Xylem P81673H User Manual

Installation,

Operation, and

Maintenance Manual

Series 1510

Introduction and Safety.........................................................................................................................3

Introduction..........................................................................................................................................3

Safety.....................................................................................................................................................3

Safety message levels......................................................................................................................3

Safety instruction decals..................................................................................................................4

User safety.........................................................................................................................................5

Environmental safety........................................................................................................................7

Product warranty.................................................................................................................................7

Transportation and Storage..................................................................................................................9

Inspect the delivery.............................................................................................................................9

Inspect the package.........................................................................................................................9

Inspect the unit..................................................................................................................................9

Lifting methods....................................................................................................................................9

Long-term storage............................................................................................................................10

Product Description.............................................................................................................................11

General description..........................................................................................................................11

Operational speciﬁcations...............................................................................................................11

Table of Contents

Installation.............................................................................................................................................13

Preinstallation....................................................................................................................................13

Pump location guidelines..............................................................................................................13

Foundation requirements.............................................................................................................14

Piping checklist...............................................................................................................................15

Pump insulation checklist..............................................................................................................16

Typical installation..........................................................................................................................16

Special installation..........................................................................................................................16

Install the pump, driver, and coupling...........................................................................................17

Level the base on a concrete foundation.......................................................................................17

Grout the baseplate..........................................................................................................................17

Coupling alignment..........................................................................................................................18

Prepare for alignment....................................................................................................................18

Align the pump using a straight edge and calipers...................................................................18

Align the pump using a dial indicator.........................................................................................20

Align the Rexnord®Omega® coupling........................................................................................21

Maximum allowable misalignment for Rexnord Omega couplings........................................22

Fastener torque values and maximum RPM for Rexnord Omega couplings.........................23

Final alignment...............................................................................................................................23

Commissioning, Startup, Operation, and Shutdown......................................................................25

Preparation for startup.....................................................................................................................25

Check the rotation..........................................................................................................................25

Start the pump...................................................................................................................................26

Pump operation precautions...........................................................................................................26

Shut down the pump........................................................................................................................27

Make the ﬁnal alignment of the pump and driver........................................................................27

Note on the packed pump operation.............................................................................................27

Maintenance.........................................................................................................................................29

Bearing maintenance........................................................................................................................29

Regrease the grease-lubricated bearings...................................................................................29

Series 1510 Installation, Operation, and Maintenance Manual 1

Table of Contents

Lubricating grease requirements.................................................................................................29

Disassembly.......................................................................................................................................29

Disassembly precautions...............................................................................................................29

Drain the pump...............................................................................................................................30

Remove the hex coupling guard..................................................................................................30

Remove the coupling.....................................................................................................................31

Remove the bearing frame and impeller assembly...................................................................31

Remove the impeller......................................................................................................................32

Remove the mechanical seal (1510 and 1510-F) ......................................................................32

Remove the seal or packing rings (1510-S, 1510-D, 1510-PF, and 1510-8G) .......................32

Pre-assembly inspections.................................................................................................................32

Replacement guidelines................................................................................................................32

Shaft and sleeve inspection..........................................................................................................33

Bearing frame inspection..............................................................................................................33

Reassembly........................................................................................................................................33

Seal assembly..................................................................................................................................33

Impeller installation........................................................................................................................37

Assemble the packed stufﬁng box (1510-PF) ............................................................................38

Reinstall the bearing frame and impeller assembly (all except 1510-8G) .............................39

Reinstall the bearing frame and impeller assembly (1510-8G)................................................39

Install the hex coupling guard......................................................................................................39

Capscrew torque values................................................................................................................40

Dealer servicing .............................................................................................................................40

2 Series 1510 Installation, Operation, and Maintenance Manual

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.

Introduction and Safety

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.

• 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.

Safety message levels

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

Series 1510 Installation, Operation, and Maintenance Manual 3

Introduction and Safety

Deﬁnitions

Safety message level Indication

NOTICE:

DANGER:

WARNING:

CAUTION:

Electrical Hazard:

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

The possibility of electrical risks if instructions are not followed in a proper manner

• A potential situation which, if not avoided, could result in undesirable conditions

• A practice not related to personal injury

Safety instruction decals

Alert symbol

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.

4 Series 1510 Installation, Operation, and Maintenance Manual

Decals

P70642

P70643

(2) Required (1 Each Side)

Alternate

Location

P70644

P70820

Introduction and Safety

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.

Make sure that all safety instruction decals are always clearly visible and readable.

User safety

General safety rules

Safety equipment

Series 1510 Installation, Operation, and Maintenance Manual 5

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

Introduction and Safety

• First-aid kit

• Safety devices

Electrical connections

Electrical connections must be made by certiﬁed electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing speciﬁcally with electrical connections.

Precautions before work

Observe these safety precautions before you work with the product or are in connection with the product:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that all safety guards are in place and secure.

• Make sure that 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.

NOTICE:

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

property.

Precautions during work

Observe these safety precautions when you work with the product or are in connection with the product:

• Never work alone.

• Always wear protective clothing and hand protection.

• Stay clear of suspended loads.

• Always lift the product by its lifting device.

• Beware of the risk of a sudden start if the product is used with an automatic level

• Beware of the starting jerk, which can be powerful.

• Rinse the components in water after you disassemble the pump.

• Do not exceed the maximum working pressure of the pump.

• Do not open any vent or drain valve or remove any plugs while the system is

• Never operate a pump without a properly installed coupling guard.

Wash the skin and eyes

control.

pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

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

6 Series 1510 Installation, Operation, and Maintenance Manual

Condition Action

Introduction and Safety

Chemicals or hazardous ﬂuids in eyes

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.

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.

Electrical installation

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

Recycling guidelines

Always follow local laws and regulations regarding recycling.

Product warranty

Coverage

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.

Limitations

The warranty does not cover defects caused by these situations:

• Deﬁcient maintenance

• Improper installation

Series 1510 Installation, Operation, and Maintenance Manual 7

Introduction and Safety

Warranty claim

• Modiﬁcations or changes to the product and installation made without consulting an Xylem authorized representative

• Incorrectly executed repair work

• Normal wear and tear

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.

8 Series 1510 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

Lifting methods

WARNING:

• Assembled units and their components are heavy. Failure to properly lift and support

this equipment can result in serious physical injury and/or equipment damage. Lift equipment only at the speciﬁcally identiﬁed lifting points. Lifting devices such as eyebolts, slings, and spreaders must be rated, selected, and used for the entire load being lifted.

• Crush hazard. The unit and the components can be heavy. Use proper lifting methods

and wear steel-toed shoes at all times.

• Do not attach sling ropes to shaft ends.

Table 1: Methods

Pump type Lifting method A bare pump without lifting

handles

A base-mounted pump. Use slings under the pump casing and the drive unit, under the base rails, or

Use a suitable sling attached properly to solid points like the casing, the ﬂanges, or the frames.

through lifting lugs, when provided.

Series 1510 Installation, Operation, and Maintenance Manual 9

Transportation and Storage

Examples

Figure 1: Example of a proper lifting method

Figure 2: Example of a proper lifting method using lifting lugs

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.

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 sales and service representative.

10 Series 1510 Installation, Operation, and Maintenance Manual

Product Description

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 bronze-ﬁtted construction

• Foot-mounted volute with back pullout bearing frame

• Center drop-out coupler

• Regreasable bearings

Intended applications

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.

The pump is intended for use with these pumped ﬂuids:

• Unheated domestic and fresh water

• Boiler feed water

• Condensate

• Hydronic cooling or heating

• Benign liquids

• Pressure boosting

• General liquid transfer

Product Description

Rotation

Pump rotation is clockwise when viewed from the back of the motor. An arrow is also located on the pump to show the direction of rotation.

Operational speciﬁcations

Mechanical seal speciﬁcations

This table describes the speciﬁcations of each mechanical seal type.

Seal type Parameter Value Standard seals, BUNA pH range limits for BUNA pH 7–9

Standard seals, EPT pH range limits for EPT pH 7–11

Flushed single seals

1,3,4

Liquid temperature range that complies with the pH range limits for BUNA

Liquid temperature range that complies with the pH range limits for EPT

pH range limits pH 7–9

Liquid 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)

Series 1510 Installation, Operation, and Maintenance Manual 11

Product Description

Seal type Parameter Value Flushed double seals

1,3,4

pH range limits pH 7–9

0˚F to 250˚F (-18˚C to 121˚C)

0˚F to 200˚F (-18˚C to 93˚C)

Packing

Liquid temperature range

pH range pH 7–9

Liquid temperature range

Table notes

1. An external ﬂush is required on low pressure systems that contain a high

concentration of abrasives.

2. Use packing on open or closed systems which require a large amount of makeup water, as well as systems that are subjected to a wide variety of chemical conditions and solids buildup.

3. For operating temperatures above 250°F, a cooled ﬂush is required and is

recommended for temperatures above 225°F for optimum seal life. On closed systems, cooling is accomplished by inserting a small heat exchanger in the ﬂush line to cool the seal ﬂushing ﬂuid.

4. Flush-line ﬁlters and sediment separators are available on request.

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