Xylem Jabsco Ballast King 22610-9007 User manual

Ballast King
DC Flexible Impeller Pump

Contents
1.0 Introduction
2.0 Symbols and using this instruction book
3.0 Safety Information
4.0 Unpack and Contents
5.0 Installation
5.1 Pump Set-up
5.2 Pump Assembly and Disassembly
5.3 Electrical Conguration
5.4 Footprint Specications
6.0 Environmental Protection
7.0 Product Operation
7.1 Operating Conditions
7.2 Permitted Fluids
7.3 Initial Start-Up
7.4 Storage and Cleaning
8.0 Technical Specications
9.0 Maintenance, Service and Customer Repair
10.0 Customer Support
11.0 Parts and Accessories
12.0 EC Declaration of Conformity
Ballast King
DC Flexible Impeller Pump
3

4
1.0 INTRODUCTION
© The copyright of this instruction book is the
property of XYLEM. This instruction book is
supplied by XYLEM on the express understanding
that it is to be used solely for the purpose for
which it is supplied. It may not be copied, used
or disclosed to others in whole or part for any
purpose except as authorised in writing by XYLEM.
XYLEM reserves the right to alter, change or
modify this document without prior notication.
In the interest of continued development XYLEM
reserves the right to alter or modify the design, or
assembly process of their products without prior
notication.
The Ballast King is a direct current (DC) electrical
exible impeller pump. Depending on what
model you have purchased (see section 4, Unpack
and Contents), will determine what installations
and what applications will be feasible for the pump
you have purchased.
2. 0 SYMBOLS AND USING THIS INSTRUCTION
BOOK
Caution, risk of danger. See note
or adjacent symbol.
Caution hot surface
Caution / risk of electric shock.
Recyclable packing material.
Do not dispose of product in normal
domestic waste.
Refer to this instruction book.
3.0 SAFETY INFORMATION
WARNING!
Prior to installation or use, read this installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
Only used with specied products. DO NOT USE
WITH LIQUIDS WITH A FLASH POINT BELOW
100°F (38°C) OR USE WHERE FLAMMABLE
VAPORS ARE PRESENT.
This product has been designed for safe operation
when used as detailed in accordance with the
Manufacturer’s instructions.
This manual also contains necessary
information for the correct installation.
This manual was developed for qualied
personnel with suitable training and
technical qualication to operate this type of
equipment.
NOTE: Failure to use this equipment
in accordance with the manufacturer’s
operating instructions may compromise
your basic safety protection afforded by the
equipment and may invalidate the warranty
/ guarantee. The warranty / guarantee
does not cover damaged caused by faulty
installation or misuse of the equipment. If
the recommended safety notices are not
strictly observed, it can lead to serious or fatal
injuries of personnel and/or material damage.
Failure to observe the recommended safety
procedures can lead to material damage.
Only qualied Service personnel should
attempt to repair / service the product.
Do not immerse any part of this machine in
water / uid.
Do not operate the machine without
appropriate piping attached.
Do not run the machine without suitable
supervision as established for safe working
practices and company procedures.
Not to be used by children and non-
authorized personnel.
Please keep this manual carefully and
available to all operators.
Always follow good working practice when
using this equipment.
Follow legislation applicable to your areas of
operation.
Do not touch the motor surface during or
after operation of the pump as the surface can
become hot.
Only use Original Equipment Manufacturer’s
Parts and Accessories.
The equipment is not spark, ame or
explosion proof and has not been designed
for use in hazardous areas in terms of the
ATEX Directive 94/9/EC.

