Page 1
Installation, Operation,
and Maintenance Manual
Series 80-SC
Page 2
Page 3
Table of Contents
Introduction and Safety..................................................................................................................2
Introduction..................................................................................................................................2
Safety.............................................................................................................................................2
Safety terminology and symbols........................................................................................... 2
Safety instruction decals......................................................................................................... 3
User safety................................................................................................................................ 4
Environmental safety...............................................................................................................5
Product warranty......................................................................................................................... 6
Transportation and Storage.......................................................................................................... 7
Inspect the delivery.....................................................................................................................7
Inspect the package................................................................................................................7
Inspect the unit........................................................................................................................ 7
Pump lifting.................................................................................................................................. 7
Long-term storage.......................................................................................................................8
Table of Contents
Product Description........................................................................................................................9
General description.................................................................................................................... 9
Operational specifications....................................................................................................... 10
Installation......................................................................................................................................11
Preinstallation............................................................................................................................ 11
Pump mounting guidelines..................................................................................................11
Pump location guidelines.....................................................................................................11
Piping checklist......................................................................................................................12
Typical installation.....................................................................................................................13
Commissioning, Startup, Operation, and Shutdown...............................................................14
Preparation for startup............................................................................................................. 14
Check the rotation.................................................................................................................14
Prime the pump.........................................................................................................................15
Start the pump...........................................................................................................................15
Pump operation precautions...................................................................................................16
Shut down the pump................................................................................................................ 16
Maintenance..................................................................................................................................17
Lubrication................................................................................................................................. 17
Disassembly............................................................................................................................... 17
Disassembly precautions......................................................................................................17
Drain the pump......................................................................................................................17
Reassembly................................................................................................................................ 17
Seal setting.............................................................................................................................17
Motor collar ring setting.......................................................................................................19
Assemble the coupler...........................................................................................................20
Replace the seal.....................................................................................................................21
Screw torque values..............................................................................................................22
Dealer servicing ....................................................................................................................22
Series 80-SC Installation, Operation, and Maintenance Manual 1
Page 4
Introduction and Safety
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.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions,
situations, or events that are not considered in this manual or in the sales documents,
please contact the nearest Xylem representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• 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:
2 Series 80-SC Installation, Operation, and Maintenance Manual
Page 5
Hazard levels
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
Introduction and Safety
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.
Series 80-SC Installation, Operation, and Maintenance Manual 3
Page 6
P70643
P70644
P70642
EYEBOLTS OR LIFTING
LUGS IF PROVIDED ARE
FOR LIFTING ONLY THE
COMPONENTS TO WHICH
THEY ARE ATTACHED.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
DEATH.
DO NOT RUN PUMP DRY.
SEAL DAMAGE MAY OCCUR.
INSPECT PUMP SEAL
REGULARLY FOR LEAKS.
REPLACE AS REQUIRED.
FOR LUBRICATION
REQUIRMENTS, CONSULT
SERVICE INSTRUCTIONS.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
ROTATING COMPONENTS
DISCONNECT AND LOCK
OUTPOWER BEFORE
SERVICING.
DO NOT OPERATE WITHOUT
ALL GUARDS IN PLACE.
CONSULT INSTALLATION
AND SERVICE INSTRUCTION
SHEET BEFORE OPERATING
OR SERVICING.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
DEATH.
S11547
ELECTRICAL SHOCK HAZARD.
TURN OFF AND LOCKOUT ALL
POWER SOURCES PRIOR TO
SERVICING PANEL.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT
IN SERIOUS PERSONAL INJURY,
DEATH, AND/OR PROPERTY
DAMAGE.
WARNING
Introduction and Safety
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.
All series 80–SC Pumps Series 80–SC with optional ITSC
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
4 Series 80-SC Installation, Operation, and Maintenance Manual
about safety devices in other chapters of this manual.
Page 7
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.
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
Introduction and Safety
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.
WARNING:
Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any
nuclear radiation.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
Series 80-SC Installation, Operation, and Maintenance Manual 5
Page 8
Introduction and Safety
Product warranty
Coverage
Xylem undertakes to remedy defects in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an local sales and service representative within the warranty
period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in
use.
