Bell and Gossett ecocirc 19-16 User manual

INSTRUCTION MANUAL
P2003557 Rev A
ecocirc®19-16

Table of Contents
1 Introduction and Safety............................................................................................ 3
1.1 Introduction........................................................................................................3
1.2 Safety...................................................................................................................3
1.2.1 Safety terminology and symbols............................................................. 4
1.3 User safety.......................................................................................................... 5
1.4 Protecting the environment............................................................................. 6
2 Transportation and Storage.....................................................................................8
2.1 Inspect the delivery........................................................................................... 8
2.1.1 Inspect the package.................................................................................. 8
2.1.2 Inspect the unit...........................................................................................8
3 Product Description.................................................................................................. 9
3.1 General description...........................................................................................9
3.2 Nomenclature.................................................................................................... 9
3.3 Operation specifications................................................................................ 10
4 Installation................................................................................................................13
4.1 Facility requirements.......................................................................................13
4.1.1 Pump location..........................................................................................13
4.2 Piping requirements....................................................................................... 14
4.3 Electrical requirements...................................................................................14
4.4 Pump installation requirements.....................................................................15
4.5 Electrical installation....................................................................................... 16
4.5.1 Precautions...............................................................................................16
4.5.2 Connect the wires....................................................................................16
5 Operation.................................................................................................................18
5.1 Preparation for startup....................................................................................18
5.2 Modes of operation.........................................................................................18
5.3 Switch between standard operating modes................................................18
5.4 Standby mode................................................................................................. 19
5.5 Activate the air purge function...................................................................... 19
5.6 Typical speed settings.................................................................................... 19
6 Maintenance............................................................................................................ 20
6.1 Precautions.......................................................................................................20
6.2 Disassemble the pump...................................................................................20
7 Troubleshooting......................................................................................................21
7.1 Display messages............................................................................................ 21
7.2 The pump is noisy........................................................................................... 21
Table of Contents
ecocirc®19-16 INSTRUCTION MANUAL 1

7.3 Excessive ambient temperature.................................................................... 21
8 Appendix..................................................................................................................22
8.1 Appendix.......................................................................................................... 22
9 Product warranty.....................................................................................................26
Table of Contents
2 ecocirc®19-16 INSTRUCTION MANUAL

1 Introduction and Safety
1.1 Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the
product. Improper use of the product can cause personal injury
and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily
available at the location of the unit.
1.2 Safety
WARNING:
• The operator must be aware of safety precautions to prevent
physical injury.
• Operating, installing, or maintaining the unit in any way that
is not covered in this manual could cause death, serious
personal injury, or damage to the equipment. This includes
any modification to the equipment or use of parts not
provided by Xylem. If there is a question regarding the
intended use of the equipment, please contact a Xylem
representative before proceeding.
• Do not change the service application without the approval
of an authorized Xylem representative.
CAUTION:
You must observe the instructions contained in this manual.
Failure to do so could result in physical injury, damage, or
delays.
1 Introduction and Safety
ecocirc®19-16 INSTRUCTION MANUAL 3

1.2.1 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety
messages and regulations carefully before handling the product. They are
published to help prevent these hazards:
•Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING: A hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION: A hazardous situation which, if not avoided, could
result in minor or moderate injury
NOTICE: Notices are used when there is a risk of equipment
damage or decreased performance, but not
personal injury.
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical
Hazard:
CAUTION:
Hot surface hazard
Hot surface hazards are indicated by a specific symbol that replaces the typical
hazard level symbols:
CAUTION:
1 Introduction and Safety
4 ecocirc®19-16 INSTRUCTION MANUAL

Qualified personnel
WARNING:
This product is intended to be operated by qualified personnel
only.
1.3 User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc
flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn
injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety
equipment within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also
see specific information about safety devices in other
chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with
all international, national, state, and local regulations. For more information
about requirements, see sections dealing specifically with electrical
connections.
Precautions before work
Observe these safety precautions before you work with the product or are in
connection with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or
damage property.
1 Introduction and Safety
ecocirc®19-16 INSTRUCTION MANUAL 5

• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in
connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic
level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is
pressurized. Make sure that the pump is isolated from the system and that
pressure is relieved before you disassemble the pump, remove plugs, or
disconnect piping.
• Never operate a pump without a properly installed coupling guard.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come
into contact with your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least
15 minutes.
3. Seek medical attention.
Chemicals or hazardous
fluids on skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.4 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
1 Introduction and Safety
6 ecocirc®19-16 INSTRUCTION MANUAL

Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to
nuclear radiation, unless Xylem has been informed and
appropriate actions have been agreed upon.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
1 Introduction and Safety
ecocirc®19-16 INSTRUCTION MANUAL 7

2 Transportation and Storage
2.1 Inspect the delivery
2.1.1 Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to
the distributor.
2.1.2 Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are
missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact a sales representative if there is any issue.
2 Transportation and Storage
8 ecocirc®19-16 INSTRUCTION MANUAL

3 Product Description
3.1 General description
The product is a shaft-less spherical motor pump, with energy-efficient,
electronically commutated permanent magnet synchronous motor. The
following features make it easy to install, operate, and service:
• A leak proof, integrated pump and motor design eliminates the need for
conventional mechanical seals or other shaft sealing devices.
• The product is lubricated with system fluid, and thus does not require
external lubrication.
• The product requires only a small amount of torque to start even after a long
period.
WARNING:
California Proposition 65 warning! This product contains
chemicals known to the state of California to cause cancer and
birth defects or other reproductive harm.
Intended applications
The product is intended for the following applications:
• Hot water heating systems
• Chilled water applications
• Heat pumps
• Solar systems
• Industrial water circulation and potable water
3.2 Nomenclature
ecocirc®19 16
Series name Maximum head 19 ft (~6 m) Maximum flow 16 GPM (~3500
L/H)
Port to port distance = 6 3/8” (162 mm)
The product is capable of satisfying heating systems of about 170,600 BTU/HR
(50 KW), which will be equivalent to:
• Radiator heating system for approximately up to 5,000 ft² (465 m²) of living
space.
•Under-floor heating systems for approximately up to 2,000 ft² (186 m²) of
floor space.
3 Product Description
ecocirc®19-16 INSTRUCTION MANUAL 9

3.3 Operation specifications
Materials of construction
Part Material
Pump housing Cast iron (GJL-200)
Stainless steel (AISI 304)
O-rings EPDM
Bearing PEEK/AI203)
All plastics, except for bearings PPE
All other wetted parts AISI 304 / AISI 316 L / AISI 316Ti stainless steel
Check valve Noryl
Technical specification
Rated voltage 115 V
Frequency 50/60 Hz
Power consumption 4–60 W
IP protection IP 44
Insulation class Class 155 (F)
Maximum system pressure 150 PSI (10 bar)
Maximum ambient temperature 104°F (40°C)
Permitted temperature range of pumped fluid¹ 14°F to 203°F (-10°C to +95°C)
Permitted pumping media² Water — in potable and domestic water
applications
Water/glycol mixtures up to 50% — in chilled water
applications
¹ For domestic hot water applications, the maximum fluid temperature is 185°F
(85°C). For chilled water applications, the fluid must not freeze. To avoid
condensation, the fluid temperature must always be higher than the ambient
temperature.
² Performance of the pump will noticeably change when pumping water/glycol
mixtures with concentrations higher than 20%.
3 Product Description
10 ecocirc®19-16 INSTRUCTION MANUAL

Performance curves
Q [m3/h]
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
H [m]
0
1
2
3
4
5
6
7
Q [US gpm]
0 2 4 6 8 10 12 14 16
H [ft]
0
5
10
15
20
Q [Imp gpm]
0 2 4 6 8 10 12 14
H [kPa]
0
10
20
30
40
50
60
7
1
2
3
4
6
5
Figure 1: Proportional pressure (factory default)
Q [m3/h]
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
H [m]
0
1
2
3
4
5
6
7
Q [US gpm]
0 2 4 6 8 10 12 14 16
H [ft]
0
5
10
15
20
Q [Imp gpm]
0 2 4 6 8 10 12 14
H [kPa]
0
10
20
30
40
50
60
7
1
2
3
4
6
5
Figure 2: Constant pressure
3 Product Description
ecocirc®19-16 INSTRUCTION MANUAL 11

