CRANE PUMPS & SYSTEMS Three Phase Simplex User manual

©SJE-Rhombus
Printed in USA
PN1008718C • Rev 11/06
Installation
This control panel must be installed and serviced by a licensed
electrician in accordance with the National Electric Code NFPA-70,
state and local electrical codes.
All conduit running from the sump or tank to the control panel must
be sealed with conduit sealant to prevent moisture or gases from enter-
ing the panel. NEMA 4X enclosures are for indoor or outdoor use, pri-
marily to provide a degree of protection against corrosion, windblown
dust and rain, splashing water and hose-directed water. Cable connec-
tors must be liquid-tight in NEMA 4X enclosures.
Crane® Pump & Systems three phase panels are designed to operate with
three floats. These floats operate the pump stop, pump start, and high
level alarm functions.
NOTE: Options ordered may affect the number of floats and their
functions. Please reference the schematic provided with the con-
trol panel for proper installation.
Installation of Floats
CAUTION: If control switch cables are not wired and mounted in the cor-
rect order, the pump system will not function properly.
WARNING: Turn off all power before installing floats in pump cham-
ber. Failure to do so could result in serious or fatal electrical shock.
1. Use float label kit to identify and label cables on both the float and
stripped ends (stop, start, alarm, etc.). See schematic for float op-
tions.
2. Determine your normal operating level, as illustrated in Figure 1.
3. Mount float switches as illustrated in Figures 2-4. Be sure that floats
have free range of motion without touching each other or other equip-
ment in the basin.
If mounting clamp is used, follow steps 4-6.
4. Place the cord into the clamp as shown in Figure 2.
5. Locate the clamp at the desired activation level and secure the clamp
to the discharge pipe as shown in Figure 2.
NOTE: Do not install cord under hose clamp.
6. Tighten the hose clamp using a screwdriver. Over tightening may
result in damage to the plastic clamp. Make sure the float cable is
not allowed to touch the excess hose clamp band during operation.
NOTE: All hose clamp components are made of 18-8 stainless steel
material. See your supplier for replacements.
Warranty void if panel is modified.
Call factory with servicing questions:
[phone]
FAX [phone]
Three Phase Simplex
Installation Instructions and
Operation/Troubleshooting Manual
Piqua, Ohio
Manual Index

suspended cable
4"
tether
length
CABLE
WEIGHT
approximate
activation level
Mounting the Control Panel
1. Determine mounting location for panel. If distance exceeds
the length of either the float switch cables or the pump power
cables, splicing will be required. For outdoor or wet instal-
lation, we recommend the use of a liquid-tight junction box
with liquid-tight connectors to make required connections.
You must use conduit sealant to prevent moisture or
gases from entering the panel.
2. Mount control panel with mounting devices furnished.
3. Determine conduit entrance locations on control panel.
NOTE: Be sure the incoming power, voltage, amperage,
and phase meet the requirements of the pump motor being
installed. If in doubt, see the pump identification plate for
electrical requirements.
4. Drill proper size holes for type of connectors being used.
NOTE: If using conduit, be sure that it is of adequate size
to pull the pump and switch cables through.
5. Attach cable connectors and/or conduit connectors to con-
trol panel.
FOR INSTALLATION REQUIRING
A SPLICE, FOLLOW STEPS 6-9;
FOR INSTALLATION WITHOUT A SPLICE,
GO TO STEP 10.
Installation Instructions
6. Determine location for mounting junction box according to
state and local code requirements. Mount junction box to
proper support.
7. Run conduit to junction box. Drill proper size holes for the
type of conduit used. Attach connectors to junction box.
8. Identify and label each wire before pulling through conduit
into control panel and junction box. Make wire splice con-
nections at junction box.
9. Firmly tighten all fittings on junction box.
10. If a junction box is not required, pull cables through conduit
into control panel.
11. Set motor protective switch:
a) set the dial to match motor full load amps
b) turn dial on motor protective switch to the ON position
NOTE: Resetting the dial with power applied to the motor
protective switch could start the motor.
12. Connect pump wires directly to the motor contactor terminal
positions T1, T2, and T3.
NOTE: Three phase motors will run in either direction. Check
pump motor before installation for proper rotation. To cor-
rect rotation, change pump cable connections on any two
terminals T1-T2-T3.
13. Connect “power-in” conductors to proper locations: 208/
240/480 on 3 position terminal block. Install tagged fac-
tory wire to appropriate transformer primary voltage tap.
VERIFY CORRECT OPERATION OF CONTROL PANEL
AFTER INSTALLATION IS COMPLETE.
FIGURE 1 - Three float simplex -
pump down installation
FIGURE 2 - Mounting clamp
detail
FIGURE 3 - Internally weighted float
7"
suspended cable
approximate
activation level
FIGURE 4 - Float with cable weight
3.5 inch (9 cm)
tether length

Operations
Alarm System (Horn and Indicator)
When an alarm condition occurs, a red light and a horn will
be activated. If the test/normal/silence switch is moved to
the silence position, the horn will be silenced. When the
alarm condition is cleared, the alarm system is reset. The
alarm system can be tested by moving the test/normal/si-
lence switch to the test position.
HOA Switch
A hand-off-automatic switch is provided for the pump. In
the hand mode, the pump will turn on unless other safety
features are employed. In the automatic mode, the pump
will turn on from commands by the float switches.
Motor Protective Switch
A motor protective switch is supplied for the pump to pro-
vide an adjustable overload, branch circuit protection and
disconnect. The overload must be set in the field. To set the
overload, dial the amp scale to the pump’s full load amps
(FLA). If the FLA’s are unknown, use a calibrated amp meter
to measure the pump amperage draw under loaded condi-
tions. An auxiliary contact is wired in series with the mag-
netic contactor coil so that on an overload trip, the magnetic
contactor will be disabled. In the event of an overload trip,
the motor protective switch must be reset by first turning
the handle counterclockwise to the OFF position and then
turning the handle 90oclockwise to the ON position.
Pump Run Light
The run light will be ON in either the hand or the automatic
mode when the pump is called to run.
Control Power Light
Light will illuminate when the control circuit has power
Alarm Power Light
Light will illuminate when the alarm circuit has power
Alarm Fuse
Provides alarm circuit protection and provides a means of
disconnecting alarm circuit power
Control Fuse
Provides control circuit protection and provides a means of
disconnecting control circuit power
Dry Auxiliary Contacts (optional)
Normally open - Contacts are open under normal condi-
tions and closed when alarm condition is present.
Normally closed - Contacts are closed under normal con-
ditions and open when alarm condition is present.
Both types automatically reset once alarm condition is
cleared.
Seal Failure Circuit and
Indicator Light (Optional)
The seal fail circuit has resistance sensitivity and will sense
the presence of water in the pump seal chamber. Upon in-
stallation, turn the sensitivity dial on the seal fail module to
the point where the light turns on, then dial back slowly until
the light turns off. If water enters the seal chamber at this
point, the seal chamber circuit will sense a change in resis-
tance. After a short time delay, the indicator light will turn on.
When the condition is cleared, the relay will de-energize and
the indicator light will turn off. The seal fail relay has a sen-
sitivity adjustment so that false readings may be tuned out.
Thermal Cutout (Optional)
The thermal cutout circuit is wired in series with the mag-
netic contactor coil. If the pump’s thermal switch opens on
high temperature, the magnetic contactor will turn off and
stop the pump. When the thermal switch cools and closes,
the magnetic contactor will turn on if the pump is called to
run.
NOTE: Some options ordered may not be included in this
manual.
Crane® Pumps & Systems three phase control panels are de-
signed to operate in a three float system as standard. When
all floats are in the open or OFF position, the panel is inactive.
As the liquid level changes and closes the stop float, the panel
remains inactive until the start float also closes. At this point
the pump will start, assuming the HOA switch is in the AU-
TOMATIC mode and the power is ON. The pump will re-
main ON until both the stop and start floats open (return to
the OFF position). If the liquid level travels beyond both the
stop and start floats and reaches the alarm float, the audio/
visual alarm will be activated. The alarm horn can be si-
lenced by pressing the silence switch.
