Installation,
Operation, and
Maintenance Manual
Series 90
Table of Contents
Introduction and Safety.........................................................................................................................2
Introduction..........................................................................................................................................2
Requesting other information.........................................................................................................2
Safety.....................................................................................................................................................2
Safety terminology and symbols....................................................................................................3
User safety.........................................................................................................................................3
Environmental safety........................................................................................................................5
Product warranty...............................................................................................................................5
Transportation and Storage..................................................................................................................7
Inspect the delivery.............................................................................................................................7
Inspect the package.........................................................................................................................7
Inspect the unit..................................................................................................................................7
Pump lifting..........................................................................................................................................7
Long-term storage...............................................................................................................................7
Product Description...............................................................................................................................9
General description............................................................................................................................9
Operational specifications.................................................................................................................9
Table of Contents
Installation.............................................................................................................................................11
Preinstallation....................................................................................................................................11
Pump location guidelines..............................................................................................................11
Piping checklist...............................................................................................................................12
Typical installation..........................................................................................................................13
Special installation..........................................................................................................................14
Connect the wiring............................................................................................................................14
Commissioning, Startup, Operation, and Shutdown......................................................................15
Preparation for startup.....................................................................................................................15
Check the rotation..........................................................................................................................15
Lubrication requirements.................................................................................................................16
Prime the pump.................................................................................................................................16
Start the pump...................................................................................................................................16
Pump operation precautions...........................................................................................................17
Shut down the pump........................................................................................................................17
Maintenance.........................................................................................................................................18
Disassembly.......................................................................................................................................18
Disassembly precautions...............................................................................................................18
Drain the pump...............................................................................................................................18
Determine the seal size..................................................................................................................19
Remove the seal assembly............................................................................................................20
Pre-assembly inspections.................................................................................................................21
Replacement guidelines................................................................................................................21
Reassembly........................................................................................................................................21
Reassemble the seal assembly.....................................................................................................21
Capscrew torque values................................................................................................................22
Dealer servicing .............................................................................................................................23
Series 90 Installation, Operation, and Maintenance Manual 1
Introduction and Safety
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions, situations,
or events that are not considered in this manual or in the sales documents, please contact
the nearest Xylem representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes
any modification to the equipment or use of parts not provided by Xylem. If there is a
question regarding the intended use of the equipment, please contact a Xylem
representative before proceeding.
• This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion
and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in
their removal.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in
physical injury, damage, or delays.
2 Series 90 Installation, Operation, and Maintenance Manual
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
Introduction and Safety
Hazard categories
DANGER:
WARNING:
CAUTION:
NOTICE:
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
A hazardous situation which, if not avoided, will result in
death or serious injury
A hazardous situation which, if not avoided, could result
in death or serious injury
A hazardous situation which, if not avoided, could result
in minor or moderate injury
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
Series 90 Installation, Operation, and Maintenance Manual 3
Introduction and Safety
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
• 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.
• 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.
Precautions before work
Observe these safety precautions before you work with the product or are in connection
with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage
• 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.
Wash the skin and eyes
property.
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
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.
4 Series 90 Installation, Operation, and Maintenance Manual
Condition Action
Introduction and Safety
Chemicals or hazardous
fluids on skin
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the Xylem manufacturer if it has been contaminated by any
nuclear radiation. Inform Xylem so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Recycling guidelines
Product warranty
Coverage
Limitations
Always follow local laws and regulations regarding recycling.
Xylem undertakes to remedy defects in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an local sales and service representative within the warranty
period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in
use.
• All service and repair work is done by Xylem authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by an EX-approved Xylem
representative are used in Ex-approved products.
The warranty does not cover defects caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting an
Xylem authorized representative
• Incorrectly executed repair work
• Normal wear and tear
Series 90 Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Warranty claim
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your local sales and
service representative.
