Page 1
Goulds Pumps
Installation, Operation, and
Maintenance Manual
i-ALERT™ Condition Monitor
Page 2
Page 3
Table of Contents
Introduction and Safety...................................................................................................................................................2
Introduction.......................................................................................................................................................................2
Requesting other information......................................................................................................................................2
Inspect the package........................................................................................................................................................2
Product warranty............................................................................................................................................................2
Safety...................................................................................................................................................................................3
Safety terminology and symbols..................................................................................................................................3
Safety regulations for Ex-approved products in potentially explosive atmospheres...........................................4
Product approval standards.............................................................................................................................................5
Certificates of conformance............................................................................................................................................7
Product Description........................................................................................................................................................13
General description i-ALERT™ Condition Monitor................................................................................................13
Installation.........................................................................................................................................................................14
Attach the i-ALERT™ Condition Monitor to the pump..........................................................................................14
Commissioning, Startup, Operation, and Shutdown............................................................................................15
Activate the i-ALERT™ Condition Monitor..............................................................................................................15
i-ALERT™ Condition Monitor routine operation....................................................................................................16
Deactivate the i-ALERT™ Condition Monitor..........................................................................................................16
Reset the i-ALERT™ Condition Monitor...................................................................................................................16
Table of Contents
Maintenance......................................................................................................................................................................17
Guidelines for i-ALERT™ Condition Monitor disposal..........................................................................................17
Troubleshooting...............................................................................................................................................................18
i-ALERT™ Condition Monitor troubleshooting.......................................................................................................18
Local ITT Contacts.........................................................................................................................................................19
Regional offices................................................................................................................................................................19
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 1
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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.
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
2 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Warranty claim
Safety
Introduction and Safety
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
ITT products are high-quality products with expected reliable operation and long life. However, should the
need arise for a warranty claim, then contact your ITT representative.
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.
Observe all safety messages highlighted in other sections of this manual.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations
carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
WARNING:
A hazardous situation which, if not avoided, will
result in death or serious injury
A hazardous situation which, if not avoided, could
result in death or serious injury
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 3
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Introduction and Safety
Hazard level Indication
A hazardous situation which, if not avoided, could
CAUTION:
result in minor or moderate injury
NOTICE:
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
• A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
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.
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.
4 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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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.
Introduction and Safety
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not
limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
• Temperature detectors
• Bearing monitors
• Leak detectors
• 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.
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 5
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2D Barcode Here
SERIAL NO.
& YEAR OF
MANUFACTURE HERE.
Introduction and Safety
Explosion-proofing standards
All explosion-proof products for use in explosive atmospheres are designed in compliance with one or
more of the following approvals:
• EN, ATEX Directive 94/9/EC
• FM According to NEC
• Class 1 Div 1 Groups “C”, and “D”
• Class 2 Div 1 Groups “E”, “F”, and “G”
• Class 3 Div 1 Hazardous Locations
ATEX/IECEx:
• Group: IIC
• Category: Ex ia
• Temperature Class: T4 (for ambients up to 100ºC)
• ATEX Marking: Ex II 1 G
CSA certification
Intrinsically safe for:
• Class I, Div. 1, Groups A, B, C, D
• Class II, Div. 1, Groups E, F, G
• Class III
• Certified to Canadian and US requirements
6 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Certificates of conformance
CSA Certificate
Introduction and Safety
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 7
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Introduction and Safety
8 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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ATEX notification
Introduction and Safety
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 9
Page 12
Introduction and Safety
IECEx Certificate of Conformity
10 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Introduction and Safety
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 11
Page 14
Introduction and Safety
Chinese Certificate of Conformity
12 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Product Description
General description i-ALERT™ Condition Monitor
Description
The i-ALERT Condition Monitor is a compact, battery-operated monitoring device that continuously
measures the vibration and temperature of the pump power end. The condition monitor uses blinking red
LEDs to alert the pump operator when the pump exceeds pre-set vibration and temperature limits. This
allows the pump operator to make changes to the process or the pump before a catastrophic failure
occurs. The condition monitor is also equipped with a single green LED to indicate when it is operational
and has sufficient battery life.
Alarm mode
The condition monitor enters alarm mode when either vibration or temperature limits are exceeded over
two consecutive readings within a ten minute period. Alarm mode is indicated with two red flashing LEDs
within two second intervals.
Temperature and vibration limits
Variable Limit
Temperature 195°F (91°C)
Vibration 100% increase over the baseline level
Product Description
Battery life
The i-ALERT Condition Monitor battery is not replaceable. You must replace the entire unit once
the battery runs out of power.
The battery life is not covered as part of the standard five-year pump warranty.
This table shows the average condition monitor battery life under normal and alarm-mode operating
conditions.
Condition monitor operational state Battery life
Normal operating and environmental conditions Three to five years
Alarm mode One year
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 13
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372T
228A
761B
Installation
Installation
Attach the i-ALERT™ Condition Monitor to the pump
CAUTION:
Always wear protective gloves. The pump and condition monitor can be hot.
Tools required:
• 5/32 inch hex wrench
1. Attach the condition monitor (761B) to the bearing frame (228A) using the hex-head screw (372T)
provided.
2. Tighten the hex-head screw with a 5/32 inch hex wrench to 6 ft-lbs (8 Nm).
14 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Magnet
761B
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation, and
Shutdown
Activate the i-ALERT™ Condition Monitor
WARNING:
Never heat the condition monitor to temperatures in excess of 300°F (149°C). Heating to these
temperatures could result in death or serious injury.
CAUTION:
Always wear protective gloves. The pump and condition monitor can be hot.
NOTICE:
Do not use the condition monitor in atmospheres containing acetic acid.
The condition monitor is ready for activation when the pump is running and has reached a steady flow,
pressure, and temperature. This process only takes a few minutes.
Place a small magnet on the condition monitor over the ITT logo and then remove it, as this example
shows.
When the condition monitor is activated it:
1. Displays a series of red LEDs followed by a solid green LED.
2. Collects eight samples that are spaced one second apart.
3. Averages these readings to establish the baseline vibration level.
4. Flashes a green LED after approximately twelve seconds.
For the first ten minutes, the green LED flashes every second for five consecutive flashes and then
pauses to take a vibration reading. More frequent measurements (every six seconds) are taken in this
startup period so that an alarm can be immediately detected.
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 15
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Commissioning, Startup, Operation, and Shutdown
i-ALERT™ Condition Monitor routine operation
Measurement interval
This table shows the measurement intervals for the condition monitor during normal operation and when
the monitor is in alarm mode.
Mode Measurement interval
Normal operating mode Five minutes
Alarm mode Two minutes
When the condition monitor measures a reading beyond the specified temperature and vibration limits, the
appropriate red LED flashes. After the process or pump condition that causes the alarm is corrected, the
condition monitor returns to normal mode after one normal-level measurement.
Alarm mode
When the condition monitor is in alarm mode, you should investigate the cause of the condition and make
necessary corrections in a timely manner.
Magnetic device considerations
Be careful when you use magnetic devices in close proximity of the condition monitor, such as magnetic
vibration-monitoring probes or dial indicators. These magnetic devices can accidentally activate or
deactivate the condition monitor resulting in improper alarm levels or loss of monitoring.
Deactivate the i-ALERT™ Condition Monitor
NOTICE: Always deactivate the condition monitor when the pump is going to be shut down for an
extended period of time. Failure to do so will result in reduced battery life.
1. Touch and hold a small magnet to the condition monitor over the ITT logo until the red LEDs blink
three times.
This should take 10-15 seconds if the condition monitor is in normal operating mode and
approximately five seconds if the condition monitor is in alarm mode.
2. Remove the magnet.
If the deactivation is successful, solid red LEDs will be displayed.
Reset the i-ALERT™ Condition Monitor
NOTICE: Always reset the condition monitor when the pump is started after maintenance, system
change, or down-time. Failure to do so may result in false baseline levels that could cause the condition
monitor to alert in error.
Touch a magnet to the condition monitor over the ITT logo to turn the power on.
The condition monitor begins to establish a new baseline vibration level.
16 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Maintenance
Guidelines for i-ALERT™ Condition Monitor disposal
Precautions
WARNING:
• Never heat the condition monitor to temperatures in excess of 300°F (149°C). Heating to these
temperatures could result in death or serious injury.
• Never dispose of the condition monitor in a fire. This could result in death or serious injury.
Guidelines
The battery contained in the condition monitor does not contain enough lithium to qualify as reactive
hazardous waste. Use these guidelines when disposing of the condition monitor.
• The condition monitor is safe for disposal in the normal municipal waste stream.
• Adhere to local laws when you dispose of the condition monitor.
Maintenance
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 17
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Troubleshooting
Troubleshooting
i-ALERT™ Condition Monitor troubleshooting
Symptom Cause Remedy
There are no green or red flashing LEDs. The battery is dead. Replace the condition monitor.
Activate the condition monitor.
Consult your ITT representative
for a warranty replacement.
vibration levels and reset the
condition monitor.
Consult your ITT representative
for a warranty replacement.
The red LEDs are flashing, but the temperature and
vibration are at acceptable levels.
The unit is deactivated.
The unit is malfunctioning.
The baseline is bad. Check the temperature and
The unit is malfunctioning.
18 i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual
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Local ITT Contacts
Regional offices
Region Address Telephone Fax
North America (Headquarters) ITT - Goulds Pumps
USA
Asia Pacific ITT Industrial Process
10 Jalan Kilang #06-01
Singapore 159410
Europe ITT - Goulds Pumps
Millwey Rise Industrial Estate
Axminster, Devon, England
EX13 5HU
Latin America ITT - Goulds Pumps
Camino La Colina # 1448
Condominio Industrial El Rosal
Huechuraba – Santiago
8580000
Chile
Middle East and Africa ITT - Goulds Pumps
Achileos Kyrou 4
Neo Psychiko 115 25 Athens
Greece
+65–627–63693 +65– 627–63685
+44–1297–630250 +44–1297–630256
+562–544–7000
+30–210–677–0770 +30–210–677–5642
+562–544–7001
Local ITT Contacts
i-ALERT™ Condition Monitor Installation, Operation, and Maintenance Manual 19
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We appreciate you taking the time to provide your feedback. Thank you for buying
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Contact Us
Goulds Pumps has offices, warehouses and manufacturing facilities worldwide,
while doing business in over 100 countries in the Americas, Europe, the Middle East
and Asia Pacific. To find your nearest distributor, use our convenient Sales and
Service Locator found on our Web site.
Visit our Web site for the latest version of this document and more information
Goulds Pumps
© 2010 ITT Corporation. The original instruction is in English. All non-English instructions are translations of the original
instruction. en-US.2010-04.IOM.i-ALERT™ConditionMonitor
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