This manual is to be used in addition to Reliance Manual B-3629-12 or
USEM Manual IN564-174A included with the pump and the Control
Panel drawing provided with the control panel.
Explosion Proof
Wastewater Pumps
Listed Class 1, Groups C and D Hazardous Locations
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
Lifting of Pump ..................................................................................................................................................................................3
Guide Rail System ..............................................................................................................................................................................3
Pump Control Panels and Wiring ......................................................................................................................................................4
Wiring and Grounding.......................................................................................................................................................................4
Selecting and Wiring Pump Control Panels and Switches ............................................................................................................. 4-5
Engineering Data ...............................................................................................................................................................................6
Three Phase Power Unbalance ...........................................................................................................................................................7
Pump Model Number:
Pump Serial Number:
Control Model Number:
Dealer:
Dealer Phone No.:
Date of Purchase: Installation:
Current Readings at Startup:
1Ø 3Ø L1-2 L2-3 L3-1
Amps: Amps:
Volts: Volts:
2
DANGER
WARNING
CAUTION
WARNING
WARNING
Hazardous voltage
can shock, burn or
cause death.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL
INJURY OR MAJOR PROPERTY DAMAGE, READ
AND FOLLOW ALL SAFETY INSTRUCTIONS IN
MANUAL AND ON PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE
INSTALLATION AND OPERATION OF THIS UNIT
AND MUST BE KEPT WITH THE PUMP.
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the pump or
in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.
Warns of hazards that WILL cause serious
personal injury, death or major property
damage.
Warns of hazards that CAN cause serious
personal injury, death or major property
damage.
Warns of hazards that CAN cause personal
injury or property damage.
NOTICE: INDICATES SPECIAL INSTRUCTIONS
WHICH ARE VERY IMPORTANT AND
MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND
WARNINGS PRIOR TO PERFORMING ANY WORK
ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
All electrical work must be performed by
a qualified technician. Always follow the
National Electrical Code (NEC), or the Canadian Electrical Code, as well as all local, state and provincial codes.
Code questions should be directed to your local electrical
inspector. Failure to follow electrical codes and OSHA
safety standards may result in personal injury or equipment damage. Failure to follow manufacturer’s installation
instructions may result in electrical shock, fire hazard,
personal injury or death, damaged equipment, provide
unsatisfactory performance and may void manufacturer’s
warranty.
Pumps are listed for use in water and sew-
age as Class 1, Groups C and D hazardous
locations. As defined by the NEC hand book, a Class 1
location is one in which flammable gases or vapors are or
may be present in quantities sufficient to produce explosive
or ignitable mixtures. See the NEC handbook for Groups C
and D definitions.
See specific pump and motor nameplates
for all agency Listings.
See motor nameplate for all electrical
ratings.
The user must provide an appropriate
motor starter (control panel) with ther-
mal (high temperature) protection, over
current protection and moisture detection circuits. The
over current protection must provide Class 10 quick trip
protection. Consult Motor Installation Manual as well
as the National Electric Code, Canadian Electric Code,
state, provincial and/or other local codes which may
apply.
This motor is rated for continuous duty
when fully submerged in liquid and
15-minute duty in air when operated at nameplate HP.
Do not exceed 15 minutes in air duty rating. Consult
motor manual for further information.
PRE-INSTALLATION CHECKS
PRE-INSTALLATION CHECKS
Open all cartons and inspect for shipping damage. Report
any damage to your supplier or shipping carrier immediately.
Verify that all equipment is the correct voltage and phase.
Warranty does not cover damage caused by connecting
pumps and controls to an incorrect power source (voltage/phase supply).
Record the model numbers and serial numbers from the
pumps and control panel on the front of this instruction
manual for future reference. Give it to the owner or affix
it to the control panel when finished with the installation.
LIFTING OF PUMP
LIFTING OF PUMP
DO NOT LIFT, CARRY OR HANG
PUMP BY THE ELECTRICAL
CABLES. DAMAGE TO THE
ELECTRICAL CABLES CAN CAUSE
SHOCK, BURNS OR DEATH.
Lift the pump with an adequately sized chain or cable attached to the lifting lugs on the motor. DO NOT damage
electrical and sensor cables while raising and lowering unit.
GUIDE RAIL SYSTEM
GUIDE RAIL SYSTEM
Hazardous Class 1 environments require
non-sparking guide rail or disconnect equipment. Mating parts constructed of brass or stainless steel will
prevent sparks during equipment installation and removal.
We offer the A10-30B, A10-40B and A10-60B cast iron and
brass guide rail assemblies for use in these locations.
