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A-C 9100
Instruction Manual
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Xylem A-C 9100 Instruction Manual

INSTRUCTION MANUAL
AC5657C
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps
Table of Contents
1 Introduction and Safety..............................................................................................................3
1.2.1 Safety terminology and symbols.................................................................................3
1.2.2 Safety instruction decals.............................................................................................. 4
1.3.1 Wash the skin and eyes................................................................................................6
2 Transportation and Storage...................................................................................................... 7
2.1.1 Examine the package................................................................................................... 7
2.1.2 Examine the unit............................................................................................................7
Table of Contents
3 Product Description................................................................................................................. 11
3.2 Operational specifications................................................................................................11
4 Installation................................................................................................................................. 13
4.1.1 Pump location guidelines..........................................................................................13
4.1.2 Typical installation...................................................................................................... 14
4.1.3 Foundation requirements..........................................................................................14
4.1.4 Level the base on a concrete foundation ............................................................... 15
4.1.5 Grout the baseplate....................................................................................................15
4.2.1 Prepare for alignment................................................................................................ 16
4.2.2 Align the pump using a straight edge and calipers...............................................16
4.2.3 Align the pump using a dial indicator......................................................................18
4.2.4 Final alignment............................................................................................................19
4.2.5 Optional alignment procedure.................................................................................19
4.2.6 Dowel the pump and driving unit.............................................................................19
4.2.7 Coupler limitations..................................................................................................... 19
4.3.1 Piping checklist........................................................................................................... 19
4.3.2 Suction piping checklist.............................................................................................20
5 Commissioning, Startup, Operation, and Shutdown.......................................................... 23
5.1.1 Pre-start checks........................................................................................................... 23
5.1.2 Priming.........................................................................................................................24
5.1.3 Starting.........................................................................................................................24
5.1.4 Operating checks....................................................................................................... 24
5.1.5 Check the rotation...................................................................................................... 24
5.1.6 Freezing protection.................................................................................................... 25
5.1.7 Change the rotation................................................................................................... 25
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 1
Table of Contents
6 Maintenance..............................................................................................................................27
6.3.1 Regrease the grease-lubricated bearings............................................................... 29
6.3.2 Lubricating grease requirements............................................................................. 30
6.4.1 Mechanical seal maintenance................................................................................... 30
6.4.2 Packed stuffing box maintenance............................................................................ 31
6.6.1 Disassembly precautions...........................................................................................31
6.6.2 Drain the pump...........................................................................................................32
6.6.3 Remove the hex coupling guard.............................................................................. 32
6.6.4 Disassemble the pump with packing on shaft sleeve............................................ 33
6.7.1 Replacement guidelines............................................................................................ 34
6.7.2 Shaft and sleeve inspection.......................................................................................34
6.9.1 Reassemble the pump with the mechanical seals on the shaft sleeve................ 35
6.9.2 Reassemble the pump with the packing on the shaft sleeve................................38
6.9.3 Install the hex coupling guard...................................................................................41
6.9.4 Adjustable wear rings................................................................................................ 41
6.9.5 Install the oil ring.........................................................................................................42
6.9.6 Change the oil for oil lubricated bearings...............................................................42
6.9.7 Limited end float coupling........................................................................................ 43
6.9.8 Assembly references.................................................................................................. 43
7 Troubleshooting....................................................................................................................... 45
8 Parts Listings and Cross-Sectional Drawings........................................................................49
9 Product warranty...................................................................................................................... 52
2 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
1 Introduction and Safety
1.1 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.
1 Introduction and Safety
1.2 Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• 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 Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays.
1.2.1 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 and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 3
DANGER:
A hazardous situation which, if not avoided, will result in death or serious injury
1 Introduction and Safety
Hazard level Indication
WARNING:
A hazardous situation which, if not avoided, could result in death or serious injury
NOTICE:
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
1.2.2 Safety instruction decals
WARNING:
Do NOT exceed the maximum working pressure of the pump. This information is listed on the nameplate of the pump.
CAUTION:
Electrical Hazard:
A hazardous situation which, if not avoided, could result in minor or moderate injury
Notices are used when there is a risk of equipment damage or decreased performance, but not personal injury.
