Goulds Pumps LF 3196 User Manual

Goulds Pumps

Installation, Operation, and

Maintenance Manual

Model LF 3196 i-FRAME

	Table of Contents
Table of Contents
Introduction and Safety...................................................................................................................................................	4
Introduction.......................................................................................................................................................................	4
Requesting other information......................................................................................................................................	4
Safety...................................................................................................................................................................................	4
Safety terminology and symbols..................................................................................................................................	5
Environmental safety.....................................................................................................................................................	6
User safety.......................................................................................................................................................................	6
Safety regulations for Ex-approved products in potentially explosive atmospheres...........................................	8
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 handling.............................................................................................................................................................	11
Lifting methods............................................................................................................................................................	11
Storage guidelines............................................................................................................................................................	13
Pump storage requirements........................................................................................................................................	13
Frostproofing................................................................................................................................................................	13
Product Description........................................................................................................................................................	14
General description LF 3196.........................................................................................................................................	14
Part description LF 3196............................................................................................................................................	15
General description i-ALERT™ Condition Monitor................................................................................................	16
Nameplate information..................................................................................................................................................	17
Installation.........................................................................................................................................................................	20
Preinstallation...................................................................................................................................................................	20
Pump location guidelines............................................................................................................................................	20
Foundation requirements............................................................................................................................................	21
Baseplate-mounting procedures....................................................................................................................................	21
Prepare the baseplate for mounting..........................................................................................................................	21
Install the baseplate using shims or wedges.............................................................................................................	22
Install the baseplate using jackscrews.......................................................................................................................	22
Install the baseplate using spring mounting.............................................................................................................	24
Install the baseplate using stilt mounting.................................................................................................................	25
Baseplate-leveling worksheet......................................................................................................................................	27
Install the pump, driver, and coupling.........................................................................................................................	28
Pump-to-driver alignment..............................................................................................................................................	28
Alignment checks.........................................................................................................................................................	28
Permitted indicator values for alignment checks....................................................................................................	29
Alignment measurement guidelines..........................................................................................................................	29
Attach the dial indicators for alignment...................................................................................................................	30
Pump-to-driver alignment instructions....................................................................................................................	30
C-face adapter...............................................................................................................................................................	33
Grout the baseplate.........................................................................................................................................................	34
Piping checklists..............................................................................................................................................................	35
General piping checklist..............................................................................................................................................	35
Suction-piping checklist..............................................................................................................................................	36
Discharge piping checklist..........................................................................................................................................	38

Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

1

Table of Contents

Commissioning, Startup, Operation, and Shutdown............................................................................................	40
Preparation for startup...................................................................................................................................................	40
Remove the coupling guard...........................................................................................................................................	40
Check the rotation...........................................................................................................................................................	43
Impeller-clearance check................................................................................................................................................	43
Impeller clearances (LF 3196)....................................................................................................................................	43
Impeller-clearance setting..............................................................................................................................................	44
Set the impeller clearance - dial indicator method (all except CV 3196) ............................................................	44
Set the impeller clearance - feeler gauge method (all except CV 3196) .............................................................	45
Couple the pump and driver..........................................................................................................................................	46
Install the coupling guard...........................................................................................................................................	46
Bearing lubrication.......................................................................................................................................................	50
Shaft-sealing options.......................................................................................................................................................	52
Mechanical seal options..............................................................................................................................................	52
Connection of sealing liquid for mechanical seals..................................................................................................	52
Packed stuffing box option.........................................................................................................................................	53
Connection of sealing liquid for a packed stuffing box.........................................................................................	53
Dynamic-seal option ..................................................................................................................................................	53
Set an elastomeric face seal.........................................................................................................................................	54
Pump priming..................................................................................................................................................................	54
Prime the pump with the suction supply above the pump...................................................................................	54
Prime the pump with the suction supply below the pump...................................................................................	55
Other methods of priming the pump.......................................................................................................................	56
Start the pump.................................................................................................................................................................	56
Activate the i-ALERT™ Condition Monitor..............................................................................................................	57
i-ALERT™ Condition Monitor routine operation....................................................................................................	58
Pump operation precautions.........................................................................................................................................	58
Shut down the pump......................................................................................................................................................	59
Deactivate the i-ALERT™ Condition Monitor..........................................................................................................	59
Reset the i-ALERT™ Condition Monitor...................................................................................................................	59
Make the final alignment of the pump and driver......................................................................................................	59
Maintenance......................................................................................................................................................................	61
Maintenance schedule.....................................................................................................................................................	61
Bearing maintenance.......................................................................................................................................................	62
Lubricating-oil requirements......................................................................................................................................	62
Regrease the grease-lubricated bearings ..................................................................................................................	63
Lubricate the bearings after a shutdown period......................................................................................................	64
Shaft seal maintenance...................................................................................................................................................	64
Mechanical-seal maintenance.....................................................................................................................................	64
Packed stuffing-box maintenance..............................................................................................................................	65
Dynamic-seal maintenance.........................................................................................................................................	65
Disassembly......................................................................................................................................................................	66
Disassembly precautions.............................................................................................................................................	66
Tools required...............................................................................................................................................................	66
Drain the pump............................................................................................................................................................	67
Remove the coupling...................................................................................................................................................	67
Remove the back pull-out assembly..........................................................................................................................	67
Remove the coupling hub...........................................................................................................................................	70
Impeller removal..........................................................................................................................................................	70
Seal-chamber cover removal.......................................................................................................................................	71
Remove the seal-chamber cover (3196, CV 3196, HT 3196, LF 3196, 3796) ...................................................	71
Remove the stuffing-box cover (3196, CV 3196, HT 3196, LF 3196, 3796) ....................................................	72
Remove the dynamic seal ...........................................................................................................................................	73
Remove the frame adapter (MTi, LTi) .....................................................................................................................	74
Remove the inboard labyrinth oil seal.......................................................................................................................	74

