INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
DESCRIPTION
Single pump unit provides pressurized water or water-glycol
mixture to a closed-loop: heating, chilled water, snowmelt,
and radiant heat systems. The unit is automatically controlled
by a pressure switch to run at the precise pressure required.
This safety alert symbol will be used in this manual and on the
Safety Instruction decal to draw attention to safety related
instructions. When used, the safety alert symbol means
AT T E N T ION! B ECOME ALERT! YOUR SAFET Y IS
INVO LV ED ! FAIL UR E TO FO LL OW TH E IN STRUCTION
MAY RESULT IN A SAFETY HAZARD!
NOTE: The information contained in this manual is intended to assist operating personnel by providing information on the char-
acteristics of the purchased equipment.
It does not relieve the user of the responsibility to adhere to local codes and ordinances and the use of accepted practices in
the installation, operation and maintenance of this equipment.
Further information pertaining to the installation, operation, and maintenance of your Glycol Make-up System can be found in
the Installation Operation and Maintenance manuals for the associated equipment provided:
A. Bell & Gossett 3530 Pump – http://fhasapp.ittind.com/literature/files/644.pdf
B. Goulds HMS Pump – http://www.goulds.com/pdf/IM083R02.pdf
C. Bell & Gossett Expansion Tank – http://fhasapp.ittind.com/literature/files/927.pdf
D. McDonnell & Miller Low Water Cut-Offs Switch – http://fhasapp.ittind.com/literature/files/1446.pdf
E. SQUARE D Pressure Switch – http://ecatalog.squared.com/pubs/Machine%20Control/Condition%20Sensors/
The Glycol Make-up unit is designed to automatically
maintain minimum pressure in closed-loop systems.
The GMU-30 uses 1/2 HP pump for systems requiring up to 30-psi. The GMU-60 uses 3/4 HP pump and
for systems requiring up to 60-psi.
Depending upon the system pressure required, a
GMU-30 or GMU-60 is used. In both units, a pressure switch starts and stops the pump(s).
1.1 PURPOSE OF MANUAL
This manual is furnished to acquaint you with some
of the practical ways to install, operate, and maintain
this unit. Read it completely before doing any work
on your unit and keep it handy for future reference.
Equipment cannot operate well without proper care.
To keep this unit at top efficiency, follow the recommended installation and servicing procedure outlined
in this manual.
1.2SAFETY INSTRUCTION
This safely alert symbol will be used in this manual
and on the unit safety instruction to draw attention to
safety related instructions. When used the safety alert
sym bol means ATTEN TION BECOME ALERT!
YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN A
SAFETY HAZARD.
ADDITIONAL SAFETY REQUIREMENTS
WARNING: Electrical shock hazard. Inspect all
electrical connections prior to powering the unit.
Wiring connections must be made by a qualified electrician
in accordance with all applicable codes, ordinances, and
good practice. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
WARNING: Prevent electrical shocks. Disconnect
the power supply before beginning installation. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
Always use accurate test meters when checking electrical components. Always work with another person
in case of emergency.
1.3 STORAGE
For long periods of storage, the unit should be covered to prevent corrosion and contamination from
dirt. It should be STORED in a clean, dry location
between 0 and 170°F. The relative humidity should
not exceed 85%. The unit should be checked periodically to ensure that no condensation has formed.
After storage, again check that it is dry before applying power.
1.4 HANDLING
Care should be taken to prevent damage due to
dropping or jolting when moving the Glycol Make-up
Unit. Transportation damage should be brought to
the carrier's attention immediately upon receipt.
1.5 TEMPERATURE AND VENTILATION
All electrical equipment is susceptible to failure if
operated in ambient temperatures outside of its rat-
ng. The OPERATING temperature range for this unit
i
is 32 to 105°F. The relative humidity should not
exceed 95% non-condensing. The unit should not be
operated outside these extremes.
1.6 ELECTRICAL CONNECTIONS - A.C. POWER &
1.7 GROUND CONNECTIONS
lug provided in the enclosure to avoid potential safety hazards. FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
1.8 POWER WIRING
1.9 FIELD CONNECTION DIAGRAMS
SIGNALS INPUT VOLTAGE
The input voltage tolerance is +10/-10% of nameplate voltage.
A grounding terminal is provided for a dedicated
ground wire connection. All provisions of the National
Electrical Code and local codes must be followed.
WARNING: Conduit grounds are not adequate. A
separate ground wire must be attached to the ground
Power wire types and sizes must be selected based
upon conformance with the National Electrical Code
and all local codes and restrictions. In addition, only
copper (Cu) wire rated for at least 75°C may be used
for the power connections. Refer to the input current
as listed on the motor nameplate when sizing wire.
Connect the input power to the screw terminals on
the Power Distribution Block labeled "L1" & "L2".
Connect a ground conductor to the ground terminal
attached to the Power Distribution Block. See wiring
diagram 1GMU01 on page 9.
The following field connection diagrams should be
reviewed prior to unit installation and operation.
Drawing # Description Page
1FC008 Typical Field piping8
1GMU01 Wiring Diagram9
3
Page 4
Section 2
2.0 INSTALLATION INSTRUCTIONS
Locate the Glycol Make-up unit for ease of inspection, maintenance, and service. For Glycol application
secondary containment is required to catch any leaks
or spills that could go down the drain or out a door
and cause a risk to the environment. Refer to local
codes for clarification.
FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY,
DEATH, AND/OR PROPERTY DAMAGE.
Place the unit preferably on a concrete floor or base.
Level the steel base, on which the pump is mounted,
in both directions by placing steel shims between the
base and the anchor bolts.
DANGER: Do not lift entire unit by any components
lift eyebolts. Lift the unit with slings placed under the
unit base rails. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
DANGER: Top of unit is heavy when it is full of fluids
and may tip if not lifted properly. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY
DAMAGE.
DANGER: Do not step on the top of the unit. It is
not designed to support the weight of a person. Any
fall can be serious, and may result in painful or incapacitating injury. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY,
DEATH, AND/OR PROPERTY DAMAGE.
A well-leveled and secured unit will result in quiet
operation as well as longevity of service.
See drawing 1FC008 for general piping requirements.
When connecting the GMU discharge line to the
make-up line of the Closed-loop system the 3/4" NPT
fitting needs to be tightened. When doing this, be
sure to use a back-up wrench on the fitting. Do not
over tighten the fitting. Inspect all visible fittings for
leaks. Tighten the fittings if any leaks are found. Be
sure to use two wrenches one to tighten the fitting
and the other to back-up the fitting. Using just one
wrench may damage the fitting. Never tighten a fitting
while there is hydraulic pressure in the fitting.
Support the discharge line independently by use of
pipe hangers or anchors. Do not attempt to spring
the discharge line into position. It is recommended
that there is a three (3) valve by-pass in the make-up
line. See drawing 1FC008 for location of valves.
IMPORTANT: Do not install and operate pumps
in closed systems unless the system is constructed
with properly sized safety devices and control
devices. Such devices include the use of properly
sized and located pressure relief valves, compression
tanks, pressure controls, temperature controls and
flow controls as appropriate. If the package includes
a pressure relief valve, make sure the discharge of
the valve is directed to the floor drain before making
the unit operational.
WARNING: The heating of water and other fluids
causes volumetric expansion. The associated forces
may cause failure of system components and release of
igh temperature fluids. This will be prevented by installing
h
properly sized and located pressure relief valves and compression tanks. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
IMPORTANT: If vibration eliminators are used, note
that unless the piping to which the vibration eliminators are connected to are properly anchored to the
floor, the benefits may not be fully realized.
WARNING: Electrical shock hazard. Inspect all
electrical connections prior to powering the unit.
Wiring connections must be made by a qualified electrician
in accordance with all applicable codes, ordinances, and
good practice. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
The power supply required for the unit is indicated on
the nameplate located inside the control panel. A
dedicated ground wire must be connected to the
unit.
WARNING: Conduit grounds are not adequate. A
separate ground wire must be attached to the ground
lug provided in the enclosure to avoid potential safety hazards. FAILURE TO FOLLOW THESE INSTRUCTIONS
CAN RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
Single phase motors have internal overload protection. The disconnecting means and short circuit protection are to be supplied and mounted by others.
Single phase panel remains fully energized at all
times, unless incoming power is disconnected. Do
not use the "POWER ON" light as a method to determine when the control panel is de-energized.
WARNING: Electrical shock hazard. Turn off and
lockout all power sources prior to servicing panel.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN SERIOUS PERSONAL INJURY, DEATH,
AND/OR PROPERTY DAMAGE.
CAUTION: Seal damage may occur. Do not run pump
dry. fill and vent the pump volute prior to operation.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD
RESULT IN PROPERTY DAMAGE AND/OR MODERATE
PERSONAL INJURY.
4
Page 5
Section 3
Adjust for cut-in point
Adjust for cut-out
PRESSURE SWITCH
3.0 PUTTING THE UNIT INTO SERVICE
CAUTION: Prevent subsequent damage. A unit show-
ing symptoms of possible problems (noise, leaks,
vibration, and/or continual operation) must be corrected
immediately. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESUL T I N PROP E R TY DAMAGE
AND/OR MODERATE PERSONAL INJURY.
MU30 is designed for systems requiring up to
G
30-psi, drawing water or water-glycol mixture up to
10-gpm from the 55-gallon tank and automatically
servicing the closed-loop system.
GMU60 is designed for systems requiring up to
60-psi, drawing water or water-glycol mixture up to
5-gpm from the 55-gallon tank and automatically servicing the closed-loop system.
When pressure in the closed-loop system decreases
to the cut-in pressure the pump will start. The pump
runs until the pressure switch reaches the cut-out
pressure. The pressure switch factory default cut-in
setting for GMU-30 is 5-psi, and the cut-out setting
is 21-psi. The pressure switch factory default cut-in
setting for GMU-60 is 30-psi, and cut-out setting is
50-psi.
3.1 ADJUSTMENTS AND SETTINGS
3.1.1 Pressure Switch
Electrical equipment should be serviced only by qualified electrical maintenance personnel.
WARNING: Electrical shock hazard. Single phase
or three phase AC power. Disconnect and lockout
power before servicing unit. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
The pressure switch is piped to the discharge line.
There are two adjusting screws located on the top of
the switch control. This adjustment must be made
before operating the system.
Adjust pressure switch as follows:
a) Cut-In (Turn nut clockwise for higher pressure or
counterclockwise for lower pressure).
b) Cut-Out (Turn nut clockwise for higher pressure or
counterclockwise for lower pressure).
c) Check switch operation after resetting.
d) See above picture for adjustment nut locations.
WARNING: Electrical shock hazard. Disconnect and
lockout power before servicing the unit. FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD RESULT IN
SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
.1.2 Triple Duty Valve
3
The Triple Duty Valve is piped to the discharge of the
pump and is used as a non-slam check valve, calibrated balance valve and shutoff valve for this unit.
he valve stem is located on the top of the valve. The
T
Triple Duty Valve has a calibrated nameplate on the
valve stem for rough system balance and position
indication. Prior to placing GMU into operation,
installer must adjust the Triple Duty Valve.
WARNING: Setting the Triple Duty Valve in excess of
100% open within the range labeled gravity flow can
allow backward flow of glycol into the 55-gallon tank and
overfill it. Adjustment must be made before placing the unit
into operation. Follow the instructions that are supplied with
the unit. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN PROPERTY DAMAGE AND/OR
MODERATE PERSONAL INJURY.
3.1.2.1 Adjust Triple Duty Valve
a) Never turn the valve stem in excess of 100% open
when system is pressured. At this position the
valve does not act as a check valve. It is a gravity
flow valve.
b) Never turn the valve stem to the closed position
when operating the system. This position provides
positive shutoff.
c) Adjust the valve between 20% to100% open.
3.1.3 Diaphragm Expansion Tank
Diaphragm expansion tank factory pre-charge is 40-psi.
Adjust pre-charge to equal incoming pressure. Refer
to the specific IOM #V58303 that was shipped with
the tank for installation and operating instructions.
3.1.4 Low Water Cut Off Switch
When the water or water-glycol mixture in the 55-gallon
reservoir falls below the low level point, the low water
cut-off switch will turn the pump off. An alarm light
will illuminate.
3.1.5 Sequence of Operation
When pressure in the system decreases to the minimum allowable fill pressure, the pressure reducing
valve opens.
The Glycol stored in the pressure tank flows to the
system, when pressure supplied to the pressure
reducing valve reaches the pump cut-in pressure, the
GMU pump will start.
Pump runs until pressure switch reaches the cut-out
pressure.
Should the Glycol solution in the 55-gallon reservoir
fall below the low level point in the reservoir, the low
level switch will turn pump off, an alarm light will be
signaled.
5
Page 6
Appendix A
Appendix B
SYSTEM PIPING AND UNIT
INSTALLATION – FINAL CHECK LIST
____ 1. Is the unit base properly leveled and secured?
____ 2. Are all lubrication points properly lubricated?
___ 3. Is the shut-off valve to the pump suction open?
_
____ 4. Is the shutoff valve to the Diaphragm Expansion
____ 5. Are the shutoff valves for the make-up line open?
____ 6. Is the Triple Duty Valve turned to suitable operating
____ 7. Is the piping properly supported to prevent strains
____ 8. Is the system, including the pumps, purged of debris
Tank line open?
position?
on unit?
and air?
CAUTION: Seal damage may occur. Do not run
pumps dry. Fill and vent the pump volute prior to
operation. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN PROPERTY DAMAGE
AND/OR MODERATE PERSONAL INJURY.
ELECTRICAL WIRING AND CONTROL
SETTINGS – FINAL CHECK LIST
____ 1. Does the feeder line voltage correspond to the unit
voltage? Check the unit nameplate or motor terminal
connection.
WARNING: Electrical shock hazard. Inspect all elec-
trical connections prior to powering the unit. Wiring
connections must be made by a qualified electrician in
accordance with all applicable codes, ordinances, and
good practices. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
____ 2. Are the feeder wires correctly sized for the load?
WARNING: Conduit grounds are not adequate. A
separate ground wire must be attached to the
ground lug provided in the enclosure to avoid potential
safety hazards. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
____ 3. Have all the power terminals in the control panel
been checked for tightness? This is imperative since
stranded wires tend to “flow” and become loose
after initial installation.
WARNING: Electrical shock hazard. Single phase
or three phase AC power. Disconnect and lockout
power before servicing unit. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
____ 4. Are the pressure controls correctly set? The pres-
sure switch needs to be set for proper operation.
Any subsequent change in system operating conditions may require resetting the controls. For best
results, use compressed air and a continuity meter
(across the switch) to reset the controls. The legend
plate on the control indicates approximate readings
only, therefore, should be used with caution.
6
Page 7
Appendix C – Troubleshooting
DANGER: Troubleshooting live control panels ex-
oses personnel to hazardous voltages. Electrical
p
troubleshooting must only be done by a qualified electrician. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS PERSONAL INJURY,
DEATH, AND/OR PROPERTY DAMAGE.
Pump will not operate:
1) Check incoming power
2) Check motor overload. Reset if tripped.
3) With contactor pulled in, check voltage of the
motor leads. Voltage should be the same as the
incoming power. If no voltage is present, replace
the contactor. If voltage is present, contact an
electrician to check the leads & motor.
4) Check pressure switch cut-in and cut-out setting.
5) Check low water cut-off switch probe point in the
reservoir.
Pump will not build pressure
1) Suction valve is closed. If closed, open.
DANGER: High voltage can kill. Disconnect and
lockout power prior to servicing unit. FAILURE TO
FOLLOW THESE INSTRUCTIONS COULD RESULT IN
SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
Pump will not start automatically
WARNING: Electrical shock hazard. Inspect all
electrical connections prior to powering the unit.
Wiring connections must be made by a qualified electrician
n accordance with all applicable codes, ordinances, and
i
good practice. FAILURE TO FOLLOW THESE INSTRUC-
TIONS COULD RESULT IN SERIOUS PERSONAL
INJURY, DEATH, AND/OR PROPERTY DAMAGE.
) No power. Restore if there is no power.
1
2) Pressure switch not adjusted properly. Refer to
pressure switch setting section 3.1.1.
2) Motor not operating at rated RPM. Have motor
checked at local motor repair shop.
3) Internal pump damage. Take pump to authorized
pump repair facility.
7
Page 8
Appendix D – Typical Field Piping - IFC008
LOW WATER
CUT OFF SWITCH
Y-STRAINER
PUMP
2" OPENING
TANK
55 GALLONS
TRIPLE
DUTY
VALVE
PRESSURE
SWITCH
PRESSURE
GAUGE
SYSTEM
OUTLET
3/4" NPT
DIAPHRAGM
EXPANSION
TANK
BY OTHERS
PRESSURE
REDUCING
VALVE
GATE VALVEGATE VALVE
BALL VALVE
SYSTEM
PRESSURE
RELIEF
VALVE
8
Page 9
Appendix E – Wiring Diagram - 1GMU01
9
Page 10
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