Goulds Pumps 3296M User Manual

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FOREWORD

This manual provides instructions for the Installation, Operation, and Maintenance of the Goulds Model 3296 “M Group” Magnetic Drive Process Pump. This manual must be read and understood before installation and start-up.

The design, materials, and workmanship incorporated in the construction of Goulds pumps makes them capable of giving, trouble-free service. The life and satisfactory service of any mechanical unit, however, is enhanced and extended by correct application, proper installation, periodic inspection, condition monitoring and careful maintenance. This instruction manual was prepared to assist operators in understanding the construction and the correct methods of installing, operating, and maintaining these pumps.

Goulds shall not be liable for physical injury, damage or delays caused by a failure to observe the instructions for Installation, Operation, and Maintenance contained in this manual.

Warranty is valid only when genuine Goulds parts are used.

Use of the equipment on a service other than stated in the order could nullify the warranty, unless written approval is obtained in advance from Goulds Pumps, Inc.

Supervision by an authorized Goulds representative is recommended to assure proper installation.

Additional manuals can be obtained by contacting your local Goulds representative or by calling 1-800-446-8537.

THIS MANUAL EXPLAINS

Proper Installation

Start Up Procedures

Operation Procedures

Routine Maintenance

Pump Overhaul

Troubleshooting

Ordering Spare or Repair Parts

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TABLE OF CONTENTS

PAGE SECTION

7 SAFETY

9 GENERAL INFORMATION

11 INSTALLATION

19 OPERATION

23 PREVENTIVE MAINTENANCE

27 DISASSEMBLY & REASSEMBLY

55 SPARE AND REPAIR PARTS

61 APPENDIX

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6 3296 M Group 6/05

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IMPORTANT SAFETY NOTICE

To: Our Valued Customers

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

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

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

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

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

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

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

www.gouldspumps.com.

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SAFETY WARNINGS

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

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

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SAFETY

DEFINITIONS

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

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

WARNING

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

Pump shall never be operated without coupling guard installed correctly.

CAUTION

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

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

ELECTRICAL HAZARD



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

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

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

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

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

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

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GENERAL PRECAUTIONS

WARNING

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

WARNING

General Precautions

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

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

WARNING

WARNING WARNING

WARNING





NEVER operate pump without safety devices installed.

 



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

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

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

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

Safety Apparel:

 Insulated work gloves when handling hot bearings or using bearing heater  Heavy work gloves when handling parts with sharp edges, especial l y

impellers

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

Receiving:

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

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

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

Alignment:

WARNING

Shaft alignment procedures must be followed to prevent catastrophic failure of



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

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WARNING

CAUTION

General Precautions

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



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

Piping:

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



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

WARNING

CAUTION

WARNING

Flanged Connections:

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

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

Startup and Operation:

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



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



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



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



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

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



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



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

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



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

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



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

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



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

coupling spacer is removed.

WARNING

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Dynamic seals are not allowed in an ATEX classified environment.



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



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

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WARNING

CAUTION

WARNING

CAUTION



General Precautions

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

Shutdown, Disassembly, and Reassembly:

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

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

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

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

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

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

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

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

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

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ATEX CONSIDERATIONS and INTENDED USE

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

1. Monitoring the pump frame and liquid end temperature.

2. Maintaining proper bearing lubrication.

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

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

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

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

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

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

Table 1

Max permissible

surface temperature

Code

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

F (oC)

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

Max permissible

liquid temperature

F (oC)

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PARTS

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

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

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GENERAL INFORMATION

PUMP DESCRIPTION .............................9

NAMEPLATE INFORMATION ........................9

RECEIVING THE PUMP ...........................10

Storage Requirements ...........................................10

Handling .....................................................10

PUMP DESCRIPTION

The Model 3296 is a sealless frame-mounted centrifugal pump with an enclosed impeller, that is driven by a synchronous magnetic coupling, and meets dimensional standards of ANSI B73.1.

Magnetic Coupling - is a coaxial synchronous type using rare earth magnets. This concept results in a compact design and allows the impeller to turn at the same speed as the motor, (i.e.) there is no slip between the drive and driven magnets.

Magnets - Two types of rare earth magnets are available. Neodymium Iron (NdFe), which is used when pumpage temperatures are less than 250°F (120°C). For liquid pumpage between 250°F (120°C) and 425°F (220°C) Samarium Cobalt (SmCo) magnets are used.

Containment Shell - isolates the pumped liquid from the atmosphere. Standard material is Hastelloy-C which provides excellent corrosion and erosion resistance.

NAMEPLATE INFORMATION

Sleeve Bearings and Thrust Bearings - Goulds

standard bearing material is Pure Sintered Alpha Grade Silicon Carbide. The sleeve bearings are flexibly mounted using O-rings.

Impeller - Model 3296 utilizes an enclosed impeller, hydraulically balanced and keyed to the shaft.

Bearing Frame - the standard configuration is cast ductile iron with flood oil lubricated ball bearings. Pure oil mist systems are available as an option. For protection and reliability of the bearings and the lubricant, a carbon filled teflon non-contacting labyrinth seal is provided. On the inboard side a lip seal is used to prevent leakage of oil into the magnetic drive assembly.

Casing - is top centerline discharge, self venting type incorporates a fully confined gasket. 150 lb. ANSI serrated raised face flanges are standard. The 3296 has been designed such that there is a metal to metal fit between the casing and frame adapter.

Every pump has 3 Goulds nameplates that provide information on your pump. The tags are located on the casing and bearing frame.

Pump Casing Tag - provides information relative to the pumps characteristics. The format of pump size information is: Discharge x Suction - Nominal Impeller Diameter, (ex.1x1

Bearing Frame Tag - provides information relative to the type of magnets being used.

3296 M Group 6/05 9

-6)

Pump Warning Tag - is permanently fastened to the bearing frame. It contains precautions to be observed during the operation, disassembly, maintenance and reassembly of the pump.

When ordering spare parts you will need to know the pump model, size, serial number, and the item number of the required parts. Information can be taken from the pump casing tag. Item number information can be found in this manual.

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RECEIVING THE PUMP

Inspect the pump as soon as it is received. Make notes of damaged or missing items on the receipt and freight bill. File any claims with the transportation company immediately.

STORAGE REQUIREMENTS

Short Term - (Less than 3 months) Goulds normal

packaging procedure is designed to protect the pump during shipping. Upon receipt store in a covered and dry location.

Long Term - (More than 6 months) Preservative treatment of bearings and machined surfaces will be required. Rotate shaft several times every 3 months. Refer to driver and coupling manuals for their long term storage procedures. Store in a dry covered location.

HANDLING

! WARNING

Failure to properly lift and support equipment could result in serious injury or damage to pumps.

Use care when moving pumps. Lifting equipment must be able to adequately support the entire assembly. Hoist bare pumps, using a sling under the suction flange and bearing housing.

the pump and driver.

Baseplate mounted units are moved with slings under

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INSTALLATION

SITE/FOUNDATION..............................11

LEVEL BASEPLATE .............................12

ALIGNMENT AND ALIGNMENT PROCEDURE .............12

Alignment Checks..............................................12

Alignment Criteria .............................................13

SetUp.......................................................13

Measurement..................................................13

Angular Alignment .............................................13

Parallel Alignment .............................................14

Complete Alignment ............................................15

Alignment Troubleshooting ......................................15

GROUT BASEPLATE .............................15

PIPING......................................16

Suction Piping .................................................16

Discharge Piping ...............................................17

Final Piping Check .............................................17

SITE/FOUNDATION

A pump should be located near the supply of liquid and have adequate space for operation, maintenance, and inspection.

Baseplate mounted pumps are normally grouted to a concrete foundation, which has been poured on a solid footing. The foundation must be able to

Fig. 4A

absorb any vibration and to form a permanent, rigid support for the pumping unit.

The location and size of the foundation bolts are shown on the outline assembly drawing, provided with the pump data package.

Foundation bolts commonly used are sleeve type (Fig. 4A) and J type (Fig. 4B). Both designs permit movement for final bolt adjustment.

Fig. 4B

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LEVEL BASEPLATE

1. Place 2 sets of wedges or shims on the foundation, one set on each side of every foundation bolt. The wedges should extend .75 in. (20 mm) to 1.5 in. (40 mm) above the foundation, to allow for adequate grouting. This will provide even support for the baseplate once it is grouted.

2. Remove water and/or debris from anchor bolt holes/sleeves prior to grouting. If the sleeve

Fig. 5A

type bolts are being used, fill the sleeves with rags to prevent grout from entering.

3. Carefully lower baseplate onto foundation bolts.

4. Level baseplate to within .125 in.(3mm) over the length of the base and .062 in. (1.5 mm) over the width of the base by adjusting shims or wedges.

5. Hand tighten bolts.

Fig. 5B

ALIGNMENT AND ALIGNMENT PROCEDURE

! WARNING

Before beginning any alignment procedure make sure driver power is locked out. Failure to lock out driver power can result in serious personal injury.

The points at which alignment is checked and adjusted are:

Initial Alignment is done prior to operation when the pump and the driver are at ambient temperature.

Final Alignment is done after operation when the pump and driver are at operating temperature.

Alignment is achieved by adding or removing shims from under the feet of the driver and shifting equipment horizontally as needed.

NOTE: Proper alignment is the responsibility of the installer of the unit.

Accurate alignment of the equipment must be attained. Trouble-free operation can be accomplished by following these procedures:.

ALIGNMENT CHECKS

Initial Alignment (Cold Alignment)

Before Grouting Baseplate- To ensure alignment can be obtained.

After Grouting Baseplate - To ensure no changes to alignment have occurred during grouting process.

After Connecting Piping -To ensure that pipe strains haven’t altered alignment. If changes have occurred, alter piping to remove pipe strains on pump flanges.

Final Alignment (Hot Alignment)

After First Run -To obtain correct alignment when both pump and driver are at operating temperature. Thereafter, alignment should be checked periodically in accordance with plant operating and maintenance procedures.

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ALIGNMENT CRITERIA

Good alignment is achieved when dial indicator readings as specified in the alignment procedure are .002 in. (.05 mm) Total Indicated Reading (T.I.R.) or less when the pump and driver are at operating temperature (Final Alignment).

MEASUREMENT

1. To ensure accuracy of indicator readings, always rotate both coupling halves together so indicators contact the same point on coupling half Y. This will eliminate any measurement problems due to runout on coupling half Y.

During the installation phase, however, it is necessary to set the parallel alignment in the vertical direction to a different criteria due to differences in expansion rates of the pump and driver. Table 1 below shows recommended cold settings for electric motor driven pumps based on different pumpage temperatures. Driver manufacturers should be consulted for recommended cold settings for other types of drivers (steam turbines, engines, etc.)

Table 1

Cold Settings of Parallel Vertical Alignment

PUMPAGE

TEMPERATURE

50°F (10°C) .002in. (.05mm) LOW

150°F (65°C) .001in. (.03mm) HIGH 250°F (120°C) .005in. (.12mm) HIGH 350°F (175°C) .009in. (.23mm) HIGH 425°F (218°C) .013in. (.33mm) HIGH

SET DRIVER SHAFT

SET UP

1. Mount two dial indicators on one of the coupling halves (X) so they contact the other coupling half (Y) (Fig. 6).

2. Check setting of indicators by rotating coupling half X to ensure indicators stay in contact with coupling half Y but do not bottom out. Adjust indicators accordingly.

2. Take indicator measurements with driver feet hold down bolts tightened. Loosen hold down bolts prior to making alignment corrections.

3. Take care not to damage indicators when moving driver during alignment corrections.

ANGULAR ALIGNMENT

A unit is in angular alignment when indicator A (Angular indicator) does not vary by more that .002 in. (.05 mm) as measured at four locations 90° apart.

Vertical Correction (Top to Bottom)

1. Zero indicator A at top dead center (12 o’clock) of coupling half Y.

2. Rotate indicators to bottom dead center (6 o’clock). Observe needle and record reading.

3. Negative Reading - The coupling halves are further apart at the bottom than at the top. Correct by either raising the driver feet at the shaft end (add shims) or lowering the driver feet at the other end (remove shims) (Fig. 7A).

Positive Reading - The coupling halves are closer at the bottom than at the top. Correct by either lowering the driver feet at the shaft end (remove shims) or raising the driver feet at the other end (add shims).

Fig. 7A

Fig. 6

4. Repeat steps 1-3 until indicator A reads .002 in (.05 mm) or less.

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Horizontal Correction (Side to Side)

1. Zero indicator A on left side of coupling half Y, 90° from top dead center (9 o’clock).

2. Rotate indicators through top dead center to the right side, 180° from the start (3 o’clock). Observe needle and record reading.

3. Negative Reading - The coupling halves are further apart on the right side than the left. Correct by either sliding the shaft end of the driver to the left or the other end to the right.

Positive Reading - The coupling halves are closer together on the right side than the left. Correct by either sliding the shaft end of the driver to the right or the other end to the left (Fig. 7B).

Positive Reading - Coupling half X is higher than coupling half Y. Correct by adding shims of thickness equal to half of the indicator reading from each driver foot (Fig. 8A).

