INSTRUCTION MANUAL
AC2008B
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
Series HSC
3
Base Mounted Centrifugal Pump
BELL & GOSSETT PUMP
MODEL
NO.
SERIAL
NO.
IDENT.
NO.
G.P.M. FT. HP R.P.M.
P.S.I.
MAX.
WORK
PRESS.
6 x 8 x 12M
HSC3 12.4 LHR
1234567
K99
1250
125
60 1800
175
PUMP
SERIES
DUTY
POINT
MAXIMUM
WORKING PRESSURE
PUMP
SIZE
SERIAL
NUMBER
MONTH
AND YEAR
DRIVER
HP-60
IMPELLER DIAMETER
12.4"
LEFT HAND
ROTATION
DESCRIPTION
The HSC3Series centrifugal pumps are frame mounted pumps
which feature – high efficiency, rugged construction, compact
design, foot mounted volute, center drop out coupler, and
regreasable bearings. These features, along with the horizontal
split case, make installation, operation, and service easy to
perform.
PUMP APPLICATION
The standard HSC3Series centrifugal pump’s bronze fitted
construction make it ideal for service with the following liquids:
unheated domestic and fresh water, boiler feed water
sate, hydronic cooling or heating, pressure boosting, general
pumping and benign liquids.
For other applications contact your local B&G representative.
, conden-
OPERATIONAL LIMITS
Unless special provisions have been made for your pump by
Bell & Gossett, the operational limits for HSC3Series Pumps
are as follows:
175# Maximum Working Pressur
75# Maximum Suction Pressure
Listed on pump nameplate.
SEAL OPERATING LIMITS
Standard Self Flushing Mechanical Seals
BUNA-PH Limitations 7-9; Temperature Range -20 to +225°F
EPT-PH Limitations 7-11; Temperature Range -20 to +250°F
For use on closed or open systems which are relatively free of
dirt and/or other abrasive particles.
e
PUMP IDENTIFICATION
Bell & Gossett pumps are designated by a series of numbers
such as Series HSC3. The pump nameplate gives identification
and rating information as identified in Illustration 1.
Permanent records for this pump ar
and it must be used with all correspondence and spare parts
orders.
e kept by the serial number
2
Illustration 1 – The Rating Plate
B. SAFETY INSTRUCTIONS
WARNING
ROTATING COMPONENTS
DISCONNECT AND LOCKOUT
POWER BEFORE SERVICING.
DO NOT OPERATE WITHOUT
ALL GUARDS IN PLACE.
CONSULT INSTALLATION
AND SERVICE INSTRUCTION
SHEET BEFORE OPERATING
OR SERVICING.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY
OR DEATH.
P70642
WARNING
EYEBOLTS OR LIFTING
LUGS IF PROVIDED ARE
FOR LIFTING ONLY THE
COMPONENTS TO WHICH
THEY ARE ATTACHED.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY
OR DEATH.
P70643
CAUTION
COUPLER ALIGNMENT IS
REQUIRED! LEVEL AND
GROUT PUMP BEFORE USE!
CHECK ALIGNMENT BEFORE
GROUTING, AFTER SYSTEM
IS FILLED, AFTER SERVICING
PUMP, AND AS REQUIRED.
CONSULT THE SERVICE
INSTRUCTIONS FOR DETAILS.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P70820
CAUTION
DO NOT RUN PUMP DRY,
SEAL DAMAGE MAY OCCUR.
INSPECT PUMP SEAL
REGULARLY FOR LEAKS,
REPLACE AS REQUIRED.
FOR LUBRICATION
REQUIREMENTS, CONSULT
SERVICE INSTRUCTIONS.
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P70644
BELL & GOSSETT PUMP
MODEL
NO.
SERIAL
NO.
IDENT.
NO.
G.P.M. FT. HR R.P.M.
P.S.I.
MAX.
WORK
PRESS.
6 x 8 x 12M
HSC3 12.4 LHR
1234567
K99
1250
125
60 1800
175
SAFETY
INSTRUCTIONS
This safety alert symbol will be used in this manual and on the
pump safety instruction decals to draw attention to safety related
instructions. When used the safety alert symbol means
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
FAILURE TO FOLLOW THE INSTRUCTION
A SAFETY HAZARD.
Your HSC3Pump should have the following safety instruction
decals displayed. If the decals are missing or illegible contact
your local B&G repr
esentative for a replacement.
S MAY RESULT IN
Additional Safety Requirements:
1. Electrical connections to be made by qualified Electrician in
accor
dance with all national, state and local codes.
2.
Motor must have properly sized starter with properly sized
heaters to provide overload and undervoltage protection.
3. If pump, motor or piping are operating at extremely high or
low temperatures, guarding or insulation is required.
4. The maximum working pressure of the pump is listed on
the pump nameplate, do not exceed this pressur
RATING PLATE
e.
Illustration 2 – Safety Instruction Decals
3
ADDITIONAL SAFETY REQUIREMENTS:
ELECTRICAL SAFETY:
MECHANICAL SAFETY:
WARNING: Electrical Shock Hazard
Electrical connections to be made by a qualified
electrician in accordance with all applicable codes, ordinances, and good practices. Failure to follow these instructions could result in serious personal injury or death,
or property damage.
WARNING: Electrical Overload Hazard
Three phase motors must have properly sized
heaters to provide overload and undervoltage protection.
Single phase motors have built-in overload protectors.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
THERMAL SAFETY:
WARNING: Extreme Temperature Hazard
If pump, motor, or piping are operating at extremely
high or low temperatures, guarding or insulation is required. Failure to follow these instructions could result in
serious personal injury or death, or pr
operty damage.
PUMP LOCATION
Locate the pump so there is sufficient room for inspection, maintenance and service. If the use of a hoist or tackle is needed,
allow ample head room.
WARNING: Unexpected Startup Hazard
Disconnect and lockout power before servicing.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
W
ARNING: Excessive System Pressure Hazard
The maximum working pressure of the pump is listed
on the nameplate, do not exceed this pressure. Do not use
air to hydr
otest pump. Failure to follow these instructions
could result in serious personal injury or death, or property
damage.
WARNING: Excessive Pressure Hazard
Volumetric Expansion
The heating of water and other fluids causes volumetric
expansion. The associated forces may cause failure of system components and release of high temperature fluids.
This will be prevented by installing properly sized and
located compression tanks and pressure relief valves.
Failure to follow these instructions could result in serious
personal injury or death, or property damage.
WARNING: Falling Objects Hazard
Eyebolts or lifting lugs, if provided, are for lifting only
the components to which they are attached. Failure to follow these instructions could result in serious personal
injury or death, or property damage.
If lifting of the entire pump is required, do so with slings placed
under the base rails as shown.
The best pump location for sound and vibration absorption is
on a concrete floor with subsoil underneath. If the pump location is overhead, special precautions should be undertaken to
reduce possible sound transmission. Consult a sound specialist.
If the pump is not on a closed system, it should be placed as
near as possible to the source of the liquid supply, and located
to permit installation with the fewest number of bends or
elbows in the suction pipe.
COMPRESSION TANK
SHOULD BE LOCA
ON THE SUCTION SIDE
OF THE PUMP
B&G REDUCING
COLD
WATER
SUPPLY
VALVE
CHILLER OR CONVER
TED
FROM BOILER
TER
B&G ROLAIRTROL
AIR SEPARATOR
ISOLATION
VALVE
SUPPLY
TO SYSTEM
B&G CIRCUIT
SETTER
B&G TRIPLE DUTY
VALVE
The installation must be evaluated to determine that the Net
Positive Suction Head Available (NPSHA) meets or exceeds the
Net Positive Suction Head Required (NPSHR), as stated by the
pump performance curve. See page 9 for more details on
proper suction piping installation.
IMPORTANT
Do not install and operate Bell & Gossett Pumps, 3D Valves,
Suction Diffusers, etc., in closed systems unless the system is
constructed with properly sized safety devices and control
devices. Such devices include the use of properly sized and
located pressure relief valves, compression tanks, pressure controls, temperature controls, and flow controls as appropriate. If
the system does not include these devices, consult the responsible engineer or architect before making pumps operational.
4
General HSC3Instructions
INTRODUCTION
1. Purpose of Manual
This manual is furnished to acquaint you with some of the
practical ways to install, operate, and maintain this pump.
Read it completely before doing any work on your unit and
keep it handy for future reference.
Equipment cannot operate well without proper care. To keep
this unit at top efficiency, follow the recommended installation
and servicing procedures outlined in this manual.
2. Warranty
Refer to your local representative for warranty coverage.
3. Pump Identification
All pumps are designated by Serial Number, Model Number,
and Size. This information is stamped on an identification
plate which is mounted on the pump. Refer to pump identification in specific instruction section of this manual for detailed
information.
4. Receiving Pump
Check pump for shortages and damage immediately upon
arrival. (An absolute must.) Prompt reporting to the carrier’s
agent with notations made on the freight bill, will expedite
satisfactory adjustment by the carrier.
Pumps and drivers normally are shipped from the factory
mounted and painted with primer and one finish coat.
Couplings may be either completely assembled or have the
coupling hubs mounted on the shafts and the connecting
members removed. When the connecting members are
removed, they will be packaged in a separate container and
shipped with the pump or attached to the base plate.
Shafts are in alignment when the unit is shipped; however, due
to shipping, the pumps may arrive misaligned and, therefore,
alignment must be established during installation. Bell &
Gossett has determined that proper and correct alignment can
only be made by accepted erection practices. Refer to the following paragraphs on “Foundation,” “Base Plate Setting,”
“Grouting Procedure,” “Alignment Procedure” and “Doweling.”
5. Temporary Storage
If the pump is not to be installed and operated soon after
arrival, store it in a clean, dry place having slow, moderate
changes in ambient temperature. Rotate the shaft periodically
to coat the bearings with lubricant and to retard oxidation,
corrosion, and to reduce the possibility of false brinelling of
the bearings.
6. Location
The pump should be installed as near the suction supply as
possible, but no less than five suction diameters (refer to page
9, suction and discharge piping section) with the shortest and
most direct suction pipe practical. The total dynamic suction
lift (static lift plus friction losses in suction line) should not
exceed the limits for which the pump was sold.
The pump must be primed before starting. Whenever possible,
the pump should be located below the fluid level to facilitate
priming and assure a steady flow of liquid. This condition provides a positive suction head on the pump. It may also be
possible to prime the pump by pressurizing the suction vessel.
When installing the pump, consider its location in relation to
the system to assure that sufficient Net Positive Suction Head
(NPSH) at pump suction is provided. Available NPSH must
always equal or exceed the required NPSH of the pump.
The pump should be installed with sufficient accessibility for
inspection and maintenance. A clear space with ample head
room should be allowed for the use of an overhead crane or
hoist sufficiently strong to lift the unit.
NOTE: Allow sufficient space to be able to dismantle pump
without disturbing the pump inlet and discharge piping.
Select a dry place above the floor level wherever possible.
Take care to prevent pump from freezing during cold weather
when not in operation. Should the possibility of freezing exist
during a shut-down period, the pump should be completely
drained, and all passages and pockets where liquid might collect should be blown out with compressed air.
Make sure there is a suitable power source available for the
pump driver. If motor driven, electrical characteristics should
be identical to those shown on motor data plate.
7. Foundation
A substantial foundation and footing should be built to suit
local conditions. It should form a rigid support to maintain
alignment. The pump assembly must be mounted to a suitable
foundation having a mass ≥ 1.5 times the weight of the unit.
The foundation should be poured without interruption to within
1
/2 to 11/2 inches of the finished height. The top surface of the
foundation should be well scored and grooved before the
concrete sets; this provides a bonding surface for the grout.
5
Foundation bolts should be set in concrete as shown in
Illustration 3. An optional 4-inch long tube around the bolts at
the top of the concrete will allow some flexibility in bolt alignment to match the holes in the base plate. Allow enough bolt
length for grout, shims, lower base plate flange, nuts and
washers. The foundation should be allowed to cure for several
days before the base plate is shimmed and grouted.
FOUNDA
TION
BOL
T
WASHER
(OPTIONAL)
PIPE
SLEEVE
BUILT-UP
CONCRETE FOUNDATION
Illustration 3 – Foundation
8. Base Plate Setting (Before Piping)
NOTE: This procedure assumes that a concrete foundation
has been prepared with anchor or hold down bolts extending
up ready to receive unit. It must be understood that pump and
motor have been mounted and rough aligned at the factory. If
motor is to be field mounted, consult factory for recommendations. Bell & Gossett cannot assume responsibility for final
alignment.
NOTE:
TO KEEP SHIMS IN
ALLOW 1" FOR SHIMS.
PLACE ON BOTH SIDES
OF ANCHOR BOLTS.
APPROX.
GAP
1"
LEVELING OF PUMP BASE
ON CONCRETE FOUNDATION.
Illustration 4 – Setting Base Plate and Grouting
PLACE ALLOW GROUT
TO FLOW AROUND
HOLD DOWN LUGS.
GROUT
CONCRETE
FOUNDATION
GROUT ONLY TO
TOP OF BASE RAIL.
PUMP
BASE RAIL
a. Use blocks and shims under base for support at anchor
bolts and midway between bolts, to position base
approximately 1" above the concrete foundation, with studs
extending through holes in the base plate.
b. By adding or removing shims under the base, level and
plumb the pump shaft and flanges.
c. Draw anchor nuts tight against base, and observe pump
and motor shafts or coupling hubs for alignment. (Temporarily remove coupling guard for checking alignment.)
6
d. If alignment needs improvement, add shims or wedges at
appropriate positions under base, so that retightening of
anchor nuts will shift shafts into closer alignment. Repeat
this procedure until a r
easonable alignment is reached.
NOTE: Reasonable alignment is defined as that which is
mutually agree upon by pump contractor and the accepting
facility (final operator). Final alignment procedures ar
e cov-
ered under “Alignment Procedures.”
e. Check to make sure the piping can be aligned to the pump
flanges without placing pipe strain on either flange.
f. Grout in base plate completely (See “Grouting Procedure”)
and allow grout to dry thoroughly befor
e attaching piping to
pump. (24 hours is sufficient time with approved grouting
procedure.)
9. Grouting Procedure
Grout compensates for uneven foundation, distributes weight
of unit, and prevents shifting. Use an approved, non-shrinking
grout, after setting and leveling unit. (See Illustration 4)
a. Build strong form around the foundation to contain grout.
b. Soak top of concrete foundation thoroughly, then remove
surface water.
c. Base plate should be completely filled with grout.
d. After the grout has thoroughly hardened, check the founda-
tion bolts and tighten if necessary.
e. Check the alignment after the foundation bolts are
tightened.
f. Approximately 14 days after the grout has been poured or
when the grout has thoroughly dried, apply an oil base paint
to the exposed edges of the grout to prevent air and moisture from coming in contact with the grout.
10. See ANSI/OSHA Coupler Guard Removal/Installation
(next page)
11. Alignment Procedure
NOTE: A flexible coupling will only compensate for small
amounts of misalignment. Permissible misalignment will vary
with the make of coupling. Consult coupling manufacturer’s
data when in doubt.
Allowances are to be made for thermal expansion during cold
alignment, so that the coupling will be aligned at operating
temperature. In all cases, a coupling must be in alignment for
continuous operation. Even though the coupling may be lubricated, misalignment causes excessive wear, vibration, and
bearing loads that result in premature bearing failure and
ultimate seizing of the pump. Misalignment can be angular,
parallel, or a combination of these, and in the horizontal and
vertical planes. Final alignment should be made by moving
and shimming the motor on the base plate, until the coupling
hubs are within the recommended tolerances measured in
total run-out. All measurements should be taken with the
pump and motor foot bolts tightened. The shaft of sleeve
bearing motors should be in the center of its mechanical float.
NOTE: Proper alignment is essential for correct pump operation. This should be performed after base plate has been
properly set and grout has dried thoroughly according to
instructions. Final alignment should be made by shimming
driver only. Alignment should be made at operating
temperatures.
WARNING: Unexpected Start-up Hazard
Disconnect and lock out power before servicing.
Failure to follow these instructions could result in serious
personal injury or death and property damage.
12. ANSI/OSHA COUPLER GUARD
INNER GUARD
ATTACH SUPPORT BRACKET
TO BEARING HOUSING
THIS OPTION USED IN PLACE OF SPACER WHERE
OVERALL LENGTH OF GUARD EXCEEDS 12 INCHES
OR GUARD WIDTH IS OVER 10 INCHES ACROSS
THE FLATS.
OUTER GUARD
NUT
LOCKWASHER
LOCATE SUPPORT ARM
BETWEEN OUTER GUARD ENDS.
ALIGN THE ARM WITH HOLES IN
THE OUTER GUARD AND HOLES IN
THE SADDLE BRACKET.
BRACKET SUPPORT
CAPSCREW
FLAT WASHER
BRACKET SUPPORT
ATTACHES INSIDE HERE
IN LINE WITH BOLT
MOTOR SADDLE BRACKET
ATTACH TO MOTOR SADDLE
SPACER WASHER
SUPPORT BRACKET
REMOVAL/INSTALLATION
W
ARNING: Unexpected Start-up Hazard
Disconnect and lock out power before servicing.
Failure to follow these instructions could result in serious
personal injury or death and pr
NOTE: Do not spread the inner and outer guards more than
necessary for guard removal or installation. Over spreading the
guards may alter their fit and appearance.
Removal
a. Remove the two capscrews that hold the outer (motor side)
coupler guard to the support bracket(s).
b. Spread the outer guard and pull it off the inner guard.
c. Remove the capscrew that holds the inner guard to the
support bracket.
d. Spread the inner guard and pull it over the coupler
Installation
a. Check coupler alignment before proceeding. Correct if
necessary.
b. Spread the inner guard and place it over the coupler.
operty damage.
.
c. With the inner guard straddling the support bracket, install a
capscrew through the hole (or slot) in the support bracket
and guard located closest to the pump. Do not tighten the
capscrew.
d. Spread the outer guard and place it over the inner guard.
e. Install the outer guard capscrews by following the step
stated below which pertains to your particular pump:
i. For pumps with a motor saddle support bracket: Ensure
the outer guard is straddling the support arm, and install
but do not tighten the two remaining capscrews.
ii. For pumps without a motor saddle support bracket:
Insert the spacer washer between the holes located
closest to the motor in the outer guard, and install, but
do not tighten, the two remaining capscrews.
f. Position the outer guard so it is centered around the shaft,
and so there is less than a 1/4" of the motor shaft exposed.
On guards that utilize a slotted support bracket, the inner
guard will have to be positioned so there is only a 1/4" of
the pump shaft exposed.
g. Holding the guard in this position, tighten the three
capscrews.
ANSI/OSHA Coupling Guard Exploded View
for Typical Series HSC3Pump Installation
7
Method 1 – Straight Edge Alignment for Standard Sleeve
STRAIGHT EDGE
FEELER GAGE
FEELER GAGE
ANGULAR ALIGNMENT PARALLEL ALIGNMENT
CORRECT ALIGNMENT
STRAIGHT EDGE
INCORRECT ALIGNMENT
DIAL
INDICATOR
INDEX LINE
R
RESILIENT
SEPARATOR
DIAL
INDICATOR
PARALLEL
ALIGNMENT
ANGULAR
ALIGNMENT
Type Coupler with Black Rubber Insert (See Illustration 5A)
Before aligning the coupler, make sure there is at least 1/8" end
clearance between the sleeve and the two coupler halves.
1. Check angular misalignment using a micrometer or caliper
Measure from the outside of one flange to the outside of
the opposite flange at four points 90° apart. DO NOT
ROTATE COUPLER. Misalignment up to 1/64" per inch of
coupler radius is permissible.
2. At four points 90° apart (DO NOT ROTATE COUPLER),
measure the parallel coupler misalignment by laying a
straight edge across one coupler half and measuring the
gap between the straight edge and opposite coupler half.
Up to a 1/64" gap is permissible.
Illustration 5A – Checking Alignment (Method 1)
Method 2 – For Orange Hytrel Inserts, 3500 RPM
Operation, or All Other Coupler Types (See Illustration 5B)
a. Make sure each hub is secured to its respective shaft and
that all connecting and/or spacing elements are removed at
this time.
.
b. The gap between the coupling hubs is set by the manufac-
turer before the units are shipped. However, this dimension
should be checked. (Refer to the coupling manufacturer’s
specifications supplied with the unit.)
c. Scribe index lines on coupling halves as shown in
Illustration 5B.
d. Mount dial indicator on one hub as shown for parallel align-
ment. Set dial to zero.
e. Tur
n both coupling halves so that index lines remain
matched. Observe dial reading to see whether driver needs
adjustment. (See paragraph i below)
f. Mount dial indicator on one hub as shown for angular align-
ment. Set dial to zero.
g. Tur
n both coupling halves so that index lines remain
matched. Observe dial reading to see whether driver needs
adjustment. (See paragraph i below)
h. Assemble coupling. Tighten all bolts and set screw(s). It
may be necessary to repeat steps c through f for a final
check.
i. For single element couplings, a satisfactory parallel mis-
alignment is .004"T.I.R., while a satisfactory angular misalignment is .004"T.I.R. per inch of radius R. (See Illustration 5B)
Final Alignment
Final alignment cannot be accomplished until the pump has
been operated initially for a sufficient length of time to attain
operating temperature. When normal operating temperature
has been attained, secure the pump to re-check alignment
and compensate for temperature accordingly. (See Alignment
Section.)
WARNING: Rotating Components Hazard
Do not operate pump without all guards in place.
Failure to follow these instructions could result in serious
personal injury or death and property damage.
8
Illustration 5B – Checking Alignment (Method 2)
OPTIONAL Alignment Procedure
If desired, the pump and motor feet can be doweled to the
base after final alignment is complete. This should not be
done until the unit has been run for a sufficient length of time
and alignment is within the tolerance. (See Doweling Section.)
CAUTION: Extreme Temperature and/or
Flying Debris Hazard
Eye protection and gloves required. Failure to follow these
instructions could result in property damage and/or moderate personal injury.
NOTE: Pump may have been doweled to base at factory.
13. DOWELING
CHECK VALVE
GATE VALVE
INCREASER
CORRECT
C OF PIPE
SUCTION PIPE INSTALLED WITH
A GRADUAL RISE TO PUMP
L
LEVEL
AIR POCKET
INCORRECT
AIR POCKET
INCORRECT
AIR POCKET
INCORRECT
GRADUAL RISE
TO PUMP
NO AIR
POCKETS
CORRECT
NO AIR
POCKETS
GRADUAL RISE
TO PUMP
ECCENTRIC
REDUCER
CORRECT
DISTANCE PLUS
ECCENTRIC REDUCER
STRAIGHTENS FLOW
CORRECT
PATH OF
WATER
INCORRECT
Dowel the pump and driving unit as follows:
a. Drill holes through diagonally opposite feet and into the
base. Holes must be of a diameter 1/64 inch less than the
diameter of the dowel pins. Clean out the chips.
b. Ream the holes in feet and base to the proper diameter for
the pins (light push fit). Clean out the chips.
c. Insert pins to be approximately flush with feet.
14. SUCTION AND DISCHARGE PIPING
General
When installing the pump piping, be sure to observe the following precautions:
Piping should always be run to the pump.
Do not move pump to pipe. This could make final alignment
impossible.
Both the suction and discharge piping should be supported
independently near the pump and properly aligned, so that no
strain is transmitted to the pump when the flange bolts are
tightened. Use pipe hangers or other supports at necessary
intervals to provide support. When expansion joints are used
in the piping system, they must be installed beyond the piping
supports closest to the pump. Tie bolts should be used with
expansion joints to prevent pipe strain. Do not install expansion joints next to the pump or in any way that would cause a
strain on the pump resulting from system pressure changes. It
is usually advisable to increase the size of both suction and
discharge pipes at the pump connections to decrease the loss
of head from friction.
