ASSEMBLY... -
Page 12: Step 6. Hole Depth And Handling Basin
STEP 6: HOLE DEPTH & BASIN HANDLING To calculate the hole depth required, add the package depth plus the amount of bedding used under the tank, then subtract 2 inches. Package depth plus bedding thickness minus two inches = Hole depth required. BEDDING MATERIAL DESCRIPTION - The basin should have a 4 to 6 inch compacted bed of round or angular crushed rock with a... -
Page 13: Step 7. Adapter / Conduit Layout
STEP 7: ADAPTER / CONDUIT LAYOUT 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 Apply thread sealant to the threads of the NPT to SLIP fi... - Page 14 Fig. 4 Fig. 6 Step 6. Insert and tighten cord grip in tapped hole until the Step 4. From the inside of the riser tap the clearance hole hex fl ange of the cord drip meets the riser wall. (See Fig. 7) from Step 3 with a ¾-14 NPT.
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Page 15: Step 8. Ballasting Requirements
48” 9.75” 0.338 Cu. Yds. ** IMPORTANT! - FOR A 36” DIAMETER ROUND FORM OR HOLE, THE ECOTRAN UNIT MUST BE SET 4” ABOVE THE BEDDING. 4” BLOCKS CAN BE USED TO ACCOMPLISH THIS. IMPORTANT! - FAILURE TO BALLAST STATION WILL VOID WARRANTY AND MAY RESULT IN PERSONAL INJURY AND PROPERTY DAMAGE. -
Page 16: Step 9. Discharge Connections
STEP 9: DISCHARGE CONNECTIONS The basin is equipped with a female 1.25 inch NPT discharge connection. Your discharge MUST include the following items: • (1) Flexible pipe coupling –supplied with station to compensate for varied settling rates of backfi ll materials •... -
Page 17: Step 10A & B. Inlet Location: Installing Flexible Inlet Flange
STEP 10: INLET LOCATION: Installing Flexible Inlet Fittings The majority of basin problems originate from excessive infl ow or infi ltration. While all aspects of basin installation are critical, the inlet installation should not be deviated from! Make sure to fully read this page before beginning your inlet installation. -
Page 18: Step 10C. Backfilling
STEP 10C: INLET INSTALLATION BACKFILLING • Backfi ll and haunch per the ASTM D 2321 specifi cation to prevent damage or failure of the inlet piping! Work in and compact the material in the haunching area to provide complete contact with the pipe bottom and ensure there are no voids. -
Page 19: Step 11. Installing Direct Burial Cable & Mounting Alarm Box
STEP 11: INSTALLING DIRECT BURIAL CABLE AND MOUNTING ALARM BOX The direct burial cable must be a UL / CSA Approved, type TC round style cable rated for burial use. FLAT TYPE UF CABLE WILL NOT BE PERMITTED AND WILL VOID WARRANTY! The 12/5 conductor size is based on a maximum length of 150 feet. -
Page 20: Step 12. Backfilling And Final Grading
STEP 12: BACKFILLING When backfi lling around the basin, care should be taken to prevent damage to the installed components. It is imperative that proper backfi ll materials and methods be used to prevent leaks, cracks and failures. Listed below are materials approved for backfi... -
Page 21: System Electrical Wiring: Step 13. Wiring The Station To Electrical Panel
STEP 13: WIRING THE STATION 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 ½ “ of the insulation off the ends of the individual leads. Wire per the illustration below B1 W1 R1 O1 CONNECTION... -
Page 22: Step 14. Wiring The Service Power To The Electrical Panel
STEP 14: WIRING SERVICE DROP TO ALARM BOX The service supply panel will be required to have a separate 25-amp double pole breaker to supply power to the pump and a separate 10-amp circuit breaker for the alarm circuit in the control panel. The following work is to be performed only by certifi... -
Page 23: Step 15. Install Pump Harness
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 fi tting and one bowline knot in the eyebolt on the pump. Step 16: INSTALLING THE PUMP CORD AND LEVEL CONTROL CORD Insert the end of the cord plug into the housing... - Page 24 Fig. 10a Fig. 11 Step 11. Attach the cover using the provided screws and washers. Hand tighten screws as shown in Fig. 12. Fig. 10b Step 10. Place the cover onto the riser. Using the cover as a template, pilot drill the screw holes into the riser using an ⅛”...
