Skimmer - OWS IOM Manual

FINAL OPERATION AND
MAINTENANCE MANUAL
DRUMMOND LTD
MINA PRIBBENOW
COLOMBIA
PURCHASE ORDER:
CMLTD-CPFME00004
EQUIPMENT:
R-HTC-J 600 OIL WATER SEPARATOR WITH
ALARMS AND WATER PUMPOUT SYSTEM
OWS MANUFACTURER:
HIGHLAND TANK AND MANUFACTURING
HIGHLAND TANK WORK ORDER NUMBER:

84232
HIGHLAND TANK DRAWING NUMBERS:
94467 / 94468
INDEX OF INCLUDED MATERIAL
TAB 1: LITERATURE & GENERAL INFORMATION
- Rectangular Oil Water Separator Literature (4 Pages)

- Interior Coating (Chemthane 4200PW) Data Sheet (3 Pages)
- Exterior Primer (Carboline Carboguard 890VOC) Data Sheet (2 Pages)
- Exterior Topcoat (Carboline Carbothane 134HG) Data Sheet (2 Pages)
TAB 2: OWS DRAWING/ACCESSORY INFORMATION
- Oil Water Separator Drawing 94467, Revision 1 (1 Page)

- OWS Notes-Details Drawing 94468, Revision 0 (1 Page)
- API 421 Coalescing Surface Area Calculation (3 Pages)
- Pump Control/Alarm Panel Drawing HT-10416 (3 Pages)
- Two Level Oil Alarm Sensor Detail (1 Page)
- Four Level Water Pump Control/Alarm Sensor (1 Page)
- Flygt CP3068 Water Pump Curve and Details (9 Pages)
- Butterfly Valve Information (5 Pages)
TAB 3: QUALITY CONTROL FORMS
- Inspection & Test Plan – Complete (3 Pages)

- HT Shop Construction Inspection Report/Traveler Form (1 Page)
- UL 142 Air Test Report Form (1 Page)
- Internal Coating Inspection Form & Blast Profiles (3 Pages)
- External Coating Inspection Form & Blast Profiles (3 Pages)
TAB 4: OPERATION MANUAL & SPARE PARTS
- Highland Tank Rectangular OWS User’s Manual (14 Pages)

- Warrick Series 67 Detail & Operation Info (16 Pages)
- Flygt 3068 Pump Installation, Care & Maintenance Manual (17 Pages)
- Basic Spare Parts List and Pricing (1 Page)
1
TAB 1
LITERATURE
& GENERAL
INFORMATION
2
Rectangular HT-2027
Oil/Water Separators
Highland Tank

Innovative, High-Quality and Cost-Effective

Highland Tank Rectangular Oil/Water oily-coated solids from oil/water • Airports & aircraft services

Separators are of the highest mixtures associated with many types • Automobile dealers

quality - constructed to American of petroleum, industrial, commercial, • Electric utilities & power plants

Petroleum Institute (API) and military and municipal facilities. • Environmental remediation

Underwriters’ Laboratories (UL) • Military & government facilities

specifications. Our high-efficiency oil/water • Petroleum marketing facilities

separators are recommended • Railroad yards

Highland Tank’s separators are for many industrial and commercial • Trucking and transportation

designed for the removal of free- applications, such as: facility vehicle services

floating oil, grease and settleable
Unmatched Quality
3 & Service
Easy to Install, Operate and Maintain
Rectangular oil/water separators
can be installed aboveground to
help industrial facilities comply with
the EPA's spill and discharge regulations.
Like our cylindrical underground units,
these separators are equipped with
our non-clogging Corella® coalescers
that accelerate the separation process
and greatly reduce the level of oil and
oily-coated solids discharged into
municipal storm or sanitary sewer.
Highland Tank oil/water separators

setthe standard for reliability. Our
separators are highly efficient -
treating wastewater under a wide
range of conditions at fueling
facilities, repair and maintenance
shops, vehicle wash areas and
many other industrial locations.
Also available with a UL-SU2215 label
Aboveground installation Electronic oil level sensor Removable, top panels

avoids costly excavation can signal remote alarm for easy access and
panel of high oil condition maintenance
4
Rectangular Separator Sizing Guide
Removable Top Cover with Lifting Handles
Length Width
Lifting Lug
INLET
Height
Velocity
Head OUTLET
Diffusion
Baffle
Optional Corella® Parallel Petro Screen Oil Dam Adjustable Effluent Optional
Sludge Hopper Plate Coalescer Coalescer Transfer Pipes Support Legs
Flow Total Recommended Tank Dimensions Inlet &

Model Rate Volume Oil Pump-out Outlet

R-HT or R-HTC Gal/Min Gallons Gallons LxWxH Diameter

100 5 100 20 5'-0" x 1'-6" x 3'-0" 1"

200 10 200 40 5'-0" x 2'-0" x 3'-0" 2"

300 25 300 60 7'-0" x 2'-0" x 3'-0" 3"

600 50 600 120 9'-0" x 3'-0" x 3'-0" 4"

900 75 900 180 10'-0" x 3'-0" x 4'-0" 6"

1,000 100 1,000 200 11'-0" x 4'-0" x 4'-0" 6"

2,000 200 2,000 400 12'-0" x 5'-0" x 5'-0" 8"

3,000 300 3,000 600 18'-0" x 5'-0" x 5'-0" 10"

4,000 400 4,000 800 18'-0" x 6'-0" x 5'-0" 10"

5,000 500 5,000 1,000 20'-0" x 6'-0" x 6'-0" 10"

6,000 600 6,000 1,200 19'-2" x 7'-0" x 6'-0" 10"

7,000 700 7,000 1,400 19'-2" x 7'-0" x 7'-0" 10"

8,000 800 8,000 1,600 19'-2" x 8'-0" x 7'-0" 10"

9,000 900 9,000 1,800 18'-10" x 8'-0" x 8'-0" 12"

10,000 1,000 10,000 2,000 20'-11" x 8'-0" x 8'-0" 12"

12,000 1,200 12,000 2,400 19'-10" x 9'-0" x 9'-0" 12"

15,000 1,500 15,000 3,000 24'-9" x 9'-0" x 9'-0" 14"

20,000 2,000 20,000 4,000 29'-9" x 10'-0" x 9'-0" 16"

25,000 2,500 25,000 5,000 33'-6" x 10'-0" x 10'-0" 18"

30,000 3,000 30,000 6,000 40'-10" x 10'-0" x 10'-0" 20"

Plate spacing and orientation may vary depending on site conditions. Custom sizing is available.
Consult Highland Tank for Series G, J, S & TF sizing information.

5
Pre-engineered Design Options
Series - G Oil/Water Separators INLET

feature an integral sand interceptor
compartment to permit sand and OUTLET
gravel to settle out before the
wastewater enters the
separation chamber.
Integral Sand Interceptor Compartment
Pump Power Pump Lift
Level Sensor Supply Chain & Rails
Series - J Oil/Water Separators

feature an integral effluent pump-out
INLET
compartment with level controls to OUTLET
END
operate a pump at prescribed levels.
The pumped effluent can then be
routed through Highland's Advanced
Hydrocarbon Filtration System to
further improve performance.
Bulkhead Effluent
Discharge Pump
Series - S Oil/Water Separators

feature an integral side product INLET
compartment for storing separated oil. Oil
OUTLET Pump-out
The special side product compartment Pipe
permits the removal of only the
skimmed oil by pump-out. The effluent
is discharged either by pump or Oil Skimmer Side Oil Storage
gravity flow. Compartment
Series - TF Oil/Water Separators High Oil Sensor Diffusion Pipe High Water Sensor
feature an integral “trickle filter" to

Vent Fitting
remove dispersed and mechanically
INLET
emulsified oils that may pass through
OUTLET
the separator untreated. Water flows
freely out of the separator to the
diffusion pipe and passes through the
oleophilc trickle filter media bags to
remove any troublesome discharges. Trickle Filter Media
The media bags can be easily removed
and replaced when necessary.
LA Please visit us at www.highlandtank.com

I GH N
One Highland Road 4535 Elizabethtown Road 958 19th Street 2700 Patterson Street 2225 Chestnut Street 1510 Stoystown Road
H
TANK Stoystown, PA 15563 Manheim, PA 17545 Watervliet, NY 12189 Greensboro, NC 27407 Lebanon, PA 17042 Friedens, PA 15541
P: 814-893-5701 P: 717-664-0600 P: 518-273-0801 P: 336-218-0801 P: 717-664-0602 P: 814-443-6800
. 6
M F G. C O F: 814-893-6126 F: 717-664-0617 F: 518-273-1365 F: 336-218-1292 F: 717-664-0631 F: 814-444-8662
&
© Highland Tank – HT– 2027 – 10/2014

 
 
ANSI/NSF 61
DRINKING WATER SYSTEM
CHEMTHANE 4200 PW COMPONENTS

16ZP
Barrier Material
Maximum use temperature: 23oC
Maximum use level: 22.5cm2
POLYURETHANE LINING, NSF/ANSI 61 - Potable Water
DESCRIPTION CHEMTHANE 4200 is a solvent-free, two component polyurethane lining

(1:1 spray ratio by volume). This product has been approved by
Underwriter’s Laboratories to comply with the NSF/ANSI 61 standard
for potable water. This product has a very short reaction time and is therefore
spray applied using plural component spray equipment. Application of this
product is made directly to surface prepared steel or ductile iron. Primers
are not necessary. Unlimited film builds may be achieved in a single coat
multi-pass application.
This product cures to form a hard polymer film that demonstrates excellent
adhesion. In addition, it is very resistant to abrasion, chemical attack, and
cathodic disbondment. This product will chalk and discolor when exposed to
ultra-violet light.
TYPICAL Solids, by volume 100%

VOC (supplied and sprayable) Zero
PROPERTIES Components Two
Curing Mechanism Chemical Reaction
Mix Ratio, by volume 1:1
Weight per mixed gallon 9.6 lbs/gallon (4.3 kg/gallon)
Color Availability Unlimited
Theoretical Coverage 1604 sq. ft. per gallon per mil
(149 sq. m/gal per mil)
Primer Requirement None Required
Application Temperature Range 35oF - 120oF (2oC - 49oC)
Recommended Thickness 15 mils minimum
Adhesion to Steel (SP10;2.5 mil) 2000 +/- 200 psi
Hardness (ASTM D 2240) 77 Shore D
Tensile Strength (ASTM D 638) 5500 psi (38mpa)
Flexibility (ASTM D 522) 180 bend over 1” mandrel @ 15 mils
Impact Strength (ASTM G 14) >30 in lbs
Abrasion Resistance (ASTM D 4060) 60 mg loss (C17, 1 kg, 1000 cycles)
Chemical Resistance (ASTM D 543) See Chemical Resistance Chart
Cathodic Disbondment (ASTM G-8) <8mm rad.
CURE TIMES Cure to the Touch 3-5 minutes @ 77oF (25oC)

Cure to Handle 15-20 minutes @ 77oF (25oC)
Time to Recoat 10-20 minutes @ 75oF (24oC)
CERTIFICATIONS z UL Certification – “Flammable and Combustible Liquid Tank

Accessories - Components”: UL Subject 2215 “Outline of
AND QUALITY Investigation for Oil Water Separators” for interior corrosion
STANDARDS protection coatings for oil water separators.
z UL Certification – “Drinking Water System Components” – ANSI/

NSF Standard 61
z AWWA Standard “C222-99: Polyurethane Coatings for the Interior

and Exterior of Steel Water Pipe and Fittings”
z Meets Green Seal standard GS-11 for VOC and Chemical

Content
z Meets ANSI/AWWA D102-03 “Coating Steel Water Storage Tanks”

–Inside Coating System No. 4
CHEMTHANE 4200 is supplied in two 55-gallon tight top drums. Keep drums
PACKAGING, tightly sealed until ready for use to prevent atmospheric moisture from
STORAGE & contaminating material. Store material at temperatures between 50-80oF (10-
SHELF LIFE 27oC) in a dry well ventilated area. Ensure that material does not freeze.
Material has a minimum shelf life of 12 months after the date of manufacture
if properly stored.
7
revised:022406
CHEMTHANE 4200 PW revised: 022406
SAFETY CHEMTHANE 4200 IS FOR INDUSTRIAL USE ONLY. Avoid contact with eyes, and skin; do not
PRECUATIONS inhale or ingest. When working with this material wear goggles, rubber gloves and a respirator.
When spraying in a confined area, also wear a fresh air hood and make provision for forced venti-
lation. Refer to MSDS regarding individual components.
APPLICATION Consult with a CHEMLINE Representative for complete and detailed application instructions. For
best results, The substrate must be dry and free from dust, oil and grease. The substrate surface
GUIDELINES temperature should be a minimum of 5oF (-15oC) above the dew point of ambient air. Use steel grit or
sand to blast the substrate surface. Steel surfaces should be cleaned to a minimum of a near white
metal finish with a minimum angular profile of 2.5 mils (Ref. SSPC-SP10; Nace 2).
CHEMTHANE 4200 is applied using a plural component, high-pressure, airless spray unit with in-line
heaters. Material supply should be agitated and heated prior to application. Vent material supply
containers with nitrogen or desiccant.
Unlimited film builds may be achieved in a single-coat multipass application. Do not apply coating
after the recoat window has been exceeded. If recoat window has been exceeded, brush blast the
original coat and create a 2.5 mil profile in the original coating; then topcoat.
WARRANTY CHEMLINE warrants this product to be free of defects in material and workmanship. CHEMLINE’s
sole obligation and Buyer’s exclusive remedy in connection with the products shall be limited, at
CHEMLINE’s option, to either replace the products not conforming to this Warranty or credit to Buyer’s
account in the invoiced amount of the nonconforming products. Any claim under this Warranty must
be made by the Buyer to CHEMLINE in writing within (5) days of Buyer’s discovery of the claimed
defect, but in no event later than the expiration of the applicable shelf life, or one year from the
delivery date, whichever is earlier. Buyer’s failure to notify CHEMLINE of such nonconformance as
required herein shall bar Buyer from recovery under this Warranty.
CHEMLINE makes no other warranties whether express, implied, or statutory, such as warranties of
merchantability or fitness for a particular purpose, shall apply. In no event shall CHEMLINE be liable
for consequential or incidental damages.
Any recommendations or suggestion relating to the use of the products made by CHEMLINE, whether
in its technical literature, or in response to specific inquiry, or otherwise, is based on data believed to
be reliable; however, the products and information are intended for use by buyers having requisite
skill and know-how in the industry, and therefore it is for Buyer to satisfy itself of the suitability of the
products for its own particular use and it shall be deemed that Buyer has done so, at its sole discretion
and risk. Variation in environment, changes in procedures of use, or extrapolation of data may cause
unsatisfactory results.
LIMITATION CHEMLINE’s liability on any claim of any kind, including claims based upon CHEMLINE’s negligence
OF LIABILITY or strict liability, for any loss or damage arising out of, connected with, or resulting from the use of the
products, shall in no case exceed the purchase price allocable to the products or part thereof which
give rise to the claim. In no event shall CHEMLINE be liable for consequential or incidental damages.
CHEMLINE INCORPORATED
5151 NATURAL BRIDGE ROAD
ST. LOUIS, MO • 63115 • USA
T: 314-664-2230 • F: 314-664-1355
www.chemline.net
©CHEMLINE INC. 2004
8
CHEMICAL RESISTANCE CHART
Chemthane 4200PW
SOLUTION IMMERSION SPLASH SOLUTION IMMERSION SPLASH
FRESH WATER Potassium Hydroxide <10% 1 1

Potassium Hydroxide >10% 1 1
Distilled Water 1 1 Sodium Hydroxide <10% 1 1
De-ionized Water 1 1 Sodium Hydroxide >10% 2 1
Soaps 1 1
SEWAGE (WASTE WATER) Detergents 1 1
Calcium Chloride 1 1
Raw Sewage 1 1
Treated Effluent 1 1 ALIPHATIC HYDROCARBONS
Hydrogen Sulfide Gas 1 1
Crude Oil 1 1
SALT WATER Diesel 1 1
1 1 Kerosene 1 1
Sea Water 2 1
1 1 Gasoline
Brine 1 1
Jet Fuel
Fuel Oil 2,4 & 6 1 1
ACIDS
Hexane 2 1
1 1 Hydraulic Oils 1 1
Sulfuric <20%
3 2 Motor Oil 1 1
Sulfuric >20%
1 1 Mineral Spiritis 2 1
Hydrochloric <15%
Hydrochloric >15% 3 2
3 2 SOLVENTS
Nitric <30%
Nitric >30% 3 3
2 1 Toluene 3 2
Phosphoric <50%
3 1 Benzene 3 2
Phosphoric >50%
2 1 Xylene 3 2
Acetic <10%
3 2 Acetone 3 3
Acetic >10%
MEK 3 3
MAK 3 3
ALKALIES
Methylene Chloride 3 3
1 1 Trichloroethylene 3 3
Ammonium Hydroxide <20%
Ammonium Hydroxide >20% 2 1
Maximum Wet Service Temperature (Water) 140F (60C)
KEY:
1 = Excellent: No significant weight gain or swelling. No loss of tensile and/or impact strength
2 = Good: Less than 5% weight gain or swelling. Slight loss in tensile and/or impact srength.
3 = Not Recommended: Not suitable for service.
Immersion, spill and splash @ 77F/25C.
Contact Chemline for specific circumstances.
All the data, statements and recommendations contained in this document are based on tests Chemline believes to be reliable. These statements are made without any expressed guarantee or warranty as to their
accuracy. Chemline products are sold assuming that the user will evalaute the product’s performance independent of any recommendations by Chemline to determine compatability with a particular application or
intended use. All risks and liability of their use is assumed by the user. Chemline assumes no liability for damage incidental to the use of the product. Liability and obligation of the seller and manufacturer shall be
limited to the replacement of material only. www.chemline.net 9
Carboguard 890 VOC
Selection & Specification Data Substrates & Surface Preparation

Cycloaliphatic Amine Epoxy General Surfaces must be clean and dry. Employ adequate
Generic Type
methods to remove dirt, dust, oil and all other
Description Highly chemical resistant epoxy mastic coating with contaminants that could interfere with adhesion of the
exceptionally versatile uses in all industrial markets. coating.
Self-priming and suitable for application over most
existing coatings, and tightly adherent to rust. Steel Non-immersion: SSPC-SP6
Carboguard 890 VOC serves as stand-alone system 1.5-3.0 mils (38-75 microns)
for a variety of chemical environments. Immersion: SSPC-SP10 1.5-3.0 mils (38-75 microns)
SSPC-SP2 or SP3 are suitable cleaning methods for
Features  Excellent chemical resistance mild environments.
 Surface tolerant characteristics
 Self-priming and primer/finish capabilities Galvanized Prime with specific Carboline primers as recommended
 Very good abrasion resistance Steel by your Carboline Sales Representative. Refer to the
 VOC compliant to current AIM regulations specific primer’s Product Data Sheet for substrate
 Suitable for use in USDA inspected facilities preparation requirements.
Color Refer to Carboline Color Guide. Certain colors may Concrete Concrete must be cured 28 days at 75°F (24°C) and
require multiple coats for hiding. Epoxies lose gloss, or CMU 50% relative humidity or equivalent. Prepare surfaces
discolor and chalk in sunlight exposure. in accordance with ASTM D4258 Surface Cleaning of
Concrete and ASTM D4259 Abrading Concrete. Voids
Finish Semi-Gloss
in concrete may require surfacing. Mortar joints should
Self-priming. May be applied over inorganic zinc be cured a min of 15 days. Prime with itself,
Primers
primers and other tightly adhering coatings. A mist Carboguard 1340, or suitable filler/sealer.
coat may be required to minimize bubbling over
inorganic zinc primers. Drywall & Joint compound and plaster should be fully cured prior
Plaster to coating application. Prime with Carbocrylic 120 or
Topcoats Acrylics, Epoxies, Polyurethanes Carboguard 1340.
Dry Film 4.0-6.0 mils (100-150 microns) per coat Previously Lightly sand or abrade to roughen surface and degloss
Thickness 6.0-8.0 mils (150-200 microns) over light rust and for Painted the surface. Existing paint must attain a minimum 3B
uniform gloss over inorganic zincs. Surfaces rating in accordance with ASTM D3359 “X-Scribe”
Don't exceed 10 mils (250 microns) in a single coat. adhesion test.
Excessive film thickness over inorganic zincs may
increase damage during shipping or erection.
Solids Content By Volume (890 VOC): 75% ± 2%

2 2
Theoretical 890 VOC: 1203 mil ft (30.0 m /l at 25 microns)
Coverage Rate 241 ft2 at 5 mils (6.0 m2/l at 125 microns)
Allow for loss in mixing and application
VOC Values
Calculated EPA As supplied 0.8lbs/gal (100 g/l)
Method 24
Thinned w/#236E 0.8lbs/gal (100 g/l)
Dry Temp. Continuous: 250°F (121°C)

Resistance Non-Continuous: 300°F (149°C)
Discoloration and loss of gloss is observed above
200°F (93°C).
Limitations Do not apply over latex coatings. Discoloration may

be objectionable if used as a topcoat. For immersion
projects use only factory made material in special
colors. Consult Technical Service for specifics.
October 2010 replaces January 2010 1029

To the best of our knowledge the technical data contained herein is true and accurate on the date of publication and is subject to change without prior notice. User must contact Carboline Company to
verify correctness before specifying or ordering. No guarantee of accuracy is given or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for
10 of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline and Carboguard
are registered trademarks of Carboline Company.
Carboguard 890 VOC
Application Equipment Application Conditions

890 VOC
Listed below are general equipment guidelines for the application of this product. Job Condition Material Surface Ambient Humidity
site conditions may require modifications to these guidelines to achieve the desired
results. General Guidelines: 60°-85°F 60°-85°F 60°-90°F
Normal 0-80%
(16°-29°C) (16°-29°C) (16°-32°C)
Spray Application This is a high solids coating and may require 50°F 50°F 50°F
(General) adjustments in spray techniques. Wet film thickness is Minimum 0%
(10°C) (10°C) (10°C)
easily and quickly achieved. The following spray 90°F 125°F 110°F
equipment has been found suitable and is available Maximum 80%
(32°C) (52°C) (43°C)
from manufacturers such as Binks, DeVilbiss and
This product simply requires the substrate temperature to be above the dew
Graco.
point. Condensation due to substrate temperatures below the dew point can
Conventional Pressure pot equipped with dual regulators, 3/8” I.D. cause flash rusting on prepared steel and interfere with proper adhesion to the
Spray minimum material hose, .070” I.D. fluid tip and substrate. Special application techniques may be required above or below
appropriate air cap. normal application conditions.
Airless Spray Pump Ratio: 30:1 (min.)*
GPM Output: 3.0 (min.) Curing Schedule
Material Hose: 3/8” I.D. (min.)
Tip Size: .017”-.021” Based on 4–8 mils, 100-200 microns dry film thickness.)
Output PSI: 2100-2300 Surface Temp. Dry to Topcoat
Filter Size: 60 mesh & 50% Relative Dry to Recoat w/ Other Final Cure
*Teflon packings are recommended and available from Humidity Finishes
the pump manufacturer. 50°F (10°C) 12 Hours 24 Hours 3 Days
Brush & Roller Multiple coats may be required to obtain desired 60°F (16°C) 8 Hours 16 Hours 2 Days
(General) appearance, recommended dry film thickness and 75°F (24°C) 4 Hours 8 Hours 1 Day
adequate hiding. Avoid excessive re-brushing or re- 90°F (32°C) 2 Hours 4 Hours 16 Hours
rolling. For best results, tie-in within 10 minutes at 75°F
(24°C). Higher film thickness, insufficient ventilation or cooler temperatures will require
Brush Use a medium bristle brush. longer cure times and could result in solvent entrapment and premature failure.
Excessive humidity or condensation on the surface during curing can interfere
Roller Use a short-nap synthetic roller cover with phenolic core. with the cure, can cause discoloration and may result in a surface haze. Any
haze or blush must be removed by water washing before recoating. During high
Mixing & Thinning humidity conditions, it is recommended that the application be done while
temperatures are increasing. Maximum recoat/topcoat times are 30 days for
Mixing Power mix separately, then combine and power mix. epoxies and 90 days for polyurethanes at 75°F (24°C). If the maximum recoat
DO NOT MIX PARTIAL KITS. times have been exceeded, the surface must be abraded by sweep blasting or
sanding prior to the application of additional coats.
Ratio 890 VOC 1:1 Ratio (A to B)
Thinning* Spray: Up to 13 oz/gal (10%) w/ #236E Packaging, Handling & Storage
Brush: Up to 16 oz/gal (12%) w/ #236E
Roller: Up to 16 oz/gal (12%) w/ #236E Shipping Weight 2 Gallon Kit 10 Gallon Kit
Use of thinners other than those supplied or (Approximate) 29 lbs (13 kg) 145 lbs (66 kg)
recommended by Carboline may adversely affect
Flash Point (Setaflash) 89°F (32°C) for Part A
product performance and void product warranty,
whether expressed or implied. 73°F (23°C) for Part B
Pot Life 890 VOC 3 Hours at 75°F (24°C) Storage Temperature 40° -110°F (4°-43°C) Store indoors.
Pot life ends when coating loses body and begins to & Humidity 0-100% Relative Humidity
sag. Pot life times will be less at higher temperatures.
Shelf Life: Part A: 24 months at 75°F (24°C)
Cleanup & Safety Part B: 15 months at 75°F (24°C)
Cleanup Use Thinner #2 or Acetone. In case of spillage, absorb

and dispose of in accordance with local applicable *Shelf Life: (actual stated shelf life) when kept at
regulations.
recommended storage conditions and in original
Safety Read and follow all caution statements on this product unopened containers.
data sheet and on the MSDS for this product. Employ
normal workmanlike safety precautions. Hypersensitive
persons should wear protective clothing, gloves and use
protective cream on face, hands and all exposed areas.
Ventilation When used as a tank lining or in enclosed areas,
thorough air circulation must be used during and after
application until the coating is cured. The ventilation
system should be capable of preventing the solvent
vapor concentration from reaching the lower explosion
limit for the solvents used. User should test and monitor
exposure levels to insure all personnel are below
guidelines. If not sure or if not able to monitor levels,
use MSHA/NIOSH approved supplied air respirator.
Caution This product contains flammable solvents. Keep away
from sparks and open flames. All electrical equipment
and installations should be made and grounded in
accordance with the National Electric Code. In areas
where explosion hazards exist, workmen should be
required to use non-ferrous tools and wear conductive
and non-sparking shoes.
October 2010 replaces January 2010

11 NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement of products.
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline and Carboguard
Carbothane® 134 HG
Selection & Specification Data Substrates & Surface Preparation

Generic Type Aliphatic Acrylic Polyurethane General Surfaces must be clean and dry. Employ
adequate methods to remove dirt, dust, oil and
Description Thin film, high gloss finish with exceptional all other contaminants that could interfere with
weathering performance characteristics. Used adhesion of the coating. For all surfaces prime
extensively in virtually all industrial markets, 134 with specific Carboline primer as recommended
HG provides a smooth, durable finish that has by your Carboline sales representative. Refer to
superior resistance to corrosion, abrasion and the specific primer’s Product Data Sheet for
chemical exposure. detailed requirements of the specified primer.
Features High solids, low VOC content Galvanized Prime with specific Carboline primer as
Excellent weatherability Steel recommended by your Carboline Sales
Far exceeds SSPC Paint 36 specification for a Representative. Refer to the specific primer’s
Level 3 urethane Product Data Sheet for substrate preparation
Available in a variety of colors including requirements.
metallic-pigmented colors
Excellent flow characteristics allow for Previously Lightly sand or abrade to roughen and degloss
application by spray or roller Painted the surface. Existing paint must attain a minimum
Superior impact and abrasion resistance Surfaces 3B rating in accordance with ASTM D3359 “X-
Indefinite recoatability Scribe” adhesion test.
VOC compliant to current AIM regulations
Color Refer to Carboline Color Guide. Certain colors,

Performance Data
particularly in non-leaded safety oranges, reds Test Method System Results
and yellows may require multiple coats for Blasted Steel
adequate hiding. Check color suitability before ASTM D4541 2562 psi
1 ct. Epoxy
use. Adhesion (Pneumatic)
1 ct. 134 HG
Blasted Steel
Finish Gloss ASTM D3359
1 ct. Epoxy 5A
Adhesion
1 ct. 134 HG
Primers Refer to Substrates & Surface Preparation 70 mg. loss after 1000
ASTM D4060 Blasted Steel
cycles, CS17 wheel, 1000
® Abrasion 1 ct. 134 HG
Topcoats Carbothane 130 Clear Coat when required gm. load
No blistering, rusting or
Dry Film 2.0-3.0 mils (50-75 µ) Blasted Steel cracking; gloss retention of
ASTM G26
Thickness May be applied up to 4 mils (100 µ) as needed 1 ct. Epoxy 85%; color change of 1
Weatherometer
1 ct. 134 HG McAdam unit after 2000
hours.
Solids Content By Volume: 70% ± 2% ASTM G53 Blasted Steel
No rusting, blistering or loss
ASTM D4587 1 ct. Org. Zinc
2 2 of adhesion; less than 5%
Theoretical 1123 mil ft (27.5 m /l at 25 µ) Accelerated 1 ct. Epoxy
gloss loss after 3000 hours
Coverage Rate Allow for loss in mixing and application Weathering 1 ct. 134 HG
Blasted Steel No rusting, blistering, loss of
VOC Values As supplied: 2.2 lbs./gal (264 g/l) ASTM B117 1 ct. Org. Zinc bond or any measurable
Thinned: Salt Fog 1 ct. Epoxy creepage from the scribe
25 oz/gal w/ #25: 3.06 lbs./gal (366 g/l) 1 ct. 134 HG after 3000 hours.
25 oz/gal w/ #214: 2.9 lbs./gal (348 g/l)
25 oz/gal w/ #215: 3.0 lbs./gal (362 g/l) Blasted Steel
ASTM D3363
These are nominal values and may vary slightly 1 ct. Epoxy H
Hardness
1 ct. 134 HG
with color.
ASTM D2794 155 inch-pounds; no visible
Blasted Steel
Impact cracking. Gardner Impact
Dry Temp. Continuous: 200°F (93°C) 1 ct. 134 HG
Resistance Tester
Resistance Non-Continuous: 250°F (121°C)
Discoloration and loss of gloss is observed No rusting in the scribe; no
above 200°F (93°C). Blasted Steel blistering, softening or
ASTM D870
1 ct. Org. Zinc discoloration after either 30
Water/Saltwater
* The alignment of aluminum flakes in aluminum-filled finishes is very 1 ct. Epoxy days of freshwater
Resistance
dependent on application conditions and techniques. Care must be 1 ct. 134 HG immersion or 30 days of salt
taken to keep conditions as constant as possible to reduce variations water immersion at 75°F.
in final appearance. It is also advisable to work from a single batch of
material since variations can occur from batch to batch. For more
information consult Carboline Technical Service Department.
March 2011 replaces December 2009 0859

12 of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and Carbothane®
Carbothane® 134 HG
Application Equipment Cleanup & Safety Cont.

Listed below are general equipment guidelines for the application of this product. Job Caution This product contains flammable solvents. Keep away
site conditions may require modification to these guidelines to achieve the desired from sparks and open flames. All electrical equipment and
results. installations should be made and grounded in accordance
General Guidelines:
with the National Electric Code. In areas where explosion
Spray Application This is a high solids coating and may require hazards exist, workmen should be required to use non-
(General) adjustments in spray techniques. Wet film thickness is ferrous tools and wear conductive and non-sparking
easily and quickly achieved. The following spray shoes.
equipment has been found suitable and is available
from manufacturers such as Binks, DeVilbiss and
Graco.
Application Conditions
Conventional Pressure pot equipped with dual regulators, 3/8” I.D. Condition Material Surface Ambient Humidity
Spray minimum material hose, .070” I.D. fluid tip and 60°-85°F 65°-85°F 65°-85°F
appropriate air cap. Normal 40-60%
(16°-29°C) (18°-29°C) (18°-29°C)
Airless Spray Pump Ratio: 30:1 (min.)* 50°F 35°F 35°F
GPM Output: 3.0 (min.) Minimum 10%
Material Hose: 3/8” I.D. (min.)
(10°C) (2°C) (2°C)
Tip Size: .015-.017” 100°F 120°F 95°F
Output PSI: 2100-2400 Maximum 85%
(38°C) (49°C) (35°C)
Filter Size: 60 mesh
*Teflon packings are recommended and available from Industry standards are for substrate temperatures to be at least 5°F (3°C) above
the pump manufacturer. the dew point.
Caution: This product is moisture sensitive in the liquid stage and during initial
Brush & Roller Multiple coats may be required to obtain desired cure. Protect from direct moisture (rain or dew) contact during initial curing
(General) appearance, recommended dry film thickness and period. Excessive exposure to moisture may result in a loss of gloss and/or
adequate hiding. Avoid excessive re-brushing or re- microbubbling of the product.
rolling. For best results, tie-in within 10 minutes at 75°F
(24°C). Curing Schedule
Brush Recommended for touch-up only. Use a medium,
natural bristle brush. Surface
Temp. & 50% Minimum
Roller Use a short-nap mohair roller cover with phenolic core. Relative Dry to Handle Final Cure
Dry to Recoat*
Humidity
Mixing & Thinning 35°F (2°C) 36 Hours 36 Hours 14 Days
Mixing Power mix Part A separately, then combine and power
mix. DO NOT MIX PARTIAL KITS. 50°F (10°C) 16 Hours 16 Hours 10 Days
Ratio (By Volume) 4:1 Ratio (A to B) 75°F (24°C) 8 Hours 8 Hours 7 Days
Thinning Spray: Up to 25 oz/gal (20%) w/ #214 or #25 90°F (32°C) 4 Hours 4 Hours 5 Days
Brush: Up to 25 oz/gal (20%) w/ #215 These times are based on a 2.0 mil (50 micron) dry film thickness. Higher film
Roller: Up to 25 oz/gal (20%) w/ #215 thickness, insufficient ventilation or cooler temperatures will require longer cure
Use of thinners other than those supplied or times and could result in solvent entrapment and premature failure.
recommended by Carboline may adversely affect
product performance and void product warranty, *Maximum recoat times are indefinite. Surface must be clean and dry. As part of
whether expressed or implied. good painting practice it is recommended to test for adhesion by wiping the
surface with Thinner 214 or 215. If the film shows a slight “tack” the surface is
Carboline Thinner #236E may also be used to thin this suitable for recoating without extensive surface preparation such as abrading.
product to minimize HAP and VOC emissions. Consult
Carboline Technical Service for guidance.
Packaging, Handling & Storage
Pot Life 4 Hours at 75°F (24°C) and less at higher temperatures.
Pot life ends when coating becomes too viscous to use. Shipping Weight 1 Gallon Kit 5 Gallon Kit
MOISTURE CONTAMINATION WILL SHORTEN POT (Approximate) 13 lbs (5kg) 57 lbs (26 kg)
LIFE AND CAUSE GELLATION.
Flash Point (Setaflash) Carbothane 134 HG Part A: 50°F (10°C)
Urethane Converter 811 Part B: 106°F (41°C)
Cleanup & Safety
Storage (General) Store Indoors.
Cleanup Use Thinner #2 or Acetone. In case of spillage, absorb
and dispose of in accordance with local applicable Storage Temperature 40° -110°F (4°-43°C)
regulations. & Humidity 0-80% Relative Humidity
Safety Read and follow all caution statements on this product
Shelf Life Part A: Min. 36 months at 75°F (24°C)
data sheet and on the MSDS for this product. Employ
normal workmanlike safety precautions. Hypersensitive Part B: Min. 24 months at 75°F (24°C)
persons should wear protective clothing, gloves and use
protective cream on face, hands and all exposed areas. *Shelf Life: (actual stated shelf life) when kept at
Ventilation When used in enclosed areas, thorough air circulation recommended storage conditions and in original
must be used during and after application until the coating unopened containers.
is cured. The ventilation system should be capable of
preventing the solvent vapor concentration from reaching
the lower explosion limit for the solvents used. User
should test and monitor exposure levels to insure all
personnel are below guidelines. If not sure or if not able
to monitor levels, use MSHA / NIOSH approved respirator.
March 2011 replaces December 2009

13 NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement of products.
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and Carbothane®
TAB 2
OWS
DRAWING/
ACCESSORY
INFORMATION
14
15
16
17
18
19
20
21
22
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24
CP 3068 HT 3~ 255
Te chnical specification
[f t] Head
88
84
80
76
72
68
64
60
56
52
48
44
49.4%
40
36
32
28
24
Note: Picture might not correspond to the current configuration.
20
16 General
255 112mm255 112mm
Shrouded single or m ulti-channel im peller pum ps with large throughlets
- and single v olute pum p casing f or liquids containing solids and f ibres.
12
C ast iron design with double sealing technology . Som e m odels
8 av ailable as s tainless steel v ersions.
4
Impeller
0
Im peller m aterial Grey cast iron
0 40 80 120 160 200 [US g.p.m.] D ischarge F lange D iam eter 1 15/16 inch
Inlet diam eter 50 m m
Water, pure Curve ISO Im peller diam eter 112 m m
N um ber of blades 1
Throughlet diam eter 1 5/16 inch
Installation: P - Semi permanent, Wet
M otor
Motor # C 3068.090 13-10-2BB-W 3.8hp
Stator v ariant 6
19" Frequency 60 H z
REF.LINE 17 3/4 (TO FURT HEST POINT) R ated v oltage 460 V
N um ber of poles 2
Phas es 3~
4 1/2 4 1/4
R ated power 3.8 hp

R ated current 5.1 A
4 1/2
Starting current 32 A
3 3/8 8 3/4 R ated speed 3395 rpm
REF.LINE 11 3/4 Power f actor
3" 7/8 1/1 Load 0.85
3/4 Load 0.78
1/2 Load 0.67
3/4" GUIDE BARS Ef f ic iency
1/1 Load 82.5 %
3/4 Load 84.5 %
2-11 1/2 NPT M IN. W .L . 1/2 Load 84.5 %
19 1/4
13"
Configuration
*5 1/4
6 5/8
Z Z
1 1/4
1"
3/4 18" MIN
* DIMENSION TO ENDS OF GUIDE BARS

1 1/4 REF.LINE
2 1/8
4 1/4
CL OF DISCH
4" BOLT Ø 1/2 (4x)
Weight (lbs)
VIEW Z- Z Pump Disch
90 20
De no m n
i at o
i n Dr awn Ch ec k e d Da t e
Dimensional drwg
by
SZK by
020211
Sc a e
l Re g no
AUTOCAD 5399
CP 3068 HT
DRAWI NG Ø2 " 6582200 0
Project Project ID Created by Created on Last update

2015-07-07
25
CP 3068 HT 3~ 255
Performance curv e
Pump M otor
Discharge Flange Diameter 1 15/16 inch Motor # C3068.090 13-10-2BB-W 3.8hp Power factor
Inlet diameter 50 m m Stator variant 6 1/1 Load 0.85
Impeller diameter 4 7/16" Frequency 60 Hz 3/4 Load 0.78
Number of blades 1 Rated voltage 460 V 1/2 Load 0.67
Throughlet diameter 1 5/16 i nch Number of poles 2
Phases 3~ Efficiency
Rated power 3.8 hp 1/1 Load 82.5 %
Rated current 5.1 A 3/4 Load 84.5 %
Starting current 32 A 1/2 Load 84.5 %
Rated speed 3395 rpm
Head
[ft]
88
84
80
76
72
68
64
60 60 ft
56
52
48
44
49.4%
40
36
32
28
24
20
16 255 112mm255 112mm
12
4
69 US g.p.m.
0
0 20 40 60 80 100 120 140 160 180 200 220 240 [US g.p.m.]
Water, pure Curve ISO

2015-07-07
26
CP 3068 HT 3~ 255
Dimensional drawing
19"
REF.LINE 17 3/4
(TO FURTHEST POINT)
4 1/2 4 1/4
4 1/2
3 3/8 8 3/4
REF.LINE 11 3/4
3" 7/8
3/4" GUIDE BARS
2-11 1/2 NPT MIN. W.L.

19 1/4
13"
*5 1/4
6 5/8
Z Z
1 1/4
1"
3/4 18" MIN
* DIMENSION TOENDS OF GUIDE BARS

1 1/4 REF.LINE
2 1/8
4 1/4
CL OF DISCH
4" BOLT Ø 1/2 (4x)
Weight (lbs)
VIEW Z-Z Pump Disch
90 20
Denomination Drawn Checked Date
Dimensional drwg
by SZK by 020211
Scale Reg no
AUTOCAD 5399
CP3068HT
DRAWING Ø2" 6582200 0

2015-07-07
27
C/D 3068 SPECIFICATION
PUMP DESIGN
The pump(s) shall be automatically and firmly connected to the discharge connection, guided by
no less than two guide bars extending from the top of the station to the discharge connection.
There shall be no need for personnel to enter the wet-well.
PUMP CONSTRUCTION
Major pump components shall be of grey cast iron, ASTM A-48, Class 35B, with smooth surfaces
devoid of blow holes or other irregularities. All exposed nuts or bolts shall be AISI type 304
stainless steel construction. All exterior metal surfaces coming into contact with the pumpage,
other than stainless steel or brass, shall be protected by a factory applied spray coating of acrylic
dispersion zinc phosphate and a polyester resin enamel finish.
All O-rings shall be of Nitrile or optional Viton rubber. The lifting handle shall be stainless steel.
Cast iron impellers shall be sprayed with primer.
COOLING SYSTEM
Motors are sufficiently cooled by the surrounding environment or pumped media. A water cooling
jacket is not required.
CABLE ENTRY SEAL

The cable entry seal design shall preclude specific torque requirements to insure a watertight and
submersible seal. The cable entry shall consist of a single cylindrical elastomer grommet, flanked
by washers, all having a close tolerance fit against the cable outside diameter and the entry
inside diameter and compressed by the body containing a strain relief function, separate from the
function of sealing the cable. The assembly shall provide ease of changing the cable when
necessary using the same entry seal.
A JUNCTION BOX SHALL BE COMPLETELY SEALED OFF FROM THE PUMPED MEDIA.
Epoxies, silicones, or other secondary sealing systems shall not be considered
acceptable.
MOTOR
The pump motor shall be induction type with a squirrel cage rotor, shell type design, housed in an
air filled, watertight chamber, NEMA B type. The stator windings and stator leads shall be
insulated with moisture resistant Class F insulation rated for 155°C (311°F). The stator shall be
dipped and baked three times in Class F varnish and shall be heat-shrink fitted into the stator
housing. The use of bolts, pins or other fastening devices requiring penetration of the stator
housing is not acceptable. The motor shall be designed for continuous duty handling pumped
media of 40°C (104°F) and capable of no less than 15 evenly spaced starts per hour. The rotor
bars and short circuit rings shall be made of cast aluminum. The motor and pump shall be
designed and assembled by the same manufacturer.
The combined service factor (combined effect of voltage, frequency and specific gravity) shall be
a minimum of 1.10. The motor shall have a voltage tolerance of plus or minus 10%. The motor
shall be designed for operation up to 40°C (104°F) ambient and with a temperature rise not to
exceed 80°C. A performance chart shall be provided showing curves for torque, current, power
factor, input/output kW and efficiency. This chart shall also include data on starting and no-load
characteristics.
The power cable shall be sized according to the NEC and ICEA standards and shall be of
sufficient length to reach the junction box without the need of any splices. The outer jacket of the
cable shall be oil resistant chlorinated polyethylene rubber. The motor and cable shall be capable
28
of continuous submergence underwater without loss of watertight integrity to a depth of 65 feet or
greater.
The motor horsepower shall be adequate so that the pump is non-overloading throughout the
entire pump performance curve from shut-off through run-out.
BEARINGS
The upper bearing shall be a single row ball bearing. The Lower bearing shall be a two row
angular contact ball bearing. Motor bearings shall be permanently grease lubricated.
MECHANICAL SEAL
Each pump shall be provided with a tandem mechanical shaft seal system consisting of two
totally independent seal assemblies. The seals shall operate in a lubricant reservoir that hydro-
dynamically lubricates the lapped seal faces at a constant rate. The lower, primary seal shall be
corrosion resistant tungsten-carbide/tungsten-carbide. The upper seal shall be
carbon/ceramic. The seals shall require neither maintenance nor adjustment nor DEPEND ON
DIRECTION OF ROTATION FOR SEALING.
Seal lubricant shall be FDA Approved, non-toxic.
PUMP SHAFT
Pump and motor shaft shall be the same unit. The motor and the pump shaft shall be of stainless
steel.
The pump shaft is an extension of the motor shaft; couplings shall not be acceptable.
IMPELLERS
C-3068: The Impeller(s) shall be of gray cast iron, dynamically balanced, closed single-vane
non-clogging design having a long throughlet without acute turns.
D-3068: The Impeller(s) shall be of gray cast iron, dynamically balanced, open vortex design.
VOLUTE
Pump volute(s) shall be single-piece grey cast iron, Class 35B, non-concentric design with
smooth passages large enough to pass any solids that may enter the impeller. Minimum inlet and
discharge size shall be as specified.
WEAR RING
A wear ring system shall be used to provide efficient sealing between the volute and the suction
inlet of the "C" impeller. The wear ring shall be stationary and made of brass, which is drive fitted
to the volute inlet.
MODIFICATIONS
1. Explosion-proof Pumps (X).
Refer to the General Guide Specifications for additional information.
29
30
Issued: 10/13 Supersedes: 5/12
Lifting Chain (Galvanized/Alloy Steel)

(for: BS/KS, CP/DP/FP/HP/NP, CS/DS/FS/HS/NS installations only)
Lifting chain is hot dipped galvanized carbon steel or stainless steel,

where indicated, and may be ordered in any length. Chain fittings
consist of two shackles and are available in kits.
3000, 5000 & 8000 Series Pumps

C, D, F, H, N Pump Galvanized/Alloy Steel Chain Chain Fittings Kit
Models: Chain Size Part Number Part Number
3045, 3057, 3068,
3080, 3085, 3102,
3127, 5520, 5530, 5/0 Straight Coil (galv.) 14-48 71 00 14-58 72 00
8050, 8053, 8056,
8058. CHAIN
3153, 3171. 5/16" Grade 30 (galv.) 14-48 71 02 14-58 72 01
3202, 5100. 3/8" Grade 30 (galv.) 14-48 71 14 14-58 72 06

SHACKLES
3301, 5150. 7/16" Grade 40 (galv.) 14-48 71 04 14-58 72 02 PUMP

HANDLE
3231.700, 3306.700,
3312.700, 3315, 1/2" Grade 40 (galv.) 14-48 71 06 14-58 72 07
3356.700, 5570.700.
3312.800, 3400.700, 5/8" Grade 40 (galv.) 14-48 71 08 *14-58 72 05

3501.700, 3531.700.
3240.800, 3351.900,
3400.800, 3501.800, KuplokTM
3531.800, 3531.900, 3/4" Grade 80 (alloy steel) 14-48 71 16 *14-48 72 24
3602.700, 3602.800,
3602.900.
3800.900 7/8" Grade 80 (alloy steel) 14-48 71 15 *14-48 72 23

AND 14-487226
* uses KuplokTM coupling link (+)
Not for use on pumps with .6xx series drive units.
2000 Series Pumps

B, D, K Pump Galvanized/Alloy Steel Chain Chain Fittings Kit
Models: Chain Size Part Number Part Number
2004, 2008, 2008S,
2071, 2125, 2140,
2610, 2620, 2630,
2640, 2660, 2670, 5/0 Straight Coil (galv.) 14-48 71 00 14-58 72 00
2730, 2740, 2750,
2830, 2840.
2201, 2250, 2290, 3/8" Grade 30 (galv.) 14-48 71 14 14-58 72 06

2860, 2870
2400 7/16" Grade 40 (galv.) 14-48 71 04 14-58 72 02

31
Standard CP/NP Discharge Connections (Cast Iron)
Dimensions
Accessories Issued: 10/06 Supersedes: 4/06
All dimensions (inches)
Pump Part Disch. Disch.

A B C D E F G H I J K
Model Number Inlet Outlet
2" - 3045, 3057, 486 55 01 2" 2"-11 1/2 NPT 3 13/16 4 4 1/2 5 1/2 7 1/4 6 3/4 3 15/16 7/8 --- --- ---
3068.
2 1/2" - 3068. 493 17 06 2 1/2" 2 1/2" 11 5/8 7 7/8 6 1/2 7 7/8 11 7/16 9 7/8 6 1/2 4 9/16 45° 90° x 4 5 5/8
3" - 3057, 555 48 01 2" 3-8 NPT 6 3/4 5 1/2 4 1/8 5 1/2 10 3/4 6 3/4 3 15/16 7/8 --- --- ---
3068.
3" - 3076, 3068, 444 68 05 3" 3" 14 9 7/8 8 10 5/8 15 3/8 15 3/4 7 7/8 4 9/16 45° 90° x 4 6
3080, 3085,
3102, 3153.
4" - 3080, 3085,

3102, 3127, 540 13 05 4" 4" 14 3/8 9 7/8 8 10 5/8 15 3/8 15 3/4 7 7/8 4 9/16 22.5° 45° x 8 7 1/2
3152, 3153,
3170, 3171,
3202.
6" - 3102, 3127,

3152, 3153, 444 70 06 5 1/2" 6" 15 9/16 11 10 12 3/16 15 3/8 17 3/4 9 7/8 4 9/16 22.5° 45° x 8 9 1/2
3170, 3171,
3201.
6" - 3153, 3171, 602 33 06 5 1/2" 6" 15 9/16 11 10 12 3/16 15 15/16 17 3/4 9 7/8 4 9/16 22.5° 45° x 8 9 7/16
3202.
6" - R3231 388 25 06 6" 6" 20 11/16 19 3/4 15 3/4 19 3/4 23 5/8 15 3/4 7 7/8 6 7/8 22.5° 45° x 8 9 7/16
6" - 3301 604 56 06 6" 6" 15 9/16 11 1/8 10 12 3/16 15 15/16 18 10 1/8 4 9/16 22.5° 45° x 8 9 7/16
Note: Alternative discharge connections may be available, contact Flygt Application Engineering.
I D
J C
A
H
F
G
Note:
E The discharge connection shown here
is typical in appearence for most pumps.
32
3/4" Upper Guide Rail Bracket 316SS ®
Product Number
F-UGRB-0009
Design Features
-Materials
316SS
-Design Load
-Open Area
-Coating
Mill
- Designates Machined Surface
Certification
-
-
-
-Country of Origin: USA
Drawing Revision
10/23/01 Designer: ARO
08/06/14 Revised By: JMM
Disclaimer
Weights (lbs/kg), dimensions (inches/mm)
and drawings provided for your guidance. We
reserve the right to modify specifications without
prior notice.
CONFIDENTIAL: This drawing is the property
of EJ Group, Inc. and embodies confidential information,
registered marks, patents, trade secret information,
and/or know-how that is the property of EJ Group, Inc.
Copyright © 2011 EJ Group, Inc.
All rights reserved.
33
Contact
800 626 4653
ejco.com
Series 6000
34
Series 6000
35
36
37
6000 Series
38
TAB 3
QUALITY
CONTROL
FORMS
39
40
41
42
43
44
45
46
47
48
49
50
TAB 4
OPERATION
MANUAL &
SPARE PARTS
51
Operation & Maintenance Manual
Aboveground Rectangular
Oil Water Separator
52
THANK YOU, for ordering a Highland Tank Product. Highland Tank has
been a manufacturer of high quality equipment since 1946. We’re proud of our
dedication and diligence in this business and of our commitment to our customers
and our employees. Now in its third generation of family ownership, Highland Tank
leads the industry with innovative design, quality materials, superior
craftsmanship, and excellent customer service.
Your Highland Tank equipment was designed and manufactured by quality

oriented and customer-minded workers. If you, for any reason, find that our
products fail to perform as you believe it should, please do not hesitate to contact
our Customer Representative or contact us directly, and explain how our product
has failed to please you.
When our customers report issues or concerns, Highland strives to correct those
problems and continue to improve our product, so please, help us to insure our
primary goal, customer satisfaction.
We hope that you find this manual useful and if you feel that there is something to
be added. Please feel free to contact Highland Tank's engineering/customer
service department with any technical questions 814-893-5701.
Please read and understand all the information in this manual before
installation, operation and performing maintenance on your equipment.
There is a lot of information provided in this manual. Do not try to read the
entire manual at once. There is a considerable amount of information to
understand all the requirements in one reading. We suggest you read one section
at a time and understand before moving on to the next section.
53
TABLE OF CONTENTS:
Definitions 4
Before You Begin 6
Installation Instructions 7
Operating Instructions 10
Maintenance Instructions 11
Typical Installation & Arrangement Drawing 13
***See Project-Specific Drawings for More Details
54
Definitions:
AHJ – Authority Having Jurisdiction – entity responsible for approving the installation and
performance of the oil water separator. This is a project specific entity and must be confirmed by
the customer or project designer.
API – American Petroleum Institute
Atmospheric Vent – A riser pipe with vent fixture is typically installed 12' above grade as per
NFPA 30, Section 27.8.2.1. The pipe & vent allows air to exit the vessel during the filling operation
and allows air to enter the tank during the withdraw process to prevent a vacuum. Requirements
for venting must be confirmed with the AHJ for each project by the installer or project designer.
AST – Aboveground storage tank – a vessel that is in its entirety is above ground. Saddles, legs,
skid, or skirt shall typically be used to support the tank.
UST – Underground storage tank – a vessel that is in its entirety is underground.
Corrosion – The erosion of metals due to chemical or environmental reactions. Relating to steel,
it is commonly referred to as rust.
Emergency Vents, Primary and Secondary – These two vents allow a storage tank to vent
during emergency situations. Primary EV vents the primary tank and the Secondary EV vents the
interstitial space of a double wall tank.
Frost Line - The depth to which the groundwater in soil or soil is expected to freeze.
Interstice / Interstitial Space – The space between the primary tank and the outer shell. The
space is commonly monitored with some type of leak detection system, electronic, mechanical or
manual stick gauging. Contact AHJ to confirm what type of detection is acceptable.
IFC - International Fire code
Manway/Removable Cover – An opening in the vessel for inspection, maintenance or personnel

entry into a vessel.
Monitor Pipe for Leak Detection – Pipe penetrating the interstitial space of a double wall vessel.
NACE - National Association of Corrosion Engineers
NFPA - National Fire Protection Association
NFPA 30 – Flammable and Combustible Liquids Code
Outer shell – The outer shell containing the primary tank, outer shell includes shell and heads.
OWS – Oil Water Separator
PEI – Petroleum Equipment Institute
55
Pitting – Small cavities on the surface of paint or steel due to corrosion.
Primary Tank- The inner tank holding product.
UFC - Uniform Fire Code
UL – Underwriters Laboratory
UL 58 – Underwriters Laboratories specification for “Steel Underground Tanks for Flammable and
Combustible Liquids”
UL 142 – Underwriters Laboratories specification for “Steel Aboveground Tanks for Flammable and
Combustible Liquids”
Secondary tank – The outer shell on a double wall tank
STI – Steel Tank Institute
Tank supports – Structures engineered to elevate the tank above grade. They may include
saddles, skids, beams, legs, etc.
56
Before you begin
Carefully read and follow these instructions.
• Local codes may apply. Check with local authorities (AHJ) prior to installation of OWS
• The amount of debris such as sand, gravel, dirt, leaves, wood, rags, etc. permitted to enter
the OWS must be minimized for maximum effectiveness. It is recommended to install an
appropriate sized Highland Tank Sand/Oil Interceptor upstream of the OWS.
• It is imperative that detergents and solvents be excluded from the separator system. The
gravity separator will not remove chemical emulsions or dissolved hydrocarbons and their
presence retards the recovery of oil that would otherwise be separated. It is recommended
to use Highland Cleaner for all cleaning applications. Highland Cleaner is a very effective
cleaner and is 100% Biodegradable, Non-emulsifying, and contains no Linear Activated
Solvents (LAS), Phosphates, Ammonia, or Acids.
• Wastewater containing a high dissolved solids concentration, such as untreated sanitary

sewage, must be excluded due to its emulsifying tendency.
• Waste oils such as automobile and truck crank case oil should not be intentionally drained
into the OWS. Filling the OWS with waste oils will adversely affect OWS performance. Waste
oil should be dumped into the waste slop tank for proper disposal.
• OWS’s should be maintained as free of accumulated oil and sediment as possible. Currently,
the most satisfactory method involves suction removal by maintenance personnel using
equipment commonly referred to as a Vac Truck.
• Locate OWS in area with sufficient truck access (top-side clearance) for removal of oil,
sludge, and water by Vac Truck.
• Inlet piping should be installed straight and true with few turns to limit turbulence.
• The absence of gravity flow to the OWS will make it necessary to pump the wastewater.
When elevation or grades at the facility fail to allow for gravity flow through the OWS,
pumping should be restricted to the clean water, effluent discharge end of the separator. If
pumping goes on ahead of the OWS, it will tend to mix the oily water and increase the
emulsified and dissolved oil content, possibly to the point that the oil and water separation
fails. If a pump is installed upstream of the separator, it must be a positive displacement
pump (progressive cavity, diaphragm, sliding shoe, etc.), at minimum gpm, and installed as
far upstream as possible to reduce the extent of mixing.
• Optional butterfly or gate valves may be provided as a means of shutting off the in-flow and
out-flow for the purposes of cleaning and emergency situations.
• The separator system should be kept from freezing at all times. Inlet and outlet piping shall
be designed so as not to trap water. Optional thermostatically controlled steam or electric
heating devices may have been supplied with the system. See customized drawing prepared
is so equipped.
• Barricade the OWS area until job is complete.
• IMPORTANT: Do not modify OWS structure in any way. Do not weld on OWS.
57
Installation Instructions
OWS Unloading
• All OWS’s must be mechanically unloaded using lifting lugs provided.
• Take extreme care when unloading the OWS as weight distribution may be uneven.
Pre-Installation Inspection
• Upon delivery, inspect the OWS for exterior damage that may have occurred during
shipping and job site handling. Contact Highland Tank for any structural damage or use
supplied coating touchup kits to repair scuffs or scratches as needed.
• Carefully, remove the OWS covers so as not to damage the gasket. Inspect the interior of
the OWS to insure that all baffles, coalescer plates and cartridges, and internal piping are
secure and have not been damaged during transport.
Foundation Preparation
• The foundation must be designed to support OWS on a well-drained, stable pad of

concrete, asphalt or similar material to prevent movement or uneven settling of the OWS.
• All aboveground OWS's are equipped with a grounding connection. The installation must be
installed in accordance with local, applicable Electrical and Fire Code Standards which may
include but not limited to: National Fire Protection Association publication NFPA 30, and the
local adopted Fire Codes. The local AHJ should be contacted for details on all applicable
codes and restrictions such as spacing from buildings, property lines, public ways, etc.
OWS Handling
• Equipment used shall be of adequate size to lift and set OWS without dragging or
dropping.
• OWS shall be carefully lifted and placed by use of cables or chains of adequate length and
capacity attached to the lifting lugs provided.
• Do not handle or install OWS without knowledge of proper procedures and inherent
dangers involved with OWS installation for storage of flammable and combustible liquids.
Reliance on skilled, professional installers is an important factor in avoidance of system
failures
• DO NOT MOVE OWS UNLESS EMPTY.
• This is a stationary OWS. Do not use for transport of any product over roads and highways.
58
Placement of OWS
• The OWS must be installed in a level and plumb position. Check elevations at each end of
the OWS’s with a transit and adjust as necessary to 1/2" in 20'-0". Check elevations across
the width of the OWS’s and adjust to 1/4" in 10'-0".
Anchoring
• If anchor bolt holes or tabs are provided in the OWS or OWS skids, install anchor bolts to
prevent OWS movement.
• High water tables or partially flooded excavation sites can exert significant buoyant forces
on OWS’s. Buoyant forces are partially resisted by the weight of the OWS and, in some
cases, anchor bolts attached to the OWS or OWS skids. Additional buoyant restraint, when
required, is obtained by using properly designed hold down straps in conjunction with
concrete hold down slabs. Contact Highland Tank engineering if flooding is a possibility in
your installation.
Above Ground Hydrostatic Test
• An optional on-site standing water hydrostatic test of the OWS can be conducted to insure
no damage has occurred during shipping and handling during installation. After the
separator has been leveled and secured to the foundation (if applicable), fill the OWS with
clean, fresh water until water is discharge from the outlet. Allow the OWS to stabilize to a
no-flow, static condition. Measure and record the fluid level accurately from the top of the
access lid to the static fluid level. After one hour, verify that the fluid level has not dropped
indicating that there may be a leak
Coating Repair
• Before installing the OWS, all dirt clods and similar foreign matter shall be cleaned from
the OWS, and areas of coating damage shall be repaired with a touchup kits provided.
• Clean damaged coating areas through removal of surface rust, dirt, contaminants, and
disbonded coating prior to application of touch-up coating (See SSPC SP-2 "Hand Tool
Cleaning" or SP-3 "Power Tool Cleaning" for additional guidance). Areas of coating damage
shall be roughened up with a wire brush approximately 1" around the damaged area and
repaired with a touchup coating provided.
Piping
• Attach inlet and outlet piping to fittings provided. OWS inlet and outlet piping must be
sloped at 1/4" minimum per foot downward to maintain gravity flow.
• OWS'S ARE DESIGNED FOR ATMOSPHERIC PRESSURE OPERATION ONLY. INLET, OUTLET,
AND TANK MUST BE SEPARATELY VENTED TO ATMOSPHERE TO ASSURE PROPER
OPERATION. Variations in design for your specific project may modify this procedure due to
pumping or other factors. Consult the customized drawings prepared for your project.
• Flame arrestor may be required by AHJ and are to be provided by installer if not
specifically ordered with the oil water separator.
59
• For OWS's with gravity oil skimmers, install oil skimmers (or confirm factory installation)
and piping from skimmer to storage tank, drum or other oil storage location. Piping between
the OWS and the waste oil tank should be sloped 1/4" per foot (or more) to maintain gravity
flow based on the oil being transferred. In outdoor applications, it may be necessary to heat
the transfer piping to maintain oil flow during low temperature operation.
• Skimmer should be set 1/4” to 3/8” above maximum operating level. This is accomplished
by operating the unit at maximum flow during system startup and manually adjusting the
skimmer. Skimming level is intended to minimize oil layer (lower skimming level) to the
extent possible without skimming of water (which occurs if skimming level is too low).
• Permanent metal plugs treated with pipe compound shall be installed by the contractor at
all unused openings.
Oil Water Separator Electronics & Accessories
• Optional oil water separator electronics and accessories may have been provided for your
project. Consult job-specific drawings and documentation to insure an understanding of the
complete system provided.
• For OWS's with sensors, pumps, alarm panel or control panel, REFER TO PANEL WIRING
DIAGRAMS, MANUFACTURER'S INSTALLATION INSTRUCTIONS AND ANY OTHER PROVIDED
DETAILS PRIOR TO INSTALLATION AND CONNECTION.
60
Operating Instructions
Standard Aboveground Oil Water Separator
• FILL OWS UNIT WITH CLEAN WATER. TO OPERATE PROPERLY, THE SYSTEM
MUST FIRST BE FILLED WITH CLEAN WATER TO THE POINT WHERE DISCHARGE
FROM THE OIL WATER SEPARATOR IS OBSERVED.
• Highland Tank Oil Water Separators are designed specifically for the removal of free
floating oil, raw petroleum hydrocarbons, grease, and settable solids from industrial
wastewater ONLY
• Highland Oil Water Separators will not effectively remove oils with a specific gravity
greater than the design requirement, chemical or physical emulsions, dissolved
hydrocarbons, solvents, or volatile organic compounds (VOC). Highland Tank &
Manufacturing may be able to offer specialty systems designed for treatment of wastewater
contaminated with these pollutants.
• CAUTION: Separated liquid oil and vapors may be flammable or combustible.
61
Maintenance Instructions
Standard aboveground Oil Water Separators have the following chambers:
• INLET/ SEDIMENT CHAMBER – Area in front of plate pack where heavy solids settle out
and are collected behind a SLUDGE BAFFLE. Concentrated oil slugs rise immediately to the
surface in this area.
• PRIMARY COALESCER (PLATE PACK) - The primary coalescer consists of a steel framework
with plates that are typically PVC, but may be galvanized, SS or other material that may be
offered on a job-specific basis. Initial coalescing of larger micron oil particles occurs in the
plate pack. Depending on project specifications, this may be the only coalescer provided.
Where specification requirements indicate performance beyond the plate pack alone, the Oil
Water Separator may be equipped with a secondary coalescer.
• SECONDARY COALESCER (PETRO SCREEN) – For enhanced oil removal efficiency, a

PETRO-SCREEN COALESCER is used to intercept droplets of oil too small to be removed by
the plate pack. Standard material for the Petro Screen is a coated steel cartridge with
polypropylene coalescing media, but custom options for the cartridge and media material, as
well as options for media support, may be included as required based on specific project
requirements.
• EFFLUENT CHAMBER (CLEAR WELL) - Standard aboveground, rectangular OWS designs

include a final effluent chamber prior to discharge. This chamber may be equipped with an
adjustment device to set the operating fluid level in the tank as noted in the skimmer
adjustment section above. If sampling is to occur in this chamber, it is important that
samples are taken below the level of any sheen or thin oil layer that can develop in this
chamber over time even when the OWS if functioning properly and meeting discharge levels.
It is preferred that sampling be from the effluent pipe during flow conditions. The presence
of significant oil buildup in this chamber indicates the need for further inspection of the OWS
coalescers and operating conditions to insure proper OWS performance.
Maintenance is required as needed, but is recommended at least:
• Once per year
• When the OWS bottom sludge is 6" deep
• When the effluent contains high contaminant levels
Oil Removal Procedures
• IMPORTANT: Oil should only be removed during non-flow conditions to insure

pure oil draw-off.
• To minimize water removal, connect the oil suction hose to the DESIGNATED OIL
PUMPOUT PIPE fitting/coupling upon HIGH OIL ALARM. The length of this pumpout pipe is
coordinated with the length of the high oil alarm sensor during the design stage for this
purpose.
• Remove oil by pump, vac truck or other means.
• Refill with OWS with clean water. (See Start-Up Instructions).
62
General OWS Cleaning Procedures / Coalescer Maintenance
NOTE: If not properly maintained, the OWS may malfunction.
NOTE: Over a period of time sediment, oil, and grease will build up on the walls and floors of the
OWS. Dirt and heavy oil may build up on the PARALLEL CORRUGATED PLATE COALESCER and the
build-up will reduce the unit's efficiency. Also, since the PETRO SCREEN will remove some
suspended solids along with the small oil droplets in the wastewater, periodic cleaning is required.
• All liquid should be removed from the OWS prior to coalescer maintenance.
• The coalescer plates and pack(s) can be accessed through the top of the OWS by removing
the covers and can be cleaned from above using a hot-water pressure wash with extension
wand or can be removed for cleaning.
• Mechanical lifting equipment will be required to remove the coalescer packs in most
oil water separators.
• Any and all oil removed from the OWS should be recycled or disposed of in accordance
with federal, state, and local codes and regulations.
• Although the OWS is designed for long-term trouble free operation, it requires the
following maintenance as needed or in accordance with the specific facilities maintenance
schedule.
• Periodic inspection of the trench drains, sand interceptors, and traps which are installed
upstream of the OWS.
• Periodic internal inspection of the OWS to check for sand, trash, sludge and oil build-
up and to confirm coating condition (if applicable).
• PRIOR TO PLACING THE SYSTEM BACK INTO OPERATION, REFILL THE OWS WITH CLEAN
WATER (See Start-Up instructions).
• IMPORTANT: Keep a log of inspection and maintenance work and have it

available for ready reference when contacting Highland Tank.
63
Figure 1 – Typical Installation – GENERAL REFERENCE ONLY
Figure 2 – General Arrangement Diagram – GENERAL REFERENCE ONLY
64
TANK
Highland
Manufacturing
Locations
One Highland Road 2225 Chestnut Street

Stoystown, PA 5563 Lebanon, PA 17042
814.893.5701 717-664-0602
FAX 893-6126 FAX 664-0631
99 West Elizabethtown Rd. 2700 Patterson Street

Manheim, PA 17545 Greensboro, NC 27407
717.664.600 336-218-0801
FAX 664-0617 FAX 218-1292
958 19th Street 1510 Stoystown Road

Watervliet, NY 12189 Friedens, PA 15541
518.273.801 814-443-6800
FAX 273-1365 FAX 444-8662
Please visit us at www.highlandtank.com
© Highland Tank
65
BJAI>";JC8I>DC8DCIGDAH
Series 67
M u lti-F u n c tio n C o n tro l
D u p lex P u m p Sy stem C o n tro l
Inverse or Direct Acting, Field Selectable
Solid State R eliability
C om p act Siz e
Fou r Indep endent C h annels – 2 Single, 2 Differential
Field Adju stable, Sensitivity and M ode Selection
L E D C h annel Indicators
B u ilt-in Silence/Ack now ledge C ircu it Series 6 7
U .L . “ Intrinsically Safe” A p p lic a tio n s

W arrick ’s Series 6 7 fou r ch annel level control is an ideal solu tion to liq u id level s(AZARDOUS s0UMP3OLENOID 6ALVES
p roblem s in h az ardou s ap p lications for th e sew age, w aste w ater, ch em ical and Atm osp h eres s3EWAGE ,IFT3TATIONS
grou ndw ater rem ediation indu stries. s-ULTIPLE &UNCTIONS s7ASTEWATER 4REATMENT
C onnected to fl oats or condu ctance p robes th is versatile control p rovides sim p lex or s3IMPLEX OR$UPLEX s#HEMICAL 0LANTS
du p lex p u m p /solenoid valve control; au tom atic or m anu al alternation; h igh and/or low s(IGH,OW ,EVEL s'ROUNDWATER
level alarm s w ith silence/ack now ledge cap abilities. Alarm s R em ediation
T h e Series 6 7 can be u sed in h az ardou s ap p lications as an intrinsically safe interface s!UTO OR-ANUAL
to non-p ow ered contacts and sensors su ch as p u sh bu tton op erators, lim it, Alternation
L6GG>8@8DC9J8I>K>INH:CHDGH
tem p eratu re, p ressu re and vacu u m sw itch es.
D im en sio n s
Designed for h az ardou s ap p lications, its low cost, integrated featu res and com p act
siz e also m ak e it ideal for non-h az ardou s ap p lications.
Sp ec ifi c a tio n s
Contact Design Standard N .O ., N .C . (form C ); O p tional N .O ., N .C .
Contact R ating
(3 0 V DC, 1 2 0 /2 4 0 V A C) 1 0 am p (sty le C ); 5 am p (sty le A)
P rim ar y V oltage 1 2 0 V AC , 5 0 /6 0 H z
S econd ar y V oltage 1 2 V AC @ 6 m A R M S
S ensitiv ity 4 .7 K - 1 0 0 K oh m s m ax im u m sp ecifi c resistance, factory set
T em p eratu re -4 0 ° F to + 1 5 0 ° F (-4 0 ° C to + 6 5 ° C )
A p p rov als U .L . 9 1 3 File # E 4 4 5 7 0
H o w to O rd er
U se th e B old ch aracters from th e ch art below to constru ct a p rodu ct code.
67 X X X X X W irin g
S eries
67
S ensitiv ity
A – 4 .7 K D– 50K
B– 10K E– 100K
C– 26K
S u p p ly V oltag e
1– 120 VAC
C ontact D esig n
A – 1 F orm A & B C – 1 F orm C
(N .O . & N .C . isolated ) (N .O ., N .C ., C ommon)
for each channel for each channel * Form A & B contacts
Enclosu re available
0 – N one 1 – N EM A 1 4 – N EM A 4
D .C . P rob e C ircu it O p tion
A – N o op tion D – D .C . P rob e C ircu it* 3EE/UR)NTERSTITIAL4ANK-ONITORING0RODUCTS
*Eliminates short cycles on p age A-2 2 .
66
Visit www.GemsSensors.com for most current information. :"&,
Form 670
Notes: Sheet P/N 100501-1
Rev. F
Warrick® Series 67
Intrinsically Safe Multi-Function Control
Installation and Operation Bulletin
Table of Contents
Page 3 Installation Instructions: Safe Sensing Circuits- General Information
- Mounting Location
- Wiring
Page 4 Installation Instructions: Intrinsically Safe Sensing Circuits

- Grounding
- Sensor Wiring

- Alarm Channel Wiring
- Alternation Circuitry
Page 7 Installation: High Voltage Circuits

- AC Supply
- Grounding
- Output Contacts
Page 8 Control Diagram
Page 9 Technical Information

- Specification
- Ordering Information
- Module Replacement
Page 10 Technical Information

- Module Replacement
Page 11 Operation Instructions

- Single Level Service: Contact Operation
- Single Level Service: Alarm Functions

- Differential Level Service: Simplex

- Differential Level Service: Duplex
Page 14 General Control Information
Page 15 Sample Wiring Diagram
Gems Sensors Inc.

One Cowles Road
Plainville, CT 06062-1198
Tel: 860-793-4579
Fax: 860-793-4580 67
Notes: Sample Wiring Diagram
L1 Figure 5 L1
Ch 4
C NC High
Level
Ch 3
C NC Low
Level
Alarm
C NC
Bell
G L2 L1 NO C NC
Ground
Pump #2 Pump #1
Starter Starter
Circuit Circuit
C NO NC C NO NC C NO NC C NO NC
Series
67C1C0A
Control
Channel 4 Channel 3 Channel 2 Channel 1
DIP Switch Alternate

Ch 4 Ch 3 Ch 2 CH1 2-1 1-2 Down
Pump
LED LED LED LED Up Note: For applications that do
not require duplex alternation, a
S4 G S3 HS2 G LS2 HS1 G LS1 2-1 1-2 G SIL jumper must be placed from “G”
to “1-2 terminal
Non-Hazardous Area Non-Hazardous Area
Hazardous Silence
Area
Auto Hazardous Area

1-2 2-1
High Level
Alarm
Standby
Pump Start Duty Pump
Low Level
Start
Pump(s) Alarm
2 68
Stop 15
General Control Information Installation: Intrinsically Safe Sensing Circuits
This bulletin should be used by experienced personnel as a guide to the installation of the series 67.
Selection or installation of equipment should always be accompanied by competent technical assis-
Figure 4 See notes 1 & 3 tance. We encourage you to contact Gems Sensors or its local representative if further
information is required.
Sensor 2
Sensor 3
Sensor 1
Sensor 4
See notes 1, 3 & 5
IMPORTANT: BEFORE PROCEEDING TO INSTALL AND WIRE THE SERIES 67
CONTROL, READ AND THROUGHLY UNDERSTAND THESE INSTRUCTIONS.
Seal Off Fitting
When installing according to these instructions, this device provides intrinsically safe sensing circuits for
interface into Class I; Groups C & D, Class II; Groups E, F, & G and Class III; Hazardous Areas. Electrical
equipment connected to associated apparatus should not exceed maximum ratings marked on product.
Series 67 - Option A Series 67 - Option C
See note 4
Contact Board Contact Board
SIL G 1-2 2-1 LS1 G HS1 LS2 G HS2 S3 G S4 *** WARNING: To prevent ignition of flammable or combustible atmospheres, disconnect power before
N.C. C N.O. L1 L2 G servicing.
Channel 1 Channel 2 Channel 3 Channel 4 Channel 1 Channel 2 Channel 3 Channel 4
N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.C. N.O. C N.C. N.O. C N.C. N.O. C N.C. N.O. C
MOUNTING LOCATION
The control must be situated in a non-hazardous area where an explosive atmosphere will not exist at any time;
otherwise, it must be mounted in a suitable U.L. approved explosion-proof enclosure with suitable U.L. approved
explosion-proof seals.
N.O. N.C. N.C. N.O. C
Earth Ground
Neutral
Close Open
on on WIRING: GENERAL INFORMATION
Hot
Fault Fault
1. Intrinsically safe wiring must be kept separate from non-intrinsically safe wiring.
Load Load
2. Intrinsically safe and non-intrinsically safe wiring may occupy the same enclosure or raceway if they are at
Load Load
least 2 inches (50mm) apart and separately tied down. Inside panels, field wiring terminals for intrinsically
Open & Close on Fault Contacts Rated
1/3 Hp 120, 240 VAC 10 A @ 120/240 safe circuits must be separated by at least 2 inches (50 mm) from non-intrinsically safe wiring.
1/8 Hp 120, 240 VAC 5A @ 120/240
VAC or 5 A @ 30 VDC
VAC or 10 A @ 30 VDC
3. Wire the control device(s) to the Series 67 relay as shown in figure 1. A separate rigid metallic conduit
1/3 Hp 120, 240 VAC 10A @ 120/240
VAC or 10 A @ 30 VDC should be used to enclose the conductors of the intrinsically safe control circuit.
4. An approved seal should be used at the point where the intrinsically safe control circuit wiring enters the
Notes: hazardous area.
5. Capacitance and inductance of the field wiring from the intrinsically safe equipment to the associated
1. All intrinsically safe wiring must be installed in accordance with article 504 of the National Electric Code, apparatus shall be calculated and must be included in the system calculations as shown in Table 1. Cable
publication ANSI/NFPA 70 or CEC, Part 1 as applicable. capacitance, Ccable, plus intrinsically safe equipment capacitance, Ci must be less than the marked
capacitance, Ca (or Co), shown on any associated apparatus used. The same applies for inductance
2. Grounding- The four mounting holes on the Series 67 provide an electrical connection for earth ground- (Lcable, Li and La or Lo, respectively).Where the cable capacitance and inductance per foot are not known,
ing between the controls internal solid state circuitry and the enclosure chassis. To insure proper the folllowing values shall be used: Ccable = 60 pF/ft., Lcable = 0.2 µH/ft.
grounding, use only metal screws and lock washers when mounting the control.
For intrinsically safe output wiring use #14 or #16 AWG type MTW or THHN wire. By using these wire types in
Terminal “G” on the supply line/load side terminal strip is a redundant system ground terminal and must conjunction with the following distance recommendations, you will not exceed the maximum capacitance for field
be connected to the earth ground buss of the controls A.C. supply line feeder. The resistance between wiring. Use Table 2 as a guide for maximum wire runs.
the system ground terminals and the earth ground buss must be less than 1 ohm.
Table 1
To prevent electrical shock from supply line/load side powered connections, the Series 67 should be I.S. Equipment Associated Apparatus
mounted in a metal enclosure of proper NEMA integrity. V max (or Ui) > Voc or Vt (or Uo) Table 2
I max (or Li) > Isc or It (or lo)
P max, Pi > Po Model
3. The maximum total length of all of the intrinsically safe wiring (of each conductor) shall not exceed an Sensitivity Distance
Ci + Ccable < Ca (or Co) Number
accumulative value of 16,000 feet, excluding any ground wiring. Li + Lcable < La (or Lo)
67AXXXA 4.7K Ohms 4,000 Feet
4. The intrinsically safe terminals of the Series 67 can be connected to any non-energy generating or
storing switch device such as a push button, a limit or float type switch or any of Warrick’s electrode Entity Parameters 67BXXXA 10K Ohms 2,400 Feet
fitting assemblies. Terminals Voc Isc Po Ca La 67CXXXA 26K Ohms 1,200 Feet
5. When wiring alternation and bell silence switches, the switches and wiring must be separated from non- SIL,G,1-2,2-1 12.82 Vdc 7.2 mA 24.5 mw 6.5 µF 100mH 67DXXXA 50K Ohms 600 Feet
intrinsically safe circuits and wired in accordance with article 504 of the National Electric Code, publica- 12.82 Vdc 7.62 mA 24.5 mw 6.5 µF 100mH
LSI,G,HSI,LS2 67EXXXA 100K Ohms 300 Feet
tion ANSI/NFPA 70 or CEC, Part 1 as applicable.
S3,G,S4 12.82 Vdc 2.54 mA 8.2 mw 6.5 µF 100mH
HS2,G 12.82 Vdc 5.08 mA 16.3 mw 6.5 µF 100mH

14 3
69
Installation: Intrinsically Safe Sensing Circuits Operation Instructions
GROUNDING:
The four mounting holes on the Series 67 provide an electrical connection for earth grounding between the
DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP DOWN WITH ALTERNATION
control’s internal solid state circuitry and the enclosure chassis. To insure proper grounding, use only metal
screws and lock washers when mounting this control. Terminal G on the supply line/load side terminal strip Common Pump Stop- The pumps will alternate each cycle with the duty pump starting when the level rises to the
is a redundant system ground terminal and must be connected to earth ground buss of the control’s AC DUTY PUMP START sensor and stops when the level recedes below the PUMP(S) STOP sensor.
supply line feeder.
If the duty pump fails or cannot meet the demand of the system and the level rises to the STANDBY PUMP START
Note: sensor, the standby pump will be started and will continue in operation until the level recedes below the PUMP(S)
1. Intrinsically safe terminals can be connected to any non-energy generating or storing switch device such STOP sensor.
as a pushbutton, limit or float type switch or any Warrick electrode and fitting assembly.
2. To prevent electrical shock from supply line/load side powered connections, the Series 67 should be Separate Pump Stops- The pumps will alternate each cycle with the duty pump starting when the level rises to
mounted in a tool accessible enclosure of proper NEMA rated integrity. the DUTY PUMP START sensor and stops when the level recedes below the DUTY PUMP STOP sensor.
3. For U.L. 913 Listed panels, a metallic partition may be necessary to provide adequate spacing between
non-intrinsically safe and intrinsically safe wiring and /or terminals. If the duty pump fails or cannot meet the demand on the system and the level rises to the STANDBY PUMP
4. For additional guidance on “Hazardous Location Installation” and “Intrinsically Safe Devices”, consult START sensor, the standby pump will be started and will continue in operation until the level recedes below the
ANSI/ISA standard RP 12-6 or NEC articles 500-516 and local codes. STANDBY PUMP STOP sensor.
SENSOR WIRING DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP UP WITH ALTERNATION

The Series 67 control has four independent intrinsically safe channels, which can be connected to different
types of sensors including floats, conductance probes, pressure switches and other non-powered contacts Common Pump Stop- The pumps will alternate each cycle with the duty pump starting when the level recedes
or sensors. The connections of the sensors to the terminals will not vary with normally open or closed below the DUTY PUMP START sensor and stops when the level rises to the PUMP(S) STOP sensor.
sensors. However, the Inverse/Direct DIP switches must be set to the proper mode for each channel to
achieve the correct operation. Consult tables 2 and 3 for the proper DIP switch setting for various sensors If the duty pump fails or cannot meet the demand of the system and the level recedes to the STANDBY PUMP
and functions. START sensor, the standby pump will be started and will continue in operation until the level rises to the PUMP(S)
STOP sensor.
The following sections cover the intrinsically safe sensor connections for single and differential level service.
Separate Pump Stops- The pumps will alternate each cycle with the duty pump starting when the level recedes to
SINGLE LEVEL SERVICE: the DUTY PUMP START sensor and stops when the level rises to the DUTY PUMP STOP sensor.
All four channels can be used for single level service. Each channel is independent and can be used for its
own single point function. However, only channels 3 and 4 have the alarm bell and silence capabilities. If the duty pump fails or cannot meet the demand on the system and the level recedes to the STANDBY PUMP
Consult the alarm sections for more information regarding the installation and operation of the alarm circuitry. START sensor, the standby pump will be started and will continue in operation until the level rises to the STANDBY
Table 2 covers the sensor style to terminal connections for all four channels. PUMP STOP sensor.
Table 2
DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP DOWN WITHOUT ALTERNATION
Terminal
Sensor Style DIP Switch Settings Same operation as above disregarding the alternation sequence. Use appropriate jumper to determine manual
Connections
pump start sequence. Refer to table 5 for the manual alternation jumper information.
Channel 1 - HS1 & G*
Normally Open: Closes on Channel 2 - HS2 & G*
Alarm Condition Channel 3 - S3 & G
Inverse Mode - Up Position DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP UP WITHOUT ALTERNATION
Channel 4 - S4 & G
Same operation as above disregarding the alternation sequence. Use appropriate jumper to determine manual
Channel 1 - HS1 & G* pump start sequence. Refer to table 5 for the manual alternation jumper information.
Normally Open: Opens on Channel 2 - HS2 & G* Direct Mode - Down Position
Channel 4 - S4 & G

Normally Closed: Closes Channel 2 - HS2 & G* Inverse Mode - Up Position
on Alarm Condition Channel 3 - S3 & G
Channel 4 - S4 & G

Normally Closed: Opens Channel 2 - HS2 & G* Direct Mode - Down Position
Channel 4 - S4 & G
* Note: Channels 1 & 2 cannot activate the alarm bell contacts

and do not have the silence/acknowledge capabilities
4 70
13
Operation Instructions Installation: Intrinsically Safe Sensing Circuits
DIFFERENTIAL LEVEL SERVICE:
DIFFERENTIAL LEVEL SERVICE: Channels 1 and 2 are designed to provide differential on/off points to control pumps, solenoid valves or other
equipment. These channels can also be used in single level service for alarms and cutoffs, however the
The following operating instructions are based on correct DIP switch settings and sensor types. Any control’s built-in silence circuitry and bell contacts cannot be used. Consult the Alarm section for more
deviation from these requirements may result in incorrect system operations. Consult table 7 for information.
further instructions.
When channels 1 and 2 are used for differential level service, the associated sensors must be normally
open. The Inverse/Direct DIP switches must also be set to the proper mode for each channel to achieve the
correct operation. Table 3 gives the correct sensor to terminal connections an DIP switch settings for vari-
ous applications.
Table 7
FOR APPLICATIONS THAT DO NOT REQUIRE DUPLEX ALTERNATION, A JUMPER WIRE MUST BE
LED PLACED FROM THE “G” TO “1-2” TERMINAL.
DIP
Activation Contact Status
Application Warrick Sensor Switch
Condition Status Sensor
Setting
Closed
Table 3
Simplex Pump-Down or Normally Open: F, M, FE, FOE Direct Sensor Closes N.O. - Closes
ON Sensor Sensor DIP Switch
Solenoid Valve Drain 3R, 3T, 3W, 3Y, 3H or 3S “Down” on Rising Level N.C. - Opens Application
Contact Style Terminal Connections Setting
Simplex Pump-Up or Normally Open: F, M, FE, FOE Inverse Sensor Closes N.O. - Opens
OFF Simplex Pump-Down or Normally Open - Start Pump / Open Valve - HS1 & G* Direct - Down
Solenoid Valve Fill 3R, 3T, 3W, 3Y, 3H or 3S “Up” on Rising Level N.C. - Closes
Solenoid Valve Drain** Closes on Rising Level Stop Pump / Close Valve - LS1 & G* Channels 1 or 2
Duplex Pump-Down - Normally Open: F, M, FE, FOE Direct Sensor Closes N.O. - Closes
Common Pump Stop “Down” on Rising Level N.C. - Opens ON Simplex Pump-Up or Normally Open - Start Pump / Open Valve - LS1 & G* Inverse - Up
3R, 3T, 3W, 3Y, 3H or 3S
Solenoid Valve FillII Closes on Rising Level Stop Pump / Close Valve - HS1 & G* Channels 1 or 2
Duplex Pump-Up - Normally Open: F, M, FE, FOE Inverse Sensor Closes N.O. - Opens
Common Pump Stop “Up” on Rising Level N.C. - Closes OFF
3R, 3T, 3W, 3Y, 3H or 3S Duty Pump Start - HS1 & G*
Duplex Pump-Down - Normally Open - Standby Pump Start - HS2 & G* Direct - Down
ON Common Pump Stop Closes on Rising Level Duty and Standby Pump Stop - LS1 & G* Channels 1 or 2
Separate Pump Stop 3R, 3T, 3W, 3Y, 3H or 3S “Down” on Rising Level N.C. - Opens
Jumper - LS1 and LS2
“Up” N.C. - Closes OFF Duty Pump Start - LS1 & G*
Separate Pump Stop 3R, 3T, 3W, 3Y, 3H or 3S on Rising Level
Duplex Pump-Up - Normally Open - Standby Pump Start - LS2 & G* Inverse - Up
Common Pump Stop Closes on Rising Level Duty and Standby Pump Stop - HS1 & G* Channels 1 or 2
Jumper - HS1 and HS2
Duty Pump Start - HS1 & G*

Separate Pump Stops Closes on Rising Level Duty and Standby Pump Stop - LS1 & G* Channels 1 or 2
Jumper - LS2 and G*
DIFFERENTIAL LEVEL SERVICE: SIMPLEX
Duty Pump Start - LS1 & G*
Simplex Pump Down- Should the level rise to the PUMP START sensor the N.O. load contacts will close Duplex Pump-Up - Normally Open - Standby Pump Start - LS2 & G* Inverse - Up
starting the pump. The pump will remain running until the level recedes below the PUMP STOP sensor and Separate Pump Stops Closes on Rising Level Duty and Standby Pump Stop - HS1 & G* Channels 1 or 2
the load contacts open. Jumper - HS2 & G*
Simples Pump UP- Should the level recede below the PUMP START sensor the N.O. load contacts will
close starting the pump. The pump will remain running until the level rises to the PUMP STOP sensor and
the load contacts open. * Note 1: If conductance probes are being used, only one “G” connection is required. Terminal “G” must be
grounded to the vessel if metallic. If the electrode fitting being used has a metallic body and is supported
Solenoid Valve Drain- Should the level rise to the VALVE OPEN sensor the N.O. load contacts will close directly upon a metallic vessel, the ground connection is facilitated by securing that end of the ground
energizing the normally closed valve to open. The valve will remain open until the level recedes below the connector beneath the head of one of the screws which fasten the terminal housing to the body of the fitting.
VALVE CLOSE sensor and the load contacts open When the vessel is non-metallic, terminal “G” must be connected to an additional electrode of length equal to
or longer than, the longest electrode. If wire suspension electrodes are being used, more than one Ground/
Solenoid Valve Fill- Should the level recede below the VALVE OPEN sensor, the N.O. load contacts will Reference probe may be required.
close energizing the normally closed valve to open. The valve will remain open until the level rises to the
VALVE CLOSE sensor and load contacts open. ** Note 2: This setup is based on the use of a Normally Closed (N.C.) solenoid valve that energizes to open
when power is applied to the coil circuit.
12 71 5
ALARM CHANNEL WIRING: The Series 67 multi-function control can be used for many different applications including: pump control,
solenoid valve control and alarm activation. The following instructions cover the most common applications.
SILENCE CIRCUITRY: If your application is not included, contact Gems Sensors or our authorized representative in your area for
A normally open pushbutton is required for the Series 67’s alarm silence circuitry. The N.O. pushbutton must be assistance.
connected to the “SIL” and “G” terminals. For more information about the operation of the silence circuitry consult
the Alarm Operation section on page 11. NOTE: THE SILENCE PUSHBUTTON IS CONNECTED TO THE The operating instructions are broken up into two general categories: SINGLE and DIFFERENTIAL LEVEL
INTRINSICALLY SAFE CIRCUITRY. THEREFORE THE PUSHBUTTON AND ITS ASSOCIATED WIRING SERVICE. The alarm functions are covered under the SINGLE LEVEL SERVICE heading while the pumping
SHOULD BE SEPARATED FROM THE NON-INTRINSICALLY SAFE WIRING AND DEVICES. CONSULT and solenoid valve functions are covered under the DIFFERENTIAL LEVEL SERVICE heading.
GENERAL WIRING INFORMATION FOR MORE INFORMATION.
SINGLE LEVEL SERVICE: CONTACT OPERATION
ALARM DIP SWITCHES:
The alarm DIP switches for channels 3 and 4 can be set to enable the bell contacts for one or both alarm channels. LOAD CONTACTS: CHANNELS 1-4
However, this does not disable the alarm contact for that channel. Table 4 covers the DIP switch settings for The activation of these contacts is dependent upon the type of sensor (normally open or closed) and the
various alarm conditions. mode of operation (direct or inverse). The table 6 gives the sensor activation condition, DIP switch settings,
Table 4 contact status and LED status for various applications and sensors.
DIP Switch Settings Bell Contact Status Table 6

3 Off - Down Channel 3 - Off - Disabled Sensor” Alarm DIP Switch Relay Status LED Status
Application Warrick Sensor Activation Condition Setting Upon Alarm Upon Alarm
4 Off - Down Channel 4 - Off - Disabled
3 On - Up Channel 3 - On - Enabled High Level Alarm FE - Reed Switch Float Inverse
Closes on Rising Level De-Energized ON
Normally Open Float for M Tilt Float UP “I”
3 On - Up Channel 3 - On - Enabled High Level Alarm FE - Reed Switch Float Direct
Opens on Rising Level De-Energized OFF
Normally Closed Float for M Tilt Float DOWN “D”
4 On - Up Channel 4 - On - Enabled
Low Level Alarm FE - Reed Switch Float Direct
3 Off - Down Channel 3 - Off - Disabled Opens on Falling Level De-Energized OFF
Normally Open Float for M Tilt Float DOWN “D”
Low Level Alarm FE - Reed Switch Float Inverse
Closes on Falling Level De-Energized ON
Normally Closed Float for M Tilt Float UP “I”
ALTERNATION CIRCUITRY High Level Alarm 3R, 3T, 3W, 3Y, 3H Probes in Contact with Invers
De-Energized ON
Conductance Probes or 3S Conductive Liquid UP “I”
AUTO OR MANUAL:
Series 67’s built-in alternator can be used to automatically alternate between two loads controlled by channels Low Level Alarm 3R, 3T, 3W, 3Y, 3H Probes not in Contact Direct
De-Energized OFF
1 and 2. However, the automatic alternation may be by-passed to become a manual operation. This can be Conductance Probes or 3S with Conductive Liquid DOWN “D”
accomplished with the use of jumper wires or a three position switch connected to the 2-1, 1-2 and “G” termi-
UNKNOWN SENSOR Inverse
nals. Table 5 covers the jumper connections for manual alternation. Refer to figure 1 for more wiring informa- Normally Open
Closes on Fault
UP “I”
De-Energized ON
tion on the wiring of the three position selector switch. NOTE: THE MANUAL ALTERNATION CIRCUITRY IS
CONSIDERED INTRINSICALLY SAFE. THEREFORE THE SELECTOR SWTICH, JUMPER WIRES AND UNKNOWN SENSOR Direct
De-Energized OFF
Opens on Fault
THEIR ASSOCIATED WIRING SHOULD BE SEPARATED FROM NON-INTRINSICALLY SAFE WIRING Normally Closed DOWN “D”
DEVICES. CONSULT GENERAL WIRING INFORMATION FOR MORE INFORMATION ON INTRINSIC
SAFETY.
Table 5
SINGLE LEVEL SERVICE: ALARM FUNCTIONS
Alternation Jumper LED Status LED Status
Status Required Pump-Down* Pump-Up*
BELL CONTACTS:
Automatic* None Either Either Under NORMAL operating conditions the alarm bell relay is held energized. The relay will de-energize to
Manual 1-2 Terminals 1-2 to “G” No. 1 ** No. 1** activate an alarm device when an abnormal condition exists on either channels 3 and/or 4. Either one or
both alarm bell circuits can be disabled by adjusting the alarm DIP switches. Consult table 4 for more
Manual 2-1* Terminals 2-1 to “G” No. 2 ** No. 2**
information on the bell DIP switch settings.
SILENCE CIRCUITRY:
Notes Should an abnormal condition exist on either channels 3 and/or 4 the normally closed (N.C.) alarm bell relay
contacts will close, activating an alarm device. The N.C. alarm bell contacts can be returned to their normal
* For non-alternation applications jumper 1-2 to “G” state (open) silencing the alarm, by depressing a normally open pushbutton connected to the “SIL” and “G”
terminals. This will NOT affect the load contacts for channels 3 or 4 as they act independent from the alarm
** The position of the 1-2 and 2-1 indicating LED’s is dependent on the application. The position bell contacts.
changes for pump-up or pump-down. Consult control diagram figure 6-1 for more information.
6 11
72
Technical Information: Module Replacement Installation: High Voltage Circuits
Diagram 3 A.C. SUPPLY:

Connect the incoming supply HOT lead to the L1 terminal, NEUTRAL lead to the L2 terminal and EARTH
GROUND lead to the “G” Terminal. Note: the incoming power supply should have the same electrical characteris-
Terminal Strip tics as indicated on the control’s label.
Removal
GROUNDING
Terminal “G” on the supply line/load side terminal strip is a redundant system ground terminal and must be con-
nected to the earth ground buss of the panel’s AC supply line feeder.
A.C., Form C Load Contacts OUTPUT CONTACTS

