BELL & GOSSETT

INSTRUCTION MANUAL
P81773
REVISION B

Series 3540 Multistage Centrifugal Pump

Installation, Operation & Service Instructions
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNERS USE.
DESCRIPTION
Series 3540 Multistage Centrifugal Pumps are specially designed for high pressure pump applications. The Series 3540 pumps are of vertical in-line design and feature: stainless steel fitted construction, high efficiencies, wear and corrosion resistant mechanical seals, and direct coupled pump to motor configurations. The Series 3540 pump is designed for long life and maintenance-free operation.

OPERATIONAL LIMITS
Unless special provisions have been made for your pump by ITT Bell & Gossett, the operational limits of the Series 3540 Pumps are as follows: DO NOT EXCEED THESE VALUES MAXIMUM WORKING PRESSURE Listed on the Nameplate STANDARD SEAL OPERATING LIMITS EPDM Elastomer Temperature range Models 20, 40, 80, 160 Models 300, 600 Models 20, 40, 80, 160 Models 300, 600 . 35F to 250F 32F to 250F 35F to 250F 32F to 250F

PUMP APPLICATION
Bell & Gossett Series 3540 Multistage Pumps may be used for Boiler Feed and Condensate Return, Irrigation, Fire Protection, Deaeration, Liquid Transfer, Water Supply as well as in other heating, cooling, agricultural, industrial and general service operations. For other applications contact your local B&G Representative.

Viton Elastomer Temperature range

Bell & Gossett

COPYRIGHT 1993, 1996 BY ITT CORPORATION

Morton Grove, IL, U.S.A.

SAFETY INSTRUCTIONS
This safety alert symbol will be used in this manual and on the pump instructions decal to draw attention to safety related instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD. Your Series 3540 Pump should have the following warning labels affixed to the pump in the approximate positions shown. If these warnings are missing or illegible, contact your local Bell & Gossett Representative for a replacement.

SAFETY REQUIREMENTS
ELECTRICAL SAFETY WARNING: ELECTRICAL SHOCK HAZARD. Electrical connections to be made by a qualified electrician in accordance with all applicable codes, ordinances and good practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage.

WARNING: ELECTRICAL OVERLOAD HAZARD. Three phase motors must have properly sized heaters to provide overload and under voltage protection. Single phase motors have built-in overload protectors. Failure to follow these instructions could result in serious personal injury, death and/or property damage. THERMAL SAFETY WARNING: EXTREME TEMPERATURE HAZARD. If the pump, motor, or piping are operating at extremely high or low temperature, guarding or insulation is required. Failure to follow these instructions could result in serious personal injury, death and/or property damage.

Place this caution label below the conduit box. The position should be 90 from the Rotating Components warning

WARNING: HOT WATER HAZARD. When disassembling a gasketed joint, always use a new gasket upon reassembly. NEVER RE-USE OLD GASKETS. Failure to follow these instructions could result in serious personal injury, death and/or property damage. MECHANICAL SAFETY WARNING: UNEXPECTED START-UP HAZARD. Disconnect and lockout power before servicing. Failure to follow these instructions could result in serious personal injury, death and/or property damage.

WARNING: EXCESSIVE SYSTEM PRESSURE HAZARD. The maximum working pressure of the pump is listed on the nameplate DO NOT EXCEED THIS PRESSURE. Failure to follow these instructions could result in serious personal injury, death and/or property damage.

Place this warning label below the lifting lug. Not all Series 3540 motors are equipped with a lifting lug.

WARNING: EXCESSIVE PRESSURE HAZARD VOLUMETRIC EXPANSION. The heating of water and other fluids causes volumetric expansion. The associated forces may cause failure of system components and release high temperature fluids. This can be prevented by installing properly sized and located compression tanks and pressure relief valves. Failure to follow these instructions could result in serious personal injury, death and/or property damage.

PUMP INSTALLATION
PUMP SUPPORT AND LOCATION The Bell & Gossett 3540 pump should be installed where there will be sufficient room for future inspection, maintenance and service. The environment should be well ventilated, dry and NOT subjected to freezing or extreme temperature variation. The motor requires an adequate air supply to prevent overheating and must not be completely enclosed. WARNING: FALLING OBJECT HAZARD. Eyebolts or lifting lugs, if provided, are for lifting only the components to which they are attached. Failure to follow these instructions could result in serious personal injury, death or property damage.

Minimize strain on the pump by supporting the suction and discharge piping with pipe hangers near the pump. Line up the vertical and horizontal piping so that the bolt-holes in both the pump and pipe flanges are aligned. DO NOT ATTEMPT TO SPRING THE SUCTION OR DISCHARGE LINES INTO POSITION. THIS MAY RESULT IN UNWANTED STRESS IN THE PUMP BODY, FLANGE CONNECTIONS AND/OR PIPING. The code for pressure piping, ANSIB31.1, lists types of supports available for various applications. Ordinary wire or band hangers are not adequate to maintain alignment. It is very important to provide strong, rigid support for the suction and discharge lines. If significant temperature variation is anticipated, expansion fittings should be installed to minimize stress on the pump flanges. Air must be kept out of the system. On an open system always place the end of the suction pipe at least three feet (3') below the surface of the water in the suction well to prevent air from being drawn into the pump. Avoid air pockets in the suction line and ensure that each section of the suction pipe is absolutely air tight. The following suction pipe sizes are the smallest recommended sizes which should be used with any B&G 3540 pump. Model 20 Model 40 1" 13/4" 2" 3" Nominal Diameter sch 40 pipe Nominal Diameter sch 40 pipe Nominal Diameter sch 40 pipe Diameter sch 40 pipe is preferable but 21/2" pipe may be used if the pumping rate is less than 88 GPM (20 M3/HR) Nominal Diameter sch 40 pipe

If lifting of the entire pump is required, do so with slings placed under the pump assembly as shown. The pump should be installed on a concrete foundation weighing at least 21/2 times the weight of the pump (check the shipping ticket for pump weight). Special precautions should be taken to avoid sound and vibration transmission. If the pump is to be located near a noise sensitive area, consult a sound specialist. If possible, bond the concrete pad to the finished floor. For open systems requiring suction lift, the pump should be located as close to the water source as possible with the fewest number of bends or elbows to reduce piping losses. The installation must be evaluated 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. IMPORTANT: In closed systems, do not install and operate Bell & Gossett pumps, 3D valves, suction diffusers, etc. without properly sized safety and control devices. Such devices include properly sized and located pressure relief valves, compression tanks and pressure, temperature, and flow controls. If the system is not equipped with these devices, consult a responsible engineer or architect before operating. SYSTEM PIPING SUCTION: Always install a section of straight pipe between the suction side of the pump and the first elbow. The length of this pipe should be equal to five times the diameter of the suction pipe size. This reduces turbulence of the suction by straightening the liquid flow path prior to pump entry. It is highly recommended that service valves (shut-off) be installed on each side of the pump to facilitate service and replacement without draining the system. Install the suction and discharge flanges on the pipe ends using teflon tape sealer or a high quality thread sealant.

Model 80/160 Model 300

Model 600

4"

DISCHARGE: It is suggested that a check valve and isolation valve be installed in the discharge pipe. Pipes, valves and fittings should be at least the same diameter as the discharge pipe or sized in accordance with good piping practices to reduce excessive fluid velocities and pipe friction loses. IMPORTANT: The pipe, valves and fittings must have pressure ratings equal to or greater than the maximum system pressure. Before the pump is installed it is recommended that the discharge piping be pressure checked to at least the maximum pressure the pump is capable of generating or as required by codes or local regulations. Whenever possible, avoid high pressure loss fittings, such as elbows or branch tees directly on either side of the pump. The piping should be adequately supported to reduce thermal and mechanical stresses on the pump. Good installation practice recommends that the system be thoroughly cleaned and flushed of all foreign materials and sediment prior to pump installation. The pump should never be installed at the lowest point of the system due to the natural accumulation of dirt and sediment. If there is excessive sediment or if suspended particles are present, it is advisable to use a strainer or filter.

SYSTEM PIPING (continued) BYPASS: A bypass or pressure relief valve should be installed in the discharge pipe if there is any possibility that the pump may operate against a closed valve in the discharge line. Flow through the pump is required to ensure sufficient cooling and lubrication is maintained. The following is used for determining the minimum flow rates in each variation of the Series 3540: Pump Type Model 20 Model 40 Model 80 Model 160 Model 300 Model 600 Minimum Flow Rates 21.2 GPM (0.25 M3/HR) 23.0 GPM (0.68 M3/HR) 25.3 GPM (1.20 M3/HR) 28.5 GPM (1.93 M3/HR) 13.5 GPM (3.07 M3/HR) 27.0 GPM (6.14 M3/HR)

WIRING INSTRUCTIONS
WARNING: ELECTRICAL GROUNDING HAZARD. The safe operation of this pump requires that it be grounded in accordance with the National Electrical Code and local governing codes or regulations. Connect the ground wire to the grounding screw in the terminal box and then to the acceptable grounding point. Failure to follow these instructions could result in serious personal injury, death and/or property damage. If it becomes necessary to change the motor, be sure to read Motor Replacement (pp. 6) for proper coupler adjustment procedures. WIRING: All wiring and electrical component sizing and installation is to be done by a qualified electrician in accordance with all applicable codes, ordinances and good practices. WARNING: ELECTRICAL SHOCK HAZARD. Disconnect and lockout the power before making electrical connections. Failure to follow these instructions could result in serious personal injury or death. POSITION OF THE TERMINAL BOX: The motor terminal box can be turned to one of the four 90 positions. To rotate the terminal box, remove the four bolts securing the motor to the pump; turn the motor to the desired location; replace and securely tighten the four bolts. See diagram for standard positions:

New Bell & Gossett flange gaskets must be installed between the flanges of the pump body and suction and discharge pipes. The gaskets should be clean and grease-free; old gaskets should never be reused.

WARNING: HOT WATER LEAKAGE HAZARD. Make certain that the flange bolts have been adequately torqued. Failure to follow these instructions could result in serious personal injury and/or property damage.

TYPICAL PIPING SCHEMATIC

WARNING: ELECTRICAL OVERLOAD HAZARD. Three phase motors must have properly sized heaters to provide overload and under voltage protection. Single phase motors have built-in overload protectors. Failure to follow these instructions could result in serious personal injury or death. SINGLE PHASE MOTORS: With the exception of 71/2 and 10 HP motors, single phase motors are equipped with inherent overheating devices and do not require external overload protection. THREE PHASE MOTORS: All three-phase motors must be used with a starter of proper size and type to ensure the motor is protected against damage from low voltage, phase failure, current imbalance and overloads. Bell & Gossett recommends a properly sized starter with an overload in each of the three legs. The overload should have manual resets and ambient-compensated extra quick-trips. The overload should be sized and adjusted to the full-load current rating of the motor. UNDER NO CIRCUMSTANCES SHOULD THE OVERLOADS BE SET TO A HIGHER VALUE THAN THE FULL LOAD CURRENT SHOWN ON THE MOTOR NAMEPLATE. THIS WILL VOID THE WARRANTY.

OPERATIONAL INSTRUCTIONS
LUBRICATION Series 3540 pump bearings are system lubricated and therefore do not require lubrication. However, the motor should be lubricated in accordance with the manufacturers recommendations. DO NOT OVER-GREASE THE MOTOR BEARINGS. Excessive grease will cause increased bearing temperature which will ultimately result in bearing and/or motor failure. ROTATION Pump rotation is counter-clockwise when viewed from the top of the motor. An arrow is provided to show the rotational direction. When checking the direction of rotation, use the following procedure: 1. Switch power off. 2. Ensure the pump has been filled and vented. 3. Remove the coupling guard and rotate the pump shaft to be certain it turns freely. Replace the coupling guard.

a steady stream of airless water runs from the priming port. Replace the plug and tighten. Completely open the isolation valves. OPEN SYSTEM I: When water source is above the pump, follow priming directions for a closed system. OPEN SYSTEM II: When the water source is below the pump inlet, the suction pipe and pump must be filled and vented of air before starting the pump. Close the discharge isolation valve and remove the priming plug. Pour water through the priming hole until the suction pipe and pump are completely filled with water. If the suction pipe does not slope downward from the pump toward the water level, the air must be purged while being filled. Replace the priming plug and tighten.

WARNING: ROTATING COMPONENT HAZARD. Do not operate pump without all guards in place. Failure to follow these instructions could result in serious personal injury or death and/or property damage. 4. Verify that the electrical connections comply with the motor wiring diagram. 5. With the power on, observe the direction of rotation. WHEN VIEWED FROM THE TOP, THE PUMP SHOULD ROTATE COUNTERCLOCKWISE. 6. To reverse the direction of rotation, first switch OFF the supply power. 7. SINGLE PHASE: Refer to connection diagram on the nameplate and make changes accordingly. THREE PHASE: Interchange any two power leads at the load side of the starter. 8. Switch the power on and again check the rotation. PRIMING AND STARTING WARNING: ELECTRICAL SHOCK HAZARD. Be certain that all connections are secure and the conduit box cover is closed before electrical power is connected. Failure to follow these instructions could result in serious personal injury, death and/or property damage.

WARNING: HOT WATER LEAKAGE HAZARD. Pressurize the pump body slowly while checking for leaks at all joints with gaskets. Failure to follow these instructions could result in serious personal injury and/or property damage. The pump should be started with the discharge valve closed and the suction valve fully open. After the pump is at operating speed, the discharge valve should be opened gradually. Opening this valve too fast may result in some water hammering in the discharge pipe. Unless used as a flow throttling device, the valve must be completely open. UNDER NO CIRCUMSTANCES SHOULD THE PUMP BE OPERATED FOR A PROLONGED PERIOD WITHOUT FLOW. An absence of flow will result in motor and pump damage.

SERVICE INSTRUCTIONS
CAUTION: SEAL DAMAGE HAZARD. Do not run the pump dry seal damage may occur. Failure to follow these instructions could result in moderate personal injury and/or property damage. Before starting, the 3540 pump must be filled with water. Manual priming may be necessary if the system does not fill the pump body automatically. Vent plugs are provided on the pump body to vent the air. Refer to the diagrams when priming. CLOSED SYSTEM: Prime the pump by closing the pumps isolation valve(s) and removing the priming plug from the pump head. Gradually open the isolation valve in the suction line until The Series 3540 pump is manufactured entirely with metric fasteners. Metric tools must be used whenever servicing this pump becomes necessary. GENERAL INSTRUCTIONS 1. Keep the motor properly lubricated. 2. If the pump is to be exposed to freezing temperatures, drain the pump. PERIODIC INSPECTION Inspect the pump regularly for leaking seals, worn gaskets, and loose or damaged components. Replace or repair as required.

REPLACING THE MOTOR

The following instructions are for replacing the motor. Replacement is required when damage to the motor is caused by bearing failure, burning or electrical failure. It is strongly recommended that any motor used as a replacement should meet the rigid specifications set forth by B&G. REPLACEMENT MOTORS MUST BE OF THE SAME NEMA C FRAME SIZE, SHOULD BE EQUIPPED WITH THE SAME OR HIGHER BEARING RATING AND HAVE THE SAME SERVICE FACTOR. It is not necessary to drain the system before removing the motor.

15. Lift the motor straight up until the shaft has cleared the bracket. 16. Before replacing the motor, clean the surfaces of the motor and pump mounting flanges. Set the motor atop the motor bracket. 17. Return the motor to its pre-removal position by rotating it until the terminal box is back in its original position. Insert the mounting bolts and diagonally tighten. 18. Insert the shaft pin in the pump shaft, position the coupler halves on the shafts and tighten the four capscrews finger tight. 9. Insert a prying device under the coupler and pry up. Note: The shaft can only be raised approximately 0.20 inches (5mm). 10. Lower the shaft half the distance it was just raised, and tighten the metric capscrews in the coupler. Be sure to tighten the top and bottom screws on one side of the coupling and then the other. Torque the coupler to the following specifications: Minimum Torque Specifications 10 ft.-lbs. 23 ft.-lbs. 46 ft.-lbs.

WARNING: ELECTRICAL SHOCK HAZARD. Disconnect and lockout the power before servicing. Failure to follow these instructions could result in serious personal injury or death. The electrical supply must be turned off and the pump service valves must be closed before servicing procedures begin. If there are no service valves, the city water supply valve should be closed.

WARNING: ELECTRICAL SHOCK HAZARD. Be certain the electrical power is not present at the motor leads before continuing. Failure to follow these instructions could result in serious personal injury or death. 11. To begin, loosen the conduit box cover screws and remove the cover. Remove the wire nuts and flexible conduit connector. Remove the coupler guard screens by inserting a screwdriver and applying a gentle outward prying force. 12. Use a metric Allen wrench to loosen and remove the four capscrews in the coupler. Remove both coupler halves and shaft pin and set aside. 13. There are four bolts fastening the motor to the motor bracket. Diagonally loosen and remove these bolts using a metric wrench. 4. Make note of the position of the terminal box. When replacing, the position of the terminal box should be to this position.

Coupling Bolt Size M6 M8 M10

11. Check that the gaps between the coupling halves are equal. Loosen and readjust if necessary. 12. Be certain that the pump shaft can be rotated by hand. If the shaft cannot be rotated or if it binds, disassemble and check for misalignment. 13. Connect the flexible conduit connector and wire nuts. Replace the conduit box cover and tighten the conduit box cover screws. Replace the two coupling guard screens.

DEALER SERVICING
If your pump requires further repair, contact your local B&G Representative. Having the following information at hand will facilitate your representatives ability to assist you: 1. Complete data from nameplate. 2. Suction and discharge pipe pressure gauge readings. 3. Ampere draw of motor.

YOUR BELL & GOSSETT REPRESENTATIVE IS

Ensure Quality and Performance with

GENUINE BELL & GOSSETT REPLACEMENT PARTS

For further information, contact ITT Bell & Gossett, 8200 N. Austin Avenue, Morton Grove, IL 60053, Phone (847) 966-3700 Facsimile (847) 966-8408.

Bell & Gossett

PRINTED IN U.S.A. 1-96

Morton Grove, IL, U.S.A.

Note: Suction Diffusers & Triple duty valves are designed for standard 125# FF and 175# MWP Note: Suction Diffusers & Triple duty valves are designed for standard 125# FF and 175# MWP B&G TRIPLE DUTY VALVE ECCENTRIC REDUCER FOOT VALVE B&G TRIPLE DUTY VALVE B&G SUCTION DIFFUSER DISCHARGE SUCTION STANDARD TERMINAL BOX 9:00 POSITION STANDARD TERMINAL BOX 3:00 POSITION Models: 20, 40 Models: 80, 160, 300, 600 Models: 80, 160, 300, 600 DRAIN PLUG

PRIMING/ VENT PLUG SUCTION DISCHARGE DRAIN PLUG PRIMING/ VENT PLUG

SUCTION DISCHARGE Models: 20, 40