Installation Instructions
Contents
1. Teflon is a registered trademark of E I DuPont de Nemours and Company NOTE The position of the conduit box is determined by the model of the motor used and must be positioned on the bottom or the side of the motor housing As shown to the left 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 Remove the screws securing the conduit box cover wiring compartment and lift off the cover Attach the appropriate size connector to the hole in the side of the conduit box I SINGLE PHASE MOTORS Single phase dual voltage motors can operate at low voltage 115V or high voltage 230V Determine the voltage at which you choose to operate your B amp G pump Locate the wiring dia gram inside the conduit box of the motor Make the connec tions as per the diagram provided with the motor Connect the ground wire to the ground screw inside the conduit box SLEEVE BEARING MOTORS ORANGE BLUE Gay TRACER WHITE HIGH VOLTAGE BLACK ORANGE BLUE TRACER M72151 LOW VOLTAGE FOR 1 HP 1 PHASE N MOTORS ONLY BALL BEARING LOW VOLTAGE LOW VOLTAGE S BROWN La L2 fa WHITE z PED BLACK BROWN ua uja BACK WHITE 6 52. 6 HIGH VOLTAGE HIGH VOLTAGE 5 WHITE wa L2 a Black Gani WHITE ua u fa stack 6 BROWN 5 6 BROWN p lt NOTE Single phase motors are protected with inherent overheating devices and do not require external overload protection Il THREE PHASE MOTORS Three phase motors can operate at either low voltage 208 230V or at high voltage 460V Determine the voltage you choose to operate your B amp G pump Wiring instructions for each option are listed below and are also found in the conduit box cover or on the motor nameplate N HIGH VOLTAGE Replace the conduit box cover and screws WARNING ELECTRICAL SHOCK HAZARD Be certain that all connections are secure and the conduit box cover is closed before electrical power is con nected Failure to follow these instructions could result in serious personal injury death and or property damage OPERATIONAL INSTRUCTIONS SYSTEM PREPARATION Prior to pump start up closed heating and cooling systems should be flushed with clean water and drained The system should then be filled with clean water having a PH between 7 and 9 LUBRICATION Although all new B amp G pumps are test run at the factory they must be lubricated thoroughly before being placed in opera tion Bell amp Gossett supplies a high quality lubricant specifically for this purpose which can be purchased from any B amp G Representative Part No L23401 Proper lubricat
3. 3 Bell amp Gossett a xylem brand Booster Pumps INSTRUCTIONS FOR THE FOLLOWING B amp G PRODUCTS 21 2 LD3 HD3 PD35 PD37 1HP amp 11 2HP INSTRUCTION MANUAL P76966E INSTALLER PLEASE LEAVE THIS MANUAL FOR THE OWNER S USE DESCRIPTION For applications requiring higher flow and head pressures Bell amp Gossett provides an entire range of booster pumps The designs of these pumps are based on three part configuration which offers complete field repairability and compact con struction All Bell amp Gossett boosters are equipped with the incomparable B amp G manufactured motor for quiet and efficient operation These pumps are for indoor use only PUMP APPLICATION Bell amp Gossett Booster Pumps may be used for hydronic heat ing and cooling systems domestic water industrial applica tions and general service operations Bell amp Gossett recom mends that bronze constructed pumps be used for pumping potable water OPERATIONAL LIMITS These pumps are designed to pump liquids compatible with their iron or bronze body construction This pump line delivers maximum capacities from 100 GPM to 150 GPM Unless spe cial provisions have been made by ITT Bell amp Gossett the operational limits for Series 21 2 LD3 HD3 PD35 PD37 PD38 amp PD40 Pumps are listed below 125 psi 225 F 115 230V 60 Hz 1PH 208 230 460V 60 Hz 3PH 115V or 230V 60 Hz 1PH Max Working Pressure Max Operating T
4. and lockout power before servicing Failure to follow these instructions could result in serious personal injury death and or property damage Loosen the conduit box cover screws and remove the cover Follow this procedure with the removal of the wire nuts and flexible conduit connector REMOVE THE MOTOR AND BEARING ASSEMBLY 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 servic ing is complete Failure to follow these instructions could result in serious personal injury death and or property damage The system should be drained by opening the boiler drain valve and the vent near the top of the system If a Flo Control valve is installed and there are balance valves on the returns then the balance valves may be closed to isolate the boiler from the system The Flo Control valve will act as a check valve on the supply and only the boiler will need to be drained Open a vent between the boiler and the system WARNING HIGH PRESSURE HAZARD Pressure may be present in the pump body This pressure can be relieved by loosening the volute cap screws and shifting the bearing assembly slightly to allow the pressurized water to escape Failure to follow these instructions could result in serious personal injury or death Separate the bearing assembly and motor from the p