Install piping as straight as possible, avoiding unnecessary
bends. Where necessary, use 45-degree or long sweep
90-degree fitting to decrease friction losses.
Make sure that all piping joints are air-tight.
Where flanged joints are used, assure that inside diameters
match properly.
Remove burrs and sharp edges when making up joints.
Do not “spring” piping when making any connections.
Provide for pipe expansion when hot fluids are to be pumped.
Suction Piping
When installing the suction piping, observe the following
precautions. (See Illustration 6)
The sizing and installation of the suction piping is extremely
important. It must be selected and installed so that pressure
losses are minimized and sufficient liquid will flow into the
pump when started and operated. Many NPSH (Net Positive
Suction Head) problems can be attributed directly to improper
suction piping systems.
Friction losses caused by undersized suction piping can
increase the fluid’s velocity into the pump. As recommended
by the Hydraulic Institute, Standard ANSI/HI 1.1-1.5-1994,
suction pipe velocity should not exceed the velocity in the
pump suction nozzle. In some situations pipe velocity may
need to be further reduced to satisfy pump NPSH requirements and to control suction line losses. Pipe friction can be
reduced by using pipes that are one to two sizes larger than
the pump suction nozzle in order to maintain pipe velocities
less than 5 feet/second.
Illustration 6 – Suction Pipe Installations
(Piping Supports Not Shown)
9
Suction piping should be short in length, as direct as possible,
WATER PRESSURE
INCREASES HERE CAUSING
A GREATER FLOW TO ONE
SIDE OF THE IMPELLER
PUMP CASING
CASING RINGS
IMPELLER
PUMP SUCTION
FLANGE
SUCTION
ELBOW
and never smaller in diameter than the pump suction opening.
If the suction pipe is short, the pipe diameter can be the same
size as the suction opening. If longer suction pipe is required,
pipes should be one or two sizes larger than the opening,
depending on piping length.
Suction piping for horizontal double suction pumps should not
be installed with an elbow close to the suction flange of the
pump, except when the suction elbow is in the vertical plane.
A suction pipe of the same size as the suction nozzle,
approaching at any angle other than straight up or straight
down, must have the elbow located 10 pipe diameters from
the suction flange of the pump. Vertical mounted pumps and
other space limitations require special piping.
There is always an uneven turbulent flow around an elbow.
When it is in a position other than the vertical it causes more
liquid to enter one side of the impeller than the other. (See
Illustration 7) This results in high unequalized thrust loads that
will overheat the bearings and cause rapid wear, in addition to
affecting hydraulic performance.
Illustration 7 – Unbalanced loading of a double suction impeller
due to uneven flow around on elbow adjacent to the pump.
When operating on a suction lift, the suction pipe should slope
upward to the pump nozzle. A horizontal suction line must
have a gradual rise to the pump. Any high point in the pipe will
become filled with air and thus prevent proper operation on
the pump. When reducing the piping to the suction opening
diameter, use an eccentric reducer with the eccentric side
down to avoid air pockets.
NOTE: When operating on suction lift, never use a straight
taper reducer in a horizontal suction line, as it tends to form an
air pocket in the top of the reducer and the pipe.
To facilitate cleaning pump liquid passage without dismantling
pump, a short section of pipe (Dutchman or spool piece), so
designed that it can be readily dropped out of the line, can be
installed adjacent to the suction flange. With this arrangement,
any matter clogging the impeller is accessible by removing the
nozzle (or pipe section).
Valves in Suction Piping
When installing valves in the suction piping, observe the following precautions:
a. If the pump is operating under static suction lift conditions,
a foot valve may be installed in the suction line to avoid the
necessity of priming each time the pump is started. This
valve should be of the flapper type, rather than the multiple
spring type, sized to avoid excessive friction in the suction
line. (Under all other conditions, a check valve, if used,
should be installed in the discharge line. (See “Valves in
Discharge Piping” below)
b. When foot valves are used, or where there are other possi-
bilities of “water hammer,” close the discharge valve slowly
before shutting down the pump.
c. Where two or more pumps are connected to the same
suction line, install gate valves so that any pump can be
isolated from the line. Gate valves should be installed on
the suction side of all pumps with a positive suction pressure for maintenance purposes. Install gate valves with
stems horizontal to avoid air pockets. Globe valves should
not be used, particularly where NPSH is critical.
d. The pump must never be throttled by the use of a valve on
the suction side of the pump. Suction valves should be
used only to isolate the pump for maintenance purposes,
and should always be installed in positions to avoid air
pockets.
e. A pump drain valve should be installed in the suction piping
between the isolation valve and the pump.
Discharge Piping
If the discharge piping is short, the pipe diameter can be the
same as the discharge opening. If the piping is long, pipe
diameter should be one or two sizes larger than the discharge
opening. On long horizontal runs, it is desirable to maintain as
even a grade as possible. Avoid high spots, such as loops,
which will collect air and throttle the system or lead to erratic
pumping.
Valves in Discharge Piping
A triple duty valve should be installed in the discharge. The
triple duty valve placed on the pump protects the pump from
excessive back pressure, and prevents liquid from running
back through the pump in case of power failure.
Pressure Gauges
Properly sized pressure gauges should be installed in both the
suction and discharge nozzles in the gauge taps (which are
provided on request). The gauges will enable the operator to
easily observe the operation of the pump, and also determine
if the pump is operating in conformance with the performance
curve. If cavitation, vapor binding, or other unstable operation
should occur, widely fluctuating discharge pressure will be
noted.
Pump Insulation
On chilled water applications most pumps are insulated. As
part of this practice, the pump bearing housings should not be
insulated since this would tend to “trap” heat inside the housing. This could lead to increased bearing temperatures and
premature bearing failures.
10
OPERATION
1. Pre-start Checks
Before initial start of the pump, make the following
inspections:
a. Check alignment between pump and motor.
b. Check all connections to motor and starting device with
wiring diagram. Check voltage, phase, and frequency on
motor nameplate with line circuit.
c. Check suction and discharge piping and pressure gauges
for proper operation.
d. Check impeller adjustment, see specific section for proper
adjustment.
e. Turn rotating element by hand to assure that it rotates
freely.
f. Check driver lubrication.
g. Assure that pump bearings are pr
h. Assure that coupling is properly lubricated, if r
i. Assure that pump is full of liquid. (See 2. Priming) and all
valves are properly set and operational, with the discharge
valve closed, and the suction valve open.
j. Check rotation. Be sure that the drive operates in the direc-
tion indicated by the arrow on the pump casing, as serious
damage can result if the pump is operated with incorrect
rotation. Check rotation each time the motor leads have
been disconnected.
WARNING: Rotating Components Hazard
Do not operate pump without all guards in place.
Failure to follow these instructions could result in serious
personal injury or death and property damage.
CAUTION: Seal Damage Hazard
Do not run pump dry, seal damage may occur.
Failure to follow these instructions could result in property
damage and/or moderate personal injury.
2. Priming
If the pump is installed with a positive head on the suction, it
can be primed by opening the suction and vent valve and
allowing the liquid to enter the casing.
If the pump is installed with a suction lift, priming must be
done by other methods such as foot valves, ejectors, or by
manually filling the casing and suction line.
operly lubricated.
equired.
W
ARNING: Rotating Components Hazard
Do not operate pump without all guards in place.
Failure to follow these instructions could result in serious
personal injury or death and pr
3. Starting
a. Close drain valves and valve in discharge line.
b. Open fully all valves in the suction line.
c. Prime the pump.
NOTE: If the pump does not prime properly, or loses prime
during start-up, it should be shutdown and the condition
corrected before the pr
d. When the pump is operating at full speed, open the dis-
charge valve slowly. This should be done promptly after
start-up to prevent damage to pump by operating at zero
flow.
4. Operating Checks
a. Check the pump and piping to assure that ther
leaks.
b. Check and record pressure gauge readings for future
reference.
c. Check and record voltage, amperage per phase, and kw if
an indicating wattmeter is available.
d. Check bearings for lubrication and temperature. Normal
temperature is 180° maximum.
e. Make all pump output adjustments with the discharge line.
CAUTION: Cavitation Damage Hazard
Do not throttle the suction line to adjust the pump
output. Failure to follow these instructions could result in
property damage and/or moderate personal injury.
5. Freezing Protection
Pumps that are shut down during freezing conditions should
be protected by one of the following methods.
a. Drain the pump; remove all liquids from the casing.
b. Keep fluid moving in the pump and insulate or heat the
pump to prevent freezing.
CAUTION: Bearing/Seal Damage Hazard
Do not let heated pump temperature rise above
150°F. Failure to follow these instructions could result in
property damage and/or moderate personal injury.
operty damage.
ocedure is repeated.
e are no
11
CHANGING ROTATION
ROTATION ROTATION
DISCHARGE DISCHARGE
SUCTION
LEFTHAND ROTATION VIEWED
FROM THE PUMP END
RIGHTHAND ROTATION VIEWED
FROM THE PUMP END
13
5
1
9
15
7
3
11
16
8
4
12
14
6
2
10
Series HSC3centrifugal pumps can be operated left hand or
right hand when viewed from the pump end of the pump. If
you wish to reverse the suction and discharge
nozzles, this can be accomplished with the same pump as
follows:
IMPORTANT: Refer to the disassembly and assembly procedures section of this manual for proper disassembly and
assembly techniques:
1. Remove the impeller from the shaft, turn it 180°
it on the shaft. (NOTE: Impeller can only come off from the
outboard end.)
2. With the rotating element out of the casing, remove the
casing from the bedplate and turn 180°.
3. Set the rotating element back in the casing and reassemble
the pump.
and replace
NOTE: The impeller and casing are in the same relationship
to each other as they were originally. The shaft and motor
are also in the same relationship to each other as they wer
originally.
4. Reassemble pump and realign the coupling as called for in
the alignment instructions.
W
ARNING: Rotating Components Hazard
Do not operate pump without all guards in place.
Failure to follow these instructions could result in serious
personal injury or death and pr
operty damage.
5. The rotation of the motor must be changed by switching the
motor leads.
NOTE: Unless the motor rotation is reversed, the impeller
will run backward.
e
Illustration 8 – Correct Relationship of Impeller and Casing
12
Illustration 9 – Main Joint Bolts
TROUBLE SHOOTING
Between regular maintenance inspections, be alert for signs of
motor or pump trouble. Common symptoms are listed below.
No Liquid Delivered
CAUSES CURES
1. Lack of prime. Fill pump and suction pipe completely with liquid.
2. Loss of prime. Check for leaks in suction pipe joints and fittings; vent casing to remove
accumulated air.
3. Suction lift too high. If no obstruction at inlet, check for pipe friction losses. However, static
lift may be too great. Measure with mercury column or vacuum gauge
while pump operates. If static lift is too high, liquid to be pumped must
be raised or pump lowered.
4. Discharge head too high. Check pipe friction losses. Large piping may correct condition. Check
that valves are wide open.
5. Speed too low. Check whether motor is directly across-the-line and receiving full voltage. Or frequency may be too low; motor may have an open phase.
6. Wrong direction of rotation. Check motor rotation with directional arrow on pump casing.
7. Impeller completely plugged. Dismantle pump and clean impeller.
Not Enough Liquid Delivered
Correct any trouble immediately and A
AND SHUTDOWN.
VOID COSTLY REPAIR
8. Air leaks in suction piping.
9. Speed too low
10. Dischar
11. Suction lift too high. See item 3.
12. Impeller partially plugged. See item 7.
13. Cavitation; insufficient NPSH a. Increase positive suction head on pump by lowering pump.
(depending on installation)
14. Defective impeller. Inspect impeller, bearings and shaft. Replace if damaged or vane sec-
15. Foot valve too small or partially Area through ports of valve should be at least as large as area of suction
obstructed. pipe – preferably 11/2 times. If strainer is used, net clear area should be
16. Suction inlet not immersed If inlet cannot be lowered, or if eddies through which air is sucked perdeep enough. sist when it is lowered, chain a board to suction pipe. It will be drawn
17. Wrong direction of rotation. Symptoms are an overloaded drive and about 1/3 rated capacity from
18. Too small impeller diameter. Check with factory to see if a larger impeller can be used; otherwise, cut
(Probable cause if none of above.) pipe losses or increase speed – or both, as needed. But be careful not
19. Speed too low. See item 5.
20. Air leaks in suction piping. See item 8.
. See item 5.
ge head too high. See item 4.
If liquid pumped is water or other non-explosive, and explosive gas or
dust is not present, test flanges for leakage with flame or match, or by
plugging inlet and putting line under pressur
leak with a drop of pr
b. Sub-cool suction piping at inlet to lower entering liquid temperature.
c. Pressurization suction vessel.
tions badly eroded.
3 to 4 times area of suction pipe.
into eddies, smothering the vortex.
pump. Compare rotation of motor with directional arrow on pump casing.
to seriously overload drive.
essure.
e. A gauge will indicate a
13
Not Enough Pressure
CAUSES CURES
21. Mechanical defects. See items 14 and 15.
22. Obstruction in liquid passages. Dismantle pump and inspect passages of impeller and casing. Remove
obstruction.
23. Air or gases in liquid. (Test in May be possible to overrate pump to point where it will provide
laboratory, reducing pressure on adequate pressure despite condition. Better to provide gas separation
liquid to pressure in suction line. chamber on suction line near pump, and periodically exhaust accumuWatch for bubble formation.) lated gas. See item 13.
24. Too small impeller diameter. See item 18.
(Probable cause if none above.)
Pump Operates For Short Time, Then Stops
25. Incomplete priming. Free pump, piping and valves of all air. If high points in suction line pre-
vent this, they need correcting. See page 19.
26. Suction lift too high. See item 3.
27. Air leaks in suction piping. See item 8.
28. Air or gases in liquid. See item 23.
Pump Takes Too Much Power
29. Head lower than rating; ther
eby Machine impeller’s OD to size advised by factory.
pumping too much liquid.
30. Cavitation
31. Mechanical defects.
32. Suction inlet not immersed
See item 13.
See items 14 and 15.
See item 16.
enough.
33. Liquid heavier (in either Use larger driver. Consult factory for recommended size. Test liquid for
viscosity or specific gravity) viscosity and specific gravity.
than allowed for.
34. Wrong direction of rotation. See item 6.
35. Casing distorted by excessive Check alignment. Examine pump for friction between impeller and
strains from suction or casing. Replace damaged parts.
discharge piping.
36. Shaft bent due to damage – Check deflection of rotor by turning on bearing journals. Total indicator
through shipment, operation, run-out should not exceed 0.002 on shaft and 0.004 inch on impeller
or overhaul. wearing surface.
37. Mechanical failure of critical Check bearings and impeller for damage. Any irregularity in these parts
pump parts. will cause a drag on shaft.
38. Misalignment. Realign pump and driver.
39. Speed may be too high Check voltage on motor.
(brake hp of pump varies as the
cube of the speed; therefore,
any increase in speed means
considerable increase in
power demand).
40. Electrical defects. The voltage and frequency of the electrical current may be lower than
that for which the motor was built; or there may be defects in motor. The
motor may not be ventilated properly due to a poor location.
41. Mechanical defects in turbine, If trouble cannot be located, consult factory.
engine or other type of drive
exclusive of motor.
14
MAINTENANCE
1. General Maintenance
Operating conditions vary so widely that to recommend one
schedule of preventative maintenance for all centrifugal
pumps is not possible. Yet some sort of regular inspection
must be planned and followed. We suggest a permanent
record be kept of the periodic inspections and maintenance
performed on your pump. This recognition of maintenance
procedure will keep your pump in good working condition, and
prevent costly breakdown.
One of the best rules to follow in the proper maintenance of
your centrifugal pump is to keep a record of actual operating
hours. Then, after a predetermined period of operation has
elapsed, the pump should be given a thorough inspection. The
length of this operating period will vary with different applica
tions, and can only be determined from experience. New
equipment, however, should be examined after a relatively
short period of operation. The next inspection period can be
lengthened somewhat. This system can be followed until a
maximum period of operation is reached which should be considered the operating schedule between inspections.
2. Maintenance of Pump Due to Flood Damage
The servicing of centrifugal pumps after a flooded condition is
a comparatively simple matter under normal conditions.
Bearings are a primary concern on pumping units. First, dismantle the bearings; clean and inspect them for any rusted or
badly worn surfaces. If bearings are free from rust and wear
reassemble and relubricate them with one of the recommended pump lubricants. Depending on the length of time the
pump has remained in the flooded area, it is unlikely that bearing replacement is necessary; however, in the event that rust
or worn surfaces appear, it may be necessary to replace the
bearings.
Next, inspect the stuffing box, and clean out any foreign matter that might clog the box. Mechanical seals should be
cleaned and thoroughly flushed.
Couplings should be dismantled and thoroughly cleaned.
Any pump that is properly sealed at all joints and connected to
both the suction and discharge should exclude outside liquid.
Therefore, it should not be necessary to go beyond the bearings, stuffing box, and coupling when servicing the pump.
3. Bearing Lubrication – Grease
Grease lubricated ball bearings are packed with grease at the
factory and ordinarily will require no attention before starting,
provided the pump has been stored in a clean, dry place prior
to its first operation. The bearings should be watched the first
hour or so after the pump has been started to see that they
are operating properly.
The importance of proper lubrication cannot be over emphasized. It is difficult to say how often a bearing should be
greased, since that depends on the conditions of operation. It
is well to add one ounce of grease at regular intervals, but it is
equally important to avoid adding too much grease. For average operating conditions, it is recommended that 1 oz. of
grease be added at intervals of three to six months, and only
clean grease be used. It is always best if unit can be stopped
while grease is added to avoid overloading.
NOTE: Excess grease is the most common cause of
overheating.
A lithium based NLGI-2 grade grease should be used for lubricating bearings where the ambient temperature is above
-20°F
. Grease lubricated bearings are packed at the factory
with Shell Alvania No. 2. Other recommended greases are
Texaco Multifak No. 2 and Mobilux No. 2 grease.
Greases made from animal or vegetable oils are not recommended due to the danger of deterioration and forming of
acid. Do not use graphite. Use of an ISO VG 100 mineral base
oil with rust and oxidation inhibitors is recommended.
The maximum desirable operating temperature for ball bearings is 180°F. Should the temperature of the bearing frame rise
above 180°F, the pump should be shut down to determine the
cause.
4. Mechanical Seals
a. Mechanical seals are precision products and should be
treated with care. Use special care when handling seals.
,
Clean parts are essential to prevent scratching the finely
lapped sealing faces. Even light scratches on these faces
could result in leaky seals.
b. Normally, mechanical seals require no adjustment or
maintenance, except routine replacement of worn, or
broken parts.
c. A mechanical seal which has been used should not be put
back into service until the sealing faces have been replaced
or relapped. (Relapping is generally economical only in
seals two inches in size and above.)
5. Cleaning Without Dismantling Pump
A short section of pipe, so designed that it can be readily
dropped out of the line, can be installed adjacent to the suction flange. With this arrangement, any matter clogging the
impeller is accessible by removing the pipe section.
If the pump cannot be freed of clogging after the above
methods have been tried, dismantle the unit as previously
described to locate the trouble.
15
IMPELLER
IMPELLER KEY
PIPE PLUG
GLAND PLATE
SOCKET HEAD
CAP SCREW
STUFFING BOX
BEARING HOUSING
JACK SCREW
LIP SEAL
INBOARD
BEARING
GREASE FITTING
COUPLING KEY
SHAFT
BEARING HOUSING
STUFFING BOX
DOWEL PIN
SUCTION SIDE
CASING GASKET
DISCHARGE SIDE
CASING GASKET
CASING RING
DOWEL PIN
CASING RING
“O” RING
MECHANICAL
SEAL
GLAND PLATE
STUFFING BOX
BEARING
LOCK WASHER
BEARING HOUSING
CAP SCREW
BEARING LOCKNUT
BEARING
HOUSING
STUFFING BOX
DOWEL PIN
OUTBOARD
BEARING
GREASE FITTING
BEARING HOUSING
JACK SCREW
LIP SEAL
GLAND PLATE
“O” RING
STUFFING BOX
“O” RING
IMPELLER
SNAP RING
CASING RING
CASING
PIPE PLUG
PIPE PLUG
BEARING HOUSING
CAP SCREW
CASING RING
DOWEL PIN
HSC3Cross-Section
Standard Mechanical Self Flushing Seal
Impeller Wear Ring
Impeller Rings can be
added — Optional extra.
SERVICE INSTRUCTIONS
FOR AN HSC3PUMP
To Replace the Mechanical Seals and Bearings
without removing Upper Half of the Casing
NOTE: In order to replace the mechanical seal and bearing
housing on the coupler end, you must use a spacer type
coupler.
WARNING: Unexpected Start-up Hazard
Disconnect and lock out power before servicing.
Failure to follow these instructions could result in serious
personal injury or death and property damage.
CAUTION: Extreme Temperature Hazard
Allow pump temperatures to reach acceptable levels
before proceeding. Open drain valve. Do not proceed until
liquid stops coming out of drain valve. If liquid does not
stop flowing from drain valve, isolation valves are not sealing and should be repaired before proceeding. After liquid
stops flowing from drain valve, leave drain valve open and
continue. Remove the drain plug located on the bottom of
the pump housing. Do not reinstall plug or close drain
valve until reassembly is completed. Failure to follow these
instructions could result in property damage and/or moderate personal injury.
16
1. Close valves on suction and discharge sides of pump. If
no valves have been installed, it will be necessary to drain
the system.
2. Remove the coupler guard. For spacer coupler, loosen the
capscrews which secure the coupler flanges to the
coupler hubs. Remove the coupler flanges and sleeve by
compressing the flanges and pulling out from beneath the
hubs or by loosening the allen set screws and sliding the
hubs back on the shafts. Remove the coupler hubs from
the pump shaft. For non-spacer couplers, loosen set
screws and slide flanges back on shafts and remove
rubber element.
3. Remove the capscrews from each of the bearing housings
and remove the bearing housings by placing two 2.0"
long full-threaded capscrews or allen set screws in the
jackscrew holes provided.
4. Bend back the lockwasher tab and remove both the lockwasher and locknut from the outboard end of the shaft
(the opposite side of the coupling).
5. Remove the socket-head capscrews holding the gland
plates to the stuffing boxes.
6. Insert threaded r
1.75" 1.75"2.0" 2.0"
.437 Ø DRILL THRU
FOR .500-13
UNC-2B THREAD
2.44"
1.25"
1.75"
2.0"
30∞
TYP
1.38"
1.25"
TYP
.25R
.50 TYP
8.0" Ø X .50 THK MIN.
H.R. STEEL
ods into the tapped holes in the gland
plate and install a fixture on the threaded rods to use a
puller. (See Illustration 10 for Dimensions of Universal
Fixture PN: AC2394) Using the puller
, tighten the bolt in
the center of the fixture to remove the bearing and gland
plate from the shaft. (See Photos 1 and 2).
CAUTION: FAILURE TO REMOVE THE SOCKET-HEAD
CAPSCREWS BEFORE TRYING TO PULL THE BEARINGS OFF COULD CAUSE DAMAGE TO THE PUMP.
Illustration 10 – Dimensions for Universal Fixture (PN: AC2394)
7. Remove the inboard bearing and gland plate in the same
manner.
NOTE: The locknut and lockwasher are not used on the
inboard bearing.
CAUTION: DO NOT REUSE THE BALL BEARINGS.
8. Remove the mechanical seal head from the pump shaft.
NOTE: To ease in the removal of the mechanical seal
heads, you may want to use 2 allen wrenches as hooks or
form hooks from wire.
9. Drive the lip-seals, the mechanical seal seats, from each
of the gland plates by tapping on them from the rear.
10. Remove the O-rings from each of the gland plates.
Assembly of the Mechanical Seals and Bearings
without removing the Upper Half of the Casing
NOTE: All bearings, O-rings, and lip-seals should be replaced
with new parts during assembly. All usable parts should be
cleaned of foreign matter before reassembly.
NOTE: Reassemble the pump by starting on the outboard end
(the end opposite the coupling). This end locks the rotating
element into position in the casing.
1. Press the stationary mechanical seal seat into the gland
plate until it bottoms out against the bore. Lightly lubricate the bore to ease assembly. (See Photo 3)
Photo 1 – Removal of bearing and
gland plate using universal fixture
Photo 2 – Gland plate and bearing removed from stuffing box
Photo 3 – Assembly mechanical seal seat into gland plate
2. Press a new lip seal into the gland plate. Before installing
the lip seal, lubricate the lip-seal with lightweight oil. Note:
Lip seals should sit against machined shoulder in the
gland plate. The lip seal should face away from the
mechanical seal seat. (See Photo 4)
Photo 4 – Assembly of lip seal into the gland plate
17
3. Lubricate and roll the O-ring into the gr
oove in the gland
plate.
IMPORTANT: Steps 4 and 5 must be completed within
10 to 12 minutes to assure proper placement of the mechanical seals.
4. Lightly coat the outboard end of the pump shaft with P-80
Rubber Lubricant Emulsion, vegetable oil, or equal and
slide the mechanical seal head onto the shaft. Do not
compress the seal spring at this time.
CAUTION: USE A FLASHLIGHT AND MAKE SURE THE
MECHANICAL SEAL SPRING IS SEATED PROPERLY
INTO THE SPRING HOLDER AND AROUND THE
BELLOWS OF THE MECHANICAL SEAL BEFORE
CONTINUING.
5. Slide the gland plate, over the shaft, being very careful
that the head and the seat of the mechanical seal do not
get damaged. Then press the gland plate with the O-ring
into the stuffing box and tighten the socket-head
capscrews.
NOTE: Because of the compression of the O-ring, it may
be difficult to press the O-ring into the stuffing box. Use
longer socket-head capscrews to start the gland plate
into the stuffing box. Draw-up the bolts evenly until the
gland plate is secure in the stuffing box. To prevent the
mechanical seal spring from pushing the gland plate back
out of the stuffing box, remove one long socket-head
capscrew at a time and replace with a regular sockethead capscrew.
6. Heat the ball bearings using dry heat or 10% – 15%
soluble oil and water, or an induction heater.
CAUTION: DO NOT EXCEED A TEMPERATURE OF 275°F.
7. Fill up the lip seal cavity with approximately .50 ounces of
grease.
8. Using gloves, slide the heated bearing onto the shaft
against the shaft shoulder. (See Photo 5)
11. Coat the inside of the bearing housing with grease and
slide it into place over the bearing. Alternately tighten the
bearing housing capscrews so as not to “cock” the bearing housing causing bearing to bind.
12. Repeat steps 1 through 11 for the inboard.
NOTE: A locknut and lockwasher are not installed on the
inboard end of the pump shaft.
13. Reinstall the coupler and check for alignment, following
the instructions on page 8. Install the coupler guard
(Refer to page 7).
Photo 6 – Installation of lockwasher and locknut
Dismantling the Pump when it is required to remove
the Rotating Element of the Pump
WARNING: Unexpected Start-up Hazard
Disconnect and lock out power before servicing.
Failure to follow these instructions could result in serious
personal injury or death and property damage.
CAUTION: Extreme Temperature Hazard
Allow pump temperatures to reach acceptable levels
before proceeding. Open drain valve, do not proceed until
liquid stops coming out of drain valve. If liquid does not
stop flowing from drain valve, isolation valves are not sealing and should be repaired before proceeding. After liquid
stops flowing from drain valve, leave drain valve open and
continue. Remove the drain plug located on the bottom of
the pump housing. Do not reinstall plug or close drain
valve until reassembly is completed. Failure to follow these
instructions could result in property damage and/or moderate personal injury.
Photo 5 – Installation of bearing
9. Install the locknut and lockwasher on the outboard end of
the shaft. Make certain that the locknut is secure and
bend over the tabs on the lockwasher. (See Photo 6)
10. Allow the bearing to cool to room temperature. Coat the
exposed sides of the bearing with two or three ounces of
recommended grease.
18
1. Close valves on suction and discharge sides of pump. If
no valves have been installed, it will be necessary to drain
the system.
2. Remove the coupler guard. For spacer couplers, loosen
the capscrews which secure the coupler flanges to the
coupler hubs. Remove the coupler flanges and sleeve by
compressing the flanges and pulling out from beneath the
hubs or by loosening the allen set screws and sliding the
hubs back on the shafts. Remove the coupler hub from
the pump shaft. For non-spacer couplers, loosen allen set
screws and slide flanges back on shafts and remove
rubber element.
3. Remove all casing main joint capscrews and dowel pins.
4. Tighten the jacking screws in the upper half of the casing
to separate the upper and lower casing halves. Then lift
off the upper half of the casing.
5. Tap the stuf
fing boxes with a soft-headed hammer to
break the seal between the stuffing box and lower casing
half, and lift the rotating element out of the lower casing.
Rotating element may be removed to a suitable location
for repair.
NOTE: A spare rotating element can be installed at this
point. (See Photo 7)
6. Remove the capscrews fr
om each of the bearing housings
and remove the bearing housings by placing two capscrews in the jackscrew holes provided.
7. Bend back the lockwasher tab and remove both the lockwasher and locknut from the outboard end of the shaft
(the opposite side of the coupling).
8. Remove the capscrews holding gland plate to the stuffing
box.
9. Insert threaded rods into the tapped holes in the gland
plate and install a fixture on the threaded r
ods to use as a
puller. (See Illustration 10 on page 17, for dimensions of
Universal Fixture). Using the puller, tighten the bolt in the
center of the fixture to remove the bearing and gland plate
from the shaft. If the bearing does not come off the shaft,
insert a spacer between the center bolt and the shaft, and
retighten the bolt. Remove the inboard bearing and gland
plate in the same manner. (See Photos 1 and 2 on page 17)
NOTE: The locknut and lockwasher are not used on the
inboard bearing.
10. Remove the gland plates from the stuffing boxes and
remove the O-rings from the stuffing boxes.
CAUTION: DO NOT REUSE THE BALL BEARINGS.
11. Remove the mechanical seal head from the pump shaft.
12. Drive the lip-seals, the mechanical seal seats, from each
of the gland plates by tapping on them from the rear.
13. Remove the O-rings from each of the gland plates.
14. Remove the two casing rings from the impeller and
remove the O-rings from each of the casing rings.
15. Remove the impeller-retaining ring with retaining pliers.
(See Photo 8). Heat the impeller hub on both ends to
350°F maximum, and pull or push the impeller from the
shaft. (Instead of heating the impeller, you may press
impeller off the shaft, if press is available.)
NOTE: Press away from the coupling end.
NOTE: For impellers with replaceable rings; remove the
rings, if necessary, by cutting with a cold chisel.
16. Remove the impeller key from the shaft.
Photo 7 – Rotating element
Photo 8 – Removal of impeller retaining ring
Photo 9 – T
rimming casing gasket
19
Reassembly of the Pump when it is required to
remove the Rotating Element of the Pump
NOTE: All bearings, O-rings, lip-seals, mechanical seals,
gaskets, impeller rings, and casing rings should be replaced
with the new parts during assembly. All reusable parts should
be cleaned of all foreign matter before reassembling. The main
casing joint gasket can be made using the upper and lower
half as a template. Lay the gasket material on the casing joint.
Trim the gasket by lightly tapping with a ball peen hammer
so that it is flush with the inside edges of the casing. (See
Photo 9 on page 19) Do not hit casing edge with hammer hard
enough to round edge.
NOTE: Precut-casing gaskets can be ordered to minimize the
amount of trimming.
1. Before assembling the r
otating element prepare the
casing and install the casing gaskets to the parting line.
2. Clean the gasket surfaces of the casing. Apply Scotch
3M-77 spray adhesive or equivalent to the lower half of
the casing.
3. Within one minute of spraying, set the untrimmed gaskets
in place on the lower half of the casing, align the holes in
the gaskets with the holes in the casing, and press the
gaskets firmly against the lower half of the casing face in
the area coated by the adhesive.
4. Trim the gaskets flush with the lower casing bores. (See
Photo 9 on page 19)
CAUTION: MACHINED-CASING BORES MUST
REMAIN SHARP AT THE CASING PARTING LINE.
GASKETS MUST BE FLUSH WITH THE BORE IN
ORDER TO CONTACT O-RINGS. LEAKAGE CAN
RESULT AROUND THE STUFFING BOX O-RING IF
THIS STEP IS NOT PROPERLY FOLLOWED.
5. Assemble the impeller key in the shaft key slot.
NOTE: For impeller with replaceable rings, heat each new
ring (approximately 300°F-400°F for bronze) and slide
onto the impeller. Using gloves, hold rings against the
impeller shoulder until cool.
6. Check the impeller and casing to determine the correct
relationship. Heat the impeller evenly to 300°F maximum
to expand the bore. (Impeller may be pressed onto the
shaft instead of heating if a suitable press is available.)
(See Photo 10)
7. Using gloves, from the outboard end, slide the impeller on
the shaft against the shaft shoulder, and install the retaining ring.
8. Lubricate and roll an O-ring into the groove in each of the
casing rings. Then slide the casing rings over the impeller.
9. Thoroughly clean the gland plates and stuffing boxes to
prevent dirt from entering the seal during startup.
10. Press the stationary mechanical seal seats into both of
the gland plates. Lightly lubricate the gland plates to ease
assembly. (See Photo 3 on page 17)
11. Press new lip seals into the gland plates. Before installing
the lip seals, lubricate the lip seals with lightweight oil.
NOTE: Lip seals should sit against the machined shoulder
in the gland plates. The lip seals should face away from
the mechanical seal seats. (See Photo 4 on page 17)
12. Lubricate and roll the O-rings into the grooves in each
gland plate.
13. Press the gland plates into the stuf
fing boxes and secure
using the socket-head capscrews.
NOTE: Because of the compression of the O-ring, it may
be difficult to press the O-ring into the stuf
fing box. Use
longer socket-head capscrews to start the gland plate
into the stuffing box. To prevent the mechanical seal
spring from pushing the gland plate back out of the stuffing box, remove one long socket-head capscrew at a time
and replace with a regular socket-head capscrew.
Photo 10 – Pressing impeller on shaft
Photo 11 – Mechanical seal head installation
Photo 12 – Installation of stuffing box
20
14. Lubricate and roll the O-rings into the gr
oove in each
stuffing box.
NOTE: At this point reassemble the rotating element by
starting on the outboard end first (the end opposite the
coupling) as this end locates the settings of the mechanical seal.
IMPORTANT: Steps 11 through 21 must be completed,
on the outboard end, within 10 to 12 minutes to assure
proper placement of the mechanical seals.
15. Lightly coat the outboard end of the pump shaft with P-80
Rubber Lubricant Emulsion, vegetable oil, or equal and
slide the mechanical seal head onto the shaft. (See Photo
11)
16. Slide the stuffing box, with the gland plate, fully on the
shaft, being very careful that the head and seat of the
mechanical seal do not get damaged. COMPRESS THE
SEAL SPRING ONLY AS FAR AS REQUIRED TO INSTALL
THE BEARINGS. (See Photo 12)
17. Fill lip seal cavity with approximately .50 ounces of
grease.
18. Heat the ball bearings using dry heat to 10% – 15%
soluble oil and water, or an induction heater.
CAUTION: DO NOT EXCEED A TEMPERATURE OF 275°F.
19. Using gloves, slide the heated bearing onto the shaft
against the shaft shoulder. (See Photo 5 on page 18)
20. Install the locknut and lockwasher on the outboard end of
the shaft. Make certain that the locknut is secure and
bend over the tabs on the lockwasher. (See Photo 6 on
page 18)
21. Allow the bearing to cool to room temperature. Coat the
exposed sides of the bearing with two or three ounces of
recommended grease.
22. Coat the inside of the bearing housing with grease and
slide it into place over the bearing. Attach the bearing
housing to the stuffing box with the capscrews.
23. Repeat steps 15 through 22 for the inboard end.
IMPORTANT: Steps 15 through 25 and must be com-
pleted within 10 to 12 minutes to assure proper placement of the mechanical seal.
NOTE: A locknut and lockwasher are not installed on the
inboard end of the pump shaft.
24. Reinstall the coupler on the end of the shaft.
25. Set the rotating element in the pump casing, assuring correct rotation. Locate both stuffing box tongues in their
respective casing grooves. Locate the pins in the stuffing
box and the casing wear rings in their respective slots at
the casing parting surface. Correct any O-ring bulging.
(See Photo 13)
CAUTION: DO NOT CUT OR DAMAGE THE O-RINGS
WHEN LOWERING THE ROTATING ELEMENT INTO
POSITION. WHEN ALL FOUR ANTI-ROTATION PINS
ARE LOCATED CORRECTLY, THERE WILL BE SOME
CASING RING LOOSENESS.
26. Apply a small bead of Dow Corning RTV silicone sealant
or equal at the parting line on top of gasket at the stuffing
box O-rings. (See Photo 14)
Photo 13 – Rotating element inside casing
Photo 14 – Addition of sealant
Photo 15 – Casing mainjoint
27. Locate the upper half of the casing into place using the
tapered dowel pins and install the casing main joint bolts
(See Photo 15). The casing joints should be tightened to
the following torques: 140 ft.-lb. minimum for 5/8"-11
hex head cap screws (Grade 5); 350ft.-lb. minimum for
7
/8"-9 Ferry Cap Counterbore screws (Grade 8). Bolt
torquing pattern is shown in Illustration 9 on page 12.
NOTE: Torque values are essential in obtaining proper
gasket compression so no leakage can occur at the main
joint.
28. Rotate the shaft by hand to assure that it turns smoothly
and it is free from rubbing or binding.
29. Assemble the coupler and check alignment, following the
instructions on page 7. Replace the coupler guard.
21
ORDERING PARTS
The pumps covered by this manual have been designed and
built with certain replaceable wearing parts. The recommended inventory of spare parts depends upon the installation
and the importance of continued operation.
For critical service requiring a minimum of “down time” a complete or “quick change” rotating element is recommended.
For normal service, with repairs to be made in the field, the
following parts are recommended for stock.
1 set of bearings
1 set of casing wearing rings
1 set of casing gaskets, “O” rings and lip seals
2 mechanical seals (complete)
CAPSCREW HEAD
TYPE MARKING
1
/4
SAE Grade 2 6 13 25 38 60 120 190 210 300
Brass
Stainless Steel or 4 10 17 27 42 83 130 200 300
Parts should be ordered as far in advance of their use as possible since circumstances beyond the control of the company
may reduce existing stock. Not all parts are stocked and must
be manufactured for each order.
To facilitate rapid handling of your order for spare parts, be
sure to include the following information:
1. Serial number of the pump.
2. Name of the part.
3. Quantity of each part.
4. Material desired. (Parts will be furnished in original
materials unless specified as a material change. All material
substitutions should be discussed with the factory.)
CAPSCREW TORQUE (FOOT-POUND)
CAPSCREW DIAMETER
5
/16
3
/8
7
/16
1
/2
5
/8
3
/4
7
/8 1
SAE Grade 5 10 20 35 60 90 180 325 525 800
SAE Grade 8 13 28 46 75 115 225 370 590 895
DEALER SERVICING
If trouble occurs that cannot be rectified, contact your local
B&G Representative. He will need the following information in
order to give you assistance.
1. Complete nameplate data of pump and motor.
2. Suction and discharge pipe pressure gauge readings.
3. Ampere draw of the motor.
4. A sketch of the pumping hook-up and piping.
Xylem Inc.
8200 N. Austin Avenue
Morton Grove, Illinois 60053
Phone: (847) 966-3700
Fax: (847) 965-8379
www.xyleminc.com/brands/bellgossett
Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries.
© 2012 Xylem Inc. AC2008B May 2012
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