Installation,
Operation, and
Maintenance Manual
Series 1510
Table of Contents
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
2
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.
12 Series 1510 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.
Evaluate the installation in order to determine that the Net Positive Suction Head Available
(NPSHA) meets or exceeds the Net Positive Suction Head Required (NPSHR), as stated by
the pump performance curve.
Installation
Pump location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this
equipment can result in serious physical injury and/or equipment damage. Lift equipment
only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and
spreaders must be rated, selected, and used for the entire load being lifted.
Guideline Explanation/comment
Keep the pump as close to the liquid source as
practically possible.
Make sure that the space around the pump is sufficient. This facilitates ventilation, inspection, maintenance, and
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.
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.
Series 1510 Installation, Operation, and Maintenance Manual 13
2
3
1
4
Installation
Guideline Explanation/comment
Take into consideration the occurrence of unwanted
noise and vibration.
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,
Foundation requirements
Requirements
• The foundation must be able to absorb any type of vibration and form a permanent,
rigid support for the unit.
• The foundation must weigh at least 2-1/2 times the weight of the pump unit.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow
movement for the final bolt adjustment.
• Tie the concrete pad in with the finished floor.
• Use foundation bolts and larger pipe sleeves to give room for final bolt location.
Diagram
The best pump location for noise and vibration
absorption is on a concrete floor with subsoil
underneath.
Consider a consultation with a noise specialist.
and provides a positive suction head on the pump.
1. Foundation bolt
2. Pipe sleeve
3. Washer
14 Series 1510 Installation, Operation, and Maintenance Manual
4. Built-up concrete foundation
Piping checklist
Installation
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
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
B&G 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 flexible piping is used on both the suction
and discharge sides of the pump when you use an
isolation base.
Check that a B&G Triple Duty® valve is installed in the
discharge line.
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.
Series 1510 Installation, Operation, and Maintenance Manual 15
—
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.
—
—
4
5
6
7
8
10
9
1
2
3
11
Installation
Pump insulation checklist
Check Checked
Check that the bearing assembly grease fittings are
accessible and visible.
Check that the vent slots on the sides and bottom of the
bearing assembly are uncovered and completely open.
Typical installation
1. Compression tank (locate the compression tank on the suction side of the pump)
2. B&G Rolairtrol® air separator
Special installation
3. Supply to system
4. B&G Circuit Setter
5. B&G Triple Duty® valve
6. B&G Series 1510 Pump
7. B&G Suction Diffuser
8. Isolation valve
9. Pipe from boiler, chiller, or converter
10. Cold water supply
11. B&G Reducing Valve
®
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
16 Series 1510 Installation, Operation, and Maintenance Manual
Installation with isolation base
4
1
5
2
3
6
7
8
When using an isolation base, flexible piping should be used on both suction and
discharge sides to reduce the strain on the flanges.
Install the pump, driver, and coupling
Perform these steps only if the unit was not installed at the factory.
1. Mount and fasten the pump on the baseplate. Use applicable bolts.
2. Mount the driver on the baseplate. Use applicable bolts and hand tighten.
3. Install the coupling.
See the installation instructions from the coupling manufacturer.
Level the base on a concrete foundation
Before leveling and grouting the base, perform an initial alignment. See Pump-to-driver
alignment.
1. Place the pump on its concrete foundation.
2. Place 1.00 in./(25.40 mm) thick steel shims or wedges on both sides of each anchor
bolt in order to support the pump .
This also provides a means of leveling the base.
Installation
1. Pump Base Rail
2. Grout only to top of base rail
3. To keep shims in place, allow non-shrinking grout to flow around hold down lugs.
4. Grout
5. Concrete Foundation
6. Shims
7. 1” (25.40 mm) Gap
8. Allow 1” for shims. Place on both sides of anchor bolts.
Grout the baseplate
Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See
the instructions provided by the grout manufacturer.
• Grout: Non-shrink grout is required.
1. Clean all the areas of the baseplate that will come into contact with the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.