6 Series 90 Installation, Operation, and Maintenance Manual
Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation and Storage
Pump lifting
WARNING:
• Assembled units and their components are heavy. Failure to properly lift and support
this equipment can result in serious physical injury and/or equipment damage. Lift
equipment only at the specifically identified lifting points. Lifting devices such as
eyebolts, slings, and spreaders must be rated, selected, and used for the entire load
being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
In order to lift the entire pump, use slings placed around the unit as shown.
Figure 1: Proper lifting method
Long-term storage
If the unit is stored for more than 6 months, these requirements apply:
• Store in a covered and dry location.
• Store the unit free from heat, dirt, and vibrations.
• Rotate the shaft by hand several times at least every three months.
Series 90 Installation, Operation, and Maintenance Manual 7
Transportation and Storage
Treat bearing and machined surfaces so that they are well preserved. Refer to the drive
unit and coupling manufacturers for their long-term storage procedures.
For questions about possible long-term storage treatment services, please contact your
local Xylem sales representative.
8 Series 90 Installation, Operation, and Maintenance Manual
Product Description
General description
The Series 90 in-line mounted centrifugal pump is a close-coupled pump.
This pump is available for pipe sizes that range from 1 inch to 2 inches.
Pump application
WARNING:
California Proposition 65 warning! This product contains chemicals known to the state of
California to cause cancer and birth defects or other reproductive harm.
You can use this pump for these types of applications:
• Hydronic heating and cooling
• Domestic hot water
• Cooling towers
• Machinery cooling
• Pressure boosting
• Industrial fluid transfer
• Refrigeration and heater exchanger circulation
This pump is for indoor use only.
Xylem recommends that you use bronze constructed pumps for pumping potable water.
For other applications, contact your local sales and service representative.
Product Description
Operational specifications
Operational limitations
Parameter Value
Maximum working pressure 175 psi
Pump construction Iron or bronze
Mechanical seal specifications
Materials of Construction BUNA carbon/ceramic EPR carbon/tungsten
Standard/optional Standard Optional Optional
Operating temperature
range
pH range 7.0–9.0 7.0–11.0 7.0–12.0
Maximum glycol/water
concentration
Maximum suction pressure Suction Pressure + TDH must not exceed MWP
Mechanical seal specifications
Materials of Construction BUNA carbon/ceramic EPR carbon/tungsten
Standard mechanical seal
EPR Sic/SiC
carbide
-20˚F to 225˚F (-29˚C to
107˚C)
50/50% 50/50% 60/40%
-20˚F to 250˚F (-29˚C to
121˚C)
carbide
0˚F to 250˚F (-18˚C to
121˚C)
EPR Sic/SiC
Standard/optional Standard Optional Optional
Series 90 Installation, Operation, and Maintenance Manual 9
Product Description
Materials of Construction BUNA carbon/ceramic EPR carbon/tungsten
EPR Sic/SiC
carbide
Operating temperature
range
-20˚F to 225˚F (-29˚C to
107˚C)
-20˚F to 250˚F (-29˚C to
121˚C)
0˚F to 250˚F (-18˚C to
121˚C)
pH range 7.0–9.0 7.0–11.0 7.0–12.0
Maximum glycol/water
50/50% 50/50% 60/40%
concentration
Maximum suction pressure Suction Pressure + TDH must not exceed MWP
10 Series 90 Installation, Operation, and Maintenance Manual
Installation
Preinstallation
Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is
properly certified.
• You must earth (ground) all electrical equipment. This applies to the pump equipment,
the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is
connected correctly.
NOTICE: Supervision by an authorized Xylem representative is recommended to ensure
proper installation. Failure to do so may result in equipment damage or decreased
performance.
Pump location guidelines
Installation
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.
Make sure that the space around the pump is sufficient.
Also make sure that you can protect the area below the
pump from water damage.
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.
Do not install and operate the equipment in closed
systems unless the system is constructed with properlysized safety devices and control devices.
