Clarke BPT 1200SS, 7237006 User guide

BOOSTER PUMP

MODEL NO: BPT1200SS

PART NO: 7237006

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC0922 - Rev 4

INTRODUCTION

Thank you for purchasing this CLARKE Booster Pump.

Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.

Upon receipt, any damage or deficiency should be reported to your CLARKE
dealer immediately.

Keep these instructions in a safe place for future reference.

DESCRIPTION

The BPT1200SS is a centrifugal, horizontal, electric pumps with a self-priming
capability and are designed with a venturi system, suitable for pumping water
from up to 46 m height.

It is designed to operate with clean water only at a maximum temperature of
35°C. Operating with contaminated or salt water should be avoided. The inlet
of the pump is higher than the inlet of the impeller so that the pump can start
operating when only the body is filled with water.

The inlet side of the pump should always be fitted with a one-way valve to
prevent water siphoning back out of the pump and to ensure the pump is
always primed for the next start-up.

The pressure tank incorporates a butyl membrane, and a pressure controller
provides automatic stop/start control. The pumps are supplied with a 1”BSP
inlet filter with easy to clean replaceable elements. The transparent filter bowl
allows for a visual check as to the condition of the filter cartridge.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt as proof of
purchase. This guarantee is invalid if the product is found to have been
abused or tampered with in any way, or not used for the purpose for which it
was intended.

Faulty goods should be returned to their place of purchase. No product can
be returned to us without prior permission. This guarantee does not effect your
statutory rights.

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SAFETY PRECAUTIONS

WARNING: AS WITH ALL MACHINERY THERE ARE CERTAIN HAZARDS
INVOLVED WITH THEIR OPERATION AND USE. EXERCISING CAUTION WILL
REDUCE THE RISK OF PERSONAL INJURY.

Please read all of the safety and operating instructions carefully before using
this product.

WORK AREA

1. Keep the work area clean and well lit. Floors should always be kept clear.
Cluttered or dark areas invite accidents.

2. Keep children and bystanders away while operating machines.
Distractions can cause loss of control.

PERSONAL SAFETY

1. ALWAYS stay alert, watch what you are doing and use common sense
when operating this pump. Do not use the pump while you are tired or
under the influence of medication, drugs or alcohol. A moment of
inattention can result in personal injury.

2. Do not over-reach. Keep your proper footing and balance at all times
when positioning the pump.

3. Never direct the water discharge towards electrical wiring or equipment.

4. ALWAYS store the pump out of reach of children and do not allow persons
unfamiliar with these instructions to operate it.

5. Never direct the discharge flow towards another person.

6. ALWAYS thoroughly familiarise yourself with this pump & its operation, and
follow all instructions in this manual.

7. ALWAYS ensure that the pump is properly positioned to prevent it from
moving during operation, and that the immediate area surrounding the
pump is kept clear.

GENERAL EQUIPMENT USE AND CARE

WARNING: THE BPT600 & 1200SS ARE NOT SUBMERSIBLE PUMPS. ON NO
ACCOUNT SHOULD THEY BE IMMERSED IN WATER.

1. ALWAYS maintain the pump with care and keep it clean.

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2. NEVER use this pump if any part is damaged. Have it inspected and
repaired by your local Clarke dealer.

3. NEVER modify this pump in any way. Use it ONLY for the purpose for which it
is designed.

4. NEVER run the pump dry. Always ensure the pump is filled or ready to be
filled with water before starting.

5. NEVER overtighten drain or filler plugs. Excessive force may damage the
threads and make the plug difficult to remove in future.

6. ALWAYS ensure the pump is in a horizontal position and is firmly anchored
via its fixing screws to a level surface.

7. NEVER use for pumping flammable liquids or corrosive chemicals. These
pumps are designed to pump WATER ONLY.

8. ALWAYS use a strainer connected to the suction (inlet) hose, to prevent
stones and other solids from being drawn up, which could cause damage
to the pump.

9. Switch the pump OFF immediately after the task is completed.

ELECTRICAL SAFETY

1. Electrical appliances must match the power outlet. Never modify the plug
in any way. Do not use adaptor plugs with earthed (grounded) appliances.
Correct plugs and outlets will reduce the risk of electric shock.