• All service and repair work is done by Xylem authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by an EX-approved Xylem
representative are used in Ex-approved products.
Limitations
The warranty does not cover defects caused by these situations:
Deficient maintenance
•
• Improper installation
• Modifications or changes to the product and installation made without consulting an
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 arise for a warranty claim, then contact your local sales and
service representative.
6 Series 80-SC Installation, Operation, and Maintenance Manual
Page 9
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.
Transportation and Storage
Pump lifting
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.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
In order to lift the entire pump, use slings placed around the unit as shown.
Series 80-SC Installation, Operation, and Maintenance Manual 7
Page 10
Transportation and Storage
Series 80–SC Series 80–SC with optional ITSC
Figure 1: Proper lifting method
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.
Treat bearing and machined surfaces so that they are well preserved. Refer to the drive
unit and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your
local sales and service representative.
8 Series 80-SC Installation, Operation, and Maintenance Manual
Page 11
Product Description
General description
The pump is a split coupled pump. These features make the pump easy to install, operate,
and service:
• High efficiency
• Rugged bronze-fitted construction
• Vertical in-line mounting
Mechanical seal options
The pump has two options for the mechanical seal.
Product Description
Intended applications
Figure 2: Inside mechanical seal
Figure 3: Outside mechanical seal
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.
Series 80-SC Installation, Operation, and Maintenance Manual 9
Page 12
Product Description
NOTICE:
• This product is not intended for potable water applications.
• This product is non-submersible. For indoor use only.
• This product has not been investigated, nor is it intended for, use in swimming pools
and marine areas.
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
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 specifications
Mechanical seal specifications
This table describes the specifications of the seals.
Seal type Parameter Value
BUNA-carbon-ceramic pH range limits pH 7–9
EPR-carbon-ceramic pH range limits pH 7–9
EPR-carbon-tungsten-carbide pH range limits pH 7–11
Table notes
1. An external flush is required on low pressure systems that contain a high
concentration of abrasives.
2. 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.
3. Flush-line filters and sediment separators are available on request.
Liquid temperature limits -20˚F to 225˚F (-29˚C to 107˚C)
Liquid temperature limits -20˚F to 250˚F (-29˚C to 121˚C)
Maximum pressure 175 psig
Liquid temperature limits -20˚F to 250˚F (-29˚C to 121˚C)
Maximum pressure 250 psig
3
3
10 Series 80-SC Installation, Operation, and Maintenance Manual
Page 13
Installation
Preinstallation
Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is
properly certified.
• You must earth (ground) all electrical equipment. This applies to the pump
equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to
verify that it is connected correctly.
• Motors without built-in protection must be provided with contactors and thermal
overload protection for single-phase motors, or starters with heaters for three-phase
motors. (See the nameplate on the drive unit to select properly-sized overloads.)
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.
Installation
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.
Pump mounting guidelines
Series 80–SC pumps can only be mounted with the motor shaft vertical (motor shaft
down).
The optional Integrated Technologic with Sensorless Control (ITSC) can be oriented to
different positions relative to the pump nozzles. This can be easily changed during pump
installation by removing the motor mounting capscrews, raising the motor assembly
slightly, 0.015 to 0.030” (if needed), and rotating the motor assembly around the pump
centerline. Raising the motor assembly more than 0.030” could damage the mechanical
seal. Replace the motor capscrews when the preferred position is determined.
CAUTION:
The pump and motor assembly must be properly supported during this procedure to
prevent the pump unit or motor assembly from falling. Failure to properly support the
pump and motor assembly could result in personal injury and or property damage.
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.
If the pump is not on a closed system, locate the pump so
that the fewest number of bends or elbows in the suction
pipe are needed.
Series 80-SC Installation, Operation, and Maintenance Manual 11
This minimizes the friction loss and keeps the suction
piping as short as possible.
Page 14
Installation
Guideline Explanation/comment
Make sure that the space around the pump is sufficient. This facilitates ventilation, inspection, maintenance,
and service.