For information regarding the operations
of options not listed here or servicing questions,
please call a customer service technician at
[phone]
FAX [phone]
Warranty void if panel is modified.

Fuses
Check the continuity of the fuse. With power OFF, pull the fuse out
of the fuse block. With the ohmmeter on the R X 1 scale, measure
resistance. A reading of infinity indicates a blown fuse and must
be replaced. Replace fuse with same type, voltage and amp rat-
ing.
Indicator Lights
If defective, replace all indicator pilot lights with same type.
Magnetic Contactor
Contacts - Check the contacts for severely burnt or welded con-
tacts. The contactor arm should move freely.
Coil - Measure the coil by disconnecting one of the coil leads.
Measure the coil resistance by setting the ohmmeter on the R X 1
scale. A defective coil will read zero or infinity, indicating a short or
opened coil respectively. Replace defective contactor with same
type.
NOTE: Readings may vary depending on accuracy of the mea-
suring device.
Motor Protective Switch
Test by inserting a paper clip or other small device into the test
hole and push to the left. The relay should trip.
Alarm Horn
Moving the alarm test/normal/silence switch to the test position or
activating the alarm float should turn on the alarm horn. If the horn
does not sound replace with horn of same type.
Alarm Light
Moving the alarm test/normal/silence switch to the test position or
activating the alarm float should turn on the alarm light. If the light
does not activate, replace with bulb of same type.
Float Controls
Check the floats during their entire range of operation. Clean, ad-
just, or replace floats.
Checking the float resistance - The float resistance can be mea-
sured to determine if the float is operating correctly or is defective.
Use the following procedure to measure the float resistance:
1. Isolate the float by disconnecting one or both of the float leads
from the float terminals.
2. Place one ohmmeter lead on one of the float wires, and the
other ohmmeter lead on the other float wire.
3. Place the ohmmeter dial to read ohms and place on the R X 1
scale. With the float in the “off” position, the scale should read
infinity (high resistance). Replace the float if you do not get
this reading. With the float in the ON position, the scale should
read nearly zero (very low resistance). Replace the float if
you do not get this reading.
NOTE: Readings may vary depending on the length of wire and
accuracy of the measuring device.
Troubleshooting
CRANE®PUMPS & SYSTEMS, INC. warrants to the original con-
sumer that this product shall be free of manufacturing defects for
three years after the date of consumer purchase. During that
time period and subject to the conditions set forth below, CRANE®
PUMPS & SYSTEMS, INC. will repair or replace, for the original
consumer, any component which proves to be defective due to
defective materials or workmanship of CRANE®PUMPS & SYS-
TEMS, INC.
ELECTRICAL WIRING AND SERVICING OF THIS PRODUCT MUST
BE PERFORMED BY A LICENSED ELECTRICIAN.
THIS WARRANTY DOES NOT APPLY: (A) to damage due to light-
ning or conditions beyond the control of CRANE®PUMPS & SYS-
TEMS, INC.; (B) to defects or malfunctions resulting from failure
to properly install, operate or maintain the unit in accordance with
printed instructions provided; (C) to failures resulting from abuse,
misuse, accident, or negligence; (D) to units which are not in-
stalled in accordance with applicable local codes, ordinances,
or accepted trade practices, and (E) to units repaired and/or modi-
fied without prior authorization from CRANE®PUMPS & SYSTEMS,
INC.
Some states do not allow limitations on how long an implied war-
ranty lasts, so the above limitation may not apply to you. Some
states do not allow the exclusion or limitation of incidental or con-
sequential damages, so the above limitation or exclusion may
not apply to you. This warranty gives you specific legal rights, and
you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE: The consumer shall assume
all responsibility and expense for removal, reinstallation, and
freight. Any item to be repaired or replaced under this warranty
must be returned to CRANE®PUMPS & SYSTEMS, INC., or such
place as designated by CRANE®PUMPS & SYSTEMS, INC..
ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS
ARE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY.
BARNES®SHALL NOT, IN ANY MANNER, BE LIABLE FOR ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES AS A RESULT OF A
BREACH OF THIS WRITTEN WARRANTY OR ANY IMPLIED WAR-
RANTY.
CRANE®Three-Year Limited Warranty