5
4.0 UNPACK AND CONTENTS
- When unpacking the product ensure the correct
unit is present.
- See ‘pump unit information’ for guidance on
unit selection, information is displayed on the
product label indicating which model you have.
Pump Unit Information:
- 22610-9007 – NPT Internal Ports, 12v, 30 minute
cycle MAX.
- 22610-2007 – BSP Internal Ports, 12v, 30 minute
cycle MAX.
Features
- The pump has been designed to pump uid
into ballast tanks.
- The pump is reversible so it can add liquid
ballast, and then pump it overboard when
needed.
- When required, the pump is switched on to ll
the tank then the pump switched off when full.
- To reduce ballast, the pump will reverse to
pump ballast back over board.
- The same operation is used for ballast transfer
between two tanks.
5.0 INSTALLATION
5.1 PUMP SET-UP
- Verify that all components are present
- Check the pump unit has not been damaged
during transit
- Ensure inlet and outlet ports are free from dirt,
dust or packaging material
- Ensure electrical data corresponds to those
indicated on the product label and ensure
the correct fuse is tted in the power line (see
section 8 for recommended fuses)
- Fit a strainer on the inlet hose to prevent larger
debris from entering the pump, ensure this is
clean and free from dirt before use.
- Before connecting the inlet and outlet hoses,
ensure they are free from dirt.
- Secure 25 mm (1”) ID hose either directly to the
discharge ports, or to ½” BSP/ NPT threaded
ttings using stainless steel hose clamps.
- Use spiral reinforced hose (with a smooth
internal bore) that will not collapse under
suction, or rigid or semi-rigid pipework systems.
- The pump can be mounted on any at suitable
surface.
- Fit the pump in a dry, well ventilated position
where there is full access for service.
- Use rubber grommets provided to minimise
vibration, do not over tighten the mounting
screws.
- All marine pumps discharging overboard must
be installed with the overboard discharge well
above both static and heeled waterlines.
- The pipework must be compatible with liquid
being pumped.
WARNING!
It is the installer’s responsibility to use hoses
with suitable properties. The use of hose that is
not suitable could cause damage to the pump,
operator or the surrounding environment.
The loosening of hose connections can cause
environmental and safety issues. Check all
connections after the initial installation and on
a daily basis thereafter. Tighten if required. It
is recommended the hose is installed prior to
installing electrical supply.
WARNING!
Use a medium strength pipe sealant for metal
threads.
- Pipe runs should be kept as straight as possible,
avoiding rising and dipping over obstructions,
shown below.
- In order to ensure good priming always keep
connections tight.
- Seal leaks should be checked and changed, as
leakage could be dangerous, shown below.
- The pump should be installed so that the motor
is protected from constant rain, wash down or
bilge water.
- The pump should not be run with a closed outlet.
- Please note the pump body can be turned 180
degrees in relation to the motor. This will change
the ow direction.
Install overboard discharge well above both
static and heeled waterlines.
x x x x

76
5.2 PUMP ASSEMBLY AND DISASSEMBLY
1. Disassembly
- Back off the end cover screws, re-move the end
cover and o-ring.
- Pull out the impeller using a Jabsco impeller
removal tool, shown below.
- Back off and remove the screws holding the body
to the motor.
- Remove the lip seal from the body.
- Do not disassemble the motor.
2. Assembly
- Moisten the new lip seal, and mount the seal
with the lip facing towards the impeller.
- Lubricate the motor shaft and t the body to
the motor by tightening the motor screws.
- Ensure the body and impeller is lubricated.
- Fit the impeller with a rotating movement in
the intended direction of the pump rotation.
- Lubricate the o-ring, t it in position and fasten
the end cover screws to the body.
- Torque value for end cover to body screws: 30
– 40 lbf.ins / 3.4 – 4.5 Nm.
- Torque value for body to motor screws: 21 – 28
lbf.ins / 2.4 – 3.1 Nm.
5.3 ELECTRICAL CONFIGURATION
- It is the responsibility of the installer to perform
the correct installation.
- Make all electrical connections in dry locations,
connections in humid environments should be
sealed to prevent corrosion.
- Protect the circuit with a correctly rated fuse
or circuit breaker in the red positive (+) lead
as close as possible to the power source (see
section 8 for recommended fuses).
- Ensure fuses for the Ballast King pump are slow
burning, being capable of handling the start-
up and reversing current.
- Connect the black motor wire to the negative
(-) battery terminal.
- Inadequate voltage at the motor terminals
when the pump is running (not less than 95%
below rated voltage at full load) due to partially
discharged batteries or insufcient cable size
may result in blowing fuses, failure to start or
poor pump performance.
- The fuse must be ignition protected.
- The motor is equipped with built in thermal
protection to prevent it from over-heating.
- The protection is automatically restored when
the motor is cooled.
- Before installation with control systems, check
the equipment to be used is of sufcient rated
capacity to accept ampere draw of motor.
- Choose the wire size in accordance with total
wire length.
- There is a motor thermal cut out switch for
protection.
- All Ballast King wiring and connections to be
carried out in accordance to ISO 10133.
WARNING!
When terminated at the power supply using
permanent connections, red leads should be
terminated to the positive and black to the
negative. If reversed pump will run in reverse.
- Install the Ballast King pump in accordance to ISO
10133.
- If installed in a vertical position, the motor must
be above the pump head, shown below. This will
prevent liquid from dripping onto the motor if
there is a seal leak.

