Page 1
Domestic® Pump
Vacuum and Boiler Feed Units
INSTRUCTION MANUAL
DN0137
REVISION D
Series VCMD
™
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
DO NOT PRESSURIZE TANK.
ISOLATE TANK DURING LEAK TEST.
DO NOT RESTRICT VENT.
DO NOT PLUG OVERFLOW.
OPEN INLET VALVES SLOWLY.
EXPLOSIBLE
(2) All Units
DN0483 (Small) - DN0484 (Large)
DO NOT USE AS A FLASH TANK.
FAILURE TO FOLLOW
INSTRUCTIONS COULD RESULT
IN SERIOUS INJURY OR DEATH.
EXPLOSIBLE
DURING LEAK TEST
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.
WARNING
ISOLATE TANK
(2) All Units
DN0485 (Small)
DN0486 (Large)
TM
SERIES HV
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
DN0116 Units with Panel
TM
Morton Grove, Illinois 60053
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
Page 2
2
Domestic®Series VCMD™Combination Boiler Feed
and Vacuum Units
Style CMHD-A vacuum unit mounted on horizontal steel boiler feed receiver.
Style CMHD-B vacuum unit with separate horizontal steel boiler feed receiver.
Style CMVD-A vacuum unit mounted on vertical steel boiler feed receiver.
Style CVM vacuum unit with separate cast iron boiler feed receiver.
FIG. 1 REPRESENTATIVE PIPING DIAGRAM - VCMD
Style CMHD-A with vacuum unit mounted on
horizontal steel boiler feed receiver, and returns
above receiver inlet. Refer to separate diagram
for piping between boiler feed pump(s) and
boiler(s).
FIG. 2 REPRESENTATIVE PIPING DIAGRAM - VCMD
Style CMHD-B with separate vacuum unit and
horizontal steel boiler feed receiver, returns above
receiver inlet. Refer to separate diagram for piping
between boiler feed pump(s) and boiler(s).
FIG. 3 REPRESENTATIVE PIPING DIAGRAM - VCMD
Style CVM with separate vacuum unit and cast iron
boiler feed receiver, returns above receiver inlet. Refer
to separate diagram for piping between boiler feed
pump(s) and boiler(s).
Page 3
DESCRIPTION
The Series VCMD family of units consists of various combinations of
boiler feed units combined with Domestic Series MJ vacuum producers. The vacuum producer may be mounted directly on the boiler
feed unit (STyle A) or the units may be independently mounted with field
piping between the units (Style B). The boiler feed units can be constructed with cast iron or steel receivers in many of the standard configurations offered as Domestic boiler feed units.
The vacuum producer acts in response to selector switch settings and
system vacuum also functions to remove excess water from the boiler
feed tank. Various controls are supplied in accordance with system
specifications and system requirements. Electrical panels are normally
supplied and specific wiring diagrams are supplied with each vacuum
producer electrical panel.
The boiler feed system functions like a standard vented boiler feed system. Again, various control options are available to match system
specifications. Electrical panels and electrical diagrams are normally
furnished.
The boiler feed units are designed to pump water into an operating
boiler. The pumps are controlled by level controls on the boiler. Low
water cut-off switches and alarms are often supplied (optional).
Receivers are non-code cast iron or steel.
PRELIMINARY INSPECTION
Assure that there is no shipping damage.
Assure that nameplate ratings agree with job specifications and actual
conditions.
HANDLING
Use caring in installing unit.
LOCATION
Place unit for easy access to all parts. Allow adequate space for
servicing. Check ambient conditions.
NOTICE/TEMPERATURE LIMITS
Motors are designed to operate in 104°F max. ambient. Insulate or
ventilate as required.
BOILER FEED SYSTEM
PIPING (General)
Pipe the unit per the Piping Diagram. Locate and support piping so as
to not load the pump discharge.
PIPING (Return)
Gravity return lines from the system must be properly pitched down to
unit inlet. Returns must also be trapped to prevent steam entry into the
unit. An inlet basket strainer is recommended.
