Installation,
Operation, and
Maintenance Manual
Series 60
Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Requesting other information.........................................................................................................3
Safety.....................................................................................................................................................3
Safety terminology and symbols....................................................................................................4
User safety.........................................................................................................................................4
Environmental safety........................................................................................................................6
Product warranty...............................................................................................................................6
Transportation and Storage..................................................................................................................8
Inspect the delivery.............................................................................................................................8
Inspect the package.........................................................................................................................8
Inspect the unit..................................................................................................................................8
Pump lifting..........................................................................................................................................8
Long-term storage...............................................................................................................................8
Product Description.............................................................................................................................10
General description..........................................................................................................................10
Operational specifications...............................................................................................................10
Table of Contents
Installation.............................................................................................................................................11
Preinstallation....................................................................................................................................11
Pump location guidelines..............................................................................................................11
Piping checklist...............................................................................................................................12
Pump orientation............................................................................................................................13
Special installation..........................................................................................................................14
Connect the wiring............................................................................................................................15
Wiring diagrams.............................................................................................................................15
Commissioning, Startup, Operation, and Shutdown......................................................................17
Preparation for startup.....................................................................................................................17
Check the rotation..........................................................................................................................18
Lubrication requirements.................................................................................................................18
Prime the pump.................................................................................................................................18
Start the pump...................................................................................................................................18
Pump operation precautions...........................................................................................................19
Shut down the pump........................................................................................................................20
Maintenance.........................................................................................................................................21
Disassembly.......................................................................................................................................21
Disassembly precautions...............................................................................................................21
Drain the pump...............................................................................................................................21
Remove the motor and coupler...................................................................................................22
Remove the bearing assembly and impeller..............................................................................22
Remove the seal.............................................................................................................................24
Pre-assembly inspections.................................................................................................................25
Replacement guidelines................................................................................................................25
Reassembly........................................................................................................................................25
Reinstall the seal.............................................................................................................................25
Reinstall the bearing assembly and impeller..............................................................................26
Reinstall the spring type coupler and motor..............................................................................26
Reinstall the elastomeric type coupler and motor.....................................................................26
Series 60 Installation, Operation, and Maintenance Manual 1
Table of Contents
Capscrew torque values................................................................................................................28
Dealer servicing .............................................................................................................................28
Parts Listings and Cross-Sectional Drawings....................................................................................29
Cross-sectional drawings.................................................................................................................29
2 Series 60 Installation, Operation, and Maintenance Manual
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
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.
Series 60 Installation, Operation, and Maintenance Manual 3
Introduction and Safety
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
Hazard levels
Hazard level Indication
Hazard categories
DANGER:
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:
A hazardous situation which, if not avoided, will result in
death or serious injury
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
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
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
4 Series 60 Installation, Operation, and Maintenance Manual
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
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.
Introduction and Safety
• 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.
• 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.
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
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.
Series 60 Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Condition Action
Chemicals or hazardous
fluids on skin
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.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Recycling guidelines
Product warranty
Coverage
Limitations
Always follow local laws and regulations regarding recycling.
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.
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
6 Series 60 Installation, Operation, and Maintenance Manual
Warranty claim
Introduction and Safety
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
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.
Series 60 Installation, Operation, and Maintenance Manual 7
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.
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.
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.
8 Series 60 Installation, Operation, and Maintenance Manual
Transportation and Storage
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.
Series 60 Installation, Operation, and Maintenance Manual 9
Product Description
Product Description
General description
The Series 60 is an in-line mounted centrifugal pump.
This pump is available for pipe sizes that range from 1 in to 2 inches.
This pump also has available power levels that range from 1/4 to 3 hp and 1750 rpm.
Pump application
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.
You can use this pump for these types of applications:
• Hydronic heating and cooling
• Domestic hot water
• Industrial fluid transfer
This pump is for indoor use only.
Xylem recommends that you use bronze constructed pumps for pumping potable water.
For other applications, contact your local sales and service representative.
Operational specifications
Operational limitations
Parameter Value
Maximum working pressure 175 psi
Pump construction Bronze fitted or all bronze
Motors 208-230/460, 575 volts for three phase
Mechanical seal specifications
Materials of
Construction
Standard/optional Standard Optional Optional Optional
Operating
temperature range
pH range 7.0–9.0 7.0–11.0 7.0–12.0 7.0–9.0
Maximum glycol/
water concentration
Maximum suction
pressure
BUNA carbon/ceramic EPR carbon/tungsten
-20˚F to 225˚F (-29˚C
to 107˚C)
50/50% 50/50% 60/40% 50/50%
Suction Pressure + TDH must not exceed MWP
Standard mechanical seal
115/230 volts for single phase with built-in overload
protection
carbide
-20˚F to 250˚F (-29˚C
to 121˚C)
EPR Sic/SiC Viton carbon/ceramic
0˚F to 250˚F (-18˚C to
121˚C)
-10˚F to 225˚F (-23˚C
to 107˚C)
10 Series 60 Installation, Operation, and Maintenance Manual
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.
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.
Pump location guidelines
Installation
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.
Also make sure that you can protect the area below the
pump from water damage.
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 properlysized safety devices and control devices.
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.
Take into consideration the occurrence of unwanted
noise and vibration.
Series 60 Installation, Operation, and Maintenance Manual 11
Vibration can be transmitted to the piping system,
which can result in objectionable noise away from the
pump.
Installation
Guideline Explanation/comment
Piping checklist
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 liquid,
The code for pressure piping, ANSI B31.1, lists types of supports available for various
applications.
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-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 the pump is not supported by placing
hangers or floor supports on the motor.
Consider a consultation with a noise specialist.
and provides a positive suction head on the pump.
Shaft misalignment and subsequent premature
coupling and bearing wear will result if motor
is improperly supported.
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.
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.
This reduces suction turbulence by
straightening the flow of liquid before it enters
the pump.
The length of the pipe must be equal to five
times the diameter of the suction pipe size
This eliminates pipe strain on the pump .
As a rule, ordinary wire or band hangers are not
adequate to maintain proper alignment.
—
Coupling and bearing wear will result if suction
or discharge lines are forced into position.
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).
Check that a B&G Triple Duty® valve is installed in the
discharge line.
12 Series 60 Installation, Operation, and Maintenance Manual
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.
1
2
3
4
5
6
7
8
Installation
Check Explanation/comment Checked
Pump orientation
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.
On an open system, check that the end of the suction
pipe is at least 3 ft. below the surface of the water in
the suction well.
This prevents air from being drawn into the
pump. Avoid air pockets in the suction line and
make sure that each section of the suction pipe
is air tight.
Check that new flange gaskets are installed between
the flanges of the pump body end suction and
discharge pipes. Make sure that these gaskets are
clean and grease-free.
Suitable fasteners for this connection are
supplied in the Xylem fastener pack. Apply a
torque of 8 to 11 ft. lbs (11 to 15 Nm) to each of
the flange bolts. Both the suction and
discharge flanges must be torqued to the same
level.
You can install this pump to discharge up, down, left, or right. However, make sure that
you install the pump according to these pump orientation guidelines:
• Reposition the pump body by removing the body bolts and rotating the body around
the bearing assembly.
• Only install the pump with the motor shaft horizontal.
• The bearing assembly vent slots or coupler access window must always face up.
• Do not reposition the motor on the bearing assembly.
• The arrow on the pump body must point in the direction of the flow.
1. Discharge
2. Body
3. Direction of flow arrow
4. Suction
5. Bearing assembly
6. Motor
7. Vent slots
8. Rotation arrow
Figure 2: Bearing assembly with vent slots facing up
Series 60 Installation, Operation, and Maintenance Manual 13
1
2
3
4
5
6
Installation
1. Body
2. Direction of flow arrow
3. Bearing assembly
4. Motor
5. Coupler access window
6. Coverplate
Figure 3: Bearing assembly with coupler access window facing up
Figure 4: Vertical mode of discharge
Figure 5: Horizontal mode of discharge
Special installation
Installation with suction diffuser and triple-duty valve
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
14 Series 60 Installation, Operation, and Maintenance Manual
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
Connect the wiring
WARNING:
• Disconnect and lock out electrical power before installing or servicing the unit.
