Goulds Pumps 5500 Installation, Operation And Maintenance Manual

Installation, Operation,
and Maintenance Manual

Model 5500

Table of Contents

Model 5500 Installation, Operation, and Maintenance Manual 1

Table of Contents

Introduction and Safety ..........................................................................................................3

Introduction .............................................................................................................................3

Safety ...................................................................................................................................... 4

Safety terminology and symbols ........................................................................................... 4

Environmental safety ............................................................................................................ 5

User safety ........................................................................................................................... 6

Product approval standards .................................................................................................... 9

Product warranty ................................................................................................................... 10

Transportation and Storage .................................................................................................11

Inspect the delivery ............................................................................................................... 11

Inspect the package ........................................................................................................... 11

Inspect the unit ................................................................................................................... 11

Transportation guidelines ................................................................................................... 11

Pump storage requirements ............................................................................................... 12

Frostproofing ......................................................................................................................... 12

Product Description .............................................................................................................. 13

General description ............................................................................................................... 13

Nameplate information .......................................................................................................... 14

Installation ............................................................................................................................. 16

Pre-installation ......................................................................................................................16

Pump location guidelines .................................................................................................... 16

Foundation requirements ................................................................................................... 16

Suction and Discharge Pipe ............................................................................................... 17

V-Belt Drive Installation Checks ......................................................................................... 17

Pump-to-drive alignment .................................................................................................... 18

Commissioning, Startup, Operation, and Shutdown ......................................................... 24

Lubricate the bearings with oil ............................................................................................... 24

Check the shaft rotation ........................................................................................................ 24

Check the motor rotation ....................................................................................................... 24

Impeller-clearance check ......................................................................................................24

Adjust the stuffing box ........................................................................................................... 24

Shaft-sealing options ............................................................................................................ 25

Maintenance ........................................................................................................................... 26

Lubricate the bearing ............................................................................................................ 26

Oil Volumes ........................................................................................................................ 26

Acceptable oil for lubricating bearings ................................................................................26

Prepare the stuffing box connection ...................................................................................... 27

Set the impeller adjustment ................................................................................................... 28

Lubricate the end cover seals ............................................................................................... 28

Disassembly ......................................................................................................................... 28

Disassemble the pump ....................................................................................................... 28

Remove the suction cover .................................................................................................. 30

Disassemble the bearing housing and shaft assembly ....................................................... 30

Guidelines for parts inspection and replacement ................................................................ 31

Reassembly ..........................................................................................................................31

Reassemble the bearing housing and shaft assembly ....................................................... 31

Reassemble the pump ........................................................................................................ 32

Table of Contents

Model 5500 Installation, Operation, and Maintenance Manual2

Troubleshooting .................................................................................................................... 35

Operation Troubleshooting ................................................................................................... 35

Alignment troubleshooting .................................................................................................... 35

Parts Listings and Cross-Sectionals ...................................................................................36

Assembly drawings (exploded views) ................................................................................... 36

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual 3

Introduction and Safety

Introduction

Purpose of this manual

The purpose of this manual is to provide necessary information for:

• Installation

• Operation

• Maintenance

CAUTION:

Failure to observe the instructions contained in this manual could result in personal injury and
property damage, and may void the warranty. Read this manual carefully before installing and
using the product.

NOTICE:

Save this manual for future reference and keep it readily available.

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.

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual4

Safety

WARNING:

• The operator must be aware of the pumpage and take appropriate safety precautions to
prevent physical injury.

• Risk of serious injury or death. If any pressure-containing device is over-pressurized, it can
explode, rupture, or discharge its contents. It is critical to take all necessary measures to
avoid over-pressurization.

• Risk of death, serious personal injury, and property damage. Installing, operating, or
maintaining the unit using any method not prescribed in this manual is prohibited.
Prohibited methods include any modification to the equipment or use of parts not provided
by ITT. If there is any uncertainty regarding the appropriate use of the equipment, please
contact an ITT representative before proceeding.

• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining
devices can cause trapped liquid to rapidly expand and result in a violent explosion. This
manual clearly identifies accepted methods for disassembling units. These methods must
be adhered to. Never apply heat to aid in their removal unless explicitly stated in this
manual.

• Risk of serious personal injury or property damage. Dry running may cause rotating parts
within the pump to seize to non-moving parts. Do not run dry.

• Running a pump without safety devices exposes operators to risk of serious personal
injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are
properly installed. See specific information about safety devices in other sections of this
manual.

• Risk of death, serious personal injury, and property damage. Heat and pressure buildup
can cause explosion, rupture, and discharge of pumpage. Never operate the pump with
suction and/or discharge valves closed.

• Never operate the pump with the suction valve closed.

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

• If the pump or motor is damaged or leaking, electric shock, fire, explosion, liberation of
toxic fumes, physical harm, or environmental damage may result. Do not operate the unit
until the problem has been corrected or repaired.

CAUTION:

Failure to observe the instructions contained in this manual could result in personal injury and
property damage, and may void the warranty. Read this manual carefully before installing and
using the product.

Risk of injury and/or property damage. Operating a pump in an inappropriate application can
cause over pressurization, overheating, and/or unstable operation. Do not change the service
application without the approval of an authorized ITT representative.

NOTICE:

Save this manual for future reference and keep it readily available.

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

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual 5

Hazard levels

Hazard level Indication

DANGER:

A hazardous situation which, if not avoided, will
result in death or serious injury

WARNING:

A hazardous situation which, if not avoided,
could result in death or serious injury

CAUTION:

A hazardous situation which, if not avoided,
could 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 station clean to avoid and/or discover emissions.

Waste and emissions regulations

Observe these safety regulations regarding waste and emissions:

• Appropriately dispose of all waste.

• Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.

• Clean up all spills in accordance with safety and environmental procedures.

• Report all environmental emissions to the appropriate authorities.

WARNING:

If the product has been contaminated in any way, such as from toxic chemicals or nuclear
radiation, do NOT send the product to ITT unless it has been properly decontaminated.

Electrical installation

For electrical installation recycling requirements, consult your local electric utility.

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual6

Recycling guidelines

Always follow local laws and regulations regarding recycling.

User safety

General safety rules

These safety rules apply:

• Always keep the work area clean.

• Pay attention to the risks presented by gas and vapors in the work area.

• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.

• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.

Safety equipment

Use safety equipment according to the company regulations. Use this safety equipment within
the work area:

• Helmet

• Safety goggles, preferably with side shields

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

Electrical connections

Electrical connections must be made by certified electricians in compliance with all internation­al, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.

Precautions before work

Observe these safety precautions before you work with the product or are in connection with
the product:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that all safety guards are in place and secure.

• Allow all system and pump components to cool before you handle them.

• 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:

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual 7

CAUTION:

Failure to observe the instructions contained in this manual could result in personal injury and
property damage, and may void the warranty. Read this manual carefully before installing and
using 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.

• Always wear protective gloves. The pump and condition monitor can be hot.

Hazardous liquids

The product is designed for use in liquids that can be hazardous to your health. Observe these
rules when you work with the product:

• Make sure that all personnel who work with biologically hazardous liquids are vaccinated
against diseases to which they may be exposed.

• Observe strict personal cleanliness.

• A small amount of liquid will be present in certain areas like the seal chamber.

Wash the skin and eyes

1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:

Condition Action

Chemicals or hazardous
fluids in eyes

1. Hold your eyelids apart forcibly with your fingers.

2. Rinse the eyes with eyewash or running water for at least 15 minutes.

3. Seek medical attention.

Chemicals or hazardous
fluids on skin

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least 1 minute.

3. Seek medical attention, if necessary.

Safety regulations for Ex-approved products in potentially explosive atmospheres

Description of ATEX

The ATEX directives are a specification enforced in Europe for electrical and non-electrical
equipment. ATEX deals with the control of potentially explosive atmospheres and the
standards of equipment and protective systems used within these atmospheres. The relevance
of the ATEX requirements is not limited to Europe. You can apply these guidelines to
equipment installed in any potentially explosive atmosphere.

Guidelines for compliance

Compliance is only fulfilled when the pump is operated within its intended use, for example
within its intended hydraulic range. The conditions of the service must not be changed without
approval of an authorized ITT representative. When installing or maintaining explosion-proof
pumps, follow these guidelines:

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual8

• Always install ATEX-approved equipment in compliance with the directive and applicable
standards (IEC/EN 60079–14).

• Do not install explosion proof products in locations that are classified as hazardous in the
national electric code, ANSI/NFPA 70–2005.

WARNING:

Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining devices
can cause trapped liquid to rapidly expand and result in a violent explosion. This manual clearly
identifies accepted methods for disassembling units. These methods must be adhered to.
Never apply heat to aid in their removal unless explicitly stated in this manual.

If there are any questions regarding these requirements, the intended use, or if the equipment
requires modification, contact an ITT representative before you proceed.

Personnel requirements

ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive

atmospheres:

• All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.

• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas and/or vapor present in hazardous areas.

• Any maintenance for Ex-approved products must conform to international and national
standards (for example IEC/EN 60079-17).

Product and product handling requirements

These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:

• Only use the product in accordance with the approved motor data stated on the
nameplates.

• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.

• Never start a pump without the proper priming.

• Before you start working with the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be energized.

• Do not open the product while it is energized or in an explosive gas atmosphere.

• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product.

• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.

• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.

• Make sure that the equipment is properly maintained:

• Monitor the pump components and the end temperature of the liquid.

• Maintain proper bearing lubrication.

• Do not modify the equipment without approval from an authorized ITT representative.

• Only use parts that have been provided by an authorized ITT representative.

Equipment for monitoring

For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:

• Pressure gauges

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual 9

• Flow meters

• Level indicators

• Motor load readings

• Temperature detectors

• Bearing monitors

• Leak detectors

• PumpSmart control system

Product approval standards

Regular standards

WARNING:

Use of equipment unsuitable for the environment can pose risks of ignition and/or explosion.
Ensure that the code classifications on the pump are compatible with the specific environment
in which the equipment is to be installed. If they are not compatible, do not operate the
equipment and contact an ITT representative before proceeding.

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

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

Introduction and Safety

Model 5500 Installation, Operation, and Maintenance Manual10

Product warranty

Coverage

ITT undertakes to remedy faults in products from ITT under these conditions:

• The faults are due to defects in design, materials, or workmanship.

• The faults are reported to an ITT representative within the warranty period.

• The product is used only under the conditions described in this manual.

• The monitoring equipment incorporated in the product is correctly connected and in use.

• All service and repair work is done by ITT-authorized personnel.

• Genuine ITT parts are used.

• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved
products.

Limitations

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.