2. Do not abuse the electrical cable. Never use the cable for pulling or
unplugging the heater. Keep the cable away from sources of heat, oil,
sharp edges or moving parts. Damaged or tangled cables increase the risk
of electric shock.

3. Keep the mains cable well away from machines and ensure an adequate
electrical supply is close at hand so that the operation is not restricted by
the length of the cable.

4. Always disconnect from the mains supply before moving the heater or
performing any maintenance tasks.

5. Inspect the mains cable regularly for signs of damage. DO NOT use if it is
damaged and always keep it away from the source of heat.

6. If the power cable is damaged, it must be replaced by the manufacturer,
its service agent, or similarly qualified persons in order to avoid a hazard.

7. Do not use the pump if the switch does not turn it on and off. Any power
product that cannot be controlled with the switch is dangerous and must
be repaired.

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8. Do not abuse the electrical cable. Keep the cable away from sources of
heat, oil, sharp edges or moving parts. Damaged or tangled cables
increase the risk of electric shock.

SERVICING

1. ALWAYS have the pump serviced by your local CLARKE dealer, using only
identical replacement parts. This will ensure the safety of the pump is
maintained. The use of non standard parts could be hazardous.

2. NEVER attempt any repairs yourself. If you have a problem with the pump
contact your local CLARKE dealer.

3. ALWAYS turn the pump off before carrying out any maintenance.

4. Your CLARKE water pump has been designed to give long and trouble free
service. If, however, having followed the instructions in this booklet
carefully, you encounter problems, take the unit to your local CLARKE
dealer.

ENVIRONMENTAL RECYCLING POLICY

By purchasing this product, the customer is taking on the obligation
to deal with its safe disposal in accordance with the Waste Electrical
and Electronic Equipment regulations (WEEE).

In effect, this means that this product must not be disposed of with
general household waste. It must be disposed of according to the laws
governing Waste Electrical and Electronic Equipment (WEEE) at a recognised
disposal facility.

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ELECTRICAL CONNECTIONS

Plug must be BS1363/A approved.

Always fit a 13 Amp fuse.

Ensure that the outer sheath of the cable is firmly held by the clamp

Neutral

(Blue)

Live

(Brown)

Earth

(Green and Yellow)

WARNING: READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE MAINS
SUPPLY.

Before switching the product on, make sure that the voltage of your electricity
supply is the same as that indicated on the rating plate. This product is
designed to operate on 230VAC 50Hz. Connecting it to any other power
source may cause damage.

This product may be fitted with a non-rewireable plug. If it is necessary to
change the fuse in the plug, the fuse cover must be refitted. If the fuse cover
becomes lost or damaged, the plug must not be used until a suitable
replacement is obtained.

If the plug has to be changed because it is not suitable for your socket, or due
to damage, it should be cut off and a replacement fitted, following the wiring
instructions shown below. The old plug must be disposed of safely, as insertion
into a mains socket could cause an electrical hazard.

If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.

•The Blue wire must be connected to the terminal which is marked N or

coloured Black.

•The Brown wire must be connected to the terminal which is marked L or

coloured Red.

•The Yellow and Green wire must be connected to the terminal which is

marked E or or coloured Green.

We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD)

If in any doubt, consult a qualified electrician. DO NOT attempt any repairs
yourself.

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PREPARATION FOR USE

Accessories designed specifically for this range of pumps are available from
your nearest CLARKE dealer. Contact your dealer for further information.

IMPORTANT: The pump MUST NOT be connected to the mains electrical
supply until all hose/pipe installation is completed.

CONNECTING THE INLET FILTER

1. Screw a non-return valve to the

pump inlet ensuring it is the right
way round, i.e., with the spring­loaded valve able to pass water in
the direction of flow. Do not
overtighten.

2. Screw the inlet filter onto the non-

return valve and tighten by hand.
Do not overtighten.

• Ensure the moulded arrow in the
filter body which indicates the direction of flow, is pointing towards
the pump and that the bowl is hanging vertically down. The filter
bleed plug should be seen at the inlet side of the filter.

