How it Works
Bell & Gossett
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P2001409A
User Manual
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Table of contents
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Bell & Gossett P2001409A User Manual

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Page 1
INSTRUCTION MANUAL
Series e-1532
Page 2
Page 3
Table of Contents
Introduction and Safety..................................................................................................................3
Introduction..................................................................................................................................3
Safety.............................................................................................................................................3
Safety terminology and symbols........................................................................................... 3
Safety instruction decals......................................................................................................... 4
User safety................................................................................................................................ 5
Environmental safety...............................................................................................................6
Product warranty......................................................................................................................... 6
Transportation and Storage.......................................................................................................... 8
Inspect the delivery.....................................................................................................................8
Inspect the package................................................................................................................8
Inspect the unit........................................................................................................................ 8
Lifting methods............................................................................................................................8
Long-term storage.......................................................................................................................9
Table of Contents
Product Description......................................................................................................................11
General description.................................................................................................................. 11
Operational specifications....................................................................................................... 11
Installation......................................................................................................................................13
Preinstallation............................................................................................................................ 13
Pump location guidelines.....................................................................................................13
Foundation requirements.................................................................................................... 14
Piping checklist......................................................................................................................14
Typical installation.................................................................................................................16
Special installation.................................................................................................................16
Install the pump with motor.....................................................................................................17
Level the base on a concrete foundation for pumps with base..........................................17
Grout the baseplate..................................................................................................................17
Install the piping........................................................................................................................18
Commissioning, Startup, Operation, and Shutdown...............................................................19
Preparation for startup............................................................................................................. 19
Prime the pump.........................................................................................................................19
Start the pump...........................................................................................................................20
Pump operation precautions...................................................................................................20
Shut down the pump................................................................................................................ 21
Note on the packed pump operation.....................................................................................21
Maintenance..................................................................................................................................22
Bearing maintenance................................................................................................................22
Disassembly............................................................................................................................... 22
Disassembly precautions......................................................................................................22
Drain the pump......................................................................................................................22
Remove the rotating assembly and motor.........................................................................23
Remove the mechanical seal (e-1532 and e-1532-F)....................................................... 23
Remove the seal or packing rings (e-1532-S, e-1532-D, and e-1532-PF)......................23
Impeller trimming guidelines.............................................................................................. 23
Pre-assembly inspections.........................................................................................................24
Page 4
Table of Contents
Shaft and sleeve inspection................................................................................................. 24
Reassembly................................................................................................................................ 25
Seal assembly........................................................................................................................ 25
Assemble the packed stuffing box (e-1532-PF)................................................................ 27
Reinstall the rotating assembly and motor........................................................................ 28
Capscrew torque values.......................................................................................................28
Dealer servicing ....................................................................................................................29
2 Series e-1532 INSTRUCTION MANUAL
Page 5

Introduction and Safety

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.
Introduction and Safety

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.

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
• Product malfunction
Page 6
Introduction and Safety
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or serious injury
Hazard categories
WARNING:
CAUTION:
NOTICE:
Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury

Safety instruction decals

WARNING:
The maximum working pressure of the pump is listed on the nameplate. Do not exceed this pressure. Failure to follow these instructions can result in serious personal injury, death, and/or property damage.
Alert symbol
This safety alert symbol is used in manuals and on the safety instruction decals on the pump to draw attention to safety-related instructions.
When used, the safety alert symbol means that failure to follow the instructions may result in a safety hazard.
Decals
Make sure your pump has these safety instruction decals and that they are located as this figure shows. If the decals are missing or illegible, contact your local sales and service representative for a replacement.
4 Series e-1532 INSTRUCTION MANUAL
Page 7
Introduction and Safety

User safety

General safety rules
Safety equipment
Make sure that all safety instruction decals are always clearly visible and readable.
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.
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.
Page 8
Introduction and Safety
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
• 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.
Wash the skin and eyes
property.
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
Chemicals or hazardous fluids on skin
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.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.

Environmental safety

The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid 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.
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.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.

