section 11010 - essco pumpssubmittals.esscopumps.com/09334apumpommanualedenglenfydaq2.pdflos...

ESSCO Pumps & Controls 4935 Telegraph Rd.

Los Angeles, Ca 90022

(323) 261-2181 Fax (323) 261-1523

www.esscopumps.com [email protected]

Thursday, March 8, 2010 Job No: 09334A Attention: Adam Hudson, Mike Craft Firm: Ontario Ref: Edenglen Temporary SEWER LIFT STATION UPGRADES Brookfield Southland Builders

3090 Bristol Street, Suite 200 Costa Mesa, CA 92626-3061

ESSCO Pumps and Controls is pleased to provide a submittal for the following pumping equipment: SECTION 11010 MECHANICAL EQUIPMENT - GENERAL PART 2 - PRODUCTS SUBMERSIBLE PUMP SYSTEM Sub Para- 2.2 PACKAGE LIFT STATION PUMP SYSTEM COMPONENTS Thru end of Sub Para- 2.2 Pages- SECTION 11310 -4 Thru SECTION 11310 -8 CONDITION POINT: Initial Condition Condition 2 Ultimate Condition

Design Capacity each

200 gpm

200 gpm

270 gpm

TDH at Design 201 ft 90 ft 126 ft Pumpage Raw Sewage Raw Sewage Raw Sewage RPM 1565 rpm 1055 rpm 1250 rpm Speed 89% 60% 71% Max Motor HP 75HP 75HP 75HP Max Shut Off Head at Full Speed

260 ft 260 ft 260 ft

Two - ESSCO model 4x16 torque fluid submersible vortex pump with a 100% recessed vortex impeller capable of passing 4" diameter and long length solids. Each unit shall be constructed of heavy duty engineered Cast Iron with High Chrome Iron 550 impeller, Cast Iron volute with Fusecote Epoxy, Cast Iron wear plate with Fusecote Epoxy, assembled with Stainless Steel hardware.

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ESSCO Pumps & Controls 4935 Telegraph Rd.

Los Angeles, Ca 90022

(323) 261-2181 Fax (323) 261-1523

www.esscopumps.com [email protected]

Each pump shall be equipped with a Cool Agivent device which shall vent the pump case, cool the motor and agitate the wet well. Reliance 75 HP, 1750 RPM, 460Volts/3Phase/60hz., 320TY frame, U.L. listed submersible explosion proof motor, rated Class 1, Division 1, Groups C&D for hazardous locations, with Buna-N O-rings, Carbon/Ceramic upper mechanical seal with Buna-N elastomers and Silicon Carbide lower mechanical Super Seal with Buna-N elastomers, 416 Stainless Steel shaft, Class F insulation, oil buffer zone, moisture sensing probes, built-in thermal overload protection, 25 ft. motor leads, and ESSCO/Reliance standard five year warranty. The exterior of the motor shall be coated with Coal Tar Epoxy. *NOTE - The submersible motor requires a Warrick seal fail warning relay that is not provided by the pump manufacturer. Please notify the design engineer and/or panel manufacturer of this requirement. This item is included in MCC/ MCP pump controls. Two - 4" Design 3 spark proof Straight-thru slide rail assembly to include cast iron stationary base, Bronze faced sliding flange, 2" 304 Stainless Steel top guide bracket, lifting yoke, and Bronze rail guides, 4" Flange x Flange cast iron footed elbow. The slide rail stationary base assembly shall be coated with Fusecote Epoxy. *Note - 2" Schedule 40 Stainless Steel guide pipe, any Stainless Steel spacers, and all Stainless Steel anchor bolts by others. SUBMERSIBLE PUMP SYSTEM SECTION 11310-3 1.9 SPARE PARTS A. The sewage pumps shall be furnished with the following spare parts: 1. Two (2) set of mechanical shaft seals for each pump. 2. Two (2) set of wearing rings for each pump.- Not Required by Pump Design 3. Two (2) set of bearings for each pump. Total for 4. Two (2) sets of O-rings or gaskets for each pump. 5. One (1) spare pump and impeller. Includes Startup as follows: 1 day ESSCO field personnel to shake down and test Pumps system prior to starting pump equipment. 1 day Formal Start Up and Training.

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**Note: Slide rail assemblies supplied by the contractor

U.L. LISTED CUSTOM CONTROL PANELS • Air Bubbler– Pressure Switch • Air Bubbler--Transducer • Float Switch • Variable Speed Drive Systems • Sonic Level Controllers • Motor Control Centers • PLC Controls • Calibration Test Benches • Custom NEMA Enclosures in

Epoxy Coated Steel and Stainless Steel

STYLES • Horizontal with Power

Frame • Horizontal Close Coupled • Vertical with Power Frame • Vertical Close Coupled • Vertical Dry Pit with Submersible Motor • Submersible • Column SIZES • 1” Thru 6” Vortex • 3” Thru 12” Non-Clog

Municipal • Raw Sewage • Grit Handling • Sludge Recirculation • Digester Cleaning • Thickened Sludge • Storm Water • Sump Pump (Pipe Gallery) • Head Works Industrial • Coal Wash • Coal Pile Runoff • Coal Slurry • Citrus Waste Handling • Sugar Waste Handling • Leather Tannery Waste • Rendering • Plant Wash Down • Clarifier Under Flow • Stone Washed Jeans • Industrial Laundries • Automobile Shredding

MATERIALS • Cast Iron • Stainless Steel • Ni-Hard • High Chrome Iron (HCI) • 20+ Other Alloys

Reliable Long-Term Solutions

For Your Toughest Pump Problems

ESSCO Pumps & Controls 4935 Telegraph Rd Los Angeles, Ca 90022 (323) 261-2181 Fax (323) 261-1523

www.esscopumps.com Email: [email protected] Member of the Hydraulic Institute Form: G-01a

Distributed By:

ESSCO Pumps & Controls 4935 Telegraph Rd. Los Angeles, Ca 90022 (323) 261-2181 Fax (323) 261-1523

Website: www.esscopumps.net Email: [email protected] Member of the Hydraulic Institute Form: G-01a

FEATURES AND BENEFITS

Features Benefits

Recessed Impeller The impeller is completely out of the liquid flow path which make it ideal for handling liquids that contain large diameter solids, long stringy solids or a combination of them. Whatever goes into the suction of the pump and is smaller that the discharge pipe diameter will come out.

