Xylem Bell & gossett 4dwc User manual

Instruction Manual

IM407

4DWC Three Phase Simplex

Control Panel

Table of Contents

1 Introduction and Safety........................................................................................................ 2

1.1 Introduction....................................................................................................................2

1.1.1 Purpose of the manual............................................................................................2

1.2 Safety............................................................................................................................ 2

1.3 Safety terminology and symbols....................................................................................2

1.4 Environmental safety..................................................................................................... 3

1.5 Recycling guidelines......................................................................................................3

1.6 User safety.................................................................................................................... 4

2 Transportation and Storage................................................................................................. 6

2.1 Examine the delivery..................................................................................................... 6

2.1.1 Examine the package............................................................................................. 6

2.1.2 Examine the unit..................................................................................................... 6

2.2 Transportation guidelines.............................................................................................. 6

2.3 Storage guidelines.........................................................................................................6

3 Product Description..............................................................................................................8

3.1 4DWC Series simplex control panel.............................................................................. 8

3.2 Enclosure Mounting: NEMA 4X RATED........................................................................8

4 Installation............................................................................................................................ 9

4.1 Panel Installation........................................................................................................... 9

5 Operation........................................................................................................................... 10

5.1 Sequence of operation:............................................................................................... 10

5.2 Remote monitoring dry contacts:.................................................................................10

6 Troubleshooting................................................................................................................. 11

7 Warranty.............................................................................................................................12

7.1 Limited consumer warranty......................................................................................... 12

7.2 Commercial warranty...................................................................................................13

Table of Contents

4DWC Three Phase Simplex Control Panel Instruction Manual 1

1 Introduction and Safety

1.1 Introduction

1.1.1 Purpose of the manual

The purpose of this manual is to provide necessary information for:

• Installation

• Operation

• Maintenance

WARNING:

Carefully read the Instruction Manual to avoid serious personal injury and property hazards

and to ensure safe use and proper care of this product.

NOTICE:

Save this manual for future reference, and keep it readily available at the location of the unit.

The information contained in this manual is intended to assist operating personnel by

providing information on the characteristics of the purchased equipment. It does not relieve

the user of the responsibility to adhere to local codes and ordinances and the use of

accepted practices in the installation, operation and maintenance of this equipment. Further

information pertaining to the installation, operation, and maintenance of your TechnoForce e-

MTV pump controller can be found in the IOMs for the associated equipment provided

Maintenance section for a list of relevant manuals. Equipment cannot operate well without

proper care. To keep this unit at top efficiency, follow the recommended installation and

servicing procedures outlined in this manual.

1.2 Safety

WARNING:

• The operator must be aware of safety precautions to prevent physical injury.

• Operating, installing, or maintaining the unit in any way that is not covered in this manual

could cause death, serious personal injury, or damage to the equipment. This includes

any modification to the equipment or use of parts not provided by Xylem. If there is a

question regarding the intended use of the equipment, please contact a Xylem

representative before proceeding.

• Do not change the service application without the approval of an authorized Xylem

representative.

CAUTION:

You must observe the instructions contained in this manual. Failure to do so could result in

physical injury, damage, or delays.

1.3 Safety terminology and symbols

About safety messages

It is extremely important that you read, understand, and follow the safety messages and

regulations carefully before handling the product. They are published to help prevent these

hazards:

1 Introduction and Safety

2 4DWC Three Phase Simplex Control Panel Instruction Manual

• Personal accidents and health problems

• Damage to the product and its surroundings

• Product malfunction

Hazard levels

Hazard level Indication

DANGER:

A hazardous situation which, if not avoided, will

result in death or serious injury

WARNING:

A hazardous situation which, if not avoided, could

result in death or serious injury

CAUTION:

A hazardous situation which, if not avoided, could

result in minor or moderate injury

NOTICE:

Notices are used when there is a risk of equipment

damage or decreased performance, but not

personal injury.

Special symbols

Some hazard categories have specific symbols, as shown in the following table.

Electrical hazard Magnetic fields hazard

Electrical Hazard:

CAUTION:

1.4 Environmental safety

The work area

Always keep the station clean to avoid and/or discover emissions.

Waste and emissions regulation

Observe these safety regulations regarding waster and emissions:

• Appropriately dispose of all waste.

• Handle and dispose of the processed liquid in compliance with applicable environmental

regulations.

• Clean up all spills in accordance with safety and environmental procedures.

• Report all environmental emissions to the appropriate authorities.

Electrical installation

For electrical installation recycling requirements, consult your local electric utility.

1.5 Recycling guidelines

Always follow local laws and regulations regarding recycling.

1 Introduction and Safety

4DWC Three Phase Simplex Control Panel Instruction Manual 3

1.6 User safety

General safety rules

These safety rules apply:

• Always keep the work area clean.

• Pay attention to the risks presented by gas and vapors in the work area.

• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash

hazards.

• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.

Safety equipment

Use safety equipment according to the company regulations. Use this safety equipment

within the work area:

• Helmet

• Safety goggles

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

NOTICE:

Never operate a unit unless safety devices are installed. Also see specific information about

safety devices in other chapters of this manual.

Electrical connections

Electrical connections must be made by certified electricians in compliance with all

international, national, state, and local regulations. For more information about requirements,

see sections dealing specifically with electrical connections.

Precautions during work

Observe these safety precautions when you work with the product or are in connection with

the product:

• Never work alone.

• Always wear protective clothing and hand protection.

• Stay clear of suspended loads.

• Always lift the product by its lifting device.

• Beware of the risk of a sudden start if the product is used with an automatic level control.

• Beware of the starting jerk, which can be powerful.

• Rinse the components in water after you disassemble the pump.

• Do not exceed the maximum working pressure of the pump.

• Do not open any vent or drain valve or remove any plugs while the system is pressurized.

Make sure that the pump is isolated from the system and that pressure is relieved before

you disassemble the pump, remove plugs, or disconnect piping.

• Never operate a pump without a properly installed coupling guard.

Wash the skin and eyes

Do the following if chemicals or hazardous fluids have come into contact with your eyes or

your skin:

1 Introduction and Safety

4 4DWC Three Phase Simplex Control Panel Instruction Manual

If you need to wash

your…

Then

Eyes • Hold your eyelids apart forcibly with your fingers.

• Rinse the eyes with eyewash or running water for at least 15 minutes.

• Seek medical attention.

Skin 1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least one minute.

3. Seek medical attentions, if required.

1 Introduction and Safety

4DWC Three Phase Simplex Control Panel Instruction Manual 5

2 Transportation and Storage

2.1 Examine the delivery

2.1.1 Examine the package

1. Examine the package for damaged or missing items upon delivery.

2. Record any damaged or missing items on the receipt and freight bill.

3. If anything is out of order, then file a claim with the shipping company.

If the product has been picked up at a distributor, make a claim directly to the distributor.

2.1.2 Examine the unit

1. Remove packing materials from the product.

Dispose of all packing materials in accordance with local regulations.

2. To determine whether any parts have been damaged or are missing, examine the

product.

3. If applicable, unfasten the product by removing any screws, bolts, or straps.

Use care around nails and straps.

4. If there is any issue, then contact a sales representative.

2.2 Transportation guidelines

Lifting methods

WARNING:

• Assembled units and their components are heavy. Failure to properly lift and support this

equipment can result in serious physical injury and/or equipment damage. Lift equipment

only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and

spreaders must be rated, selected, and used for the entire load being lifted.

• Crush hazard. The unit and the components can be heavy. Use proper lifting methods

and wear steel-toed shoes at all times.

CAUTION:

Care should be taken to prevent damage due to dropping or jolting when moving the

controller. Transportation damage should be brought to the carrier’s attention immediately

upon receipt.

2.3 Storage guidelines

Storage location

The product must be stored in a covered and dry location protected from extreme cold, heat,

dirt, and vibrations.

NOTICE:

Protect the product against humidity, heat sources, and mechanical damage.

Do not place heavy weights on the packed products.

Long-term storage

If the controller is stored for more than 6 months, these requirements apply:

• Store in a covered and dry location.

• Store the unit free from heat, dirt, and vibrations.

• Recommended storage includes but not limited to a tarp over the unit.