FLOAT SWITCHES
Floats are locked in place to prevent damage during shipment. Remove
shipping locks. Check factory settings. Floats are adjustable for various
levels of operation. The water make-up float switch should “make” at a
higher level than low water cut-off switch “breaks”.
VACUUM SYSTEM
PIPING (General)
Pipe the unit per the Piping Diagram shipped with the unit or as shown
herein. Locate and support piping so as to not load the pump discharge.
PIPING (Suction) (Style B)
Use a suction line at least as large as the unit inlet fitting. Vacuum
storage tanks will reduce system surges or short cycling and a vertical
tank can trap liquids and solids.
PIPING (Vent)
Install a vent pipe to atmosphere. Pipe to be size of vent port on unit.
Do not restrict or reduce vent opening or exceed 20 feet vertical height
unless an overflow connection is provided.
PIPING (Overflow)
Pipe overflow port to drain.
VACUUM SWITCH ADJUSTMENTS
Vacuum switches, when furnished, are factory adjusted and tested for
the specified operating range. If settings must be readjusted, refer to
manufacturer’s instructions.
HURLING WATER MAKE-UP AND CONTROL
The hurling water level is automatically controlled by a solenoid valve
actuated by a float switch.
Connect the water make-up assemblies to city water. Use piping at
least as large as the valve piping provided. Install a manual fill valve if
not included on the unit. The vacuum producer and the boiler feed unit
have separate make-ups.
To operate at a high vacuum, the hurling water must be at a low temperature resulting in a low vapor pressure. Cooling water can be automatically admitted by using an optional temperature limit switch. This
switch actuates the solenoid valve if the temperature rises above a
preset point.
The optional condensate Temperature Limit Switch will stop normal
operation of the vacuum unit when condensate exceeds the set point
temperature (usually 160ºF). Vacuum is not normally required when the
system is up to temperature and operation of the vacuum pumps with
hot condensate results in condensate loss due to evaporation.
INTERCONNECTING PIPING
On style B units, the interconnecting piping between the boiler feed
unit and the vacuum producer must be the size of the vacuum producer inlet. The two vacuum inlets on duplex vacuum producers must
be connected to the boiler feed tank.
ELECTRICAL WIRING & CONTROLS
Connect power wiring per NEC. Recheck nameplate vs. Specifications
and conditions. All single phase motors have internal thermal
protection.
Three phase motors must be use starters with properly sized overload
relays. Overload relays furnished are designed for manual reset.
EQUALIZING LINE
A vacuum may be formed on radiation side of system when steam
stops flowing in mains. This vacuum may be higher than return line
vacuum, which would prevent condensate from flowing back to pump.
To correct this in an unzoned system, install equalizer line as shown in
Figures 1 thru 3. To correct this in a zoned system, also install equalizer line for each zoned section or install a vacuum breaker on supply
line on radiation side of each zone valve.
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.
3
CAUTION: UNIT LIFTING EYE
Use unit lifting eyes only to lift unit as shipped from factory.
Unit must be empty and disconnected from pipes, anchors and
other restraints. Use proper rigging procedures. Failure to follow
these instructions could result in injury or property damage.
CAUTION: NOT A CHEMICAL PUMP
Inject boiler feed compounds from chemical feed tank into
boiler feed piping – never into condensate tank. Failure to follow
these instructions could result in injury or property damage.
WARNING: HIGH VOLTAGE ELECTRICITY
Disconnect and lock out power before connecting or servic-
ing unit. Failure to follow these instructions could result in injury or
property damage.
FIG. 4 EQUALIZING CONNECTIONS FOR ZONED SYSTEMS
ZONE CONTROL
VALVE
STEAM MAIN
M
TO ZONE
RETURN MAIN
Page 4
PUTTING THE UNIT INTO SERVICE
1. Assure that the unit is piped in accordance with instructions.
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 for free operation. Assure that shipping locks have
been removed.
4. Check power leads in accordance with wiring diagram enclosed in
control cabinet (when furnished).
5. Install drain plugs.
6. Fill receiver (upper compartment on Series VLR) 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 assemblies to city water. Use piping at
least as large as the valve piping provided. Provide a manual fill
valve if not included on the unit. Vacuum producer and boiler feed
unit have separate make-ups.
10. Vacuum switches are factory set per job specifications and readjustment should not be necessary. Refer to switch manufacturer’s literature for details of adjusting procedure. If resetting is
required, it is helpful to disconnect wiring and set one switch at a
time. The “lead” switch must make and break at a slightly deeper
vacuum than the “lag” switch.
Typical vacuum switch settings are as follows:
Switch Make Break
LEAD 3" 8"
LAG 2
1
/2"8"
11. 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).
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.
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.
4
WARNING: HIGH VOLTAGE
Disconnect and lock out power before connecting or servic-
ing unit. Failure to follow these instructions could result in serious
injury or death.
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.
OVERVIEW
SIMPLE AUTOMATIC OVERFLOW CONTROL
If excess condensate enters the boiler feed receiver, the water level will
rise above a preselected height, and float switch will actuate the air
pump. The resulting vacuum draws excess water through the air suction line into the separation chamber of the air pump from where it simply overflows to a drain. An overflow pump is not necessary or recommended unless the drain is located above the overflow of the air pump.
If such a drain exists, an overflow pump can be furnished. The float
switch will then start the overflow pump instead of the air pump.
FIG. 5 ADJUSTMENT OF OVERFLOW CONTROL FLOAT SWITCH
1. Close inlet valve. Set all selector switches to “Off”.
2. Add water to condensate receiver until it is flooded.
3. Operate air pump to bring water level to bottom of air suction (lift)
pipe; turn selector switch(es) to “Off”.
4. Adjust float switch to open about
1
/2" above this level.
5. Set the other quadrant as close as possible for minimum differential.
OVERFLOW
SWITCH
CONTACTS
CLOSE
1/2"
CONTACTS
OPEN
ADJUST SWITCH
FOR MINIMUM
DIFFERENTIAL
AIR
VENT
VACUUM PUMP IMPELLER
MULTI-JET
NOZZLE
VENTURI
VACUUM SWITCHES
AIR
WATER
AIR & WATER
VACUUM PUMP
SOLENOID VALVE FOR
HURLING WATER
CONTROL
OVERFLOW (GRAVITY)
FLOAT SWITCH FOR
HURLING WATER
CONTROL
AIR SUCTION
CHECK VALVE
DEAERATING CASCADE
BAFFLE
HURLING
WATER
AIR
SUCTION
AND OVERFLOW
CONDENSATE
BOILDER FEED RECEIVER
BOILER FEED
PUMPS
INLET
STRAINER
(OPTIONAL)
MECHANICAL
WATER MAKE
UP VA LVE
Page 5
HURLING CHAMBER FLOAT SWITCH ADJUSTMENT
The switch which controls the hurling water makeup valve is located
inside the float housing near the vacuum unit overflow.
The switch is under a triangular cover plate which is retained by one #6
screw (loosen bolts retaining the cover edges only if necessary). The
actuating cam can be rotated for testing by using a screwdriver in the
slot provided.
Adjusting the switch location so that the switch snaps at approximately mid-range of the cam travel. The #6 screw near the cam goes
thru a slot in the switch mounting plate. Loosen this screw (and the
farthermost screw thru the switch) to permit adjustment of the switching position. Tighten screws and recheck operation after making any
adjustment.
The cam should be positioned on the shaft for maximum switch roller
movement in operation. The cam is retained by a socket set screw.
Replacement seal tube assemblies are available in case of leakage
around the float pivot shaft.
OPERATION AND MAINTENANCE
Operators must be familiar with all sections of this manual to under-
stand the operation of the unit.
Hot water, steam and electricity can be hazardous.
LUBRICATION
The only pump bearing requiring lubrication is the ball bearing in the
motor support just below the flexible coupling. It has a reservoir, which
is filled with moisture resistant high temperature grease.
Remove pipe plug in motor support and add approximately 3 ounces
of Shell Alvania RL 2 grease (or equivalent) from once a year (normal)
to twice a year for extremely hot conditions. Do not use ordinary
grease.