• 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.)
Electrical Hazard:
Make sure that all connections are secure and the conduit box cover is closed before you
connect the electrical power.
1. Remove the screws that secure the conduit box cover.
2. Lift off the cover.
3. Attach the appropriately sized connector to the hole in the side of the conduit box.
The circulators are thermally protected by impedance or on-winding thermal protectors
and do not require external overload protection.
Installation
Wiring diagrams
Single-phase motors
These wiring diagrams are typical and might not be representative for all motor types.
Refer to the motor or motor nameplate for specific diagrams.
Single-phase motors are protected with inherent overheating devices and do not require
external overload protection.
Single-phase motors can operate at either a low voltage (115 V) or a high voltage (230 V).
Choose the voltage at which you want to operate your pump and make the wiring
connections according to these diagrams:
Standard For 1 hp, 1 phase motors only
Series 60 Installation, Operation, and Maintenance Manual 15
Installation
Three-phase motors
Three-phase motors can operate at either a low voltage (208 to 230 V) or at a high voltage
(460 V). Choose the voltage at which you want to operate your pump and make the wiring
connections according to this diagram:
16 Series 60 Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation,
and Shutdown
Preparation for startup
WARNING:
Explosion hazard. Do not short battery terminals together or damage the battery.
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
order to prevent premature failure at initial startup.
• 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
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.
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.
Series 60 Installation, Operation, and Maintenance Manual 17
Commissioning, Startup, Operation, and Shutdown
Check the rotation
WARNING:
• 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.
1. Unlock power to the driver.
2. Make sure that everyone is clear, and then jog the driver long enough to determine
that the direction of rotation corresponds to the arrow on the pump.
Pump rotation is clockwise when viewed from the back of the motor. An arrow is
provided to show rotational direction.
3. Lock out power to the driver.
Lubrication requirements
These pumps are permanently lubricated.
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
WARNING:
Pressurize the pump body slowly while you check for leaks at all joints with gaskets. Failure
to follow these instructions can result in serious personal injury and/or property damage.
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 flow.
18 Series 60 Installation, Operation, and Maintenance Manual
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) 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.
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.
Commissioning, Startup, Operation, and Shutdown
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 cooling coils. Failure to do so can cause liquid to freeze and damage the pump.
Series 60 Installation, Operation, and Maintenance Manual 19
Commissioning, Startup, Operation, and Shutdown
Shut down the pump
1. Slowly close the discharge valve.
2. Shut down and lock the driver to prevent accidental rotation.
20 Series 60 Installation, Operation, and Maintenance Manual
Maintenance
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.
• After you disassemble a gasket joint, always use a new gasket upon reassembly. Never
reuse old gaskets. Failure to follow these instructions can result in serious personal
injury, death, and/or property damage.
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.
Do not 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.
Series 60 Installation, Operation, and Maintenance Manual 21
Maintenance
Remove the motor and coupler
WARNING:
• Disconnect and lock out electrical power before installing or servicing the unit.
• 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.
1. Turn off and lock out power to the motor.
2. Remove the conduit box cover.
3. Disconnect the power leads from the motor leads.
4. Remove the conduit and power leads from the conduit box.
5. Support the motor and then remove the four screws that hold the motor to the bearing
assembly.
6. On pumps with spring type couplers, remove the motor side coupler half from the
motor shaft.
7. Pull the motor off of the bearing assembly.
8. Remove the coupler:
If your coupler type is... Then...
Spring Almost completely back out the coupler setscrews and then slide the pump-side
coupler half off of the motor shaft.
Elastomeric Loosen the coupler setscrews and remove the coupler halves from the pump and
motor shafts.