Fig. 8A

NOTE: Equal amounts of shims must be added to or removed from each driver foot. Otherwise the vertical angular alignment will be affected.

4. Repeat steps 1 through 3 until indicator P reads within .002 in. (.05 mm) or less when hot, or per Table 1 when cold.

Fig. 7B

4. Repeat steps 1 through 3 until indicator A reads .002 in. (.05 mm) or less.

5. Re-check both horizontal and vertical readings to ensure adjustment of one did not disturb the other. Correct as necessary.

PARALLELALIGNMENT

A unit is in parallel alignment when indicator P (parallel indicator) does not vary by more than .002 in. (.05 mm) as measured at four points 90° apart at operating temperature. Note the preliminary cold setting criteria, Table 1.

Vertical Correction (Top to Bottom)

1. Zero indicator P at top dead center of coupling (12 o’clock) half Y (Fig. 6).

2. Rotate indicator to bottom dead center (6 o’clock). Observe needle and record reading.

3. Negative Reading - Coupling half X is lower than coupling half Y. Correct by removing shims of thickness equal to half of the indicator reading under each driver foot.

Horizontal Correction (Side to Side)

1. Zero indicator P on the left side of coupling half Y, 90° from top dead center (9 o’clock).

2. Rotate indicators through top dead center to the right side, 180° from the start. Observe needle and record reading (3 o’clock).

3. Negative Reading - Coupling half Y is to the left of coupling half X. Correct by sliding driver evenly in the appropriate direction (Fig. 8B).

Positive Reading - Coupling half Y is to the right of coupling half X. Correct by sliding driver evenly in the appropriate direction.

Fig. 8B

NOTE: Failure to slide motor evenly will affect horizontal angular correction.

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4. Repeat steps 1 through 3 until indicator P reads .002 in. (.05 mm) or less.

5. Re-check both horizontal and vertical readings to ensure adjustment of one did not disturb the other.

Correct as necessary.

COMPLETE ALIGNMENT

A unit is in complete alignment when both indicators A (angular) and P (parallel) do not vary by more than .002 in. (.05 mm) as measured at four points 90° apart.

Vertical Correction (Top to Bottom)

1. Zero indicators A and P at top dead center (12 o’clock) of coupling half Y.

2. Rotate indicator to bottom dead center (6 o’clock). Observe the needles and record the readings.

Alignment Troubleshooting

PROBLEM PROBABLE CAUSE REMEDY

Cannot obtain horizontal (Side-to-Side) alignment, angular or parallel

Cannot obtain vertical (Top to Bottom) alignment, angular or parallel

Driver feet bolt bound

Baseplate not leveled properly, probably twisted.

Baseplate not leveled properly, probably bowed.

3. Make corrections as outlined previously.

Horizontal Correction (Side to Side)

1. Zero indicators A and P on the left side of coupling half Y, 90° from top dead center (9 o’clock).

2. Rotate indicators through top dead center to the right side, 180° from the start (3 o’clock). Observe the needle, measure and record the reading.

3. Make corrections as outlined previously.

4. Recheck both vertical and horizontal readings to ensure adjustment of one did not disturb the other. Correct as necessary.

NOTE: With experience, the installer will understand the interaction between angular and parallel and will make corrections appropriately.

Table 2

Loosen pump hold down bolts and slide pump and driver until horizontal alignment is achieved.

Determine which corner(s) of the baseplate are high or low and remove or add shims at the appropriate corner(s) and realign.

Determine if center of baseplate should be raised or lowered and correct by evenly adding or removing shims at the center of the baseplate.

GROUT BASEPLATE

1. Clean areas of baseplate that will contact grout. Do not use an oil-based cleaner because grout will not bond to it.

2. Build a dam around foundation (Fig. 9A). Thoroughly wet foundation.

3. Pour grout slowly through grout holes in baseplate, until level with the top of the dam. The use of non-shrink epoxy grout is recommended, follow manufacturers recommendations. If cementitious grout is used, remove air by puddling or with a vibrator (Fig. 9A).

Fig. 9A

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4. Allow grout to set.

6. Allow grout to set at least 48 hours.

5. Fill remainder of baseplate with grout. Remove air as before (Fig. 9B).

Fig. 9B

PIPING

Guidelines for piping are given in the “Hydraulic Institute Standards” (Edition 14, Centrifugal pump section) and should be reviewed prior to pump installation.

1. All piping must be supported independently and must line up naturally with the pump flanges.

! WARNING

Never draw piping into place by forcing at the flanged connections of the pump. This will impose dangerous strains on the unit and cause misalignment between pump and driver. Pipe strain can adversely effect the operation of the pump. That could result in serious personal injury and damage to equipment.

2. Piping runs shall be designed to minimize friction losses.

3. DO NOT make final connection of piping to pump until grout has hardened and pump and driver hold-down bolts have been tightened.

7. Tighten foundation bolts.

Alignment Check

Re-check alignment before continuing, using methods previously described.

7. Gasket installation and materials must be suitable for the service.

SUCTION PIPING

Properly installed suction piping is a necessity for trouble free pump operation. Suction piping should be flushed BEFORE connection to the pump.

1. Use of elbows close to the pump suction flange should be avoided. There should be a minimum of 2 pipe diameters of straight pipe between the elbow and suction inlet. Any elbows used should be long radius.

2. Size suction pipe one or two sizes larger than pump suction, with a reducer at suction flange. Suction piping must never be of smaller diameter than the pump suction.

3. Reducers, if used, must be eccentric at pump suction flange with sloping side down.

4. Piping that handles hot liquids requires proper installation of expansion loops/joints so that linear expansion of piping will not cause mis-alignment.

5. Piping should be arranged to allow pump flushing and draining prior to the removal of pump for servicing.

6. System should be thoroughly cleaned prior to installation.

4. Suction strainers, when used, must have a net “free area” of at least three times the suction pipe area.

5. Separate suction lines are recommended when more than one pump is operating from the same source of supply.

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Suction Lift Conditions

1. Suction pipe must continuously slope upward towards pump suction to eliminate air pockets.

2. All joints must be air tight.

FINAL PIPING CHECK

After Connecting Piping to the Pump

1. Rotate shaft several times by hand to be sure that there is no binding and all parts are free.

3. A means of priming the pump must be provided, such as a foot valve.

Suction Head/Flooded Suction Conditions

1. An isolation valve should be installed in suction line to permit closing of the line for pump inspection and maintenance.

2. Piping should be level or slope gradually downward from source of supply.

3. No portion of piping should extend below pump suction flange.

4. The suction pipe shall be submerged sufficiently below the liquid surface to prevent vortices and air entrainment at the supply.

DISCHARGE PIPING

1. Isolation and check valves should be installed in discharge line. Locate check valve between isolation valve and pump which will permit inspection of check valve. An isolation valve is required for isolating, priming, regulation of flow, inspection and maintenance of the pump. A check valve prevents pump damage due to reverse flow when driver is turned off.

2. Check alignment, per the alignment procedure outlined previously to determine absence of pipe strain. If pipe strain exists, correct piping.

2. Increasers, if used, should be placed between pump and check valves.

3. Cushioning devices should be used to protect pump from surges and water hammer, if quick-closing valves are installed in system.

3296 M Group 6/05 17

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18 3296 M Group 6/05

Page 23

OPERATION

PREPARATION FOR START-UP ......................19

Flushing Pump ................................................19

Checking Rotation .............................................19

Couple Pump and Driver ........................................20

Install Coupling Guard ..........................................20

Lubricating Bearings............................................20

Connect Condition Monitoring Devices .............................20

Priming Pump .................................................20

STARTING PUMP ...............................21

OPERATION ..................................21

General Considerations ..........................................21

Operating at Reduced Capacity ...................................21

Operating Under Freezing Conditions ..............................21

SHUTDOWN ..................................22

FINAL ALIGNMENT .............................22

PREPARATION FOR START-UP

FLUSHING PUMP

The 3296 is flushed with Ethylene Glycol Solution at the factory to prevent accidental freezing during shipping or storage at the customers site. Residual amounts will remain in the pump but if this is a problem, the 3296 can be flushed out following the below procedure before pump is installed.

Procedure

1. Remove flush liquid supply.

2. Devise a means of collecting flush liquid as it drains out the suction nozzle or casing drain if supplied.

3. Turn flush supply on and run for 5 minutes to remove Ethylene Glycol residue.

4. When done, raise the coupling end of the pump (suction flange down) to drain remaining flush liquid from pump internals. Or, if pump is equipped with a casing drain plug, remove it to drain remaining liquid.

" NPT plug (408A) and connect clean

! WARNING

Failure to properly lift and support equipment could result in serious injury or damage to pumps.

5. Replace any plugs removed and continue preparation for start up.

CHECKING ROTATION

! CAUTION

Serious damage may result if pump is run in the wrong rotation.

1. Lock out power to driver.

! WARNING

Lock out driver power to prevent accidental start-up that could result in serious personal injury.

2. Make sure coupling spacer is removed and coupling hubs are fastened tightly to the shafts and are not loose.

3296 M Group 6/05 19

Page 24

NOTE: Pump is shipped with coupling spacer removed.

3. unlock driver power.

4. Make sure everyone is clear. Jog driver just long enough to determine direction of rotation. Rotation must correspond to arrow on bearing frame.

Pure Oil Mist Lubrication - Pure oil mist is an optional feature for the 3296. If your pump is equipped with pure oil mist refer to oil mist generator manufacturer’s instruction book for proper operation.

! WARNING

Operation of the unit without proper lubrication will cause bearing failure, and pump seizure.

5. Lock out power to driver.

COUPLE PUMP AND DRIVER

! WARNING

Lock out driver power to prevent accidental start-up that could result in serious personal injury.

Lubricate coupling per manufacturer’s instructions and install coupling spacer.

INSTALL COUPLING GUARD

Install coupling guard as defined in the appendix.

! WARNING

Never operate a pump without a coupling guard properly installed. Operating pump without a properly installed coupling guard can result in serious personal injury.

LUBRICATING BEARINGS

Flood Oil Lubrication - Pumps are shipped without

oil. Fill bearing frame with oil, through filler connection until oil level reaches center of sight-glass (Fig A). A high quality turbine type oil, with rust and oxidation inhibitors should be used as specified in Table 5.

CONNECT CONDITION MONITORING DEVICES

Always connect thermocouple to control panel and/or temperature switch in driver starter. If unit is also equipped with leak detection and vibration monitoring systems, these must also be connected. (See Appendix for wiring diagrams.)

PRIMING PUMP

Never start pump until properly primed (pump casing and suction piping are full of liquid). Components such as internal sleeve bearings depend on liquid for lubrication and will quickly fail if run dry.

Your particular system conditions will dictate method used to prime pump.

Fig. A

20 3296 M Group 6/05

Page 25

STARTING PUMP

1. Make sure suction valve and any recirculation or cooling lines are open.

2. Fully close or partially open discharge valve as dictated by system conditions.

3. Start driver.

! CAUTION

Immediately observe pressure gauges. If discharge pressure is not quickly attained - stop driver, reprime and attempt to restart.

4. Slowly open discharge valve until the desired flow is obtained.

OPERATION

GENERAL CONSIDERATIONS

Always vary capacity with valve in discharge line. NEVER throttle flow from suction side.

Driver may overload or magnets de-couple if pumpage specific gravity (density) is greater than originally assumed, or rated flow rate is exceeded.

Always operate the pump at or near the rated conditions to prevent damage resulting from cavitation or recirculation.

! CAUTION

Do not operate above rated temperature range of magnets as this will weaken or ruin the magnets.

Table 3

Temperature Ratings

Magnetic Types

Neodymium Iron

NdFe

Samarium

Cobalt

SmCo

Drive

Designation

A,B,C,D,E,F 250°F (120°C)

AA,BB,CC,DD,

EE,FF

OPERATING AT REDUCED CAPACITY

Rated

Temperature

425°F (220°C)

! CAUTION

Continuous operation against closed discharge valve will cause pump to overheat. Overheating the magnetic drive assembly will weaken or ruin the magnets.

! WARNING

Continuous operation against closed discharge valve may vaporize liquid creating an explosive hazard due to confined vapor under high pressure and temperature.

Table 4

Minimum Allowable Flow

Minimum Flow*

60 Hertz 50 Hertz

Pump

Group

* Based on water with a specific Gravity of 1.0 and

Specific Heat of 1.0

Size

2x3-8 60 32 11 6 3x4-8 - 112.5 40 23

3x4-8G 150 75 30 14

1x2-10 17 8.5 3 1.6 2x3-10 80 44 16 8

3x4-10H - 150 - 28

x3-13 - 41 - 8

2x3-13 - 80 - 15

GPM m

3600 1800 2900 1500

OPERATING UNDER FREEZING CONDITIONS

Exposure to freezing conditions, while pump is idle, could cause liquid to freeze and damage the pump. Liquid inside pump should be drained. Liquid inside cooling coils, if supplied, should also be drained.

! WARNING

Do NOT operate pump below minimum rated flows or with discharge valve closed. These conditions may vaporize liquid creating an explosive hazard due to confined vapor under high pressure and temperature.

3296 M Group 6/05 21

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SHUTDOWN

1. Slowly close discharge valve.

2. Shut down and lock out driver to prevent accidental rotation.

FINAL ALIGNMENT

1. Run the unit under actual operating conditions for a sufficient length of time to bring the pump and driver up to operating temperature.

! WARNING

When handling hazardous and/or toxic fluids, skin, eye and respiratory protection are required. If pump is being drained, precautions must be taken to prevent injury or environmental contamination. Pumpage must be handled and disposed of in conformance with applicable environmental regulations.

2. Check and reset alignment per alignment procedure outlined earlier.

3. Reinstall coupling guard per instruction in appendix.

22 3296 M Group 6/05

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PREVENTIVE MAINTENANCE

GENERAL COMMENTS ...........................23

MAINTENANCE SCHEDULE ........................23

MAINTENANCE OF BEARINGS ......................24

TROUBLESHOOTING ............................25

GENERAL COMMENTS

A routine maintenance program can extend the life of your pump. Well maintained equipment will last longer and require fewer repairs. You should keep maintenance records, this will help pinpoint potential causes of problems. A sample form is in the appendix that can be copied and used for this purpose.

MAINTENANCE SCHEDULE

Routine Maintenance

Bearing lubrication

Temperature monitoring

Vibration analysis

Discharge pressure

Routine Inspections

Check level and condition of oil through sight glass on bearing frame.

Check for unusual noise, vibration, and bearing temperatures.

Inspect pump and piping for leaks.

3 Month Maintenance

Check foundation hold down bolts of motor and pump for tightness.

Change oil per section V-C.

Check alignment per section III-B.

Yearly Inspections

Check pump capacity, pressure, and power. If the pump performance does not satisfy your process requirements, the pump should be disassembled and inspected. Worn parts should be replaced.

3296 M Group 6/05 23

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MAINTENANCE OF BEARINGS

OIL LUBRICATED BEARINGS

Oil level is measured through sight glass. Oil level must not fall below center of site glass. An increase in level may be noted after start up due to oil circulation within the bearing frame. Change Oil after 200 hours for new bearings, thereafter every 4000 operating

Bearing Frame Lubrication Requirement

Pumpage Temp. of

Oil Grades

ISO Grade VG 68 Synthetic VG 68

Approximate SSU

100°F (38°C)

DIN 51517 C 68 Synthetic C68

Kenematic Viscosity at 40°C

(105°F)

(mm

/sec)

Acceptable

less than 325°F (160°C)

Exxon Teresstic EP 68 Chevron GTS Oil 68 Mobil DTE 26 Gulf Harmony 68 Shell Tellus Oil 68 Phillips Mangus Oil 315 Phillips MM SAE 20-20W Phillips HDS SAE 20-20W

hours or 6 months, which ever period is shorter. Change oil every 2000 operating hours under severe operating conditions, such as high temperature services [pumpage temperatures in excess of 325°F (160°C)].

We recommend using Table 5 to help determine your lubricating oil needs.

Table 5

Pumpage Temp. of

325° - 375°F

(160° - 190C°)

with bearing frame cooling

300 Synthetic 300

68 Synthetic 68

Pumpage Temp. of greater than 375°F

(190°C)

with bearing frame cooling

Royal Purple Synfilm 68

NOTE: This is a list of oils that meet the lubrication requirements of this pump. It is not intended to be an endorsement of products listed nor exclude other oils that meet these requirements.

24 3296 M Group 6/05

Page 29

Table 6

Troubleshooting Pump

PROBLEM /

MALFUNCTION PROBABLE CAUSE REMEDY

No liquid delivered

Pump not producing rated flow or head

Pump starts then stops pumping

Pump not primed.

Suction line clogged.

Impeller clogged with foreign material. Disassemble and remove blockage.

Magnet de-coupling

Air leak in suction line Check for leakage and correct.

Impeller partly clogged Back flush pump to clean impeller

Worn impeller rings Replace defective part as required

Insufficient suction head

Worn or broken impeller Inspect and replace if necessary

Improperly primed pump Reprime pump

Air leak in suction line Check for leakage and correct

Magnet de-coupling

Air or vapor pockets in suction line

Reprime pump, check that pump and suction line are full of liquid.

Check suction line pressure. If low, locate and remove obstructions.

Shut down. Check temperature and viscosity of pumpage. Check magnets with breakaway torque test.

Ensure that suction line shutoff valve is fully open and line is unobstructed. Check suction pressure

Shut down. Check temperature and viscosity of pumpage. Check magnets with breakaway torque test.

Rearrange piping as necessary, to eliminate air pockets

Bearings run hot

Pump is noisy or vibrates

Improper lubrication Check lubricant for suitability and level

Lube cooling Check cooling system

Improper alignment Check pump alignment

Improper pump/driver alignment Align shafts

Partly clogged impeller causing imbalance

Broken or bent impeller or shaft Replace as required

Base not rigid enough

Worn bearings Replace

Suction or discharge piping not anchored or properly supported

Pump is cavitating Increase NPSH available.

Disassemble and remove blockage

Tighten hold down bolts of pump and motor or adjust stilts. Check grout.

Anchor per Hydraulic Institute Standards recommendations (Edition 14, Centrifugal pump section).

3296 M Group 6/05 25

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Table 6

Troubleshooting Pump

PROBLEM /

MALFUNCTION PROBABLE CAUSE REMEDY

Motor requires excessive power

Condition monitoring device shuts down pump

Head lower than rating. Pumps too much liquid

Liquid heavier than expected. Check specific gravity and viscosity.

Head higher than rating, capacity at rating

Rotating parts binding or severly worn

Damaged sleeve & thrust bearings Replace as required.

Plugged recirculation circuit

Recirculation liquid vaporization

Damaged containment shell Replace as required.

Magnets decoupled

Pump run dry

Excessive motor power

Install throttle valve.

Check impeller diameter.

Check internal wearing parts for proper clearances.

Disassemble and remove blockage. Determine and correct cause of blockage.

Check actual liquid temperature versus design temperature. Check actual NPSH available versus design. Check minimum flow requirement for pump size. Check recirculation circuit and flush screen for blockage. Correct all as necessary.

Check temperature and viscosity of pumpage. Check magnets with breakaway torque test.

Check control device for proper operation. Check

suction line for blockage. Reprime pump.

System head lower than rating. Pumps too much liquid. Check rotating parts for binding and wear. Liquid heavier than expected.

26 3296 M Group 6/05

Page 31

DISASSEMBLY & REASSEMBLY

REQUIRED TOOLS ..............................27

PREPARATION FOR DISASSEMBLY ...................29

DISASSEMBLY.................................29

INSPECTIONS .................................36

Casing .......................................................36

Wear Ring Clearances...........................................36

Impeller......................................................37

Flush Screen ..................................................37

Frame Adapter ................................................37

Silicon Carbide Bearings ........................................38

Containment Shell..............................................38

Magnets......................................................38

Bearing Frame.................................................38

REASSEMBLY .................................39

SECTIONALS, PARTS LIST, MATERIALS OF CONSTRUCTION ....50

REQUIRED TOOLS

! WARNING

This pump contains extremely strong magnets. The use of non-magnetic tools and work surface are required.

Non-Magnetic Tools

1-5/16" Socket wrench with 6" minimum extension

9/16" Socket wrench with speed handle

Tools

NOTE: Keep magnetic tools away from magnets.

3296 Tool Kit

Assorted Open end wrenches

3/4", 15/16" sockets

Socket wrench with minimum 4" minimum extension

Needle nose pliers

Torque wrench

Screw drivers

1/2", 5/8" stud drivers

Lip seal driver

Non-metallic hammer

Hammer

Heat gun

Non-Magnetic Support blocks

3296 M Group 6/05 27

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Table 7

3296 M Tool Kit #R296TK01

Tool Use Qty Tool Number Mat’l

B O-ring Installation Tool 1 A03817A Nylon C Shaft Wrench 1 A01676A 304SS

E Sleeve Bearing Driver 1 A03817A Nylon

Bearing Frame Jacking Screw Drive Carrier Jacking Screws

Wear Ring Jacking Screw Wear Ring Alignment Screw End Cover Jacking Screw

4 A03777A02 304SS

3 49521 61 304SS

28 3296 M Group 6/05

Page 33

PREPARATION FOR DISASSEMBLY

! WARNING

The 3296 usually handles hazardous and/or toxic fluids. Skin, eye and respiratory protection required. Precautions must be taken to prevent injury or environmental contamination.

! WARNING

If pump has failed, pumpage may be present in the area between the adapter and the frame and also inside of the bearing frame.

1. Lock out power to driver.

2. Shut off all valves controlling flow to and from pump.

3. Drain and decontaminate pump in accordance with all Federal, State, local and company regulations. The 3296 should be drained and thoroughly flushed before it is removed from the piping. After isolating the pump from the system flush the pump using a compatible liquid.

DISASSEMBLY

! WARNING

Ensure pump is isolated from system and pressure is relieved before any plugs are removed or piping disconnected.

4. To decontaminate pump recirculation path, remove plug 408A and inject flush into external flush connection.

5. Disconnect all piping and auxiliary equipment.

6. Remove coupling guard.

7. Remove coupling.

NOTE: If the only service required is to change the impeller, the flush screen or the wear ring, please refer to the appendix “Changing the Impeller”.

8. Remove casing foot and bearing frame foot bolts.

9. Remove bare pump from baseplate and take to shop.

! WARNING

Each component must be individually decontaminated using procedures in accordance with all federal, state, local and company environmental regulations.

! WARNING

The magnets contained in this unit are extremely powerful. Keep magnetic drive components and magnetic tools apart from each other by a minimum of six (6) feet [two (2) meters]. Serious injury to fingers and hands will result.

NOTE: When working on pump use a bench with a non-magnetic work surface such as wood with a brass surface.

! CAUTION

The shop area must be clean and free of any substances that would contaminate the magnets, ex. ferrous metals.

1. Remove thermocouple (758B) (Fig. A).

2. Remove casing nuts (425). Remove casing (100) (Fig. A).

3. Remove casing gasket (351) and discard (Fig. A).

4. Place shaft wrench on coupling end as shown. Remove impeller bolt (198), impeller lockwasher (199A) and impeller washer (199) (Fig. B).

3296 M Group 6/05 29

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5. Place unit in vertical position resting on non-magnetic blocks (Fig. C).

! WARNING

Pump and some individual components weigh more than 50 lbs (23 kg). Care should be taken when handling.

6. Remove frame adapter bolts (370) (Fig. C).

! WARNING

Do NOT attempt to remove bearing frame (228) without using the jacking screws. Personal injury and damage to the magnets will occur.

8. Evenly tighten bearing frame jacking screws until bearing frame (228) is above containment shell (750) as shown. Lift bearing frame (228) off frame adapter (108) and set aside away from attracting metals.

Use of a lifting device with a strap through two opposite eyes in the jacking screws is recommended.

Remove adapter to frame gasket (360W) and discard (Fig. E).

! WARNING

The magnets contained in this unit are extremely powerful. Keep magnetic drive components and magnetic tools apart from each other by a minimum of six (6) feet [two (2) meters]. Serious

7. Remove bearing frame using four (4) jacking screws (Fig. D).

injury to fingers and hands will result.

! WARNING

This component can weigh more than 50 lbs (23 kg). Care should be taken when handling.

30 3296 M Group 6/05

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9. Remove clamp ring screws (370B) and lock washers (136A) (Fig. F).

NOTE: Place a folded clean cloth or cardboard under frame adapter assembly to soften impact of driven magnet assembly (740A) on work surface. Shaft and magnet assembly should rest on work surface.

13. Remove impeller (101) (Fig. H).

NOTE: It may be necessary to use a puller. Puller must be placed under vanes so as not to damage the impeller.

! WARNING

Use non-magnetic socket and speed wrench to avoid personal injury or damage to parts.

10. Remove clamp ring (141C) and containment shell (750) simultaneously (Fig. F).

11. Remove O-ring (412M) and discard (Fig. F).

12. Orient frame adapter assembly in vertical position and support on blocks (Fig. G).

14. Press driven shaft (122A) out until it disengages (Fig. I).

NOTE: Light tapping with a non-metallic hammer may be necessary to disengage shaft.

3296 M Group 6/05 31

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! WARNING

15. Lift frame adapter (108) off shaft (122). Set aside.

18. Press driven shaft (122A) out of driven magnet assembly (740A). Remove key (178X) (Fig. K).

19. Wrap driven magnet assembly (740A) in a clean cloth to keep clean and set aside away from attracting metals.

! WARNING

NOTE: Outboard rotary sleeve bearing will remain on shaft.

! WARNING

This component can weigh more than 50 lbs (23 kg). Care should be taken when handling.

16. Remove thrust bearing holder key from shaft (178S) (Fig. J).

17. Remove outboard rotary sleeve bearing (117C) and two spacer gaskets (360). Discard spacer gaskets (Fig. J).

178S

20. Remove and discard four shaft O-rings (497P) (Fig. L). Set shaft aside.

21. Place frame adapter (108) on work bench as shown. Remove wear ring bolts (353B) and flush screen (187) (Fig. M).

32 3296 M Group 6/05

Page 37

22. Place wear ring jacking screws in threaded jacking screw holes in wear ring (144) as shown. Tighten bolts evenly and in sequence until wear ring (144) can be removed (Fig. N).

NOTE: Do not over tighten jacking bolts. Tighten until snug and move to next one in sequence.

23. Remove wear ring (144) and stationary bearing key (178K) (Fig. N).

25. Set frame adapter (108) on blocks, impeller side down, and place clean cloth underneath as shown to absorb impact when bearings drop (Fig. P).

! CAUTION

The bearing material is extremely brittle. Take every precaution necessary to avoid shock to the bearings.

26. Press out thrust bearing assembly (212) and inboard stationary sleeve bearing (117B) using hand pressure and sleeve bearing driver oriented as shown (Fig. P).

Jacking Screws

24. Remove inboard rotary sleeve bearing (117D) and two spacer gaskets (360) (Fig. O). Discard gaskets.

27. Set aside thrust bearing assemblies (212) and outboard stationary sleeve bearing (117B).

28. Press outboard stationary sleeve bearing (117A) out of frame adapter (108) using sleeve bearing driver oriented as shown (Fig. Q).

Sleeve Bearing Driver

29. Invert frame adapter (108), impeller end up, and set on bench. Remove outboard stationary O-rings (496A) and inboard stationary O-rings (496B). Discard O-rings (Fig. R).

3296 M Group 6/05 33

Page 38

30. Bolt or clamp bearing frame (228A) to bench (Fig. S).

31. Place shaft wrench on drive shaft (122B) and loosen the drive magnet assembly hex nut (355A) until it can be removed by hand. Leave nut on shaft for now (Fig. T).

! WARNING

Use non-magnetic socket and extension to avoid personnel injury or damage to parts.

Fig. R

Fig. T

32. Remove two rub ring retaining screws (372Y) (Fig. U).

33. Thread two rub ring jacking screws into holes provided in rub ring (144A) until they bottom (Fig. U).

34. Tighten jacking screws until rub ring can be removed.

Fig. S

Fig. U

35. Carefully invert bearing frame assembly, drive magnet assembly up. Clamp firmly to work bench (Fig. V).

! WARNING

This component can weigh more than 50 lbs (23 kg). Care should be taken when handling.

34 3296 M Group 6/05

Page 39

NOTE: A workbench with a two inch hole in the surface to accommodate the coupling end of shaft works well (Fig. V).

Fig. V

Fig. W

36. Remove drive magnet assembly nut (355A) from shaft (Fig. W).

37. Thread the drive carrier jacking screws into holes provided in drive magnet assembly (740B) until screws bottom against frame (Fig. W).

38. Tighten jacking screws evenly and in sequence until drive magnet assembly is free from shaft.

Using a lifting strap through the eyebolts and a lifting device, raise drive magnet assembly.

Remove from frame and set aside away from attracting metals (Fig. W).

! WARNING

This component can weigh more than 50 lbs (23 kg). Care should be taken when handling.

! WARNING

40. Remove bearing end cover bolts (370C) (Fig. X).

41. Install jacking screws in jacking screw holes, tighten evenly to back off bearing end cover (109A) (Fig. X).

42. Slide bearing end cover (109M) back. Labyrinth oil seal (332A) will slide back with end cover (Fig. X).

43. Remove labyrinth seal (332A) (Fig. X).

44. Remove bearing end cover (109A). Remove gasket (360A) and discard (Fig. X).

39. Remove drive magnet assembly key (178Y) (Fig. W).

Fig. X

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45. Remove bearing wavewasher (529) from bearing bore (Fig. Y).

46. Remove drive shaft (122B) with ball bearings (112) from bearing housing (228) (Fig. Y).

Fig. Y

INSPECTIONS

47. Press bearings (112) off shaft and discard.

48. Remove lip seal (333D) as shown and discard (Fig. Z).

Fig. Z

Model 3296 parts must be inspected to the following criteria before reassembly to ensure pump will run properly. Any part not meeting required criteria should be replaced.

NOTE: Various tolerances specified on the 3296 are held extremely close, measure parts at standard temperature 68°F(20°C) to ensure accurate measurement.

CASING (100)

Casing (100) should be inspected for excessive wear or pitting. It should be repaired or replaced if it exceeds the following criteria.

Table 8

Minimum Casing

Thickness

Minimum

Thickness Inches

Group Pump Size

2x3-8 3x4-8 3x4-8G

1x2-10 2x3-10 3x4-10H

x3-13

2x3-13

(mm)

0.31 (7.9)

0.37 (9.4)

WEAR RING CLEARANCES

Refer to Table 9 to check wear ring clearances.

36 3296 M Group 6/05

Page 41

Group Size

2x3-8

3x4-8

3x4-8G

1x2-10

2x3-10

3x4-10H

x3-13

2x3-13

Table 9

Diametrical Wear Ring Clearance

LOCATION

Impeller to casing

in. (mm)

New Replace New Replace New Replace New Replace

.024 - .028

(.61 - .71) .026- .030

(.66 - .76)

.026 - .030

(.66 - .76)

.022 - .026

(.56 - .66)

.026 - .030

(.66 - .76)

.027 - .031

(.69 - .79)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

.048 (1.22)

.052 (1.32)

.044 (1.12)

.052 (1.32)

.054 (1.37)

.052 (1.32)

Impeller to wear ring

.024 - .028

(.61 - .71)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

.026 - .030

(.66 - .76)

in. (mm)

.048

(1.22)

.052

(1.32)

.052

(1.32)

.052

(1.32)

.052

(1.32)

.052

(1.32)

.052

(1.32)

.052

(1.32)

Driven magnet

to adapter

in (mm)

.024 - .028

(.61 - .71)

.048 (1.22)

Drive Magnet

to Rub Ring

in (mm)

.067 - .073

(1.70 -

1.85)

.090 (2.29)

IMPELLER (101)

1. Inspect wear ring surface for signs of pitting.

2. Inspect front and back wear ring clearance per wear ring clearance Table 9.

3. Inspect leading and trailing edges of vanes for pitting, and erosion or corrosion damage.

4. Check impeller bore and keyway. Bore should measure .7490 to .7505 in. (19.025 to 19.063 mm). If oversize, replace impeller.

5. Check impeller balance per Table 10. Values are based on ISO - 1940/1 grade 2.5 at 3000 RPM.

Table 10

Impeller Balance Specification

Part # Pattern # Part Name oz-inches

C03333A 68455 2x3-8 Impeller .04

C03363A 68491 3x4-8 Impeller .06

C03362A 68490 3x4-8G Impeller .05

C03335A 68456 1x2-10 Impeller .06

C03172A 68325 2x3-10 Impeller .06

C03367A 68457 3X4-10H Impeller .07

C03360A 68358 1.5x3-13 Impeller .09

C03265A 68383 2x3-13 Impeller .09

FLUSH SCREEN (187)

1. Must be clean and free from holes or tears.

2. Inspect for erosion and corrosion.

FRAME ADAPTER (108)

1. Inspect wear ring clearances per clearance Table

2. Check all internal recirculation passages to make sure they are open and free from excessive wear due to erosion or corrosion.

3296 M Group 6/05 37

Page 42

SILICON CARBIDE BEARINGS (117A-D)

Sleeve Bearings

1. Inspect bearings for cracks and chips.

2. Inspect dimensions per Table 11.

Table 11

Bearing Clearances

Group Location

Shaft to Bearing

Thrust Bearings (237)

1. Inspect for cracks or chips.

Bearing to

Bearing

Bearing to

Adapter

New Clearance

in. (mm)

.0045 - .0065

(.114 - .165)

.003 - .006

(.076 - .152)

.0015 - .0035

(.038 - .089)

Replace

in. (mm)

.0085

(.216)

.008

(.203)

.0055

(.140)

CONTAINMENT SHELL (750)

1. Wall thickness .050 in. (1.3 mm) minimum.

2. Must be free from pitting or cracks.

3. Grooves in excess of .005 in. (.13 mm) require containment shell replacement.

MAGNETS (740A & B)

Driven Magnet Assembly (740A)

! WARNING

Drive Magnet Assembly (740B)

! WARNING

NOTE: The magnets are extremely brittle. It is normal to have chips (up to 10% of the magnet

surface) per MMPA standard no. 0100-90.

1. Magnets must be free of major cracks (extending over 50% of surface) and also free of imperfections that create loose particles.

2. If magnets and drive magnet carrier were exposed to product, they should be replaced.

3. Inspect drive magnet carrier for cracks and replace if any are found.

4. Drive magnet carrier hub O.D. must be free from grooves and scratches greater than .005 in. (.13 mm).

5. Inspect magnets for proper bonding to metal carrier.

BEARING FRAME (228)

1. Visually inspect frame and frame foot for cracks.

2. Inspect for corrosion or pitting if frame has been exposed to pumpage

3. Inspect frame bearing bores. The maximum acceptable bore is 3.1506 in. (80.025 mm).

4. Inspect ball bearings for contamination and damage.

1. Must be free from bulges.

2. Must be free of pits and scratches exceeding .005 in. (.13 mm) deep.

3. Must be free of erosion or corrosion exceeding .005 in. (.13 mm) deep.

4. Inspect wear ring clearance per wear ring clearance Table 9.

5. Check pump-out vanes for cracks or corrosion.

6. Ensure circulation holes are open.

5. Make sure gasket surfaces are clean.

6. Visually inspect bearing end cover (109A) for cracks and pits. Gasket surface must be clean.

7. Inspect labyrinth seal O-rings (332A) for cuts and cracks.

8. Replace lip seal.

38 3296 M Group 6/05

Page 43

REASSEMBLY

Please refer to the Appendix for assembly and inspection checklist for your convenience. Make a copy and checkoff parts as they are assembled.

Refer to Table 12 for torque values while reassembling pump.

Table 12

*Bolt Torque Table

Ft-Lbs (Nm)

Location

Drive Magnet Assy Nut (355A)

Wear Ring Screw (353B)

Clamp Ring Screws (370B)

Impeller Nut (198)

Adapter to Frame Srews (370)

Casing Nuts (425) * Torque values based on Dry Threads

! WARNING

Dry

Threads

120 (160)

17 (25) 12 (16) 45 (60) 50 (70) 45 (60)

3. Place the first spacer gasket (360) over driven shaft (122A) (Fig. B) and shoulder against driven magnet assembly.

NOTE: Use new spacer gaskets when reassembling.

NOTE: Spacer gaskets require care when handling to avoid damage.

4. Place O-ring installation tool on driven shaft (122A) and install impeller washer (199) and bolt (198), hand tighten. Install two outboard shaft O-rings (497P) (Fig. B).

NOTE: Cover first three O-ring (497P) grooves with tape before installing O-rings. Remove tape as necessary to install O-rings (497P). O-rings may have to be heat shrunk to be fully seated in O-ring grooves. Do not overheat O-rings

Fig. B

1. Install key (178X) on driven shaft (112A) (Fig. A).

NOTE: Ensure shaft O-ring, grooves, shaft keyways and keyway in driven carrier are free of burrs.

2. Install driven shaft (122A) into driven magnet assembly (740A) (Fig. A).

5. Put lube on O-rings.

6. Install outboard rotary sleeve bearing (117C) on driven shaft (122A) using bearing driver (Fig. C).

7. Place the second spacer gasket (360) over driven shaft (122A). Shoulder against outboard rotary sleeve bearing (117C) (Fig. C).

3296 M Group 6/05 39

Page 44

Fig. C

8. Set partially built driven assembly aside well away from attracting metals. Prepare to build up frame adapter assembly.

! WARNING

! CAUTION

Carefully stretch O-rings so when installed they fit securely in O-ring groove. Care must be taken not to over stretch the O-rings.

9. Install outboard anti-rotation pin (445B) in frame adapter (108) (Fig. D).

Fig. D

10. Install outboard stationary O-rings (496A) (Fig. E). Lubricate O-rings and bores.

Fig. E

11. Install inboard stationary O-rings (496B) (Fig. F). Lubricate O-rings.

40 3296 M Group 6/05

Page 45

Fig. F

12. Install outboard stationary sleeve bearing (117A) (Fig. G). The anti-rotation slot in bearing (117A) must line up with anti-rotation pin (445B) in outboard end of frame adapter (108). Press outboard stationary sleeve bearing (117A) in by hand using sleeve bearing driver.

14. With partially assembled rotating assembly positioned as shown install into partially built frame adapter assembly (Fig. H).

Fig. H

15. Carefully roll adapter with rotary assembly onto face of rotary assembly (impeller end of shaft facing up).

! WARNING

Ensure rotary assembly does not fall out of adapter. This could cause bodily injury and damaged parts.

16. Install a tolerance ring (505) into both thrust bearing holders (212) (Fig. I). Shoulder tolerance ring against face in thrust bearing holder.

NOTE: It may be necessary to form ring with your fingers to insure good contact between ring OD and holder bore.

Fig. G

13. Install thrust bearing holder key (178S) into driven shaft (122A) (Fig. H). Use a small amount of O-ring lube in keyway to hold key in place.

3296 M Group 6/05 41

Fig. I

Page 46

17. Install thrust collar bearing (237) (chamfered side in) into bore of thrust bearing with the tolerance ring (Fig. J). Ensure bearing is fully seated in holder.

Fig. J

NOTE: To ease assembly and minimize the risk of damage to the thrust bearing (237), the use of an arbor press is recommended during installation (Fig. K). Use a small amount of O-ring lube on the tolerance ring and O.D. of thrust collar before assembly.

19. Install thrust bearing holder gasket (428C) into groove on back of thrust bearing assembly on shaft (Fig. L). Use a small amount of O-ring lube in groove to hold gasket in place.

20. Install the other thrust bearing holder onto the shaft with the bearing facing up (towards the impeller end) (Fig. L). Again, carefully align the keyway with the key.

21. Place the third spacer gasket (360) over driven shaft and shoulder against inboard thrust bearing assembly (Fig. L).

NOTE: Ensure thrust holder key and keyways are free of burrs.

NOTE: Take a pencil and make a reference mark locating the thrust bearing key (178S) in relation to the frame adaptor. This will help align the keyway of the thrust bearing assemblies (212) with the thrust bearing key (178S).

Fig. L

22. Place O-ring installation tool on driven shaft (122A) and install impeller washer (199) and bolt

Fig. K

18. Install one of the thrust bearing assemblies onto the shaft with the bearing facing down (towards the driven magnet assembly)

(198) as before (Fig. B). Install two shaft O-rings (497P) and then remove tool.

NOTE: Tape first groove on shaft to allow O-ring to slide over. O-ring may have to be heated to seat in groove. Do not overheat O-rings.

(Fig. L). Be careful to align the keyway on the thrust bearing assembly with the thrust bearing key (178S) on the shaft.

42 3296 M Group 6/05

Page 47

23. Press inboard stationary sleeve bearing (117B) into frame adapter (108) by hand using bearing driver. The stationary inboard key slot in the inboard stationary bearing (117B) must line up with the woodruff key slot in the frame adapter (108) as shown. Press inboard stationary bearing in by hand using bearing driver (Fig. M).

Fig. M

24. Press inboard rotary sleeve bearing (117D) onto driven shaft (122A) using bearing driver (Fig. N).

178K

Fig. O

27. Install wear ring (144) (Fig. P). Place wear ring alignment screws through unthreaded holes in wear ring (144) and thread into wear ring bolt holes in frame adapter (108). These are used to align the wear ring holes in the frame adapter (108). Press wear ring (144) into the frame adapter (108). Remove alignment screws after wear ring is in place.

Fig. N

25. Install stationary inboard bearing key (178K) in

Fig. P

frame adapter (108) (Fig. O).

26. Install the fourth spacer gasket (360) (Fig. O) and shoulder against face of inboard rotary sleeve bearing (117D).

3296 M Group 6/05 43

28. Install flush screen (187) (Fig. Q).

29. Install wear ring clamp screws (353B) (Fig. Q).

Page 48

30. Bend long narrow tang of impeller lockwasher (199A) so tang will fit in slot on impeller washer (199) (Fig. R).

Fig. R

NOTE: Support bottom end of shaft to prevent shaft from moving during installation of thrust bearing assemblies and impeller.

NOTE: Ensure impeller key and keyway are free of burrs.

31. Install impeller key (178) and impeller (101) (Fig. S). Install impeller washer (199) and impeller bolt (198). Hand tighten impeller bolt (198) only.

NOTE: Unit can now be moved safely. Rotary assembly will not fall out of adapter once impeller is installed.

Fig. S

32. Place unit on non-magnetic blocks, as shown, with impeller facing down (Fig. T).

33. Install containment shell to adapter O-ring (412M) (Fig. U).

34. Install containment shell (750) and containment shell clamp ring (141C) (Fig. U).

35. Install containment shell clamp ring screws (370B) and lock washers (136A) (Fig. U). Torque per bolt Torque Table 12 in beginning of this section.

44 3296 M Group 6/05

Page 49

! WARNING

Use non-magnetic socket and speed wrench to avoid personal injury or damage to parts.

Fig. W.

38. Bolt or clamp bearing frame (228) to work bench (Fig. X).

36. Install ball bearings (112) on drive shaft (122B) (Fig. V).

NOTE: There are several methods used to install bearings. The preferred method is to use an induction heater that heats as well as demagnetizes the bearings.

37. Install inboard lip seal (333D) (Fig. W).

Fig. X

39. Install drive shaft (122B) with ball bearings (112) in bearing frame (228) as shown. The threaded end of the shaft goes toward the magnets (Fig. Y).

NOTE: It may be necessary to lightly press shaft with bearings into the bearing frame (228). It is important to press the bearings in by putting a sleeve on the inner race of the outboard ball bearing.

3296 M Group 6/05 45

Page 50

40. Place bearing wavewasher (529) in bearing bore and shoulder against outer race of outboard ball bearing (Fig. Y).

Fig. Y

41. Install bearing end cover gasket (360A) and bearing end cover (109A) (Fig. Z). Install bearing end cover screws (370C).

NOTE: Bolt pattern for the bearing end cover (109A) is not symmetric so the bearing end cover gasket (360A) and bearing end cover (109A) can only go on one way.

43. Carefully invert bearing frame assembly, drive magnet assembly up. Clamp firmly to workbench (Fig. AA)

! WARNING

Pump and some individual components weigh more than 50 lbs (23 kg). Care should be taken when handling.

NOTE: A workbench with a two inch (2 in.) hole in the surface to accommodate the coupling end of shaft works well (Fig. AA).

Fig. AA

42. Install labyrinth seal (332A). Ensure O-rings are in grooves of labyrinth seal. Orient expulsion ports to the 6 o’clock position and press stationary part into bearing end cover (109A) until it is shouldered against end cover. Slide rotating part of labyrinth seal on shaft until it is in contact with stationary part. No adjustment is necessary (Fig. Z).

NOTE: The bearing driver can be used to install stationary part of the labyrinth seal (332A) if necessary.

NOTE: Ensure drive carrier key and keyway are free of burrs.

44. Install drive magnet carrier key (178Y) on to drive shaft (122B) (Fig. BB).

45. Thread two drive carrier jacking screws into holes provided in drive magnet assembly (740B). Do not thread jacking screws past back side of magnet assembly. Using a lifting strap through the eyebolt and a lifting device, lower drive magnet assembly onto drive shaft. Be careful not to disengage key (178Y) (Fig. BB).

! WARNING

Pump and some individual components weigh more than 50 lbs (23 kg). Care should be taken when handling.

46. Thread drive magnet assembly nut (355A) on shaft and hand tighten (Fig BB).

46 3296 M Group 6/05

Page 51

Fig. BB

47. Place frame horizontal and rebolt to workbench (Fig. X).

! CAUTION

Do NOT hammer drive magnet assembly (740B) on to shaft. this will damage ball bearings (112).

48. Place shaft wrench on drive shaft (122B). Torque nut (355A) per Torque Table 12 in this section.

! WARNING

Use non-magnetic socket and extension wrench to avoid personal injury or damage to parts.

49. Install one gasket (360W) in bearing frame. Install rub ring (144A) so that the two milled slots are at the 3:00 and 9:00 positions. Thread the rub ring retaining screws (372Y) into each side of the frame. Tighten screws ensuring they are fully engaged into milled slots on rub ring (Fig. CC)

Fig. CC

50. Install bearing frame jacking screws into bearing frame (228) (Fig. DD).

! WARNING

When installing jacking screws make sure threads extends a minimum of 8 inches beyond inside face of bearing frame (228). Serious personal injury or damage to the drive magnet assemble (740B) will result if this is not done.

! WARNING

Eight

! WARNING

If rub ring retaining screws are not fully engaged, ring may fall out during installation of adapter assembly. This could cause personal injury and damage to parts.

3296 M Group 6/05 47

Page 52

51. Place frame adapter assembly on blocks (Fig. EE).

! WARNING

The frame adapter (108) must be completely supported before proceeding. If unit is not stable it may tip over which can result in personal injury or damage to the unit.

52. Install a second rub ring gasket (360W) (Fig. EE).

53. Place bearing frame (228) on frame adapter (108) (Fig. EE). Use of a lifting device with a strap through the opposite eyes in the jacking screws is required.

! WARNING

Pump and some individual components weigh more than 50 lbs (23 kg). Care should be taken when handling.

NOTE: Bearing frame jacking screws pass through the clearance holes in the adapter (108). The top of the adapter (108) has two NPT holes in it. Make sure the top of the bearing frame (228) and the top of the frame adapter (108) coincide.

54. Lower bearing frame (228) on to frame adapter (108) using jacking screws. Jacking screws should be backed off in sequence so that bearing frame (228) is lowered evenly. Lower bearing frame (228) until it is firmly seated in frame adapter. Remove jacking screws (Fig. EE).

55. Install frame-to-adapter bolts (370) into frame adapter as shown. Torque bolts per Torque Table 12 at the beginning of this section (Fig. FF).

Fig. FF

56. Remove unit from blocks and place on bench (Fig. GG). Place shaft wrench on coupling end of drive shaft (122B) as shown and tighten impeller screw (198) refer to Torque Table 12 at beginning of this section.

57. Check rotary assembly end play by placing a dial indicator on the face of the impeller. End play should be between .020 and .060 in. (.5 to 1.5 mm).

58. Bend one of the impeller lockwasher tangs that best lines up with flat on impeller bolt against that flat.

59. Install casing gasket (351), casing (100) and casing nuts (425) (Fig. HH).

48 3296 M Group 6/05

Page 53

60. Tighten casing nuts (425) in a crisscross pattern and refer to Torque Table 12 at the beginning of this section for torque values.

61. Install thermocouple (458) (Fig. HH).

62. Install all plugs and auxiliary equipment.

63. Turn drive shaft (122B), to check for freedom of rotation.

64. Install pump on baseplate, connect piping, align driver in accordance with sections 1 through 4 of this manual.

3296 M Group 6/05 49

Page 54

SECTIONALS

50 3296 M Group 6/05

Page 55

3296 M Group 6/05 51

Page 56

52 3296 M Group 6/05

Page 57

PARTS LIST AND MATERIALS OF CONSTRUCTION

Item Qty/ Pump Construction

No. Pump Part Name 316SS Alloy 20 Hastelloy C

100 101 108

109A

112 113A 117A

117B

117C 117D 122A

122B 136A

141C

144

144A

178

178K

178S 178X 178Y

187 198 199

199A

212 228 237 241

319 332A 333D

351

353B 355A 356A

358W

360

360A

360W

370 370B 370C 370F

372Y

408

408A

408B

412M

425 428C

437

Casing

Impeller

Adapter

Bearing End Cover

Ball Bearing

Oil Filler Plug

Outboard Stationary Sleeve Bearing

Inboard Stationary Sleeve Bearing

Outboard Rotating Sleeve Bearing

Inboard Rotating Sleeve Bearing

Driven Shaft

Drive Shaft

Lockwasher

Containment Shell Clamp Ring

Wear Ring

Rub Ring

Impeller Key

Stationary Inboard Bearing Key

Thrust Bearing Holder Key

Driven Magnet Carrier Key

Drive Magnet Carrier Key

Flush Screen

Impeller Cap Screw

Impeller Washer

Impeller Lock Washer

Thrust Bearing Holder

Bearing Frame

Thrust Collar Bearing

Frame Foot

Sight Window (Not Shown)

Labyrinth Oil Seal

Lip Seal

Casing Gasket

Wear Ring to Adapter Cap Screw

Flange Hex Nut

Casing Stud

Pipe Plug – 1/4" (not shown) Spacer Gaskets

Bearing End Cover Gasket

Adapter to Frame Gasket

Adapter to Frame Cap Screw

Containment Shell to Adapter Hex Cap Screw

Bearing End Cover Cap Screw

Frame Foot Cap Screw

Rub Ring Cap Screw

Drain Plug (not shown) Adapter Pipe Plug - 1/2"

Adapter Flush Plug - 3/8" Containment Shell to Adapter O-ring

Casing Nut

Holder Gasket

Frame Foot Lock Washer

1203 1204 1215 1203 1204 1215 1203 1204 1215

1013 Steel

Steel Silicon Carbide Silicon Carbide Silicon Carbide Silicon Carbide

2229 2230 2248

2238

2228

3211

1203 1204 1215

1104

2248

2213

316SS Hastelloy C Hastelloy C

2248

2229 2230 2248

1013 Silicon Carbide

1001

Glass/Steel

Carbon Filled Teflon

Buna Rubber

Grafoil

2248

2210

2228

2210

Grafoil

Varnished Kraft

Aramid Fiber with EPDM Binder

2228

2210

2228

2210

2229 2230 2248 2229 2230 2248

PFA Encapsulated Viton

2228

Grafoil

2210

3296 M Group 6/05 53

Page 58

PARTS LIST AND MATERIALS OF CONSTRUCTION

Item Qty/ Pump Construction

No. Pump Part Name 316SS Alloy 20 Hastelloy C

445B 496A 496B

497P

505 529

740A 1 740B 1

750 1

758B 1

Outboard Stationary Bearing Roll Pin

Outboard Stationary Bearing O-ring

Inboard Stationary Bearing O-ring

Driven Shaft O-ring

Tolerance Ring

Wave Washer

Driven Magnet Assembly Drive Magnet Assembly Containment Shell Thermocouple

PFA Encapsulated Viton PFA Encapsulated Viton PFA Encapsulated Viton

316SS Alloy 20 Hastelloy C

(con'td)

2248

Hastelloy C

Steel

1013 3212

Aluminum/304

* For 8" Pumps — Quantity is 8 For 10" Pumps — Quantity is 12 For 13" Pumps — Quantity is 16

Hastelloy™ is a Trademark of Haynes International, Inc. Teflon™ is a Trademark of E.I. DuPont Graphoil™ is a Trademark of Union Carbide

MATERIAL CROSS REFERENCE CHART

Cast Iron 1001 A48 Class 20

Ductile Iron 1013 A536 Gr60-42-10

Bronze 1104 B584-C93200

316SS 1203 A744 CF-8M

GA20 1204 A744 CN-7M

Hastelloy C 1215 A494 CW-7M Carbon Steel 2210 A108 Gr1211 Carbon Steel 2213 A108 Gr1018-B1112

304SS 2228 A276 Type 304 316SS 2229 A276 Type 316

Carpenter 20 2230 B473 (N08020)

4140 Steel 2238 A434 Gr4140

Alloy C-276 2248 B574 (N10276)

316SS 3211 A240 Type 316

Hastelloy C 276 3212 B575 (N10276)

Fasteners/Plugs

Carbon Steel 2210 A307 Gr.B.

Stainless Steel 2228 A193 B 316 Stainless Steel 2272 A193 B8M 316 Stainless Steel 2229 A193 B8

Alloy Steel 2239 A193 Grade B7

54 3296 M Group 6/05

Page 59

SPARE AND REPAIR PARTS

RECOMMENDED SPARES ..........................55

HOW TO ORDER ...............................56

INTERCHANGEABILITY ..........................57

RETURN OF MATERIALS ..........................58

When ordering parts, always refer to part name, Goulds serial No., and indicate item No. from the sectional drawing.

RECOMMENDED SPARES

Pump Repair Kit

M-Group - Part No. R296-MKM081013

Part

Casing Gasket-8in.

Casing Gasket - 10 in.

Casing Gasket - 13 in.

End Cover Gasket

Containment Shell O-ring

Labyrinth Seal O-ring

Driven Shaft O-ring

Outboard KStationary Bearing O-ring

Inboard Stationary Bearing O-ring

Rub Ring Gasket

Spacer Gasket

Ball Bearing

Lip Seal

Hex Flange Nut

Impeller Lockwasher

Aramid Fiber/EPDM Binder 360W 2

Material Item Quantity

Grafoil 351 1 Grafoil 351 1 Grafoil 351 1

Varnished Kraft 360A 1

PFA/Viton 412M 1

Viton 497F 1

Viton 497G 1 PFA/Viton 497P 4 PFA/Viton 496A 2 PFA/Viton 496B 2

Grafoil 360 4

Steel 112A 2

BUNA 333D 1

Steel 355A 1

Hast C 199A 1

Sleeve Bearing Kit - Silicon Carbide

M-Group - A03746A02 - 6127

Part

Outboard Stationary Sleeve Bearing

Inboard Stationary Sleeve Bearing

Outboard Rotary Sleeve Bearing

Inboard Rotary Sleeve Bearing

Thrust Collar Bearing

3296 M Group 6/05 55

Item Quantity

117A 1 117B 1 117C 1 117D 1

237 2

Page 60

PARTS

Impeller (101)

Impeller cap screw and washer (198, 199)

Impeller key (178)

Driven Magnet Assembly (740A)

HOW TO ORDER PARTS

When ordering parts call

or your local Goulds representative.

Drive Magnet Assembly (740B)

Containment Shell (760)

Driven Shaft (122A)

Wear ring (144)

Flange Nut (355A)

1-800-446-8537

3296 M Group 6/05

Page 61

INTERCHANGEABILITY

M GROUP

3296 M Group 6/05 57

Page 62

RETURN OF MATERIALS

If it is necessary to return the pump to a Goulds factory or repair facility for service certain procedures must be followed.

A Return Material Label must be completed by the USER prior to the return of the pump. The USER must also contact a Goulds representative

prior to the return of the pump for instructions and authorization to return the pump.

Before shipping check with your carrier for special procedures that may be required when shipping highly magnetic materials.

All pumps must be decontaminated prior to return, reference Section 4, Flushing Pump.

58 3296 M Group 6/05

Page 63

APPENDIX

COUPLING GUARD INSTALLATION ...................59

CHANGING THE IMPELLER ........................62

CONDITION MONITORING DEVICES...................66

METRIC CONVERSION ...........................86

COUPLING GUARD INSTALLATION

! WARNING

Before assembly or disassembly of the coupling guard is performed the motor must be de-energized, the motor controller/starter put in a locked-out position and a caution tag placed at the starter indicating the disconnect. Replace coupling guard before resuming normal operation of the pump. Goulds Pumps, Inc. assumes no liability for avoiding this practice.

End Plate

(Driver End)#234A

"-16 Nut (3 Reqd.)

End Plate

(Pump End)

" Washer (6Reqd.)

Guard Half

#501B (2 Reqd.)

ASSEMBLY:

NOTE: If end plate (pump end) is already installed, make any necessary coupling adjustments and then proceed to Step 2.

1. Align end plate (pump end) to the Bearing Frame and install (Fig. B)

NOTE: Coupling adjustments should be completed before proceeding with coupling guard assembly.

- 13x

" hex head bolts.

Fig. B

-13 x

" Hex Head Bolt (4 Reqd.)

2. Spread bottom of coupling guard half (pump end) slightly and place over pump end plate as shown in Figure C. The annular groove in the guard half

- -16 x 2" Hex Head Bolt (3

Fig. A

locates around the end plate. See detail drawing, Figure E.

Simplicity of design allows complete assembly of the coupling guard in about five minutes.

3296 M Group 6/05 59

Page 64

Annular Groove

Pump End Plate

Guard Half

Coupling Guard Half

Pump

End

Plate

Fig. C

3. After the coupling guard half (pump end) is located around the end plate, secure it with a

- 16x2"

hex head bolt, nut and two (2) washers through the round hole at the front end of the guard half as shown in Figure D. Tighten securely. See detail drawing, Figure E.

Washer

Bolt

Nut

Fig. E

4. Spread bottom of coupling guard half (driver end) slightly and place over coupling guard half (pump end) so that annular groove in coupling guard half (driver end) faces the motor as shown in Figure F.

Coupling Guard Half

Motor

Fig. F

Fig. D

60 3296 M Group 6/05

Page 65

5. Place end plate (driver end) over motor shaft as shown in Figure G. Locate the end plate in the annular groove at the rear of the coupling guard half (driver end) and secure with a bolt, nut, and two (2) washers through the round hole at the rear of the guard half. Finger tighten only.

Motor End Plate

Slide to Fit

Motor

6. Adjust length of coupling guard to completely cover shafts and coupling as shown in Figure H by sliding coupling guard half (driver end) towards motor. After adjusting guard length, secure with bolt, nut and two (2) washers through the slotted holes at the center of the guard and tighten. Check all nuts on the guard assembly for tightness.

! WARNING

Before assembly or disassembly of the coupling guard is performed the motor must be de-energized, the motor controller/starter put in a locked-out position and a caution tag placed at the starter indicating the disconnect. Replace coupling guard before resuming normal operation if the pump. Goulds Pumps, Inc. assumes no liability for avoiding this practice.

Coupling Guard

Fig. G

Fig. H

DISASSEMBLY

The coupling guard must be removed for certain maintenance and adjustments to the pump, such as adjustment of the coupling, impeller clearance adjustment, etc. The coupling guard must be replaced after maintenance is completed.

DO NOT resume normal pump operation with the coupling guard removed.

NOTE: Refer to illustrations for disassembly in reverse order.

1. Remove nut, bolt, and washers from center slotted hole in the coupling guard. Slide motor end coupling guard half towards pump. Figure H.

2. Remove nut, bolt, and washers from coupling guard half (driver end), and remove end plate. Figure G.

3. Spread bottom of coupling guard half slightly and lift off. Figure F.

4. Remove remaining nut, bolt, and washers from coupling guard half (pump end). Spread bottom of coupling guard half slightly and lift off. Figure C.

This completes disassembly of the coupling guard.

NOTE: It is not necessary to remove the end plate (pump end) from the pump bearing housing. The end plate will not interfere with maintenance or repair of the pump.

3296 M Group 6/05 61

Page 66

CHANGING THE IMPELLER

1. Refer to Section 6, Preparation for Disassembly

Note and observe all warnings.

Follow steps 1 through 7.

2. Remove bearing frame foot bolts from baseplate and note the presence of any shims between frame foot and baseplate. Save shims and reuse during installation.

3. Remove casing nuts (425) and remove back pull-out assembly from casing (Fig. A).

4. Remove casing gasket (351) and discard (Fig. A).

! CAUTION

Do not use force such as a press or a hammer to install impeller as the driven shaft (122A) will slide rearward. This will loosen the bearing stack and cause damage to the sleeve bearings, the remaining spacer gaskets (360) and possibly the containment shell (750).

Fig. B

Fig. A

5. Place shaft wrench on coupling end of shaft and remove impeller bolt (198), lockwasher (199A) and impeller washer (199).

6. Remove impeller (101). It may be necessary to use a puller. Puller must be placed as close to vanes as practical so as not to damage the impeller.

NOTE: At this time, maintenance can be conducted on the flush screen or the wear ring. Refer to the appropriate steps in Section 6.

7. Ensure keyway on replacement impeller is free of burrs.

8. Clean old spacer gasket (360) from rotary sleeve bearing face (117D) and replace with new gasket.

9. Make an impeller installation tool similar to that shown in Fig. B.

10. Thread jacking nut on threaded rod back about 6 inches (150 mm).

11. Place spool on threaded rod against nut and impeller on threaded rod against spool.

12. Carefully align impeller bore with driven shaft (122A) and install threaded rod into impeller screw hole in shaft (Fig. C).

13. Tighten jacking nut by hand until impeller is supported by end of shaft and spool (Fig. C).

Fig. C

62 3296 M Group 6/05

Page 67

14. Ensure impeller key (178) is in shaft keyway and align impeller keyway to it.

15. While keeping light tension on the threaded rod, prevent rod from turning while tightening the jacking nut. Tighten nut until impeller is seated.

! CAUTION

Ensure impeller starts squarely on the shaft. If impeller cocks, loosen nut slightly and tap LIGHTLY on the outside diameter of the impeller until it is square. Ensure shaft does not slide rearward.

16. Remove threaded rod and install impeller screw (198), lockwasher (199A) and impeller washer (199).

17. Torque impeller bolt, set lockwasher, install back pull-out, align pump, etc. As specified in Section 6, Reassembly, steps 56 through 64.

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3296 M ASSEMBLY AND INSPECTION CHECKLIST

POWER END INSPECTIONS

Bearing Frame (228) Clean

Gasket Surfaces Clean

No Cracks or Excessive Corrosion

Bearing Bores Maximum 3.1506 in. (80.025mm)

Ball Bearings (112) New or Clean

Oil Seal (333D) New

Labyrinth Seal (332A) O-rings serviceble

Labyrinth Seal (332A) Drain Port at 6:00

Drive Mag Assembly (740B) Clean, Free of Filings

Shaft (122B) Keyways and Keys Free of Burrs

Drive Shaft TIR < .0015 in. (.038mm)

CHECK

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LIQUID END INSPECTIONS

Parts Clean, Free of Burrs

Keyways and Keys Free of Burrs

O-ring Grooves Free of Burrs

Gasket Surfaces Clean

Casing (100) Thickness Meets Table 8

Containment Shell (750) Thicker Than .050 in. (1.25mm)

Cooling Passages in Adapter (108) Clear

Flush Screen (187)Clear

Bearings (117) Free of Cracks and Major Chips

O-ring Lube Compatible with Pumpage?

Driven Mag Assy (740A) Free of Erosion/Corrosion

Driven Assy Axial Travel .020-.060 in. (.5 to 1.5mm)

New Gaskets used for Assembly

Impeller Lockwasher (199A) Set

CHECKS

*BOLT TORQUE Ft-lbs. (NlM) Check

Drive Mag Assy Nut (355A)

Wear Ring Screw (353B)

Clamp Ring Screws (370B)

Impeller Screw (198)

Adapter to Frame Screws (370)

Casing Nuts (425)

* Torque Values based on Dry Threads

170 (230)

17 (25) 12 (16) 45 (60) 50 (70) 45 (60)

CLEARANCES

Wear Ring (Compare to Table 9)

Impeller to Casing ............. Actual

Impeller to Wear Ring .......... Actual

Driven Magnet to Adapter .......Actual

Drive Magnet to Rub Ring .......Actual

Sleeve Bearings (Compare to Table 11)

Shaft to Bearing ............... Actual

Bearing to Bearing .............Actual

Bearing to Adapter ............. Actual

EQUIPMENT # _________________________ DATE_________________________________

SERIAL # _____________________________ WORK ORDER # _______________________

PUMP SIZE____________________________ NAME ________________________________

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CONDITION MONITORING SYSTEM

Temperatue Sensor (Option)

DESCRIPTION

A temperature sensor is used to sense the metal containment shell temperature. The customer is required to wire the temperature sensor to their condition monitoring system.

COMPONENTS SUPPLIED

(1) Thermocouple with specifications as noted:

Specification:

Type “J” undergrounded junction Spring loaded 316SS sheath (ensures contact with shell) Internally sealed (Vapor tight, does not allow leakage through

conduit)

NEMA 4 aluminum screw cover heard (NEMA 7 optional) Connection for customer’s conduit

INSTRUCTION

Wire temperature sensor to customer’s monitoring system to either sound an alarm and / or shut unit off. Set point should be set 30° F (17° C) above pumpage temperature to protect the unit (for most applications) or should be set at a temperature predetermined to cause a pump problem due to the unique characteristic of the liquid being pumped (problems such as recirculation, liquid vaporization or polymerization). A wiring diagram for a Type J thermocouple is below:

Thermocouple Head Top View, Cover Removed

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CONDITION MONITORING DEVICES

Temperature Controller (Option)

DESCRIPTION

The temperature controller monitors the temperature signal from the temperature sensor (usually the thermocouple) to alarm and/or stop the pump if an over-temperature condition exists. If the customer does not have a controller to work with the thermocouple, this option should be provided. Common set points are the maximum temperature of the magnetic coupling, the boiling point of the pumpage or solidification temperature of the pumpage. The controller will also trip if the temperature sensor is disconnected or the electrical power supply is interrupted.

COMPONENTS SUPPLIED

(1) Controller with instructions (1) Terminal Socket

Specifications

Make – Omega Model – 6102 Type – J Range – 0° F to 500° F Supply Voltage – 120 VAC 50/60 Hz Power Consumption–2VA Output Relay – 7A

MOUNTING LOCATION

It is recommended to mount components in an enclosure to avoid excessive shock, vibration, dirt, moisture and oil. an area with ambient temperature between 32° F and 122° F (0° C and 50° C), such as the motor starter enclosure or in a control room.

INSTRUCTION

Wire to thermocouple, motor starter control circuit (and/or alarm) and to 120 VAC source as shown in wiring diagram. Set trip point to desired alarm/shutdown temperature.

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Wiring Diagram

Temperature Controller

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CONDITION MONITORING DEVICES

Low Amp Relay (Option)

DESCRIPTION

The Low Amp Relay System senses the current level of the electric motor. The monitor triggers to sound an alarm and/or shutdown the pump when the current falls below a preset level (indicating a pump problem such as magnet decoupling, dry running or low flow operation). Sensing low current provides pump protection, preventing pump damage from operation problems.

COMPONENTS SUPPLIED

(1) Current Monitor (1) Terminal Socket (1) Current Transformer (supplied only if full load

operating current exceeds 8 amps)

Specifications

Current Monitor

Make - Diversified Electronics Series - CMU Control Voltage - 120 VAC 50/60 Hz Trip Points - Drop Out - Adjustable

- Pick Up - 5% Above Drop Out

Response Times - Operate - .1 Seconds

- Release - .1 to 5 Secs. Adjustable

Output - DPDT, 10 Amps at 120 VAC, Resistive

Current Transformer

24 in. leads 600 V Insulation 25 - 400 Hz Operation

Rating Ratios: 25/5 (as specified on 50/5 transformer 100/5 supplied) 200/5

NOTE: Maximum operating current must be less than

twice the rated current.

MOUNTING LOCATION

It is recommended to mount components in an enclosure to avoid excessive shock, vibration, dirt, moisture and oil. Ambient temperature should be between 15° F to 150° F (-10° C to +65° C). Typically, the motor starter enclosure or a control room is adequate. Note that unit should be mounted in close proximity to motor electrical leads for convenience.

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INSTRUCTION

NOTE: Do not install low amp relay system until after pump is installed and operational. Various current measurements must

I. Measure and record current levels

A. No load motor current (INL) = ______________

1. Use motor manufacturer's data or measure motor current with motor uncoupled from pump and running.

be taken to verify selection of system components and to adjust trip point of the controller.

B. Full load operating current (I

1. Operate pump at highest flow that the system will allow and measure motor current.

C. No flow operating current (I

1. With pump operating, close discharge valve momentarily (no more than 1 minute) and measure motor current.

! WARNING

▲

Continuous operation against closed discharge valve may vaporize liquid, creating an explosive hazard due to confined vapor under HIGH pressure and temperature.

II. Verify selection of system components

A. Find the current transformer ratio and the minimu current setting from Table I. based on the full load

operating current (I

B. Ensure the transformer specified from Table I is the same as that supplied. If it is not, contact your

Goulds representative.

C. Ensure the minimum current setting from Table I is less than the no flow operating current (I

measured above. It is is not, contact your Goulds representative.

) measured above.

FLO

) = ____________

FLO

) = _____________

NFO

)

Table I

FLO

(Amps)

4 to 8 None N/A 1.0 A03790A01

8 to 11 25/5 4 1.25 A03790A02 11 to 22 24/5 2 2.5 A03790A02 22 to 45 25/5 1 5.0 A03790A02 45 to 60 100/5 3 6.5 A03790A04 60 to 90 50/5 1 10 A03790A03

90 to 120 200/5 3 13 A03790A05

120 to 180 200/5 2 20 A03790A05

Current

Transformer

Ratio

Current

Transformer

(No. of Turns)

Minimum

Current Setting

(Amps)

Part

Number

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INSTALLATION

1. Mount the Current Transformer (CT), if supplied, in an area that is convenient to loop one of the motor leads through it, usually the motor starter enclosure.

2. Loop one of the motor leads through the CT the number of turns specified in Table I.

3. Mount the Terminal Socket at desired location.

4. Connect wiring (Not Supplied) per wiring Diagram I for use with no Current Transformer and per wiring Diagram II for use with a Current Transformer.

5. Plug Motor into Terminal Socket.

SETTINGS

1. To protect against dry running, set Current Adjuster to a current value midway between full load operating current (I

NOTE: The minimum current setting shown in Table I corresponds to "I" on the Current Adjuster Dial. Each setting on the dial is a multiple of the minimum setting.

2. To protect against Low Flow Operation, operate pump at desired flow and slowly increase setting on Current Adjuster until pump shuts off.

3. Set time delay from .1 to 5 seconds as desired. Delay is used to prevent nuisance tripping that occurs from variations in line voltage.

) and no load motor current (INL).

NFO

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CONDITION MONITORING DEVICES

NEMA 4 Pressure Switch (Option)

Leak Detector

DESCRIPTION

This detector senses a leak in the containment shell by detecting pressure in the bearing frame bell housing. A pressure switch preset to trip at 10 PSIG on increasing pressure is supplied. The switch must be wired to the customer's monitoring system to sound an alarm and/or stop the pump. Recommended for use with volatile liquids (liquids that will flash when exposed to atmospheric pressure). Should be provided to those customers who require warning of containment shell leakage.

LIMITATIONS

1. The total developed pressure of the pump plus suction pressure must be above 15 PSIG in order to have sufficient pressure in containment shell to trip switch should there be a leak.

! CAUTION

This method of leak detection may not prevent release of pumpage to the atmosphere. It is possible that liquid could infiltrate bearing frame lubricating oil.

COMPONENTS SUPPLIED

(1) Pressure Switch - Custom Control Sensors, Inc., Model 6703 G 8001

Specifications

Rating - NEMA4 ¼ - 18 NPT Pressure Port ½ - 14 NPT Conduit Connection 18" Free Leads Wetted Parts * Aluminum

* Polyimide * Buna N * Cadmium Plated Steel * 300SS

Trip Point - Preset at 10 PSIG (69 kPa) on increasing pressure

Switch Element * SPDT

* 120/240 VAC * 50/60 Hz * 11 Amps

Ambient Temperature Range -30° F to 160° F (-34° C - 71° C)

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INSTRUCTION

1. Remove ¼" NPT pressure switch plug (408C) from bearing frame bell housing (Fig. 1).

2. Put suitable thread sealer on ¼" NPT threads on pressure switch and install switch in bell housing.

3. Mount a junction box near switch and run conduit to control room. Use flexible conduit from junction box to switch.

4. Wire switch to customer supplied monitoring system for either normally open (N.O.) or normally closed (N.C.) as shown (Fig. 1).

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CONDITION MONITORING DEVICES

NEMA 7 Pressure Switch (Option)

Leak Detector

DESCRIPTION

This detector senses a leak in the containment shell by detecting pressure in the bearing frame bell housing. A pressure switch preset to trip at 10 PSIG on increasing pressure is supplied. The switch must be wired to the customer's monitoring system to sound an alarm and/or stop the pump. This liquid leak detector is identical in operation and function to the NEMA 4 pressure switch leak detector. The only difference is the NEMA rating. Recommended usage is also for volatile liquids.

LIMITATIONS

1. The total developed pressure of the pump plus suction pressure must be above 15 PSIG in order to have sufficient pressure in containment shell to trip switch should there be a leak.

! CAUTION

This method of leak detection may not prevent release of pumpage to the atmosphere. It is possible that liquid could infiltrate bearing frame lubricating oil.

COMPONENTS SUPPLIED

(1) Pressure Switch - Custom Control Sensors, Inc., Model 511GCE1

Specifications

Rating - NEMA7 Explosion Proof: DIV 1,2 ¼ - 18 NPT Pressure Port ½ - 14 NPT Conduit Connection 18" Free Leads Wetted Parts * 316SS

Trip Point - Preset at 10 PSIG (69 kPa) on increasing pressure

Switch Element * SPDT

* 120/240 VAC * 50/60 Hz * 11 Amps

Ambient Temperature Range -30° F to 160° F (-34° C - 71° C)

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INSTRUCTION

1. Remove 1/4" NPT pressure switch plug (408C) from bearing frame bell housing (Fig. 2).

2. Put suitable thread sealer on 1/4" NPT threads on pressure switch and install switch in bell housing.

3. Mount a junction box near switch and run conduit to control room. Use flexible conduit from junction box to switch.

4. Wire switch to customer supplied monitoring system for either normally open (N.O.) or normally closed (N.C.) as shown (Fig. 2).

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CONDITION MONITORING DEVICES

Vibration Monitor (Option)

DESCRIPTION

The vibration monitor senses the vibration signal from an accelerometer mounted on the pump bearing frame. The monitor has two fully adjustable set points and relays. Typically, one set point is used for an alarm and the second set point is used to stop the pump.

COMPONENTS SUPPLIED

(1) Vibration monitor with instructions (1) Vibration transmitter (Accelerometer)

Specifications

Vibration Monitor

Make - Balmac Inc. Phone 614-876-1295 Model - 1112 Input - 4-20 milliamp 500 OHM load Limits - Dual limit 0-100%

- Jumper selects either N.O. or N.C. operation

Limit Output - Relay 10 VAC max. 200VDC max. switching voltage

1.5A switching current Time Delay - Adjustable (each limit) 1 to 7 secs. Reset - Automatic or remote Mute - Available, inhibits the relay operation with a

circuit closure between the "GND"

and "GND TO MUTE" terminals. Power - 115 VAC Weight - 13 ounces (369 grams) Mounting - 0.156 diameter holes (4 places) Temperature - 32° F to 120° F Size - 6.0" x 5.1875" x 1.75"

Current Transformer

Make - Balmac Model - 191 Vibration Range - Output 4 to 20 mA Model - 191-1–0to1in/sec Frequency Range-7Hzto1300 Hz -3 dB Supply Voltage (Vs)-8to50Vdc, unregulated:

Black neg., red pos., with reverse voltage protection Maximum Load - (RL)50 (Vs-8) ohms Resistance Isolation - 500 V, circuit-to-case Electrical Connection - 2-wire, AWG #18, 24 in. Temperature Range - -20° C to +100° C Environment Rating - NEMA 4, weatherproof Case Cadmium-plated steel Mount - 1/2 in NPT thread Conduit Connection - 1" NPT

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MOUNTING LOCATION

It is recommended to mount monitor in a control room to avoid excessive shock, vibration, dirt, moisture and oil. The transmitter must be mounted on pump bearing frame, in hole provided. Run connecting wiring through conduit.

INSTRUCTION

1. After pump installation is complete, thread ½" NPT end of transmitter into hole provided in pump bearing frame (Fig. 3). Tighten until snug.

NOTE: Hole is predrilled on M Group. Hole is only predrilled on S Frames at the factory when Vibration Monitor System is ordered with the pump. The S Frame is scheduled to come from the factory predrilled in

1993.

2. Mount monitor in appropriate location.

3. Mount a junction box near transmitter and run conduit to monitor. Use flexible conduit from junction box to transmitter.

! WARNING

Ensure electrical power is OFF until all connections are made and system is ready for operation.

4. Wire transmitter to monitor (Fig. 3).

5. Wire monitor to alarm circuit (Fig. 3).

NOTE: The design of the alarm and motor starter control circuits is the responsibility of the user.

6. Wire monitor to motor starter circuit (Fig. 3).

7. Wire rest for either automatic (Fig. 3) or remote (See Balmac, Inc. instruction).

8. If a relay mute is desired, wire according to Balmac, Inc. instructions.

9. Wire monitor to 120 VAC source (Fig. 3)

LIMIT SETTINGS

1. Limit 1 is intended to be an early warning to alert the operator of a potential problem. Set limit to trip at a vibration level 25% over the baseline. The baseline is the vibration level measured during operation of a new properly installed pump. If the baseline exceeds .3 in/sec., determine cause of vibration and correct. Set delay 1 to maximum delay (7 seconds) to avoid nuisance alarms that may occur during transient operation.

2. Limit 2 is intended to shut down the pump to prevent catastrophic failure. Set limit to trip at .5 in/sec. Set delay 2 to minimum delay (1 second) for quick shutdown response.

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CONDITION MONITORING DEVICES

Goulds Total Protection System (Option)

DESCRIPTION

The Goulds Total Protection System (GTP System) is a controller designed to protect the 3296 from damage that may occur due to abnormal operating conditions. Five input channels provide sensing capability for AC motor `current, containment shell temperature, vibration level, containment shell leakage and a system pressure switch. The controller will sound an alarm and/or shut down the pump if any of the system set points are exceeded.

COMPONENTS

Supplied with Unit

(1) GTP System Controller with (1) AC Current Sense Transformer and instructions Part No. A03792A

Available - Must be Ordered Separately

(1) Leak Detection Pressure Switch - NEMA 4 Part No. A03787A

- NEMA 7 Part No. A03788A

(1) Vibration Transmitter - NEMA 4 Part No. A05075A

- NEMA 7 Not Available

NOTE: To attain a NEMA 7 rating on the vibration transmitter, a safety barrier is required to limit power to the unit. This specialized equipment is beyond the scope of Goulds' supply and responsibility. Contact Balmac, Inc. 614-876-1295 for further information.

Not Supplied

System Pressure Switch - This must be supplied by the customer due to the diversity of requirements such as pressure range and materials of construction.

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SPECIFICATIONS

GTP Controller and AC Current Transformer - Keytron, Inc., Model K1000

Input Power ....................120/240 VAC, 50/60 Hz, 6 VA

AC Current Sense Range.............. 0.2to20,2to200and20to300Amp

Type AC Current Sensor ..............Toroidal transformer

AC Current Adjustments ..............Overcurrent and undercurrent setpoint

AC Sense Accuracy ................± 3% (proportional and fixed errors).

Temperature Input interference ..........Switchbale between thermocouple and RTD

Temperature Control ................ Setpoint.

Temperature Display Range ............0°to2000°C. Actual range depends on type sensor used.

4 to 20 mA Display Range .............0-1, 0 to 10, 0 to 100.

4 to 20 mA Controls ................Setpoint and Span.

Auxiliary Inputs (2) ................Momentary opening of sensor switch contacts

Switches ...................... a. 120/240 AC Line Select

........................... b. ACCurrent Range

........................... c. Therm/RED Select

........................... d. 4-20 mA Meter Decimal Select.

........................... e. Hi/Lo AC Threshold Select.

........................... f. Relay OFF/ON.

........................... g. Auto Reset OFF/ON.

Alarm & Control Relay Contacts ......... NC,5.0amps resistive, 240 VAC.

will trigger and set latch.

Alarm Circuit.................... Alarm relay contacts will open if AC power to the K1000 or

Start Delay .....................10Seconds (for inrush current)

DC Supply for External Sensors ..........15Volts DC, 50 ma regulated

Reset ........................ Front panel pushbutton switch, or remotely from K1000

Auto-Reset ..................... Selectable, effective on undercurrent mode only. One minute

Panel Meter .................... 3½digit LCD type meter

Indicators...................... 6LEDredstatus indicators, which flash in the on state, and

Enclosure...................... Molded polyester fiberglass, NEMA-4X UL and CSA

Enclosure Size and Mounting Dim.........6"x6"x4",6.94" x 4.00"

Line Protection ...................Transient suppressor

Operating Temperature Range ...........-25to+55° C.

Leak Detection Pressure Switch -

NEMA 4 - Custom Control Sensors, Inc., Model G 8001, REF Instruction D. NEMA 7 - Custom Control Sensors, Inc., Model 611GCE1, REF Instruction E.

internal supply fails

terminal block.

delay.

one green AC Line indicator.

approved.

Vibration Transmitter

NEMA 4 - Balmac, Inc., Model 191, REF Instruction F.

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SET UP INSTRUCTIONS

The following are setup instructions which, along with the GTP System instruction manual, will guide you through the proper setup and operation of the total protection package.

Mounting Location

The Goulds Total Protection System can be located most non-hazardous plant locations where a NEMA 4X enclosure is appropriate. If a NEMA 7 enclosure is required, the GTP Controller should be mounted in a separate NEMA 7 enclosure, such as a junction box, that is supplied by the customer. It should be in an area that is convenient to view, monitor and make adjustments. It should also be mounted near the starter to simplify wiring to the AC current sense transformer and to the motor starter control circuit. Note that if the starter control transformer secondary voltage is 120 VAC ro 240 VAC, the GTP System can be wired to it because of its low power requirement (6 VA).

The current transformer should be mounted in the starter on one of the legs of the power cable between the starter contacts and the motor. The cable is passed through the current transformer once if AC current range switch is set at 200 or 300. Route the cable through the sense transformer 4 times if the range switch is set at 20 (Total of 5 lines through transformer window) Refer to current settings for appropriate switch setting.

Wiring

To prevent personal injuries, follow the INSTALLATION WARNING instructions in the GTP system instruction manual when wiring the GTP controller to the starter, current transformer, thermocouple and auxiliary sensor. Be sure to route power and sensor wiring in different conduit runs and have each cable properly grounded.

Alarm Level Settings

Follow the ADJUSTMENT PROCEDURE section of the GTP system instruction manual when making adjustments to the threshold levels for the temperature and current and the delay control adjustments. This instruction covers the levels required to properly protect the 3296 pump and avoid nuisance trips and alarms as follows:

Current Settings

The GTP System protects the 3296 from dry running, low flow, magnet decoupling and AC motor overload by monitoring both under current and over current.

Dry Running Protection

To protect against dry running the pump, the current level measurements of the motor uncoupled as well as with the 3196 pump running at shutoff are needed. Although these values can be calculated from the motor manufacturer's data for no load motor current and the horsepower from the pump performance curve, it is best to obtain them during the initial installation and startup of the motor and pump using the GTP system. While operating the motor uncoupled the current level is obtained directly from the GTP System panel meter, with the selection switch set at "AC Level." With the pump coupled, started and stabilized, reduce pump flow to zero and read the current level from the meter. (CAUTION: DO NOT OPERATE THE PUMP AT ZERO FLOW FOR LONGER THAN 1 MINUTE). Set the under current threshold level to the average of these two current values (REF GTP system manual) adjustment procedure, Step 2).

Low Flow Protection

To protect against low flow operation of the pump, set the pump to the minimum flow desired (refer to Goulds Supplemental Engineering Data 725.9A108 for minimum flow for 3296 pumps), read the current level on the meter and set this current level for the under current threshold (REF GTP system manual adjustment procedure, Step 2).

Magnetic Decoupling and Motor Overload Protection

Set the over current threshold level to prevent magnetic decoupling of the 3296 pump or over current operation of the motor, depending on which threshold is lower. Refer to the pump performance curve and note the maximum drive power listed. Calculate the current draw for the HP on the motor selected to drive the pump. This is the over current threshold level to set for preventing decoupling. If this level exceeds the full load current of the motor, use the motor full load current value as the threshold level. This will protect the motor from over current operation as well as magnetic decoupling of the pump (REF GTP system manual adjustment procedure, Step 3).

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High Temperature Protection

The temperature circuit monitors the containment shell skin temperature and shuts down the pump once a predetermined temperature level is reached. The temperature set point should be adjusted to alarm at a temperature of 30° F (17° C) above the anticipated pumpage temperature (for most applications) or should be set at a temperature predetermined to cause a pump problem due to the unique characteristics of the liquid being pumped (problems such as recirculation, liquid vaporization or polymerization). This set point should not exceed the maximum continuous operating temperature for the magnetic material supplied in the pump. If neodymium magnets were supplied the maximum temperature set point is 125 C (250° F). For Samarium Cobalt magnets, the maximum temperature set point is 220° C (428° F). (REF GTP system manual adjustment procedure, Step 4).

Vibration Transmitter (Optional)

The vibration monitor circuit detects vibration and shuts down the pump once a predetermined vibration level is reached. (REF 3296 instruction F). With the meter selector switch set to "VIBRA LEVEL" (Vibration Level), the vibration reading in IN/SEC is displayed on the meter.

The transmitter is not installed at the factory in order to minimize the risk of shipping damage. It, therefore, must be installed by the user - refer to Vibration Monitor Option in this manual as shown.

Adjust meter span to read the desired full scale reading, usually 1.00 (Refer to GTP system manual adjustment procedure Steps 5 and 6). Adjust the decimal select switch as required to make this adjustment.

Set the limit to trip at a vibration level 50% higher than the baseline vibration, but not to exceed .5 IN/SEC. The baseline is the vibration level shown on the monitor during operation of a new properly installed pump. If the baseline exceeds .3 IN/SEC, determine cause of vibration and correct.

NOTE: This is an analogue 4-20 mA circuit and is, therefore, compatible with any sensor that produces a 4-20 mA signal. If the vibration transmitter is not purchased, this circuit is available to the user to measure another parameter as desired. Be sure to relabel face of GTP controller to reflect new function.

Liquid Leak Detector (Optional)

The switch is not installed at the factory in order to minimize the risk of shipping damage. It, therefore, must be installed by the user - Again, refer to the pressure switch section.

For the NEMA 4 switch, connect the wire labeled "common" to terminal No. 9 on the GTP System controller and the wire labeled "N.O." (Normally Open) to terminal No. 14. The N.C. (Normally Closed) wire is not used and must be taped. For the NEMA 7 switch, connect in the same way except, in addition, run the green wire to ground per applicable electrical codes.

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System Pressure

This circuit, if utilized, shuts down the pump if it is operating dry or at too low a suction pressure. A user supplied pressure switch monitoring pressure in either the discharge or the suction pipe is required. This switch is not available through Goulds due to the diversity in pressure, materials of construction and connection sizes.

Dry Running Protection

A pressure switch monitoring the pressure in the discharge pipe senses low pressure, indicating a loss of prime or operation at too high a flow. Switch should be normally closed, SPDT, adjustable set point, trigger on decreasing pressure, capable of system pressure, compatible with pumpage and compatible with plant environment. Adjust set point to trigger at 2 PSI below the lowest discharge pressure reading attained during normal operation. Connect wiring to terminal 15, common and ground as required.

Low Suction Pressure Protection

A pressure switch monitoring the pressure in the suction pipe senses low pressure, indicating low tank level, clogged suction screen, or closed suction valve. The switch should be normally closed, SDPT, adjustable set point, trigger on decreasing pressure, capable of system pressure, compatible with environment. Adjust set point to trigger at 1 PSI below the lowest pressure reading attained during normal operation. Ensure NPSH requirements of pump are met under these conditions. Note that suction pressure detection alone does not in itself monitor NPSH available to pump. Connect wiring to terminals 15, common and ground as required.

NOTE: If the Liquid Leak Detector and/or the System Pressure Monitors are not used, terminals 14 and/or 15 are available for use with any latched type switch. A temperature switch or vibration switch could also be utilized to satisfy a particular user's need. Be sure to relabel face of GTP controller to reflect new function.

NOTE: If these terminals, 14 and 15, are not used, they must be shorted to common in order for the GTP System to operate properly.

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METRIC CONVERSIONS

Measurement English Metric Conversion

Capacity

Gallons/Minute

Head Feet (ft)

Power

Temperature

Pressure

Horsepower

Fahrenheit

Pounds/Sq. Inch

Volume

Length

(GPM)

(HP)

(°F)

(PSI)

Gallons

(G)

Inch

(in)

Cubic Meter/Hour

Meters

(m)

Kilowatts

(kw)

Celsius

(°C)

Kilograms/Sq.Centimeter

)

(kg/cm

Cubic Meters

)

Milimeters

(mm)

GPM x 0.2271 = m

Ft x 0.3048 =m

HP x 0.746 = kw

(°F-32) x 0.556 = °C

PSI x 0.0703 =kg/cm

G x 0.003785 = m

inx25.4=mm

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Goulds Pumps 3296M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual