OWNERS MANUAL - Rainmaker Pump Stations

OWNERS MANUAL
INSTALLATION AND OPERATING INSTRUCTIONS
REPAIR PARTS LIST
Close Coupled Motor Driven
Centrifugal Pump
1134 0694
IMPORTANT
For best possible performance and continuous, satisfactory operation,
read these instructions before installing your new pump.
Should service be required, this manual can be a valuable guide.
It should be kept near the installation for ready reference.
Record nameplate data from pump on blank nameplate inside this
manual for future reference.
Berkeley Pumps / 293 Wright Street / Delavan, WI 53115
F00634 (Rev. 10/27/06)
Table of Contents
Page
• SAFETY .................................................................................................................................................................3
• INSTALLATION
General Information ................................................................................................................................... 4, 5
Foundation ......................................................................................................................................................5
Suction Connection for Centrifugal Pump Installation..............................................................................4, 6-9
Suction Connection for Swimming Pool Installation.............................................................................4, 10-11
Discharge Connection..........................................................................................................................4, 12-13
Electrical Connection ................................................................................................................................4, 14
• START-UP
General Information ......................................................................................................................................15
Check Pump Rotation .............................................................................................................................15, 16
Priming ....................................................................................................................................................15, 17
• MAINTENANCE
General Information / Observational Maintenance / Pump Protection ..........................................................18
Packing ...................................................................................................................................................18, 19
Mechanical Shaft Seal .......................................................................................................................18, 20-21
• PUMP NOMENCLATURE
General Information ......................................................................................................................................22
Parts Breakdown...........................................................................................................................................23
• TROUBLESHOOTING
Chart .............................................................................................................................................................24
BERKELEY/WICOR CANADA WARRANTY
Berkeley/Wicor Canada, Inc. (“Wicor”) warrants to the original consumer purchaser (“Purchaser”) of its products that they are free from defects in
material or workmanship.
If within twelve (12) months from the date of installation or twenty-four (24) months from the date of manufacture any such product shall prove to be
defective, it shall be repaired or replaced at Berkeley’s/Wicor’s option, subject to the terms and conditions set forth below.
General Terms and Conditions
Purchaser must pay all labor and shipping charges necessary to replace product covered by this warranty. This warranty shall not apply to products
which, in the sole judgement of Berkeley/Wicor, have been subject to negligence, abuse, accident, misapplication, tampering, alteration; nor due to
improper installation, operation, maintenance or storage; nor to other than normal application, use or service, including but not limited to,
operational failures caused by corrosion, rust or other foreign materials in the system, or operation at pressures in excess of recommended
maximums.
Requests for service under this warranty shall be made by contacting the installing Berkeley/Wicor dealer as soon as possible after the discovery of
any alleged defect. Berkeley/Wicor will subsequently take corrective action as promptly as reasonably possible. No requests for service under this
warranty will be accepted if received more than 30 days after the term of the warranty.
The warranty on all three phase submersible motors is void if three-leg overload protection of recommended size is not used.
This warranty sets forth Berkeley’s/Wicor’s sole obligation and purchaser’s exclusive remedy for defective products.
BERKELEY/WICOR SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS WARRANTIES. IMPLIED WARRANTIES,
INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
SHALL NOT EXTEND BEYOND THE DURATION OF THE APPLICABLE EXPRESS WARRANTIES PROVIDED HEREIN.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts, so
the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary
from state to state.
In the U.S.: Berkeley, 293 Wright St., Delavan, WI 53115
In Canada: Wicor Canada, Inc., 4544 Fieldgate Parkway, Mississauga, Ontario L4W 3W6
Page 2
F00634
Safety First
READ AND FOLLOW
SAFETY INSTRUCTIONS!
This is the safety alert symbol. When you see
this symbol on your pump or in this manual, look for
one of the following signal words and be alert to the
potential for personal injury:
General Safety
Do not allow pump, piping, or any other system
component containing water to freeze. Freezing may
damage system, leading to injury or flooding. Allowing
pump or system components to freeze will void
warranty.
Pump approved liquids only with this pump.
warns about hazards that will cause
serious personal injury, death or major property
damage if ignored.
Periodically inspect pump and system components.
warns about hazards that will or can
cause serious personal injury, death or major property
damage if ignored.
Keep work area clean, uncluttered and properly
lighted; store properly all unused tools and equipment.
Wear safety glasses at all times when working on
pumps.
Keep visitors at a safe distance from the work areas.
warns about hazards that will or can
cause minor personal injury or property damage if
ignored.
The label NOTICE indicates special instructions which
are important but not related to hazards.
Carefully read and follow all safety instructions in
this manual and on pump.
Keep safety labels in good condition.
Replace missing or damaged safety labels.
Electrical Safety
WARNING
Wire motor for correct
voltage. See “Electrical”
section of this manual and
motor nameplate.
Ground motor before
connecting to power supply.
Hazardous voltage.
Can shock, burn, or
cause death.
Ground pump before
connecting to power
supply.
Meet National Electrical
Code and local codes for all
wiring.
Follow wiring instructions
in this manual when
connecting motor to power
lines.
Make workshops childproof; use padlocks and master
switches; remove starter keys.
Swimming Pool and Spa Installation Safety
Incorrectly installed or tested
equipment may fail, causing severe
injury or property damage.
Read and follow instructions in owner's
manual when installing and operating equipment. Have
a trained pool professional perform all pressure tests.
1. Do not connect system to a high pressure or city
water system.
2. Install pump with at least 2 hydraulically balanced
main drains equipped with correctly installed,
screw-fastened, anti-entrapment certified covers.
See Page 11.
3. Trapped air in system can cause explosion. BE
SURE all air is out of system before operating or
testing equipment.
Before pressure testing, make the following safety
checks:
• Check all clamps, bolts, lids, and system
accessories before testing.
• Release all air in system before testing.
• Tighten Berkeley trap lids to 30 ft. lbs. (4.1 kg-cm)
torque for testing.
• Water pressure for test must be less than 25 PSI
(172 kPa).
• Water Temperature for test must be less than
100° F. (38° C).
• Limit test to 24 hours. After test, visually check
system to be sure it is ready for operation. Remove
trap lid and retighten hand tight only.
NOTICE: These parameters apply to Berkeley
equipment only. For non-Berkeley equipment,
consult manufacturer.
F00634
Page 3
Installation
General Information
Proper Lifting Procedure
Heavy weight crushing hazard. NEVER
walk or reach under a suspended pump.
DO NOT screw an eye bolt into the motor housing and
attempt to lift assembly! The lifting point built into the
motor case is not designed to support the combined
weight of the motor and pump.
The crane or hoist must have a capacity in excess of the
combined weight of the motor and pump. Use a
minimum of two chains or straps to lift motor/pump
assembly. Each chain or strap must have a capacity in
excess of the combined weight of the motor and pump.
MOTOR / PUMP LIFTING PROCEDURE:
Wrap the first chain or strap under the fan end of the
motor up tight against the motor feet, and the second
chain or strap under the pump bracket between the
pump end and the motor.
Raise motor/pump assembly slowly to ensure that the
chains or straps will not slip when put under tension.
Balance motor and pump with chains or straps to
maintain proper weight distribution. If not balanced,
release tension on the chains or straps and readjust.
2498 0497
Page 4
F00634
Installation
General Information
Pump Foundation
LOCATION:
Locate the pump as near the water source as practical. Make
the pipe run as short and straight as possible, especially if a
suction lift is required.
Careful attention should be taken to assure that net positive
suction head available (NPSHA) exceeds net positive suction
head required (NPSHR) by the pump or reduced performance
and severe pump damage may result. If in doubt, check with
your nearest Berkeley professional dealer. Install pump in a
clean, dry and drained location readily accessible for
inspection and maintenance. Provide ample ventilation.
1/2" or thicker
Sole Plate tapped
for hold down bolts
Pump or
Motor Frame
Anchor
Bolts
ge
ina
Dra
Concrete Foundation
Pump or
Motor Frame
FOUNDATION: Refer to illustrations at right.
Heavy weights. Use care and proper
equipment when handling pump for installation. Pump should
be set on a concrete foundation which is sufficiently substantial
to absorb vibration and which provides a permanent and rigid
support.
Pump or
Motor Frame
PIPING:
System piping should be at least one commercial pipe size
larger than pump connections and flow velocity should not
exceed eight (8) feet per second. In pool installation, flow
velocity should not exceed six (6) feet per second.
NOTICE: Take care to align piping with pump case.
Misalignment or excessive pipe strain can cause distortion of
pump components resulting in rubbing, breakage and reduced
pump life.
Support pipe in such a way that no force is exerted on pump
connections. Check alignment as follows: with the pump shut
down and isolation valves closed, remove pipe flange bolts. If
the mating flanges come apart or shift, misalignment is present
and causing pressure on the connections. Adjust pipe supports
until flanges mate without any force. This procedure can be
done throughout piping system.
Steel
Channel
Anchor
Bolt
Shims
for alignment
Wedges
Various Heights
Tack
Weld
Grout
Grout
Dam
Dra
in
Concrete
Foundation
age
SUCTION PIPING:
Refer to Pages 10 and 11 for installation instructions for
swimming pool circulating pump applications. Refer to Pages 6
through 9 for recommended and not recommended practices
in suction connections in centrifugal installations.
DISCHARGE PIPING:
Refer to illustrations on Page 12 and 13 for recommended and
not recommended practices in discharge connections.
ELECTRICAL CONNECTION:
Hazardous voltage. Can shock, burn, or
cause death. All wiring should be done by a qualified
electrician. Disconnect power to pump before servicing.
Check voltage and phase stamped on pump motor nameplate
before wiring. Be sure they agree with your electric current
supply. They MUST be the same. If in doubt, check with your
local power company.
Refer to illustration on Page 14 for minimum recommended
pumping panel components that help safeguard your pump
during operation.
F00634
Shims
ge
ina
Dra
Concrete
Foundation
797 0394
• There are several types of permanent pump/ foundation
installations in use. Those pictured above are typical.
• If grout is used, top of concrete should be left rough to
provide a good bonding surface.
• Foundation should slope away from pump to prevent liquid
from pooling.
Page 5
Installation
Centrifugal Pump Suction Connection
Suction Lift
See Pages 10 and 11 for
Swimming Pool Installation requirements.
Short length of straight pipe after reducer.
( 2 times pipe diameter minimum )
For Han-Dee Primer
connection, see start-up.
Suction
Gauge
Straight run, short as possible but
at least 6 times pipe diameter ("D")
after elbow to stabilize flow.
503 0194
Eccentric Reducer
flat side up.
See foundation
section.
Standard or long
radius elbow.
Support pipe
as required
Slope upward
to pump.
NOTICE: All connections
must be air tight.
As close
as possible
• Use pipe, tubing, or reinforced hose to make suction
connection. Hose must have sufficient strength to
resist collapse under the pressure differential that
occurs while pump is running.
• Suction pipe size should be at least one commercial
pipe size larger than opening of pump inlet. Flow
velocity should not exceed 8 ft./sec.
Pipe diameter ("D")
4 x "D"
minimum
• Suction screen must screen out solids that could clog
pump impeller.
• Suction screen area must be at least four times
suction pipe area.
• Net Positive Suction Head Available (NPSHA) must
exceed Net Positive Suction Head Required
(NPSHR) by the pump or reduced performance and
severe pump damage may result.
1 x "D" minimum
from bottom
• All suction piping must have continuous rise to the
pump suction inlet. A 1/4 inch per foot minimum slope
is recommended.
Strainer prevents debris
from entering pump
suction and prevents
entrapment
Strainer
/ Foothazard.
Valve
To keep
debris
entering
Foot
valvefrom
maintains
pump suction
and
to
maintain
pump after
prime shut-off.
after shutoff.
pump prime
Recommended
Page 6
F00634
Installation
Centrifugal Pump Suction Connection
Suction Lift
See Pages 10 and 11 for
Swimming Pool Installation requirements.
Do not use
Concentric
Reducer.
1152 0794
Concentric Reducer causes high spots
along the suction line resulting in air pockets.
Do not install valves
in suction line.
No support or
uneven mounting
not recommended.
Unsupported
pipe causes
excessive stress
on pump and fittings.
Excess use of pipe fittings
means potential air leaks.
Elbow immediately in
front of pump intake
not recommended.
• Suction pipe sloping downward to pump inlet will trap
air which will reduce performance and may cause
pump to lose prime.
Long run
not recommended
Pipe diameter
("D") undersized
reduces performance
Vortex caused by
insufficient submergence
may cause pump to
lose prime.
• Suction piping that is undersized will create excess
friction losses that may cause cavitation and a
reduction in pump performance.
• Excess fittings and bends in suction line results in
trapped air, reduced performance, and high friction
losses which may cause cavitation.
Suction entrapment hazard if strainer is
High suction
lift should
be avoided.
Less than
4 x "D"
No strainer
may cause
pump to
clog.
not used.
Insufficient bottom
clearance
Not Recommended
F00634
Page 7
Installation
Centrifugal Pump Suction Connection
When Flooded Suction Exists
See Pages 10 and 11 for
Swimming Pool Installation requirements.
Short run of straight pipe after reducer
(2 times pipe diameter).
Water under
pressure
Maintain minimum liquid
level to prevent vortexing.
Eccentric Reducer
flat side up.
Suction
Gauge
0294
Isolation Valve
full open when
pumping.
Straight run, short as possible but
at least 6 times pipe diameter after
pipe fitting to stabilize flow.
Slope upward to pump.
Support pipe
as required
• Use pipe, tubing, or reinforced hose to make suction
connection. Hose must have sufficient strength to
resist collapse under the atmospheric pressure
differential that may occur while pump is running.
• It is important, even with a flooded suction condition,
that proper pipe fittings are used so water is delivered
to impeller eye with a smooth flow and consistent
velocity.
Standard or
long radius
elbow.
• An isolation valve is used in a pressurized suction
pipe to permit servicing pump.
• Piping run and connection fittings should be properly
aligned and independently supported to reduce strain
on pump case.
• If solids are present, a strainer should be used to
protect the pump.
• Suction pipe size should be at least one commercial
pipe size larger than opening of pipe inlet. Flow
velocity should not exceed 8 ft./sec.
Recommended
Page 8
F00634
Installation
Centrifugal Pump Suction Connection
When Flooded Suction Exists
See Pages 10 and 11 for
Swimming Pool Installation requirements.
Inverted Eccentric Reducer
may result in air pocket.
Water under
pressure
Valve in upward
position may trap
air.
Do not leave
valve partially
closed.
703 0294
Check Valve
in suction pipe
not needed.
Concentric Reducer may
cause air pockets.
Unsupported
pipe causes
excessive stress
on pump and fittings.
Miter elbow or short
radius elbow not
recommended.
• Suction piping that is undersized will create excess
friction losses that may cause cavitation and a
reduction in pump performance.
Elbow immediately in front
of pump intake not recommended.
• Excess fittings and bends in suction line results in
trapped air, reduced performance, and high friction
losses which may cause cavitation.
• If check valve is required for back flow prevention,
locate on the discharge side of pump.
Not Recommended
F00634
Page 9
Installation
Swimming Pool Pump Suction Connection
Typical Swimming Pool
Short length of straight
pipe after reducer.
( 2 times pipe
diameter minimum )
Eccentric Reducer
flat side up.
Flow
Through
Skimmer
0801
55
LI STED SUCT
A-R I
ITE
M
Isolation See
foundation
Valve
Return to Pool section.
One size larger
than Pump Discharge
port to reduce friction
0 -0 0 1 0
P
G
Equalizer
Fitting
ST
Flow-Through
Strainer
ION FITTING
Suction
Gauge
To Pump
Suction
Straight run, as short
as possible but at least 6 times the
pipe diameter ("D") after strainer
to stabilize flow.
All suction outlets must have
correctly installed, screw-fastened
covers in place.
Isolation
Valve
Standard
or long
radius
elbow.
No shutoff valve
betweenTee and
Main Drains
Support pipe
as required
NOTICE: All connections
must be air tight.
• At least two hydraulically balanced main drains for
each pump suction line. Main drain must be at least
three feet center to center.
Not
to
Scale
• The pump suction system must provide protection3080 1097
against the hazard of suction entrapment or hair
entrapment/entanglement. All suction outlet covers
must be maintained. They must be replaced if
• The system must not be able to operate with the
cracked, broken, or missing.
pump drawing water from only one main drain (that
• If 100% of the pump’s flow comes from the main
is, there must be at least two main drains connected
drain system, the maximum water velocity in the
to the pump whenever it is running.) However, if two
pump suction hydraulic system must be six feet per
main drains run into a single suction line, the single
second or less even if one main drain (suction
suction line may be equipped with a valve which will
fitting) is completely blocked.
shut off both main drains from the pump.
Page 10
F00634
Installation
Swimming Pool Pump Suction Connection
Suction Requirements
Pump suction is hazardous and can
trap and drown or disembowel bathers. Do not use
or operate swimming pools, spas, or hot tubs if a
suction outlet cover is missing, broken, or loose.
Follow the guidelines below for a pump installation
which minimizes risk to users of pools, spas, and hot
tubs.
Entrapment Protection
The pump suction system must provide protection
against the hazard of suction entrapment or hair
entrapment/entanglement.
Suction Outlet Covers
All suction outlet covers must be maintained. They
must be replaced if cracked, broken, or missing.
All suction outlets must have correctly installed, screwfastened covers in place.
Testing and Certification
Suction outlet covers must have been tested by a
nationally recognized testing laboratory and found to
comply with the lastest ASME/ANSI Specification for
Suction Fittings For Use in Swimming Pools, Spas, Hot
Tubs, and Whirlpool Bathtub Applications.
An NSF certified hair and lint strainer must be installed
with the pump in order to comply with NSF Standard
50.
F00634
Outlets Per Pump
Provide at least two hydraulically balanced main
drains, with covers (see Page 10), for each swimming
pool pump suction line. The centers of the main drains
(suction fittings) must be at least three feet apart.
The system must be built so that it cannot operate with
the pump drawing water from only one main drain (that
is, there must be at least two main drains connected to
the pump whenever it is running). However, if two main
drains run into a single suction line, the single suction
line may be equipped with a valve which will shutoff
both main drains from the pump.
More than one pump can be connected to a single
suction line as long as the requirements above are
met.
Water Velocity
The maximum water velocity through any suction outlet
must be 1.5 feet per second. In any case, do not
exceed the suction fitting’s maximum designed flow
rate.
If 100% of the pump’s flow comes from the main drain
system, the maximum water velocity in the pump
suction hydraulic system must be six feet per second
or less even if one main drain (suction fitting) is
completely blocked.
Page 11
Installation
Discharge Connection
Expansion joint with tie
rods where needed.
Isolation
Valve
Use Concentric Reducer
to mimimize friction losses.
Discharge pipe diameter at
least one nominal pipe size
larger than discharge opening
in pump.
This view shows discharge
fittings typical of pump
with flooded suction.
This fitting may be used to
check shut-off head.
706 0294
Pressure
Gauge
Support piping
as required
Align piping to
minimize flange
stress.
These two views show discharge
fittings typical of pump with
suction lift.
Isolation valve to
permit servicing of
check valve or pump.
• Use pipe, tubing or reinforced hose to make
discharge connection. Material selected must have
sufficient strength for operating pressures.
• Discharge pipe should be sized so that flow velocity
is below 8 feet per second.
• Use ONLY non-slamming check valves to prevent
hydraulic shock (water hammer).
Non-Slam or
spring loaded
check valve.
• Use gate, ball, or butterfly valve for isolation. Valve
should be full open during operation.
• Maintain proper pipe size throughout discharge
system, using as few elbows and tees as possible to
keep friction loss to a minimum.
• Install pressure gauge after reducer as shown to
check operating pressure or shut-off head.
Discharge
Priming
Valve
Recommended
Page 12
F00634
Installation
Discharge Connection
Avoid check valves
that cause hydraulic
shock.
708 0294
Avoid undersized
pipe diameter.
Do not force alignment
that can cause flange
stresses.
Do not leave
pipe unsupported.
Do not use Gate Valve
to throttle flow.
Avoid abrupt change
in pipe size.
• Avoid excess friction loss caused by numerous
fittings, insufficient pipe diameter, and sharp turns in
pipe run.
• Swing type check valves can permit build-up of
reverse velocity before closing causing hydraulic
shock or “water hammer.”
Not Recommended
F00634
Page 13
Installation
Electrical Connection
Protect Your Investment
Incoming Power
1
4
2
5
3
L1
AMP
L2
L3
TIME
AUTO
STOP
HAND
START
NEMA 3R Enclosure
Minimum recommended components to protect your
pump during operation. Check all local electrical codes
prior to installation.
❶ Contactor
❷ Lightning Arrestor
❸ Loss of Prime Protection
❹ Fuseable Disconnect
884 0494
Page 14
❺ Starter
F00634
Start-up
General Information
CHECK ROTATION:
Before pump is put into operation, rotational direction
must be checked to assure proper performance of
pump. Refer to illustration on Page 16.
Hazardous voltage. Can shock, burn, or
cause death. Disconnect power to pump before
servicing.
Do not attempt any wiring changes without first
disconnecting power to pump.
PRIMING:
Pump priming is the displacement of air with water in
the pump and suction piping. Pump MUST BE
completely filled with water when operating.
Refer to Page 17 for instruction on the following
conditions:
1. Suction lift with priming pump (water source
below pump).
2. Suction lift with foot valve (water source below
pump).
3. Flooded suction (water source above pump, or
incoming water pressure is greater than
atmospheric pressure).
SPECIAL CASE - HYDRAULIC BALANCED PUMPS:
Hydraulic balanced pumps operate with a very low
positive pressure across the stuffing box, permitting a
much looser fit of the packing rings around the shaft
sleeve to control the loss of water from the pump
through the stuffing box. Because of the looser fit of
the packing rings, air can be more easily drawn into the
pump through the stuffing box when priming the pump
with an air evacuation type primer.
A grease fitting, communicating through the side of the
stuffing box to a lantern ring in the packing set, is
provided to grease-seal the stuffing box to prevent air
leakage during priming.
F00634
If pump cannot be primed due to air leakage through
stuffing box, DO NOT tighten packing. Instead, pump
grease into lantern ring until back pressure occurs
forcing grease into the lantern ring, grease-sealing the
stuffing box. After priming, when unit is put into
operation, the grease will be flushed out through the
packing by the water flowing outward through the
stuffing box. Proceed with normal adjustment of the
packing as described on Page 18. Note that the grease
seal only is used for control of air leaking during
priming, and that only the packing gland is used to
control flow of water through the stuffing box during
normal operation.
When necessary to replenish the grease supply use an
NLGI no. 4 Water Pump Grease.
STARTING:
Never run pump dry. Running pump
without water will overheat pump and damage internal
parts. Always make sure pump is primed prior to startup.
NOTICE: Refer to maintenance section if pump has
packing for adjustment prior to start-up.
Prime pump by one of the above procedures. Turn on
power to pump. Slowly open discharge valve until
desired flow rate is achieved. Place the “Hand-Off-Auto”
selector switch in the “Auto” position. The pump will be
started automatically when the pilot device signals the
motor starter.
STOPPING:
Pump will stop automatically when the pilot device deenergizes the motor starter. Turn the “Hand-Off-Auto”
selector switch to “Off” position if you want to stop the
pump while it is running.
Page 15
Start-up
Clock
wis
e
Determine Pump Rotation
on
tati
ro
12
9
Viewed from
this direction
3
6
As viewed
Engage start switch momentarily
(bump motor) to observe rotational
direction.
1129 0694
Direction of Pump Rotation is determined by viewing liquid end of pump
from the back or shaft side, and not from looking into the impeller eye
or front of volute case. A rotation direction arrow is cast into the pump
body and shows correct rotation.
• Electric Motors:
Single Phase: Refer to wiring information on the
motor plate to obtain proper rotation.
• Pump running backward - Centrifugal pumps will still
pump liquids, however, GPM and head (discharge
pressure) will be a fraction of the published
performance.
Three Phase: If pump runs backwards, reverse any
two leads coming off incoming power (L1, L2, L3)
until proper rotation is obtained. Reverse L1 and L2,
or L2 and L3, or L1 and L3.
Page 16
F00634
Start-up
Pump Priming
Han-Dee
Primer
Discharge Priming
Valve
Primer Isolation
Valve
787 0394A
Suction to
Water Source
Installations With Flooded Suction.
• Open air vent (or pipe plug) in the highest tapped
opening in pump case.
• Open inlet isolation valve, allowing water to fill the
pump completely and force all air out through vent.
• Rotate shaft slowly allowing any air trapped in
impeller to escape.
• Close vent opening when water without air emerges.
Installations With Suction Lift and Foot Valve.
• Close air tight valve on discharge.
• Remove pipe plug from highest opening on pump
case.
Installations With Suction Lift and Priming Pump.
• Close air tight valve.
• Han-Dee Primer operation:
1. Open Han-Dee Primer isolation valve.
2. Work handle of Han-Dee primer up and down to
evacuate air from the suction line.
(Refer to primer owner’s manual for proper
procedure).
3. When water flows freely from primer, close HanDee Primer isolation valve.
(Pump case should now be filled with water).
• Immediately start pump.
• Slowly open butterfly valve (if used) until desired flow
is achieved.
(Discharge Priming Valve will open automatically).
• Completely fill pump and suction piping with water.
• Rotate shaft slowly allowing any air trapped in
impeller to escape.
• When all air has been forced out of pump, replace
pipe plug. Use pipe joint compound on plug threads
and tighten as necessary to prevent leakage.
F00634
Page 17
Maintenance
General Information
LUBRICATION:
LIQUID END of pump requires no lubrication. Wear
rings, packing rings, and models using a mechanical
shaft seal, are lubricated by the liquid being pumped. Do
not run dry!
NOTE: Grease fitting in packing area is for priming only.
See PRIMING in start-up section for instruction.
MOTOR bearings are lubricated at the factory. Relubrication at intervals consistent with the amount of use
will provide maximum bearing life. Refer to motor
Instruction Manual for proper motor lubrication and
maintenance instructions.
PERFORMANCE CHECK:
Periodically check the output of the pump. If performance is noticeably reduced, refer to Troubleshooting
Chart.
OBSERVATIONAL MAINTENANCE:
When the pump and system operation have been
stabilized, verify that pump unit is operating properly.
Observe the following:
VIBRATION: All rotating machines can be expected to
produce some vibration, however, excessive vibration
can reduce the life of the unit. If the vibration seems
excessive, discontinue operation, determine cause of
the excessive vibration, and correct.
NOISE: When the unit is operating under load, listen
closely for unusual sounds that might indicate that the
unit is in distress. Determine the cause and correct.
OPERATING TEMPERATURE: During operation, heat
is dissipated from the pump and the driver. After a
short period of time, the surface of the pump bracket
will be quite warm (as high as 150°F), which is normal.
If the surface temperature of the pump bracket or
driver is excessive, discontinue operation, determine
cause of the excessive temperature rise, and correct.
Bearings will run hotter for a brief run-in period after
packing which is normal. However, worn bearings will
cause excessive temperatures and need to be
replaced. The pump unit is cooled by the water flowing
through it, and will normally be at the temperature of
the water being pumped.
STUFFING BOX: After a short period of operation,
verify that the stuffing box area and gland are not hot.
Page 18
If heating is detected, loosen the gland nuts evenly
until water is just running out of stuffing box in a
DROPLET form. Water must not be streaming or
spraying out. Verify cool operation periodically. Adjust
gland nuts EVENLY as necessary for lubrication and
cooling of the packing. If packing has been tightened to
the limit of the packing gland travel, additional packing
is necessary.
PACKING: Starting new pump.
Before starting pump for the first time, loosen gland nuts
and retighten finger tight. Proceed with pump start-up
procedure. Allow packing to leak liberally for a few
moments. Then tighten gland nuts one complete turn
each until leakage is reduced to 40 to 60 drops per
minute.
REPACKING:
Refer to Page 19.
MECHANICAL SEAL:
Adjustment or maintenance is normally not required.
The seal is enclosed within the pump and is self
adjusting. Seal is cooled and lubricated by the liquid
being pumped. Refer to Pages 20 and 21 for removal
and replacement. Do not run dry!
PUMP PROTECTIONCOLD WEATHER/
WET WEATHER INSTALLATIONS:
SYSTEM DRAINS: Provide drain valves to empty
system, including pump case, to prevent freezing
damage.
SHELTER: If possible, provide shelter for unit to protect
from weather. Allow adequate space around pump unit
for service. When effectively sheltered, a small amount
of heat will keep temperature above freezing. Provide
adequate ventilation for unit when running. For severe
weather problems, where other shelter is not practical, a
totally enclosed fan-cooled enclosure can be considered
for electric motors.
CONDENSATION: When the temperature of metal parts
is below dew point and the surrounding air is moist,
water will condense on the metal surfaces and can
cause corrosion damage. In severe situations, a space
heater can be considered to warm the unit.
F00634
Maintenance
Packing Ring Replacement
Removal
1
Packing
Gland
2
Packing
Hooks
Motor / Engine not shown
for clarity.
Motor / Engine not shown
for clarity.
826 0394
• Unfasten hardware holding Packing Gland in place
and slide back on shaft to expose packing rings. A
split Packing Gland is shown.
• Remove packing rings from Stuffing box using two
commercially available Packing Hooks as shown.
• Slide Lantern Ring (if used) back to expose any
remaining rings, including metallic. Remove them in
the same manner.
Installing New Rings
Motor / Engine not shown
for clarity.
Typical Packing Arrangement
Ring Joints
1147 0794
Packing
Rings
Metallic Ring
Lantern Ring
• Clean shaft sleeve and Packing Gland.
• Inspect shaft sleeve for wear, replace if needed.
• Install new packing rings in stuffing box by placing
over shaft sleeve and pushing them in as far as they
will go.
• Rotate ring joint 90 degrees when installing each ring
as shown.
F00634
• Slide packing gland into position, then gently and
evenly tighten nuts to force rings into place and seat
(do not overtighten). Loosen nuts again to hand tight.
• Start primed pump and allow packing to leak liberally.
• Tighten gland nuts one complete turn each until
leakage is reduced to 40 to 60 drops per minute.
Page 19
Maintenance
Mechanical Shaft Seal
Removal
1
2
1135 0794
1137 0794
• Unfasten hardware holding volute to bracket.
NOTE: For model B4EY, consult factory for special
instructions.
• Peel off old gasket or O-Ring and discard.
• Hold impeller stationary and remove impeller screw
and associated hardware.
• Remove volute to expose impeller.
Gear Puller
Finger
3
4
Key
Note:
A hexnut placed between the
jackscrew and shaft end will
prevent damage to the shaft
and impeller screw threads.
1139 0794
Shaft
Sleeve
1138 0794
Gear Puller
Jackscrew
Gear Puller
Finger
• Remove capscrews holding bracket to motor.
• Rotate gear puller jackscrew until impeller clears
shaft. Mechanical shaft seal will come off with motor
bracket.
• Install a standard gear puller to shaft end and motor
bracket placing puller fingers in the area shown.
• If a seal retaining ring is part of the assembly, it will
need to be replaced.
Stationary
Seat
5
Rotating
Seat
Spring
Spring
Retainer
1140 0794
• Push stationary seal out of seal cavity from the back
of bracket.
Stationary
Seat
1189 0794
• Clean seal cavity in bracket thoroughly.
Procedure and parts will vary slightly depending on pump style.
Page 20
F00634
Maintenance
Mechanical Shaft Seal
Installing New Seal
1
Cardboard washer
(Supplied with seal)
If shaft is threaded, cover threads
with tape to protect seal during
installation.
2
Polished Face
Do not scratch or chip
polished ceramic face.
Also . . .do not touch
polished surface
1143 0794
1142 0794
• Place bracket on a smooth, flat surface, pump side
up.
ceramic face with cardboard washer and press
straight in using a piece of pipe or tubing.
• Apply a small amount of mineral oil to O-Ring on
stationary seal and press into seal cavity. Cover
• Reinstall bracket on motor using extreme care not to
scratch or chip ceramic face of seal with shaft.
3
4
Key
1145 0794
1144 0794
Truarc
• Clean threads thoroughly.
• Apply a small amount of mineral oil to inside diameter
of rubber ring in rotating seat and outside of shaft
sleeve. Slide rotating seat onto shaft, polished face
first, until it is tight against ceramic face.
• Apply non-permanent thread adhesive to impeller
capscrew and shaft threads.
• Install impeller washer, shakeproof lockwasher, and
capscrew.
• Compress seal spring and install retaining ring in
shaft sleeve groove (if used).
• Place impeller key in motor shaft keyway. Slide
impeller on to shaft as far as possible.
5
• Install gasket and volute on bracket. Use a new
gasket or O-Ring when reassembling to prevent
leakage ( a coat of grease on gasket will aid in future
disassembly and maintenance).
1146 0794
• Apply anti-seizing compound to capscrews and
tighten securely.
Procedure and parts will vary slightly depending on pump style.