CAUTION:
Alert symbol
Decals
This safety alert symbol is used in manuals and on the safety instruction decals on the pump to draw attention to safety-related instructions.
When used, the safety alert symbol means that failure to follow the instructions may result in a safety hazard.
Make sure your pump has these safety instruction decals and that they are located as this figure shows. If the decals are missing or illegible, contact your local sales and service representative for a replacement.
4 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
P70642
P70643
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.
DO NOT RUN PUMP DRY. SEAL DAMAGE MAY OCCUR.
INSPECT PUMP SEAL REGULARLY FOR LEAKS. REPLACE AS REQUIRED.
LUBRICATION REQUIRMENTS CONSULT MANUALS. PUMP: POLYUREA-BASED GREASE
FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN INJURY OR PROPERTY DAMAGE.
ROTATING COMPONENTS
DISCONNECT AND LOCK OUTPOWER 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.
P70820
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.
RATING PLATE
P2002458
Make sure that all safety instruction decals are always clearly visible and readable.
1.3 User safety
1 Introduction and Safety
General safety rules
Safety equipment
Electrical connections
Precautions before work
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.
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Hard hat
• 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 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.
Observe these safety precautions before you work with the product or are in connection
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 5
with the product:
1 Introduction and Safety
• 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 you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
1.3.1 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 fluids in eyes
Chemicals or hazardous fluids on skin
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.4 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
6 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
2 Transportation and Storage
2 Transportation and Storage
2.1 Examine the delivery
2.1.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company. If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.1.2 Examine the unit
1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps. Use care around nails and straps.
4. If there is any issue, then contact a sales representative.
Shipping information
• Pumps and drivers are normally shipped from the factory mounted and painted with primer and one finish coat.
• Couplings are shipped either 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.
Shaft alignment
• Shafts are in alignment when the unit is shipped; however, misalignment can occur due to shipping.
• Refer to recommended alignment procedures in this manual if it is necessary to realign the shaft.
2.2 Safe handling requirements
WARNING:
• Personal protective equipment should be worn when handling this equipment.
• Transportation & installation of this equipment should only be performed by qualified personnel.
• A professional rigging company should be consulted before lifting the pump assembly.
• Only use properly sized, certified lifting equipment & lifting devices, including slings, suitably rated for the weights to be lifted.
• Slings, when used, must be of identical materials to avoid differences in stretch rates.
• Do not use lifting devices that are frayed, kinked, unmarked, or worn.
• Lifting eyebolts fitted on single components of the assembly (pump or motor) must not be used to lift the complete assembly.
• Failure to observe these instructions could result in equipment or property damage, serious injury, or death.
The pump assembly can arrive in a variety of ways:
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 7
2 Transportation and Storage
• Pump end only (bare pump)
• Pump less motor
• Pump, motor, & baseplate
Use the following recommended ways of handling HSC pump assemblies.
• The pump assembly should remain horizontal during transport and lifting.
• Lifting the pump end only (bare pump) should be done by placing one end of the slings around or as close to the casing barrel as possible. After the slings are attached to the unit, recheck to ensure they are securely in place. Make sure the slings are adjusted to obtain an even lift.
Figure 1: Lifting pump end only with nylon sling, chain, or wire rope
• Lifting the pump less motor or the pump, motor, & baseplate should be done by utilizing a forklift under the entire unit. Always take extra precaution to ensure the weight is balanced & equally distributed across both forks. When the baseplate of the assembly is structural channel construction, the pump and base plate should be set in place first. The motor should then be separately lifted & mounted to the unit.
• Pump, base, and driver assemblies where the base length exceeds 100 inches may not be safe to lift as a complete assembly. Damage to the baseplate may occur. If the driver has been mounted on the baseplate at the factory, it is safe to lift the entire assembly. If driver has not been mounted at the factory and the overall baseplate length exceeds 100 inches, do not lift the entire assembly consisting of pump, base, and driver. Instead lift the pump and baseplate to its final location without the driver. Then mount the driver.
8 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
Figure 2: Lift using a forklift
30° MAX.