This minimizes the friction loss and keeps the suction
piping as short as possible.
This facilitates ventilation, inspection, 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.
Acceptable devices:
• Pressure relief valves
• Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices, consult the
engineer or architect in charge before you operate the
pump.
Take into consideration the occurrence of unwanted
noise and vibration.
Series 90 Installation, Operation, and Maintenance Manual 11
Vibration can be transmitted to the piping system,
which can result in objectionable noise away from the
pump.
Installation
Guideline Explanation/comment
Mode of discharge
Piping checklist
If the pump location is overhead, undertake special
precautions to reduce possible noise transmission.
When possible, locate the pump below the fluid level. This facilitates priming, ensures a steady flow of liquid,
You can install this pump to discharge either vertically or horizontally. The arrow on the
pump body must point in the direction of the flow.
You can install the pump with the motor either vertical or horizontal. Do not install the
motor below the pump body.
WARNING:
• The heating of water and other fluids causes volumetric expansion. The associated forces
can cause the failure of system components and the release of high-temperature fluids.
In order to prevent this, install properly sized and located compression tanks and
pressure-relief valves. Failure to follow these instructions can result in serious personal
injury or death, or property damage.
• Avoid serious personal injury and property damage. Make sure that the flange bolts are
adequately torqued.
• Never force piping to make a connection with a pump.
Check Explanation/comment Checked
Consider a consultation with a noise specialist.
and provides a positive suction head on the pump.
Check that a section of straight pipe, with a length that
is five times its diameter, is installed between the
suction side of the pump and the first elbow, or that a
suction diffuser is installed.
Check that the suction and discharge pipes are
supported independently by use of pipe hangers near
the pump .
Check that there is a strong, rigid support for the
suction and discharge lines.
For pumps with flanges, check that the bolt holes in
the pump flanges match the bolt holes in the pipe
flanges.
Check that the suction or discharge lines are not
forced into position.
Check that fittings for absorbing expansion are
installed in the system when considerable
temperature changes are expected.
Check that you have a foot valve of equal or greater
area than the pump suction piping when you use an
open system with a suction lift.
This reduces suction turbulence by
straightening the flow of liquid before it enters
the pump.
This eliminates pipe strain on the pump .
As a rule, ordinary wire or band hangers are not
adequate to maintain proper alignment.
—
Coupling and bearing wear will result if suction
or discharge lines are forced into position.
This helps to avoid strain on the pump.
Prevent clogging by using a strainer at the
suction inlet next to the foot valve. Make sure
that the strainer has an area three times that of
the suction pipe with a mesh hole diameter of
no less than 0.25 in. (0.64 cm).
Check that a triple duty valve is installed in the
discharge line.
12 Series 90 Installation, Operation, and Maintenance Manual
This valve serves as a check valve that protects
the pump from water hammer, and serves as
an isolation valve for servicing and for
throttling.
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Installation
Check Explanation/comment Checked
Check that the pipeline has isolation valves around
the pump and has a drain valve in the suction pipe.
Use PTFE tape sealer or a high quality thread sealant
when you install the suction and discharge
connections to a threaded pump housing.
On an open system, check that the end of the suction
pipe is at least 3 ft. below the surface of the water in
the suction well.
Check that new flange gaskets are installed between
the flanges of the pump body end suction and
discharge pipes. make sure that these gaskets are
clean and grease-free.
Typical installation
—
—
This prevents air from being drawn into the
pump. Avoid air pockets in the suction line and
make sure that each section of the suction pipe
is air tight.
Suitable fasteners for this connection are
supplied in the Xylem fastener pack. Apply a
torque of 8 to 11 ft. lbs (11 to 15 Nm) to each of
the flange bolts. Both the suction and
discharge flanges must be torqued to the same
level.
1. Locate the compression tank on the suction side of the pump
2. Rolairtrol air separator
3. System supply
4. Circuit setter
5. Triple duty valve
6. Series 90 pump
7. Suction diffuser
8. Isolation valve
9. Pipe from boiler chiller or converter
10. Cold water supply
11. Reducing valve
Series 90 Installation, Operation, and Maintenance Manual 13
Installation
Special installation
Installation with suction diffuser and triple-duty valve
Do not install and operate triple-duty valves and suction diffusers in closed systems unless
the system is designed with these safety and control devices:
• Pressure relief valves
• Compression tanks
• Pressure controlling equipment
• Temperature controlling equipment
• Flow controlling equipment
Check that the control and safety devices have these characteristics:
• Properly sized for their purpose
• Placed correctly in the system before putting the system into operation
Connect the wiring
WARNING:
• Disconnect and lock out electrical power before installing or servicing the pump.
• 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.)
Electrical Hazard:
Make sure that all connections are secure and the conduit box cover is closed before you
connect the electrical power.
1. Remove the screws that secure the conduit box cover.
2. Lift off the cover.
3. Attach the appropriately sized connector to the hole in the side of the conduit box.
The circulators are thermally protected by impedance or on-winding thermal protectors
and do not require external overload protection.
14 Series 90 Installation, Operation, and Maintenance Manual
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation,
and Shutdown
Preparation for startup
WARNING:
• Failure to follow these precautions before you start the unit will lead to serious personal
injury and equipment failure.
• Do not operate the pump below the minimum rated flows or with the suction or
discharge valves closed. These conditions can create an explosive hazard due to
vaporization of pumped fluid and can quickly lead to pump failure and physical injury.
• If the pump, motor, or piping operate at extremely high or low temperatures, then
guarding or insulation is required. Failure to follow these instructions can result in
serious personal injury or death, and property damage.
• Never operate the pump without the coupling guard correctly installed.
• 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.
• Operating the pump in reverse rotation can result in the contact of metal parts, heat
generation, and breach of containment.
NOTICE:
You must follow these precautions before you start the pump:
At initial startup, do not adjust the variable-speed drivers or check for speed governor or
over-speed trip settings while the variable-speed driver is coupled to the pump. If the
settings have not been verified, then uncouple the unit and refer to instructions supplied
by the driver manufacturer.
Check the rotation
WARNING:
• Operating the pump in reverse rotation can result in the contact of metal parts, heat
• Always disconnect and lock out power to the driver before you perform any installation
• Verify the driver settings before you start any pump.
• Make sure that the warm-up rate does not exceed 2.5°F (1.4°C) per minute.
• Flush and clean the system thoroughly to remove dirt or debris in the pipe system in
order to prevent premature failure at initial startup.
• Bring variable-speed drivers to the rated speed as quickly as possible.
• If temperatures of the pumped fluid will exceed 200°F (93°C), then warm up the pump
prior to operation. Circulate a small amount of fluid through the pump until the casing
temperature is within 100°F (38°C) of the fluid temperature.
generation, and breach of containment.
or maintenance tasks. Failure to disconnect and lock out driver power will result in
serious physical injury.
1. Unlock power to the driver.
2. Make sure that everyone is clear, and then jog the driver long enough to determine
that the direction of rotation corresponds to the arrow on the pump.
Series 90 Installation, Operation, and Maintenance Manual 15
Commissioning, Startup, Operation, and Shutdown
Pump rotation is clockwise when viewed from the back of the motor. An arrow is
provided to show rotational direction.
3. Lock out power to the driver.
Lubrication requirements
Motor size Lubrication schedule
5 hp and smaller These pumps are permanently lubricated.
7.5, 10, and 15 hp These pumps are furnished with grease fittings and should be
Prime the pump
CAUTION:
Do not run the pump dry.
lubricated in accordance with the nameplate instructions from the
manufacturer.
Xylem supplies a high quality lubricant specifically for this
purpose which you can purchase from your Xylem representative
(part number L23401).
Make sure that the pump body is full of liquid before startup. If the system does not
automatically fill the pump body with liquid, then you must manually prime the pump.
1. Loosen the vent plugs on the pump body.
2. While venting the air from the pump body, rotate the pump shaft a few times by hand.
3. After all air has been purged from the pump, close the vent plugs.
Start the pump
WARNING:
Pressurize the pump body slowly while you check for leaks at all joints with gaskets. Failure
to follow these instructions can result in serious personal injury and/or property damage.
CAUTION:
• Observe the pump for vibration levels, bearing temperature, and excessive noise. If
normal levels are exceeded, shut down the pump and resolve the issue.
Before you start the pump, you must perform these tasks:
• Open the suction valve.
• Open any recirculation or cooling lines.
1. Fully close or partially open the discharge valve, depending on system conditions.
2. Start the driver.
3. Slowly open the discharge valve until the pump reaches the desired flow.
4. Immediately check the pressure gauge to ensure that the pump quickly reaches the
5. If the pump fails to reach the correct pressure, perform these steps:
6. Monitor the pump while it is operating:
correct discharge pressure.
a) Stop the driver.
b) Restart the driver.
16 Series 90 Installation, Operation, and Maintenance Manual
a) Check the pump for bearing temperature, excessive vibration, and noise.
b) If the pump exceeds normal levels, then shut down the pump immediately and
correct the problem.
7. Repeat steps 5 and 6 until the pump runs properly.
Pump operation precautions
General considerations
CAUTION:
• Vary the capacity with the regulating valve in the discharge line. Never throttle the flow
from the suction side since this can result in decreased performance, unexpected heat
generation, and equipment damage.
• Do not overload the driver. Driver overload can result in unexpected heat generation
and equipment damage. The driver can overload in these circumstances:
• The specific gravity of the pumped fluid is greater than expected.
• The pumped fluid exceeds the rated flow rate.
• Make sure to operate the pump at or near the rated conditions. Failure to do so can
result in pump damage from cavitation or recirculation.
Operation at reduced capacity
Commissioning, Startup, Operation, and Shutdown
WARNING:
Never operate any pumping system with a blocked suction and discharge. Operation,
even for a brief period under these conditions, can cause confined pumped fluid to
overheat, which results in a violent explosion. You must take all necessary measures to
avoid this condition.
CAUTION:
• Avoid excessive vibration levels. Excessive vibration levels can damage the bearings,
stuffing box or seal chamber, and the mechanical seal, which can result in decreased
performance.
• Avoid increased radial load. Failure to do so can cause stress on the shaft and bearings.
• Avoid heat build-up. Failure to do so can cause rotating parts to score or seize.
• Avoid cavitation. Failure to do so can cause damage to the internal surfaces of the pump.
Operation under freezing conditions
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump
and the cooling coils. Failure to do so can cause liquid to freeze and damage the pump.
Shut down the pump
1. Slowly close the discharge valve.
2. Shut down and lock the driver to prevent accidental rotation.
Series 90 Installation, Operation, and Maintenance Manual 17
Maintenance
Maintenance
Disassembly
Disassembly precautions
WARNING:
• This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion
and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in
their removal.
• Make sure that the pump is isolated from the system and that pressure is relieved before
you disassemble the pump, remove plugs, open vent or drain valves, or disconnect the
piping.
• 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.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
• After you disassemble a gasket joint, always use a new gasket upon reassembly. Never
reuse old gaskets. Failure to follow these instructions can result in serious personal
injury, death, and/or property damage.
Drain the pump
NOTICE:
Make sure that all replacement parts are available before you disassemble the pump for
overhaul.
CAUTION:
• Allow all system and pump components to cool before you handle them to prevent
physical injury.
1. Disconnect the electrical supply and lock it out of service.
2. Loosen the conduit box cover screws and remove the cover.
3. Disconnect the conduit and wiring.
4. Close the isolation valves on the suction and discharge sides of the pump.
You must drain the system if no valves are installed.
5. Open the drain valve.
Do not proceed until liquid stops coming out of the drain valve. If liquid continues to
flow from the drain valve, the isolation valves are not sealing properly and you must
repair them before you proceed.
6. Leave the drain valve open.
Do not close the drain valve until the reassembly is complete.
7. Drain the liquid from the piping and flush the pump if it is necessary.
8. Disconnect all auxiliary piping and tubing.
9. Loosen the volute capscrews but do not remove them.
10. Shift the pump position slightly in order to allow the pressurized water to escape.
18 Series 90 Installation, Operation, and Maintenance Manual
11. Remove the volute capscrews and remove the pump assembly from the volute.
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Determine the seal size
All seals, except the 1.25 in. (3.16 cm), require a spring retainer as part of the seal
assembly.
1. Determine if you have an A or AA-type pump using these diagrams and refer to these
diagrams whenever seal replacement becomes necessary.
The primary feature that distinguishes the A from the AA-type pumps is size. Most
components of the A and AA pump seals are similar, but not interchangeable.
Maintenance
WARNING:
Make certain that the internal pressure is relieved before you continue.
Failure to follow these instructions can result in serious personal injury
and/or property damage.
1. Shaft 8. Volute
2. Slinger 9. Impeller capscrew
3. Bracket coverplate 10. Gauge tapping
4. Volute capscrew 11. Suction
5. Discharge 12. Volute gasket
6. Companion flange 13. Seal assembly
Series 90 Installation, Operation, and Maintenance Manual 19
1
2
3
4
5
6
7
8
9
10
11
12
13
14
4
Maintenance
7. Impeller 14. Shaft sleeve
Figure 2: Size A
1. Shaft 8. Volute
2. Measure the diameter of the shaft sleeve in order to determine nominal seal size.
Remove the seal assembly
1. Remove the motor assembly from the system.
2. Use either a strap wrench or a rag in order to prevent the impeller from turning with
3. For all except the 1.25 in. (3.16 cm) seal assembly, lift the spring retainer and the seal
4. Remove the compression ring from the seal collar by inserting a small screwdriver
2. Slinger 9. Impeller locknut
3. Bracket coverplate 10. Gauge tapping
4. Volute capscrew 11. Suction
5. Discharge 12. Volute gasket
6. Companion flange 13. Seal assembly
7. Impeller 14. Shaft sleeve
Figure 3: Size AA
There are three nominal seal sizes:
• 0.50 in. (1.27 cm)
• 0.75 in. (1.91 cm)
• 1.25 in. (3.16 cm)
one hand while you loosen the impeller nut with the other hand.
spring from the shaft.
underneath the ring and carefully applying an upward force.
20 Series 90 Installation, Operation, and Maintenance Manual
NOTICE:
These seal assemblies consist of a stationary seal insert assembly and a rotating seal
assembly. Each of these components must be replaced when you replace the
mechanical seal. Never replace individual components separately.
5. Remove the ring collar and remaining seal components from the shaft.
6. Use a clean, lint free rag in order to remove any debris that has accumulated in the seal
recess.
Pre-assembly inspections
Guidelines
Before you assemble the pump parts, make sure you follow these guidelines:
• Inspect the pump parts according to the information in these pre-assembly topics
before you reassemble your pump. Replace any part that does not meet the required
criteria.
• Make sure that the parts are clean. Clean the pump parts in solvent in order to remove
oil, grease, and dirt.
NOTICE: Protect machined surfaces while you clean the parts. Failure to do so may
result in equipment damage.
Maintenance
Replacement guidelines
Impeller replacement
This table shows the criteria for replacing the impeller:
Impeller parts When to replace
Impeller vanes
Vane edges When you see cracks, pitting, or corrosion damage
Gaskets, O-rings, and seats replacement
• Replace all gaskets and O-rings at each overhaul and disassembly.
