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Goulds Pumps
Installation, Operation, and
Maintenance Manual
Model 3796 i-FRAME
|
Table of Contents |
Table of Contents |
|
Introduction and Safety................................................................................................................................................... |
4 |
Introduction....................................................................................................................................................................... |
4 |
Requesting other information...................................................................................................................................... |
4 |
Inspect the package........................................................................................................................................................ |
4 |
Inspect the unit............................................................................................................................................................... |
4 |
Product warranty............................................................................................................................................................ |
4 |
Safety................................................................................................................................................................................... |
5 |
Safety terminology and symbols.................................................................................................................................. |
5 |
Environmental safety..................................................................................................................................................... |
6 |
User health and safety................................................................................................................................................... |
7 |
Safety regulations for Ex-approved products in potentially explosive atmospheres........................................... |
8 |
Product approval standards........................................................................................................................................... |
10 |
Certificates of conformance.......................................................................................................................................... |
11 |
Transportation and Storage.......................................................................................................................................... |
17 |
Pump handling................................................................................................................................................................. |
17 |
Lifting methods............................................................................................................................................................ |
17 |
Pump storage requirements........................................................................................................................................... |
19 |
Frostproofing................................................................................................................................................................... |
19 |
Product Description........................................................................................................................................................ |
20 |
General description 3796............................................................................................................................................... |
20 |
Part description 3796................................................................................................................................................... |
21 |
General description i-ALERT™ Condition Monitor................................................................................................ |
22 |
Nameplate information.................................................................................................................................................. |
23 |
Installation......................................................................................................................................................................... |
26 |
Preinstallation................................................................................................................................................................... |
26 |
Pump location guidelines............................................................................................................................................ |
26 |
Foundation requirements............................................................................................................................................ |
27 |
Piping checklists........................................................................................................................................................... |
28 |
Baseplate-mounting procedures.................................................................................................................................... |
32 |
Prepare the baseplate for mounting.......................................................................................................................... |
32 |
Install the baseplate using shims or wedges............................................................................................................. |
32 |
Install the baseplate using jackscrews....................................................................................................................... |
33 |
Install the baseplate using spring mounting............................................................................................................. |
35 |
Install the baseplate using stilt mounting................................................................................................................. |
36 |
Baseplate-leveling worksheet...................................................................................................................................... |
38 |
Install the pump, driver, and coupling......................................................................................................................... |
39 |
Pump-to-driver alignment.............................................................................................................................................. |
39 |
Alignment checks......................................................................................................................................................... |
39 |
Permitted indicator values for alignment checks.................................................................................................... |
40 |
Alignment measurement guidelines.......................................................................................................................... |
40 |
Attach the dial indicators for alignment................................................................................................................... |
40 |
Pump-to-driver alignment instructions.................................................................................................................... |
41 |
C-face adapter............................................................................................................................................................... |
44 |
Grout the baseplate......................................................................................................................................................... |
44 |
Commissioning, Startup, Operation, and Shutdown............................................................................................ |
46 |
Preparation for startup................................................................................................................................................... |
46 |
Remove the coupling guard........................................................................................................................................... |
46 |
Check the rotation........................................................................................................................................................... |
49 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
1 |
Table of Contents
Impeller-clearance check................................................................................................................................................ |
49 |
Impeller clearances (3796).......................................................................................................................................... |
49 |
Impeller-clearance setting.............................................................................................................................................. |
50 |
Set the impeller clearance - dial indicator method (all except CV 3196) ............................................................ |
50 |
Set the impeller clearance - feeler gauge method (all except CV 3196) ............................................................. |
51 |
Couple the pump and driver.......................................................................................................................................... |
51 |
Install the coupling guard........................................................................................................................................... |
52 |
Bearing lubrication....................................................................................................................................................... |
56 |
Shaft-sealing options....................................................................................................................................................... |
58 |
Mechanical seal options.............................................................................................................................................. |
58 |
Connection of sealing liquid for mechanical seals.................................................................................................. |
58 |
Packed stuffing box option......................................................................................................................................... |
58 |
Connection of sealing liquid for a packed stuffing box......................................................................................... |
58 |
Pump priming.................................................................................................................................................................. |
59 |
Pump priming with the suction supply below the pump (3796).......................................................................... |
59 |
Start the pump................................................................................................................................................................. |
60 |
Activate the i-ALERT™ Condition Monitor.............................................................................................................. |
60 |
i-ALERT™ Condition Monitor routine operation.................................................................................................... |
61 |
Pump operation precautions......................................................................................................................................... |
62 |
Shut down the pump...................................................................................................................................................... |
62 |
