Bell & Gossett Instruction Manual P86101 REVISION C C UL ® US LISTED TM Series LR Circulators Installation, Operation & Service Instructions INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE. This pump is for indoor use only. SAFETY INSTRUCTIONS This safety alert symbol will be used in this manual and on the pump Safety Instruction 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. 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 UNIQUEMENT A L’INTERIEUR. WARNING RISK OF ELECTRIC SHOCK; THIS PUMP HAS NOT BEEN INVESTIGATED FOR USE IN SWIMMING POOL AND MARINE AREAS. -NONSUBMERSIBLE PUMP- TM Your Series LR Circulator should have the warning/caution label and nonsubmersible warning label displayed to the right (Fig. 1) on the pump conduit box. If this warning and caution label is missing or illegible, contact your local B&G Representative for a replacement. FIG. 1 P86313 NOTE: Bell & Gossett recommends Bronze or Stainless Steel Booster Pumps be used for pumping potable water. DESCRIPTION OPERATIONAL LIMITS The Series LR Circulator features maintenance-free system liquid lubricated bearings, non-overloading permanent split capacitor motor with impedance protection and quiet operation. These pumps are designed to pump liquids compatible with their iron, bronze or stainless steel body constructions. PUMP APPLICATION The Series LR Circulator may be used for water circulating applications in hydronic and solar systems. Maximum Operating Pressure: 150 PSI (10 bars) Maximum Operating Temperature: 225°F (107°C) Electrical Rating: 115V, 60Hz, 1Ø This pump is nonsubmersible, for indoor use only. It has not been investigated, nor is it intended for use in swimming pool and marine areas. 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, ordinances and good practices. 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 expansion tanks and pressure relief valves. 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. Use a copper conductor at least the size of the circuit connectors supplying the pump. Connect the ground wire to the green grounding screw in the wiring compartment. 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: RISK OF ELECTRIC SHOCK Do not install this pump in swimming pool or marine areas. Failure to follow these instructions could result in serious personal injury, death and/or property damage. REMOVAL OF PUMP FROM EXISTING SYSTEM FOR REPLACEMENT 2 WARNING: ELECTRICAL SHOCK HAZARD Disconnect and lockout the power before servicing. 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 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.) 2. Loosen the conduit box cover screw and remove the cover. WARNING: HOT WATER HAZARD Before draining the system, allow water to cool to at least 100°F, 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. 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. 3. Disconnect the electrical supply lines to the pump. 4. Remove the flange nuts and bolts. Then remove the pump from the piping. 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 circulators to facilitate servicing or replacement of the circulator without draining the system. CAUTION: The use of Teflon ®*impregnated pipe compound and Teflon® tape on pipe threads provides lubricity which can lead to overtightening and breakage. Do not overtighten. Failure to follow this instruction can result in moderate personal injury from hot water and/or property damage. Apply torque in even increments to both flange bolts until a value of 115 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 or ring nuts have been adequately tightened and that the solder connections do not leak. Failure to follow these instructions could result in serious personal injury, death and/or property damage. MODE OF DISCHARGE Install suction and discharge flanges or union connectors 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 the bolt-holes in the pump flanges match the bolt-holes in the pipe flanges. If union connections are used, line up the pump threads with union tail pieces. 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 pump body flanges and the suction and discharge pipe flanges. Use 7/16" diameter x 11/2" long cap screw and matching nut to connect the pump to the flanges. 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. WARNING: HOT WATER HAZARD Make sure that each flange gasket remains seated in the flange groove during and after installation. Failure to follow these instructions could result in serious personal injury, death and/or property damage. The Series LR Circulator 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 the flow, the conduit box must be positioned on the top or to the side of the motor housing (see figure 2). If the conduit box position must be changed, it is best to do so before installation. However, if the pump is already installed, see the section titled “REMOVAL OF PUMP FROM EXISTING SYSTEM FOR REPLACEMENT” before proceeding. CAUTION: Make sure the power is turned off before placing anything inside the discharge opening to move the impeller. Failure to follow these instructions could result in serious personal injury, death and/or property damage. TO CHANGE THE CONDUIT POSITION 1. Remove the four (4) 1/4-20 Allen screws (3/16 wrench) while supporting the motor assembly. 2. Remove the motor assembly from the pump body and rotate it to the desired position (see figure 2). 3. Replace the Allen screws and tighten evenly in a diagonal method to 60 in-lbs. 4. Check to see that the impeller turns freely. Insert your finger in the discharge port of the pump body (the arrow on the pump body points in the direction of the discharge) until you can feel the impeller and rotate it with your fingertip. If the impeller does not turn easily, repeat the disassembly/reassembly process. * Teflon is a registared trademark of E. I. DuPont deNemours and Company. FIG. 2 3 WARNING: ELECTRICAL SHOCK HAZARD Disconnect and lock out the power before making electrical connections. Failure to follow these instructions could result in serious personal injury or death. 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. WIRING INSTRUCTIONS A. Loosen the screw securing the conduit box cover (wiring compartment), and remove the screw & cover. TYPICAL WIRING INSTALLATION SCHEMATIC 1Ø POWER SOURCE B. Attach the appropriate size connector to the hole in the side of the conduit box. C. Using a minimum size of 14 AWG copper electrical wire (refer to your local code for wiring restrictions), wire the motor to a single phase power source that matches the electrical rating on the pump nameplate. See Fig. 3. Use the size of electrical wire as dictated by local code. D. Connect the ground wire to the inside of the conduit box with one of the green screws provided inside the box. See Fig. 4. FUSIBLE DISCONNECT OR CIRCUIT BREAKER BY OTHERS S TO REMOTE CONTROL IF REQUIRED NOTE: Electrical supply and grounding wires must be suitable for at least 90°C (194°F). L N PUMP MOTOR NOTE: Series LR Circulators are impedance protected and do not require external overload protection. PUMP MOTOR IMPEDANCE PROTECTED FIG. 3 CONDUIT BOX WIRING DETAIL GREEN GROUND SCREW LINE LEADS FIG. 4 1 L SYSTEM PREPARATION Prior to pump start-up, closed heating and cooling systems should be cleaned, drained, and refilled with clean water. The system fluid pH must be maintained between 7 and 9. 7 N ALTERNATE GROUND SCREW WARNING: HOT WATER LEAKAGE HAZARD Pressurize the body slowly while checking for leaks at all joints with gaskets or solder connections. Failure to follow these instructions could result in serious personal injury and/or property damage. START-UP 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. The system must be completely vented prior to pump operation. Do not run Series LR Circulators dry. Pump operation without water circulation could result in pump and motor damage. © COPYRIGHT 2007 BY ITT CORPORATION PRINTED IN U.S.A. 12-07 THE ITT ENGINEERED BLOCKS SYMBOL AND ENGINEERED FOR LIFE ARE REGISTERED TRADEMARKS OF ITT CORPORATION ITT 8200 N. Austin Avenue Morton Grove, IL 60053 Phone: (847) 966-3700 Fax: (847) 966-9052 www.bellgossett.com PERIODIC INSPECTION Bell & Gossett Series LR Circulators are designed to provide years of trouble free service. It is recommended that periodic inspections be made to check for potential problems with the pump. If any leakage or evidence of leakage is present, repair or replace the unit.