AAON BL Series Manual

BL SERIES
BOILER IN PACKAGED MECHANICAL ROOM
INSTALLATION, SERVICE
&
OWNER’S INFORMATION MANUAL

2
TABLE OF CONTENTS
SECTION Page
GENERAL DESCRIPTION………………………………………………………………………………………………….
Unpacking…………………………………………………………………………………………………………...
04
04
OWNER’S INFORMATION……………………………………………………………………….......................................
Wiring Diagrams…………………………………………………………………….................................................
General Maintenance ……………………………………………………………………………………..…………
Boilers ……………………………………………………………………………………………………………....
Primary/Secondary Pumping………………………………………………………………………………………..
Make-up Water………………………………………………………………………………………………………
Expansion tank.……………………………………………………………………………………………………...
Pressure Relief Valve…………………………………………………………………………….………………….
Automatic Air Vent…………………………………………………………………………….…………………....
Dual Pumps………………………………………………………………………………………………………….
Pressure Gauges and Thermometers………………..……………………………………………………………….
Pipe Insulation………………………………………………………………………………………………………
04
04
04
04
05
05
06
06
06
06
07
07
INSTALLATION…………………………………………………………………………….…………………………….....
Lifting and Handling……………………………………….……………………………………………………….
Boiler Placement ……………………………………………………………………………………………………
Service Clearances…………………………………………………………………………………………………..
Water Connection…………………………………………………………………………………………………...
Gas Connection……………………………………………………………………………………………………...
Boiler Exhaust Connection………………………………………………………………………………………….
Boiler Intake Connection……………………………………………………………………………………………
Access Doors………………………………………………………………………………………………………..
Electrical…………………………………………………………………………………………………………….
07
07
07
07
07
07
08
10
10
10
STARTUP…………………………………………………………………………………………………………………….
Pre Startup…………………………………………………………………………………………………………..
Startup……………………………………………………………………………………………………………….
10
10
10
SERVICING & MAINTENANCE……………………………………………………………………………………….......
General ……………………………………………………………………………………………………………...
Lubrication……………………………………………………………………………………………………...…...
Service Information…………………………………………………………………………………………………
11
11
11
11
APPENDIX: Piping Component Information………………………………………………………………………………..
BL START-UP FORM……………………………………………………………………………………………………….
12
33

3
It is the intent of AAON, Inc. to provide accurate and current specification information. However, in the
interest of product improvement, AAON, Inc. reserves the right to change pricing, specifications, and/or
design of its products without notice, obligation or liability
© 2007 AAON, Inc., all rights reserved throughout the world.
AAON & AAONAIRE are registered trademarks of AAON, Inc., Tulsa, OK.
R53480 ·Rev. A ·6-07

4
GENERAL DESCRIPTION
AAON 'BL Series' boilers are complete self-
contained liquid heating units. They are factory
assembled, wired, and run-tested.
Unpacking:
When received, the unit should be checked for
damage that might have occurred in transit. If
damage is found it should be noted on the
carrier’s Freight Bill. A request for inspection by
carrier’s agent should be made in writing at once.
Also check the unit nameplate to ensure the
correct model sizes and voltage have been
received to match the job requirements
OWNER'S INFORMATION
Warning:
• Failure to observe the following instructions
will result in premature failure of your system,
and possible voiding of the warranty.
• Never cut off the main power supply to the unit,
except for complete shutdown.
• Always control the system from the building
management system, or control panel, never at
the main power supply (except for emergency or
for complete shutdown of the system).
• Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury or loss of life.
Installation and service must be performed by a
qualified installer, service agency or if gas fired
units, the gas supplier. Refer to installation
instructions provided with the unit and this
manual.
Wiring Diagrams:
A complete set of unit specific wiring diagrams
in both ladder and point-to-point form are
laminated in plastic and located inside the control
compartment door.
General Maintenance:
When the initial startup is made and on a
periodic schedule during operation, it is
necessary to perform routine service checks on
the performance of the boiler.
Boilers:
• Boilers and pumping packages are factory
installed.
• The boiler systems use primary/secondary
pumping packages as described in the following
section. There can be 1-4 boilers in parallel and
each boiler has its own primary pump. The
heating loop must be designed to return at least
120°F water to the boiler during normal
operation. Failure to return 120°F water to the
boiler will create condensation, which will
reduce the life of the heat exchanger and void the
boiler warranty. See unit submittal for unit
specific piping schematics. See the boiler
“Installation, Operating, and Service
Instructions” that is included with the unit for
specific information about the boiler
manufactured by Thermal Solutions.
• Once the boiler is given a run signal, the boiler
secondary pump will be activated and the AAON
controls package will stage boilers as necessary
to maintain the leaving water temperature
setpoint.
• The AAON controls package will also control
the speed of the secondary pump in the boiler
system to maintain differential pressure across
the pump.

