Xylem Bell & Gossett 15GDS User manual

Models 15GDS/20GDS
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
INSTRUCTION MANUAL
IM214R02

2 15GDS/20GDS Installation, Operation and Maintenance Manual

15GDS/20GDS Installation, Operation and Maintenance Manual 1
Table of Contents
Introduction and Safety ........................................................................................................................2
Data Plate Interpretation ......................................................................................................................7
Product Description..............................................................................................................................8
General Design of a 15GDS/20GDS Pump............................................................................................9
Installation..........................................................................................................................................11
Electrical Connections ........................................................................................................................13
Cable Chart ........................................................................................................................................15
Colors and Markings of Leads ............................................................................................................16
Transportation and Storage .................................................................................................................17
Operation ...........................................................................................................................................18
Care and Maintenance........................................................................................................................19
Oil Change .........................................................................................................................................20
Service Log .........................................................................................................................................22
Owners Information
Complete this information for your records.
Model number and serial number may be found
on the tag mounted to the motor adapter.
Model Number ___________________________
Serial Number ____________________________
Dealer ___________________________________
Dealer phone number ______________________
Date of purchase __________________________
Date of installation ________________________
Table of Contents

2 15GDS/20GDS Installation, Operation and Maintenance Manual
I. Introduction and Safety
Introduction
Description
This manual provides instructions for the Installation, Operation and Maintenance of the
Bell & Gossett 15GDS/20GDS pumps.
Requirement
This manual must be read and understood before installation and start-up. Bell & Gossett
shall not be liable for physical injury, damage or delays caused by a failure to observe the
instructions for installation, operation and maintenance contained in this manual.
Content
This instruction manual covers several different pump models that all have similar power
end configurations. Most assembly, disassembly and inspection procedures are the same for
all the pumps. However, where there are differences, they are called out separately within
the manual. The design, materials and workmanship incorporated in the construction
of Bell & Gossett makes them capable of giving long, trouble free service. The life and
satisfactory service of any mechanical unit, however, is enhanced and extended by correct
application, proper installation, periodic inspection, condition monitoring and careful
maintenance. This instruction manual was prepared to assist operators in understanding the
construction and the correct methods of installing, operating and maintaining these pumps.
Key Topics
Data Plate Interpretation
Product Description
General Design
Installation
Electrical Connections
Cable Chart
Transportation and Storage
Operation
Care and Maintenance
Oil Change
Introduction and Safety

15GDS/20GDS Installation, Operation and Maintenance Manual 3
Safety
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling an Bell & Gossett product. They are published to help
prevent
• personal accidents and health problems
• damage to the product
• product malfunction
Observe all safety messages highlighted in other sections of this manual.
A pump is a pressure-containing device with rotating parts that can be dangerous.
Caution: You must observe the instructions for installation, operation, and main-
tenance contained in this manual. Failure to do so could result in physical injury,
damage, or delays.
Safety message levels
Table 1: Definitions
Safety message level Indication
Danger: Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Warning: Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Caution: Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
Note: Indicates a potential situation which, if not avoided,
may result in undesirable results or state. Indicates a
practice not related to personal injury.
Electrical Hazard: Indicates the possibility of electrical risks if
direction are not applied in a proper manner.
Environmental safety
Preventive measures for the working area
Always keep the pump station clean to avoid and/or discover emissions.
Recycling guidelines
Always recycle according to the guidelines listed below:
1. Follow local laws and regulations regarding recycling if the unit or parts are accepted by
an authorized recycling company.
2. If the first guideline is not applicable then return the unit or parts to the nearest Bell &
Gossett representative.
Introduction and Safety (continued)

4 15GDS/20GDS Installation, Operation and Maintenance Manual
Waste and emissions
Observe these safety regulations regarding waste and emissions:
• Dispose appropriately of all waste.
• Handle and dispose of the pumpage in compliance with applicable environmental
regulations.
• Clean-up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
Reference for electrical installation
For electrical installation recycling requirements, consult your local electric utility.
User health and safety
Safety equipment
Use safety equipment according to the company regulations. The following safety
equipment should be used within the working area depending on the fluid being pumped:
• helmet
• safety goggles (with side shields)
• protective shoes
• protective gloves
• gas mask
• hearing protection
Note: The noise level of the product is lower than 70 dB. However, the
noise level of 70 dB may be exceeded in some installations and at certain
operating points on the performance curve. Make sure that you understand
the noise level requirements in the environment where the pump is
installed. Failure to do so may result in hearing loss or violation of local
laws.
The working area
Observe these regulations and warnings in the working area:
• Always keep the work area clean.
• Pay attention to the chemical and physical characteristics of the gas and vapors present
in hazardous areas.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
Product and product positioning requirements
Observe these requirements for the product and the product positioning:
• Never operate a pump unless safety devices are installed.
• Three-phase motors must have a properly sized starter with properly sized heaters
to provide overload and under voltage protection. Single-phase motors have built-in
overload protectors.
• Never start a pump without the proper priming.
• Never run a pump below the minimum rated flow or with any suction or discharge
valve closed.
Electrical connections
Electrical connections must be made by authorized electricians in compliance with all
international, national, state and local rules.
Introduction and Safety (continued)

