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Bell & Gossett
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10 001 247 R3
User Manual
36 pgs944.13 Kb0
Table of contents
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Bell & Gossett 10 001 247 R3 User Manual

Mechanical Installation,
Operation, and
Maintenance Manual
TechnoForce and TechnoForce XLS Package System
Table of Contents
Introduction and Safety..................................................................................................................3
Safety terminology and symbols........................................................................................... 3
Environmental safety...............................................................................................................4
Transportation and Storage.......................................................................................................... 7
Inspect the package................................................................................................................7
Inspect the unit........................................................................................................................ 7
Lifting methods........................................................................................................................7
Long term storage...................................................................................................................8
Table of Contents
Product Description......................................................................................................................10
Operational limits..................................................................................................................10
Installation......................................................................................................................................12
Commissioning, Startup, Operation, and Shutdown...............................................................15
Prestartup checklist...............................................................................................................15
Final installation checks........................................................................................................16
Final adjustments.................................................................................................................. 16
Confirm the job site voltage.................................................................................................16
Field install the supply water temperature sensor (constant speed units only)............ 17
Connect the storage tank.....................................................................................................17
Check for available suction water....................................................................................... 17
Start the package.................................................................................................................. 18
Check the pump rotation..................................................................................................... 18
Set the system operating pressure..................................................................................... 18
Enter the setup menu........................................................................................................... 18
Test the package................................................................................................................... 18
Maintenance..................................................................................................................................20
TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance Manual
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Table of Contents
Troubleshooting........................................................................................................................... 22
The pump station does not power up................................................................................ 22
The station powers up, but the pumps do not run........................................................... 22
The pumps run but do not build desired pressure...........................................................23
The pump station experiences excessive vibration..........................................................24
The pump station does not shut down and no water is used..........................................24
The pump station cycles or hunts erratically......................................................................24
Technical Reference..................................................................................................................... 26
Pump station with e-SV pumps............................................................................................26
Pump station with NPE pumps............................................................................................ 27
Pump station with SSH pumps.............................................................................................28
Product warranty...........................................................................................................................31
2 TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance
Manual

Introduction and Safety

Introduction

Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Introduction and Safety

Safety

WARNING:
The operator must be aware of safety precautions to prevent physical injury.
•
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.

Safety terminology and symbols

About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
•
Personal accidents and health problems
• Damage to the product
• Product malfunction
TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance Manual
3
Introduction and Safety
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or serious injury
Hazard categories
WARNING:
CAUTION:
NOTICE:
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
• A potential situation which, if not avoided, could result in undesirable conditions
A practice not related to personal injury
•
Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific
symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:
•
Crush hazard
• Cutting hazard
• Arc flash hazard

Environmental safety

The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
4 TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance
Manual
Recycling guidelines

User safety

General safety rules
Safety equipment
Introduction and Safety
Always follow local laws and regulations regarding recycling.
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
• Never operate a pump without a properly installed coupling guard.
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.
control.
pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance Manual
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Introduction and Safety
Condition Action Chemicals or hazardous fluids in
eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous fluids on skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
6 TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance
Manual

Transportation and Storage

Inspect the delivery

Inspect the package

1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the
distributor.

Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.
4. Contact the local sales representative if there is any issue.
Transportation and Storage

Transportation guidelines

Lifting methods

WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.
• Tip over hazard. Do not use component eyebolts to lift the pump station. The eyebolts are only designed to lift the components to which they are attached.
• Do not attach sling ropes to the panel stand.

Storage guidelines

Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
•
Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.

Storage between use

Observe the following for long-term storage of a pump station.
• Insure system is drained of any water.
• Remove transducers to ensure that they do not freeze.
• System may be top-heavy, brace to keep from tipping.
TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance Manual
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Transportation and Storage

Long term storage

The following procedure applies to Boosters and HVAC Packages.
1. Customer furnished equipment and accessories that are not offered as standard or
2. Storage longer than one month Is considered long term storage.
3. Pumps should be prepared for storage using the following procedure. SAFETY
• Select a storage location that will prevent potential hazards to persons allowed access
• Appropriate precautions should be taken to ensure safe on-site receipt and transit.
• Potential energy risk should be minimized. Keep product at ground level and prevent
LOCATION AND TREATMENT
• Indoor Storage
• Outdoor Storage
• Installed But Not in Service
EQUIPMENT PROTECTION
optional by the factory must be handled in accordance with the respective manufacturer's recommendations.
to the storage area.
stacking or other unsafe positioning that could result in falling, dropping, and/or tipping.
• Little extra preparation is needed if indoor storage area is dry and clean.
• Care should be taken to prevent extremes In temperature (below 32°F and above 110°F). Also, keep the pump out of direct sunlight and covered to protect it from dust and dirt.
• Care should be taken to prevent moisture build-up around the pump, either by allowing proper ventilation or tightly sealing the pump in the cover with a suitable amount of desiccant to ensure dryness.
• If indoor storage area is humid or dirty, such as an unfinished building, treat the pump as if it were to be stored outdoors.
• If exposure to condensation is expected, un-painted external steel or cast-iron surfaces should be coated with rust-inhibiting oil such as Cortec’s VCI-329.
• Storage location should also provide minimal exposure to vibration and other damage potentially transmitted from adjacent operating equipment.
• Product supplied in factory cartons, pallets or similar Xylem packaging should be kept in ‘as-shipped’ condition where possible.
• Inspect suction and discharge manifold flange covers.
• Pump should be covered to protect it from weather and direct sunlight.
• All coverings should be property secured to withstand high wind.
• Care must be exercised in covering pumps to prevent moisture build-up under the cover. This can be done either by allowing proper ventilation or tight sealing cover with suitable amount of desiccant to ensure dryness.
• Extreme heat and cold are to be avoided, as rubber parts and seals could age prematurely (below 32°F and above 110°F).
• Storage area should be inspected weekly, and after storms for damage to protective covers.
• Inspect suction and discharge manifold flange covers.
• Preparation for storage under these conditions is the same as for indoor and outdoor, except the suction and discharge piping will serve as flange covers.
• The suction and discharge valves must be tightly closed and all water removed from the pump and attached piping. The interior of the pump and piping must be thoroughly dried.
• Inspect un-painted external steel or cast-iron surfaces once a month for moisture and replace volatile corrosion inhibitor at that time (see section 1.B.a.v)
8 TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance
Manual
Transportation and Storage
• Pumps
• Every 30 days, the pump and motor shaft should be rotated by hand (10-15 turns) to prevent bearing damage and potential for binding. Be sure shaft comes to rest in different positions.
• Close-coupled pumps may have minimal access to exposed shaft areas. In those cases, care must be taken to avoid damage to the shaft though use of channel­lock pliers or similar tools.
• If removal of the coupling guard is required for hand-rotation of the pump and motor shafts, this guarding must be reinstalled prior to removal of lock-out tag-out and start-up.
• Control Panels, VFDs, and Electronics
• For storing electrical control panels, drives and other electrical items for more than 3 months, insertion of moisture absorbing packets within the enclosure by be necessary. Periodically replace as required. Remove packets prior to equipment start-up.
• Package Enclosures
• Housing vents and/or openings will be sealed with plastic wrap and waterproof tape.
• Condensation protection shall be provided in accordance to instructions previously noted.
PREPARATION FOR OPERATION
• Remove all rust inhibitor from exposed machined surfaces using the method described by the supplier.
• Remove all corrosion protection devices or material from package.
• Remove flange covers, tape, and all unnecessary pipe plugs.
TechnoForce and TechnoForce XLS Package System Mechanical Installation, Operation, and Maintenance Manual
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