2	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Table of Contents
Power-end disassembly...............................................................................................................................................	75
Disassemble the bearing frame..................................................................................................................................	80
Guidelines for i-ALERT™ Condition Monitor disposal.......................................................................................	80
Disassemble the C-face adapter.................................................................................................................................	81
Pre-assembly inspections...............................................................................................................................................	81
Replacement guidelines...............................................................................................................................................	81
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
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.....................................................................................................................................................	107
Attach the i-ALERT™ Condition Monitor to the pump....................................................................................	109
Post-assembly checks................................................................................................................................................	110
Install the back pull-out assembly (except HT 3196) ..........................................................................................	110
Assembly references..................................................................................................................................................	112
Spare parts...................................................................................................................................................................	114
Interchangeability drawings.........................................................................................................................................	114
LF 3196 interchangeability.......................................................................................................................................	114
Lubrication conversion.................................................................................................................................................	115
Frame lubrication conversion..................................................................................................................................	115
Convert from greased-for-life or regreaseable to oil-lubricated bearings.........................................................	115
Conversion from flood-oil to pure-oil mist...........................................................................................................	116
Convert from flood oil to regreaseable..................................................................................................................	116
Troubleshooting.............................................................................................................................................................	117
Operation troubleshooting..........................................................................................................................................	117
Alignment troubleshooting..........................................................................................................................................	118
Assembly troubleshooting...........................................................................................................................................	118
i-ALERT™ Condition Monitor troubleshooting.....................................................................................................	119
Parts Listings and Cross-Sectional Drawings.......................................................................................................	120
Parts list..........................................................................................................................................................................	120
Certification: CE or CE ATEX..................................................................................................................................	131
Certificates of conformance........................................................................................................................................	131
Other Relevant Documentation or Manuals.........................................................................................................	137
For additional documentation.....................................................................................................................................	137
Local ITT Contacts.......................................................................................................................................................	138
Regional offices.............................................................................................................................................................	138

Model LF 3196 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.

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.

•This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.

•Do not change the service application without the approval of an authorized ITT representative.

CAUTION:

You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.

4	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Introduction and Safety

Safety terminology and symbols

About safety messages

It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:

•Personal accidents and health problems

•Damage to the product

•Product malfunction

Hazard levels

Hazard level		Indication
		A hazardous situation which, if not avoided, will
	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

The Ex symbol

The Ex symbol indicates safety regulations for Ex-approved products when used in atmospheres that are potentially explosive or flammable.

Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

5

Introduction and Safety

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.

Electrical installation

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

Recycling guidelines

Always follow local laws and regulations regarding recycling.

User safety

General safety rules

These safety rules apply:

•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

NOTICE:

Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual.

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.

•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.

•Make sure that you have a clear path of retreat.

6	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Introduction and Safety

•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.