5
OWNER'S INFORMATION cont.
Primary/Secondary Pumping:
• Water enters the unit through the return water
piping, and then travels through a suction guide
with strainer. The end of the suction guide is
removable for strainer access. The strainer
assembly is composed of two parts, the
operational strainer, and the startup strainer,
(located inside the operational strainer) which is
to be removed 24 hours after startup.
• The pump is installed after the suction guide,
and before a combination valve (Flo-Trex). This
combination valve acts as isolation valve, check
valve, and flow balancing valve. The boiler is
placed after the combination valve in the water
circuit.
• The primary/secondary pumping option
provides variable flow to the system. It consists
of a constant flow pump for the boiler, and a
variable flow pump for the building. The AAON
controls package senses differential pressure
across the pump with pressure transducers
installed at the suction and discharge, and varies
the speed of the pump using a VFD in order to
maintain a given differential pressure across the
pump.
• The primary/secondary pumping package is
essentially composed of two piping loops
coupled together. The primary loop has a
constant flow rate in order to maintain water
temperature through the boiler, and the
secondary, variable flow loop, provides water to
the building. The two loops are coupled via a
water line that compensates for excess flow in
either loop. As the flow in the secondary loop
increases above the flow in the primary, excess
flow bypasses the building loop and circulates
through the primary loop. If on the other hand,
the flow in the secondary loop decreases below
the primary loop, flow will bypass the boiler.
• The secondary pump has its own suction guide,
combination valve, and isolation valve, similar to
the primary pump, with the addition of an air
separator to remove any air that is entrapped in
the water.
• See appendix for additional information on
installation, operation and maintenance of
pumps.
Make-up Water:
• A city make-up water connection is provided to
replace water that is lost from the system.
• Glycol units require a glycol feeder (optional
factory installed or field installed) to replace
fluid that is lost in the system. Make-up water
should not be added to glycol applications as this
would dilute the glycol concentration and
thereby increase the freezing temperature of the
fluid.
• The make-up water connection is provided with
a backflow preventer that has isolation valves on
the inlet and outlet for service. The chart below
shows the pressure drop versus flow rate for the
backflow preventer.
• There is a pressure-reducing valve after the
backflow preventer. This valve reduces the city
water pressure to maintain the operating pressure
of the system. This valve is adjustable from 10-
35 psig with a factory setting of 30 psig. The
system pressure varies with the height of the
system. The pressure-reducing valve setting
should be set so that the pressure at the high
point in the system is high enough to vent air
from the system (usually 4 psig). There should
be air vents at all parts in the system where air
could be trapped. If the pressure is not high
enough throughout the system, flashing could
occur in the piping or the pump could cavitate.
There is an isolation valve on the inlet and outlet
of the pressure-reducing valve for service.
• The pressure reducing valve fills the system at a
reduced rate. There is a bypass around the
pressure reducing valve for the initial fill of the
system to increase the initial fill speed. After the
initial system fill, this valve should be closed.

