BenQ AWL300 Network Card User Manual
Contents
1. NOTES Page 22 lll QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment Check pump foundation for soundness and see that all hold down bolts are secure Complete any lubrication requirements as dictated by pump and driver owner s manual Inspect packing or mechanical seal for possible replacement Examine shaft sleeve if present for wear and replace if necessary Inspect pumping plant panel for signs of wear ie replace pitted contactors etc as needed Check pump and motor bearings from signs of wear Repack or replace as necessary Check alignment of couplings and or pulleys and belt tension if applicable IV QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment Check pump foundation for soundness and see that all hold down bolts are secure Complete any lubrication requirements as dictated by pump and driver owner s manual Inspect packing or mechanical seal for possible replacement Examine shaft sleeve if present for wear and replace if necessary Inspect pumping plant panel for signs of wear ie replace pitted contactors etc as needed Check pump and motor bearings from signs of wear Repack or replace as necessary Check alignment of couplings and or pulleys and belt tension if applicable ANNUAL INSPECTION Inspect pump and entire pumping system for signs of wear In2. Install pump in a clean dry and well drained location if possible and protect against moisture and adverse weather conditions Pump should be located on a level hard surface to prevent shifting or tipping Locate to be readily accessible for inspection and maintenance Careful attention should be taken to assure that Net Positive Suction Head Available NPSHA exceeds Net Positive Suction Head Required NPSHR by the pump or reduced performance and severe pump damage may result Figure 1 Page 3 illustrates where these terms NPSHA NPSHR originate and how to determine if the pumping conditions at which you want to operate meet the proper criteria When in doubt consult your nearest Berkeley Professional Dealer NOTE If pump site is 1000 feet above sea level sub tract 1 2 feet from the NPSHA equation and an ad ditional 1 2 feet for each additional 1000 feet of eleva tion FO0633 Installation General Information NPSHR EXAMPLE NPSHA E a this point S Si this point ON LY B4ZRKS 30 9 5 Feet total friction loss ae aa BEN ATT AR Rda A TEET T AS AS BREE ERR FESTENS 2000 RPM Reg ei SES eg Mee K re et BEER GG SS BERG 0 0 100 200 300 400 500 600 700 Gallons Per Minute A Model B4ZRKS operating at 450 GPM with 95 Feet of Head has a NPSHR of 8 Feet gt OK _NPSHA 9 5 Feet at that point on the performance curve A Model B4ZRKS operating at 550 GPM with 85 Feet of Head ha
3. reciprocating parts drag C Speed too high Refer to pump and engine power curves Adjust D Loose or broken parts Refer to engine manufacturer s manual F Fuel supply Check fuel supply fuel pump filters etc ll MECHANICAL A Flow through pump completely or Locate and remove obstruction Refer to Repair Instructions partially obstructed for disassembly B Wrong direction of rotation Reverse rotation of three phase motor by interchanging any two leads See manufacturer s Instructions for reversing single phase motor C Pump not primed Reprime Inspect suction system for air leaks D Internal leakage Check impeller for wear of controlled clearances See Repair Instructions E Loose parts Inspect Repair F Stuffing box not properly adjusted Adjust gland A Pressure required by system at design Compare pump pressure and flow rate against pump characteristic curve flow rate exceeds pressure rating of pump Check for closed or partially closed valve in discharge piping system Reduce system pressure requirement Increase pressure capability of pump B Obstruction in suction piping Locate and remove obstruction C Pressure rating of pump exceeds pressure Compare pump pressure and flow rate against pump characteristic curve requirement of system at design flow rate Inspect discharge piping system for breaks leaks open by pass valves etc If necessary reduce flow rate by partially closing discharge valve E Improper adjus
4. determine cause of the excessive vibration and correct NOISE When the unit is operating under load listen closely for unusual sounds that might indicate that the unit is in distress Determine the cause and correct OPERATING TEMPERATURE During operation heat is dissipated from the pump and the driver After a short period of time the surface of the pump bracket will be quite warm as high as 150 F which is normal If the surface temperature of the pump bracket or driver is excessive discontinue operation determine cause of the excessive temperature rise and correct F00633 Bearings will run hotter for a brief run in period after packing which is normal However worn bearings will cause excessive temperatures and need to be replaced The pump unit is cooled by the water flowing through it and will normally be at the temperature of the water being pumped STUFFING BOX After a short period of operation verify that the stuffing box area and gland are not hot If heating is detected loosen the gland nuts evenly until water is just running out of stuffing box in a DROPLET form approximately 40 60 drops per minute Water must not be streaming or spraying out Verify cool operation periodically Adjust gland nuts EVENLY as necessary for lubrication and cooling of the packing If packing has been tightened to the limit of the packing gland travel additional packing is necessary PUMPS WITH PACKING Starting new pump
