ITT Goulds Pumps HSUL User manual

Installation, Operation,
and Maintenance Manual
HSUL

Table of Contents
HSUL Installation, Operation, and Maintenance Manual 1
Table of Contents
Introduction ............................................................................................................................. 2
Inspect the package ................................................................................................................ 2
Inspect the unit ........................................................................................................................ 2
Safety ........................................................................................................................................ 3
Safety terminology and symbols ............................................................................................. 3
Environmental safety .............................................................................................................. 4
User safety .............................................................................................................................. 5
Precautions before work ....................................................................................................... 5
Precautions during work ....................................................................................................... 5
Safety regulations for Ex-approved products in potentially explosive atmospheres ................ 6
Transportation and Storage ................................................................................................... 8
Receive the unit ...................................................................................................................... 8
Unpack the unit ....................................................................................................................... 8
Pump handling ........................................................................................................................ 8
Lifting methods ..................................................................................................................... 8
Pump storage requirements .................................................................................................... 9
Preservation and Storage ..................................................................................................... 10
Installation ............................................................................................................................. 11
Inspect the Pump .................................................................................................................. 11
Install the sump ..................................................................................................................... 11
Install the motor .................................................................................................................... 11
Install the pump ..................................................................................................................... 11
Slide rail system (optional) .................................................................................................... 11
Install the base component assembly ................................................................................. 11
Install the guide bracket / pivot bracket assembly .............................................................. 12
Install the lifting bracket assembly ...................................................................................... 12
Install the slide rail .............................................................................................................. 13
Commissioning, Startup, Operation, and Shutdown ......................................................... 16
Start the pump ...................................................................................................................... 16
Maintenance ........................................................................................................................... 17
Maintenance - O-ring, pump flange to slide rail base flange ................................................. 17
Disassembly .......................................................................................................................... 18
Disassemble the pump ......................................................................................................... 18
Pre-assembly ......................................................................................................................... 20
Pre-assembly inspections ..................................................................................................... 20
Replacement guidelines ........................................................................................................ 20
Reassembly ........................................................................................................................... 21
Reassemble the pump .......................................................................................................... 21
Troubleshooting .................................................................................................................... 23
Troubleshooting .................................................................................................................... 23

Introduction
HSUL Installation, Operation, and Maintenance Manual2
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product
can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales
contract for any modifications or special version characteristics. For instructions, situations, or
events that are not considered in this manual or in the sales documents, please contact the
nearest ITT representative.
Always specify the exact product type and identification code when requesting technical
information or spare parts.
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.

Safety
HSUL Installation, Operation, and Maintenance Manual 3
Safety WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is over-
pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes any
modification to the equipment or use of parts not provided by ITT. If there is a question
regarding the intended use of the equipment, please contact an ITT representative before
proceeding.
• Do not change the service application without the approval of an authorized ITT
representative.
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• Never use heat to disassemble the pump due to the risk of an explosion from trapped
liquid.
• Always lockout power to the driver before performing pump maintenance.
• Never operate any pumping system with a blocked suction and discharge. Operation, even
for a brief period under these conditions, can cause confined pumped fluid to overheat. If
pump becomes plugged, shut down and unplug prior to restarting pump.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and
observe proper decontamination procedures in order to eliminate the possible exposure to
any hazardous or toxic fluids. Wear the proper personal protective equipment. Potential
hazards include, but are not limited to, high temperature, flammable, acidic, caustic,
explosive, and other risks. You must handle and dispose of pumped fluid in compliance
with the applicable environmental regulations.
• If the pump/motor is damaged or leaking oil, do not operate as it may cause an electric
shock, fire, explosion, liberation of toxic fumes, physical harm, or environmental damage.
Correct/repair the problem prior to putting back in service.
• Never apply heat to remove an impeller. The use of heat may cause an explosion due to
trapped liquid, resulting in severe physical injury and property damage.
• Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will
result in death or serious injury

Safety
HSUL Installation, Operation, and Maintenance Manual4
Hazard level Indication
WARNING: A hazardous situation which, if not avoided, could result in death or serious injury
CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury
NOTICE: • A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
Hazard categories Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental
regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the manufacturer if it has been contaminated by any nuclear
radiation. Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.

Safety
HSUL Installation, Operation, and Maintenance Manual 5
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment Use safety equipment according to the company regulations. Use this safety equipment within
the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other sections of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all internation-
al, national, state, and local regulations. For more information about requirements, see sections
dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with
the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the
product:
• Never work alone.