F00634
Page 21
Pump Nomenclature
General Information
ORDERING REPLACEMENT PARTS:
Locate the Berkeley nameplate on the pump; plate is
normally on the motor bracket. Information found on this
plate is shown below. To be sure of receiving correct
parts, provide all nameplate data when ordering. The
BM (Bill of Material) number is most important. Write
your nameplate information on the blank nameplate
below for future reference as nameplates can become
worn or lost.
Illustrations on the following page show typical
components used in the assembly of motor drive
centrifugal pumps. Both mechanical seal and packing
styles are shown. Refer to these drawings when
ordering any replacement parts.
SAMPLE ONLY
BERKELEY PUMPS
MODEL
S.N. OR DATE
B3TPMS
G100894
IMPELLER DIA.
B.M.
6-1/8"
B54598
788 0394
BERKELEY PUMPS
MODEL
S.N. OR DATE
IMPELLER DIA.
B.M.
344 1093
Record your nameplate data here.
Page 22
F00634
Pump Nomenclature
Electric Motor Drive
Mechanical Seal
Clack Weight
Clack Washer
Suction
Cover
Motor
Bracket
Impeller
Impeller
Lock Nut
Case Gasket
Seal Retaining
Ring
Pump Case
(Volute)
rc
ua
Tr
Impeller
Mechanical
Seal
Impeller Washer
Shakeproof Lockwasher
Impeller Capscrew
Shaft
Sleeve
Rubber Clack
(Check Valve)
Volute
Case
• Electric motor not shown.
Wear Ring
• Drawing shows typical motor drive pump with packing or
a mechanical shaft seal. Parts on some models will vary
slightly.
Gasket
or O-Ring
5530 1006
Packing
Impeller
Shakeproof
Lockwasher
Gasket
or O-Ring
Packing
Gland
Lantern
Ring
Shaft
Sleeve
Impeller
Packing Grease
Cup or fitting
Impeller
Washer
Impeller
Capscrew
Packing
Rings
Metallic
Ring
Balance Ring
Gasket
Clack
Weight
Volute Case
Clack
Washer
5531 1006
Impeller
Lock Nut
Motor
Bracket
Case Gasket
Pump Case
(Volute)
Balance
Ring
Suction
Cover
Rubber Clack
(Check Valve)
F00634
Page 23
Maintenance
Troubleshooting
PROBABLE CAUSE
SYMPTOM
A
Pump runs, but no water delivered
Not enough water delivered
Not enough pressure
Excessive vibration
Abnormal noise
Pump stops
Overheating
X
B
X
X
C
GROUP I
ELECTRICAL
D
E
F
X
X
X
X
X
X
X
X
G
H
I
X
X
X
X
X
X
A
X
X
X
X
X
E
F
X
X
X
GROUP III
SYSTEM
A
B
C
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
CAUSE
GROUP II
MECHANICAL
B
C
D
X
X
X
X
X
X
X
X
X
X
CORRECTIVE ACTION
I. ELECTRICAL
A. No voltage in power system
Check phase-to-phase on line side of starter contactor.
Check circuit breaker or fuses.
B. No voltage on one phase
(Three Phase Units)
Check phase voltage on line side of starter contactor. Isolate open circuit
(circuit breaker, fuse, broken connections, etc.)
C. Low voltage at motor
Running voltage across each leg of motor must be ±10% of nominal
voltage shown on nameplate.
D. Motor leads improperly grouped
for voltage
Refer to lead grouping diagram on motor nameplate.
E. Control failure
Check control device, starter contactor, H-O-A selector switch, etc.,
for malfunction.
F. Thermal overload switch open
Check phase-to-phase on line side of starter contactor.
G. Installation failure
Check motor or windings to ground with megohmmeter.
H. Open windings
Check leg-to-leg with ohmmeter.
I. Frequency variation
Check frequency of power system. Must be less than 5% variation from
motor nameplate rating.
II. MECHANICAL
A. Flow through pump completely or
partially obstructed
Locate and remove obstruction. Refer to Repair Instructions
for disassembly.
B. Wrong direction of rotation
Reverse rotation of three phase motor by interchanging any two leads.
See manufacturer’s Instructions for reversing single phase motor.
C. Pump not primed
Reprime. Inspect suction system for air leaks.
D. Internal leakage
Check impeller for wear of controlled clearances (See Repair Instructions).
E. Loose parts
Inspect. Repair.
F. Stuffing box not properly adjusted
Adjust gland.
III. SYSTEM
A. Pressure required by system at design
flow rate exceeds pressure rating of pump
Compare pump pressure and flow rate against pump characteristic curve.
Check for closed or partially closed valve in discharge piping system.
Reduce system pressure requirement. Increase pressure capability of pump.
B. Obstruction in suction piping
Locate and remove obstruction.
C. Pressure rating of pump exceeds pressure
requirement of system at design flow rate
Compare pump pressure and flow rate against pump characteristic curve.
Inspect discharge piping system for breaks, leaks, open by-pass valves, etc.
If necessary, reduce flow rate by partially closing discharge valve.
Page 24
F00634