5. possible but at least 6 times pipe diameter after pipe fitting to stabilize flow Water under pressure Suction P Gauge Isolation Valve full open when pumping W o Support pipe Standard or as required long radius elbow wv e An isolation valve is used in a pressurized suction pipe to permit servicing pump e Piping run and connection fittings should be properly aligned and independently supported to reduce strain on pump case e f solids are present a strainer should be used to protect the pump Recommended Page 10 F00633 Installation Suction Connection When Flooded Suction Exists Water under pressure Valve in upward position may trap air Check Val in suction pipe and fittings Concentric Reducer may Miter elbow or short _ cause air pockets radius elbow not recommended lt 5 o J Do not make elbow Been connection directly to pump suction e Suction piping that is undersized will create excess friction losses that may cause cavitation and a reduction in pump performance e Excess fittings and bends in suction line results in trapped air reduced performance and high friction losses which may cause cavitation e f check valve is required for back flow prevention locate on the discharge side of pump NotRecommended F00633 Page 11 Installation Discharge Connection gt Non Slam or
6. suction system for air leaks D Internal leakage Check impeller for wear of controlled clearances See Repair Instructions E Loose parts Inspect Repair F Stuffing box not properly adjusted Adjust gland A Pressure required by system at design Compare pump pressure and flow rate against pump characteristic curve flow rate exceeds pressure rating of pump Check for closed or partially closed valve in discharge piping system Reduce system pressure requirement Increase pressure capability of pump B Obstruction in suction piping Locate and remove obstruction C Pressure rating of pump exceeds pressure Compare pump pressure and flow rate against pump characteristic curve requirement of system at design flow rate Inspect discharge piping system for breaks leaks open by pass valves etc If necessary reduce flow rate by partially closing discharge valve Page 20 FO0633 Maintenance Troubleshooting SYMPTOM GROUP II GROUP Ilil C Ser JL ween 1 Ss SS Pump runs butnowaterdeivered x x x gt x x Not enough water delivered x x xx x ECKER Notenough pressure x 1 x xx x x x Excessive vibraion x x x x x x x Abnormalnoise xl Px x x xfxp xix a x hi SSES ES RSR SES Overheating x x x tx tx xtxtx te CAUSE CORRECTIVE ACTION A Speed too low Refer to engine manufacturer s manual B Rotating and or Refer to engine manufacturer s manual
7. B2XRKS B3TRKS Page 18 BERKELEY PUMPS S N OR DATE IMPELLER DIA 344 1093 Record your nameplate data here The following illustrations show typical components used in the assembly of self priming bearing frame mounted centrifugal pumps Refer to these drawing when order ing any replacement parts Q Pump Case Volute A Clack Rubber Clack Weight Check Valve Clack F00633 Pump Nomenclature Self Prime Bearing Frame Outboard Bearing AS Outer Bearing Inboard Cap we Bearing a ee S Ba S 1 lt Bearing Bearing Bearing Lock Frame Lock Nut 7 Inner Bearing Cap Slinger Packing Gland Packing Ring Assembly Shaft S SE SS Suction Flange Impeller Gasket Rubber Washer SE Clack Clamp je Pump Case gt Washer Volute a MW Clack Assembly Suction Flange neh wenn B 22 Ri K L Check Valve Outboard _ Bearing a gt Bearing P Spacer Outer Bearing ge Ze SE ffe Cap ys gt j Bearing Ba ae B D Y B earing N Beari earing Bag Frame A L Lock Nut washer Inner Bearing Cap TA Se 7 Slinger Oon oe W Clack Weight Clack Wash EES SE Suction Impeller Lock Nut Case Gasket Pump Case Volute s E e Rubber Clack Check Valve B4ZRKS FO0633 Page 19 Maintenance Troubleshooting PROBABLE CAUSE SYMPTOM GROUP I GROU
8. Before starting pump for the first time loosen gland nuts and retighten finger tight Proceed with pump start up procedure Allow packing to leak liberally for a few moments Then tighten gland nuts one complete turn each until leakage is reduced to 40 to 60 drops per minute REPACKING Refer to illustration on Page 16 PUMPS WITH MECHANICAL SEAL Adjustment or maintenance is normally not required The seal is enclosed within the pump and is self adjusting Seal is cooled and lubricated by the liquid being pumped Consult factory for proper replacement procedure SHAFT Bearing frame shaft assemblies should be periodically torn down for inspection of worn parts cleaning and re greasing Most importantly to check shaft sleeve and bearings for pitting Replace worn components as necessary Page 15 Maintenance Packing Ring Replacement Packing Gland 2239 0196 Unfasten hardware holding Packing Gland in place and slide back on shaft to expose packing rings Remove packing rings from Stuffing box using two commercially available Packing Hooks as shown Packing Hooks Packing Ring e Slide Lantern Ring if used back to expose any remaining rings including metallic Remove them in the same manner Installing New Rings Stagger ring joints 90 degrees apart Packing Rings Clean shaft sleeve and Packing Gland Inspect shaft sleeve for wear replace if needed Install new packing
9. Concrete Foundation Shims for alignment Motor Frame Pum Motor or rame Anchor Steel Bolt Channel Wedges Various Heights am we Ee O F Tack D gens Weld on e GE teeta d SPE Annet Zeen Anert A Grout k 8 b e O L am d A d A d KEP EW WW Concrete Lef A Foundation TE TE WW EW Pump and Motor Page 4 e There are several types of permanent pump foundation installations in use Those pictured above are typical e If grout is used top of concrete should be left rough to provide a good bonding surface e Foundation should slope away from pump to prevent liquid from pooling F00633 Installation Direct Coupling Drive Table Distance from Centerline Maximum Allowable T I R 1 00 inch 0 035 inches 2 00 inches 3 00 inches 4 00 inches Awarnine Rotating shaft can catch and trap clothing or body Coupling guard must ALWAYS be in place when pump is running Coupling guard shown in phantom for pictorial clarity ALIGNMENT OF PUMP AND MOTOR SHAFT A flexible coupling except for double universal joint shaft will not compensate for misalignment After the pump unit is fastened on the foundation it is nec essary to see that the shafts of the pump and motor are properly aligned Each mo
10. Motor Detail 1 625 Flange Face to end of shaft Pump Shaft to coupling Hydraulic Motor must have an SAE Standard SAE J744C mounting flange and shaft size B with 30 degree involute spline 13T 16 32 pitch Hydraulic Motor must produce the Torque required to drive the centrifugal pump at the desired operating speed For centrifugal pump GPM and TDH read the required RPM and BHP from pump performance curve and calculate required torque in Lbs Ft as follows 5252 x BHP Torque RPM Hydraulic Motor selected must match with the flow and pressure capability of the hydraulic power source system The operating speed of the centrifugal pump will be controlled by the valves in the hydraulic power source system F00633 Length and diameter factory machined for precision fit Coupling Precision machined to fit SAE standard Hydraulic Motor Shaft Spline Coupling is installed on shaft and locked in place with drive key and set screw 2237 0196 Page 7 Installation Suction Connection Suction Lift Pump driven by remote power source direct coupling or pulley belt connection Short length of straight pipe after reducer 2 times pipe diameter minimum Suction Straight run short as possible but at least 6 times pipe diameter D lt after elbow to stabilize flow 2114 1095 a Standard or lon Eccentric Reducer radius elbow See founda
11. OWNERS MANUAL INSTALLATION AND OPERATING INSTRUCTIONS REPAIR PARTS LIST Self Prime Frame Mounted Centrifugal Pump Direct Coupling Drive Belt Driven Hydraulic Drive IMPORTANT For best possible performance and continuous satisfactory operation read these instructions before installing your new pump Should service be required this manual can be a valuable guide It should be kept near the installation for ready reference Record nameplate data from pump on blank nameplate inside this manual for future reference Berkeley Pumps 293 Wright Street Delavan WI 53115 F00633 Rev 4 18 05 Safety First General Information General Safety Do not allow pump piping or any other system component containing water to freeze Freezing may damage system leading to injury or flooding Allowing pump or system components to freeze will void warranty Pump approved liquids only with this pump Periodically inspect pump and system components Wear safety glasses at all times when working on pumps Keep work area clean uncluttered and properly lighted store properly all unused tools and equipment Keep visitors at a safe distance from the work areas A WARNING Rotating parts Can catch hands feet or clothing Stay clear of equipment and keep shields in place while pump is running Stop motor or engine before servicing pump Read owner s manual before using equipment Electrical Safety A Wire moto
12. P Il GROUP III ELECTRICAL MECHANICAL SYSTEM SIE oe EIST RITTER EIETIA RTE O EES ER ESCHER ECSECS ES A A eT TET TT a a a a a a TT eT ET a pope px eT CAUSE CORRECTIVE ACTION A No voltage in power system Check phase to phase on line side of starter contactor Check circuit breaker or fuses B No voltage on one phase Check phase voltage on line side of starter contactor Isolate open circuit Three Phase Units circuit breaker fuse broken connections etc C Low voltage at motor Running voltage across each leg of motor must be 10 of nominal voltage shown on nameplate D Motor leads improperly grouped Refer to lead grouping diagram on motor nameplate for voltage E Control failure Check control device starter contactor H O A selector switch etc for malfunction F Thermal overload switch open Check phase to phase on line side of starter contactor G Installation failure Check motor or windings to ground with megohmmeter H Open windings Check leg to leg with ohmmeter Frequency variation Check frequency of power system Must be less than 5 variation from motor nameplate rating A Flow through pump completely or Locate and remove obstruction Refer to Repair Instructions partially obstructed for disassembly B Wrong direction of rotation Reverse rotation of three phase motor by interchanging any two leads See manufacturer s Instructions for reversing single phase motor C Pump not primed Reprime Inspect
13. Reverse L1 and L2 L2 and L3 or L1 and L3 Pump running backwards Centrifugal pumps will still Page 14 2238 0196 open at start up and allow pump to evacuate air from the suction line After several minutes of operation pump will be fully primed and pumping water Priming time will vary depending on length and diameter of suction line STARTING Electric Motor NOTICE Never run pump dry Running pump without water will overheat pump and damage internal parts Always make sure pump is primed prior to start up NOTICE Refer to maintenance section if pump has packing for adjustment prior to start up Prime pump by the above method Turn on power to pump Slowly open discharge valve until desired flow rate is achieved Place the Hand Off Auto selector switch in the Auto position The pump will start automatically when the pilot device signals the motor starter STOPPING Electric Motor Pump will stop automatically when the pilot device de energizes the motor starter Turn the Hand Off Auto selector switch to Off position if you want to stop the pump while it is running Counter Clockwise Rotation B2ZRKL Si Z Q As viewed Engage start switch momentarily bump driver to observe rotational direction pump liquids however GPM and head will be a fraction of the published performance ENGINE DRIVEN If engine is used for pump driver check with engine instruction
14. and operation manual or engine manufacturer to determine how rotation is defined then use above illustration for proper connection FO0633 Maintenance General Information T LUBRICATION LIQUID END of pump requires no lubrication Wear rings packing rings and models using a mechanical shaft seal are lubricated by the liquid being pumped Do not run dry BEARING FRAME add approximately 2 ounces of a lithium based NGLI No 2 extra pressure ball bearing grease to each bearing during quarterly inspection NOTE Excess grease will cause bearings to run hot The following are factory approved brands of grease for use with Berkeley Pumps Alvania EP2 Shell Oil Mobilith AW2 Mobil Oil Ronex MP Exxon Litholine EP2 Atlantic Richfield and Amolith EP2 Amoco ELECTRIC MOTOR Refer to motor manufacturer s operating manual for complete instruction GAS DIESEL ENGINE Refer to engine manufacturer s operating manual for complete instruction PERFORMANCE CHECK Periodically check the output of the pump If perform ance is noticeably reduced refer to Troubleshooting Chart OBSERVATIONAL MAINTENANCE When the pump and system operation have been stabilized verify that pump unit is operating properly Observe the following VIBRATION All rotating machines can be expected to produce some vibration however excessive vibration can reduce the life of the unit If the vibration seems excessive discontinue operation
15. eet Total Friction Loss 9 5 Feet 10 5 Feet Total 18 5 Feet 19 5 Feet 550 GPM 9 Feet Static Lift Theoretical static 4 lift of centrifugal pump at sea level 34 0 Feet Safety Factor 6 0 Feet Practical Limit 28 0 Feet 28 0 Feet Minus 18 5 Feet 19 5 Feet lt _ NPSHA 8 5 Feet 8 5 Feet SE flanges mate without any force This procedure can be done throughout piping system SUCTION PIPING Refer to illustrations on Page 8 through Page 11 for recommended and not recommended practices in suction connections DISCHARGE PIPING Refer to illustrations on Pages 12 through 13 for recommended and not recommended practices in discharge connections ELECTRICAL CONNECTION If electric motor is used NOTE All wiring should be done by a qualified electrician A WARNING Hazardous voltage Can shock burn or cause death Disconnect power to pump before servicing Check voltage and phase stamped on pump motor nameplate before making wiring connections to electrical system Be sure they agree with your electric current supply They MUST be the same If in doubt check with your local power company Refer to illustration on Page 7 for minimum recom mended pumping panel components that help safeguard your pump during operation Page 3 Installation Pump Foundation 1 2 or thicker Sole Plate tapped for hold down bolts Pump or Anchor Bolts r i a A d d P
16. for One Pump e Oil Seal s e Bearings If having a pump non operational has severe con sequences a back up pump should be considered Otherwise a back up impeller volute case bearings and shaft would be prudent PUMP PROTECTION COLD WEATHER WET WEATHER INSTALLATIONS SYSTEM DRAINS Provide drain valves to empty system including pump case to prevent freezing damage SHELTER If possible provide shelter for unit to protect from weather Allow adequate space around pump unit for service When effectively sheltered a small amount of heat will keep temperature above freezing Provide adequate ventilation for unit when running For severe weather problems where other shelter is not practical a totally enclosed fan cooled enclosure can be considered for electric motors CONDENSATION When the temperature of metal parts is below dew point and the surrounding air is moist water will condense on the metal surfaces and can Cause corrosion damage In severe situations a space heater can be considered to warm the unit FO0633 WINTERIZING If pump is to be out of service for an extended period of time such as the winter months the following storage procedures should be followed e Remove exterior dirt and grime or any substance that may trap moisture Exposed metal is subject to oxidation prime and repaint if necessary If this is not possible coat with grease or heavy oil e Flush suction and discharge lines Check fo
17. ge 6 Alignment Proper Belt Tension xN D Centerline Incorrect Centerline B represents center of belt and pulley This centerline must be straight for proper alignment Centerline NOTICE Belts must be tight enough to prevent slip ping during operation Loose belts result in early belt failure and reduced performance However excessive tightness of belts will result in overheating of the belts and excessive bearing load in the pump and driver e Most Vee belts will stretch slightly after initial installation After a short period of operation re check belt tension and adjust as necessary Center of span Slack should not be more than one belt thickness Se Proper tension allows one revolution of belt B View A A 1423 1294 F00633 Installation Electric Motor Hydraulic Motor Minimum recommended components to protect your pump during operation Check all local electrical codes prior to installation Contactor Incoming Power Lightning A Arrestor Loss of Prime Protection ei Fuseable Disconnect z Starter aici NEMA 3R Enclosure Tasielielilela Mounting Hydraulic Motor and Adapter Mounting Bracket Hydraulic Motor Fits on bearing bracket in place of outer bearing See Motor Detail for fit requirements cap Supports Hydraulic Motor and maintains exact shaft alignment
18. n pipe run e Swing type check valves can permit build up of reverse velocity before closing causing hydraulic shock or water hammer NotRecommended FO0633 Page 13 General Information SSS CHECK ROTATION Before pump is put into operation rotational direction must be checked to assure proper performance of pump Refer to illustration below to varify proper rotational direction for each model covered in this manual A WARNING Hazardous voltage Can shock burn or cause death Disconnect power to pump before servicing Do not attempt any wiring changes without first disconnecting power to pump PRIMING Pump priming is the displacement of air with water in the pump and suction piping Pump MUST BE completely filled with water when operating A self priming pump only needs to be manually primed at the first start up Once primed under normal conditions pump will reprime automatically at each subsequent start up To prime remove plug from top of pump case and fill case with water Replace plug and start pump Unit is equipped with a flapper type check valve which will Clockwise Rotation B2XRKS B3TRKS B4ZRKS Viewed from this direction As viewed ELECTRIC MOTORS Single Phase Refer to wiring information on the motor plate to obtain proper rotation Three Phase If pump runs backwards reverse any two leads coming of incoming power L1 L2 L3 until proper rotation is obtained
19. ntacting the installing Berkeley Wicor dealer as soon as possible after the discovery of any alleged defect Berkeley Wicor will subsequently take corrective action as promptly as reasonably possible No requests for service under this warranty will be accepted if received more than 30 days after the term of the warranty The warranty on all three phase submersible motors is void if three leg overload protection of recommended size is not used This warranty sets forth Berkeley s Wicor s sole obligation and purchaser s exclusive remedy for defective products BERKELEY WICOR SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL INCIDENTAL OR CONTINGENT DAMAGES WHATSOEVER THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE DURATION OF THE APPLICABLE EXPRESS WARRANTIES PROVIDED HEREIN Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state In the U S Berkeley 293 Wright St Delavan WI 53115 In Canada Wicor Canada 4544 Fieldgate Parkway Mississauga Ontario L4W 3W6 Page 24 FO0633
20. or B The maximum allow able total indicated runout is 005 inches Should either angular or parallel misalignment exceed the value shown shift or shim the motor until mis alignment is within the allowable limits shown Do not move pump unless absolutely necessary When shimming be sure that all feet on the pump and motor are equally supported to avoid strains on the castings when the hold down bolts are tightened Page 5 Installation Belt Drive Incorrect Centerline A of each shaft and pulley must be parallel for proper alignment ALIGNMENT Drive belt can catch and trap clothing AWARNING 5 body Belt guard must ALWAYS be in place when pump is running Belt guard is not shown for pictorial clarity e Drive and pump shaft centerlines A must be parallel as shown Belt centerlines B must be straight as shown e When installing belts move the driver toward the pump to allow belts to be placed on pulley Then move the driver away from pump to obtain proper belt tension as described below TENSION e Multiple belt soans must be equal tension in all belts Proper belt tension varies with the size of belt being used however a general rule is Belts are properly tensioned when one belt can be depressed one belt thickness at the center of the span when pressing with thumb Another method is that a properly tensioned belt can be rotated twisted one quarter revolution at the center of span Pa
21. r for correct A WARNING voltage See Electrical section of this manual and motor nameplate Ground motor before connecting to power supply Meet National Electrical Code and local codes Hazardous voltage for all wiring Can shock burn or cause death Follow wiring instructions in this manual when connecting motor to power lines Ground pump before connecting to power supply Page 2 READ AND FOLLOW SAFETY INSTRUCTIONS A This is the safety alert symbol When you see this symbol on your pump or in this manual look for one of the following signal words and be alert to the potential for personal injury aoe warns about hazards that will cause serious personal injury death or major property damage if ignored A waRnine Warns about hazards that will or can Cause serious personal injury death or major property damage if ignored A CAUTION Warns about hazards that will or can cause minor personal injury or property damage if ignored The label NOTICE indicates special instructions which are important but not related to hazards Carefully read and follow all safety instructions in this manual and on pump Keep safety labels in good condition Replace missing or damaged safety labels LOCATION Locate the pump as near to the water source as practical Make the suction pipe run short and straight with as few pipe fittings as possible to keep total friction loss to a minimum
22. r leaks at this time and replace any worn gaskets e Remove lowest plug in pump and drain pump casing and suction and discharge lines e Lubricate bearings e f possible keep unit clean and dry during storage period to guard against corrosion e Seal all open ports to keep out foreign objects such as insects rodents dust and dirt e Rotate driver shaft periodically to prevent freeze up of internal components e Shelter unit from elements if possible e Work oil into impeller wear ring by dripping oil into the gap while rotating by hand SPRING START UP e Inject sufficient grease into the bearings to displace old grease e Visual inspection e Rotate by hand if any binding occurs disassemble and inspect Page 17 Pump Nomenclature General Information T ORDERING REPLACEMENT PARTS Locate the Berkeley nameplate on the pump plate is normally on the bearing bracket Information found on this plate is shown below To be sure of receiving correct parts provide all nameplate data when ordering The BM Bill of Material number is most important Write your nameplate information on the blank nameplate below for future reference as nameplates can become worn or lost SAMPLE ONLY BERKELEY PUMPS MODEL S N OR DATE IMPELLER DIA B M 788 0394 Belt Drive ts Sheave lt 2 a s e Bearing ae Frame Water Slinger Gasket Mechanical Seal 2137N 1195 Impeller
23. rings in stuffing box by placing over shaft sleeve and pushing them in as far as they will go Rotate ring joint 90 degrees when installing each ring as shown Page 16 2240 0196 Slide packing gland into position then gently and evenly tighten nuts to force rings into place and seat do not overtighten Loosen nuts again to hand tight Start primed pump and allow packing to leak liberally Tighten gland nuts one complete turn each until leakage is reduced to 40 to 60 drops per minute F00633 Maintenance General Pump Care SSS ROUTINE MAINTENANCE A well maintained pumping system will extend the life of the unit and will require fewer repairs This means less down time which can be very critical when a constant delivery of water is required A routine maintenance and inspection schedule should be set up on a weekly quarterly and annual basis with records kept of these actions For weekly checks see observational maintenance on Page 15 For quarterly and annual maintenance refer to check list on Page 22 Copy page as necessary for continual usage RECOMMENDED SPARE PARTS It is recommended that the following spare parts be kept on site as a minimum back up to service your pump and reduce down time Check your model style against parts breakdown drawing on Pages 18 and 19 when selecting spares e Mechanical Shaft Seal e Packing Set and Packing Hooks e Shaft Sleeve s e All Gaskets and O Rings Required
24. s a NPSHR of 9 Feet FIGURE 1 at that point on the performance curve FOUNDATION Refer to illustration on Page 4 AWARNING Heavy weights risk of bodily harm due to crushing Use care and proper lifting equipment when handling pump for installation Size and weight of some units will require hoists for safe handling Pump should be set on a concrete foundation which is sufficiently substantial to absorb vibration and which provides a permanent and rigid support When properly positioned the unit will be level and the suction and discharge openings of the pump will be aligned with system piping PIPING System piping should be at least one commercial pipe size larger than pump connections and flow velocity should not exceed eight 8 feet per second Suction and discharge pipes must be naturally aligned with pump connections NOTICE Misalignment of piping with pump case or excessive pipe strain can cause distortion of pump components resulting in rubbing breakage and reduced pump life Insure that piping is supported in a manner that prevents the exertion of force on pump connections This can be checked by the following procedure With the pump shut down remove pipe flange bolts If the mating flanges come apart or shift misalignment is present and causing pressure on the connections Adjust pipe supports until FO0633 CAVITATION 450 Gallons per minute 450 GPM Static Lift 9 0 Feet 9 0 F
25. spect system valves screens etc If electric motor is used check windings for degred ation rewind if necessary Check pump impeller eye for clearance Inspect impeller volute case and seal chamber for signs of excessive wear or corrosion FO0633 Maintenance Notes Des F00633 Page 23 Berkeley Warranty Berkeley Wicor Canada Inc Wicor warrants to the original consumer purchaser Purchaser of its products that they are free from defects in material or workmanship If within twelve 12 months from the date of installation or twenty four 24 months from the date of manufacture any such product shall prove to be defective it shall be repaired or replaced at Berkeley s Wicor s option subject to the terms and conditions set forth below General Terms and Conditions Purchaser must pay all labor and shipping charges necessary to replace product covered by this warranty This warranty shall not apply to products which in the sole judgement of Berkeley Wicor have been subject to negligence abuse accident misapplication tampering alteration nor due to improper installation operation maintenance or storage nor to other than normal application use or service including but not limited to operational failures caused by corrosion rust or other foreign materials in the system or operation at pressures in excess of recommended maximums Requests for service under this warranty shall be made by co
26. spring loaded check valve ws Isolation valve to permit servicing of check valve or pump Isolation Valve Use Concentric Reducer to mimimize friction losses Discharge pipe diameter at least one nominal pipe size larger than discharge opening in pump P i ipi Support piping Align piping to minimize flange as required SES 2118 1195 Use pipe tubing or reinforced hose to make dis charge connection Material selected must have sufficient strength for operating pressures Discharge pipe should be sized so that flow velocity is below 8 feet per second Use ONLY non slamming check valves to prevent hydraulic shock water hammer Use gate ball or butterfly valve for isolation Valve should be full open during operation Maintain proper pipe size throughout discharge system using as few elbows and tees as possible to keep friction loss to a minimum Install pressure gauge after reducer as shown to check operating pressure or shut off head Recommended Page 12 FO0633 Installation Discharge Connection Do not use Gate Valve to throttle flow Ber Avoid abrupt change S in pipe size Tx Pes Avoid check valves that may cause hydraulic shock Avoid undersized pipe diameter 2119 1195 EX Do not force alignment that can cause flange stresses e Avoid excess friction loss caused by numerous fittings insufficient pipe diameter and sharp turns i
27. tion flat side up section Support pipe Slope upward as required NOTICE All connections must be air tight e Use pipe tubing or reinforced hose to make suction connection Hose must have sufficient strength to resist collapse under the pressure differential that occurs while pump is running e Suction pipe size should be at least one commercial pipe size larger than opening of pump inlet Flow velocity should not exceed 8 ft sec e Suction screen must screen out solids that could clog pump impeller e Suction screen area must be at least four times suction pipe area e Net Positive Suction Head Available NPSHA must exceed Net Positive Suction Head Required NPSHR by the pump or reduced performance and severe pump damage may result e All suction piping must have continuous rise to the pump suction inlet A 1 4 inch per foot minimum slope is recommended Recommended Page 8 FO0633 Installation Suction Connection auses high spots esulting in air pockets Do not instal in suction line No support or uneven mounting not recommended ss Unsupported pipe Causes excessive stress on pump and fittings Excess use of pipe fittings yng run means potential air leaks acommended Elbow immediately in front of pump intake lt not recommended gt Z gt bh Pipe diameter Q D undersized a reduces performance m High s
28. tment Check fuel and ignition systems Adjust per engine manufacturers manual F00633 Page 21 Maintenance Routine Inspection L QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment Check pump foundation for soundness and see that all hold down bolts are secure Complete any lubrication requirements as dictated by pump and driver owner s manual Inspect packing or mechanical seal for possible replacement Examine shaft sleeve if present for wear and replace if necessary Inspect pumping plant panel for signs of wear ie replace pitted contactors etc as needed Check pump and motor bearings from signs of wear Repack or replace as necessary Check alignment of couplings and or pulleys and belt tension if applicable E ll QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment Check pump foundation for soundness and see that all hold down bolts are secure Complete any lubrication requirements as dictated by pump and driver owner s manual Inspect packing or mechanical seal for possible replacement Examine shaft sleeve if present for wear and replace if necessary Inspect pumping plant panel for signs of wear ie replace pitted contactors etc as needed Check pump and motor bearings from signs of wear Repack or replace as necessary Check alignment of couplings and or pulleys and belt tension if applicable
29. tor and pump foot should be shimmed to avoid shifting or soft foot COURSE ALIGNMENT By moving the entire unit bring suction and discharge openings of the pump into alignment with the system piping Install piping at this time Pipes should align naturally with the pump see Installation Section Bring the pump and motor shaft into approximate alignment by shifting or shimming the motor Use a straight edge to check alignment of the shafts Use calipers or a wedge thickness gauge to check the distance between coupling halves The distance between halves should be equal at 90 degree intervals around the coupling and the shafts should be concentric when checked with a straight edge FO0633 Centerline FINE ALIGNMENT e Angular and parallel misalignment of the coupling may be corrected simultaneously Maintain a sep aration between coupling halves per manufacturer s specifications to avoid preloading of pump and motor bearings Clamp dial indicators to the pump and motor shaft as shown above Start with angular alignment and finish check with parallel alignment Rotate both the shaft and coupling together by hand Note the total indicated runout shown on indicator A The maximum allowable angular misalignment is 1 degree Limits of reading on indicator A at various distances from shaft centerline are shown in Table I Continue to rotate both shafts by hand and note the runout shown on indicat
30. uction k Ke lift should A B be avoided E Vortex caused by insufficient submergence may cause pump to lose prime e Suction pipe sloping downward to pump inlet will trap K air which will reduce performance and may cause pump to lose prime CO e Suction piping that is undersized will create excess friction losses that may cause cavitation and a reduction in pump performance e Excess fittings and bends in suction line results in trapped air reduced performance and high friction losses which may cause cavitation Not Recommended F00633 Page 9 Installation Suction Connection When Flooded Suction Exists Pump driven by remote power source direct coupling or pulley belt d J 2214 0196 See foundation section Slope upward to pump e Use pipe tubing or reinforced hose to make suction connection Hose must have sufficient strength to resist collapse under the atmospheric pressure differential that may occur while pump is running e tis important even with a flooded suction condition that proper pipe fittings are used so water is delivered to impeller eye with a smooth flow and consistent velocity e Suction pipe size should be at least one commercial pipe size larger than opening of pipe inlet Flow velocity should not exceed 8 ft sec Short run of straight pipe after reducer 2 times pipe diameter Eccentric Reducer gt flat side up Straight run short as
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