Q [m3/h]
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
H [m]
0
1
2
3
4
5
6
7
Q [US gpm]
0 2 4 6 8 10 12 14 16
H [ft]
0
5
10
15
20
Q [Imp gpm]
0 2 4 6 8 10 12 14
H [kPa]
0
10
20
30
40
50
60
7
1
2
3
4
6
5
Figure 3: Constant speed
Dimensions and weight
See Figure 4: Dimensions and weight on page 22.
3 Product Description
12 ecocirc®19-16 INSTRUCTION MANUAL

4 Installation
Precautions
WARNING:
• Observe accident prevention regulations in force.
• Use suitable equipment and protection.
• Always refer to the local and/or national regulations,
legislation, and codes in force regarding the selection of the
installation site, plumbing, and power connections.
4.1 Facility requirements
4.1.1 Pump location
DANGER:
Do not use this unit in environments that may contain
flammable/explosive or chemically aggressive gases or
powders.
Guidelines
Observe the following guidelines regarding the location of the product:
• Make sure that the installation area is protected from any fluid leaks, or
flooding.
• If possible, place the pump slightly higher than the floor level.
• Provide shut-off valves on the suction and discharge sides of the pump.
• The relative humidity of the ambient air must be less than 95% non-
condensing.
• This pump is suitable for indoor use only.
• These pumps are electronically thermally overload protected.
CAUTION:
CAUTION: PROPERTY DAMAGE HAZARD. It is not advisable to
install circulators in an attic or upper floor over finished living
space. If the circulator must be installed over head, or over
expensive equipment, provide adequate drainage in the event
of leakage. Failure to follow these instructions could result in
property damage.
4 Installation
ecocirc®19-16 INSTRUCTION MANUAL 13

4.2 Piping requirements
Precautions
CAUTION:
• Use pipes suited to the maximum working pressure of the
pump. Failure to do so can cause the system to rupture, with
the risk of injury.
• Make sure that all connections are performed by qualified
installation technicians and in compliance with the
regulations in force.
• Do not use a shut-off valve on the discharge side in the
closed position for more than a few seconds. If the pump
must operate with the discharge side closed for more than a
few seconds, a bypass circuit must be installed to prevent
overheating of the water inside the pump.
Piping checklist
• Pipes and valves must be correctly sized.
• Pipe work must not transmit any load or torque to pump flanges.
• Be sure to minimize any pipe-strain on the pump:
– Support suction and discharge piping by the use of pipe hangers near
the pump.
– Line up the vertical and horizontal piping so that the bolt-holes in the
pump flanges match the bolt-holes in the pipe flanges.
– Do not attempt to spring the suction or discharge lines in position. This
may result in unwanted stress in the pump body, flange connections and
piping.
– The code for pressure piping (ANSI B31.1) lists many types of supports
available for various applications.
Install the check valve
The discharge nozzle is machined to accept a 1” Noryl check valve. If a check
valve is required for installation follow these steps:
1. Insert the O-ring end of the check valve into the discharge port of the pump
body.
2. Hand press the check valve body into place until it snaps into position.
The check valve will be shipped loose with each pump for field installation.
Once it is installed, it cannot be removed without damage.
See Figure 5: Parts on page 23 for proper installation of the check valve.
4.3 Electrical requirements
• The NEC, CEC and local codes must be followed at all times. If a branch
circuit is fitted with ground fault circuit breaker, ensure that the circuit
breaker is suitable for use with inverter-driven appliances.
4 Installation
14 ecocirc®19-16 INSTRUCTION MANUAL

Electrical connection checklist
Check that the following requirements are met:
• The electrical wires are protected from high temperature and vibration.
• The current type and power supply voltage connection must correspond to
the specifications on the name plate on the pump.
• Use wires at least 14 AWG to supply power to the pump. Follow all local and
NEC wiring codes and practices.
• The branch circuit supplying power to the pump shall be provided with a 15
Amps or less circuit breaker.
• Attach appropriate sized electrical connector to one f the 7/8" diameter
holes on the side of the conduit box.
• Connect ground wire to one of the ground screws inside the conduit box.
• Make sure electrical connections are tightly secured before replacing the
motor cover.
The electrical control panel checklist
NOTICE:
The electrical supply must match the electrical rating of the
pump. Improper combination could fail to guarantee protection
of the unit.
Check that the following requirements are met:
• The control panel circuit breaker is sized properly to protect the pump
against short-circuit.
• These pumps are electronically thermally overload protected. No additional
overload protection is required.
The motor checklist
Electrical supply and grounding wires must be suitable for at least 194°F (90°C).
4.4 Pump installation requirements
• Install the pump according to the liquid flow direction arrows.
• Install the pump according to the allowed pump positions.
• Make sure that the pump is adequately supported by the piping system and
properly aligned to eliminate any stress on the pump or the piping
• Install the pump at a point closest to the highest static pressure point but
above the absolute lowest point in the system to avoid dirt and sediment
build-up.
4 Installation
ecocirc®19-16 INSTRUCTION MANUAL 15

• If required by application and code, install a safety relief valve to protect
against over temperature and over pressure.
• Do not install with the motor above the impeller. This installation can cause
the pump to run dry leading to premature failure of the pump and voids the
warranty.
4.5 Electrical installation
4.5.1 Precautions
WARNING:
• Make sure that all connections are performed by a qualified
electrician in accordance with all applicable codes,
ordinances and good practices. Failure to follow these
instructions could result in serious injury, death and/or
property damage.
• Before starting work on the unit, make sure that the unit and
the control panel are isolated from the power supply and
cannot be energized.
• Risk of Electrical Shock. To reduce the risk of electric shock,
connect only to a properly grounded, grounding type
receptacle. This warning applies to pumps fitted with flexible
cord connections.
• Electrical Grounding Hazard. Adequate electrical grounding
is required for the safe operation of B&G pumps. The use of
grounded metal conduit assures this requirement. If the
means of connection to the supply-connection box (wiring
compartment) is other than grounded metal conduit, ground
the pump back to the service. Use copper wire at least the
size of the wires supplying power to the pump. Connect the
ground wire to the ground terminal in the wiring
compartment. Failure to follow these instructions could
result in serious personal injury, death and or property
damage.
4.5.2 Connect the wires
1. Loosen the screw that secures the motor cover and remove the screw and
cover.
See Figure 6: Electrical connections on page 24 for more information.
2. Attach an appropriately sized electrical connector to one of the 7/8”
diameter holes on the side of the conduit box.
4 Installation
16 ecocirc®19-16 INSTRUCTION MANUAL

3. Connect the ground wire to one of the ground screws inside the conduit
box.
4. Make sure that the electrical connections are tightly secured before
replacing the motor cover.
4 Installation
ecocirc®19-16 INSTRUCTION MANUAL 17

5 Operation
5.1 Preparation for startup
Follow these precautions before startup:
• The system must be thoroughly rinsed to prevent the presence of unwanted
objects and impurities which could block the pump.
• Fill completely with pumped media (water or water/glycol mixture).
• Purge the entrained air.
– See Activate the air purge function on page 19.
– The air purge function can be activated at any time during operation,
when presence of air is suspected in the system.
– The air purge function can be repeated several times in a sequence if
necessary.
– Audible flow noise indicates presence of air that is entrained in the pump.
5.2 Modes of operation
The product has three standard and two auxiliary modes of operation.
Proportional
pressure (PP)
Turn the knob to any position between 1 and 7, with 7 being
the highest, to set the speed of the pump. The pump
automatically decreases its speed at low flow, thus providing
energy savings. This mode is the default setting.
Constant
pressure (CP)
Turn the knob to any position between 1 and 7, with 7 being
the highest, to set the speed of the pump. The preset
pressure remains constant, independent of the flow.
Constant speed
(CS)
Turn the knob to any position between 1 and 7, with 7 being
the fastest, to set the speed of the pump. The preset speed
remains constant, independent of the flow rate.
Automatic air
purge
This mode is used to purge air that is trapped in the pump
housing. See Activate the air purge function on page 19 for
instruction.
Standby This mode is used to keep power consumption low (<1 W),
when pump operation is not required.
5.3 Switch between standard operating modes
1. Turn the knob to the lowest setting.
2. Turn the know back to the desired setting within 5 seconds.
Pump indicates mode change by color of the knob LED:
Mode LED color
Proportional pressure (PP) Blue
Constant pressure (CP) Green
Constant speed (CS) White
5 Operation
18 ecocirc®19-16 INSTRUCTION MANUAL