Crane UltraGRIND 100 Simplex UGP Series User manual

UltraGRINDCONTROL PANELS
INSTALLATION & OPERATION MANUAL
Form No. 099813-Rev. D
IMPORTANT: Read all instructions in this manual before operating. 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.
Series: 100 - Simplex
UGP, UGP-P, UCP & UCP-P
Series: 200 - Duplex
UGP & UCP
420 Third Street/P.O. Box 603 83 West Drive, Brampton
Piqua, Ohio 45356-0603 Ontario, Canada L6T 2J6
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
www.cranepumps.com
PUMPS & SYSTEMS
A Crane Co. Company
DISCONTINUED
Parts may
NOT be available
Manual Index

TABLE OF CONTENTS
USERS GUIDE .....................................................................................................................3
WARNINGS AND SAFETY PRECAUTIONS........................................................................ 4
SPECIFICATIONS ................................................................................................................ 5 - 6
A. GENERAL INFORMATION
Receiving, Storage, Service Centers, Location..................................................................... 7
B. PRODUCT REVIEW
General Component Description)..........................................................................................7 - 8
Principles of Operation - Simplex.......................................................................................... 8
Principles of Operation - Duplex ........................................................................................... 8
C. INSTALLATION OF WALL MOUNT PANELS....................................................................... 11
INSTALLATION OF PANELS IN BASIN COVER ................................................................. 11 - 12
D. REPLACEMENT PARTS ...................................................................................................... 12
TYPICAL UGP SIMPLEX WALL MOUNT SCHEMATIC ...................................................... 13
TYPICAL UGP-P SIMPLEX COVER M OUNT SCHEMATIC ............................................... 14
TYPICAL UGP DUPLEX WALL MOUNT SCHEMATIC ........................................................ 15
TYPICAL UGP COMPONENT DRAWING /PARTS LIST ..................................................... 16
TYPICAL UCP SIMPLEX WALL MOUNT SCHEMATIC ...................................................... 17
TYPICAL UCP-P SIMPLEX COVER MOUNT SCHEMATIC ............................................... 18
TYPICAL UCP COMPONENT DRAWING /PARTS LIST ..................................................... 19
ELECTRICAL DATA ............................................................................................................. 20
RETURNED GOODS POLICY .............................................................................................. 21
WARRANTY
REGISTRATION
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. 1997, 2000, 2003 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 fitted 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 non-leaded 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 infiltration or direct flow 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 confined 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 backflow from the pressure sewer.)
15. Make sure level controls are provided at time of installation.
PUMPS
16. Recommended no more than 10 starts per hour.
17. Pumps build up heat and pressure during operation-allow time for pumps to cool before handling or servicing.
18. Only qualified personnel should install, operate and repair pump.
19. Keep clear of suction and discharge openings. DO NOT insert fingers in pump with power connected.
20. Do not pump hazardous materials (flammable, caustic, etc.) unless the pump is specifically designed and designated to handle
them.
21. Do not block or restrict discharge hose, as discharge hose may whip under pressure.
22. Make sure lifting handles are securely fastened each time before lifting.
23. Do not lift pump by the power cord.
24. Do not exceed manufacturers recommendation for maximum performance, as this could cause the motor to overheat.
25. Secure the pump in its operating position so it can not tip over, fall or slide.
26. Keep hands and feet away from impeller when power is connected.
27. Submersible Pumps are not approved for use in swimming pools, recreational water installations, decorative fountains or any
installation where human contact with the pumped fluid is common.
28. Do not operate pump without safety devices in place.
29. Always replace safety devices that have been removed during service or repair.
ELECTRICAL
30. 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.
31. To reduce risk of electrical shock, always disconnect the pump from the power source before handling or servicing. Lock out
power and tag.
32. Any wiring of pumps should be performed by a qualified electrician.
33. Never operate a pump with a power cord that has frayed or brittle insulation.
34. Cable should be protected at all times to avoid punctures, cut, bruises and abrasions - inspect frequently.
35. Never handle connected power cords with wet hands.
36. Do not remove cord and strain relief. Do not connect conduit to pump.
37. 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.
38. Do Not operate the pump in the "HAND" control position and leave the pump unattended.
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