2 Transportation and Storage

6 4DWC Three Phase Simplex Control Panel Instruction Manual

Extended storage of VFDs may require special attention prior to start-up. See

manufacturer’s IOM for details.

2 Transportation and Storage

4DWC Three Phase Simplex Control Panel Instruction Manual 7

3 Product Description

3.1 4DWC Series simplex control panel

The 4DWC Series simplex control panels will control one pump in sewage, wastewater, and

dewatering applications. All panels are UL Listed for the United States and Canada and

come with a five-year warranty.

Model FLA Range

NSS39014 (9.0-14.0 FLA)

NSS31318 (13.0-18.0 FLA)

NSS31723 (17.0-23.0 FLA)

NSS32432 (24.0-32.0 FLA)

NSS33040 (30.0-40.0 FLA)

NSS33750 (37.0-50.0 FLA)

NSS34865 (48.0-65.0 FLA)

NSS365115* (65.0-115.0 FLA)

3.2 Enclosure Mounting: NEMA 4X RATED

Mounting Brackets

A mounting bracket and screw pack are provided with the premium enclosures. To

assemble, turn the enclosure upside down on a flat surface, place the mounting bracket over

the square boss either horizontally or vertically, and fasten the mounting bracket with the

1/4"-20 x 0.5 SS, countersunk Phillips drive screws or vertically, with the mounting brackets

in any configuration, using any acceptable fastening technique.

Covers/Doors

Covers/doors have a gasket pre-assembled to seal against the base.

Note: The control panel should not be mounted in a location that may be subject to

submersion.

3 Product Description

8 4DWC Three Phase Simplex Control Panel Instruction Manual

4 Installation

4.1 Panel Installation

1. Caution: To maintain the NEMA 4X rating, make all wiring connections with seal-tight

cable grips or conduit connections.

2. Run pump cables and floats cables through conduit. Make field connections as shown on

the wiring schematic.

3. Run power line conductor through the conduit, wire to terminals per enclosed schematic.

4. Branch circuit protection is to be provided by the installer.

5. Panel circuit breakers are closed.

6. Floats are accurately mounted at the correct levels.

Note: Floats shall have free range of motion without touching each other or other

equipment.

7. Connect service conductors 208/240/480V to the proper location.

Figure 1: Typical Installation of 4DWC Simplex Control

Panel

1. Submersible pump

2. Pump stop float

3. Pump start float

4. High liquid alarm float

5. Simplex control panel

4 Installation

4DWC Three Phase Simplex Control Panel Instruction Manual 9

5 Operation

5.1 Sequence of operation:

1. When the “Stop” and “Lead” float contact closes, the pump will energize and the “Pump

Run” light will illuminate. The pump will remain operational until the “Stop” float opens.

2. If the level continues to rise, the “High” float will alarm. This will illuminate the 360 -

degree visible beacon and buzzer will sound 85 decibels at 10’.

5.2 Remote monitoring dry contacts:

Normally Open dry contacts for high level, Pump run, and Pump fault.

Note: Refer to wiring schematic for proper termination.

5 Operation

10 4DWC Three Phase Simplex Control Panel Instruction Manual

6 Troubleshooting

Caution: Before checking electrical connections within the control or attempting to replace

any components, turn off all branch circuits supplying power to the main control panel.

Alarm Circuit:

To test the alarm light and buzzer, press the "Test" button on the front panel. If either the

light or buzzer does not indicate, replace the light bulb or buzzer with the same type.

Control Board and Fuse:

If the "Power On" light is not illuminating on the front panel, check the voltage at TS1-1 and

TS1-2 with a voltage meter. The voltage should read 120VAC. If voltage is present, check

the fuse in the fuse box. If the fuse is blown, replace the fuse with the same type. The dry

contacts are rated for 120 VAC or 24 VDC, 1 amp max.

Floats:

The control board has individual float status indicators that will illuminate when the floats are

in the closed position. Check floats for entanglement, and a full range of motion. Replace

damaged floats.