Channels 1-4: Each channel has a dedicated non-powered contacts. These can be either Form C or Form A & B
and Sensor Terminals depending on the model. These contacts will change state when their respective channel activates. In DIRECT
mode the relay will energize and the contacts will change state when the probe circuit sensor closes. In INVERSE
mode the relay will energize and contacts will change state upon power up. The channel will then de-energize and
return the contacts to their shelf state when the probe circuit sensor closes.
Form C- This contact configuration consists of one (1) Normally Open contact and one (1) Normally Closed
contact. There are three terminals for electrical connections, N.O., N.C. and Common. Each terminal will accept
up to two (2) #14 AWG wires
Form A & B: This contact configuration consists of one (1) Normally Open contact and one (1) Normally Closed
contact which are electrically isolated from each other. There are two terminals for each contact. Each will accept
one (1) # 14 AWG wire.
Alarm Bell: The alarm bell contacts are non-powered Form C construction. This contact configuration consist of
Separation consists of one (1) Normally Open contact and one (1) Normally Closed contact. There are three terminals for
Point electrical connections, N.O., N.C. and Common. Each terminal will accept up to two (2) #14 AWG wires
When the output contacts are used to drive loads they should be wired in series with the load. This series
branch circuit should then be connected across a power source compatible with the load. See figure 1.
Field wiring
Terminal Strip Figure 1

Form A & B Contacts
Removal
Load Contacts Alarm Bell Contacts

See Output Board Options
N.C. C N.O. L1 L2 G

Separation N.C. N.O. C
Earth Ground
N.O. N.C.
Neutral
Close Open
Point on on
Hot
Fault Fault
Load Load
Load Load
1/3 Hp 120, 240 VAC 10 A @ 120/240
Field wiring VAC or 10 A @ 30 VDC
1/8 Hp 120, 240 VAC 5A @ 120/240
VAC or 5 A @ 30 VDC
1/3 Hp 120, 240 VAC 10A @ 120/240
10 73
7
Control Diagram Technical Information
Figure 2 SPECIFICATIONS
Contact Design: Standard SPDT (1 form C): one normally open (N.O.) and one normally closed (N.C.),
non powered contacts Contact Ratings for each channel. Optional 1 Form A (N.O.) and 1 Form B (N.C.) isolated
Load Contact Ratings: Standard Form C- 10A @ 120/240 VAC resistive and 30 VDC resistive, 1/3 Hp @ 120/
240 VAC. Optional Form A & B - 5A @120/240 VAC and 30 VDC resistive, 1/8 Hp @ 120/240 VAC.
Bell Contacts: 1 Form C (N.O.), N.C., C)
AC Supply CH 3/4 Alarm
Bell Contact Ratings: 10A @ 120/240 VAC and 30 VDC resistive, 1/3 Hp @ 120/240 VAC
Contact Life: Mechanical - 10 million operations. Electrical - 1,000,000 operations minimum at rated load.
Primary Voltage: 120 or 240 VAC models + 10% - 15%, 50/60 Hz.
Supply Current: Relays energized - 60ma @ 120 VAC, 30ma @ 240 VAC
Secondary Circuit: 12 VAC RMS voltage on probes, 6ma current RMS.
Sensitivity: Models operate from 4700-100,000 ohms maximum specific resistance
Temperature: -40° to 150° F Ambient
G L2 L1 NO C NC Electronics Module: Solid state components enclosed in a black nylon housing
Terminals: Standard Form C removable terminal strip containing a size 4 pan head screw with a clamping plate.
Will accept up to two (2) #14 AWG wires per terminal. Optional Form A & B relay board will accept up to one (1)
* Form A & B #14 AWG wire per terminal. Use copper (60-75° C) wire only. Torque to 20 inch pounds.
Load 4* Load 3* Load 2* Load 1*
contacts available
Listings: U.L. Intrinsically Safe (UL 913) File Number: E87112
ORDERING INFORMATION
67 X X X X X
O I
A N
M
L
O
A A 4.7K 1 120 VAC 1 Form A & B (N.O.) 0 None A AC on Probe Circuit
D
Channel 4 Channel 3 Channel 2 Channel 1 R A & N.C. Isolated) for
E B 10K 2 240 VAC 1 NEMA 1 D DC on Probe Circuit
M O 4 3 4 3 2 1 D each channel
F C 26K 4 NEMA 4
F D 50K C 1 Form C (N.O., N.C.)
for each channel
E 100K
Ch 4 Ch 3 Ch 2 CH1 2-1 1-2 Down
LED LED LED LED

Pump MODULE REPLACEMENT
Up DIP Switch Blow Up
Non-Hazardous S4 G S3 HS2 G LS2 HS1 G LS1 2-1 1-2 G SIL If the electronic module needs to be replaced:
Area
1. Turn off power to the control and load devices
2. Remove the metal partition located across the center of the module ( when required).
{
{
{
Silence 3. Remove all field wiring terminal blocks from the electronic module. The field wires do not need to be
Hazardous Area removed from the terminal blocks. The terminal blocks separate from the board as show in figure 8-1.
Ch 4 Ch 3 Ch 2 CH1
Auto 4. Remove the four (4) retaining screws from the base of the electronic module. The module can now be re-
Sensors 1-2 2-1 moved from the control panel.
Note: For applications that do not require duplex
5. Install a new module and reinstall all of the terminal blocks.
alternation, a jumper wire must be placed from the
“G” to “1-2” terminal.
6. Reinstall the metal partition (when required).
7. Set all DIP switches according to previous instructions.
8 74 9
Control Diagram Technical Information
Figure 2 SPECIFICATIONS
Contact Design: Standard SPDT (1 form C): one normally open (N.O.) and one normally closed (N.C.),
non powered contacts Contact Ratings for each channel. Optional 1 Form A (N.O.) and 1 Form B (N.C.) isolated
Load Contact Ratings: Standard Form C- 10A @ 120/240 VAC resistive and 30 VDC resistive, 1/3 Hp @ 120/
240 VAC. Optional Form A & B - 5A @120/240 VAC and 30 VDC resistive, 1/8 Hp @ 120/240 VAC.
Bell Contacts: 1 Form C (N.O.), N.C., C)
AC Supply CH 3/4 Alarm
Bell Contact Ratings: 10A @ 120/240 VAC and 30 VDC resistive, 1/3 Hp @ 120/240 VAC
Contact Life: Mechanical - 10 million operations. Electrical - 1,000,000 operations minimum at rated load.
Primary Voltage: 120 or 240 VAC models + 10% - 15%, 50/60 Hz.
Supply Current: Relays energized - 60ma @ 120 VAC, 30ma @ 240 VAC
Secondary Circuit: 12 VAC RMS voltage on probes, 6ma current RMS.
Sensitivity: Models operate from 4700-100,000 ohms maximum specific resistance
Temperature: -40° to 150° F Ambient
G L2 L1 NO C NC Electronics Module: Solid state components enclosed in a black nylon housing
Terminals: Standard Form C removable terminal strip containing a size 4 pan head screw with a clamping plate.
Will accept up to two (2) #14 AWG wires per terminal. Optional Form A & B relay board will accept up to one (1)
* Form A & B #14 AWG wire per terminal. Use copper (60-75° C) wire only. Torque to 20 inch pounds.
Load 4* Load 3* Load 2* Load 1*
contacts available
Listings: U.L. Intrinsically Safe (UL 913) File Number: E87112
ORDERING INFORMATION
67 X X X X X
O I
A N
M
L
O
A A 4.7K 1 120 VAC 1 Form A & B (N.O.) 0 None A AC on Probe Circuit
D
Channel 4 Channel 3 Channel 2 Channel 1 R A & N.C. Isolated) for
E B 10K 2 240 VAC 1 NEMA 1 D DC on Probe Circuit
M O 4 3 4 3 2 1 D each channel
F C 26K 4 NEMA 4
F D 50K C 1 Form C (N.O., N.C.)
for each channel
E 100K
Ch 4 Ch 3 Ch 2 CH1 2-1 1-2 Down
LED LED LED LED

Pump MODULE REPLACEMENT
Up DIP Switch Blow Up
Non-Hazardous S4 G S3 HS2 G LS2 HS1 G LS1 2-1 1-2 G SIL If the electronic module needs to be replaced:
Area
1. Turn off power to the control and load devices
2. Remove the metal partition located across the center of the module ( when required).
{
{
{
Silence 3. Remove all field wiring terminal blocks from the electronic module. The field wires do not need to be
Hazardous Area removed from the terminal blocks. The terminal blocks separate from the board as show in figure 8-1.
Ch 4 Ch 3 Ch 2 CH1
Auto 4. Remove the four (4) retaining screws from the base of the electronic module. The module can now be re-
Sensors 1-2 2-1 moved from the control panel.
Note: For applications that do not require duplex
5. Install a new module and reinstall all of the terminal blocks.
alternation, a jumper wire must be placed from the
“G” to “1-2” terminal.
6. Reinstall the metal partition (when required).
7. Set all DIP switches according to previous instructions.
8 75 9
Technical Information: Module Replacement Installation: High Voltage Circuits
Diagram 3 A.C. SUPPLY:

Connect the incoming supply HOT lead to the L1 terminal, NEUTRAL lead to the L2 terminal and EARTH
GROUND lead to the “G” Terminal. Note: the incoming power supply should have the same electrical characteris-
Terminal Strip tics as indicated on the control’s label.
Removal
GROUNDING
Terminal “G” on the supply line/load side terminal strip is a redundant system ground terminal and must be con-
nected to the earth ground buss of the panel’s AC supply line feeder.
A.C., Form C Load Contacts OUTPUT CONTACTS

Channels 1-4: Each channel has a dedicated non-powered contacts. These can be either Form C or Form A & B
and Sensor Terminals depending on the model. These contacts will change state when their respective channel activates. In DIRECT
mode the relay will energize and the contacts will change state when the probe circuit sensor closes. In INVERSE
mode the relay will energize and contacts will change state upon power up. The channel will then de-energize and
return the contacts to their shelf state when the probe circuit sensor closes.
Form C- This contact configuration consists of one (1) Normally Open contact and one (1) Normally Closed
contact. There are three terminals for electrical connections, N.O., N.C. and Common. Each terminal will accept
up to two (2) #14 AWG wires
Form A & B: This contact configuration consists of one (1) Normally Open contact and one (1) Normally Closed
contact which are electrically isolated from each other. There are two terminals for each contact. Each will accept
one (1) # 14 AWG wire.
Alarm Bell: The alarm bell contacts are non-powered Form C construction. This contact configuration consist of
Separation consists of one (1) Normally Open contact and one (1) Normally Closed contact. There are three terminals for
Point electrical connections, N.O., N.C. and Common. Each terminal will accept up to two (2) #14 AWG wires
When the output contacts are used to drive loads they should be wired in series with the load. This series
branch circuit should then be connected across a power source compatible with the load. See figure 1.
Field wiring
Terminal Strip Figure 1

Form A & B Contacts
Removal
Load Contacts Alarm Bell Contacts

See Output Board Options
N.C. C N.O. L1 L2 G

Separation N.C. N.O. C
Earth Ground
N.O. N.C.
Neutral
Close Open
Point on on
Hot
Fault Fault
Load Load
Load Load
1/3 Hp 120, 240 VAC 10 A @ 120/240
Field wiring VAC or 10 A @ 30 VDC
1/8 Hp 120, 240 VAC 5A @ 120/240
VAC or 5 A @ 30 VDC
1/3 Hp 120, 240 VAC 10A @ 120/240
10 76
7
ALARM CHANNEL WIRING: The Series 67 multi-function control can be used for many different applications including: pump control,
solenoid valve control and alarm activation. The following instructions cover the most common applications.
SILENCE CIRCUITRY: If your application is not included, contact Gems Sensors or our authorized representative in your area for
A normally open pushbutton is required for the Series 67’s alarm silence circuitry. The N.O. pushbutton must be assistance.
connected to the “SIL” and “G” terminals. For more information about the operation of the silence circuitry consult
the Alarm Operation section on page 11. NOTE: THE SILENCE PUSHBUTTON IS CONNECTED TO THE The operating instructions are broken up into two general categories: SINGLE and DIFFERENTIAL LEVEL
INTRINSICALLY SAFE CIRCUITRY. THEREFORE THE PUSHBUTTON AND ITS ASSOCIATED WIRING SERVICE. The alarm functions are covered under the SINGLE LEVEL SERVICE heading while the pumping
SHOULD BE SEPARATED FROM THE NON-INTRINSICALLY SAFE WIRING AND DEVICES. CONSULT and solenoid valve functions are covered under the DIFFERENTIAL LEVEL SERVICE heading.
GENERAL WIRING INFORMATION FOR MORE INFORMATION.
SINGLE LEVEL SERVICE: CONTACT OPERATION
ALARM DIP SWITCHES:
The alarm DIP switches for channels 3 and 4 can be set to enable the bell contacts for one or both alarm channels. LOAD CONTACTS: CHANNELS 1-4
However, this does not disable the alarm contact for that channel. Table 4 covers the DIP switch settings for The activation of these contacts is dependent upon the type of sensor (normally open or closed) and the
various alarm conditions. mode of operation (direct or inverse). The table 6 gives the sensor activation condition, DIP switch settings,
Table 4 contact status and LED status for various applications and sensors.
DIP Switch Settings Bell Contact Status Table 6

3 Off - Down Channel 3 - Off - Disabled Sensor” Alarm DIP Switch Relay Status LED Status
Application Warrick Sensor Activation Condition Setting Upon Alarm Upon Alarm
3 On - Up Channel 3 - On - Enabled High Level Alarm FE - Reed Switch Float Inverse
Closes on Rising Level De-Energized ON
Normally Open Float for M Tilt Float UP “I”
3 On - Up Channel 3 - On - Enabled High Level Alarm FE - Reed Switch Float Direct
Opens on Rising Level De-Energized OFF
Normally Closed Float for M Tilt Float DOWN “D”
Low Level Alarm FE - Reed Switch Float Direct
3 Off - Down Channel 3 - Off - Disabled Opens on Falling Level De-Energized OFF
Normally Open Float for M Tilt Float DOWN “D”
Low Level Alarm FE - Reed Switch Float Inverse
Closes on Falling Level De-Energized ON
Normally Closed Float for M Tilt Float UP “I”
ALTERNATION CIRCUITRY High Level Alarm 3R, 3T, 3W, 3Y, 3H Probes in Contact with Invers
De-Energized ON
Conductance Probes or 3S Conductive Liquid UP “I”
AUTO OR MANUAL:
Series 67’s built-in alternator can be used to automatically alternate between two loads controlled by channels Low Level Alarm 3R, 3T, 3W, 3Y, 3H Probes not in Contact Direct
De-Energized OFF
1 and 2. However, the automatic alternation may be by-passed to become a manual operation. This can be Conductance Probes or 3S with Conductive Liquid DOWN “D”
accomplished with the use of jumper wires or a three position switch connected to the 2-1, 1-2 and “G” termi-
UNKNOWN SENSOR Inverse
nals. Table 5 covers the jumper connections for manual alternation. Refer to figure 1 for more wiring informa- Normally Open
Closes on Fault
UP “I”
De-Energized ON
tion on the wiring of the three position selector switch. NOTE: THE MANUAL ALTERNATION CIRCUITRY IS
CONSIDERED INTRINSICALLY SAFE. THEREFORE THE SELECTOR SWTICH, JUMPER WIRES AND UNKNOWN SENSOR Direct
De-Energized OFF
Opens on Fault
THEIR ASSOCIATED WIRING SHOULD BE SEPARATED FROM NON-INTRINSICALLY SAFE WIRING Normally Closed DOWN “D”
DEVICES. CONSULT GENERAL WIRING INFORMATION FOR MORE INFORMATION ON INTRINSIC
SAFETY.
Table 5
SINGLE LEVEL SERVICE: ALARM FUNCTIONS
Alternation Jumper LED Status LED Status
Status Required Pump-Down* Pump-Up*
BELL CONTACTS:
Automatic* None Either Either Under NORMAL operating conditions the alarm bell relay is held energized. The relay will de-energize to
Manual 1-2 Terminals 1-2 to “G” No. 1 ** No. 1** activate an alarm device when an abnormal condition exists on either channels 3 and/or 4. Either one or
both alarm bell circuits can be disabled by adjusting the alarm DIP switches. Consult table 4 for more
Manual 2-1* Terminals 2-1 to “G” No. 2 ** No. 2**
information on the bell DIP switch settings.
SILENCE CIRCUITRY:
Notes Should an abnormal condition exist on either channels 3 and/or 4 the normally closed (N.C.) alarm bell relay
contacts will close, activating an alarm device. The N.C. alarm bell contacts can be returned to their normal
* For non-alternation applications jumper 1-2 to “G” state (open) silencing the alarm, by depressing a normally open pushbutton connected to the “SIL” and “G”
terminals. This will NOT affect the load contacts for channels 3 or 4 as they act independent from the alarm
** The position of the 1-2 and 2-1 indicating LED’s is dependent on the application. The position bell contacts.
changes for pump-up or pump-down. Consult control diagram figure 6-1 for more information.
6 11
77
Operation Instructions Installation: Intrinsically Safe Sensing Circuits
DIFFERENTIAL LEVEL SERVICE:
DIFFERENTIAL LEVEL SERVICE: Channels 1 and 2 are designed to provide differential on/off points to control pumps, solenoid valves or other
equipment. These channels can also be used in single level service for alarms and cutoffs, however the
The following operating instructions are based on correct DIP switch settings and sensor types. Any control’s built-in silence circuitry and bell contacts cannot be used. Consult the Alarm section for more
deviation from these requirements may result in incorrect system operations. Consult table 7 for information.
further instructions.
When channels 1 and 2 are used for differential level service, the associated sensors must be normally
open. The Inverse/Direct DIP switches must also be set to the proper mode for each channel to achieve the
correct operation. Table 3 gives the correct sensor to terminal connections an DIP switch settings for vari-
ous applications.
Table 7
FOR APPLICATIONS THAT DO NOT REQUIRE DUPLEX ALTERNATION, A JUMPER WIRE MUST BE
LED PLACED FROM THE “G” TO “1-2” TERMINAL.
DIP
Activation Contact Status
Application Warrick Sensor Switch
Condition Status Sensor
Setting
Closed
Table 3
Simplex Pump-Down or Normally Open: F, M, FE, FOE Direct Sensor Closes N.O. - Closes
ON Sensor Sensor DIP Switch
Solenoid Valve Drain 3R, 3T, 3W, 3Y, 3H or 3S “Down” on Rising Level N.C. - Opens Application
Contact Style Terminal Connections Setting
Simplex Pump-Up or Normally Open: F, M, FE, FOE Inverse Sensor Closes N.O. - Opens
OFF Simplex Pump-Down or Normally Open - Start Pump / Open Valve - HS1 & G* Direct - Down
Solenoid Valve Fill 3R, 3T, 3W, 3Y, 3H or 3S “Up” on Rising Level N.C. - Closes
Solenoid Valve Drain** Closes on Rising Level Stop Pump / Close Valve - LS1 & G* Channels 1 or 2
Common Pump Stop “Down” on Rising Level N.C. - Opens ON Simplex Pump-Up or Normally Open - Start Pump / Open Valve - LS1 & G* Inverse - Up
3R, 3T, 3W, 3Y, 3H or 3S
Solenoid Valve FillII Closes on Rising Level Stop Pump / Close Valve - HS1 & G* Channels 1 or 2
Common Pump Stop “Up” on Rising Level N.C. - Closes OFF
3R, 3T, 3W, 3Y, 3H or 3S Duty Pump Start - HS1 & G*
ON Common Pump Stop Closes on Rising Level Duty and Standby Pump Stop - LS1 & G* Channels 1 or 2
Separate Pump Stop 3R, 3T, 3W, 3Y, 3H or 3S “Down” on Rising Level N.C. - Opens
Jumper - LS1 and LS2
“Up” N.C. - Closes OFF Duty Pump Start - LS1 & G*
Separate Pump Stop 3R, 3T, 3W, 3Y, 3H or 3S on Rising Level
Duplex Pump-Up - Normally Open - Standby Pump Start - LS2 & G* Inverse - Up
Common Pump Stop Closes on Rising Level Duty and Standby Pump Stop - HS1 & G* Channels 1 or 2
Jumper - HS1 and HS2
Duty Pump Start - HS1 & G*

Separate Pump Stops Closes on Rising Level Duty and Standby Pump Stop - LS1 & G* Channels 1 or 2
Jumper - LS2 and G*
DIFFERENTIAL LEVEL SERVICE: SIMPLEX
Duty Pump Start - LS1 & G*
Simplex Pump Down- Should the level rise to the PUMP START sensor the N.O. load contacts will close Duplex Pump-Up - Normally Open - Standby Pump Start - LS2 & G* Inverse - Up
starting the pump. The pump will remain running until the level recedes below the PUMP STOP sensor and Separate Pump Stops Closes on Rising Level Duty and Standby Pump Stop - HS1 & G* Channels 1 or 2
the load contacts open. Jumper - HS2 & G*
Simples Pump UP- Should the level recede below the PUMP START sensor the N.O. load contacts will
close starting the pump. The pump will remain running until the level rises to the PUMP STOP sensor and
the load contacts open. * Note 1: If conductance probes are being used, only one “G” connection is required. Terminal “G” must be
grounded to the vessel if metallic. If the electrode fitting being used has a metallic body and is supported
Solenoid Valve Drain- Should the level rise to the VALVE OPEN sensor the N.O. load contacts will close directly upon a metallic vessel, the ground connection is facilitated by securing that end of the ground
energizing the normally closed valve to open. The valve will remain open until the level recedes below the connector beneath the head of one of the screws which fasten the terminal housing to the body of the fitting.
VALVE CLOSE sensor and the load contacts open When the vessel is non-metallic, terminal “G” must be connected to an additional electrode of length equal to
or longer than, the longest electrode. If wire suspension electrodes are being used, more than one Ground/
Solenoid Valve Fill- Should the level recede below the VALVE OPEN sensor, the N.O. load contacts will Reference probe may be required.
close energizing the normally closed valve to open. The valve will remain open until the level rises to the
VALVE CLOSE sensor and load contacts open. ** Note 2: This setup is based on the use of a Normally Closed (N.C.) solenoid valve that energizes to open
when power is applied to the coil circuit.
12 78 5
GROUNDING:
The four mounting holes on the Series 67 provide an electrical connection for earth grounding between the
DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP DOWN WITH ALTERNATION
control’s internal solid state circuitry and the enclosure chassis. To insure proper grounding, use only metal
screws and lock washers when mounting this control. Terminal G on the supply line/load side terminal strip Common Pump Stop- The pumps will alternate each cycle with the duty pump starting when the level rises to the
is a redundant system ground terminal and must be connected to earth ground buss of the control’s AC DUTY PUMP START sensor and stops when the level recedes below the PUMP(S) STOP sensor.
supply line feeder.
If the duty pump fails or cannot meet the demand of the system and the level rises to the STANDBY PUMP START
Note: sensor, the standby pump will be started and will continue in operation until the level recedes below the PUMP(S)
1. Intrinsically safe terminals can be connected to any non-energy generating or storing switch device such STOP sensor.
as a pushbutton, limit or float type switch or any Warrick electrode and fitting assembly.
2. To prevent electrical shock from supply line/load side powered connections, the Series 67 should be Separate Pump Stops- The pumps will alternate each cycle with the duty pump starting when the level rises to
mounted in a tool accessible enclosure of proper NEMA rated integrity. the DUTY PUMP START sensor and stops when the level recedes below the DUTY PUMP STOP sensor.
3. For U.L. 913 Listed panels, a metallic partition may be necessary to provide adequate spacing between
non-intrinsically safe and intrinsically safe wiring and /or terminals. If the duty pump fails or cannot meet the demand on the system and the level rises to the STANDBY PUMP
4. For additional guidance on “Hazardous Location Installation” and “Intrinsically Safe Devices”, consult START sensor, the standby pump will be started and will continue in operation until the level recedes below the
ANSI/ISA standard RP 12-6 or NEC articles 500-516 and local codes. STANDBY PUMP STOP sensor.
SENSOR WIRING DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP UP WITH ALTERNATION

The Series 67 control has four independent intrinsically safe channels, which can be connected to different
types of sensors including floats, conductance probes, pressure switches and other non-powered contacts Common Pump Stop- The pumps will alternate each cycle with the duty pump starting when the level recedes
or sensors. The connections of the sensors to the terminals will not vary with normally open or closed below the DUTY PUMP START sensor and stops when the level rises to the PUMP(S) STOP sensor.
sensors. However, the Inverse/Direct DIP switches must be set to the proper mode for each channel to
achieve the correct operation. Consult tables 2 and 3 for the proper DIP switch setting for various sensors If the duty pump fails or cannot meet the demand of the system and the level recedes to the STANDBY PUMP
and functions. START sensor, the standby pump will be started and will continue in operation until the level rises to the PUMP(S)
STOP sensor.
The following sections cover the intrinsically safe sensor connections for single and differential level service.
Separate Pump Stops- The pumps will alternate each cycle with the duty pump starting when the level recedes to
SINGLE LEVEL SERVICE: the DUTY PUMP START sensor and stops when the level rises to the DUTY PUMP STOP sensor.
All four channels can be used for single level service. Each channel is independent and can be used for its
own single point function. However, only channels 3 and 4 have the alarm bell and silence capabilities. If the duty pump fails or cannot meet the demand on the system and the level recedes to the STANDBY PUMP
Consult the alarm sections for more information regarding the installation and operation of the alarm circuitry. START sensor, the standby pump will be started and will continue in operation until the level rises to the STANDBY
Table 2 covers the sensor style to terminal connections for all four channels. PUMP STOP sensor.
Table 2
DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP DOWN WITHOUT ALTERNATION
Terminal
Sensor Style DIP Switch Settings Same operation as above disregarding the alternation sequence. Use appropriate jumper to determine manual
Connections
pump start sequence. Refer to table 5 for the manual alternation jumper information.
Normally Open: Closes on Channel 2 - HS2 & G*
Inverse Mode - Up Position DIFFERENTIAL LEVEL SERVICE: DUPLEX PUMP UP WITHOUT ALTERNATION
Channel 4 - S4 & G
Same operation as above disregarding the alternation sequence. Use appropriate jumper to determine manual
Channel 1 - HS1 & G* pump start sequence. Refer to table 5 for the manual alternation jumper information.
Normally Open: Opens on Channel 2 - HS2 & G* Direct Mode - Down Position
Channel 4 - S4 & G

Normally Closed: Closes Channel 2 - HS2 & G* Inverse Mode - Up Position
Channel 4 - S4 & G

Normally Closed: Opens Channel 2 - HS2 & G* Direct Mode - Down Position
Channel 4 - S4 & G
* Note: Channels 1 & 2 cannot activate the alarm bell contacts

and do not have the silence/acknowledge capabilities
4 79
13
General Control Information Installation: Intrinsically Safe Sensing Circuits
This bulletin should be used by experienced personnel as a guide to the installation of the series 67.
Selection or installation of equipment should always be accompanied by competent technical assis-
Figure 4 See notes 1 & 3 tance. We encourage you to contact Gems Sensors or its local representative if further
information is required.
Sensor 2
Sensor 3
Sensor 1
Sensor 4
See notes 1, 3 & 5
IMPORTANT: BEFORE PROCEEDING TO INSTALL AND WIRE THE SERIES 67
CONTROL, READ AND THROUGHLY UNDERSTAND THESE INSTRUCTIONS.
Seal Off Fitting
When installing according to these instructions, this device provides intrinsically safe sensing circuits for
interface into Class I; Groups C & D, Class II; Groups E, F, & G and Class III; Hazardous Areas. Electrical
equipment connected to associated apparatus should not exceed maximum ratings marked on product.
See note 4
SIL G 1-2 2-1 LS1 G HS1 LS2 G HS2 S3 G S4 *** WARNING: To prevent ignition of flammable or combustible atmospheres, disconnect power before
N.C. C N.O. L1 L2 G servicing.
MOUNTING LOCATION
The control must be situated in a non-hazardous area where an explosive atmosphere will not exist at any time;
otherwise, it must be mounted in a suitable U.L. approved explosion-proof enclosure with suitable U.L. approved
explosion-proof seals.
N.O. N.C. N.C. N.O. C
Earth Ground
Neutral
Close Open
on on WIRING: GENERAL INFORMATION
Hot
Fault Fault
1. Intrinsically safe wiring must be kept separate from non-intrinsically safe wiring.
Load Load
2. Intrinsically safe and non-intrinsically safe wiring may occupy the same enclosure or raceway if they are at
Load Load
least 2 inches (50mm) apart and separately tied down. Inside panels, field wiring terminals for intrinsically
1/3 Hp 120, 240 VAC 10 A @ 120/240 safe circuits must be separated by at least 2 inches (50 mm) from non-intrinsically safe wiring.
1/8 Hp 120, 240 VAC 5A @ 120/240
VAC or 5 A @ 30 VDC
3. Wire the control device(s) to the Series 67 relay as shown in figure 1. A separate rigid metallic conduit
1/3 Hp 120, 240 VAC 10A @ 120/240
VAC or 10 A @ 30 VDC should be used to enclose the conductors of the intrinsically safe control circuit.
4. An approved seal should be used at the point where the intrinsically safe control circuit wiring enters the
Notes: hazardous area.
5. Capacitance and inductance of the field wiring from the intrinsically safe equipment to the associated
1. All intrinsically safe wiring must be installed in accordance with article 504 of the National Electric Code, apparatus shall be calculated and must be included in the system calculations as shown in Table 1. Cable
publication ANSI/NFPA 70 or CEC, Part 1 as applicable. capacitance, Ccable, plus intrinsically safe equipment capacitance, Ci must be less than the marked
capacitance, Ca (or Co), shown on any associated apparatus used. The same applies for inductance
2. Grounding- The four mounting holes on the Series 67 provide an electrical connection for earth ground- (Lcable, Li and La or Lo, respectively).Where the cable capacitance and inductance per foot are not known,
ing between the controls internal solid state circuitry and the enclosure chassis. To insure proper the folllowing values shall be used: Ccable = 60 pF/ft., Lcable = 0.2 µH/ft.
grounding, use only metal screws and lock washers when mounting the control.
For intrinsically safe output wiring use #14 or #16 AWG type MTW or THHN wire. By using these wire types in
Terminal “G” on the supply line/load side terminal strip is a redundant system ground terminal and must conjunction with the following distance recommendations, you will not exceed the maximum capacitance for field
be connected to the earth ground buss of the controls A.C. supply line feeder. The resistance between wiring. Use Table 2 as a guide for maximum wire runs.
the system ground terminals and the earth ground buss must be less than 1 ohm.
Table 1
To prevent electrical shock from supply line/load side powered connections, the Series 67 should be I.S. Equipment Associated Apparatus
mounted in a metal enclosure of proper NEMA integrity. V max (or Ui) > Voc or Vt (or Uo) Table 2
I max (or Li) > Isc or It (or lo)
P max, Pi > Po Model
3. The maximum total length of all of the intrinsically safe wiring (of each conductor) shall not exceed an Sensitivity Distance
Ci + Ccable < Ca (or Co) Number
accumulative value of 16,000 feet, excluding any ground wiring. Li + Lcable < La (or Lo)
67AXXXA 4.7K Ohms 4,000 Feet
4. The intrinsically safe terminals of the Series 67 can be connected to any non-energy generating or
storing switch device such as a push button, a limit or float type switch or any of Warrick’s electrode Entity Parameters 67BXXXA 10K Ohms 2,400 Feet
fitting assemblies. Terminals Voc Isc Po Ca La 67CXXXA 26K Ohms 1,200 Feet
5. When wiring alternation and bell silence switches, the switches and wiring must be separated from non- SIL,G,1-2,2-1 12.82 Vdc 7.2 mA 24.5 mw 6.5 µF 100mH 67DXXXA 50K Ohms 600 Feet
intrinsically safe circuits and wired in accordance with article 504 of the National Electric Code, publica- 12.82 Vdc 7.62 mA 24.5 mw 6.5 µF 100mH
LSI,G,HSI,LS2 67EXXXA 100K Ohms 300 Feet
tion ANSI/NFPA 70 or CEC, Part 1 as applicable.
S3,G,S4 12.82 Vdc 2.54 mA 8.2 mw 6.5 µF 100mH
HS2,G 12.82 Vdc 5.08 mA 16.3 mw 6.5 µF 100mH

14 3
80
Notes: Sample Wiring Diagram
L1 Figure 5 L1
Ch 4
C NC High
Level
Ch 3
C NC Low
Level
Alarm
C NC
Bell
G L2 L1 NO C NC
Ground
Pump #2 Pump #1
Starter Starter
Circuit Circuit
Series
67C1C0A
Control
Channel 4 Channel 3 Channel 2 Channel 1

Ch 4 Ch 3 Ch 2 CH1 2-1 1-2 Down
Pump
LED LED LED LED Up Note: For applications that do
not require duplex alternation, a
S4 G S3 HS2 G LS2 HS1 G LS1 2-1 1-2 G SIL jumper must be placed from “G”
to “1-2 terminal
Non-Hazardous Area Non-Hazardous Area
Hazardous Silence
Area
Auto Hazardous Area

1-2 2-1
High Level
Alarm
Standby
Pump Start Duty Pump
Low Level
Start
Pump(s) Alarm
2 Stop
81 15
Installation, Care and Maintenance
3068
893333/06
82
CONTENTS
Safety __________________________________ 2 Transportation and storage ____________ 11
Data plate interpretation ________________ 3 Operation ______________________________ 11
Product description ____________________ 4 Care and maintenance _________________ 12
General design of a Flygt pump _________ 5 Oil change _____________________________ 13
Installation ______________________________ 6 Hydraulic ends ________________________ 14
Electrical connections __________________ 7 Trimming of the impeller and
Cable chart _____________________________ 9 cutting device _________________________ 16
SAFETY
This manual contains basic information on the installa- Qualifications of personnel
tion, operating and maintenance and should be followed An authorized (certified) electrician and mechanic shall
carefully. It is essential that these instructions are carry out all work.
carefully read before installation or commissioning by
both the installation crew as well as those responsible
for operation or maintenance. The operating instruc- Safety regulations for the owner/operator
tions should always be readily available at the location All government regulations, local health and safety
of the unit. codes shall be complied with.
All dangers due to electricity must be avoided (for
details consult the regulations of your local electricity
supply company).
Identification of safety and warning symbols Unilateral modification and spare parts manu-
facturing
Modifications or changes to the unit/installation should
General Danger: only be carried out after consulting with ITT Flygt.
Non-observance given to safety Original spare parts and accessories authorized by the
instructions in this manual, which manufacturer are essential for compliance. The use of
could cause danger to life have other parts can invalidate any claims for warranty or
been specifically highlighted with compensation.
this general danger symbol.
Dismantling and re-assembly
If the pump has been used to pump hazardous media,
High Voltage: care must be taken that, when draining the leakage,
The presence of a dangerous volt- personnel and environment are not endangered.
age is identified with this safety All waste and emissions such as used coolant must be
symbol. appropriately disposed of. Coolant spills must be
cleaned up and emissions to the environment must be
reported.
The pumping station must be kept tidy and in good
WARNING! Non-observance to this warning
order at all times.
could damage the unit or affect its
function All government regulations shall be observed.
The pictures in this manual may differ somewhat from the delivered pump depending on the hydraulic end configuration.
83
DATA PLATE INTERPRETATION
General data plate
A Serial number
A B Product code + Number
C Curve code / Propeller code
B C D Country of origin
E Product number
F Additional information
D G Phase; Type of current; Frequency
H Rated voltage
Made in Germany I Thermal protection
E J Thermal class
F K
L
Rated shaft power
International standard
X M Degree of protection
G N Rated current
V O Rated speed
H P Max. submergence
U Q Direction of rotation: L=left, R=right
I R Duty class
S Duty factor
T Product weight
J K L M N O P Q R S T U Locked rotor code letter
V Power factor
X Max. ambient temperature
Approval plates
These approval plates apply to an explosion-proof submersible Flygt pump.
The plates are used together with the general data plate on the pump.
EN: European Norm

ATEX Directive
EN 50014, EN 50018, EN 1127-1
II 2 G EEx dII T4 . . . . . 3068.090, 3068.590, 3068.890
I M 2 EEx dI . . . . . . . . 3068.690
A B C A Approval
B Approval authority + Approval Number
C Approval for Class I
D Approved drive unit
E Stall time
O F Starting current / Rated current
D N G Duty class
H Duty factor
M I Input power
J Rated speed
L K Controller
L Additional information
E K M Max. ambient temperature
N Serial number
O ATEX marking
F G H I J
84
PRODUCT DESCRIPTION
Introduction General technical data
Thank you for buying a submersible Flygt pump . In Liquid temperature: max. 40°C (104°F). The pump
this Installation, Care and Maintenance manual you can be operated at full load only if at least half the
will find general information on how to install and stator housing is submerged.
service the 3068 pump to give it a long and reliable Liquid density: max. 1100 kg/m3 (9.2 lb per US gal.).
life.
The pH of the pumped liquid: 6—13 (cast iron pumps).
Depth of immersion: max. 20 m (65 ft).
Application
This Installation, Care and Maintenance manual — In some installations and at
applies to a submersible Flygt pump. If you have certain operating points on the
bought an Ex-approved pump (please see approval performance curve, the noise
plate on your pump) special handling instructions apply level of 70 dB or the noise level
as described in this document. specified for the actual pump
may be exceeded.
M-version
— Only Ex-approved pumps may be
— pumping of waste water,
used in an explosive or flammable
— pumping of sewage if the solids need to be cut into environment.
small pieces.
B, C, D, F-versions
Warranty claim
Depending on the hydraulic end, the pump is intended
to be used for: Flygt pumps are high quality products with expected
reliable operation and long life. However, should the
— pumping of waste water
need arise for a warranty claim, please contact your
— pumping of light liquid manure and urine Flygt representative.
— pumping of sludge
— pumping of ground water
— pumping of sewage if the solids need to be cut into
small pieces.
The pumps must not be used in highly corrosive liquids.

See pH limits below.
The pump is available for permanent installation in a
sump or portable installation with hose connection and
stand.
For further information on applications, contact your
nearest Flygt representative.
Specific technical data

For specific technical data regarding your pump,
please see the data plate.
85
GENERAL DESIGN OF A FLYGT PUMP
Design
The pump is a submersible, electric motor-driven 6. Motor
product. Squirrel-cage 1-phase or 3-phase induction motor for
50 Hz or 60 Hz.
1. Impeller
The motor can be started by direct on-line or star-delta
The pump is available with a wide range of impellers
starting.
for different applications and capacities.
The motor can be run continuously or intermittently
2. Shaft seals with a maximum of 15 evenly spaced starts per hour.
The pump has two mechanical face seals – one inner Flygt motors are tested in accordance with IEC 34-1.
and one outer, with an intermediate oil housing. The stator is insulated in accordance with class F
(155°C, 310°F). The motor is designed to deliver its
3. Shaft rated output at ± 5% variation from the rated voltage.
The shaft is delivered with the rotor as an integral part. Without overheating the motor, ± 10% variation from
Shaft material: stainless steel. the rated voltage can be accepted provided that the
motor does not run continuously at full load. The
4. Bearings motor is designed to operate at a voltage imbalance
of up to 2% between the phases.
The bearings of the shaft consist of single-row ball
bearings. Monitoring equipment
5. Oil housing The stator incorporates thermal contacts connected in
series for some versions.
The oil lubricates and cools the seals and acts as a
buffer between the pump housing and the electric The pump can be equipped with a sensor (FLS) for
motor. sensing water in the stator housing (not applicable for
Ex-approved pumps).
86
INSTALLATION
Handling equipment Safety precautions
Lifting equipment is required for handling the pump. In order to minimize the risk of accidents in connection
with the service and installation work, the following
rules should be followed:
— Stay clear of suspended loads.
— Always lift the pump by its lifting
handle - never by the motor cable
or the hose.
The minimum height between the lifting hook and the

floor shall be sufficient to lift the pump out of the
sump.
The lifting equipment shall be able to hoist the pump
straight up and down in the sump, preferably without
the need for resetting the lifting hook.
Oversize lifting equipment could cause damage if the
pump should stick when being lifted.
Make sure that the lifting equipment is securely
anchored.
General recommendations
To ensure proper installation, please see the dimen-
sions on the dimensional drawing in the Parts List.
NOTE! The end of the cable must not be submerged.
It must be above flood level, as water may penetrate
through the cable into the junction box or the motor.
Check that the lifting handle and chain are in good
condition.
For automatic operation of the pump (level control),
it is recommended that the level regulators be used
at low voltage. The data sheet delivered with the regu-
lators gives the permissible voltage. Local rules may
specify otherwise.
Clean out all debris from the sump before the pump is
lowered down and the station is started.
Special rules apply to installation in

explosive atmosphere.
— Intrinsically safe circuits are

normally required (Ex i) for the
automatic level control system by
level regulators.
— Minimum stop level should be

according to the dimensional
drawing.
— The pump must never run dry.
87
1.9.
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rail.
ELECTRICAL CONNECTIONS
— Before starting work on the All electrical work shall be carried out under the super-
pump, make sure that the pump vision of an authorized electrician.
and the control panel are isolated
Local codes and regulations shall be complied with.
from the power supply and cannot
be energized. Check on the data plate which voltage supply is valid
— If the pump is equipped with for your pump.
automatic level control, there is Check that the main voltage and frequency agree with
a risk of sudden restart. the specifications on the pump data plate.
— All electrical equipment must be If the pump can be connected to different voltages, the
earthed. This applies to both pump connected voltage is specified by a yellow sticker.
equipment and any monitoring
equipment. Failure to heed this Connect the motor cable to the starter equipment as
warning may cause a lethal illustrated in the wiring diagrams.
accident. Make sure that the earth Conductors that are not in use must be isolated.
lead is correctly connected by
testing it. The cable should be replaced if the outer sheath is
damaged. Contact a Flygt service shop.
— If persons are likely to come into
physical contact with the pump or Make sure that the cable does not have any sharp
pumped media (liquid), e.g on con- bends and is not pinched.
struction sites and farms, the
Under no circumstances may the starter equipment be
earthed (grounded) socket must
installed in the sump.
have an additional earth-(ground-)
fault protection device (GFI) NOTE! For safety reasons, the earth conductor
connected. should be approx. 50 mm (2.0") longer than the phase
When pumping near a lake (jetties, conductors. If the motor cable is jerked loose by
beaches, ponds, fountains etc) mistake, the earth conductor should be the last
a safety-distance of at least 20 m conductor to come loose from its terminal. This
(65 ft) between the person and the applies to both ends of the cable.
pump is applicable.
Thermal contacts are incorporated in the stator for
The pump must never be placed
some versions. The thermal contacts can be
directly into a swimming pool. If
connected to max 250 V, breaking current max 4 A.
used in connection with swimming
Flygt recommends that they be connected to 24 V
pools, special safety regulations
over separate fuses to protect the other automatic
apply.
equipment.
Make sure that the pump is correctly earthed (grounded).
NOTE for Ex version When using a variable-frequency-drive (VFD)
— Electrical connections on the the shielded cable (type NSSHÖU.../3E+St) should be
explosion-proof motor must be used. Contact your Flygt representive and ask your
made by authorized personnel. VFD-supplier for electrical limitations.
Flygt disclaims all responsibility

for work done by untrained, un-
authorized personnel.
— The pump may be used only in
accordance with the approved
motor data stated on the data
plates.
— Thermal contacts must be
connected to protection circuit
intended for that purpose
according to the approval of the
product.
88
ELECTRICAL CONNECTIONS
Remember that the starting current in direct on-line Monitoring equipment
starting can be up to six times higher than the rated
current. Make sure that the fuses or circuit breakers The FLS sensor consists of a small float switch for
are of the proper rating. sensing water in the stator housing. Its design makes
it suitable for pumps in vertical installations.
The data plate gives rated current. Fuse rating and The FLS sensor is installed in the bottom of the stator
cable shall be selected in accordance with local rules housing.
and regulations. Note that with long cables, the
voltage drop in the cable must be taken into consider- The sensor is not applicable to Ex-approved pumps.
ation, since the motor’s rated voltage is the voltage Check:
that is measured at the terminal board in the pump. — signals and tripping function,
The overload protection (motor protection breaker) for — that relays, lamps, fuses and connections are
direct on-line starting shall be set to the motor rated intact.
current as given on the data plate. Replace defective equipment.
Check the phase sequence in the mains with the
phase sequence indicator.
If intermittent operation is prescribed (see data plate),
the pump shall be provided with control equipment
that provides such operation.
Single phase operation

The Flygt single phase 3068 pumps must be equipped
with a starter which has a capacitor.
A special Flygt designed starter is required for the
operation of single phase pumps. The connection of
the motor cable to the starter is shown in the wiring
diagram.
NOTE! It is not possible to change the direction of
rotation of a single phase pump by changing the cable
conductors on the starter. Please contact your nearest
Flygt representative.
89
CABLE CHART
7GX
3-phase, direct on-line starting 3-phase, star-delta starting

Conductors Connection starter Conductors Connection starter
SUBCAB 4Gx 1 brown ***red L1 SUBCAB 7Gx 1 black L1
***SUBCAB xAWG/4 2 blue ***white L2 2 black L2
HØ7RN-F 4Gx 3 black ***black L3 3 black L3
BIHF 4Gx silicon yellow/green earth 4 black L1
5 black L2
SUBCAB 4Gx+2x1,5 1 brown L1 6 black L3
2 blue L2 yellow/green earth
3 black L3
yellow/green earth SUBCAB 7Gx+2x1,5 1 black L1
T1 black T1* 2 black L2
T2 black T2* 3 black L3
4 black L1
SUBCAB 7Gx 1 black L1 5 black L2
HØ7RN-F 7Gx 2 black L2 6 black L3
3 black L3
4 black cut off T1 black T1*
5 black T1* T2 black T2*
6 black T2* yellow/green earth
yellow/green earth
For Canada/USA red L1
***SUBCAB xAWG/7 white L2 Stator leads U1 = red V2 = blue
black L3 V1 = brown W2 = black
yellow GC** W1 = yellow U2 = green
yellow/green earth
orange T1*
blue T2*
* Terminal for connection of thermal contacts in the motor and monitoring equipment.
** GC = Ground Check
Stator leads U1 = red V2 = blue *** SUBCAB/AWG
V1 = brown W2 = black
W1 = yellow U2 = green SUBCAB is a registered trademark of ITT Flygt AB for electrical cables.
90
CABLE CHART
7GX
Single phase
Conductors Connection starter Stator leads U1 = red U5 = red
SUBCAB 4Gx 1 brown ***red 1 V1 = brown V5 = brown
***SUBCAB xAWG/4 2 black ***black 2 W1 = yellow W5 = yellow
HØ7RN-F 4Gx 3 blue ***white 3 U2 = green U6 = green
V2 = blue V6 = blue
BIHF 4Gx silicon yellow/green earth
W2 = black W6 = black
SUBCAB 4Gx+2x1,5 1 brown 1
2 black 2
3 blue 3
yellow/green earth
T1 black T1*
T2 black T2*
SUBCAB 7Gx 1 black 1
2 black 2
3 black 3
4 black cut off
5 black T1*
6 black T2*
yellow/green earth
For Canada/USA red 1
***SUBCAB xAWG/7 black 2
white 3
yellow GC**
yellow/green earth
orange T1*
blue T2*
Stator leads U1 = red U2 = brown

Z1 = yellow Z2 = black
* Terminal for connection of thermal contacts in the motor and monitoring equipment.
** GC = Ground Check
*** SUBCAB/AWG
10
91
TRANSPORTATION AND STORAGE
The pump can be transported and stored in a vertical A frozen impeller can be thawed by allowing the pump
or horizontal position. to stand immersed in the liquid for a short period
before it is started. Never use a naked flame to thaw
the pump.
— Always lift the pump by its lifting For longer periods of storage, the pump must be
handle – never by the motor cable protected against moisture and heat. The impeller
or the hose. should be rotated occasionally (for example every
— Make sure that the pump cannot other month) to prevent the seals from sticking
roll or fall over and injure people together.
or damage property. After a long period of storage, the pump should be
inspected before it is taken into operation. Pay special
attention to the seals and the cable entry.
The pump is frostproof as long as it is operating or is
Follow the instructions under the heading “Before
immersed in the liquid. If the pump is raised when
starting”.
the temperature is below freezing, the impeller may
freeze.
The pump shall be run for a short period after being
raised in order to discharge all remaining water.
OPERATION
Before starting
Starting jerk
— Before starting work on the pump,
make sure that the pump is
isolated from the power supply
and cannot be energized.
— Make sure that the pump cannot
roll or fall over and injure people
or damage property.
Check that the visible parts on the pump and

installation are undamaged and in good condition.
Check the oil level in the oil housing.
Remove the fuses or open the circuit breaker and
check that the impeller can be rotated freely.
Check that the monitoring equipment (if any) works.
Check the direction of rotation. The impeller shall
rotate clockwise, as viewed from above. When
started, the pump will jerk in the opposite direction to
the direction in which the impeller rotates. See the
figure. Watch out for the starting jerk,
Transpose two phase leads if the impeller rotates in which can be powerful.
the wrong direction (3 ~).
In some installations the pump

surface and the surrounding liquid
may be hot. Bear in mind the risk of
burn injuries.
11
92
CARE AND MAINTENANCE
Before starting work on the pump, Inspection
make sure that the pump is isolated
from the power supply and cannot Regular inspection and preventive maintenance
be energized. ensure more reliable operation.
The pump should be inspected at least once a year,
This applies to the control circuit
but more frequently under severe operating
as well.
conditions.
Under normal operating conditions, the pump should
have a major overhaul in a service shop at least every
NOTE for Ex version third year for permanent installation and every year for
All work on the explosion-proof portable pumps. This requires special tools and should
motor section must be performed by be done by an authorized service shop.
personnel authorized by Flygt. If the seals have been replaced an inspection of the
Flygt disclaims all responsibility for oil is recommended after one week of operation.
work done by untrained, unauthorized NOTE! Regular check of the condition of the lifting
personnel. handle and chain is important.
Inspection of hot water applications

Make sure that the pump cannot Pumps in hot water applications shall undergo
roll or fall over and injure people inspection or overhaul at a service shop as follows,
or damage property. depending on the time they have been submerged in
the hot water:
Temp. Mode of Inspection Shop

The following points are important in connection with operation overhaul
work on the pump:
— Make sure that the pump has been thoroughly <_70°C Continuous 1000 hours 4000 hours
cleaned. (160°F)
— Beware of the risk of infection. <_70°C Intermittent twice a year once a year
(160°F)
— Follow local safety regulations.
<_90°C Cont./Int. 6 times a year twice a year
The pump is designed for use in liquids which can be (195°F)
hazardous to health. In order to prevent injury to the
eyes and skin, observe the following points when
working on the pump:
— Always wear goggles and rubber gloves.
— Rinse the pump thoroughly with clean water before
starting work.
— Rinse the components in water after dismantling.
— The oil housing may be under pressure. Hold a rag
over the oil screw (oil plug) to prevent splatter.
Proceed as follows if hazardous chemicals have
splashed into your eyes:
— Rinse your eyes immediately in running water
for 15 minutes. Hold your eyelids apart with your
fingers.
— Contact an eye specialist.
On your skin:
— Remove contaminated clothes.
— Wash your skin with soap and water.
— Seek medical attention, if required.
12
93
OIL CHANGE
A check of the condition of the oil can show whether
there has been leakage. Note! Air/oil mixture can be
confused with water/oil mixture.
Insert a tube (or hose) into the oil hole. Cover the top
end of the tube and take up a little oil from the bottom.
Change the oil if it contains too much water, i.e. if it is
heavily emulsified (cream-like), or if the oil housing
contains free water. Check again one week after
changing the oil.
The oil housing may be under

pressure. Hold a rag over the oil
plug to prevent splatter.
1. Lay the pump on its side on a bench or over two

supports. Unscrew the oil housing screw (oil plug)
and drain the oil.
2. Fill with new oil.

A paraffin oil with viscosity close to ISO VG15 is
recommended (e.g. Mobil Whiterex 309). The
pump is delivered from factory with this type of oil.
In applications where poisonous properties are of
0,6 l (0.63 US quarts)
less concern, a mineral oil with viscosity up to ISO
VG32 can be used.
3. Replace the O-rings under the oil housing screws

(plugs) with new ones.
10 Nm (7 ft lb)
13
94
HYDRAULIC ENDS
C M
B F
14
95
HYDRAULIC ENDS
D D
15
96
TRIMMING OF THE IMPELLER AND
CUTTING DEVICE — M-version
1. Place 3–4 washers (0.25 mm each, 312 88 00) on 7. Assemble the stationary cutter plate (make sure
the shaft. it’s not out of line).
2. Assemble the key on the shaft. 8. Place 2–3 washers (0.25 mm each, 312 88 00) on
3. Slide the impeller and the rotating cutter on the the impeller hub (between impeller and cutting
shaft and mount them by tightening the impeller wheel).
screw. 9. Assemble the rotating cutter and fasten it with a
4. Assemble the suction cover without the stationary force of 17 Nm.
cutter (do not screw down). 10. Re-adjust the clearance between the cutting wheel
5. Adjust the clearance between impeller vanes and and cutting desk with the adjusting screws on the
suction cover (maximum allowed clearance suction cover to the minimum clearance. Fasten
0.2 mm) with the adjusting screws on the suction the suction cover. (If necessary, adjust with extra
cover. or reduced numbers of washers on the impeller
hub, into the final minimum of clearance.)
6. Remove the rotating cutter.
CAUTION
Rotating cutting wheel

disconnect power
before lifting pump
16
97
98
www.flygt.com
3068.01.06. Eng. 2M. 02.01 © ITT FLYGT AB Printed in Sweden KT 210115 893333
SPARE PARTS LIST
DRUMMOND LTD
MINA PRIBBENOW COLOMBIA
Highland Tank Work Order Number: 84232
Equipment: Oil Water Separator - Model R-HTC-J 600 with Alarm & Water
Pumpout System (Drawings 94467 & 94468)
OWS Petro Screen: Secondary Polypropylene Coalescer

Replacement: 5 – 7 years or as required
Cost: Media - $757, Media and steel cartridges - $1,657
Lead Times: Media – 1-2 weeks, With Cartridges – 3 weeks
Sensors: Four Level (Water) and Two Level (Oil) Sensors

Replacement: As required
Cost: Four Level: $814, Two Level: $570
Lead Time: 2 weeks
Control Panel Relays: Warrick Series 27B1E0 and Series 67C1C0D

Cost: Series 27: $464, Series 67: $1,214
Lead Time: 2-3 weeks
Pumps: Basic Repair Kit

Cost: $1,060 Each
Lead Time: 2-3 weeks
NOTES:
1. Pricing good through 12/31/2016. Stocked inventory and lead times may vary.
2. All lights, fuses, etc in control panel considered standard operating components.
Contact Highland Tank for pricing as needed.
3. Contact Highland Tank for pricing on replacement pumps or any pump parts as may
be required.
99

Skimmer - OWS IOM Manual

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FINAL OPERATION AND

HIGHLAND TANK WORK ORDER NUMBER:

TAB 1: LITERATURE & GENERAL INFORMATION

- Rectangular Oil Water Separator Literature (4 Pages)

TAB 2: OWS DRAWING/ACCESSORY INFORMATION

- Oil Water Separator Drawing 94467, Revision 1 (1 Page)

TAB 3: QUALITY CONTROL FORMS

- Inspection & Test Plan – Complete (3 Pages)

TAB 4: OPERATION MANUAL & SPARE PARTS

- Highland Tank Rectangular OWS User’s Manual (14 Pages)

Innovative, High-Quality and Cost-Effective     

Highland Tank oil/water separators

Also available with a UL-SU2215 label

Aboveground installation Electronic oil level sensor Removable, top panels

Removable Top Cover with Lifting Handles

Flow Total Recommended Tank Dimensions Inlet &

Series - G Oil/Water Separators INLET

Series - J Oil/Water Separators

Series - S Oil/Water Separators

feature an integral “trickle filter" to

LA Please visit us at www.highlandtank.com

© Highland Tank – HT– 2027 – 10/2014

CHEMTHANE 4200 PW COMPONENTS

DESCRIPTION CHEMTHANE 4200 is a solvent-free, two component polyurethane lining

TYPICAL Solids, by volume 100%

CURE TIMES Cure to the Touch 3-5 minutes @ 77oF (25oC)

CERTIFICATIONS z UL Certification – “Flammable and Combustible Liquid Tank

z UL Certification – “Drinking Water System Components” – ANSI/

z AWWA Standard “C222-99: Polyurethane Coatings for the Interior

z Meets Green Seal standard GS-11 for VOC and Chemical

z Meets ANSI/AWWA D102-03 “Coating Steel Water Storage Tanks”

SOLUTION IMMERSION SPLASH SOLUTION IMMERSION SPLASH

FRESH WATER Potassium Hydroxide <10% 1 1

Maximum Wet Service Temperature (Water) 140F (60C)

Selection & Specification Data Substrates & Surface Preparation

Solids Content By Volume (890 VOC): 75% ± 2%

Allow for loss in mixing and application

Dry Temp. Continuous: 250°F (121°C)

Limitations Do not apply over latex coatings. Discoloration may

October 2010 replaces January 2010 1029

Application Equipment Application Conditions

Cleanup Use Thinner #2 or Acetone. In case of spillage, absorb

October 2010 replaces January 2010

Selection & Specification Data Substrates & Surface Preparation

Color Refer to Carboline Color Guide. Certain colors,

March 2011 replaces December 2009 0859

Application Equipment Cleanup & Safety Cont.

March 2011 replaces December 2009

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R ated power 3.8 hp

3/4 18" MIN

* DIMENSION TO ENDS OF GUIDE BARS

4" BOLT Ø 1/2 (4x)

Project Project ID Created by Created on Last update

16 255 112mm255 112mm

Project Project ID Created by Created on Last update

3/4" GUIDE BARS

2-11 1/2 NPT MIN. W.L.

3/4 18" MIN

* DIMENSION TOENDS OF GUIDE BARS

4" BOLT Ø 1/2 (4x)

Project Project ID Created by Created on Last update

Innovative, High-Quality and Cost-Effective

!" #$%$

!" #$%$

U .L . “ Intrinsically Safe” A p p lic a tio n s