Berkley B2ZRKL, homeappliance

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OWNERS MANUAL INSTALLATION AND OPERATING INSTRUCTIONS REPAIR PARTS LIST Self Prime Frame Mounted Centrifugal Pump B4ZRKS B2ZRKL B3TRKS B2XRKS Direct Coupling Drive/ Belt Driven/Hydraulic Drive 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 F00633 (Rev. 4/18/05) General Safety Safety First General Information Pump Location READ AND FOLLOW 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. Periodically inspect pump and system components. Wear safety glasses at all times when working on pumps. Keep work area clean, uncluttered and properly lighted; store properly all unused tools and equipment. Keep visitors at a safe distance from the work areas. WARNING Rotating parts. Can catch hands, feet, or clothing. Stay clear of equipment and keep shields in place while pump is running. Stop motor or engine before servicing pump. Read owner's manual before using equipment. Electrical Safety WARNING Wire motor for correct voltage. See "Electrical" section of this manual and motor nameplate. Ground motor before connecting to power supply. Meet National Electrical Code and local codes 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: warns about hazards that will cause serious personal injury, death or major property damage if ignored. warns about hazards that will or can cause serious personal injury, death or major property damage if ignored. 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. LOCATION: Locate the pump as near to the water source as practical. Make the suction pipe run short and straight with as few pipe fittings as possible to keep total friction loss to a minimum. Install pump in a clean, dry and well drained location if possible and protect against moisture and adverse weather conditions. Pump should be located on a level, hard surface to prevent shifting or tipping. Locate to be readily accessible for inspection and maintenance. 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. Figure 1, Page 3, illustrates where these terms (NPSHA / NPSHR) originate, and how to determine if the Hazardous voltage. Can shock, burn, or cause death. Ground pump before connecting to power supply. for all wiring. Follow wiring instructions in this manual when connecting motor to power lines. pumping conditions at which you want to operate meet the proper criteria. When in doubt, consult your nearest Berkeley Professional Dealer. NOTE: If pump site is 1000 feet above sea level, sub tract 1.2 feet from the NPSHA equation and an ad ditional 1.2 feet for each additional 1000 feet of eleva tion. Page 2 F00633 NPSHR NPSHR at this point Installation General Information EXAMPLE ONLY NPSHA 150 = 8 FeetNPSHR at this point = 9 Feet 2000 RPM B4ZRKS 30 20 10 0 9.5 Feet total friction loss @ 450 Gallons per minute. t 10.5 Feet total friction loss e @ 550 Gallons per minute. e F n i H S P N 450 GPM 550 GPM Static Lift = 9.0 Feet 9.0 Feet H DT 100 50 Total Friction Loss = 9.5 Feet Total = 18.5 Feet Theoretical static lift of centrifugal 10.5 Feet 19.5 Feet 9 Feet Static Lift pump at sea level = 34.0 Feet 0 0 100 200 300 400 500 600 700 Gallons Per Minute Safety Factor - 6.0 Feet Practical Limit = 28.0 Feet 28.0 Feet A Model B4ZRKS operating at 450 GPM with 95 Feet of Head has a NPSHR of.......... 8 Feet at that point on the performance curve. A Model B4ZRKS operating at 550 GPM Minus 18.5 Feet OK NPSHA = 9.5 Feet 19.5 Feet 2111 1095 FIGURE 1 with 85 Feet of Head has a NPSHR of.......... 9 Feet at that point on the performance curve. CAVITATION NPSHA = 8.5 Feet FOUNDATION: Refer to illustration on Page 4. Heavy weights; risk of bodily harm due to crushing. Use care and proper lifting equipment when handling pump for installation. Size and weight of some units will require hoists for safe handling. Pump should be set on a concrete foundation which is sufficiently substantial to absorb vibration and which provides a permanent and rigid support. When properly positioned, the unit will be level, and the suction and discharge openings of the pump will be aligned with system piping. 