Deactivate the i-ALERT™ Condition Monitor.......................................................................................................... |
63 |
Reset the i-ALERT™ Condition Monitor................................................................................................................... |
63 |
Make the final alignment of the pump and driver...................................................................................................... |
63 |
Maintenance...................................................................................................................................................................... |
64 |
Maintenance schedule..................................................................................................................................................... |
64 |
Bearing maintenance....................................................................................................................................................... |
65 |
Lubricating-oil requirements...................................................................................................................................... |
65 |
Regrease the grease-lubricated bearings .................................................................................................................. |
66 |
Lubricate the bearings after a shutdown period...................................................................................................... |
67 |
Shaft seal maintenance................................................................................................................................................... |
67 |
Mechanical-seal maintenance..................................................................................................................................... |
67 |
Packed stuffing-box maintenance.............................................................................................................................. |
68 |
Disassembly...................................................................................................................................................................... |
68 |
Disassembly precautions............................................................................................................................................. |
68 |
Tools required............................................................................................................................................................... |
68 |
Drain the pump............................................................................................................................................................ |
69 |
Remove the coupling................................................................................................................................................... |
69 |
Remove the back pull-out assembly.......................................................................................................................... |
69 |
Remove the coupling hub........................................................................................................................................... |
72 |
Impeller removal.......................................................................................................................................................... |
72 |
Seal-chamber cover removal....................................................................................................................................... |
73 |
Remove the seal-chamber cover (3196, CV 3196, HT 3196, LF 3196, 3796) ................................................... |
73 |
Remove the stuffing-box cover (3196, CV 3196, HT 3196, LF 3196, 3796) .................................................... |
74 |
Remove the frame adapter (MTi, LTi) ..................................................................................................................... |
75 |
Remove the inboard labyrinth oil seal....................................................................................................................... |
75 |
Power-end disassembly............................................................................................................................................... |
75 |
Disassemble the bearing frame.................................................................................................................................. |
80 |
Guidelines for i-ALERT™ Condition Monitor disposal....................................................................................... |
81 |
Disassemble the C-face adapter................................................................................................................................. |
81 |
Pre-assembly inspections............................................................................................................................................... |
82 |
Replacement guidelines............................................................................................................................................... |
82 |
Shaft and sleeve replacement guidelines................................................................................................................... |
83 |
Bearing-frame inspection............................................................................................................................................ |
83 |
C-face adapter inspection........................................................................................................................................... |
84 |
Seal chamber and stuffing box cover inspection..................................................................................................... |
85 |
Bearings inspection...................................................................................................................................................... |
86 |
2 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Table of Contents |
|
Bearing-housing inspection........................................................................................................................................ |
87 |
Bearing fits and tolerances.......................................................................................................................................... |
88 |
Reassembly....................................................................................................................................................................... |
88 |
Assemble the rotating element and the bearing frame ( STi and MTi ) ............................................................. |
88 |
Assemble the rotating element and the bearing frame ( STi and MTi with duplex bearings)......................... |
91 |
Assemble the rotating element and the bearing frame ( LTi ).............................................................................. |
94 |
Assemble the frame..................................................................................................................................................... |
97 |
INPRO labyrinth oil seal description..................................................................................................................... |
100 |
Assemble the INPRO labyrinth oil seal................................................................................................................. |
100 |
Assemble the C-face adapter.................................................................................................................................... |
101 |
Shaft sealing................................................................................................................................................................ |
101 |
Install the impeller..................................................................................................................................................... |
106 |
Attach the i-ALERT™ Condition Monitor to the pump.................................................................................... |
108 |
Post-assembly checks................................................................................................................................................ |
109 |
Install the back pull-out assembly (except HT 3196) .......................................................................................... |
109 |
Assembly references.................................................................................................................................................. |
111 |
Spare parts................................................................................................................................................................... |
112 |
Interchangeability drawings......................................................................................................................................... |
113 |
3796 interchangeability.............................................................................................................................................. |
113 |
Lubrication conversion................................................................................................................................................. |
113 |
Frame lubrication conversion.................................................................................................................................. |
113 |
Convert from greased-for-life or regreaseable to oil-lubricated bearings......................................................... |
114 |
Conversion from flood-oil to pure-oil mist........................................................................................................... |
115 |
Convert from flood oil to regreaseable.................................................................................................................. |
115 |
Troubleshooting............................................................................................................................................................. |
116 |
Operation troubleshooting.......................................................................................................................................... |
116 |
Alignment troubleshooting.......................................................................................................................................... |
117 |
Assembly troubleshooting........................................................................................................................................... |
117 |
i-ALERT™ Condition Monitor troubleshooting..................................................................................................... |
118 |
Parts Listings and Cross-Sectional Drawings....................................................................................................... |
119 |
Parts list.......................................................................................................................................................................... |
119 |
Other Relevant Documentation or Manuals......................................................................................................... |
130 |
For additional documentation..................................................................................................................................... |
130 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
3 |
Introduction and Safety
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
•Installation
•Operation
•Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales contract for any modifications or special version characteristics. For instructions, situations, or events that are not considered in this manual or in the sales documents, please contact the nearest ITT representative.
Always specify the exact product type and identification code when requesting technical information or spare parts.
Inspect the package
1.Inspect the package for damaged or missing items upon delivery.
2.Note any damaged or missing items on the receipt and freight bill.
3.File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1.Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2.Inspect the product to determine if any parts have been damaged or are missing.
3.If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.
4.Contact your sales representative if anything is out of order.
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
•The faults are due to defects in design, materials, or workmanship.
•The faults are reported to an ITT representative within the warranty period.
•The product is used only under the conditions described in this manual.
•The monitoring equipment incorporated in the product is correctly connected and in use.
•All service and repair work is done by ITT-authorized personnel.
•Genuine ITT parts are used.
•Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
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Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Introduction and Safety (Continued)
Limitations
The warranty does not cover faults caused by these situations:
•Deficient maintenance
•Improper installation
•Modifications or changes to the product and installation made without consulting ITT
•Incorrectly executed repair work
•Normal wear and tear
ITT assumes no liability for these situations:
•Bodily injuries
•Material damages
•Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your ITT representative.
Safety
WARNING:
•The operator must be aware of safety precautions to prevent physical injury.
•Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized. Take all necessary measures to avoid over-pressurization.
•Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of the equipment, please contact an ITT representative before proceeding.
•Installation, Operation, and Maintenance manuals clearly identify accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.
•Do not change the service application without the approval of an authorized ITT representative.
•Never operate the pump below the minimum rated flow, when dry, or without prime.
•Never operate the pump without safety devices installed.
•Never operate the pump with the discharge valve closed.
•Never operate the pump with the suction valve closed.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
•Personal accidents and health problems
•Damage to the product
•Product malfunction
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
5 |
Introduction and Safety (Continued)
Hazard levels
Hazard level |
Indication |
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A hazardous situation which, if not avoided, will |
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DANGER: |
|
|
result in death or serious injury |
|
A hazardous situation which, if not avoided, could
WARNING: result in death or serious injury
|
A hazardous situation which, if not avoided, could |
|
CAUTION: |
||
result in minor or moderate injury |
NOTICE: |
• |
A potential situation which, if not avoided, |
|
could result in undesirable conditions |
|
|
|
|
|
• |
A practice not related to personal injury |
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:
•Crush hazard
•Cutting hazard
•Arc flash hazard
Environmental safety
The work area
Always keep the pump station clean to avoid and/or discover emissions.
Recycling guidelines
Always recycle according to these guidelines:
1.If the unit or parts are accepted by an authorized recycling company, then follow local recycling laws and regulations.
2.If the unit or parts are not accepted by an authorized recycling company, then return them to the nearest ITT representative.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
•Dispose appropriately of all waste.
•Handle and dispose of the pumped fluid in compliance with applicable environmental regulations.
•Clean up all spills in accordance with safety and environmental procedures.
•Report all environmental emissions to the appropriate authorities.
6 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Introduction and Safety (Continued)
Reference for electrical installation
For electrical installation requirements, consult your local electric utility.
User health and safety
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
•Helmet
•Safety goggles (with side shields)
•Protective shoes
•Protective gloves
•Gas mask
•Hearing protection
The work area
Observe these regulations and warnings in the work area:
•Always keep the work area clean.
•Pay attention to the risks presented by gas and vapors in the work area.
•Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
Product and product positioning requirements
Observe these requirements for the product and the product positioning:
WARNING:
•Only use fasteners of the proper size and material.
•Replace all corroded fasteners.
•Make sure that all fasteners are properly tightened and that there are no missing fasteners.
•Never operate a pump unless safety devices are installed.
•Never operate a pump unless a coupling guard is installed.
•Never force the piping in order to make a connection with a pump.
•Never start a pump without the proper priming.
•Never start a pump without the proper liquid level in self-priming pumps.
•Never run a pump below the minimum rated flow or with any suction or discharge valve closed.
Electrical connections regulations
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations.
Observe these guidelines and warnings for electrical connections:
•Make sure that the product is isolated from the power supply and cannot be energized by mistake. This guideline also applies to the control circuit.
•Make sure that the thermal contacts are connected to a protection circuit according to the product approvals, and that they are in use.
Earthing (grounding)
All electric equipment must be earthed (grounded). This rule applies to pumps and mixers as well as monitoring equipment.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with the product:
•Provide a suitable barrier around the work area, for example, a guard rail.
•Make sure that all safety guards are in place and secure.
•Make sure that the equipment is properly insulated when it operates at extreme temperatures.
•Allow all system and pump components to cool before you handle them.
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
7 |
Introduction and Safety (Continued)
•Make sure that you have a clear path of retreat.
•Make sure that the product cannot roll or fall over and injure people or damage property.
•Make sure that the lifting equipment is in good condition.
•Use a lifting harness, a safety line, and a breathing device as required.
•Make sure that the product is thoroughly clean.
•Make sure that there are no poisonous gases within the work area.
•Make sure that you have quick access to a first-aid kit.
•Disconnect and lock out power before servicing.
•Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
•Never work alone.
•Always wear protective clothing and hand protection.
•Stay clear of suspended loads.
•Always lift the product by its lifting device.
•Beware of the risk of a sudden start if the product is used with an automatic level control.
•Beware of the starting jerk, which can be powerful.
•Rinse the components in water after you disassemble the pump.
•Do not exceed the maximum working pressure of the pump.
•Do not open any vent or drain valve or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.
•Never operate a pump without a properly installed coupling guard.
•Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
•Never heat the condition monitor to temperatures in excess of 300°F (149°C).
•Never expose the condition monitor to open flames.
•Do not use the condition monitor in atmospheres containing acetic acid.
•Always wear protective gloves. The pump and condition monitor can be hot.
Clean chemicals from the eyes
1.Hold your eyelids apart forcibly with your fingers.
2.Rinse the eyes for at least 15 minutes. Use an eyewash or running water.
3.Seek medical attention.
Clean chemicals from the body
1.Remove contaminated clothing.
2.Wash the skin with soap and water for at least one minute.
3.Seek medical attention, if required.
Safety regulations for Ex-approved products in potentially explosive atmospheres
Description of ATEX
The ATEX directives are a specification enforced in Europe for electrical and non-electrical equipment. ATEX deals with the control of potentially explosive atmospheres and the standards of equipment and protective systems used within these atmospheres. The relevance of the ATEX requirements is not limited to Europe. You can apply these guidelines to equipment installed in any potentially explosive atmosphere.
8 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Introduction and Safety (Continued)
General guidelines
ATEX compliance is only fulfilled when the pump is operated within its intended use, for example within its intended hydraulic range. The conditions of the service must not be changed without approval of an authorized ITT representative. When installing or maintaining ATEX-compliant pumps, follow these guidelines:
•Always install ATEX-approved equipment in compliance with the directive and applicable standards (IEC/EN 60079–14).
•Do not install FM-approved products in locations that are classified as hazardous in the national electric code, ANSI/NFPA 70–2005.
WARNING:
Installation, Operation, and Maintenance manuals clearly identify accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.
If there are any questions regarding these requirements, the intended use, or if the equipment requires modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:
•All work on the product must be carried out by certified electricians and ITT-authorized mechanics. Special rules apply to installations in explosive atmospheres.
•All users must know about the risks of electric current and the chemical and physical characteristics of the gas and/or vapor present in hazardous areas.
•The maintenance operation for Ex-approved products must be made in conformity to the international or national standards (IEC/EN 60079-17).
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres:
•Only use the product in accordance with the approved motor data stated on the nameplates.
•The Ex-approved product must never run dry during normal operation. Dry running during service and inspection is only permitted outside the classified area.
•Never start a pump without the proper priming.
•Before you start working with the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized.
•Do not open the product while it is energized or in an explosive gas atmosphere.
•Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product.
•Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0.
•The yield stress of fasteners must be in accordance with the approval drawing and the product specification.
•Make sure that the equipment is properly maintained:
•Monitor the pump components and the end temperature of the liquid.
•Maintain proper bearing lubrication.
•Do not modify the equipment without approval from an authorized ITT representative.
•Only use parts that have been provided by an authorized ITT representative.
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
9 |
Introduction and Safety (Continued)
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices:
•Pressure gauges
•Flow meters
•Level indicators
•Motor load readings
•Temperature detectors
•Bearing monitors
•Leak detectors
•PumpSmart control system
Product approval standards
Regular standards
All standard products are approved according to CSA standards in Canada and UL standards in USA. The drive unit degree of protection follows IP68. See the nameplate for maximum submersion, according to standard IEC 60529.
All electrical ratings and performance of the motors comply with IEC 600341.
Explosion-proofing standards
All explosion-proof products for use in explosive atmospheres are designed in compliance with one or more of the following approvals:
•EN, ATEX Directive 94/9/EC
•FM According to NEC
•Class 1 Div 1 Groups “C”, and “D”
•Class 2 Div 1 Groups “E”, “F”, and “G”
•Class 3 Div 1 Hazardous Locations
ATEX/IECEx:
•Group: IIC
•Category: Ex ia
•Temperature Class: T4 (for ambients up to 100ºC)
•ATEX Marking: Ex II 1 G
2D Barcode Here
CSA certification
Intrinsically safe for:
•Class I, Div. 1, Groups A, B, C, D
•Class II, Div. 1, Groups E, F, G
•Class III
•Certified to Canadian and US requirements
SERIAL NO.& YEAR OF
MANUFACTURE HERE.
10 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Introduction and Safety (Continued)
Certificates of conformance
CSA Certificate
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
11 |
Introduction and Safety (Continued)
12 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Introduction and Safety (Continued)
ATEX notification
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
13 |
Introduction and Safety (Continued)
IECEx Certificate of Conformity
14 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Introduction and Safety (Continued)
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
15 |
Introduction and Safety (Continued)
Chinese Certificate of Conformity
16 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Transportation and Storage
Transportation and Storage
Pump handling
WARNING:
•Make sure that the pump cannot roll or fall over and injure people or damage property.
•These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or subject it to shock loads as this can damage the internal ceramic components.
NOTICE: Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
WARNING:
•Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
•Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steeltoed shoes at all times.
•Do not attach sling ropes to shaft ends.
Table 1: Methods
Pump type |
Lifting method |
A bare pump without lifting |
Use a suitable sling attached properly to solid points like the casing, the |
handles |
flanges, or the frames. |
|
|
A bare pump with lifting handles |
Lift the pump by the handles. |
|
|
A base-mounted pump |
Use slings under the pump casing and the drive unit, or under the base |
|
rails. |
|
|
Mounted on top of a Polyshield |
See separate information regarding the Polyshield ANSI Combo. |
ANSI Combo |
|
Examples
Figure 1: Example of a proper lifting method
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
17 |
Transportation and Storage (Continued)
NOTICE: Do not use this lifting method to lift a Polyshield ANSI Combo with the pump and motor mounted. Doing so may result in equipment damage.
Figure 2: Example of a proper lifting method
NOTICE: Do not use this lifting method to lift a Polyshield ANSI Combo with the pump and motor mounted. Doing so may result in equipment damage.
Figure 3: Example of a proper lifting method
NOTICE: When lifting a unit that does not have a way to secure the strap on the suction flange, you must secure the strap around the frame adapter. Failure to do so may result in equipment damage.
Figure 4: Example of a proper lifting method with a strap secured around the frame adapter
18 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Transportation and Storage (Continued)
Pump storage requirements
Storage requirements depend on the amount of time that you store the pump. The normal packaging is designed only to protect the pump during shipping.
Length of time in storage |
Storage requirements |
|
Upon receipt/short-term (less than six months) |
• |
Store in a covered and dry location. |
|
• |
Store the unit free from dirt and vibrations. |
|
|
|
Long-term (more than six months) |
• |
Store in a covered and dry location. |
|
• |
Store the unit free from heat, dirt, and |
|
|
vibrations. |
|
• |
Rotate the shaft by hand several times at least |
|
|
every three months. |
|
|
|
Treat bearing and machined surfaces so that they are well preserved. Refer to drive unit and coupling manufacturers for their long-term storage procedures.
Frostproofing
Table 2: Situations when the pump is or is not frostproof
When the pump is... |
Then... |
Operating |
The pump is frostproof. |
|
|
Immersed in a liquid |
The pump is frostproof. |
|
|
Lifted out of a liquid into a temperature below |
The impeller might freeze. |
freezing |
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|
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Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
19 |
Product Description
Product Description
General description 3796
The 3796 is a horizontal overhung, self-priming, open impeller, centrifugal pump. This model is based on 3 power ends and 8 hydraulic pump sizes.
Figure 5: 3796 pump
This table shows the number of hydraulic sizes available for each drive-unit size group.
Pump size group |
Number of hydraulic sizes |
STi |
2 |
|
|
MTi |
6 |
|
|
LTi |
6 |
|
|
20 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Product Description (Continued)
Part description 3796
Casing |
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Impeller |
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Cover |
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Power end |
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3196
3796
HT 3196
CV 3196
LF 3196
NM 3196
3198
Figure 6: 3796 part description
This table describes the pump casing parts.
Table 3: Casing
Part |
Description |
Discharge |
Top-centerline |
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Casing ventilation |
Self-venting |
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Priming chamber |
integrally cast allowing the pump to evacuate air to prime itself |
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Gasket |
fully confined |
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Mounting method |
Integral foot support for maximum resistance to misalignment and distortion due |
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to piping loads |
Standard flange |
ANSI class 150 raised-face serrated flange |
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Optional heater |
Immersion heater to prevent the liquid in the priming chamber from freezing in |
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outdoor applications |
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Impeller
The impeller is
•fully open
•screwed onto the shaft
The threads are sealed from the pumped liquid by a Teflon O-ring.
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
21 |
Product Description (Continued)
Cover
Standard seal
•The 3796 is available with a stuffing-box cover designed for a packing and a BigBore or a TaperBore PLUS seal chamber.
Optional seal
•a dynamic seal is available which uses a repeller to pump liquid out of the stuffing box while the pump operates. A static seal prevents leakage when the pump is shut down.
This table describes the main parts of the power end.
Table 4: Power end
Part |
Description |
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Frame adapter |
The ductile iron frame adapter has |
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• |
a machined rabbet fitted to the seal chamber/ stuffing box cover |
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• |
a precision dowel pin fitted to the bearing frame. |
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Power end |
• |
Flood-oil lubrication is standard. |
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• |
No machining is required to convert from oil to grease or oil-mist lubrication. |
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Regreasable bearings and oil-mist lubrication are optional. |
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• |
The oil level is checked through a sight glass. |
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• |
The power end is sealed with labyrinth seals. |
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• |
The power end is made in the following sizes: |
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• |
STi |
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• MTi |
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• |
LTi |
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Shaft |
The shaft is available with or without a sleeve. |
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Bearings |
The inboard bearing |
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• |
carries only radial loads. |
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• |
is free to float axially in the frame. |
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is a single-row deep-groove ball bearing |
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The outboard bearing |
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• |
is shouldered and locked to the shaft and housing to enable it to carry radial |
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and thrust loads. |
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is a double-row angular-contact bearing, except for the LTi which uses a pair of |
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single-row angular-contact ball bearings mounted back-to-back. |
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General description i-ALERT™ Condition Monitor
Description
The i-ALERT Condition Monitor is a compact, battery-operated monitoring device that continuously measures the vibration and temperature of the pump power end. The condition monitor uses blinking red LEDs to alert the pump operator when the pump exceeds pre-set vibration and temperature limits. This allows the pump operator to make changes to the process or the pump before a catastrophic failure occurs. The condition monitor is also equipped with a single green LED to indicate when it is operational and has sufficient battery life.
Alarm mode
The condition monitor enters alarm mode when either vibration or temperature limits are exceeded over two consecutive readings within a ten minute period. Alarm mode is indicated with two red flashing LEDs within two second intervals.
Temperature and vibration limits
Variable |
Limit |
Temperature |
195°F (91°C) |
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22 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
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Product Description (Continued) |
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Variable |
Limit |
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Vibration |
100% increase over the baseline level |
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Battery life
The i-ALERT Condition Monitor battery is not replaceable. You must replace the entire unit once the battery runs out of power.
The battery life is not covered as part of the standard five-year pump warranty.
This table shows the average condition monitor battery life under normal and alarm-mode operating conditions.
Condition monitor operational state |
Battery life |
Normal operating and environmental conditions |
Three to five years |
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Alarm mode |
One year |
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Nameplate information
Important information for ordering
Every pump has nameplates that provide information about the pump. The nameplates are located on the casing and the bearing frame.
When you order spare parts, identify this pump information:
•Model
•Size
•Serial number
•Item numbers of the required parts
Refer to the nameplate on the pump casing for most of the information. See Parts List for item numbers.
Nameplate types
Nameplate |
Description |
Pump casing |
Provides information about the hydraulic characteristics of the pump. |
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The formula for the pump size is: Discharge x Suction - Nominal Maximum Impeller |
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Diameter in inches. |
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(Example: 2x3-8) |
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Bearing frame |
Provides information about the lubrication system used. |
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ATEX |
If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the |
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baseplate, or the discharge head. The nameplate provides information about the ATEX |
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specifications of this pump. |
IECEx |
If applicable, your pump unit might have the following IECEx nameplate affixed to the |
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pump and/or baseplate. The nameplate provides information about the IECEx |
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specifications of this pump. |
Nameplate on the pump casing using English units
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
23 |
Product Description (Continued)
Table 5: Explanation of nameplate on the pump casing
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Nameplate field |
Explanation |
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IMPLR. DIA. |
Impeller diameter, in inches |
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MAX. DIA. |
Maximum impeller diameter, in inches |
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GPM |
Rated pump flow, in gallons per minute |
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FT HD |
Rated pump head, in feet |
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RPM |
Rated pump speed, revolutions per minute |
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MOD. |
Pump model |
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SIZE |
Size of the pump |
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STD. NO. |
ANSI standard designation |
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MAT L. CONST. |
Material of which the pump is constructed |
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SER. NO. |
Serial number of the pump |
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MAX DSGN PSI |
Maximum pressure at 100ºF according to the pump design |
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@ 100F |
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Nameplate on the pump casing using metric units |
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Table 6: Explanation of the nameplate on the pump casing
Nameplate field |
Explanation |
IMPLR. DIA. |
Impeller diameter |
|
|
MAX. DIA. |
Maximum impeller diameter |
|
|
M3/HR |
Rated pump flow, in cubic meters per hour |
M HD |
Rated pump head, in meters |
|
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RPM |
Rated pump speed, in revolutions per minute |
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|
MOD. |
Pump model |
|
|
SIZE |
Size of the pump |
|
|
STD. NO. |
ANSI standard designation |
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MAT L. CONST |
Material of which the pump is constructed |
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SER. NO. |
Serial number of the pump |
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MAX. DSGN KG/CM3 @ |
Kilograms per cubic centimeter at 20°C |
20°C |
|
24 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Product Description (Continued)
Nameplate on the bearing frame
Table 7: Explanation of the nameplate on the bearing frame
Nameplate field |
Explanation |
MOD. |
Pump model |
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SIZE |
Size of the pump |
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SER. NO. |
Serial number of the pump |
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LUBE |
Lubricant, oil or grease |
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ATEX nameplate
Nameplate field |
Explanation |
II |
Group 2 |
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2 |
Category 2 |
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G/D |
Pump can be used when gas and dust are present |
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T4 |
Temperature class |
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NOTICE: Make sure that the code classifications on the pump are compatible with the specific environment in which you plan to install the equipment. If they are not compatible, do not operate the equipment and contact your ITT representative before you proceed.
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
25 |
Installation
Installation
Preinstallation
Precautions
WARNING:
•When installing in a potentially explosive environment, make sure that the motor is properly certified.
•You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly.
NOTICE: Supervision by an authorized ITT representative is recommended to ensure proper installation. Failure to do so may result in equipment damage or decreased performance.
Pump location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.
Guideline |
Explanation/comment |
||
Keep the pump as close to the liquid source as |
This minimizes the friction loss and keeps the |
||
practically possible. |
suction piping as short as possible. |
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||
Make sure that the space around the pump is |
This facilitates ventilation, inspection, maintenance, |
||
sufficient. |
and service. |
||
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|
||
If you require lifting equipment such as a hoist or |
This makes it easier to properly use the lifting |
||
tackle, make sure that there is enough space above |
equipment. |
||
the pump. |
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||
Protect the unit from weather and water damage |
This is applicable if nothing else is specified. |
||
due to rain, flooding, and freezing temperatures. |
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||
Do not install and operate the equipment in closed |
Acceptable devices: |
||
systems unless the system is constructed with |
• |
Pressure relief valves |
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properly-sized safety devices and control devices. |
|||
• |
Compression tanks |
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|||
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• |
Pressure controls |
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|
• |
Temperature controls |
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• |
Flow controls |
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|
If the system does not include these devices, consult |
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|
the engineer or architect in charge before you |
||
|
operate the pump. |
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||
Take into consideration the occurrence of unwanted |
The best pump location for noise and vibration |
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noise and vibration. |
absorption is on a concrete floor with subsoil |
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underneath. |
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||
If the pump location is overhead, undertake special |
Consider a consultation with a noise specialist. |
||
precautions to reduce possible noise transmission. |
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26 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
Installation (Continued)
Foundation requirements
Requirements
Sleeve-type bolts
J-type bolts
•The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the pump unit.
•The location and size of the foundation bolt holes must match those shown on the assembly drawing provided with the pump data package.
•The foundation must weigh between two and three times the weight of the pump.
•Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts.
•Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow movement for the final bolt adjustment.
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1 |
6 |
2 |
5 |
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3 |
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4 |
1.Baseplate
2.Shims or wedges
3.Foundation
4.Sleeve
5.Dam
6.Bolt
1
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5 |
4 |
2 |
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3 |
1.Baseplate
2.Shims or wedges
3.Foundation
4.Dam
5.Bolt
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
27 |
Installation (Continued)
Piping checklists
General piping checklist
Precautions
CAUTION:
•Never draw piping into place by using force at the flanged connections of the pump. This can impose dangerous strains on the unit and cause misalignment between the pump and driver. Pipe strain adversely affects the operation of the pump, which results in physical injury and damage to the equipment.
•Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the suction side. This action can result in decreased performance, unexpected heat generation, and equipment damage.
Piping guidelines
Guidelines for piping are given in the Hydraulic Institute Standards available from the Hydraulic Institute at 9 Sylvan Way, Parsippany, NJ 07054-3802. You must review this document before you install the pump.
Checklist
Check |
Explanation/comment |
Checked |
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Check that all piping is supported |
This helps to prevent: |
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independently of, and lined up |
• |
Strain on the pump |
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naturally with, the pump flange. |
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|||
• |
Misalignment between the pump and the drive unit |
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Wear on the pump bearings and the coupling |
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Wear on the pump bearings, seal, and shafting |
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Keep the piping as short as |
This helps to minimize friction losses. |
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possible. |
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Check that only necessary fittings |
This helps to minimize friction losses. |
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are used. |
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Do not connect the piping to the |
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pump until: |
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The grout for the baseplate or |
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sub-base becomes hard. |
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The hold-down bolts for the |
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pump and the driver are |
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tightened. |
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Make sure that all the piping |
This prevents air from entering the piping system or |
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joints and fittings are airtight. |
leaks that occur during operation. |
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If the pump handles corrosive |
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fluids, make sure that the piping |
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allows you to flush out the liquid |
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before you remove the pump. |
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If the pump handles liquids at |
This helps to prevent misalignment due to linear |
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elevated temperatures, make sure |
expansion of the piping. |
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that the expansion loops and |
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joints are properly installed. |
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28 |
Model 3796 i-FRAME Installation, Operation, and Maintenance Manual |
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