Typical wastewater collection systems are possibly
dangerous environments due to gases collected in the
wet well. Most codes do not allow personnel to enter a
wetwell without the correct protective equipment and
training. Guide rail systems are designed to allow easy
removal of the pump without the need for entry into the
wetwell or need to disturb piping.
An optional guide rail system facilitates pump installation
and removal for inspection and maintenance. Guide rails
eliminate this safety concern. They save time as there is
no need to disturb piping to pull a pump for service.
NOTICE: FOLLOW THE INSTALLATION
INSTRUCTIONS THAT ARE SUPPLIED
WITH THE GUIDE RAIL SYSTEM.
Installation of the guide rail should locate the pump
opposite the influent opening preventing stagnate areas
where solids can settle.
The pit floor must be flat under the guide rail base and
have sufficient loading capacity to support the entire
weight of the guide rail, discharge piping and the pump.
See Typical Installations Drawings.
3
WARNING
Hazardous
voltage
WARNING
WARNING
DANGER
DANGER
WARNING
WARNING
WARNING
PIPING
PIPING
Discharge piping should be no smaller than the pump
discharge diameter and kept as short as possible, avoiding
unnecessary fittings to minimize friction losses.
Install an adequately sized check valve matched to the solids
handling capability of the pump to prevent fluid backflow.
Backflow can allow the pump to “turbine” backwards and
may cause premature seal and/or bearing wear. If the pump is
turning backwards when it is called on to start the increased
torque may cause damage to the pump motor and/or motor
shaft and some single-phase pumps may actually run backwards.
Install an adequately sized gate valve AFTER the check valve
for 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 within
the wetwell, 2” (51mm) above the pump discharge but below
the check valve. The relief hole allows any air to escape from
the casing. Allowing liquid into the casing will insure that the
pump can start when the liquid level rises. Unless a relief hole
is provided, a bottom intake pump could “air lock” and will
not pump water even though the impeller turns.
All piping must be adequately supported, so as not to impart
any piping strain or loads on the pump.
The pit access cover must be of sufficient size to allow for
inspection, maintenance and crane or hoist service.
PUMP CONTROL PANELS AND WIRING
PUMP CONTROL PANELS AND WIRING
Mandatory Control Panel Features: Due to
the Hazardous environment and the Class
1 Listing on the equipment, the pumps and float switches
require special circuitry in the control panel for safe, reliable
operation and to comply with code. The following panel options are required to insure the warranty and Agency Listing
are maintained.
Intrinsically Safe Relays: Class 1 explosion
proof pumps are normally used in areas where
there is a danger created due to potentially explosive gases or
fluids. It is important that all electrical devices in the Class 1
wetwell are safe in that environment. If using float switches
you must use “intrinsically safe relays” to power the control
float switches. These relays operate on very low voltage and
amperage to eliminate the danger of a spark in the wetwell
in the event a power cord becomes damaged or severed.
Intrinsically Safe Relays are available as a panel option from
most panel suppliers. The intrinsically safe sensor wiring must
be separated from other input wiring in separate conduits or
raceways. Other level control systems are available on the
market and may be applicable for this type environment,
consult with your control manufacturer for specific data.
Moisture Detection System: The pumps
require a moisture detection circuit, also
referred to as a “Seal Fail Circuit”, built into the control panel
for proper operation and to maintain the Class 1 Listing. The
circuit in the control panel connects to the motor’s moisture
sensing probes, control leads W1 and W2, and signals a failure of the outer seal. Compatible CentriPro™, ITT Industries
Inc. controls are available through your authorized pump
distributor and from Charles Warrick Co. in Royal Oak, MI.
Failure to provide a seal failure circuit for the moisture sensing probes will void the warranty and the agency listing. See
“Moisture Detection System” in the Motor Manual included
with the pump.
4
Thermal (High Temperature) Protection System: The pumps contain a built-in “Thermal
Protection System” which must be connected in series with
the holding coil of the magnetic starter in the control panel.
Control leads P1and P2 are used for this connection. Failure
to properly connect or utilize this system voids the motor
warranty and the agency listing. See “Thermal Protection
System” in the Motor Manual included with the pump.
Overload (Over Current) Protection: Class
10, quick-trip, overload protection must
be provided in both three phase and single phase controls.
The overload protection is to protect against over current
as opposed to the over temperature protection provided by
the Thermal Protection Circuit. The overload protection
may be accomplished by using Class 10 adjustable solid state
overloads, as used on the Furnas Class 14, ESP100 starter or
bimetal ambient compensated “heater” overloads.