Remove the bearing assembly and impeller
WARNING:
Pressure might be present in the pump body. You can relieve this pressure by loosening
the eight volute capscrews and shifting the bearing assembly slightly in order to allow the
pressurized water to escape. Failure to follow these instructions can result in serious
personal injury or death.
1. Remove the eight capscrews that hold the bearing assembly or adapter ring to the
volute.
2. Remove the bearing assembly.
3. Insert a long punch between the impeller vanes or grasp the impeller with a strap
wrench in order to prevent the impeller from turning.
4. Remove the impeller nut, lockwasher, impeller, and adapter ring.
5. Remove these items from the bearing assembly:
If your bearing
assembly is...
Then...
Cast iron
Aluminum Remove the two bearing-holder retaining screws that are located at the bottom of the
6. Pull the shaft assembly from the bearing bracket.
If necessary, strike the coupler end of the shaft with a soft-faced hammer in order to
remove the assembly.
22 Series 60 Installation, Operation, and Maintenance Manual
1. Remove all of the seal parts and the coverplate.
2. Remove the seat and seat gasket from the coverplate.
3. Remove the three screws that hold the bearing cap in place.
coupler cavity.
7. Pull the wave spring out of the rear bearing bore.
1
2
3
4
5
6
7
Maintenance
1. Adapter ring used in 2 x 2 x 6-1/4 and 1-1/2 x 1-1/2 x 6-1/4 pumps 5. Wave spring
2. Gasket used on 2 x 2 x 6-1/4 and 1-1/2 x 1-1/2 x 6-1/4 pumps 6. Faceplate
3. Seal assembly 7. Gasket
4. Retaining screws —
Figure 6: Small bearing assembly
Series 60 Installation, Operation, and Maintenance Manual 23
1
2
3
4
5
6
7
8
Maintenance
1. Coverplate 5. Seal assembly
2. Gasket 6. Wave spring
3. Seat gasket 7. Retaining screws
4. Seat 8. Bearing cap
Figure 7: Large bearing assembly
Remove the seal
1. Remove the spring retainer and seal spring.
2. Pry the compression ring off the seal boot.
3. Insert a standard screwdriver under the seal head and carefully pry the seal head off
the shaft.
Do not scratch the shaft sleeve.
4. Use a small screwdriver in order to loosen and remove the seal seat and gasket.
5. If the seat retainer is in good condition, leave it in the faceplate. If it is in bad condition,
pry it out and replace it with the new one provided in the seal kit.
24 Series 60 Installation, Operation, and Maintenance Manual
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.
Replacement guidelines
Impeller replacement
This table shows the criteria for replacing the impeller:
Impeller parts When to replace
Maintenance
Impeller vanes
Vane edges When you see cracks, pitting, or corrosion damage
Gaskets, O-rings, and seatsreplacement
• Replace all gaskets and O-rings at each overhaul and disassembly.
• Inspect the seats. They must be smooth and free of physical defects.
• Replace parts if the seats are defective.
Reassembly
Reinstall the seal
1. Clean the shaft sleeve and seal seat recess.
You can use crocus cloth in order to polish the sleeve. Do not scratch or gouge the
recess or sleeve.
2. Install the seat gasket and seat into the seal recess in the faceplate or coverplate.
On ceramic seats there are two dimples located on one of the faces. The dimples
indicate the side of the seat that rests against the seat gasket. Tungsten carbide faces
can be inserted with either face against the gasket.
3. Lubricate the seal boot with soapy water and then slide the complete seal head
(carbon ring, seal boot, driver, and compression ring) over the shaft.
Do not attempt to install the seal head by placing the components on the shaft
individually.
4. Slide the seal head on until the carbon ring contacts the seat. Make sure that the
protrusions in the driver remain engaged in the notches in the carbon.
5. Use the flat face of a screwdriver and firmly press on the top of the edge of the
compression ring at several locations in order to make sure that the seal head sits flat
against the seat.