2 Transportation and Storage
Figure 3: Vertical - Half Pedestal - Model 200
• Place nylon sling, chain or wire rope around both flanges. Use a latch hook or standard shackle and end loops. Be sure the lifting equipment is of sufficient length to keep the lift angle less than 30° from the vertical (See Figure 3).
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 9
2 Transportation and Storage
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
2.3 Storage requirements
If the unit will not be installed and put into operation immediately upon arrival at the site, or for an extended shutdown after the unit is in operation, the following requirements for short-term storage apply:
• Store in a covered and dry location.
• Store the unit free from excessive cold or heat (below 32°F and above 110°F), dirt, and vibration.
• Rotate the shaft by hand several times (10–15 turns) at least every 30 days.
For initial storage longer than three months, or for pump shut down after being in operation longer than three months, contact your local sales and service representative for long-term storage guidelines.
10 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
3 Product Description
3.1 General description
Description
The pump is a centrifugal, frame-mounted pump. The following pump features make it easy to install, operate, and service:
• High efficiency
• Rugged construction
• Compact design
• Foot-mounted volute
• Center drop out coupler
• regreasable bearings
• Horizontal split case
Intended applications
WARNING:
This product can expose you to chemicals including Lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to: www.P65Warnings.ca.gov.
3 Product Description
The pump’s bronze fitted construction make it ideal for use with the following liquids:
• Unheated domestic and fresh water
• Boiler feed water
• Condensate
• Hydronic cooling or heating
• Pressure boosting
• General pumping
• Benign liquids
3.2 Operational specifications
Maximum working pressure
The maximum working pressure is listed on the pump nameplate.
Mechanical seal specifications
Seal type Parameter Value
Standard self-flushing pH range limits for Viton pH 7–9
Table notes
1. For use on closed or open systems which are relatively free of dirt and/or other abrasive particles.
Liquid temperature range that complies with the pH range limits for Viton
-10˚F to 220˚F (-23˚C to 104˚C)
3.3 Nameplate information
The pump nameplate gives identification and rating information about the pump. Permanent records for this pump are kept by the serial number and it must be used will all
correspondence and spare parts orders.
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 11
21 3 4 5 6
7
8
9
G&L PUMPS
3 Product Description
Nameplate
1. Impeller diameter
2. Pump rotation — for example, LHR = left hand rotation
3. Pump size — for example, 8 x 8 x 17M
4. Serial number — for example, 1–21937–1–1
5. Driver HP
6. Identification number — for example, Month and year = CWP-11
7. Pump series and model number
8. Duty points — GPM, feet, RPM
9. Maximum working pressure
12 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
4 Installation
4.1 Preinstallation
Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is properly certified.
• You must ground (earth) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the ground (earth) lead to verify that it is connected correctly.
• Motors without built-in protection must be provided with contactors and thermal overload protection for single-phase motors, or starters with heaters for three-phase motors. (See the nameplate on the drive unit to select properly-sized overloads.)
NOTICE:
Supervision by an authorized Xylem representative is recommended to ensure proper installation. Failure to do so may result in equipment damage or decreased performance.
4 Installation
4.1.1 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 practically possible.
If the pump is not on a closed system, locate the pump so that the fewest number of bends or elbows in the suction pipe are needed.
Make sure that the space around the pump is sufficient. This facilitates ventilation, inspection,
If you require lifting equipment such as a hoist or tackle, make sure that there is enough space above the pump.
Protect the unit from weather and water damage due to rain, flooding, and freezing temperatures.
Take into consideration the occurrence of unwanted noise and vibration.
If the pump location is overhead, undertake special precautions to reduce possible noise transmission.
Make sure there is a suitable power source available for the pump driver.
This minimizes the friction loss and keeps the suction piping as short as possible.
maintenance, and service.
This makes it easier to properly use the lifting equipment and safely remove and relocate the components to a safe location.
This is applicable if nothing else is specified.
The best pump location for noise and vibration absorption is on a concrete floor with subsoil underneath.
Consider a consultation with a noise specialist.
The electrical supply must match the motor nameplate specifications.
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 13
4
5
6
7
8
9
1
2
3
4 Installation
4.1.2 Typical installation
1. Compression tank (locate the compression tank on the suction side of the pump)
2. Air separator
3. Supply to system
4. Circuit setter
5. Triple duty valve
6. Isolation valve
7. From boiler chiller or converter
8. Cold water supply
9. Reducing valve
4.1.3 Foundation requirements
Requirements
• A substantial foundation and footing should be built to suit local conditions and form a rigid support to maintain alignment.
• The foundation must be able to absorb any type of vibration and form a permanent, rigid support for the unit.
• The foundation must weigh at least five times the weight of the pump unit.
• Pour the foundation without interruption to within 1/2 to 1–1/2 inches of the finished height.
• The top surface of the foundation should be scored and grooved before the concrete sets. This provides a bonding surface for the grout.
• 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.
• Allow the foundation to cure for several days before you proceed with the pump installation.
Diagram
• Allow enough bolt length for grout, shims, lower baseplate flange, nuts, and washers.
14 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
2
3
1
4
1. Foundation bolt
4
1
5
2
3
6
7
8
2. Pipe sleeve
3. Washer
4. Built-up concrete foundation
4.1.4 Level the base on a concrete foundation
1. Place the pump on its concrete foundation.
2. Place 1.00 in./(25.40 mm) thick steel shims or wedges on both sides of each anchor bolt in order to support the pump .
This also provides a means of leveling the base.
4 Installation
1. Pump Base Rail
2. Grout only to top of base rail
3. Locate the shims to allow removal after grouting.
4. Grout
5. Concrete foundation
6. Shims
7. 1” (25.40 mm) Gap
8. Allow 1” for shims. Place on both sides of anchor bolts.
4.1.5 Grout the baseplate
Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See the instructions provided by the grout manufacturer.
• Grout: Non-shrink grout is required.
1. Clean all the areas of the baseplate that will come into contact with the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.
4. Pour grout through the grout hole into the baseplate up to the level of the dam. When you pour the grout, remove air bubbles from it by using one of these methods:
G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL 15
4 Installation
– Puddle with a vibrator. – Pump the grout into place.
5. After the grout has thoroughly hardened, check the foundation bolts and tighten if necessary. Check alignment after tightening the bolts.
6. After the grout has dried, apply an oil base paint to the exposed edges to prevent moisture from coming in contact with the grout.
4.2 Coupling alignment
WARNING:
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.
Alignment guidelines
Follow these guidelines when you align the coupling:
• Only perform alignment by moving or shimming the motor.
• Since adjustments in one direction can alter the alignment in another direction, check the alignment in all directions after you make a correction.
• Make sure that the pump and motor bolts are tight when you take all measurements.
• Perform a final alignment check after the unit reaches its final operating temperature.
4.2.1 Prepare for alignment
1. Check the pump and motor shafts and remove any paint, burrs, and rust.
2. Slide the hubs and bushings on the shafts with keys.
3. Hold one half element on the hubs in order to determine the appropriate hub spacing.
4. If you use spacer elements with high speed rings, hold both half elements on the hubs in order to make sure the hubs do not interfere with the rings.
5. You can install the hubs with the hub extension facing in or out. Make sure the shaft extends into the hubs at least 0.8 times the diameter of the shaft.
6. Lightly fasten the hubs to the shafts in order to prevent them from moving during alignment.
7. Align the hubs to the values shown in Maximum allowable misalignment for couplings. You can perform alignment with lasers, dial indicators, or with a straight edge and
calipers.
4.2.2 Align the pump using a straight edge and calipers
1. Check the angular misalignment:
Tool Procedure
Calipers 1. Gauge the distance between the two hubs at various points around the circumference.
Do not rotate the shafts.
2. Reposition the equipment until the difference between the minimum and maximum distance values is within the permissible range.
See Maximum allowable misalignment for couplings.
Feeler gauges
2. Check the parallel alignment: a) Place a straight edge across the two hubs.
b) Measure the maximum offset at various points around the periphery of the hubs.
1. Insert feeler gauges between the coupling faces at various points around the circumference. Do not rotate the shafts.
2. Reposition the equipment until the difference between the minimum and maximum distance values is within the permissible range.
16 G&L Pumps Series A-C 9100 Base Mounted Centrifugal Pumps INSTRUCTION MANUAL
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