3. A male inlet connector is required which must be screwed into the filter
inlet port and hand tightened.

POSITIONING THE PUMP

A typical installation of the pump is shown above. An air-tight seal is essential
when connecting the suction and discharge hoses to the pump.

• Ensure there is no damage to the hoses which must be well

protected and well supported.

• The pump must always be installed and operated in a horizontal

position i.e. with the outlet port facing vertically upwards.

• The fixing holes in the feet should be used to secure the pump firmly

in its operating position.

• Always ensure there is adequate air circulation around the pump

motor.

• Avoid situations where the pump could become drenched with

water. Neither the motor or terminal box are designed to be
waterproof.

Position the pump as near to the water source as possible.

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• Ensure there is adequate drainage and there is no risk of damage to

property as a result of water being discharged.

• The performance of your pump will be affected by the diameter of

the inlet pipe - any restriction will greatly reduce the flow. We
strongly recommend that you use as large a pipe diameter as
practical.

• A gate valve may be installed on the delivery (outlet) side of the

pump which can be adjusted as required to regulate the flow of
water and can also assist in priming the pump.

CAUTION: DO NOT PLACE ANY RESTRICTION ON THE SUCTION (INLET)
SIDE OF THE PUMP UNLESS IT IS AN ISOLATOR VALVE IN A GRAVITY FED
SYSTEM. THESE PUMPS SHOULD NOT BE OPERATED WITH THE DELIVERY
VALVE COMPLETELY CLOSED.

• To prevent unnecessary strain or possible distortion to the pump,

ensure that adequate support is provided to the hoses/pipes. They
will be considerably heavier when filled with water.

• Where the pump is to be a permanent fixture, the fittings to the

pump must be flexible, i.e. a short piece of hose should be installed
between the rigid pipework and the pump.

IMPORTANT: An air leak in the suction line will prevent priming and reduce
the capacity of the pump.

Pay particular attention to the following:

a. Keep all hoses as short and straight as possible and avoid sharp bends.

b. Ensure there is adequate drainage for the discharged water.

c. If a flexible hose must be laid across a roadway, protect it with planking.

(Instantaneous shut off pressure, applied when a vehicle runs across an
unprotected hose, could cause “hydraulic shock”, which can damage the
pump and/or the hose).

USING A FOOT VALVE/FILTER

Instead of using the pump for boosting an existing water supply, the pump
may typically be used for drawing raw water from a well or excavation. In
these applications a foot valve/coarse filter should be fitted to the lower end
of the suction hose as illustrated on page 9. This will retain water in the suction
system and more importantly, to prevent the possibility of large objects
entering the pump body

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1. Attach the foot valve to the end of the suction
hose to prevent stones etc, from being drawn
up, which could cause damage to the pump.
Keep the foot valve clean. If it is likely to clog
with dirt or debris, proceed by either:

• Preparing a bed of stones on which to rest

the foot valve.

• Positioning the valve so that it stays clear of

the bottom of the pit, pond or excavation.

• Tie the foot valve inside a basket or bucket.

PREPARING THE BOOSTER PRESSURE TANK

These pumps utilise an air pressure tank with a pressure regulator to provide a
constant pressure at the outlet. The pump will automatically cut in when the
water pressure reduces to 1.5 Bar, and cut out when the pressure reaches 3
Bar. These pressures are factory set and must not be altered. The pump may
continue to operate for a short while, after the tap is turned off, until the cut­out pressure is reached.

In order for the system to operate
correctly, it is necessary to pressurise
the air chamber to 1.5 Bar (22psi),
which is carried out as follows

1. Unscrew the large protective cap
on the end of the pressure tank to
reveal the air valve as shown.

2. Use an airline or foot pump to
pressurize the tank.

3. Check the pressure with a
standard pressure gauge and
replace the protective cap when
completed.

IMPORTANT: This procedure must be carried out before connecting to the
water supply.

PRIMING THE PUMP

When suction lift is used to draw water into the pump it is essential that all
connections and hoses are completely tight or the system will not work.