6. Place the spring and spring retainer on top of the seal head.
• When grooved deeper than 1/16 in. (1.6 mm), or
• When worn evenly more than 1/32 in. (0.8 mm)
Series 60 Installation, Operation, and Maintenance Manual 25
Maintenance
Reinstall the bearing assembly and impeller
WARNING:
Whenever the bearing assembly is removed from the piping, use a new gasket when you
reinstall. Failure to follow these instructions can result in serious personal injury or property
damage.
1. Wipe the bearing bores clean and remove any rust or scale deposits with a fine emery
cloth.
2. Insert the new wave spring into the rear bearing bore.
3. Lubricate the OD of the rear bearing with grease:
• On shaft assemblies that go into aluminum housings, lubricate the OD of the
bearing holder, not the faceplate.
• On shaft assemblies that go into cast iron housings, lubricate the OD of the front
bearing.
4. Insert the shaft assembly into the housing and then install and tighten the retaining
screws.
5. For cast iron bearing assemblies, install the coverplate on the housing.
6. If used, install the adapter ring and gasket on the new bearing assembly.
7. Install the impeller on the new bearing assembly and use the new impeller nut and
lockwasher provided with the new bearing assembly.
8. Insert a long punch between the impeller vanes or grasp the impeller with a strap
wrench to prevent the impeller from turning.
9. Torque the impeller nut to 96 to 144 lb-in. for nuts used on 3/8 in. fine threaded shafts
or 204 to 264 lb-in. for nuts used on 7/16 in. fine threaded shafts.
10. Clean the old body gasket from the volute.
11. Put a new body gasket on the bearing assembly and then install the assembly on the
pump body.
12. Install the eight volute capscrews and tighten them according to the torque
specifications in the Capscrew torque values table.
Reinstall the spring type coupler and motor
1. Install the new coupler on the pump shaft.
2. Make sure that the coupler setscrew is seated in the shaft dimple.
3. Lift the motor into position and attach the motor side coupler half.
Make sure that the coupler setscrew is seated in the shaft dimple.
4. Support the motor and then install the four screws that hold the motor to the bearing
assembly.
5. Attach the conduit and power leads to the conduit box.
6. Connect the power leads to the motor leads.
7. Replace the conduit box cover.
8. Check for proper motor rotation. The proper rotation is clockwise when viewed from
the back of the motor.
Reinstall the elastomeric type coupler and motor
1. Position the coupler half on the pump shaft:
If your pump shaft... Then...
Contains a dimple Locate the coupler half on the shaft so that a coupler setscrew is positioned
over the dimple. Tighten the setscrew so that it seats in the dimple. Tighten
the other setscrew if there is one.
26 Series 60 Installation, Operation, and Maintenance Manual
If your pump shaft... Then...
Maintenance
Is keyed and uses a size 3J
Slide the coupler half on the shaft. Do not tighten the setscrew.
coupler
Is keyed and uses a size 4J
coupler
Is keyed and uses a size 5J
coupler
Slide the coupler half onto the shaft so that the shaft end extends 0.25 in.
(0.64 cm) past the coupler half flange face. Tighten the setscrews.
Slide the coupler half onto the shaft so that the shaft end is flush with the
coupler half flange face. Tighten the setscrews.
2. Position the coupler half on the motor shaft:
If... Then...
The motor shaft contain a
dimple
Locate the coupler half on the shaft so that a coupler setscrew is positioned over
the dimple. Tighten the setscrew and make sure it seats in the dimple. Tighten
the other setscrew if there is one.
The motor shaft is keyed Slide the coupler half onto the motor shaft. Do not tighten the setscrews.
3. Place the new insert in the pump side coupler half.
4. Lift the motor into position, align the insert and motor coupler half, and then bolt the
motor in place.
5. Slide the coupler over the insert:
If... Then...
The motor and pump shafts both
Proceed to the next step.
contain a dimple
The motor shaft contains a
dimple and the pump shaft is
keyed
1. Use a screwdriver to slide the pump side coupler over the insert
as far as possible.
2. Gap the coupler by sliding the pump coupler half back 1/16 in.
3. Tighten the setscrews
The motor shaft is keyed and the
pump shaft is either dimpled or
keyed
1. Use a screwdriver to slide the motor side coupler over the insert
as far as possible.
2. Gap the coupler by sliding the motor coupler half back 1/16 in.
3. Tighten the setscrews
When an elastomeric type coupler is used with a keyed pump and/or motor shaft, do
not leave the insert compressed between the coupler halves. There must be a gap
between the ends of the insert and the coupler flanges to accommodate shaft
expansion and contraction. If the insert is not gapped, the pump and motor bearings
are subjected to excessive loads, which leads to premature failure. However, it is
possible to have too large a gap. The gap is considered excessive when the insert
teeth are not completely engaged in the coupler halves.
6. Insert the conduit and power leads on the conduit box.
7. Connect the power leads to the motor leads.
8. Install the conduit box cover.
9. Check that the motor rotation is clockwise when viewed from the back of the motor.
10. Fill and bleed the system and then check for leaks.
WARNING:
• Pressurize the pump body slowly while you check for leaks at all
joints with gaskets. Failure to follow these instructions can result in
serious personal injury or property damage.
Series 60 Installation, Operation, and Maintenance Manual 27
Maintenance
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)
Head
marking
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.
Brass or
stainless
steel
or
SAE grade 5 10 (14) 20 (27) 35 (47) 60 (81) 90 (122) 180 (244) 325 (441) 525 (712) 800 (1085)
4 (5) 10 (14) 17 (23) 27 (37) 42 (57) 83 (113) 130 (176) 200 (271) 300 (407)
Dealer servicing
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
28 Series 60 Installation, Operation, and Maintenance Manual
1
2
4
5
6
7
8
10
11
12
13
14
15
16
17
18
19
20
21
22
3
9
Parts Listings and Cross-Sectional Drawings
Parts Listings and Cross-Sectional
Drawings
Cross-sectional drawings
Pump body for sizes 1 x 5-1/4, 1-1/4 x 5-1/4, 1-1/2 x 5-1/4, 2 x 5-1/4, 1-1/2 x 6-1/4, and 2 x 6-1/4
1. Volute 12. Motor bracket
2. Gasket 13. Bearing housing
3. Key 14. Wave spring
4. Impeller 15. Rear spring
5. Impeller lockwasher 16. Shaft
6. Impeller nut 17. Bearing retainer
7. Adapter ring capscrew 18. Front bearing
8. Faceplate 19. Seal assembly
9. Front bearing holder 20. Volute capscrew
10. Spring coupler 21. Adapter ring, on 2 x 6-1/4 and 1-1/2 x 6-1/4 pumps only
11. Motor 22. Adapter ring gasket
Series 60 Installation, Operation, and Maintenance Manual 29
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
19
Parts Listings and Cross-Sectional Drawings
Pump body for sizes 1-1/2 x 7 and 2 x 7
1. Impeller 11. Coupler
2. Impeller lockwasher 12. Motor
3. Impeller nut 13. Coupler cover
4. Volute 14. Bearing housing
5. Bearing retainer 15. Shaft sleeve
6. Front bearing 16. Seal assembly
7. Shaft 17. Volute gasket
8. Rear bearing 18. Volute capscrew
9. Wave spring 19. Coverplate
10. Coupler elastomeric insert 20. Key
30 Series 60 Installation, Operation, and Maintenance Manual
Seal assembly
1
2
3
4
5
6
7
8
9
10
11
12
Parts Listings and Cross-Sectional Drawings
1. Seat retainer
2. Insert gasket
3. Seal insert
4. Primary ring
5. Driver
6. Bellows
7. Compression ring
8. Spring
9. Spring retainer
10. Shaft
11. Key
12. Sleeve
Series 60 Installation, Operation, and Maintenance Manual 31
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We're 12,500 people unified in a common purpose: creating
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bellgossett
Visit our Web site for the latest version of this
document and more information
The original instruction is in English. All nonEnglish instructions are translations of the original
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2013 Xylem Inc.
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P82893_D_en.US_2013-01_IOM.Series60
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