6
OWNER'S INFORMATION cont.
Expansion tank:
• As the water temperature in the system
increases, the volume that water displaces
increases. In order to compensate for these
expansion forces, an expansion tank must be
used. AAON uses a pre-pressurized diaphragm
expansion tank that is preset for 12 psig.
• The factory pre-charge pressure may need to be
field adjusted. The tank must be pre-charged to
system design fill pressure before placing into
operation. Remove the pipe plug covering the
valve enclosure. Check and adjust the charge
pressure by adding or releasing air.
• If the system has been filled, the tank must be
isolated from the system and the tank emptied
before charging. This ensures that all fluid has
exited the diaphragm area and proper charging
will occur.
• If the pre-charge adjustment is necessary, oil
and water free compressed air or nitrogen gas
may be used. Check the pre-charge using an
accurate pressure gauge at the charging valve and
adjust as required. Check the air valve for
leakage. If evident, replace the Schrader valve
core. Do not depend on the valve cap to seal the
leak. After making sure the air charge is correct,
replace the pipe plug over the charging valve for
protection.
• Purge air from system before placing tank into
operation. All models have system water
contained behind the diaphragm.
• It is recommended that the pre-charge be
checked annually to ensure proper system
protection and long life for the vessel.
Pressure Relief Valve:
AAON installs the required pressure relief valve
in the unit. This valve is set at 125 psig. The
chart below shows inlet pressure versus capacity
for this pressure relief valve. See appendix for
additional information.
Automatic Air Vent:
There is an automatic air vent installed at the
high point of the system inside the pumping
package compartment. The air vent valve must
be in the proper position for operation. Ensure
that the small vent cap is loosened two turns
from the closed position, allowing air to be
vented from the system. It is advisable to leave
the cap on to prevent impurities from entering
the valve. See appendix for additional
information.
Dual Pumps:
• When redundant pumping is required, factory
installed dual pumps or two single pumps can be
ordered. A dual pump is a pump with two
independent motors and pumps in a single
casing. This dual pump has a swing split-flapper
valve in the discharge port to prevent liquid
recirculation when only one pump is operating.
Isolation valves in the casing allow one pump to
be isolated and removed for service while the
other pump is still operating.
• When redundant pumping is required with high
flow rates, AAON will install two independent
pumps in parallel. Each pump will have its own
suction guide/strainer, combination valve, and
isolation valves.
• The AAON controls package will activate the
pump when the unit is given a run command. If
the controls do not recognize flow in 60 seconds,
the second pump will be activated and an alarm
signal will be generated. If the second pump
does not activate, the cooling will be locked out.
See appendix for additional information
regarding dual pumps.

7
OWNER'S INFORMATION cont.
Pressure Gauges and Thermometers:
Pressure gauges and thermometers are available
as a factory installed option. Thermometers are
installed on the inlet and outlet of the unit. One
pressure gauge is installed at each pump. This
pressure gauge is connected in three places to the
water piping before the suction guide/strainer,
after the suction guide and before the pump, and
after the pump. There is also a needle valve at
each of these points to isolate the pressure. To
measure the pressure at any given point, open the
needle valve at that point and close the other two
needle valves. One gauge is used so that the
calibration of the pressure gauge is irrelevant in
the calculation of the differential pressure.
Pipe Insulation:
The water piping and components on BL units
with pumping packages are not insulated at the
factory. Insulation should be installed on the
water piping after the system has been checked
for leaks.
INSTALLATION
Lifting and Handling:
• If cables or chains are used to hoist the unit
they must be the same length and care should be
taken to prevent damage to the cabinet.
• Before lifting unit, be sure that all shipping
material has been removed from unit. Secure
hooks and cables at all lifting points/ lugs
provided on the unit.
• Do not push, pull or lift the unit from anything
other than its base.
UNIT MUST BE RIGGED AT ALL
MARKED LIFTING POINTS (Typical)
Boiler Placement:
• The AAON BL Series is designed for outdoor
applications and mounting at ground level or on
a rooftop. It must be placed on a level and solid
foundation that has been prepared to support its
weight. When installed at ground level, a one-
piece concrete slab should be used with footings
that extend below the frost line.
Service Clearances:
UNIT SIZE
LOCATION All BL Units
Back 100"
Front 100"
Left Side 100"
Right Side 100"
Top UNOBSTRUCTED
Water Connection:
Connect the BL Series supply and return water
lines. The connection size is listed on the unit
rating sheet, along with the designed volumetric
flow rate. The Maximum operating pressure for
the AAON BL Series Boiler is 125 psi.
Gas Connection:
• Size gas piping to supply the unit with proper
pressure when all gas consuming devices in the
building connected to the same gas system are
operating. The maximum gas train inlet pressure
for all boiler sizes is 5 psig. The minimum gas
train inlet pressure for the 500 MBH boiler is 7
inches of water column, and for all other boilers,
5 inches of water column.
• Carefully consider all current and future gas
usage. The following table details the input rate
for each boiler unit.
• Gas connection sizes are listed on the unit
rating.

8
INSTALLATION cont.
Rated Input*
Rated Capacity (CFH)
Boiler Size Natural LP/Propane
500 MBH 500 200
750 MBH 750 300
1000 MBH 1000 400
1500 MBH 1500 600
*Note: Indicated Rating is for sea level
conditions.
For additional information regarding the gas
piping connection, see the boiler “Installation,
Operating, and Service Instructions” that are
included with the unit for specific information
about the boiler manufactured by Thermal
Solutions.
Boiler Exhaust Connection:
In addition to gas connection installation, each
boiler requires installation of the exhaust vent
piping and inlet vent hood. The exhaust panel
with chimney cutout is removed for shipping,
and replaced with a shipping cover.
Remove the shipping cover and attach the
exhaust panel shipped with the unit. When the
exhaust panel is securely fastened with sheet
metal screws, locate the exhaust piping that is
also shipped along with the unit. The exhaust
piping that must be attached to the internal
exhaust vent piping includes the vent length, 90
degree elbow and rain cap. Examine all
components prior to installation. The female end
of each vent pipe component incorporates a
sealing gasket and a mechanical locking band.
Intake and Exhaust covers are in place for
shipping. These must be removed and
external intake/exhaust components must be
installed prior to boiler operation.

9
INSTALLATION cont.
Gaskets must be in proper position or flue
gases could leak.
Securely fasten the vent pipe joints according
to the following procedure:
1. Insert the male end into the female section.
Push the units together and turn them until the
bead of the male end is seated against the flared
end of the female section. This creates the
necessary airtight seal. Align the seams on the
vent lengths and orient them upward in all
horizontal applications.
2. Tighten the locking band with a nut driver
until snug plus 1/4 turn.
Before proceeding, recheck all joints and
ensure that all male sections extend to the top
of the flared female end and all clamps are
tightened.
Stop bead on male end must be pushed directly
against the flared end of the female end. When
checking the inside of the joint, the gasket is
fully covered and out of sight.

10
INSTALLATION cont.
Boiler Intake Connection:
Remove the intake shipping cover. The round
collar on the back of the intake vent passes
through the cabinet wall and slides over the
crimped end of the air intake pipe inside the unit.
This joint should be secured with aluminum foil
tape. The outer flange of the wall vent is fastened
to the outer wall of the cabinet using sheet metal
screws.
Access Doors:
• A lockable access door is provided to the
compressor and electrical compartment. A
separate access door is also provided to the
evaporator/heat exchanger compartment.
• A light switch is on the wall of the compressor
control compartment.
Electrical:
• The single point electrical power connections
are made in the electrical control compartment.
• The microprocessor control furnished with the
unit is supplied with its own power supply
factory wired to the main power of the BL.
• Check the unit data plate voltage to make sure
it agrees with the power supply. Connect power
to the unit according to the wiring diagram
provided with the unit.
• The power and control wiring may be brought
up through the utility entry. Protect the branch
circuit in accordance with code requirements.
Control wires and power should not be run inside
the same conduit. The unit must be electrically
grounded in accordance with the current National
Electric Code.
• Power wiring is to the unit terminal block or
main disconnect. All wiring beyond this point
has been done by the manufacturer and cannot be
modified without effecting the unit's
agency/safety certification.
Note: Startup technician must check motor
amperage to ensure that the amperage listed
on the motor nameplate is not exceeded.
STARTUP
Pre Startup:
After the installation and immediately before the
startup of the boiler be sure that these items have
been checked.
1. Verify that electrical power is available to the
unit.
2. Verify that any remote stop/start device
connected to the boiler controller is requesting
the boiler to start.
3. Verify that liquid flow is present through the
boiler from the building.
4. There should be a building load of at least
25% of the boiler capacity in order to properly
check operation.
5. With the main power switch off, review the
Controller Manual provided with the boiler.
Understand the keypad functions, how to set the
leaving water temperature setpoint and how to
initiate the Run State.
While performing the Startup, use the BL Startup
Form at the rear of this booklet to record motor
amps and any additional comments.
Startup:
• Use the General Check List at the top of the
Form to make a last check that all the
components are in place, water flow is present,
and the power supply is energized.
• Using the keypad, individually set the outputs
in “Manual On” to confirm relay closure.