If you require lifting equipment such as a hoist or tackle,
make sure that there is enough space above the pump.
For pumps with the optional ITSC installed, be careful not to
damage the ITSC during lifting. Do not wrap the sling around
the ITSC.
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.
When possible, locate the pump below the fluid level. This facilitates priming, ensures a steady flow of
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
• Expansion 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.
liquid, and provides a positive suction head on the
pump.
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 hightemperature 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
B&G Suction Diffuser is installed.
Check that the suction and discharge pipes are
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
the pump flanges match the bolt holes in the pipe
flanges.
This reduces suction turbulence by
straightening the flow of liquid before it enters
the pump.
This eliminates pipe strain on the pump .
As a rule, ordinary wire or band hangers are not
adequate to maintain proper alignment.
—
12 Series 80-SC Installation, Operation, and Maintenance Manual
Page 15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Installation
Check Explanation/comment Checked
For pumps mounted in vertical piping with the motor
in the horizontal position, check that adequate
support is provided.
Check that the suction or discharge lines are not
forced into position.
Check that fittings for absorbing expansion are
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.
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.
Check that the pipeline has isolation valves around
the pump and has a drain valve in the suction pipe.
This prevents strain on the pump parts and
piping. Do not mount the pump with the motor
vertically downward. Do not use motor lift rings
to suspend the pump.
Coupling and bearing wear will result if suction
or discharge lines are forced into position.
The code for Pressure Piping (A.S.A.B. 31.1) lists
many types of supports available for various
applications.
This helps to avoid strain on the pump.
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).
—
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.
—
Typical installation
1. Expansion tank
2. B&G Rolairtrol® air separator
3. Supply to system
4. TPV tank purge system
5. B&G Triple Duty® valve
6. B&G Series 80–SC 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
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
13. B&G #7 or #87 Air Vent
14. Drain valve
Series 80-SC Installation, Operation, and Maintenance Manual 13
Page 16
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:
You must follow these precautions before you start 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.
Check the rotation
WARNING:
• 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.
• Flush and clear the system thoroughly to remove dirt or debris in the pipe system in
order to prevent premature failure at initial startup.
• Bring variable-speed drivers to the rated speed as quickly as possible.
• Run a new or rebuilt pump at a speed that provides enough flow to flush and cool the
close-running surfaces of the stuffing-box bushing.
• If temperatures of the pumped fluid will exceed 200°F (93°C), then warm up the pump
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.
• Operating the pump in reverse rotation can result in the contact of metal parts, heat
generation, and breach of containment.
• 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.
14 Series 80-SC Installation, Operation, and Maintenance Manual
Page 17
1. Unlock power to the driver.
2. Make sure that everyone is clear, and then jog the driver long enough to determine
3. Lock out power to the driver.
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.
Start the pump
CAUTION:
• Observe the pump for vibration levels, bearing temperature, and excessive noise. If
Commissioning, Startup, Operation, and Shutdown
that the direction of rotation corresponds to the arrow on the pump.
normal levels are exceeded, shut down the pump and resolve the issue.
If your Series 80–SC pump is equipped with the optional ITSC, refer to the ITSC IOM for
proper setup and running requirements.
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 flow.
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.
Series 80-SC Installation, Operation, and Maintenance Manual 15
Page 18
Commissioning, Startup, Operation, and Shutdown
Pump operation precautions
General considerations
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.
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
and the flush lines. 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.
16 Series 80-SC Installation, Operation, and Maintenance Manual
Page 19
Maintenance
Lubrication
The pump motor has been lubricated at the factory. Keep the motor properly lubricated in
accordance with the motor manufacturer's instructions.
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.
Maintenance
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.
Reassembly
Seal setting
If the pump is fully disassembled and the shaft or bearing are replaced, it may be
necessary to reset the seal.
Series 80-SC Installation, Operation, and Maintenance Manual 17
Page 20
1
2
3
Maintenance
Set the inside seal
Unitized inside seal
The position of the unitized seal is set with a snap ring placed on the pump shaft. The
snap ring is positioned on the shaft by a machined groove and no adjustment is possible.
The unitized seal sets directly up to the snap ring.
1. Seal distance
2. Seal cap bolts
3. Seal spring retainer with two setscrews
Multi-part inside seal
1. To set the multi-part inside seal position, set the bottom edge of the spring retainer
the following distance from the shaft shoulder:
• 11/4” seal, set the distance to 1.125”.
• 15/8” seal, set the distance to 1.414”.
2. Tighten the seal spring retainer set screws to 20 in-lb torque to ensure the spring
retainer will hold in position.
3. Lubricate the seal with P80 and slide into place over the shaft.
4. Install the seal cap.
Make sure to tighten the four bolts evenly to avoid misalignment and seal seat
damage.
Set the outside seal
1. Leave the seal holding clips in the seal.
2. Lubricate the seal with P80 and slide over the shaft.
3. Tighten the seal gland bolts evenly.
4. Install the coupling to properly position the pump shaft.
5. Ensure the seal is tight against the seat.
6. Tighten the seal set screws onto the shaft.
7. Remove seal holding clips. The seal is now set.
Keep the seal holding clips in case the seal has to be removed in the future.
18 Series 80-SC Installation, Operation, and Maintenance Manual
Page 21
Motor collar ring setting
1
2
3
1
2
3
CAUTION:
The motor collar ring must be set on the motor shaft at the correct position and set screws
torqued to the proper value.
The motor collar ring must be set on the motor shaft at a specified distance for both TC
motors and IEC motors to insure the pump impeller is in the proper position during pump
operation. The distance to set the collar (DC) is measured from the motor mounting
surface to the surface of the collar ring closest to the motor.
Figure 4: Motor collar ring setting for TC motor
Maintenance
Figure 5: Motor collar ring setting for IEC motor
1. Motor mounting surface
2. Collar ring
3. DC
The collar ring is held in position on the motor shaft with set screws. These set screws
must be tightened to the proper torque to ensure that the collar does not slip as a result
of pump rotor weight and pump hydraulic thrust.
Place a small amount of Loctite 222MS on each setscrew before installing them into the
motor collar.
Table 1: Collar setting distance
This table describes the collar setting distance, set screw size, and set screw torque for TC
and IEC motors.
Motor frame size Distance
Collar (DC)
Set screw size Set screw torque
in-lbs
in (mm)
182TC — 184TC 2.121 (53.87) #8–32UNC 20
213TC — 215TC 2.597 (65.96) #10–32UNF 36
254TC — 256TC 3.227 (81.97) #10–32UNF 36
284TC — 286TC 3.735 (94.87) .25–28UNF 87
324TSC — 365TSC 2.855 (72.52) .25–28UNF 87
Series 80-SC Installation, Operation, and Maintenance Manual 19
Page 22
Maintenance
Motor frame size Distance
D80 IEC 1.076 (27.33) #8–32UNC 20
D90 IEC 1.470 (37.34) #8–32UNC 20
D100 — D112 IEC 1.863 (47.32) #8–32UNC 20
D132 IEC 2.627 (66.73) #10–32UNF 36
D160 IEC 3.686 (93.62) .25–28UNF 87
D180 IEC 3.686 (93.62) .25–28UNF 87
D200 IEC 3.686 (93.62) .25–28UNF 87
D225 IEC 4.762 (120.95) .313–24UNF 165
D250 IEC 4.762 (120.95) .313–24UNF 165
324TC-326TC 4.375 (111.13) .25–28UNF 87
364TC-365TC 4.875 (123.83) .313–24UNF 165
404TC-405TC 6.25 (158.75) .313–24UNF 165
444TC-445TC 7.50 (190.5) .313–24UNF 165
447TC-449TC 7.50 (190.5) .313–24UNF 165
Assemble the coupler
1. Ensure that the coupler halves are clean and burr free. Use sand paper to remove any
burrs and sharp edges within the keyways, collar ring groove, and set screw collar
groove. Rings and keys must slide within their grooves without interference.
2. Install the collar rings in the coupling as matched pairs, with the letter pointing toward
the pump impeller.
The halves of the collar rings are matched and must only be used together. The collar
ring has a letter on each half identifying the set. The letters must match.
The pump coupling uses keys, collar rings, which are split collars, and set screw
collars, which are full rings with set screws, to maintain the motor and pump shaft
position. The pump shaft always has one collar ring. The TC and IEC motors have a set
screw collar set on the motor shaft. An HP type motor uses a split collar ring that fits
into the motor shaft groove.
3. Install the motor set screw collar first for TC or IEC motor types.
4. The impeller weight and seal spring force causes the shaft to move downward;
therefore, half the coupler should be assembled into the pump shaft with collar. Then
the pump shaft must be pulled up and the motor collar ring or motor set screw collar
inserted into the coupling.
5. Install the keys and the other half of the collar ring or rings.
6. Install the second half of the coupler.
7. Insert the coupler hex head bolts and place a lock washer and nut on each bolt.
The bolt heads on opposite sides of the coupling should face in different directions.
Collar (DC)
in (mm)
Set screw size Set screw torque
in-lbs
20 Series 80-SC Installation, Operation, and Maintenance Manual
Page 23
1
Maintenance
Figure 6: Coupling
1. Gap
Note: Couplings use either four, six, or eight bolts depending on the motor size.
8. Tighten the bolts evenly to avoid misalignment.
9. Rotate the shaft by hand and make sure the gap on both sides of the coupler is
approximately equal.
If the gap is not equal, loosen the bolts and repeat the tighten step.
10. Make sure that the gap from the top to the bottom of the coupling is equal.
11. Slowly rotate the shaft by hand and check to see if any rubs occur.
• If no rubs occur, prime and start the pump for two minutes and determine if the
pump runs smooth and vibration free.
• If problems occur, check installation of the coupling and repeat as necessary.
Replace the seal
The inside and outside seal can be replaced without removing the motor.
1. Remove the coupling guard.
2. Remove the
flush line from the seal cap.
3. If an outside seal, put seal clips in the seal and then loosen the set screws that hold the
seal on the shaft.
4. Remove the coupler halves. Tape the collar rings together in pairs as assembled
previously.
The shaft drops down when the coupling is removed.
5. If an outside seal, remove the seal.
6. Remove the seal cap or seal gland through the space between shafts.
a) Remove the seal seat from the seal cap or gland.
b) If an inside seal, remove the seal using a pair of screwdrivers, to pry out the seal.
7. Clean the seal box, seal cap, or gland and shaft.
CAUTION:
Avoid touching the carbon face and ceramic face of the seal and
getting it dirty.
8. Place the seal seat in the seal cap or gland. Use P80 with an inside seal.
Series 80-SC Installation, Operation, and Maintenance Manual 21
Page 24
Maintenance
9. Refer to Set the outside seal (page 18)for seal installation instructions.
10. If an inside seal, lubricate the inside of the seal with P80.
a) Slide the seal and spring over the shaft to the proper position.
b) Install the seal cap and the four bolts.
c) Tighten the four seal cap bolts evenly to avoid misalignment.
11. Install the coupling to the pump shaft. Tighten the bolts evenly.
12. Reinstall the flush line.
13. Reinstall the coupling guard.
Screw torque values
Capscrew torque in ft-lb (Nm)
Capscrew
type
SAE grade
2
Brass and
stainless
steel
SAE grade
5
Head
marking
or 4 (5) 10 (14) 17 (23) 27 (37) 42 (57) 83 (113) 130 (176) 200 (271) 300 (407)
Dealer servicing
Capscrew diameter (in inches)
1/4 5/16 3/8 7/16 1/2 5/8 3/4 7/8 1
6 (8) 13 (18) 25 (34) 38 (52) 60 (81) 120 (163) 190 (258) 210 (285) 300 (407)
10 (14) 20 (27) 35 (47) 60 (81) 90 (122) 180 (244) 325 (440) 525 (712) 800 (1085)
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
22 Series 80-SC Installation, Operation, and Maintenance Manual
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Tel: 1-847-966-3700
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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
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P71396_C_en-US_2013-05_IOM.Series80-SC
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