Clarke BPT600 Installations- und Betriebshandbuch

OPERATING & MAINTENANCE

INSTRUCTIONS GC0711

BOOSTER PUMPS

Models Nos: BPT600 & BPT1200SS

Part Nos: 7237004 & 7237006

INTRODUCTION

Thank you for purchasing this CLARKE Booster Pump.

Before attempting to operate the pump, it is essential that you read this

manual thoroughly and carefully follow all instructions given. In doing so you

will ensure the safety of yourself and that of others around you, and you can

also look forward to the pump giving you long and satisfactory service.

GUARANTEE

This CLARKE product is guaranteed against faulty manufacture for a period of

12 months from the date of purchase. Please keep your receipt as proof of

purchase.

This guarantee is invalid if the product is found to have been abused or

tampered with in any way, or not used for the purpose for which it was

intended.

Faulty goods should be returned to their place of purchase, no product can

be returned to us without prior permission.

This guarantee does not effect your statutory rights.

ENVIRONMENTAL PROTECTION

Do not dispose of this product with general household waste. All tools,

accessories and packaging should be sorted, taken to a recycling

centre and disposed of appropriately.

PARTS & SERVICE

For parts & Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: [email protected]

SERVICE: [email protected]

CONTENTS

Introduction ............................................................................................ 2

Guarantee .............................................................................................. 2

Environmental Protection ...................................................................... 2

Parts & Service ....................................................................................... 2

Table of Contents ................................................................................... 3

Description ............................................................................................. 3

General Safety Precautions .................................................................. 4

Electrical connections .......................................................................... 6

Preparation for Use ................................................................................ 7

Operation ............................................................................................. 10

Maintenance ........................................................................................ 11

Troubleshooting .................................................................................... 12

Technical Specification ....................................................................... 14

Accessories .......................................................................................... 14

Parts Lists and Diagrams ..................................................................... 15

Declaration of Conformity .................................................................. 19

DESCRIPTION

The BPT600 and BPT1200SS are centrifugal, horizontal, electric pumps with a

self-priming capability and are designed with a venturi system, suitable for

pumping water from up to 35 m height (BPT600) / 46 m height (BPT1200SS).

They are designed to operate with clean water only at a maximum

temperature of 35°C. Operating with contaminated or salt water should be

avoided. The inlet of the pump is higher than the inlet of the impeller so that

the pump can start operating when only the body is filled with water.

The inlet side of the pump should always be fitted with a one-way valve to

prevent water syphoning back out of the pump and to ensure the pump is

always primed for the next start-up.

The pressure tank incorporates a butyl membrane, and a pressure controller

provides automatic stop/start control. The pumps are supplied with a 1”BSP

inlet filter with easy to clean replaceable elements. The transparent filter

bowl allows for a visual check as to the condition of the filter cartridge.

Upon receipt, any damage or deficiency should be reported to your CLARKE

dealer immediately.

GENERAL SAFETY PRECAUTIONS

As with all machinery, there are certain hazards involved with its

operation and use. Exercising caution will reduce the risk of

personal injury.

WORK AREA

1. Keep the work area clean and well lit. Floors should always be kept clear.

Cluttered or dark areas invite accidents.

2. Keep children and bystanders away while operating machines.

Distractions can cause loss of control.

PERSONAL SAFETY

1. ALWAYS stay alert, watch what you are doing and use common sense

when operating this pump. Do not use the pump while you are tired or

under the influence of medication, drugs or alcohol. A moment of

inattention can result in personal injury.

2. Do not over-reach. Keep your proper footing and balance at all times

when positioning the pump.

3. NEVER direct the water discharge towards electrical wiring or equipment.

4. ALWAYS store the pump out of reach of children and do not allow persons

unfamiliar with these instructions to operate it.

5. NEVER direct the discharge flow towards another person.

6. ALWAYS thoroughly familiarise yourself with this pump & its operation, and

follow all instructions in this manual.

7. ALWAYS ensure that the pump is properly positioned to prevent it from

moving during operation, and that the immediate area surrounding the

pump is kept clear.

GENERAL EQUIPMENT USE AND CARE

WARNING: The BPT600 & BPT1200SS pumps are not submersible

pumps. On no account should they ever be immersed in water.

1. ALWAYS maintain the pump with care and keep it clean.

2. NEVER use this pump if any part is damaged. Have it inspected and

repaired by your local Clarke dealer.

3. NEVER modify this pump in any way. Use it ONLY for the purpose for which

it is designed.

4. NEVER run the pump dry. Always ensure the pump is filled or ready to be

filled with water before starting.

