Bell & Gossett DN0132F User Manual

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Domestic® Pump Vented Boiler Feed Units Series CM,™ CSM,™ CBEM,™ CBM,™ CMED,™ and
CMHD
INSTRUCTION MANUAL
DN-0132
REVISION F
TM
CMED Boiler Feed Unit
CBEM Boiler Feed Unit
CBM Boiler Feed Unit
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
SAFETY
INSTRUCTIONS
This safety alert symbol will be used in this manual and on
the unit safety instruction decals to draw attention to safety related instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.
WARNING
EXPLOSIBLE
ISOLATE TANK
DURING LEAK TEST
(2) All Units DN0485 (Small) DN0486 (Large)
EXPLOSIBLE
(2) All Units
DN0483 (Small) - DN0484 (Large)
WARNING
DO NOT PRESSURIZE TANK. ISOLATE TANK DURING LEAK TEST. DO NOT RESTRICT VENT. DO NOT PLUG OVERFLOW. OPEN INLET VALVES SLOWLY. DO NOT USE AS A FLASH TANK.
FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.
If the decals as noted below are missing or are illegible contact
your local B&G representative for a replacement.
1. Electrical connections to be made by qualified Electrician in accordance with all National, State and Local codes.
2. Motor must have properly sized starter with properly sized heaters to provide overload and undervoltage protection.
3. If pump, motor or piping are operating at extremely high or low temperatures, guarding or insulation is required.
4. Operating personnel should be trained in the operation of boiler feed units.
TM
SERIES
MODEL
SERIAL
GPM PSI PUMP
CFM IN HG. PUMP
DWGS
POWER V. PH. HZ 60
CONTROL V. PH. 1 HZ 60
TOTAL LARGEST MOTOR F.L. AMP F.L. AMP
DN0016
TM
Morton Grove, Illinois 60053
DN0116
Units with Panel
SERIES
MODEL
SERIAL
GPM PSI PUMP
POWER V. PH. HZ60
CONTROL V. PH. 1 HZ60
TOTAL LARGEST MOTOR F.L. AMP F.L. AMP
TM
TM
Morton Grove, Illinois 60053
DN0019
Units Less/Panel
CAUTION
DO NOT RUN PUMP DRY, SEAL DAMAGE MAY OCCUR.
INSPECT PUMP SEAL REGULARLY FOR LEAKS, REPLACE AS REQUIRED.
FOR LUBRICATION REQUIREMENTS, CONSULT SERVICE INSTRUCTIONS.
FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN INJURY OR PROPERTY DAMAGE.
P70644
All Units
P70644
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Page 3
OPERATION AND MAINTENANCE
Operators must be familiar with all sections of this manual to
understand the operation of the unit. Hot water, steam and electricity can be hazardous.
Check motor nameplate for any lubrication requirements. Pumps require no lubrication.
NOTICE / AUTO RESTART
Single phase motors will restart automatically after thermal
overload protector trips. Overload thermal relays in starters must be reset manually.
A properly installed unit should function unattended for long periods of time. Periodic checks to assure proper operations are highly recommended. Refer to trouble shooting section when necessary.
A variety of control options are available and are furnished in accordance with user specifications. Refer to wiring diagrams (when furnished) to determine control switch settings.
The inlet strainer (when furnished) is intended to protect the pump and system. Periodic cleaning should be included in the maintenance schedule. Check frequently in new systems.
PUTTING THE UNIT INTO SERVICE
1. Assure that the unit is piped in accordance with instructions
on page 2.
2. Isolate tank before performing any system leak test. Do not pressurize the tank as part of the leak test. Failure to do this can result in serious injury or death.
3. Check floats and alternators for free operation.
4. Check power leads in accordance with wiring diagram enclosed in control cabinet (when furnished).
5. Install drain plugs.
6. Fill receiver half full of water to prime pump(s) and prevent possible damage to pump seals. Avoid freezing conditions after unit receiver has been filled.
7. Check for proper rotation of all three phase motors. Rotation must be clockwise looking down on the motor as indicated by directional arrow on pump casting. If pump runs backwards, interchange two wires (3 phase only).
