Page 1
Goulds Pumps
3180 / 3185
3181 / 3186
Installation, Operation, and
Maintenance Manual
Models 3180, 3181, 3185, and 3186
Page 2
Page 3
Table of Contents
Introduction and Safety...................................................................................................................................................4
Introduction.......................................................................................................................................................................4
Requesting other information......................................................................................................................................4
Safety...................................................................................................................................................................................4
Safety terminology and symbols..................................................................................................................................5
Environmental safety.....................................................................................................................................................5
User safety.......................................................................................................................................................................6
Safety regulations for Ex-approved products in potentially explosive atmospheres...........................................8
Product approval standards.............................................................................................................................................9
Product warranty.............................................................................................................................................................10
Transportation and Storage..........................................................................................................................................11
Inspect the delivery.........................................................................................................................................................11
Inspect the package.....................................................................................................................................................11
Inspect the unit.............................................................................................................................................................11
Transportation guidelines...............................................................................................................................................11
Precautions....................................................................................................................................................................11
Pump handling.............................................................................................................................................................11
Lifting methods............................................................................................................................................................11
Storage guidelines............................................................................................................................................................13
Storage location............................................................................................................................................................13
Pump storage requirements........................................................................................................................................13
Frostproofing................................................................................................................................................................14
Table of Contents
Product Description........................................................................................................................................................15
General description.........................................................................................................................................................15
Part description............................................................................................................................................................15
General description i-ALERT™ Condition Monitor................................................................................................18
Nameplate information..................................................................................................................................................18
Installation.........................................................................................................................................................................21
Preinstallation...................................................................................................................................................................21
Pump location guidelines............................................................................................................................................21
Foundation requirements............................................................................................................................................22
Baseplate-mounting procedures....................................................................................................................................22
Prepare the baseplate for mounting..........................................................................................................................22
Install the baseplate using shims or wedges.............................................................................................................23
Install the baseplate using jackscrews.......................................................................................................................23
Spring mounted installation........................................................................................................................................25
Baseplate-leveling worksheet......................................................................................................................................30
Install the pump, driver, and coupling.........................................................................................................................31
Pump-to-driver alignment..............................................................................................................................................31
Alignment checks.........................................................................................................................................................31
Permitted indicator values for alignment checks....................................................................................................32
Alignment measurement guidelines..........................................................................................................................32
Attach the dial indicators for alignment...................................................................................................................32
Pump-to-driver alignment instructions....................................................................................................................33
Grout the baseplate.........................................................................................................................................................36
Bypass-piping considerations........................................................................................................................................36
Piping checklists..............................................................................................................................................................37
General piping checklist..............................................................................................................................................37
Suction-piping checklist..............................................................................................................................................38
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 1
Page 4
Table of Contents
Discharge piping checklist..........................................................................................................................................40
Auxiliary-piping checklist............................................................................................................................................41
Final piping checklist...................................................................................................................................................42
Commissioning, Startup, Operation, and Shutdown............................................................................................43
Preparation for startup...................................................................................................................................................43
Remove the coupling guard...........................................................................................................................................43
Check the rotation...........................................................................................................................................................44
Impeller-clearance check................................................................................................................................................44
Impeller axial clearances.............................................................................................................................................44
Check the Shearpeller™ axial clearance....................................................................................................................45
Impeller-clearance setting..............................................................................................................................................45
Set the impeller clearance - dial indicator method .................................................................................................45
Set the impeller clearance - feeler gauge method ...................................................................................................46
Couple the pump and driver..........................................................................................................................................46
Install the coupling guard...........................................................................................................................................47
Bearing lubrication..........................................................................................................................................................49
Oil volumes...................................................................................................................................................................50
Lubricating oil requirements......................................................................................................................................50
Acceptable oil for lubricating bearings.....................................................................................................................50
Lubricate the bearings with oil...................................................................................................................................50
Greased-for-life bearing lubrication..........................................................................................................................51
Shaft-sealing options.......................................................................................................................................................51
Mechanical seal options..............................................................................................................................................51
Connection of sealing liquid for mechanical seals..................................................................................................52
Packed stuffing box option.........................................................................................................................................52
Connection of sealing liquid for a packed stuffing box.........................................................................................52
Seal the shaft with a packed stuffing box.................................................................................................................53
Dynamic-seal option (3180 and 3185 S, M, L, and XL groups only)..................................................................54
Pump priming..................................................................................................................................................................55
Prime the pump with the suction supply above the pump...................................................................................55
Prime the pump with the suction supply below the pump...................................................................................56
Other methods of priming the pump.......................................................................................................................57
Start the pump.................................................................................................................................................................57
Activate the i-ALERT™ Condition Monitor..............................................................................................................58
i-ALERT™ Condition Monitor routine operation....................................................................................................59
Pump operation precautions.........................................................................................................................................59
Shut down the pump......................................................................................................................................................60
Deactivate the i-ALERT™ Condition Monitor..........................................................................................................60
Reset the i-ALERT™ Condition Monitor...................................................................................................................60
Make the final alignment of the pump and driver......................................................................................................60
Maintenance......................................................................................................................................................................62
Maintenance schedule.....................................................................................................................................................62
Bearing maintenance.......................................................................................................................................................63
Lubricating oil requirements......................................................................................................................................63
Lubricating-grease requirements...............................................................................................................................64
Lubricate the bearings after a shutdown period......................................................................................................65
Shaft-seal maintenance...................................................................................................................................................65
Mechanical-seal maintenance.....................................................................................................................................65
Packed stuffing-box maintenance..............................................................................................................................66
Dynamic seal maintenance (3180 and 3185 S, M, L, and XL groups only) .......................................................66
Disassembly......................................................................................................................................................................68
Disassembly precautions.............................................................................................................................................68
Tools required...............................................................................................................................................................68
Drain the pump............................................................................................................................................................68
Remove the back pull-out assembly..........................................................................................................................69
2 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 5
Table of Contents
Remove the casing wear ring (S, M, L, and XL)......................................................................................................71
Remove the casing wear ring (for XL1, XL2-S, and XL2)....................................................................................71
Remove the suction sideplate.....................................................................................................................................72
Impeller removal..........................................................................................................................................................73
Remove the stuffing box cover..................................................................................................................................76
Remove the TaperBore PLUS™ seal chamber........................................................................................................78
Remove the dynamic seal............................................................................................................................................80
Remove the frame adapter from the frame (XL1, XL2-S, and XL2)...................................................................81
Disassemble the bearing frame..................................................................................................................................81
Guidelines for i-ALERT™ Condition Monitor disposal.......................................................................................83
Disassemble the spring-mounted baseplate (second generation).........................................................................83
Preassembly inspections.................................................................................................................................................85
Replacement guidelines...............................................................................................................................................85
Bearing-frame inspection............................................................................................................................................85
Reassembly.......................................................................................................................................................................85
Assemble the bearing frame.......................................................................................................................................85
Assemble the frame adapter to the frame (XL1, XL2-S, and XL2).....................................................................91
Assemble the TaperBore PLUS™ seal chamber.....................................................................................................92
Assemble the stuffing-box cover...............................................................................................................................93
Install the dynamic seal (S, M, L, and XL)...............................................................................................................95
Impeller installation.....................................................................................................................................................97
Install the suction sideplate......................................................................................................................................100
Install the casing wear ring (S, M, L, and XL enclosed impeller).......................................................................100
Install the casing wear ring (XL1, XL2-S, and XL2 enclosed impeller)............................................................101
Install the back pull-out assembly...........................................................................................................................101
Attach the i-ALERT™ Condition Monitor to the pump....................................................................................103
Post-assembly checks................................................................................................................................................104
Assembly references..................................................................................................................................................104
Troubleshooting.............................................................................................................................................................113
Operation troubleshooting..........................................................................................................................................113
Alignment troubleshooting..........................................................................................................................................114
Assembly troubleshooting...........................................................................................................................................114
i-ALERT™ Condition Monitor troubleshooting.....................................................................................................115
Parts Listings and Cross-sectional Drawings.......................................................................................................116
Parts list .........................................................................................................................................................................116
Assembly drawings (exploded views).........................................................................................................................126
Envelope drawings for packed box and seal chamber............................................................................................132
Certification: CE or CE ATEX..................................................................................................................................146
Certificates of conformance........................................................................................................................................146
Other Relevant Documentation or Manuals.........................................................................................................152
For additional documentation.....................................................................................................................................152
Local ITT Contacts.......................................................................................................................................................153
Regional offices.............................................................................................................................................................153
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 3
Page 6
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 ITT 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 ITT. If there is a question regarding the intended use of
the equipment, please contact an ITT representative before proceeding.
• This manual clearly identify accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply
heat to impellers, propellers, or their retaining devices to aid in their removal.
• Do not change the service application without the approval of an authorized ITT representative.
• Never operate the pump below the minimum rated flow, when dry, or without prime.
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• Never operate the pump with the suction valve closed.
Observe all safety messages highlighted in other sections of this manual.
4 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 7
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
DANGER:
WARNING:
Introduction and Safety
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
Hazard categories
A hazardous situation which, if not avoided, could
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
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
Environmental safety
The work area
Always keep the pump station clean to avoid and/or discover emissions.
Recycling guidelines
Always recycle according to these guidelines:
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 5
Page 8
Introduction and Safety
1. If the unit or parts are accepted by an authorized recycling company, then follow local recycling laws
and regulations.
2. If the unit or parts are not accepted by an authorized recycling company, then return them to the
nearest ITT representative.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Dispose appropriately of all waste.
• Handle and dispose of the pumped fluid 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.
Reference for electrical installation
For electrical installation requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
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.
• 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.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work
area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety
devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national,
state, and local regulations. For more information about requirements, see sections dealing specifically with
electrical connections.
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 the equipment is properly insulated when it operates at extreme temperatures.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
6 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 9
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
• Do not exceed the maximum working pressure of the pump.
• Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure
that the pump is isolated from the system and that pressure is relieved before you disassemble the
pump, remove plugs, or disconnect piping.
• Never operate a pump without a properly installed coupling guard.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
• Never heat the condition monitor to temperatures in excess of 300°F (149°C).
• Never expose the condition monitor to open flames.
• Do not use the condition monitor in atmospheres containing acetic acid.
• Always wear protective gloves. The pump and condition monitor can be hot.
Introduction and Safety
Hazardous liquids
Wash the skin and eyes
The product is designed for use in liquids that can be hazardous to your health. Observe these rules when
you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against
diseases to which they may be exposed.
• Observe strict personal cleanliness.
Do the following if chemicals or hazardous fluids have come into contact with your eyes or your skin:
If you need to wash
your...
Eyes
Skin
Then...
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 one minute.
3. Seek medical attention, if required.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 7
Page 10
Introduction and Safety
Safety regulations for Ex-approved products in potentially explosive atmospheres
Description of ATEX
The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment.
ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and
protective systems used within these atmospheres. The relevance of the ATEX requirements is not limited
to Europe. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.
Guidelines for compliance
Compliance is only fulfilled when the pump is operated within its intended use, for example within its
intended hydraulic range. The conditions of the service must not be changed without approval of an
authorized ITT representative. When installing or maintaining explosion-proof pumps, follow these
guidelines:
• Always install ATEX-approved equipment in compliance with the directive and applicable standards
(IEC/EN 60079–14).
• Do not install explosion proof products in locations that are classified as hazardous in the national
electric code, ANSI/NFPA 70–2005.
WARNING:
This manual clearly identify accepted methods for disassembling units. These methods must be adhered to.
Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to
impellers, propellers, or their retaining devices to aid in their removal.
If there are any questions regarding these requirements, the intended use, or if the equipment requires
modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized mechanics.
Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical characteristics of
the gas and/or vapor present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national standards
(for example IEC/EN 60079-17).
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially
explosive atmospheres:
• Only use the product in accordance with the approved motor data stated on the nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during service
and inspection is only permitted outside the classified area.
• Never start a pump without the proper priming.
• Before you start working with the product, make sure that the product and the control panel are
isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the approval
classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the level
regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the product
specification.
8 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 11
• Make sure that the equipment is properly maintained:
2D Barcode Here
• Monitor the pump components and the end temperature of the liquid.
• Maintain proper bearing lubrication.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not
limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system
Product approval standards
Regular standards
All standard products are approved according to CSA standards in Canada and UL standards in USA. The
drive unit degree of protection follows IP68. See the nameplate for maximum submersion, according to
standard IEC 60529.
All electrical ratings and performance of the motors comply with IEC 600341.
Introduction and Safety
Explosion-proofing standards
All explosion-proof products for use in explosive atmospheres are designed in compliance with one or
more of the following approvals:
• EN, ATEX Directive 94/9/EC
• FM According to NEC
• Class 1 Div 1 Groups “C”, and “D”
• Class 2 Div 1 Groups “E”, “F”, and “G”
• Class 3 Div 1 Hazardous Locations
ATEX/IECEx:
• Group: IIC
• Category: Ex ia
• Temperature Class: T4 (for ambients up to 100ºC)
• ATEX Marking: Ex II 1 G
CSA certification
Intrinsically safe for:
• Class I, Div. 1, Groups A, B, C, D
• Class II, Div. 1, Groups E, F, G
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 9
Page 12
SERIAL NO.
& YEAR OF
MANUFACTURE HERE.
Introduction and Safety
• Class III
• Certified to Canadian and US requirements
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT 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 ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
Limitations
Warranty claim
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
ITT products are high-quality products with expected reliable operation and long life. However, should the
need arise for a warranty claim, then contact your ITT representative.
10 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 13
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 your sales representative if anything is out of order.
Transportation and Storage
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Pump handling
WARNING:
• Make sure that the pump cannot roll or fall over and injure people or damage property.
• These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or
subject it to shock loads as this can damage the internal ceramic components.
NOTICE: Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the
pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 11
Page 14
Transportation and Storage
WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support this equipment
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-
• Do not attach sling ropes to shaft ends.
Table 1: Methods
Pump type Lifting method
A bare pump without lifting
handles
A bare pump with lifting handles Lift the pump by the handles.
A base-mounted pump Use slings under the pump casing and the drive unit, or under the base
A base-mounted pump with
baseplate lifting lugs
Examples
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.
toed shoes at all times.
Use a suitable sling attached properly to solid points like the casing, the
flanges, or the frames.
rails.
Use slings through the baseplate lifting lugs.
Figure 1: Example of a proper lifting method
NOTICE:
Do not use this lifting method to lift a Polyshield base with the pump and motor mounted. Doing so may
result in equipment damage.
Figure 2: Example of a proper lifting method
12 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 15
Transportation and Storage
NOTICE:
Do not use this lifting method to lift a Polyshield base with the pump and motor mounted. Doing so may
result in equipment damage.
Figure 3: Example of a proper lifting method
Figure 4: Example of a proper lifting method
NOTICE: When lifting a unit that does not have a way to secure the strap on the suction flange, you must
secure the strap around the frame adapter. Failure to do so may result in equipment damage.
Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Pump storage requirements
Storage requirements depend on the amount of time that you store the pump. The normal packaging is
designed only to protect the pump during shipping.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 13
Page 16
Transportation and Storage
Length of time in storage Storage requirements
Upon receipt/short-term (less than six months)
Long-term (more than six months)
Treat bearing and machined surfaces so that they are well preserved. Refer to drive unit and coupling
manufacturers for their long-term storage procedures.
You can purchase long-term storage treatment with the initial pump order or you can purchase it and
apply it after the pumps are already in the field. Contact your local ITT sales representative.
Frostproofing
This table shows to what degree the pump is frostproof:
When the pump is... Then...
Operating The pump is frostproof.
Immersed in a liquid The pump is frostproof.
Lifted out of a liquid into a temperature below freezing The impeller might freeze.
• Store in a covered and dry location.
• Store the unit free from dirt and vibrations.
• 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.
14 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 17
Product Description
General description
The 3180 models are horizontal, end-suction, centrifugal pumps designed for heavy-duty process
applications.
Figure 5: Model of 3180 and 3185
Product Description
Figure 6: Model of 3181 and 3186
Part description
Casing
Feature Description
Discharge This discharge has top centerline for ease in handling air-entrained liquids.
Gasket The gasket is fully confined between the casing and the stuffing box cover and is
composed of this material:
• 3180 and 3185: aramid fiber
• 3181 and 3186: spiral-wound metallic
Mounting
method
Flange drilling For the S, M, L, and XL groups, the flange drilling meets these standards:
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 15
• 3180 and 3185: foot mount
• 3181 and 3186: centerline mount
• 3180: ANSI class 125/150
• 3181: ANSI class 300
• 3185: ISO or JIS 16 bar
• 3186: ISO NP40 or JIS 40K
For the XL1, XL2-S, and XL2 groups, the flange drilling is ANSI class 150.
Page 18
Product Description
Impeller
Impeller option Description
Open with suction
sideplate (not available
on XL1, XL2-S, and
XL2)
• Provided as standard with models 3180 and 3185 (except on XL1, XL2-S,
and XL2)
• Provided as optional with models 3181 and 3186
• Available for all sizes of pumps (except on XL1, XL2-S, and XL2)
• Is fully open, end-suction type
• Contains Francis or radial design inlet
• Constructed with large balance holes and back pump-out vanes that reduce
stuffing box pressure and axial thrust
• Keyed to the shaft and held in position by an impeller locknut
• Sealed by a Viton O-ring
• Sealed on the sleeve side by a Teflon O-ring for a dry shaft design
• Handles the tough paper stock and process services
The suction sideplate has these benefits:
• Protects against casing wear
• Removed easily
• Secured to the casing with corrosion-resistant studs and capnuts
• Sealed with a gasket and O-ring
Enclosed with wear rings
(standard on XL1, XL2S, and XL2)
• Standard with the 3181 and 3186
• Optional with selected sizes of the S, M, L, and XL 3180 and 3185. Standard
on XL1, XL2-S, and XL2 3180 and 3185.
• Uses replaceable impeller wear ring and casing wear ring
• Wear ring configuration allows for axial impeller adjustment to renew and
maintain proper wear ring clearances
• Can handle fine solids
TM
Shearpeller
suction sideplate
with
• Provided as optional with eight sizes of models for 3180 and 3185
• Is fully open, end-suction type
• Constructed with radial design inlet
• Has scalloped shroud and back pump-out vanes that reduce axial thrust
• Can handle the tough recycle mill applications
• Can handle long, stringy solids without plugging or clogging
Stuffing box cover/seal chamber
The cover functions both as a way to seal the chamber and as a replaceable wear part. It is secured with a
series of clamping lugs at the outside diameter of models 3180 and 3185, and it is through-bolted with
capscrews on models 3181 and 3186. XL1, XL2-S, and XL2 sizes are through-bolted using a frame adapter
to secure the stuffing box cover or seal chamber.
The table shows the four available design options:
Seal chamber option Description
Packed box
• Uses five rings of 1/2 in. (12.5 mm) packing, plus a lantern ring
• Has a single flush connection at the lantern ring
• Has an optional second connection at the lantern ring and the stuffing box
throat
• Has a plain split gland
• Has a throat bushing
TaperBore™ PLUS
• Used with mechanical seals
• Uses an optional Vane Particle Ejector (VPE) ring for increased seal life
16 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 19
Power end
Seal chamber option Description
TaperBore™ PLUS with
packing conversion sleeve
Dynamic seal (not available
on XL1, XL2-S, and XL2)
• Only used with the 3181 and 3186
• Used with packing during startup, then converted to mechanical seal
• Only used with the S, M, L, and XL 3180 and 3185
• Used for tough applications where conventional mechanical seals or
packing require outside flush
• Contains a repeller mounted between the impeller and stuffing box cover
to pump the liquid out of the stuffing box while the pump is running
• Provides a static seal to prevent pumped fluid from leaking when the pump
is shut down
Part Description
Bearing
frame and
housing
For the S, M, L, and XL groups:
• The bearing frame and housing are constructed of cast iron.
• The frame is bolted and rabbeted to the stuffing box cover.
• The frame is sealed with labyrinth seals.
• No special parts are required to convert from grease to oil lubrication.
• The bearing frame cooling can be supplied as an option with oil lubrication.
• The bearing locknut and coupling extension are dimensioned in inches for models 3180 and
in millimeters for models 3185 and 3186.
For the XL1, XL2-S, and XL2 groups:
• The bearing frame and housing are constructed of cast iron.
• The frame is bolted and rabbeted to the frame adapter.
• The frame is sealed with labyrinth seals.
• Grease lubrication and bearing frame cooling are not available.
• The bearing locknut is in millimeters.
• The coupling extension is in inches.
Shaft
sleeve
For the S, M, L, and XL groups:
• The shaft sleeve is a renewable hook type, positively driven by the impeller key.
• One end is free to expand with possible temperature variations.
• A Teflon O-ring prevents leaks under the sleeve.
• The sleeve is dimensioned in inches for models 3180 and 3181 and in millimeters for
models 3185 and 3186.
For the XL1, XL2-S, and XL2 groups:
• The shaft sleeve is a renewable hook type, positively driven by the impeller key.
• One end is free to expand with possible temperature variations.
• A Teflon O-ring prevents leaks under the sleeve.
• The packing sleeve is dimensioned in millimeters, and the mechanical seal sleeve is
dimensioned in inches.
Bearings
• The inboard bearing carries only radial loads.
• The inboard bearing is free to float axially in the frame.
• The outboard bearings are a 40° angular-contact, duplex set, mounted back-to-back.
• The outboard bearings carry both radial and axial loads.
• The outboard bearings are locked onto the shaft by a threaded locknut.
Product Description
Hardware
All fasteners and tapped connections are metric.
Direction of rotation
The direction of rotation is clockwise (right hand) when viewed from the driver end.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 17
Page 20
Product Description
ISO 2858 conformance
The Models 3185 and 3186 conform to the ISO 2858 Standard where applicable. The ISO standard allows
for 125 mm flanges, which are nominal 5 in. flanges. Because ANSI standards no longer permit 5 in.
flanges, they are not used on models 3185 and 3186.
General description i-ALERT™ Condition Monitor
Description
The i-ALERT Condition Monitor is a compact, battery-operated monitoring device that continuously
measures the vibration and temperature of the pump power end. The condition monitor uses blinking red
LEDs to alert the pump operator when the pump exceeds pre-set vibration and temperature limits. This
allows the pump operator to make changes to the process or the pump before a catastrophic failure
occurs. The condition monitor is also equipped with a single green LED to indicate when it is operational
and has sufficient battery life.
Alarm mode
The condition monitor enters alarm mode when either vibration or temperature limits are exceeded over
two consecutive readings within a ten minute period. Alarm mode is indicated with two red flashing LEDs
within two second intervals.
Temperature and vibration limits
Variable Limit
Temperature 195°F (91°C)
Vibration 100% increase over the baseline level
Battery life
The i-ALERT Condition Monitor battery is not replaceable. You must replace the entire unit once
the battery runs out of power.
The battery life is not covered as part of the standard five-year pump warranty.
This table shows the average condition monitor battery life under normal and alarm-mode operating
conditions.
Condition monitor operational state Battery life
Normal operating and environmental conditions Three to five years
Alarm mode One year
Nameplate information
Important information for ordering
Every pump has nameplates that provide information about the pump. The nameplates are located on the
casing and the bearing frame.
When you order spare parts, identify this pump information:
• Model
• Size
• Serial number
• Item numbers of the required parts
Refer to the nameplate on the pump casing for most of the information. See Parts List for item numbers.
18 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 21
Nameplate on the pump casing using English units
Table 2: Explanation of nameplate on the pump casing
Nameplate field Explanation
IMPLR. DIA. Impeller diameter, in inches
MAX. DIA. Maximum impeller diameter, in inches
GPM Rated pump flow, in gallons per minute
FT HD Rated pump head, in feet
RPM Rated pump speed, revolutions per minute
MOD. Pump model
SIZE Size of the pump
STD. NO. Does not apply
MAT L. CONST. Material of which the pump is constructed
SER. NO. Serial number of the pump
MAX DSGN PSI
Maximum pressure at 100ºF according to the pump design
@ 100F
Product Description
Nameplate on the pump casing using metric units
Table 3: Explanation of the nameplate on the pump casing
Nameplate field Explanation
IMPLR. DIA. Impeller diameter
MAX. DIA. Maximum impeller diameter
M3/HR Rated pump flow, in cubic meters per hour
M HD Rated pump head, in meters
RPM Rated pump speed, in revolutions per minute
MOD. Pump model
SIZE Size of the pump
STD. NO. Does not apply
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 19
Page 22
Product Description
Nameplate field Explanation
MAT L. CONST Material of which the pump is constructed
SER. NO. Serial number of the pump
MAX. DSGN KG/
CM2@20°C
Nameplate on the bearing frame
Table 4: Explanation of the nameplate on the bearing frame
Nameplate field Explanation
MOD. Pump model
SIZE Size of the pump
SER. NO. Serial number of the pump
LUBE Lubricant, oil or grease
Kilograms per square centimeter at 20°C
ATEX nameplate
Nameplate field Explanation
II Group 2
2 Category 2
G/D Pump can be used when gas and dust are present
T4 Temperature class
NOTICE: Make sure that the code classifications on the pump are compatible with the specific
environment in which you plan to install the equipment. If they are not compatible, do not operate the
equipment and contact your ITT representative before you proceed.
20 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 23
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 ITT representative is recommended to ensure proper installation.
Failure to do so may result in equipment damage or decreased performance.
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.
Installation
Guideline Explanation/comment
Keep the pump as close to the liquid source as
practically possible.
Make sure that the space around the pump is
sufficient.
If you require lifting equipment such as a hoist or
tackle, make sure that there is enough space above
the pump.
Protect the unit from weather and water damage
due to rain, flooding, and freezing temperatures.
Do not install and operate the equipment in
closed systems unless the system is constructed
with properly-sized safety devices and control
devices.
Take into consideration the occurrence of
unwanted noise and vibration.
This minimizes the friction loss and keeps the suction
piping as short as possible.
This facilitates ventilation, inspection, maintenance,
and service.
This makes it easier to properly use the lifting
equipment and safely remove and relocate the
components to a safe location.
This is applicable if nothing else is specified.
Acceptable devices:
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices, consult
the engineer or architect in charge before you operate
the pump.
The best pump location for noise and vibration
absorption is on a concrete floor with subsoil
underneath.
If the pump location is overhead, undertake
special precautions to reduce possible noise
transmission.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 21
Consider a consultation with a noise specialist.
Page 24
1
2
3
4
5
6
1
3
2
4
5
Installation
Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid support for
the pump unit.
• The location and size of the foundation bolt holes must match those shown on the assembly drawing
provided with the pump data package.
• The foundation must weigh between two and three times the weight of the complete pump, baseplate,
and drive assembly.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you
tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for
the final bolt adjustment.
Sleeve-type bolts
1. Baseplate
2. Shims or wedges
3. Foundation
4. Sleeve
5. Dam
6. Bolt
J-type bolts
1. Baseplate
2. Shims or wedges
3. Foundation
4. Dam
5. Bolt
Baseplate-mounting procedures
Prepare the baseplate for mounting
1. Remove all the attached equipment from the baseplate.
2. Clean the underside of the baseplate completely.
22 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
3. If applicable, coat the underside of the baseplate with an epoxy primer.
Use an epoxy primer only if you used an epoxy-based grout.
4. Remove the rust-proofing coat from the machined mounting pads using an appropriate solvent.
5. Remove water and debris from the foundation-bolt holes.
Page 25
Install the baseplate using shims or wedges
1
1
Required tools:
• Two sets of shims or wedges for each foundation bolt
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure is applicable to cast iron and fabricated steel baseplates.
1. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from
entering the bolt holes.
2. Put the sets of wedges or shims on each side of each foundation bolt.
The sets of wedges should have a height of between 0.75 in. (19 mm) and 1.50 in. (38 mm).
Installation
1. Shims or wedges
Figure 7: Top view
1. Shims or wedges
Figure 8: Side view
3. Lower the baseplate carefully onto the foundation bolts.
4. Put the machinist's levels across the mounting pads of the driver and the mounting pads of the pump.
NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the
correct leveling. Failure to do so can result in equipment damage or decreased performance.
5. Level the baseplate both lengthwise and across by adding or removing shims or moving the wedges.
These are the leveling tolerances:
• A maximum difference of 0.125 in. (3.2 mm) lengthwise
• A maximum difference of 0.059 in. (1.5 mm) across
You can use the baseplate-leveling worksheet when you take the readings.
6. Hand-tighten the nuts for the foundation.
Install the baseplate using jackscrews
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 23
Tools required:
• Anti-seize compound
• Jackscrews
• Bar stock
Page 26
1
2
3
4
1
2
3
4
5
6
Installation
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure is applicable to the feature-fabricated steel baseplate and the advantage base baseplate.
1. Apply an anti-seize compound on the jackscrews.
The compound makes it easier to remove the screws after you grout.
2. Lower the baseplate carefully onto the foundation bolts and perform these steps:
a) Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce stress
concentrations.
b) Put the plates between the jackscrews and the foundation surface.
c) Use the four jackscrews in the corners in order to raise the baseplate above the foundation.
Make sure that the distance between the baseplate and the foundation surface is between 0.75 in.
(19 mm) and 1.50 in. (38 mm).
d) Make sure that the center jackscrews do not touch the foundation surface yet.
1. Jackscrew
2. Baseplate
3. Foundation
4. Plate
3. Level the driver mounting pads:
NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the
correct leveling. Failure to do so can result in equipment damage or decreased performance.
a) Put one machinist's level lengthwise on one of the two pads.
b) Put the other machinist's level across the ends of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and
across.
Use the baseplate-leveling worksheet when you take the readings.
1. Machinist's levels
2. Driver's mounting pads
3. Foundation bolts
4. Jackscrews
5. Grout hole
6. Pump's mounting pads
4. Turn the center jackscrews down so that they rest on their plates on the foundation surface.
24 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 27
1
2
3
4
5
6
Installation
5. Level the pump mounting pads:
NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the
correct leveling. Failure to do so can result in equipment damage or decreased performance.
a) Put one machinist's level lengthwise on one of the two pads.
b) Put the other level across the center of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and
across.
1. Driver's mounting pads
2. Machinist's levels
3. Foundation bolts
4. Jackscrews
5. Grout hole
6. Pump's mounting pads
6. Hand-tighten the nuts for the foundation bolts.
7. Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts if
necessary.
The correct level measurement is a maximum of 0.002 in./ft (0.0167 mm/m).
Spring mounted installation
WARNING:
Springs can store energy that can launch parts at a high velocity. Before you perform any tasks, make sure
that all springs are positively locked against free expansion.
NOTICE: The spring-mounted baseplate is designed only to support piping loads from thermal
expansion. You must support the suction and discharge piping individually. Failure to do so may result in
equipment damage.
Determine which spring-mounted baseplate you are working with:
If... Then...
The springs are of equal lengths with some mounted
above the baseplate and some mounted below the
baseplate.
The springs are of different lengths and mounted
below the baseplate.
Install the baseplate using spring mounting (first generation)
Check these items before you start this procedure:
• All springs in the first-generation spring-mounted baseplate are identical and have the same spring
constant.
• The foundation pads are not provided with the baseplate. Make sure that the foundation pads are 316
stainless steel plates, which have a 63 to 125 micro-inch surface finish.
• Make sure that the foundation pads are correctly installed on the foundation/floor. See the
instructions from the manufacturer.
Complete the steps in Install the baseplate using
spring mounting (first generation).
Complete the steps in Install the baseplate using
spring mounting (second generation).
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 25
Page 28
1
2
3
4
5
6
7
Installation
1. Put the baseplate on a support above the foundation/floor.
Make sure that there is enough space between the baseplate and the foundation/floor in order to
install the spring assemblies.
2. Assemble the spring assemblies:
a) Set a hex jam nut and a hex nut on a spring stud to the height of 2.00 in. (5.00 cm).
b) Install a bearing pad on the stud.
c) Hand-tighten the stud to the bearing pad.
d) Set the bottom adjusting nuts on the stud to the height (X) indicated on the certified GA
dimension drawing.
e) Install a flat washer on the stud.
f) Install a spring follower on the stud with the flat bottom facing downward.
g) Install a spring on the stud.
h) Install another spring follower with the flat bottom facing upward.
i) Install this subassembly from under the baseplate, pushing the stud up through the mounting
bracket.
j) Install a spring follower on the stud with the flat bottom facing downward.
k) Install another spring on the stud.
l) Install a spring follower with the flat bottom facing upward.
m) Install a flat washer on the stud.
n) Install a hex nut and a hex jam nut on the stud.
1. Hex jam nut
2. Follower
3. Flat washer
4. Bearing assembly
5. Spring
6. Hex nut
7. Stud
3. Repeat step 2 for each spring assembly.
4. Lower the baseplate so that the spring assemblies fit into the foundation pads.
5. Level the baseplate and make the final height adjustments:
a) Loosen the upper hex jam nuts and hex nuts.
26 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
b) Adjust the height and level the baseplate by moving the lower adjusting nuts.
Page 29
c) When the baseplate is level, tighten the upper hex nuts so that the upper springs are not loose in
the spring followers.
6. Fasten the lower and upper jam nuts on each spring assembly.
Install the baseplate using spring mounting (second generation)
Check these items before you start this procedure:
• The foundation pads are not provided with the baseplate. Make sure that the foundation pads are 316
stainless steel plates, which have a 63 to 125 micro-inch surface finish.
• Make sure that the foundation pads are correctly installed on the foundation/floor. See the
instructions from the manufacturer.
Installation
The springs in the second-generation spring-mounted baseplate are supplied in two sizes:
Free length of spring Spring rate Location Length of stud used
with the spring
7.125 in. (181 mm) 885 lbs/in.(149.72
newtons/mm)
11 in. (280 mm) 176 lbs/in.(30.82
newtons/mm)
1. Put the baseplate on a support above the foundation/floor.
Make sure that there is approximately 16 in. (406 mm) between the baseplate and the foundation/
floor in order to provide enough space to install the spring assemblies.
2. Apply an anti-galling compound to the threads of the studs, nuts, and bearing pads.
3. Assemble the spring assemblies:
a) Set a hex nut and a hex jam nut on a spring stud and thread it down 1 in. (25 mm).
b) Insert the stud from the top of the mounting bracket on the baseplate.
Refer to the GA outline dimension drawing in order to determine the correct length of the studs
for each location.
c) Install a follower with the flat side facing up.
d) Install a spring.
Refer to the GA outline dimension drawing in order to determine the correct spring for each
location.
e) Install a follower with the flat side facing down.
f) Install a flat washer, a hex nut, and a hex jam nut and thread them up 2 in. (54 mm).
g) Install a bearing pad on the lower end of the stud.
h) Hand-tighten the stud to the bearing pad.
The depth of the thread in the bearing pad is 1 in. (25 mm).
i) Set the bottom adjusting nuts on the stud to the heights (X1 and X2) indicated on the certified
GA dimension drawing.
Mounted under the
baseplate below the
pump
Mounted under the
baseplate below the
motor
16 in. (406 mm)
22 in. (559 mm)
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 27
Page 30
1
2
3
4
5
6
7
8
Installation
Adjust distances by moving the hex nut and the hex jam nut up or down.
4. Repeat step 3 for each stud and spring assembly.
5. Check the X1 and X2 dimensions again.
6. Lower the baseplate so that the spring assemblies fit into the foundation pads.
The weight of the baseplate compresses the springs, which leaves the upper nuts loose. You might
have to level the baseplate.
1. Hex jam nut
2. Follower
3. Flat washer
4. Foundation pad
5. Bearing assembly
6. Spring
7. Hex nut
8. Stud
7. Level the baseplate and make the final height adjustments:
a) Thread each of the upper hex nuts down to the baseplate mounting bracket.
b) Turn the upper hex nuts on the studs that hold the larger springs under the motor. This allows
you to compress each spring until the baseplate is level.
c) Hand tighten the upper hex nuts on the studs that hold the smaller springs under the pump.
Hand tighten only in cold setting.
28 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 31
• Make sure the distance (H) from the bottom of the baseplate to the floor mounting pads is equal
to the dimension shown on the certified GA dimension drawing.
• Make sure the height of the centerline of the suction flange is equal to the dimension shown on
the certified GA dimension drawing
• In order to level the baseplate, the X1 and X2 dimensions can vary slightly from the dimensions
shown on the certified GA dimension drawing.
8. Fasten the lower and upper hex jam nuts against the hex nuts on each spring assembly.
NOTICE: Do not cut off the additional length of the studs. The additional length is needed in order
to remove the springs safely. Keep the additional threads lubricated with grease or a rust inhibitor.
Installation
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 29
Page 32
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1)____________________
2)____________________
3)____________________
4)____________________
5)____________________
6)____________________
7)____________________
8)____________________
9)____________________
10)___________________
11)___________________
12)___________________
13)___________________
14)___________________
15)___________________
16)___________________
17)___________________
18)___________________
Level measurements
Installation
Baseplate-leveling worksheet
30 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 33
Install the pump, driver, and coupling
1. Mount and fasten the pump on the baseplate. Use applicable bolts.
2. Mount the driver on the baseplate. Use applicable bolts and hand tighten.
3. Install the coupling.
See the installation instructions from the coupling manufacturer.
Pump-to-driver alignment
Precautions
WARNING:
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or
unintended contact of rotating parts. Follow the coupling installation and operation procedures from
the coupling manufacturer.
• 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.
NOTICE: Proper alignment is the responsibility of the installer and the user of the unit. Check the pumpto-driver alignment before you operate the unit. Failure to do so can result in equipment damage or
decreased performance.
Installation
NOTICE: Proper alignment is the responsibility of the installer and the user of the unit. Check the
alignment of frame-mounted units before you operate the unit. Failure to do so can result in equipment
damage or decreased performance.
Alignment checks
When to perform alignment checks
You must perform alignment checks under these circumstances:
• The process temperature changes.
• The piping changes.
• The pump has been serviced.
Types of alignment checks
Type of check When it is used
Initial alignment (cold alignment)
check
Final alignment (hot alignment)
check
Initial alignment (cold alignment) checks
When Why
Before you grout the baseplate This ensures that alignment can be accomplished.
After you grout the baseplate This ensures that no changes have occurred during the grouting
After you connect the piping This ensures that pipe strains have not altered the alignment.
Prior to operation when the pump and the driver are at ambient
temperature.
After operation when the pump and the driver are at operating
temperature.
process.
If changes have occurred, you must alter the piping to remove pipe
strains on the pump flanges.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 31
Page 34
Installation
Final alignment (hot alignment) checks
When Why
After the first run This ensures correct alignment when both the pump and the driver
are at operating temperature.
Periodically This follows the plant operating procedures.
Permitted indicator values for alignment checks
NOTICE: The specified permitted reading values are valid only at operating temperature. For cold
settings, other values are permitted. You must use the correct tolerances. Failure to do so can result in
misalignment and reduced pump reliability.
When dial indicators are used to check the final alignment, the pump and drive unit are correctly aligned
when the total indicator runout is a maximum of 0.002 in. (0.05 mm) at operating temperature.
Cold settings for parallel vertical alignment
Introduction
This section shows the recommended preliminary (cold) settings for electric motor-driven pumps based on
different temperatures of pumped fluid. Consult driver manufacturers for recommended cold settings for
other types of drivers such as steam turbines and engines.
Models 3181 and 3186 should be set at 50°F (10°C) for all temperatures due to the centerline-mounted
casing.
Recommended settings for model 3180 and 3185
Pumped fluid temperature Recommended setting for driver shaft
50°F (10°C) 0.002 in. (0.05 mm), low
150°F (65°C) 0.001 in. (0.03 mm), high
250°F (120°C) 0.005 in. (0.12 mm), high
350°F (175°C) 0.009 in. (0.23 mm), high
450°F (218°C) 0.013 in. (0.33 mm), high
Alignment measurement guidelines
Guideline Explanation
Rotate the pump coupling half and the driver coupling half
together so that the indicator rods have contact with the same
points on the driver coupling half.
Move or shim only the driver in order to make adjustments. This prevents strain on the piping
Make sure that the hold-down bolts for the driver feet are tight
when you take indicator measurements.
Make sure that the hold-down bolts for the driver feet are loose
before you make alignment corrections.
Check the alignment again after any mechanical adjustments. This corrects any misalignments that an
This prevents incorrect measurement.
installations.
This keeps the driver stationary since
movement causes incorrect
measurement.
This makes it possible to move the driver
when you make alignment corrections.
adjustment may have caused.
Attach the dial indicators for alignment
You must have two dial indicators in order to complete this procedure.
1. Attach two dial indicators on the pump coupling half (X):
a) Attach one indicator (P) so that the indicator rod comes into contact with the perimeter of the
driver coupling half (Y).
32 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 35
This indicator is used to measure parallel misalignment.
P
A
Y
X
X
Y
Shims
b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner end of
the driver coupling half.
This indicator is used to measure angular misalignment.
2. Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver
coupling half (Y) but do not bottom out.
3. Adjust the indicators if necessary.
Pump-to-driver alignment instructions
Perform angular alignment for a vertical correction
Installation
1. Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the driver
coupling half (Y).
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.
When the
reading
value is...
Negative The coupling halves are farther apart at the bottom than at the top. Perform one of
Positive The coupling halves are closer at the bottom than at the top. Perform one of these
Then...
these steps:
• Add shims in order to raise the feet of the driver at the shaft end.
• Remove shims in order to lower the feet of the driver at the other end.
steps:
• Remove shims in order to lower the feet of the driver at the shaft end.
• Add shims in order to raise the feet of the driver at the other end.
Figure 9: Side view of an incorrect vertical alignment
4. Repeat the previous steps until the permitted reading value is achieved.
Perform angular alignment for a horizontal correction
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 33
1. Set the angular alignment indicator (A) to zero on left side of the driver coupling half (Y), 90° from
the top-center position (9 o’clock).
Page 36
Y X
Y
X
Shims
Installation
2. Rotate the indicator through the top-center position to the right side, 180° from the start position
(3 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The coupling halves are farther apart on the right side than
the left. Perform one of these steps:
• Slide the shaft end of the driver to the left.
• Slide the opposite end to the right.
Positive The coupling halves are closer together on the right side
than the left. Perform one of these steps:
• Slide the shaft end of the driver to the right.
• Slide the opposite end to the left.
Figure 10: Top view of an incorrect horizontal alignment
4. Repeat the previous steps until the permitted reading value is achieved.
Perform parallel alignment for a vertical correction
Before you start this procedure, make sure that the dial indicators are correctly set up.
A unit is in parallel alignment when the parallel indicator (P) does not vary by more than 0.002 in.
(0.05 mm) as measured at four points 90° apart at the operating temperature.
1. Set the parallel alignment indicator to zero at the top-center position (12 o’clock) of the driver
coupling half.
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.
When the
reading value
is...
Negative The pump coupling half (X) is lower than the driver coupling half (Y). Remove
Positive The pump coupling half (X) is higher than the driver coupling half. Add shims of
NOTICE:
You must use an equal amount of shims with each driver foot to prevent misalignment. Failure to do
so can result in equipment damage or decreased performance.
Then...
shims of a thickness equal to half of the indicator reading value under each driver
foot.
a thickness equal to half of the indicator reading value to each driver foot.
Figure 11: Side view of an incorrect vertical alignment
34 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 37
4. Repeat the previous steps until the permitted reading value is achieved.
Y
X
Perform parallel alignment for a horizontal correction
A unit is in parallel alignment when the parallel indicator (P) does not vary by more than 0.002 in.
(0.05 mm) as measured at four points 90° apart at the operating temperature.
1. Set the parallel alignment indicator to zero on the left side of the driver coupling half (Y), 90° from
the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start position
(3 o’clock).
3. Record the indicator reading.
When the reading value is... Then...
Negative The driver coupling half is to the left of the pump coupling half.
Positive The driver coupling half is to the right of the pump coupling half.
4. Slide the driver carefully in the appropriate direction.
NOTICE: Make sure to slide the driver evenly. Failure to do so can negatively affect horizontal
angular correction.
Installation
Figure 12: Top view of an incorrect horizontal alignment
5. Repeat the previous steps until the permitted reading value is achieved.
Perform complete alignment for a vertical correction
A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P) do not
vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart.
1. Set the angular and parallel dial indicators to zero at the top-center position (12 o’clock) of the driver
coupling half (Y).
2. Rotate the indicators to the bottom-center position (6 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment until you
obtain the permitted reading values.
Perform complete alignment for a horizontal correction
A unit is in complete alignment when both the angular indicator (A) and the parallel indicator (P) do not
vary by more than 0.002 in. (0.05 mm) as measured at four points 90° apart.
1. Set the angular and parallel dial indicators to zero at the left side of the driver coupling half (Y), 90°
from the top-center position (9 o’clock).
2. Rotate the indicators through the top-center position to the right side, 180° from the start position
(3 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment until you
obtain the permitted reading values.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 35
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Installation
Grout the baseplate
Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the instructions
provided by the grout manufacturer.
• Grout: Non-shrink grout is recommended.
1. Clean all the areas of the baseplate that will come into contact with the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.
4. Pour grout through the grout hole into the baseplate up to the level of the dam.
When you pour the grout, remove air bubbles from it by using one of these methods:
• Puddle with a vibrator.
• Pump the grout into place.
5. Allow the grout to set.
1. Baseplate
2. Shims or wedges
3. Grout
4. Foundation
5. Sleeve
6. Dam
7. Bolt
6. Fill the remainder of the baseplate with grout, and allow the grout to set for at least 48 hours.
1. Baseplate
2. Grout
3. Foundation
4. Dam
5. Bolt
7. Tighten the foundation bolts.
8. Recheck the alignment.
Bypass-piping considerations
When to use a bypass line
Provide a bypass line for systems that require operation at reduced flows for prolonged periods. Connect a
bypass line from the discharge side (before any valves) to the source of suction.
36 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 39
When to install a minimum-flow orifice
You can size and install a minimum-flow orifice in a bypass line in order to prevent bypassing excessive
flows. Consult your ITT representative for assistance in sizing a minimum-flow orifice.
When a minimum-flow orifice is unavailable
Consider an automatic recirculation control valve or solenoid-operated valve if a constant bypass
(minimum-flow orifice) is not possible.
Piping checklists
General piping checklist
Precautions
CAUTION:
• Never draw piping into place by using force at the flanged connections of the pump. This can impose
dangerous strains on the unit and cause misalignment between the pump and driver. Pipe strain
adversely affects the operation of the pump, which results in physical injury and damage to the
equipment.
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the
suction side. This action can result in decreased performance, unexpected heat generation, and
equipment damage.
Installation
Piping guidelines
Checklist
Guidelines for piping are given in the Hydraulic Institute Standards available from the Hydraulic Institute
at 9 Sylvan Way, Parsippany, NJ 07054-3802. You must review this document before you install the pump.
Check Explanation/comment Checked
Check that all piping is supported
independently of, and lined up
naturally with, the pump flange.
Keep the piping as short as
possible.
Check that only necessary fittings
are used.
Do not connect the piping to the
pump until:
• The grout for the baseplate or
sub-base becomes hard.
• The hold-down bolts for the
pump and the driver are
tightened.
Make sure that all the piping
joints and fittings are airtight.
If the pump handles corrosive
fluids, make sure that the piping
allows you to flush out the liquid
before you remove the pump.
This helps to prevent:
• Strain on the pump
• Misalignment between the pump and the drive unit
• Wear on the pump bearings and the coupling
• Wear on the pump bearings, seal, and shafting
This helps to minimize friction losses.
This helps to minimize friction losses.
—
This prevents air from entering the piping system or
leaks that occur during operation.
—
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 37
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Installation
Check Explanation/comment Checked
If the pump handles liquids at
elevated temperatures, make sure
that the expansion loops and
joints are properly installed.
Example: Installation for expansion
Correct Incorrect
This illustration shows a correct installation for
expansion:
This helps to prevent misalignment due to linear
expansion of the piping.
This illustration shows an incorrect installation for
expansion:
1. Expansion loop/joint
Suction-piping checklist
Performance curve reference
CAUTION:
Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction
side. This action can result in decreased performance, unexpected heat generation, and equipment damage.
Suction-piping checks
Check Explanation/comment Checked
Check that the distance between the inlet flange of the
pump and closest flow disruption (elbow, valve,
strainer, or expansion joint) is at least five pipe
diameters.
Check that elbows in general do not have sharp bends. See the Example sections for
Check that the suction piping is one or two sizes larger
than the suction inlet of the pump.
Install an eccentric reducer between the pump inlet and
the suction piping.
Suction pipe reducers should have no more than two
pipe diameter changes per reducer.
This minimizes the risk of cavitation in
the suction inlet of the pump due to
turbulence.
See the Example sections for
illustrations.
illustrations.
The suction piping must never have a
smaller diameter than the suction inlet
of the pump.
See the Example sections for
illustrations.
38 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 41
Check Explanation/comment Checked
Check that the eccentric reducer at the suction flange
of the pump has the following properties:
• Sloping side down
• Horizontal side at the top
If suction strainers or suction bells are used, check that
they are at least three times the area of the suction
piping.
If more than one pump operates from the same liquid
source, check that separate suction-piping lines are used
for each pump.
If necessary, make sure that the suction piping includes
a drain valve and that it is correctly installed.
Liquid source below the pump
Check Explanation/comment Checked
Make sure that the suction piping is free from
air pockets.
Installation
See the example illustrations.
Suction strainers help to prevent
clogging.
Mesh holes with a minimum diameter
of 1/16 in. (1.6 mm) are
recommended.
This recommendation helps you to
achieve a higher pump performance.
—
This helps to prevent the occurrence of air
and cavitation in the pump inlet.
Check that the suction piping slopes upwards
from the liquid source to the pump inlet.
If the pump is not self-priming, check that a
device for priming the pump is installed.
Liquid source above the pump
Check Explanation/comment Checked
Check that an isolation valve is installed in the
suction piping at a distance of at least two times
the pipe diameter from the suction inlet.
Make sure that the suction piping is free from
air pockets.
Check that the piping is level or slopes
downward from the liquid source.
Make sure that no part of the suction piping
extends below the suction flange of the pump.
Make sure that the suction piping is adequately
submerged below the surface of the liquid
source.
—
Use a foot valve with a diameter that is at least
equivalent to the diameter of the suction
piping.
This permits you to close the line during
pump inspection and maintenance.
Do not use the isolation valve to throttle the
pump. Throttling can cause these problems:
• Loss of priming
• Excessive temperatures
• Damage to the pump
• Voiding the warranty
This helps to prevent the occurrence of air
and cavitation in the pump inlet.
—
—
This prevents air from entering the pump
through a suction vortex.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 39
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Installation
Example: Elbow (or other flow disruption) close to the pump suction inlet
Correct Incorrect
The correct distance between the inlet flange of the pump
and the closest flow disruption (elbow, valve, strainer, or
expansion joint) must be a least five pipe diameters.
NOTICE: This illustration shows a correctly installed
elbow.
Example: Suction piping equipment
Correct Incorrect
1. Suction pipe sloping upwards from liquid source
2. Long-radius elbow
3. Strainer
4. Foot valve
5. Eccentric reducer with a level top
NOTICE: This illustration shows correctly
installed equipment for the suction piping.
NOTICE: This illustration shows an
incorrectly installed elbow.
1. Air pocket, because the eccentric reducer is not
used and because the suction piping does not slope
gradually upward from the liquid source
NOTICE: This illustration shows incorrectly
installed equipment for the suction piping.
Discharge piping checklist
Checklist
Check Explanation/comment Checked
40 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Check that an isolation valve is
installed in the discharge line.
The isolation valve is required for:
• Priming
• Regulation of flow
• Inspection and maintenance of the pump
Page 43
Check Explanation/comment Checked
1
2
3
4
2
1
Check that a check valve is installed in
the discharge line, between the
isolation valve and the pump discharge
outlet.
If increasers are used, check that they
are installed between the pump and the
check valve.
If quick-closing valves are installed in
the system, check that cushioning
devices are used.
Example: Discharge piping equipment
Correct Incorrect
Installation
See Example: Discharge piping equipment for
illustrations.
The location between the isolation valve and the
pump allows inspection of the check valve.
The check valve prevents damage to the pump and
seal due to the back flow through the pump, when
the drive unit is shut off. It is also used to restrain
the liquid flow.
See Example: Discharge piping equipment for
illustrations.
See Example: Discharge piping equipment for
illustrations.
This protects the pump from surges and water
hammer.
1. Bypass line
2. Shut-off valve
3. Check valve
4. Discharge isolation valve
1. Check valve (incorrect position)
2. The isolation valve should not be positioned
between the check valve and the pump.
Auxiliary-piping checklist
Precautions
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 41
WARNING:
• Cooling systems such as those for bearing lubrication and mechanical-seal systems must be operating
properly to prevent excess heat generation, sparks, and premature failure.
• Sealing systems that are not self-purging or self-venting, such as plan 23, require manual venting prior
to operation. Failure to do so will result in excess heat generation and seal failure.
NOTICE:
The mechanical seal must have an appropriate seal-flush system. Otherwise, excess heat generation and
seal failure can occur.
Page 44
Installation
When to install
Checklist
You may need to install auxiliary piping for bearing cooling, seal-chamber cover cooling, mechanical seal
flush, or other special features supplied with the pump. Consult the pump data sheet for specific auxiliary
piping recommendations.
Check Explanation/
Check that the minimum flow for each component is 1 gpm (4 lpm).
If the bearing and seal chamber cover cooling are provided, then the
auxiliary piping must flow at 2 gpm (8 lpm).
Check that the cooling water pressure does not exceed 100 psig (7.0 kg/
cm2).
Final piping checklist
Check Explanation/comment Checked
Check that the shaft rotates smoothly. Rotate the shaft by hand. Make sure there is no
Re-check the alignment to make sure that
pipe strain has not caused any
misalignment.
Checked
comment
–
–
rubbing that can lead to excess heat generation or
sparks.
If pipe strain exists, then correct the piping.
42 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 45
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation, and
Shutdown
Preparation for startup
WARNING:
• Failure to follow these precautions before you start the pump 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.
• 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.
Precautions
NOTICE:
• Verify the driver settings before you start the 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 clean 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.
Remove the coupling guard
1. Remove the nut, bolt, and washers from the slotted hole in the center of the coupling guard.
2. Slide the driver half of the coupling guard toward the pump.
3. Remove the nut, bolt, and washers from the driver half of the coupling guard.
4. Remove the driver-side end plate.
5. Remove the driver half of the coupling guard:
a) Slightly spread the bottom apart.
b) Lift upwards.
6. Remove the remaining nut, bolt, and washers from the pump half of the coupling guard.
It is not necessary to remove the end plate from the pump side of the bearing housing. You can access
the bearing-housing tap bolts without removing this end plate if maintenance of internal pump parts
is necessary.
7. Remove the pump half of the coupling guard:
a) Slightly spread the bottom apart.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 43
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Commissioning, Startup, Operation, and Shutdown
b) Lift upwards.
1. Coupling guard
2. Coupling
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. Lock out power to the driver.
2. Make sure that the coupling hubs are fastened securely to the shafts.
3. Make sure that the coupling spacer is removed.
The pump ships with the coupling spacer removed.
4. Unlock power to the driver.
5. 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 bearing housing, or close-coupled frame.
6. Lock out power to the driver.
Impeller-clearance check
The impeller-clearance check ensures the following:
• The pump turns freely.
• The pump operates at optimal efficiency for long equipment life and low energy consumption.
Impeller axial clearances
Total axial adjustment
The total axial adjustment of the impeller between the suction sideplate or case ring and the stuffing box
cover should be between 0.028 in. and 0.087 in. (0.7 mm and 2.2 mm).
44 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 47
Cold temperature axial clearance for the open and closed impeller
For pumped liquid temperatures over 122°F (50°C), the cold setting must be increased to the values in this
table. This prevents the impeller from contacting the suction sideplate or wear ring due to shaft expansion
from the higher operating temperatures.
Temperature Clearance
122°F (50°C) 0.015 in. (0.38 mm)
212°F (100°C) 0.018 in. (0.45 mm)
302°F (150°C) 0.020 in. (0.50 mm)
392°F (200°C) 0.022 in. (0.55 mm)
446°F (230°C) 0.026 in. (0.65 mm)
Check the Shearpeller™ axial clearance
The Shearpeller™ requires a large front clearance in order to handle stringy solids. The front clearance
between the Shearpeller™ and the suction sideplate is 0.375 in. (9.50 mm). With this large clearance, the
pump is not as sensitive to small changes in the front clearance. No cold setting is required with the
Shearpeller™ option due to the large clearances.
1. Back the Shearpeller™ up until the back pump-out vanes contact the seal chamber.
2. Move the Shearpeller™ forward 0.062 in. (1.57 mm).
The total axial adjustment of the Shearpeller™ between the suction sideplate and the seal chamber is 0.437
in. (11.00 mm).
Commissioning, Startup, Operation, and Shutdown
Impeller-clearance setting
Importance of a proper impeller clearance
A proper impeller clearance ensures that the pump runs at high performance.
WARNING:
• 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 you use a cartridge mechanical seal, you must install the centering clips and loosen the set screws
before you set the impeller clearance. Failure to do so could result in sparks, heat generation, and
mechanical seal damage.
The clearance is set at 0.015 in. (0.4 mm) at the factory but could change due to piping attachment during
installation. A change in pump performance may be noted over time by a drop in head or flow or an
increase in power required.
Impeller clearance methods
You can set the impeller clearance with either of these methods:
• Dial indicator method
• Feeler gauge method
Set the impeller clearance - dial indicator method
WARNING:
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. Remove the coupling guard.
2. Set the indicator so that the button contacts either the shaft end or the face of the coupling.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 45
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Commissioning, Startup, Operation, and Shutdown
3. Loosen the jam nuts (423B) on the jack bolts (371A), and then back the bolts out about two turns.
4. Tighten the locking bolts evenly (370C), bringing the bearing housing (134A) towards the frame (228)
until the impeller contacts the casing.
5. Turn the shaft to ensure that there is contact between the impeller and the sideplate or wear ring.
6. Set the indicator to zero and loosen the locking bolt (370C) about one turn.
7. Thread in the jack bolts (371A) until the jack bolts evenly contact the bearing frame.
8. Tighten the jack bolts evenly about one flat at a time, moving the bearing housing (134A) away from
the bearing frame until the indicator shows the correct clearance.
Refer to the impeller clearance table to determine the correct clearance.
9. Tighten the bolts evenly in this order:
a) Tighten the locking bolts (370C).
b) Tighten the jack bolts (371A).
Make sure to keep the indicator reading at the proper setting.
10. Make sure the shaft turns freely.
11. Replace the coupling guard.
12. Check both the thrust (332A) and the radial (333A) labyrinth seals to make sure they are seated
properly in the housing.
Set the impeller clearance - feeler gauge method
WARNING:
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. Lock out the driver power and remove the coupling guard.
2. Loosen the jam nuts (423B) on the jack bolts (371A), and then back the bolts out about two turns.
3. Evenly tighten the locking bolts (370C), bringing the bearing housing (134A) towards the frame (228)
until the impeller contacts the casing.
4. Turn the shaft to ensure that there is contact between the impeller and the sideplate or wear ring.
5. With a set of feeler gauges, measure and record the gap between the bearing housing and the frame.
6. Turn back the locking bolt (370C) one turn.
7. Add the proper impeller clearances to the feeler gauge stack and back the housing away from the
frame with the adjusters (371A) until the feeler gauge fits.
Evenly tighten adjuster bolts (371A) (about one flat at a time) in making this adjustment.
8. Evenly tighten the locking bolts (370C) and then the adjuster bolts (371A) while keeping the indicator
reading at the proper setting.
9. Make sure the shaft turns freely.
10. Replace the coupling guard.
11. Check both the thrust (332A) and radial (333A) labyrinth seals to make sure they are seated properly
in the housing.
Couple the pump and driver
WARNING:
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.
46 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
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Commissioning, Startup, Operation, and Shutdown
Couplings must have proper certification to be used in an ATEX classified environment. Use the
instructions from the coupling manufacturer in order to lubricate and install the coupling.
1. Coupling guard
2. Coupling
Figure 13: Coupling guard assembly
Install the coupling guard
WARNING:
• Never operate a pump without a properly installed coupling guard. Personal injury will occur if you
run the pump without a coupling guard.
• 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.
• The coupling used in an Ex-classified environment must be properly certified and must be
constructed from a non-sparking material.
Required parts:
1. End plate, drive end
2. End plate, pump end
3. Guard half, 2 required
4. 3/8-16 nut, 3 required
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 47
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Commissioning, Startup, Operation, and Shutdown
5. 3/8 in. washer
6. 3/8-16 x 2 in. hex head bolt, 3 required
1. De-energize the motor, place the motor in a locked-out position, and place a caution tag at the starter
that indicates the disconnect.
2. Put the pump-side end plate in place.
If the pump-side end plate is already in place, make any necessary coupling adjustments and then
proceed to the next step.
3. Put the pump-half of the coupling guard in place:
a) Slightly spread the bottom apart.
b) Place the coupling guard half over the pump-side end plate.
1. Annular groove
2. Pump-side end plate
3. Driver
4. Pump half of the coupling guard
The annular groove in the coupling guard half must fit around the end plate.
1. Annular groove
2. End plate (pump end)
3. Guard half
4. Use a bolt, a nut, and two washers to secure the coupling guard half to the end plate. Tighten securely.
48 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
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Commissioning, Startup, Operation, and Shutdown
1. Nut
2. Washer
3. Bolt
5. Put the driver half of the coupling guard in place:
a) Slightly spread the bottom apart.
b) Place the driver half of the coupling guard over the pump half of the coupling guard.
The annular groove in the coupling guard half must face the motor.
6. Place the driver-side end plate over the motor shaft.
7. Place the driver-side end plate in the annular groove of the driver-half of the coupling guard.
8. Use a bolt, a nut, and two washers to secure the coupling guard half to the end plate. Hand-tighten
only.
The hole is located on the driver-side of the coupling guard half.
9. Slide the driver-half of the coupling guard towards the motor so that the coupling guard completely
covers the shafts and coupling.
10. Use a nut, a bolt, and two washers to secure the coupling guard halves together.
11. Tighten all nuts on the guard assembly.
WARNING:
Never operate the pump without the coupling guard correctly installed.
Bearing lubrication
WARNING:
Make sure to properly lubricate the bearings. Failure to do so can result in excess heat generation, sparks,
and premature failure.
NOTICE: Be certain to check the greasing on a pump that has been out of service for a long period of
time and re-grease if necessary.
Pumps are shipped without oil. You must lubricate oil-lubricated bearings at the job site.
Grease-lubricated bearings are lubricated at the factory.
The bearing manufacturer fills greased-for-life bearings with grease and seals them at the factory. You do
not need to lubricate or seal these bearings.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 49
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Commissioning, Startup, Operation, and Shutdown
Oil volumes
Oil volume requirements
This table shows the required amount of oil for oil-lubricated bearings.
Frame Quarts Liters
S 1.1 1.0
M 2.1 2.0
L 2.1 2.0
XL 3.2 3.0
XL1 12.2 11.6
XL2-S and XL2 24.0 22.7
Lubricating oil requirements
Quality requirements
Use a high quality turbine oil with rust and oxidation inhibitors.
Lubricating oil requirements
ISO grade ISO viscosity grade 68 ISO viscosity grade 100
Approximate SSU at 100°F (38°C) 300 470
DIN 51517 C68 C100
Kinematic viscosity at 105°F
(40°C) mm2/sec
Bearing temperature below
180°F (82°C)
68 100
Bearing temperature above
180°F (82°C)
Acceptable oil for lubricating bearings
Acceptable lubricants
Brand Lubricant type
Chevron GTS Oil 68
Exxon Teresstic EP 68
Mobil DTE 26 300 SSU @ 100°F (38°C)
Philips Mangus Oil 315
Gulf Harmony 68
Lubricate the bearings with oil
WARNING:
Make sure to properly lubricate the bearings. Failure to do so can result in excess heat generation, sparks,
and premature failure.
• Fill the bearing frame with oil:
MM motor oil SAE 20-20W
HDS motor oil SAE 20-20W
50 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 53
If... Then...
1
You do not
have the
constant
level oiler
option
You do
have the
constant
level oiler
option
Pour oil in the filler connection located on top of the bearing frame until the level reaches
the mark in the middle of the sight glass. Use a high-quality turbine type oil with rust and
oxidation inhibitors.
The Watchdog® oiler system was designed for use on closed system environments. The
Inpro VBXX-D labyrinth seals used on these pumps can create a situation where unequal
pressure causes the oiler to overfill. This might occur during intermittent operation. In
order to eliminate the pressure differential that creates this problem, Watchdog supplies a
breather with a filter.
If plant environments or requirements are not suitable for vented bearing frames, then do
not use the Watchdog oiler.
Install the Watchdog oiler in the connection for the sight glass. The oiler does not require
any setting dimensions.
Commissioning, Startup, Operation, and Shutdown
1. Control point that determines the level of the oil in the oiler
Greased-for-life bearing lubrication
The bearing manufacturer fills greased-for-life bearings with grease and seals them at the factory. You do
not need to lubricate or seal these bearings. Refer to the Maintenance chapter for re-greasing and
maintenance procedures for these bearings.
Shaft-sealing options
In most cases, the manufacturer seals the shaft before shipping the pump. If your pump does not have a
sealed shaft, see the Shaft-seal maintenance section in the Maintenance chapter.
This model uses these types of shaft seals:
• Cartridge mechanical seal
• Conventional inside-component mechanical seal
• Dynamic seal
• Packed-stuffing-box option
Mechanical seal options
Pumps are usually shipped with mechanical seals installed. If they are not, then refer to the mechanical seal
manufacturer's installation instructions.
These are the mechanical seal options for this pump:
• Cartridge mechanical seal
• Conventional inside component mechanical seal
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 51
Page 54
Commissioning, Startup, Operation, and Shutdown
Connection of sealing liquid for mechanical seals
Seal lubrication is required
Seal faces must have liquid film between them for proper lubrication. Locate the taps using the illustrations
shipped with the seal.
Seal flushing methods
You can use these methods in order to flush or cool the seal:
Method Description
Product flush Run the piping so that the pump pushes the pumped fluid from the casing and
injects it into the seal gland. If necessary, an external heat exchanger cools the
pumped fluid before it enters the seal gland.
External flush Run the piping so that the pump injects a clean, cool, compatible liquid directly
into the seal gland. The pressure of the flushing liquid must be 5 to 15 psi (0.35 to
1.01 kg/cm2) greater than the seal chamber pressure. The injection rate must be 0.5
to 2 gpm (2 to 8 lpm).
Other You can use other methods that employ multiple gland or seal chamber
connections. Refer to the mechanical seal reference drawing and seal flush/cooling
piping diagrams.
Packed stuffing box option
WARNING:
Packed stuffing boxes are not allowed in an ATEX-classified environment.
The factory does not install the packing, lantern ring, or split gland.
These parts are included with the pump in the box of fittings. Before you start the pump, you must install
the packing, lantern ring, and split gland according to the Packed stuffing box maintenance section in the
Maintenance chapter.
Connection of sealing liquid for a packed stuffing box
WARNING:
Packed stuffing boxes are not allowed in an ATEX-classified environment.
NOTICE:
Make sure to lubricate the packing. Failure to do so may result in shortening the life of the packing and the
pump.
You must use an external sealing liquid under these conditions:
• The pumped fluid includes abrasive particles.
• The stuffing-box pressure is below atmospheric pressure when the pump is running with a suction lift
or when the suction source is in a vacuum. Under these conditions, packing is not cooled and
lubricated and air is drawn into pump.
Conditions for application of an external liquid
If... Then...
The stuffing box pressure is above atmospheric
pressure and the pumped fluid is clean.
52 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Normal gland leaks of 40 to 60 drops per minute is
usually sufficient to lubricate and cool the packing.
You do not need sealing liquid.
Page 55
If... Then...
The stuffing box pressure is below atmospheric
pressure or the pumped fluid is not clean.
An outside source of clean compatible liquid is
required.
Seal the shaft with a packed stuffing box
WARNING:
Packed stuffing boxes are not allowed in an ATEX-classified environment.
CAUTION:
Never replace the packing until the driver is properly locked out and the coupling spacer is removed.
Pumps are shipped without the packing, lantern ring, or split gland installed. These parts are included with
the box of fittings shipped with each pump and must be installed before startup.
1. Carefully clean the stuffing-box bore.
2. Twist the packing enough to get it around the shaft.
Commissioning, Startup, Operation, and Shutdown
An outside source of clean compatible liquid is
required.
You must connect the piping to the lantern ring
connection with a 40 to 60 drops-per-minute leak
rate. The pressure must be 15 psi (1.01 kg/cm2)
above the stuffing box pressure.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 53
Page 56
Packing Rings
Correct
Incorrect
Lantern Rings
Correct
Incorrect
3
1
2
Commissioning, Startup, Operation, and Shutdown
1. Lantern ring flush connection
2. Split gland (non-quench)
3. Lantern ring
3. Insert the packing and stagger the joints in each ring by 90°.
Install the stuffing-box parts in this order:
a) Two packing rings
b) One lantern ring (two-piece)
c) Three packing rings
NOTICE:
Make sure that the lantern ring is located at the flushing connection to ensure that flush is obtained.
Failure to do so may result in decreased performance.
4. Install the gland halves and evenly hand-tighten the nuts.
Dynamic-seal option (3180 and 3185 S, M, L, and XL groups only)
WARNING:
Dynamic seals are not allowed in an ATEX-classified environment.
54 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 57
Commissioning, Startup, Operation, and Shutdown
The dynamic seal consists of two parts:
• A repeller seal that prevents leaks during operation
• A secondary seal that prevents leaks when unit is off
Table 5: Dynamic seal part function
Part Description and function
Repeller seal A repeller seal prevents liquid from entering the stuffing box during operation.
The repeller normally does not require a flush. Some services might require a
flush if solids have built up on the repeller. The unit contains a flush tap for
that purpose. The unit also contains a drain tap to drain the repeller chamber if
there is a danger that the unit might freeze.
Secondary seal The secondary seal prevents leaks during pump shutdown. The seal can be one
of these types:
• Graphic packing
• Diaphragm seal
Table 6: Secondary seal part function
Secondary seal type Description and operation
Graphic packing Graphite packing provides adequate life running dry but can provide longer
performance if lubricated with clean water or grease.
• If you lubricate with clean water, then the repeller reduces both the
quantity and pressure of seal water that is necessary. If the suction head is
less than the repeller capability, then the stuffing box pressure is the same
as the atmospheric pressure. Water pressure for the seal must be high
enough to overcome static head when the pump is not operating to keep
solids in the pumped fluid out of the packing. There must be enough flow
to cool the packing.
• If you lubricate with grease, then you must use spring-loaded grease
lubricators in order to maintain a constant supply of grease.
Diaphragm seal
This is an elastomeric disk that seals against a follower when the pump is not
operating. The position of the follower is set at the factory but should be
checked prior to start-up. The step on the follower should line up with the face
of the gland plate. Some adjustment might be required.
This seal is non-contacting during operation so no flush is required.
NOTICE: Do not flush the box through the lantern ring connection. If the
box becomes pressurized during operation from a flush or excessive suction
pressures, this will cause the diaphragm to contact the follower and destroy the
diaphragm.
Use the repeller flush connection if you need to flush the repeller. Never use
more than 20 psig (1.4 kg/cm2) with the diaphragm option.
Pump priming
WARNING:
These pumps are not self priming and must be fully primed at all times during operation. Loss of prime
can lead to excessive heat and severe damage to the pump and seal.
Prime the pump with the suction supply above the pump
1. Slowly open the suction isolation valve.
2. Open the air vents on the suction and discharge piping until the pumped fluid flows out.
3. Close the air vents.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 55
Page 58
1
2
3
1
2
3
4
5
Commissioning, Startup, Operation, and Shutdown
1. Discharge isolation valve
2. Check valve
3. Suction isolation valve
Prime the pump with the suction supply below the pump
Use a foot valve and an outside source of liquid in order to prime the pump. The liquid can come from
one of these sources:
• A priming pump
• A pressurized discharge line
• Another outside supply
1. Close the discharge isolation valve.
2. Open the air vent valves in the casing.
3. Open the valve in the outside supply line until only liquid escapes from the vent valves.
4. Close the vent valves.
5. Close the outside supply line.
This illustration is an example of priming the pump with a foot valve and an outside supply:
1. Discharge isolation valve
2. Shutoff valve
3. From outside supply
4. Foot valve
5. Check valve
This illustration is an example of priming the pump with a foot valve using a bypass around the check
valve:
56 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 59
1
2
3
4
5
1. By-pass line
2. Shutoff valve
3. Foot valve
4. Check valve
5. Discharge isolation valve
Commissioning, Startup, Operation, and Shutdown
Other methods of priming the pump
You can also use these methods in order to prime the pump:
• Prime by ejector
• Prime by automatic priming pump
Start the pump
CAUTION:
• Immediately observe the pressure gauges. If discharge pressure is not quickly attained, stop the driver,
reprime, and attempt to restart the pump.
• 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.
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.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 57
Page 60
Magnet
761B
Commissioning, Startup, Operation, and Shutdown
b) If the pump exceeds normal levels, then shut down the pump immediately and correct the
problem.
A pump can exceed normal levels for several reasons. See Troubleshooting for information about
possible solutions to this problem.
7. Repeat steps 5 and 6 until the pump runs properly.
Activate the i-ALERT™ Condition Monitor
WARNING:
Never heat the condition monitor to temperatures in excess of 300°F (149°C). Heating to these
temperatures could result in death or serious injury.
CAUTION:
Always wear protective gloves. The pump and condition monitor can be hot.
NOTICE:
Do not use the condition monitor in atmospheres containing acetic acid.
The condition monitor is ready for activation when the pump is running and has reached a steady flow,
pressure, and temperature. This process only takes a few minutes.
Place a small magnet on the condition monitor over the ITT logo and then remove it, as this example
shows.
When the condition monitor is activated it:
1. Displays a series of red LEDs followed by a solid green LED.
2. Collects eight samples that are spaced one second apart.
3. Averages these readings to establish the baseline vibration level.
4. Flashes a green LED after approximately twelve seconds.
For the first ten minutes, the green LED flashes every second for five consecutive flashes and then
pauses to take a vibration reading. More frequent measurements (every six seconds) are taken in this
startup period so that an alarm can be immediately detected.
58 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 61
Commissioning, Startup, Operation, and Shutdown
i-ALERT™ Condition Monitor routine operation
Measurement interval
This table shows the measurement intervals for the condition monitor during normal operation and when
the monitor is in alarm mode.
Mode Measurement interval
Normal operating mode Five minutes
Alarm mode Two minutes
When the condition monitor measures a reading beyond the specified temperature and vibration limits, the
appropriate red LED flashes. After the process or pump condition that causes the alarm is corrected, the
condition monitor returns to normal mode after one normal-level measurement.
Alarm mode
When the condition monitor is in alarm mode, you should investigate the cause of the condition and make
necessary corrections in a timely manner.
Magnetic device considerations
Be careful when you use magnetic devices in close proximity of the condition monitor, such as magnetic
vibration-monitoring probes or dial indicators. These magnetic devices can accidentally activate or
deactivate the condition monitor resulting in improper alarm levels or loss of monitoring.
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.
• 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.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 59
Page 62
Commissioning, Startup, Operation, and Shutdown
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.
Shut down the pump
WARNING:
The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe proper
decontamination procedures in order to eliminate the possible exposure to any hazardous or toxic fluids.
Wear the proper personal protective equipment. Potential hazards include, but are not limited to, high
temperature, flammable, acidic, caustic, explosive, and other risks. You must handle and dispose of
pumped fluid in compliance with the applicable environmental regulations.
1. Slowly close the discharge valve.
2. Shut down and lock the driver to prevent accidental rotation.
Deactivate the i-ALERT™ Condition Monitor
NOTICE: Always deactivate the condition monitor when the pump is going to be shut down for an
extended period of time. Failure to do so will result in reduced battery life.
1. Touch and hold a small magnet to the condition monitor over the ITT logo until the red LEDs blink
three times.
This should take 10-15 seconds if the condition monitor is in normal operating mode and
approximately five seconds if the condition monitor is in alarm mode.
2. Remove the magnet.
If the deactivation is successful, solid red LEDs will be displayed.
Reset the i-ALERT™ Condition Monitor
NOTICE: Always reset the condition monitor when the pump is started after maintenance, system
change, or down-time. Failure to do so may result in false baseline levels that could cause the condition
monitor to alert in error.
Touch a magnet to the condition monitor over the ITT logo to turn the power on.
The condition monitor begins to establish a new baseline vibration level.
Make the final alignment of the pump and driver
WARNING:
• 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.
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or
unintended contact of rotating parts. Follow the coupling installation and operation procedures from
the coupling manufacturer.
You must check the final alignment after the pump and driver are at operating temperature. For initial
alignment instructions, see the Installation chapter.
60 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 63
Commissioning, Startup, Operation, and Shutdown
1. Run the unit under actual operating conditions for enough time to bring the pump, driver, and
associated system to operating temperature.
2. Shut down the pump and the driver.
3. Remove the coupling guard.
See Remove the coupling guard in the Maintenance chapter.
4. Check the alignment while the unit is still hot.
See Pump-to-driver alignment in the Installation chapter.
5. Reinstall the coupling guard.
6. Restart the pump and driver.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 61
Page 64
Maintenance
Maintenance
Maintenance schedule
Maintenance inspections
A maintenance schedule includes these types of inspections:
• Routine maintenance
• Routine inspections
• Three-month inspections
• Annual inspections
Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the
environment is classified as potentially explosive.
Routine maintenance
Perform these tasks whenever you perform routine maintenance:
• Lubricate the bearings.
• Inspect the seal.
Routine inspections
Perform these tasks whenever you check the pump during routine inspections:
• Check the level and condition of the oil through the sight glass on the bearing frame.
• Check for unusual noise, vibration, and bearing temperatures.
• Check the pump and piping for leaks.
• Analyze the vibration.
• Inspect the discharge pressure.
• Inspect the temperature.
• Check the seal chamber and stuffing box for leaks.
• Ensure that there are no leaks from the mechanical seal.
• Adjust or replace the packing in the stuffing box if you notice excessive leaking.
Three-month inspections
Perform these tasks every three months:
• Check that the foundation and the hold-down bolts are tight.
• Check the packing if the pump has been left idle, and replace as required.
• Change the oil every three months (2000 operating hours) at minimum.
• Check the shaft alignment, and realign as required.
Annual inspections
Perform these inspections one time each year:
• Check the pump capacity.
• Check the pump pressure.
• Check the pump power.
If the pump performance does not satisfy your process requirements, and the process requirements have
not changed, then perform these steps:
1. Disassemble the pump.
2. Inspect it.
3. Replace worn parts.
• Change the oil more often if there are adverse atmospheric or other conditions that might
contaminate or break down the oil.
62 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 65
Bearing maintenance
These bearing lubrication sections list different temperatures of the pumped fluid. If the pump is ATEXcertified and the temperature of the pumped fluid exceeds the permitted temperature values, then consult
your ITT representative.
Bearing lubrication schedule
Type of bearing First lubrication Lubrication intervals
Oil-lubricated bearings Add oil before you install and start
Grease-lubricated bearings Grease-lubricated bearings are
Lubricating oil requirements
Quality requirements
Use a high quality turbine oil with rust and oxidation inhibitors.
Lubricating oil requirements
ISO grade ISO viscosity grade 68 ISO viscosity grade 100
Approximate SSU at 100°F (38°C) 300 470
DIN 51517 C68 C100
Kinematic viscosity at 105°F
(40°C) mm2/sec
After the first 200 hours, change
the pump. Change the oil after 200
hours for new bearings.
initially lubricated at the factory.
Bearing temperature below
180°F (82°C)
68 100
the oil every 2000 operating hours
or every three months.
Regrease bearings every 2000
operating hours or every three
months.
Bearing temperature above
180°F (82°C)
Maintenance
Oil volumes
Oil volume requirements
This table shows the required amount of oil for oil-lubricated bearings.
Frame Quarts Liters
S 1.1 1.0
M 2.1 2.0
L 2.1 2.0
XL 3.2 3.0
XL1 12.2 11.6
XL2-S and XL2 24.0 22.7
Acceptable oil for lubricating bearings
Acceptable lubricants
Brand Lubricant type
Chevron GTS Oil 68
Exxon Teresstic EP 68
Mobil DTE 26 300 SSU @ 100°F (38°C)
Philips Mangus Oil 315
MM motor oil SAE 20-20W
HDS motor oil SAE 20-20W
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 63
Page 66
Maintenance
Brand Lubricant type
Gulf Harmony 68
Lubricating-grease requirements
Precautions
NOTICE:
• Never mix greases of different consistencies (NLGI 1 or 3 with NLGI 2) or with different thickeners.
For example, never mix a lithium-based grease with a polyurea-based grease. Doing so may result in
decreased performance.
• Remove the bearings and old grease if you need to change the grease type or consistency. Failure to
do so may result in equipment damage or decreased performance.
Bearing temperature
Bearing temperatures are generally about 45°F (25°C) greater than bearing-housing outer surface
temperatures.
This table shows the type of grease required for the operating temperature of the pump.
Bearing temperature Type of grease
5°F to 230°F (-15°C to 110°C) Use a lithium-based mineral-oil grease with a
Exceed 230°F (110°C) Use a high-temperature grease. Mineral-oil greases
consistency of NLGI 2.
should have oxidation stabilizers and a consistency
of NGLI 3.
Grease recommendations based on temperature
This table shows which brand of grease to use when lubricating the pump.
Brand When temperature of pumped
Mobil Mobilux EP2 N/A
Exxon Unirex N2 Unirex N3
Sunoco Mutipurpose 2EP N/A
SKF LGMT 2 LGMT 3
Texaco Multifak 2 N/A
Shell Alvania 2 EP Grease 2 N/A
Grease amounts
Frame Initial grease in ounces (grams) Regrease1 in ounces (grams)
Thrust (angular
contact)
S 7 (185) 6 (165) 2.5 (70.0) 2.5 (70.0)
M 10 (290) 7 (180) 4 (115) 2.5 (70.0)
L 17 (475) 10 (280) 7 (200) 4 (115)
XL 28 (800) 16 (450) 12 (345) 6.5 (190.0)
1
The regrease amount is based on purging half of the old grease from the housing reservoir. Not available
on the XL1, XL2-S, and XL2 sizes.
fluid is less than 230°F (110°C)
– NLGI consistency 2
Radial (cylindrical
roller)
Thrust (angular
contact)
When temperature of pumped
fluid is greater than230°F
(110°C) – NLGI consistency 3
Radial (cylindrical
roller)
64 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 67
Regrease the grease-lubricated bearings
NOTICE:
Make sure that the grease container, the greasing device, and the fittings are clean. Failure to do this can
result in impurities entering the bearing housing when you regrease the bearings.
1. Wipe dirt from the grease fittings.
2. Remove the two grease-relief plugs from the bottom of the frame.
3. Fill both of the grease cavities through the fittings with a recommended grease until the fresh grease
comes out of the relief holes.
4. Make sure that the frame seals are seated in the bearing housing.
If they are not, press them in place with the drains located at the bottom.
5. Run the pump for about 30 minutes or until grease no longer comes out of the housing.
6. Reinstall the grease-relief plugs.
7. Wipe off any excess grease.
8. Recheck the alignment.
Maintenance
The bearing temperature usually rises after you regrease due to an excess supply of grease. Temperatures
return to normal in about two to four operating hours as the pump runs and purges the excess grease
from the bearings.
Lubricate the bearings after a shutdown period
1. Flush out the bearings and bearing frame with a light oil to remove contaminants.
During flushing, make sure to rotate the shaft slowly by hand.
2. Flush the bearing housing with the proper lubricating oil to ensure oil quality after cleaning.
Shaft-seal maintenance
Mechanical-seal maintenance
WARNING:
The mechanical seal used in an Ex-classified environment must be properly certified. Prior to startup,
make sure that all areas that could leak pumped fluid to the work environment are closed.
CAUTION:
Never operate the pump without liquid supplied to mechanical seal. If you run a mechanical seal dry, even
for a few seconds, this can cause seal damage. Physical injury can occur if a mechanical seal fails.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 65
Page 68
Maintenance
NOTICE:
• The mechanical seal must have an appropriate seal flush system or excess heat generation and seal
failure can occur.
Reference drawing
The manufacturer supplies a reference drawing with the data package. Keep this drawing for future use
when you perform maintenance and seal adjustments. The seal drawing specifies the required flush fluid
and attachment points.
Before you start the pump
Check the seal and all flush piping.
Mechanical seal life
The life of a mechanical seal depends on the cleanliness of the pumped fluid. Due to the diversity of
operating conditions, it is not possible to give definite indications as to the life of a mechanical seal.
Packed stuffing-box maintenance
WARNING:
• Never attempt to replace the packing until the driver is properly locked out and the coupling spacer is
removed.
Accepted leakage rate
It is not necessary to shut down or disassemble the pump to inspect the packing operation. During normal
operation, the packing should leak approximately one drop per minute.
Adjustment of gland
Adjust the gland if the leakage rate is greater than or less than the specified rate.
Evenly adjust each of the two gland bolts with a one-quarter (1/4) turn until the desired leakage rate is
obtained. Tighten the bolts to decrease the rate. Loosen the bolts to increase the rate.
Tightening of packing
NOTICE: Never over-tighten packing to the point where less than one drop per minute is observed.
Over-tightening can cause excessive wear and power consumption during operation.
If you cannot tighten the packing to obtain less than the specified leakage rate, then replace the packing.
Dynamic seal maintenance (3180 and 3185 S, M, L, and XL groups only)
Precautions
WARNING:
• Packed stuffing boxes are not allowed in an ATEX-classified environment.
• Dynamic seals are not allowed in an ATEX-classified environment.
Dynamic seal parts
Dynamic seal parts normally do not wear enough to affect operation unless the service is particularly
abrasive. The dynamic seal consists of two parts:
• The repeller seal prevents leakage during operation.
• The secondary seal prevents or minimizes leakage during shutdown of the unit. The seal can be either
one of these types:
• Graphite packing, which provides adequate life when it runs dry but can provide longer
performance if it is lubricated with clean water or grease.
• Diaphragm seal, which is an elastomeric disk that seals against a follower when the pump is not
operating.
66 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 69
Repeller seal maintenance
Some services might require a flush if solids have built up on the repeller. The unit contains a flush tap for
that purpose. The unit also contains a drain tap in order to drain the repeller chamber if there is a danger
that the unit might freeze.
Graphite packing maintenance
Graphite packing requires the same maintenance as any other packing. When adjustments can no longer be
made with the gland because it contacts the box face, perform these maintenance tasks:
• Shut down the pump.
• Relieve the pressure.
• Add another ring of packing to the box.
If the lantern ring connection is used but no longer lines up with the flush port, you need to clean and
repack the stuffing box. The repacking procedure is the same as the procedure outlined in the
Commissioning, Startup, Operation, and Shutdown chapter except this is the arrangement:
• One ring of packing
• The lantern ring
• Two rings of packing
Diaphragm seal maintenance
The diaphragm seal normally does not require maintenance because the seal is non-contacting during
operation. If the seal is short-lived, it is due to one of four factors:
• The pump was assembled improperly.
• The suction head is higher than the repeller sealing capability.
• The follower is not set properly.
• The box is bound with foreign material.
Maintenance
Acceptable leaks
Stuffing box cover
Drain tap
Injected liquid
Slight leaks can be considered normal, but excessive dripping or spray indicates a problem. You can usually
obtain extra life by resetting the follower towards the diaphragm by 0.040 in (1 mm.) increments and
allowing the diaphragm to reseat during operation. If this is not successful, replace the diaphragm and
follower (if scored).
The stuffing box cover used with the dynamic seal option is equipped with two lantern ring connections:
• One repeller flush connection
• One repeller drain connection
The lantern ring connection can be used to inject flush liquid or grease when required on specific
applications, but not when using a diaphragm seal.
NOTICE:
Do not flush the stuffing box through the lantern ring connection when a diaphragm static seal is used.
This may cause premature seal failure.
The drain tap allows you to drain the liquid that remains in the repeller chamber upon pump shutdown.
Consider removing this liquid before you service the pump in order to prevent it from hardening, or
protect the pump during freezing weather. The flush tap allows injection of water or steam directly into the
repeller chamber near the base of the repeller vanes.
During operation, the injected liquid can prevent de-watering of stock or similar problems. On shutdown,
it can be used in conjunction with the drain in order to flush the chamber of solids or potentially harmful
liquids.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 67
Page 70
Maintenance
Disassembly
Disassembly precautions
WARNING:
• This manual clearly identify accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply
heat to impellers, propellers, or their retaining devices to aid in their removal.
• 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 steeltoed shoes at all times.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe
proper decontamination procedures in order to eliminate the possible exposure to any hazardous or
toxic fluids. Wear the proper personal protective equipment. Potential hazards include, but are not
limited to, high temperature, flammable, acidic, caustic, explosive, and other risks. You must handle
and dispose of pumped fluid in compliance with the applicable environmental regulations.
NOTICE:
Make sure that all replacement parts are available before you disassemble the pump for overhaul.
Tools required
In order to disassemble the pump, you need these tools:
Drain the pump
CAUTION:
• Allen wrenches
• Cleaning agents and solvents
• Chisel
• Dial indicators
• Feeler gauges
• Hoist and strap
• Induction heater
• Pry bars
• Sockets
• Soft face hammer
• Spanner wrench
• Torque wrench
• Wrenches
• 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.
68 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 71
1
2
Maintenance
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.
6. Remove the coupling guard.
7. Disconnect the coupling.
1. Coupling guard
2. Coupling
8. If the pump is oil lubricated, drain the oil from the bearing frame.
Remove the back pull-out assembly
1. Place a sling from the hoist through the bearing frame (228) arms above the pump shaft.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 69
Page 72
748
370A
370A
388K
Maintenance
This example shows the 3180 and 3185 S, M, L, and XL group pump:
This example shows the 3180 and 3185 XL1, XL2-S, and XL2 group pump:
This example shows the 3181 and 3186 pump:
2. Remove the hold-down bolts of the bearing frame.
70 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 73
3. Remove the back pull-out assembly from the casing:
222E
164
100
Maintenance
If your pump
model is...
3180 or 3185 S, M,
L, or XL group
3181 or 3186 or;
3180 or 3185 XL1,
XL2-S, or XL2
group
Then...
1. Loosen the casing bolts (370A) enough to turn the casing lugs (748) 180°
out of the way.
Use your hand to keep the lug in place.
2. Remove the two sets of bolts and lugs and thread them into the two holes
provided in the cover for use as a jack.
3. Tighten the bolts until they are bottomed out.
4. Remove the back pull-out assembly by hand if it is loose enough.
If it is not loose enough, loosen the jack and place a shim 0.25 in. (6 mm)
between the lug and the casing and then re-tighten.
1. Remove the casing bolts (370A).
2. Evenly tighten the jacking bolts (388K) until the back pull-out assembly is
free enough to remove from the casing.
Remove the casing wear ring (S, M, L, and XL)
This procedure only applies to pumps with an enclosed impeller.
1. Remove the set screws (222E) from the casing wear ring (164).
2. Remove the wear ring (164) from the casing (100) using a pry bar, if necessary.
Remove the casing wear ring (for XL1, XL2-S, and XL2)
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 71
This procedure only applies to pumps with an enclosed impeller.
1. Remove the hex nuts (357A) from the casing wear ring studs (356E).
2. Remove the casing wear ring (164) from the casing (100) using a pry bar in the slot provided.
3. Remove the casing wear ring gasket (360P).
Page 74
164
360P
356E
100
357A
Maintenance
Remove the suction sideplate
WARNING:
Sideplates are heavy. Use the proper support to avoid personal injury.
72 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 75
This procedure only applies to models that have an open impeller or a ShearpellerTM.
1. Remove the hex nuts (357A) from the sideplate studs (356E).
2. Remove the sideplate (176) from the casing (100) using a pry bar in the provided slot.
3. Remove the O-ring (412C) from the groove and gasket (360P).
Maintenance
Impeller removal
WARNING:
Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped liquid,
resulting in severe physical injury and property damage.
CAUTION:
Use pry points under the impeller vanes to prevent impeller damage.
The pump has one of these impellers. Choose the removal procedure that applies to the impeller in the
pump:
• Open impeller
• Enclosed impeller
• Shearpeller
Remove an open impeller
1. Secure the back pull-out assembly firmly to the workbench.
2. Lock the shaft (122) to prevent turning.
3. Remove the impeller nut (304) and O-ring (412A).
™
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 73
Page 76
1
2
101
1
122
1
2
178
412F
101
412A
304
Maintenance
1. Pry bar (above)
2. Pry bar (below)
4. Pry the impeller off of the shaft using two bars opposite of each other. Place the pry bars between the
cover and the impeller.
You can also use an impeller puller.
1. Impeller puller
Remove an enclosed impeller
1. Secure the back pull-out assembly firmly to the workbench.
2. Lock the shaft (122) to prevent turning.
3. Remove the impeller nut (304) and O-ring (412A).
1. Pry bar (above)
2. Pry bar (below)
4. Pry the impeller off of the shaft using two bars opposite of each other. Place them between the cover
and the impeller shroud.
You can also use an impeller puller.
74 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 77
1
202
320
101
1
2
Maintenance
1. Impeller puller
5. Remove the socket head capscrews (320) from the impeller wear ring (202).
You might have to drill the heads of the socket head capscrews (320) off using a 3/8 in (10.0 mm)
drill bit if the heads are worn. Remove the remaining shank with locking pliers.
6. For the S, M, L, and XL groups, remove the wear ring (202) from the impeller by striking it with a
chisel.
The wear ring is usually loose, but corrosion might cause it to bind.
Remove a Shearpeller
1. Secure the back pull-out assembly firmly to the workbench.
2. Lock the shaft (122) to prevent turning.
3. Remove the Shearpeller nut (304), O-ring (412A), and Shearpeller sleeve (126A).
1. Pry bar (above)
2. Pry bar (below)
4. Pry the ShearpellerTM off of the shaft using two bars opposite of each other, placed between the cover
and the ShearpellerTM shroud.
You can also use an impeller puller.
™
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 75
Page 78
101
1
Maintenance
1. Impeller puller
Remove the stuffing box cover
WARNING:
Stuffing box covers are heavy. Use proper support to avoid personal injury.
1. Remove the packing gland halves (107), packing (106), lantern ring (105), and throttle bushing (125).
2. Thread a 10 mm eye bolt into the tapped hole provided in the cover (184) and sling to a hoist.
3. Remove the hex head bolts:
If your pump group is... Then...
S, M, L, and XL Remove the eight hex head bolts (370B) from the cover (184).
XL1, XL2-S, and XL2 Remove the two hex head bolts (370H) from the frame adapter (108).
4. Remove the cover:
If your pump group
is...
S, M, L, and XL Gently tap the cover from the frame using a soft-blow hammer on the dry
XL1, XL2-S, and XL2 Evenly tighten the two jacking bolts (418) until the cover is free enough to
76 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Then...
side of the cover.
remove from the frame adapter. If required, gently tap the cover from the
frame adapter using a soft-blow hammer on the dry side of the cover.
Page 79
This example shows S, M, L, and XL:
108
370H
418
184
351
This example shows XL1, XL2-S, and XL2:
Maintenance
5. Remove the shaft sleeve (126).
Use a puller if necessary.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 77
Page 80
1
356Y
Maintenance
1. Sleeve puller.
Remove the TaperBore PLUS™ seal chamber
WARNING:
Seal chambers are heavy. Use proper support to avoid personal injury.
1. Re-engage the setting clips on the mechanical seal.
2. Thread a 10 mm eye bolt into the tapped hole provided in the seal chamber (184) and sling to a hoist.
3. Remove the hex head bolts:
If your pump group is... Then...
S, M, L, and XL Remove the eight hex head bolts (370B) from the cover (184).
XL1, XL2-S, and XL2 Remove the two hex head bolts (370H) from the frame adapter (108).
4. Remove the cover:
If your pump group
Then...
is...
S, M, L, and XL Gently tap the cover from the frame using a soft-blow hammer on the dry
side of the cover.
78 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 81
108
370H
418
184
351
Maintenance
If your pump group
Then...
is...
XL1, XL2-S, and XL2 Evenly tighten the two jacking bolts (418) until the cover is free enough to
remove from the frame adapter. If required, gently tap the cover from the
frame adapter using a soft-blow hammer on the dry side of the cover.
This example shows the S, M, L, and XL:
This example shows the XL1, XL2-S, and XL2:
5. Remove the four hex nuts (355) from the seal gland plate.
6. Loosen the set screws on the seal drive collar and slide the sleeve out of the seal.
7. Service according to the seal manufacturer’s instructions.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 79
Page 82
Maintenance
Remove the dynamic seal
WARNING:
Covers are heavy, use the proper support to avoid personal injury.
This procedure only applies to the 3180 and 3185 pump models.
1. Remove box-to-backplate nuts (357J).
2. Remove the backplate (444) by tapping on the end of the studs with soft-faced hammer.
3. Remove the repeller (262):
a) Use two bars that are 180° apart to pry between the repeller and shroud and the cover.
b) Make sure that the gasket surfaces are not damaged.
4. Remove the secondary seal:
If your secondary seal is a...Then...
Packed box Remove the packing gland halves, the packing (106), lantern ring
(105), and throttle bushing (125).
Diaphragm seal Remove the gland (107) and the diaphragm (146) from the stuffing
box.
5. Thread a 10 mm eye bolt into the tapped hole provided in the cover (184) and sling to a hoist.
6. Remove eight hex head bolts (370B) from the cover (184).
7. Gently tap the cover from the frame using a soft-blow hammer on the dry side of the cover.
8. Remove the shaft sleeve (126).
Use a puller if necessary.
80 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 83
1
1. Sleeve puller.
228
370B
108
Remove the frame adapter from the frame (XL1, XL2-S, and XL2)
1. Thread a 20 mm eye bolt into the tapped hole provided at the top of the frame adapter (108) and sling
to a hoist.
2. Remove the eight hex head bolts (370B) from the frame adapter (108)
3. Gently tap the frame adapter from the frame (228) using a soft-blow hammer on the dry side of the
frame adapter.
Maintenance
Disassemble the bearing frame
1. Secure the bearing-frame assembly firmly to a workbench.
2. Remove the coupling hub from the shaft by loosening the set screw (if provided) and using a puller.
3. Remove the coupling key (400).
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 81
4. Remove the coupling guard end plate by removing the bearing-housing adjuster screws (370C).
5. Remove the labyrinth shaft-seal assemblies (332A and 333A) from each end of the frame.
Page 84
1
2
370C
497F
400
497J
497H
333A
241
370D
497G
332A
228
360
109A
370K
1
Maintenance
1. Coupling guard end plate
2. Coupling hub
6. For the XL1, XL2-S, and XL2 groups, remove the radial end cover (109A) and radial end-cover gasket
(360) from the bearing frame (228) by removing the eight socket-head capscrews (370K).
For the S, M, L, and XL groups the radial end cover is installed permanently at the factory and does
not require removal.
7. Slide the rotating element out of the frame (228).
Tap the impeller end of the shaft with a soft-face hammer to assist in removal.
1. Rotating element.
8. Remove the thrust-bearing retainer ring (253B) by removing the socket-head cap screws (236A)
9. Slide the thrust-bearing housing (134A) off of the thrust bearings.
82 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 85
1
Maintenance
10. Disengage the thrust-bearing lockwasher (382) from the lock nut (136) and remove both from the
shaft.
11. Remove the bearings (112 and 409) from the shaft using a suitable puller that only contacts the inner
races of the bearings.
1. Bearing pullers.
Guidelines for i-ALERT™ Condition Monitor disposal
Precautions
WARNING:
• Never heat the condition monitor to temperatures in excess of 300°F (149°C). Heating to these
temperatures could result in death or serious injury.
• Never dispose of the condition monitor in a fire. This could result in death or serious injury.
Guidelines
The battery contained in the condition monitor does not contain enough lithium to qualify as reactive
hazardous waste. Use these guidelines when disposing of the condition monitor.
• The condition monitor is safe for disposal in the normal municipal waste stream.
• Adhere to local laws when you dispose of the condition monitor.
Disassemble the spring-mounted baseplate (second generation)
WARNING:
Springs can store energy that can launch parts at a high velocity. Before you perform any tasks, make sure
that all springs are positively locked against free expansion.
NOTICE: The spring-mounted baseplate is designed only to support piping loads from thermal
expansion. You must support the suction and discharge piping individually. Failure to do so may result in
equipment damage.
1. Remove the pump and motor from the baseplate in order to remove the springs.
2. Make sure all the springs are positively locked against free expansion.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 83
3. Raise the baseplate and support it so the mounting brackets for the spring assemblies are
approximately 16 in. (406 mm) above the foundation/floor.
4. Remove the upper hex jam nuts from each stud.
Page 86
1
2
3
4
5
6
7
8
9
10
11
12
Maintenance
5. Carefully unthread the upper nuts, and allow the springs to expand slowly until the springs are loose
between the followers.
Leave the upper hex nuts on the studs.
6. Unthread and remove the studs from the bearing pads.
7. Unthread and remove the lower hex jam nuts from the studs.
8. Remove the lower hex nuts and lower followers.
9. Remove the springs.
10. Remove the upper followers.
11. Inspect studs, springs, followers, and nuts for any wear, damage, or corrosion.
Replace when necessary.
12. Inspect each Lubrite pad for excessive wear.
Replace when necessary.
1. Hex jam nut
2. Hex nut
3. Plain washer
4. Stud
5. Baseplate mounting bracket
6. Follower
7. Spring
8. Follower
9. Plain washer
10. Hex nut
11. Hex jam nut
12. Bearing pad assembly
Figure 14: Exploded view of the spring assembly
84 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 87
Preassembly inspections
Replacement guidelines
Casing check and replacement
Inspect the casing for cracks and excessive wear or pitting. Thoroughly clean gasket surfaces and alignment
fits in order to remove rust and debris.
• Localized wear or grooving that is greater than 1/8 in. (3.2 mm) deep
• Pitting that is greater than 1/8 in. (3.2 mm) deep
• Irregularities in the casing-gasket seat surface
Impeller replacement
This table shows the criteria for replacing the impeller:
Impeller parts When to replace
Vane edges When you see cracks, pitting, or corrosion damage
Keyway and bores When you see damage
Gaskets, O-rings, and seats replacement
• 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.
Maintenance
Wear rings or suction sideplate checks
Check the surfaces for pitting, and excessive wear or corrosion damage.
Stuffing box cover and seal chamber replacement
• Thoroughly clean the gasket surfaces and fits to remove rust and debris.
• Inspect surfaces for pitting, and excessive wear or corrosion damage.
Bearing-frame inspection
Checklist
Check the bearing frame for these conditions:
• Visually inspect the bearing frame and frame foot for cracks.
• Check the inside surfaces of the frame for rust, scale, or debris. Remove all loose and foreign material.
• Make sure that all lubrication passages are clear.
• If the frame has been exposed to pumped fluid, inspect the frame for corrosion or pitting.
• Inspect the inboard-bearing bores.
If any bores are outside the measurements in the Bearing fits and tolerances table, replace the bearing
frame.
• Inspect the shafts and sleeves for wear.
• Inspect the labyrinth seal O-rings for cuts and cracks.
Reassembly
Assemble the bearing frame
WARNING:
Do not use a flame to heat bearings. This will damage the bearing surfaces.
1. Install the bearings on the shaft:
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 85
Page 88
1
409
122
253B
112
382
136
Maintenance
a) Use an induction bearing heater in order to heat the bearings to approximately 250°F (121°C ).
This expands the bearings to ease their installation on the shaft.
b) Install the radial bearing (409) onto the shaft (122). For the S, M, L, and XL groups, make sure
that the spacer ring is placed between the shaft shoulder and inner race.
Care must be taken to keep the inner race together with the roller assembly during installation.
c) Place the thrust-bearing retainer ring (253B) on the shaft between the bearing fits with a small
diameter-facing coupling end.
d) Determine the orientation of the angular contact thrust bearings (112) for back-to-back mounting.
This is with the thick shoulders of the outer races together.
e) Slide the angular contact duplex bearings (112) onto the shaft while you maintain the correct
orientation.
f) Push the inner races firmly together against the shoulders until they cool and lock into place.
g) After the bearings have cooled, place the lockwasher (382) on the shaft and install the bearing
locknut (136).
h) Tighten the bearing locknut firmly with a spanner wrench while you clamp the bearing set against
the shaft shoulder.
i) Bend the tang of lockwasher into a slot on the bearing locknut.
1. Spacing ring.
2. If the frame is grease lubricated, hand pack all three bearings with grease.
3. Lubricate and install the O-ring (496) on the thrust bearing housing (134A):
a) Slide the thrust bearing housing over the bearings.
b) Attach the thrust-bearing retaining ring (253B) to the thrust bearing housing with socket head
capscrews (236A).
Tighten firmly in a crossing sequence in order to make sure there is even contact with the bearing
races. See Maximum torque values for fasteners.
For the S, M, L, and XL groups: For the XL1, XL2-S, and XL2 groups:
There will be a gap of approximately 0.12 to
0.16 in. (3.05 to 4.06 mm) between the retaining
ring and bearing housing.
There will be a gap of approximately 0.16 to
0.21 in. (4.06 to 5.33 mm) between the retaining
ring and bearing housing.
86 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 89
Assembled rotating element:
228
1
4. Prepare the bearing frame for either grease or oil lubrication.
If your bearing frame is... Then...
Oil lubricated Make sure that the oil return is fully open (no plug).
Maintenance
1. Oil return
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 87
Page 90
228
360
109A
370K
Maintenance
If your bearing frame is... Then...
Grease lubricated Make sure that the plug (370E) is installed in the radial end oil return.
If you are changing the lubrication from grease to oil, remove the accumulated grease from the oil
return after you remove the plug.
5. Complete these steps if you removed the radial end cover (109A):
If your
pump
group
is...
S, M, L,
and XL
XL1,
XL2-S,
and XL2
Then...
1. Degrease the surfaces and those in the frame.
2. Apply Loctite 518 to the outer diameter of the cover.
3. Tap the cover in place using a soft blow hammer.
1. Degrease the surfaces and those in the frame.
2. Install the radial end cover gasket (360).
3. Install the radial end cover (109A) using the eight socket-head capscrews (370K) into
the frame (228).
6. Lightly lubricate the bearing bores (outer diameter of radial bearing), thrust bearing housing, and Oring with grease or light oil. Carefully insert the rotating element into the bearing frame.
88 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 91
1. Rotating element
TOP
OIL
TOP
GREASE
134A
TOP
OIL
TOP
GREASE
134A
7. Orient the bearing housing depending on the lubrication.
If the
pump uses
this kind of
lubrication
...
Then,
these
words
should
appear on
And, the bearing housing looks like this...
top...
Maintenance
Grease
lubrication
Oil
"TOP
GREASE"
"TOP OIL"
lubrication
8. Assemble the end plate of the coupling guard to the bearing housing:
a) Align the coupling guard end plate to the bearing housing frame holes in the thrust bearing
housing and install the hex cap bolts (370C).
b) Adjust the housing so that there is a gap of approximately 0.12 in. (3.05 mm) between the housing
and the frame.
These measurements show the gap after you set the impeller:
• 0.25 in. (6.35 mm) on the S and M frames
• 0.38 in. (9.65 mm) on the L, XL, XL1, XL2-S, and XL2 frames
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 89
Page 92
1
Maintenance
1. Coupling guard end plate.
9. Lubricate the O-rings on the labyrinth oil seals.
10. Install the seal assembly into the bearing frame until the shoulders seat against the bearing frame.
11. Install these items on the bearing frame:
• Oil fill plug (408H)
• Shaft key (400)
• Coupling hub
• Frame foot (241)
12. Lubricate the bearing frame for grease or oil:
If you lubricate
with...
Oil
Grease (not
available for the
XL1, XL2-S,
and XL2
groups)
Then...
1. Install these four plugs (408C) as viewed from the coupling end:
• One on the left side of the frame (228)
• Two on the right side of the coupling end
• One at the stuffing box end at the top of the frame (228)
2. Install the oil level sight glass (319) on the right side of the frame (228).
3. If installing a sight oiler (251), install it on the left side of the frame as viewed
from the coupling end. Refer to separate instruction for sight oiler installation.
1. Install two grease fittings (193H) as viewed from the coupling end:
• One on the left side of the frame (228)
• One at the stuffing box end at the top of the frame
2. Install two plugs (408C and 408D) on the right side of the frame (228).
90 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 93
Maintenance
13. If your pump is equipped with an oil cooler, install the cooler assembly as follows (as viewed from the
coupling end):
a) Install one tube fitting with a straight bore on the left side of the frame in the tapped opening
provided.
b) Slide the finned tube through the hole on the right side of the frame.
c) Install the reducer bushing on the right side of the frame and thread a second tube fitting (with a
straight bore) into the reducer bushing.
d) Center the tube in the frame and tighten the ferrule nuts on the tube fittings.
e) Install one tube fitting with a stepped bore on each end of the tube and tighten the ferrule nuts.
Assemble the frame adapter to the frame (XL1, XL2-S, and XL2)
1. Thread a 20 mm eye bolt into the tapped hole provided at the top of the frame adapter (108) and sling
to a hoist.
2. Install the frame adapter (108) to the frame using eight hex head bolts (370B).
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 91
Page 94
228
370B
108
Maintenance
Assemble the TaperBore PLUS™ seal chamber
1. Apply a liberal amount of an anti-galling compound, such as Loctite Nickel Anti-seize, to the shaft
sleeve (126) bore and shaft (122).
2. Slide the sleeve onto the shaft.
3. Install the cartridge seal on the sleeve.
4. Use an eye bolt, strap, and sling as required.
5. Install the seal chamber (184):
If your pump
group is...
S, M, L, and XL Install the seal chamber (184) and hex head bolts (370B) on the bearing frame (228).
Then...
92 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 95
108
370H
418
184
351
126
Maintenance
If your pump
group is...
XL1, XLS-2,
and XL2
Then...
Install the seal chamber (184) and hex head bolts (370H) on the frame adapter (108).
6. Slide the cartridge seal on the gland studs and make sure that the tap connections are in the correct
orientation.
7. Hand-tighten the gland nuts.
8. Install the impeller and set the clearance.
9. Set the seal:
a) Tighten the set screws in the drive collar while the setting clips are engaged.
b) Tighten the gland nuts (355) evenly.
c) Disengage the setting clips.
Assemble the stuffing-box cover
WARNING:
Do not use packing that contains asbestos, it may cause personal injury.
1. Apply a liberal amount of an anti-galling compound, such as Loctite Nickel Anti-seize, to the bore of
the sleeve (126) and on the shaft (122).
2. Slide the sleeve onto the shaft.
3. Slide the throttle bushing (125) to the back of the shaft sleeve.
4. Use an eye bolt, strap, and sling as required.
5. Install the seal chamber (184):
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 93
Page 96
108
370H
418
184
351
126
125
Maintenance
If your
pump
group
is...
S, M, L,
and XL
XL1,
XLS-2,
and XL2
Then...
Install the seal chamber (184) and hex head bolts (370B) on the bearing frame (228).
Install the seal chamber (184) and hex head bolts (370H) on the frame adapter (108).
6. Install and adjust the packing after the impeller is installed and the clearance is set.
If you use conventional component seals, install them according to the instructions from the seal
manufacturer and the installation drawings.
94 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 97
Install the dynamic seal (S, M, L, and XL)
WARNING:
Do not use packing that contains asbestos, it may cause personal injury.
This procedure only applies to the 3180 and 3185 pumps.
1. Apply a liberal amount of a anti-galling compound, such as Loctite Nickel Anti-seize, to the shaft
sleeve (126) bore and shaft (122).
2. Install the sleeve on the shaft.
3. Perform these steps based on your dynamic seal configuration:
Maintenance
If your dynamic seal is
a...
Diaphragm seal
Packed box
4. Keep the repeller and sleeve assembly shouldered to the shaft, and adjust the rotating element until
the repeller-to-cover clearance is approximately 0.015 in. (0.4 mm).
5. Fit the gasket (264) on the backplate (444).
6. Install the backplate on the cover and tighten the nuts (357J) on the backplate studs (265A).
7. Perform these steps based on your seal:
Then...
1. Place an O-ring in the groove at the inner diameter of the follower
(385) and slide the assembly to the back of the sleeve.
2. Place a gland plate over the follower (385) and slide the diaphragm
(146) over the sleeve to the face of the seat.
3. Install four gland studs (353) in the stuffing box cover (184).
4. Use the eye bolt, strap, and sling as required.
5. Install the cover on the bearing frame (228) with eight hex bolts
(370B).
6. Fit the sleeve O-ring (412U) on the shaft sleeve.
7. Install the repeller (262) tight against the sleeve and make sure that the
O-ring stays in the groove.
1. Slide the throttle bushing (125) to the back of the sleeve.
2. Install two gland studs (353) in the stuffing box cover (184).
3. Install the cover on the bearing frame (228) with eight hex bolts
(370B).
4. Use the eye bolt, strap, and sling as required.
5. Fit the repeller O-ring (412U) on the shaft sleeve and install the
repeller (262) tight against the sleeve.
6. Make sure that the O-ring stays in the groove.
If your dynamic seal is
a...
Diaphragm seal
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 95
Then...
1. Slide the diaphragm (146) over the gland studs (353) and up against
the face of the stuffing box.
2. Slide the gland plate (107) over the gland studs (353) and up against
the diaphragm (146).
3. Thread the gland nuts (355) on and tighten evenly in a crossing
pattern.
4. Install the impeller and set the clearance per the instructions in the
Commissioning, Start-up, Operations, and Shut-down chapter.
5. Slide the follower (385) through the gland (107) until the step on the
seal is aligned with the exposed face of the gland.
Page 98
Maintenance
If your dynamic seal is
a...
Packed box
Then...
1. Install the impeller and set the clearance according to the instructions
in the Commissioning, Start-up, Operations, and Shut-down chapter.
2. Install and adjust the packing.
96 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
Page 99
184
146107
1
385
126
Maintenance
1. Alignment of step on follower with exposed face of gland.
Impeller installation
If your pump uses this type of impeller... Then refer to this installation procedure...
Enclosed impeller Install an enclosed impeller.
Open impeller Install an open impeller.
Shearpeller
Install an open impeller
1. Install the shaft key (178) on the shaft (122).
2. Fit the sleeve O-ring (412F) on the shaft sleeve (126).
3. Apply a liberal coating of an anti-galling compound, such as Loctite Nickel Anti-seize, to the impeller
4. Apply a coating of Loctite 272 approximately 1/8 in. wide along the entire thread length.
5. Slide the impeller (101) onto the shaft and make sure that the sleeve O-ring (412F) stays in the groove.
6. Fit the O-ring (412A) into the impeller nut (304) and install it on the shaft.
™
bore and shaft.
Install a Shearpeller™.
Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual 97
Page 100
178
101
412A
304
412F
320
202
101
Maintenance
7. Prevent the coupling end of the shaft from turning and torque the impeller nut to the specified
amount in the Maximum torque values for fasteners table in the Reassembly section of the
Maintenance chapter.
CAUTION:
Failure to torque the impeller nut can result in serious mechanical damage.
Install an enclosed impeller
1. For the S, M, L, and XL sizes, install the wear ring (202) on the impeller and align the holes.
2. Apply an anti-galling compound, such as Loctite Nickel Anti-seize, to the socket head capscrews
(320), and install and tighten.
For the S, M, L, and XL sizes, thread sealer is used to ease future disassembly.
3. Turn the impeller ring OD to the dimensions shown in Radial ring clearances for enclosed impellers,
found in the Commissioning, Startup, Operation, and Shutdown chapter.
For the S, M, L, and XL sizes, it might be necessary to drill and tap new holes for wear ring screws. In
this case, use the wear ring as a drilling template and offset (rotate) away from any previous holes.
4. Install the shaft key (178) on the shaft (122).
5. Fit the sleeve O-ring (412F) on the shaft sleeve (126).
6. Apply a liberal coating of an anti-galling compound, such as Loctite Nickel Anti-seize, to the impeller
bore and shaft.
7. Apply a coating of Loctite 272 approximately 1/8 in. wide along the entire thread length.
8. Slide the impeller (101) onto the shaft and make sure that the sleeve O-ring (412F) stays in the groove.
9. Fit the O-ring (412A) into the impeller nut (304) and install it on the shaft.
98 Models 3180, 3181, 3185, and 3186 Installation, Operation, and Maintenance Manual
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