Bunn Coffee Maker ICB Installation Manual

GOULDS PUMPS

Installation, Operation

and

Maintenance Instruction

Volute Casing Pumps

Model:

ICB

ICBI

IMPORTANT SAFETY NOTICE

To: Our Valued Customers

User safety is a major focus in the design of our products. Following the precautions outlined in this manual will minimize your risk of injury.

ITT Goulds pumps will provide safe, trouble-free service when properly installed, maintained, and operated.

Safe installation, operation, and maintenance of ITT Goulds Pumps equipment are an essential end user responsibility. This Pump Safety Manual identifies specific safety risks that must be considered at all times during product life. Understanding and adhering to these safety warnings is mandatory to ensure personnel, property, and/or the environment will not be harmed. Adherence to these warnings alone, however, is not sufficient — it is anticipated that the end user will also comply with industry and corporate safety standards. Identifying and eliminating unsafe installation, operating and maintenance practices is the responsibility of all individuals involved in the installation, operation, and maintenance of industrial equipment.

Please take the time to review and understand the safe installation, operation, and maintenance guidelines outlined in this Pump Safety Manual and the Instruction, Operation, and Maintenance (IOM) manual. Current manuals are available at your nearest Goulds Pumps sales representative.

www.gouldspumps.com/literature_ioms.html or by contacting

These manuals must be read and understood before installation and star t-up.

For additional information, contact your nearest Goulds Pumps sales representative or visit our Web site at

www.gouldspumps.com.

S-1

SAFETY WARNINGS

Specific to pumping equipment, significant risks bear reinforcement above and beyond normal safety precautions.

WARNING

A pump is a pressure vessel with rotating parts that can be hazard o us. An y press ure vessel can explode, rupture, or discharge its contents if sufficiently ove r press u r i zed causi n g deat h, personal injury, property damage, and/or damage to the environment. All necessary measures must be taken to ensure over pressurization does not occur.

WARNING

Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Operation, even for a brief period under these conditions, can cause superheating of enclosed pumpage and result in a violent explosion. All necessary measures must be taken by the end user to ensure this condition is avoided.

WARNING

The pump may handle hazardous and/or toxic fluids. Care must be taken to identify the contents of the pump and eliminate the possibility of exposure, particularly if hazardous and/or toxic. Potential hazards include, but are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks.

WARNING

Pumping equipment Instruction, Operation, and Maintenance manuals clearly identify accepted methods for disassembling pumping units. These methods must be adhered to. Specifically, applying heat to impellers and/or impeller retaining devices to aid in their removal is strictly forbidden. Trapped liquid can rapidly expand and result in a violent explosion and injury.

ITT Goulds Pumps will not accept responsibility for physical injury, damage, or delays caused by a failure to observe the instructions for installation, operation, and maintenance contained in this Pump Safety Manual or the current IOM available at www.gouldspumps.com/literature.

S-2

SAFETY

DEFINITIONS

Throughout this manual the words WARNING, CAUTION, ELECTRICAL, and ATEX are used to indicate where special operator attention is required.

Observe all Cautions and Warnings highlighted in this Pump Safety Manual and the IOM provided with your equipment.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Example:

Pump shall never be operated without coupling guard installed correctly.

CAUTION

Indicates a hazardous situation which, if not avoi ded, could result in minor or moderate injury.

Example: Throttling flow from the suction side may cause cavitation and pump damage.

ELECTRICAL HAZARD



Indicates the possibility of electrical risks if directions are not followed.

Example: Lock out driver power to prevent electric shock, accidental start-up, and physical injury.

 When installed in potentially explosive atmospheres, the instructions that follow the Ex symbol must be

followed. Personal injury and/or equipment damage may occur if these instructions are not followed. If there is any question regarding these requirements or if the equipment is to be modified, please contact an ITT Goulds Pumps representative before proceeding.

Example: parts, resulting in a spark and heat generation.

 Improper impeller adjustment could cause contact between the rotating and stationary

S-3

GENERAL PRECAUTIONS

WARNING

A pump is a pressure vessel with rotating parts that can be hazardous. Hazardous fluids may be contained by the pump including high temperature, flammable, acidic, caustic, explosive, and other risks. Operators and maintenance personnel must realize this and follow safety measures. Personal injuries will result if procedures outlined in this manual are not followed. ITT Goulds Pumps will not accept responsibility for physical injury, damage or delays caused by a failure to observe the instructions in this manual and the IOM provided with your equipment.

WARNING

General Precautions

NEVER use heat to disassemble pump due to risk of explosion from tapped liquid.

NEVER APPLY HEAT TO REMOVE IMPELLER. It may explode due to trapped liquid.

WARNING

WARNING WARNING

WARNING





NEVER operate pump without safety devices installed.

 



NEVER operate pump without coupling guard correctly installed. NEVER run pump below recommended minimum flow when dry, or without

prime. ALWAYS lock out power to the driver befo re per fo rming pump maintenance.

NEVER operate pump with discharge valve closed. NEVER operate pump with suction valve closed.

DO NOT change service application without approval of an authorized ITT Goulds Pumps representative.

Safety Apparel:

 Insulated work gloves when handling hot bearings or using bearing heater  Heavy work gloves when handling parts with shar p ed ges, especially

impellers

 Safety glasses (with side shields) for eye protection  Steel-toed shoes for foot protection when handling parts, heavy tools, etc.  Other personal protective equipment to protect against hazardous/toxic fluids

Receiving:

Assembled pumping units and their components are heavy. Failure to properly lift and support equipment can result in serious physical injury and/or equipment damage. Lift equipment only at specifically identified lifting points or as instructed in the current IOM. Current manuals are available at

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

Pumps sales representative. Note: Lifting devices (eyebolts, slings, spreaders, etc.) must be rated, selected, and used for the entire load being lifted.

Alignment:

WARNING

Shaft alignment procedures must be followed to prevent catastrophic failure of



drive components or unintended contact of rotating parts. Follow coupling manufacturer’s coupling installation and operation procedures.

S-4

WARNING

CAUTION

General Precautions

Before beginning any alignment procedure, make sure driver power is locked out.



Failure to lock out driver power will result in serious physical injury.

Piping:

Never draw piping into place by forcing at the flan ged con necti on s of t he pump. This may impose dangerous strains on the unit and cause misalignment between



pump and driver. Pipe strain will adversely effect the operation of the pump resulting in physical injury and damage to the equipment.

WARNING

CAUTION

WARNING

Flanged Connections:

Use only fasteners of the proper size and material. Replace all corroded fasteners.

Ensure all fasteners are properly tightened and there are no missing fasteners.

Startup and Operation:

When installing in a potentially explosive environment, please ensure that the



motor is properly certified. Operating pump in reverse rotation may result in contact of metal parts, heat



generation, and breach of containment. Lock out driver power to prevent accidental start-up and physical injury.



The impeller clearance setting procedure must be followed. Improperly setting the clearance or not following any of the proper procedures can result in sparks,



unexpected heat generation and equipment damage. If using a cartridge mechanical seal, the centering clips must be installed and set

screws loosened prior to setting impeller clearance. Failure to do so could result



in sparks, heat generation, and mechanical seal damage. The coupling used in an ATEX classified environment must be properly certified



and must be constructed from a non-sparking material. Never operate a pump without coupling guard properly installed. Personal injury

will occur if pump is run without coupling guard. Make sure to properly lubricate the bearings. Failure to do so may result in excess



heat generation, sparks, and / or premature failure. The mechanical seal used in an ATEX classified environment must be properly

certified. Prior to start up, ensure all points of potential leakage of process fluid to



the work environment are closed. Never operate the pump without liquid supplied to mechanical seal. Running a

mechanical seal dry, even for a few seconds, can cause seal damage and must be



avoided. Physical injury can occur if mechanical seal fails. Never attempt to replace packing until the driver is properly locked out and the

coupling spacer is removed.

WARNING

S-5

Dynamic seals are not allowed in an ATEX classified environment.



DO NOT operate pump below minimum rated flows or with suction and/or discharge valve closed. These conditions may create an explosive hazard due to



vaporization of pumpage and can quickly lead to pump failure and physical injury.

WARNING

CAUTION

WARNING

CAUTION



General Precautions

Ensure pump is isolated from system and pressure is relieved before disassembling pump, removing plu gs, ope ni n g vent or drain valves, or disconnecting piping.

Shutdown, Disassembly, and Reassembly:

Pump components can be heavy. Proper methods of lifting must be employed to avoid physical injury and/or equipment damage. Steel toed shoes must be worn at all times.

The pump may handle hazardous and/or toxic fluids. Observe proper decontamination procedures. Proper personal protective equipment should be worn. Precautions must be taken to prevent physical injury. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

Operator must be aware of pumpage and safety precautions to prevent physical injury.

Lock out driver power to prevent accidental startup and physical injury. Allow all system and pump components to cool before handling them to prevent

physical injury. If pump is a Model NM3171, NM3196, 3198, 3298, V3298, SP3298, 4150, 4550,

or 3107, there may be a risk of static electric discharge from plastic parts that are not properly grounded. If pumped fluid is non-conductive, pump should be drained and flushed with a conductive fluid under conditions that will not allow for a spark to be released to the atmosphere.

Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped fluid, resulting in severe physical injury and property damage.

Wear heavy work gloves when handling impellers as sharp edges may cause physical injury.

Wear insulated gloves when using a bearing heater. Bearings will get hot and can cause physical injury.

S-6

ATEX CONSIDERATIONS and INTENDED USE

Special care must be taken in potentially explosive environments to ensure that the equipment is properly maintained. This includes but is not limited to:

1. Monitoring the pump frame and liquid end temperature.

2. Maintaining proper bearing lubrication.

3. Ensuring that the pump is operated in the intended hydraulic range.

The ATEX conformance is only applicable when the pump unit is operated within its intended use. Operating, installing or maintaining the pump unit in any way that is not covered in the Instruction, Operation, and Maintenance manual (IOM) can cause serious personal injury or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT Goulds Pumps. If there is any question regarding the intended use of the equipment, please contact an ITT Goulds represe ntative before proceeding. Current IOMs are available at Pumps Sales representative.

All pumping unit (pump, seal, coupling, motor and pump accessories) certified for use in an ATEX classified environment, are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted. A typical tag would look like this:

www.gouldspumps.com/literature_ioms.html or from your local ITT Goulds

The CE and the Ex designate the ATEX compliance. The code directly below these symbols reads as follows:

II = Group 2 2 = Category 2 G/D = Gas and Dust present T4 = Temperature class, can be T1 to T6 (see Table 1)

Table 1

Max permissible

surface temperature

Code

T1 842 (450) 700 (372) T2 572 (300) 530 (277) T3 392 (200) 350 (177) T4 275 (135) 235 (113) T5 212 (100) Option not available T6 185 (85) Option not available

F (oC)

The code classification marked on the equipment must be in accordance with the specified area where the equipment will be installed. If it is not, do not operate the equipment and contact your ITT Goulds Pumps sales representative before proceeding.

Max permissible

liquid temperature

F (oC)

S-7

PARTS

The use of genuine Goulds parts will provide the safest and most reliable operation of your pump. ITT Goulds Pumps ISO certification and quality control procedures ensure the parts are manufactured to the highest quality and safety levels.

Please contact your local Goulds representative for details on genuine Goulds parts.

S-8

Installation, Operation and Maintenance Instruction

TABLE of CONTENTS

Pump Name Plate .....................................................2

ATEX-Label (only for pumps in compliance with

EC directive 94/9/EC)................................................ 2

1. General ..................................................................3

1.1 Guarantee.........................................................3

2. Safety Regulations ............................................... 3

2.1 Marking of References in the Operating

Instructions..............................................................3

2.2 Dangers of non-observance of the Safety

Instructions..............................................................4

2.3 Safety Instructions for the Operator / Worker...4

2.4 Safety Instructions for Maintenance, Inspections

and Mounting Work.................................................4

2.5 Unauthorized Alteration and Spare Parts

Production............................................................... 4

2.6 Undue Operation............................................... 4

2.7 Explosion Protection......................................... 4

2.8 Use acc. to Regulations.................................... 6

3. Description............................................................ 6

3.1 Design............................................................... 6

3.1.1 Design Coding System ..................................6

3.2 Shaft Sealing..................................................... 7

3.3 Bearing..............................................................7

3.4 Approximate Value for Sound Pressure Level.. 7

3.5 Permitted Nozzle Loads and Torques at the

Pump Nozzles ........................................................ 7

3.6 Permitted pressures and temperatures ............ 8

3.7 Condensate....................................................... 9

4. Transport, Handling, Storage.............................. 9

4.1 Transport, Handling ..........................................9

4.2 Storage / Conservation.....................................9

5. Mounting / Installation ......................................... 9

5.1 Mounting of Pump / Unit ...................................9

5.2 Connection of Pipings to the Pump ................10

5.3 Drive................................................................10

5.4 Electric Connection.........................................10

5.5 Final Control.................................................... 11

6. Start-up, Operation, Shut down ........................11

ICB 100-English page 1

Article No 21999991

6.1 Initial start-up...................................................11

6.2 Switch on drive................................................11

6.3 Restarting........................................................11

6.4 Limits of Operation ..........................................11

6.5 Lubrication.......................................................12

6.6 Monitoring........................................................12

6.7 Shutting down..................................................12

6.8 Storage / longer periods of non-operation.......12

7. Servicing, Maintenance......................................13

7.1 General remarks..............................................13

7.2 Mechanical seals.............................................13

7.3 Motor bearings ................................................13

7.4 Cleaning of pump ............................................13

8. Dismantling and repair of pump........................13

8.1 General remarks..............................................13

8.2 General............................................................13

8.3 Removal and Installation of screen in the motor

lantern....................................................................13

8.4 Removal of the Back Pull Out Assembly.........14

8.5 Removal of Impeller ........................................14

8.6 Removal of Shaft Sealing................................14

8.7 Removal of Stub Shaft ....................................14

8.8 Reconditioning.................................................15

8.9 Mounting..........................................................15

9. Spare parts, Spare pumps .................................16

9.1 Spare parts......................................................16

9.2 Stand-by pumps ..............................................16

10. Faults - Causes and Solutions.........................17

Appendix

Installation Manual - Single mech. seal without shaft

sleeve (Design code S1..2).......................................19

Installation Manual - Single mech. seal with quench

without shaft sleeve (Design code S4..2) ………......

20 Sectional drawing pump unit (Design code S1..2),

Impeller with back vanes.......................................... 23

Sectional drawing pump unit (Design code S1..2),

Impeller with balancing holes................................... 24

Sectional drawing pump unit (Design code S4..2),

Impeller with back vanes.......................................... 25

Sectional drawing pump unit (Design code S4..2),

Impeller with balancing holes................................... 26

Connections............................................................. 27

Dimensional drawing................................................ 28

Model ICB

Revision 00

Issue 05/2006

Installation, Operation and Maintenance Instruction

Pump Name Plate

Model ICB

TYPE *) Type and size of pump S/N *) Serial number YEAR Year of construction Q Rated capacity at the operating point P Rated power at the operating point H Head (Energy head) at the operating point N Speed P

Max. permitted casing-operation-pressure

all w C

(=highest discharge pressure at the rated operating temperature to which the pump casing can be used).

TEMP Rated operating temperature of pumped

liquid

ITEM NO Customer equipment number

*) All details of design and materials are defined with this information. They must be stated on all inquiries to the manufacturer resp. orders of spare.

MATL Material of construction

ATEX-Label (only for pumps in compliance with EC directive 94/9/EC)

CE Marking of compliance with the EC directive

94/9/EC Ex specific marking for explosion protection II Symbol for the appliance group 2G Symbol for the category (2), explosive

atmosphere due to gases, vapors or mist (G) c Symbol for used ignition protection

(constructual safety "c") T1-T. Symbol for classification of the theoretically

available range of the temperature classes -

data for temperature class refer to chapter

2.7.5; Data for maximum permitted

temperature of pumped liquid refer to pump

name plate, data sheet and / or order

confirmation.

ICB 100-English page 2

Article No 21999991

The conformity with the EC directive 94/9/EC " Equipment and Protective Systems for Use in Potentially Explosive Atmospheres " is declared by the issue of the EC-Declaration of Conformity and the attachment of the ATEX-label at the pump (adapter). The ATEX-label is attached additionally to the pump name plate.

Revision 00

Issue 05/2006

Installation, Operation and Maintenance Instruction

1. General

Model ICB

This product corresponds with the requirements of the Machine directive 98/37/EG (former 89/392/EWG).

The staff employed on installation, operation, inspection and maintenance must be able to prove that they know about the relevant accident prevention regulations and that they are suitably qualified for this work. If the staf does not have the relevant knowledge, they should be provided with suitable instruction.

The operation safety of the delivered pump resp. unit (= pump with motor) can only be guaranteed on designated use according to the attached data sheet and / or order confirmation resp. chapter 6 "Start-up, Operation, Shut down". The operator is responsible for following the instructions and complying with the safety requirements given in these Operating Instructions. Smooth operation of the pump or pump unit can only be achieved if installation and maintenance are carried out carefully in accordance with the rules generally applied in the field of engineering and electrical engineering. If not all the information can be found in these Operating Instructions, please contact us. The manufacturer takes no responsibility for the pump or pump unit if the Operating Instructions are not followed. These Operating Instructions should be kept in a safe place for future use. If this pump or pump unit is handed on to any third party, it is essential that these Operating Instructions and the operating conditions and working limits given in the Confirmation of Order are also passed on in full. These Operating Instructions do not take into account all design details and variants nor all the possible

chance occurrences and events which might happen during installation, operation and maintenance. We retain all copyright in these Operating Instructions; they are intended only for personal use by the owner of the pump or the pump unit. The Operating Instructions contain technical instructions and drawings which may not, as a whole or in part, be reproduced, distributed or used in any unauthorised way for competitive purposes or passed on to others.

1.1 Guarantee

The guarantee is given in accordance with our Conditions of Delivery and / or the confirmation of order. Repair work during the guarantee period may only be carried out by us, or subject to our written approval. Otherwise the guarantee ceases to apply. Longer-term guarantees basically only cover correct handling and use of the specified material. The guarantee shall not cover natural wear and tear and all parts subject to wear, such as impellers, shaft sealings, shafts, shaft sleeves, bearings, wear rings etc. or damage caused by transport or improper handling. In order for the guarantee to apply, it is essential that the pump or pump unit is used in accordance with the operating conditions given on the name plate, confirmation of order and in the data sheet. This applies particularly for the endurance of the materials and smooth running of the pump and shaft sealing. If one or more aspects of the actual operating conditions are different, we should be asked to confirm in writing that the pump is suitable.

2. Safety Regulations

These Operating Instructions contain important instructions which must be followed when the pump is assembled and commissioned and during operating and maintenance. For this reason, these Operating Instructions must be read by the skilled staff responsible and / or by the operator of the plant before it is installed and commissioned, and they must be left permanently available at the place where the pump or pump unit is in use.

These Operating Instructions do not refer to the General Regulations on Accident Prevention or local safety and / or operating regulations. The operator is responsible for complying with these (if necessary by calling in additional installation staff).

Equally, instructions and safety devices regarding handling and disposal of the pumped media and/or auxilliary media for flushing, lubrication a.s.o., especially if they are explosive, toxical, hot a.s.o., are not part of this operating instruction.

ICB 100-English page 3

Article No 21999991

For the competent and prescribed handling only the operator is responsible.

2.1 Marking of References in the Operating Instructions

The safety regulations contained in these Operating Instructions are specially marked with safety signs acc. to nach DIN 4844:

Safety reference! Non-observance can impair the pump and its function.

EC-Ex Marking Products intended for use in explosive atmospheres must be marked.

General Symbol for Danger! Persons can be endangered.

Warning of electric voltage!

Revision 00

Issue 05/2006

Installation, Operation and Maintenance Instruction

Safety instructions attached directly to the pump resp. unit must be followed under any circumstances. Further they must be kept in good readable condition.

In the same way, as these Operating Instructions of the pump, all possibly attached Operating Instructions of accessories (e.g. motor) must be noticed and kept available.

2.2 Dangers of non-observance of the Safety Instructions

Non-observance of the Safety Instructions can lead to loss of any claim for damages.

Further, non-observance can lead to following risks:  Failure of important functions of the machine or

facility.

 Failure of electronic appliances and measuring

instruments by magnetic fields.

 Endangering of persons and their personal

property by magnetic fields.

 Endangering of persons by electric, mechanic and

chemical influences.

 Endangering of environment through leakage of

dangerous substances.

On application of the unit in areas endangered to explosion special attention must be paid to sections marked with Ex.

2.3 Safety Instructions for the Operator / Worker

 Depending on the operating conditions, wear and

tear, corrosion or age will limit the working life of the pump/pump unit, and its specified characteristics. The operator must ensure that regular inspection and maintenance are carried out so that all parts are replaced in good time, which would otherwise endanger the safe operation of the system. If abnormal operation or any damage are observed, the pump must cease operation immediately.

 If the breakdown or failure of any system or unit

could lead to people being hurt or property being damaged, such system or unit must be provided with alarm devices and/or spare modules, and they should be tested regularly to ensure that they function properly.

 If there is any risk of injury from hot or cold

machine parts, these parts must be protected against contact by the user, or suitable warning signs must be affixed.

 Contact protection on moving parts (e.g. coupling

guards) must not be removed from systems that are in operation.

 If the sound level of a pump or pump unit is above

85 dB(A) an ear protection has to be used when staying near the pump for some time.

 If dangerous media (e.g. explosive, toxic, hot)

leak out (e.g. from shaft seals), these must be directed away so that there is no danger to people or the environment. The provisions of the law must be observed.

ICB 100-English page 4

Article No 21999991

 Measures should be taken to exclude any danger

from electricity (e.g. by complying with the local regulations on electrical equipment). If work is carried out on live electrical components, they should be unplugged from the mains or the main switch turned off and fuse unscrewed. A motor protection switch is to be provided.

Model ICB

2.4 Safety Instructions for Maintenance, Inspections and Mounting Work

 The operator is responsible that any maintenance,

inspections and mounting work is made by authorized competent personnel, which must be informed by having read the Operating Instructions.

 Basically, all work on the pump or pump unit

should only be carried out when the pump is stationary and not under pressure. All parts must be allowed to return to ambient temperature. Make sure that no-one can start the motor during such work. It is essential that the procedure for stopping the system described in the Operating Instructions is observed. Pumps or pump systems that carry media that are dangerous to health must be decontaminated before being taken apart. Safety Data Sheets for the various liquids handled. Immediately after finishing work, all safety and protective devices must be replaced or restarted.

2.5 Unauthorized Alteration and Spare Parts Production

Alteration or changes of the machine are permitted after agreement with the manufacturer. Original spare parts and accessory authorized by the manufacturer are serving the safety. The use of other parts can lead to loss of liability for therefrom resulting consequences.

2.6 Undue Operation

The operating safety of the delivered machine can only be guaranteed by designated use acc. to the following chapters of the Operating Instructions. The limits stated in the data sheet and / or order confirmation must not be exceeded under any circumstances.

2.7 Explosion Protection

On application of units in areas endangered to explosion measures and references in the chapters

2.7.1 to 2.7.6 must be observed, so that explosion protection is guaranteed.

2.7.1 Filling of unit

Revision 00

Issue 05/2006

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