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Model CV 3196 i-FRAME Installation, Operation, and Maintenance Manual

Summary of Contents for Goulds Pumps CV 3196 i-FRAME

Page 1: ...Installation Operation and Maintenance Manual Model CV 3196 i FRAME ...

Page 2: ......

Page 3: ...scription i ALERT 2 Equipment Condition Monitor 20 3 3 Nameplate information 21 4 Installation 24 4 1 Pre installation 24 4 1 1 Pump location guidelines 24 4 1 2 Foundation requirements 25 4 2 Baseplate mounting procedures 26 4 2 1 Prepare the baseplate for mounting 26 4 2 2 Install the baseplate using shims or wedges 26 4 2 3 Install the baseplate using jackscrews 27 4 2 4 Install the baseplate u...

Page 4: ...eal option 62 5 7 6 Set an elastomeric face seal 62 5 8 Install the shaft guard if provided 63 5 9 Pump priming 63 5 9 1 Prime the pump with the suction supply above the pump 63 5 9 2 Prime the pump with the suction supply below the pump 63 5 9 3 Other methods of priming the pump 65 5 10 Start the pump 65 5 11 Activate the i ALERT Health Monitor 66 5 12 i ALERT 2 Equipment Health Monitor 67 5 13 P...

Page 5: ...6 5 8 Bearing fits and tolerances 108 6 6 Reassembly 109 6 6 1 Assemble the rotating element and the bearing frame STi and MTi 109 6 6 2 Assemble the rotating element and the bearing frame STi and MTi with duplex bearings 112 6 6 3 Assemble the rotating element and the bearing frame LTi 115 6 6 4 Assemble the rotating element and the bearing frame XLT i and i17 119 6 6 5 Assemble the rotating elem...

Page 6: ...g 154 7 4 i ALERT 2 Equipment Health Monitor troubleshooting 155 8 Parts Listings and Cross Sectionals 156 8 1 Parts list 156 9 Certification CE or CE ATEX 168 9 1 Certificates of conformance 168 10 Other Relevant Documentation or Manuals 174 10 1 For additional documentation 174 11 Local ITT Contacts 175 11 1 Regional offices 175 Table of Contents 4 Model CV 3196 i FRAME Installation Operation an...

Page 7: ...personal injury Applying heat to impellers propellers or their retaining devices can cause trapped liquid to rapidly expand and result in a violent explosion This manual clearly identifies accepted methods for disassembling units These methods must be adhered to Never apply heat to aid in their removal unless explicitly stated in this manual The operator must be aware of the pumpage and take appro...

Page 8: ...ing and or unstable operation Do not change the service application without the approval of an authorized ITT representative 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 p...

Page 9: ...icable environmental regula tions Clean up all spills in accordance with safety and environmental procedures Report all environmental emissions to the appropriate authorities WARNING If the product has been contaminated in any way such as from toxic chemicals or nuclear radi ation do NOT send the product to ITT until it has been properly decontaminated and advise ITT of these conditions before ret...

Page 10: ...ure that you have a clear path of retreat 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 lo...

Page 11: ...n 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 2 4 Ex approved products Follow these specia...

Page 12: ...T representative 1 3 Product approval standards Regular standards WARNING Use of equipment unsuitable for the environment can pose risks of ignition and or explosion Ensure the pump driver and all other auxiliary components meet the required area classifica tion at the site If they are not compatible do not operate the equipment and contact an ITT representative before proceeding All standard prod...

Page 13: ...d repair work is done by ITT authorized personnel Genuine ITT parts are used Only Ex approved spare parts and accessories authorized by ITT are used in Ex approved prod ucts Limitations The warranty does not cover faults caused by these situations Deficient maintenance Improper installation Modifications or changes to the product and installation made without consulting ITT Incorrectly executed re...

Page 14: ...erature IOMs or from your local ITT Goulds Pumps Sales representative All pumping unit pump seal coupling motor and pump accessories certified for use in an ATEX classi fied environment are identified by an ATEX tag secured to the pump or the baseplate on which it is mounted A typical tag would look like this Figure 1 ATEX nameplate The CE and the Ex designate the ATEX compliance The code below re...

Page 15: ...se property damage and or personal injury Ensure that the unit is properly supported and secure during lifting and handling CAUTION Risk of injury or equipment damage from use of inadequate lifting devices Ensure lifting devi ces such as chains straps forklifts cranes etc are rated to sufficient capacity 2 2 2 Lifting methods WARNING Risk of serious personal injury or equipment damage Proper lifti...

Page 16: ...r the pump casing and the drive unit or under the base rails Examples Figure 2 Example of a proper lifting method Figure 3 Example of a proper lifting method NOTICE Do not use this method to lift a Polyshield ANSI Combo with the pump and motor mounted These items are not designed to handle the heavy weight of the Polyshield system Doing so may result in equipment damage 2 2 Transportation guidelin...

Page 17: ...tem Doing so may result in equipment damage Figure 5 Example of a proper lifting method NOTICE When lifting a unit for which a strap cannot be secured at the suction flange secure the strap through the frame frame adapter Securing at the frame adapter will prevent slipping of the strap and possible equipment damage 2 2 Transportation guidelines Model CV 3196 i FRAME Installation Operation and Main...

Page 18: ...kaging is designed only to protect the unit during shipping Length of time in storage Storage requirements Upon receipt short term less than six months Store in a covered and dry location Store the unit free from dirt and vibrations Long term more than six months Store in a covered and dry location Store the unit free from heat dirt and vibrations Rotate the shaft by hand several times at least ev...

Page 19: ...es 2 3 2 Frostproofing Table 3 Situations when the pump is or is not frostproof Situation Condition Operating The pump is frostproof Immersed in a liquid The pump is frostproof Lifted out of a liquid into a temperature below freezing The impeller might freeze 2 3 Storage guidelines Model CV 3196 i FRAME Installation Operation and Maintenance Manual 17 ...

Page 20: ...ows the number of hydraulic sizes available for each drive unit size group Pump size group Number of hydraulic sizes STi 1 MTi 4 LTi 5 XLT i 1 WARNING Use of equipment unsuitable for the environment can pose risks of ignition and or explosion Ensure the pump driver and all other auxiliary components meet the required area classifica tion at the site If they are not compatible do not operate the eq...

Page 21: ...g out solids Gasket Fully confined Mounting method Integral foot support for maximum resistance to misalignment distortion due to piping loads Standard flange ANSI class 150 flat face serrated flange Impeller The impeller is fully open and recessed from the casing equipped with curved vanes screwed onto the shaft The threads are sealed from the pumped liquid by a PTFE O ring Cover Standard seal 3 ...

Page 22: ...gular contact bearing except for the LTi which uses a pair of single row angular contact ball bearings mounted back to back 3 2 General description i ALERT 2 Equipment Condition Monitor Description The i ALERT 2 Equipment Condition Monitor is a compact battery operated monitoring device that con tinuously measures the vibration and temperature of the pump power end The i ALERT 2 sensor uses blinki...

Page 23: ...ation Important information for ordering Every pump has nameplates that provide information about the pump The nameplates are located on the casing and the bearing frame When you order spare parts identify this pump information Model Size Serial number Item numbers of the required parts Item numbers can be found in the spare parts list Refer to the nameplate on the pump casing for most of the info...

Page 24: ...gallons per minute FT HD Rated pump head in feet RPM Rated pump speed revolutions per minute MOD Pump model SIZE Size of the pump STD NO ANSI standard designation MAT L CONST Material of which the pump is constructed SER NO Serial number of the pump MAX DSGN PSI 100ºF Maximum pressure at 100ºF according to the pump design Nameplate on the pump casing using metric units Figure 11 Metric units namep...

Page 25: ...N Serial number of the pump LUBE Lubricant oil or grease ATEX nameplate Figure 13 ATEX nameplate WARNING Use of equipment unsuitable for the environment can pose risks of ignition and or explosion Ensure the pump driver and all other auxiliary components meet the required area classifica tion at the site If they are not compatible do not operate the equipment and contact an ITT representative befo...

Page 26: ...spection maintenance and serv ice 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...