Safety
HSUL Installation, Operation, and Maintenance Manual6
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these
rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated
against diseases to which they may be exposed.
• Observe strict personal cleanliness.
• A small amount of liquid will be present in certain areas like the seal chamber.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes 1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least
15 minutes.
3. Seek medical attention.
Chemicals or hazardous
fluids on skin 1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Safety regulations for Ex-approved products in potentially
explosive atmospheres
Guidelines for compliance
WARNING:
This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and
injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal
unless explicitly stated in this manual.
If there are any questions regarding these requirements, the intended use, or if the equipment
requires modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized
mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas and/or vapor present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example IEC/EN 60079-17).

Safety
HSUL Installation, Operation, and Maintenance Manual 7
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data stated on the
nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during
service and inspection is only permitted outside the classified area.
• Before you start working with the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the
level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include
but are not limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system

Transportation and Storage
HSUL Installation, Operation, and Maintenance Manual8
Transportation and Storage
Receive the unit
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
4. Pump should be placed in upright position only.
Unpack the unit
1. Remove packing materials from the unit.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the unit to determine if any parts have been damaged or are missing.
3. Contact your ITT representative if anything is out of order.
4. Pump should be placed in upright position only.
Pump handling
WARNING:
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• These pumps might use carbon or ceramic silicon carbide components. Do not drop the
pump or subject it to shock loads as this can damage the internal ceramic components.
NOTICE:
Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the
pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
WARNING:
• All lifting must be done in compliance with all applicable regulations/standards.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and
wear steel-toed shoes at all times.
Use the supplied lifting lugs and suitable slings in order to lift the entire pump to a vertical
position and lower the unit into the sump. Then use the lifting lugs on the motor and a suitable
sling, or optional slide rail system to hoist the motor into position. Use a tag line attached to the
casing end in order to prevent the pump from swinging.

Transportation and Storage
HSUL Installation, Operation, and Maintenance Manual 9
Examples
Figure 1: Example of proper lifting method using lifting lugs
Pump storage requirements
Requirements Submersible units require proper preparation for storage and regular maintenance during
storage. The unit is considered in storage when it has been delivered to the job site and is
awaiting installation.

Transportation and Storage
HSUL Installation, Operation, and Maintenance Manual10
For specific requirements for storing motors, gearheads, and engines, contact the equipment
manufacturer.
Storage preparation
Condition Proper preparation
Indoor storage area (preferred) • Pave the area.
• Clean the area.
• Drain the area and keep it free from flooding.
Outdoor storage area (when indoor
storage is not available) • Observe all indoor storage requirements.
• Use weather-proof coverings such as flame-resistant sheet-
ing or tarpaulins.
• Place coverings in a manner that maximizes drainage and
air circulation.
• Tie coverings down in order to protect the pump from wind
damage.
Placement of pumps and component
parts • Place the unit on skids, pallets, or shoring higher than 6 in.
(15 cm) from the ground for good air circulation.
• Sort the parts in order to permit easy access for inspection
and/or maintenance without excessive handling.
Stacking of units or component parts • Make sure that racks, containers, or crates bear the full
weight of units or parts in order to prevent distortion.
• Keep identification markings readily visible.
• Immediately replace any cover you remove for internal
access.
Rotation of the pump and bowl assem-
bly shaft • Make sure that the shaft rotates freely.
Controlled storage facilities • Maintain an even temperature of 10°F (6°C) or higher
above the dew point.
• Keep the relative humidity to less than 50%.
• Make sure that there is little or no dust.
Uncontrolled storage facilities that
have uneven temperatures, higher hu-
midity, and/or dusty conditions) • Inspect the unit periodically to make sure that all preserva-
tives are intact.
• Seal all pipe threads and flanged pipe covers with tape.
When pump is not in regular operation
If a pump has been installed, but is not in regular operation for an extended period of time, such
as during a seasonal shutdown, then operate it for at least 15 minutes every two weeks, if
possible.
Preservation and Storage
ITT Goulds Pump Division's normal domestic shipping and storage preparation is suitable for
protecting the pump during shipment in covered trucks. Although this is a submersible pump,
storage in a clean, dry area will help preserve the paint and prevent corrosion. Hand rotation of
the shaft every thirty days is recommended to keep the seals free and the bearings lubricated.
For additional storage requirements, reference ABB/Baldor/Reliance Submersible motor
Instruction Manual.

Installation
HSUL Installation, Operation, and Maintenance Manual 11
Installation
Inspect the Pump
Install the sump
1. The sump floor should be level and firm where the pump will be placed.
2. Make sure the sump and sump inlet line are free from large pieces of debris which could
eventually obstruct the pump inlet.
Install the motor
The motor is furnished with thermal protection and a moisture probe.
1. Wire the motor according to the motor manufacturer's wiring diagram in the motor IOM.
2. Recheck the protective circuits after the wiring is completed to avoid a possible motor
failure because of an oversight.
3. The motor must be completely submerged for continuous operation. It can be operated for
a maximum of 15 minutes without being submerged, The sump controls should be set to
allow a maximum possible run of 15 minutes after the motor is no longer completely
submerged if the sump is large enough to not have completed the pump-down in that time.
Motor is rated for a maximum 10 starts per hour.
NOTICE: The motor is rated for full horsepower with liquid temperatures of 104°F (40°C) or
lower, unless noted otherwise on nameplate or ITT documentation.
Install the pump
1. Make sure the lifting device is securely fastened to the motor lugs or hooks so the unit will
not be dropped when it is lowered into the sump.
2. Check the 1/8" vent hole in the adapter plate, between the motor and the casing, to make
certain it is not plugged and then carefully lower the unit into position in the sump.
3. Check the pump for being approximately level.
4. Support the discharge pipe to prevent excessive loads from being transmitted to the pump
flange and casing.
Slide rail system (optional)
Install the base component assembly
1. Apply gasket adhesive to item #360W and place on side shown in Section Y-Y to base
upright.
NOTICE: Quantity two 1/2" holes may need to be punched or cut in gasket to allow
clearance for items #372K.
2. Position item #787G, sump flange adapter, as shown in section Y-Y and secure to base
upright using items #372K.
3. Apply gasket adhesive to item #360W and place in section Y-Y and secure to base upright.
4. Insert short-threaded end of stubs, items #787U, through base uprights and into the top two
holes of the sump flange adapter, item #787G.

Installation
HSUL Installation, Operation, and Maintenance Manual12
5. Position top two holes of the discharge elbow, item #315, over the two studs, items #787U,
and thread nuts, items #787V, onto studs finger tight. Insert items #370S, hex head cap
screws, through remaining elbow and base upright holes, and thread into sump flange
adapter finger tight.
6. Level discharge flange then tighten nuts and hex head cap screws, items #370S and
#787V.
7. Secure item #787H, adjusting bracket, to sump flange adapter using items 370T, hex head
cap screws.
8. Thread quantity one nut, item #357, onto the entire length of item #787J, adjusting bolts,
and insert into the hole centered in item #787H, adjusting bracket.
NOTICE: The adusting bolt's head should face towards the sump flange adapter.
Install the guide bracket / pivot bracket assembly
Apply Loctite 242 on all hardware unless otherwise specified.
1. Apply gasket adhesive to item #360W and place on side shown in Section "Y"-"Y" to base
upright. Note, quantity two 1/2" holes may need to be punched or cut in gasket to allow
clearance for items
2. Position item #787G, sump flange adapter, as shown in section "Y"-"Y" and secure to base
upright using items #372K.
3. Apply gasket adhesive to item #360W and place on opposite side shown in Section "Y"-"Y"
to base upright..
4. Insertshort-threaded end of studs, items #787U, through base upright and into the top two
holes of the sump flange adapter, item#787G.
5. Position top two holes of the discharge elbow, item #315, over the two studs, items #787U,
and thread nuts, items #787V, onto studs finger tight. Insert items #370S, hex head cap
screws, through remaining elbow and base upright holes, and thread into sump flange
adapter finger tight.
6. Level discharge flange then tighten nuts and hex head cap screws, items #370S and
#787V.
7. Secure item #787H, adjusting bracket, to sump flange adapter using items 370T, hex head
cap screws.
8. Thread quantity one nut, item #357, onto the entire length of item #787J, adjusting bolt, and
insert into the hole centered in item #787H, adjusting bracket. Note, the adjusting bolt's
head should face towards the sump flange adapter.
Install the lifting bracket assembly
Apply Loctite 271 to all lifting bracket hardware.
1. Position left and right lifting brackets as shown on the top and elevation views of the
drawing. Insert item #370R, hex head cap screw, through the right lifting bracket, the
motor's lifting lug, and out left lifting bracket. Thread item #357C onto item #370R finger
tight.
2. Place washers, items #788B, over items # 788A, hex head cap screws, and insert them into
the holes located in the motor adapter, item #240, finger tight. Note, drill and tap holes in
motor adapter at the location shown on page 4 of the slide rail installation instructions.
Pump does not need to be disassembled for drill and tap operation.
3. Insert item #371G, hex head cap screw, through both lifting brackets and thread heavy hex
nut, item #357A, finger tight. Do not apply Loctite 271to items #371G and #357A at this
time. Text of third step.
4. Tighten items #788A and #357C.
5. Remove items #371G and #357A and position lift cable loop between lifting brackets. Apply
Loctite 271 and reinsert item #371G, hex head cap screw, through cable and lifting
brackets and thread heavy hex nut, item #357A, and item #415A, jam nut, onto item
#371G. Check cable clamps..

Installation
HSUL Installation, Operation, and Maintenance Manual 13
Install the slide rail
Refer to drawing B1-445153SLR and B2-445153SLR
1. With anchor bolts in position, lower the base, item #787A, onto a flat, clean foundation and
tighten anchor bolt nuts.
2. Insert the slide rails, items #787C over the cylinders on the base and insert intermediate
bracket, item #787P, cylinders into the tops of the slide rails. Allow .25" gap between the
top of the slide rails and the intermediate bracket for thermal expansion. Secure the
intermediate bracket to the sump wall. Repeat as necessary with the remainder of the rails
and brackets.
3. Install the discharge pipe.
4. Lift the pump using the lift cable and lower it to have the guide bracket fit between the rail
pipes. The pump should be reasonably level to keep the guide bracket from exerting too
much force on the rail pipes when the pump is lowered or raised
5. Carefully lower the pump into position. Turn the adjusting bolts, items #787J, to provide the
proper o-ring compression. The pump may need to be raised and lowered back into
position a few times until the proper adjustment is found. The pump should properly lock
into place with no visible gap between the o-ring and sump flange adapter. Tighten items
#357, hex nuts, against items #787H, adjusting brackets, to prevent movement of adjusting
bolts.

Installation
HSUL Installation, Operation, and Maintenance Manual14
Figure 2: Slide rail system (optional)

Installation
HSUL Installation, Operation, and Maintenance Manual 15
Figure 3: Slide rail system (optional)
NOTICE:
Pump shown is a JCU, not an HSUL. For illustrative purposes only.

Commissioning, Startup, Operation, and Shutdown
HSUL Installation, Operation, and Maintenance Manual16
Commissioning, Startup, Operation, and
Shutdown
Start the pump
The most important concern is the prevention of motor overloading.
1. Refer to the motor nameplate for full load ampere rating of the motor.
2. Install an ammeter on the motor leads and check the motor draw immediately after the unit
is started.
NOTICE: A lower than expected current draw with a 3-phase motor may be an indication of
incorrect rotation. If the amps are lower than expected, check rotation.
a) Observe the discharge for flow rate. If it is lower than expected change two of the three
motor leads to reverse the direction of rotation.
NOTICE: Single-phase motors are internally wired for correct rotation.
b) Check the motor overload at some other condition from that encountered at start-up
The ammeter on the motor leads should be checked for overload at all sump level
heights with the liquid that will be normally pumped. The horsepower will tend to
increase as the level in the sump rises, due to increased flow.

Maintenance
HSUL Installation, Operation, and Maintenance Manual 17
Maintenance
Maintenance - O-ring, pump flange to slide rail base flange
Whenever the pump is removed from the sump using the slide rail system, the pump flange to
slide rail base flange O-ring should be inspected for wear. If it does not appear to be in good
condition, a replacement O-ring should be installed after the groove has been cleaned and
dried so the adhesive will bond to the metal and rubber.
NOTICE: Cleaning the guide bracket around the hinge pin 9868 will help ensure proper
operation when the pump is lowered back into place.

Disassembly
HSUL Installation, Operation, and Maintenance Manual18
Disassembly
Disassemble the pump
1. Disconnect all electrical service. Mark leads for reassembly.
2. Remove fasteners which secure casing (100) to motor adapter (340) and separate the
parts.
3. Remove impeller cap screw (370C) and impeller washer (528J). Impeller is keyed to shaft.
Carefully slide impeller off shaft.
4. Remove fasteners attaching motor adapter (340) to motor (9700) and separate parts.
Figure 4: HSUL pump