Crane Barnes ESPS Series User manual

A Crane Co. Company
INSTALLATION MANUAL
IMPORTANT! Read all instructions in this manual before operating pump.
As a result of Crane Pumps & Systems, Inc., constant product improvement program,
product changes may occur. As such Crane Pumps & Systems reserves the right to
change product without prior written notification.
420 Third Street 83 West Drive, Bramton
Piqua, Ohio 45356 Ontario, Canada L6T 2J6
Phone: [phone] Phone: [phone]
Fax: [phone] Fax: [phone]
www.cranepumps.com Form No. 116953-Rev. N
ENVIRONMENTALLY SEALED PRESSURE SWITCH
Manual Index

2
Other brand and product names are trademarks or registered trademarks of their respective holders.
® Barnes is a registered trademark of Crane Pumps & Systems, Inc
© Crane Pumps & Systems, Inc. 2003, 2/2006, 9/06, 10/06 Alteration Rights Reserved
TABLE OF CONTENT
SAFETY FIRST................................................................................................3
INTRODUCTION..............................................................................................4
SWITCH WIRING SCHEMATIC.......................................................................5
SIMPLEX SCHEMATIC....................................................................................5
DUPLEX SCHEMATIC.....................................................................................5
ESPS-100 WIRING DIAGRAM
JUNTION BOX TO CONTROL PANEL ............................................................6
ESPS-100 WIRING DIAGRAM
SWITCH TO CONTROL PANEL (UltraCAP2)..................................................7
IDENTIFICATION OF STEALTH CONTROL PANELS ....................................8
STEALTH-R & -O “E” SERIES PANELS
JUNCTION BOX TO CONTROL PANEL..........................................................9
DUPLEX STEALTH R & O, G and C SERIES PANELS
1 HP & 2 HP 200/240 VOLT - 1 PHASE ..........................................................10
DUPLEX STEALTH UGP, UCP SERIES PANELS
ALL UGP/UCP HP, VOLTAGE & PHASE
STEALTH -R, -O, -G and -C Except 200 or 240 Volt, 1Ph ...............................11
ELECTRICAL CORD CONNECTION ..............................................................12
RAIL MOUNTING ASSEMBLY.........................................................................13
NON-RAILED MOUNTING ASSEMBLY .......................................................... 14
ATTACHED ROPE TO SWITCH ......................................................................15

3
Please Read This Before Installing Or Operating Pump.
This information is provided for SAFETY and to PREVENT
EQUIPMENT PROBLEMS. To help recognize this information,
observe the following symbols:
IMPORTANT! Warns about hazards that can result
in personal injury orIndicates factors concerned with
assembly, installation, operation, or maintenance which
could result in damage to the machine or equipment if
ignored.
CAUTION ! Warns about hazards that can or will cause minor
personal injury or property damage if ignored. Used with symbols
below.
WARNING ! Warns about hazards that can or will cause serious
personal injury, death, or major property damage if ignored. Used
with symbols below.
Only qualified personnel should install, operate and repair
pump. Any wiring of pumps should be performed by a qualified
electrician.
WARNING ! - To reduce risk of electrical shock, pumps
and control panels must be properly grounded in
accordance with the National Electric Code (NEC) or
the Canadian Electrical Code (CEC) and all applicable
state, province, local codes and ordinances.
WARNING! - To reduce risk of electrical shock, always
disconnect the pump from the power source before
handling or servicing. Lock out power and tag.
Prevent large articles of clothing, large amounts of chemicals,
other materials or substances such as are uncommon in
domestic sewage from entering the system.
During power black-outs, minimize water consumption at the
home(s) to prevent sewage from backing up into the house.
Always keep the shut-off valve completely open when system is
in operation (unless advised otherwise by the proper authorities).
Before removing the pump from the basin, be sure to close the
shut-off valve. (This prevents backflow from the pressure sewer.)
Keep the control panel locked or confined to prevent
unauthorized access to it.
If the pump is idle for long periods of time, it is advisable to start
the pump occasionally by adding water to the basin.
CAUTION! Pumps build up heat and pressure
during operation-allow time for pumps to cool
before handling or servicing.
WARNING! - DO NOT pump hazardous materials
(flammable, caustic, etc.) unless the pump is specifically
designed and designated to handle them.
Do not block or restrict discharge hose, as discharge hose may
whip under pressure.
WARNING! - DO NOT wear loose clothing that may
become entangled in the impeller or other moving parts.
WARNING! - Keep clear of suction and discharge
openings. DO NOT insert fingers in pump with power
connected.
Make sure lifting handles are securely fastened each time before
lifting. Do not operate pump without safety devices in place.
Always replace safety devices that have been removed during
service or repair.
Do not exceed manufacturers recommendation for maximum
performance, as this could cause the motor to overheat.
Secure the pump in its operating position so it can not tip over,
fall or slide.
Cable should be protected at all times to avoid punctures, cut,
bruises and abrasions - inspect frequently.
Never handle connected power cords with wet hands.
To reduce risk of electrical shock, all wiring and junction
connections should be made per the NEC or CEC
and applicable state or province and local codes.
Requirements may vary depending on usage and
location.
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.
Do not remove cord and strain relief. Do not connect conduit to
pump.
Products Returned Must Be Cleaned, Sanitized, Or
Decontaminated As Necessary Prior To Shipment, To
Insure That Employees Will Not Be Exposed To Health
Hazards In Handling Said Material. All Applicable Laws
And Regulations Shall Apply.
Bronze/brass and bronze/brass fitted pumps may
contain lead levels higher than considered safe for
potable water systems. Lead is known to cause cancer
and birth defects or other reproductive harm. 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.
IMPORTANT! - Crane Pumps & Systems, 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.
SAFETY FIRST!
Hazardous fluids can
cause fire or explo-
sions, burnes or death
could result.
Extremely hot - Severe
burnes can occur on contact.
Biohazard can cause
serious personal injury.
Hazardous fluids can Hazard-
ous pressure, eruptions or ex-
plosions could cause personal
injury or property damage.
Rotating machinery
Amputation or severe
laceration can result.
Hazardous voltage can
shock, burn or cause death.

4
INTRODUCTION
Thank you for purchasing your new Barnes brand level control. The ESPS series of level control switches have been
designed to provide years of reliable service when properly used with Barnes brand pumps and packages. Please
completely read this manual and follow all installation instructions to insure your level control provides the best service
possible.
When attempting to use this product in stations made by other manufacturers, care should be taken to ensure the
application is compatible with the characteristics of the Barnes brand ESPS level control being used. Misapplication of
this product will void the warranty.
This switch is designed to be a “Non-Serviceable” item. If a switch is suspected to be inoperative,
contact your local service center for service replacement options.
The level control contains pressure sensitive components and diaphragms. Care should be taken when handling the unit
to insure damage does not occur. Damage may result in improper function or undesirable performance. All actuation
points are factory set and cannot be changed. Any attempt to change the actuation points will void the warranty.
Before placing switch into service, switch should be brought to operational temperature range. Excessive or direct
heating or cooling should NOT be used.
OPERATION TEMPERATURE RANGE: +35°F (2°C) to +120°F (49°C)
SHIPPING / STORAGE TEMPERATURE: -20°F (-29°C) to +150F (66°C)
SWITCH COMPONENT DESCRIPTION
FUNDAMENTALS OF OPERATIONS
The ESPS-100 Level control is designed to be used in conjunction with a simplex pump control panel identical to those
used with conventional floats. It will signal the panel to turn the pump “On” at a point below the alarm bell as the liquid
level rises in the basin. The pump will then run until the liquid level drops to a point above the lower switch housing
where the panel will be signaled to turn the pump “Off”. In the event the pump does not turn on or the pump cannot keep
up with the inflow, the alarm circuit will be activated once the liquid level submerges the Alarm Air Bell Tube. It will stay
activated until the condition is corrected and the liquid level drops below the Alarm Air Bell Tube.
The ESPS-200 Level control is designed to be used in conjunction with a duplex pump control panel identical to those
used with conventional floats. It will signal the panel to turn the lead pump “On” at a point below the alarm bell as
the liquid level rises in the basin. The pump will then run until the liquid level drops to a point above the lower switch
housing where the panel will be signaled to turn the pump “Off”. During periods of high inflow where the lead pump
cannot keep up with the inflow, the level control will signal the panel to turn the lag pump on at a point between the
lead point and the alarm bell. In the event the pump does not turn on or both pumps cannot keep up with the inflow,
the alarm circuit will be activated once the liquid level submerges the Alarm Air Bell Tube. It will stay activated until the
condition is corrected and the liquid level drops below the Alarm Air Bell Tube.

5
SWITCH WIRING SCHEMATIC

6
ESPS-100 WIRING DIAGRAM
JUNCTION BOX TO CONTROL PANEL (Where Applicable)
IF J-BOX IS NOT USED, WIRE ACCORDING TO CHART HEADING
“ESPS CONTROL CORD” AND “TERMINAL NUMBER”
TERMINAL
NUMBER
DIRECT BURIAL
CABLE*
ESPS CONTROL
CORD
1 RED RED
2 BLACK BLACK
3 YELLOW WHITE
4 ORANGE ORANGE
5 BLUE GREEN
NOT USED BROWN NOT USED
NOTES:
1. Check for nicks and defects in cable.
2. Cord jacket should be slightly visible inside cord grips. Approximatelt 1/4” to 1/2”
3. Tighten cord grips 1/4 turn past hand tight.
*Colors may vary on DBC

7
ESPS-100 WIRING DIAGRAM
SWITCH TO CONTROL PANEL (UltraCAP2)
TERMINAL
NUMBER
LEAD COLOR LEAD LENGTH LEAD
STRIP LENGTH
TERMINAL STRIP
TORQUE
1 RED
7.00 in .50 in 18 in lbs
2 BLACK
3 WHITE
4 ORANGE
5 GREEN
NOTES:
1. Check for nicks and defects in cable.
2. Cord jacket should be slightly visible inside cord grips. Approximately 1/4” to 1/2”
3. Strip wire lengths and tighten per chart
4. Tighten gland nut 3 turns past hand tight
5. Tighten control panel cord grip 1/4 turn past hand tight

8
IDENTIFICATION OF BARNES STEALTH SERIES DUPLEX CONTROL
PANEL FOR ESPS-200 LEVEL CONTROL WIRING
To determine the proper wiring schematic you will need to first determine the panel type you have using the information
listed below. The information can be located inside the control panel door on the panel schematic.
For STEALTH -R & -O “E” Series Panels:
- Carries an “E” designation on the end of the model callout
- This control panel identified with a build date of March, 2006 or later
- All horsepower, voltage, and phase combination will use this wiring type
- Example is a STEALTH-R-204-26E or STEALTH-O-202-22E
For STEALTH, R & O Series Panels - 200 or 240 Volt, 1 Phase, 1 & 2 HP:
- 1 or 2 Horsepower, 200 or 240 Volt, 1-Phase ratings
- This control panel identified with a build date prior to March, 2006 or earlier
- Carries one of the following designations
STEALTH-R or STEALTH-O
For STEALTH G, C, R, O, UGP and UCP Series Panels - All Voltage/Phase & HP:
- 2.0 Horsepower, 200, 240, 480, or 600 Volt, 3-Phase ratings, 200 or 240 volt, 1 phase (Except STEALTH -R
& -O), 200/240V 1Ph
- 3.0, 5.0, or 7.5 Horsepower, 200 or 240 Volt, 1-Phase or 200, 240, 480, or 600
Volt, 3-Phase ratings
- This control panel identified with a build date prior to March, 2006 or earlier
- Carries one of the following designations:
STEALTH-R or STEALTH-O
STEALTH-G or STEALTH-C
UGP or UCP
STEALTH -R -101 -2 1E -P
PUMP SERIES:
UGP = SGV Grinders
UCP = SGPC Grinders
G = SGV Grinders
C = SGPC Grinders
R = SGV Grinders
O = OGP, OGVF/OGVH & SGPC Grinders
PANEL MODEL:
101 thru 116, Simplex
201 thru 216, Duplex
HORSEPOWER:
1 = 1HP
2 = 2HP
3 = 3HP
5 = 5HP
7 = 7.5HP
VOLTAGE:
0* = 200 Volt, 1 Phase, 60Hz
1* = 120 Volt, 1 Phase, 60Hz
2* = 240 Volt, 1 Phase, 60Hz
3* = 240 Volt, 3 Phase, 60Hz
4* = 480 Volt, 3 Phase, 60Hz
5* = 600 Volt, 3 Phase, 60Hz
6* = 200 Volt, 3 Phase, 60Hz
(*) If "E" - ESPS-200 Compliant.
If Blank - Requires ESPS-200 wiring modification and/or kit.
MOUNTING:
* = Wall Mount (STD)
P = Poly Drywell Mount
(*) Left Blank

9
DUPLEX STEALTH-R & -O “E” SERIES PANELS
JUNCTION BOX TO CONTROL PANEL
TERMINAL
NUMBER
DIRECT BURIAL
CABLE
ESPS CONTROL CORD
1 RED RED
2 YELLOW WHITE
3 (*) NONE FACTORY INSTALLED JUMPER PLACED BETWEEN TERMINAL 3 & 4
4 (*) NONE FACTORY INSTALLED JUMPER PLACED BETWEEN TERMINAL 3 & 4
5 ORANGE BLACK
6 NONE N/A
7 NONE N/A
8 RED/BLACK ORANGE
9 BLUE/BLACK GREEN
NOTES:
1. Check for nicks and defects in cable.
2. Cord jacket should be slightly visible inside cord grips. Approximately 1/4” to 1/2”
3. Tighten cord grips 1/4 turn past hand tight

10
DUPLEX STEALTH R & O SERIES PANELS
1 HP & 2 HP 200/240 VOLT - 1 PHASE
TERMINAL
NUMBER
DIRECT BURIAL CABLE LEVEL CONTROL CORD
1 RED RED
4 YELLOW WHITE
L3 on MS2 BLACK BLACK
7 ORANGE ORANGE
8 BLUE GREEN
BROWN NOT USED
RED/BLACK NOT USED
BLUE/BLACK NOT USED
NOTES:
1. Wire used for the jumpers is not supplied. Wire size must be #18 to #14 AWG, standed copper
2. To test functionallity of changes, the ESPS-200 switch should be ran through two complete cycles from off to
alarm, making sure the lead and lag pumps change between each cycle identifies the wiring change has been
properly performed.

11
DUPLEX STEALTH UGP, UCP SERIES PANELS
ALL UGP/UCP HP, VOLTAGE & PHASE, STEALTH -R, -O, -G and -C
Except STEALTH -R & -O, 200 or 240 Volt, 1 Ph
TERMINAL
NUMBER
DIRECT BURIAL CABLE LEVEL CONTROL CORD
1 RED RED
4 YELLOW WHITE
53 on MS2 BLACK BLACK
7 ORANGE ORANGE
8 BLUE GREEN
BROWN NOT USED
RED/BLACK NOT USED
BLUE/BLACK NOT USED
NOTES:
1. Wire used for the jumpers is not supplied. Wire size must be #18 to #14 AWG, standed copper
2. To test functionallity of changes, the ESPS-200 switch should be ran through two complete cycles from off to
alarm, making sure the lead and lag pumps change between each cycle identifies the wiring change has been
properly performed.

12
ELECTRICAL CORD CONNECTIONS
CORD CABLES - The cord assembly mounted to the switch must NOT be modified in any way except
for shortening to a specific application. Any modifications to the switch cord will void the warranty.
OVER-TEMPERATURE PROTECTION - The type of in-line over-temperature protector used in this level
control is referred to as an inherent overheating protector and operates on the affect of temperature rise.
This means that the over-temperature protector will trip out and shut the pump off if the switch becomes
too hot. It will then automatically reset after the switch cools to a safe temperature. In the event of an
over-temperature, the source of this condition should be determined and rectified immediately.
DO NOT LET THE PUMP CYCLE OR RUN IF AN OVER-TEMPERATURE CONDITION OCCURS!
CORD CONNECTION - Insert female end of cord plug into housing bore aligning alignment mark with
detent in terminal block, See Figure Below.
Tighten bolts until the corners of the compression flange are drawn down to the top of the level control.
DO NOT OVER TORQUE.

13
“C” CHANNEL RAIL MOUNTING ASSEMBLY
ITEM QTY DESCRIPTION PART NUMBER MATERIAL
1 1 SWITCH, ESPS N/A
2 1 MOUNTING, BRKT, SLIDE 114580 Cast Iron
3 3 WASHER, FLAT, 1/4 20-5-1 Stainless Steel
4 5 WASHER, LOCK, 1/4 20-13-1 Stainless Steel
5 3 SCREW, BHCS, 1/4-20 x .75 26-80-1 Stainless Steel
6 2 SCREW, HXHD, 1/4-20 x .63 1-4-1 Stainless Steel
71
CORD, 18/5, SOW, 8 Ft.
CORD, 18/5, SOW, 15 Ft.
CORD, 18/5, SOW, 30 Ft.
CORD, 18/5, SOW, 50 Ft.
CORD, 18/5, SOW, 75 Ft.
CORD, 18/5, SOW, 100 Ft.
113288A
113288
113288XC
113288XF
113288XJ
113288XL
8 VARIES ROPE, 1/4” DIA. 3 STRAND 115664 Polypropylene
NOTES:
1. Bracket may be reversed to allow
switch mounting on either side of the
guid rail to avoid obstructions and
inlets in basin
2. Secure cord to avoid possible
hazards
3. Install the pump before sliding the
level control down the “C” channel

14
NON-RAIL MOUNTING ASSEMBLY
ITEM QTY DESCRIPTION PART NUMBER MATERIAL
1 1 SWITCH, ESPS N/A
2 1 ESPS 100/150 BASE
ESPS 200 BASE
(ESPS 200 includes Hose Clamp)
130979P
116876A
Cast Iron
Buna/Stainless Steel
31
CORD, 18/5, SOW, 8 Ft.
CORD, 18/5, SOW, 15 Ft.
CORD, 18/5, SOW, 30 Ft.
CORD, 18/5, SOW, 50 Ft.
CORD, 18/5, SOW, 75 Ft.
CORD, 18/5, SOW, 100 Ft.
113288A
113288
113288XC
113288XF
113288XJ
113288XL
4 3 WASHER, LOCK, 1/4 20-13-1 Stainless Steel
5 6 SCREW, HXHD, 1/4-20 x .63 1-4-1 Stainless Steel
6 1 HOOK, S, 13 GA, 1.01” 109489 Stainless Steel
7 1 WASHER, FLAT, 1/4” 20-5-1 Stainless Steel
8 VARIES ROPE, 1/4” DIA. 3 STRAND 115664 Polypropylene
9 3 Washer, Flat 131836 Stainless Steel
NOTES:
1. Position level control in basin in a
level loction and not in direct flow of
inlets
2. Secure cord to avoid possible
hazards
3. On ESPS-200 installation, remove
ring from adapter boot

15
ATTACH ROPE TO SWITCH
STEPS & TIPS:
• Attach lifting device to pump.
1. Make a small overhand loop in the rope.
2. Bring the short end through the
overhand loop.
3. Place short end behind the fixed part of
the rope.
4. Bring end around and back into the
loop.
5. Pull on the fixed end of the rope away
from the loop to tighten the knot.
NEVER LOWER OR RAISE PUMP BY
THE CORD!
ESPS-200
ESPS-100

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RETURNED GOODS
RETURN OF MERCHANDISE REQUIRES A “RETURNED GOODS AUTHORIZATION”.
CONTACT YOUR LOCAL CRANE PUMPS & SYSTEMS, INC. DISTRIBUTOR.
Products Returned Must Be Cleaned, Sanitized,
Or Decontaminated As Necessary Prior To Shipment,
To Insure That Employees Will Not Be Exposed To Health
Hazards In Handling Said Material. All Applicable Laws
And Regulations Shall Apply.
IMPORTANT!
WARRANTY REGISTRATION
Your product is covered by the enclosed Warranty.
To complete the Warranty Registration Form go to:
http://www.cranepumps.com/ProductRegistration/
If you have a claim under the provision of the warranty, contact your local
Crane Pumps & Systems, Inc. Distributor.

Notes