Page 1
INSTRUCTION MANUAL
DN0154
REVISION D
Hoffman Specialty
®
Vented Condensate Units
Series HC™ and HS
™
SERIES HS™with
Optional Panel & Equipment
SERIES HC
Optional Panel & Equipment
™
with
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
condensate return 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
Page 2
Page 3
3
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. Remove start-up label (below) from panel (if applicable)
after complying with instructions.
10. 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.
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.
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. Check exterior only.
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).
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.
Page 4
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.
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. 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.
4. A valve in the discharge line is closed or throttled too
tightly. Check valve is installed backwards.
5. The impeller eye is clogged.
6. Pump is too small for system.
Condensate 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.
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. Rotation of three phase motors
may be corrected by interchanging any two of the three
wires. Rotation should be clockwise looking down on motor.
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
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.
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.
Page 5
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 the 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
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.
PUMP SERVICE INSTRUCTIONS FOR 609PF (WATCHMAN®) 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.
1
10
7
3
4
8
6
9
5
2
FIG. 2
2DPF01
Page 6
PUMP SERVICE INSTRUCTIONS FOR CENTRIFUGAL PUMPS (EXCEPT WATCHMAN®/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.
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.
6
CUT-AWAY VIEW OF MECHANICAL
SEAL TYPE PUMP
VIEW OF THREADED IMPELLER
SLINGER
SEAL
MOTOR
WEAR
RING
IMPELLER
VOLUTE
BRACKET
2DPF03
Page 7
7
NOTES:
Page 8
Xylem
1) The tissue in plants that brings water upward from the roots;
2) a leading global water technology company.
We’re 12,700 people unied in a common purpose: creating innovative solutions
to meet our world’s water needs. Developing new technologies that will improve
the way water is used, conserved, and re-used in the future is central to our work.
We move, treat, analyze, and return water to the environment, and we help people
use water efciently, in their homes, buildings, factories and farms. In more than
150 countries, we have strong, long-standing relationships with customers who
know us for our powerful combination of leading product brands and applications
expertise, backed by a legacy of innovation.
For more information on how Xylem can help you, go to www.xyleminc.com
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. DN0154D April 2013
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