4. Pour grout into the baseplate up to top of the base rails.
Series 1510 Installation, Operation, and Maintenance Manual 17
Installation
To hold wedges or shims in place, allow the grout to flow around them.
When you pour the grout, remove air bubbles from it by using one of these methods:
• Puddle with a vibrator.
• Pump the grout into place.
5. Allow the grout to set.
Coupling alignment
WARNING:
Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious
physical injury.
Alignment guidelines
Follow these guidelines when you align the coupling:
• Only perform alignment by moving or shimming the motor.
• Since adjustments in one direction can alter the alignment in another direction, check
the alignment in all directions after you make a correction.
• Make sure that the pump and motor bolts are tight when you take all measurements.
• Perform a final alignment check after the unit reaches its final operating temperature.
Prepare for alignment
1. Check the pump and motor shafts and remove any paint, burrs, and rust.
2. Slide the hubs and bushings on the shafts with keys.
3. Hold one half element on the hubs in order to determine the appropriate hub spacing.
4. If you use spacer elements with high speed rings, hold both half elements on the hubs
in order to make sure the hubs do not interfere with the rings.
5. You can install the hubs with the hub extension facing in or out.
Make sure the shaft extends into the hubs at least 0.8 times the diameter of the shaft.
6. Lightly fasten the hubs to the shafts in order to prevent them from moving during
alignment.
7. Align the hubs to the values shown in Maximum allowable misalignment for Rexnord
Omega couplings.
You can perform alignment with lasers, dial indicators, or with a straight edge and
calipers.
Align the pump using a straight edge and calipers
1. Check the angular misalignment:
Tool Procedure
Calipers
1. Gauge the distance between the two hubs at various points around the
circumference.
Do not rotate the shafts.
2. Reposition the equipment until the difference between the minimum and maximum
distance values is within the permissible range.
See Maximum allowable misalignment for Rexnord Omega couplings.
18 Series 1510 Installation, Operation, and Maintenance Manual
Tool Procedure
1
2
1
2
Angular Parallel
Installation
Feeler
gauges
1. Insert feeler gauges between the coupling faces at various points around the
circumference.
Do not rotate the shafts.
2. Reposition the equipment until the difference between the minimum and maximum
distance values is within the permissible range.
2. Check the parallel alignment:
a) Place a straight edge across the two hubs.
b) Measure the maximum offset at various points around the periphery of the hubs.
Do not rotate the shafts.
c) Reposition the equipment until the offset is within the permissible range.
See Maximum allowable misalignment for Rexnord Omega couplings.
A E10 coupling with a 3° angular misalignment will have a 0.191 in. (0.485 cm) difference
in measurements between L1 and L2. This is within the 0° to 4° misalignment that is
allowed for that size of coupling.
1. Straight edge
2. Feeler guage
Figure 3: Check the alignment using a straight edge - correct
1. Straight edge
2. Feeler guage
Figure 4: Check the alignment using a straight edge - incorrect
In this figure, the arrows show the angular misalignment:
Series 1510 Installation, Operation, and Maintenance Manual 19
P
A
R
1
1
2
3
Installation
Figure 5: Check the alignment using calipers
Align the pump using a dial indicator
1. Check the angular misalignment:
a) Mount the dial indicator base to one coupling half, or shaft.
b) Position the dial indicator button on the front face or rear face of the opposite
coupling half.
c) Mark the index lines on the coupling halves as this figure shows:
A Angular alignment
P Parallel alignment
1 Dial indicators
2 Index line
3 Resilient separator
d) Set the dial to zero.
20 Series 1510 Installation, Operation, and Maintenance Manual
e) Rotate both coupling halves together and make sure that the index lines remain
1
2
matched.
f) Reposition the equipment until the offset is within the permissible value.
2. Check the parallel misalignment:
a) Mount the dial indicator base to one coupling half, or shaft.
b) Position the dial indicator button on the outside diameter of the opposite coupling
half.
c) Set the dial to zero.
d) Rotate both coupling halves together and make sure that the index lines remain
matched.
e) Reposition the equipment until the offset is within the permissible value.
Align the Rexnord®Omega® coupling
WARNING:
• Install coupling capscrews and setscrews using either a torque wrench or another torque
measuring device. Hardware that is not installed per the listed torque values can become
loose and dislodge from the coupling assembly. Failure to follow these instructions can
result in serious personal injury or death, or property damage.
• Do not use capscrews with damaged or absent thread lock coating. Otherwise, you do
not achieve the required counterforce and the hardware can become loose and
dislodge from the coupling assembly. Failure to follow these instructions can result in
serious personal injury or death, or property damage.
Installation
1. Recheck the hubs to be certain that both the angular and parallel alignments are still
within the proper range.
2. Loosen the setscrew on the pump hub.
3. Torque all element and high speed ring capscrews to the values shown in Fastener
torque values and maximum RPM for Rexnord Omega couplings.
If possible, recheck angular and parallel alignments.
4. Loosely install one half of the coupling opposite the hub setscrews.
5. Loosely install the other half of the element onto the hubs.
6. Install capscrews on the high speed rings.
If the capscrews and the holes in the elements do not line up properly due to hub
misalignment, slightly rotate the shafts.
7. Torque both hub setscrews to the values shown in the Fastener torque values and
maximum RPM for Rexnord Omega couplings table.
For QD or Taperlock hubs, follow the instructions supplied with the bushings.
1. Element
2. Hub
Figure 6: Rexnord Omega coupling – typical spacer
Series 1510 Installation, Operation, and Maintenance Manual 21
1
2
3
4
OUT IN
Installation
1. Setscrew
2. Element
3. Capscrew
4. BTS hub
Figure 7: Rexnord Omega coupling – typical non-spacer
• Omega and Rexnord are registered trademarks of Rexnord Industries, LLC
Maximum allowable misalignment for Rexnord Omega couplings
Table 2: Allowable gap in inches (centimeters)
Coupling size 1° angular
misalignment
E2 0.032 (0.081) 0.065 (0.165) 0.097 (0.247) 0.129 (0.328)
E3 0.040 (0.102) 0.081 (0.206) 0.121 (0.307) 0.162 (0.411)
E4 0.045 (0.114) 0.091 (0.231) 0.136 (0.345) 0.181 (0.460)
E5 0.055 (0.140) 0.109 (0.277) 0.164 (0.417) 0.218 (0.554)
E10 0.064 (0.163) 0.127 (0.323) 0.191 (0.485) 0.218 (0.554)
E20 0.078 (0.198) 0.156 (0.396) 0.234 (0.595) —
E30 0.095 (0.241) 0.189 (0.480) 0.284 (0.721) —
E40 0.116 (0.295) 0.231 (0.587) 0.347 (0.881) —
E50 0.142 (0.361) 0.284 (0.721) 0.425 (1.080) —
E60 0.153 (0.389) 0.305 (0.774) — —
E70 0.161 (0.409) 0.323 (0.820) — —
E80 0.196 (0.498) 0.393 (0.998) — —
2° angular
misalignment
3° angular
misalignment
4° angular
misalignment
22 Series 1510 Installation, Operation, and Maintenance Manual
Parallel
Angular
1
2
3
1. Sizes E2 - E10
2. Sizes E20 - E50
3. Sizes E60 - E80
Fastener torque values and maximum RPM for Rexnord Omega couplings
Installation
Basic size (see
element)
Element and ring
capscrew torque ft-lbs
(Nm)
Standard hubs set
screw torque ft-lbs
(Nm)
Maximum rpm
Standard Spacer
E2 17 (2) 7 (1) 7500 7500
E3 7 (1) 7500 7500
E4 14 (2) 7500 7500
E5 23 (3) 7500 7500
E10 23 (3) 7500 7500
E20 30 (3) 50 (6) 6600 4800
E30 50 (6) 5800 4200
E40 100 (11) 5000 3600
E50 100 (11) 4200 3100
E60 75 (8) 167 (19) 3800 2800
E70 167 (19) 3600 2600
E80 167 (19) 2000 1800
Final alignment
You cannot perform the final alignment until you initially operate the pump long enough to
reach operating temperature. When the pump reaches the normal operating temperature,
then secure the pump and re-check the alignment. Make sure that you compensate for
temperature accordingly.
Series 1510 Installation, Operation, and Maintenance Manual 23
Installation
NOTICE:
Elastomeric couplings are specifically designed to accommodate angular shaft
misalignment, as well as parallel offset of the pump and motor shafts. However, the
amount of the offset and/or misalignment depends on the style of the applied flexible
coupling. If you do not correct this coupling misalignment, there is a significant impact on
the overall life of the mechanical seals and the bearings of the pump.
24 Series 1510 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 at zero flow or with suction and 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.
• 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.
• Run a new or rebuilt pump at a speed that provides enough flow to flush and cool the
close-running surfaces of the stuffing-box bushing.
• 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. Lock out power to the driver.
2. Make sure that the coupling hubs are fastened securely to the shafts.
3. Unlock power to the driver.
4. 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 1510 Installation, Operation, and Maintenance Manual 25
Commissioning, Startup, Operation, and Shutdown
5. Lock out power to the driver.
Start the pump
CAUTION:
• Immediately observe the pressure gauges. If discharge pressure is not quickly attained,
stop the driver, reprime, and attempt to restart the pump.
• 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
correct discharge pressure.
5. If the pump fails to reach the correct pressure, perform these steps:
a) Stop the driver.
b) Prime the pump again.
c) Restart the driver.
6. Monitor the pump while it is operating:
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
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.
26 Series 1510 Installation, Operation, and Maintenance Manual
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.
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.
Commissioning, Startup, Operation, and Shutdown
Make the final alignment of the pump and driver
WARNING:
• Always disconnect and lock out power to the driver before you perform any installation
or maintenance tasks. Failure to disconnect and lock out driver power will result in
serious physical injury.
• Follow shaft alignment procedures in order to prevent catastrophic failure of drive
components or unintended contact of rotating parts. Follow the coupling installation and
operation procedures from the coupling manufacturer.
You must check the final alignment after the pump and driver are at operating
temperature. For initial alignment instructions, see the Installation chapter.
1. Run the unit under actual operating conditions for enough time to bring the pump,
driver, and associated system to operating temperature.
2. Shut down the pump and the driver.
3. Remove the coupling guard.
See Remove the coupling guard in the Maintenance chapter.
4. Check the alignment while the unit is still hot.
See Pump-to-driver alignment in the Installation chapter.
5. Reinstall the coupling guard.
6. Restart the pump and driver.
Note on the packed pump operation
Tighten the gland nuts
Before you start the pump, back off the packing gland nuts or screws until the gland is
loose.
Hand tighten until the gland is snug against the first packing ring. Initially, water might
freely run from the packing. This is normal and should be allowed to continue for a period
of time before you continue to tighten the gland. Tighten the gland nuts slowly and one
flat at a time.
Series 1510 Installation, Operation, and Maintenance Manual 27
Commissioning, Startup, Operation, and Shutdown
Leakage rate
An adequate leakage rate is not one single value for all pumps and installations, but is the
amount required to provide adequate cooling and lubrication. The required leakage is
influenced by operating pressure, fluid temperature, shaft speed, and so forth. For fluid
temperatures in the range of 32°F to 190°F (0°C to 88°C), average leakage rates of 60 to
80 drops per minute are recommended. However, each individual pump and installation
has unique operating conditions that result in widely-variable leakage rate requirements.
Maximum fluid temperature
At fluid operating temperatures near the upper limit of 190°F (88°C), the maximum
temperature rise of the leakage is important. Never operate a packed pump with steam
forming at the gland. This limits the temperature rise to a maximum of about 20°F (-7°C). If
the formation of steam persists at higher leakage rates, you must provide cooling water by
means of an external supply, or a heat exchanger used to cool the bypass flush.
28 Series 1510 Installation, Operation, and Maintenance Manual
Maintenance
Bearing maintenance
Bearing lubrication schedule
Type of bearing First lubrication Lubrication intervals
Grease-lubricated bearings N/A Regrease bearings every 2500
Regrease the grease-lubricated bearings
NOTICE:
Make sure that the grease container, the greasing device, and the fittings are clean. Failure
to do this can result in impurities entering the bearing housing when you regrease the
bearings.
1. Wipe dirt from the grease fittings.
2. Fill both of the grease cavities through the fittings with a recommended grease until
the fresh grease comes out of the relief holes.
3. Wipe off any excess grease.
4. Recheck the alignment.
Maintenance
operating hours or every six months.
The bearing temperature usually rises after you regrease due to an excess supply of
grease. Temperatures return to normal in about two to four operating hours as the pump
runs and purges the excess grease from the bearings.
Lubricating grease requirements
NOTICE:
• Never mix greases of different consistencies (NLGI 1 or 3 with NLGI 2) or with different
thickeners. For example, never mix a lithium-based grease with a polyurea-based
grease. This can result in decreased performance.
• Remove the bearings and old grease if you need to change the grease type or
consistency. Failure to do so can result in equipment damage or decreased
performance.
Specifications
• Regrease the pump while the pump is running.
• Regrease the pump bearing with NLGI grade 2 lithium base petroleum grease.
• Regrease the pump every 2500 operating hours or every six months.
• Lubricate the motor per the motor manufacturer's instructions.
• Always keep the pump and motor properly lubricated.
Disassembly
Disassembly precautions
This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to.
Series 1510 Installation, Operation, and Maintenance Manual 29
Maintenance
Drain the pump
WARNING:
• 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.
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. Close the isolation valves on the suction and discharge sides of the pump.
You must drain the system if no valves are installed.
2. 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.
3. Leave the drain valve open and remove the drain plug located on the bottom of the
pump housing.
Do not reinstall the plug or close the drain valve until the reassembly is complete.
4. Drain the liquid from the piping and flush the pump if it is necessary.
5. Disconnect all auxiliary piping and tubing.
Remove the hex coupling guard
1. Remove the two capscrews that hold the outer (motor side) coupling guard to the
support brackets.
2. Spread the outer guard apart and pull it off the inner guard.
Do not spread the outer and inner guards more than necessary to remove the guard. It
could alter their fit and appearance.
3. Remove the capscrew that holds the inner guard to the support bracket.
4. Spread the inner guard apart and pull it over the coupling.
30 Series 1510 Installation, Operation, and Maintenance Manual
1
2
3
4
5
6
12
10
9
8
7
11
Maintenance
1. Outer guard
2. Inner guard
3. Attach the support bracket inline with the bolt
4. Support bracket
5. Nut
6. Lockwasher
7. Capscrew
8. Flat washer
9. Spacer washer
10. Option used instead of the spacer where overall guard length exceeds 12 in. (30 cm) or the guard width is
over 10 in. (25 cm) across the flats
11. Locate the support arm between the outer guard ends. Align the arm with holes in the outer guard and
holes in the saddle bracket.
12. Motor saddle bracket attached to the motor saddle
Figure 8: Hex guard exploded view for typical installation
Remove the coupling
1. Loosen the setscrews in both coupling halves.
2. Slide each half as far back as possible on the shaft.
3. Remove the sleeve.
If you use a full-diameter impeller, you might have to remove the pump-side coupler half
and slide the motor back on its base. This allows you to gain sufficient clearance in order to
remove the pump assembly from the volute.
Remove the bearing frame and impeller assembly
1. Remove the support foot capscrews.
2. Loosen the volute capscrews but do not remove them.
3. Use the capscrews in the jackscrew holes for all models except for the 1510-8G.
4. Loosen the bearing frame and impeller assembly from the volute.
5. Remove the seal flushing tube if it is used.
Series 1510 Installation, Operation, and Maintenance Manual 31
WARNING:
Make certain that the internal pressure of the pump is relieved before
you continue. Failure to follow these instructions could result in serious
personal injury or death, or property damage.
Maintenance
6. Remove the volute capscrews.
7. Remove the bearing frame and impeller assembly from the volute.
Remove the impeller
WARNING:
Never apply heat to remove an impeller. The use of heat may cause an explosion due to
trapped liquid, resulting in severe physical injury and property damage.
CAUTION:
Wear heavy work gloves when you handle impellers. The sharp edges can cause physical
injury.
1. For all models except the 1510-8G, remove the impeller capscrew.
2. Remove these parts:
• For all models except the 1510-8G, remove the lockwasher and the washer.
• For the 1510-8G, remove the impeller nut and the washer.
3. Remove the impeller.
4. Remove the impeller key.
Remove the mechanical seal (1510 and 1510-F)
1. Remove the rotating portion of the seal.
If necessary, use a screwdriver to loosen the rubber ring.
2. Remove the seal insert, the insert gasket, and the retainer if it is used.
Remove the seal or packing rings (1510-S, 1510-D, 1510-PF, and 1510-8G)
1. Remove the hex nuts from the seal cap bolts.
2. For the 1510-8G, remove the spacer sleeve and the hex nuts that hold the packing
gland to the stuffing box.
3. Remove the coverplate screws.
4. Remove the coverplate from the bracket.
5. Remove the seal assembly or packing rings.
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.
Replacement guidelines
Impeller replacement
This table shows the criteria for replacing the impeller:
32 Series 1510 Installation, Operation, and Maintenance Manual
Impeller parts When to replace
Maintenance
Impeller vanes
Vane edges When you see cracks, pitting, or corrosion damage
Gaskets, O-rings, and seatsreplacement
• 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.
Shaft and sleeve inspection
Inspection criteria
Inspect the shaft and sleeve according to this criteria:
• Thoroughly clean the shaft and sleeve.
• Thoroughly clean the coverplate seal cavity.
• Inspect the surface for damage such as pitting, corrosion, nicks, and scratches.
Replace these parts if they are damaged.
Bearing frame inspection
Check the bearing frame for these conditions:
• Visually inspect the bearing frame and support foot for cracks.
• Inspect the bearing frame for smooth and free operation.
• Inspect the bearing frame for contamination by pumped fluids.
Repair or replace the bearing frame as necessary.
• When grooved deeper than 1/16 in. (1.6 mm), or
• When worn evenly more than 1/32 in. (0.8 mm)
Reassembly
Seal assembly
Assemble the standard mechanical seal (1510 and 1510-F)
1. Lubricate the shaft sleeve and coverplate seal cavity with soapy water.
Do not use a petroleum lubricant.
2. Install a new insert gasket.
3. Install a new seal insert and make sure that the indentation is against the insert gasket.
4. Slide a new rotating seal assembly onto the shaft sleeve.
5. Push the top of the compression ring with a screwdriver until the seal is tight against
the seal insert.
6. Install the seal spring and point the narrow end toward the seal.
Series 1510 Installation, Operation, and Maintenance Manual 33
2
1
3
4
5
6
7
8
9
11
13
14
16
17
18
10
12
15
Maintenance
1. Impeller
2. Vent Plug
3. Volute
4. Volute Gasket
5. Coverplate
6. Seal Assembly
7. Bearing Frame
8. Shaft
9. Support Foot
10. Support Foot Capscrews
11. Slinger
12. Bearing Frame Capscrews
13. Shaft Sleeve
14. Impeller Key
15. Impeller Washer
16. Impeller Lock Washer
17. Drain Plug
18. Impeller Capscrew
Figure 9: 1510, 1510–F
Assemble the standard mechanical seal (1510-8G)
1. Lubricate the outer surface of the shaft sleeve, the interior of the stuffing box, and the
seal elastomer with soapy water.
Do not use a petroleum lubricant.
2. Install the stationary element and rotating assembly of the mechanical seal on the shaft
sleeve.
Make sure that the two wearing surfaces face each other and that the rotating half of
the seal is installed closest to the impeller end.
3. Install the seal spring and spring retainer onto the shaft sleeve.
4. Slide the coverplate onto the bearing frame.
5. Apply Dow Corning Silicone Rubber #732 or an equivalent to the shaft at the sleeve
location.
6. Slide the shaft sleeve onto the shaft and spin the sleeve in order to distribute the
sealant.
34 Series 1510 Installation, Operation, and Maintenance Manual
5
4
2
1
15
14
13
16
12
11
10
9
8
7
3
6
17
Maintenance
7. Wipe off any excess sealant.
8. Slide the seal gland on the shaft and make sure that the flat side faces the stuffing box.
1. Impeller Key
2. Spacer Sleeve
3. Gland
4. Shaft Sleeve
5. Shaft
6. Bearing Frame
7. Slinger
8. Mechanical Seal
9. Coverplate
10. O-Ring
11. Drain Plug
12. Impeller
13. Impeller Nut
14. Volute
15. Flush Tube
16. Wearing Ring
17. View of Optional Casing Wear Ring
Figure 10: 1510–8G
Assemble the single mechanical seal (1510-S)
1. Lubricate the shaft sleeve and seal cap with soapy water.
Do not use a petroleum lubricant.
2. Insert a stationary seal with an O-ring into the seal cap and slide it onto the shaft.
3. Replace the seal cap gasket.
4. Slide the rotating portion of the seal assembly onto the shaft sleeve and lock it in place.
ID seal size Distance between collar and impeller end of the shaft sleeve
1-1/4 in. (3.175 cm) 1-13/32 in. (3.571 cm)
1-5/8 in. (4.128 cm) 1-1/4 in. (3.175 cm)
2-3/8 in. (6.033 cm) 1-1/4 in. (3.175 cm)
5. Assemble the coverplate onto the bracket.
6. Tighten the capscrews according to the Capscrew torque table.
7. Attach the seal cap to the coverplate.
Series 1510 Installation, Operation, and Maintenance Manual 35
2
3
4
5
6
7
9
1
8
Maintenance
8. Tighten the hex nuts on the seal cap bolts according to the Capscrew torque table.
1. O-ring
2. Coverplate
3. For 1-1/4 in. seal: 1-13/32 in. (3.571 cm)
4. For 1-5/8 in. seal and 2-2/3 in. seal; 1-1/4 in. (3.175 cm)
5. Seal locking collar
6. Seal cap bolt
7. Seal cap
8. O-ring
9. Motor end
Figure 11: 1510–S
Assemble the double mechanical seal (1510-D)
1. Lubricate the shaft sleeve, seal cap, and coverplate cavity with soapy water.
Do not use a petroleum lubricant.
2. Insert a stationary seal and O-ring into the seal cap.
For the 1-1/4 in. ID seal, both parts are housed in the coverplate. A seal cap gasket is
not used.
36 Series 1510 Installation, Operation, and Maintenance Manual
1
2
1
Maintenance
1. O-rings
2. Motor end
Figure 12: 1510–D
3. Insert another stationary seal and O-ring into the coverplate.
4. Slide the seal cap onto the shaft.
5. Replace the seal cap gasket.
6. Slide the rotating portion of the seal assembly onto the shaft sleeve.
7. Assemble the coverplate onto the bracket.
8. Tighten the capscrews according to the Capscrew torque values table.
9. Attach the seal cap to the coverplate.
10. Tighten the hex nuts on the seal cap bolts according to the Capscrew torque values
table.
Impeller installation
Install the impeller (all except the 1510-8G)
1. Install the impeller, impeller washer, lock washer, and capscrew.
2. Tighten the capscrew according to the Capscrew torque values table.
Install the impeller (1510-8G)