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. Suction and discharge pipes must be naturally aligned with pump connections. NOTICE: Misalignment of piping with pump case or excessive pipe strain can cause distortion of pump components resulting in rubbing, breakage and reduced pump life. Insure that piping is supported in a manner that prevents the exertion of force on pump connections. This can be checked by the following procedure. With the pump shut down, 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. SUCTION PIPING: Refer to illustrations on Page 8 through Page 11 for recommended and not recommended practices in suction connections. DISCHARGE PIPING: Refer to illustrations on Pages 12 through 13 for recommended and not recommended practices in discharge connections. ELECTRICAL CONNECTION: If electric motor is used. NOTE: All wiring should be done by a qualified electrician. Hazardous voltage. Can shock, burn, or cause death. Disconnect power to pump before servicing. Check voltage and phase stamped on pump motor nameplate before making wiring connections to electrical system. 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 7 for minimum recom mended pumping panel components that help safeguard your pump during operation. F00633 Page 3 1/2" or thicker Sole Plate tapped for hold down bolts Anchor Bolts Drainage Installation Pump Foundation Typical Installations Pump or Motor Frame Concrete Foundation Pump or Motor Frame Anchor Shims for alignment Steel Bolt Channel Wedges Various Heights Pump and Motor Base Tack Weld Grout Concrete Foundation Grout Dam Drainage Shims Drainage • There are several types of permanent pump/ foundation installations in use. Those pictured above Concrete Foundation 1300 1094 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 4 F00633 Installation Direct Coupling Drive Shaft Alignment Table I Distance from Centerline Maximum Allowable T.I.R. 1.00 inch 0.035 inches Straight Edge 2.00 inches 3.00 inches 4.00 inches 0.070 inches 0.105 inches 0.140 inches Fine Alignment "B" Parallel "A" Angular Course Alignment Centerline 2112 1095 Caliper Rotating shaft can catch and trap clothing or body. Coupling guard must ALWAYS be in place when pump is running. Coupling guard shown in phantom for pictorial clarity. ALIGNMENT OF PUMP AND MOTOR SHAFT • A flexible coupling (except for double universal joint shaft) will not compensate for misalignment. After the pump unit is fastened on the foundation, it is nec essary to see that the shafts of the pump and motor are properly aligned. • Each motor and pump foot should be shimmed to avoid shifting or soft foot. COURSE ALIGNMENT • By moving the entire unit, bring suction and discharge openings of the pump into alignment with the system piping. Install piping at this time. Pipes should align naturally with the pump (see Installation Section). • Bring the pump and motor shaft into approximate alignment by shifting or shimming the motor. Use a straight edge to check alignment of the shafts. • Use calipers, or a wedge thickness gauge to check the distance between coupling halves. The distance between halves should be equal at 90 degree intervals around the coupling, and the shafts should be concentric when checked with a straight edge. FINE ALIGNMENT • Angular and parallel misalignment of the coupling may be corrected simultaneously. Maintain a sep aration between coupling halves, per manufacturer's specifications, to avoid preloading of pump and motor bearings. Clamp dial indicators to the pump and motor shaft as shown above. • Start with angular alignment and finish check with parallel alignment. • Rotate both the shaft and coupling together by hand. Note the total indicated runout shown on indicator "A". The maximum allowable angular misalignment is 1 degree. Limits of reading on indicator "A" at various distances from shaft centerline are shown in Table I. • Continue to rotate both shafts by hand and note the runout shown on indicator "B". The maximum allow able total indicated runout is .005 inches. Should either angular or parallel misalignment exceed the value shown, shift or shim the motor until mis alignment is within the allowable limits shown. Do not move pump unless absolutely necessary. When shimming, be sure that all feet on the pump and motor are equally supported to avoid strains on the castings when the hold down bolts are tightened. F00633 Page 5 Incorrect Installation Belt Drive Alignment/Proper Belt Tension B B Incorrect A A Centerline - A of each shaft and pulley must be parallel for proper alignment. B 2113 1095 A Centerline A Centerline - B represents center of belt and pulley.This centerline must be straight for proper alignment. Centerline B ALIGNMENT Drive belt can catch and trap clothing or body. Belt guard must ALWAYS be in place when pump is running. Belt guard is not shown for pictorial clarity. • Drive and pump shaft centerlines (A) must be parallel as shown. Belt centerlines (B) must be straight as shown. • When installing belts, move the driver toward the pump to allow belts to be placed on pulley. Then, move the driver away from pump to obtain proper belt tension as described below. TENSION • Multiple belt spans must be equal tension in all belts. Proper belt tension varies with the size of belt being used, however a general rule is: Belts are properly tensioned when one belt can be NOTICE: Belts must be tight enough to prevent slip ping during operation. Loose belts result in early belt failure and reduced performance. However, excessive tightness of belts will result in overheating of the belts and excessive bearing load in the pump and driver. • Most Vee-belts will stretch slightly after initial installation. After a short period of operation, re check belt tension and adjust as necessary. Center of span. Slack should not be more than one belt thickness. A depressed one belt thickness at the center of the span when pressing with thumb. Another method is that a properly tensioned belt can be rotated (twisted) one-quarter revolution at the center of span. A 1423 1294 View Proper tension allows one quarter revolution of belt. A-A Page 6 F00633 Installation Electric Motor / Hydraulic Motor p p gp Minimum recommended components to protect your pump during prior to installation. 1. Contactor operation. Check all local electrical codes prior to installation. 2. Lightning Arrestor 1 Incoming Power ❶ Contactor ❷ Lightning Arrestor ❸ Loss of Prime Protection ❹ Fuseable Disconnect ❺ Starter 3. Loss of Prime Protection 4. Fuseable Disconnect 5. Starter 2 3 AMP TIME 4 5 L1 L2 L3 AUTO OFF HAND 2116 1195 NEMA 3R Enclosure NEMA 3R Enclosure START Motor Detail .38 Protect Your Investment Installation Mounting Hydraulic Motor and Adapter Mounting Bracket Hydraulic Motor (See Motor Detail for fit requirements) Fits on bearing bracket in place of outer bearing cap. Supports Hydraulic Motor and maintains exact shaft alignment. Coupling .56 Bolt Clearance Shoulder 3.998 4.000 1.625 Flange Face to end of shaft .875 O.D. Pump Shaft Precision machined to fit SAE standard Hydraulic Motor Shaft Spline.Coupling is installed on shaft and locked in place with drive key and set screw. 5.750 Length and diameter factory machined for precision fit to coupling. Hydraulic Motor must have an SAE Standard (SAE J744C) mounting flange and shaft size B , with 30 degree involute spline, 13T, 16/32 pitch. Hydraulic Motor must produce the Torque required to drive the centrifugal pump at the desired operating speed. For centrifugal pump GPM and TDH, read the required RPM and BHP from pump performance curve, and calculate required torque 2237 0196 in Lbs-Ft, as follows: Torque = (5252) x (BHP) (RPM) Hydraulic Motor selected must match with the flow and pressure capability of the hydraulic power source system. The operating speed of the centrifugal pump will be controlled by the valves in the hydraulic power source system. F00633 Page 7 Pump driven by remote power source, direct coupling or pulley/belt connection. 2114 1095 Installation Suction Connection Suction Lift Short length of straight pipe after reducer. ( 2 times pipe diameter minimum ) Suction Gauge Straight run, short as possible but at least 6 times pipe diameter ("D") after elbow to stabilize flow. Eccentric Reducer flat side up. See foundation section. Support pipe as required NOTICE: All connections must be air tight. • 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. Standard or long radius elbow. Slope upward to pump. As close as possible • 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. • 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. • All suction piping must have continuous rise to the pump suction inlet. A 1/4 inch per foot minimum slope is recommended. Pipe diameter ("D") 4 x "D" minimum 1 x "D" minimum from bottom Strainer / Foot Valve To keep debris from entering pump suction and to maintain pump prime after shut-off. Recommended Page 8 F00633 Installation Suction Connection Suction Lift No support or uneven mounting not recommended. Do not use Concentric Reducer. Excess use of pipe fittings means potential air leaks. Elbow immediately in front of pump intake not recommended. Concentric Reducer causes high spots along