11
STARTUP cont.
Cycle on all boilers to make sure they operating
within tolerance?
• Use BL Startup Form to record observations of
boiler amps
• When all is running properly, place the
controller in the Run mode and observe the
system until it reaches a steady state of operation.
Note: For more information on programming the
controller refer to the Control Manual provided
with the BL.
SERVICING AND MAINTENANCE
General:
• Qualified technicians must perform routine
service checks and maintenance.
Lubrication:
• All original motors and bearings are furnished
with an original factory charge of lubrication.
Certain applications require bearings be re-
lubricated periodically. The schedule will vary
depending on operating duty, temperature
variations, or severe atmospheric conditions.
• Bearings should be re-lubricated at normal
operating temperatures, but not when running.
Rotate the motor shaft by hand and add only
enough grease to purge the seals. DO NOT
OVERLUBRICATE.
Service:
If the unit will not operate correctly and a service
company is required, only a company with
service technicians qualified and experienced in
both boilers and pumping systems are permitted
to service the systems to keep warranties in
effect. If assistance is required, the service
technician must contact AAON.
Note: Service technician must provide the
model and serial number of the unit in all
correspondence with AAON.
Replacement parts for AAON equipment may be
obtained from AAON. When ordering parts,
always reference the unit model number, serial
number and part number.
AAON, Inc.
www.aaon.com
Customer Service Department
2425 South Yukon Ave • Tulsa, OK 74107
Phone: [phone] • Fax: [phone]
ALWAYS USE AAON SPECIFIED PARTS
To order parts from the AAON Parts store
online go to www.aaonparts.com.

12
BL Series
APPENDIX
Piping Component Information
CONTENTS
Water Pressure Reducing Valves…………………………………………………………………….…………….................
Water Pressure Relief valves…………………………………………………………………………..…………..................
Automatic Air Vent Valves…………………………………………………………………….……….………………….....
13
14
15
Pumps: Introduction…………………………………………………………………………………..…….…………………
Pumps: Operation ……………….…………………………..……………………………………..………………………….
Pumps: Dual Pump Specific Information…………………….……………….………………………………………………
17
18
21
Horizontal and Vertical Expansion Tanks………………………………………………………………….………………....
Suction Guides …………………………………………………………………………..…………………………………....
Glycol Auto Fill Unit ………………………………………………………………………………………………………...
Flo-Trex Combination Valve………………………………………………………………………………………………….
25
26
27
28