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Page 25: Step 17. Assembling The Cord Connector
Step 17: RECORDING PUMP NAMEPLATE INFORMATION The nameplate is located on top of the pump. This contains the pumps part number, horsepower voltage, phase, and serial number, as well as other information. The start-up form located in the back of this manual contains a place to record this data. - Page 26 Step 20: TIDY-UP & COVER INSTALLATION • Coil, secure and loop the cords and harnesses to the harness hooks • Fix any ruts or depressions, which may have occurred during installation. • Check fi nal grade, (page 19) so it does not interfere with station operation STANDARD VENTED ROCK COVER INSTALLATION The cover gasket is a large soft O-ring that is factory installed.
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Page 27: Step 21. Tidy-Up & Std. Vented Rock Cover Installation
Step 21: START UP PRE-CHECKLIST Prior to performing an electrical and hydraulic performance check of the complete station, verify all of the following criteria are met: The shut-off and redundant check valve at force main are installed in the lateral discharge and are in the open position Discharge piping has been pressure tested to 150 PSI max without leakage Inlet has a minimum of 1/8”... -
Page 28: Trouble Shooting
TROUBLE SHOOTING - EcoTRAN CAUTION ! Always disconnect the pump from the electrical power source before handling. If the system fails to operate properly, carefully read instructions and perform maintenance recommendations. If operating problems persist, the following chart may be of assistance in identifying and correcting them: MATCH “CAUSE”... -
Page 29: Appendix 2: Pod Removal
Appendix 2: POD REMOVAL To remove the pod you need to Shut power OFF to station, Close the isolation valve at the street . Remove the level control and pump. Actuate the station ball valve with the red and green ball valve control harness so the valve is between open and closed. -
Page 31: Parts List
FHHS Screw 1/4-20 x 1.00” Lg 100159 Flexible Discharge Fitting 118259 Valve-Receiver Grommet 118245 Ball Valve 625-01558 O-Ring 118247 119069 EcoTRAN Tank Assembly 094270 Cord Grip 123049 30 Ft. Electrical Connection 12/5 DBC 123049A 50 Ft. 123049C 100 Ft 133886 Panel, Alarm/Auto with Gen. Recepticle... -
Page 32: Warranty Terms
Limited 24 Month Warranty Crane Pumps & Systems warrants that products of our manufacture will be free of defects in material and workmanship under normal use and service for twenty-four (24) months after manufacture date, when installed and maintained in accordance with our instructions.This warranty gives you speci• c legal rights, and there may also be other rights which vary from state to state. - Page 33 IMPORTANT! WARRANTY REGISTRATION Your product is covered by the enclosed Warranty. To complete the Warranty Registration Form go to: http://www.cranepumps.com/ProductRegistration/ If you have a claim under the provision of the warranty, contact your local Crane Pumps & Systems, Inc. Distributor. RETURNED GOODS RETURN OF MERCHANDISE REQUIRES A “RETURNED GOODS AUTHORIZATION”.
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Page 34: Start-Up Form (Mail In)
A Crane Co. Company START-UP REPORT General Information Pump Owner’s Name: __________________________________________________________ Address: ____________________________________________________________________ Location of Installation: _________________________________________________________ Contact Person: __________________________________Phone: _______________________ Purchased From: _____________________________________________________________ Nameplate Data Pump Model #: ___________________ Serial #: _____________________________________ Part #: __________________________ Impeller Diameter: ____________________________ Voltage: _________ Phase: _____ Ø... - Page 35 Submersible Pumps Resistance of cable and pump motor (measured at pump control): Red-Black:_______Ohms(•) Red-White:_______Ohms(•) White-Black:_______Ohms(•) Resistance of Ground Circuit between Control Panel and outside of pump: __________Ohms(•) MEG Ohms check of insulation: Red to Ground: _________ White to Ground: __________ Black to Ground: ____________ Operational Checks Is there noise or vibration present? YES___ NO___ Source of noise/vibration: ___________...
- Page 36 Notes...
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