WIRING AND GROUNDING
WIRING AND GROUNDING
Important notice: Read Safety Instructions before proceeding with any wiring.
Use only stranded copper wire to pump/motor and
ground. The ground wire must be at least as large as the
power supply wires. Wires should be color coded for
ease of maintenance and troubleshooting.
Install wire and ground according to the National Electrical Code (NEC), or the Canadian Electrical Code, as
well as all local, state and provincial codes.
Install an all leg disconnect switch where required by
code.
Disconnect and lockout electrical power before performing any service or installation.
The electrical supply voltage and phase must match all
equipment requirements. Incorrect voltage or phase can
cause fire, motor and control damage, and voids the
warranty. See motor nameplate for all electric ratings.
All splices must be waterproof. If using splice kits follow
manufacturer’s instructions.
Select the correct type and NEMA
grade junction box for the application
and location. The junction box must insure dry, 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
SELECTING AND WIRING
PUMP CONTROL PANELS AND SWITCHES
PUMP CONTROL PANELS AND SWITCHES
MATCH EQUIPMENT TO POWER SUPPLY:
Important: Always match the pump nameplate Amps,
Voltage, Phase and HP ratings to your control panel and
power supply. Any problem or questions pertaining to
another brand control must be referred to that control
supplier or manufacturer. Our technical people have no
technical schematics or trouble shooting information for
other companies' controls.
PANEL WIRING DIAGRAMS:
Control panels are shipped with instructions and wiring
diagrams. Use those instructions in conjunction with this
IOM. Electrical installation should be performed only by
qualified technicians.
ALARMS:
We recommend the installation of an alarm on all Wastewater pump installations. Many standard control panels
come equipped with alarm circuits. If a control panel is
not used, a stand alone high liquid level alarm is available. The alarm alerts the owner of a high liquid level in
the system so they can contact the appropriate service
personnel to investigate the situation.
OPTIONAL PANEL FEATURES:
Guaranteed Pump Submergence Float: Many engineers
specify a redundant OFF float, also referred to as a Guaranteed Pump Submergence Circuit. This provides a second OFF float as protection from “OFF” float failure or
hang up which protects the pump(s) from running dry.
FLOAT SWITCHES
FLOAT SWITCHES
We recommend using a narrow angle hermetically sealed
mercury float switch such as Model Number A2K23(W)
or an equivalent in Class 1 hazardous environments. The
A2K23(W) can be ordered with longer cords by changing the 4th digit in the number, all lengths are acceptable.
They are designed for use with Intrinsically Safe Relays.
OFF Float: Should be set at or above the top of the
pump/motor dome. This will insure that the motor is
properly cooled and provide the best overall pump life.
The pump should be fully submerged when running. The
outer (lower) shaft seal must be in liquid when motor is
operated, whether motor is submerged or in air. Seal life
will be affected if run dry. Exception: it is allowable to
bump or jog the motor for a few seconds to check impeller rotation! See Motor Manual under Application.
Guaranteed Pump Submergence Float: When used this
should be the lowest float. Set a few inches below the
other OFF Float.
ON Float(s): Should be set far enough above the highest
OFF Float to allow the pump(s) to run for a 2 minute
cycle.
Alarm Float: Set above the ON float(s) and below the
basin inlet.
See Float Switch and Panel Chart.
INSTALLATION
INSTALLATION
Connect the pump(s) to the guide rail pump adapters or
to the discharge piping.
Guide rail bases should be anchored to the wetwell floor.
Complete all wiring per the Motor Manual, Control
Panel wiring diagrams and NEC, Canadian, state,
provincial and/or local codes.
This a good time to check for proper rotation of the
motors/impellers.
CHECK ROTATION
CHECK ROTATION
Always verify correct rotation. Correct rotation is indicated on the pump casing. Both three phase and single
phase motors in this series are reversible. It is allowable to
bump or jog the motor for a few seconds to check impeller
rotation. It is easier to check rotation before installing the
pump.
See the Motor Manual for Instructions to Change Rotation.
Lower the pump(s) into the wetwell.
Check to insure that the floats will operate freely and not
contact the piping.
NOTICE: DO NOT SWITCH PRIMARY POWER
LEADS COMING INTO ANY THREE
PHASE PANEL, THIS WILL REVERSE ROTATION ON ALL THREE PHASE MOTORS
CONNECTED TO THE PANEL.
NOTICE: MOTOR STARTUP TORQUE, "KICKBACK",
!
DANGER
Hazardous Machinery
OPERATION
OPERATION
Fill the wetwell with clear water.