Although the pump is of the ‘self-priming’ type, it is still necessary to
completely fill the inlet side of the pump with water prior to initial starting, or if
the system has been drained for any other reason. Priming is carried out as
follows.

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1. Remove the filler plug on top of the pump and slowly fill with water until all
air is expelled.

• Refilling is necessary only if the pump has been drained or if the

water has been lost. Never allow the pump to run dry.

2. Open any valve(s) fitted to
the outlet side of the pump so
as to ensure as great a flow
as possible.

• If the inlet filter is being

used, it is recommended
that you remove the brass
plug on top of the filter unit
and fill the filter bowl with
water.

3. Switch on the pump and
check for leaks. Water should
start to flow through the
system after a short while. If this does not happen, check to ensure that:

• the inlet pipe is completely secure and free from any defects.

• the pump body has been correctly primed.

OPERATION

1. Open any valves in the pipeline.

2. Connect the power supply and switch the pump ON.

3. Wait for the pump to prime.

4. If the motor fails to start or does not deliver water, refer to Faultfinding on
page 12.

NOTE: Filling the suction pipe with water will speed up the priming process,

and it is recommended that a non-return valve be fitted to the end of
the suction pipe.

• If debris has entered the pump causing a blockage, the end

housing can be taken off and the pump cleaned out as described
under Maintenance on page 11.

NOTE: Contaminated water is water containing small solids in suspension, NOT

slurry, sludge, sand, or mud.

5. Stop the pump by switching the pump OFF.

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6. After use, drain residual water from the pump if there is danger of freezing.
If the pump has been used with contaminated or salty water, it should be
thoroughly flushed with clean water following use, both inside and out
before replacing the plug.

MAINTENANCE

For any problems requiring the dismantling and overhaul of the pump,
contact your CLARKE International Service Department on 020-8988-7400.

THE FILTER

The separate inlet filter (Part number 7175100)
supplied with this pump will need regular cleaning
out after use. Unscrew the filter bowl from the top
section as shown and wash out the bowl and filter
element with clean, soapy water.

CLEANING

The only other maintenance required is a regular
inspection to ensure that nothing is blocking the
passage of water through the pump.

If you suspect the pump is blocked by mud, silt,
leaves etc, disconnect it from the mains power
supply and backflush to clear any blockage.

Always keep the pump in a clean condition,
checking regularly for loose bolts or a damaged
power cable etc.

If the pump has been used under
arduous conditions leading to
internal fouling or damage, the
end cover can be removed by
undoing the four socket-headed
cover bolts shown in Fig 6. The
impeller can then be inspected for
damage.

STORAGE

Store in a clean, dry environment
protected from the weather.

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FAULTFINDING

Problem Cause Solution

Pump does not run No mains supply. Check power supply and

replace fuse if necessary
(check fuse rating)

Impeller seized/blocked. Disconnect pump from

mains supply. Investigate
cause and clear block­age

Pump fails to prime Priming chamber not filled

correctly.

Air leaks through suction hose
joints (damaged hose, broken
clamp, damaged/ill-fitting
gasket).

Blocked inlet hose. Clean foot valve &

Pump runs but gives
poor output.

Inlet pipeline blockage. Check inlet pipe and

Inlet filter is blocked Check and clean the

Impeller/mechanical seal is
badly worn.

Congested material inside
pump.

Impeller damaged and mak­ing poor seal.

Suction lift too high Set pump as close as pos-

Suction or delivery pipeline
obstructed.

Fill priming chamber
leaving no air gap as
described on page 9.

Repair connections/
replace hose as neces­sary.

ensure it is not sub­merged in mud/sediment
etc. Ensure there are no
kinks in the inlet hose.

connector for leaks.
Tighten as required.

foot valve.

Return to Clarke dealer
for repair.

Dismantle pump and
clean out.

Return to Clarke dealer
for repair.

sible to the level of liquid
being pumped.

Remove obstruction and
ensure there are no kinks
in the pipeline.

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Congestion in the suction line Avoid unnecessary

Air leaks through damaged
seal.

Sudden loss of flow Loose or leaking connection

to inlet pipe.