Product warranty

Coverage
Xylem undertakes to remedy defects in products from Xylem under these conditions:
6 Series e-1532 INSTRUCTION MANUAL
Page 9
Limitations
Introduction and Safety
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to a local sales and service representative within the warranty period.
• The product is used only under the conditions that are described in this manual.
• The monitoring equipment that is incorporated in the product is correctly connected and in use.
• All service and repair work that is done by Xylem authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories that are authorized by an Ex-approved Xylem representative are used in Ex-approved products.
The warranty does not cover defects that are caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation that are made without consulting a Xylem authorized representative
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
Xylem products are high-quality products with expected reliable operation and long life. However, should the need for a warranty claim arise, contact your local sales and service representative.
Page 10

Transportation and Storage

Transportation and Storage

Inspect the delivery

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.

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 the local sales representative if there is any issue.

Lifting methods

WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
Table 1: Methods
Pump type Lifting method A pump without base. Use a suitable sling attached properly to solid points under the casing and motor. A base-mounted pump. Use slings under the pump casing and the drive unit, under the base rails, or
this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
and wear steel-toed shoes at all times.
through lifting lugs, when provided.
8 Series e-1532 INSTRUCTION MANUAL
Page 11
Examples
Transportation and Storage
Figure 1: Example of a proper lifting method for pump without base
Figure 2: Example of a proper lifting method for base mounted pump
Figure 3: Example of a proper lifting method using lifting lugs for base mounted pump

Long-term storage

If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the shaft by hand several times at least every three months.
Page 12
Transportation and Storage
Treat bearing and machined surfaces so that they are well preserved. Refer to the drive unit manufacturer for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your local sales and service representative.
10 Series e-1532 INSTRUCTION MANUAL
Page 13

Product Description

General description

Description
The pump is a centrifugal, close-coupled pump. The following pump features make it easy to install, operate, and service:
• High efficiency
• Rugged stainless steel-fitted construction
• Foot-mounted volute
Intended applications
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.
The pump is intended for use with these pumped fluids:
• Unheated domestic and fresh water
• Boiler feed water
• Condensate
• Hydronic cooling or heating
• Benign liquids
• Pressure boosting
• General liquid transfer
Product Description
Rotation
Pump rotation is clockwise when viewed from the back of the motor. An arrow is also located on the pump to show the direction of rotation.
Operational
Mechanical seal specifications
specifications
This table describes the specifications of each mechanical seal type.
Seal type Parameter Value Standard seals, BUNA pH range limits for BUNA pH 7–9
Standard seals, EPR pH range limits for EPR pH 7–11
Flushed single seals
2
Packing
1,3,4
Liquid temperature range that complies with the pH range limits for BUNA
Liquid temperature range that complies with the pH range limits for EPR
pH range limits pH 7–9 Liquid temperature range 0˚F to 250˚F (-18˚C to 121˚C) pH range pH 7–9 Liquid temperature range 0˚F to 200˚F (-18˚C to 93˚C)
-20˚F to 225˚F (-29˚C to 107˚C)
-20˚F to 250˚F (-29˚C to 121˚C)
Table notes
Page 14
Product Description
1. An external flush is required on low pressure systems that contain a high concentration of abrasives.
2. Use packing on open or closed systems which require a large amount of makeup water, as well as systems that are subjected to a wide variety of chemical conditions and solids buildup.
3. For operating temperatures above 250°F, a cooled flush is required and is recommended for temperatures above 225°F for optimum seal life. On closed systems, cooling is accomplished by inserting a small heat exchanger in the flush line to cool the seal flushing fluid.
4. Flush-line filters and sediment separators are available on request.
12 Series e-1532 INSTRUCTION MANUAL
Page 15

Installation

Preinstallation

Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is properly certified.
• You must ground (earth) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the ground (earth) lead to verify that it is connected correctly.
NOTICE:
Supervision by an authorized Xylem representative is recommended to ensure proper installation. Failure to do so may result in equipment damage or decreased performance.
Evaluate the installation in order to determine that the Net Positive Suction Head Available (NPSHA) meets or exceeds the Net Positive Suction Head Required (NPSHR), as stated by the pump performance curve.
Installation

Pump location guidelines

WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
Guideline Explanation/comment Keep the pump as close to the liquid source as
practically possible. Make sure that the space around the pump is
sufficient.
If you require lifting equipment such as a hoist or tackle, make sure that there is enough space above the pump.
Protect the unit from weather and water damage due to rain, flooding, and freezing temperatures.
Do not install and operate the equipment in closed systems unless the system is constructed with properly-sized safety devices and control devices.
Take into consideration the occurrence of unwanted noise and vibration.
If the pump location is overhead, undertake special precautions to reduce possible noise transmission.
This minimizes the friction loss and keeps the suction piping as short as possible.
This facilitates ventilation, inspection, maintenance, and service.
This makes it easier to properly use the lifting equipment and safely remove and relocate the components to a safe location.
This is applicable if nothing else is specified.
Acceptable devices:
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices, consult the engineer or architect in charge before you operate the pump.
The best pump location for noise and vibration absorption is on a concrete floor with subsoil underneath.
Consider a consultation with a noise specialist.
Page 16
2
3
1
4
Installation
Guideline Explanation/comment When possible, locate the pump below the fluid
level.

Foundation requirements

Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the unit.
• The foundation must weigh at least 2-1/2 times the weight of the pump unit.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for the final bolt adjustment.
• Tie the concrete pad in with the finished floor.
• Use foundation bolts and larger pipe sleeves to give room for final bolt location.
Diagram
This facilitates priming, ensures a steady flow of liquid, and provides a positive suction head on the pump.
1. Foundation bolt
2. Pipe sleeve
3. Washer
4. Built-up concrete foundation

Piping checklist

WARNING:
• The heating of water and other fluids causes volumetric expansion. The associated forces can cause the failure of system components and the release of high-
14 Series e-1532 INSTRUCTION MANUAL
temperature fluids. In order to prevent this, install properly sized and located compression tanks and pressure-relief valves. Failure to follow these instructions can result in serious personal injury or death, or property damage.
• Avoid serious personal injury and property damage. Make sure that the flange bolts are adequately torqued.
• Never force piping to make a connection with a pump.
Check Explanation/comment Checked Check that a section of straight pipe, with a length that
is five times its diameter, is installed between the suction side of the pump and the first elbow, or that a
This reduces suction turbulence by straightening the flow of liquid before it enters the pump.
B&G Suction Diffuser is installed.
Page 17
Installation
Check Explanation/comment Checked Check that the suction and discharge pipes are
This eliminates pipe strain on the pump . supported independently by use of pipe hangers near the pump .
Check that there is a strong, rigid support for the suction and discharge lines.
For pumps with flanges, check that the bolt holes in
As a rule, ordinary wire or band hangers are not
adequate to maintain proper alignment.
— the pump flanges match the bolt holes in the pipe
flanges.
Check that the suction or discharge lines are not forced into position.
Check that fittings for absorbing expansion are
Coupling and bearing wear will result if suction
or discharge lines are forced into position.
This helps to avoid strain on the pump. installed in the system when considerable temperature changes are expected.
Check that you have a foot valve of equal or greater area than the pump suction piping when you use in an open system with a suction lift.
Prevent clogging by using a strainer at the
suction inlet next to the foot valve. Make sure
that the strainer has an area three times that of
the suction pipe with a mesh hole diameter of
no less than 0.25 in. (0.64 cm). Check that flexible piping is used on both the suction
— and discharge sides of the pump when you use an isolation base.
Check that a B&G Triple Duty® valve is installed in the discharge line.
This valve serves as a check valve that protects
the pump from water hammer, and serves as an
isolation valve for servicing and for throttling. Check that the pipeline has isolation valves around
— the pump and has a drain valve in the suction pipe.
Use PTFE tape sealer or a high quality thread sealant
— when you install the suction and discharge connections to a threaded pump housing.
Page 18
3
4
5
6
7
8
2
9
10
11
1
12
13
14
Installation

Typical installation

1. Expansion tank
2. B&G Rolairtrol® air separator
3. Supply to system
4. TPV Tank Purge Valve
5. B&G Triple Duty® valve
6. B&G Series e-1532 Pump
7. B&G Suction Diffuser
8. Isolation valve
9. Pipe from boiler, chiller, or converter
10. Cold water supply
11. B&G Pressure Reducing Valve
12. B&G Model 107A — High capacity vent
13. B&G #7 or #87 Air Vent
14. Drain valve

Special installation

Installation with suction diffuser and triple-duty valve
Installation with isolation base
Do not install and operate triple-duty valves and suction diffusers in closed systems unless the system is designed with these safety and control devices:
• Pressure relief valves
• Compression tanks
• Pressure controlling equipment
• Temperature controlling equipment
• Flow controlling equipment
Check that the control and safety devices have these characteristics:
• Properly sized for their purpose
• Placed correctly in the system before putting the system into operation
When using an isolation base, discharge sides to reduce the strain on the flanges.
flexible piping should be used on both suction and
16 Series e-1532 INSTRUCTION MANUAL
Page 19

Install the pump with motor

4
1
5
2
3
6
7
8
1. Place the pump with motor where it will be mounted, on the floor, on a raised concrete pad or on a base, with two 0.060 in (1.5 mm) thick shims provided under each of the four hold down bolt locations of the pump volute feet. With certain tall motors and short pumps, one or two additional 1” (25.4 mm) thick steel shims will be provided to go under the pump casing feet to make the volute level with the bottom of the motor support or motor feet.
2. Then add additional shims at each of the four volute hold down bolt locations, as required, until the volute feet are fully supported, the pump discharge and there is a gap under the motor saddle or motor feet. Tighten the four bolts at the volute feet.
3. Loosen the bolts between the motor and the motor saddle, when a saddle is used,
fill any gaps to fully support the motor by adding shims under the motor feet at
and each of the motor’s four hold down bolt locations, as required, until all four hold down hole locations of the motor saddle or motor feet contact the floor, pad, or base. Tighten the bolting between the motor and motor saddle, when a saddle is used.
4. When mounted on a baseplate, then tighten the four hold down bolts at the corners of the motor support or motor feet. For pumps mounted directly on the floor or concrete pad, all four motor saddle or motor hold down bolt locations must be in contact with the
5. If any hold down bolt tightening results in pump movement that could induce stress in the pump frame, stop and re-shim the pump volute, motor saddle or motor.
floor or pad, but hold down bolting at these locations is optional.
Installation
flange is level,

Level the base on a concrete foundation for pumps with base

1. Place the pump on its concrete foundation.
2. Place 1.00 in./(25.40 mm) thick steel shims or wedges on both sides of each anchor bolt in order to support the pump .
This also provides a means of leveling the base.
1. Pump Base Rail
2. Grout only to top of base rail
3. Locate the shims to allow removal after grouting.
4. Grout
5. Concrete Foundation
6. Shims
7. 1” (25.40 mm) Gap
8. Allow 1” for shims. Place on both sides of anchor bolts.

Grout the baseplate

Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the instructions provided by the grout manufacturer.
• Grout: Non-shrink grout is required.
Page 20
Installation
1. Clean all the areas of the baseplate that will come into contact with the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.
4. Pour grout into the baseplate up to top of the base rails. Locate shims to allow removal after grouting. When you pour the grout, remove air bubbles from it by using one of these methods:
5. Allow the grout to set. It is recommended to remove shims, retighten anchor bolts, and fill shim gaps with grout.

Install the piping

Connect piping to pump without pipe strain on the pump.
• Puddle with a vibrator.
• Pump the grout into place.
18 Series e-1532 INSTRUCTION MANUAL
Page 21

Commissioning, Startup, Operation, and Shutdown

Commissioning, Startup, Operation, and Shutdown

Preparation for startup

WARNING:
• Failure to follow these precautions before you start the unit will lead to serious personal injury and equipment failure.
• Do not operate the pump below the minimum rated flows or with the suction or discharge valves closed. These conditions can create an explosive hazard due to vaporization of pumped fluid and can quickly lead to pump failure and physical injury.
• If the pump, motor, or piping operate at extremely high or low temperatures, then guarding or insulation is required. Failure to follow these instructions can result in serious personal injury or death, and property damage.
• Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.
• Operating the pump in reverse rotation can result in the contact of metal parts, heat generation, and breach of containment.
NOTICE:
• Verify the driver settings before you start any pump.
• Make sure that the warm-up rate does not exceed 2.5°F (1.4°C) per minute.
You must follow these precautions before you start the pump:
• Flush and clear the system thoroughly to remove dirt or debris in the pipe system in
• Bring variable-speed drivers to the rated speed as quickly as possible.
• If temperatures of the pumped fluid will exceed 200°F (93°C), then warm up the pump
At initial startup, do not adjust the variable-speed drivers or check for speed governor or over-speed trip settings while the variable-speed driver is coupled to the pump. If the settings have not been verified, then uncouple the unit and refer to instructions supplied by the driver manufacturer.

Prime the pump

CAUTION:
Do not run the pump dry.
Make sure that the pump body is full of liquid before startup. If the system does not automatically fill the pump body with liquid, then you must manually prime the pump.
1. Loosen the vent plugs on the pump body.
2. While venting the air from the pump body, rotate the pump shaft a few times by hand.
3. After all air has been purged from the pump, close the vent plugs.
order to prevent premature failure at initial startup.
prior to operation. Circulate a small amount of fluid through the pump until the casing temperature is within 100°F (38°C) of the fluid temperature.
Page 22
Commissioning, Startup, Operation, and Shutdown

Start the pump

CAUTION:
• Observe the pump for vibration levels, bearing temperature, and excessive noise. If normal levels are exceeded, shut down the pump and resolve the issue.
Before you start the pump, you must perform these tasks:
• Open the suction valve.
• Open any recirculation or cooling lines.
1. Fully close or partially open the discharge valve, depending on system conditions.
2. Start the driver.
3. Slowly open the discharge valve until the pump reaches the desired
4. Immediately check the pressure gauge to ensure that the pump quickly reaches the correct discharge pressure.
5. If the pump fails to reach the correct pressure, perform these steps: a) Stop the driver.
b) Prime the pump again. c) Restart the driver.
6. Monitor the pump while it is operating: a) Check the pump for bearing temperature, excessive vibration, and noise.
b) If the pump exceeds normal levels, then shut down the pump immediately and
correct the problem.
7. Repeat steps 5 and 6 until the pump runs properly.
flow.

Pump operation precautions

General considerations
WARNING:
Do NOT exceed the maximum working pressure of the pump. This information is listed on the nameplate of the pump.
CAUTION:
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side since this can result in decreased performance, unexpected heat generation, and equipment damage.
• Do not overload the driver. Driver overload can result in unexpected heat generation and equipment damage. The driver can overload in these circumstances:
• The specific gravity of the pumped fluid is greater than expected.
• The pumped fluid exceeds the rated flow rate.
• Make sure to operate the pump at or near the rated conditions. Failure to do so can result in pump damage from cavitation or recirculation.
Operation at reduced capacity
WARNING:
Never operate any pumping system with a blocked suction and discharge. Operation, even for a brief period under these conditions, can cause confined pumped fluid to overheat, which results in a violent explosion. You must take all necessary measures to avoid this condition.
20 Series e-1532 INSTRUCTION MANUAL
Page 23
CAUTION:
Avoid excessive vibration levels. Excessive vibration levels can damage the bearings, stuffing box or seal chamber, and the mechanical seal, which can result in decreased performance.
NOTICE:
• Avoid increased radial load. Failure to do so can cause stress on the shaft and bearings.
• Avoid heat build-up. Failure to do so can cause rotating parts to score or seize.
• Avoid cavitation. Failure to do so can cause damage to the internal surfaces of the pump.
Operation under freezing conditions
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump. Failure to do so can cause liquid to freeze and damage the pump.

Shut down the pump

1. Slowly close the discharge valve.
2. Shut down and lock the driver to prevent accidental rotation.
Commissioning, Startup, Operation, and Shutdown

Note on the packed pump operation

Tighten the gland nuts
Before you start the pump, back off the packing gland nuts or screws until the gland is loose.
Hand tighten until the gland is snug against the freely run from the packing. This is normal and should be allowed to continue for a period of time before you continue to tighten the gland. Tighten the gland nuts slowly and one flat at a time.
Leakage rate
An adequate leakage rate is not one single value for all pumps and installations, but is the amount required to provide adequate cooling and lubrication. The required leakage is influenced by operating pressure, fluid temperature, shaft speed, and so forth. For fluid temperatures in the range of 32°F to 190°F (0°C to 88°C), average leakage rates of 60 to 80 drops per minute are recommended. However, each individual pump and installation has unique operating conditions that result in widely-variable leakage rate requirements.
Maximum fluid temperature
At fluid operating temperatures near the upper limit of 190°F (88°C), the maximum temperature rise of the leakage is important. Never operate a packed pump with steam forming at the gland. This limits the temperature rise to a maximum of about 20°F (-7°C). If the formation of steam persists at higher leakage rates, you must provide cooling water by means of an external supply, or a heat exchanger used to cool the bypass flush.
first packing ring. Initially, water might
Page 24

Maintenance

Maintenance

Bearing maintenance

Bearing lubrication schedule
Type of bearing First lubrication Lubrication intervals Motor bearings No initial lubrication. The motor was

Disassembly

Disassembly precautions

This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to.
WARNING:
• Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, open vent or drain valves, or disconnect the piping.
• Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.
lubricated at the factory.
Refer to the motor manufacturer's recommendations for lubrication intervals.

Drain the pump

NOTICE:
Make sure that all replacement parts are available before you disassemble the pump for overhaul.
CAUTION:
• Allow all system and pump components to cool before you handle them to prevent physical injury.
1. Close the isolation valves on the suction and discharge sides of the pump. You must drain the system if no valves are installed.
2. Open the drain valve. Do not proceed until liquid stops coming out of the drain valve. If liquid continues to
flow from the drain valve, the isolation valves are not sealing properly and you must repair them before you proceed.
3. Leave the drain valve open and remove the drain plug located on the bottom of the pump housing.
Do not reinstall the plug or close the drain valve until the reassembly is complete.
4. Drain the liquid from the piping and flush the pump if it is necessary.
5. Disconnect all auxiliary piping and tubing.
22 Series e-1532 INSTRUCTION MANUAL
Page 25

Remove the rotating assembly and motor

1. Remove the motor foot capscrews.
2. Loosen the volute capscrews but do not remove them.
3. Loosen the rotating assembly from the volute.
WARNING:
Make certain that the internal pressure of the pump is relieved before you continue. Failure to follow these instructions could result in serious personal injury or death, or property damage.
4. Remove the seal flushing tube if it is used.
5. Remove the volute capscrews.
6. Remove the rotating assembly and motor from the volute.
7. Remove the impeller capscrew, lock washer, and washer.
8. Remove the impeller.

Remove the mechanical seal (e-1532 and e-1532-F)

1. Remove the rotating portion of the seal. If necessary, use a screwdriver to loosen the rubber ring.
2. Remove the seal insert, the insert gasket, and the retainer if it is used.
Maintenance

Remove the seal or packing rings (e-1532-S, e-1532-D, and e-1532-PF)

1. Remove the hex nuts from the seal cap bolts.
2. For the e-1532-PF, remove the hex nuts from the packing gland.
3. Remove the coverplate screws.
4. Remove the coverplate from the bracket.
5. Remove the seal assembly or packing rings.

Impeller trimming guidelines

Machining
When it is necessary to reduce the pump flow rate and generated head by trimming the impeller diameter, the following guidelines apply for stainless steel impellers:
• Review the pump hydraulic selection data and consult your local Xylem representative to select the proper reduced diameter.
• For the 1532-4AD model, before trimming the impeller refer to the e-1532-4AD angle cut guidelines.
• The recommended machining insert is Sandvick CNMG 432-1125 or equal without coolant at 250 surface feet per minute (SFM) (76.2 surface meter per minute (SMM)).
• To calculate the spindle speed (RPM), use the formula RPM=(SFM*12)/(3.1416* diameter of cut, in.) (RPM=(SMM*39.37)/(3.1416* diameter of cut, mm/25.4)). This results in the following:
Impeller Maximum Diameter Recommended Maximum Spindle Speed (RPM) 7 in. (177.8 mm) 136
9.5 in. (241.3 mm) 100 11 in. (279.4 mm) 87
13.5 in. (342.9 mm) 71
• Recommended rough cut feed rate per revolution is 0.008 in. (0.20 mm) and depth of cut is 0.050 in (1.27 mm).
• Recommended finish cut feed rate per revolution is 0.015 in. (0.38 mm) and depth of cut is 0.010 in (0.25 mm).
Page 26
ØA ØB
C
Maintenance
Balancing
Angle cut guidelines
It is recommended that impellers trimmed more than 5% in diameter be rebalanced per ISO 1940 grade G6.3.
Model e-1532-4AD pump impellers must be angle cut at reduced diameters according to the following information.
Figure 4: 4AD impeller trim — 0.125 in. (3.17 mm) increments
A B C Hydraulic diameter, nominal, as
shown on selection curves From maximum diameter 7 in.
(177.8 mm) to 6.125 in. (155.6 mm) 6, 5.875, 5.75, 5.625 in. (162.4 to
142.9 mm)
5.5, 5.375, 5.25, 5.125, minimum 5 in. (139.7 to 127.0 mm)

Pre-assembly inspections

Guidelines
Before you assemble the pump parts, make sure you follow these guidelines:
• Inspect the pump parts according to the information in these pre-assembly topics before you reassemble your pump. Replace any part that does not meet the required criteria.
• Make sure that the parts are clean. Clean the pump parts in solvent in order to remove oil, grease, and dirt.
NOTICE:
Protect machined surfaces while you clean the parts. Failure to do so may result in equipment damage.
Diameter at impeller inlet side shroud
Use diameter from selection curves 0 degrees, no angle
B = A plus 0.250 in. (6.35 mm) 8 degrees
B = A plus 0.375 in. (9.53 mm) 8 degrees
Trim angle
Areas to inspect
Inspect the pump regularly for leaking seals, worn gaskets, and loose or damaged components. Replace or repair these parts as required.

Shaft and sleeve inspection

Inspection criteria
Inspect the shaft and sleeve according to this criteria:
24 Series e-1532 INSTRUCTION MANUAL
Page 27

Reassembly

1
2
3
4
5
6
7
8
9
10

Seal assembly

Maintenance
• Thoroughly clean the shaft and sleeve.
• Thoroughly clean the coverplate seal cavity.
• Inspect the surface for damage such as pitting, corrosion, nicks, and scratches.
Replace these parts if they are damaged.
Assemble the standard mechanical seal (e-1532 and e-1532-F)
1. Lubricate the shaft sleeve and coverplate seal cavity with soapy water. Do not use a petroleum lubricant.
2. Install a new cup gasket and a new seal insert with the indentation side down into the cup.
3. Slide a new rotating seal assembly onto the shaft sleeve.
4. Push the top of the compression ring with a screwdriver until the seal is tight against the seal insert.
5. Install the seal spring and point the narrow end toward the seal.
1. Impeller
2. Impeller capscrew
3. Drain plug
4. Volute
5. Volute capscrews
6. Motor bracket
7. Motor foot capscrews
8. Shaft sleeve
9. Seal assembly
10. Volute gasket
Assemble the single mechanical seal (e-1532-S)
1. Lubricate the shaft sleeve and seal cap with soapy water. Do not use a petroleum lubricant.
2. Insert a stationary seal with an O-ring into the seal cap and slide it onto the shaft.
3. Replace the seal cap gasket.
4. Slide the rotating portion of the seal assembly onto the shaft sleeve and lock it in place.
ID seal size Distance between collar and impeller end of the shaft sleeve 1-1/4 in. (3.175 cm) 1-13/32 in. (3.571 cm)
Page 28
2
3
4
5
6
7
9
1
8
Maintenance
ID seal size Distance between collar and impeller end of the shaft sleeve 1-5/8 in. (4.128 cm) 1-1/4 in. (3.175 cm)
5. Assemble the coverplate onto the bracket.
6. Tighten the capscrews according to the Capscrew torque table.
7. Attach the seal cap to the coverplate.
8. Tighten the hex nuts on the seal cap bolts according to the Capscrew torque table.
1. O-ring
2. Coverplate
3. For 1-1/4 in. seal: 1-13/32 in. (3.571 cm)
4. For 1-5/8 in. seal: 1-1/4 in. (3.175 cm)
5. Seal locking collar
6. Seal cap bolt
7. Seal cap
8. O-ring
9. Motor end
Figure 5: Single mechanical seal (e-1532–S)
Assemble the double mechanical seal (e-1532-D)
1. Lubricate the shaft sleeve, seal cap, and coverplate cavity with soapy water. Do not use a petroleum lubricant.
2. Insert a stationary seal and O-ring into the seal cap. For the 1-1/4 in. ID seal, both parts are housed in the coverplate. A seal cap gasket is
not used.
26 Series e-1532 INSTRUCTION MANUAL
Page 29
1
2
1
Maintenance
1. O-rings
2. Motor end
Figure 6: Double mechanical seal (e-1532–D)
3. Insert another stationary seal and O-ring into the coverplate.
4. Slide the seal cap onto the shaft.
5. Replace the seal cap gasket.
6. Slide the rotating portion of the seal assembly onto the shaft sleeve.
7. Assemble the coverplate onto the bracket.
8. Tighten the capscrews according to the Capscrew torque values table.
9. Attach the seal cap to the coverplate.
10. Tighten the hex nuts on the seal cap bolts according to the Capscrew torque values table.
Assemble the packed stuffing box (e-1532-PF)
1. Insert two packing rings into the
2. Insert the lantern ring and the last two pieces of packing. Make sure that the joints on the packing rings are staggered 90º.
3. Install, but do not tighten, the packing gland.
4. Install the coverplate over the pump shaft.
5. Tighten the capscrews according to the Capscrew torque table in the Maintenance chapter.
6. Tighten the packing gland to compress the packing. See the note on the packed pump operation in the Operations chapter for more
information.
stuffing box.
Page 30
1
2
3
4
5
Maintenance
1. Flushing tube
2. Coverplate capscrew
3. Packing gland
4. Bracket
5. Coverplate

Reinstall the rotating assembly and motor

1. Install the impeller, impeller washer, lock washer, and capscrew, and then tighten per the Capscrew torque values table.
2. Install a new volute gasket.
3. Install the rotating assembly and motor into the volute.
4. Tighten the volute capscrews according to the Capscrew torque values table.
5. Install a seal flushing tube if it is used.
6. Install the support foot capscrews and tighten them according to the Capscrew torque values table.
7. Install the drain plug and close the drain valve.
8. Open the isolation valves and inspect the pump for leaks. Return the pump to service if you do not detect any leaks. See the Note on the packed
pump operation in the Commissioning, Startup, Operations, and Shutdown chapter.

Capscrew torque values

Capscrew torque in ft-lbs (Nm)
Capscrew type
SAE grade 2 6 (8) 13 (18) 25 (34) 38 (52) 60 (81) 120 (163) 190 (258) 210 (285) 300 (407)
Brass or stainless steel
Head marking
or
1/4 in. 5/16 in. 3/8 in. 7/16 in. 1/2 in. 5/8 in. 3/4 in. 7/8 in. 1 in.
4 (5) 10 (14) 17 (23) 27 (37) 42 (57) 83 (113) 130 (176) 200 (271) 300 (407)
SAE grade 5 10 (14) 20 (27) 35 (47) 60 (81) 90 (122) 180 (244) 325 (441) 525 (712) 800 (1085)
28 Series e-1532 INSTRUCTION MANUAL
Page 31
Pipe plug torque values
Table 2: Pipe plug torque, ft-lb (Nm)
Size Turns past finger tight Approximate torque 1/8 in NPT 1.5 to 3 12 (16) 1/4 in NPT 1.5 to 3 25 (34) 3/8 in NPT 1.5 to 3 40 (54) 1/2 in NPT 1.5 to 3 54 (73)

Dealer servicing

Maintenance
If trouble occurs that cannot be
rectified, contact your local sales and service
representative and be prepared to provide this information:
1. Complete nameplate data of pump and motor
2. Suction and discharge pipe pressure gauge readings
3. Ampere draw of the motor
4. A sketch of the pump hook-up and piping
Page 32
Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots
2) A leading global water technology company
We're 12,900 people unified in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efficiently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation.
For more information on how Xylem can help you, go to xyleminc.com
Xylem Inc 8200 N. Austin Avenue Morton Grove IL 60053 Tel: (847) 966–3700 Fax: (847) 965–8379 www.bellgossett.com
Visit our Web site for the latest version of this document and more information
The original instruction is in English. All non-English instructions are translations of the original instruction.
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2014 Xylem Inc
Bell & Gossett is a trademark of Xylem Inc or one of its subsidiaries.
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