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User Manual
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Goulds Pumps 3296 User Manual

Installation, Operation, and Maintenance Manual
Model 3296 EZMAG
Table of Contents
Introduction and Safety .......................................................................................................... 3
Introduction ............................................................................................................................. 3
Safety ...................................................................................................................................... 3
Safety terminology and symbols ........................................................................................... 4
Safety regulations for Ex-approved products in potentially explosive atmospheres ............. 6
Product warranty ..................................................................................................................... 7
Transportation and Storage ................................................................................................... 9
Inspect the delivery ................................................................................................................. 9
Inspect the package ............................................................................................................. 9
Transportation guidelines ........................................................................................................ 9
Pump handling ..................................................................................................................... 9
Lifting methods ..................................................................................................................... 9
Storage guidelines ................................................................................................................ 10
Pump storage requirements ............................................................................................... 10
Table of Contents
Product Description .............................................................................................................. 12
General description ............................................................................................................... 12
Nameplate information .......................................................................................................... 12
Installation ............................................................................................................................. 15
Preinstallation ....................................................................................................................... 15
Pump location guidelines .................................................................................................... 15
Foundation requirements ................................................................................................... 15
Baseplate-mounting procedures ........................................................................................... 16
Prepare the baseplate for mounting ................................................................................... 16
Install the baseplate using shims or wedges ...................................................................... 16
Install the baseplate using jackscrews ................................................................................ 17
Baseplate-leveling worksheet ............................................................................................. 20
Pump-to-driver alignment ...................................................................................................... 21
Alignment checks ............................................................................................................... 21
Permitted indicator values for alignment checks ................................................................ 22
Alignment measurement guidelines ................................................................................... 22
Attach the dial indicators for alignment ............................................................................... 22
Pump-to-driver alignment instructions ................................................................................ 23
Grout the baseplate .............................................................................................................. 26
Piping checklists ................................................................................................................... 27
General piping checklist ..................................................................................................... 27
Suction-piping checklist ...................................................................................................... 28
Discharge piping checklist .................................................................................................. 31
Final piping checklist .......................................................................................................... 31
Commissioning, Startup, Operation, and Shutdown ......................................................... 33
Preparation for startup .......................................................................................................... 33
Remove the coupling guard .................................................................................................. 34
Check the rotation - Frame Mounted ..................................................................................... 36
Check the rotation - Close Coupled ...................................................................................... 36
Couple the pump and driver .................................................................................................. 36
Install the coupling guard .................................................................................................... 37
Bearing lubrication ................................................................................................................ 41
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 1
Table of Contents
Lubricating-oil requirements ............................................................................................... 41
Acceptable oil for lubricating bearings ................................................................................ 42
Lubricate the bearings with oil ............................................................................................ 42
Greased-for-life bearing lubrication .................................................................................... 42
Pump priming ........................................................................................................................ 42
Prime the pump with the suction supply above the pump ................................................... 43
Prime the pump with the suction supply below the pump ................................................... 43
Other methods of priming the pump ................................................................................... 45
Start the pump ...................................................................................................................... 45
Minimum continuous recommended flow ........................................................................... 46
Pump operation precautions ................................................................................................. 46
Shut down the pump ............................................................................................................. 47
Make the final alignment of the pump and driver ................................................................... 47
Maintenance ........................................................................................................................... 49
Maintenance schedule .......................................................................................................... 49
Bearing maintenance ............................................................................................................ 50
Disassembly ......................................................................................................................... 50
Disassembly precautions ................................................................................................... 50
Required tools .................................................................................................................... 50
Prepare the pump for disassembly ..................................................................................... 51
Remove the frame assembly and shaft (frame-mounted pump) ......................................... 51
Remove the frame assembly and shaft (close-coupled pump) ........................................... 54
Disassemble the liquid end ................................................................................................. 56
Pre-assembly inspections ..................................................................................................... 58
Replacement guidelines ..................................................................................................... 58
Magnet inspections ............................................................................................................ 60
Bearing-frame inspection ................................................................................................... 60
Bearings inspection ............................................................................................................ 60
Minimum running clearances .............................................................................................. 61
Reassembly .......................................................................................................................... 61
Reassemble the frame assembly and shaft (frame-mounted pumps) ................................ 61
Reassemble the frame assembly and shaft (close-coupled pumps) .................................. 64
Reassemble the liquid end ................................................................................................. 66
Complete the pump reassembly ......................................................................................... 71
Bolt torque values ............................................................................................................... 71
Troubleshooting .................................................................................................................... 72
Operation troubleshooting ..................................................................................................... 72
Alignment troubleshooting .................................................................................................... 73
Parts Listings and Cross-Sectionals ................................................................................... 74
Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — stainless steel .......................... 74
Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — Hastelloy-C .............................. 76
S-group with bearing frame — stainless steel ....................................................................... 78
S-group with bearing frame — Hastelloy-C ........................................................................... 80
Frame cooling options ........................................................................................................... 82
M-group with bearing frame — stainless steel ...................................................................... 83
M-group with bearing frame — Hastelloy-C .......................................................................... 85
Spare and repair parts .......................................................................................................... 86
Interchangeability drawings .................................................................................................. 87
Other Relevant Documentation or Manuals ........................................................................ 89
Condensed power monitor .................................................................................................... 89
Local ITT Contacts ................................................................................................................ 92
Regional offices .................................................................................................................... 92
2 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

Introduction and Safety

Introduction

Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Introduction and Safety
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales contract for any modifications or special version characteristics. For instructions, situations, or events that are not considered in this manual or in the sales documents, please contact the nearest 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 over­pressurized. 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 identifies 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 unless explicitly stated in this manual.
• If the pump/motor is damaged or leaking, do not operate as it may cause an electric shock, fire, explosion, liberation of toxic fumes, physical harm, or environmental damage. Correct/repair the problem prior to putting back in service.
• Do not change the service application without the approval of an authorized ITT representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 3
Introduction and Safety

Safety terminology and symbols

About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: result in death or serious injury
A hazardous situation which, if not avoided, will
Hazard categories
WARNING: result in death or serious injury
CAUTION: result in minor or moderate injury
NOTICE:
A hazardous situation which, if not avoided, could
A hazardous situation which, if not avoided, could
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury
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

Environmental safety

The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.
4 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
WARNING:
Do NOT send the product to the ITT manufacturer if it has been contaminated by any nuclear radiation. Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling 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:
Introduction and Safety
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
• 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:
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.
• 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.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Magnetic precautions
WARNING:
Magnetic drive pumps contain very strong magnets that can pose health risks. Always observe these guidelines:
• Avoid working with, being in proximity of, or handling the magnets contained in this pump if you have
• Individuals who have had any surgery, especially to the chest or head, and do not know if metallic
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
any of these conditions:
• An artificial cardiac pacemaker
• An implanted defibrillator
• A metallic prosthetic heart valve
• Internal wound clips, from surgery
• Prosthetic joints
• Metallic wiring
• Any other type of metallic, prosthetic device
clips were surgically implanted need to avoid work on this unit unless their physician can confirm that no metallic devices exist.
your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in eyes
Chemicals or hazardous fluids on skin
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.

Safety regulations for Ex-approved products in potentially explosive atmospheres

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).
WARNING:
This manual clearly identifies 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 unless explicitly stated in this manual.
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.
6 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
• 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.
• Make sure that the equipment is properly maintained:
• 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.
Introduction and Safety
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

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.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 7
Introduction and Safety
Limitations
Warranty claim
Spare parts
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.
ITT guarantees that spare parts will be available for 10 years after the manufacture of this product has been discontinued.
8 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

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 guidelines

Transportation and Storage

Pump handling

WARNING:
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

WARNING:
• Make sure that the unit 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.
• All lifting must be done in compliance with all applicable regulations/standards.
• 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 hoist rings, shackles, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
• Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.
• Do not attach sling ropes to shaft ends.
Table 1: Methods
Pump type Lifting method
A bare pump without lifting han- Use a suitable sling attached properly to solid points like the casing, dles the flanges, or the frames.
A base-mounted pump Use slings under the pump casing and the drive unit, or under the base
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 9
rails.
Transportation and Storage
Examples
Figure 1: Proper lifting method for a bare pump
NOTICE:
Do not use this lifting method to life a Polyshield ANSI Combo with the pump and motor mounted. This can result in equipment damage.
Figure 2: Proper lifting method for a pump with a base and driver

Storage guidelines

Pump storage requirements

Storage requirements depend on the amount of time that you store the unit. The normal packaging is designed only to protect the unit during shipping.
Length of time in storage Storage requirements
Upon receipt/short-term (less than six months)
10 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
• Store in a covered and dry location.
• Store the unit free from dirt and vibrations.
Transportation and Storage
Length of time in storage Storage requirements
Long-term (more than six months)
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibra­tions.
• Rotate the shaft by hand several times at least every three months.
Treat bearing and machined surfaces so that they are well preserved. Refer to drive unit and coupling manufacturers for their long-term storage procedures.
You can purchase long-term storage treatment with the initial unit order or you can purchase it and apply it after the units are already in the field. Contact your local ITT sales representative.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 11

Product Description

Product Description

General description

Model 3296 EZMAG
The Model 3296 EZMAG is a sealless centrifugal pump with an enclosed impeller that is driven by a synchronous magnetic coupling. Model 3296 EZMAG meets the dimensional standards of ANSI B73.1.
Casing
The casing is top centerline discharge and is self-venting. It incorporates a fully-confined gasket with ANSI Class 150 flanges that are serrated and raised-faced. ANSI Class 300 flanges that are serrated and raised-face are optional. The 3296 EZMAG is designed to have a metal-to-metal fit between the casing and the backplate.
Magnetic coupling
The magnetic coupling is a coaxial synchronous type that uses rare earth magnets. This concept results in a compact design and allows the impeller to turn at the same speed as the motor, which means that there is no slip between the drive and the driven magnets.
Magnets
Two types of rare earth magnets are available:
• Neodymium Iron (NdFe) is used when pumped liquid temperatures are less than 365°F (180°C).
• Samarium Cobalt (SmCo) is used when pumped liquid temperatures are between 365°F (180°C) and 536°F (280°C).
Containment shell
The containment shell isolates the pumped liquid from the atmosphere and is constructed from Hastelloy-C.
Sleeve bearings and thrust bearings
Goulds standard bearing material is Pure Sintered Alpha Grade Silicon Carbide. Dryguard bearings are available for dry-run protection.
Impeller
The 3296 EZMAG uses an enclosed impeller that is hydraulically-balanced and keyed to the shaft.
Bearing frame
The standard configuration is cast iron with ball bearings that are flood oil–lubricated. Greased­for-life bearings systems are available as an option. Bronze bearing isolators are provided for protection and reliability of the bearings and the lubricant.

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
12 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
• 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.
Nameplate types
Nameplate Description
ATEX If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the
baseplate, or the discharge head. The nameplate provides information about the ATEX specifications of this pump.
Nameplate on the pump casing using English units
Product Description
Nameplate on the pump casing using metric units
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
Table 2: Temperature class definitions
Code Maximum permissible surface Minimum permissible surface
T1 842 (450) 700 (372) T2 572 (300) 530 (277) T3 392 (200) 350 (177) T4 275 (135) 235 (113) T5 212 (100) Option not available T6 185 (85) Option not available
temperature in °F (°C) temperature in °F (°C)
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 13
Product Description
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.
14 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

Installation

Preinstallation

Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is properly certified.
• You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly.
• Electrical Connections must be made by certified electricians in compliance with all international, national, state, and local rules.
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.
Evaluate the installation in order to determine that the Net Positive Suction Head Available (NPSHA) meets or exceeds the Net Positive Suction Head Required (NPSHR), as stated by the pump performance curve.
Installation

Pump location guidelines

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

Foundation requirements

Requirements
• The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the unit.
• The location and size of the foundation bolt holes must match those shown on the assembly drawing provided with the pump data package.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 15
Installation
Sleeve-type bolts
• 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.
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.
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.

Install the baseplate using shims or wedges

Required tools:
• Two sets of shims or wedges for each foundation bolt
• Two machinist's levels
16 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
Installation
• Baseplate-leveling worksheet
This procedure is applicable to cast iron and fabricated steel baseplates.
1. Remove water and debris from the anchor bolt holes and sleeves.
2. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from entering the bolt holes.
3. Put the sets of wedges or shims on each side of each foundation bolt. Make sure that the wedges extend 0.75 in. (19 mm) to 1.5 in. (38 mm) above the foundation to provide adequate space for grouting. The wedges will provide adequate support for the baseplate after it is grouted.
1. Shims or wedges
Figure 3: Top view
1. Shims or wedges
Figure 4: Side view
4. Lower the baseplate carefully onto the foundation bolts.
5. 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.
6. 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.
7. Hand-tighten the nuts for the foundation.

Install the baseplate using jackscrews

Tools required:
• Anti-seize compound
• Jackscrews
• Bar stock
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 17
Installation
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure applies 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.
18 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
Installation
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.
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).
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 19
Installation

Baseplate-leveling worksheet

20 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

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.
• Electrical connections must be made by certified electricians in compliance with all international,
national, state, and local rules.
• Refer to driver/coupling/gear manufacturers installation and operation manuals (IOM) for specific
instructions and recommendations.
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

Installation
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) Prior to operation when the pump and the driver are at ambient check temperature.
Final alignment (hot alignment) After operation when the pump and the driver are at operating check temperature.
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.
Final alignment (hot alignment) checks
When Why
After the first run This ensures correct alignment when both the pump and the driver
Periodically This follows the plant operating procedures.
process.
If changes have occurred, you must alter the piping to remove pipe strains on the pump flanges.
are at operating temperature.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 21
Installation

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 these conditions are true:
• The total indicator runout is a maximum of 0.002 in. (0.05 mm) at operating temperature.
• The tolerance of the indicator is 0.0005 in./in. (0.0127 mm/mm) of indicator separation 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.
Recommended settings
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 This prevents incorrect measurement. 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 This prevents strain on the piping installations. adjustments.
Make sure that the hold-down bolts for the driver This keeps the driver stationary since movement feet are tight when you take indicator measure- causes incorrect measurement. ments.
Make sure that the hold-down bolts for the driver This makes it possible to move the driver when you feet are loose before you make alignment correc- make alignment corrections. tions.
Check the alignment again after any mechanical This corrects any misalignments that an adjustment adjustments. 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). This indicator is used to measure parallel misalignment.
22 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
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
Before you start this procedure, make sure that the dial indicators are properly attached for measurement.
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... Then...
Negative The coupling halves are farther apart at the
Positive The coupling halves are closer at the bottom than
Installation
bottom than at the top. Perform one of 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.
at the top. Perform one of these 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 5: 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
Before you start this procedure, make sure that the dial indicators are properly attached for measurement.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 23
Installation
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).
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 6: 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
Refer to the alignment table in "Permitted indicator values for alignment checks" (see Table of Contents for location of table) for the proper cold alignment value based on the motor temperature rise and the pump operating temperature.
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.
When aligning a cold unit, see the Cold settings for vertical parallel alignment table.
1. Set the parallel alignment indicator (P) 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... Then...
Negative The pump coupling half (X) is lower than the
Positive The pump coupling half (X) is higher than the
NOTICE:
driver coupling half (Y). Remove shims of a thickness equal to half of the indicator reading value under each driver foot.
driver coupling half (Y). Add shims of a thickness equal to half of the indicator reading value to each driver foot.
24 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
Figure 7: Side view of an incorrect vertical alignment
4. Repeat the previous steps until the permitted reading value is achieved.
Perform parallel alignment for a horizontal correction
Before you start this procedure, make sure that the dial indicators are properly attached for measurement.
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 (P) 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 (Y) is to the left of the
Positive The driver coupling half (Y) is to the right of the
Installation
pump coupling half (X).
pump coupling half (X).
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.
Figure 8: 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
Before you start this procedure, make sure that the dial indicators are properly attached for measurement.
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.
When the procedure is complete, both the angular and parallel alignment must meet the permitted tolerances.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 25
Installation
Perform complete alignment for a horizontal correction
Before you start this procedure, make sure that the dial indicators are properly attached for measurement.
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.
When the procedure is complete, both the angular and parallel alignment must meet the permitted tolerances.

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
26 Model 3296 EZMAG Installation, Operation, and Maintenance Manual
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.

Piping checklists

Installation
Fastening
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing fasteners.

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.
CAUTION:
Flange loads from the piping system, including those from the thermal expansion of the piping, must not exceed the limits of the pump. Deformation can result in contact with rotating parts, which can result in excess heat generation, sparks, and premature failure.
Piping guidelines
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.
Model 3296 EZMAG Installation, Operation, and Maintenance Manual 27
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