Installation Instructions
Contents
1. Maximum Working Pressure 125 psi Maximum Operating Temperature 225 F Electrical Rating 115V 60 Hz 1PH Motors with special electrical characteristics are available on request Contact your local Bell amp Gossett Representative for details SAFETY INSTRUCTIONS This safety alert symbol will be used in this manual and on the pump instructions decal to draw attention to safety related instructions When used the safety alert symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD WARNING BEFORE INSTALLING USING OR amp WARNING SERVICING THIS PRODUCT A WARNING RISK OF ELECTRIC SHOCK READ THE WARNING NOTES AND INSTRUCTIONS IN INSTRUCTION MANUAL FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE V56845 THIS PUMP HAS NOT BEEN INVESTIGATED FOR USE IN SWIMMING POOL AND MARINE AREAS NONSUBMERSIBLE PUMP Your Booster Pump should have these warning labels affixed near the conduit box cover If these warnings are missing or illegible contact your local Bell amp Gossett Representative for replacement labels SAFETY REQUIREMENTS MECHANICAL SAFETY A WARNING EXCESSIVE SYSTEM PRESSURE HAZARD The maximum working pressure of the pump is listed on the nameplate DO NOT EXCEED THIS PRESSURE Failure to follow these instructions could result in serious personal injury death and or property damage2. fJ Bell amp Gossett a xylem brand Series 100 Series HV Series PR INSTRUCTION MANUAL P81748G ae SS g 2 yal Iron amp Bronze Booster Pumps INSTALLER PLEASE LEAVE THIS MANUAL FOR THE OWNER S USE DESCRIPTION Bell amp Gossett Booster Pumps feature oil lubricated sleeve bearings a carbon ceramic seal and a noise dampening spring coupler Bell amp Gossett Booster Pump motors are designed specifically for quiet operation and are built with thermal pro tection and drip proof construction The motor is non over loading at any point on the pump curve This pump is nonsubmersible for indoor use only PUMP APPLICATION Bell amp Gossett Pumps may be used for water circulating appli cations in hydronic solar and chilled water systems Bell amp Gossett recommends that bronze constructed pumps be used for pumping potable water For other applications contact your local Bell amp Gossett Representative Note that some local codes require using a check valve in the supply line when recir culating potable water It has not been investigated nor is it intended for use in swim ming pool and marine areas OPERATIONAL LIMITS These pumps are designed to pump liquids compatible with their iron or bronze body construction Unless special provi sions have been made by ITT Bell amp Gossett the operational limits for Series 100 HV PR and 2 Pumps are listed below Do not exceed these values
3. essary to drain the system WARNING HOT WATER HAZARD Before draining the system allow water to cool to 100 F max open the drain valve take precautions against water damage and leave the drain valve open until servicing is complete Failure to follow these instructions could result in serious personal injury death and or property damage WARNING ELECTRICAL SHOCK HAZARD Be certain the electrical power is not present at the motor leads before continuing Failure to follow these in structions could result in serious personal injury or death 2 Loosen the conduit box cover screw and remove the cover WARNING UNEXPECTED START UP HAZARD Single phase motors are equipped with automatic reset overload protectors The pump can restart without warning Disconnect and lockout power before servicing Failure to follow these instructions could result in serious personal injury death and or property damage 3 Disconnect the electrical supply lines to the pump WARNING HIGH PRESSURE HAZARD Pressure may be present in the pump body This pressure can be relieved by loosening the flange bolts and shifting the pump assembly slightly to allow the pressur ized water to escape Failure to follow these instructions could result in serious personal injury or death 4 Remove the flange bolts and remove the pump from the piping PUMP INSTALLATION CAUTION PROPERTY DAMAGE HAZARD It is not advisable to install circulators
4. 847 966 3700 Fax 847 965 8379 xylem Let s Solve Water OPERATIONAL INSTRUCTIONS SYSTEM PREPARATION Prior to pump start up closed heating and cooling systems should be flushed with clean water and drained The system should then be filled with clean water having a PH between 7 and 9 LUBRICATION Although the new B amp G pumps are test run at the factory they must be lubricated thoroughly before being placed in opera tion Bell amp Gossett supplies a high quality lubricant specifi cally for this purpose which can be purchased from any B amp G Representative Part No L23401 Proper lubrication proce durs are as follows 1 PUMP BEARINGS Fill the bearing frame according to the oiling instructions decal At the time of installation add approximately 1 oz of B amp G 20 weight non detergent oil An SAE 20 non detergent or 10W 30 oil may be substituted Re lubrication is required at the start of each heating sea son or every three months for continuous service Re lubricate with 1 teaspoon of oil More frequent lubrication may be required under adverse conditions such as high ambient temperatures Less frequent lubrication is required if oil overflows from the reservoir 2 MOTOR BEARINGS Lubricate through the two motor oil cups according to the lubrication decal At the time of installation the motor bearings use approx 12 drops each At re lubrication intervals fill each motor bearing with approx 6 8 dro
5. AY RESULT IN UNWANTED STRESS IN THE PUMP BODY FLANGE CONNECTIONS AND OR PIPING The code for pressure piping ANSI B31 1 lists types of supports for various applications Ordinary wire or band hangers are not adequate to maintain alignment It is very important to provide strong rigid support for the suction and discharge lines IMPORTANT Do not support the pump by its power pack To function properly the motor power pack must not be strained MODE OF DISCHARGE Bell amp Gossett Pumps can be installed to discharge up down left or right The oiling ports must always be in the twelve o clock position on top with motor and bearing assembly in a horizontal position THE ARROW ON THE PUMP BODY MUST POINT IN THE DIRECTION OF THE FLOW If it becomes nec essary to change the mode of discharge refer to B amp G Instruction Manual HS 105 SM for specific instructions in removing the motor and bearing assembly from the pump body OIL PORTS NOTE The position of the conduit box is determined by the model of the motor used The oiling ports must always be in the up position PUMP FLANGES New Bell amp Gossett flanges gaskets must be installed between the flanges of the pump body and suction and discharge pipes The gaskets should be clean and grease free old gas kets should never be reused WARNING HOT WATER HAZARD When disassembling a gasketed joint always use a new gasket upon reassembly NEVER RE USE OLD GASKETS Fai
6. WARNING EXCESSIVE PRESSURE HAZARD VOLUMETRIC EXPANSION The heating of water and other fluids causes volumetric expansion The associated forces may cause failure of sys tem components and release high temperature fluids This can be prevented by installing properly sized and located expansion tanks and pressure relief valves Failure to follow these instructions could result in serious personal injury death and or property damage THERMAL SAFETY WARNING EXTREME TEMPERATURE HAZARD If the pump motor or piping are operating at ex tremely high or low temperature guarding or insulation is required Failure to follow these instructions could result in serious personal injury death and or property damage WARNING HOT WATER HAZARD When disassembling a gasket joint always use a new gasket upon reassembly NEVER RE USE OLD GASKETS Failure to follow these instructions could result in serious personal injury death and or property damage ELECTRICAL SAFETY WARNING ELECTRICAL SHOCK HAZARD Electrical connections are to be made by a qualified electrician in accordance with all applicable codes ordi nances and good practices Failure to follow these instruc tions could result in serious personal injury death and or property damage WARNING ELECTRICAL OVERLOAD HAZARD Three phase motors must have properly sized heaters to provide overload and under voltage protection Single phase motors have built in overload protecto
7. ector to the hole in the side of the conduit box 2 Using a minimum size 14 AWG copper electrical wire refer to your local code for wiring restrictions wire the motor to a 115 volt 60 hertz single phase power source TYPICAL WIRING INSTALLATION SCHEMATIC POWER SOURCE 115 VOLT 60 HZ 19 gt r7 I FUSIBLE DISCONNECT i OR CIRCUIT BREAKER BY OTHERS i fe TN eee cd TO REMOTE CONTROL IF REQUIRED r i aeiewense THERMALLY PROTECTED 3 Connect the ground wire to the green screw inside the conduit box NOTE Single phase motors are protected with inherent over heating devices and do not require external overload protection NOTE If a motor with special characteristics is selected the electrical rating of the power source must be the same as that of the motor WARNING ELECTRICAL SHOCK HAZARD Be certain that all connections are secure and the conduit box cover is closed before electrical power is con nected Failure to follow these instructions could result in serious personal injury death and or property damage SERVICE INSTRUCTIONS 1 Keep the pump and motor properly lubricated 2 If the system is to be exposed to freezing temperatures drain the pump PERIODIC INSPECTION Inspect the pump regularly for leaking seals worn gaskets and loose or damaged components Replace or repair as required Xylem Inc 8200 N Austin Avenue Morton Grove Illinois 60053 Phone
8. in an attic or upper floor over finished living space If the circulator must be installed over head or over expensive equipment provide adequate drainage in the event of leakage Failure to follow these instructions could result in property damage PUMP LOCATION Bell amp Gossett Booster Pumps should be installed where there will be sufficient room for future inspection maintenance and service It is highly recommended that service valves shut off also be installed on each side of circulator pumps to facilitate servicing or replacing the pump without draining the system IMPORTANT In closed systems do not install and operate Bell amp Gossett pumps 3D valves suction diffusers etc with out properly sized safety and control devices Such devices include the properly sized and located pressure relief valves expansion tanks and pressure temperature and flow con trols If the system is not equipped with these devices consult the responsible engineer or architect before operating PUMP SUPPORTING AND PIPING Install the suction and discharge flanges on the pipe ends using Teflon tape sealer or high quality thread sealant Minimize strain on the pump by supporting the suction and discharge piping with pipe hangers near the pump Line up the vertical and horizontal piping so that the bolt holes in both the pump and pipe flanges are aligned DO NOT ATTEMPT TO SPRING THE SUCTION OR DISCHARGE LINES INTO POSI TION THIS M
9. lure to follow these instructions could result in serious personal injury death and or property damage WARNING HOT WATER HAZARD Make sure that each flange gasket remains seated in the flange groove during and after installation Failure to fol low these instructions could result in serious personal injury death and or property damage Apply torque in even increments to both flange bolts until the value listed in the table below is reached Both the suction and 100 With Full Face 100 With Ring Pump Series Flange Gasket Flange Gasket 2 Bolt Torque 150 180 in Ibs 96 132 in Ibs 96 132 in Ibs 96 132 in Ibs 96 132 in Ibs 12 5 15 ft Ibs 8 11 ft Ibs 8 11 ft Ibs 8 11 ft Ibs 8 11 ft Ibs Full turns of the nut from 1 1 4 1 1 3 4 34 finger tight No longer used WARNING WATER LEAKAGE HAZARD To prevent leakage make certain that the flange bolts have been adequately torqued Failure to follow these instructions could result in serious personal injury and or property damage Teflon is a registered trademark of E I DuPont de Nemours and Company WIRING INSTRUCTIONS WARNING ELECTRICAL SHOCK HAZARD Disconnect and lockout the power before making electrical connections Failure to follow these instructions could result in serious personal injury or death 1 Remove the screws securing the conduit box cover wiring compartment and lift off the cover Attach the appropriate size conn
10. ps More or less frequent re lubrication may be required depending on the installation conditions NOTE Over oiling can cause motor mount deterioration and may cause spillage onto surrounding surfaces Deteriorated motor mounts will lead to misalignment and excessive coupler wear CAUTION SEAL DAMAGE HAZARD Do not run the pump dry seal damage may occur Failure to follow these instructions could result in moderate personal injury and or property damage PRIMING AND STARTING Do not run B amp G circulator pumps dry Before starting the pump must be filled with water Air should be vented from the system by means of a system air vent or by an alternate method ADDITIONAL PUMP REPAIR Refer to the following manuals for additional repair instruc tions for Bell amp Gossett Iron amp Bronze Booster Pumps Coupler amp Motor Mount Replacement 515900 Rev D Booster Pump Service Manual HS 105 SM Rev 3 www xyleminc com brands bellgossett Bell amp Gossett is a trademark of Xylem Inc or one of its subsidiaries 2013 Xylem Inc P81748G January 2013
11. rs Failure to follow these instructions could result in serious personal injury death and or property damage WARNING ELECTRICAL GROUNDING HAZARD Adequate electrical grounding is required for the safe operation of B amp G Pumps The use of grounded metal con duit assures this requirement If the means of connection to the supply connection box wiring compartment is other than grounded metal conduit ground the pump back to the service by connecting a copper conductor at least the size of the circuit conductors supplying the pump to the green grounding screw provided within the wiring compartment Failure to follow these instructions could result in serious personal injury death and or property damage WARNING RISK OF ELECTRIC SHOCK Do not install this pump in swimming pool or marine areas Failure to follow these instructions could result in serious personal injury death and or property damage WARNING California Proposition 65 warning This product contains chemicals known to the state of California to cause cancer and birth defects of other reproductive harm REMOVAL OF THE PUMP FROM EXISTING SYSTEM FOR REPLACEMENT WARNING ELECTRICAL SHOCK HAZARD Disconnect and lockout the power before servicing Failure to follow these instructions could result in serious personal injury or death 1 Close the valves on the suction and discharge sides of the pump If no valves have been installed it may be nec
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