Xylem P81884 RevI Series PL Booster Pumps - Manual (Page 2)

ELECTRICAL SAFETY
2
MECHANICAL SAFETY
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 damage.
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 the release of 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.
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.
THERMAL SAFETY
WARNING: ELECTRICAL GROUNDING HAZARD
Adequate electrical grounding is required for the safe
operation of B&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: ELECTRICAL SHOCK HAZARD
Disconnect and lockout the power before servicing.
Failure to follow these instructions could result in serious
personal injury or death.
REMOVAL OF THE PUMP FROM EXISTING SYSTEM FOR REPLACEMENT
PUMP INSTALLATION
1. Close the valves on the suction and discharge sides of
the pump. If no valves have been installed, it may be nec-
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 servic-
ing is complete. Failure to follow these instructions could
result in serious personal injury, death and/or property
damage.
2. Loosen the conduit box cover screw and remove the cover.
3. Disconnect the electrical supply lines to the pump
.
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.
4. Remove the flange bolts and nuts and then remove the
pump from the piping.
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.
Locate the pump so there is sufficient room for inspection,
maintenance and service. Bell & Gossett recommends the
installation of service valves on the suction and discharge of
all pumps to facilitate servicing or replacement of the pump
without draining the system.
Install suction and discharge flanges on the pipe ends. The
use of teflon tape sealer or a high quality thread sealant is
recommended.
Be sure to minimize any pipe-strain on the pump. Support the
suction and discharge piping by the use of pipe hangers near
the pump. Line up the vertical and horizontal piping so that
the bolt-holes in the pump flanges match the bolt-holes in the
pipe flanges. (DO NOT ATTEMPT TO SPRING THE SUCTION
OR DISCHARGE LINES IN POSITION. THIS MAY RESULT IN
UNWANTED STRESS IN THE PUMP BODY, FLANGE CON-
NECTIONS AND PIPING.) The code for Pressure Piping
(ANSI B31.1) lists many types of supports available for various
applications.
Bell & Gossett flange gaskets must be installed between the
Series PL
™ pump body flanges and the suction and discharge
pipe flanges. Use 7 /
16
" diameter x 1 1 /
2
" long capscrew and
matching nut to connect the pump to the flanges.
SAFETY REQUIREMENTS
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.
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: 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.
Apply torque in even increments to both flange bolts until a
value of 96-132 in-lbs. is reached. Both the suction and dis-
charge flange bolts must be torqued in this manner.
Do not start pump until the system has been filled and vented.
Air should be vented from the system by means of an air vent
located at a high point in the system, or by an alternate
method. The system must be completely vented prior to
pump operation. Do not run pumps dry. Pump operation with-
out water circulation could result in pump and motor damage.
MODE OF DISCHARGE
The Series PL
™ pump can be installed to discharge up or
down, horizontally, left or right, but the motor shaft must
remain in the horizontal position, the arrow on the body must
point in the direction of flow and the conduit box must be
positioned on the top of the motor housing (see figure 2).
3
WARNING: HOT WATER HAZARD
When disassembling a gasketed joint, always use a
new gasket upon reassembly. NEVER RE-USE OLD GAS-
KETS. Failure to follow these instructions could result in
serious personal injury, death and/or property damage.
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.
A. Loosen the screw securing the conduit box cover (wiring
compartment), and remove the screw & cover.
B. Attach the appropriate size connector to the hole on the
side of the conduit box.
C. Using a minimum size 14 AWG copper electrical wire (refer
to your local code for wiring restrictions), wire the motor to
a single phase power source as listed on the pump name-
plate. See Fig. 3.
D. Connect the ground wire to the inside of the conduit box
with one of the green screws provided inside the box. See
Fig. 4.
NOTE: Electrical supply and grounding wires must be suit-
able for at least 90°C (194°F).
NOTE: Series PL ™ Booster Pumps are thermally protected
and do not require external overload protection.
WIRING INSTRUCTIONS
SYSTEM PREPARATION
Prior to pump start up, closed heating and cooling systems
should be cleaned, drained and refilled with clean water.
System ph must be maintained between 7 and 9.
STARTUP
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.
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.
FIG. 2
FIG. 3
PUMP BODY MAY BE ROTATED AS SHOWN,
BUT CONDUIT BOX MUST REMAIN AT TOP.
CAUTION: SEAL DAMAGE HAZARD
Do not run pump dry, seal damage may occur. Failure
to follow these instructions could result in property damage
and/or moderate personal injury.
TYPICAL WIRING INSTALLATION SCHEMATIC
FOR 1Ø POWER SOURCE
FUSIBLE DISCONNECT
OR CIRCUIT BREAKER
BY OTHERS
PUMP MOTOR
THERMALLY
PROTECTED
TO REMOTE
CONTROL
IF REQUIRED
WARNING: HOT WATER LEAKAGE HAZARD
Pressurize the body slowly while checking for leaks
at all joints with gaskets. Failure to follow these instructions
could result in serious personal injury 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.
FIG. 4
CONDUIT BOX WIRING DETAIL
ALTERNATE
GROUND SCREW GREEN
GROUND
SCREW
LINE
LEADS