the suction line resulting in air pockets. Do not install valves in suction line. Unsupported pipe causes excessive stress on pump and fittings. Long run not recommended Pipe diameter ("D") undersized reduces performance High suction lift should be avoided. Vortex caused by insufficient submergence may cause pump to lose prime. • Suction pipe sloping downward to pump inlet will trap air which will reduce performance and 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 Less than 4 x "D" No strainer may cause pump to trapped air, reduced performance, and high friction losses which may cause cavitation. clog. Insufficient bottom clearance Not Recommended F00633 Page 9 Pump driven by remote power source, direct coupling or pulley/belt connection. 2214 0196 See foundation section. Installation Suction Connection When Flooded Suction Exists Short run of straight pipe after reducer (2 times pipe diameter). Eccentric Reducer flat side up. Suction Gauge Straight run, short as possible but at least 6 times pipe diameter after pipe fitting to stabilize flow. Slope upward to pump. Water under pressure Maintain minumum liquid level to prevent vortexing. Isolation Valve full open when pumping. Support pipe as required Standard or long radius elbow. • 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. • 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. • 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. Recommended Page 10 F00633 2215 0196 Installation Suction Connection When Flooded Suction Exists Inverted Eccentric Reducer may result in air pocket. Valve in upward position may trap air. Do not leave valve partially closed. Check Valve in suction pipe not needed. Unsupported pipe causes excessive stress on pump and fittings. Concentric Reducer may cause air pockets. Water under pressure Miter elbow or short radius elbow not recommended. Do not make elbow connection directly to pump suction. • 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. • If check valve is required for back flow prevention, locate on the discharge side of pump. Not Recommended F00633 Page 11 Isolation Valve Use Concentric Reducer to mimimize friction losses. Pressure Gauge Discharge pipe diameter at least one nominal pipe size larger than discharge opening in pump. Align piping to minimize flange stress. Installation Discharge Connection Non-Slam or spring loaded check valve. Isolation valve to permit servicing of check valve or pump. Support piping as required 2118 1195 • Use pipe, tubing or reinforced hose to make dis charge 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). • 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. Recommended Page 12 F00633 Avoid check valves that may cause hydraulic shock. Avoid undersized pipe diameter. Do not leave Installation Discharge Connection Avoid abrupt change in pipe size. Do not use Gate Valve to throttle flow. 2119 1195 pipe unsupported. Do not force alignment that can cause flange stresses. • 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 F00633 Page 13 CHECK ROTATION: Start-up General Information open at start-up and allow pump to evacuate air from Before pump is put into operation, rotational direction must be checked to assure proper performance of pump. Refer to illustration below to varify proper rotational direction for each model covered in this manual. 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. A self-priming pump only needs to be manually primed at the first start-up. Once primed, under normal conditions pump will reprime automatically at each subsequent start-up. To prime, remove plug from top of pump case and fill case with water. Replace plug and start pump. Unit is equipped with a flapper type check valve which will Clockwise Rotation the suction line. After several minutes of operation, pump will be fully primed and pumping water. Priming time will vary, depending on length and diameter of suction line. STARTING (Electric Motor): NOTICE: Never run pump dry. Running pump without water will overheat pump and damage internal parts. Always make sure pump is primed prior to start-up. NOTICE: Refer to maintenance section if pump has packing for adjustment prior to start-up. Prime pump by the above method. 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 start automatically when the pilot device signals the motor starter. STOPPING (Electric Motor): Pump will stop automatically when the pilot device de energizes the motor starter. Turn the "Hand-Off-Auto" selector switch to "Off" position if you want to stop the pump while it is running. Counter-Clockwise Rotation B2XRKS B3TRKS B4ZRKS Viewed from ise rotation w k c o 12 Counter-Clock 12 w is e B2ZRKL this direction lC 9 3 6 9 3 6 As viewed As viewed 2238 0196 Engage start switch momentarily (bump driver) to observe rotational direction. ELECTRIC MOTORS: Single Phase: Refer to wiring information on the motor plate to obtain proper rotation. Three Phase: If pump runs backwards, reverse any two leads coming of incoming power (L1, L2, L3) until proper rotation is obtained. Reverse L1 and L2, L2 and L3, or L1 and L3. Pump running backwards - Centrifugal pumps will still pump liquids, however, GPM and head will be a fraction of the published performance. ENGINE DRIVEN: If engine is used for pump driver, check with engine instruction and operation manual or engine manufacturer to determine how rotation is defined, then use above illustration for proper connection. Page 14 F00633 LUBRICATION: Maintenance General Information Bearings will run hotter for a brief run-in period after 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! BEARING FRAME - add approximately 2 ounces of a lithium-based NGLI No. 2 extra pressure ball bearing grease to each bearing during quarterly inspection. NOTE: Excess grease will cause bearings to run hot. The following are factory approved brands of grease for use with Berkeley Pumps: Alvania EP2, Shell Oil; Mobilith AW2, Mobil Oil, Ronex MP, Exxon, Litholine EP2, Atlantic Richfield; and Amolith EP2, Amoco. ELECTRIC MOTOR: Refer to motor manufacturer's operating manual for complete instruction. GAS/DIESEL ENGINE: Refer to engine manufacturer's operating manual for complete instruction. PERFORMANCE CHECK: Periodically check the output of the pump. If perform ance 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. 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. If heating is detected, loosen the gland nuts evenly until water is just running out of stuffing box in a DROPLET form (approximately 40-60 drops per minute). 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. PUMPS WITH 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 illustration on Page 16. PUMPS WITH 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. Consult factory for proper replacement procedure. SHAFT: Bearing frame shaft assemblies should be periodically torn down for inspection of worn parts, cleaning and re greasing. Most importantly, to check shaft sleeve and bearings for pitting. Replace worn components as necessary. F00633 Page 15 Packing Gland Shaft Maintenance Packing Ring Replacement Removal Packing Hooks Packing 2239 0196 Ring 1 2 1 2 x Scale 2 • Unfasten hardware holding Packing Gland in place and slide back on shaft to expose packing rings. • 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. Stagger ring joints 90 degrees apart Packing Rings Lantern Ring • Clean shaft sleeve and Packing Gland. Installing New Rings Shaft 2240 0196 Metallic Ring • Slide packing gland into position, then gently and • 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. 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 16 F00633 ROUTINE MAINTENANCE Maintenance General Pump Care WINTERIZING A well maintained pumping system will extend the life of the unit and will require fewer repairs. This means less down time which can be very critical when a constant delivery of water is required. A routine maintenance and inspection schedule should be set up on a weekly, quarterly, and annual basis with records kept of these actions. For weekly checks see observational maintenance on Page 15. For quarterly and annual maintenance, refer to check list on Page 22. Copy page as necessary for continual usage. RECOMMENDED SPARE PARTS It is recommended that the following spare parts be kept on-site as a minimum back-up to service your pump and reduce down-time. Check your model/style against parts breakdown drawing on Pages 18 and 19 when selecting spares. • Mechanical Shaft Seal • Packing Set and Packing Hooks • Shaft Sleeve(s) • All Gaskets and O-Rings Required for One Pump • Oil Seal(s) • Bearings If having a pump non-operational has severe con sequences, a back-up pump should be considered. Otherwise, a back-up impeller, volute case, bearings and shaft, would be prudent. PUMP PROTECTION-COLD 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. If pump is to be out of service for an extended period of time, such as the winter months, the following storage procedures should be followed. • Remove exterior dirt and grime or any substance that may trap moisture. Exposed metal is subject to oxidation, prime and repaint if necessary. If this is not possible, coat with grease or heavy oil. • Flush suction and discharge lines. Check for leaks at this time and replace any worn gaskets. • Remove lowest plug in pump and drain pump casing and suction and discharge lines. • Lubricate bearings. • If possible, keep unit clean and dry during storage period to guard against corrosion. • Seal all open ports to keep out foreign objects such as insects, rodents, dust and dirt. • Rotate driver shaft periodically to prevent freeze-up of internal components. • Shelter unit from elements if possible. • Work oil into impeller wear ring by dripping oil into the gap while rotating by hand. SPRING START-UP • Inject sufficient grease into the bearings to displace old grease. • Visual inspection. • Rotate by hand, if any binding occurs, disassemble and inspect. F00633 Page 17 Pump Nomenclature General Information ORDERING REPLACEMENT PARTS: Locate the Berkeley nameplate on the pump, plate is normally on the bearing bracket. Information found on this plate is shown below. To be sure of receiving correct BERKELEY PUMPS MODEL S.N. OR DATE 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. SAMPLE ONLY IMPELLER DIA. B.M. 344 1093 BERKELEY PUMPS MODEL S.N. OR DATE Record your nameplate data here. The following illustrations show typical components used B2ZRKL G021196 B3TPMS G100894 in the assembly of self priming bearing frame mounted IMPELLER DIA. 9.00" 6-1/8" Belt B.M. B52346 B54598 788 0394 centrifugal pumps. Refer to these drawing when order ing any replacement parts. Shaft / Bearing Drive Coupling Drive Sheave Bearing Frame Case Gasket Assembly Pump Case (Volute) Water Slinger 2137N 1195 Mechanical Seal Impeller Clack Weight Rubber Clack (Check Valve) Clack Washer Suction B2XRKS/B3TRKS Cover Page 18 F00633 Outer Bearing Cap Pump Nomenclature Self Prime Bearing Frame Parts Breakdown Outboard Bearing Bearing Spacer Inboard Bearing Bearing Frame Shaft Case Gasket Bearing Lock- washer Bearing Lock Nut Inner Bearing Cap 2135N 1195 Impeller Impeller Impeller Screw Slinger Suction Flange Gasket Packing Gland Packing Ring Assembly Shaft Sleeve Lantern Ring Rubber Clack B2ZRKL Outer Bearing Washer Pump Case (Volute) Outboard Bearing Bearing Spacer Suction Flange (Check Valve) ClampWasher Weight Clack Assembly (Check Valve) Cap Bearing Frame Shaft Inboard Bearing Bearing Lock- washer Bearing Lock Nut Inner Bearing Cap Shaft Sleeve Retaining Ring Truarc 2106N 1095 Oil Seal Mechanical Seal Slinger Impeller Impeller Lock Nut Clack Weight Clack WasherSuction Cover B4ZRKS Case Gasket Pump Case (Volute) Rubber Clack (Check Valve) F00633 Page 19 Maintenance Troubleshooting Electrical Drive Pumps PROBABLE CAUSE SYMPTOM GROUP I GROUP II GROUP III ELECTRICAL MECHANICAL SYSTEM ABC D E FGH I A BCD EF A BC Pump runs, but no water delivered X X X X Not enough water delivered X X X X X X X X Not enough pressure X X X X X X X X Excessive vibration X X X X X X Abnormal noise X X X XX XX Pump stops X X X X X X X X Overheating X X X X X X X X X CAUSE 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 Check phase voltage on line side of starter contactor. Isolate open circuit (Three Phase Units) (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 Refer to lead grouping diagram on motor nameplate. for voltage 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 Locate and remove obstruction. Refer to Repair Instructions partially obstructed 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 Compare pump pressure and flow rate against pump characteristic curve. flow rate exceeds pressure rating of pump 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 Compare pump pressure and flow rate against pump characteristic curve. requirement of system at design flow rate Inspect discharge piping system for breaks, leaks, open by-pass valves, etc. If necessary, reduce flow rate by partially closing discharge valve. Page 20 F00633 Maintenance Troubleshooting Engine Drive Pumps PROBABLE CAUSE SYMPTOM GROUP I GROUP II GROUP III ENGINE MECHANICAL SYSTEM ABC D E FAB C D E F A BC Pump runs, but no water delivered X X X X X Not enough water delivered X X X X X X X Not enough pressure