5 Year Wear Warranty for recessed impeller pumps for Industrial and Municipal applica-tions.

Substantial savings for replacement parts (no other pump company offers this).

Virtually no radial thrust loads on pump and motor bearings.

Can operate anywhere on the pump curve. Low flow and high heads, pumping solids.

Wear Plates (behind the impeller) for Re-cessed Impeller and Non Clog Impeller pumps.

Substantially longer life (3-4 times) on motor bracket and mechanical seals! No expensive mechanical seals.

Mechanical Seal Spring Protector Protects the mechanical seal’s spring from rag-ging up and premature failure. ESSCO offers Carbon Ceramic seal faces as well as Tungsten Carbide and Silicon Carbide as standard options.

Hard Irion Impellers that can be trimmer to a specific design point on the pump curve.

Eliminates the high cost of belt drives and VFD.

ESSCO manufactures pumps in over 20 differ-ent alloys.

The pumped media can be matched to a spe-cific metallurgy that will provide extended life even in the most demanding applications.

SUBMERSIBLE PUMPS WITH

100% RECESSED IMPELLER

ESSCO submersible pumps are of the 100% re-cessed impeller design. Each unit is capable of handling long stringy material, large size solids and slurries, with maximum solids handling effi-ciency. The ESSCO pump incorporates the vortex pumping action along with unique pump design, allowing the greatest flexibility in the submersible pump field. ESSCO offers special materials, spe-cialty coatings and special mechanical seals along with many other options. VOLUTE: Each ESSCO volute is designed with maximum life in mind. ESSCO provides extra ma-terial in high wear areas as well as special de-signs to handle heavy grit slurries. With casting thickness up to 1.25". IMPELLER: ESSCO pumps have various im-pellers available to allow for high capacity and low head capability, or high head and low

capacity applications. ESSCO also incorporates a special machining technique to shred and break down any solids which might come into contact with the impeller. Standard impeller is ductile iron. COOL AGIVENT: Each ESSCO submersible pump includes a Cool Agivent® apparatus which is for venting pump cases and cooling external surface of the motor. This patented device will al-low a more shallow wet well design, as well as keep the motor cool when not submerged. All ESSCO submersible pumps are capable of run-ning dry continuously. (Consult factory for specific applications.) MOTOR: Reliance U.L. listed for Class 1, Div. 1, Group D, hazardous location, complete with a moisture detector and thermal protection. Heavy duty thrust bearings and dual seals give added protection and on special request high tem-perature or abrasion resistant seals are available. SIZES AVAILABLE: 2" through 6" discharge. SPECIAL MATERIALS: ESSCO submersible pumps are available in materials other than cast iron. Special materials include 316 S.S., bronze and high chromium iron (Brinnell 550-650 hard-ness). Other materials are available on special re-quests. ESSCO maintains a large stock of com-plete pump units and spare parts for quick ship-ment. Pump test certification available upon re-quest. All ESSCO Pumps Manufactured, Assembled and Tested in the U.S.A.

ESSCO Pumps & Controls 4935 Telegraph Rd. Los Angeles, Ca 90022 (323) 261-2181 Fax (323) 261-1523 www.esscopumps.com Email [email protected]

Distributed By:

ESSCO 6x12 submersible vortex pump pictured above.

ESSCO SUPER SEAL

One of the nagging problems in the pump industry spe-cifically with submersible pumps and pumps with a sin-gle spring that is exposed to pumped debris laden liq-uids is choking of the seal spring. The single spring seal design may be a good system for clean clear liq-uids but in severe and harsh duty applications they sim-ply do not hold up. Reaching a balance between dependable mechanical seal life and economics has never been more important than it is today. ESSCO has developed an economical approach to the problem. The ESSCO Super Seal fea-tures many items which increase the overall life of a mechanical seal. Many times a low cost mechanical seal is desirable but fails quickly in liquids containing stringy, abrasive and/ or gritty material. In many situations ESSCO’s Super Seal improves seal life dramatically and provides the end user with a good solution for difficult applications.

Features: • Multiple springs put even pressure on the mechani-

cal seal faces. • Face springs are completely protected from stringy

material and grit to increase seal life. • Large drive band and collar protect against shear

stress as observed with similar style mechanical seals.

• Large locking collar for setting proper seal length. • O ring seal against shaft that acts as a fluid barrier. • Seal Faces are available in Silicon Carbide and

Tungsten Carbide. Carbon vs. Ceramic faces are available as on option but are not normally in stock.

• Standard seals match setting lengths of a John Crane Type 21 seal.

• Custom sizes and are available upon request. For more information contact ESSCO Pumps for a distributor nearest your location or call (323) 261-2181

ESSCO Pumps & Controls 4935 Telegraph Rd. Los Angeles, CA 90022 (323) 261-2181 Fax: (323) 261-1523 www.esscopumps.com Email: [email protected]

Distributed By:

Form: SuperSeal

ESSCO’s Super Seal pictured above eliminates choked springs in mechanical seals which cause premature seal leaking and early failure.

“Choked” mechanical seal. Rags wrapped around a single spring mechanical seal and caused reduced pressure on the mechanical seal faces which al-lowed liquid to enter the oil chamber.

Test Date: 9/28/2010 ESSCO PumpsMember of Hydraulic Institute

Pump Model: 4x16 Pump Type: SubGPM TDH Tested By: Pump Serial #: 09334-1

200 201 Audel Volute Style: Centerline DischargePump RPM 1600 Test Number: 8326

Motor Info: BHP RPM FLA Test Voltage/Phase TRIM Vanes75 1750 91.3 460 15.13 10

Reading No. 1 2 3 4 5 6GPM 500 400 300 200 100 0

PSI 80.2 82.5 84 85.1 86.1 89Feet 185.26 190.58 194.04 196.58 198.89 205.59

Water to CL of Gage 4.00 4.00 4.00 4.00 4.00 4.00Hf Header 2.66 1.76 1.03 0.49 0.13 0.00Vel Head 0.09 0.07 0.05 0.04 0.02 0.00

TDH 192.01 196.40 199.12 201.10 203.04 209.59Volts 460 460 460 460 460 460

Amps 80.2 75.9 68.1 66.7 64.9 62.6KW Reading 0 0 0 0 0 0

Power Factor 0 0 0 0 0 0

GPM 0 100 200 300 400 500TDH 209.6 203.0 201.1 199.1 196.4 192.0BHP 51.38 53.28 54.78 55.98 62.35 65.87

% EFF 0 10 19 27 32 37+

Witnessed By: Date:

Certified By: Date:

Certified Test

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Pump Model: 4x16 Pump Type: SubGPM TDH Tested By: Pump Serial #: 09334-1b



Reading No. 1 2 3 4 5 6GPM 500 400 300 200 100 0

PSI 32.6 34.1 35.9 37.2 38 39.3Feet 75.31 78.77 82.93 85.93 87.78 90.78


TDH 82.05 84.60 88.01 90.45 91.93 94.78Volts 460 460 460 460 460 460

Amps 50.7 49.1 46.1 43.4 42.8 41.6KW Reading 0 0 0 0 0 0


GPM 0 100 200 300 400 500TDH 94.8 91.9 90.5 88.0 84.6 82.1BHP 34.21 35.18 35.67 37.86 40.29 41.67

% EFF 0 7 13 18 21 25+

Witnessed By: Date:

Certified By: Date:

Certified Test

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Pump Model: 4x16 Pump Type: SubGPM TDH Tested By: Pump Serial #: 09334-1c



Reading No. 1 2 3 4 5 6GPM 500 400 270 200 100 0

PSI 49.7 51.4 53.2 54.8 56.1 57Feet 114.81 118.73 122.89 126.59 129.59 131.67


TDH 121.55 124.56 127.79 131.11 133.74 135.67Volts 460 460 460 460 460 460

Amps 60.6 57.1 52.1 50.8 49.4 47.7KW Reading 0 0 0 0 0 0


GPM 0 100 200 270 400 500TDH 135.7 133.7 131.1 127.8 124.6 121.6BHP 39.15 40.58 41.71 42.80 46.93 49.78

% EFF 0 8 16 20 27 31+

Witnessed By: Date:

Certified By: Date:

Certified Test

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Pump Model: 4x16 Pump Type: SubGPM TDH Tested By: Pump Serial #: 09334-2a



Reading No. 1 2 3 4 5 6GPM 500 400 300 200 100 0

PSI 80.6 82.3 84.5 85.4 87.8 90.5Feet 186.19 190.11 195.20 197.27 202.82 209.06


TDH 192.93 195.94 200.28 201.80 206.97 213.06Volts 460 460 460 460 460 460

Amps 75.9 70.6 68.5 64.4 62.6 60.8KW Reading 0 0 0 0 0 0


GPM 0 100 200 300 400 500TDH 213.1 207.0 201.8 200.3 195.9 192.9BHP 49.91 51.46 52.93 56.28 57.99 62.34

% EFF 0 10 19 27 34 39+

Witnessed By: Date:

Certified By: Date:

Certified Test

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Reading No. 1 2 3 4 5 6GPM 500 400 300 200 100 0

PSI 33.3 35.2 36.8 37.4 39 40.9Feet 76.92 81.31 85.01 86.39 90.09 94.48


TDH 83.67 87.14 90.09 90.92 94.24 98.48Volts 460 460 460 460 460 460

Amps 49.4 47.1 44.7 42.3 40.4 39.9KW Reading 0 0 0 0 0 0


GPM 0 100 200 300 400 500TDH 98.5 94.2 90.9 90.1 87.1 83.7BHP 32.75 33.22 34.77 36.73 38.65 40.61

% EFF 0 7 13 19 23 26+

Witnessed By: Date:

Certified By: Date:

Certified Test

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PSI 50 52.3 54.3 55.2 56 58Feet 115.50 120.81 125.43 127.51 129.36 133.98


TDH 122.25 126.64 130.33 132.03 133.51 137.98Volts 460 460 460 460 460 460

Amps 59.0 53.7 51.1 49.6 48.4 46.4KW Reading 0 0 0 0 0 0


GPM 0 100 200 270 400 500TDH 138.0 133.5 132.0 130.3 126.6 122.2BHP 38.10 39.79 40.76 41.95 44.10 48.46

% EFF 0 8 16 21 29 32+

Witnessed By: Date:

Certified By: Date:

Certified Test

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Pump Model: 4x16 Pump Type: SubGPM TDH Tested By: Pump Serial #: 09334-3a



Reading No. 1 2 3 4 5 6GPM 500 400 300 200 100 0

PSI 80.5 83.1 84.8 86.5 89.2 91.2Feet 185.96 191.96 195.89 199.82 206.05 210.67


TDH 192.70 197.79 200.97 204.34 210.20 214.67Volts 460 460 460 460 460 460

Amps 78.2 74.5 70.4 67.0 62.2 59.8KW Reading 0 0 0 0 0 0


GPM 0 100 200 300 400 500TDH 214.7 210.2 204.3 201.0 197.8 192.7BHP 49.14 51.10 55.02 57.86 61.17 64.27

% EFF 0 10 19 26 33 38+

Witnessed By: Date:

Certified By: Date:

Certified Test

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PSI 33.6 35.5 37.1 38.5 39.4 40.5Feet 77.62 82.01 85.70 88.94 91.01 93.56


TDH 84.36 87.83 90.79 93.46 95.17 97.56Volts 460 460 460 460 460 460

Amps 49.6 47.5 45.4 41.9 40.4 39.5KW Reading 0 0 0 0 0 0


GPM 0 100 200 300 400 500TDH 97.6 95.2 93.5 90.8 87.8 84.4BHP 32.41 33.22 34.46 37.30 39.00 40.78

% EFF 0 7 14 18 23 26+

Witnessed By: Date:

Certified By: Date:

Certified Test

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PSI 50.3 52.1 54.5 56.2 57.3 59Feet 116.19 120.35 125.90 129.82 132.36 136.29


TDH 122.94 126.18 130.79 134.34 136.52 140.29Volts 460 460 460 460 460 460

Amps 59.6 56.2 52.1 50.8 48.4 36.7KW Reading 0 0 0 0 0 0


GPM 0 100 200 270 400 500TDH 140.3 136.5 134.3 130.8 126.2 122.9BHP 30.17 39.79 41.71 42.82 46.17 48.98

% EFF 0 9 16 21 28 32+

Witnessed By: Date:

Certified By: Date:

Certified Test

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THIS MANUAL APPLIES TO:

