Xylem IM010 User Manual [en, es, fr]

INSTRUCTION MANUAL

IM010

Models 3656 / 3756

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Owner’s Information

Please ﬁll in information and give this booklet to homeowner. Warranty information is on page 14.

Model Number: Serial Number: Dealer: Dealer’s Phone No. Date of Purchase: Installation Date:

Table of Contents

SUBJECT PAGE

Safety Instructions ......................................................................2

Description and Speciﬁcations ................................................... 2

Engineering Data ........................................................................ 2

Installation ..................................................................................2

Location .................................................................................. 2

Close-Coupled Units .............................................................. 2

Frame-Mounted Units ............................................................ 3

SAE Engine Driven Pumps .........................................................3

Coupling Alignment ................................................................... 6

Frame-Mounted Units Only ..................................................6

Piping .......................................................................................... 6

Suction .................................................................................... 6

Discharge ................................................................................ 6

Wiring and Grounding ...............................................................7

Rotation ......................................................................................7

Operation....................................................................................7

Maintenance ............................................................................... 7

Disassembly ................................................................................8

Reassembly..................................................................................8

Packed Box Instructions .............................................................9

Troubleshooting ........................................................................10

Repair Parts ...............................................................................11

Limited Warranty .....................................................................14

SAFETY INSTRUCTIONS

DANGER

WARNING

CAUTION

WARNING

Hazardous fluids can cause fire, burns or death.

NOTICE: INSPECT UNIT FOR DAMAGE AND REPORT ALL DAMAGE TO CARRIER IMMEDIATELY.

DESCRIPTION and SPECIFICATIONS

The series 3656/3756 are single stage, end suction, centrifugal pumps for general liquid transfer, booster applications, irrigation and general service pumping. Pumps are available in three different materials of construction: all iron, bronze-ﬁtted and all bronze (“S” group only).

Pump impellers are fully enclosed, key driven and held in position by an impeller bolt and washer. Casings are full volute in design with replaceable wear rings.

Dependant on the pump size, the suction and discharge connections will be threaded or ﬂanged. Shafts are protected with stainless steel shaft sleeves.

Close-coupled units have NEMA standard JM or JP motors with C-face mounting and key driven shaft extension. SAE drive units bolt directly to the engine ﬂywheel housing for SAE sizes 1, 2, 3, 4 or 5. Optional elastomer element couplings are available for 6½, 7½, 8, 10, 11½ and 14 inch ﬂywheels. Frame mounted units can be coupled to motors through a spacer coupling, or belt driven.

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THE MANUAL AND ON THE PUMP.

This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage.

Warns of hazards that WILL cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause serious personal injury, death or major property damage.

Warns of hazards that CAN cause personal injury or property damage.

NOTICE: INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED.

THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT. THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP.

MAINTAIN ALL SAFETY DECALS.

UNIT NOT DESIGNED FOR USE WITH HAZARDOUS LIQUIDS OR FLAMMABLE GASES.

Engineering Data

Maximum Liquid Temperature: 212º F (100º C) – standard seal or packing 250º F (120º C) – Optional high temp. seal Maximum Working Pressure (Fluid temperature dependant): – NPT connections, 200 PSI (1379 kPa) – 125# ANSI ﬂanged connections, 200 PSI (1379 kPa) Maximum Suction Pressure: 100 PSI (689.5 kPa) Starts per Hour: 20, evenly distributed

Group Size Suction Discharge

1½ x 2-6 (H) 2" NPT 1½" NPT 1 x 2-7 2" NPT 1" NPT 2½ x 3-7 3" NPT 2½" NPT

1 x 2-8 2" NPT 1" NPT 1½ x 2-8 2" NPT 1½" NPT 2 x 2-5 2" NPT 2" NPT 2½ x 2½-5 2½" NPT 2½" NPT LH 3 x 3-5 3" NPT 3" NPT 4 x 4-5 4" Flange 4" Flange 5 x 5-6 5" Flange 5" Flange 2½ x 3-8 3" NPT 2½" NPT 3 x 4-8 4" Flange 3" Flange 4 x 5-8 5" Flange 4" Flange 1½ x 2-10 2" NPT 1½" NPT 2½ x 3-10 3" Flange 2½" Flange

4 x 6-10 6" Flange 4" Flange 2½ x 3-13 3" Flange 2½ " Flange 3 x 4-13 4" Flange 3" Flange 4 x 6-13 6" Flange 4" Flange 6 x 8-13 8" Flange 6" Flange L 8 x 10-13 10" Flange 8" Flange 4 x 6-16 6" Flange 4" Flange

3 x 4-7 4" Flange 3" Flange

3 x 4-10 4" Flange 3" Flange

Installation

LOCATION

• Locate the pump as near liquid source as practical; below

level of liquid for automatic repriming capability.

• Allow adequate space for servicing and ventilation. Protect

the unit from weather and water damage due to rain, ﬂooding or freezing temperatures.

• Protect the pump and piping from freezing temperatures.

• Allow adequate space around the unit for service and

ventilation.

CLOSE-COUPLED UNITS

• Units may be installed horizontally, inclined or vertically with

the motor above the pump.

• The motor feet MUST be bolted to a substantial surface

(horizontal or vertical) that is capable of complete and rigid support for the pump and motor. For L-Group pumps, the motor adapter feet must also be bolted to the supportive surface.

• For vertical operation, the motor should be tted with a drip

cover or otherwise protected against liquid entering the motor (rain, spray, condensation, etc.)

NOTICE: DO NOT INSTALL WITH MOTOR BELOW PUMP. ANY LEAKAGE OR CONDENSATION WILL AFFECT THE MOTOR.

FRAME-MOUNTED UNITS

• A at substantial foundation surface MUST be provided to

avoid distortion and/or strain when tightening the foundation bolts. A rubber mounting is acceptable to reduce noise or excessive vibration.

• Tighten motor hold-down bolts BEFORE connecting piping

to pump.

Finished grouting

(1/2 to 3/4”) Allowance

for leveling

Wood frame

(

Leveling wedges or shims – left in place

Sleeve

Washer

Lug

BaseGrout hole

Grout

Top of foundation – clean and wet down

/4”)

Figure 1

• It is recommended that the baseplate be grouted to a

foundation with solid footing. Refer to Figure 1.

• Place unit in position on wedges located at four points, two

below approximate center of driver and two below approximate center of pump. Adjust wedges to level unit. Level or plumb suction and discharge connections.

• Make sure bedplate is not distorted and nal coupling

alignment can be made within the limits of movement of motor and by shimming, if necessary.

• Tighten foundation bolts nger tight and build dam around

foundation. Pour grout under bedplate making sure the areas under the pump and motor feet are ﬁlled solid. Allow grout to harden 48 hours before fully tightening foundation bolts.

• Tighten pump and motor hold-down bolts before aligning

shaft or connecting the piping to pump.

• Allow grout to harden for 48 hours before tightening 4

foundation bolts.

SAE – Engine Driven Pumps

The SAE engine drive bearing frame is designed to bolt directly to the ﬂywheel housing for engines with an SAE no. 1, 2, 3, 4 or 5 mount. The pump shaft extension is sized for use with couplings bolted directly to the ﬂywheel. Goulds Water Systems optional couplings are sized for 6½", 7½", 8", 10", and 14" ﬂywheels. Although other ﬂywheel mount couplings may be used, it is recommended that the Goulds Water Systems coupling be used to ensure long and trouble-free operation from your Goulds Pump.

REQUIREMENTS FOR PROPER OPERATION

Pump End:

When delivering the required capacity (GPM) to the system piping, the pump must add the amount of Head required by the system at the capacity. The operating head-capacity point should be as close as possible to the highest efﬁciency line shown on the performance curve, and must be below the head-capacity line labeled “maximum” RPM. The maximum operaton RPM for the pump is determined by bearing life, or in some cases, by the pressure limits of the pump. Suction and discharge openings are NPT tapped for standard pipe, or faced and drilled per ANSI B16.1, class 125 for standard ﬂanges as

indicated. Maximum working pressure for class 30 cast iron, per ANSI B16.1, is 175 PSI.

Internal combustion engines are variable speed and variable power machines. The power output depends on the engine speed (RPM) and will be reduced when operating altitude, and/or the air temperature increases. When driving the pump at the RPM required to deliver water into the system piping, the engine must operate within the Engine Manufacturers minimum and maximum RPM limits. The power output to supply the pump power demand must not exceed the continuous power rating of the engine, after derating for all power consuming engine accessories, and adjustmaner for installation site altitude and air temperature.

DRIVE-TRAIN SIZING (BHP)

The BHP Equation is: (Flow x TDH) / 3960 x Eff.) Note: For internal combustion units the BHP calculation must be de-rated for the following conditions:

• 20% for continuous duty

• 5% for right-angle drive

• 3% for each 1,000 feet above sea level

• 1% for each 10º F above 60º F.

DRIVE-TRAIN SIZING (TORQUE)

Other than sizing an engine for BHP, torque calculations also are required for proper sizing. Typically the horsepower and torque rating do not follow the same relationship throughout the usable range of a diesel engine (Figure 2). The equation for torque (lbs/ft) is (5250 x BHP) / RPM.

600

500

400

300

200

TORQUE (LBS/FT)

100

1500 1600 1700 1800 1900 2000 2100 2200 2300

RPM

180

178

176

174

172

170

168

166

164

162

160

Figure 2: HP (◆) vs. Torque (■)

VERIFY MATCH OF PUMP END TO ENGINE

SAE Bracket Size:

Engine drive pumps are available to ﬁt engines having a standard SAE 5 through SAE 1 ﬂywheel housing.

For a new engine, the engine supplier can provide the SAE housing number.

For an existing engine, the ﬂywheel housing bore and bolt circle can be measured and compared against the standard SAE housing dimensions listed in Table 1, to identify the housing SAE number.

• Measure the ywheel housing bore (A), and the bolt circle

(B), as accurately as possible with a tape measure (to the nearest 1/32 inch).

• Count the number of threaded holes in the ywheel housing

(C). Test the threaded holes with a bolt, to determine the thread series.

• Compare the measured dimensions (A), (B), and (C) against

Table 1, to determine the SAE number of the ﬂywheel housing, to be sure it matches the SAE number of your pump.

Flywheel

SAE Flywheel Housing Size

Housing

1 2 3 4 5

Dimensions

A 201⁄8 175⁄8 161⁄8 141⁄4 123⁄8 B 207⁄8 183⁄8 167⁄8 15 131⁄8 C No. 12 12 12 12 8 Size 7⁄16-14

⁄8-16

Table 1

Figure 3

INSTALLATION

• The pump may be installed horizontally, with the discharge

rotated to any position allowed by the casing bolt pattern (13). It is recommended that the discharge be located horizontally, above the suction.

• The casing must be supported on all pumps by a rigid support which is anchored to the unit base or foundation.

• For M-Group pumps it is recommended that this support

is bolted to the motor adapter ring using 2 or more of the casing bolts (13). It is likely that longer bolts will be required for the additional support thickness. Use SAE grade 5 bolts, torqued as indicated in this manual.

• For L-Group pumps it is recommended that the pump is

supported beneath the two feet cast into the motor adapter (3). These feet must be bolted to the support.

PUMP TO ENGINE ASSEMBLY (SPLINE COUPLING)

Preparation for Assembly of Pump on Engine

• Clean face and register t of ywheel housing and ywheel

as necessary to remove all grease, dirt, or rust (and all traces of rust preventative) which would interfere with installation of pump and/or prevent correct alignment. If ﬂywheel is ﬁtted with a pilot bearing for a transmission shaft, remove and discard. The pilot bearing is not required for installation of the pump end, and could interfere with the pump shaft.

• Examine shaft spline closely. Use a le, if necessary, to

remove any burrs that would prevent coupling from sliding freely onto the shaft.

• Lubricate pump shaft spline sparingly with light grease.

Don’t lubricate straight keyed shaft.

• Slide the coupling onto shaft until it is stopped against the

shaft (refer to page 5 for straight shaft installation).

• Measure the distance from the engine side of the ywheel

coupling adapter ring to the mounting face of the pump bracket. Refer to Figure 4 below, Dimension “A”.

• Next, measure depth from face of ywheel housing on

engine, to face on ﬂywheel against which coupling will be bolted. Refer to Figure 4 below, Dimension “B”.

• Pump measurement must be less than engine measurement

or axial interference will result in thrust force on engine crank shaft bearings. Simply stated, Dimension “A” must be less than Dimension “B”.

FLYWHEEL COUPLING

• The ywheel coupling transmits power from the engine

ﬂywheel to the pump shaft. The maximum power that a coupling can safely handle is shown by a rating number, “R”, which is listed in the coupling dimensions tables.

• When selecting a ywheel coupling for a pump and engine,

ﬁrst determine the power rating that the pump will demand. On the pump performance curve, ﬁnd the RPM and BHP values required to produce the spplication head-capacity point.

• Divide the BHP by the RPM, then multiply the result times

100. The result will be the demand number for the pump. For example, a 20BFSAE1AO can deliver 800 GPM at 270 feet Total Head when running at 1800 RPM. The power required by the pump will be 75 BHP. The demand number will be: (75 / 1800) x 100 = 4.16

• Next, select a coupling that can safely transmit the power,

and which will ﬁt the ﬂywheel dimensions. For a coupling to be suitable, it must have an “R” rating number GREATER THAN the pump demand number. In the above example, the minimum coupling “R” number whould be 5.

• Torsional compatibility of the engine, pump, and coupling

is the responsibility of the assembler. Goulds Water Systems will supply data for the pump and coupling for use by the assembler for a torsional analysis.

NOTE: If the ﬂywheel is ﬁtted with a pilot bearing pressed into a bore at the center, remove it to avoid interference with the pump shaft.

Figure 4 Figure 5

FLYWHEEL FOR INDUSTRIAL TYPE OVERCENTER CLUTCHES

• Figure 6 shows the hollowed-out appearance of the ywheels made for use with overcenter type clutch power take-off assemblies.

• These ywheels will have a recessed bore machined into the

face, and a set of tapped holes, which will be used to attach the coupling to the ﬂywheel. Dimensions are governed by an SAE standard and are listed in Tables 1A and 1B, Figure

3. The “clutch size” shown in the table is the nominal clutch facing diameter for Drive Ring Type Overcenter Clutches.

OTHER FLYWHEELS

• Some engines are tted with ywheels especially machined

for coupling to other kinds of machinery (electrical generators, torque converters, etc.), and require nonstandard ﬂywheel couplings. These may be purchased from third party vendors or suppliers.

Figure 6

Table IA – Wide RPM Range, Elastomer Mounted Hub – Spline Shaft

Flywheel Dimensions Flywheel Coupling (Spline) Clutch D Shaft

Size (UNC) Number Dia.

6½" 6 5⁄16-18 8½ OD 7.88 3.94 1.19 1.69 7 A00569C 1 1½" 10T 7½" 8 5⁄16-18 9½" OD 8.75 3.69 1.19 1.69 7 A00569C 2 1½" 10T 8" 6 3⁄8-16 103⁄8" OD 9.62 4.81 2.44 2.94 7 A00569C 3 1½" 10T 10" 8 3⁄8-16 123⁄8" OD 11.62 4.47 2.13 2.75 7 A00569C 4 1½" 10T 10" 8 3⁄8-16 123⁄8" OD 11.62 4.47 2.13 2.75 9 A00569C 6 1½" 10T 11½" 8 3⁄8-16 137⁄8" OD 13.12 5.06 1.56 2.69 7 A00569C 5 1½" 10T 11½" 8 3⁄8-16 137⁄8" OD 13.12 5.06 1.56 2.69 9 A00569C 7 1½" 10T 14" 8 ½-13 183⁄8" OD 17.25 6.63 1.00 2.13 9 A00569C 8 1½" 10T

* R = Coupling Rating Max. Coupling Rating = (Rated horsepower x 100) / Rated RPM

Size E BC F G H R* Catalog Spline

Qty.

Table IB – Wide RPM Range, Elastomer Mounted Hub – Straight Shaft

Flywheel Dimensions Flywheel Coupling Clutch D Shaft

Size (UNC) Number Dia.

