Hartell Pumps PlenumPlus KL-1DG-115 User manual

PlenumPlus™
Commercial Grade
Condensate Removal Pumps
(KL-1DG-115, KL-1DG-230 and KL-1DG-277)
IOM Manual
Manual No. : 52200
Rev. : A
Rev. Date : 2019

1Installation, Operation & Maintenance Manual
HARTELL KL-1DG-115, KL-1DG-230 and KL-1DG-277 series condensate pump is guaranteed to be free
from defects in workmanship or materials and to function satisfactorily, when properly installed. See our
website for additional warranty information at www.hartell.com.
This guarantee does not apply if the product has been misapplied or mechanically damaged, HARTELL
assumes no liability for resultant damages of any kind arising out of the use of its products.
ONE YEAR LIMITED WARRANTY
SECTION 1 - INTRODUCTION ............................................................... 1
SECTION 2 - INSTALLATION AND OPERATION ................................................. 2
2.1 INSTALLATION .................................................................. 2
2.1.1 Piping ....................................................................... 2
2.1.2 Electrical Connections............................................................ 3
2.1.3 Line Voltage ................................................................... 3
2.1.4 Low Voltage-Auxiliary Safety Switch ................................................. 3
2.2 OPERATION .................................................................... 3
SECTION 3 - MAINTENANCE ............................................................... 4
3.1 PUMP DOES NOT RUN ........................................................... 4
3.2 PUMP MOTOR RUNS WITH NO DISCHARGE ......................................... 4
TABLE OF CONTENTS

2Installation, Operation & Maintenance Manual
HARTELL condensate pumps are designed
to collect and automatically remove the water
produced from an air conditioner evaporative
coil and/or a gas-condensing furnace. This pump
has been carefully engineered to provide long,
trouble free service and is of the highest quality
workmanship and materials.
These pumps have been thoroughly inspected
and tested, then carefully packaged to insure
safe delivery and operation. When you receive
your pump, examine it carefully to determine that
there are no damaged or broken parts. If damage
is detected, notify the rm from where the pump
was purchased. They will assist with a repair or
replacement.
See the precautions listed below before continuing.
READ ALL INSTRUCTIONS
CAREFULLY BEFORE STARTING
INSTALLATION.
1 Pump should only be used with liquids compatible
with pump component materials. Do not use to
pump ammable or explosive uids. Do not use
in explosive atmospheres.
2The pump is supplied with Pigtails to hard
wire the pump. To reduce the risk of electrical
shock be certain that it is connected to a ground
wire.
3In any installation where property damage
and/or personal injury might result from an
inoperative or leaking pump due to power
outages, discharge line blockage, or any other
reason, a back up system(s) (aux. switch)
and/or alarm should be used.
SECTION 1 - INTRODUCTION
4 Do not handle pump with wet hands or when
standing on a wet or damp surface, or in
water.
5Shut off the electrical power at the fuse box
before making any connections. All wiring must
comply with local codes.

3Installation, Operation & Maintenance Manual
SECTION 2 - INSTALLATION AND OPERATION
2.1 INSTALLATION
Carefully unpack the pump and select a mounting
location in the Plenum area (see Figure 1). The
pump must be level and the inlet must be below the
lowest drain, either coil or furnace. If wall or case
mounting, use the mounting tabs on either side of
the reservoir to secure the pump.
2.1.1 Piping
Run exible tubing or pipe from the evaporator and
furnace to the pump. Connect to either inlet barbed
tting. Make sure the pipe does not interfere with
the oat. If barbed tting is not used, cut an angle
on the inlet pipe so that it doesn’t close off against
the bottom of the pump.
Connect tubing to the check valve. Extend this
tubing straight up as high as necessary. (Do not
extend this tubing past the head/GPH of the pump
installed). Do not kink the tubing, as this will block
the ow. From this high point, slope the discharge
tubing downward to a point above the drain, then
turn down and extend to a point below or level
with the bottom of the condensate pump. If it is not
possible to slope the discharge tubing downwards,
make an inverted “U” trap directly above the pump
at the highest point (Figure 2).
Figure 2
Discharge tube should
slope down towards
oulet if possible
3/8” ID Tubing
To Floor Drain
Do not kink tube !
Hose Clamp
Active/Circulating
Plenum Airspace
Forced-Air Return
Forced-Air Supply
Living/Working Space of a
Typical Commercial building
Drop
Ceiling
Figure 1

4Installation, Operation & Maintenance Manual
SECTION 2 - INSTALLATION AND OPERATION
2.1.2 Electrical Connections
NOTE:
Review precautions in Section 1.
2.1.3 Line Voltage
Hard wire red lead and white lead to a Power
Source to the proper voltage as indicated on the
motor nameplate. Connect only to a source of
constant power, not an intermittent source such
as a fan or limit control circuit.
2.1.4 Low Voltage-Auxiliary Safety Switch
Connect the leads of auxiliary safety switch
to the thermostat control circuit of the
air conditioner/furnace. This will disrupt the
thermostat demand in a high water condition
(Figure 3).
Condensate
Pump
Wire Nut From Thermostat
Yellow
Yellow
Furnace / A.C.
Red
White
Green
Yellow
Figure 3
THERMOSTAT DEMAND DISRUPTION
SHOULD NOT BE UTILIZED IF
COOLING OR HEATING REQUIREMENTS ARE A NECESSITY.
AN ALARM SYSTEM SHOULD BE USED WITH THE AUXILIARY
SWITCH INSTEAD.
2.2 OPERATION
After proper installation, the operation of the
HARTELL condensate pump is automatic. Water
is collected in the reservoir and pumped out when
the oat raises to a pre-set point. As the water level
goes down the oat turns off the motor at another
pre-set point. Under most circumstances the pump
requires little maintenance for efcient operation. If
a problem occurs, please refer to the maintenance
instructions below.

5Installation, Operation & Maintenance Manual
SECTION 3 - MAINTENANCE
Visually inspect this pump seasonally to ensure
there is no buildup of any kind inside the unit. If
any problems develop, or a buildup is seen during
visual inspection, the following guidelines can help
to return the pump to service.
3.1 PUMP DOES NOT RUN
1 Check to see that the power to the system
(air conditioner and/or furnace) is on to allow
production of condensate.
2Check that the pump is plugged in and the circuit
is active (i.e. fuse or breaker not blown).
3Check the level of water in the reservoir; the
level must be within ½” of the reservoir top
to activate the switch. (The inlet tube may be
blocked and require cleaning if no water is
entering the reservoir).
4If there is a proper amount of water in the
reservoir, the oat may be stuck due to dirt or
algae formation. (Flush the reservoir with warm
water and a mild soap or detergent). See note
from point 3.2.
3.2 PUMP MOTOR RUNS WITH
NO DISCHARGE
1 Inspect the discharge tubing for its full length to
make sure it is clear; make sure the tubing end
is not plugged.
2 Make sure the check valve is not clogged.
(If clogged, UNPLUG THE PUMP, remove the
tting and clean with mild soap or detergent).
See note below.
3The discharge port of the impeller chamber may
be clogged due to an accumulation of debris.
NOTE:
In case of extreme algae formation,
UNPLUG THE PUMP, and ll the reservoir with
a commercially available algaecide. Follow
directions for destroying the algae. After the
proper waiting period DUMP the algaecide
out of the reservoir. Rinse with water, repeat
if necessary. Be careful not to clog the check
valve when starting the pump after this thorough
cleaning.
Keep these instructions with the pump. They may be valuable if service is needed under the terms of
the warranty.
Model #
Date of Installation:
Installer:
Date Code:
Dealer: