INSTALLATION MANUAL UltraGRIND Package Systems with Pressure Switches

INSTALLATION MANUAL UltraGRIND Package Systems with Pressure Switches Underwriters Laboratories Inc File No. E151564 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, Inc., reserves the right to change product without prior written notification. A Crane Co. Company PUMPS & SYSTEMS 420 Third Street/P.O. Box 603 83 West Drive, Brampton Piqua, Ohio 45356-0603 Ontario, Canada L6T 2J6 Phone: (937) 778-8947 Phone: (905) 457-6223 Fax: (937) 773-7157 Fax: (905) 457-2650 www.cranepumps.com Form No. 089027-Rev. C

TABLE OF CONTENTS USER GUIDE...3 SAFETY FIRST...4 A. GENERAL INFORMATION (Receiving, Storage, Service Centers, Unpacking, Location)...5 B. INSTALLATION (Bedding, Gravel Specifications, Placing into Hole) (Fig. 1, 2 & 3)...5-6 (Locating and Installing Inlet) (Fig. 4, 5)...6 (Discharge) (Fig. 6)...6-7 (Incoming Cable Location) (Fig. 7 & 8)...7 (Backfilling) (Fig. 9)...8 (Pump Installation) (Fig. 10 & 11)...8 (Control/Junction Box Connections) (Fig. 12)...8-9 C. REPLACEMENT PARTS...9 CONTROL/JUNCTION BOX WIRING FOR PRESSURE SWITCHES: Simplex with Temp (Fig. 13)...10 Simplex with Moist/Temp (Fig. 14)...11 Duplex with Temp (Fig. 15)...12 Duplex with Moist/Temp (Fig.16)...13 EXPLODED VIEW - SIMPLEX w/pressure SWITCHES...14 PARTS LIST...15 EXPLODED VIEW - DUPLEX w/pressure SWITCHES...16 PARTS LIST...17 CROSS SECTION - SIMPLEX CONTROL BOX...18 CROSS SECTION - DUPLEX CONTROL BOX...19 DIRECT BURIAL CABLE REQUIREMENTS...20 BASIN VOLUME CHART...21 BASIN BALLAST REQUIREMENTS...22 RETURNED GOODS POLICY...24 WARRANTY Other brand and product names are trademarks or registered trademarks of their respective holders. UltraGRIND is a trademark of Barnes Pumps, Inc. Barnes is a registered trademark of Barnes Pumps, Inc. Barnes Pumps, Inc. 1994, 1997, 2002 Alteration Rights Reserved. Printed in U.S.A. 2

USER GUIDE Congratulations on your purchase of a Barnes UltraGRIND grinder pump system. With proper care and by following a few simple guidelines your grinder pump will give you many years of dependable service. Use and Care The UltraGRIND grinder pump station is designed to handle routine, domestic sewage. Solid waste materials should be thrown in the trash. While your station is capable of accepting and pumping a wide range of materials, regulatory agencies advise that the following items should not be introduced into any sewer either directly or through a kitchen waste disposal: Glass Metal Diapers Socks, rags or cloth Plastic objects (e.g., toys, utensils, etc.) Sanitary napkins or tampons In addition you must NEVER introduce into any sewer: Explosives Flammable Material Lubricating Oil and/or Grease Strong Chemicals Gasoline General Information Your home wastewater disposal service is part of a low pressure sewer system. The key element in this system is the Barnes UltraGRIND grinder pump station. The basin collects all wastewater from the house. The solids in the sewage are then ground to a small size suitable for pumping in the slurry. The grinder pump generates sufficient pressure to pump this slurry from your home to the wastewater plant. Power Failure Your grinder pump cannot dispose of wastewater or provide an alarm signal without electrical power. If electrical power service is interrupted, keep water usage to a minimum. Warranty Your grinder pump is furnished with a warranty against defects in material or workmanship. A properly completed Start Up/Warranty Registration form must be on file at the Barnes factory in order to activate your warranty. In addition your pump must be installed in accordance with the installation instructions. If you have a claim under the provisions of the warranty, contact your local Barnes Pumps, Inc. Distributor. When contacting your representative for service, please include your station serial number, pump model number, and pump serial number. For future reference, record the following information: Station Serial No: Pump Model No: Pump Serial No: Local Distributor: Distributor Telephone: 3

SAFETY FIRST! PLEASE READ THIS BEFORE INSTALLING OR OPERATING PUMP. GENERAL 1. Most accidents can be avoided by using COMMON SENSE. 2. Read this operation and maintenance instruction manual. 3. Do not wear loose clothing that may become entangled in the impeller or other moving parts. 4. Always wear appropriate safety gear, such as safety glasses, when working on the pump or piping. 5. Bronze/brass and bronze/brass fi tted pumps may contain lead levels higher than considered safe for potable water systems. Various government agencies have determined that leaded copper alloys should not be used in potable water applications. For nonleaded copper alloy materials of construction, please contact factory. 6. Minimize the amount of cooking grease entering the system. 7. Do Not leave pump cover off the basin, except while servicing, to prevent entrance of foreign materials such as rocks, metal, soil, animals or humans. 8. Prevent large articles of clothing, large amounts of chemicals, other materials or substances such as are uncommon in domestic sewage from entering the system. 9. During power black-outs, discontinue water consumption at the home(s) to prevent sewage from backing up into the house. 10. Prevent infi ltration or direct fl ow of rain or run-off water into the pump basin to minimize pump cycling. This will prevent overloading the treatment facility, and will facilitate swift transportation of sewage. 11. Always keep the shut-off valve completely open when system is in operation (unless advised otherwise by the proper authorities). 12. Keep the control panel locked or confi ned to prevent unauthorized access to it. 13. If the pump is idle for long periods of time, it is advisable to start the pump occasionally by adding water to the basin. 14. Before removing the pump from the basin, be sure to close the shut-off valve. (This prevents back fl ow from the pressure sewer.) 15. Make sure level controls are provided at time of installation. 16. This basin system is intended for use with water, sewage and effl uent applications. This basin must be vented in accordance with local codes. This basin system is not to be installed in locations in which the basin interior would be classifi ed as a hazardous location in accordance with NEC ANSI/NPFA 70. PUMPS 17. Recommended no more than 10 starts per hour. 18. Pumps build up heat and pressure during operation-allow time for pumps to cool before handling or servicing. 19. Only qualifi ed personnel should install, operate and repair pump. 20. Keep clear of suction and discharge openings. DO NOT insert fi ngers in pump with power connected. 21. Do not pump hazardous materials (flammable, caustic, etc.) unless the pump is specifically designed and designated to handle them. 22. Do not block or restrict discharge hose, as discharge hose may whip under pressure. 23. Make sure lifting handles are securely fastened each time before lifting. 24. Do not lift pump by the power cord. 25. Do not exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat. 26. Secure the pump in its operating position so it can not tip over, fall or slide. 27. Keep hands and feet away from impeller when power is connected. 28. Submersible Pumps are not approved for use in swimming pools, recreational water installations, decorative fountains or any installation where human contact with the pumped fl uid is common. 29. Do not operate pump without safety devices in place. 30. Always replace safety devices that have been removed during service or repair. ELECTRICAL 31. To reduce risk of electrical shock, pump must be properly grounded in accordance with the National Electric Code (NEC) and all applicable state and local codes and ordinances. 32. To reduce risk of electrical shock, always disconnect the pump from the power source before handling or servicing. Lock out power and tag. 33. Any wiring of pumps should be performed by a qualifi ed electrician. 34. Never operate a pump with a power cord that has frayed or brittle insulation. 35. Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently. 36. Never handle connected power cords with wet hands. 37. Do not remove cord and strain relief. Do not connect conduit to pump. 38. To reduce risk of electrical shock, all wiring and junction connections should be made per the NEC and applicable state and local codes. Requirements may vary depending on usage and location. See wiring diagrams in manual. 39. Do Not operate the pump in the HAND control position and leave the pump unattended. 40. CAUTION - This unit may have more than one connection to the source of supply. To reduce the risk of electric shock, disconnect all such connections before servicing. 41. All connections inside this tank and/or junction box must be made with listed watertight connectors. IMPORTANT! BARNES PUMPS, INC. IS NOT RESPONSIBLE FOR LOSSES, INJURY, OR DEATH RESULTING FROM A FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS, MISUSE OR ABUSE OF PUMPS OR EQUIPMENT. 4

SECTION A: GENERAL INFORMATION A-1) RECEIVING: Upon receiving the Basin Package System, it should be inspected for damage or shortages. If damage has occurred, file a claim immediately with the company that delivered the basin package. A-2) STORAGE: If Basin Packages are going to be stored make sure all outside openings are sealed, i.e. discharge coupling, electrical coupling (if equipped) etc., also secure access door or basin cover. A-3) SERVICE CENTERS: For the location of the nearest Barnes Pumps Service Center, check your catalog, your Barnes Pumps, Inc. representative or Barnes Pumps, Inc. Service Department in Piqua, Ohio, telephone (937) 778-8947. A-4) UNPACKING: Before installing Basin Package remove the tape from all outside openings, discharge coupling, etc. Remove basin cover on simplex or open access door on duplex units being careful not to damage gasket, to unpackage anything that was secured for shipment. A-5) LOCATION: This basin system is intended for use with water and sewage applications. The standard basin is vented, any alterations from the standard must be in accordance with local codes. This basin system is not to be installed in locations in which the basin interior would be classified as a HAZARDOUS location in accordance with NEC ANSI/NFPA 70. GRAVEL SPECIFICATION: 1. A naturally rounded aggregate is required, clean and free flowing with particle size not less than 1/8" or more than 3/4" in diameter. Use this description when specifying or ordering because material is known by different names in different areas. This material is commonly called "pea gravel". 2. Stone or gravel crushing with angular particle size not less than 1/8" or more than 1/2" diameter washed and free flowing is acceptable as an alternate material. This material must meet ASTM C-33 paragraph 9.1 requirements for quality and soundness. B-2) PLACING STATION INTO HOLE: Lifting the basin system, into place should be done with a cloth or nylon type strap around basin or by a lifting harness connected to eyebolts that are set into the concrete pad that is connected to basin by anchor bolts. Never use chain or cable type lifting device around outer basin. This can and may create a fracture in the fiberglass. See Figures 2 and 3. Figure 2 SECTION B: INSTALLATION B-1) BEDDING: Prepare the hole to the proper depth. Add and level bedding of select aggregate (pea gravel-see Gravel Specifications) of 4 to 6 inches or concrete pad or a concrete donut shall be laid before basin is lowered into the ground. The aggregate must conform to the bottom of the basin and reach a compaction of 85% Standard Proctor Density. See Figure 1. Figure 1 Lower the basin, centering it into the hole and orienting it to allow for proper inlet installation. A minimum clearance of 4 to 6 inches should be maintained between the tank wall and the surrounding earth. ALL OSHA PROCEDURES SHOULD BE FOLLOWED REGARDING INSTALLATION OF BASIN. The basin must be leveled after placement to within 1/2 bubble. To prevent the basin from floating upward when the ground water is high, a weight of 63 pounds per cubic foot of basin volume must anchor the basin in place (see "BALLAST REQUIREMENTS" on page 22). This can be done by fastening the ballast support flange to a concrete pad or donut, or by adding the equivalent amount of gravel and/or concrete to the surrounding basin area (surrounding the 2" flange). 5

NOTE: Schedule 40 and SDR35 pipe require different sizes of flexible pipe fittings. Check to be sure the inlet pipe matches the flexible pipe fitting supplied. Figure 3 To install the inlet pipe into the flexible pipe fitting, chamfer the end and lube the pipe with soapy water for ease of installation, see Figure 4. An OPTIONAL adapter or caulking hub may be used in place of the flexible pipe fitting. B-3) LOCATING & INSTALLING INLET: B-3.1) FLEXIBLE PIPE FITTING INLET: The flexible pipe fitting for the inlet must be installed. 1. Find the location where the center of the coupling will be positioned on basin. See Fig. 5 for recommended location. 2. Using a HOLE SAW, cut the hole in the basin (DO NOT use a Saber Saw). Refer to the chart below for hole size. 3. Install flexible pipe fitting in the opening. See Figure 4. Figure 5 24" - 30" DIA Simplex Basin 36" And Larger Simplex And All Duplex Basins FIGURE 5 Angle "A" Should Be Between 30-60 Angle "B" Should Be 45 Maximum. FLEXIBLE PIPE FITTING SIZE 1-1/4 1-1/2 2 Figure 4 HOLE SIZE COLOR CODE 3" Black -40 Black/Red-40 Black/Blue-40 3 4" White-40 4 5" Grey-40, Maroon-35 6 7" Black-40, Yellow-35 B-3.2) Discharge: Connect the sanitary main to the NPT discharge connection located on the outside of the basin (See Figure 6). It is recommended that a shut-off valve, and a redundant check valve be located at the property line near the sanitary main (by others). A flexible pipe coupling should also be installed at the basin. The check valve should be of a flap style able to operate in a horizontal position. It is recommended that in cold regions the piping above the frost grade be insulated. Consult factory for severely cold climates. 6

CONTROL/JUNCTION BOX CABLE GRIPS BASIN WALL 6"- 8" Approx. DRIP LOOP Figure 7 CABLE GRIPS DIRECT BURIAL CABLE B-3.3) Control Panel: Next locate and mount electrical control panel, and run wire to the basin package (see Control Panel Manual). CAUTION! ALL MODEL PUMPS AND CONTROL PANELS MUST BE PROPERLY CONNECTED AND PROPERLY GROUNDED PER THE NATIONAL ELECTRICAL CODE, STATE, AND LOCAL CODES. IMPROPER GROUNDING VOIDS WARRANTY. NOTE: A proper motor controller must be provided that is compatible with the pump(s) being installed. (Motor Controller is part of control panel when factory supplied.) B-4) INCOMING CABLE LOCATION: Figure 6 B-4.1) Direct Burial Cable with Cable Grips: Backfill and compact to a convenient level to work around top of basin. Locate and drill holes (see page 20 for hole sizes) for the direct burial cable grips in the basin wall. Holes should be located 18 inches below grade. Feed the direct burial cable through the cable grips and into the junction box and tighten the grips on the box and the basin. It is important to leave enough cable slack between the junction box and basin wall to form a drip loop (see Figure 7). B-4.2) Direct Burial Cable with Conduit Coupling: Backfill and compact to a convenient level to work around top of basin. To install an OPTIONAL conduit coupling (see Figure 8). 1. Find the location where the center of the coupling will be positioned on basin. 2. Using a HOLE SAW, cut the hole in the basin to the outside diameter of the coupling being installed. 3. Place coupling on basin wall and drill mounting holes in basin. 4. Apply gasket or sealing caulk to back of coupling, and mount coupling on basin. 5. Insert bolts, washers and nuts through basin wall and coupling, and tighten. OPTIONAL Conduit Hub Installation: JUNCTION BOX BASIN WALL CABLE GRIPS 6"- 8" Approx. DRIP LOOP Figure 8 DIRECT BURIAL CABLE CONDUIT COUPLING After coupling has been installed, run the direct burial cable through the coupling and into the junction box and tighten the grips on the box. It is important to leave enough cable slack between the junction box and basin wall to form a drip loop (see Figure 8). 7

Rope or Chain Figure 10 Figure 9 B-5) Backfill: Finish backfill and compaction (see Figure 9). Place at least 4 inches and preferably 6 inches of aggregate in layers around the entire periphery of the basin in the ground, being careful not to damage or loosen any connections. CAUTION! NOTE: A hoist or crane may be used in lowering and removing the pump. Center the pump under the hook so that the pump can be lifted straight up. Lifting a pump that is not centered will create side pulls which may strain the crane and/or cause the pump to bind in the guide rail. Follow all general precautions in the crane s manual when installing and operating the crane. See Figure 11. IN FREEZING CONDITIONS BACKFILL MUST BE DRY AND FREE OF ICE. DO NOT use backfill materials other than those specified above. In areas where specified materials are not available contact Barnes Pumps, Inc. for information on approved alternate materials. The basin warranty is automatically voided if other than approved bed and backfill materials are employed without advance written approval. B-6) PUMP INSTALLATION: First attach lifting rope or chain to the pump (see Figure 10). Remove basin cover or open access door. Record Pump Model, Part and Serial numbers in Start-Up manual and on User Guide. Rotate pump impeller by hand and then lower pump and movable assembly, utilizing the lifting chain or rope, down the rail slowly (DO NOT DROP!) Observe OSHA recommendations when installing and removing pump. CAUTION! RISK OF ELECTRICAL SHOCK. DO NOT LOWER PUMP BY THE POWER CORD. Figure 11 B-6) CONTROL/JUNCTION BOX CONNECTIONS: IMPORTANT! CHECK TO BE CERTAIN THAT ALL POWER IS OFF. IMPORTANT! ALL CONNECTIONS INSIDE THIS TANK AND/OR JUNCTION BOX MUST BE MADE WITH "UL" LISTED WATER TIGHT CONNECTORS. 8

CAUTION! THIS UNIT MAY HAVE MORE THAN ONE CONNECTION TO THE SOURCE OF SUPPLY. TO REDUCE THE RISK OF ELECTRIC SHOCK, DISCONNECT ALL SUCH CONNECTIONS BEFORE SERVICING. Wire Size: Consult a qualified electrician for proper wire size. See Pump Manual for electrical information. Remove junction box cover to connect pump, sensor and control cords to incoming direct burial cables. Refer to Figures 13 through 16. Direct Burial Cable: Due to the availability of multi conductor direct burial cables, several options have been left to the installer (see "DIRECT BURIAL CABLE REQUIREMENTS" on page 20). For OPTIONAL conduit from the basin to the motor controller, it is recommended that a packing material such as a sprayable urethane foam be used in the conduit line, placed around the wires, at the conduit coupling to help prevent gases from entering the motor controller. Packing is recommended for ALL entries into the motor control panel. It is very important to keep the conduit line dry and free from moisture during this process. Reactivation: 1. Turn the control panel breaker to the "ON" position. 2. Test the pump by running manually for 5 to 10 seconds. SECTION: C REPLACEMENT PARTS C-1 ORDERING REPLACEMENT PARTS: When ordering replacement parts, ALWAYS furnish the following information: 1. Serial number and date code. (C-4) 2. Model number. (C-3) 3. Part number. (C-2) 4. Part description. 5. Item part number. 6. Quantity required. 7. Shipping instructions. 8. Billing instructions. 2 1 3 Figure 12 B-7) WINTERIZATION: 1. Remove the basin cover. 2. Manually pump the station fluid level down to the normal "OFF" level. Do not pump below the suction entrance of the pump. 3. Add fresh fluid until pump automatically turns "ON". Repeat until most of the sewage has been pumped out. 4. With the fluid level in the basin at the normal "OFF" position, add an equal amount of propylene glycol (non-toxic) to the basin. Mix by closing discharge valve and allow pump to run for one (1) minute. 5. Run the pump for 5 to 10 seconds to add winterized fluid to the discharge lines. 6. Reinstall the basin cover. 7. Turn the control panel breaker to the "OFF" position. C-2 PART NUMBER: The part number consists of a six (6) digit number, which appears in the catalog. A one or two letter suffix may follow this number to designate the design configuration. This number is used for ordering and obtaining information. C-3 MODEL NUMBER: This designation consists of numbers and letters which represent the diameter, depth and design. This number is used for ordering and obtaining information. C-4 SERIAL NUMBER: The serial number block will consist of a six digit number, which is specific to each unit and may be preceded by an alpha character, which indicates the plant location. This number will also be suffixed with a four digit number, which indicates the date the unit was built (Date Code). EXAMPLE: A012345 0490. Reference the six digit portion (Serial Number) of this number when referring to the product. 9

Simplex Pressure Switch - 2, 3, 5,& 7.5HP Grinder with Pump Cable and 14/2 Sensor Cable. Figure 13 10

Simplex Pressure Switch - 2, 3, 5,& 7.5HP Grinder with Pump Cable and 18/5 Sensor Cable. Figure 14 11

Duplex Pressure Switch - 2, 3, 5,& 7.5HP Grinder with Pump Cable and 14/2 Sensor Cable. Figure 15 12

Duplex Pressure Switch - 2, 3, 5,& 7.5HP Grinder with Pump Cable and 18/5 Sensor Cable. Figure 16 13

SIMPLEX - PRESSURE SWITCHES 14

SIMPLEX - PRESSURE SWITCHES or UltraSWITCH REPAIR KITS UltraSWITCH For SGV Pumps...P/N: 098874 UltraSWITCH For SGPC Pumps...P/N: 102817 PARTS LIST IMPORTANT! Specify Package Model Number & Part Number when ordering parts or service inquiries. ITEM QTY. DESCRIPTION 1 1 Basin 2 1 Basin Cover 3 12 Cap Screw 3/8-16 x 1.25" Lg Stainless 4 12 Flat Washer 1" O.D. x 3/8" I.D. Stainless 5 6 Lock Washer 3/8" Stainless 6 6 Hex Nut 3/8-16 Stainless 7 1 Discharge Coupling 8 4 Lock Washer 3/4" O.D. x 3/8" I.D. Stainless 9 4 Hex Nut 5/16-18 Stainless 10 1 Gasket, Discharge Buna-N 11 1 Stainless "C" Channel: (Must use Rail Extensions for deeper Basins.) 12 2 Right Brace, Stainless 13 2 Left Brace, Stainless 14 1 True Union Ball Valve 15 1 Extension Handle 16 1 Close Nipple 17 1 Stationary Fitting 18 1 Diaphragm 19 8 Lock Washer, Internal Tooth No. 10, Stainless 20 8 Hex Nut 10-32, Stainless 21 1 Lifting Device (Not Shown) Polypropylene Rope, Stainless Cable, Steel Chain 22 1 Mounting Bracket (Included with #29) Stainless 23 1 Cover Gasket 28 1 J-Bolt Stainless 29 1 Juction Box (For UltraSWITCH ) 30 1 UltraSWITCH 32 1 Extention Handle Bracket 33 1 Nipple 34 1 Serial Plate 35 2 Cap Screw 37 8 Sealing Washer 3/8" 38 1 Bug Free Vent 2" 40 1 Vent Flange, 2"7 41 3 Strain Relief Cable Grip (STD) Electrical Coupling 1.50" (OPTIONAL) Electrical Coupling 2.00" (OPTIONAL) 42 2 Hex Hd Screw 3/8-16 x 1-1/2" Lg. Stainless 43 2 Lock Washer 3/8" Stainless 44 1 Inlet, Flexible Pipe Fitting 4" Sch. 40 PVC 4" SDR 35, PVC (STD) 6" Sch. 40 PVC 6" SDR 35, PVC 45 1 Close Nipple 2", NPT, Stainless 46 8 Hex Hd Screw 5/16-18 x 1-1/4" Lg, Stainless 48 4 Hex Hd Screw 1/4-20 x.75" Lg, Stainless 49 4 Lockwasher 1/4", Stainless 50 4 Hex Nut 1/4-20, Stainless 51 2 U-Bolt 2.50" Stainless 15

DUPLEX - PRESSURE SWITCHES 16

DUPLEX - PRESSURE SWITCHES or UltraSWITCH REPAIR KITS UltraSWITCH For SGV Pumps...P/N: 098874 UltraSWITCH For SGPC Pumps...P/N: 102817 PARTS LIST IMPORTANT! Specify Package Model Number & Part Number when ordering parts or service inquiries. ITEM QTY. DESCRIPTION PART No. 1 1 Basin Various Depths & Diameters 2 1 Basin Cover, One Piece 36" Dia. Basin, Fiberglass 094489 Basin Cover, w/access Door 36" Dia. Basin, Steel 094708 42" Dia. Basin, Steel 094163 48" Dia. Basin, Steel 094165 60" Dia. Basin, Steel 094167 36" Dia. Basin, Aluminum 094709 42"Dia. Basin, Aluminum 094164 48"Dia. Basin, Aluminum 094166 60"Dia. Basin, Aluminum 094168 3 6 Cap Screw 3/8-16 x 1.25" Lg Stainless 022893 4 24 Flat Washer 1" O.D. x 3/8" I.D. Stainless 082727 5 10 Lock Washer 3/8" Stainless 035792 6 12 Hex Nut 3/8-16 Stainless 15-23-1 7 1 Discharge Coupling For 36" Dia. Basin Only 094801 1.50" NPT, Stainless 075580 2.00" NPT, Stainless 075582 8 8 Lock Washer 3/4" O.D. x 3/8" I.D. Stainless 062941 9 4 Hex Nut 5/16-18 Stainless 15-19-1 10 1 Cap Plug (For Shipping Only) 097368 11 2 Stainless "C" Channel 48" Basin Depth 093980 60" Basin Depth 086236 72" Basin Depth 086238 84" Basin Depth 086240 90" Basin Depth 086241 96" Basin Depth 086242 108" Basin Depth 086244 120" Basin Depth 086246 132" Basin Depth 086248 144" Basin Depth 086250 156" Basin Depth 086252 (Must use Rail Extensions for deeper Basins) 12 2 Right Brace, Stainless 36" Dia. Basin 094942 42" Dia. Basin 094942A 48" Dia. Basin 094942B 60" Dia. Basin 094942C 72" Dia. Basin 095049 13 2 Left Brace, Stainless 36" Dia. Basin 094943 42" Dia. Basin 094943A 48" Dia. Basin 094943B 60" Dia. Basin 094943C 72" Dia. Basin 095048 14 2 True Union Ball Valve 1.25" NPT, PVC 085115 2.00" NPT, PVC 089873 15 2 Extension Handle 48" Deep 094780 60" Deep 094781 72" Deep 094782 78" Deep 094783 84" Deep 094784 90" Deep 094785 96" Deep 094786 108" Deep 094787 120" Deep 094788 144" Deep 097003 16 2 Pipe Nipple 1.25" NPT x Close, Stainless 075476 1.25" NPT x Close, PVC 093925 2" NPT x Close, Stainless 075478 2" NPT x Close, PVC 093927 17

SIMPLEX - CONTROL BOX w/pressure SWITCHES PARTS LIST Parts Kit*...P/N: 098120 IMPORTANT! Specify Package Model Number & Part Number when ordering parts or service inquiries. ITEM QTY. DESCRIPTION 1 1 * Pressure Switch Pump ON 2 1 * Pressure Switch Pump OFF 3 1 * Pressure Switch HI-LEVEL 4 1 NEMA 6 Enclosure 5 1 Heater 6 2 * Tee Union, Comp., Brass 7 1 Reducer, Brass.50 x.138 8 1 Pipe, PVC,.50" Sch. 40 9 1 * Elbow, Comp. 1/8" NPT, Brass3 10 11 * Tubing.170 ID x.250 OD, Vinyl 11 1 Coin Plug (Use as required)3 12 1 Cord Grip, Valox 13 3 Cord Grip, Valox 14 1 * Bracket, Stainless 15 1 Mounting Bracket, Stainless 16 2 SKHD Screw #8-32 x.625, Stainless 17 1 Male Connector.50" Sch. 40, PVC 18 2 O-Ring 20 1 Reducer 4" x 2", PVC 21 1 Reducer Bushing 2-1/2", PVC 22 3 * Nut.437-24, Brass 30 4 Coin Plug 31 1 Cord Grip, Valox 32 1 Flat Washer, Stainless4 33 3 * Lock Washer, Ext. 7/16, ZP 18

DUPLEX - CONTROL BOX w/pressure SWITCHES PARTS LIST Parts Kit*...P/N: 098121 IMPORTANT! Specify Package Model Number & Part Number when ordering parts or service inquiries. ITEM QTY. DESCRIPTION 1 1 * Pressure Switch Pump 1 ON 2 1 * Pressure Switch Pumps OFF 3 1 * Pressure Switch Pump 2 ON 4 1 * Pressure Switch Hi-Level Alarm 5 1 NEMA 6 Enclosure 6 1 Heater Assy 7 3 * Tee Union, Barb, Brass 8 1 Reducer, Brass.50 x.13 9 1 Pipe, PVC,.50 Sch. 40 10 1 Reducer, Barb, Brass 1/8 x.170 11 1 * Tubing, Vinyl.170 ID x.25 OD 13 2 Cord Grip, Valox 14 4 Cord Grip, Valox 15 1 * Bracket, Switch, Stainless 16 1 Mounting Bracket 17 4 Cord Grip, Valox 18 1 Male Connector.50", Sch 40 19 1 Connector Nut 21 1 Reducer, PVC 4" x 2" 22 1 Reducer Bushing, PVC 2-1/2" 28 2 Hex Screw 5/16 x.75" Lg, Stainless 29 2 Hex Nut 5/16-18, Stainless 32 1 Flat Washer Stainless 33 8 Coin Plug (Use as required) 34 2 Coin Plug (Use as required)3 35 3 * Lock Washer 7/16", ZP 19

DIRECT BURIAL CABLE REQUIRMENTS For *Wall Mount Control Panels. CONTROL PANEL SERIES 101, 102, 102B, 105, 106, 109, 110, 113, 114 UGP CONTROL CABLE SIZE UCP CONTROL CABLE SIZE SIMPLEX + NUMBER CONTROL CABLES UGP POWER CABLE SIZE UCP POWER CABLE SIZE 18/8 18/6 1 10/4 12/3 (230V) 10/3 (115V) NUMBER POWER CABLES PUMP CONTROL (SGV) 1 Temp Sensor 103, 104, 107, 108, 111, 112, 115, 116 18/10 18/6 1 10/4 12/3 (230V) 10/3 (115V 1 Temp Sensor, Moisture Sensor 201, 202, 205, 206, 209, 210, 213, 214 DUPLEX 18/12 18/8 1 10/4 12/3 (230V) 10/3 (115V 2 Temp Sensor 203, 204, 207, 208, 210, 212, 215, 216 18/6 18/8 3 (SGV) 1 (SGPC) 10/4 12/3 (230V) 10/3 (115V 2 Temp Sensor Moisture Sensor CABLE DESCRIPTION; Ref. NEC article #340 Type TC (ROUND) tray cable, THHN or THWN (TFFN) UL recognized, direct burial cable. Volts, rated 600V continuous use at 90C dry and 75C wet. Cable to meet requirements of UL83 for THHN or THWN. Jacket to be printed or indented, size and number of conductors THHN or THWN (TFFN) type TC 600V (UL). * For Convertable Cover, 1-10/5 DBC required for UGP 1-12/5 for UCP 230 Volt Panels, 1-10/4 DBC required for UCP 115 Volt. THROUGH BASIN WALL USE CABLE PART NUMBER GRIP RANGE CORD GRIP # LOCK NUT DRILL SIZE 10/3 102195 0.236-0.472 100607 100609 7/8" 10/4 098118 0.236-0.472 100607 100609 7/8" 10/5 102197 0.354-0.629 094270 097310 1" 12/3 104060 0.236-0.472 100607 100609 7/8" 12/5 104061 0.236-0.472 100607 100609 7/8" 18/4 100204 0.236-0.472 100607 100609 7/8" 18/6 096555 0.236-0.472 100607 100609 7/8" 18/8 101726 0.236-0.472 100607 100609 7/8" 18/10 101727 0.236-0.472 100607 100609 7/8" 18/12 098117 0.354-0.629 094270 097310 1" Required from home to control panel: 10/4 (3 power 1 ground) and 30 Amp breaker at the service drop. 20

BASIN VOLUME CHART IN U.S. GALLONS SIZE Dia X Ht VOLUME GALLONS VOLUME "OFF" VOLUME "ON" VOLUME "ALARM" VOLUME BETWEEN ON - OFF 24 x 48 94.0 19.6 43.1 51.0 23.5 24 x 60 117.5 " " " " 24 x 72 141.0 " " " " 24 x 78 152.9 " " " " 24 x 84 164.6 " " " " 24 x 90 176.4 " " " " 24 x 96 188.2 " " " " 24 x 108 211.7 " " " " 24 x 120 235.2 " " " " 24 x 144 282.2 " " " " 30 x 48 146.9 30.6 76.3 79.6 36.7 30 x 60 183.6 " " " " 30 x 72 220.3 " " " " 30 x 78 238.7 " " " " 30 x 84 257.0 " " " " 30 x 90 275.0 " " " " 30 x 96 293.8 " " " " 30 x 108 330.5 " " " " 30 x 120 367.2 " " " " 30 x 144 440.6 " " " " 36 x 48 211.7 44.1 97.0 114.7 52.9 36 x 60 264.6 " " " " 36 x 72 317.5 " " " " 36 x 78 344.0 " " " " 36 x 84 370.4 " " " " 36 x 90 396.9 " " " " 36 x 96 423.4 " " " " 36 x 108 476.3 " " " " 36 x 120 529.2 " " " " 36 x 132 581.7 " " " " 36 x 144 634.6 " " " " 36 x 150 661.0 " " " " 42 x 48 287.9 60.0 131.9 155.9 72.0 42 x 60 359.8 " " " " 42 x 72 431.8 " " " " 42 x 78 467.8 " " " " 42 x 84 503.8 " " " " 42 x 90 539.8 " " " " 42 x 96 575.8 " " " " 42 x 108 647.7 " " " " 42 x 120 719.7 " " " " 42 x 144 863.7 " " " " 48 x 48 376.0 78.3 172.3 203.7 94.0 48 x 60 469.8 " " " " 48 x 72 563.7 " " " " 48 x 78 610.7 " " " " 48 x 84 657.7 " " " " 48 x 90 704.7 " " " " 48 x 96 751.7 " " " " 48 x 108 845.6 " " " " 48 x 120 939.6 " " " " 48 x 144 1227.5 " " " " 60 x 48 587.5 122.4 269.3 318.2 146.9 60 x 60 734.4 " " " " 60 x 72 881.3 " " " " 60 x 78 954.7 " " " " 60 x 84 1028.4 " " " " 60 x 90 1101.6 " " " " 60 x 96 1175.0 " " " " 60 x 108 1321.9 " " " " 60 x 120 1468.8 " " " " 60 x 144 1762.6 " " " " 72 x 162 2855.3 176.3 387.8 458.4 211.6 NOTES: 1) Pump will displace approximately 3.3 gallons. 2) Ref. 1 gallon = 0.0034 x height (inches) x diameter (inches). 21

BASIN BALLAST REQUIREMENTS 63 LB. PER CUBIC FOOT OF VOLUME REQUIRED SIZE Dia X Ht BASIN VOLUME CU. FT. REQUIRED BALLAST LBS. REQUIRED BALLAST CU. FT. 24 x 48 12.57 791.8 5.5 24 x 60 15.71 989.7 7.0 24 x 72 18.85 1187.7 8.5 24 x 78 20.44 1287.9 9.1 24 x 84 22.00 1386.4 9.9 24 x 90 23.58 1485.8 10.6 24 x 96 25.16 1585.2 11.3 24 x 108 28.30 1783.2 12.7 24 x 120 31.45 1981.1 14.1 24 x 144 37.73 2377.0 17.0 30 x 48 19.64 1237.4 8.8 30 x 60 24.55 1546.5 11.0 30 x 72 29.45 1855.6 13.3 30 x 78 31.91 2010.6 14.4 30 x 84 34.40 2164.7 15.5 30 x 90 36.77 2316.4 16.5 30 x 96 39.28 2474.7 17.7 30 x 108 44.19 2783.8 20.0 30 x 120 49.09 3093.0 22.0 30 x 144 58.90 3711.2 25.7 36 x 48 28.30 1783.2 12.7 36 x 60 35.38 2228.8 15.9 36 x 72 42.45 2674.3 19.1 36 x 78 45.99 2897.5 20.7 36 x 84 49.52 3119.9 22.3 36 x 90 53.07 3343.1 23.8 36 x 96 56.61 3566.3 25.5 36 x 108 63.68 4011.9 28.7 36 x 120 70.75 4457.5 31.8 36 x 132 77.77 4899.7 35.0 36 x 144 85.00 5348.7 38.2 36 x 150 88.37 5567.7 39.8 42 x 48 38.49 2425.0 17.3 42 x 60 48.11 3030.6 21.6 42 x 72 57.73 3637.1 26.0 42 x 78 62.54 3940.3 28.1 42 x 84 67.35 4243.6 30.3 42 x 90 72.17 4546.8 32.5 42 x 96 76.98 4850.0 34.6 42 x 108 86.59 5455.6 38.9 42 x 120 96.22 6062.1 43.3 42 x 144 115.48 7275.0 51.9 48 x 48 50.27 3167.1 22.6 48 x 60 62.81 3957.2 28.3 48 x 72 75.37 4748.1 33.9 48 x 78 81.65 5144.0 36.7 48 x 84 87.93 5539.9 39.5 48 x 90 94.21 5935.8 42.4 48 x 96 100.50 6331.6 45.2 48 x 108 113.06 7122.6 50.8 48 x 120 125.62 7914.3 56.5 48 x 144 164.12 10339.3 73.8 60 x 48 78.54 4948.6 35.3 60 x 60 98.19 6185.9 44.2 60 x 72 117.83 7423.3 53.0 60 x 78 127.64 8041.5 57.4 60 x 84 137.47 8660.6 62.0 60 x 90 147.28 9279.0 66.3 60 x 96 157.10 9897.1 70.6 60 x 108 176.73 11134.5 79.5 60 x 120 196.37 12371.9 88.4 60 x 144 235.66 14846.6 106.0 72 x 162 381.75 24050.5 171.8 NOTES: 1) Gallons x.1337 = cu. ft. 2) One cu. ft. ballast = 140 lbs. 22

NOTES: 23

IMPORTANT! WARRANTY REGISTRATION Your product is covered by the enclosed Warranty. Complete the Warranty Registration Form and returned to Crane Pumps & Systems, Inc. Warranty Service Group IMPORTANT! 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". CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR. Products Returned Must Be Cleaned, Sanitized, Or Decontaminated As Necessary Prior To Shipment, To Insure That Employees Will Not Be Exposed To Health Hazards In Handling Said Material. All Applicable Laws And Regulations Shall Apply. 24

Limited 1 Year Warranty We warrant to our immediate customer and to the ultimate consumer that products of our manufacture will be free of defects in material and workmanship under normal use and service for the following time periods, when installed and maintained in accordance with our instructions. Twelve (12) months after notice of owner s acceptance, but no greater than twenty-four (24) months after receipt of shipment. As used herein, "the ultimate consumer" is defined as the purchaser who first uses the product after its initial installation It is the purchaser s or any sub-vendee s obligation to make known to the ultimate consumer the terms and conditions of this warranty. This warranty gives you specific legal rights, and there may also be other rights which vary from state to state. In the event the product is covered by the Federal Consumer Product Warranties Law (1) the duration of any implied warranties associated with the product by virtue of said law is limited to the same duration as stated herein, (2) this warranty is a LIMITED WARRANTY, and (3) no claims of any nature whatsoever shall be made against us, until the ultimate consumer, his successor, or assigns, 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. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY AND ALL WARRANTIES WITH RESPECT TO ANY PRODUCT SHALL BE TO REPLACE OR REPAIR AT OUR ELECTION, F.O.B. POINT OF MANUFACTURE OR AUTHORIZED REPAIR STATION, SUCH PRODUCTS AND/OR PARTS AS PROVEN DEFECTIVE. THERE SHALL BE NO FURTHER LIABILITY, WHETHER BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE. Unless expressly stated otherwise, guarantees in the nature of performance specifications furnished in addition to the foregoing material and workmanship warranties on a product manufactured by us, if any, are subject to laboratory tests corrected for field performance. Any additional guarantees, in the nature of performance specifications must be in writing and such writing must be signed by our authorized representative. Due to inaccuracies in field testing if a conflict arises between the results of field testing conducted by or for user, and laboratory tests corrected for field performance, the latter shall control. Components or accessories supplied by us but manufactured by others are warranted only to the extent of and by the terms and conditions of the original manufacturer s warranty. RECOMMENDATIONS FOR SPECIAL APPLICATIONS OR THOSE RESULTING FROM SYSTEMS ANALYSES AND EVALUATIONS WE CONDUCT WILL BE BASED ON OUR BEST AVAILABLE EXPERIENCE AND PUBLISHED INDUSTRY INFORMATION. SUCH RECOMMENDATIONS DO NOT CONSTITUTE A WARRANTY OF SATISFACTORY PERFORMANCE AND NO SUCH WARRANTY IS GIVEN. This warranty shall not apply when damage is caused by (a) improper installation, (b) improper voltage (c) lightning (d) sand or other abrasive material (e) scale or corrosion build-up due to excessive chemical content. 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 parts. Neither will we 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 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, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 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. PUMPS & SYSTEMS A Crane Co. Company 420 Third Street/P.O. Box 603 83 West Drive, Brampton Piqua, Ohio 45356-0603 Ontario, Canada L6T 2J6 Phone: (937) 778-8947 Phone: (905) 457-6223 Fax: (937) 773-7157 Fax: (905) 457-2650 www.cranepumps.com

Barnes Pressure Sewer Systems Piqua, Ohio