Suction head is too high and
causing cavitation.

Undue vibration or
noise.

Suction head is too high and
causing cavitation.

Excessive flow of water Adjust local regulator

Resistance in inlet pipeline
caused by obstruction.

Loose rotating component Return to Clarke dealer

Installation of pump not stable Stop pump and re-posi-

Air pocket in pump or pipeline Release drain plug in

Damaged impeller Return to Clarke dealer

Pump switches on
and off repeatedly

Pump switches on
and off when no
water is being

Low air pressure Check pressure.

Membrane damaged Return to Clarke dealer

Leak in output side. Investigate and correct.

Non-return valve faulty. Check and rectify.

drawn.

Pump does not

Pressure switch faulty Return to Clarke dealer

switch off

No water at pump inlet Check for blockage

Damaged impeller Dismantle and investi-

curves, restrictions or
valves.

Renew seal.

Check pipeline and cor­rect.

Check suction head and
lower the position of the
pump.

Check suction head and
lower the position of the
pump.

valve

Check pipe and leak out
as necessary.

for repair.

tion

impeller housing to
release air.

for repair.

for repair.

for repair.

gate.

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TECHNICAL SPECIFICATIONS

Model BPT1200ss

Weight 12.25 kg

Dimensions (L x W x H) 455 x 270 x 497

Max Rated Delivery 61 Litre/min

Max Head 46 m

Water Classification Clean water (not suitable for drinking)

Connecting thread 1” BSP

Tank Capacity 19 Litre

Tank Rated Pressure 3 Bar

Operating Temperature

Power Supply Required 230V @ 50Hz

Sound Pressure Level 73 dB LpA

Sound Power Level 83 dB LwA

Guaranteed Sound Power <86 dB LwA

Please note that the details and specifications contained herein, are correct
at the time of going to print. However, CLARKE International reserve the right
to change specifications at any time without prior notice. Always consult the
pump’s data plate.

Max 35

o

C

ACCESSORIES

A wide range of airline accessories is available, including Filters, Foot Valves,
Hoses, Couplings, etc. Contact your Clarke dealer for further information or
Clarke International Sales Department on 01992 565333.

The use of parts other than genuine Clarke replacement parts may result in
possible safety hazards or decreased machine performance, and will
invalidate your warranty.

The use of parts other than genuine CLARKE replacement parts may result in
safety hazards, decreased performance, and will invalidate your warranty.

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COMPONENT PARTS

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COMPONENT PARTS

ID DESCRIPTION ID DESCRIPTION

1 Fan Cover 29 Mechanical Seal

2 Retainer 30 O-ring 140 dia

3 Cooling Fan 31 Diffuser Plate

4 Motor End Casting 32 Fixed Ring

5 Wave Washer 33 O-ring

6 120mm Motor Tie Bolt 34 Impeller

7 Motor Stator 35 Diffuser

8 Motor Bearing 6202-2Z 36 Discharge Elbow

9 Rotor 37 O-Ring 30 dia

10 Motor Bearing 6201-2Z 38 End Housing

11 Motor Casting 39 Threaded Plug 15mm

12 Capacitor 12uF 40 O-ring

13 Screw 41 Plastic Hood

14 Cable Clip 42 Braided Hose

15 Cable Gland 43 O-Ring

16 Power Cable & Plug 44 Middle Sealing Bush

17 Grommet 45 Mechanical Pressure Switch

18 Switch Junction Box 46 5-Way Connector

19 Junction Box Cover 47 Drain Plug

20 Machine Screw 10mm 48 O-Ring

21 Waterproof Switch 49 Pressure Gauge

22 Self-tapping Screw 50 Pressure Tank

23 Allen headed bolt 20mm 51 Plastic Foot

24 Plastic Base 52 Nut M8

25 Shouldered Bolt M8 53 Washer

26 Frame Casting 54 Connecting Flange

27 Connecting Cable 55 Air Inlet Valve

28 Nut M8 56 Protective Cover

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DECLARATION OF CONFORMITY - UK

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DECLARATION OF CONFORMITY - CE

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NOTES

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