Page 27: ...de a flat substantial concrete foundation in order to prevent strain and distortion when you tighten the foundation bolts Sleeve type bolts 1 2 3 4 5 6 Item Description 1 Baseplate 2 Shims 3 Foundation 4 Sleeve 5 Dam 6 Bolt Figure 14 Sleeve type bolts J type bolts 1 3 2 4 5 Item Description 1 Baseplate 2 Shims or wedges 3 Foundation 4 Dam 5 Bolt Figure 15 J type bolts 4 1 Pre installation Model CV...

Page 28: ...cable to cast iron and fabricated steel baseplates 1 If you use sleeve type bolts fill the bolt sleeves with packing material or rags to prevent grout from entering the bolt holes 2 Put the sets of wedges or shims on each side of each foundation bolt The sets of wedges should have a height of between 19 mm 0 75 in and 38 mm 1 50 in 1 1 Shims or wedges Figure 16 Top view 1 1 Shims or wedges Figure ...

Page 29: ...s The compound makes it easier to remove the screws after you grout 2 Lower the baseplate carefully onto the foundation bolts and perform these steps a Cut the plates from the bar stock and chamfer the edges of the plates in order to reduce stress concentrations b Put the plates between the jackscrews and the foundation surface c Use the four jackscrews in the corners in order to raise the basepla...

Page 30: ...ng pads 3 Foundation bolts 4 Jackscrews 5 Grout hole 6 Pump s mounting pads Figure 19 Level driver mounting pads 4 Turn the center jackscrews down so that they rest on their plates on the foundation surface 5 Level the pump mounting pads NOTICE Remove all dirt from the mounting pads in order to ensure that the correct leveling is achieved Failure to do so can result in equipment damage or decrease...

Page 31: ...ake sure that the foundation pads are correctly installed on the founda tion floor see the manufacturer s instructions 1 Put the baseplate on a support above the foundation floor Make sure that there is enough space between the baseplate and the foundation floor in order to install the spring assemblies 2 Install the lower part of the spring assembly a Screw the lower jam nut onto the spring stud ...

Page 32: ...3 Washer 4 Foundation pads 5 Spring 6 Upper adjusting nut 7 Spring stud Figure 21 Example of an installed spring assembly 4 2 5 Install the baseplate using stilt mounting NOTICE The stilt mounted baseplate is not designed to support static piping loads Ensure that the suc tion and discharge piping are supported individually Failure to do so may result in equipment damage 1 Put the baseplate on a s...

Page 33: ...6 Lower the baseplate so that the stilts fit into the foundation cups 7 Level the baseplate and make the final height adjustments a Loosen the upper jam nuts and adjusting nuts b Adjust the height and level the baseplate by moving the lower adjusting nuts c When the baseplate is level tighten the top adjusting nuts 8 Fasten the lower and upper jam nuts on each stilt 1 2 3 4 5 6 7 8 1 Mounting plat...

Page 34: ..._________ 7 ____________________ 8 ____________________ 9 ____________________ 10 ___________________ 11 ___________________ 12 ___________________ 13 ___________________ 14 ___________________ 15 ___________________ 16 ___________________ 17 ___________________ 18 ___________________ Level measurements 4 2 Baseplate mounting procedures 32 Model CV 3196 i FRAME Installation Operation and Maintenan...

Page 35: ... under these circumstances The process temperature changes The piping changes The pump has been serviced Types of alignment checks Type of check When it is used Initial alignment cold alignment check Prior to operation when the pump and the driver are at ambient temperature Final alignment hot alignment check After operation when the pump and the driver are at operating temperature Initial alignme...

Page 36: ...ngines Recommended settings for models 3196 CV 3196 and LF 3196 Pumpage temperature Recommended setting 10 C 50 F 0 05 mm 0 002 in low 65 C 150 F 0 03 mm 0 001 in high 120 C 250 F 0 12 mm 0 005 in high 175 C 350 F 0 23 mm 0 009 in high 218 C 450 F 0 33 mm 0 013 in high 228 C 550 F 0 43 mm 0 017 in high 343 C 650 F 0 53 mm 0 021 in high 371 C 700 F 0 58 mm 0 023 in high 4 4 3 Alignment measurement ...

Page 37: ... if necessary 4 4 5 Pump to driver alignment instructions 4 4 5 1 Perform angular alignment for a vertical correction 1 Set the angular alignment indicator to zero at the top center position 12 o clock of the driver cou pling half Y 2 Rotate the indicator to the bottom center position 6 o clock 3 Record the indicator reading When the reading val ue is Then Negative The coupling halves are farther ...

Page 38: ...f the driver to the right Slide the opposite end to the left Y X Figure 25 Top view of an incorrect horizontal alignment 4 Repeat the previous steps until the permitted reading value is achieved 4 4 5 3 Perform parallel alignment for a vertical correction Refer to the alignment table in Permitted indicator values for alignment checks see Table of Contents for location of table for the proper cold ...

Page 39: ...icator values for alignment checks see Table of Contents for location of table for the proper cold alignment value based on the motor temperature rise and the pump operating temperature A unit is in parallel alignment when the parallel indicator P does not vary by more than 0 05 mm 0 002 in as measured at four points 90 apart at the operating temperature 1 Set the parallel alignment indicator P to...

Page 40: ...ccording to the separate instructions for angular and parallel alignment until you obtain the permitted reading values 4 4 5 6 Perform complete alignment for a horizontal correction A unit is in complete alignment when both the angular indicator A and the parallel indicator P do not vary by more than 0 05 mm 0 002 in as measured at four points 90 apart 1 Set the angular and parallel dial indicator...

Page 41: ... the pump use a foot mounted drive unit on a precision machined baseplate and perform a conventional alignment 4 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 recommended 1 Clean all the areas of the baseplate that will come into contact with t...

Page 42: ...1 Baseplate 2 Grout 3 Foundation 4 Dam 5 Bolt Figure 30 Fill remainder of baseplate with grout 7 Tighten the foundation bolts 4 6 Piping checklists 4 6 1 General piping checklist Precautions WARNING Risk of premature failure Casing deformation can result in misalignment and contact with rotating parts causing excess heat generation and sparks Flange loads from the piping 4 6 Piping checklists 40 M...

Page 43: ...re given in the Hydraulic Institute Standards available from the Hydraulic Institute at 9 Sylvan Way Parsippany NJ 07054 3802 You must review this document before you install the pump Checklist Check Explanation comment Checked Check that all piping is supported in dependently of and lined up naturally with the pump flange Strain on the pump Misalignment between the pump and the drive unit Wear on...

Page 44: ...fasteners are properly tightened and that there are no missing fasteners 4 6 2 Suction piping checklist Performance curve reference Net positive suction head available NPSHA must always exceed NPSH required NPSHR as shown on the published performance curve of the pump Suction piping checks Check Explanation comment Checked Check that the distance between the inlet flange of the pump and the closes...

Page 45: ...ds with specific gravity less than 0 60 a pressure drop across the suction strainer may be due to ice buildup Ice buildup can cause turbulence low pres sure areas and pumpage vaporization If more than one pump operates from the same liquid source check that separate suction piping lines are used for each pump This recommendation helps you to achieve a higher pump performance and prevent vapor lock...

Page 46: ...occurrence of air and cavita tion in the pump inlet Check that the piping is level or slopes downward from the liquid source Make sure that no part of the suction pip ing extends below the suction flange of the pump Make sure that the suction piping is ade quately submerged below the surface of the liquid source This prevents air from entering the pump through a suction vortex Example Elbow close ...

Page 47: ...he pump Reduce risk of pumpage vaporization and vapor locking at low flow rates for low specific gravity liq uids See Example Discharge piping equipment for illustra tions Check that a check valve is installed in the discharge line between the isolation valve and the pump discharge outlet The location between the isolation valve and the pump allows inspection of the check valve The check valve pre...

Page 48: ...d water hammer Example Discharge piping equipment Correct Incorrect 1 2 3 4 1 Bypass line 2 Shut off valve 3 Check valve 4 Discharge isolation valve 2 1 1 Check valve incorrect position 2 The isolation valve should not be positioned be tween the check valve and the pump 4 6 Piping checklists 46 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 49: ...aft failure and or loss of prime WARNING Risk of death serious personal injury and property damage Heat and pressure buildup can cause explosion rupture and discharge of pumpage Never operate the pump with suction and or discharge valves closed Running a pump without safety devices exposes operators to risk of serious personal in jury or death Never operate a unit unless appropriate safety devices...

