Crane Barnes XSGV Series User manual

A Crane Co. Company
INSTALLATION MANUAL
Submersible Grinder Pump
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. 082188-Rev. X
Series: XSGV
2, 3, 5, 7.5HP, 60Hz,
3450RPM
For Class I, Group D, Division 1
Underwriters Laboratories Inc ®
File No. E73842
Canadian Standards Association
File No. 160440
C US
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.
1990, 1997, 1998, 2000, 2001, 2002, 10/03, 3/06, 9/06, 2/07 Alteration Rights Reserved
TABLE OF CONTENTS
SAFETY FIRST............................................................................................3
A. PUMP SPECIFICATIONS ................................................................................4 - 5
B. GENERAL INFORMATION ..............................................................................6
C. INSTALLATION ................................................................................................6 - 10
D. START-UP OPERATION..................................................................................10 - 11
E. PREVENTATIVE MAINTENANCE ...................................................................11
F. SERVICE and REPAIR ....................................................................................11 - 13
G. REPLACEMENT PARTS..................................................................................13
TROUBLE SHOOTING....................................................................................14
CROSS-SECTION, 2HP (Fig. 8)......................................................................15
EXPLODED VIEW, 2HP (Fig. 9) ......................................................................16
PARTS LIST ...................................................................................................17
CROSS-SECTION, 3, 5, 7.5HP (Fig. 10).........................................................18
EXPLODED VIEW, 3, 5, 7.5HP (Fig. 11) .........................................................19
PARTS LIST ...................................................................................................20
ELECTRICAL DATA .........................................................................................21
SUSPENDED SYSTEM (Fig. 12).....................................................................22
NON-SPARKING MOVABLE for 2HP (Fig. 13)................................................23
NON-SPARKING MOVABLE for 3, 5, 7.5HP (Fig. 14).....................................24
RETURNED GOODS POLICY.........................................................................25
WARRANTY ...................................................................................................26
START-UP REPORT........................................................................................29 - 30
WARRANTY REGISTRATION
SPECIAL TOOLS AND EQUIPMENT
INSULATION TESTER (MEGGER)
DIELECTRIC TESTER
SEAL TOOL KIT ( see parts list)
PRESSURE GAUGE KIT (see parts list)

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 qualied personnel should install, operate and repair
pump. Any wiring of pumps should be performed by a qualied
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 backow from the pressure sewer.)
Keep the control panel locked or conned 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
(ammable, caustic, etc.) unless the pump is specically
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 ngers 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
uid 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 tted pumps may contain
lead levels higher than considered safe for potable water
systems. Lead is know 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.
Hazardous uids can
cause re or explo-
sions, burnes or death
could result.
Extremely hot - Severe
burnes can occur on contact.
Biohazard can cause
serious personal injury.
Hazardous uids 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.
SAFETY FIRST!

4
DISCHARGE.................... 1¼” NPT, Vertical
LIQUID TEMP .................. 104°F (40°C) Continuous
VOLUTE .......................... Cast Iron ASTM A-48, Class 30
MOTOR HOUSING .......... Cast Iron ASTM A-48, Class 30
SEAL PLATE .................. Cast Iron ASTM A-48, Class 30
IMPELLER: Design.......... 10 Vane,Vortex, With Pump Out
Vanes On Back Side. Dynamically
Balanced, ISO G6.3.
Material ........ 85-5-5-5 Bronze
SHREDDING RING ......... Hardened 440C Stainless Steel
Rockwell® C-55.
CUTTER ..........................Hardened 440CStainless Steel,
Rockwell® C-55.
SHAFT ............................416 Stainless Steel
SQUARE RINGS ............. Buna-N
HARDWARE .................... 300 Series Stainless Steel
PAINT .............................. Air Dry Enamel.
SEAL: Design ..........Tandem Mechanical, Oil Filled
Reservoir.
Material.........Rotating Faces - Carbon
Stationary Faces - Ceramic
Elastomer - Buna-N
Hardware - 300 Series Stainless
CORD ENTRY.................. 30 ft. (9.1m) Std. Cord. Epoxy
Sealed Housing with Secondary
Pressure Gromment for Sealing
and Strain Relief
UPPER BEARING:
Design ..........Single Row, Ball, Oil Lubricated
Load .............Radial
LOWER BEARING:
Design ..........Single Row, Oil Lubrication
Load..............Radial & Thrust
MOTOR: Design ..........NEMA L-Single Phase,
NEMA B-Three Phase Torque
Curve. Oil-Filled, Squirrel Cage
Induction
Insulation ......Class B.
SINGLE PHASE...............Capacitor Start/Capacitor Run.
Requires overload protection to be included in control
panel. Requires Barnes® Starter or Control Panel which
Includes Capacitors, or Capacitor pack.
THREE PHASE................ Dual Voltage 230/460; Requires
Overload Protection to be Included in control panel.
MOISTURE SENSORS.... Normally Open (N/O), Requires
relay in control panel
TEMP SENSORS .............Normally Closed (N/C),
Requires relay in control panel
OPTIONAL EQUIPMENT. Seal Material, Impeller Trims,
Cord Length
SECTION A-1 - PUMP SPECIFICATIONS: XSGV 2 HP
inches
(mm)
IMPORTANT !
1.) MOISTURE AND TEMPERATURE SENSORS MUST BE CONNECTED TO VALIDATE THE UL LISTING.
2.) A NON-SPARKING BREAK AWAY FITTING MUST BE USED TO VALIDATE THE UL LISTING.
3.) A SPECIAL MOISTURE SENSOR RELAY IS REQUIRED IN THE CONTROL PANEL FOR PROPER OPERATION OF THE MOISTURE SENSORS.
CONTACT BARNES PUMPS FOR INFORMATION CONCERNING MOISTURE SENSING RELAYS FOR CUSTOMER SUPPLIED CONTROL PANELS.
4.) THESE PUMPS ARE UL LISTED FOR PUMPING WATER AND WASTEWATER. DO NOT USE TO PUMP FLAMMABLE LIQUIDS.
5.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIDED FOR VISUAL ENJOYMENT MUST BE INSTALLED
IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSI/NFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION. THIS PUMP IS
NOT INTENDED FOR USE IN SWIMMING POOLS, RECREATIONAL WATER PARKS, OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH
PUMPED MEDIA IS A COMMON OCCURRENCE.

5
DISCHARGE.................... 2” NPT, Vertical
LIQUID TEMP .................. 104°F (40°C) Continuous
VOLUTE ..........................Cast Iron ASTM A-48, Class 30
MOTOR HOUSING .......... Cast Iron ASTM A-48, Class 30
SEAL PLATE ..................Cast Iron ASTM A-48, Class 30
IMPELLER: Design.......... 12 Vane,Vortex, With Pump Out
Vanes On Back Side. Dynamically
Balanced, ISO G6.3.
Material ........Cast Iron
SHREDDING RING ......... Hardened 440C Stainless Steel
Rockwell® C-55.
CUTTER ..........................Hardened 440CStainless Steel,
Rockwell® C-55.
SHAFT ............................416 Stainless Steel
SQUARE RINGS ............. Buna-N
HARDWARE .................... 300 Series Stainless Steel
PAINT .............................. Air Dry Enamel.
SEAL: Design ..........Tandem Mechanical, Oil Filled
Reservoir.
Material.........Rotating Faces - Carbon
Stationary Faces - Ceramic
Elastomer - Buna-N
Hardware - 300 Series Stainless
CORD ENTRY.................. 30 ft. (9.1m) Std. Cord. Epoxy
Sealed Housing with Secondary
Pressure Gromment for Sealing
and Strain Relief
UPPER BEARING:
Design ..........Single Row, Ball, Oil Lubricated
Load .............Radial
LOWER BEARING:
Design ..........Single Row, Oil Lubrication
Load..............Radial & Thrust
MOTOR: Design ..........NEMA L-Single Phase,
NEMA B-Three Phase Torque
Curve. Oil-Filled, Squirrel Cage
Induction
Insulation ......Class F.
SINGLE PHASE...............Capacitor Start/Capacitor Run.
Requires overload protection to be included in control
panel. Requires Barnes® Starter or Control Panel which
Includes Capacitors, or Capacitor pack.
THREE PHASE................ Dual Voltage 230/460; Requires
Overload Protection to be Included in control panel.
MOISTURE SENSORS.... Normally Open (N/O), Requires
relay in control panel
TEMP SENSORS .............Normally Closed (N/C),
Requires relay in control panel
OPTIONAL EQUIPMENT. Seal Material, Impeller Trims,
Cord Length
inches
(mm)
IMPORTANT !
1.) MOISTURE AND TEMPERATURE SENSORS MUST BE CONNECTED TO VALIDATE THE UL LISTING.
2.) A NON-SPARKING BREAK AWAY FITTING MUST BE USED TO VALIDATE THE UL LISTING.
3.) A SPECIAL MOISTURE SENSOR RELAY IS REQUIRED IN THE CONTROL PANEL FOR PROPER OPERATION OF THE MOISTURE SENSORS.
CONTACT BARNES PUMPS FOR INFORMATION CONCERNING MOISTURE SENSING RELAYS FOR CUSTOMER SUPPLIED CONTROL PANELS.
4.) THESE PUMPS ARE UL LISTED FOR PUMPING WATER AND WASTEWATER. DO NOT USE TO PUMP FLAMMABLE LIQUIDS.
5.) INSTALLATIONS SUCH AS DECORATIVE FOUNTAINS OR WATER FEATURES PROVIDED FOR VISUAL ENJOYMENT MUST BE INSTALLED
IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE ANSI/NFPA 70 AND/OR THE AUTHORITY HAVING JURISDICTION. THIS PUMP IS
NOT INTENDED FOR USE IN SWIMMING POOLS, RECREATIONAL WATER PARKS, OR INSTALLATIONS IN WHICH HUMAN CONTACT WITH
PUMPED MEDIA IS A COMMON OCCURRENCE.
SECTION A-2 - PUMP SPECIFICATIONS: XSGV 3, 5 & 7.5HP

6
SECTION B: GENERAL INFORMATION
B-1) To the Purchaser:
Congratulations! You are the owner of one of the nest
pumps on the market today. CP&S pumps are products
engineered and manufactured of high quality components.
Over one hundred years of pump building experience along
with a continuing quality assurance program combine
to produce a pump which will stand up to the toughest
applications. This manual will provide helpful information
concerning installation, maintenance, and proper service
guidelines.
B-2) Receiving:
Upon receiving the pump, it should be inspected for damage
or shortages. If damage has occurred, le a claim immediately
with the company that delivered the pump. If the manual
is removed from the packaging, do not lose or misplace.
B-3) Storage:
Short Term- CP&S Pumps are manufactured for efcient
performance following short inoperative periods in storage.
For best results, pumps can be retained in storage, as
factory assembled, in a dry atmosphere with constant
temperatures for up to six (6) months. Long Term- Any
length of time exceeding six (6) months, but not more
than twenty-four (24) months. The unit should be stored
in a temperature controlled area, a roofed over walled
enclosure that provides protection from the elements (rain,
snow, wind-blown dust, etc.), and whose temperature can
be maintained between +40 deg. F and +120 deg. F. (4.4
- 49°C). Pump should be stored in its original shipping
container. On initial start up, rotate impeller by hand to
assure seal and impeller rotate freely. If it is required that
the pump be installed and tested before the long term
storage begins, such installation will be allowed provided:
1.) The pump is not installed under water for more than
one (1) month.
2.) Immediately upon satisfactory completion of the test,
the pump is removed, thoroughly dried, repacked in the
original shipping container, and placed in a temperature
controlled storage area.
B-4) Service Centers:
For the location of the nearest Barnes Service Center, check
your Barnes representative or Crane Pumps & Systems,
Inc., Service Department in Piqua, Ohio, telephone
[phone] or Crane Pumps & Systems Canada, in
Brampton, Ontario, [phone].
SECTION C: INSTALLATION
C-1) Location:
These self-contained pumping units are Underwriters
Laboratory Listed for Class I, Group D, Division 1
Locations and are recommended for use in a sump,
lift station or basin. This pump is designed to pump
sewage, efuent, wastewater or other nonexplosive or
noncorrosive liquids not above 104°F (40°C).
Never install the pump in a trench, ditch or hole with a dirt
bottom; the pump will sink into the dirt and the suction
will become plugged. DO NOT operate pump when it is
setting on the bottom of the wet well. A clearance of
3 inches between bottom of pump and bottom of wet
well must be maintained to insure proper operation of
pump. Otherwise pump warranty is null and void.
C-1.1) Submergence:
The pump should always be operated in the submerged
condition and the sump liquid level should never be less
than 10” above the pump bottom (see Fig. 1).
C-2) Discharge:
Discharge piping should be as short as possible. Both
a check valve and a shut-off valve are recommended
for each pump being used. The check valve is used to
prevent backow into the sump. Excessive backow can
cause ooding and/or damage to the pump. The shut-off
valve is used to stop system ow during pump or check
valve servicing.
Barnes supplies a Non-Sparking Stainless Rail Package
and stainless rail for concrete wet wells, designed to allow
the pump to be installed or removed without requiring
personnel to enter the wet well.
Non-Sparking Stainless Rail Package (Not Shown)
The non-sparking package system comes complete and
ready to place into the ground as outlined in the project
specications. The movable portion of the Break Away
Fitting (BAF), check valve, piping and guide bracket
comes assembled on the pump along with the lifting
rope. Insert pump bracket and movable portion of BAF
into the guide channel and lower pump into basin (DO
NOT DROP). Now connect power and control cables to
the junction box or control panel depending on system
design.
FIGURE 1

7
The type of basin system will determine the exact
installation procedure. If a rigid conduit is used to install
the pump it must meet Class I, Division 1 requirements
of the National Electrical Code or the Canadian Electrical
Code. Conduit must be stainless steel or coated metal,
resistant to sewage water.
C-3) Liquid Level Controls: Intrinsically safe
WARNING!-Levelcontroloatsused
within the hazardous location, must be in
an intrinsically safe control circuit suitable
for use in CLASS I, GROUP D, HAZARDOUS
LOCATIONS.
The level controls are to be supported by a mounting
bracket that is attached to the sump wall, cover or rail
bracket. Cord grips are used to hold the cords in place on
the mounting bracket. The control level can be changed by
loosening the grip and adjusting the cord length as per the
plans and specications. Be certain that the level controls
cannot hang up or foul in it’s swing.
A Warrick intrinsically safe control relay, Series 27, is an
acceptable panel mounted relay, providing the relay is
properly installed and maintained.
The primary (A.C. supply line) circuit is not intrinsically
safe, therefore the relay must be located in a “SAFE”
location. The secondary circuit is intrinsically safe,
however any splice must be made in a “SAFE” location
and any control cord that is cut or damaged must be
replaced immediately.
C-3.1) Level Control Float System:
It is recommended to use a two oat, on and off, level
control system. An additional oat, incorporated with an
alternator switching system will be required for a duplex
system. A high level alarm may be required to alert
maintenance personnel. A low level cut off may be required
to provide system shutdown if the main level control
system malfunctions. The off or low level oat should be
positioned so that the liquid level never drops below the
minimum submergence level (see Fig. 1).
C-4) Electrical Connections:
WARNING! - All model pumps and control
panels must be properly grounded per the
national electric code or the canadian electric
code and state, province and local codes.
Improper grounding voids warranty.
All electrical controls and motor starting equipment must
be installed outside the hazardous area unless approved
explosion proof controls are used.
C-4.1) Power/Control Cord:
The cord assembly mounted to the pump must not be
modied in any way except for shortening to a specic
application. Any splice between the pump and the control
panel must be made in accordance with the electric code
and all applicable state, province and local electric codes.
It is recommended that a junction box with sealed ttings, if
used, be mounted outside the sump or be of at least Nema
7 (EEMAC-7) explosion proof construction if located within
the wet well. A U.L. listed sealed tting MUST be used in
conduit leaving the hazardous location. Do not use the
power or control cords to lift pump.
NOTE: The white wire is NOT a neutral or ground lead, but
a power carrying conductor.
FIGURE 2
SINGLE PHASE 200/230 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
White 5 (Common)
Black 4 (Run)
Red 8 (Start)
THREE PHASE 200 & 575 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
White 3
Black 1
Red 2

8
THREE PHASE, 230 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
White 3 & 9
Red 2 & 8
Black 1 & 7
4, 5 & 6 Together
THREE PHASE, 460 VOLT AC
Power Cable Motor Lead Number
Green (Ground) Green
White 3
Red 2
Black 1
4 & 7 Together
5 & 8 Together
6 & 9 Together
CONTROL CABLE CONNECTION
Color Lead Number
Black P1 - In series with starter coil.
White P2 - In series with starter coil.
Red W1 - Moisture detection control.
Orange W2 - Moisture detection control.
Green Ground
C-4.2) Wire Size:
If additional cable is required consult a qualied electrician
for proper wire size. See table on page 21 for further
electrical information.
WARRANTY NOTE:
Both The Temperature Sensor And Moisture
Detection System Must Be Connected To The
Motor Circuitry Such That The Motor Will Be
De-energized If Excessive Motor Temperatures
Are Reached And/or If Water Is Detected In The
Oil And/or Motor Chamber. Failure To Have
The Above Mentioned Systems Installed And
Operative,NulliesWarranty.
C-4.3) Overload Protection:
The normally closed (N/C) thermal sensor is embedded in
the motor windings and will detect excessive heat in the
event an overload condition occurs which will then trip and
stop the pump. The thermal sensor leads marked P1 and
P2 MUST be connected in series with the stop button of
the pilot circuit of the magnetic motor controller located in
the control panel so that the thermostat will open the circuit
before dangerous temperatures are reached.
FIGURE 2
Connectors
Connectors
Connectors
Connector

9
FIGURE 3
A manual momentary start switch is required to prevent
the automatic restarting of the motor when the thermostat
resets. For a typical wiring diagram, refer to Fig. 3. In the
event of an overload, the source of this condition should
be determined and rectied before the pump is put back
into normal operation.
DO NOT LET THE PUMP CYCLE OR RUN IF AN OVER-
LOAD CONDITION OCCURS !
If current through the temperature sensor exceeds the
values listed, an intermediate control circuit relay must
be used to reduce the current or the sensor will not work
properly.
TYPICAL THERMAL PROTECTION WIRING DIAGRAM
FIGURE 4

10
TEMPERATURE SENSOR ELECTRICAL RATINGS
Volts Continuous
Amperes
Inrush
Amperes
110-120 3.00 30.0
220-240 1.50 15.0
440-480 0.75 7.5
C-4.4) Moisture Sensors:
A normally open (N/O) detector is installed in the pump
seal chamber, which will detect any moisture present,
and a continuity test resistor built into the motor. The
test resistor is rated 1 watt at 330K ohms. The moisture
sensors MUST be connected to moisture detector control,
which includes a continuity test circuit, see Fig. 4 for
typical wiring diagram. The normally closed (N/C) contact
of the moisture detector MUST be connected in series with
the stop button of the pilot circuit of the magnetic motor
controller. A Warrick moisture detection control, Type
2800 is an acceptable control if properly installed and
maintained. Wiring must be provided from the moisture
detector sensor probe leads of the motor designated W1
and W2 to terminals 9 and 10 of the 2800-XXX control.
Terminal pair 1-2 must be continuously energized from an
A-C supply line of electrical characteristics shown on the
data table.
In the event of a moisture detect, the pump should be
pulled and the source of the failure located and repaired.
IF A MOISTURE DETECT HAS OCCURRED SCHEDULE
MAINTENANCE AS SOON AS POSSIBLE!
C-4.5) Control Panel and Electrical System:
The control panel and the electrical system MUST be
properly designed and wired to include at least, but not
limited to the following;
a. Proper grounding per NEC.
b. A temperature sensing circuit (see Fig. 3)
c. A moisture detection circuit with continuity test circuit
(see Fig. 4)
d. An intrinsically safe level control system.
e. A main power manual disconnect and lock out.
f. A motor starter and overload system.
g. Single phase only, requires a capacitor power pack
(see Fig. 3).
Control panels for single phase pumps MUST be
purchased from the factory and it is advisable that all three
phase control panels are also purchased from the factory.
SECTION: D START-UP OPERATION
D-1) Check Voltage and Phase:
Before operating pump, compare the voltage and phase
information stamped on the pump’s identication plate to
the available power.
D-2) Check Pump Rotation:
Before putting pump into service for the rst time, the
motor rotation must be checked. Improper motor rotation
can result in poor pump performance and can damage
the motor and/or pump. To check the rotation, suspend
the pump freely, momentarily apply power and observe
the “kickback”. “Kickback” should always be in a counter-
clockwise direction as viewed from the top of the pump
motor housing.
D-2.1) Incorrect Rotation for Three-Phase Pumps:
In the event that the rotation is incorrect for a three-phase
installation, interchange any two power cable leads at the
control box. DO NOT change leads in the cable housing
in the motor. Recheck the “kickback” rotation again by
momentarily applying power.
D-2.2) Incorrect Rotation for Single-Phase Pumps:
In the unlikely event that the rotation is incorrect for a
single phase pump, contact a Barnes Service Center.
D-2.3) Test Procedure For Moisture Sensor Control:
With a Warrick moisture detection control, type 2800, a
normally closed push button and neon indicating lamp is
provided as a means of checking the moisture sensing
components. When the push button is depressed, the
indicating lamp will be illuminated to indicate (A) power is
supplied to the control, (B) the control is operative, and
(C) wiring to the moisture sensing probes in the motor is
intact. This procedure should be performed periodically to
conrm integrity of the circuit.
D-2.4) Operation Precautions:
1. Do not operate the pump in the “hand” control position
and leave the pump unattended.
2. Minimize the amount of cooking grease entering the
system
3. Do not leave pump cover off the basin cover, except
while servicing, to prevent entrance of foreign materials
such as rocks, metal, soil, animals or humans.
4. Prevent large articles of clothing, large amounts of
chemicals, other materials or substances such as are
uncommon of domestic sewage from entering the
system.
5. During power black-outs, discontinue water
consumption at the home(s) to prevent sewage from
backing up into the house.
6. Prevent inltration or direct ow of rain or run-off water
into the pump basin to minimize pump cycling, This will
prevent overloading the treatment facility, and will
facilitate swift transportation of sewage.
7. Always keep the shut-off valve completely open when
system is in operation, (unless advised otherwise by
the proper authorities).
8. Keep the control box locked or conned to prevent
unauthorized access to it.
9. If the pump is idle for long periods of time, it is
advisable to start the pump occasionally by adding
water to the basin.

11
10. Before removing the pump from the basin, be sure to
close the shut-off valve. (This prevents backow from
the pressure sewer.)
11. Make sure level controls are provided at time of
installation.
12. Recommended starts per hour, 6 to 8, no more than
10.
D-3) Start-Up Report:
Included at the end of this manual are two start-up report
sheets, these sheets are to be completed as applicable.
Return one copy to Barnes and store the second in the
control panel or with the pump manual if no control panel
is used. It is important to record this data at initial start-
up since it will be useful to refer to should servicing the
pump be required in the future.
D-3.1) Identication Plate:
Record the numbers from the pump’s identication plate
on both START-UP REPORTS provided at the end of the
manual for future reference.
D-3.2) Insulation Test:
Before the pump is put into service, an insulation
(megger) test should be performed on the motor. The
resistance values (ohms) as well as the voltage (volts)
and current (amps) should be recorded on the start-up
report.
D-3.3) Pump-Down Test:
After the pump has been properly wired and lowered into
the basin, sump or lift station, it is advisable to check
the system by lling with liquid and allowing the pump
to operate through it’s pumping cycle. The time needed
to empty the system, or pump-down time along with the
volume of water, should be recorded on the start-up
report.
SECTION E: PREVENTATIVE MAINTENANCE
As the motor and seal chambers are oil lled, no
lubrication or other maintenance is required, and
generally Barnes pumps will give very reliable service
and can be expected to operate for years on normal
sewage pumping without failing. However as with any
mechanical piece of equipment a preventive maintenance
program is recommended and suggested to include the
following checks:
1) Test moisture detector control “Test Switch” for
continuity of circuit. - Water in the seal chamber will
energize a seal leak warning light at the control panel.
This is a warning light only and does not stop the
motor. It indicates the seal has leaked and must be
repaired. This should be done as soon as possible to
prevent further damage. See section D-2.3.
2) Inspect impeller and body for excessive build-up or
clogging and repair as required per section F-3.
3) Check motor for ground leakage and proper amp
draw. See section D-3.2.
4) Inspect outer seal for wear or leakage and repair as
required per section F-4.
SECTION F: SERVICE AND REPAIR
NOTE: All item numbers in ( ) refer to Figures 8 & 9 for
2HP and 10 & 11 for 3, 5 & 7.5HP Pumps.
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.
CAUTION! - operating pump builds
up heat and pressure; allow time for
pump to cool to room temperature
before handling or servicing.
F-1) Motor & Shaft Seal Service
WARNING! - Motor & upper shaft seal repair:
Motor and upper shaft seal must only
be serviced at the BARNES factory. Any
unauthorizedeldrepairvoidswarranty.
The XSGV Submersible Pump motor is designed to meet
the requirements for Underwriters Laboratory Class I,
Group D service and must only be serviced as described
above.
F-2) Conduit Box and Cable Assembly:
WARNING ! - The conduit box and cable
assemblyshouldnotbeeldserviced.Ifa
problem develops in the power or control
cord the complete pump should be removed
and serviced only by authorized personnel as
described above.
F-3) Impeller, Cutters and Volute Service:
F-3.1) Disassembly and Inspection:
To obtain access to the impeller (13) or shredding ring
(9), rst remove screw (6) and washer (7). Then holding
the motor shaft stationary with a screwdriver, tap the
radial cutter (8) loose in the counter-clockwise direction
and remove, (Heat may be needed to break the screw (6)
loose.)
Next remove nuts (3) and washers (4) from stud (2) and
pull the body (1) and square ring (5) from the rest of the
pump. Remove shims (12) from shaft, then impeller (13)
can be removed by turning it counter-clockwise while
holding stationary the motor shaft with a screwdriver.
NOTE: With the impeller (13) removed, the seal spring is
relaxed and some oil may seep from the seal cavity. DO
NOT store this pump without the impeller (13) in place to
hold the seal shut.

12
To remove or reverse the shredding ring (9) rst remove
the three at head allen screws (10) and lift the throat (11)
out of the body (1). The shredding ring (13) is press tted
in the body (1) and must be removed with an arbor press.
After a number of years of service or whenever the
shredding ring (13) cutting edges dull, the part can be
pressed out of the body (1) and reversed to utilize the
opposite cutting edges and replaced in the body (1). To
maintain efcient grinder pump operation, care should be
taken to keep both the radial cutter (8) and shredding ring
(13) cutting edges sharp. Neither part can be sharpened
to renew the cutting ability. The radial cutter (8) must
be replaced and the shredding ring either reversed or
replaced.
F-3.2) Reassembly:
To replace impeller (13) on shaft, turn clockwise while
holding shaft stationary with a screwdriver. Then replace
shims (12) on motor shaft. Important that the same
quantity be replaced as removed.
Next install shredding ring (9) by pressing into body (1) with
the use of an arbor press. Then insert throat (11) into body
(1) with three at head allen screws (10). Apply a thin coat
of petroleum jelly to the square ring (5) and place on body
(1). Place motor assembly on body (1) , being careful not to
damage square ring (5). Place washers (4) and nuts (3) on
studs (2) and tighten.
Screw radial cutter (8) on shaft clockwise. Hold motor
shaft stationary with screwdriver and tighten. Then replace
washer (7) and screw (6). Radial cutter (8) to be ush with
shredding ring (9) on suction side to within ± .020.
F-4) OUTER SHAFT SEAL SERVICE:
CAUTION! - Handle seal parts with extreme
care. DO NOT scratch or mar lapped surfaces.
F-4.1) Disassembly and Inspection:
Outer Seal - To expose outer shaft seal (17) for
examination disassemble volute, cutter and impeller as
outlined in paragraph F-3.1. Set pump so that the shaft is
in the upright position, this will keep the oil from draining
out while servicing the outer shaft seal. To inspect seal
further, remove retaining ring (17d), spring (17c) and
rotating member (17b) from shaft (see Fig. 5). Examine all
seal parts and especially contact faces. Inspect seal for
signs of wear such as uneven wear pattern on stationary
members, chips and scratches on either seal face. DO
NOT interchange seal components, replace the entire
shaft seal (17). If replacing seal, remove stationary (17a)
by prying out with at screw driver.
F-4.2) Reassembly:
Outer Seal - Clean and oil seal cavities in seal plate (DO
NOT remove seal plate). Lightly oil (DO NOT use
grease) outer surface of stationary member (17a). Press
stationary member (17a) rmly into seal plate, using a seal
pusher (see parts list- seal tool kit). Nothing but the seal
pusher is to come in contact with seal face (see Fig. 6).
FIGURE 5
Stationary Member (17A)
Seal Plate Seal Pusher
FIGURE 6
MOTOR END
(INBOARD END
Spring (17c)
SEAL
ASSEMBLY
(17)
Seal Plate (DO NOT REMOVE)
Stationary (17a)
Rotating Member (17b)
Retaining Ring (17d)
PUMP END
(OUTBOARD END)

13
IMPORTANT ! - DO NOT hammer on the seal
pusher- it will damage the seal face.
Make sure the stationary member is in straight. Slide a
bullet (see parts list-seal tool kit) over motor shaft. Lightly
oil (DO NOT use grease) shaft, bullet and inner surface of
bellows on rotating member (17b) see Fig. 7. With lapped
surface of rotating member (17b) facing inward toward
stationary member (17a), slide rotating member (17b) over
bullet and onto shaft, using seal pusher, until lapped faces
of (17a) and (17b) are together (see Fig. 7).
IMPORTANT ! - It is extremely important to
keep seal faces clean during assembly. Dirt
particles lodged between these faces will
cause the seal to leak.
Place spring (17c) over shaft and in place on rotating
member (17b), making sure it is seated on retainer and not
cocked or resting on bellows tail. Slide retaining ring (17d)
over shaft and let rest on spring (17c). Assemble impeller,
cutter and volute as outlined in paragraph F-3.2.
SECTION: G REPLACEMENT PARTS
G-1 ORDERING REPLACEMENT PARTS:
When ordering replacement parts, ALWAYS furnish the
following information:
1. Pump serial number and date code. (Paragraph G-4)
2. Pump model number. (Paragraph G-3)
3. Pump part number. (Paragraph G-2)
4. Part description.
5. Item part number.
6. Quantity required.
7. Shipping instructions.
8. Billing Instructions.
G-2 PART NUMBER:
The part number consists of a six (6) digit number, which
appears in the catalog. A one or two letter sufx may follow
this number to designate the design conguration. This
number is used for ordering and obtaining information.
G-3 MODEL NUMBER:
This designation consists of numbers and letters which rep-
resent the discharge size, series, horsepower, motor phase
and voltage, speed and pump design. This number is used
for ordering and obtaining information.
G-4 SERIAL NUMBER:
The serial number block will consist of a six digit number,
which is specic to each pump and may be preceded by
a alpha character, which indicates the plant location. This
number will also be sufxed with a four digit number, which
indicates the date the unit was built (Date Code).
EXAMPLE: A012345 0490.
Reference the six digit portion (Serial Number) of this num-
ber when referring to the product.
Rotating Member (17D)
Bullet
Motor & Intermediate
Seal Pusher
Stationary
FIGURE 7

14
TROUBLE SHOOTING
CAUTION ! Always disconnect the pump from the electrical power source before handling.
If the system fails to operate properly, carefully read instructions and perform maintenance recommendations.
If operating problems persist, the following chart may be of assistance in identifying and correcting them:
MATCH “CAUSE” NUMBER WITH CORRELATING “CORRECTION” NUMBER.
NOTE: Not all problems and corrections will apply to each pump model.
PROBLEM CAUSE CORRECTION
Pump will not run 1. Poor electrical connection, blown fuse,
tripped breaker or other interruption of power,
improper power supply.
2. Motor or switch inoperative (to isolate
cause, go to manual operation of pump).
2a. Float movement restricted.
2b. Switch will not activate pump or is defec-
tive.
3. Insufcient liquid level.
1. Check all electrical connections for
security. Have electrician measure current
in motor leads, if current is within ±20%
of locked rotor Amps, impeller is probably
locked. If current is 0, overload may be
tripped. Remove power, allow pump to cool,
then recheck current.
2a. Reposition pump or clean basin as
required to provide adequate clearance for
oat.
2b. Disconnect level control. Set ohmmeter
for a low range, such as 100 ohms full scale
and connect to level control leads. Actuate
level control manually and check to see that
ohmmeter shows zero ohms for closed switch
and full scale for open switch. (Float Switch).
3. Make sure liquid level is at least equal to
suggested turn-on point.
4. Recheck all sizing calculations to
determine proper pump size.
5. Check discharge line for restrictions,
including ice if line passes through or into
cold areas.
6. Remove and examine check valve for
proper installation and freedom of operation.
7. Open valve.
8. Check cutter for freedom of operation,
security and condition. Clean cutter and inlet
of any obstruction.
9. Loosen union slightly to allow trapped air
to escape.Verify that turn-off level of switch
is set so that the suction is always ooded.
Clean vent hole.
10. Remove & examine for damage. Replace
pump stator if required.
11. Repair xtures as required to eliminate
leakage.
12. Check pump temperature limits & uid
temperature.
13. Replace portion of discharge pipe with
exible connector.
14. Turn to automatic position.
15. Check for leaks around basin inlet and
outlets.
Pump will not turn off 2a. Float movement restricted.
2b. Switch will not activate pump or is defec-
tive.
4. Excessive inow or pump not properly sized
for application.
9. Pump may be airlocked.
14. H-O-A switch on panel is in “HAND” posi-
tion
Pump hums but does not run 1. Incorrect voltage
8. Cutter jammed or loose on shaft, worn or
damaged, inlet plugged.
Pump delivers insufcient capacity 1. Incorrect voltage.
4. Excessive inow or pump not properly sized
for application.
5. Discharge restricted.
6. Check valve stuck closed or installed
backwards.
7. Shut-off valve closed.
8. Cutter jammed or loose on shaft, worn or
damaged, inlet plugged.
9. Pump may be airlocked.
10. Pump stator damaged/torn.
Pump cycles too frequently or runs
periodically when xtures are not in use
6. Check valve stuck closed or installed
backwards.
11. Fixtures are leaking.
15. Ground water entering basin.
Pump shuts off and turns on indepen-
dent of switch, (trips thermal overload
protector). CAUTION! Pump may start
unexpectedly. Disconnect power supply.
1. Incorrect voltage.
4. Excessive inow or pump not properly sized
for application.
8. Cutter jammed, loose on shaft, worn or
damaged, inlet plugged.
12. Excessive water temperature.
Pump operates noisily or vibrates
excessively
4. Operating at too high a pressure.
5. Discharge restricted.
8. Cutter broken.
13. Piping attachments to buiding structure too
rigid or too loose.

15
FIGURE 8
2HP - XSGV SERIES

16
FIGURE 9
2HP - XSGV SERIES

17
PARTS KITS
Cutter Kit .......................... P/N-085226
Tools: Seal Pusher........... P/N- TL-21360
Bullet..................... P/N- TL-21375
PARTS LIST - Standard
ITEM QTY PART NO. DESCRIPTION
1 1 067561 Volute (Standard)
102795 (OPTIONAL) Moveable Fitting
2 4 018925 Stud 5/16-18 x 2.25 lg Stainless
3 4 15-19-1 Hex Nut 5/16-18 Stainless
4 4 026322 Lockwasher 5/16 Stainless
5 1 067564 Square Ring
6 1 070704 Flat Hd. Cap Screw 1/4-20 x .75 lg Stainless
7 1 067556 Washer Stainless
8 1 082088 Radial Cutter
9 1 082085 Shredding Ring
10 3 067569 Flat Hd. Cap Screw #10-24 x 3/4 lg Stainless
11 1 067554 Throat
12 2 016079 Shim (as required) .010”
13 1 067552 Impeller, Bronze 5.62” Dia., (STD)
067552TD 5.00” Dia.
067552TE 4.88” Dia.
067552TF 4.75” Dia.
067552TG 4.62” Dia.
067552TH 4.50” Dia.
067552TJ 4.38” Dia.
067552TK 4.25” Dia.
067552TL 4.12” Dia.
067552TM 4.00” Dia.
067552TN 3.88” Dia.
067552TP 3.75” Dia.
067552TR 3.62” Dia.
067552TS 3.50” Dia.
14 1 082134 Lifting Handle
15 2 1-130-1 Hex Hd. Cap Screw 5/16-18 x 1.50 lg Stainless
16 1 ----- Motor Assy--(Includes: Motor, 30 ft. Cable, C/C/B Inner & Outer Seals )
128617 2HP, 230V, 1PH--XSGV2022L
128618 2HP, 200V, 3PH--XSGV2062L
128619 2HP, 230V, 3PH--XSGV2032L
128620 2HP, 460V, 3PH--XSGV2042L
128621 2HP, 575V, 3PH--XSGV2052L
17 1 067562 Outer Shaft Seal (Standard) Carbon/Ceramic/Buna-N
067562SB Tungsten/Tungsten/Buna-N
067562SD Silicon/Silicon/Buna-N
067562SF Carbon/Ceramic/Viton®
067562SH Tungsten/Tungsten/Viton®
067562SK Silicon/Silicon/Viton®
() 3, 4, 6, 7, 8, 9, 10, 12
2HP - XSGV SERIES

18
FIGURE 10
3, 5, 7.5HP - XSGV SERIES

19
FIGURE 11
3, 5, 7.5HP - XSGV SERIES

20
3, 5, 7.5HP - XSGV SERIES
PARTS KITS
Cutter Kit .......................... 085225
Tools: Seal Pusher........... P/N- TL-21362
Bullet ..................... P/N- TL-21382
PARTS LIST
ITEM QTY. PART No. DESCRIPTION
1 1 072084B Volute, Standard
083527 (OPTIONAL) Moveable Fitting
2 4 070706 Stud 7/16-14 x 3.25 lg Stainless
3 4 027116
Hex Nut 7/16-14 Stainless
4 6 027115
Lockwasher 7/16 Stainless
5 1 019289
Square Ring
6 1 070703
Flat Hd. Cap Screw 3/8-16 x 1.75 lg Stainless
7 1 070702
Washer Stainless
8 1 070728
Radial Cutter HT Stainless
9 1 070729
Shredding Ring
12 2 070707
Shim (as required) .010”
13 1 132462 Impeller, Cast Iron 6.46” Dia., (STD for 7.5HP)
132462TA 6.38” Dia.
132462TB 6.25” Dia., (STD for 5HP)
132462TC 6.12” Dia.
132462TD 6.00” Dia.
132462TE 5.88” Dia.
132462TF 5.75” Dia.
132462TG 5.62” Dia.
132462TH 5.50” Dia.
132462TJ 5.38” Dia.
132462TK 5.25” Dia.
132462TL 5.12” Dia.
132462TM 5.00” Dia., (STD for 3HP)
132462TN 4.88” Dia.
132462TP 4.75” Dia.
132462TQ 4.62” Dia.
132462TR 4.50” Dia.
132462TS 4.38” Dia.
132462TT 4.25” Dia.
132462TU 4.12” Dia.
132462TV 4.00” Dia.
14 1 082165 Lifting Handle
15 2 1-319-1 Hex Hd. Cap Screw 7/16-14 x 2 lg Stainless
16 1 Motor Assy--(Includes: Motor, 30 Ft. Cable and C/C/B Inner & Outer Seals)
128622 3HP, 200V, 1PH--XSGV3002L
128623 3HP, 230V, 1PH--XSGV3022L
128624 3HP, 200V, 3PH--XSGV3062L
128625 3HP, 230V, 3PH--XSGV3032L
128626 3HP, 460V, 3PH--XSGV3042L
128627 3HP, 575V, 3PH--XSGV3052L
128628 5HP, 200V, 1PH--XSGV5002L
128629 5HP, 230V, 1PH--XSGV5022L
128630 5HP, 200V, 3PH--XSGV5062L
128631 5HP, 230V, 3PH--XSGV5032L
128632 5HP, 460V, 3PH--XSGV5042L
128633 5HP, 575V, 3PH--XSGV5052L
128634 7.5HP, 230V, 3PH--XSGV7532L
128635 7.5HP, 460V, 3PH--XSGV7542L
128636 7.5HP, 575V, 3PH--XSGV7552L
17 1 070712 Outer Shaft Seal, (Standard) Carbon/Ceramic/Buna-N
070712SB Tungsten/Tungsten/Buna-N
070712SD Silicon/Silicon/Buna-N
070712SF Carbon/Ceramic/Viton®
070712SH Tungsten/Tungsten/Viton®
070712SK Silicon/Silicon/Viton®
() 3, 4, 5, 6, 7, 8, 9, 10, 12