6 Troubleshooting

4DWC Three Phase Simplex Control Panel Instruction Manual 11

7 Warranty

7.1 Limited consumer warranty

Warranty. For goods sold for personal, family or household purposes, Seller warrants the

goods purchased hereunder (with the exception of membranes, seals, gaskets, elastomer

materials, coatings and other “wear parts” or consumables all of which are not warranted

except as otherwise provided in the quotation or sales form) will be free from defects in

material and workmanship for a period of one (1) year from the date of installation or two (2)

years from the product date code, whichever shall occur first, unless a longer period is

provided by law or is specified in the product documentation (the “Warranty”).

Except as otherwise required by law, Seller shall, at its option and at no cost to Buyer, either

repair or replace any product which fails to conform with the Warranty provided Buyer gives

written notice to Seller of any defects in material or workmanship within ten (10) days of the

date when any defects or non-conformance are first manifest. Under either repair or

replacement option, Seller shall not be obligated to remove or pay for the removal of the

defective product or install or pay for the installation of the replaced or repaired product and

Buyer shall be responsible for all other costs, including, but not limited to, service costs,

shipping fees and expenses. Seller shall have sole discretion as to the method or means of

repair or replacement. Buyer’s failure to comply with Seller’s repair or replacement directions

shall terminate Seller’s obligations under this Warranty and render this Warranty void. Any

parts repaired or replaced under the Warranty are warranted only for the balance of the

warranty period on the parts that were repaired or replaced.

Seller shall have no warranty obligations to Buyer with respect to any product or parts of a

product that have been: (a) repaired by third parties other than Seller or without Seller’s

written approval; (b) subject to misuse, misapplication, neglect, alteration, accident, or

physical damage; (c) used in a manner contrary to Seller’s instructions for installation,

operation and maintenance; (d) damaged from ordinary wear and tear, corrosion, or

chemical attack; (e) damaged due to abnormal conditions, vibration, failure to properly

prime, or operation without flow; (f) damaged due to a defective power supply or improper

electrical protection; or (g) damaged resulting from the use of accessory equipment not sold

or approved by Seller. In any case of products not manufactured by Seller, there is no

warranty from Seller; however, Seller will extend to Buyer any warranty received from

Seller’s supplier of such products.

THE FOREGOING WARRANTY IS PROVIDED IN PLACE OF ALL OTHER EXPRESS

WARRANTIES. ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, ARE LIMITED TO ONE(1) YEAR FROM THE DATE OF INSTALLATION OR

TWO (2) YEARS FROM THE PRODUCT DATE CODE, WHICHEVER SHALL OCCUR

FIRST. EXCEPT AS OTHERWISE REQUIRED BY LAW, BUYER’S EXCLUSIVE REMEDY

AND SELLER’S AGGREGATE LIABILITY FOR BREACH OF ANY OF THE FOREGOING

WARRANTIES ARE LIMITED TO REPAIRING OR REPLACING THE PRODUCT AND

SHALL IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY THE BUYER FOR THE

DEFECTIVE PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY OTHER

FORM OF DAMAGES, WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL,

CONSEQUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL DAMAGES, INCLUDING BUT

NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE,

LOSS OF INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF

OPPORTUNITY OR LOSS OF REPUTATION.

Some states do not allow limitations on how long an implied warranty lasts, so the above

limitation may not apply to you. Some states do not allow the exclusion or limitation of

incidental or consequential damages, so the above exclusions may not apply to you. This

warranty gives you specific legal rights, and you may also have other rights which may vary

from state to state.

7 Warranty

12 4DWC Three Phase Simplex Control Panel Instruction Manual

To make a warranty claim, check first with the dealer from whom you purchased the product

or call +1-847-966-3700 for the name and location of the nearest dealer providing warranty

service.

7.2 Commercial warranty

Warranty. For goods sold to commercial buyers, Seller warrants the goods sold to Buyer

hereunder (with the exception of membranes, seals, gaskets, elastomer materials, coatings

and other “wear parts” or consumables all of which are not warranted except as otherwise

provided in the quotation or sales form) will be (i) be built in accordance with the

specifications referred to in the quotation or sales form, if such specifications are expressly

made a part of this Agreement, and (ii) free from defects in material and workmanship for a

period of one (1) year from the date of installation or two (2) years from the date of

manufacture, whichever shall occur first, unless a longer period is specified in the product

documentation (the “Warranty”).