Place Control Panel switch(es) in Automatic position and
thoroughly test the operation of the ON, OFF, Alarm
and, where used, the Guaranteed Pump Submergence
Floats. Important: Failure to provide a Neutral from the
power supply to a 1Ø Control Panel will not allow the
panel control circuit to operate. The Neutral is necessary
to complete the 115 volt control circuit.
Check voltage and amperage and record data on the
front of this manual for future reference. Compare the
amperage readings to the pump nameplate maximum
amperage. If higher than nameplate amperage investigate
cause. Operating the pump off the curve, i.e. with too
little head or with high or low voltage will increase amperage. The motor will operate with frequency not more
than 5% and voltage not more than 10% above or below
pump nameplate data. Performance within this range will
not necessarily be the same as the published performance
at the exact rated nameplate frequency and voltage.
Correct the problem before proceeding. Three phase unbalance is also a possible cause. See the Section on Three
Phase Power Unbalance and follow the instructions listed.
Reset the Alarm circuit, place pump switch(es) in the Automatic position and Control Switch in ON position. The
system is now ready for automatic operation.
Explain the operation of the pumps, controls and alarms
to the end user. Leave the paperwork with the owner or
at the control panel if in a dry, secure location.
WILL CAUSE THE MOTOR TO TWIST
IN THE DIRECTION OPPOSITE ROTATION. INSURE THAT THE PUMP
ASSEMBLY IS ADEQUATELY RESTRAINED.
DO NOT PLACE HANDS IN PUMP
SUCTION WHILE CHECKING
MOTOR ROTATION. TO DO SO
WILL CAUSE SEVERE PERSONAL
INJURY.
5
Inlet
Alarm SW3
Pump On SW2
Pump Off SW1
Discharge
Optional
Guaranteed
Submergence
Float
Inlet
Alarm SW4
Lag Pump On
SW3
Pump Off
SW1
Discharge
Lead Pump On
SW2
Optional
Guaranteed
Submergence
Float
6" (15.3 cm)
6" (15.3 cm)
8" (20.3 cm) TURN ON LEVEL
WEIGHT
TYPICAL FLOAT SWITCH PLACEMENT
TYPICAL FLOAT SWITCH PLACEMENT
The charts show the required switch quantities and the
function of each in a typical system.
Simplex System:
Three (3) floats are for: Pump OFF, Pump ON, Alarm
ON/OFF.
Four (4) floats are for: Guaranteed Pump Submergence
or 2nd Pump OFF, Pump OFF, Pump ON, Alarm ON/
OFF.
Duplex System:
Four (4) floats are for: Pumps OFF, Lead Pump ON, Lag
Pump ON, Alarm ON.
Five (5) floats are for: Guaranteed Pump Submergence
or 2nd Pump(s) OFF, Pump(s) OFF, Lead Pump ON, Lag
Pump On, Alarm ON.
The OFF float(s) is the lowest float and the Alarm will
always be the uppermost float.
ENGINEERING DATA
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 this instruction
manual to complete the wiring.
Continuous
Duty
Single-Action Float Switch
6
SimplexDuplex
Minimum Submergence
Fully Submerged
"Typical" Installation
PUMP OPERATION
Continuous
Operation
Maximum Fluid Temperature
104º F 40º C
THREE PHASE POWER UNBALANCE
THREE PHASE POWER UNBALANCE
A full three phase supply consisting of three individual
transformers or one three phase transformer is recommended. “Open” delta or wye connections using only
two transformers can be used, but are more likely to
cause poor performance, overload tripping or early motor failure due to current unbalance.
Check the current in each of the three motor leads and
calculate the current unbalance as explained below.
If the current unbalance is 2% or less, leave the leads as
connected.
If the current unbalance is more than 2%, current readings should be checked on each leg using each of the
three possible hook-ups. Roll the motor leads across the
starter 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 average
current (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
result by 100 to determine percent of unbalance.
Current unbalance should not exceed 5% at service
factor load or 10% at rated input load. If the unbalance
cannot be corrected by rolling leads, the source of the
unbalance must be located and corrected. If, on the three
possible hookups, the leg farthest from the average stays
on the same power lead, most of the unbalance is coming
from the power source.
Contact your local power company to resolve the imbalance.
Normal Ohm and Megohm Values between all leads and ground
Condition of Motor and Leads Ohm Value Megohm Value
A new motor (without drop cable). 20,000,000 (or more) 20 (or more)
A used motor which can be reinstalled in well. 10,000,000 (or more) 10 (or more)
Motor in well. Readings are for drop cable plus motor.