13
WATER PRESSURE REDUCING
VALVE
Water Pressure Reducing Valves are designed to
reduce incoming water pressure to protect
plumbing system components and reduce water
consumption.
Overview:
• Standard construction includes Z3 sealed spring
cage and corrosion resistant adjusting cage
screws for outdoor/waterworks pit installations
• Integral stainless steel strainer
• Replaceable seat module
• Bronze body construction
• Serviceable in line
• High temperature resistant reinforced
diaphragm for hot water
• Low pressure range 10 – 35psi (69 – 241 kPa)
Materials:
Body: Bronze
Seat: Replaceable stainless steel
Integral Strainer: Stainless steel
Diaphragm: Reinforced EPDM
Valve Disc: EPDM
Standards:
Meets requirements of ASSE Standard 1003; (ANSI
A112.26.2); CSA Standard B356; Southern Standard
Plumbing Code and listed by IAPMO.
Teflon® is a registered trademark of E.I. Dupont de
Nemours & Company.
Capacity:
MAINTENANCE INSTRUCTIONS
To clean strainer remove the bottom plug and
pull out strainer.
Adjustment:
To adjust pressure setting, loosen the lock nut
and turn the adjusting bolt clockwise to increase
pressure, counter clockwise to decrease pressure.
Note: Use a pressure gauge downstream to adjust
and verify the pressure setting.
Troubleshooting
High System Pressure:
If the downstream system pressure is higher than
the set pressure under no flow conditions, the
cause could be thermal expansion, pressure creep
or dirt/debris on the seat. Thermal expansion
occurs whenever water is heated in a closed
system. The system is closed when supply
pressure exceeds 150 psi, or a check valve or
backflow preventer is installed in the supply
piping. To determine if this is the result of
thermal expansion, try briefly opening the cold
water tap. If the increased pressure is caused by
thermal expansion, the pressure will immediately
be relieved and the system will return to the set
pressure.

14
PRESSURE REDUCING VALVE cont.
Dimensions-Weights:
WATER PRESSURE RELIEF VALVE
Overview:
• ASME Rated, Design Certified and Listed by
C.S.A.
• Used for protection against excessive pressure
on domestic storage tanks or tankless water
heaters, the pressure relief valve has no
temperature relieving element.
• Standard setting, 125 psi Size 3⁄4" x 3⁄4"
(20mm x 20mm).
• ASME construction and is tested, listed and
certified by the National Board of Boiler and
Pressure Vessel Inspectors.
ANSI Z21.22 “Relief Valves for Hot Water Supply Systems.”
DESIGN CERTIFIED and listed by C.S.A.

15
AUTOMATIC AIR VENT VALVES
• Automatic Air Vent Valves provide automatic
air venting for hot or cold water distribution
systems. These vents purge air that may be in the
water system.
• The vent valve utilizes a float to actuate the
valve plug which is located at the top of the
valve. Once the air is displaced and the system
pressure is sustained, the valve plug seals and
prevents any water from escaping from the
system.
• The float vent can also operate as an anti-
vacuum device since it will permit air to enter the
system when it must be drained. It can also be
installed to permit the separation and dispersal of
air while fluid is actually circulating in the
system.
Overview:
• Body and cover are brass construction
• Air vent with silicone rubber seal
• Impurities do not usually affect function as
maximum float line of water is always lower
than the valve seal
• Float is high temperature resistant polyethylene
• Suitable for use with glycol systems
•Can be disassembled for inspection and cleaning
Operating Range:
Minimum working pressure: 1.45psi (10 kPa)
Maximum working pressure: 150psi (10 bars)
Temperature Range: 33°F – 240°F (5°C –
116°C)
Performance:
Performance curve details the quantity of air
vented by the “Float Vent” according to the
pressure in the system.
Note: In order to get the best results in venting
air from risers, use connecting pipes of at least
1⁄2" diameter between the “Float Vent” valves
and installation.
Installation:
When the air vent valve is installed as shown, the
air will not be vented while the fluid is
circulating in the system, but it can vent when
the system is shut off.
The figure below shows the installation of the
vent valve for the venting of air while the fluid is
circulating in the system and the required
increase in pipe size in order to obtain proper
separation of air from water.