6½" 6 5⁄16-18 8½ OD 7.88 3.94 1.19 1.69

3.51 CD625

7½" 8 5⁄16-18 9½" OD 8.75 3.69 1.19 1.69

3.51 CD725

8" 6 3⁄8-16 103⁄8" OD 9.62 4.81 2.44 2.94

3.51 CD825

2.28 CD1016

3.51 CD1025 10" 8 3⁄8-16 123⁄8" OD 11.62 4.47 2.13 2.75 5.71 CD1030

8.57 CD1050

11.23 CD1080

2.28 CD1116

3.51 CD1125

5.71 CD1130 11½" 8 3⁄8-16 137⁄8" OD 13.12 5.06 1.56 2.69 8.57 CD1150

11.23 CD1180

12.62 CD1190

16.85 CD11110H

2.28 CD1416

3.51 CD1425

5.71 CD1430 14" 8 3⁄8-16 183⁄8" OD 17.25 6.63 1.00 2.13 8.57 CD1450

11.23 CD1480

12.62 CD1490

16.85 CD14110H Dimensions in inches

* R = Coupling Rating Max. Coupling Rating = (Rated horsepower x 100) / Rated RPM

Size E BC F G H R* Catalog Spline

Qty.

2.28 CD616

2.28 CD716

2.28 CD816

1.625-

1.624Ø

⁄8 x 3⁄

Keyway

• For Goulds Water Systems straight shaft keyed couplings –

Ensure that the coupling hub set screw is backed out enough to ensure clearance for the shaft key during assembly.

• Mount the coupling assembly to the engine ywheel using

the bolts provided torqued as follows in a crossing sequence: 6½" or 7½" Flywheel – 11 lbs.-ft. (15 N.m) 8", 10" or 11½" Flywheel – 20 lbs.-ft. (27 N.m) 14" Flywheel – 50 lbs.-ft. (68 N.m) (For other couplings follow manufacturers

recommended installation procedure.)

• Place the pump shaft key into the pump shaft (122) and align

the shaft to the coupling. Slide the pump into the coupling

until the engine adapter ring (340) contacts the engine

ﬂywheel housing.

INSTALLATION OF COUPLING ON FLYWHEEL

Flywheel Coupling Overcenter Type:

• These couplings are aligned concentrically with the ywheel

by register ﬁt on the ﬂywheel.

• Be sure to remove all preservatives from the engine’s y-

wheel.

• Fit the coupling into the ywheel. Align the bolt holes and

engage coupling with register ﬁt on ﬂywheel. Tap coupling

with a soft heavy hammer, if necessary, to be sure that it is

seated ﬂat against ﬂywheel. Secure coupling tightly to ﬂy-

wheel with capscrews and lockwasher.

INSTALLATION OF PUMP ON ENGINE

• Lift pump with suitable lifting apparatus and align pump shaft

with coupling. End of pump shaft has a pilot diameter which

epermits wasy engagement of pump shaft into coupling.

• Reach into pump suction opening and rotate impeller slightly

Hazardous machinery can cause personal injury or death.

WARNING

until the shaft will engage the coupling. Verify that there is no gap between bracket and ﬂywheel housing faces. Rotate pump as necessary to align bracket holes with engine. Install capscrews and bolt pump end securely to engine.

NOTE: If any interference, or incompatibility of parts is detected during installation, DO NOT proceed with assembly. Direct the problem to your nearest Goulds Pumps distributor.

• Mount the pump to the engine using the bolts and lock-

washers provided, torqued as follows in a crossing sequence:

SAE #2, #3, #4, #5 – 20 lbs.-ft. (27 N.m) SAE #1 – 50 lbs.-ft. (68 N.m)

• Install coupling guards (501N).

• Bolt motor adapter (3) to the rigid support described above.

Coupling Alignment

FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTENANCE CAN CAUSE SEVERE PERSONAL INJURY.

FRAME-MOUNTED UNITS ONLY

• Alignment MUST be checked prior to running. See Figure 7.

Parallel

• All piping MUST be independently supported and MUST

NOT place any piping loads on the pump NOTICE: DO NOT FORCE PIPING INTO PLACE

AT PUMP SUCTION AND DISCHARGE CONNECTIONS.

• All pipe joints MUST be airtight.

PIPING – SUCTION

• For suction lifts over 10 ft. (3 m) and liquid temperatures

over 120° F (49° C), consult pump performance curve for

net positive suction head required (NPSHR).

• If a pipe size larger than pump suction is required, an ec-

centric pipe reducer, with the straight side up, MUST be

installed at the pump suction.

• If pump is installed below the liquid source, install a gate

valve in the suction for pump inspection and maintenance. NOTICE: DO NOT USE THE GATE VALVE TO

THROTTLE PUMP. THIS MAY CAUSE LOSS OF PRIME, EXCESSIVE TEMPERATURES AND DAMAGE TO PUMP, VOIDING WARRANTY.

• If the pump is installed above the liquid source, the following

MUST be provided:

• To avoid air pockets, no part of the piping should be above

the pump suction connection.

• Slope the piping upward from liquid source.

• Use a foot valve or check valve ONLY if necessary for

priming or to hold prime during intermittent duty.

• The suction strainer or suction bell MUST be at least

3 times the suction pipe diameter area.

• Insure that the size and minimum submergence over suction inlet is sufﬁcient to prevent air from entering pump through a suction vortex. See Figures 8 through 11.

Angular

Figure 7

• Tighten all hold-down bolts before checking alignment.

• If realignment is necessary, always move the motor. Shim

as required.

• Parallel misalignment, shafts with axis parallel but not

concentric. Place dial indicator on one hub and rotate this hub 360° while taking readings on the outside diameter of the other hub. Parallel alignment is achieved when reading is

0.010" (0.254 mm) TIR, or less.

• Angular misalignment, shaft with axis concentric but not parallel. Place dial indicator on one hub and rotate this hub 360° while taking readings on the face of the other hub. Angular alignment is achieved when reading is 0.020" (0.508 mm) TIR, or less.

• Final alignment is achieved when parallel and angular requirements are satisﬁed with motor hold-down bolts tight.

NOTICE: ALWAYS RECHECK BOTH ALIGNMENTS AFTER MAKING ANY MECHANICAL ADJUSTMENTS.

Piping

• Piping should be no smaller than pump’s discharge and

suction connections and kept as short as possible, avoiding unnecessary ﬁttings to minimize friction losses. See Table 1.

H min.

Figure 8 Figure 9

3.0D min.

1.5D min.

H min.

D min.

D D

H min.

16 15 14 13 12 11 10

9 8 7 6 5 4 3 2

H = Min. Submergence in feet

12345678910 11121314 1516

V = Velocity in feet per second

= GPM x 0.321

Area

GPM x 0.4085

Figure 10 Figure 11

PIPING – DISCHARGE

• Install a check valve suitable to handle the ow, liquids and

to prevent backﬂow. After the check valve, install an appropriately sized gate valve to be used to regulate the pump capacity, pump inspection and for maintenance.

• When required, pipe increaser should be installed between

the check valve and the pump discharge.

Wiring and Grounding

WARNING

Hazardous voltage can shock, burn or cause death.

WARNING

Hazardous voltage

Hazardous machinery can cause personal injury or death.

WARNING

Hazardous voltage can shock, burn or cause death.

Extreme heat can cause personal injury or property damage.

WARNING

Hazardous fluids can cause personal injury or property damage.

WARNING

Hazardous voltage can shock, burn or cause death.

Hazardous pressure can cause personal injury or property damage.

CAUTION

Install, ground and wire according to local and National Electrical Code Requirements.

Install an all leg electrical power disconnect switch near the pump.

Disconnect and lockout electrical power before installing or servicing the pump.

Electrical supply MUST match pump’s nameplate speciﬁcations. Incorrect voltage can cause ﬁre, damage motor and void the warranty.

Motors without built-in protection MUST be provided with contactors and thermal overloads for single phase motors, or starters with heaters for three phase motors. See motor nameplate.

• Use only copper wire to motor and ground. The ground

wire MUST be at least as large as the wire to the motor. Wires should be color coded for ease of maintenance.

• Follow motor manufacturer’s wiring diagram on the motor

nameplate or terminal cover carefully.

FAILURE TO PERMANENTLY GROUND THE PUMP, MOTOR AND CONTROLS BEFORE CONNECTING TO ELECTRICAL POWER CAN CAUSE SHOCK, BURNS OR DEATH.

OPERATION AT OR NEAR ZERO FLOW CAN CAUSE EXTREME HEAT, PERSONAL INJURY OR PROPERTY DAMAGE.

NOTICE: NO NOT RUN PUMP DRY OR SEAL

DAMAGE WILL RESULT.

• After stabilizing the system at normal operating conditions,

check the piping. If necessary, adjust the pipe supports.

• On frame-mounted units, coupling alignment may have

changed due to the temperature differential between pump and motor. Recheck alignment following procedures and hazard warnings in “COUPLING ALIGNMENT” section of this manual.

Maintenance

FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTENANCE CAN CAUSE SHOCK, BURNS OR DEATH.

NOTICE: INCORRECT ROTATION MAY CAUSE

DAMAGE TO THE PUMP AND VOIDS THE WARRANTY.

• Correct rotation is right-hand, CLOCKWISE when viewed

• To reverse three phase motor rotation, interchange any two

Rotation

from the motor end. For frame mounted units, switch power on and off quickly to observe rotation. On close coupled units, remove motor end plug or cover to observe rotation.

power supply leads.

Operation

DO NOT OPERATE FRAME MOUNTED OR SAE UNITS WITHOUT SAFETY GUARDS IN PLACE OR SEVERE PERSONAL INJURY MAY RESULT.

SPLASHING OR IMMERSING OPEN DRIP PROOF MOTORS IN FLUID CAN CAUSE FIRE, SHOCK, BURNS OR DEATH.

FAILURE TO RELIEVE SYSTEM PRESSURE AND DRAIN SYSTEM BEFORE ATTEMPTING ANY MAINTENANCE CAN CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

IF PIPING HAZARDOUS OR TOXIC FLUIDS, SYSTEM MUST BE FLUSHED PRIOR TO PERFORMING SERVICE.

CLOSE-COUPLED UNITS

• Bearings are located in and are part of the motor. For lubrication information, refer to motor manufacturer’s instructions.

FRAME-MOUNTED UNITS

• Model 3756 S-group has greased for life bearings.

No regreasing is possible or necessary.

• Model 3756 M or L-group bearing frame and SAE drive

bearing frame should be regreased every 2,000 hours or at a three month interval, whichever occurs ﬁrst. Use a #2 sodium or lithium based grease. Fill until grease comes out of relief ﬁttings, or lip seals, then wipe off excess.

• Follow motor or engine and coupling manufacturer’s lubrication instructions.

• Recheck alignment.

SEASONAL SERVICE

• To REMOVE pump from service, remove drain plug and

drain all unprotected piping.

• To RETURN pump to service, replace drain plug using

Teﬂon™ tape or equivalent on male threads.

• Reconnect suction line if removed, examine union and repair

if necessary.

• Refer to OPERATION section of manual.

Disassembly

• Follow ALL warnings and instructions in the “MAINTE- NANCE” section of this manual.

• Close-coupled units: Remove motor hold-down bolts.

• Frame-mounted units: Remove coupling guard, spacer, cou-

pling and frame hold-down bolts.

LIQUID END

1. Remove casing bolts (13).

2. Remove back pull-out assembly from casing (1).

3. Remove casing wear ring (4) if excessively worn.

NOTICE: DO NOT INSERT SCREWDRIVER BETWEEN IMPELLER VANES TO PREVENT ROTATION.

4. On close-coupled units, remove motor end plug or cover

to expose screwdriver slot or ﬂats on end of motor shaft.

5. While restraining shaft with an appropriate tool (close-

coupled units) or with a strap wrench (frame-mounted units) remove impeller bolt (6). Impeller bolt may need to be heated with torch to remove. Discard.

NOTICE: EXERCISE CAUTION WHEN HANDLING HOT IMPELLER BOLT.

NOTICE: FOR SAE DRIVE UNITS, REMOVE IMPELLER NUT SET SCREW (22A) PRIOR TO REMOVING IMPELLER NUT (22). IMPELLER SET SCREW AND IMPELLER NUT MAY NEED TO BE HEATED TO BE REMOVED.

6. Remove impeller washer (7).

7. Insert two pry bars, 180° apart, between impeller (2) and

seal housing (3). CAREFULLY pry off impeller.

8. Remove impeller key (8).

9. Remove seal housing bolts (14) and seal housing (3)

pulling with it the mechanical seal assembly. Discard seal assembly and seal housing o-ring (9). For packed box pumps see “PACKED BOX INSTRUCTIONS”.

10. Remove adapter (108).

11. Inspect shaft sleeve (11). If badly scored, remove by

heating with torch. Discard.

12. Push out the mechanical seal stationary seat from the

seal housing. Discard.

13. On units equipped, remove seal housing wear ring (5)

if excessively worn.

DISASSEMBLY OF BEARING FRAME OR SAE BEARING FRAME

1. Remove deﬂector (123) from shaft.

2. Remove bearing cover (134).

3. Remove shaft assembly from frame.

4. Remove lip seals (138, 139) from bearing frame (228) and

bearing cover (134) if worn. Discard.

5. Remove retaining ring (361).

6. Use bearing puller or arbor press to remove ball bearings (112, 168).

Reassembly

• All parts should be cleaned before assembly.

NOTICE: O-RING SHOULD BE REPLACED AFTER ANY DISASSEMBLY OF UNIT.

BEARING FRAME

1. Replace lip seals if removed.

2. Replace ball bearings if loose, rough or noisy when rotated.

3. Check shaft (122) for runout. Maximum permissible is

0.002" (0.05 mm) TIR.

4. Refer to the “MAINTENANCE” section of this manual for M-group bearing frame regreasing instructions.

LIQUID END

1. Inspect shaft removing any debris or burrs.

2. Treat shaft with LOCQUIC® Primer “T”, or equivalent, following manufacturer’s instructions carefully.

3. When replacing shaft sleeve, spray new shaft sleeve’s bore with LOCQUIC® Primer “T”, or equivalent. Let parts dry and then apply LOCTITE® #262 on the same surfaces. Slide new sleeve over shaft with a twisting motion, wipe off excess. Let cure according to instructions.

NOTICE: MECHANICAL SEAL MUST BE REPLACED WHENEVER SEAL HAS BEEN REMOVED. FOLLOW SEAL MANUFACTURER’S INSTRUCTIONS CAREFULLY. FOR PACKED BOX PUMPS SEE “PACKED BOX INSTRUCTIONS”.

4. Replace seal housing wear ring, if removed.

5. For mechanical seal pumps, stationary seal seat may be dipped in water to ease installation. Place stationary seal seat squarely into seal housing bore. Cover the polished face of the seat with a thin piece of cardboard or paper towel. Press seat ﬁrmly into bore using a round piece of plastic or wood that disperses the force over the entire seal face. NOTE: If mechanical seal is supplied with a spring retainer, remove and discard the retainer.

6. Place adapter, concave face pointing up, over motor shaft and lower it onto the motor.

7. Replace seal housing o-ring. This o-ring may be lubricated with water or glycerin to ease in installation. Install seal housing on adapter. Exercise care in that the motor shaft does not dislodge or damage seal seat.

8. Fully and squarely install the rotary assembly of seal against the stationary seat.

NOTICE: REPLACE IMPELLER BOLT AND WASHER WHENEVER IMPELLER IS REMOVED.

9. Install impeller key in shaft keyway. Mount impeller on shaft and push until it bottoms. Hold in place. For SAE units, apply LOCTITE 271 to the impeller bore, keyway and shaft. Mount impeller on shaft and push until it bottoms. Hold in place.

10. Install new impeller washer. Impeller washer not used for SAE units..

11. Apply LOCTITE® #271 or equivalent, to new impeller bolt

CORRECT WRONG

threads and tighten to: 3⁄8"-16 bolts 20 lbs.-ft. (27 N.m)

½"-13 bolts 38 lbs.-ft. (51 N.m) Impeller bolt not used for SAE units.

12. For SAE units apply LOCTITE® #271 to the external

threads of the shaft and internal threads of the impeller nut (22). Tighten impeller nut to the following:

½"-Impeller Nut (SAE M-Group) 80 lbs.-ft. (107 N.m) ¾"-Impeller Nut (SAE L-Group) 100 lbs.-ft. (134 N.m)

13. For SAE units, after impeller nut (22) has been installed,

apply

LOCTITE® #271 to set screw (22A). Install impeller set screw into face of impeller nut (22) and tighten hand-tight.

14. Replace casing wear ring, if removed.

15. Replace casing bolts and tighten, in a crossing sequence, to torque values indicated below:

3⁄8"-16 bolts (bronze casing) 25 lbs.-ft. (34 N.m) ½"-16 bolts (cast iron casing) 37 lbs.-ft. (50 N.m) ½"-13 bolts (cast iron casing) 90 lbs.-ft. (122 N.m) ¾"-10 bolts (cast iron casing) 175 lbs.-ft. (237 N.m)

16. Check reassembled unit for binding by rotating shaft with appropriate tool from motor end.

17. If rubbing exists, loosen casing bolts and proceed with tightening sequence again.

18. Replace motor hold-down bolts and motor end plug or cover on close-coupled units.

19. Replace coupling, spacer, coupling guard and frame hold-down bolts on frame-mounted units.

NOTICE: ALWAYS RECHECK BOTH ALIGNMENTS AFTER MAKING ANY ADJUSTMENTS.

20. Refer to the “COUPLING ALIGNMENT” section of this manual to realign shaft.

21. Assembly is complete.

Packed Box

1. Make sure stufﬁng box is free of foreign materials and clean before beginning packing of packed box. Refer to Sectional Assembly in the repair parts section.

2. Take special care during installation of packing rings because they are die-formed. To install, twist the ring sideways just enough to ﬁt it around the shaft sleeve. DO NOT ATTEMPT TO PULL RINGS STRAIGHT

OUT. See Figure 12.

Figure 12

3. Install the two piece Teﬂon lantern ring supplied as shown in ﬁgure 13. Note: two pieces make one ring. Notches on ring must face each other, but alignment is not necessary.

Teﬂon Lantern Ring

Figure 13

4. Install the packing rings and lantern ring in the following sequence to pack the packed box. Install two rings of packing, then the lantern ring, followed by the ﬁnal three rings of packing. Install each ring separately and ﬁrmly seat. The use of a wooden split bushing is recommended to accomplish this. See Figure 14. Use gland to jack the bushing and ring into the box. Stagger joints in each ring 90°. Make sure the ﬂush tap in the packed box lines up with the center of the lantern ring. Any extra rings are spares.

WOODEN “SPLIT BUSHING”

GLAND

STUFFING

BOX

SHAFT

Figure 14

5. Tighten gland nuts evenly, but not tight. When the pump is started, slowly tighten the gland nuts until the leak rate is between 40 and 60 drops per minute. A grease lubricant can be used when the pumpage contains abrasive particles or for a suction lift condition.

REMOVAL OF PACKED BOX

• Follow these steps to remove the packing from the

packed box.

1. Remove gland assembly.

2. With a “packing hook” remove packing.

3. Insert a wire hook into the ring on the outer edge to remove the lantern ring.

4. Clean the packed box.

PRIME SAFE ARRANGEMENT (Optional – M & L Group Only)

• The Prime Safe arrangement can be provided with grease or

an oiler feed lubrication.

1. The grease gland (24) will have the letters "G" and "O" stamped on the outside diameter and have two 1⁄8" NPT connections for mounting a grease feeder or oiler.

2. For grease feed applications, the grease gland is assembled

WARNING

Hazardous voltage can shock, burn or cause death.

with the “G” stamp in the 12 o' clock position. The grease feeder (23) will mount in the grease gland at a 30 degree angle from the horizontal. This is done to gain access to the grease ﬁtting located on the grease feeder. The lip seal (26) mounted in the grease gland will be assembled as shown in Figure 15.

3. For oiler feed applications, the grease gland is assembled with the “O” stamp in the 12 o' clock position. The two

⁄8" NPT connections on the grease gland will be located on the horizontal, which is to ensure proper function of the oiler. The lip seal (26) is to be mounted in the reverse or opposite direction as shown in Figure 10.

4. The mounting of a grease feeder or oiler may require additional pipe extensions and/or ﬁttings that will be provided from the factory as needed.

5. The grease feeder (23) will come with three springs (blue, red and silver). The use of the different springs will be varied depending on the operating temperature and the lubricant (grease) to be used.

Grease Feeder Spring Size Operating Temperature No. 1 Grease No. 2 Grease No. 3 Grease

-10ºF (-23ºC) to 40ºF (4ºC) SILVER RED —

-40ºF (-40ºC) to 110ºF (43ºC) SILVER SILVER RED

-110ºF (-79ºC) to 200ºF (93ºC) BLUE SILVER SILVER Use SAE 30W oil for oiler application.

Troubleshooting Guide

DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE A SHOCK, BURN OR DEATH.

SYMPTOM

MOTOR NOT RUNNING See Probable Cause – 1 through 5

LITTLE OR NO LIQUID DELIVERED See Probable Cause – 6 through 13

EXCESSIVE POWER CONSUMPTION See Probable Cause – 3, 13, 14, 15

EXCESSIVE NOISE and VIBRATION See Probable Cause – 3, 6, 7, 10, 12, 14, 16, 17

PROBABLE CAUSE

1. Motor thermal protector tripped

2. Open circuit breaker or blown fuse

3. Impeller binding

4. Motor improperly wired

5. Defective motor

6. Pump is not primed, air or gases in pumpage

7. Discharge, suction plugged or valve closed

8. Incorrect rotation (3 phase only)

9. Low voltage or phase loss

10. Impeller worn or plugged

11. System head too high

12. NPSHA too low – Excessive Suction lift or losses

13. Incorrect impeller diameter

14. Discharge head too low – excessive ﬂow rate

15. Fluid viscosity, speciﬁc gravity too high

16. Worn bearing

17. Pump, motor or piping loose

Figure 15

Repair Parts Series 3656/3756

SAE M & L

Replaces 6 & 7

4 6 7 8 2 5 9 10 3 11

2222A

16 17 18

12 1

Packed Box Arrangement

LIQUID END COMPONENTS Item No. Description Material

1 Casing 2 Impeller Cast iron or Sil-brass* 3 Adapter 4 Wear ring (casing) Cast iron or bronze* 5** Wear ring (seal housing) 6 Impeller bolt 7 Impeller washer

AISI Type 300 stainless steel

8 Impeller key Steel 9 Seal housing o-ring (optional materials) BUNA-N/EPR/Viton 10 Mechanical seal Consult factory 11 Shaft sleeve AISI Type 300

stainless steel 12 Drain plug – ¼ or 3⁄8 NPT 13 Hex head cap screw (casing to adapter) Zinc plated steel 14 Hex head cap screw (adapter to motor/frame) 15 Hex head cap screw (Adapter to seal housing) 16 Lantern ring Teﬂon™ 17 Packing, 5 rings Teﬂon™ impregnated 18 Gland AISI 300SS 19 Shaft sleeve 20 Gland stud

AISI Type 300 stainless steel

21 Gland nut 22 Impeller nut (SAE only) 304 SS 22A Set screw, impeller nut (SAE only) 23 Grease feeder (oiler optional) Polycarbonate

Prime Safe Arrangement (optional – M & L group only)

LIQUID END COMPONENTS Item No. Description Material

24 Grease gland Aluminum 25 Pipe plug Zinc plated steel 26 Lip seal Buna * Lead free

** Item #5 supplied on S-group model 2½ x 3-7 (7½, 10 and 15 HP) and M-group (except 3 x 4-10).

POWER END COMPONENTS (shown on next page) Item No. Description Material

112 Ball bearing (outboard) Steel 122 Pump shaft 122A Pump shaft (SAE) AISI 4140 steel 123 V-ring, deﬂector BUNA-N 134 Bearing cover Cast iron 138 Lip seal (outboard) BUNA-N 139 Lip seal (inboard) 168 Ball bearing (inboard) Steel 193 Grease ﬁtting (M & L group) 327C Screw (cover to adapter) (SAE only) Zinc plated steel 340 Adapter/engine (SAE only) Cast iron 361 Retaining ring Steel 370C Hex head cap screw (frame to cover) Zinc plated steel 371C Hex head cap screw (adapter to frame)

(SAE only)

NOT SHOWN

Steel 399 Key, coupling 501N Cover/adapter (SAE only) Galvanized steel

3656/3756 Power Frames

370C

361 370C112

168

361

139

123 168 122 134

S-Group Power Frame M-Group Power Frame

370C

361

168

399

138

123

139

371L

112122193123

399

138

193 134

193

139

399

138

193 134

112122193123

122A

112193168

L-Group Power Frame SAE Power Frame

361

399

327C

138

501N

370C

340

134

GOULDS WATER TECHNOLOGY LIMITED WARRANTY

This warranty applies to all water systems pumps manufactured by Goulds Water Technology. Any part or parts found to be defective within the warranty period shall be replaced at no charge to the dealer during the warranty period. The warranty period shall exist for a

period of twelve (12) months from date of installation or eighteen (18) months from date of manufacture, whichever period is shorter. A dealer who believes that a warranty claim exists must contact the authorized Goulds Water Technology distributor from whom the pump was purchased and furnish complete

details regarding the claim. The distributor is authorized to adjust any warranty claims utilizing the Goulds Water Technology Customer Service Department.

The warranty excludes:

(a) Labor, transportation and related costs incurred by the dealer; (b) Reinstallation costs of repaired equipment; (c) Reinstallation costs of replacement equipment; (d) Consequential damages of any kind; and,

(e) Reimbursement for loss caused by interruption of service.

For purposes of this warranty, the following terms have these deﬁnitions:

(1) “Distributor” means any individual, partnership, corporation, association, or other legal relationship that stands between Goulds Water Technology and the dealer in

purchases, consignments or contracts for sale of the subject pumps. (2) “Dealer” means any individual, partnership, corporation, association, or other legal relationship which engages in the business of selling or leasing pumps to customers. (3) “Customer” means any entity who buys or leases the subject pumps from a dealer. The “customer” may mean an individual, partnership, corporation, limited liability

company, association or other legal entity which may engage in any type of business.

THIS WARRANTY EXTENDS TO THE DEALER ONLY.

Xylem, Inc. 2881 East Bayard Street Ext., Suite A Seneca Falls, NY 13148 Phone: (800) 453-6777 Fax: (888) 322-5877 www.xyleminc.com/brands/gouldswatertechnology

Goulds is a registered trademark of Goulds Pumps, Inc. and is used under license.

MANUAL DE INSTRUCCIÓN

IM010

Modelos 3656 y 3756

INSTRUCCIONES DE INSTALACIÓN, FUNCIONAMIENTO Y MANTENIMIENTO

+ 33 hidden pages