Xylem G&L A-C 8100 Series, Instruction Manual

Page 1: ...INSTRUCTION MANUAL AC5659D G L Pumps Series A C 8100 Base Mounted Centrifugal Pump...

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Page 3: ...undation requirements 14 4 1 4 Level the base on a concrete foundation 15 4 1 5 Grout the baseplate 16 4 2 Coupling alignment 16 4 2 1 Prepare for alignment 16 4 2 2 Align the pump using a straight ed...

Page 4: ...nical seal on the shaft 33 6 6 5 Disassemble the pump with mechanical seals on shaft sleeve 34 6 6 6 Disassemble the pump with packing 36 6 7 Pre assembly inspections 37 6 7 1 Replacement guidelines 3...

Page 5: ...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...

Page 6: ...als WARNING Do NOT exceed the maximum working pressure of the pump This information is listed on the nameplate of the pump Alert symbol This safety alert symbol is used in manuals and on the safety in...

Page 7: ...hin 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 sa...

Page 8: ...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...

Page 9: ...ey 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...

Page 10: ...ution 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...

Page 11: ...ard shackle and end loops Be sure the lifting equipment is of sufficient length to keep the lift angle less than 30 from the vertical See Figure 3 Storage location The product must be stored in a cove...

Page 12: ...or 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...

Page 13: ...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 This product can ex...

Page 14: ...eplate 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 corresponden...

Page 15: ...ed 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 liq...

Page 16: ...upply 9 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 found...

Page 17: ...late does not have to be level 4 1 5 2 3 6 7 1 Locate the shims to allow removal after grouting 2 Grout only to top of base rail 3 Pump base rail 4 Grout 5 Concrete foundation 6 1 25 40 mm Gap 7 Allow...

Page 18: ...ollow 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...

Page 19: ...adius 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...

Page 20: ...ipped 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 coupli...

Page 21: ...erature 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 mi...

Page 22: ...2 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 4 3 Piping checklists 4 3 1 Piping checkl...

Page 23: ...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 suctio...

Page 24: ...ws the unbalanced loading of a double suction impeller due to the uneven flow around an elbow that is adjacent to the pump 1 2 3 4 5 1 Pump casing 2 Impeller 3 Pump suction flange 4 Suction elbow 5 Wa...

Page 25: ...2 1 1 No air pockets 2 Eccentric reducer 3 Gradual rise Figure 14 Gradual rise to the pump correct 1 1 Distance plus eccentric reducer straightens the flow Figure 15 Suction pipe above the pump correc...

Page 26: ...e 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 f...

Page 27: ...ing 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 Che...

Page 28: ...r 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 th...

Page 29: ...Figure 18 Main joint bolts 5 Commissioning Startup Operation and Shutdown G L Pumps Series A C 8100 Base Mounted Centrifugal Pump INSTRUCTION MANUAL 27...

Page 30: ...sary Use the grade recommended Make sure the seal cages are centered in the stuffing box at the entrance of the stuffing box piping connection Take vibration readings on the bearing housings Compare t...

Page 31: ...of the lubricants recommended by the coupling manufacturer 6 3 Bearing maintenance Bearing lubrication schedule Type of bearing First lubrication assembled pumps and replacement bearing frames First l...

Page 32: ...built with Lithium based greases NLGI 2 and do not have lubrication label on pump or bearing frame indicating pump grease type ExxonMobil PolyrexTM EM Shell Gadus S2 V100 2 was Alvania RL 2 Chevron SR...

Page 33: ...ly before you install new packing Check the condition of the shaft or sleeve for possible scoring or eccentricity and make replacements as necessary When placing new non asbestos packing into the stuf...

Page 34: ...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...

Page 35: ...river or pry bar into the slots between the upper and lower casing halves separate joint 4 Remove all casing main joint capscrews and dowels 2 916 1 Lift off the upper casing half 5 Tap the stuffing b...

Page 36: ...emove coupling guard and disconnect coupling Refer to instructions on how to remove the hex coupling guard a Remove external tubing 1 939 9 if supplied 3 Loosen but do not remove main joint capscrews...

Page 37: ...ead 3 402 0 from the pump shaft If set collar 3 421 9 must be removed scribe a line on shaft sleeve 3 009 9 flush with end of seal 13 Loosen set screw 3 902 3 in shaft nut 3 015 9 and remove the nut O...

Page 38: ...mer to break the seal between the stuffing box and lower casing half and lift the rotating element out of the lower casing A spare rotating element can be installed at this point 6 Remove the four cap...

Page 39: ...11 1 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 b...

Page 40: ...spect the surface for damage such as pitting corrosion nicks and scratches Replace these parts if they are damaged 6 8 Dimensions Pump with mechanical seal on the shaft Figure 20 Cross section Figure...

Page 41: ...55 6x4x14 6 62 6 75 6 00 6 12 7 00 7 12 9 755 8x6x12 6 63 6 75 6 00 6 12 7 00 7 12 9 755 8x6x13 7 31 7 50 6 69 6 88 7 81 8 00 10 625 8x6x17 7 31 7 50 6 69 6 88 7 81 8 00 10 625 8x8x12 7 31 7 50 6 69 6...

Page 42: ...ng line Figure 28 Cross section Pump size Dimension A Packing size 3x2x11 8 755 3 8 6x4x9 9 312 6x4x10A 9 312 6x4x10 10 625 1 2 6x4x11 10 75 3 8 6x4x12A 10 625 1 2 6x4x12 9 755 3 8 6x4x14 6x6x9 9 312...

Page 43: ...ould be made using the upper half as a template Lay the gasket material on the casing joint and mark it by pressing it against the edges of the casing Trim the gasket so that it is flush with the insi...

Page 44: ...within 10 12 minutes to assure proper placements of the mechanical seal 9 Lightly coat the outboard end of the shaft with soapy water or vegetable oil and slide the mechanical seal head 3 402 0 onto t...

Page 45: ...urface Correct and excessive O ring buckling NOTE Do not cut or damage O rings when lowering the rotating element into position When all four pins are correctly located there will be some casing ring...

Page 46: ...key slot 2 Apply 1 2 wide bead of Loctite or Permatex sealant to outboard end of shaft 3 from the impeller hub 3 Slide sleeve 3 009 9 onto shaft rotating the sleeve to evenly distribute the sealant ap...

Page 47: ...Using gloves press the heated bearing onto the shaft against the shaft shoulder 15 Install the locknut and lockwasher or snap ring 3 915 4 on the outboard end of the shaft 16 Cool the bearing to room...

Page 48: ...bolt torque pattern is shown in the following figure 24 Rotate the shaft by hand to assure that it turns smoothly and is free from rubbing or binding 25 Install the coupling and align Replace the coup...

Page 49: ...dimension C is maintained Drill a shallow recess in the shaft through the set screw hold in the nut Lock the nut in position with the set screw 3 902 3 6 Repeat steps 3 through 5 for the inboard shaft...

Page 50: ...uckling NOTE Do not cut or damage O rings when lowering the rotating element into position When all four pins are correctly located there will be some casing ring looseness 19 Install a new 1 64 in th...

Page 51: ...he 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...

Page 52: ...he 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 spe...

Page 53: ...tatic 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...

Page 54: ...d 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 temperatur...

Page 55: ...nlet 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 l...

Page 56: ...lection of rotor by turning 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...

Page 57: ...arranted 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 th...

Page 58: ...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 Selle...

Page 59: ...he dealer from whom you purchased the product or visit www xyleminc com for the name and location of the nearest dealer providing warranty service 8 Product warranty G L Pumps Series A C 8100 Base Mou...

Page 60: ...ork technologies and advanced analytics solutions for water electric and gas utilities In more than 150 countries we have strong long standing relationships with customers who know us for our powerful...