16
AIR VENT VALVES cont.
The valve should be mounted only in a vertical
position as its operation is based on the vertical
movement of the float.
While the air vent valve is in operation, back off
the small vent cap two turns. This is the proper
operating setting which will allow air to be
vented from the system. It is advisable to leave
the cap on to prevent impurities from entering
the valve.
Maintenance:
No maintenance is normally necessary. However,
if the FV-4M1 is disassembled for inspection or
cleaning it is important that when re-assembling
to ensure that the spring loaded lever properly
engages under the float collar
Dimensions – Weights:

17
PUMPS: INSTALLATION AND
OPERATING INSTRUCTIONS
Introduction:
This document contains specific information
regarding the safe installation, operating and
maintenance of Vertical In-Line pumps and
should be read and understood by installing,
operating and maintenance personnel. The
equipment supplied has been designed and
constructed to be safe and without risk to health
and safety when properly installed, operated and
maintained. The instructions following must be
strictly adhered to. If clarification is needed on
any point please contact Armstrong quoting the
equipment serial number.
Where under normal operating conditions the
limit of 68°C/155°F (Restricted Zone) for normal
touch, or 80°C/176°F (Unrestricted Zone) for
unintentional touch, may be experienced, steps
should be taken to minimize contact or warn
operators/users that normal operating conditions
will be exceeded. In certain cases where the
temperature of the pumped liquid exceeds the
above stated temperature levels, pump casing
temperatures may exceed 100°C/212°F and not
withstanding pump insulation techniques
appropriate measures must be taken to minimize
risk for operating personnel.
Storage:
Pumps removed from service and stored, must be
properly prepared to prevent excessive rusting.
Pump port protection plates must not be removed
until the pump is ready to connect to the piping.
Rotate the shaft periodically (At least monthly)
to keep rotating element free and bearings fully
functional.
For long term storage, the pump must be placed
in a vertical position in a dry environment.
Internal rusting can be prevented by removing
the plugs at the top and bottom of the casing and
drain or air blow out all water to prevent rust
buildup or the possibility of freezing. Be sure to
reinstall the plugs when the unit is made
operational. Rustproofing or packing the casing
with moisture absorbing material and covering
the flanges is acceptable. When returning to
service be sure to remove the drying agent from
the pump.
Handling Large VIL Units:
One effective way of lifting a large pumping unit
is to place lifting hooks through the motor lifting
rings or straps around the upper part of the
motor. The pump and motor unit will free-stand
on the casing ribs. Remove the coupling guard
and place (2) lifting straps through the
pump/motor pedestal, one on each side of the
motor shaft and secure to the lifting device.
With the straps in place, using a spacer bar if
necessary to protect the motor fan cover, the
whole assembly can now be lifted securely.
Note: Handling, transportation and installation of
this equipment should only undertaken by trained
personnel with proper use of lifting equipment.
Remove coupling guard and place lifting straps
on each side of coupling, use spacer bar if
necessary to protect motor fan cover.
Vertical Inline Pump Lifting Strap
Positioning:

18
PUMPS cont.
Pump Piping – General:
Caution:
The discharge valve only is to be used to throttle
pump flow, not the suction valve. Care must be
taken in the suction line layout and installation,
as it is usually the major source of concern in
centrifugal pump applications
OPERATION
Starting Pump:
• Ensure that the pump turns freely by hand, or
with some mechanical help such as a strap and
lever on larger pumps. Ensure that all protective
guarding is securely fixed in position.
• The pump must be fully primed on start up. Fill
the pump casing with liquid and rotate the shaft
by hand to remove any air trapped in the
impeller. On split coupled units, any air trapped
in the casing as the system is filled must be
removed by the manual air vent in the seal flush
line. Close-coupled units are fitted with seal
flush/vent lines piped to the pump suction area.
When these units operate residual air is drawn
out of the pump towards the suction piping.
• “Bump” or energize the motor momentarily and
check that the rotation corresponds with the
directional arrow on the pump casing.
• To reverse rotation of a three phase motor,
interchange any two power leads.
• Start the pump with the discharge valve closed
and the suction valve open, and then gradually
open the discharge valve when the motor is at
operating speed. The discharge valve may be
cracked” or open slightly at start up to help
eliminate trapped air.
• When stopping the pump: Close the discharge
valve and de-energize the motor.
• DO NOT run the pump against a closed
discharge valve for an extended period of time.
(A few minutes maximum)
• Should the pump be noisy or vibrate on start-up
a common reason is overstated system head.
Check this by calculating the pump operating
head by deducting the suction pressure gauge
value from the discharge gauge reading. Convert
the result into the units of the pump head as
stated on the pump nameplate and compare the
values. Should the actual pump operating head
be significantly less than the nameplate head
value it is typically permissible to throttle the
discharge isolation valve until the actual
operating head is equal to the nameplate value.
Any noise or vibration usually disappears. The
system designer or operator should be made
aware of this soon as some adjustment may be
required to the pump impeller diameter or drive
settings, if applicable, to make the pump suitable
for the system as installed.
Caution:
Check rotation arrow prior to operating the unit.
The rotation of all Vertical In-Line units is
“clockwise” when viewed from the drive end.
(Looking from on top of / behind the motor)

19
PUMPS cont.
General Care:
• Vertical In-Line pumps are built to operate
without periodic maintenance, other than motor
lubrication on larger units. A systematic
inspection made at regular intervals, will ensure
years of trouble-free operation, giving special
attention to the following:
• Keep unit clean
• Keep moisture, refuse, dust or other loose
particles away from the pump and ventilating
openings of the motor.
• Avoid operating the unit in overheated
surroundings (Above 100ºF/40ºC).
• Any possibility of the unit starting while being
serviced must be eliminated.
• If mechanical seal environmental accessories
are installed, ensure water is flowing through the
sight flow indicator and that filter cartridges are
replaced as recommended.
LUBRICATION
Pump:
• Lubrication is not required. There are no
bearings in the pump that need external
lubrication service.
• Large Series split-coupled units are installed
with a shaft bushing located beneath the impeller
that is lubricated from the pump discharge. This
bearing is field removable for service on the
20x20x19 size without disturbing the motor or
other major pump components.
Motor:
• Follow the lubrication procedures
recommended by the motor manufacturer. Many
small and medium sized motors are permanently
lubricated and need no added lubrication.
Generally if there are grease fittings evident the
motor needs periodic lubrication, and if there are
no grease fittings evident, no periodic lubrication
is required.
• Check the lubrication instructions supplied with
the motor for the particular frame size indicated
on the motor nameplate.
Mechanical Seal:
• Mechanical seals require no special attention.
The mechanical seal is fitted with a flush line.
The seal is flushed from discharge of the pump
casing on split-coupled pumps and is
flushed/vented to the suction on close coupled
pumps.
• The split-coupled pump is flushed from the
pump discharge because the mechanical seal
chamber is isolated from the liquid in the pump
by a throttle bushing. Because the seal chamber
is isolated, seal environmental controls such as
filters and separators, when installed in the split-
coupled flush line are very effective, as only the
seal chamber needs cleansing, and will prolong
seal life in HVAC systems.
• Do not run the pump unless properly filled with
water as the mechanical seals need a film of
liquid between the faces for proper operation.
• Mechanical seals may ‘weep’ slightly at start-
up. Allow the pump to continue operating for
several hours and the mechanical seal to ‘seat’
properly prior to calling for service personnel.
System Cleanliness:
• Before starting the pump the system must be
thoroughly cleaned, flushed and drained and
replenished with clean liquid.
• Welding slag and other foreign materials, “Stop
Leak” and cleaning compounds and improper or
excessive water treatment are all detrimental to
the pump internals and sealing arrangement.
• Proper operation cannot be guaranteed if the
above conditions are not adhered to.

20
PUMPS cont.
Note:
Particular care must be taken to check the
following before the pump is put into operation:
1. Pump primed?
2. Rotation OK?
3. Lubrication OK?
4. Pipe work properly supported?
5. Voltage supply OK?
6. Overload protection OK?
7. Is the system clean?
8. Is the area around the pump clean?
Warranty:
Does not cover any damages to the equipment
resulting from failure to observe the above
precautions.
Noise Levels:
Estimated Pumping Unit Sound Power Level, Decibels, A-Weighted, at 1 m (3 ft.) from unit.
Vibration Levels:
Vertical In-Line pumps are designed to meet vibration levels set by Hydraulic Institute Standard HI Pump
Vibration 9.6.4. Standard levels are as detailed below: