Page 1
Bell & Gossett
LISTED
INSTRUCTION MANUAL
REVISION A
U
L
®
C US
P
™
TM
L
Booster Pumps
P86074
Installation, Operation, & Service Instructions
INSTALLER:
NOTE: Bell & Gossett recommends Bronze Booster Pumps
This safety alert symbol will be used in this manual and on the
pump safety instructions decal to draw attention to safety
related instructions. When used, the safety alert symbol
means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED! FAILURE TO FOLLOW THE INSTRUCTIONS MAY
RESULT IN A SAFETY HAZARD.
Your Series PL-VS
caution label (Fig. 1) displayed on the pump conduit box. If
this warning and caution is missing or illegible, contact your
local Bell & Gossett Representative for a replacement.
DESCRIPTION
The Series PL-VS™pumps feature permanently lubricated
bearings, a range of available hydraulic performance levels,
115V single phase power input, 4-20 mA or (switchable)
0-10VDC control input, a relay for external fault detection,
manual speed override and built in diagnostic indicator.
be used for pumping potable water
SAFETY
INSTRUCTIONS
™
Booster Pump should have the warning/
PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
OPERATIONAL LIMITS
These pumps are designed to pump liquids compatible
with their iron or bronze body construction.
Maximum Working Pressure: 150 psi (10 bar)
Maximum Operating Temperature: 225°F (107°C)
Electrical Rating: 115V, 60 Hz, 1PH
Do not exceed these values.
WARNING
BEFORE INSTALLING, USING
OR SERVICING THIS PRODUCT, READ THE INSTRUCTIONS. TO REDUCE RISK
OF ELECTRICAL SHOCK
SEE INSTRUCTIONS FOR
PROPER INSTALLATION.
CAUTION
FOR SUPPLY CONNECTIONS
USE WIRE SUITABLE FOR AT
LEAST 90°C. USE COPPER
CONDUCTORS ONLY.
EMPLOYER DES FILS
D’ALIMENTATION ADEQUATS
POUR 90°C. FOR INDOOR USE
ONLY. EMPLOYER UNIQUE MENT A L’INTERIEUR.
FIG. 1
P48405
PUMP APPLICATION
The Series PL-VS™Booster Pump may be used for water
circulating applications in hydronic heating, solar systems
chilled water systems. The speed of the pump can be adjusted
manually or by a 4-20 mA or 0-10VDC control input.
and
Bell & Gossett
Page 2
SAFETY REQUIREMENTS
MECHANICAL SAFETY
WARNING: EXCESSIVE SYSTEM PRESSURE
HAZARD
The maximum working pressure of the pump is listed on
the nameplate – DO NOT EXCEED THIS PRESSURE.
Failure to follow these instructions could result in serious
personal injury, death and/or property damage.
WARNING: EXCESSIVE PRESSURE HAZARD –
VOLUMETRIC EXPANSION
The heating of water and other fluids causes volumetric
expansion. The associated forces may cause failure of system components and the release of high temperature fluids.
This can be prevented by installing properly sized and
located compression tanks and pressure relief valves.
Failure to follow these instructions could result in serious
personal injury, death and/or property damage.
THERMAL SAFETY
WARNING: EXTREME TEMPERATURE HAZARD
If the pump, motor including drive, or piping are operating at extremely high or low temperature, guarding or insulation is required. Failure to follow these instructions could result in serious personal injury, death and/or property damage.
This pump is for indoor use only.
ELECTRICAL SAFETY
WARNING: ELECTRICAL SHOCK HAZARD
Electrical connections are to be made by a qualified
electrician in accordance with all applicable codes, ordinances and good practices. Failure to follow these instructions could result in serious personal injury, death and/or
property damage.
WARNING: ELECTRICAL GROUNDING HAZARD
Adequate electrical grounding is required for the safe
operation of B&G Pumps. The use of grounded metal conduit assures this requirement. If the means of connection to
the supply-connection box (wiring compartment) is other
than grounded metal conduit, ground the pump back to the
service. Connect a copper conductor at least the size of the
circuit conductors supplying the pump to the grounding
screw provided within the wiring compartment. Failure to
follow these instructions could result in serious personal
injury, death and/or property damage.
WARNING: ELECTRICAL SHOCK HAZARD
After power is disconnected from the pump, high
voltage levels are maintained by the DC link capacitor.
There are no serviceable parts inside the control box. Do
not touch electrical components until the power has
been disconnected for at least 9 minutes. Failure to fol-
low these instructions could result in serious personal
injury, death and/or property damage.
REMOVAL OF THE PUMP FROM EXISTING SYSTEM FOR REPLACEMENT
WARNING: ELECTRICAL SHOCK HAZARD
Disconnect and lockout the power before servicing.
Failure to follow these instructions could result in serious
personal injury or death.
1. Close the valves on the suction and discharge sides of
the pump. If no valves have been installed, it may be necessary to drain the system.
WARNING: HOT WATER HAZARD
Before draining the system, allow water to cool to
100°F max., open the drain valve (take precautions against
water damage) and leave the drain valve open until servicing is complete. Failure to follow these instructions could
result in serious personal injury, death and/or property
damage.
PUMP INSTALLATION
Locate the pump so there is sufficient room for inspection,
maintenance and service. Bell & Gossett recommends the
installation of service valves on the suction and discharge of
all pumps to facilitate servicing or replacement of the pump
without draining the system.
Install suction and discharge flanges on the pipe ends. The
use of teflon tape sealer or a high quality thread sealant is
recommended.
Be sure to minimize any pipe-strain on the pump. Support the
suction and discharge piping by the use of pipe hangers near
the pump. Line up the vertical and horizontal piping so that
2
WARNING: ELECTRICAL SHOCK HAZARD
Be certain the electrical power is not present at the
motor leads before continuing. Failure to follow these instructions could result in serious personal injury or death.
2. Loosen the conduit box cover screw and remove the cover.
3. Disconnect the electrical supply and control lines to the
pump.
WARNING: HIGH PRESSURE HAZARD
Pressure may be present in the pump body. This
pressure can be relieved by loosening the flange bolts and
shifting the pump assembly slightly to allow the pressurized water to escape. Failure to follow these instructions
could result in serious personal injury or death.
4. Remove the flange bolts and nuts and then remove the
pump from the piping.
the bolt-holes in the pump flanges match the bolt-holes in the
pipe flanges. (DO NOT ATTEMPT TO SPRING THE SUCTION
OR DISCHARGE LINES IN POSITION. THIS MAY RESULT IN
UNWANTED STRESS IN THE PUMP BODY, FLANGE CONNECTIONS AND PIPING.) The code for Pressure Piping
(ANSI B31.1) lists many types of supports available for various
applications.
Bell & Gossett flange gaskets must be installed between the
Series PL-VS™pump body flanges and the suction and
discharge pipe flanges. Use 7/16" diameter and appropriate
length cap screws and matching nuts to connect the pump to
the flanges.
Page 3
WARNING: HOT WATER HAZARD
When disassembling a gasketed joint, always use a
new gasket upon reassembly. NEVER RE-USE OLD GASKETS. Failure to follow these instructions could result in
serious personal injury, death and/or property damage.
Apply torque in even increments to the flange bolts until a
value of 96-132 in-lbs. is reached. Both the suction and discharge flange bolts must be torqued in this manner.
WARNING: WATER LEAKAGE HAZARD
To prevent leakage, make certain that the flange
bolts have been adequately torqued. Failure to follow these
instructions could result in serious personal injury and/or
property damage.
WIRING INSTRUCTIONS
WARNING: ELECTRICAL SHOCK HAZARD
Disconnect and lockout the power before making
electrical connections. Failure to follow these instructions
could result in serious personal injury or death.
A. Loosen the two screws that secure the conduit box cover
(wiring compartment) and remove the cover.
B. Attach the appropriate size connector(s) to the hole(s) in
the side of the conduit box.
C. Using a minimum size 14 AWG copper electrical wire (refer
to your local code for wiring restrictions), wire the motor to
a single phase power source as listed on the pump nameplate. See Page 4.
D. Connect the ground wire to the ground terminal inside
the conduit box.
E. If the control input and fault relay will be used, connect 300V
minimum wire to the appropriate terminals. See Page 4.
NOTE: Electrical supply, grounding, control input, and fault
relay wires must be suitable for 90°C (194°F).
NOTE: Series PL-VS™Booster Pumps are thermally pro-
tected and do not require external overload protection.
NOTE: Pumps are shipped from the factory in the manual
hand overrride position-set at full speed.
STARTUP
CAUTION: SEAL DAMAGE HAZARD
Do not run pump dry, seal motor damage may occur.
Failure to follow these instructions could result in property
damage and/or moderate personal injury.
Do not start pump until the system has been filled and vented.
Air should be vented from the system by means of an air vent
located at a high point in the system, or by an alternate
method. The system must be completely vented prior to
pump operation. Do not run pumps dry. Pump operation without water circulation could result in pump and motor damage.
WARNING: HOT WATER LEAKAGE HAZARD
Pressurize the body slowly while checking for leaks
at all joints with gaskets. Failure to follow these instructions
could result in serious personal injury and/or property
damage.
MODE OF DISCHARGE
The Series PL-VS™pump can be installed to discharge up or
down, horizontally, left or right, but the motor shaft must
remain in the horizontal position, the arrow on the body
must point in the direction of flow and the conduit box
must be positioned on the top of the motor housing
(see figure 2).
WARNING: ELECTRICAL SHOCK HAZARD
Be certain that all connections are secure and the
conduit box cover is closed before electrical power is connected. Failure to follow these instructions could result in
serious personal injury, death and/or property damage.
SYSTEM PREPARATION
Prior to pump start up, closed heating and cooling systems
should be cleaned, drained and refilled with clean water.
System ph must be maintained between 7 and 9.
FIG. 2
PUMP BODY MAY BE ROTATED AS SHOWN,
BUT CONDUIT BOX MUST REMAIN AT TOP.
3
Page 4
CONDUIT BOX
SHAFT SLEEVE
PUMP BODY
BODY GASKET
COVER PLATE ASM
IMPELLER ASM
W/THREADED HUB
SEAL ASM
FRONT BEARING
HOUSING/STATOR ASM
SHAFT/ROTOR
FIG. 3
REAR
BEARING
SPEED CONTROL POTENTIOMETER IS
ACTIVE WHEN #1 HAND OVERRIDE
IS SELECTED AND CONTROL
INPUTS ARE DISCONNECTED
CLOCKWISE=INCREASE SPEED
COUNTER CLOCKWISE=DECREASE SPEED
CAUTION: DO NOT APPLY EXCESSIVE
TORQUE TO THE SPEED CONTROL POT.
FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN DAMAGE TO THE DRIVE.
L N
{
{
{
ROTARY
SELECTOR SWITCH*
#0 OFF
#1 HAND OVERRIDE
OF SPEED CONTROL
#2 SPEED CONTROLLED
BY 4-20 mA
CONTROL INPUT
#3 SPEED CONTROLLED
BY 0-10V CONTROL
INPUT
RELAY FOR FAULT INDICATION
AT REMOTE LOCATION.
N/O CONTACTS CLOSE
IF A PUMP FAULT IS DETECTED
FAULT RELAY RATING IS 60 VA
AT 2 AMPS MAXIMUM
4-20 mA OR (SWITCHABLE)
0-10 VDC CONTROL INPUT CONNECTIONS MUST BE
DISCONNECTED WHEN THE PUMP IS OPERATED IN HAND MODE
WARNING: FAILURE TO DISCONNECT INPUT CONNECTIONS
WHEN PLACED IN HAND OVERRIDE MAY DAMAGE THE DRIVE.
115V 60Hz
SINGLE
PHASE POWER
CONNECTIONS
DIAGNOSTIC
INDICATOR LIGHT
– CONSTANT ON
INDICATES POWER
IS APPLIED TO THE
PUMP AND THE
PUMP IS OPERATING
PROPERLY.
– FLASHING LIGHT
AT 1 FLASH PER 2
SECONDS INDICATES
THE CURRENT LIMIT
HAS BEEN EXCEEDED
– FLASHING LIGHT
AT 2 FLASHES PER
SECOND INDICATES
THE TEMPERATURE
LIMIT HAS BEEN
EXCEEDED
1
0
2
3
1
0
2
3
CONTROL BOX FEATURES
*NOTE: Pumps are shipped from the factory on
4
#1 hand overrride with control speed
set at full speed.
Page 5
INSTRUCTIONS FOR REPAIRING
A
E
D
B
C
49/16
(116)
MECHANICAL SEAL
11. Follow steps 1 through 4 of section titled
PUMP FROM EXISTING SYSTEM FOR REPLACEMENT.”
12. Loosen the four capscrews that hold the motor housing to
the pump body. Remove these screws and remove the
housing from the pump body.
13. Place the pump on a flat work surface and insert a screw-
driver into one of the endplate ventilation slots until it
engages one of the rotor cooling fins. While holding the
rotor with the screwdriver, turn the impeller clockwise.
Note that the impeller is molded around a metal hub with a
left hand thread. Remove the impeller from the shaft.
14. Remove the seal assembly from the shaft by sliding it off
the shaft sleeve.
15. Clean the seal seat with a clean rag and inspect for groov-
ing or cracks. If it shows no grooving or cracks, it may be
cleaned and reused.
16. If the seal seat is to be replaced, the face plate must be
removed from the motor housing. Remove it by gently prying it away from the housing.
17. Remove the seal seat and cup. Lubricate the cup with
soapy water and install new parts in the face plate recess.
DO NOT USE GREASE/OIL. Reposition the face plate on
“REMOVAL OF
the motor housing. Gently tap the face plate evenly
around its diameter to drive it into the recess provided in
the motor housing.
18. Clean the shaft and sleeve before installing the new seal.
19. Slide the new carbon seal head onto the shaft sleeve until
it contacts the seal seat. Slide the new “O-Ring” and
back-up ring along the shaft sleeve until they fit inside the
counter bore in the seal head. Place the seal spring
between the back-up ring and the seal cage while positioning the seal cage flush with the end of the sleeve.
Place the small end of the spring against the back-up ring.
The three driving legs of the seal cage should engage the
three slots on the seal head. While holding the rotor
assembly with the screwdriver, thread the impeller onto the
shaft in a counter clockwise direction. Tighten the impeller
with light hand pressure. Take care to avoid bending a
rotor cooling fin or damaging the shaft sleeve.
10. Clean the recess in the pump body and install a new body
gasket.
11. Install the pump in the body and secure with four capscrews. Apply torque evenly in a criss cross pattern in 40
in-lb (4.52 N•m) increments to a torque of 80 in-lb (9.04 N•m).
12. Reinstall into the system using new flange gaskets. For
instructions, see sections “PUMP INSTALLATION” and
“WIRING INSTRUCTIONS” on pages 2 and 3.
PERIODIC INSPECTION
Bell & Gossett Booster Pumps are designed to provide years
of trouble free service. It is recommended that periodic in-
PERIODIC INSPECTION
pump. If any leakage or evidence of leakage is present repair
or replace the unit.
spections be made to check for potential problems with the
DIMENSIONS AND WEIGHTS
MODEL SIZE MOTOR
NUMBER INCHES – NPT HP
PL-36VS
PL-45VS and PL-50VS 1, 11/4 & 11/2
PL-75VS 2 11 (279) 81/2 (216) 83/8 (213) 53/16 (132) 45/8 (117) 18.5 (8.4)
Dimensions are approximate and subject to changes. Contact factory for certified dimensions.
FLANGE APPROX.
3
/4, 1, 11/4 & 11/2 91/4 (235) 63/8 (162) 73/4 (197) 43/8 (111) 45/8 (117) 13.1 (6.0)
1
/6 93/4 (248) 81/2 (216) 715/16 (202) 45/8 (117) 45/8 (117) 14.5 (6.6)
A B C D E LBS. (KG)
DIMENSIONS – INCHES (MM)
SHPG. WT.
5
Page 6
Loading...