Page 50: ...a small amount of fluid through the pump until the casing tem perature is within 38 C 100 F of the fluid temperature Accomplish this by flowing fluid from pump inlet to discharge drain optionally the casing vent can be included in warm up circuit but not required Soak for 2 hours at process fluid temperature At initial startup do not adjust the variable speed drivers or check for speed governor or...

Page 51: ...ng You can access the bearing housing tap bolts without removing this end plate if maintenance of internal pump parts is necessary 6 Remove the pump half of the coupling guard a Slightly spread the bottom apart b Lift upwards 1 2 3 4 Item Description 1 Annular groove 2 Pump side end plate 3 Driver 4 Pump half of the coupling guard 5 2 Remove the coupling guard Model CV 3196 i FRAME Installation Op...

Page 52: ...n jog the driver long enough to determine that the direc tion of rotation corresponds to the arrow on the bearing housing or close coupled frame 6 Lock out power to the driver 5 4 Impeller clearance check The impeller clearance check ensures the following The pump turns freely The pump operates at optimal efficiency for long equipment life and low energy consumption 5 4 1 Impeller clearances CV 31...

Page 53: ...t Clearance 100A 822 356B 357B 122 561 Figure 31 Impeller clearance measurement 5 5 1 Set the impeller clearance dial indicator method CV 3196 only Before you can begin this procedure you must lock out the driver power and then remove the coupling guard according to the instructions in this manual WARNING Failure to disconnect and lock out driver power may result in serious physical injury or deat...

Page 54: ...remove the coupling guard according to the instructions in this manual WARNING Failure to disconnect and lock out driver power may result in serious physical injury or death Always disconnect and lock out power to the driver before performing any installation or main tenance tasks Electrical connections must be made by certified electricians in compliance with all inter national national state and...

Page 55: ...ings must have proper certification to be used in an ATEX classified environment Use the instruc tions from the coupling manufacturer in order to lubricate and install the coupling Refer to driver coupling gear manufacturers IOM for specific instructions and recommendations 5 6 1 Install the coupling guard WARNING Running a pump without safety devices exposes operators to risk of serious personal ...

Page 56: ...n place make any necessary coupling adjustments and then proceed to the next step If the pump size is Then STi MTi LTi Align the pump side end plate to the bearing frame You do not need to adjust the impeller XLT i 1 Align the end plate on the pump side to the bearing housing so that you meet these conditions 1 The large slots on the end plate do not touch the bearing housing tap bolts 2 The small...

Page 57: ...part b Place the coupling guard half over the pump side end plate 1 2 3 4 Item Description 1 Annular groove 2 Pump side end plate 3 Driver 4 Pump half of the coupling guard Figure 36 Guard half installation The annular groove in the coupling guard half must fit around the end plate 5 6 Couple the pump and driver Model CV 3196 i FRAME Installation Operation and Maintenance Manual 55 ...

Page 58: ...tem Description 1 Nut 2 Washer 3 Bolt Figure 38 Secure coupling guard half to end plate 5 Put the driver half of the coupling guard in place a Slightly spread the bottom apart b Place the driver half of the coupling guard over the pump half of the coupling guard The annular groove in the coupling guard half must face the motor 5 6 Couple the pump and driver 56 Model CV 3196 i FRAME Installation Op...

Page 59: ...ular groove of the driver half of the coupling guard 8 Use a bolt a nut and two washers to secure the coupling guard half to the end plate Hand tighten only The hole is located on the driver side of the coupling guard half 9 Slide the driver half of the coupling guard towards the motor so that the coupling guard completely covers the shafts and coupling 5 6 Couple the pump and driver Model CV 3196...

Page 60: ...mp that has been out of service for a long period of time and re grease if nec essary Pumps are shipped without oil You must lubricate oil lubricated bearings at the job site Grease lubricated bearings are lubricated at the factory The bearing manufacturer fills greased for life bearings with grease and seals them at the factory You do not need to lubricate or seal these bearings 5 6 2 1 Oil volum...

Page 61: ...Lubricant type Chevron GST Oil 68 Exxon Teresstic EP 68 Mobil DTE Heavy Medium Phillips 66 Turbine Oil VG68 Shell Turbo T 68 Sunoco Sunvis 968 Royal Purple SYNFILM ISO VG 68 Synthetic Oil 5 6 2 4 Lubricate the bearings with oil WARNING Risk of explosive hazard and premature failure from sparks and heat generation Ensure bearings are properly lubricated prior to startup Use a high quality turbine o...

Page 62: ...earings 5 7 Shaft sealing options In most cases the manufacturer seals the shaft before shipping the pump If your pump does not have a sealed shaft see the Shaft seal maintenance section in the Maintenance chapter This model uses these types of shaft seals Cartridge mechanical seal Conventional inside component mechanical seal Conventional outside component mechanical seal Dynamic seal Packed stuf...

Page 63: ...l the packing lantern ring or split gland These parts are included with the pump in the box of fittings Before you start the pump you must install the packing lantern ring and split gland according to the Packed stuffing box maintenance section in the Maintenance chapter 5 7 4 Connection of sealing liquid for a packed stuffing box NOTICE Make sure to lubricate the packing Failure to do so may resu...

Page 64: ...ase If you lubricate with clean water then the repeller reduces both the quantity and pressure of seal water that is necessary If the suction head is less than the repeller capability then the stuffing box pressure is the same as the atmospheric pressure Water pressure for the seal must be high enough to overcome static head when the pump is not operating to keep pumped fluid out of the packing Th...

Page 65: ...ting shaft between pump seal and bearing frame Avoid contact and or install proper guard ing If guarding is not provided with the pump contact Goulds for price and availability of proper guard ing 5 9 Pump priming 5 9 1 Prime the pump with the suction supply above the pump 1 Slowly open the suction isolation valve 2 Open the air vents on the suction and discharge piping until the pumped fluid flow...

Page 66: ... valves 4 Close the vent valves 5 Close the outside supply line 1 2 3 4 5 Item Description 1 Discharge isolation valve 2 Shutoff valve 3 From outside supply 4 Foot valve 5 Check valve Figure 44 Pump priming with suction supply below pump with foot valve and an outside supply 5 9 Pump priming 64 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 67: ...e by ejector Prime by automatic priming pump 5 10 Start the pump WARNING Risk of equipment damage seal failure and breach of containment Ensure all flush and cool ing systems are operating correctly prior to starting pump NOTICE Risk of equipment damage due to dry operation Immediately observe the pressure gauges If discharge pressure is not quickly attained stop the driver immediately reprime and...

Page 68: ... pump immediately and correct the prob lem A pump can exceed normal levels for several reasons See Troubleshooting for information about possible solutions to this problem 7 Repeat steps 5 and 6 until the pump runs properly 5 11 Activate the i ALERT Health Monitor WARNING Explosive hazard and risk of personal injury Heating to high temperatures could cause com bustion of the condition monitor Neve...

Page 69: ...ent Health Monitor WARNING Explosive hazard and risk of personal injury Heating to high temperatures could cause com bustion of the condition monitor Never heat the condition monitor to temperatures in excess of 149 C 300 F or dispose of in a fire For all information refer to the i ALERT 2 Equipment Health Monitor Installation Operation and Mainte nance manual http www ittproservices com aftermark...

Page 70: ...ssive heat build up If normal levels are exceeded shut down and resolve NOTICE Cavitation can cause damage to the internal surfaces of the pump Ensure net positive suction head available NPSHA always exceeds NPSH required NPSH3 as shown on the published performance curve of the pump Operation under freezing conditions NOTICE Do not expose an idle pump to freezing conditions Drain all liquid that w...

Page 71: ...ful solid red LEDs will be displayed 5 16 Reset the i ALERT 2 Health Monitor To deactivate or reset the i ALERT 2 monitor please refer to the i ALERT 2 IOM http i alert com Always reset the health monitor when the pump is started after maintenance system change or being shut down for an extended period of time Failure to do so may result in false baseline levels that could cause the health monitor...

Page 72: ...f the installer and the user of the unit Check the alignment of all drive components prior to operating the unit Follow the coupling installation and operation procedures from the coupling manu facturer You must check the final alignment after the pump and driver are at operating temperature For initial alignment instructions see the Installation chapter 1 Run the unit under actual operating condi...

Page 73: ...sual noise vibration and bearing temperatures Check the pump and piping for leaks Analyze the vibration Inspect the discharge pressure Inspect the temperature Check the seal chamber and stuffing box for leaks Ensure that there are no leaks from the mechanical seal Adjust or replace the packing in the stuffing box if you notice excessive leaking Three month inspections Perform these tasks every thr...

Page 74: ...cated at the factory Regrease bearings every 2000 oper ating hours or every three months 6 2 1 Lubricating oil requirements Oil requirements based on temperature For the majority of operating conditions bearing temperatures run between 49 C 120 F and 82 C 180 F and you can use an oil of ISO viscosity grade 68 at 38 C 100 F If temperatures exceed 82 C 180 F refer to the table for temperature requir...

Page 75: ...tion 1 Wipe dirt from the grease fittings 2 Remove the two grease relief plugs from the bottom of the frame 3 Fill both of the grease cavities through the fittings with a recommended grease until the fresh grease comes out of the relief holes 4 Make sure that the frame seals are seated in the bearing housing If they are not press them in place with the drains located at the bottom 5 Reinstall the ...

Page 76: ...ons based on temperature Most pumps use Sunoco 2EP grease High temperature units that can pump fluids with a temper ature greater than 177 C 350 F use Mobil SCH32 This table shows which brand of grease to use when lubricating the pump Brand When temperature of pumped fluid is less than 177 C 350 F NLGI consistency 2 When temperature of pumped fluid is greater than177 C 350 F NLGI consistency 3 Mob...

Page 77: ... a mechanical seal depends on the cleanliness of the pumped fluid Due to the diversity of op erating conditions it is not possible to give definite indications as to the life of a mechanical seal 6 3 2 Packed stuffing box maintenance WARNING Packed stuffing boxes are not allowed in an ATEX classified environment Failure to disconnect and lock out driver power may result in serious physical injury ...

Page 78: ... 4 1 Disassembly precautions WARNING Failure to disconnect and lock out driver power may result in serious physical injury or death Always disconnect and lock out power to the driver before performing any installa tion or maintenance tasks Electrical connections must be made by certified electricians in compliance with all international national state and local rules Refer to driver coupling gear ...

Page 79: ...equired In order to disassemble the pump you need these tools Bearing puller Brass drift punch Cleaning agents and solvents Dial indicators Feeler gauges Hex wrenches Hydraulic press Induction heater Leveling blocks and shims Lifting sling Micrometer Rubber mallet Screwdriver Snap ring pliers Torque wrench with sockets Wrenches Lifting eyebolt dependent on pump motor size 6 4 3 Drain the pump CAUT...

Page 80: ...k pull out assembly removal oil lubricated bearing frame Oil analysis should be part of a preventive maintenance program that determines the cause of a fail ure Save the oil in a clean container for inspection 2 The back pull out assembly consists of all parts except the casing 100 The casing 100 can re main on the foundation and in the piping if it is not the casing itself which must be repaired ...

Page 81: ... hold down bolts of the bearing frame foot 5 Tighten the jackscrews evenly using an alternating pattern in order to remove the back pull out as sembly You can use penetrating oil if the adapter to the casing joint is corroded 6 Remove the back pull out assembly from the casing 100 6 4 Disassembly Model CV 3196 i FRAME Installation Operation and Maintenance Manual 79 ...

Page 82: ...asket surfaces Clean surfaces prevent the casing gasket from partially adhering to the casing due to binders and adhesives in the gasket material 6 4 6 Remove the coupling hub 1 Clamp the frame adapter securely to the workbench 2 Remove the coupling hub Mark the shaft for relocation of the coupling hub during reassembly Figure 53 Coupling hub removal 6 4 Disassembly 80 Model CV 3196 i FRAME Instal...

Page 83: ...the work surface 3 To loosen the impeller quickly turn it counter clockwise viewed from the impeller end of the shaft while impacting the wrench handle on the workbench or a solid block Shaft Wrench 101 Figure 54 Loosen impeller 4 Repeat step 3 until the impeller becomes loose 5 Remove and discard the impeller O ring 412A You will insert a new O ring during reassembly 412A Figure 55 O ring for mod...

Page 84: ... the shaft wrench A05107A over the shaft 122 and key 5 Rotate the impeller clockwise viewed from the impeller end of the shaft and raise the wrench off of the work surface 6 To loosen the impeller quickly turn the impeller counter clockwise viewed from the impeller end of the shaft while impacting the wrench handle on the workbench or a solid block 7 Repeat step 6 until the impeller becomes loose ...

Page 85: ... clip that retains the bolt on the guard to maintain a captive fastener 3 Retain each guard half with fasteners for reinstallation 1 2 Item Description 1 Retaining clip do not remove 2 Mounting bolt Figure 57 Shaft guard installation 6 4 8 2 Remove the shaft guard MTi LTi XLTi i17 1 Remove the bolt for each shaft guard half that mounts the halves to the brackets on each side 2 Do not remove the cl...

Page 86: ...l chamber cover Table 14 Procedures for seal chamber cover removal by model Model Procedure 3196 CV 3196 HT 3196 LF 3196 3796 Remove the seal chamber cover NM 3196 3198 Remove the seal chamber cover and or backplate 6 4 10 Remove the seal chamber cover 3196 CV 3196 HT 3196 LF 3196 3796 1 Remove the gland stud nuts 355 2 Remove the seal chamber stud nuts 370H 3 Remove the seal chamber 184 6 4 Disas...

Page 87: ...ng the setscrews and sliding it off the sleeve Refer to the mechanical seal instructions for more information 6 Remove the gland 250 the stationary portion of the seal and the O ring 360Q 126 383 360Q 383 250 Figure 60 Gland removal 6 4 11 Remove the stuffing box cover 3196 CV 3196 HT 3196 LF 3196 3796 1 Remove the gland nuts 355 and the gland 107 2 Remove the stuffing box cover nuts 370H 3 Remove...

Page 88: ... 4 Remove the shaft sleeve 126 105 184 106 Figure 63 Remove the shaft sleeve 5 Remove the packing 106 and lantern ring 105 from the stuffing box cover 184 A lantern ring does not come with self lubricating graphite packing 6 4 Disassembly 86 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 89: ...et head cap screws 265 4 Remove the packed stuffing box cover 184 and gasket 264 5 Remove the repeller 262 from the backplate 444 444 184 262 264 107 355 106 265 Figure 66 Repeller removal 6 4 13 Remove the frame adapter MTi LTi XLT i The 3198 frame adapter is not interchangeable with the adapter of any other model 6 4 Disassembly Model CV 3196 i FRAME Installation Operation and Maintenance Manual...

Page 90: ...el Type of fit STi O ring fit into the bearing frame adapter 228A MTi LTi XLT i O ring fit into the frame adapter 2 Remove the O rings 497H and 497J and the seal 333A 497H 497J 333A 108 Figure 67 O ring removal 6 4 15 Power end disassembly 6 4 15 1 Disassemble the power end STi MTi 1 Remove the clamp screws 370C and back off the jam nuts 423 2 Tighten the jack screws 370D evenly to move the bearin...

Page 91: ... 168A 496 Figure 69 Outboard bearing retaining snap ring removal 7 Remove the bearing housing 134 and bearings 112A and 168A from the shaft 122 134 112 361A 168A 122 Figure 70 Bearing housing and bearings removal 8 Remove the bearing locknut 136 and bearing lock washer 382 9 Remove the inboard bearing 168A 10 Remove the outboard bearing 112A 6 4 Disassembly Model CV 3196 i FRAME Installation Opera...

Page 92: ...board bearing removal 6 4 15 2 Disassemble the power end STi and MTi with duplex bearings 1 Remove the clamp screws 370C and back off the jam nuts 423 2 Tighten the jack screws 370D evenly to move the bearing housing 134 out of the bearing frame 228A 3 Remove the shaft assembly from the bearing frame 228A 228A 134 370D 423 370C Figure 72 Shaft assembly removal 4 Remove the jack screws 370D with th...

Page 93: ... clamp ring from the shaft 7 Remove the bearing housing 134 and the bearings 112A and 168A from the shaft 122 250 184 355 370H Figure 74 Bearing housing and bearing removal 8 Remove the inboard bearing 168A 122 168A 253B 382 136 112A Figure 75 Inboard bearing removal 9 Remove the bearing locknut 136 and bearing lockwasher 382 10 Remove the outboard bearings 112A 6 4 Disassembly Model CV 3196 i FRA...

Page 94: ...G 332A 497F Figure 76 Outboard labyrinth oil seal removal 6 4 15 3 Disassemble the power end LTi 1 Remove the clamp screws 370C and back off the jam nuts 423 2 Evenly tighten the jack screws 370D to move the bearing housing 134 out of the bearing frame 228A 3 Remove the shaft assembly from the bearing frame 228A 228A 134 370D 423 370C Figure 77 Shaft assembly removal 4 Remove the jack screws 370D ...

Page 95: ...122 168A 248A 112A 136 382 253B Figure 80 O ring removal 8 Remove the flinger so that the flinger seating surface on the shaft can be cleaned 9 Remove the bearing locknut 136 and the bearing lockwasher 382 10 Remove the outboard bearings 112A and the clamp ring 253B NOTICE Use force only on the inner race when pressing bearings from the shaft Failure to do so may result in equipment damage 6 4 Dis...

Page 96: ...ring removal 6 4 15 4 Disassemble the power end XLT i and i17 1 Remove the bearing frame from the frame foot 241 using the frame foot bolts 370F 228A 241 370F 370D 423 134 370C 2 Remove the clamp screws 370C and back off the jam nuts 423 3 Tighten the jack screws 370D evenly to move the bearing housing 134 out of the bearing frame 228A 4 Remove the shaft assembly from the bearing frame 228A 5 Remo...

Page 97: ... 371C 360C 10 Remove the bearing housing 134 and the bearing 112A from the shaft 122 134 122 112A 11 Remove the bearing locknut 136 the bearing lockwasher 382 and the outboard bearing 112A NOTICE Use force only on the inner race when pressing bearings from the shaft Failure to do so may result in equipment damage NOTICE Do not reuse bearings if removed from shaft Doing so may result in equipment d...

Page 98: ...move the shaft assembly from the bearing frame 228A 5 Remove the jack screws 370D and the nuts 423 6 Remove the bearing housing O ring 496 and the inboard bearing 168A 122 168A 248A 112A 136 382 253B 7 Remove the bolts 371C the end cover 109A and the gasket 360C 8 If necessary remove the outboard labyrinth oil seal 332A from the end cover 109A and remove the O rings 497F and 497G Labyrinth oil sea...

Page 99: ... Failure to do so may result in equipment damage NOTICE Do not reuse bearings if removed from shaft Doing so may result in equipment damage Re place the bearings before reassembly 122 382 136 112A 6 4 16 Disassemble the bearing frame 1 Remove these plugs from the bearing frame 228A oil fill plug 113A oil drain plug 408A sight oiler plug 408J four oil mist grease connection plugs 408H 6 4 Disassemb...

Page 100: ...300 F or dispose of in a fire Guidelines The battery contained in the condition monitor does not contain enough lithium to qualify as reactive haz ardous waste Use these guidelines when disposing of the condition monitor The condition monitor is safe for disposal in the normal municipal waste stream Adhere to local laws when you dispose of the condition monitor 6 4 18 Disassemble the C face adapte...

Page 101: ...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 cleaning the parts Failure to do so may result in equipment damage 6 5 1 Replacement guidelines Casing check and replacement WARNING Risk of death or serious injury Leaking fluid can cause fire and or burns Inspect and ensure gasket sealing surfa...

Page 102: ...2 in Pumpout vanes When worn or bent more than 0 8 mm 1 32 in Vane edges When you see cracks pitting or corrosion damage Impeller areas to inspect 101 Figure 84 Areas to inspect for wear on the CV 3196 impeller Frame adapter check and replacement Replace the frame adapter if it has cracks or excessive corrosion damage Make sure the gasket surface is clean 6 5 Pre assembly inspections 100 Model CV ...

Page 103: ...ain dimensional relationships with other surfaces Replace parts if the seats are defective Fasteners WARNING Risk of serious personal injury or property damage Fasteners such as bolts and nuts are criti cal to the safe and reliable operation of the product Ensure appropriate use of fasteners during installation or reassembly of the unit Use fasteners of the proper size and material only Replace al...

Page 104: ... inches Coupling fit in millimeters inches With sleeve 0 025 0 001 0 025 0 001 Without sleeve 0 051 0 002 0 025 0 001 Shaft and sleeve check 126 Figure 86 Shaft and sleeve check Check the shaft and sleeve 126 surface for grooves and pitting Replace the shaft and sleeve if any grooves or pits are found 6 5 3 Bearing frame inspection Checklist Check the bearing frame for these conditions Visually in...

Page 105: ...ide surface inspection locations This figure shows the areas to inspect for wear on the bearing frame inside surface 241 Figure 88 Inside surface inspection locations 6 5 4 C face adapter inspection Checklist Visually inspect the C face adapter 340 for cracks Check all surfaces for rust scale or debris and remove all loose and foreign material Check for corrosion or pitting 6 5 Pre assembly inspec...

Page 106: ...these surfaces are clean Seal chamber and stuffing box cover Mounting Make sure there is no pitting or wear greater than 3 2 mm 1 8 in deep Replace the seal chamber and stuffing box cover if pitting or wear exceeds this measurement Inspect the machined surfaces and mating faces noted in the figures These images point to the areas to inspect 184 Figure 90 BigBoreTM chamber 6 5 Pre assembly inspecti...

Page 107: ...184 Figure 91 Stuffing box cover 444 Figure 92 Dynamic seal backplate 184 Figure 93 TaperBoreTM Plus 6 5 Pre assembly inspections Model CV 3196 i FRAME Installation Operation and Maintenance Manual 105 ...

Page 108: ...7 Bearing housing inspection Checklist Inspect the bearing housing 134 bore according to the bearing fits and tolerances table Replace the bearing housing if the dimensions exceed acceptable values Reference see Bearings fits and tolerances Visually inspect the bearing housing for cracks and pits Checklist for specific models This table shows bearing housing checks that are required for specific m...

Page 109: ...134 Figure 94 STi and MTi bearing housing 134 Figure 95 LTi bearing housing 6 5 Pre assembly inspections Model CV 3196 i FRAME Installation Operation and Maintenance Manual 107 ...

Page 110: ...oose 0 000 0 0000 loose 0 038 0 0015 loose 0 000 0 0000 loose 0 043 0 0017 loose 0 000 0 0000 loose Bearing OD Inboard 72 000 2 8346 71 986 2 8341 100 000 3 9370 99 985 3 9364 120 000 4 7244 119 985 4 7238 140 000 5 5118 139 982 5 5111 Shaft OD Outboard 30 010 1 1815 30 002 1 1812 45 014 1 7722 45 004 1 7718 50 013 1 9690 50 003 1 9686 65 016 2 5597 65 004 2 5592 Clearance 0 020 0 0008 tight 0 003...

Page 111: ...d to install bearings The recommended method is to use an induction heater that heats as well as demagnetizes the bearings Failure to use this method may result in equipment damage 1 Prepare the bearing frame 228 as follows see the illustration a Install the oil fill plug 113A b Install the oil drain plug 408A c Install the sight glass 319 d Install the sight oiler plug 408J e Install the plug for...

Page 112: ...aring 112 on the shaft 122 against the shoulder and snug the locknut 136 against the bearing until it is cool The locknut prevents the bearing from moving away from the shaft shoulder as it cools g Remove the bearing locknut 136 after the bearing 112 cools 3 Put the lockwasher 382 onto the shaft 122 4 Thread the locknut 136 onto the shaft 122 and tighten it until it is snug 5 Bend the tangs of the...

Page 113: ... damage Make sure that the shaft rotates freely f Install the outboard labyrinth oil seal 332A into the bearing housing 134 Place the drain slots of the oil seal at the bottom position 6 o clock Make sure that the edges of the keyway are free from burrs To protect the O ring cover the keyway lengthwise with a piece of electrical tape before you install the oil seal 332A 134 112 361A 168A 496 Figur...

