instruction manual - National Pump Supply

INSTRUCTION MANUAL
AC2008_Rev E
Series HSC³ Base Mounted
Centrifugal Pump
Table of Contents
Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.2 Safety..................................................................................................................................... 3
1.2.1 Safety terminology and symbols.................................................................................3
1.2.2 Safety instruction decals.............................................................................................. 4
1.3 User safety.............................................................................................................................5
1.4 Protecting the environment................................................................................................6
2 Transportation and Storage...................................................................................................... 7
2.1 Inspect the delivery..............................................................................................................7
2.1.1 Inspect the package..................................................................................................... 7
2.1.2 Inspect the unit..............................................................................................................7
2.2 Safe handling requirements............................................................................................... 7
2.3 Storage requirements..........................................................................................................9
3 Product Description................................................................................................................. 10
3.1 General description...........................................................................................................10
3.2 Operational specifications................................................................................................10
3.3 Nameplate information..................................................................................................... 11
4 Installation................................................................................................................................. 12
4.1 Preinstallation..................................................................................................................... 12
4.1.1 Pump location guidelines.......................................................................................... 12
4.1.2 Typical installation...................................................................................................... 13
4.1.3 Foundation requirements..........................................................................................13
4.1.4 Level the base on a concrete foundation ............................................................... 14
4.1.5 Grout the baseplate....................................................................................................15
4.2 Coupling alignment...........................................................................................................15
4.2.1 Prepare for alignment................................................................................................ 15
4.2.2 Align the pump using a straight edge and calipers............................................... 16
4.2.3 Align the pump using a dial indicator......................................................................17
4.2.4 Final alignment............................................................................................................18
4.2.5 Optional alignment procedure.................................................................................18
4.2.6 Dowel the pump and driving unit.............................................................................18
4.2.7 Coupler limitations..................................................................................................... 19
4.3 Piping checklists.................................................................................................................19
4.3.1 Piping checklist........................................................................................................... 19
4.3.2 Suction piping checklist............................................................................................. 20
5 Commissioning, Startup, Operation, and Shutdown.......................................................... 23
5.1 Preparation for startup...................................................................................................... 23
5.1.1 Pre-start checks........................................................................................................... 23
5.1.2 Priming......................................................................................................................... 24
5.1.3 Starting......................................................................................................................... 24
5.1.4 Operating checks....................................................................................................... 24
5.1.5 Check the rotation...................................................................................................... 24
5.1.6 Freezing protection.................................................................................................... 25
5.1.7 Change the rotation................................................................................................... 25
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
1
Table of Contents
6 Maintenance..............................................................................................................................27
6.1 Maintenance schedule...................................................................................................... 27
6.2 Flood-damaged pumps.................................................................................................... 28
6.3 Bearing maintenance........................................................................................................ 28
6.3.1 Regrease the grease-lubricated bearings............................................................... 28
6.3.2 Lubricating grease requirements............................................................................. 29
6.4 Shaft-seal maintenance..................................................................................................... 29
6.4.1 Mechanical seal maintenance................................................................................... 29
6.5 Cleaning without dismantling the pump........................................................................ 29
6.6 Disassembly........................................................................................................................30
6.6.1 Disassembly precautions........................................................................................... 30
6.6.2 Drain the pump........................................................................................................... 30
6.6.3 Remove the hex coupling guard.............................................................................. 30
6.6.4 Replace the mechanical seals and bearings without removing the upper
half of the casing.............................................................................................................. 31
6.6.5 Dismantling the pump when it is required to remove the rotating element
of the pump...................................................................................................................... 33
6.7 Pre-assembly inspections................................................................................................. 35
6.7.1 Replacement guidelines............................................................................................ 35
6.7.2 Shaft inspection...........................................................................................................35
6.8 Dimensions......................................................................................................................... 35
6.9 Reassembly.........................................................................................................................35
6.9.1 Assembly of the mechanical seals and bearings without removing the
upper half of the casing.................................................................................................. 35
6.9.2 Reassembly of the pump when it is required to remove the rotating element.. 37
6.9.3 Install the hex coupling guard...................................................................................42
6.9.4 Assembly references.................................................................................................. 43
7 Troubleshooting....................................................................................................................... 45
7.1 Operation troubleshooting.............................................................................................. 45
8 Product warranty...................................................................................................................... 49
2
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
1 Introduction and Safety
1 Introduction and Safety
1.1 Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
1.2 Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Operating, installing, or maintaining the unit in any way that is not covered in this
manual could cause death, serious personal injury, or damage to the equipment. This
includes any modification to the equipment or use of parts not provided by Xylem. If
there is a question regarding the intended use of the equipment, please contact a
Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result
in physical injury, damage, or delays.
1.2.1 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level
Indication
DANGER:
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
A hazardous situation which, if not avoided, will result in
death or serious injury
3
1 Introduction and Safety
Hazard level
Indication
WARNING:
A hazardous situation which, if not avoided, could result
in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result
in minor or moderate injury
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
NOTICE:
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard
Magnetic fields hazard
Electrical Hazard:
CAUTION:
1.2.2 Safety instruction decals
WARNING:
The maximum working pressure of the pump is listed on the nameplate. Do not exceed
this pressure. Failure to follow these instructions can result in serious personal injury,
death, and/or property damage.
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.
Decals
Make sure your pump has these safety instruction decals and that they are located as this
figure shows. If the decals are missing or illegible, contact your local sales and service
representative for a replacement.
4
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
1 Introduction and Safety
DO NOT RUN PUMP DRY, SEAL
DAMAGE MAY OCCUR.
INSPECT PUMP SEAL
REGULARLY FOR LEAKS,
REPLACE AS REQUIRED.
LUBRICATION REQUIREMENTS
CONSULT MANUALS.
PUMP: POLYUREA-BASED GREASE
FAILURE TO FOLLOW
INSTRUCTIONS COULD
RESULT IN INJURY OR
PROPERTY DAMAGE.
P2002458
Make sure that all safety instruction decals are always clearly visible and readable.
1.3 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.
• 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.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Electrical connections
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.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
5
1 Introduction and Safety
• Make sure that the product cannot roll or fall over and injure people or damage
property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product has been thoroughly cleaned.
• Disconnect and lock out power before you service the pump.
• Check the explosion risk before you weld or use electric hand tools.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition
Action
Chemicals or hazardous fluids in
eyes
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.
Chemicals or hazardous fluids on
skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.4 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless
Xylem has been informed and appropriate actions have been agreed upon.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
6
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
2 Transportation and Storage
2 Transportation and Storage
2.1 Inspect the delivery
2.1.1 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.
2.1.2 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 the local sales representative if there is any issue.
Shipping information
• Pumps and drivers are normally shipped from the factory mounted and painted with
primer and one finish coat.
• Couplings are shipped either assembled or have the coupling hubs mounted on the
shafts and the connecting members removed.
• When the connecting members are removed, they will be packaged in a separate
container and shipped with the pump or attached to the base plate.
Shaft alignment
• Shafts are in alignment when the unit is shipped; however, misalignment can occur
due to shipping.
• Refer to recommended alignment procedures in this manual if it is necessary to realign
the shaft.
2.2 Safe handling requirements
WARNING:
• Personal protective equipment should be worn when handling this equipment.
• Transportation & installation of this equipment should only be performed by qualified
personnel.
• A professional rigging company should be consulted before lifting the pump
assembly.
• Only use properly sized, certified lifting equipment & lifting devices, including slings,
suitably rated for the weights to be lifted.
• Slings, when used, must be of identical materials to avoid differences in stretch rates.
• Do not use lifting devices that are frayed, kinked, unmarked, or worn.
• Lifting eyebolts fitted on single components of the assembly (pump or motor) must not
be used to lift the complete assembly.
• Failure to observe these instructions could result in equipment or property damage,
serious injury, or death.
The pump assembly can arrive in a variety of ways:
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
7
2 Transportation and Storage
• Pump end only (bare pump)
• Pump less motor
• Pump, motor, & baseplate
Use the following recommended ways of handling HSC pump assemblies.
• The pump assembly should remain horizontal during transport and lifting.
• Lifting the pump end only (bare pump) should be done by placing one end of the
slings around or as close to the casing barrel as possible. After the slings are attached
to the unit, recheck to ensure they are securely in place. Make sure the slings are
adjusted to obtain an even lift.
Figure 1: Lifting pump end only with nylon sling, chain, or wire rope
• Lifting the pump less motor or the pump, motor, & baseplate should be done by
utilizing a forklift under the entire unit. Always take extra precaution to ensure the
weight is balanced & equally distributed across both forks. When the baseplate of the
assembly is structural channel construction, the pump and base plate should be set in
place first. The motor should then be separately lifted & mounted to the unit.
• Pump, base, and driver assemblies where the base length exceeds 100 inches may not
be safe to lift as a complete assembly. Damage to the baseplate may occur. If the
driver has been mounted on the baseplate at the factory, it is safe to lift the entire
assembly. If driver has not been mounted at the factory and the overall baseplate
length exceeds 100 inches, do not lift the entire assembly consisting of pump, base,
and driver. Instead lift the pump and baseplate to its final location without the driver.
Then mount the driver.
8
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
2 Transportation and Storage
Figure 2: Lift using a forklift
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and
vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
2.3 Storage requirements
If the unit will not be installed and put into operation immediately upon arrival at the site,
or for an extended shutdown after the unit is in operation, the following requirements for
short-term storage apply:
• Store in a covered and dry location.
• Store the unit free from excessive cold or heat (below 32°F and above 110°F), dirt, and
vibration.
• Rotate the shaft by hand several times (10–15 turns) at least every 30 days.
For initial storage longer than three months, or for pump shut down after being in
operation longer than three months, contact your local sales and service representative
for long-term storage guidelines.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
9
3 Product Description
3 Product Description
3.1 General description
Description
The pump is a centrifugal, frame-mounted pump. The following pump features make it
easy to install, operate, and service:
• High efficiency
• Rugged construction
• Compact design
• Foot-mounted volute
• Center drop out coupler
• regreasable bearings
• Horizontal split case
Mechanical seal types
Mechanical
seal
• Preferred over packing on some applications because of better sealing qualities and longer
serviceability.
• Leakage is eliminated when a seal is properly installed and normal life is much greater than that
of packing on similar applications.
• Pumps containing single mechanical seals normally utilize the pumped liquid to lubricate the
seal faces. This method is preferred when the pumped liquid is neither abrasive nor corrosive.
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’s bronze fitted construction make it ideal for use with the following liquids:
• Unheated domestic and fresh water
• Boiler feed water
• Condensate
• Hydronic cooling or heating
• Pressure boosting
• General pumping
• Benign liquids
3.2 Operational specifications
Maximum working pressure
The maximum working pressure is listed on the pump nameplate.
10
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
3 Product Description
Mechanical seal specifications
Seal type
Parameter
Value
Standard self-flushing
pH range limits for BUNA
pH 7–9
Liquid temperature range that
-20˚F to 225˚F (-29˚C to 107˚C)
complies with the pH range limits for
BUNA
pH range limits for EPT
pH 7–11
Liquid temperature range that
-20˚F to 250˚F (-29˚C to 121˚C)
complies with the pH range limits for
EPT
Table notes
1. For use on closed or open systems which are relatively free of dirt and/or other
abrasive particles.
3.3 Nameplate information
The pump nameplate gives identification and rating information about the pump.
Permanent records for this pump are kept by the serial number and it must be used will all
correspondence and spare parts orders.
Nameplate
1
2
3
4
5
6
Bell & Gossett
7
1.
2.
3.
4.
5.
6.
7.
8.
9.
8
9
Impeller diameter
Pump rotation — for example, LHR = left hand rotation
Pump size — for example, 8 x 8 x 17M
Serial number — for example, 1–21937–1–1
Driver HP
Identification number — for example, Month and year = CWP-11
Pump series and model number
Duty points — GPM, feet, RPM
Maximum working pressure
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
11
4 Installation
4 Installation
4.1 Preinstallation
Precautions
WARNING:
• When installing in a potentially explosive environment, make sure that the motor is
properly certified.
• You must ground (earth) all electrical equipment. This applies to the pump equipment,
the driver, and any monitoring equipment. Test the ground (earth) lead to verify that it
is connected correctly.
• Motors without built-in protection must be provided with contactors and thermal
overload protection for single-phase motors, or starters with heaters for three-phase
motors. (See the nameplate on the drive unit to select properly-sized overloads.)
NOTICE:
Supervision by an authorized Xylem representative is recommended to ensure proper
installation. Failure to do so may result in equipment damage or decreased performance.
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.
4.1.1 Pump location guidelines
WARNING:
Assembled units and their components are heavy. Failure to properly lift and support this
equipment can result in serious physical injury and/or equipment damage. Lift equipment
only at the specifically identified lifting points. Lifting devices such as eyebolts, slings, and
spreaders must be rated, selected, and used for the entire load being lifted.
Guideline
Explanation/comment
Keep the pump as close to the liquid source as practically
possible.
If the pump is not on a closed system, locate the pump so
that the fewest number of bends or elbows in the suction
pipe are needed.
This minimizes the friction loss and keeps the suction
piping as short as possible.
Make sure that the space around the pump is sufficient.
This facilitates ventilation, inspection, maintenance,
and service.
If you require lifting equipment such as a hoist or tackle,
make sure that there is enough space above the pump.
This makes it easier to properly use the lifting
equipment and safely remove and relocate the
components to a safe location.
Protect the unit from weather and water damage due to
rain, flooding, and freezing temperatures.
This is applicable if nothing else is specified.
Do not install and operate the equipment in closed systems Acceptable devices:
unless the system is constructed with properly-sized safety
• Pressure relief valves
devices and control devices.
• 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.
12
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
4 Installation
Guideline
Explanation/comment
Take into consideration the occurrence of unwanted noise
and vibration.
The best pump location for noise and vibration
absorption is on a concrete floor with subsoil
underneath.
If the pump location is overhead, undertake special
precautions to reduce possible noise transmission.
Consider a consultation with a noise specialist.
Make sure there is a suitable power source available for the The electrical supply must match the motor nameplate
pump driver.
specifications.
4.1.2 Typical installation
1
9
8
2
3
7
6
4
5
1.
2.
3.
4.
5.
6.
7.
8.
9.
Compression tank (locate the compression tank on the suction side of the pump)
Air separator
Supply to system
Circuit setter
Triple duty valve
Isolation valve
From boiler chiller or converter
Cold water supply
Reducing valve
4.1.3 Foundation requirements
Requirements
• A substantial foundation and footing should be built to suit local conditions and form a
rigid support to maintain alignment.
• The foundation must be able to absorb any type of vibration and form a permanent,
rigid support for the unit.
• Pour the foundation without interruption to within 1/2 to 1–1/2 inches of the finished
height.
• The top surface of the foundation should be scored and grooved before the concrete
sets. This provides a bonding surface for the grout.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion
when you tighten the foundation bolts.
• Sleeve-type and J-type foundation bolts are most commonly used. Both designs allow
movement for the final bolt adjustment.
• Allow the foundation to cure for several days before you proceed with the pump
installation.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
13
4 Installation
Diagram
• An optional 4–inch long tube around the bolts at the top of the concrete allows some
flexibility in bolt alignment to match the holes in the baseplate.
• Allow enough bolt length for grout, shims, lower baseplate flange, nuts, and washers.
1
2
5
3
4
1.
2.
3.
4.
5.
Foundation bolt
Pipe sleeve
Washer
Built-up concrete foundation
Optional 4–inch tube around the bolts
4.1.4 Level the base on a concrete foundation
1. Place the pump on its concrete foundation.
2. Place 1.00 in./(25.40 mm) thick steel shims or wedges on both sides of each anchor
bolt in order to support the pump .
This also provides a means of leveling the base.
Add and remove shims under the base to level and plumb the pump shaft and flanges.
The baseplate does not have to be level.
7
1
2
3
4
6
5
1.
2.
3.
4.
5.
6.
7.
Locate the shims to allow removal after grouting.
Grout only to top of base rail
Pump base rail
Grout
Concrete foundation
1” (25.40 mm) Gap
Allow 1” for shims. Place on both sides of anchor bolts.
3. Draw anchor bolts tight against the base and observe pump and motor shafts or
coupling hubs for alignment.
Temporarily remove the coupling guard for checking alignment.
4. If the alignment needs improvement, add shims or wedges at appropriate positions
under the base so that retightening of anchor nuts shifts shafts into closer alignment.
Repeat this procedure until a reasonable alignment is reached.
A reasonable alignment is that which is agreed upon by the pump contractor and the
accepting facility. Final alignment procedures are covered in “Alignment procedures.”
14
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
4 Installation
5. Check to make sure that the piping can be aligned to the pump flanges without
placing pipe strain on either flange.
6. Grout the baseplate. See “Grout the baseplate.”
4.1.5 Grout the baseplate
Required equipment:
• Cleaners: Do not use an oil-based cleaner because the grout will not bond to it. See
the instructions provided by the grout manufacturer.
• Grout: Non-shrink grout is required.
1.
2.
3.
4.
Clean all the areas of the baseplate that will come into contact with the grout.
Build a dam around the foundation.
Thoroughly wet the foundation that will come into contact with the grout.
Pour grout through the grout hole into the baseplate up to the level of the dam.
When you pour the grout, remove air bubbles from it by using one of these methods:
– Puddle with a vibrator.
– Pump the grout into place.
5. After the grout has thoroughly hardened, check the foundation bolts and tighten if
necessary. Check alignment after tightening the bolts.
6. After the grout has dried, apply an oil base paint to the exposed edges to prevent
moisture from coming in contact with the grout.
4.2 Coupling alignment
WARNING:
Always disconnect and lock out power to the driver before you perform any installation or
maintenance tasks. Failure to disconnect and lock out driver power will result in serious
physical injury.
Alignment guidelines
Follow these guidelines when you align the coupling:
• Only perform alignment by moving or shimming the motor.
• Make allowances for thermal expansion during cold alignment so that the coupling is
aligned at operating temperature.
• 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.
• Make final alignment by moving and shimming the motor on the baseplate until the
coupling hubs are within the recommended tolerances measured in total runout.
NOTICE:
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.
4.2.1 Prepare for alignment
1. Check the pump and motor shafts and remove any paint, burrs, and rust.
2. Slide the hubs and bushings on the shafts with keys.
3. Hold one half element on the hubs in order to determine the appropriate hub spacing.
4. If you use spacer elements with high speed rings, hold both half elements on the hubs
in order to make sure the hubs do not interfere with the rings.
5. You can install the hubs with the hub extension facing in or out.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
15
4 Installation
Make sure the shaft extends into the hubs at least 0.8 times the diameter of the shaft.
6. Lightly fasten the hubs to the shafts in order to prevent them from moving during
alignment.
7. Align the hubs to the values shown in Maximum allowable misalignment for couplings.
You can perform alignment with lasers, dial indicators, or with a straight edge and
calipers.
4.2.2 Align the pump using a straight edge and calipers
For standard sleeve type coupler with black rubber insert
Before aligning the coupler, make sure there is at least 1/8” end clearance between the
sleeve and the two coupler halves.
1. Check the angular misalignment:
Tool
Procedure
Calipers
1. Measure the outside of one flange to the outside of the opposite flange at four points 90°
apart. Do not rotate coupler. Misalignment of up to 1/64 per inch of coupler radius is
permissible.
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 coupler halves.
b) Measure the maximum offset at four points 90° apart. Do not rotate coupler.
c) Reposition the equipment until the gap is within the 1/64” permissible offset.
A 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
2
1. Straight edge
2. Feeler guage
Figure 3: Check the alignment using a straight edge - correct
1
Angular
2
Parallel
1. Straight edge
2. Feeler gauge
Figure 4: Check the alignment using a straight edge - incorrect
16
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
4 Installation
In this figure, the arrows show the angular misalignment:
Figure 5: Check the alignment using calipers
4.2.3 Align the pump using a dial indicator
• Make sure that each hub is secured to its respective shaft and that all connecting
and/or spacing elements are removed at this time.
• The gap between the coupling hubs is set by the manufacturer before the units are
shipped. However, this dimension should be checked. Refer to the coupling
manufacturer’s specifications supplied with the unit.
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:
P
1
2
R
3
A
A
Angular alignment
P
Parallel alignment
1
Dial indicators
2
Index line
1
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
17
4 Installation
3
Resilient separator
d) Set the dial to zero.
e) Rotate both coupling halves together and make sure that the index lines remain
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.
f) Assemble coupling. Tighten all bolts and set screw(s). It may be necessary to repeat
steps for a final check.
For single element couplings, a satisfactory parallel misalignment is .004” T.I.R., while a
satisfactory angular misalignment is .004” T.I.R. per inch of radius R.
4.2.4 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.
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.
4.2.5 Optional alignment procedure
If desired, the pump and motor feet can be doweled to the base after final alignment is
complete. This should not be done until the unit has been run for a sufficient length of
time and alignment is with the tolerance. See doweling section.
NOTE: Pump may have been doweled to base at factory.
4.2.6 Dowel the pump and driving unit
1. Drill holes through diagonally opposite feet and into the base. Holes must be of a
diameter 1/64 inch less then the diameter of the dowel pins.
2. Ream the holes in feet and base to the proper diameter for the pins (light push fit).
Clean out the chips.
3. Insert pins to be approximately flush with feet.
18
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
4 Installation
4.2.7 Coupler limitations
Brand
TB Wood’s
Sure-Flex
(Neoprene
sleeve)
TB Wood’s
Sure-Flex
(Hytrel Sleeve)
Suitable for
Minimum
Allowable installation misalignment limits
variable speed recommended Coupler size Parallel (inch) Angular (inch
application
speed
or degree)
Y Dimension
(inch)
3
0.010
0.035
1.188
4
0.010
0.043
1.500
5
0.015
0.056
1.938
6
0.015
0.070
2.375
7
0.020
0.081
2.563
8
0.020
0.094
2.938
9
0.025
0.109
3.500
10
0.025
0.128
4.063
11
0.032
0.151
4.875
12
0.032
0.175
4.688
13
0.040
0.195
6.688
14
0.045
0.242
7.750
3
—
—
—
4
—
—
—
5
—
—
—
6
0.010
0.016
2.375
7
0.012
0.020
2.563
8
0.015
0.025
2.938
9
0.017
0.028
3.500
10
0.020
0.032
4.063
11
0.022
0.037
4.875
12
0.025
0.042
5.688
13
0.030
0.050
6.625
14
0.035
0.060
7.750
50% of full
speed
Yes
No
N/A
Maximum
temperature
Minimum
temperature
200°F
–0°F
250°F
–65°F
4.3 Piping checklists
4.3.1 Piping checklist
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 hightemperature 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.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
19
4 Installation
Check
Explanation/Comment
Always run piping to the pump.
Do not move pump to pipe. This could make final
alignment impossible.
Check that the suction and discharge piping are
supported independently near the pump and properly
aligned.
This helps to avoid strain on the pump when the flange
bolts are tightened.
Check that pipe hangers or other supports are installed.
Place supports at necessary intervals.
Check if expansion joints are installed correctly.
When expansion joints are used in the piping system,
they must be installed beyond the piping supports
closest to the pump. Tie bolts should be used with
expansion joints to prevent pipe strain. Do not install
expansion joints next to the pump or in any way that
would cause a strain on the pump resulting in system
pressure changes.
Check that pipe size is larger at pump connections.
It is usually advisable to increase the size of both suction
and discharge pipes at the pump connection to decrease
the loss of head from friction.
Install piping as straight as possible to avoid unnecessary Use 45 degree or long sweep 90 degree fitting to
bends.
decrease friction losses.
Make sure that all piping joints are air tight.
Where flanged joints are used, assure that inside
diameters match properly.
Do not “spring” piping when making any connections.
Provide for pipe expansion when hot fluids are to be
pumped.
4.3.2 Suction piping checklist
The sizing and installation of the suction piping is extremely important. It must be selected
and installed so that pressure losses are minimized and sufficient liquid flows into the
pump when it is started and operated. Many NPSH problems can be directly attributed to
improper suction piping systems.
Piping checklist
Check
Explanation/comment
Checked
Keep the suction piping short in length, as If the suction pipe is short, the pipe diameter can be
direct as possible, and never smaller in
the same size as the suction opening. If longer suction
diameter than the pump suction opening. piping is required, pipes should be one or two sizes
larger than the opening depending on piping length.
Check that the elbows in the suction piping
for horizontal double-suction pumps are
installed per the Hydraulics Institute
Standards since there is always an uneven
turbulent flow around an elbow.
When there is an elbow in a position other than the
vertical when in relation to the pump suction nozzle,
this causes more liquid to enter one side of the
impeller than the other. The result is highly
unequalized thrust loads that overheat the bearings
and cause rapid wear, which adversely affects the
hydraulic performance. See the Example of
unbalanced loading figure.
Check that pipe reducers on the inlet side
have no more than one pipe diameter
reduction in a single reducer.
This avoids excessive turbulence and noise.
When operating on a suction lift, check that A horizontal suction line must have a gradual rise to
the suction pipe slopes upward to the
the pump. Any high point in the pipe can become
pump nozzle.
filled with air and prevent proper operation of the
pump.
20
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
4 Installation
Check
Explanation/comment
(Optional) You can install a short section of
pipe adjacent to the suction flange such as
Dutchman or a spool piece that is designed
so that it can be readily dropped out of the
line.
This facilitates the cleansing of the liquid passage of
the pump without dismantling the pump. With this
arrangement, anything that clogs the impeller is
accessible with the removal of the spool piece or pipe
section.
Checked
Example of unbalanced loading
This figure shows the unbalanced loading of a double-suction impeller due to the uneven
flow around an elbow that is adjacent to the pump:
1
5
4
1.
2.
3.
4.
5.
3
2
Pump casing
Impeller
Pump suction flange
Suction elbow
Water velocity increases here and causes a greater flow to one side of the impeller.
Examples
2
3
4
1
1.
2.
3.
4.
Level centerline of pipe
Check valve
Gate valve
Increaser
Figure 6: Suction pipe installed with a gradual rise to the pump – correct
1
1. Air pocket
Figure 7: Suction pipe installed with a gradual rise to the pump – incorrect
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
21
4 Installation
1
1. Air pocket
Figure 8: Suction pipe installed with a reducer – incorrect
1
1. Air pocket
Figure 9: Incorrect
2
1
1. No air pockets
2. Gradual rise
Figure 10: Correct
1
3
2
1. No air pockets
2. Eccentric reducer
Figure 11: Gradual rise to the pump – correct
1
1. Distance plus eccentric reducer straightens the flow
Figure 12: Suction pipe above the pump – correct
1
1. Path of the water
Figure 13: Suction pipe above the pump – incorrect
22
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
5 Commissioning, Startup, Operation, and Shutdown
5 Commissioning, Startup,
Operation, and Shutdown
5.1 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.
• 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.
• Make sure that all components are properly guarded or insulated when operating at
extremely high or low temperatures.
NOTICE:
• 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.
You must follow these precautions before you start the pump:
• Flush and clear the system thoroughly to remove dirt or debris in the pipe system in
order to prevent premature failure at initial startup.
• 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.
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.
5.1.1 Pre-start checks
Before initial start of the pump, make the following inspections:
1. Check alignment between pump and motor.
2. Check all connections to motor and starting device with wiring diagram. Check
voltage, phase, and frequency on motor nameplate with line circuit.
3. Check suction and discharge piping and pressure gauges for proper operation.
4. Check impeller adjustment, see specific section for proper adjustment.
5. Turn rotating element by hand to assure that it rotates freely.
6. Check driver lubrication.
7. Assure that pump bearings are properly lubricated.
8. Assure that coupling is properly lubricated, if required.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
23
5 Commissioning, Startup, Operation, and Shutdown
9. Assure that pump is full of liquid (see priming) and all valves are properly set and
operational, with the discharge valve closed, and the suction valve open.
10.Check rotation. Be sure that the driver operates in the direction indicated by the arrow
on the pump casing as serious damage can result if the pump is operated with
incorrect rotation. Check rotation each time the motor leads have been disconnected.
5.1.2 Priming
Type of installation
Procedure
Positive head on the suction
Open the suction and vent valve and allow the liquid to enter the
casing.
Suction lift
Use other methods such as foot valves, ejectors or by manually filling
the casing and suction line.
5.1.3 Starting
1. Close drain valves and valve in discharge line.
2. Open fully all valves in the suction line.
3. Prime the pump.
NOTE: If the pump does not prime properly, or loses prime during start-up, it should
be shut down and the condition corrected before the procedure is repeated.
4. When the pump is operating at full speed, open the discharge valve slowly. This
should be done after start-up to prevent damage to pump by operating at zero flow.
5.1.4 Operating checks
1. Check the pump and piping to assure that there are no leaks.
2. Check and record pressure gauge readings for future reference.
3. Check and record voltage, amperage per phase, and kw if an indicating wattmeter is
available.
4. Check bearings for lubrication and temperature. Normal temperature is 180°F
maximum.
5. Make all pump output adjustments with the discharge line.
CAUTION:
• Do not throttle the suction line to adjust the pump output.
• Do not let heated pump temperature rise above 150°F.
5.1.5 Check the rotation
WARNING:
• Operating the pump in reverse rotation can result in the contact of metal parts, heat
generation, and breach of containment.
• 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.
CAUTION:
Never operate the pump without liquid supplied to mechanical seal. If you run a
mechanical seal dry, even for a few seconds, this can cause seal damage. Physical injury
can occur if a mechanical seal fails.
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.
3. Lock out power to the driver.
24
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
5 Commissioning, Startup, Operation, and Shutdown
5.1.6 Freezing protection
NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump
and connected pipes. Failure to do so can cause liquid to freeze and damage the pump.
Pumps that are shut down during freezing conditions should be protected by one of the
following methods:
• Drain the pump; remove all liquids from the casing.
• Keep fluid moving in the pump and insulate or heat the pump to prevent freezing.
5.1.7 Change the rotation
The pump can be operated left hand or right hand when viewed from the pump end of
the pump. If you wish to reverse the suction and discharge nozzles, this can be
accomplished with the same pump as follows. IMPORTANT: Refer to the disassembly and
assembly procedures in this manual for proper disassembly and assembly techniques.
1. Remove the impeller from the shaft, turn it 180° and replace it on the shaft. Note:
Impeller can only come off from the outboard end.
2. With the rotating element out of the casing, remove the casing from the bedplate and
turn 180°.
3. Set the rotating element back in the casing and reassemble the pump.
– The impeller and casing are in the same relationship to each other as they were
originally. The shaft and motor are also in the same relationship to each other as
they were originally.
4. Reassemble pump and realign the coupling as called for in the alignment procedures.
WARNING:
Never operate a pump without a properly installed coupling guard.
Personal injury will occur if you run the pump without a coupling guard.
5. The rotation of the motor must be changed by switching the motor leads.
– Unless the motor rotation is reversed, the impeller will run backward.
1
1
3
2
2
4
5
Figure 14: Correct relationship of impeller and casing
1.
2.
3.
4.
5.
Rotation
Discharge
Suction
Left-hand rotation viewed from the pump end
Right-hand rotation viewed from the pump end
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
25
5 Commissioning, Startup, Operation, and Shutdown
Figure 15: Main joint bolts
26
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
6 Maintenance
6.1 Maintenance schedule
CAUTION:
Shorten the inspection intervals if the pumped liquid is abrasive or corrosive, or if the
environment is classified as potentially explosive.
NOTICE:
This timetable assumes that the unit has been constantly monitored after startup. Adjust
the timetable for any extreme or unusual applications or conditions.
Monthly inspections
Check the bearing temperature with a thermometer. Do not check the temperature by
hand. If the bearings are running over 180°F (82°C), then there is too much or too little
lubricant.
If changing the lubricant or adjusting to the proper level does not correct the condition,
then disassemble and inspect the bearings.
Three-month inspections
Perform these tasks every three months:
• Check the oil on oil-lubricated units.
• Check the grease-lubricated bearings for saponification. This condition is usually
caused by the infiltration of water or other fluid. Saponification gives the grease a
whitish color. If this condition occurs, then wash out the bearings with a clean industrial
solvent and replace the grease with the proper type as recommended.
Six-month inspections
Perform these tasks every six months:
• Take vibration readings on the bearing housings. Compare the readings with the last
set of readings to check for possible pump component failure.
• Check the shaft for scoring.
• Check the alignment of the pump and driver. Shim the units if necessary. If
misalignment reoccurs frequently, then inspect the entire piping system. Unbolt the
piping at the suction and discharge flanges to see if it springs away, which indicates
strain on the casing. Inspect all piping supports for soundness and effective support of
load. Correct as necessary.
Annual inspections
Perform these inspections one time each year:
• Remove the upper half of the casing. Inspect the pump thoroughly for wear. Order
replacement parts if necessary.
• Check the wear ring clearances. Replace the wear rings when clearances become
three times their normal clearance or when you observe a significant decrease in
discharge pressure for the same flow rate.
• Remove any deposit or scaling.
• Clean out the stuffing box piping.
• Measure the total dynamic suction and discharge head in order to test pump
performance and pipe condition. Record the figures and compare them with the
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
27
6 Maintenance
figures of the last test. This is especially important where the pumped liquid tends to
form a deposit on internal surfaces.
• Inspect foot valves and check valves. A faulty foot or check valve will cause poor
performance. The check valve safeguards against water hammer when the pump
stops.
6.2 Flood-damaged pumps
If the pump is properly sealed at all joints and connected to both suction and discharge,
then it will exclude outside liquid. Therefore, it is only necessary to service the bearings,
stuffing box, and coupling after flood damage.
Perform the following service on a centrifugal pump after a flooded condition:
• Dismantle the frame, and then inspect the bearings for any rusted or badly worn
surfaces. Clean as necessary. If the bearings are free from rust and wear, then
reassemble and relubricate them with one of the recommended lubricants.
Depending on the length of time the pump has remained in the flooded area, it is
unlikely that bearing replacement is necessary. Only replace the bearings if rust or
worn surfaces appear.
• Inspect the stuffing box and clean out any foreign matter that will clog the box. Clean
and thoroughly flush mechanical seals.
• Dismantle and thoroughly clean the couplings. Lubricate the couplings where required
with one of the lubricants recommended by the coupling manufacturer.
6.3 Bearing maintenance
Bearing lubrication schedule
Type of bearing First lubrication, First lubrication,
assembled pumps replacement bearings
and replacement
bearing frames
Greaselubricated
bearings
Not applicable,
Hand pack bearings
lubricated before before pressing on the
shipment
shaft. After bearing
frame assembly, follow
relube instructions to
lube bearings.
Lubrication interval, pump, polyurea-based grease,
operating hours
• 3600 hours, 2 pole
• 7200 hours, 4 pole
• 50% for severe conditions: dirty, wet and/or
above 100°F (38°C) ambient
• 50% for bearing frame temperature above 180°F
(82°C)
• 75% for lithium-based grease
6.3.1 Regrease the grease-lubricated bearings
It is important to lubricate pumps and motors that require regreasing with the proper
grease. See the motor service instructions and nameplate for motor regreasing
information. Pumps are to be regreased using the grease types listed below or approved
equal. Always keep pump and motor properly lubricated.
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. With fully enclosed coupling guards, regrease pump while pump is running.
a) With old style open ended guards, stop pump, re-grease, and hand turn shaft
before re-starting.
2. Wipe dirt from the grease fittings before greasing.
3. Fill both of the grease cavities through the fittings with the recommended grease. Stop
when grease leaks out at shaft.
28
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
4. If needed, stop pump and wipe off excess grease.
5. Restart pump.
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. Maximum normal bearing housing
temperature for polyurea-based grease is 225°F (107°C) and for lithium-based grease
180°F (82°C).
6.3.2 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 — grease types
Polyurea-based greases
Lithium-based greases, NLGI 2
Pumps built on or after Dec 1, 2014 use Polyurea-based Pumps built before Dec 1, 2014 were built with Lithiumgreases. See date code label and lubrication label on
based greases, NLGI 2, and do not have lubrication label
pump or bearing frame indicating polyurea-base grease on pump or bearing frame indicating pump grease type
ExxonMobil PolyrexTM EM
Shell Gadus® S2 V100 2 (was Alvania RL 2)
Chevron SRI NLGI 2
Chevron Multifak® EP 2
Shell Gadus® S5 T100 2
ExxonMobil UnirexTM N2
6.4 Shaft-seal maintenance
6.4.1 Mechanical seal maintenance
Keep in mind the following general rules regarding mechanical seal maintenance. Refer
to the instructions provided by the seal manufacturer for detailed information.
• Mechanical seals are precision products that must be treated with care. Use special
care when handling seals. Make sure that oil and parts are clean in order to prevent
scratching the finely lapped sealing faces. Even light scratches on these faces can
result in leaky seals.
• Mechanical seals typically require no adjustment or maintenance except for routine
replacement of worn or broken parts.
• A used mechanical seal should not be put back into service unless the sealing faces
have been replaced or relapped. Relapping is practical only for seals that are 2 in. (5.1
cm) or larger.
For optimum seal life, always follow these precautions:
• Keep the seal faces as clean as possible.
• Keep the seal as cool as possible.
• Make sure the seal always has proper lubrication.
• If the seal is lubricated with filtered fluid, then clean the filter frequently.
6.5 Cleaning without dismantling the pump
A short section of pipe so designed that it can be readily dropped out of the line can be
installed adjacent to the suction flange. With this arrangement, any matter clogging the
impeller is accessible by removing the pipe section.
If the pump cannot be freed of clogging after the above methods have been tried,
dismantle the unit as previously described to locate the trouble.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
29
6 Maintenance
6.6 Disassembly
6.6.1 Disassembly precautions
This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to.
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.
6.6.2 Drain the pump
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.
6.6.3 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 HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
2
1
11
3
5
6
7
8
9
4
12
10
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 16: Hex guard exploded view for typical installation
6.6.4 Replace the mechanical seals and bearings without removing the upper half of the
casing
WARNING:
• Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
• Extreme temperature hazard: Allow pump temperatures to reach acceptable levels
before proceeding. Open drain valve, do not proceed until liquid stops coming out of
the drain valve. If liquid does not stop flowing from drain valve, isolation valves are not
sealing and should be repaired before proceeding. After liquid stops flowing from
drain valve, leave drain valve open and continue. Remove the drain plug located on
the bottom of the pump housing. Do not reinstall plug or close drain valve until
reassembly is completed. Failure to follow these instructions could result in property
damage and/or moderate personal injury.
1. Close valves on suction and discharge sides of pump. If no valves have been installed,
it will be necessary to drain the system.
2. Remove the coupler guard. For spacer coupler, loosen the capscrews which secure the
coupler flanges to the coupler hubs. Remove the coupler flanges and sleeves by
compressing the flanges and pulling out from beneath the hubs or by loosening the
allen set screws and sliding the hubs back on the shaft. Remove the coupler hubs from
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
31
6 Maintenance
3.
4.
5.
6.
the pump shaft. For non-spacer couplers, loosen set screws and slide flanges back on
shafts and remove rubber element.
Remove the capscrews from each of the bearing housings and remove the bearing
housings by placing two 2.0” long full-threaded capscrews or allen set screws in the
jackscrew holes provided.
Bend back the lockwasher tab and remove both the lockwasher and locknut from the
outboard end of the shaft (the opposite side of the coupling).
Remove the socket-head capscrews holding the gland plates to the stuffing boxes.
Insert threaded rods into the tapped holes in the gland plate and install a fixture on the
threaded rods to use a puller. See illustration below for dimensions of the Universal
Fixture PN: AC2394.
7. Using the puller, tighten the bolt in the center of the fixture to remove the bearing and
gland plate from the shaft. (See photos below)
8. Remove the inboard bearings and gland plate in the same manner.
NOTE: the locknut and lockwasher are not used on the inboard bearing.
32
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
CAUTION:
Do not reuse ball bearings.
9. Remove the mechanical seal head form the pump shaft.
NOTE: To ease the removal of the mechanical seal heads, you may want to use 2 allen
wrenches as hooks or form hooks from wire.
10.Drive the lip-seals, the mechanical seal seats, from each of the gland plates by tapping
on them from the rear.
11.Remove the O-rings from each of the gland plates.
6.6.5 Dismantling the pump when it is required to remove the rotating element of the
pump
WARNING:
• Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
• Extreme temperature hazard: Allow pump temperatures to reach acceptable levels
before proceeding. Open drain valve, do not proceed until liquid stops coming out of
the drain valve. If liquid does not stop flowing from drain valve, isolation valves are not
sealing and should be repaired before proceeding. After liquid stops flowing from
drain valve, leave drain valve open and continue. Remove the drain plug located on
the bottom of the pump housing. Do not reinstall plug or close drain valve until
reassembly is completed. Failure to follow these instructions could result in property
damage and/or moderate personal injury.
1. Close valves on suction and discharge sides of pump. If no valves have been installed,
it will be necessary to drain the system.
2. Remove the coupler guard. For spacer coupler, loosen the capscrews which secure the
coupler flanges to the coupler hubs. Remove the coupler flanges and sleeves by
compressing the flanges and pulling out from beneath the hubs or by loosening the
allen set screws and sliding the hubs back on the shaft. Remove the coupler hubs from
the pump shaft. For non-spacer couplers, loosen set screws and slide flanges back on
shafts and remove rubber element.
3. Remove all casing main joint capscrews and dowel pins.
4. Tighten the jacking screws in the upper half of the casing to separate the upper and
lower casing halves. Then lift off the upper half of the casing.
5. Tap the stuffing boxes with a soft-headed hammer to break the seal between the
stuffing box and lower casing half, and lift the rotating element out of the lower casing.
Rotating element may be removed to a suitable location for repair.
Note: A spare rotating element can be installed at this point. (See photo below)
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
33
6 Maintenance
6. Remove the capscrews from each of the bearing housings and remove the bearing
housings by placing two capscrews in the jackscrew holes provided.
7. Bend back the lockwasher tab and remove both the lockwasher and locknut from the
outboard end of the shaft (the opposite side of the coupling).
8. Remove the capscrews holding gland plate to the stuffing box.
9. Insert threaded rods into the tapped holes in the gland plate and install a fixture on the
threaded rods to use a puller (See illustration in section “Replace the Mechanical Seals
and Bearings Without Removing Upper Half of the Casing”, step 6, for dimensions of
Universal Fixture). Using the puller, tighten the bolt in the center of the fixture to
remove the bearings and gland plate from the shaft. If the bearing does not come off
the shaft, insert a spacer between the center bolt and the shaft, and retighten the bolt.
Remove the inboard bearing and gland plate in the same manner. See photos in “To
Replace the Mechanical Seals and Bearings Without Removing Upper Half of the
Casing”, step 7.
Note: The locknut and lockwasher are not used on the inboard bearing.
10.Remove the gland plates from the stuffing boxes and remove the O-rings from the
stuffing boxes.
CAUTION:
Do not reuse ball bearings.
11.Remove the mechanical seal head from the pump shaft.
12.Drive the lip-seals, the mechanical seal seats, from each of the gland plates by tapping
on them from the rear.
13.Remove O-rings from each of the gland plates.
14.Remove the two casing rings from the impeller and remove the O-rings from each of
the casing rings.
15.Remove the impeller-retaining ring with retaining pliers. See photo below. Heat the
impeller hub on both ends to 350°F maximum, and pull or push the impeller from the
shaft. (Instead of heating the impeller, you may press impeller off the shaft, if press is
available).
NOTE: Press away from the coupling end.
NOTE: For impellers with replaceable rings; remove the rings, if necessary, by cutting
with a cold chisel.
16.Remove the impeller key from the shaft.
34
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
6.7 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.
6.7.1 Replacement guidelines
Impeller replacement
This table shows the criteria for replacing the impeller:
Impeller parts
Impeller vanes
Vane edges
When to replace
• When grooved deeper than 1/16 in. (1.6 mm), or
• When worn evenly more than 1/32 in. (0.8 mm)
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.
6.7.2 Shaft inspection
Inspection criteria
Inspect the shaft according to this criteria:
• Thoroughly clean the shaft .
• 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.
6.8 Dimensions
6.9 Reassembly
6.9.1 Assembly of the mechanical seals and bearings without removing the upper half of
the casing
NOTE: All bearings, O-rings, and lip-seals should be replaced with new parts during
assembly. All reusable parts should be cleaned of foreign matter before reassembly.
NOTE: Reassemble the pump by starting on the outboard end (the opposite the
coupling). This end locks the rotating element into position in the casing.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
35
6 Maintenance
1. Press the stationary mechanical seal seat into the gland plate until it bottoms out
against the bore. Lightly lubricate the bore to ease assembly. (See photo below)
2. Press a new lip seal into the gland plate. Before installing the lip seal, lubricate the lipseal with lightweight oil.
NOTE: Lip seals should sit against the machined shoulder in the gland plate. The lip
seal should face away from the mechanical seal seat (see photo below)
3. Lubricate and roll the O-ring into the grove in the gland plate.
IMPORTANT: Steps 4 and 5 must be completed within 10 to 12 minutes to assure
proper placement of the mechanical seals.
4. Lightly coat the outboard end of the pump shaft with P-80 Rubber Lubricant Emulsion,
vegetable oil, or equal and slide the mechanical seal head onto the shaft. Do not
compress the seal spring at this time.
CAUTION:
Use a flashlight and make sure the mechanical seal spring is searing
properly into the spring holder and around the bellows of the
mechanical seal before continuing.
5. Slide the gland plate, over the shaft, being careful that the head and the seat of the
mechanical seal do not get damaged. Then press the gland plate with the O-ring into
the stuffing box and tighten the socket-head capscrews.
NOTE: Because of the compression of the O-ring, it may be difficult to press the O-ring
into the stuffing box. Use longer socket-head capscrews to start the gland plate into
the stuffing box. Draw-up the bolts evenly until the gland plate is secure in the stuffing
box. To prevent the mechanical seal spring from pushing the gland plate back out of
the stuffing box. Remove one long socket-head capscrew at a time and replace with a
regular socket-head screw.
6. Heat the ball bearings using dry heat or 10% - 15% soluble oil and water, or an
induction heater.
36
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
CAUTION: Do not exceed a temperature of 275°F.
7. Fill up the lip seal cavity with approximately .50 ounces of grease.
8. Using gloves slide the heated bearing onto the shaft against the shaft shoulder. (See
photo below)
9. Install the locknut and lockwasher on the outboard end of the shaft. Make certain that
the locknut is secure and bend over the tabs on the lockwasher. (See photo below)
10.Allow the bearing to cool to room temperature. Coat the exposed sides of the bearing
with two or three ounces of recommended grease.
11.Coat the inside of the bearing housing with grease and slide it into place over the
bearing. Alternately tighten the bearing housing capscrews so as not to “cock” the
bearing housing causing bearing to bind.
12.Repeat steps 1 thru 11 for the inboard.
Note: a locknut and lockwasher are not installed on the inboard end of the pump shaft.
13.Reinstall the coupler and check for alignment, following the instructions found in the
“Coupling Alignment” section of this manual.
6.9.2 Reassembly of the pump when it is required to remove the rotating element
NOTE: All bearing, O-rings, lip-seals, mechanical seals, gaskets, impeller rings, and casing
rings should be replaced with new parts during assembly. All reusable parts should be
cleaned of all foreign matter before reassembling. The main casing joint gasket can be
made using the upper and lower half as a template. Lay the gasket material on the casing
joint. Trim the gasket by lightly tapping with a peen hammer so it is flush with the inside
edges of the casing (do not hit casing edge with hammer hard enough to round edge.
NOTE: Precut-casing gaskets can be ordered to minimize the amount of trimming.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
37
6 Maintenance
1. Before assembling the rotating element prepare the casing and install the casing
gaskets to the parting line.
2. Clean the gasket surfaces of the casing. Apply Scotch 3M-77 spray adhesive or
equivalent to the lower half of the casing.
3. Within one minute of spraying, set the untrimmed gaskets in place on the lower half of
the casing, align the holes in the gaskets with the holes in the casing, and press the
gaskets firmly against the lower half of the casing face in the area coated by the
adhesive.
4. Trim the gaskets flush with the lower casing bores, see photo below.
CAUTION:
Machined casing bores must remain sharp at the casing parting line.
Gaskets must be flush with the bore in order to contact O-rings.
Leakage can result around the stuffing box O-ring if this step is not
followed properly.
5. Assemble the impeller key in the shaft key slot.
Note: For impeller with replaceable rings, heat each new ring (approximately
300°F-400°F for bronze) and slide onto the impeller. Using gloves hold rings against
the impeller shoulder until cool.
6. Check the impeller and casing to determine the correct relationship. Heat the impeller
evenly to 300°F maximum to expand the bore. (Impeller may be pressed onto the shaft
instead of heating if a suitable press is available, see photo below)
7. Using gloves, from the outboard end, slide the impeller on the shaft against the shaft
shoulder, and install the retaining ring.
8. Lubricate and roll an O-ring into the grove in each of the casing rings. Then slide the
casing rings over the impeller.
9. Thoroughly clean the gland plates and stuffing boxes to prevent dirt from entering the
seal during the startup.
38
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
10.Press the stationary mechanical seal seats into both of the gland plates. Lightly
lubricate the gland plates to ease assembly. See photo below.
11.Press new lip seals into the gland plates. Before installing the lip seals, lubricate the lip
seals with lightweight oil.
NOTE: Lip seals should sit against the machined shoulder in the gland plates. The lip
seals should face away from the mechanical seal set. See photo below.
12.Lubricate and roll the O-rings into the grooves in each of the gland plate.
13.Press the gland plates into the stuffing boxes and secure using the socket-head
capscrews.
NOTE: Because of the compression of the O-ring, it may be difficult to press the O-ring
into the stuffing box. Use longer socket-head capscrews to start the gland plate into
the stuffing box. To prevent the mechanical seal spring from pushing the gland plate
back out of the stuffing box, remove one long socket-head capscrews at time and
replace with a regular socket-head capscrew.
14.Lubricate and roll the O-rings into the groove in each stuffing box.
NOTE: At this point reassemble the rotating element by starting on the outboard end
first (the end opposite the coupling) as this end locates the settings of the mechanical
seal.
IMPORTANT: Steps 11 through 21 must be completed, on the outboard end, within 10
to 12 minutes to assure proper placement of the mechanical seals.
15.Lightly coat the outboard end of the pump shaft with P-80 Rubber Lubricant Emulsion,
vegetable oil, Or equal and slide the mechanical seal head onto the shaft) See photo
below.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
39
6 Maintenance
16.Slide the stuffing box, with the gland plate, fully on the shaft, being very careful that
the head and set of the mechanical seal do not get damaged. Compress the seal
springs only as far as required to install the bearings.
17.Fill lip seal cavity with approximately .50 ounces of grease.
18.Heat the ball bearings using dry heat to 10%-15% soluble oil and water, or an
induction heater.
CAUTION: Do not exceed a temperature of 275°F
19.Using gloves slide the heating bearing onto the shaft against the shaft shoulder. See
photo below.
20.Install the locknut and lockwasher on the outboard end of the shaft. Make certain that
the locknut is secure and bend over the labs on the lockwasher. See photo below.
40
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
21.Allow the bearing to cool to room temperature. Coat the exposed sides of the bearing
with two or three ounces of recommended grease.
22.Coat the inside of the bearing housing with grease and slide it into place over the
bearing. Attach the bearing housing to the stuffing box with the capscrews.
23.Repeat steps 15 through 22 for inboard end.
IMPORTANT: Steps 15 through 25 must be completed within 10 to 12 minutes to
assure proper placement of the mechanical seal.
NOTE: A locknut and lockwasher are not installed on the inboard end of the pump
shaft.
24.Reinstall the coupler on the end of the shaft.
25.Set the rotating element in the pump casing, assuring correct rotation. Locate both
stuffing box tongues in their respective casing grooves. Locate the pins in the stuffing
box and casing wear ring in their respective slots at the casing parting surface. Correct
any O-ring bulging. See photo below
CAUTION:
Do not cut or damage the O-rings when lowering the rotating element
into position. When all four anti-rotation pins are located correctly,
there will be some casing ring looseness.
26.Apply a small bead of Dow Corning RTV silicone sealant or equal at the parting line on
top of gasket at the stuffing box O-rings. See photo below.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
41
6 Maintenance
27.Locate the upper half of the casing into place using the tapered dowel pins and install
the casing main joint bolts. See photo below. The casing joints should be tightened to
the following torques: 140 ft-lb minimum for 5/8”-11 head cap screws (Grade 5);
350ft.-lb minimum for 7/8”-9 Ferry Cap Counterbore screws (Grade 8). Bolt torqueing
pattern is show in illusion in the “Change the Rotation” section of this manual.
NOTE: Torque values are essential for obtaining proper gasket compression so no
leakage can occur at the main joint.
28.Rotate the shaft by hand to assure that it turns smoothly and it is free from rubbing or
binding.
29.Assemble the coupler and check alignment, following instructions found in the
“Coupling Alignment” section of this manual. Replace the coupler guard.
6.9.3 Install the hex coupling guard
1. Check coupler alignment before proceeding. Correct if necessary.
2. Slide the inner guard into the outer guard.
3. 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.
4. 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.
5. Install the outer guard capscrews according to the directions in this table.
42
If...
Then...
The pump has a motor saddle
support bracket
Ensure that the outer guard straddles the support arm and install the two
remaining capscrews.
Do not tighten the capscrews.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
6 Maintenance
If...
Then...
The pump does not have a motor Insert the spacer washer between the holes located closest to the motor in
saddle support bracket
the outer guard and install the two remaining capscrews.
Do not tighten the capscrews.
6.
7.
8.
9.
Position the outer guard so that there is less than 1/4 in. (0.64 cm) of exposed shaft.
Hold the guard in this position and tighten the three capscrews.
Open the isolation valves and inspect the pump for leaks.
Return the pump to service if it is not leaking.
6.9.4 Assembly references
6.9.4.1 Ordering parts
The pumps covered by this manual have been designed and built with certain
replaceable wearing parts. The recommended inventory of spare parts depends upon the
installation and the importance of continued operation.
For critical service requiring a minimum of “down time” a complete or “quick change”
rotating element is recommended.
For normal service, with repairs to be made in the field, the following parts are
recommended for stock.
• 1 set of bearings
• 1 set of wearing rings
• 1 set of gaskets, O-rings, and grease seals
• 2 mechanical seals (complete)
• 1 set of shaft sleeves
Parts should be ordered as far in advance of their use as possible since circumstances
beyond the control of the company may reduce existing stock. Not all parts are stocked
and must be manufactured for each order.
To facilitate rapid handling of your order for spare parts, be sure to include the following
information:
1. Serial number of the pump.
2. Catalog number of the part.
3. Quantity of each part.
4. Name of the part.
5. Material desired. (Parts will be furnished in original materials unless specified as a
material change. All material substitutions should be discussed with the factory.
6.9.4.2 Screw torque values
Capscrew torque in ft-lb (Nm)
Capscrew
type
Head
marking
SAE grade
2
Brass and
stainless
steel
SAE grade
5
or
Capscrew diameter (in inches)
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1
6 (8)
13 (18)
25 (34)
38 (52)
60 (81)
120 (163)
190 (258)
210 (285)
300 (407)
4 (5)
10 (14)
17 (23)
27 (37)
42 (57)
83 (113)
130 (176)
200 (271)
300 (407)
10 (14)
20 (27)
35 (47)
60 (81)
90 (122)
180 (244)
325 (440)
525 (712)
800 (1085)
6.9.4.3 Dealer servicing
If trouble occurs that cannot be rectified, contact your local sales and service
representative and be prepared to provide this information:
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
43
6 Maintenance
1.
2.
3.
4.
44
Complete nameplate data of pump and motor
Suction and discharge pipe pressure gauge readings
Ampere draw of the motor
A sketch of the pump hook-up and piping
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
7 Troubleshooting
7 Troubleshooting
7.1 Operation troubleshooting
Between regular maintenance inspections, be alert for signs of motor or pump trouble.
Correct any trouble immediately and avoid costly repair and shutdown.
Symptom
Cause
Remedy
Lack of prime
Fill pump and suction pipe
completely with liquid.
Loss of prime
Check for leaks in suction pipe joints
and fittings; vent casing to remove
accumulated air.
Suction lift too high.
If no obstruction at inlet, check for
pipe friction losses. Static lift may be
too great. Measure with mercury
column or vacuum gauge while
pump operates. If static lift is too
high, liquid to be pumped must be
raised or pump lowered.
Discharge head too high.
Check pipe friction losses. Large
piping may correct condition. Check
that valves are wide open.
The motor speed is too low.
Check whether motor is directly
across-the-line and receiving full
voltage. Or frequency may be too low;
motor may have an open phase.
Wrong direction of rotation.
Check motor rotation with directional
arrow on pump casing.
Impeller completely plugged.
Dismantle pump and clean impeller.
No liquid delivered
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
45
7 Troubleshooting
Symptom
Not enough liquid being delivered
46
Cause
Remedy
Air leaks in suction piping
If liquid pumped is water or other
non-explosive, and explosive gas or
dust is not present, test flanges for
leakage with flame or match, or by
plugging inlet and putting line under
pressure. A gauge will indicate a leak
with a drop of pressure.
The motor speed is too low.
Check whether motor is directly
across-the-line and receiving full
voltage. Or frequency may be too low;
motor may have an open phase.
Discharge head too high
Check pipe friction losses. Large
piping may correct condition. Check
that valves are wide open.
Suction lift too high
If no obstruction at inlet, check for
pipe friction losses. Static lift may be
too great. Measure with mercury
column or vacuum gauge while
pump operates. If static lift is too
high, liquid to be pumped must be
raised or pump lowered.
Impeller partially plugged
Dismantle pump and clean impeller.
Cavitation; insufficient NPSH
(depending on installation)
1. Increase positive suction head on
pump by lowering pump.
2. Sub-cool suction piping at inlet to
lower entering liquid
temperature.
3. Pressurization suction vessel.
Defective impeller.
Inspect impeller, bearings and shaft.
Replace is damaged or vane sections
badly eroded.
Foot valve too small or partially
obstructed.
Area through ports of valve should be
at least as large as area of suction
pipe — preferable 1½ times. If
strainer is used, net clear area should
be 3 to 4 times area of suction pipe.
Suction inlet not immersed deep
enough.
If inlet cannot be lowered, or if eddies
through which air is sucked persist
when it is lowered, chain a board to
suction pipe. It will be drawn into
eddies, smothering the vortex.
Too small impeller diameter.
Probable cause if none of above)
Check with factory to see if a larger
impeller can be used; otherwise, cut
pipe losses or increase speed — or
both, if needed. Be careful not to
seriously overload drive.
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
7 Troubleshooting
Symptom
Not enough pressure
Cause
Remedy
Mechanical defects
See “Defective impeller” and “Foot
valve too small or partially
obstructed”.
Obstruction in liquid passages.
Dismantle pump and inspect
passages of impeller and casing.
Remove obstruction.
Air or gases in liquid. (Test in
laboratory, reducing pressure on
liquid to pressure in suction line.
Watch for bubble formation.)
May be possible to over rate pump to
point where it will provide adequate
pressure despite condition. Better to
provide gas separation chamber on
suction line near pump, and
periodically exhaust accumulated
gas. See “Cavitation; insufficient
NPSH”.
Too small impeller diameter.
(Probable cause if none above.)
Check with factory to see if a larger
impeller can be used; otherwise, cut
pipe losses or increase speed — or
both, if needed. Be careful not to
seriously overload drive.
Incomplete priming.
Free pump, piping and valves of all
air. If high points in suction prevent
this, they need correcting.
Suction lift too high.
If no obstruction at inlet, check for
pipe friction losses. Static lift may be
too great. Measure with mercury
column or vacuum gauge while
pump operates. If static lift is too
high, liquid to be pumped must be
raised or pump lowered.
Air leaks in suction piping.
If liquid pumped is water or other
non-explosive, and explosive gas or
dust is not present, test flanges for
leakage with flame or match, or by
plugging inlet and putting line under
pressure. A gauge will indicate a leak
with a drop of pressure.
Air or gasses in liquid.
May be possible to over rate pump to
point where it will provide adequate
pressure despite condition. Better to
provide gas separation chamber on
suction line near pump, and
periodically exhaust accumulated
gas. See “Cavitation; insufficient
NPSH”.
Head lower than rating; thereby
pumping too much liquid.
Machine impeller’s OD to size
advised by factory.
Cavitation
1. Increase positive suction head on
pump by lowering pump.
2. Sub-cool suction piping at inlet to
lower entering liquid
temperature.
3. Pressurization suction vessel.
Mechanical defects
See “Defective impeller” and “Foot
valve too small or partially
obstructed”.
Pump operates for short time, then
stops
Pump takes too much power
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
47
7 Troubleshooting
Symptom
Cause
Remedy
Suction inlet not immersed enough.
If inlet cannot be lowered, or if eddies
through which air is sucked persist
when it is lowered, chain a board to
suction pipe. It will be drawn into
eddies, smothering the vortex.
Liquid heavier (in either viscosity or
specific gravity) than allowed for.
Use larger driver. Consult factory for
recommended size. Test liquid for
viscosity and specific gravity.
Wrong direction of rotation.
Check motor rotation with directional
arrow on pump casing.
Casing distorted by excessive strains
from suction or discharge piping.
Check alignment. Examine pump for
friction between impeller and casing.
Replace damaged parts.
Shaft bent due to damage — through Check deflection of rotor by turning
shipment, operation, or overhaul.
on bearing journals. Total indicator
run-out should not exceed 0.002 on
shaft and 0.004 on impeller wearing
surface.
Mechanical failure of critical pump
parts.
Check bearings and impeller for
damage. Any irregularity in these
parts will cause a drag on shaft.
Misalignment
Realign pump and driver.
Speed may be too high (brake hp of Check voltage on motor.
pump varies as the cube of the speed;
therefore, any increase in speed
means considerable increase in
power demand).
Electrical defects.
The voltage and frequency of the
electrical current may be lower than
that for which the motor was built; or
there may be defects in motor. The
motor may not be ventilated properly
due to poor location.
Mechanical defects in turbine, engine If trouble cannot be located, consult
or other type of drive exclusive of
factory.
motor.
48
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
8 Product warranty
8 Product warranty
Commercial warranty
Warranty. For goods sold to commercial buyers, Seller warrants the goods sold to Buyer
hereunder (with the exception of membranes, seals, gaskets, elastomer materials,
coatings and other "wear parts" or consumables all of which are not warranted except as
otherwise provided in the quotation or sales form) will be (i) be built in accordance with
the specifications referred to in the quotation or sales form, if such specifications are
expressly made a part of this Agreement, and (ii) free from defects in material and
workmanship for a period of one (1) year from the date of installation or eighteen (18)
months from the date of shipment (which date of shipment shall not be greater than thirty
(30) days after receipt of notice that the goods are ready to ship), whichever shall occur
first, unless a longer period is specified in the product documentation (the “Warranty”).
Except as otherwise required by law, Seller shall, at its option and at no cost to Buyer,
either repair or replace any product which fails to conform with the Warranty provided
Buyer gives written notice to Seller of any defects in material or workmanship within ten
(10) days of the date when any defects or non-conformance are first manifest. Under
either repair or replacement option, Seller shall not be obligated to remove or pay for the
removal of the defective product or install or pay for the installation of the replaced or
repaired product and Buyer shall be responsible for all other costs, including, but not
limited to, service costs, shipping fees and expenses. Seller shall have sole discretion as to
the method or means of repair or replacement. Buyer’s failure to comply with Seller’s
repair or replacement directions shall terminate Seller’s obligations under this Warranty
and render the Warranty void. Any parts repaired or replaced under the Warranty are
warranted only for the balance of the warranty period on the parts that were repaired or
replaced. Seller shall have no warranty obligations to Buyer with respect to any product or
parts of a product that have been: (a) repaired by third parties other than Seller or without
Seller’s written approval; (b) subject to misuse, misapplication, neglect, alteration,
accident, or physical damage; (c) used in a manner contrary to Seller’s instructions for
installation, operation and maintenance; (d) damaged from ordinary wear and tear,
corrosion, or chemical attack; (e) damaged due to abnormal conditions, vibration, failure
to properly prime, or operation without flow; (f) damaged due to a defective power
supply or improper electrical protection; or (g) damaged resulting from the use of
accessory equipment not sold or approved by Seller. In any case of products not
manufactured by Seller, there is no warranty from Seller; however, Seller will extend to
Buyer any warranty received from Seller’s supplier of such products.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER
EXPRESS OR IMPLIED WARRANTIES, GUARANTEES, CONDITIONS OR TERMS OF
WHATEVER NATURE RELATING TO THE GOODS PROVIDED HEREUNDER, INCLUDING
WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE HEREBY EXPRESSLY DISCLAIMED
AND EXCLUDED. EXCEPT AS OTHERWISE REQUIRED BY LAW, BUYER’S EXCLUSIVE
REMEDY AND SELLER’S AGGREGATE LIABILITY FOR BREACH OF ANY OF THE
FOREGOING WARRANTIES ARE LIMITED TO REPAIRING OR REPLACING THE PRODUCT
AND SHALL IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY THE BUYER FOR THE
DEFECTIVE PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY OTHER FORM
OF DAMAGES, WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL,
CONSEQUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL DAMAGES, INCLUDING BUT
NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE,
LOSS OF INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF
OPPORTUNITY OR LOSS OF REPUTATION.
Limited consumer warranty
Warranty. For goods sold for personal, family or household purposes, Seller warrants the
goods purchased hereunder (with the exception of membranes, seals, gaskets, elastomer
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
49
8 Product warranty
materials, coatings and other "wear parts" or consumables all of which are not warranted
except as otherwise provided in the quotation or sales form) will be free from defects in
material and workmanship for a period of one (1) year from the date of installation or
eighteen (18) months from the product date code, whichever shall occur first, unless a
longer period is provided by law or is specified in the product documentation (the
“Warranty”).
Except as otherwise required by law, Seller shall, at its option and at no cost to Buyer,
either repair or replace any product which fails to conform with the Warranty provided
Buyer gives written notice to Seller of any defects in material or workmanship within ten
(10) days of the date when any defects or non-conformance are first manifest. Under
either repair or replacement option, Seller shall not be obligated to remove or pay for the
removal of the defective product or install or pay for the installation of the replaced or
repaired product and Buyer shall be responsible for all other costs, including, but not
limited to, service costs, shipping fees and expenses. Seller shall have sole discretion as to
the method or means of repair or replacement. Buyer’s failure to comply with Seller’s
repair or replacement directions shall terminate Seller’s obligations under this Warranty
and render this Warranty void. Any parts repaired or replaced under the Warranty are
warranted only for the balance of the warranty period on the parts that were repaired or
replaced. The Warranty is conditioned on Buyer giving written notice to Seller of any
defects in material or workmanship of warranted goods within ten (10) days of the date
when any defects are first manifest.
Seller shall have no warranty obligations to Buyer with respect to any product or parts of a
product that have been: (a) repaired by third parties other than Seller or without Seller’s
written approval; (b) subject to misuse, misapplication, neglect, alteration, accident, or
physical damage; (c) used in a manner contrary to Seller’s instructions for installation,
operation and maintenance; (d) damaged from ordinary wear and tear, corrosion, or
chemical attack; (e) damaged due to abnormal conditions, vibration, failure to properly
prime, or operation without flow; (f) damaged due to a defective power supply or
improper electrical protection; or (g) damaged resulting from the use of accessory
equipment not sold or approved by Seller. In any case of products not manufactured by
Seller, there is no warranty from Seller; however, Seller will extend to Buyer any warranty
received from Seller’s supplier of such products.
THE FOREGOING WARRANTY IS PROVIDED IN PLACE OF ALL OTHER EXPRESS
WARRANTIES. ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE LIMITED TO ONE (1) YEAR FROM THE DATE OF INSTALLATION OR
EIGHTEEN (18) MONTHS FROM THE PRODUCT DATE CODE , WHICHEVER SHALL
OCCUR FIRST. EXCEPT AS OTHERWISE REQUIRED BY LAW, BUYER’S EXCLUSIVE
REMEDY AND SELLER’S AGGREGATE LIABILITY FOR BREACH OF ANY OF THE
FOREGOING WARRANTIES ARE LIMITED TO REPAIRING OR REPLACING THE PRODUCT
AND SHALL IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY THE BUYER FOR THE
DEFECTIVE PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY OTHER FORM
OF DAMAGES, WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL,
CONSEQUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL DAMAGES, INCLUDING BUT
NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE,
LOSS OF INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF
OPPORTUNITY OR LOSS OF REPUTATION.
Some states do not allow limitations on how long an implied warranty lasts, so the above
limitation may not apply to you. Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above exclusions may not apply to you. This
warranty gives you specific legal rights, and you may also have other rights which may
vary from state to state.
To make a warranty claim, check first with the dealer from whom you purchased the
product or visit www.xyleminc.com for the name and location of the nearest dealer
providing warranty service.
50
Series HSC³ Base Mounted Centrifugal Pump INSTRUCTION MANUAL
Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots;
2) a leading global water technology company.
We’re a global team unified in a common purpose: creating advanced
technology solutions to the world’s water challenges. Developing new
technologies that will improve the way water is used, conserved, and re-used in
the future is central to our work. Our products and services move, treat, analyze,
monitor and return water to the environment, in public utility, industrial,
residential and commercial building services, and agricultural settings. With its
October 2016 acquisition of Sensus, Xylem added smart metering, network
technologies and advanced data analytics for water, gas and electric utilities to
its portfolio of solutions. In more than 150 countries, we have strong, longstanding relationships with customers who know us for our powerful
combination of leading product brands and applications expertise with a strong
focus on developing comprehensive, sustainable solutions.
For more information on how Xylem can help you, go to www.xylem.com
Xylem Inc.
8200 N. Austin Avenue
Morton Grove IL 60053
Tel: (847) 966–3700
Fax: (847) 965–8379
www.bellgossett.com
Visit our Web site for the latest version of this document
and more information
The original instruction is in English. All non-English
instructions are translations of the original instruction.
©
2017 Xylem Inc
Bell & Gossett is a trademark of Xylem Inc or one of its
subsidiaries.
AC2008 Rev E