NOTICE/AUTO RESTART
Single phase motors will restart automatically after thermal overload
protector trips.
Overload thermal relays in starters must be reset manually.
GAGE GLASS MAINTENANCE (Vented Systems)
Clean gage glass as required using commercial glass cleaner. Dilute
muratic acid may be used if required (observe handling precautions).
Never clean gage glass with wire brushes, scrapers or harsh abrasives.
Do not reuse gage glass or packing or seals.
Immediately replace glass which is broken, cracked, chipped,
scratched or otherwise damaged. Inspect periodically with a bright
concentrated light. Anything which glistens and catches the fingernail
or any star-shaped or crescent-shaped mark which glistens is cause
for replacement. Any gage glass which appears cloudy or roughened
and will not respond to cleaning procedures should be replaced.
When replacing gage glass, use new packings specified for this use.
Install glass with sufficient end clearance for expansion (keep glass to
metal clearance at each end) and tighten nuts just enough to avoid
leakage (do not over tighten).
INSPECTIONS
A properly installed unit should function unattended for long periods of
time. Periodic checks to assure proper operation 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.
WARNING: EXPLOSIBLE
The installer 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 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.
5
12. Check that the pump discharge pressure exceeds the maximum
operating pressure of the boiler.
13. Manually move the make-up water float indicator and assure that
the make-up solenoid admits water.
14. Manually move the low water cut-off float switch indicator to check
for pump shut-off.
15. Make sure that the make-up valve on the vacuum producer has
operated and filled the hurling chamber to 2" to 6" below the overflow (recommended).
16. Remove start-up label (below) from panel (if applicable) after complying with instructions.
17. If possible, observe operation thru several cycles.
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.
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: HIGH VOLTAGE
Disconnect and lock out power before connecting or servic-
ing 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
FLOAT ROD
MICRO SWITCH
CAM
FLOAT BALL
CAM SET
SCREW
Page 6
6
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 in 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 of makeup system.
PUMP RUNS CONTINUOUSLY
1. Pump is running backward. Rotation of three phase motor 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 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.
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. The piping is too small to drain properly.
4. A defective trap is holding condensate in steam supply line.
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 the pitch of the line.
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. Steam blowing thru a defective trap.
7. A priming boiler is discharging water with the steam. Consult boiler
manufacturer.
TROUBLE SHOOTING PROCEDURES - BOILER FEED SYSTEM
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 in 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. System has vacuum and vacuum switches are open.
8. Temperature limit switch open due to high condensate temperature.
9. Temperature limit switch improperly wired.
PUMP RUNS CONTINUOUSLY
1. Pump is running backward. Rotation of three phase motor may be
corrected by interchanging any two of the three wires. Rotation
should be clockwise looking down on motor.
2. System flow or leaks prevent the unit from developing design vacuum. Vacuum system must be tight.
3. System is drawing vacuum greater than the vapor pressure of liquid
– the liquid is being boiled and then condensed in the vacuum unit.
4. Holes in the nozzle plate are plugged or worn and the system will
not develop vacuum. Inspect and clean nozzle plates.
SYSTEM OVERFLOWS
1. System may be normal. Cooling water is required to lower vapor
pressure of hurling water to be able to draw deep vacuum.
2. Temperature limit switch is set lower than required and adds unnecessary water.
3. The design vacuum is greater than the vapor pressure of a liquid
within the system. The liquid is being boiled from the system and
condensed in the hurling chamber.
4. Temperature limit switch is wired incorrectly.
5. Float switch is improperly adjusted. Remove float switch cover
plate and readjust the cam activating the electrical switch.
6. Boiler feed receiver sized too small to accommodate system
surges.
7. water make-up valve open or float switch set too high.
8. Water make-up valve leaks.
SYSTEM STARTS AND STOPS RAPIDLY
1. Pumping against a small closed system. Add vacuum storage tank
or reset vacuum switches.
BOTH PUMPS RUN
1. Improper vacuum switch adjustment. Readjust lead vacuum switch
to make and break at deeper vacuums than the lag switch. Refer to
manufacturers’ literature.
2. Low vacuum in system causing lag system switch to be closed.
TROUBLE SHOOTING PROCEDURES - VACUUM PRODUCER
Page 7
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. Prevent the motor shaft from turning by inserting a large screwdriver into the screwdriver slot located under the plug on the rear
motor endbell. Back the impeller off (counter clockwise) using a
rectangular bar or other flat tool inserted between the impeller
vanes.
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 midway between motor lugs. 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 the conduit opening on motor. Use care to insure tight
gasket fit to prevent water leakage. When replacing pump case, the
wire spacer eye should seat in pump case notch for fit up. If this
does not occur inspect for proper alignment and reassemble.
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
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.
7
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.
1
10
7
3
4
8
6
9
5
2
PUMP SERVICE INSTRUCTIONS FOR SERIES C35,
MODEL 609PF CENTRIFUGAL PUMPS
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.
Page 8
8
PUMP SERVICE INSTRUCTIONS FOR CENTRIFUGAL PUMPS (EXCEPT ‘B’ OR 609)
Vertical mounting puts motor above floor direct 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 tool.
(2) Carefully place bracket in position on motor shaft without
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.
CAUTION: PRESSURIZED SYSTEM
Operating system may contain very hot water. Close inlet
and open drains before servicing. When servicing,
loosen screws
and move components to assure pressure is relieved before
remov-
ing
screws. Keep drains open during servicing. Failure to follow
these instructions could result in injury or death.
CAUTION: HOT SURFACE
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 servicing
unit. 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 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 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 serious injury or
death.
VOLUTE
IMPELLER
WATER
SLINGER
VIEW OF
THREADED
IMPELLER
MECHANICAL
SEAL
MOTOR BRACKET
WEAR RING
2DPF03
Page 9
9
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 the pressure is relieved per
caution note.
6. Complete the removal of the 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.
(1) Threaded Motor Shafts (3Hp and less). Remove propeller 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.
7b.Remove propeller, propeller stem and diffuser from the assembly
as follows:
8. Remove capscrews holding motor bracket and pump volute
together. Remove motor and bracket assembly from the volute by
lifting straight away from volute.
9. 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.
10. Remove rotating part of seal from shaft, being careful not break
carbon face.
11. Remove capscrews holding motor bracket to motor and remove
bracket.
12. Remove stationary part of seal assembly, being careful not to chip
or break ceramic seal.
13. 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 without
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.
14. Place impeller on shaft. Make sure impeller is seated.
15. Reassemble volute to bracket.
16. Install stem over drive pin in impeller eye. Tighten lock nut.
17. Set stem to .004 TIR.
CAUTION: PRESSURIZED SYSTEM
Operating system may contain very hot water. Close inlet
and open drains before servicing. When servicing,
loosen screws
and move components to assure pressure is relieved before
remov-
ing
screws. Keep drains open during servicing. Failure to follow
these instructions could result in injury or death.
CAUTION: HOT SURFACE
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 servicing
unit. Failure to follow these instructions could result in serious injury
or death.
Page 10
18. Install diffuser.
19. Install propeller and tighten set screws.
20. Using new gasket and noting alignment pin, install assembly on
suction housing.
21. Install suction housing and discharge fasteners and tighten.
22. Reconnect pump bleed line and motor wiring.
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 serious injury or
death.
23. Close drain and slowly open inlet valves. See warning.
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.
24. Jog to check motor rotation. See caution.
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 serious injury or death.
25. Observe operation thru several cycles.
TM
DEALER SERVICE
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. Vacuum readings.
4. Ampere draw of the motors.
5. A sketch of the pump hook-up and piping.
6. Complete information on boiler control switches and any
motorized or solenoid valves in the boiler feed piping.
SERIES HV
TM
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
Morton Grove, Illinois 60053
Xylem Inc.
8200 N. Austin Avenue
Morton Grove, Illinois 60053
Phone: (847) 966-3700
Fax: (847) 965-8379
www.xyleminc.com/brands/bellgossett
Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries.
© 2012 Xylem Inc. DN0137D November 2012
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