Page 114: ... steel toed shoes gloves etc at all times Seek assistance if necessary CAUTION Risk of physical injury from hot bearings Wear insulated gloves when using a bearing heater NOTICE Ensure that the pipe threads are clean Apply thread sealant to the plugs and fittings Failure to do so may result in oil leaks and equipment damage NOTICE There are several methods used to install bearings The recommended ...

Page 115: ...ard bearings 112A on the shaft 122 The regreasable bearing has a single shield Make sure that the bearing is installed with the shield away from the impeller The duplex bearings are mounted back to back Make sure that the orientation of the bearings are correct a Inspect the shaft 122 to ensure that it is clean dimensionally correct and is free of nicks and burrs 122 112 136 Figure 102 Shaft inspe...

Page 116: ...82 onto the shaft 122 4 Thread the locknut 136 onto the shaft 122 and tighten it until it is snug 5 Bend the tangs of the lockwasher into the slots of the locknut 6 Place the bearing clamp ring 253B onto the shaft 122 Make sure that the orientation of the bearing clamp ring is correct 7 Coat the inner surfaces of the bearings with lubricant 8 Put the inboard bearing 168 onto the shaft 122 122 168A...

Page 117: ...s follows see the illustration a Coat the outside of the bearing housing 134 with oil b Coat all the internal surfaces of the bearing frame 228 with oil c Install the shaft assembly into the bearing frame 228 Make sure that the shaft rotates freely d Install the clamp bolts 370C in the bearing housing 134 and tighten by hand e Install the jack bolts 370D with the locknuts 423 in the bearing housin...

Page 118: ... cooler inlet 408L f Install the plug for the oil cooler outlet 408M g Install four oil mist connection plugs 408H Or Install two grease fittings 193 and two grease relief plugs 113 h Attach the bearing frame foot 241 and fasten the bolts 370F by hand 370F 241 408A 408L 319 228A 408W 113A 372T 761B 408W 408M 408N Figure 106 Attach the bearing frame foot 2 Install the oil flinger 248A onto the shaf...

Page 119: ... Position the bearings 112 on the shaft 122 against the shoulder and snug the locknut 136 against the bearings until they are cool The locknut prevents the bearings from moving away from the shaft shoulder as they cool Rotate the outer bearing rings relative to each other as they are placed on the shaft to assure good align ment h Remove the bearing locknut 136 after the bearings 112 are cool 5 Pu...

Page 120: ...rom burrs To protect the O ring cover the keyway lengthwise with a piece of electrical tape before you install the oil seal 236A 253B 134 496 332A Figure 110 Outboard labyrinth oil seal reassembly 12 Install the shaft assembly into the bearing frame as follows see the illustration a Coat the outside of the bearing housing 134 with oil b Coat all the internal surfaces of the bearing frame 228 with ...

Page 121: ...ittings Failure to do so may result in oil leaks and equipment damage NOTICE There are several methods used to install bearings The recommended method is to use an induction heater that heats as well as demagnetizes the bearings Failure to use this method may result in equipment damage 1 Prepare the bearing frame 228 as follows see the illustration a Install the oil fill plug 113A b Install the oi...

Page 122: ...C 230 F f Position the bearing 112 on the shaft 122 against the shoulder and snug the locknut 136 against the bearing until it is cool The locknut prevents the bearing from moving away from the shaft shoulder as it cools g Remove the bearing locknut 136 after the bearing 112 cools 3 Put the lockwasher 382 onto the shaft 122 4 Thread the locknut 136 onto the shaft 122 and tighten it until it is snu...

Page 123: ...e that the bearing is installed with the shield away from the impeller 122 168A 9 Install the remaining parts onto the bearing shaft as follows see the illustration a Install a new O ring 496 b Install the outboard labyrinth oil seal 332A into the end cover 109A Place the drain slots of the oil seal at the bottom position 6 o clock Make sure that the edges of the keyway are free from burrs To prot...

Page 124: ...ng housing 134 and tighten by hand f Attach the bearing frame foot 241 and fasten the bolts 370F by hand 228A 134 370D 423 370C 6 6 5 Assemble the rotating element and the bearing frame XLT i and i17 with duplex bearings WARNING Lifting and handling heavy equipment or components poses a crush hazard Use caution dur ing lifting and handling and wear appropriate Personal Protective Equipment PPE suc...

Page 125: ...sight oiler plug 408J e Install the plug for the oil cooler inlet 408L f Install the plug for the oil cooler outlet 408M g Install four oil mist connection plugs 408H Or Install two grease fittings 193 and two grease relief plugs 113 370F 241 408A 408L 319 228A 113A 408N 408M 2 Install the outboard bearings 112A on the shaft 122 The regreasable bearing has a single shield Make sure that the bearin...

Page 126: ...way from the shaft shoulder as they cool Rotate the outer bearing rings relative to each other as they are placed on the shaft to assure good align ment h Remove the bearing locknut 136 after the bearings 112 are cool 3 Put the lockwasher 382 onto the shaft 122 4 Thread the locknut 136 onto the shaft 122 and tighten it until it is snug 5 Bend the tangs of the lockwasher into the slots of the lockn...

Page 127: ...e bearing shaft as follows see the illustration a Install a new O ring 496 b Install the outboard labyrinth oil seal 332A into the end cover 109A Place the drain slots of the oil seal at the bottom position 6 o clock Make sure that the edges of the keyway are free from burrs To protect the O ring cover the keyway lengthwise with a piece of electrical tape before you install the oil seal 332A 109A ...

Page 128: ...e shaft end play by moving the shaft forward and backward by hand and note any indica tor movement If the total indicator reading is greater than the values in this table then disassemble the shaft and determine the cause Table 19 Shaft end play Use this table as a reference for shaft end play values Frame Double row bearing Duplex bearing STi millimeters inches 0 028 0 0011 0 048 0 0019 0 018 0 0...

Page 129: ...peller on the shaft until hand tight c Rotate the shaft 360º d If the total indicator reading is greater than 0 051 mm 0 002 in then disassemble the shaft sleeve and determine the cause e Remove the impeller and shaft sleeve 6 6 Reassembly Model CV 3196 i FRAME Installation Operation and Maintenance Manual 127 ...

Page 130: ...eck frame face run out 5 Place the manila gasket 360D on the frame 228 and hold the gasket in place by inserting the dowel pins 469B in their holes The gasket is designed to fit only one way 6 Install the frame adapter a Place the frame adapter 108 onto the frame assembly b Align the bolt holes and dowel locations on the frame adapter with the bolt holes and dowel lo cations on the frame 6 6 Reass...

Page 131: ...r than 0 13 mm 0 005 in then determine the cause and cor rect it before you proceed Figure 117 Check adapter fit 7 Install the labyrinth oil seal 333A into the adapter 108 and the bearing frame 228 The labyrinth oil seal is an O ring fit 8 Position the labyrinth oil seal drain slots at the bottom 6 o clock position Refer to Assemble the INPRO labyrinth oil seal for more information on the labyrint...

Page 132: ... in place by an elastomeric drive ring 4 The drive ring causes the rotor to turn with the shaft and provides a positive static seal against the shaft Since there is no metal to metal contact there are no friction or wear concerns NOTICE The labyrinth seal is a one piece design Do not attempt to separate the rotor from the stator Doing so will damage the seal 6 6 Reassembly 130 Model CV 3196 i FRAM...

Page 133: ...is compatible with the O ring material and the pump system standards 3 Use an arbor press to install the outboard INPRO VBXX D into the bearing cover with the expulsion port 6 at the 6 o clock position Press the outboard INPRO VBXX D down to where the stator location ramp 9 starts to avoid an gular misalignment There is a nominal 0 051 mm 0 002 in interference fit 4 Discard any residual material f...

Page 134: ...ry threads 143TC 145TC 11 Nm 8 ft lb 16 Nm 12 ft lb 182TC 286TC 20 ft lb 27 Nm 41 Nm 30 ft lb 324TC 365TC 39 ft lb 53 Nm 80 Nm 59 ft lb 6 6 10 Shaft sealing WARNING The mechanical seal used in an Ex classified environment must be properly certified CAUTION Running a mechanical seal dry even for a few seconds can cause seal failure and physical injury Never operate the pump without liquid supplied ...