SUBMERSIBLE VORTEX PUMPS SUBMERSIBLE NON-CLOG PUMPS

VERTICAL DRY PIT SUBMERSIBLE VORTEX PUMPS VERTICAL DRY PIT SUBMERSIBLE NON-CLOG

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

CAUTION

CAREFULLY READ ALL SECTIONS IN THIS MANUAL AND ALL OTHER INSTRUCTION

MANUALS PROVIDED BY MANUFACTURERS OF OTHER EQUIPMENT SUPPLIED WITH THIS PUMP

CAUTION

PRIOR TO WORKING ON ANY ELECTRICAL OR PUMP EQUIP-MENT, SAFETY ELECTRICAL LOCKOUT CIRCUITS SHOULD BE IN-STALLED AND LOCKED OUT TO PREVENT SERIOUS INJURY OR

DEATH. REVIEW ALL LOCAL, STATE, FEDERAL CODES AND OSHA REQUIREMENTS BEFORE WORKING ON ANY PUMPING

EQUIPMENT. SAFETY IS YOUR RESPONSIBILITY

ESSCO PUMP DIVISION ENGINEERS SALES-SERVICE CO., INC. 4935 TELEGRAPH RD. LOS ANGELES, CA. 90022 Tel. (323) 261-2181 Fax. (323) 261-1523 www.esscopumps.com

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Table of Contents

DESCRIPTION PAGE

1. Pump Identification 4 2. Pump Description 4 3. Caution Notes and Storage of Pumps 4

4. Important Safety Notice 4 5. Storage of Pumps A. Special Instructions B. A Unit is in Storage When...

4

6. Introduction 5

7. Installation Submersible and Dry Pit Submersible Pumps 5 8. Unpacking and Inspection 5 9. Cool Agivent 5

10. Dry Pit Pump Vent 5 11. Minimum Submergence of Pump Suction and Pit Design 5 12. Installation When Pumps Are Furnished With Bolt Down Stand Or Vertical Pump Stand A. Foundation for Pump Stands B. Leveling of the Pump Unit and Anchor Bolts

6

13. Grouting 6 14. Piping 6 15. Operating at Reduced Capacity 7

16. Initial Start Up of the Pump A. Mechanical Seals B. Power Cord C. Potential Seal Damage

7

17. Submersible Vortex Pump Troubleshooting A. Insufficient Discharge Pressure or Flow B. Loss of Suction During Operation C. Excessive Power Consumption D. Vibration or Noise

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18. Dry Pit Submersible Vortex Pump A. Priming the pump B. Starting the pump C. Reverse Rotation

9

3

Table of Contents Continued

DESCRIPTION PAGE

19. Dry Pit Submersible Vortex Pump Troubleshooting A. Insufficient Discharge Pressure or Flow B. Loss of Suction During Operation C. Excessive Power Consumption D. Vibration or Noise

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20. Submersible Non-Clog Pump Troubleshooting A. Insufficient Discharge Pressure or Flow B. Loss of Suction During Operation C. Excessive Power Consumption D. Vibration or Noise

10

21. Dry Pit Submersible Non-Clog Pump A. Priming the pump B. Starting the pump C. Reverse Rotation

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22. Dry Pit Submersible Non-Clog Pump Troubleshooting A. Insufficient Discharge Pressure or Flow B. Loss of Suction During Operation C. Excessive Power Consumption D. Vibration or Noise

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23. Preventative Maintenance Log 13

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PUMP IDENTIFICATION Congratulations! You are the owner of the very best submersible pump commercially available. With proper care and maintenance it will pro-vide you with reliable service for many years. ESSCO pumps are of the heavy duty design with vortex or non-clog impellers. ESSCO of-fers a wide variety of impeller designs to allow for equipment flexibility. ESSCO pumps are ideally suited for applications such as sewage, slurry, food waste handling, food handling and a variety of other services. Standard construc-tion is cast iron with a carbon ceramic lower mechanical seal. Standard optional materials are available such as 316 S.S. (CF8M), High Chromium Iron, Nihard, CD4MCu, Bronze, and many others. Not all pump models are avail-able in all materials. ESSCO pumps are engi-neered to accept a wide variety of mechanical seal materials. This manual applies to: All sizes of Submersible and Dry Pit Submersi-ble pumps.

CAUTION NOTES AND STORAGE OF PUMPS

These instructions apply to the pump only and are intended to be general and not specific. If the operating conditions change, refer to the factory or local factory representative or dis-tributor for reapplication. Always refer to the manuals provided by manufacturers of the other equipment for their separate instructions and maintenance schedules.

STORAGE OF PUMPS If the equipment is not to be immediately in-stalled and operated, store it in a clean, dry, well ventilated place, free from vibrations, mois-ture, rapid and wide variations in temperature. A UNIT IS IN STORAGE WHEN: 1. It has been delivered to the jobsite and is awaiting installation.

4x12x*-10-4 Vortex Pump(1) 4x4x10x3-10-4 Non-Clog Pump

4x12 Pump size- 4" suction and discharge, 12" max. diameter impeller passing 4” solids.

4x4x10x3 Pump size- 4" suction, 4" discharge, 10" max. diameter impeller passing 3” solids

-* ESSCO vortex pumps will pass solids equal to the discharge diameter.

-10 Horsepower.

-4 RPM 4= 1750, 6= 1160, 8= 870

In some cases a vortex pump model will be pre-ceded by the suction size such as 8x6x17-100-6. (1) ESSCO vortex pumps will pass solids equal to the discharge diameter.

CAUTION IMPORTANT SAFETY NOTICE

The installation, use and operation of this type of equipment is affected by various federal, state and local laws and the regulations concerning OSHA. Compliance with such laws relating to the proper installation, safe operation and maintenance of this type of equipment is the responsibility of the equip-ment owner and all necessary steps should be taken by the owner to assure compliance with such laws prior to operation and after performing equip-ment maintenance.

WARNING DO NOT SUBMERGE CUT ENDS OF POWER CORDS IN LIQUID. THIS WILL DAMAGE CABLES AND VOID THE MANU-FACTURER'S WARRANTY. SUBMERSIBLE PUMP POWER CORDS SHOULD BE IN-SPECTED THOROUGHLY EACH TIME THE PUMP IS REMOVED FROM SERVICE. BE SURE TO CHECK FOR SIGNS OF WEAR, CRACKS IN THE OUTER CABLE JA CKET AND SIGNS OF CHEMICAL ATTACK.

5

factory involved, any missing parts or damage incurred during shipment. You must file a "damaged or lost in shipment" claim with the carrier immediately.

COOL AGIVENTS All ESSCO submersible pumps are furnished with Cool Agivents. Cool Agivents are used to cool the exterior of the motor surface while the motor is operating exposed to the atmosphere for extended periods of time. The Cool Agivents also agitate the wet well and vent the pump case. Do not plug the Cool Agivents.

DRY PIT PUMP VENT ESSCO Dry Pit Submersible pumps are shipped with a vent valve and short nipple ready for field installation. It is recommended that the pumpage from the vent valve be piped back to the wet well above the high water level.

MINIMUM SUBMERGENCE OF PUMP SUCTION AND PIT DESIGN

Generally it is required that an evenly distrib-uted flow of non-aerated water be supplied to the pump suction. Improper pit design or insuf-ficient suction submergence can result in intake vortexing which reduces the pump's perform-ance and can result in severe damage to the pump. We recommend that you secure the advice of a qualified Consulting Engineer for the analysis and design of the suction pit. Significant engi-neering data on pit design is provided in the Hy-draulic Institute Standards. Upon request, ESSCO will review plans and give general comments on the installation, but will not approve such plans for a specific instal-lation and will accept no responsibility or liability for the performance of the pump intake struc-ture.

2. It has been installed but operation is delayed pending completion of construction. 3. There are long periods (30 days or more) be-tween operation cycles. 4. The pump is shut down for periods of longer than 30 days. NOTE: Storage requirements vary depending

on the length of storage, the climatic environment and the equipment. For storage periods of three months or longer, contact the manufacturer for specific instructions. Improper storage could damage the equipment which would result in non-warranty covered restoration or non-warranty covered product failures.

INTRODUCTION

This manual contains information which is the result of engineering research and experience. It is designed to supply instructions for the installa-tion, operation and maintenance of your pump. Failure or neglect to properly install, operate or maintain your pump may result in personal in-jury, property damage or unnecessary damage to the equipment. Variations exist in both the equipment used with these pumps and in the particular installation of the pump and motor. Specific operating instruc-tions are not within the scope of this manual. The manual contains general rules for installa-tion, operation and maintenance of the pump. Observe and heed all caution or danger tags at-tached to the equipment or included in this book-let. INSTALLATION OF SUBMERSIBLE AND DRY

PIT SUBMERSIBLE PUMPS

UNPACKING AND INSPECTION Upon receipt, carefully unpack and inspect the pump and driver assemblies and individual parts to insure none are missing or damaged. Inspect all boxes and packing material for loose parts before discarding and report immediately to the

CAUTION UNDER NO CIRCUMSTANCES SHALL THE MINIMUM SUBMERGENCE LEVEL BE BE-LOW THE PUMP VOLUTE AND MOTOR BRACKET ADAPTER PLATE.

6

fit firmly between the foundation and the stand. If leveling nuts are installed on the anchor bolts and are used for alignment, follow the same procedure as with shims or wedges. Support the pump with additional shims or wedges if necessary. Make sure that all nuts and shims are in firm contact with the stand. Tighten the foundation bolts snugly, but not too firmly, and recheck for alignment before grouting.

GROUTING When the alignment is correct, the unit should be grouted using a high grade non-shrinking grout. Do not fill the pipe sleeves with grout. If leveling nuts are used, make sure they are not embedded in grout. Provide access in the grout to the leveling nuts so that they can be backed off after the grout has cured. Allow the grout to fully cure before backing off the level-ing nuts (if used) and firmly tightening the foun-dation bolts. Then recheck the alignment be-fore connecting the piping.

PIPING

INSTALLATION WHEN PUMPS ARE FURNISHED WITH A BOLT DOWN STAND OR

VERTICAL PUMP STAND

FOUNDATION FOR PUMP STANDS The foundation should have a level surface and be of sufficient mass to prevent vibration and form a permanent rigid support for the unit. The most satisfactory foundations are concrete with anchor bolts of adequate size embedded in the foundation in pipe sleeves with an inside diame-ter 2-1/2 times larger than the bolt diameter. This will allow for final accurate positioning of the unit. Recommended anchor bolt design is shown be-low.

LEVELING OF THE PUMP UNIT Lower the pump onto the foundation, positioning the pump so the anchor bolts are aligned in the middle of the holes. Set the pump on metal shims or metal wedges placed directly under the part of the stand carry-ing the greatest weight, and spaced close enough to give uniform support and stability. Adjust the metal shims or wedges until the dis-charge flange of the submersible pump is level and plumb. Make sure that all shims or wedges

CAUTION DO NOT OVER-TIGHTEN ANCHOR BOLTS OR THE STAND MAY BE DISTORTED.

CAUTION ALL PIPING CONNECTIONS MUST BE MADE WITH THE PIPE IN A FREE SUP-PORTED STATE, AND WITHOUT THE NEED TO APPLY VERTICAL OR SIDE PRESSURE TO OBTAIN ALIGNMENT OF THE PIPING WITH THE PUMP DISCHARGE FLANGE. DO NOT USE PUMP TO SUPPORT DIS-CHARGE PIPING.

CAUTION THE MOTOR THERMAL CIRCUIT AND MOISTURE DETECTORS MUST BE CON-NECTED PER MANUFACTURER'S RE-QUIREMENTS, OTHERWISE THE MOTOR WARRANTY WILL BE VOID.

7

A. After the pump is installed and with the discharge valve closed, start the motor ac -cording to the manufacturer's instructions. B. Open the discharge valve slowly to pre-vent water hammer, and to allow the dis-charge line to fill completely. C. Monitor the motor amperage as the dis -charge gate valve is opened. Do not ex-ceed the service factor of the motor or ex-treme damage to the motor may occur.

OPERATING AT REDUCED CAPACITY In a typical application covering a wide range of flow rates, a variable speed driver is often used to adjust pump capacity and this is taken into consideration by ESSCO when selecting the pump and impeller trim. Although these pumps are applicable over a wide range of operating conditions, care should be exercised when doing so, especially when the actual conditions differ from the sold for conditions. You should always contact your nearest ESSCO representative be-fore operating the pumps at any condition other than that for which they were sold.

INITIAL STARTUP OF THE PUMPS

MECHANICAL SEALS

For Dry Pit Submersible pumps be sure the vent valve is open to allow air to escape from the vo-lute. If the vent valve is not open an air pocket can form and cause damage to the mechanical seal.

CAUTION DRY OPERATION OF THE PUMP WILL CAUSE DAMAGE TO THE MECHANICAL SEAL. MAKE ABSOLUTELY CERTAIN THE VOLUTE IS PRIMED.

WARNING DO NOT SUBMERGE CUT ENDS OF POWER CORDS IN LIQUID. THIS WILL DAMAGE CA-BLES AND VOID THE MANUFACTURERS WARRANTY. SUBMERSIBLE PUMP POWER CORDS SHOULD BE INSPECTED THOR-OUGHLY EACH TIME THE PUMP IS RE-MOVED FROM SERVICE. BE SURE TO CHECK FOR SIGNS OF CHEMICAL ATTACK.

WARNING BEFORE APPLYING POWER TO PUMP MO-TOR CHECK SUPPLY VOLTAGE TO BE SURE IT IS CORRECT. BE SURE MOTOR IS WIRED FOR CORRECT VOLTAGE.

CAUTION

PRIOR TO WORKING ON ANY ELECTRI-CAL OR PUMP EQUIPMENT, SAFETY

ELECTRICAL LOCKOUT CIRCUITS SHOULD BE INSTALLED AND LOCKED OUT TO PREVENT SERIOUS INJURY OR

DEATH. REVIEW ALL LOCAL, STATE, FED-ERAL CODES AND OSHA REQUIREMENTS

BEFORE WORKING ON ANY PUMPING EQUIPMENT.

SAFETY IS YOUR RESPONSIBILITY

8

4. Specific gravity or viscosity of liquid pumped is too high.

5. Mechanical defects: Shaft bent. Rotating element bind.

6. System head lower than design. 7. Incorrect diameter impeller.

VIBRATION OR NOISE 1. Foundation bolts loose or defect in grouting. 2. Mechanical defects: Shaft bent. Rotating

element bind. 3. Head lower than rating, pumps too much liq-

uid. 4. Pump strain - improperly supported or

aligned. 5. Pump running at shut-off condition. 6. Air in liquid. 7. Suction partially plugged. 8. Pump operating in the wrong rotation.

NOTE: ALL REPAIRS ON U.L. LISTED SUB-MERSIBLE MOTORS SHOULD BE PERFORMED BY AN AUTHORIZED REPAIR FACILITY.

SUBMERSIBLE VORTEX PUMP TROUBLESHOOTING

If you have followed the installation and startup procedures outlined in this manual, your pump should provide reliable service and long life. However, if operating problems do occur, signifi-cant time and expense can be saved if you use the following check list to eliminate the most common causes of those problems.

IF THE PUMP IS OPERATING IN THE REVERSE ROTATION, THE MOTOR WILL DRAW UP TO 50% MORE AMPERAGE THAN WHEN OPERATING IN THE CORRECT ROTATION. INSUFFICIENT DISCHARGE PRESSURE OR

FLOW 1. Pump not primed, Cool Agivents plugged. 2. Speed too low. Check driver. 3. Discharge head too high. 4. Impeller damaged. 5. Air in liquid. 6. Impeller diameter too small. 7. Insufficient net positive suction head. 8. Discharge valves not open.

LOSS OF SUCTION DURING OPERATION 1. Air or gases in liquid. 2. Wrong direction of rotation.

EXCESSIVE POWER CONSUMPTION 1. Pumps are running in wrong direction. 2. Speed too high. 3. Head lower than rating, pumps too much liq-

uid.

CAUTION TO REDUCE POSSIBILITY OF IGNITION OF HAZARDOUS MATERIALS DO NOT OPEN ELECTRICAL EQUIPMENT UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS, AND ALL ELECTRICAL POWER IS DISCON-NECTED TO ELECTRICAL EQUIPMENT.

CAUTION ALL ELECTRICAL EQUIPMENT INSTALLED IN THE WET WELL SHALL BE RATED FOR HAZARDOUS LOCATIONS OR BE INTRINS I-CALLY SAFE.

CAUTION U.L. LISTING APPLIES ONLY TO CLASS 1, DIVISION 1, GROUPS C AND D WHEN USED WITH RELIANCE OR US ELECTRICAL SUB-MERSIBLE MOTOR.

CAUTION PRIOR TO WORKING ON ANY ELECTRI-

CAL OR PUMP EQUIPMENT, SAFETY ELECTRICAL LOCKOUT CIRCUITS

SHOULD BE INSTALLED AND LOCKED OUT TO PREVENT SERIOUS INJURY OR




9

INSUFFICIENT DISCHARGE PRESSURE

OR FLOW 1. Pump not primed, Cool vent plugged. 2. Speed too low. Check driver. 3. Discharge head too high. 4. Impeller damaged. 5. Air in liquid. 6. Impeller diameter too small. 7. Insufficient net positive suction head. 8. Discharge valves not open. 9. Pump operating in the wrong rotation.

LOSS OF SUCTION DURING OPERATION 1. Air or gases in liquid. 2. Wrong direction of rotation.

EXCESSIVE POWER CONSUMPTION

1. Pumps are running in wrong direction. 2. Speed too high. 3. Head lower than rating, pumps too much liq-

uid. 4. Specific gravity or viscosity of liquid pumped

is too high. 5. Mechanical defects: Shaft bent. Rotating

element bind. 6. System head lower than design. 7. Incorrect diameter impeller.

VIBRATION OR NOISE 1. Foundation bolts loose or defect in grouting. 2. Mechanical defects: Shaft bent. Rotating

element bind. 3. Head lower than rating, pumps too much liq-


aligned. 5. Pump running at shut-off condition. 6. Air in liquid.

DRY PIT SUBMERSIBLE VORTEX PUMPS

PRIMING THE PUMP The priming procedure is different for positive and negative head* systems. The following pro-cedures should be followed for a positive or flooded suction head system:

1. Open the vent valve on the highest point of the pump casing or motor flange. 2. Open all suction valves. 3. Allow the liquid to flow from the vent valve until all the air bubbles have es-caped. 4. Be sure the vent openings remain open to avoid air locking the pump. 5. The pump is now primed.

*- Consult ESSCO or ESSCO's local representa-tive before using a vortex pump in a system where a negative head condition exists.

STARTING THE PUMP

A. After the pump is primed, and with the discharge valve closed and the suc-tion valve open, start the motor accord-ing to the manufacturer's instructions.

B. Open the discharge valve slowly to prevent water hammer, and allow the discharge line to fill completely.

C. Monitor the motor amperage as the discharge gate valve is opened. Do not exceed the service factor of the motor or extreme damage to the motor may oc-cur.

DRY PIT SUBMERSIBLE VORTEX PUMPS

TROUBLESHOOTING If you have followed the installation and startup procedures outlined in this manual, your pump should provide reliable service and long life. However, if operating problems do occur, signifi-cant time and expense can be saved if you use the following check list to eliminate the most common causes of those problems.

CAUTION IF THE PUMP IS OPERATING IN THE RE-VERSE ROTATION, THE MOTOR WILL DRAW UP TO 50% MORE AMPERAGE THAN WHEN OPERATING IN THE CORRECT RO-TATION.

10

4. Impeller damaged. 5. Air in liquid. 6. Impeller diameter too small. 7. Insufficient net positive suction head. 8. Discharge valves not open. 9. Pump operating in the wrong rotation.

LOSS OF SUCTION DURING OPERATION 1. Air or gases in liquid. 2. Suction plugged or smothered.

EXCESSIVE POWER CONSUMPTION 1. Speed too high. 2. Head lower than rating, pumps too much liq-

uid. 3. Specific gravity or viscosity of liquid is too

high. 4. Mechanical defects: Shaft bent. Rotating

element bind. 5. System head lower than design. 6. Incorrect diameter impeller.

VIBRATION OR NOISE

1. Foundation bolts loose or defect in grouting. 2. Mechanical defects: Shaft bent. Rotating

element binds. 3. Head lower than rating, pumps too much liq-


aligned. 5. Pump running at shut-off condition. 6. Air in liquid. 7. Suction partially plugged and/or impeller par-

tially plugged. 8. Pump is running in the wrong direction. 9. Impeller and case wear ring clearance too

close.

7. Suction partially plugged. 8. Pump operating in the wrong rotation.

SUBMERSIBLE NON-CLOG PUMPS

TROUBLESHOOTING If you have followed the installation and startup procedures outlined in this manual, your pump should provide reliable service and long life. However, if operating problems do occur, signifi-cant time and expense can be saved if you use the following check list to eliminate the most common causes of those problems.

INSUFFICIENT DISCHARGE PRESSURE OR FLOW

1. Pump not primed, Cool Agivents plugged. 2. Speed too low. Check driver. 3. Discharge head too high.


CAUTION U.L. LISTING APPLIES ONLY TO CLASS 1, DIVISION 1, GROUPS C AND D WHEN USED WITH RELIANCE OR US ELECTRICAL SUBMERSIBLE MOTOR.

CAUTION TO REDUCE POSSIBILITY OF IGNITION OF HAZARDOUS MATERIALS DO NOT OPEN ELECTRICAL EQUIPMENT UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS, AND ALL ELECTRICAL POWER IS DISCON-NECTED TO ELECTRICAL EQUIPMENT. IF THE PUMP IS OPERATING IN THE RE-VERSE ROTATION, THE PUMP WILL VI-BRATE AND PRODUCE UNSTABLE FLOW AND PRESSURE. IN SOME CASES THE PUMPS MAY MAKE NOISE.


CAUTION U.L. LISTING APPLIES ONLY TO CLASS 1, DIVISION 1, GROUPS C AND D WHEN USED WITH A RELIANCE OR US ELECTRI-CAL SUBMERSIBLE MOTOR.

11

water hammer, and allow the discharge line to fill completely.

C. Monitor the motor amperage as the dis -

charge gate valve is opened. Do not ex-ceed the service factor of the motor or extreme damage to the motor may occur.

If you have followed the installation and startup procedures outlined in this manual, your pump should provide reliable service and long life. However, if operating problems do occur, sig-nificant time and expense can be saved if you use the following check list to eliminate the most common causes of those problems. DRY PIT SUBMERSIBLE NON-CLOG PUMPS

TROUBLESHOOTING If you have followed the installation and startup procedures outlined in this manual, your pump should provide reliable service and long life. However, if operating problems do occur, sig-nificant time and expense can be saved if you use the following check list to eliminate the most common causes of those problems.

INSUFFICIENT DISCHARGE PRESSURE OR

FLOW 1. Pump not primed, Cool vent plugged. 2. Speed too low. Check driver. 3. Discharge head too high. 4. Impeller damaged. 5. Air in liquid.

NOTE: ALL REPAIRS ON U.L. LISTED SUB-MERSIBLE MOTORS SHOULD BE PERFORMED BY AN AUTHORIZED REPAIR FACILITY.

DRY PIT SUBMERSIBLE NON-CLOG PUMPS

PRIMING THE PUMP

The priming procedure is different for positive and negative head* systems. The following pro-cedures should be followed for a positive or flooded suction head system:

1. Open the vent valve on the highest point of the pump casing or motor flange.

2. Open all suction valves. 3. Allow the liquid to flow from the vent valve

until all the air bubbles have escaped. 4. Be sure the vent openings remain open to

avoid air locking the pump. 5. The pump is now primed. *- Consult ESSCO or ESSCO's local repre-

sentative before using a non-clog pump in a system where a negative head condition exists.

STARTING THE PUMP

A. After the pump is primed, and with the dis-

charge valve closed and the suction valve open, start the motor according to the manufacturer's instructions.

B. Open the discharge valve slowly to prevent







CAUTION TO REDUCE POSSIBILITY OF IGNITION OF HAZARDOUS MATERIALS DO NOT OPEN ELECTRICAL EQUIPMENT UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS, AND ALL ELECTRICAL POWER IS DISCON-NECTED TO ELECTRICAL EQUIPMENT. IF THE PUMP IS OPERATING IN THE RE-VERSE ROTATION, THE PUMP WILL VI-BRATE AND PRODUCE UNSTABLE FLOW AND PRESSURE. IN SOME CASES THE PUMPS MAY MAKE NOISE.

12

6. Impeller diameter too small. 7. Insufficient net positive suction head. 8. Discharge valves not open. 9. Pump operating in the wrong rotation.

LOSS OF SUCTION DURING OPERATION 1. Air or gases in liquid. 2. Suction plugged or smothered.

EXCESSIVE POWER CONSUMPTION 1. Speed too high. 2. Head lower than rating, pumps too much liq-

uid. 3. Specific gravity or viscosity of liquid is too

high. 4. Mechanical defects: Shaft bent. Rotating ele-

ment bind. 5. System head lower than design. 6. Incorrect diameter impeller.

VIBRATION OR NOISE 1. Foundation bolts loose or defect in grouting. 2. Mechanical defects: Shaft bent. Rotating ele-

ment binds. 3. Head lower than rating, pumps too much liq-


aligned. 5. Pump running at shut-off condition. 6. Air in liquid. 7. Suction partially plugged and/or impeller par-

tially plugged. 8. Pump is running in the wrong direction.


CAUTION U.L. LISTING APPLIES ONLY TO CLASS 1, DIVISION 1, GROUPS C AND D WHEN USED WITH A RELIANCE OR US ELECTRI-CAL SUBMERSIBLE MOTOR.







13

Pump Model Number: Pump Serial Number:

Date ETM Hour Meter Reading

Amp Reading Comments

PREVENTATIVE MAINTENANCE LOG

5 Year Warranty

1. The ESSCO VORTEX impeller pump liquid end is warranted for a period of five years from date of shipment to origi-nal buyer, to be free from defects in ma-terial and workmanship and to conform to any applicable drawings and specifi-cations approved by ESSCO.

2. The five year warranty is prorated as

shown below. (Parts will be replaced within the time period noted and buyer will be invoiced at the percentage rate noted with prices in effect at time of shipment of replacement parts.)

3. If within this period ESSCO receives from original buyer written notice of any alleged defect in any such apparatus


Website: www.esscopumps.com Email: [email protected] Member of the Hydraulic Institute Form 5YearStandardWarranty

and if the apparatus is found not to be in conformity with this warranty (the buyer having provided ESSCO a reasonable op-portunity to perform any appropriate test thereon), ESSCO will, at its option and ex-pense, either repair the same or supply a replacement thereof.

4. ESSCO, under either option, shall have the

right to require the original buyer to deliver the apparatus for this purpose to a desig-nated service center and the original buyer shall pay only the direct and actual cost of apparatus repair or replacement as pro-vided above.

5. Labor charges for in-warranty repairs per-

formed by ESSCO or its designated ser-vice center shall be assumed by ESSCO if the repair is completed within 6 months from date of shipment to original buyer.

6. On a repaired pump, the warranty period

shall be the residual of the original pump supplied.

ESSCO STANDARD FIVE YEAR WARRANTY

Effective Date Upon Shipment Pump S/N__________

0-18 19-31 32-45 46-60

0 % 25 % 50 % 75 %

Months From Effective Date to Original Buyer in %

Applies To:

Pump Material

Cast Iron Submersible

Stainless Steel Horizontal (HDP)

Vertical (VDP)

Column (VSCP)

Pump Type

7. Pumps destined for long term storage

shall be stored in accordance with ESSCO suggested service bulletins. Any damage to the pump and motor due to improper storage shall void this warranty.

8. ESSCO'S LIABILITY UNDER THIS

WARRANTY OR ANY OTHER WAR-RANTY WHETHER EXPRESSED OR IMPLIED IN LAW OR FACT SHALL BE LIMITED TO THE REPAIR OR RE-PLACEMENT OF DEFECTIVE MATE-RIAL AND WORKMANSHIP AND AND IN NO EVENT SHALL ESSCO BE LI-ABLE FOR CONSEQUENTIAL OR INDIRECT DAMAGES OR COSTS AS-SOCIATED WITH REMOVAL OR RE-INSTALLATION OF THE PUMPING EQUIPMENT.

9. ESSCO reserves the right to reject any

claim due to mis-application, abuse, neglect or non-maintenance of equip-ment. All rotating parts are subject to the above replacement schedule. Cast iron, ductile iron, stainless steel pumps put into grit service, without prior written factory approval, shall void all warran-ties whether expressed or implied.

10. ESSCO extends the warranty on

ESSCO manufactured parts and pumps only. All "buy-out" items carry their standard manufacturer's warranty. ESSCO'S warranty does not cover me-chanical seals. Pump units subjected to chemical attack will void this warranty.


Website: www.esscopumps.com Email: [email protected] Member of the Hydraulic Institute Form 5YearStandardWarranty

Wear Warranty 5 Year

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ESSCO PUMPS RELIANCE ELECTRIC MOTOR DATA& U.L. LISTED CONTROLS Pg ED-6

LOCKED-ROTOR INDICATING CODELETTERS

POWER CABLE SIZE

CODE LETTER KV-AMP PER HP WITHLOCKED ROTOR

SIZE DIAMETER

F 5.0 - 5.59 14 .590 +\- .030

G 5.6 - 6.29 12 .675 +\- .035

H 6.3 - 7.09 10 .735 +\- .035

J 7.1 - 7.99 8 .985 +\- .060

K 8.0 - 8.99 6 1.125 +\- .075

L 9.0 - 9.99 4 1.35 +\- .100

M 10.0 - 11.19 2 1.55 +\- .100

N 11.2 - 12.49 1 1.68 +\- .030

P 12.5 - 13.99 1\0 1.79 +\- .040

R 14.0 - 15.99 2\0 1.93 +\- .040

- POWER CABLE IS 4 CONDUCTOR CABLE- CONTROL CABLE IS 5 CONDUCTOR CABLE MOISTURE SENSING - RED & ORANGE THERMAL SWITCH - WHITE & BLACK GROUND - GREEN

3\0 2.07 +\- .050

CONTROL CABLE SIZE

SIZE DIAMETER

18 .485 +\- .025

MOTOR MODEL # HP RPM FRAME CAPACITOR VOLTS

C17G2701 1 1750 140TY 216MFD 125

C17G2702 1.5 1750 140TY 324MFD 110

C18G2702 2 1750 180TY 430MFD 110

C18G2703 3 1750 180TY 590MFD 125

C21G2702 5 1750 210TY 161MFD 250

C18G2700 1 1150 180TY 270MFD 125

C18G2701 1.5 1150 180TY 340MFD 125

C18G2700 2 1150 210TY 378MFD 125

C21G2701 3 1150 210TY 460MFD 125

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section 11010 - essco pumpssubmittals.esscopumps.com/09334apumpommanualedenglenfydaq2.pdflos...

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