Bell & Gossett DN0158E User Manual
Domestic® Pump
Vented Condensate Units
INSTRUCTION MANUAL
DN0158
REVISION E
Series CC,™ CS,™ CB,™ CBE,™ CHD,™ CED
SERIES CB™with
Optional Panel & Equipment
SERIES CS
Not Pictured
™
, CHD™, CED
™
SERIES CBE
Optional Panel & Equipment
™
with
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
SERIES CC
Optional Panel & Equipment
™
™
with
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.
®
DOMESTIC
PUMPS
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
DOMESTIC
SERIES
MODEL
SERIAL
GPM PSI PUMP
POWER V. PH. HZ60
CONTROL V. PH. 1 HZ60
TOTAL LARGEST MOTOR
F.L. AMP F.L. AMP
®
PUMPS
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
2
DESCRIPTION
Pumps are float operated to return accumulated condensate to
a boiler feed tank.
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 care 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 104ºF. (40°C) max. ambient.
Insulate or ventilate as required.
PIPING (General)
Pipe the unit per the Elementary Piping Diagram. Locate and
support piping so as to not load the pump discharge.
PIPING (Returns)
Gravity return lines from system should 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.
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 using an overflow loop when con-
densate temperature will exceed 200ºF. (93°C).
FLOAT SWITCHES & MECHANICAL ALTERNATORS
Floats are locked in place to prevent damage during shipment.
Remove shipping locks. Check factory settings. Floats and
mechanical alternators are adjustable for various levels of operation. The lead pump should start with tank
3
/4 full and shut off
at 2" or more above pump inlet. Lag pump should start before
the tank overflows. Settings should avoid “short cycling” of the
pump.
ELECTRICAL WIRING & CONTROLS
Connect power wiring per NEC. Recheck nameplate vs. spec-
ifications and conditions. All single phase motors have internal
thermal protection.
Three phase motors must use starters with properly sized overload relays. Overload relays furnished are designed for manual
reset.
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.
INSTALLATION AND DESCRIPTION
(Vented Condensate Units)
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: 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
servicing unit. Failure to follow these instructions could
result in serious injury or death.
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.
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