X X X X X X X Excessive vibration X X X X X X X X Abnormal noise X X X X X X X X X X Pump stops X X X X Overheating X X X X X X X X X CAUSE CORRECTIVE ACTION I. ENGINE A. Speed too low Refer to engine manufacturer's manual. B. Rotating and/or Refer to engine manufacturer's manual. reciprocating parts drag C. Speed too high Refer to pump and engine power curves. Adjust. D. Loose or broken parts Refer to engine manufacturer's manual. E. Improper adjustment Check fuel and ignition systems. Adjust per engine manufacturer's manual. F. Fuel supply Check fuel supply, fuel pump, filters, etc. II. MECHANICAL A. Flow through pump completely or Locate and remove obstruction. Refer to Repair Instructions partially obstructed 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 Compare pump pressure and flow rate against pump characteristic curve. flow rate exceeds pressure rating of pump 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 Compare pump pressure and flow rate against pump characteristic curve. requirement of system at design flow rate Inspect discharge piping system for breaks, leaks, open by-pass valves, etc. If necessary, reduce flow rate by partially closing discharge valve. F00633 Page 21 I. QUARTERLY INSPECTION Maintenance Routine Inspection Record III. QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment. Check pump foundation for soundness and see that all hold-down bolts are secure. Complete any lubrication requirements as dictated by pump and driver owner's manual. Inspect packing or mechanical seal for possible replacement. Examine shaft sleeve, if present, for wear and replace if necessary. Inspect pumping plant panel for signs of wear (ie: replace pitted contactors, etc., as needed). Check pump and motor bearings from signs of wear. Repack or replace as necessary. Check alignment of couplings and/or pulleys and belt tension if applicable. ________________________________________ II. QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment. Check pump foundation for soundness and see that all hold-down bolts are secure. Complete any lubrication requirements as dictated by pump and driver owner's manual. Inspect packing or mechanical seal for possible replacement. Examine shaft sleeve, if present, for wear and replace if necessary. Inspect pumping plant panel for signs of wear (ie: replace pitted contactors, etc., as needed). Check pump and motor bearings from signs of wear. Repack or replace as necessary. Check alignment of couplings and/or pulleys and belt tension if applicable. ________________________________________ NOTES: Inspect all system piping connections for leakage or possible misalignment. Check pump foundation for soundness and see that all hold-down bolts are secure. Complete any lubrication requirements as dictated by pump and driver owner's manual. Inspect packing or mechanical seal for possible replacement. Examine shaft sleeve, if present, for wear and replace if necessary. Inspect pumping plant panel for signs of wear (ie: replace pitted contactors, etc., as needed). Check pump and motor bearings from signs of wear. Repack or replace as necessary. Check alignment of couplings and/or pulleys and belt tension if applicable. ________________________________________ IV. QUARTERLY INSPECTION Inspect all system piping connections for leakage or possible misalignment. Check pump foundation for soundness and see that all hold-down bolts are secure. Complete any lubrication requirements as dictated by pump and driver owner's manual. Inspect packing or mechanical seal for possible replacement. Examine shaft sleeve, if present, for wear and replace if necessary. Inspect pumping plant panel for signs of wear (ie: replace pitted contactors, etc., as needed). Check pump and motor bearings from signs of wear. Repack or replace as necessary. Check alignment of couplings and/or pulleys and belt tension if applicable. ________________________________________ ANNUAL INSPECTION Inspect pump and entire pumping system for signs of wear. Inspect system valves, screens, etc. If electric motor is used, check windings for degred ation, rewind if necessary. Check pump impeller eye for clearance. Inspect impeller, volute case, and seal chamber for signs of excessive wear or corrosion. Page 22 F00633 MaintenanceNotes F00633 Page 23 Berkeley 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, 4544 Fieldgate Parkway, Mississauga, Ontario L4W 3W6 Page 24 F00633