• Inspect the seats. They must be smooth and free of physical defects.
• Replace parts if the seats are defective.
Reassembly
Reassemble the seal assembly
WARNING:
After you disassemble a gasket joint, always use a new gasket upon reassembly. Never
reuse old gaskets. Failure to follow these instructions can result in serious personal injury,
death, and/or property damage.
• When grooved deeper than 1/16 in. (1.6 mm), or
• When worn evenly more than 1/32 in. (0.8 mm)
1. Install the seal insert:
Series 90 Installation, Operation, and Maintenance Manual 21
Maintenance
If your seal size
is...
0.50 in. (1.27 cm)
and 0.75 in. (1.91
cm)
1.25 in. (3.16 cm)
2. Lubricate the rubber seal collar with soapy water.
The rotating seal assembly includes these parts:
• Seal ring
• Bellows
• Seal housing
3. Push the entire rotating seal assembly onto the shaft as one unit.
Do not attempt to assemble the seal by placing the components on the shaft
individually. Align the notches in the collar with the recesses found on each side of the
carbon ring.
4. Press the seal housing tightly against the upper end of the rubber collar.
Use a screwdriver and press at several points along the periphery in order to provide a
tight and even fit. Do not tap on the seal because you can break the ceramic or carbon
insert.
5. Place the seal spring on the shaft and then the spring retainer.
You do not need to do this for the 1.25 in. (3.16 cm) seal.
6. Place the impeller and lockwasher on the shaft.
7. Thread the impeller nut onto the shaft and tighten according to these values:
• 3/8 in. nut to 8 – 12 ft. lbs. (11 – 16 Nm)
• 7/16 in. nut to 17 – 22 ft. lbs (23 – 30 Nm)
• 3/8 in. capscrews to 10 – 14 ft. lbs (14 – 19 Nm)
Do not overtighten.
8. Clean the pump body of excess debris.
9. Place a new gasket in the recess of the pump body.
10. Replace the motor assembly by inserting the impeller in the pump body and evenly
tighten the eight capscrews.
See the Capscrew torque values.
Then...
1. Place the new retainer in the seal recess of the faceplate.
2. Set the thin seat gasket in the recess and set the seat insert on top of the
gasket.
A ceramic insert has a top side and bottom side. The bottom is identifiable by
its slightly recessed grooves.
3. Make sure the grooves face down towards the rubber gasket.
1. Set the seal insert into the elastomeric seat cup.
2. Lubricate the seat cup with soapy water and set it into the recess of the
faceplate.
Capscrew torque values
Capscrew torque in ft-lbs (Nm)
Capscrew
type
SAE grade 2 6 (8) 13 (18) 25 (34) 38 (52) 60 (81) 120 (163) 190 (258) 210 (285) 300 (407)
22 Series 90 Installation, Operation, and Maintenance Manual
Head
marking
1/4 in. 5/16 in. 3/8 in. 7/16 in. 1/2 in. 5/8 in. 3/4 in. 7/8 in. 1 in.
Maintenance
Capscrew
type
Brass or
stainless
steel
SAE grade 5 10 (14) 20 (27) 35 (47) 60 (81) 90 (122) 180 (244) 325 (441) 525 (712) 800 (1085)
Head
marking
or
1/4 in. 5/16 in. 3/8 in. 7/16 in. 1/2 in. 5/8 in. 3/4 in. 7/8 in. 1 in.
4 (5) 10 (14) 17 (23) 27 (37) 42 (57) 83 (113) 130 (176) 200 (271) 300 (407)
Dealer servicing
If trouble occurs that cannot be rectified, contact your local sales and service
representative and be prepared to provide this information:
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 pump hook-up and piping
Series 90 Installation, Operation, and Maintenance Manual 23
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bellgossett
Visit our Web site for the latest version of this
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The original instruction is in English. All nonEnglish instructions are translations of the original
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P81547_D_en.US_2012-09_IOM.Series90
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