Standard Features:
•NEMA 4X Fiberglass enclosure.
•Pump circuit breaker.
•UGP - IEC rated motor starter with ambient
compensated overload relay. UCP - Pumps have
motor overload intragal in pump motor windings.
•Motor Start pushbutton.
•Separate circuit fuses for Control and Alarm circuits.
•25 watt high level alarm light.
•UGP - Pre-installed start capacitor kit.
UCP - SGPC pumps have capacitor internal to pump.
•Terminal strip and ground lug for all incoming
connections.
Optional Features:
•90 db alarm horn with 10 amp Silence control relay
and NEMA 4X Silence pushbutton.
•7 digit elapsed time meter with meter running indicator.
•30 amp Automatic Transfer Switch with easy access
30 amp reverse pin portable generator receptacle and
weatherproof cover.
•Seal Leak Indication with 120 volt indicator lamp and
terminals for 2 leak probe wires (UGP Only).
UGP Panels used with SGV Grinder Pumps.
UCP Panels used with SGPC Grinder Pumps.
UGP
SIMPLEX
UGP
DUPLEX
UCP
SIMPLEX
UCP
DUPLEX
DESCRIPTION
UGP-101 UGP-201 UCP-101 UCP-201 NEMA 4X Fiberglass Enclosure, Operating Controls, Alarm Light.
UGP-102 UGP-202 UCP-102 UCP-202 NEMA 4X Fiberglass Enclosure, Operating Controls, Audio Alarm
w/Push Button Silence & Alarm Light.
UGP-103 UGP-203 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, & Alarm Light.
UGP-104 UGP-204 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Audio Alarm w/Push Button Silence & Alarm Light.
UGP-105 UGP-205 UCP-105 UCP-205 NEMA 4X Fiberglass Enclosure, Operating Controls, Generator
Receptacle & Alarm Light.
UGP-106 UGP-206 UCP-106 UCP-206 NEMA 4X Fiberglass Enclosure, Operating Controls, Generator
Receptacle, Audio Alarm w/Push Button Silence & Alarm Light.
UGP-107 UGP-207 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Generator Receptacle & Alarm Light.
UGP-108 UGP-208 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Generator Receptacle, Audio Alarm w/Push Button Silence
& Alarm Light.
UGP-109 UGP-209 UCP-109 UCP-209 NEMA 4X Fiberglass Enclosure, Operating Controls, Alarm Light &
Elapsed Time Meter.
UGP-110 UGP-210 UCP-110 UCP-210 NEMA 4X Fiberglass Enclosure, Operating Controls, Audio Alarm
w/Push Button Silence, Alarm Light & Elapsed Time Meter.
UGP-111 UGP-211 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Alarm Light & Elapsed Time Meter.
UGP-112 UGP-212 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Audio Alarm w/Push Button Silence, Alarm Light & Elapsed
Time Meter.
UGP-113 UGP-213 UCP-113 UCP-213 NEMA 4X Fiberglass Enclosure, Operating Controls, Generator
Receptacle, Alarm Light & Elapsed Time Meter.
UGP-114 UGP-214 UCP-114 UCP-214 NEMA 4X Fiberglass Enclosure, Operating Controls, Generator
Receptacle, Audio Alarm w/Push Button Silence, Alarm Light, &
Elapsed Time Meter.
UGP-115 UGP-215 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Generator Receptacle, Alarm Light & Elapsed Time Meter.
UGP-116 UGP-216 N/A N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak
Detection, Generator Receptacle, Audio Alarm w/Push Button Silence,
Alarm Light & Elapsed Time Meter.
IMPORTANT: Control panel sizes and options will vary depending on contract specifications.
Standard UGP & UCP UltraGRIND Control Panels
5

Standard Features:
•NEMA 4X Fiberglass enclosure.
•Pump circuit breaker.
•UGP - IEC rated motor starter with ambient
compensated overload relay. UCP - Pumps have
motor overload intragal in pump motor windings.
•Motor Start pushbutton.
•Separate circuit fuses for Control and Alarm circuits.
•25 watt high level alarm light.
•UGP - Pre-installed start capacitor kit.
UCP - SGPC pumps have capacitor internal to pump.
•Terminal strip and ground lug for
all incoming connections.
Optional Features:
•90 db alarm horn with 10 amp Silence control relay
and NEMA 4X Silence pushbutton.
•7 digit elapsed time meter with meter running indicator.
•30 amp Automatic Transfer Switch with easy access
30 amp reverse pin portable generator receptacle and
weatherproof cover.
•Seal Leak Indication with 120 volt indicator lamp and
terminals for 2 leak probe wires.
UGP Panels used with SGV Grinder Pumps.
UCP Panels used with SGPC Grinder Pumps.
-P panels used with CONVERTIBLE Cover.
UGP-P
SIMPLEX
UCP-P
SIMPLEX
DESCRIPTION
UGP-101/2-P UCP-101/2-P NEMA 4X Fiberglass Enclosure, Operating Controls & Remote Alarm Light.
UGP-101/2-P UCP-101/2-P NEMA 4X Fiberglass Enclosure, Operating Controls, with Remote Audio Alarm
w/Push Button Silence & Alarm Light.
UGP-103/4-P N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak Detection, & Alarm
Light.
UGP-103/4-P N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak Detection, Remote
Audio Alarm w/Push Button Silence & Alarm Light.
UGP-109/10-P UCP-109/10-P NEMA 4X Fiberglass Enclosure, Operating Controls, Elapsed Time Meter, Remote
Alarm Light.
UGP-109/10-P UCP-109/10-P NEMA 4X Fiberglass Enclosure, Operating Controls, Elapsed Time Meter, Remote
Audio Alarm w/Push Button Silence & Alarm Light.
UGP-111/12-P N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak Detection, Elapsed
Time Meter, Remote Alarm Light.
UGP-111/12-P N/A NEMA 4X Fiberglass Enclosure, Operating Controls, Seal Leak Detection, Elapsed
Time Meter, Remote Audio Alarm w/Push Button Silence & Alarm Light.
IMPORTANT: Control panel sizes and options will vary depending on contract specifications.
Standard UGP-P & UCP-P UltraGRIND Control Panels
MOUNTING:
* = WALL MOUNT (STD).
P = POLY INSERT MOUNT
* Left Blank
VOLTAGE:
0 = 200 VOLT, 1 PHASE, 60HZ
1 = 115 VOLT, 1 PHASE, 60HZ
2 = 230 VOLT, 1 PHASE, 60HZ
3 = 230 VOLT, 3 PHASE, 60HZ
4 = 460 VOLT, 3 PHASE, 60HZ
5 = 575 VOLT, 3 PHASE, 60HZ
6 = 200 VOLT, 3 PHASE, 60HZ
UCP -101 -2 1 -P
PUMP SERIES:
UGP =UltraGRIND
UCP =UltraCAV
HORSEPOWER:
1 = 1HP
2 = 2HP
3 = 3HP
5 = 5HP
7.5 = 7.5HP
PANEL MODEL:
101 thru 116, Simplex
201 thru 216, Duplex
6

SECTION A: GENERAL INFORMATION
A-1) RECEIVING:
Upon receiving the Control Panel, 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:
For best results, control panels should be stored in a
temperature controlled area that provides protection from the
elements and humidity.
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 [phone].
A-4) LOCATION:
Any alterations from the standard must be in accordance with
local codes. These control panels are not to be installed in
locations that would be classified as a HAZARDOUS location
in accordance with NEC ANSI/NFPA 70.
SECTION B - PRODUCT OVERVIEW
The UGP & UCP Series Panels were developed to support the
Barnes UltraGRIND low pressure sewer grinder packages.
The electrical hardware has been designed to function with the
Barnes SGV & SGPC Series Grinder Pumps. A detailed wiring
diagram is enclosed in each control panel, and should be
referred to during installation and package start-up.
B-1) GENERAL COMPONENTS DESCRIPTION:
The control panel is the brain of the pressure sewer basin
package. It receives water level or pump temperature signals
through the wiring from the basin package system. The panel
will turn the pump "ON" or "OFF" depending on the signals
received. A typical control wiring diagram can be seen on
pages 13, 14, 15 & 18, 19 20. The following are descriptions
of each component and their operation.
Circuit Breaker (CB) - The circuit breaker serves two
purposes. First it is a main disconnect for the simplex UGP and
UCP panels and pump power disconnect for duplex panels.
When servicing the pump or control panel, this circuit breaker
should be turned off and fuses pulled (duplex only). For stations
with panels mounted in the cover, this DOES NOT disconnect
the incoming power passing through the alarm box. The
second function of the circuit breaker is protection against short
circuit conditions. The circuit breaker will open or break a power
circuit under a catastrophic failure such as a motor winding or
cable short. The purpose of this action is to prevent fire and
wire damage.
Motor Start Contactor (MS) - The motor starter is a device
made up of two main components; the motor contacts and
electromagnetic coil. When the coil is energized by a 120 volt
control voltage, the armature closes the "double break" starter
contacts applying 115 or 230 volt power to the motor depending
on pump voltage. Terminal "T1" & "T2" are the pump
connection points for the SGPC pumps.
Control Circuit Fuses (FU1, FU2) - These fuses offer
overload protection to the control and alarm circuits. They are
down stream of the breaker (simplex). These fuses are sized
to protect the control circuit from a short and connected directly
to incoming power on duplex.
Overload (OL) (UGP Panels Only) - The overload relay is
installed attached to the motor starter. The purpose of the
overload relay is to protect the motor and turn it off when an
overload condition is sensed. The overload relay has three
"heaters" inside along with control contacts for use in the
control. When the operating current of the motor exceeds the
current set on the overload relay, the normally closed contact
in the control circuit will open and stop the motor. The overload
relay will need to be manually reset if it has been tripped due
to an overload situation.
Start & Run Capacitor (SC, RC) (UGP Panels Only) - On
single phase pumps, a capacitor is placed in series with the
start windings and in series with the run windings. These are
commonly referred to as the start and run capacitors. The start
capacitor improves the starting torque of the pump. The run
capacitor is designed to improve the motor efficiency during
operation.
Start Relay (SR) (UGP Panels Only)- The start relay is
installed in conjunction with the start and run capacitors on a
single phase motor. This device allows the motor to start and
accelerate up to speed under a load. When the motor contactor
is initially closed, the start capacitor boosts voltage to the
motor. The start relay monitors this voltage and disconnects
the start capacitor when the voltage reaches the designed
value, corresponding to a desired motor speed. The run
capacitor remains attached to the start winding at all times.
Alarm Light - A red indicator light located on the top of wall
mounted panels, or on the alarm box for panels located in the
cover. It is designed to be turned on when the fluid level in the
basin is above the normal pump "ON" point. When the Alarm
Light is lit, it either indicates a severe inflow of fluid, or a failure
of the pump to turn on. Service of the basin in a timely manner
will generally be required.
Audible Alarm Horn - An option on the UGP and UCP series
panels is to have an Audible Alarm Horn sound when the Alarm
Light is activated. The audible alarm can then be manually
silenced by pressing the silence button on the wall mounted
panels which de-energizes the alarm horn relay, or by turning
the manual On/Off switch located on the alarm box, to "Off" for
panels mounted in the cover. Remember to reset the Alarm
Horn once the problem has been corrected for units with the
manual switch.
7

Seal Leak Indicator (UGP Only) - This is an optional feature
on the UGP panel. A separate circuit in the UGP panel can be
wired to a SGV Grinder pump with seal probes, and if the outer
seal on the pump has failed allowing pumping fluid into the
chamber, a indicator light will be lit. The pump then can be
pulled for evaluation and service.
Terminal Strip - This is the connection point for all signal wires
going to and from the control panel. Connection are made here
for level controls, thermal sensors, optional moisture probes,
pump connections (UGP Only), and remote alarm (panel in
cover Only).
Start Button - The Start Button allows for the manual operation
of the pump by bypassing the level control circuit. With the
"OFF" switch closed, the Start Button can be pushed and the
pump will start. The pump will turn off once the "OFF" switch
has opened the control circuit. If the fluid level is below the off
switch, the Start Button will need to be held in to keep the pump
"ON".
Alternator (ALT) - This is an electromechanical device that is
used in the Duplex panels to alternate which pump runs when
the "ON" float is closed. This device is designed to keep the
amount of time each pump run equal. At the beginning of each
cycle, the unit alternates and energizes the motor starter coil
for the lead pump in that cycle.
B-2) PRINCIPLES OF OPERATION - SIMPLEX:
The 115 volt control ladder circuit is made up of a power line
(L1) and a separate neutral feed.
The alarm circuit and control circuit are split and are fused
separately. The fuse FU1 is for the alarm circuit, and the fuse
FU2 is for the control circuit.
For UGP panels LS1 is the "OFF" level control switch and is
connected between nodes one and two of the control circuit.
For UCP panles LS1 is the "REDUNDANT OFF" and LS2 is
"NORMAL OFF" and is connected between nodes one and
two of the control circuit.
LS2 for UGP panels and LS3 for UCP panels is the "ON" level
control switch and is connected between nodes two and three.
Contactor MS forms a latch around the "ON" switch that will
hold this portion of the circuit closed until the MS coil that is in
series with the control circuitry is denergized by the opening of
the "OFF" level control switch.
In UGP panels, the thermal sensor (TS) and motor overload
(OL) are wired in series with the control circuit and when open
will denergize the pump.
The alarm circuit is energized by LS3 on UGP panels and LS4
on UCP panels. In wall mounted panels, this initiates the
lighting of the Alarm Light and closing of the relay CR which
actuates the Audible Alarm Horn. Pressing the "Silence" button
will de-energize the CR coil and open the CR contact, thus
turning the Audible Alarm Horn off.
In cover mounted panels, this energizes the alarm signal line
going back to the alarm box, thus turning on both the alarm
light and audible horn. The horn can be silenced by switching
the manual silence switch on the alarm junction box from the
"On" to the "Off" position. NOTE: Remember to turn the audible
alarm switch back to the "On" position once the alarm condition
has been corrected.
B-3) PRINCIPLES OF OPERATION - DUPLEX:
The 115 volt control ladder circuit is made up of a power line
(L1) and a separate neutral feed.
The alarm circuit and the control circuit are split and are fused
separately.
The fuse FU2 is for the alarm circuit, and the FU1 is for the
control circuit.
For UGP panels LS1 is the "OFF" level control switch and is
connected between nodes one and two of the control circuit.
For UCP panles LS1 is the "REDUNDANT OFF" and LS2 is
"NORMAL OFF" and is connected between nodes one and
two of the control circuit.
LS2 for UGP panels and LS3 for UCP panels is the "ON" level
control switch and is connected between nodes three (3) and
four (4).
The LS2 level control is in series with a mechanical alternator
(ALT) that will alternated from MS1 to MS2 at the beginning of
each pump cycle. This alternation defines which pump is the
lead and which pump is the lag pump for each cycle.
The contactor (MS1 or MS2) forms a latch around the "ON"
switch that will hold this portion of the circuit closed until the
MS coil has been denergized by the opening of the "OFF" level
control switch.
If an exceptional amount of flow has entered the basin, and the
fluid level raises, the LS3 float for UGP panels or LS4 for UCP
panles will close, energizing the lag motor contactor (MS1 or
MS2), and turning the lag pump on. Once the "OFF" level
control opens, the control circuit is denergized and all pumps
are turned off.
In UGP Panels, the thermal sensor (TS) and motor overload
(OL) are wired in series with the control circuit and when open,
will denergize the pump with the thermal or overload condition.
The alarm circuit is energized by the closing of LS4 for UGP
panels and LS5 for UCP panels. This initiates the lighting of
the Alarm Light and closing of the relay CR coil and open the
CR contact, thus silencing the Audible Alarm Horn.
WARNING !
ELECTRICAL POWER TO THE PUMP MOTORS MUST
BE DISCONNECTED AND LOCKED OUT TO PREVENT
ANY DANGEROUS ELECTRICAL HAZARDS OR
PERSONNEL DANGER BEFORE ANY SERVICE WORK
IS DONE TO THE PUMP.
8

Figure 1
Figure 2
9

Figure 3
10

SECTION: C - INSTALLATION
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.
IMPORTANT
CHECK TO BE CERTAIN THAT ALL POWER IS OFF
C-1 INSTALLATION OF WALL MOUNT PANELS:
1. Verify that the proper panel has been selected.
Make sure that the panel will support the Grinder HP
and Voltage required, as well as have the desired
features.
2. Select the desired mounting location. The UGP & UCP
panel can be mounted on the side of a building, or on
a post located near the basin (see Figure 1). The panel
should be located so that easy access can be made for
servicing. NOTE: The enclosure needs to be mounted
on a flat surface to avoid damage due to stress.
All panel alarm indicator lights and horns should be
visible/audible from the chosen location.
3. The electrical enclosure will come with either a flange
on the exterior or a set of mounting holes found under
the front cover. The proper size fasteners should be
used to mount the panel. Care should be taken to
insure that the panel is mounted flat. A back plate may
be required.
4. The panels use a NEMA 4X enclosure. Approved
electrical conduit should be used to connect the wiring
from the service panel in the home or separate electrical
feed to the panel. Conduit should also be used to connect
the panel to the basin. When using direct burial cable, the
conduit should be run to 18" below grade then only cable
need be run to the basin. The basin installation manual
should be consulted to determine the number and size of
direct burial wires required.
5. The terminal connection points are noted on the
electrical wiring diagram that is enclosed in each panel.
Care should be taken to insure that all wires are
connected to the proper terminals. Note that each
panel requires a separate neutral wire for the 115 volt
control circuitry. Be sure that a separate neutral wire is
pulled from the power source to the panel. Each
terminal should be torqued to the value noted in the
electrical wiring diagram.
6. The wires entering through the conduit into the panel
must be sealed to prevent condensation from building
in the enclosure. A sprayable urethane foam should
be used as a backing material in each conduit.
A sealing caulk should be placed in front of the foam
for a final sealing (see Figure 2).
7. The Start-Up manual should be consulted for proper
test and operations procedures of the control panel.
C-2 INSTALLATION OF PANELS IN BASIN COVER:
1. Verify that the proper panel has been selected.
Make sure that the panel will support the Grinder HP
and Voltage required, as well as have the desired
features.
2. Select the desired mounting location for the Alarm Box.
The box can be mounted on the side of a building or on a
post located near the basin (See Fig. 1).
The alarm box should be located so that easy access
can be made for servicing. The location should also
insure that all alarm lights and horns can be recognized
in event a problem should arise. The control panel is
already mounted in its proper orientation in the
UltraCAP insert.
3. The alarm box has four tabs with mounting holes.
Care should be taken to insure that the box is mounted
flat using appropriate hardware. A back plate may be
required.
4. The panel and alarm box use a NEMA 4X enclosure.
Approved electrical conduit should be used to connect
the wiring from the service panel in the home or
separate electrical feed to the Alarm box.
Conduit should also be used to connect the alarm box
to the basin. When using direct burial cable, the conduit
should be run 18" below grade or per NEC and local
codes. Then only cable needs to be run to the basin. The
Basin Installation Manual should be consulted to
determine the number, size and type of direct burial
cable required.
Figure 4
Control Panel
Cord Grips
Cord Grips
11

5. The direct burial, pump, and level control wires should be
run through the appropriate cord grips in the bottom of the
insert and then through the appropriate cord grips in the
panel making sure that each cord grip is tightened
securely (see Fig. 4).
The connection points are noted on the electrical wiring
diagram in each panel and alarm box. Care should be
taken to insure that all wires are connected in accordance
with the diagram. Note that each system requires a
separate neutral wire for the 115 volt circuitry. Be sure that
a separate neutral wire is pulled from the power source to
the system. Each terminal and connection should be
torqued to the value noted in the electrical wiring diagram.
6. The wires entering through the conduit into the alarm box
must be sealed to prevent condensation from building
in the enclosure. A sprayable urethane foam should
be used as a backing material in each conduit.
A sealing caulk should be placed in front of the foam
for a final sealing (see Figure 2).
7. The Start-Up manual should be consulted for proper
test and operations procedures of the control panel.
SECTION: D REPLACEMENT PARTS
D-1 ORDERING REPLACEMENT PARTS:
When ordering replacement parts, ALWAYS furnish the
following information:
1. Model number or Project. (D-3)
2. Part number.(D-2)
3. Part description.
4. Item part number.
5. Quantity required.
6. Shipping instructions.
7. Billing Instructions.
D-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.
D-3 MODEL NUMBER:
This designation consists of numbers and letters which
represent the features supplied on the panel. The Project name
may also be used here. This number is used for ordering and
obtaining information.
Reference the Part number and Project or Model Number
when referring to the product.
2
1
12

TYPICAL SIMPLEX UGP PANEL
(Wall Mount)
13

TYPICAL SIMPLEX UGP-P PANEL
(Cover Mounted)
14

TYPICAL DUPLEX UGP PANEL
(Wall Mount)
15

REPLACEMENT PARTS - 2HP
PART No. DESCRIPTION
099198 Start Capacitor - Single Phase (SC)
099199 Run Capacitor - Single Phase (RC)
099200 Start Relay - Single Phase (START)
099201 Control Fuse (FU1 & FU2)
099202 Overload Relay (OL)
099203 Motor Starter (MS)
100195 Control Relay (CR)
100199 Circuit Breaker (CB)
100190 Alarm Light Lens
096698 Alarm Horn Assy.
100184 Alarm Light Gasket
100201 Alarm Bulb
NOTE: Panels designed for a special project may have different components.
Consult replacement parts list in project documentations.
TYPICAL SIMPLEX UGP PANEL
(Wall Mount)
16

TYPICAL DUPLEX UGP PANEL
(Wall Mount)
REPLACEMENT PARTS - 2HP
PART No. DESCRIPTION
099198 Start Capacitor - Single Phase (SC)
099199 Run Capacitor - Single Phase (RC)
099200 Start Relay - Single Phase (START)
099201 Control Fuse (FU1 & FU2)
099202 Overload Relay (OL)
099203 Motor Starter (MS)
100195 Control Relay (CR)
Contact Factory Circuit Breaker (CB)
100190 Alarm Light Lens
096698 Alarm Horn Assy.
100184 Alarm Light Gasket
100201 Alarm Bulb
104408 Alternator
NOTE: Panels designed for a special project may have different components.
Consult replacement parts list in project documentations.
17

TYPICAL SIMPLEX UCP PANEL
(Wall Mounted)
18

TYPICAL DUPLEX UCP PANEL
(Wall Mounted)
19

TYPICAL SIMPLEX UCP-P PANEL
(Cover Mounted)
20