5. emperature Electrical Rating 1 4 HP only Motors with special electrical characteristics are available on request Contact your local Bell amp Gossett Representative for details SAFETY INSTRUCTIONS 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 A WARNING BEFORE INSTALLING USING OR SERVICING THIS PRODUCT READ THE WARNING NOTES AND INSTRUCTIONS IN INSTRUCTION MANUAL FAILURE TO DO SO MAY RESULT IN SERIOUS INJURY OR PROPERTY DAMAGE V56845 Your Booster Pump should have this warning label affixed to the pump near the conduit box cover If this warning is missing or illegible contact your local Bell amp Gossett Representative for a replacement SAFETY REQUIREMENTS MECHANICAL SAFETY ELECTRICAL 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 ELECTRICAL SHOCK HAZARD Electrical connections are to be made by a qualified electrician in accordance with all applicable codes ordi nances and good practices Failure to follow these instruc t
6. ion proce dures are as follows 1 PUMP BEARINGS Fill the bearing frame according to the oiling instructions decal At the time of installation or start of each heating season add approximately 1 oz of B amp G 20 weight non detergent oil A SAE 20 non deter gent or 10W 30 oil may be substituted More frequent lubrication may be required under adverse conditions such as high ambient temperatures 2 MOTOR BEARINGS Lubricate through the two motor oil ports according to lubrication decal once every four months more often under adverse conditions Use eight to ten drops in each oil cup Does not apply to PD38 amp PD40 pumps These models use permanently lubricated ball bearing motors For non Bell amp Gossett Motors lubrication should be in accor dance with the motor manufacturer s instructions on the nameplate NOTE Over oiling can cause motor mount deterioration and may cause spillage onto surrounding surfaces Deteriorated motor mounts will lead to misalignment and excessive coupler wear ROTATION Pump rotation for the 21 2 LD3 and HD3 is counterclockwise when viewed from the back of the motor Whereas the rota tion is clockwise when views from the back of the motor for the PD35 PD37 PD38 and PD40 pumps An arrow is provid ed to show the rotational direction PRIMING AND STARTING CAUTION SEAL DAMAGE HAZARD Do not run the pump dry seal damage may occur Failure to follow these instructions could resu
7. ions 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 sys tem 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 WARNING ELECTRICAL OVERLOAD HAZARD Three phase motors must have properly sized heaters to provide overload and under voltage protection Single phase motors have built in overload protectors 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 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 WARNING HOT WATER HAZARD When disassembling a gasketed joint always use a new gasket upon reassembly NEVER REUSE OLD GAS KETS Failure to follow these instructions could result in serious personal injury death and or property damage WARNING ELECTRICAL GROUNDING HAZARD Adequate electrical grounding is requi
8. lt in moderate personal injury and or property damage Do not run B amp G circulator pumps dry Before starting the pump must be filled with water Air should be vented from the system by means of a system air vent at a high point in the system or by an alternate method The system must be com pletely vented prior to pump operation WARNING HOT WATER LEAKAGE HAZARD Pressurize the pump 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 The pump should be started with the discharge valve closed and the suction valve fully open After the pump is at operat ing speed the discharge valve should be opened gradually REPLACING THE SEAL DISCONNECT THE ELECTRICAL SUPPLY WARNING ELECTRICAL SHOCK HAZARD Disconnect and lockout the power before servicing Failure to follow these instructions could result in serious personal injury or death The electrical supply must be turned off and the pump service valves must be closed before servicing procedures begin If no service valves are installed the city water supply valve should be closed 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 WARNING UNEXPECTED START UP HAZARD Disconnect
9. ng D Companion Flange i included except 2 1 2 REPLACEMENT PROCEDURE With the bearing assembly and motor removed from the sys tem use the following instructions to facilitate the replacement 1 Use a strap wrench or rag to prevent the impeller from turning with one hand and loosen the impeller nut with the other 2 Lift the spring retainer and the seal spring from the shaft Remove the compression ring from the seal collar by inserting a small screwdriver underneath the ring and carefully applying an upward prying force Remove the ring collar and the remaining seal components from the shaft NOTE Bell amp Gossett seal assemblies consist of an insert retainer rubber gasket ceramic insert carbon seal ring rub ber collar brass collar and compression ring spring and spring retainer Each of these components must be replaced when replacing the mechanical seal NEVER REPLACE INDI VIDUAL COMPONENTS SEPARATELY 3 Using a clean lint free rag remove any debris that may have accumulated in the seal recess 4 Place the new retainer in the bearing assembly s seal recess Seat the thin rubber gasket in the recess and set the ceramic insert atop the gasket The ceramic has a top side and bottom side The bottom is identifiable by its slightly recessed grooves These grooves should face downward toward the rubber gasket 5 Before proceeding place the shaft end on a wooden block the wooden block should push the shaft
10. pports for various applications Ordinary wire or band hangers are not adequate to maintain alignment It is very important to provide strong rigid support for the suction and discharge lines IMPORTANT Do not support the pump by its power pack To function properly the power pack must not be restrained PUMP FLANGES New Bell amp Gossett flange gaskets must be installed between the flanges of the pump body and suction and discharge pipes The gaskets should be clean and grease free old gaskets should never be reused WARNING HOT WATER HAZARD When disassembling a gasketed joint always use a new gasket upon reassembly NEVER RE USE OLD GAS KETS Failure to follow these instructions could result in serious personal injury death and or property damage WARNING HOT WATER HAZARD Make sure that each flange gasket remains seated in the flange groove during and after installation Failure to fol low these instructions could result in serious personal injury death and or property damage Apply torque in even increments to all 4 flange bolts using a diagonal tightening pattern to a value of 96 132 in lbs 8 11 ft lbs Both the suction and discharge flanges 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
11. r amp Motor Mount Replacement Booster Pump Service Manual YOUR BELL amp GOSSETT REPRESENTATIVE IS www xyleminc com brands bellgossett Bell amp Gossett is a trademark of Xylem Inc or one of its subsidiaries 2012 Xylem Inc P76966E April 2012
12. red for the safe operation of B amp G Pumps The use of grounded metal con duit 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 by connecting a copper conductor at least the size of the circuit conductors supplying the pump to the green grounding screw provided within the wiring compartment Failure to follow 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 nec essary 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 servic ing is complete Failure to follow these instructions could result in serious personal injury death and or property damage 2 Loosen the conduit box cover screw and remove the cover WARNING UNEXPECTED START UP HAZARD Single phase motors are equipped with automatic reset overload protectors The pump can restart without wa
13. rning Disconnect and lockout power before servicing Failure to follow these instructions could result in serious personal injury death and or property damage 3 Disconnect the electrical supply 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 pressur ized water to escape Failure to follow these instructions could result in serious personal injury or death WARNING ELECTRICAL SHOCK HAZARD Be certain the electrical power is not present at the motor leads before continuing Failure to follow these in structions could result in serious personal injury or death 4 Remove the flange bolts and nuts and then remove the pump from the piping PUMP INSTALLATION PUMP LOCATION Bell amp Gossett booster pumps should be installed where there will be sufficient room for future inspection maintenance and service It is highly recommended that service valves shut off also be installed on each side of circulator pumps to facilitate servicing or replacing the pump without draining the system If it is required to lift the entire pump do so with slings placed around the pump assembly as shown below IMPORTANT In closed systems do not install and operate Bell amp Gossett pumps 3D valves suction diffusers etc with out properly sized safety and con
14. to its for ward most position there should not be any end play in the shaft 6 Lubricate the rubber seal collar with soapy water The entire rotating seal assembly which includes the carbon seal ring rubber collar brass collar and compression ring is to be pushed onto the shaft as one unit Do not attempt GENERAL INSTRUCTIONS 1 Keep the pump and motor properly lubricated 2 If the system is to be exposed to freezing temperatures drain the pump PERIODIC INSPECTION Inspect the pump for leaking seals worn gaskets and looses or damaged components Replace or repair as required DEALER SERVICING If your pump requires further repair contact your local B amp G Representative Having the following information at hand will facilitate your representative s ability to assist you 1 Complete data from nameplate 2 Suction and discharge pipe pressure gauge readings 3 Ampere draw of the motor 4 Asketch of the pumping system includes pipes valves etc xylem Let s Solve Water Xylem Inc 8200 N Austin Avenue Morton Grove Illinois 60053 Phone 847 966 3700 Fax 847 965 8379 to assemble the seal by placing the components on the shaft individually The notches in the brass collar should be aligned with the recesses found on each side of the carbon ring 7 Press the brass compression ring tightly against the upper end of the rubber collar A screwdriver can be used at several points along its peripher
15. trol devices Such devices include the properly sized and located pressure relief valves compression tanks and pressure temperature and flow con trols If the system is not equipped with these devices consult the responsible engineer or architect before operating PUMP SUPPORT AND PIPING Install the suction and discharge flanges on the pipe ends using Teflon tape sealer or high quality thread sealant Minimize strain on the pump by supporting the suction and dis charge piping with pipe hangers near the pump Line up the vertical and horizontal pipings so that the bolt holes in both the pump and pipe flanges are aligned DO NOT ATTEMPT TO SPRING THE SUCTION OR DISCHARGE LINES INTO POSI MODE OF DISCHARGE Bell amp Gossett Pumps can be installed to discharge up down left or right The oiling ports must always be in the twelve o clock position on top as shown below with the motor and bearing assembly always in a horizontal position as shown to the right THE ARROW ON THE PUMP BODY MUST POINT IN THE DIRECTION OF THE FLOW If it becomes necessary to change the mode of discharge refer to B amp G Instruction Manual HS 105 SM for specific instructions in removing the motor and bearing assembly from the pump body OIL PORTS CAPACITOR ON SINGLE PHASE ONLY Mewocene TION THIS MAY RESULT IN UNWANTED STRESS IN THE PUMP BODY FLANGE CONNECTIONS AND OR PIPING The code for pressure piping ANSI B31 1 lists types of su
16. ump body by removing the volute capscrews from the bearing bracket or cover plate see diagrams at right DETERMINE THE SEAL TYPE Cut away diagrams have been provided to illustrate the compo nents of the booster bearing assemblies The primary feature distinguishing the mechanical seals of the 21 2 LD3 HD3 PD35 and PD37 pumps from the PD38 and PD40 is the shape of the spring retainer which is seated between the spring and the impeller Refer to the following diagrams whenever seal replacement becomes necessary PUMP BODY DIAGRAM 1 2 SEAL Series 21 2 LD3 HD3 PD35 PD37 Discharge Gage Tapping on side opposite Volute Gasket Seal Assembly Coupler Assembly Impeller Enclosed Impeller Key Pump Shaft Impeller Lock Nut Motor Bracket Assembly Face Plate Bearing Bracket Assembly Companion Flange Suction Gage included Tapping Seal Housing GE Seat Insert PUMP BODY DIAGRAM 3 4 SEAL Series PD38 PD40 Discharge Gage Tapping on side opposite Volute Gasket Rear Bearing Lip Seal Mechanical Seal i Seal Assembly mh Impeller Enclosed Impeller Key Coupler Assembly Pump Shaft Impeller Lock Nut y nej Impeller Lock Washer ih ee 1 i T Motor Bracket Front Bearing Assembly Volute Capscrews 7 A Cover Plate A Volute Shaft Sleeve Bearing Bracket Assembly Suction Gage Tappi
17. y to provide a tight and even fit Press with the screwdriver do not tap Tapping on the seal may break the ceramic or carbon insert 8 With the shaft resting on the wooden block place the seal spring and spring retainer on the shaft Next place the impeller and lock washer Thread the impeller nut to the shaft and tighten to 96 144 in lbs 8 12 ft Ibs Do not overtighten WARNING HOT WATER HAZARD Whenever the bearing assembly is removed from the piping use a new gasket when re installing Failure to fol low these instructions could result in serious personal injury and or property damage 9 Clean the pump body of excess debris Place a new gas ket in the recess of the pump body ensure that it sits flush against the gasket surface 10 Replace the motor and bearing assembly by inserting the impeller in the pump body and evenly tightening the cap screws to 156 in lbs 13 ft lbs using a diagonal tight ening pattern 11 Refer to the WIRING INSTRUCTIONS section in this manual to properly configure all electrical connections 12 Following the OPERATIONAL INSTRUCTIONS section in this manual to 1 check the PH of the system water 2 to check the rotation of the pump and 3 to prime the sys tem prior to starting ADDITIONAL PUMP REPAIR Refer to the following manual for further repair instructions for the Bell amp Gossett Pumps pated P06452 or S15900 Rev D EEE HS 105 SM Rev 3 Couple
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