1. Install the spacer sleeve over the shaft sleeve.
2. Install the impeller key, impeller, washer, and impeller nut.
3. Tighten the impeller nut to 25-30 ft-lbs (34-41 Nm).
4. Install and tighten the gland nuts evenly against the stuffing box.
Series 1510 Installation, Operation, and Maintenance Manual 37
1
2
3
5 4
6
7
8
11
12
13
14
16
20
19
910
15
17
18
Maintenance
Assemble the packed stuffing box (1510-PF)
1. Impeller
2. Volute
3. Volute Gasket
4. Coverplate
5. Coverplate Capscrews
6. Flushing Tube
7. Lantern Ring
8. Packing
9. Packing Gland
10. Bearing Frame
11. Shaft
12. Slinger
13. Shaft Sleeve
14. Bracket
15. Impeller Key
16. Impeller Washer
17. Volute Capscrews
18. Impeller Lock Washer
19. Drain Plug
20. Impeller Capscrew
1. Insert two packing rings into the stuffing box.
2. Insert the lantern ring and the last two pieces of packing.
Make sure that the joints on the packing rings are staggered 90º.
3. Install, but do not tighten, the packing gland.
4. Install the coverplate over the pump shaft.
5. Tighten the capscrews according to the Capscrew torque table in the Maintenance
chapter.
6. Tighten the packing gland to compress the packing.
See the note on the packed pump operation in the Operations chapter for more
information.
38 Series 1510 Installation, Operation, and Maintenance Manual
Reinstall the bearing frame and impeller assembly (all except 1510-8G)
1. Install a new volute gasket.
2. Install the bearing frame assembly into the volute.
3. Tighten the volute capscrews according to the Capscrew torque values table.
4. Install a seal flushing tube if it is used.
5. Install the support foot capscrews and tighten them according to the Capscrew torque
values table.
6. Install and align the coupling.
7. Install the drain plug and close the drain valve.
Reinstall the bearing frame and impeller assembly (1510-8G)
1. Inspect the volute O-ring for damage and replace it if necessary.
2. Install the O-ring around the coverplate seat.
3. Slide the bearing frame and impeller assembly into the volute.
The coverplate flush tube fitting must be on the top.
4. Install the volute capscrews and gradually tighten them in a star pattern.
Tighten the capscrews to 25 to 30 ft-lbs (34 to 41 Nm).
5. Install and align the coupling.
6. Install the drain plug and close the drain valve.
Maintenance
Install the hex coupling guard
1. Slide the inner guard into the outer guard.
2. Spread the guards and place them over the coupling.
Do not spread the inner and outer guards more than necessary for guard installation,
as it can alter their fit and appearance.
3. Straddle the support bracket with the guards and install a capscrew through the hole
in the support bracket and guard located closest to the pump.
Do not tighten the capscrew.
4. Install the outer guard capscrews according to the directions in this table.
If... Then...
The pump has a motor saddle
support bracket
The pump does not have a motor
saddle support bracket
5. Position the outer guard so that there is less than 1/4 in. (0.64 cm) of exposed shaft.
6. Hold the guard in this position and tighten the three capscrews.
7. Open the isolation valves and inspect the pump for leaks.
8. Return the pump to service if it is not leaking.
Ensure that the outer guard straddles the support arm and install the two
remaining capscrews.
Do not tighten the capscrews.
Insert the spacer washer between the holes located closest to the motor in
the outer guard and install the two remaining capscrews.
Do not tighten the capscrews.
Series 1510 Installation, Operation, and Maintenance Manual 39
Maintenance
Capscrew torque values
Capscrew torque
This table contains the capscrew torque values.
Table 3: Capscrew torque, Ft-Lb (Nm) table
Dealer servicing
Capscrew
type
SAE grades
1 and 2
Stainless
steel
SAE grade 5 8 (11) 17 (23) 30 (41) 50 (68) 76 (103) 48 (65)
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
Head
marking
1/4 in. 5/16 in. 3/8 in. 7/16 in. 1/2 in. 5/8 in.
3 (4) 6 (8) 10 (14) 16 (22) 24 (33) 46 (62)
3 (4) 6 (8) 10 (14) 16 (22) 24 (33) 46 (62)
40 Series 1510 Installation, Operation, and Maintenance Manual
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The original instruction is in English. All nonEnglish instructions are translations of the original
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2012 Xylem Inc.
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P81673_H_en.US_2012-11_IOM.1510
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