15GDS/20GDS Installation, Operation and Maintenance Manual 5
Observe the following regulations and warnings for electrical connections.
• Make sure that the product is isolated from the power supply and can not be
energized by mistake. This rule applies to the control circuit as well.
• Make sure that the thermal contacts are connected to a protection circuit according
to the product approvals, and that they are in use.
Observe the following regulations for grounding connections.
Table 2: Grounding
Grounding regulation Comment
All electric equipment must be grounded. This rule applies to pumps and mixers as
well as monitoring equipment.
Precautions before work
Observe the following safety precautions before working with or in connection with the
product:
• Make sure that there are no poisonous gases within the work area.
• 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 the equipment is properly insulated when operating at extreme
temperatures.
• Allow all system and pump components to cool before you handle them.
• 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.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product has been thoroughly cleaned.
• Make sure that a first-aid kit is close at hand.
• Check the explosion risk before welding or using electric hand tools.
Precautions during work
Observe the following safety precautions when working with or in connection with the
product:
• Never work alone.
• 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 disassembling the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valves or remove any plugs while the system is
pressurized. Ensure that the pump is isolated from the system and that pressure is
relieved before you disassemble the pump, remove plugs, or disconnect piping.
Introduction and Safety (continued)

6 15GDS/20GDS Installation, Operation and Maintenance Manual
• Always bear in mind the risk of:
• electrical accidents
• burn injuries
Clean chemicals from the eyes
1. Forcibly hold the eyelids apart with the fingers.
2. Rinse the eyes for at least 15 minutes. Use an eyewash or running water.
3. Seek medical attention.
Clean chemicals from the body
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. If required, seek medical attention.
Product approval standards
Regular standards
All electrical ratings and performance of the motors comply with UL, CSA and NEMA
standards.
Product warranty
Personnel requirements
All work on the product must be carried out by certified electricians and Bell & Gossett
authorized service centers.
Bell & Gossett disclaims all responsibility for work done by untrained and unauthorized
personnel.
Modification and spare parts
Modifications or changes to the product/installation should only be carried out after
consulting with Bell & Gossett. Original spare parts and accessories authorized by Bell &
Gossett are essential for compliance. The use of other parts can invalidate any claims for
warranty or compensation and explosion-proof approvals.
Warranty claim
For warranty claim, contact your Bell & Gossett representative.
Introduction and Safety (continued)

15GDS/20GDS Installation, Operation and Maintenance Manual 7
II. Data Plate Interpretation
General Data Plate
A Internal L Operating duty, cont./int.
B Serial number M Impeller/propeller diameter
C Shaft power N Factory code
D Rated speed Q Temperature class
E Product number R/U Rated voltage
F Weight S/V Rated current
H Curve code, first digit = number of poles T/X Stator connection
J Number of phases, type of current, frequency W Special order number
K Power factor Y Motor number
Approval Plate
This approval plate applies to an explosion-proof submersible Bell & Gossett pump. The
plate is used together with the general data plate on the pump.
FM: Factory Mutual
Class I, Division I, Group C and D
Class II and III, Division I, Group E, F and G
Maximum Operating Temperature T4
Explosion Proof for use in
Class I, Division 1, Group C and D
Dust Ignition Proof for use in
Class II, Division 1, Group E, F and G
Suitable for use in Class III, Division 1
Hazardous Locations
104º F (40º C) Ambient Limits
CAUTION: DEENERGIZE PUMP BEFORE OPENING
Data Plate Interpretation
FM
APPROVED
B
A
H
N
M
Y
K
L
D
F
J
Q
E
W
C
T/X
R/U
S/V
A
vHz
mm
%
IEC 34-1 1969 cl.F kg
r/min
cos �

8 15GDS/20GDS Installation, Operation and Maintenance Manual
III. Product Description
Introduction
Thank you for buying a submersible Bell & Gossett pump. In this Installation, Care and
Maintenance manual, you will find general information on how to install and service the
15GDS or 20GDS pump to give it a long and reliable life. In the Parts List you will find all
the specific technical data for your pump.
Application
This Installation, Care and Maintenance manual applies to a submersible Bell & Gossett
15GDS or 20GDS pump. If you have bought an explosion proof pump (please see approval
plate on your pump or Parts List) special handling instructions apply as described in this
document.
The pump is intended to be used for pumping of sewage for high head application.
The pumps must not be used in highly corrosive liquids. See pH limits below.
The pump is available for permanent installation in a sump or portable installation.
For further information on applications, contact your nearest Bell & Gossett wastewater
representative.
Specic Technical Data
For specific technical data regarding your pump, please see Parts List.
General Technical Data
Liquid Temperature: Maximum 104º F (40º C). The pump can be operated at full load only
if fully submerged.
Liquid Density: Maximum 9.2 lb per US gallon (1100 kg/m3)
The pH of the Pumped Liquid: 6-13 (cast iron pumps)
Depth of Immersion: Maximum 65 ft (20 m)
In some installations and at certain operating points on the performance curve,
the noise level of 70 dB or the noise level specified for the actual pump may be
exceeded.
Only ex-approved pumps may be used in an explosive or flammable
environment.
Warranty Claim
The pumps are high quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, please contact your Bell & Gossett
representative.
Product Description

15GDS/20GDS Installation, Operation and Maintenance Manual 9
IV. General Design of a 15GDS/20GDS Pump
Design
The pump is a submersible, electric motor-driven product.
1. Impeller
The impeller has a cutter mounted at the inlet which grinds solids.
2. Shaft Seals
The pump has two mechanical face seals - one inner and one outer, with an intermediate
oil housing.
3. Shaft
The shaft is delivered with the rotor as an integral part. Shaft material: stainless steel.
4. Bearings
The support bearing of the rotor consists of a single-row ball bearing. The main bearing
of the rotor consists of a two-row angular contact ball bearing.
5. Oil Housing
The oil lubricates and cools the seals and acts as a buffer between the pump housing and
the electric motor.
6. Motor
Squirrel-cage 1-phase or 3-phase induction motor.
The motor can be started by direct on-line or star-delta starting.
The motor can be run continuously or intermBell & Gossettently with a maximum of 15
evenly spaced starts per hour.
General Design of a 15GDS/20GDS Pump

10 15GDS/20GDS Installation, Operation and Maintenance Manual
The motors are tested in accordance with IEC 34-1, 1969.
The stator is insulated in accordance with class F (310º F, 155º C). The motor is designed
to deliver its rated output at ± 5% variation from the rated voltage. Without overheating
the motor, ± 10% variation from the rated voltage can be accepted provided that the
motor does not run continuously at full load. The motor is designed to operate at a
voltage imbalance of up to 2% between the phases.
Monitoring Equipment
The stator incorporates thermal contacts connected in series.
The pump can be equipped with sensors for sensing water in the stator housing.
General Design of a 15GDS/20GDS Pump (continued)

15GDS/20GDS Installation, Operation and Maintenance Manual 11
V. Installation
Handling Equipment
Lifting equipment is required for handling the pump.
Stay clear of suspended loads.
Always lift the pump by its lifting handle, never by the motor cable or the hose.
The minimum height between the lifting hook and the floor shall be sufficient to lift the
pump out of the sump.
The lifting equipment shall be able to hoist the pump straight up and down in the sump,
preferable without the need for resetting the lifting hook.
Oversize lifting equipment could cause damage if the pump should stick when being lifted.
Make sure that the lifting equipment is securely anchored.
General Recommendations
To ensure proper installation, please see the dimensions on the dimensional drawing in the
Parts List.
NOTE: The end of the cable must not be submerged. It must be above flood level, as water
may penetrate through the cable into the junction box or the motor.
Check that the lifting handle and chain are in good condition.
For automatic operation of the pump (level control), it is recommended that the level
regulators be used at low voltage. The data sheet delivered with the regulators gives the
permissible voltage. Local rules may specify otherwise.
Clean out all debris from the sump before the pump is lowered down and the station is
started.
Special rules apply to installation in explosive atmosphere. Intrinsically safe
circuits are normally required (Ex I) for the automatic level control system by
level regulators.
Safety Precautions
In order to minimize the risk of accidents in connection with the service and installation
work, the following rules should be followed:
1. Never work alone. Use a lifting harness, safety line and a respirator as required. Do not
ignore the risk of drowning!
2. Make sure there are no poisonous gases within the work area.
3. Check the explosion risk before welding if using electric hand tools.
4. Do not ignore health hazards. Observe strict cleanliness.
5. Bear in mind the risk of electrical accidents.
6. Make sure that the lifting equipment is in good condition.
Installation

12 15GDS/20GDS Installation, Operation and Maintenance Manual
7. Provide a suitable barrier around the work area, e.g. a guard rail.
8. Make sure you have a clear path of retreat!
9. Use safety helmet, safety goggles and protective shoes.
10. All personnel who work with sewage systems must be vaccinated against diseases to
which they may be exposed.
11. A first-aid kit must be close at hand.
12. Note that special rules apply to installation in explosive atmosphere.
Follow all other health and safety rules and local codes and ordinances.
Installation (continued)

15GDS/20GDS Installation, Operation and Maintenance Manual 13
VI. Electrical Connections
Before starting work on the pump, make sure that the pump and the control
panel are isolated from the power supply and cannot be energized.
If the pump is equipped with automatic level control, there is a risk of sudden
restart.
All electrical equipment must be earthed. This applies to both pump equipment
and any monitoring equipment. Failure to heed this warning may cause a lethal
accident. Make sure that the earth lead is correctly connected by testing it.
If persons are likely to come into physical contact with the pump or pumped
media (liquid), e.g. on construction sites and farms, the earthed (grounded)
socket must have an additional earth-(ground-) fault protection device (GFI)
connected.
When pumping near a lake (jetties, beaches, ponds, fountains, etc.) a safety-
distance of at least 65 feet (20 m) between the person and the pump is
applicable.
The pump must never be placed directly into a swimming pool. If used in
connection with swimming pools, special safety regulations apply.
NOTE FOR EX-VERSION: Electrical connections on the explosion-proof
motor must be made by authorized personnel. Bell & Gossett disclaims all
responsibility for work done by untrained, unauthorized personnel.
The pump may be used only in accordance with the approved motor data stated
on the pump’s plates.
Thermal contacts must be connected to protection circuit intended for that
purpose according to the approval of the product.
All electrical work shall be carried out under the super-vision of an authorized electrician.
Local codes and regulations shall be complied with.
Check on the data plate which voltage supply is valid for your pump.
Check that the main voltage and frequency agree with the specifications on the pump data
plate.
If the pump can be connected to different voltages, the connected voltage is specified by a
yellow sticker.
Connect the motor cable to the starter equipment as illustrated in the wiring diagrams.
Conductors that are not in use must be isolated.
The cable should be replaced if the outer sheath is damaged. Contact a Bell & Gossett
service shop.
Make sure that the cable does not have any sharp bends and is not pinched.
Electrical Connections

14 15GDS/20GDS Installation, Operation and Maintenance Manual
Under no circumstances may the starter equipment be installed in the sump.
NOTE: For safety reasons, the earth conductor should be approximately 2.0” (50 mm)
longer than the phase conductors. If the motor cable is jerked loose by mistake, the earth
conductor should be the last conductor to come loose from its terminal. This applies to both
ends of the cable.
Thermal contacts are incorporated in the stator. The thermal contacts can be connected to
maximum 250 V, breaking current maximum 4 A. Bell & Gossett recommends that they be
connected to 24 V over separate fuses to protect the other automatic equipment.
Make sure that the pump is correctly earthed (grounded).
When using a variable-frequency-drive (VFD) special rules have to be followed to avoid
clogging and over-heating. Contact your VFD supplier and ask for electrical limitations.
Remember that the starting current in direct online starting can be up to six times higher
than the rated current. Make sure that the fuses or circuit breakers are of the proper rating.
The Parts List gives rated current. Fuse rating and cable shall be selected in accordance with
local rules and regulations. Note that with long cables, the voltage drop in the cable must be
taken into consideration, since the motor’s rated voltage is the voltage that is measured at
the terminal board in the pump.
The overload protection (motor protection breaker) for direct online starting shall be set to
the motor rated current as given on the data plate.
Check the phase sequence in the mains with the phase sequence indicator.
If intermittent operation is prescribed (see Data Plate), the pump shall be provided with
control equipment that provides such operation.
Single Phase Operation
The single phase pumps must be equipped with a starter which has start and run capacitors.
A special designed starter is required for the operation of single phase pumps. The
connection of the motor cable to the starter is shown in the wiring diagram.
NOTE: It is not possible to change the direction of rotation of a single phase pump by
changing the cable conductors on the starter. Please contact your nearest Bell & Gossett
representative.
Monitoring Equipment
The FLS sensor consists of a small float switch for sensing water in the stator housing. Its
design makes it suitable for pumps in vertical installations. The FLS sensor is installed in the
bottom of the stator housing.
The MiniCas II is a monitoring relay to which FLS is connected.
Check:
• signals and tripping function.
• that relays, lamps, fuses and connections are intact.
Replace defective equipment.
Electrical Connections (continued)

15GDS/20GDS Installation, Operation and Maintenance Manual 15
VII. Cable Chart
3-Phase, Direct Online Starting
Connection
Conductors Starter
For Canada/USA
SUBCAB xAWG/4
red L1
white L2
black L3
yellow/green ground
SUBCAB xAWG/7
red L1
white L2
black L3
yellow GC**
yellow/green ground
orange T1*
blue T2*
Cable Chart
Single Phase
Connection
Conductors Starter
For Canada/USA
SUBCAB xAWG/4
red 1
black 2
white 3
yellow/green ground
SUBCAB xAWG/7
red 1
black 2
white 3
yellow GC**
yellow/green ground
orange T1*
blue T2*
* Terminal for connection of thermal contacts in the motor and monitoring equipment.
** GC = Ground Check
SUBCAB is a registered trademark of Bell & Gossett Flygt AB for electrical cables.
3~
GC L1 L2 L3 T1 T2
GC
L1 L2 L3
T1
T2
SUBCAB
1~
GC
123
T1 T2
GC
123
T1
T2
SUBCAB

16 15GDS/20GDS Installation, Operation and Maintenance Manual
Colors and Markings of Leads
Motor Connection
Mains
SUBCAB 7GX
Screenflex 7GX
SUBCAB 4GX
Screenflex 4GX
SUBCAB
AWG
SUBCAB
Screened
Colors and markings of main leads
1~ 3~
Color Standard Stator Leads 1 L1 BK 1 BN RD BN
BN = Brown
BK = Black
WH = White
OG = Orange
GN = Green
GN/YE = Green-Yellow
RD = Red
GY = Grey
BU = Blue
YE = Yellow
U1.U5 RD
U2.U6 GN
V1.V5 BN
V2.V6 BU
W1.W5 YE
W2.W6 BK
T1.T2 WH/YE
2 L2 BK 2 BK BK BK
3 L3 BK 3 GY WH GY
L1 BK 4 — — —
L2 BK 5 — — —
L3 BK 6 — — —
GN/YE GN/YE GN/YE
**Screen/
PE from
cores
*SUBCAB AWG
**Ground Conductor is stranded around cores
GS = Ground Check
Screen
(WH)
Screen
(WH) —Screen (WH)
772 17 00 (Rev.6) GC — — YE —
The Prepared SUBCAB® Cable
1. T1 + T2 twisted pairs in control element
2. Drain wire in control element (bare copper wire)
3. Screened copper pt-foil
4. Insulation sheath (jacket) or PT-foil for control element
5. Power cores
6. Ground (earth) core
Cable Chart (continued)

15GDS/20GDS Installation, Operation and Maintenance Manual 17
VIII. Transportation and Storage
The pump can be transported and stored in a vertical or horizontal position.
Always lift the pump by its lifting handle, never by the motor cable or the hose.
Make sure that the pump cannot roll or fall over and injure people or damage
property.
The pump is frostproof as long as it is operating or is immersed in the liquid. If the pump is
raised when the temperature is below freezing, the impeller may freeze.
The pump shall be run for a short period after being raised in order to discharge all
remaining water.
A frozen impeller can be thawed by allowing the pump to stand immersed in the liquid for a
short period before it is started. Never use a naked flame to thaw the pump.
For longer periods of storage, the pump must be protected against moisture and heat. The
impeller should be rotated occasionally (for example every other month) to prevent the
seals from sticking together.
After a long period of storage, the pump should be inspected before it is taken into
operation. Pay special attention to the seals and the cable entry.
Follow the instructions under the heading “Before Starting”.
Transportation and Storage

18 15GDS/20GDS Installation, Operation and Maintenance Manual
IX. Operation
Before Starting
Before starting work on the pump, make sure that the pump is isolated from the
power supply and cannot be energized.
Make sure that the pump cannot roll or fall over and injure people or damage
property.
Check that the visible parts on the pump and installation are undamaged and in good
condition.
Check the oil level in the oil housing.
Remove the fuses or open the circuit breaker and check that the impeller can be rotated
freely.
Check that the monitoring equipment (if any) works.
Check the direction of rotation. The impeller shall rotate clockwise, as viewed from above.
When started, the pump will jerk in the opposite direction to the direction in which the
impeller rotates. See the figure.
In the case of dry installation, check the direction of rotation through the inlet elbow access
cover.
Transpose two phase leads if the impeller rotates in the wrong direction (3~).
In some installations the pump surface and the surrounding liquid may be hot.
Bear in mind the risk of burn injuries.
Starting Jerk
Watch out for the starting jerk, which can be powerful.
Operation