Page 135: ... backplate 5 Install four socket head capscrews 265 and tighten them securely 6 Install a new sealing element into the gland 7 Install a gasket 360Q and gland 107 on the stuffing box cover 184 8 Install the nuts 355 9 Install a dynamic seal assembly and nuts 370H 370H Figure 121 Dynamic seal installation 10 Check the stuffing box cover runout and rotate the indicator through 360 degrees An indicat...

Page 136: ...e packing lantern ring or split gland installed These parts are included with the box of fittings shipped with each pump and must be installed before startup 1 Carefully clean the stuffing box bore 2 Twist the packing enough to get it around the shaft Packing rings Lantern rings 1 3 4 2 3 4 1 Packing rings 2 Lantern rings 3 Correct 4 Incorrect Figure 123 Packing rings and lantern rings 3 Insert th...

Page 137: ...2 Assemble the seal chamber 3 Slide the cartridge seal into the seal chamber and secure using the four studs and nuts 4 Continue with the pump reassembly 5 Set the impeller clearance Refer to the Impeller clearance setting topic for more information 6 Tighten the setscrews in the seal locking ring in order to secure the seal to the shaft 7 Remove the centering clips from the seal 6 6 10 4 Seal the...

Page 138: ... chamber cover runout Rotate the indicator through 360º If the total indicator reading is greater than 0 13 mm 0 005 in ches determine the cause and correct the issue before you proceed c Install the shaft sleeve 126 6 6 Reassembly 136 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 139: ... Use the scribed line and the seal reference dimension 9 Reinstall the seal chamber 10 Slide the gland on the seal chamber studs and secure them with the gland nuts Tighten the nuts evenly so that the gland is seated on the seal chamber pilot and is perpendicular to the shaft 11 Complete the reassembly of the pump 6 6 10 5 Seal the shaft with a conventional outside component mechanical seal WARNIN...

Page 140: ...Check seal chamber cover runout Rotate the indicator through 360 degrees If the total indicator reading is greater than 0 13 mm 0 005 in determine the cause and correct the issue before you proceed c Install the shaft sleeve 126 6 6 Reassembly 138 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 141: ... seal chamber 9 Reinstall the seal chamber 10 Complete the reassembly of the pump 6 6 11 Shaft guard installation if provided 6 6 11 1 Install the shaft guard STi WARNING Running a pump without safety devices exposes operators to risk of serious personal in jury or death Never operate a unit unless appropriate safety devices guards etc are properly installed Failure to disconnect and lock out driv...

Page 142: ...te coverage is maintained for rotating components Figure 131 Shaft guard assembly 6 6 11 2 Install the shaft guard MTi LTi XLTi i17 WARNING Running a pump without safety devices exposes operators to risk of serious personal in jury or death Never operate a unit unless appropriate safety devices guards etc are properly installed Failure to disconnect and lock out driver power may result in serious ...

Page 143: ...bly 2 required 5 1 4 20 x 50 in Hex Flange Screw 4 required bracket to frame adapter Figure 132 Required parts MTi LTi XLTi i17 1 Ensure that the mounting bolt for each shaft guard half is inserted with the bolt retainer in place for captive hardware 2 If brackets were removed during disassembly attach brackets to the frame adapter on each side of the pump 3 Assemble a guard half from each side of...

Page 144: ... Use a new impeller O ring 412A CV 3196 412A 101 126 Figure 134 Install the impeller 2 Attach a shaft wrench and a coupling key on the shaft a When the impeller 101 makes firm contact with the sleeve 126 raise the shaft wrench counterclockwise viewed from the impeller end of the shaft off of the bench and slam it down clockwise viewed from the impeller end of shaft b Apply a few sharp raps to tigh...

Page 145: ...k nuts 423 This approximates the impeller position when it is set to 0 38 mm 0 015 in from the casing Per form a final impeller adjustment after you install the impeller into the casing 6 Check the impeller 101 runout Check vane tip to vane tip If the total indicator reading is greater than 0 13 mm 0 005 in deter mine the cause and correct the issue before you proceed The CV 3196 impeller face is ...

Page 146: ...to the pump Tools required 5 32 inch hex wrench 1 Attach the condition monitor 761B to the bearing frame 228A using the hex head screw 372T provided 372T 228A 761B Figure 138 Attaching the condition monitor to bearing the frame 2 Tighten the hex head screw to 8 Nm 6 ft lbs More detailed information is available on http www ittproservices com aftermarket products monitoring i alert2 i ALERT2 com 6 ...

Page 147: ...es a crush hazard Use caution during lifting and handling and wear appropriate Personal Protective Equipment PPE such as steel toed shoes gloves etc at all times Seek assistance if necessary 1 Clean the casing fit and install the casing gasket 351 on the seal chamber and stuffing box cover 2 Loosen the clamping bolts 370C and jack bolts 370D on the bearing housing 423 370D 370C Figure 139 Loosen c...

Page 148: ...d tighten the casing bolts 370 Refer to the bolt torque values for information on how to tighten the casing bolts 5 Install and tighten the casing jackscrews 418 NOTICE Do not overtighten the casing jackscrews Doing so may result in equipment damage 6 6 Reassembly 146 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 149: ...information 9 Replace the auxiliary piping 10 Fill the pump with the proper lubricant See Lubricating oil requirements 11 Reinstall the coupling guard See Install the coupling guard for more information NOTICE When a cartridge mechanical seal is used ensure that the set screws in the seal locking ring are tightened and that the centering clips have been removed prior to startup This prevents seal ...

Page 150: ...h A307 Grade B casing bolts Alloy casing with 304SS F593 Grade 1 or 316SS F593 Grade 2 casing bolts Ductile iron and alloy cas ings with A193 grade B7 casing bolts Frame Casing bolt diameter in Lube Dry Lube Dry Lube Dry 8 in STi 0 50 27 20 41 30 47 35 73 54 79 58 118 87 6 in STi 0 625 53 39 80 59 96 71 145 107 156 115 235 173 MTi 0 625 53 39 80 59 96 71 145 107 156 115 235 173 LTi 0 625 53 39 80 ...

Page 151: ...ning ring 361A Bearing lockwasher 382 Bearing locknut 136 Impeller O ring 412A Bearing housing O ring 496 Outboard labyrinth seal rotary O ring 497F Outboard labyrinth seal stationary O ring 497G Inboard labyrinth seal rotary O ring 497H Inboard labyrinth seal stationary O ring 497J Lantern ring half 105 packed stuffing box Stuffing box packing 106 packed stuffing box Packing gland 107 packed stuf...

Page 152: ... grease type or consistency remove the rotor and old grease from the housing before re greasing Use a grease that is suitable for high temperatures when you have frame pumpage temperatures greater than 177 C 350 F Ensure that mineral oil greases have oxidation stabilizers and a consistency of NLGI 3 Table 27 Lubricating grease requirements Most pumps use Sunoco 2EP grease High temperature units wi...

Page 153: ...ent damage 3 Replace both bearings with unshielded oil lubricated bearings Table 28 Bearing types Frame Inboard bearing Outboard bearing Double row Duplex STi 6207 3306 7306 MTi 6309 3309 7309 LTi 6311 Not applicable 7310 XLT i i17 6313 3313 7313 4 Remove the grease fittings 193 to prevent accidental greasing Two plugs 408H are required to replace the two grease fittings 529 370F 241 408A 408L 319...

Page 154: ...lure to do so may result in equipment damage or decreased performance NOTICE Ensure that the pipe threads are clean Apply thread sealant to the plugs and fittings Failure to do so may result in oil leaks and equipment damage Consult your local ITT representative for further information on this topic Oil mist systems The ITT X Series Power Ends accept a variety of oil mist systems These are the two...

Page 155: ...essary The pump starts and then stops pumping The pump is not primed Re prime the pump and check that the pump and suction line are full of liquid The suction line has air or vapor pockets Rearrange the piping in order to eliminate air pockets The suction line has an air leak Repair the leak The bearings are running hot The pump and driver are not aligned prop erly Realign the pump and driver Ther...

Page 156: ...leveled properly and is probably twisted 1 Determine which corners of the baseplate are high or low 2 Remove or add shims at the appropriate cor ners 3 Realign the pump and driver 7 3 Assembly troubleshooting Symptom Cause Remedy There is excessive shaft end play The internal clearance of the bearings exceeds the recommended amount Replace the bearings with a bear ing of the correct type The snap ...

Page 157: ...no green or red flashing LEDs The battery is dead Replace the condition monitor The unit is deactivated Activate the condition monitor The unit is malfunctioning Consult your ITT representative for a warranty replacement The red LEDs are flashing but the tempera ture and vibration are at acceptable levels The baseline is bad Check the temperature and vibra tion levels and reset the condition monit...

Page 158: ...ng 1001 136 1 Bearing Locknut Steel 168A 1 Radial Bearing Single row ball 184 1 Seal Chamber Stuffing Box Cover 1012 1012 1203 1216 1204 193 2 Grease Fitting Steel 228 1 Bearing Frame STi 1013 All others 1001 236A 10 Cap Screw Bearing Clamp Ring 2210 239 1 Support Casing 2201 2201 2201 241 1 Frame Foot 1001 248 1 Oil Thrower 2210 250 1 Gland Mechanical Seal Material varies 253B 1 Bearing Clamp Rin...

Page 159: ...er 2210 408L 1 Plug Oil Cooler Inlet 2210 408M 1 Plug Oil Cooler Outlet 2210 408N 1 Plug Sight Glass 2210 412A 1 O Ring Graphoil Impeller 418 3 Jack Bolt Adapter to Case 2228 423 3 Jam Nut Bearing Housing Jack Bolt 2210 423B 2 Hex Nut Stuffing Box Cover to Adapter 2228 428 1 Gasket Plug PTFE 437 1 Lockwasher Casing to Support 2210 458Y 1 Plug Impeller 2229 2230 469B 2 Dowel Pin Frame to Adapter St...

Page 160: ...me Adapter 1013 109C 1 Outboard Bearing End Cover 1001 112A 1 Outboard Bearing Double row angular contact duplex pair for LTi 113 2 Plug Grease Relief 2210 113B 1 Plug Oil Fill 2210 122 1 Shaft Less Sleeve 2232 2150 2155 2248 2247 122 1 Shaft With Sleeve 2229 126 1 Shaft Sleeve 2232 2150 2155 2248 2247 134 1 Bearing Housing 1001 136 1 Bearing Locknut Steel 168A 1 Radial Bearing Single row ball 184...

Page 161: ...ng Housing 2210 382 1 Bearing Lockwasher Steel 383 1 Mechanical Seal Material varies 400 1 Coupling Key 2210 408A 1 Plug Oil Drane 2210 408H 4 Plug Oil Mist Connection 2210 408J 1 Plug Oiler 2210 408L 1 Plug Oil Cooler Inlet 2210 408M 1 Plug Oil Cooler Outlet 2210 408N 1 Plug Sight Glass 2210 412A 1 O Ring Graphoil Impeller 418 3 Jack Bolt Adapter to Case 2228 423 3 Jam Nut Bearing Housing Jack Bo...

Page 162: ...er D I PFA 100 1 Casing 1220 6929 9639 101 1 Impeller 1220 6929 6944 105 1 Lantern Ring PTFE 106 1 set Stuffing Box Packing Non asbestos braid 107 1 Gland Packed Box 1220 108 1 Frame Adapter 1013 109C 1 Outboard Bearing End Cover 1001 112A 1 Outboard Bearing Double row angluar contact duplex pair for LTi 113 2 Plug Grease Relief 2210 113B 1 Plug Oil Fill 2210 122 1 Shaft Less Sleeve 2156 2229 122 ...

Page 163: ...Bolt Frame Foot to Frame 2210 370H 2 Stud Stuffing Box Cover to Adapter 2228 370Y 2 Bolt Cap Casing to Support 371C 6 Cap Screw End Cover to Bearing Housing 2210 382 1 Bearing Lockwasher Steel 383 1 Mechanical Seal Material varies 400 1 Coupling Key 2210 408A 1 Plug Oil Drane 2210 408H 4 Plug Oil Mist Connection 2210 408J 1 Plug Oiler 2210 408L 1 Plug Oil Cooler Inlet 2210 408M 1 Plug Oil Cooler O...

Page 164: ...55C 2 Elbow Female Frame Cooling Brass 555D 1 Conn TC Sealed PWR Cast iron 761B 1 i ALERT Condition Monitor Stainless steel epoxy Table 32 Key to table symbols Not applicable Only applicable for HT 3196 3 for STi MTi LTi 4 for XLT i 4 for 6 in STi 8 for 8 in STi and MTi 16 for 13 in MTi LTi XLT I 24 for 15 in XLT I 12 for 10 in MTi LTi i17 Table 33 Material code reference Material Goulds material ...

Page 165: ...Carbon Steel 2210 A108Gr1211 304SS 2228 A276 Type 304 316SS 2229 A276 Type 316 Alloy 20 2230 B473 N08020 317SS 2232 A276 4150 Steel 2237 A322Gr4150 4140 Steel 2238 A434Gr4140 4140 Steel 2239 A193 Gr B7 Alloy B 2 2247 B335 N10665 Alloy C 276 2248 B574 N10276 GMP 2000 6929 N A PFA Lined Steel 6944 N A PFA Lined 316SS 6947 N A PFA Lined Ductile Iron 9639 N A 8 1 Parts list Model CV 3196 i FRAME Insta...

Page 166: ...408A 168 408L 241 319 423B 370D 497G 497N 332A 122 400 497F 136 370C 382 134 496 112 228A 361A 408W 113A 370B 108 360D 497J 370 351 126 Figure 144 CV 3196 cross sectional drawing 8 1 Parts list 164 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 167: ...113A 408W Figure 145 STi bearing frame exploded view 497F 332A 497G 370C 370D 423 134 496 136 382 112A 361A 400 122 370E 241 408A 408L 370B 319 408W 113A 372T 761B 408W 408N 408M 168A Figure 146 MTi bearing frame exploded view 8 1 Parts list Model CV 3196 i FRAME Installation Operation and Maintenance Manual 165 ...

Page 168: ...72T 761B 408W 408L 228A Figure 147 LTi bearing frame exploded view 497F 332A 497G 371C 109 360C 136 382 112 370D 423 370C 408H 496 122 400 168A 241 370E 408N 408M 372T 761B 408W 319 408L 408A Figure 148 XLT i bearing frame exploded view 8 1 Parts list 166 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 169: ...oler is standard on HT 3196 and optional on all other models 555C 555B 551D 494 555B 555C Figure 149 Finned tube oil cooler exploded view 8 1 Parts list Model CV 3196 i FRAME Installation Operation and Maintenance Manual 167 ...

Page 170: ...9 Certification CE or CE ATEX 9 1 Certificates of conformance CSA Certificate 9 Certification CE or CE ATEX 168 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 171: ...9 1 Certificates of conformance Model CV 3196 i FRAME Installation Operation and Maintenance Manual 169 ...

Page 172: ...ATEX notification 9 1 Certificates of conformance 170 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 173: ...IECEx Certificate of Conformity 9 1 Certificates of conformance Model CV 3196 i FRAME Installation Operation and Maintenance Manual 171 ...

Page 174: ...9 1 Certificates of conformance 172 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 175: ...Chinese Certificate of Conformity 9 1 Certificates of conformance Model CV 3196 i FRAME Installation Operation and Maintenance Manual 173 ...

Page 176: ...Manuals 10 1 For additional documentation For any other relevant documentation or manuals contact your ITT representative 10 Other Relevant Documentation or Manuals 174 Model CV 3196 i FRAME Installation Operation and Maintenance Manual ...

Page 177: ...95 8523 Asia Pacific ITT Fluid Technology Asia Pte Ltd 1 Jalan Kilang Timor 04 06 Singapore 159303 65 627 63693 65 627 63685 Europe ITT Goulds Pumps Millwey Rise Industrial Estate Axminster Devon England EX13 5HU 44 1297 639100 44 1297 630476 Latin America ITT Goulds Pumps Camino La Colina 1448 Condominio Industrial El Rosal Huechuraba Santiago 8580000 Chile 562 544 7000 562 544 7001 Middle East a...

Page 178: ...re information http www gouldspumps com ITT Goulds Pumps Inc 240 Fall Street Seneca Falls NY 13148 USA 2019 ITT Inc The original instruction is in English All non English instructions are translations of the original instruction Form IOM CV3196 i FRAME en US 2019 12 ...

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