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.

Wash the skin and eyes

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

Condition	Action
Chemicals or hazardous	1.	Hold your eyelids apart forcibly with your fingers.
fluids in eyes	2.	Rinse the eyes with eyewash or running water for at least 15 minutes.
	3.	Seek medical attention.
Chemicals or hazardous	1.	Remove contaminated clothing.
fluids on skin	2.	Wash the skin with soap and water for at least 1 minute.
	3.	Seek medical attention, if necessary.

Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

7

Introduction and Safety

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:

•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:

This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.

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.

8	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Introduction and Safety

•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

•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

Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

9

Introduction and Safety

•Class III

•Certified to Canadian and US requirements

SERIAL NO.& YEAR OF

MANUFACTURE HERE.

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.

10	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Transportation and Storage

Transportation and Storage

Inspect the delivery

Inspect the package

1.Inspect the package for damaged or missing items upon delivery.

2.Note any damaged or missing items on the receipt and freight bill.

3.File a claim with the shipping company if anything is out of order.

If the product has been picked up at a distributor, make a claim directly to the distributor.

Inspect the unit

1.Remove packing materials from the product.

Dispose of all packing materials in accordance with local regulations.

2.Inspect the product to determine if any parts have been damaged or are missing.

3.If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.

4.Contact your sales representative if anything is out of order.

Transportation guidelines

Pump handling

WARNING:

•Make sure that the unit cannot roll or fall over and injure people or damage property.

•These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or subject it to shock loads as this can damage the internal ceramic components.

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.

Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

11

Transportation and Storage

	Pump type	Lifting method
	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

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

12	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Transportation and Storage

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

Storage guidelines

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.

NOTICE:

Risk of damage to the mechanical seal or shaft sleeve on units supplied with cartridge mechanical seals. Make sure to install and tighten the centering clips and loosen the set screws in the seal locking ring.

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

Situation	Condition
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

Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

13

Product Description

Product Description

General description LF 3196

The LF 3196 is a horizontal overhung, open impeller, centrifugal pump. This pump is ANSI B73.1 compliant. It is designed for low-flow high-head applications.

The model is based on 3 drive-unit sizes and 4 hydraulic sizes.

Figure 5: LF 3196 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	2
LTi	2

14	Model LF 3196 i-FRAME Installation, Operation, and Maintenance Manual

Product Description

Part description LF 3196

Casing				Impeller		Cover		Power end

3196

3796

HT 3196

CV 3196

LF 3196

NM 3196

3198

Figure 6: LF 3196 part description

This table describes the pump casing parts.

Table 3: Casing

Part	Description
Discharge	Top-centerline
Casing ventilation	Self venting
Gasket	Fully confined
Mounting method	Integral foot support for maximum resistance to misalignment and distortion due
	to piping loads.
Standard flange	• ANSI class 150 raised-face serrated flanges are standard on 4 in., 8 in., and 10
	in. sizes
	• ANSI class 300 raised face serrated flange is standard on the 13 in. size
Optional flanges	ANSI class 300 raised-face serrated flange is optional on 4 in., 8 in., and 10 in.
	sizes.

Impeller

The impeller is

•fully open with radial vanes and balance holes

•screwed onto the shaft

The threads are sealed from the pumped liquid by a Teflon O-ring.

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15

Product Description

Cover

Standard seal

•The LF 3196 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
Frame adapter	The ductile iron frame adapter has
	•	a machined rabbet fitted to the seal chamber/ stuffing box cover
	•	a precision dowel pin fitted to the bearing frame.
Power end	•	Flood-oil lubrication is standard.
	•	No machining is required to convert from oil to grease or oil-mist lubrication.
		Regreasable bearings and oil-mist lubrication are optional.
	•	The oil level is checked through a sight glass.
	•	The power end is sealed with labyrinth seals.
	•	The power end is made in the following sizes:
	•	STi
	• MTi
	•	LTi
Shaft	The shaft is available with or without a sleeve.
Bearings	The inboard bearing
	•	carries only radial loads.
	•	is free to float axially in the frame.
	•	is a single-row deep-groove ball bearing
	The outboard bearing
	•	is shouldered and locked to the shaft and housing to enable it to carry radial
		and thrust loads.
	•	is a double-row angular-contact bearing, except for the LTi which uses a pair of
		single-row angular-contact ball bearings mounted back-to-back.

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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		Product Description
	Variable	Limit
	Vibration	100% increase over the baseline level

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

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.
	The formula for the pump size is: Discharge x Suction - Nominal Maximum Impeller
	Diameter in inches.
	(Example: 2x3-8)
Bearing frame	Provides information about the lubrication system used.
ATEX	If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the
	baseplate, or the discharge head. The nameplate provides information about the ATEX
	specifications of this pump.
IECEx	If applicable, your pump unit might have the following IECEx nameplate affixed to the
	pump and/or baseplate. The nameplate provides information about the IECEx
	specifications of this pump.

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17

Product Description

Nameplate on the pump casing using English units

Table 5: Explanation of nameplate on the pump casing

Nameplate field

Explanation

IMPLR. DIA.

Impeller diameter, in inches

MAX. DIA.

Maximum impeller diameter, in inches

GPM

Rated pump flow, in gallons per minute

FT HD

Rated pump head, in feet

RPM

Rated pump speed, revolutions per minute

MOD.

Pump model

SIZE

Size of the pump

STD. NO.

ANSI standard designation

MAT L. CONST.

Material of which the pump is constructed

SER. NO.

Serial number of the pump

MAX DSGN PSI

Maximum pressure at 100ºF according to the pump design

@ 100F

Nameplate on the pump casing using metric units

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
RPM	Rated pump speed, in revolutions per minute
MOD.	Pump model
SIZE	Size of the pump
STD. NO.	ANSI standard designation

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Product Description

	Nameplate field	Explanation
	MAT L. CONST	Material of which the pump is constructed
	SER. NO.	Serial number of the pump
	MAX. DSGN KG/CM3 @	Kilograms per cubic centimeter at 20°C
	20°C
Nameplate on the bearing frame

Table 7: Explanation of the nameplate on the bearing frame

Nameplate field	Explanation
MOD.	Pump model
SIZE	Size of the pump
SER. NO.	Serial number of the pump
LUBE	Lubricant, oil or grease

ATEX nameplate

Nameplate field	Explanation
II	Group 2
2	Category 2
G/D	Pump can be used when gas and dust are present
T4	Temperature class

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.

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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.
	Make sure that the space around the pump is	This facilitates ventilation, inspection, maintenance,
	sufficient.	and service.
	If you require lifting equipment such as a hoist or	This makes it easier to properly use the lifting
	tackle, make sure that there is enough space	equipment and safely remove and relocate the
	above the pump.	components to a safe location.
	Protect the unit from weather and water damage	This is applicable if nothing else is specified.
	due to rain, flooding, and freezing temperatures.
	Do not install and operate the equipment in	Acceptable devices:
	closed systems unless the system is constructed	•	Pressure relief valves
	with properly-sized safety devices and control
		•	Compression tanks
	devices.
		•	Pressure controls
		•	Temperature controls
		•	Flow controls
		If the system does not include these devices, consult
		the engineer or architect in charge before you operate
		the pump.
	Take into consideration the occurrence of	The best pump location for noise and vibration
	unwanted noise and vibration.	absorption is on a concrete floor with subsoil
		underneath.
	If the pump location is overhead, undertake	Consider a consultation with a noise specialist.
	special precautions to reduce possible noise
	transmission.

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Installation

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 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.

	1
6	2
5
	3
	4

1.Baseplate

2.Shims or wedges

3.Foundation

4.Sleeve

5.Dam

6.Bolt

1

	5
4	2
	3

1.Baseplate

2.Shims or wedges

3.Foundation

4.Dam

5.Bolt

Baseplate-mounting procedures

Prepare the baseplate for mounting

1.Remove all the attached equipment from the baseplate.

2.Clean the underside of the baseplate completely.

3.If applicable, coat the underside of the baseplate with an epoxy primer. Use an epoxy primer only if you used an epoxy-based grout.

4.Remove the rust-proofing coat from the machined mounting pads using an appropriate solvent.

5.Remove water and debris from the foundation-bolt holes.

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21

Installation

Install the baseplate using shims or wedges

Required tools:

•Two sets of shims or wedges for each foundation bolt

•Two machinist's levels

•Baseplate-leveling worksheet

This procedure is applicable to cast iron and fabricated steel baseplates.

1.If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from entering the bolt holes.

2.Put the sets of wedges or shims on each side of each foundation bolt.

The sets of wedges should have a height of between 0.75 in. (19 mm) and 1.50 in. (38 mm).

1

1. Shims or wedges

Figure 7: Top view

1

1. Shims or wedges

Figure 8: Side view

3.Lower the baseplate carefully onto the foundation bolts.

4.Put the machinist's levels across the mounting pads of the driver and the mounting pads of the pump.

NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct leveling. Failure to do so can result in equipment damage or decreased performance.

5.Level the baseplate both lengthwise and across by adding or removing shims or moving the wedges. These are the leveling tolerances:

•A maximum difference of 0.125 in. (3.2 mm) lengthwise

•A maximum difference of 0.059 in. (1.5 mm) across

You can use the baseplate-leveling worksheet when you take the readings.

6.Hand-tighten the nuts for the foundation.

Install the baseplate using jackscrews

Tools required:

•Anti-seize compound

•Jackscrews

•Bar stock

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Installation

•Two machinist's levels

•Baseplate-leveling worksheet

This procedure is applicable to the feature-fabricated steel baseplate and the advantage base baseplate. 1. Apply an anti-seize compound on the jackscrews.

The compound makes it easier to remove the screws after you grout.

2. Lower the baseplate carefully onto the foundation bolts and perform these steps:

a) Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce stress concentrations.

b) Put the plates between the jackscrews and the foundation surface.

c) Use the four jackscrews in the corners in order to raise the baseplate above the foundation.

Make sure that the distance between the baseplate and the foundation surface is between 0.75 in. (19 mm) and 1.50 in. (38 mm).

d) Make sure that the center jackscrews do not touch the foundation surface yet.

1 2

4 3

1.Jackscrew

2.Baseplate

3.Foundation

4.Plate

3.Level the driver mounting pads:

NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct leveling. Failure to do so can result in equipment damage or decreased performance.

a)Put one machinist's level lengthwise on one of the two pads.

b)Put the other machinist's level across the ends of the two pads.

c)Level the pads by adjusting the four jackscrews in the corners.

Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and across.

Use the baseplate-leveling worksheet when you take the readings.

		1	2
	3	5	6
	4

1.Machinist's levels

2.Driver's mounting pads

3.Foundation bolts

4.Jackscrews

5.Grout hole

6.Pump's mounting pads

4.Turn the center jackscrews down so that they rest on their plates on the foundation surface.

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Installation

5.Level the pump mounting pads:

NOTICE: Remove all dirt from the mounting pads in order to make sure that you achieve the correct leveling. Failure to do so can result in equipment damage or decreased performance.

a)Put one machinist's level lengthwise on one of the two pads.

b)Put the other level across the center of the two pads.

c)Level the pads by adjusting the four jackscrews in the corners.

Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and across.

		1	2
3	5		6
4

1.Driver's mounting pads

2.Machinist's levels

3.Foundation bolts

4.Jackscrews

5.Grout hole

6.Pump's mounting pads

6.Hand-tighten the nuts for the foundation bolts.

7.Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts if necessary.

The correct level measurement is a maximum of 0.002 in./ft (0.0167 mm/m).

Install the baseplate using spring mounting

NOTICE: The spring-mounted baseplate is designed only to support piping loads from thermal expansion. You must support the suction and discharge piping individually. Failure to do so may result in equipment damage.

The foundation pads are not provided with the baseplate. Make sure that the foundation pads are 316 stainless-steel plates, which have a 16-20 micro-inch surface finish.

Before you start this procedure, make sure that the foundation pads are correctly installed on the foundation/floor (see the manufacturer's instructions).

1.Put the baseplate on a support above the foundation/floor.

Make sure that there is enough space between the baseplate and the foundation/floor in order to install the spring assemblies.

2.Install the lower part of the spring assembly:

a)Screw the lower jam nut onto the spring stud.

b)Screw the lower adjusting nut onto the spring-stud, on top of the jam nut.

c)Set the lower adjusting nut to the correct height.

The correct height depends on the required distance between the foundation/floor and the baseplate.

d)Put a washer, a follower, a spring, and one more follower onto the lower adjusting nut.

3.Install the spring assembly on the baseplate:

a)Insert the spring assembly into the baseplate's anchorage hole from below.

b)Put a follower, a spring, another follower, and a washer onto the spring stud.

c)Fasten the spring assembly with the upper adjusting nut by hand.

4.Thread the upper jam nut onto the spring stud by hand.

5.Repeat steps 2 through 4 for all the spring assemblies.

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Installation

6.Lower the baseplate so that the spring assemblies fit into the foundation pads.

7.Level the baseplate and make the final height adjustments:

a)Loosen the upper jam nuts and adjusting nuts.

b)Adjust the height and level the baseplate by moving the lower adjusting nuts.

c)When the baseplate is level, tighten the top adjusting nuts so that the top springs are not loose in their followers.

8.Fasten the lower and upper jam nuts on each spring assembly.

7 6 1

2

5

3

4

1.Upper jam nut

2.Follower

3.Washer

4.Foundation pads

5.Spring

6.Upper adjusting nut

7.Spring stud

Figure 9: Example of an installed spring assembly

Install the baseplate using stilt mounting

NOTICE: The stilt-mounted baseplate is not designed to support static piping loads. Make sure to individually support the suction and discharge piping. Failure to do so may result in equipment damage.

1.Put the baseplate on a support above the foundation/floor.

Make sure that there is enough space between the baseplate and the foundation/floor to install the stilts.

2.Install the lower part of the stilt assembly:

a)Screw the lower jam nut and adjusting nut onto the stilt.

b)Set the lower adjusting nut to the correct height.

The correct height depends on the required distance between the foundation/floor and the baseplate.

c)Put a washer onto the lower adjustingnut.

3.Install the stilt assembly on the baseplate:

a)Insert the stilt assembly into the baseplate's anchorage hole from below.

b)Put a washer onto the stilt.

c)Fasten the stilt assembly with the upper adjusting nut by hand.

4.Screw the upper jam nut onto the stilt by hand.

5.Repeat steps 2 through 4 for all the stilt assemblies.

6.Lower the baseplate so that the stilts fit into the foundation cups.

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Installation

7.Level the baseplate and make the final height adjustments:

a)Loosen the upper jam nuts and adjusting nuts.

b)Adjust the height and level the baseplate by moving the lower adjusting nuts.

c)When the baseplate is level, tighten the top adjusting nuts.

8.Fasten the lower and upper jam nuts on each stilt.

	8
	7
6
5
	1
4	2
	3

1.Mounting plate

2.Mounting nut

3.Stilt bolt

4.Foundation cups

5.Washer

6.Upper adjustment nut

7.Mounting washer

8.Mounting bolt

Figure 10: Example of an installed stilt assembly

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Installation

Baseplate-leveling worksheet

Level measurements

				3
	5						7
	8			2			9
	4						6
				1

											14					10
17						15					16					18
						11
												12
								13

1)____________________

2)____________________

3)____________________

4)____________________

5)____________________

6)____________________

7)____________________

8)____________________

9)____________________

10)___________________

11)___________________

12)___________________

13)___________________

14)___________________

15)___________________

16)___________________

17)___________________

18)___________________

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Installation

Install the pump, driver, and coupling

1.Mount and fasten the pump on the baseplate. Use applicable bolts.

2.Mount the driver on the baseplate. Use applicable bolts and hand tighten.

3.Install the coupling.

See the installation instructions from the coupling manufacturer.

Pump-to-driver alignment

Precautions

WARNING:

•Follow shaft alignment procedures in order to prevent catastrophic failure of drive components or unintended contact of rotating parts. Follow the coupling installation and operation procedures from the coupling manufacturer.

•Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.

NOTICE: Proper alignment is the responsibility of the installer and the user of the unit. Check the alignment of frame-mounted units before you operate the unit. Failure to do so can result in equipment damage or decreased performance.

Alignment checks

When to perform alignment checks

You must perform alignment checks under these circumstances:

•The process temperature changes.

•The piping changes.

•The pump has been serviced.

Types of alignment checks

	Type of check	When it is used
	Initial alignment (cold alignment)	Prior to operation when the pump and the driver are at ambient
	check	temperature.
	Final alignment (hot alignment)	After operation when the pump and the driver are at operating
	check	temperature.
Initial alignment (cold alignment) checks
	When	Why
	Before you grout the baseplate	This ensures that alignment can be accomplished.
	After you grout the baseplate	This ensures that no changes have occurred during the grouting
		process.
	After you connect the piping	This ensures that pipe strains have not altered the alignment.
		If changes have occurred, you must alter the piping to remove pipe
		strains on the pump flanges.

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