5. NEVER overtighten drain or filler plugs. Excessive force may damage the

threads and make the plug difficult to remove in future.

6. ALWAYS ensure the pump is in a horizontal position and is firmly anchored

via its fixing screws to a level surface.

7. NEVER use for pumping flammable liquids or corrosive chemicals. These

pumps are designed to pump WATER ONLY.

8. ALWAYS use a strainer connected to the suction (inlet) hose, to prevent

stones and other solids from being drawn up, which could cause damage

to the pump.

SERVICING

1. ALWAYS have the pump serviced by your local CLARKE dealer, using only

identical replacement parts. This will ensure the safety of the pump is

maintained. The use of non standard parts could be hazardous.

2. NEVER attempt any repairs yourself. If you have a problem with the pump

contact your local CLARKE dealer.

3. ALWAYS turn the pump off before carrying out any maintenance.

Your CLARKE water pump has been designed to give long and trouble free

service. If, however, having followed the instructions in this booklet carefully,

you encounter problems, take the unit to your local CLARKE dealer.

ELECTRICAL CONNECTIONS

WARNING! Read these electrical safety instructions thoroughly

before connecting the product to the mains supply.

Before switching the machine on, make sure that the voltage of your

electricity supply is the same as that indicated on the rating plate. This

product is designed to operate using 230 VAC mains power. Connecting it to

any other power source may cause damage.

This product may be fitted with a non-rewireable plug. If it is necessary to

change the fuse in the plug, the fuse cover must be refitted. If the fuse cover

becomes lost or damaged, the plug must not be used until a suitable

replacement is obtained.

If the plug has to be changed because it is not suitable for your socket, or

due to damage, it should be cut off and a replacement fitted, following the

wiring instructions shown below. The old plug must be disposed of safely, as

insertion into a mains socket could cause an electrical hazard.

WARNING! The wires in the power cable of this product are

coloured in accordance with the following code:

Blue = Neutral Brown = Live Yellow and Green = Earth

If the colours of the wires in the power cable of this product do not

correspond with the terminal markings of your plug, proceed as follows.

•The wire which is coloured Blue must be connected to the terminal

which is marked N or coloured Black.

• The wire which is coloured Brown must be connected to the

terminal which is marked L or coloured Red.

• The wire which is coloured Yellow and Green must be connected to

the terminal which is marked E or or coloured Green.

Plug must be BS1363/A approved

Earth Always fit a 13 Amp fuse.

(Green and Yellow)

Neutral Live

(Blue) (Brown)

Ensure that the outer sheath of the cable is firmly held by the clamp

We strongly recommend that this machine is connected to the mains supply

via a Residual Current Device (RCD).

If in doubt, consult a qualified electrician. DO NOT attempt repairs yourself.

PREPARATION FOR USE

Accessories designed specifically for this range of pumps are available from

your nearest CLARKE dealer. Contact your CLARKE dealer for further

information, or CLARKE International Sales Department on 01992 565333.

IMPORTANT: The pump MUST NOT be connected to the mains electrical supply

until all hose/pipe installation is completed.

CONNECTING THE INLET FILTER (FIG 1)

1. Screw the male inlet

connector into the pump

inlet port and tighten by

hand.

2. Screw the inlet filter onto the

inlet connector and tighten

by hand. Do not

overtighten.

•Ensure the moulded arrow

in the filter body which

indicates the direction of

flow, is pointing towards

the pump and that the

bowl is hanging vertically

down.

3. Screw a non-return valve to the inlet filter, ensuring it is the right way round,

ie, with the spring-loaded valve able to pass water into the filter. Do not

overtighten.

POSITIONING THE PUMP

A typical installation of the pump is shown in Fig 1. An air-tight seal is essential

when connecting the suction and discharge hoses to the pump.

•Ensure there is no damage to the hoses which must be well

protected and well supported.

•The pump must always be installed and operated in a horizontal

position i.e. with the outlet port facing vertically upwards.

•The fixing holes in the feet should be used to secure the pump firmly

in its operating position.

•Always ensure there is adequate air circulation around the pump

motor.

•Avoid situations where the pump could become drenched with

water. Neither the motor or terminal box are designed to be

waterproof.

Fig. 1

•Position the pump as near to the water source as possible.

•Ensure there is adequate drainage and there is no risk of damage

to property as a result of water being discharged.

•The performance of your pump will be affected by the diameter of

the inlet pipe - any restriction will greatly reduce the flow. We

strongly recommend that you use as large a pipe diameter as

practical.

•A gate valve may be installed on the delivery (outlet) side of the

pump which can be adjusted as required to regulate the flow of

water and can also assist in priming the pump.

CAUTION: DO NOT PLACE ANY RESTRICTION ON THE SUCTION (INLET)

SIDE OF THE PUMP UNLESS IT IS AN ISOLATOR VALVE IN A GRAVITY FED

SYSTEM. THESE PUMPS SHOULD NOT BE OPERATED WITH THE DELIVERY

VALVE COMPLETELY CLOSED.

•To prevent unnecessary strain or possible distortion to the pump,

ensure that adequate support is provided to the hoses/pipes. They

will be considerably heavier when filled with water.

•Where the pump is to be a permanent fixture, the fittings to the

pump must be flexible, i.e. a short piece of hose should be installed

between the rigid pipework and the pump.

IMPORTANT: An air leak in the suction line will prevent priming and reduce the

capacity of the pump.

Pay particular attention to the following:

a. Keep all hoses as short and straight as possible and avoid sharp

bends.

b. Ensure there is adequate drainage for the discharged water.

c. If a flexible hose must be laid across a roadway, protect it with

planking.

(Instantaneous shut off pressure, applied when a vehicle runs across an

unprotected hose, could cause “hydraulic shock”, which can damage the

pump and/or the hose).

USING A FOOT VALVE/FILTER

Instead of using the pump for boosting an existing water supply,the pump

may typically be used for drawing raw water from a well or excavation. In

these applications a foot valve/coarse filter should be fitted to the lower end

of the suction hose as illustrated in Fig 2. This will retain water in the suction

system and more importantly, to prevent the possibility of large objects

entering the pump body.

1. Attach the foot valve to the end of the suction

hose to prevent stones etc, from being drawn

up, which could cause damage to the pump.

Keep the foot valve clean. If it is likely to clog

with dirt or debris, proceed by either:

a. Preparing a bed of stones on which to rest the

foot valve.

b. Position the valve so that it stays clear of the

bottom of the pit, pond or excavation.

c. Tie the foot valve inside a basket or bucket.

PREPARING THE BOOSTER PRESSURE TANK

These pumps utilise an air pressure tank and regulator to provide a constant

water pressure at the outlet. The pump will automatically cut in when the

water pressure reaches a pre-set value. The regulator pressure is factory set

and must not be altered.

For the system to operate correctly,

it is necessary to pressurise the

pressure tank to between its rated

operating pressure of 1.5 bar (22 psi)

and 3.0 bar (44 psi) as follows;

1. Unscrew the large protective

cap on the end of the pressure

tank to reveal the air valve as

shown in Fig 3.

2. Use an airline or foot pump to

pressurise the tank.

3. Check the pressure with a

standard pressure gauge and

replace the protective cap when completed.

Important; This procedure must be carried out before connecting to the water

supply.

PRIMING THE PUMP

When suction lift is used to draw water into the pump it is essential that all

connections and hoses are completely tight or the system will not work.

Although the pump is of the ‘self-priming’ type, it is still necessary to

completely fill the inlet side of the pump with water prior to initial starting, or if

the system has been drained for any other reason. Priming is carried out as

follows.

Fig 3

Foot

Valve

Filter

Fig. 2

1. Remove the filler plug on top of

the pump and slowly fill with

water until all air is expelled.

•Refilling is necessary only if the

pump has been drained or if

the water has been lost. Never

allow the pump to run dry.

2. Open any valve(s) fitted to the

outlet side of the pump so as to

ensure as great a flow as

possible.

•If the inlet filter is being used, it is

recommended that you

remove the brass plug on top of the filter unit and fill the filter bowl with

water.

3. Switch on the pump and check for leaks. Water should start to flow

through the system after a short while. If this does not happen, check to

ensure that:

a. the inlet pipe is completely secure and free from any defects.

b. the pump body has been correctly primed.

OPERATION

1. Open any valves in the pipeline.

2. Connect the power supply and switch the pump ON.

3. Wait for the pump to prime.

4. If the motor fails to start or does not deliver water, refer to Troubleshooting

on page 12.

NOTE: Filling the suction pipe with water will speed up the priming

process, and it is recommended that a non-return valve be fitted

to the end of the suction pipe.

•If debris has entered the pump causing a blockage, the end

housing can be taken off and the pump cleaned out as described

under Maintenance on page 11.

REMEMBER: Contaminated water is water containing small solids in

suspension, NOT slurry, sludge, sand, or mud.

5. Stop the pump by switching the pump OFF.

6. After use, drain residual water from the pump if there is danger of freezing.

If the pump has been used with contaminated or salty water, it should be

thoroughly flushed with clean water following use, both inside and out

before replacing the plug.

Fig 4

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