6.0 ENVIRONMENTAL PROTECTION
- Due consideration to environmental issues
within the design and manufacturing process
of this product without compromising product
performance and value.
WEEE Policy
- The Waste Electrical and Electronic Equipment
Directive (WEEE Directive) is a European
Community Directive 2012/19/EU.
- Xylem Water Services Limited has identied that
there product range comes under Category 6
(Electrical tools) and as such will undertake their
responsibilities in line with the above directive
and will fulll their legal obligation by means of
joining a compliance scheme.
- All products are identied by means of the
Wheelie bin logo as laid down in the above
directive.
The Water Process Limited WEEE producer
registration number is RM07081
Full details of scheme can be found @
Valpak Limited
Unit 4
Montague House
Stratford-upon-Avon Business and Technology Park
Banbury Road
Stratford-upon-Avon
Warwickshire
CV37 7GW
- At the end of your product and accessories life, it
must not be discarded as domestic waste.
- Please contact your distributor / supplier for
further information.
- For end users outside of the EU consult
applicable regulations.
- This product should only be dismantled for
recycling by an authorized recycling company.
- At the product’s end of life please dispose of the
product according to the applicable law.
- Where applicable, please disassemble the
product and recycle the parts material.
5.4 FOOTPRINT SPECIFICATIONS:
- Weight – 3 Kg (6.6 lb).
7
78.2
84.6
4 MOUNTING HOLE O6
IN RUBBER FEET 14 AWG LEAD WIRES
250 +20 IN LENGTH, STRIP LENGTH
TO BE 14 +2 +VE WIRE RED/
-VE WIRE BLACK
203.4
21
31.5 18 17
50.6
120
A
106.2
90 A
61.3
6
9.7 45 25.25 TO SUIT
O25.4 (1”) HOSE

8
7.0 PRODUCT OPERATION
7. 1 OPERATING CONDITIONS
- Maximum ambient temperature is +60 deg. C
(140 deg. F), with minimum temperature -
15 deg. C (5 deg. F).
- The life of the impeller depends upon the
temperature of the liquid being pumped.
- High and low temperatures can affect impeller
life.
7.2 PERMITTED FLUIDS:
- Only use the pump with specied products,
including fresh and salt water solutions.
- Do not use any Jabsco pump for petrol,
petroleum products or any products with
a ash point below 37 deg. C, (98 deg. F),
explosion or death may occur, shown below.
- If in doubt about pump material compatibly,
consult the website or a sales representative.
- If in doubt about the use of the pump in a
potentially explosive atmosphere, consult the
website or a sales representative.
- If corrosive products are pumped, pump life will
be prolonged if pump is ushed with water at the
end of each cycle.
7.3 INITIAL START-UP:
- Complete the installation (as per section 5).
- This is a continuously rated pump for
recommended duty cycle of 30 minutes.
- The pump is self-priming to 1.2 m (4 ft).
- Intake lines must be air-tight to ensure self-
priming.
- The pump will run dry up to 1 off for 5 minutes.
- Priming may take up to 35 seconds, if priming
takes longer than the designated time, check:
- There are no blockages in the suction hose,
- The inlet lter is not blocked,
- The suction pipework is airtight,
- The height you are priming to falls within the
priming capabilities listed in section 7.
- Do not operate any switches with wet hands.
- Never operate a motor which in any way has been
manipulated and lost its full enclose.
WARNING!
The working temperature of the motor may
reach a maximum of approx. +80 deg. C (surface
temperature) which may burn your skin.
- Motors can spark and explosion and death can
occur, with incorrect wiring causing injury or
death.
7.4 STORAGE AND CLEANING
- If any pump unit needs to be removed for
storage purposes, it must be stored in a cool dry
location
- Pump units are rated to IP55. It is recommended
that the unit is wiped down after use.
- Liquids must not be allowed to freeze in
the pump body, to winterise your system all
water must be drained from the entire system,
including the pump.
8.0 TECHNICAL SPECIFICATIONS
- The data specied in the above table refers
to performance running at the ideal efciency
points on water at 20 deg. C. with fully charged
battery (12.8v).
- The ‘MAX AMP DRAW’ refers to the pumps
running at their maximum pressure, which is past
their recommended duty point.
- For longer installations, t thicker cables
(reference ISO 10133).
- The wire length is the total distance from the
battery to the pump and back to the battery. It is
recommended to use a relay to shorten the main
leaders.
- If the fuse fails repeatedly, do not t a heavier
fuse or bridge the fuse terminals with silver
paper or metal wire. Failure to observe this
instruction may result in a re hazard due to
overheating of cables.
- Exceeding recommended pump discharge
pressure will shorten the impeller life.
Total Head
(DIFF) Flow Current
M FT LPM US GPM AMPS
0 0 60 16 14
2 7 56 14.8 14.5
4 13 50 13.2 15
6 20 42 11.4 16
8 26 32 8.5 17
10 33 18 4.7 18
12 39 5 1.6 19
Model
Number
Voltage
(V DC)
Maximum
AMP Draw
(A)
Minimum
Fuse Size
(A)
Minimum
Wire Size
(mm2)
Maximum
Total Length
Between (+)
& (-) Battery
Terminals
22610-9007 12.8 19 25 8 4.5
22610-2007 12.8 19 25 8 4.5

4
9.0 MAINTENANCE, SERVICE AND CUSTOMER
REPAIR
- The Jabsco Ballast King pump is designed to
require minimal amounts maintenance.
- However it is recommended as good practice to:
- Check that all hose connections are not loose and
keep the inlet lter clean once a week
- Check the electrical connectors and cables are in
good condition once a month
10.0 CUSTOMER SUPPORT
- If any pump units for any reason need to be
returned, please ensure the pump unit has been
fully drained.
- Please contact customer services for more
information.
- No used pumps/ parts will be accepted as returns
unless complete details of liquids pumped are
supplied.
Item
Number Quantity Part Number
1 1 23094-9000/ -2000
2 1 98012-9334
3 1 9328-0200
4 2 X3001-147F
5* 1 23095-0107
6 1 23005-2529/ -2530
7* 1 SP2701-52
8 4 92900-0380
9* 1 X5251-049
10 3 SP1004-09
11 1 6342-6000
Minor Service Kit
(contains items marked *) 18753-5049
11.0 PARTS AND ACCESSORIES
- 22610-9007/ -2007 PUMP (NPT OR BSP PORTS)
SECTION AA
84
11
1
9
3
10
572 6
6
2
11
4
1
9
3
10
5
7
8
9

10
12.0 EC DECLARATION OF CONFORMITY
Declaration of Conformity
In accordance with EN ISO 17050-1:2010
In accordance with the following Directive(s):
2004/108/EC Electromagnetic Compatibility
2003/44/EC Recreational Craft Directive
2011/65/EU RoHS Directive (RoHS 2)
ISO 8846 Small craft Small craft - Electrical devices -
Protection against ignition of surrounding ammable gases
hereby declare that: Ballast King 12 V d.c. Flexible Impeller Pump
Equipment / 22610-2007
Model number 22610-9007
is in conformity with the applicable requirements of the following documents:
Directive Reference Number Title Edition/Date
EMC IEC 60945 Maritime navigation and radio communication
equipment and systems. General requirements. 2002
ELVD BS EN ISO 10133 Small craft – Electrical systems – Extra-Low-
Voltage d.c. systems .dc installations 2012
ISO ISO 8846 Small craft -- Electrical devices -- Protection
against ignition of surrounding ammable gases 1990
ENV
EN 60068-2-1 Cold 2007
EN 60068-2-2 Hot 2007
EN 60068-2-6 Vibration - General 2008
Vibration - Resonance
EN 60068-2-14 Cycling & Shock 2009
EN 60068-2-27 Shock & Bump 2006
EN 60068-2-30 Humidity 2005
EN 60068-2-31 Drop 2009
EN 60068-2-52 Salt Mist 2004
EN 60068-2-64 Vibration - Random 2008
RoHS
RoHS 2 deals with the
same six hazardous
substances and the same
maximum concentration
limits as RoHS 1
Lead (0.1%)
Mercury (0.1%)
Cadmium (0.01%)
Hexavalent chromium (0.1%)
Polybrominated biphenyls [PBB] (0.1%)
Polybrominated diphenyl ethers [PBDE] (0.1%)
2011