8. Throttle plug cock in discharge line until pressure at pump (while pump is discharging) approaches pump rated pres­sure. Tighten plug nut to secure adjustment.
9. Connect the water make-up assembly to city water. Use piping at least as large as valve piping provided. Provide a manual fill valve if not included on the unit.
10.
Boiler Level Controls
Assure that the controls on and related to the boiler match
the control systems provided on the unit (see the wiring dia­gram furnished) (applicable when electrical control panel is furnished).
11. Check that the pump discharge pressure exceeds the max­imum operating pressure of the boiler.
12. Manually move the make-up water float indicator and assure that the make-up solenoid admits water.
13. Manually move the low water cut-off float switch indicator to check for pump shut-off.
14. Remove start-up label (below) from panel (if applicable) after complying with instructions.
15. If possible, observe operation thru several cycles.
WARNING: EXPLOSIBLE
Do not pressurize receiver. Isolate receiver during leak
test. Do not plug overflow. Do not restrict vent opening to atmosphere. Open valves slowly. Failure to follow these instructions could result in serious injury or death.
WARNING: HIGH VOLTAGE
Disconnect and lock out power before connecting or
servicing unit. Failure to follow these instructions could result in serious injury or death.
CAUTION: DO NOT RUN DRY.
SEAL DAMAGE MAY OCCUR.
Inspect pump seal regularly for leaks. Replace as required.
Failure to follow these instructions could result in injury or property damage.
CAUTION: DO NOT REVERSE
Reverse operation can cause extensive damage to
pumps. Jog the motor to test for direction of rotation. Failure to follow these instructions could result in injury or property damage.
WARNING: EXPLOSIBLE
Do not pressurize receiver. Isolate receiver during leak
test. Do not plug overflow. Do not restrict vent opening to atmosphere. Open valves slowly. Failure to follow these instructions could result in serious injury or death.
WARNING: HIGH VOLTAGE
Disconnect and lock out power before connecting or
servicing unit. Failure to follow these instructions could result in serious injury or death.
CAUTION: SUBSEQUENT DAMAGE
A unit showing symptoms of possible problems
(overflow, noise, leaks, vibrations, continual operation, etc.) must be corrected immediately. Failure to follow these instructions may result in full liability for subsequent injury or property damage.
SAFETY INSTRUCTIONS
SEE COVER OF THIS MANUAL
ELECTRICIAN/INSTALLER/OPERATOR
REMOVE AND DESTROY THIS TAG AFTER
1. ASSURING THAT ALL PUMPS ROTATE CLOCKWISE PER ARROWS CAST ON VOLUTES. (JOG PUMP MOMENTARILY TO TEST – INTERCHANGE ANY TWO MOTOR POWER WIRES TO REVERSE 3PH MOTORS.)
2. ASSURING THAT SHIPPING LOCKS HAVE BEEN REMOVED FROM ALL FLOAT SWITCHES.
WARNING: EXPLOSIBLE
The installed boiler feed unit becomes an integral part
of the boiler system. Boiler operation and maintenance requires specific skills and training and may require licensing or certification. The boiler feed unit must be operated and maintained so as not to jeopardize the boiler operation. Failure to follow these instructions could result in serious injury, death or extensive property damage.
WARNING: MAINTAIN BOILER SAFETY FEATURES
When connecting the boiler feed unit to the boiler,
assure that all boiler safety controls (burner cutoff, etc.) are and remain operational. With certain control arrangements, dedicated boiler controllers are required for the boiler feed pumps. Failure to follow these instructions could result in serious injury, death or extensive property damage.
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4
TROUBLE SHOOTING PROCEDURES
All units are thoroughly tested at the factory before shipment.
They should operate satisfactorily without further adjustment if properly installed and providing they have not been damaged by rough handling in transit. If system or unit performance is not satisfactory, refer to the following check list.
Pump Will Not Start
1. The power supply has been interrupted, disconnect switch
is open, or selector switch is improperly positioned.
2. Incorrect voltage for motor. Check voltage and wiring with motor characteristics.
3. Incorrect starter coil for power supply.
4. The overload relays and the starter have tripped out and must be reset. Ambient temperature may be too high.
5. Check pump controls or other controls for proper operation.
6. Wiring to control cabinet is incorrect or connections are loose.
7. The strainer is dirty thus retarding flow. Clean periodically.
8. Boiler is full or boiler control switch is defective.
9. The low water cut-off float switch is open due to low water, incorrect adjustment or failure.
Pump Runs Continuously
1. Pump is running backward. Rotation of three phase motors
may be corrected by interchanging any two of the three wires. Rotation should be clockwise looking down on motor.
2. Steam traps are blowing through causing condensate to return at excessive temperatures. This may reduce the capacity of pump below its rating, depending on the unit and type of pump furnished. Traps should be repaired or replaced.
3. Pump discharge pressure is less than operating pressure of the boiler.
4. The total required pressure at the pump discharge is greater than the pressure for which the pump was designed. Check the total pressure which includes atmospheric pressure, the friction head and the static head.
5. A valve in the discharge line is closed or throttled too tightly. Check valve is installed backwards.
6. The impeller eye is clogged.
7. Pump is too small for system.
Boiler Feed Pump is Noisy
1. The pump is working against a lower pressure than
designed for. While pump is discharging, adjust plug cock in discharge line until pressure at pump approaches pump rated pressure.
2. Excessive condensate temperature. Correct system conditions. However, this applies to certain units only; others are designed to handle boiling water.
3. Magnetic hum or bearing noise in motor. Consult motor manufacturer’s authorized service station nearest unit location.
4. Starter chatters. Trouble is caused by low line voltage, poor connections, defective starter coil, or burned contacts.
5. Pump is running backward.
The System is Noisy
1. Banging in the steam mains is usually caused by steam
imploding in condensate lying in low points in lines. These problems can be eliminated by dripping low points, prop­erly supporting the pipe, or by increasing th pitch of the lines.
2. Improper dripping of the steam mains and risers; where there is a rise in the steam main, or where it branches off into a riser, a drip trap must be installed in the drain line.
3. The piping is too small to drain properly.
4. A defective trap is holding condensate in steam supply line.
5. Defective check valve permits steam to vent thru pump into the boiler feed tank.
6. A priming boiler is discharging water with the steam. Consult boiler manufacturer.
Excessive Water Overflow From Unit
1. Receiver sized too small to accommodate system surges.
2. Water make-up valve open or float switch set too high.
3. Water make-up valve leaks.
Morton Grove, Illinois 60053
TM
TM
SERIES
MODEL
SERIAL
GPM PSI PUMP
CFM IN HG. PUMP
DWGS
POWER V. PH. HZ 60
CONTROL V. PH. 1 HZ 60
TOTAL LARGEST MOTOR F.L. AMP F.L. AMP
DN0016
DEALER SERVICING
If trouble occurs that cannot be rectified, contact your local
B&G representative. He will need the following information in order to give you assistance.
1. Complete nameplate data of pump and motor. SEE RATING NAMEPLATE.
2. Suction and discharge pipe pressure gauge readings.
3. Ampere draw of the motor.
4. A sketch of the pump hook-up and piping.
5. Provide complete information on boiler control switches and any motorized or solenoid valves in the boiler feed piping.
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5
These close coupled vertical centrifugal pumps are equipped with mechanical seals. If system has not been properly cleaned prior to installation of pump, foreign matter such as dirt, pipe scale, core sand, etc. may clog the impeller and damage the seal. A strainer is recommended in return line to pump.
Pump
must not be operated dry.
Seals may be damaged if operated
without water present.
1. Close inlet line gate valve and operate pump momentarily
to remove as much liquid as possible from pump. Close discharge line gate valve.
2. Shut-off and lock-out power.
3. Disconnect wiring to motor.
4. Make sure unit is cool enough that pump can be handled
safely. Open receiver drain to remove remaining liquid.
5. Loosen the motor to pump volute fasteners. Assure that
pressure is relieved per caution note.
6. Remove four capscrews (7) holding pump case to motor
and lift motor and impeller out of pump case.
7. Remove pump/motor assembly and place on work bench.
8. Hold top end of motor shaft with large screwdriver via
screwdriver slot in shaft and back of impeller (counter­clockwise) with a rectangular bar or other flat tool inserted between the vanes of the impeller.
9. Remove the rotating part of the mechanical seal from the
end of the shaft.
10. Remove seal holder (2) with stationary ceramic part of mechanical seal and cup rubber from the end of the shaft.
11. Remove stationary ceramic part of mechanical seal and cup rubber from recess in seal holder.
12. To install new seal, proceed as follows: Clean recess in seal holder thoroughly. Orient motor so that conduit opening on motor is to the left when looking at motor shaft. Replace seal holder on the face of the motor maintaining concen­tricity with motor face. Place new ceramic part of seal in the cup rubber over motor shaft and press firmly into recess of seal holder by hand, making certain both parts bottom evenly. If assembly cannot be bottomed with fingers place a wooden or cardboard tube over shaft onto ceramic and push into place. Using a clean, lint-free cloth, wipe the mat­ing surfaces of the seal clean of any foreign matter. Moisten the carbon section of the rotating part of the seal and place onto shaft to seat against the ceramic. Place seal spring onto shaft.
13. Hold motor shaft as described in #8 and replace the impeller on the shaft (clockwise rotation) making sure it is tight.
14. Orient motor for pump reassembly with conduit opening to the left. When mounting the pump case, discharge should be 90˚ to the right of conduit opening on motor. Use care to insure tight gasket fit to prevent water leakage.
15. Replace four capscrews (7). Tighten down capscrews evenly to avoid damage.
16. Reconnect pump bleed line (where applicable) and motor wiring.
17. Close drain and slowly open inlet valves. See warning.
18. Jog to check motor rotation. See caution.
19. Observe operation thru several cycles.
1. Motor
2. Seal Holder
3. Seal
4. Impeller
5. Gasket
6. Case
7. Capscrew (motor to volute)
8. Wear Ring
9. Pipe Plug
10. Slinger
1
10
7
3
4
8
6
9
5
2
PUMP SERVICE INSTRUCTIONS FOR 609PF CENTRIFUGAL PUMPS
FIG. 2
2DPF01
WARNING: EXPLOSIBLE
Do not pressurize receiver. Isolate receiver during leak
test. Do not plug overflow. Do not restrict vent opening to atmosphere. Open valves slowly. Failure to follow these instructions could result in serious injury or death.
WARNING: HIGH VOLTAGE
Disconnect and lock out power before connecting or
servicing unit. Failure to follow these instructions could result in serious injury or death.
CAUTION: PRESSURIZED SYSTEM
Operating system may contain very hot water under
pressure. Close inlet and open drains before servicing. When servicing,
loosen screws and move components to
assure pressure is relieved before
removing screws. Keep
drains open during servicing. Failure to follow these instructions could result in injury or property damage.
CAUTION: DO NOT RUN DRY.
SEAL DAMAGE MAY OCCUR.
Inspect pump seal regularly for leaks. Replace as
required. Failure to follow these instructions could result in injury or property damage.
CAUTION: DO NOT REVERSE
Reverse operation can cause extensive damage to
pumps. Jog the motor to test for direction of rotation. Failure to follow these instructions could result in injury or property damage.
CAUTION: HOT SURFACES
Surfaces are hot when system is in operation. Do not
touch hot receiver, let unit cool before servicing. Failure to follow these instructions could result in injury or property damage.
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6
PUMP SERVICE INSTRUCTIONS FOR CENTRIFUGAL PUMPS (EXCEPT ‘B’ OR 609)
Vertical mounting puts motor above floor dirt and water
Close coupled centrifugal pumps are designed for years of
trouble free service. Units have mechanical shaft seals.
1. Close inlet gate valve and operate pump momentarily to remove as much liquid as possible from pump. Close dis­charge line gate valve.
2. Shut-off and lock out power.
3. Make sure unit is cool enough that pump can be handled safely. Open drain to remove remaining liquid.
4. Carefully remove pump drain plug and bleed line. Wait for complete drainage.
5. Loosen the motor bracket to pump volute capscrews. Assure that the pressure is relieved per caution note.
6. Complete the removal of the hardware. Remove pump/ motor assembly and place on work bench.
7. Remove self locking stainless steel capscrews and stain­less steel washer (or self locking brass cap nut and washer) that secure the impeller in place.
8. To remove impeller from motor shaft proceed as follows: (1) Keyed Shafts. Remove impeller with gear puller or other
means which will not damage impeller or bend motor shaft.
(2) Threaded Shafts. Hold end of motor shaft opposite
pump with large screwdriver or other suitable tool and back impeller off with a rectangular bar or other flat tool inserted between the vanes of the impeller.
9. Remove rotating part of seal from shaft, being careful not break carbon face.
10. Remove capscrews holding motor bracket to motor and remove bracket.
11. Remove stationary part of seal assembly, being careful not to chip or break ceramic seal.
12. To install seal proceed as follows: (1) Clean recess in bracket thoroughly. Coat recess and
rubber portion of seat with soap solution. Press seat into recess firmly by hand making certain both parts bot­tom evenly. If seal cannot be bottomed with fingers place cardboard shipping disc on ceramic and force into place with flat tool.
(2) Carefully place bracket in position on motor shaft with-
out displacing ceramic seat and secure bracket to motor with capscrews.
(3) Place motor vertically with pump end up. Do not attempt
assembly of seal and impeller with shaft horizontal.
(4) The carbon of rotating part of seal should not be loose.
If it is, hold in place with grease, Using clean, lint free cloth, wipe mating surfaces perfectly clean. Soap shaft and push seal onto shaft so that carbon will contact ceramic seal. If spacer is required, use grease to cause spacer to adhere to bottom of seal after seal has been put on shaft. Be sure spacer is on larger diameter of shaft so that will not catch between shoulder and impeller.
13. Replace impeller on shaft. Replace stainless steel washer and secure impeller with capscrew or cap nut.
14. Place new gasket on pump volute and reassemble motor and pump subassembly on pump volute.
15. Reconnect pump bleed line and motor wiring.
16. Close drain and slowly open inlet valves. See warning.
17. Jog to check motor rotation. See caution.
18. Observe operation thru several cycles.
Pump Motor
Water Slinger
Mechanical Seal
Air Relief
Head Ring
Head Gasket
Motor Bracket
Volute
Washer
Wearing Ring
Motor Shaft Keyed or Threaded
Locking Cap Nut or Capscrew
Impeller
CUT-AWAY VIEW OF MECHANICAL
SEAL TYPE PUMP
CAUTION: PRESSURIZED SYSTEM:
Operating system may contain very hot water under
pressure. Close inlet and open drains before servicing. When servicing,
loosen screws and move components to
assure pressure is relieved before
removing screws. Keep
drains open during servicing. Failure to follow these instructions could result in injury or property damage.
WARNING: HIGH VOLTAGE
Disconnect and lock out power before connecting or
servicing unit. Failure to follow these instructions could result in serious injury or death.
CAUTION: HOT SURFACES
Surfaces are hot when system is in operation. Do not
touch hot receiver, let unit cool before servicing. Failure to follow these instructions could result in serious injury or death.
WARNING: EXPLOSIBLE
Do not pressurize receiver. Isolate receiver during leak
test. Do not plug overflow. Do not restrict vent opening to atmosphere. Open valves slowly. Failure to follow these instructions could result in serious injury or death.
CAUTION: DO NOT RUN DRY.
SEAL DAMAGE MAY OCCUR.
Inspect pump seal regularly for leaks. Replace as
required. Failure to follow these instructions could result in injury or property damage.
CAUTION: DO NOT REVERSE
Reverse operation can cause extensive damage to
pumps. Jog the motor to test for direction of rotation. Failure to follow these instructions could result in injury or property damage.
Page 7
1. Close pump isolation valve or system return line valve.
Operate pump momentarily to discharge as much water as possible. Close pump discharge valve.
2. Shut-off and lock out power.
3. Make sure unit is cool enough that pump can be handled safely. Open drain to remove remaining liquid.
4. Carefully remove pump drain plug and bleed line. Wait for complete drainage.
5. Loosen both the discharge connection and the suction housing to pump volute fasteners. Assure that pressure is relieved per caution note.
6. Complete the removal of the above hardware. Remove pump/motor assembly and place on work bench.
7a. Remove the suction housing capscrews and separate the
pump/motor assembly from the suction housing. Note, the diffuser should separate from the suction housing to allow the pump/motor assembly to be removed.
7b. Remove propeller, propeller stem and diffuser from the
assembly as follows: (1) Threaded Motor Shafts (3Hp and less). Remove pro-
peller lock nut. Remove propeller with propeller stem as an assembly with the diffuser. To install a new propeller, remove the propeller set screws and separate from the stem.
(2) Keyed Motor Shafts (5Hp and larger). Remove propeller
set screws. Remove propeller, remove diffuser, and unscrew the propeller stem.
8. Remove capscrews holding motor bracket and pump
volute together. Remove motor and bracket assembly from volute by lifting straight away from volute.
9a. To remove impeller from motor shaft proceed as
follows: (1) Keyed Shafts. Remove impeller with gear puller or
other means which will not damage impeller or bend motor shaft.
(2) Threaded Shafts. Hold end of motor shaft opposite
pump with large screwdriver or other suitable tool and back impeller off with a rectangular bar or other flat tool inserted between the vanes of the impeller.
9b. Remove rotating part of seal from shaft, being careful not
to break carbon face.
10. Remove capscrews holding motor bracket to motor and remove bracket.
11. Remove stationary part of seal assembly, being careful not to chip or break ceramic seal.
12. To install seal proceed as follows: (1) Clean recess in bracket thoroughly. Coat recess and
rubber portion of seat with soap solution. Press seat into recess firmly by hand making certain both parts bottom evenly. If seal cannot be bottomed with fingers place cardboard shipping disc on ceramic and force into place with tool.
(2) Carefully place bracket in position on motor shaft with-
out displacing ceramic seat and secure bracket to motor with capscrews.
(3) Place motor vertically with pump end up. Do not
attempt assembly of seal and impeller with shaft horizontal.
(4) The carbon of rotating part of seal should not be
loose. If it is, hold in place with grease. Using clean, lint free cloth, wipe mating surfaces perfectly clean. Soap shaft and push seal onto shaft so that carbon with con­tact ceramic seal. If spacer is required, use grease to cause spacer to adhere to bottom of seal after seal has been put on shaft. Be sure spacer is on larger dia­meter of shaft so that it will not catch between shoulder and impeller.
13. Place impeller on shaft. Make sure impeller is seated.
14. Reassemble volute to bracket.
15. Install stem over drive pin in impeller eye. Tighten lock nut.
16. Set stem to .004 TIR.
17. Install diffuser.
18. Install propeller and tighten set screws.
19. Using new gasket and noting alignment pin, install assembly on suction housing.
20. Install suction housing and discharge fasteners and tighten.
PUMP SERVICE INSTRUCTIONS FOR SERIES B35 PUMPS
CAUTION: PRESSURIZED SYSTEM
Operating system may contain very hot water and
steam under pressure. Close inlet and open drains before servicing. When servicing,
loosen screws and move compo-
nents to assure pressure is relieved before
removing screws.
Keep drains open during servicing. Failure to follow these instructions could result in injury or property damage.
CAUTION: HOT SURFACES
Surfaces are hot when system is in operation. Do not
touch hot receiver, let unit cool before servicing. Failure to follow these instructions could result in serious injury or death.
WARNING: HIGH VOLTAGE
Disconnect and lock out power before connecting or
servicing unit. Failure to follow these instructions could result in serious injury or death.
7
IMPELLER AXIAL FLOW PROPELLER
PROPELLER SET SCREW
SUCTION HOUSING
HEAVY DUTY BALL BEARING MOTOR
WATER SLINGER
MECHANICAL SEAL
STAINLESS STEEL SHAFT
MOTOR BRACKET
PUMP VOLUTE W/WEAR RING
IMPELLER
2DPB01
Page 8
Xylem Inc.
8200 N. Austin Avenue Morton Grove, Illinois 60053 Phone: (847) 966-3700 Fax: (847) 965-8379 www.bellgossett.com
Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries. © 2013 Xylem Inc. DN0132F April 2013
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