New motor. 2,000,000 (or more) 2 (or more)
Motor in good condition. 500,000 - 2,000,000 .5 - 2
Insulation damage, locate and repair. Less than 500,000 Less than .5
Insulation resistance varies very little with rating. Motors of all HP, voltage and phase ratings have similar values
of 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.
7
TROUBLESHOOTING
WARNING
Hazardous
voltage
TROUBLESHOOTING
FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL
POWER BEFORE ATTEMPTING ANY SERVICE CAN CAUSE
SHOCK, BURNS OR DEATH.
SYMPTOM PROBABLE CAUSE RECOMMENDED ACTION
MOTOR NOT RUNNING Motor thermal protector tripped. Allow motor to cool. Insure minimum pump submergence. Clear debris from casing and impeller.
NOTE: If circuit breaker
“OPENS” repeatedly,
Open circuit breaker or blown fuse. Determine cause, call a qualified electrician.
DO NOT reset. Call
Pump impeller binding or jammed. Check motor amp draw. If two or more times higher
qualified electrician.
than listed on pump nameplate, impeller is locked,
a) Manual operation Power cable is damaged. motor bearings or shaft is damaged. Clear debris
Inadequate electrical connection
in control panel.
Resistance between power leads and ground should
b) Automatic operation No neutral wire read infinity. If any reading is incorrect, call a connected to control panel. qualified electrician.
Inadequate electrical connection Inspect control panel wiring. Call a qualified in control panel. electrician.
Defective liquid level switch. With switch disconnected, check continuity while
NOTE: Check the pump
activating liquid level switch. Replace switch, as
in manual mode first to
required.
confirm operation. If
pump operates, the auto-
Insufficient liquid level to Allow liquid level to rise 3" to 4" (76 mm - 101 mm)
matic control or wiring is
activate controls. above turn-on level.
at fault. If pump does not
Liquid level cords tangled. Untangle cords and insure free operation.
operate, see above.
PUMP WILL NOT Liquid level cords tangled. Untangle cords and insure free operation.
TURN OFF
Pump is air locked. Shut off pump for approximately one minute, then restart. 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 approximately
2" (51 mm) above the discharge connection.
from casing and impeller, consult with dealer.
Influent flow is matching pump’s Larger pump may be required. discharge capacity.
LITTLE OR NO LIQUID Check valve installed backwards, Check flow arrow on valve and check valve
DELIVERED BY PUMP plugged or stuck closed. operation.
Excessive system head. Consult with dealer.
Pump inlet plugged. Inspect and clear as required.
Improper voltage or wired Check pump rotation, voltage and wiring.
incorrectly. Consult with qualified electrician.
Pump is air locked. See recommended action, above.
Impeller is worn or damaged. Inspect impeller, replace as required.
Liquid level controls defective Inspect, readjust or replace as required.
or improperly positioned.
PUMP CYCLES Discharge check valve inoperative. Inspect, repair or replace as required.
CONSTANTLY
Liquid level controls defective or Inspect, readjust or replace as required. improperly positioned.
Influent excessive for this size Consult with dealer.
pump.
Sewage containment area too small. Consult with dealer.
8
TYPICAL INSTALLATIONS
TYPICAL INSTALLATIONS
Typical Effluent, Sewage and
Dewatering Pump Installations
9
BELL & GOSSETT LIMITED WARRANTY
This warranty applies to all water systems pumps manufactured by Bell & Gossett.
Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The warranty period shall exist for a
period of twelve (12) months from date of installation or eighteen (18) months from date of manufacture, whichever period is shorter.
A dealer who believes that a warranty claim exists must contact the authorized Bell & Gossett distributor from whom the pump was purchased and furnish complete details
regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the Bell & Gossett Customer Service Department.
The warranty excludes:
(a) Labor, transportation and related costs incurred by the dealer;
(b) Reinstallation costs of repaired equipment;
(c) Reinstallation costs of replacement equipment;
(d) Consequential damages of any kind; and,
(e) Reimbursement for loss caused by interruption of service.
For purposes of this warranty, the following terms have these definitions:
(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between Bell & Gossett and the dealer in purchases,
consignments or contracts for sale of the subject pumps.
(2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing pumps to customers.
(3) “Customer” means any entity who buys or leases the subject pumps from a dealer. The “customer” may mean an individual, partnership, corporation, limited liability
company, association or other legal entity which may engage in any type of business.
THIS WARRANTY EXTENDS TO THE DEALER ONLY.
Xylem, Inc.
2881 East Bayard Street Ext., Suite A
Seneca Falls, NY 13148
Phone: (866) 325-4210
Fax: (888) 322-5877
www.xyleminc.com/brands/bellgossett
Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries.