Wilo American-Marsh Pumps 482 EGB Series User manual

A WILO BRAND
Installation and Operating Manual
AMP_IOM_482 EGB_0623
482 Series EGB
End Gun Booster Pumps

Check shipment for shortage and damage
immediately upon arrival. Note damage or shortage
on freight bill (bill of lading); immediately le claim
with carrier.
EXTERIOR — Pay particular attention to conduit
box, external hardware, and accessories. Touch up
abrasions or scratches with approved paint.
INTERNAL — If extensive or serious external damage
is noted, if impeller is damaged (look in ports), or
if shaft binds or sticks, disassemble as required to
permit internal inspection.
Location — Pump location should provide the
following:
1. Install as close to suction supply as possible.
2. Shortest and most direct suction pipe practical.
Suction lift must not exceed limit for pump.
NPSH available must equal or exceed pump
requirement.
3. Suction port below uid level to provide priming.
4. Room for inspection and maintenance.
5. Correct power supply to motor; all wiring should
meet National Electrical and Local Codes and
Regulations.
6. If outdoors, protection from the elements,
freezing and water damage due to ooding.
Piping — Suction and discharge gauges are useful
to check pump operation and are excellent trouble
indicators. Install gauges in the lines if pump ports do
not have gauge taps. Observe these precautions when
installing piping:
1. Support close to, but independently of pump.
2. Use the next larger pipe size for suction and
discharge.
Suction — Size and install suction piping to keep
pressure loss to a minimum and to provide correct
NPSH by observing the following:
1. The suction pipe should be equal in size or
preferably one size larger than the suction
connection of the pump. If pipe is larger than the
pump suction, an eccentric pipe reducer should
be used at the pump.
2. Pipe should slope upward to pump, even for
horizontal run.
3. Use 45-degree or long-sweep 90-degree elbows.
4. A valve in the suction is necessary only on
positive suction head installation and must not
be used to throttle the pump. The suction valve
should be installed for maintenance purposes
only.
Handling
Handle with care. Dropping or jarring can seriously
damage motor bearings or break pump parts. Lift
with device having capacity for pump weight, and use
lifting hooks or eye bolts (if provided) or rig double
sling around motor frame and pump casing. Do not
use sling through pump motor adapter nor around
suction or discharge anges.
Installation
Discharge —Pumps permit discharge port location
at any of four positions, 90 degrees apart. Change by
removing cover bolts, rotating casing, and replacing
bolts. Do not slice O-ring. AMP does not recommend
bottom vertical discharge due to erratic pump
performance. Ensure there is adequate clearance with
selected position between wall or tank, motor conduit
box, and grease ttings. Casing may extend beyond
base or feet.
1. Short discharge lines may be the same size as
the discharge port. Long runs require a pipe
larger than the discharge port.
2. Long horizontal runs require a grade as even as
possible. Avoid high spots and loops. Trapped
air will throttle ow and may result in erratic
pumping.
3. Install check and gate valves in discharge line;
check valve (if used) between pump and gate
valve.
3. Keep as straight as possible. Avoid bends and
ttings.
4. Remove burrs and sharp edges, ream pipe cuts,
and make joints air-tight.
5. Don’t spring pipe to make connections. Strain
must not be transmitted to pump.
6. Allow for pipe expansion with hot uids; expan-
sion joints are not recommended.
IOM482EGB
0623 2
Inspection

Priming —If pump is installed with a positive
head on the suction, prime by opening suction
valve and allowing liquid to enter the casing, at
the same time venting all air out of the top of
the casing. If pump is installed with a suction lift,
priming must be done by other methods, such as
foot valves, ejectors, or by manually lling casing
and suction line.
CAUTION - DO NOT RUN PUMP DRY. Serious
damage may result if started dry.
Starting — Proceed as follows to start pump:
1. Close drain valves and valve in discharge line.
2. Fully open all valves in the suction line.
3. Prime the pump. If pump does not prime
properly, or loses prime during start-up, shut
down and correct condition before repeating
procedure.
4. For pumps moving high temperature liquids,
open warm-up valve to circulate liquid for
preheating. Close valve after pump has
warmed up.
5. Start the motor (pump).
6. When pump is operating at full speed, open
discharge valve slowly.
Running — Periodically inspect pump while
running, but especially after rst start and
following repair.
1. Check pump and piping for leaks. Repair
immediately.
Cleaning — Remove oil, dust, dirt, water, and
chemicals from exterior of motor and pump. Keep
motor air inlet and outlet open. Blow out interior
of open motor with clean compressed air at low
pressure. Regularly drain moisture from TEFC
motors.
Temperature — Total temperature, not the rise,
is the measure of safe operation for a motor. If
temperature by thermometer exceeds limits for
insulation class, investigate and change operating
conditions.
Labeled Motors — It is imperative for repair of
a motor with Underwriters’ Laboratories label that
original clearances be held; that all plugs, screws,
other hardware be fastened securely, and that
parts replacements be exact duplicates or approved
equals. Violation of any of the above invalidates
Underwriters’ label.
Lubrication — Pumps should require no
maintenance, other than the motor bearings,
according to the following instructions:
DOUBLE SHIELDED. When double shielded
prelubricated bearings are furnished, no
lubrication is required for the life of the bearings.
Inspect bearings periodically to determine the
condition of the grease and replace the bearings if
necessary.
SINGLE SHIELDED W/GREASE FITTING
PROVISIONS. When single shield bearings
are furnished, periodic inspection, cleaning
and relubrication is required. See motor
manufacturer’s specic instructions for lubrication.
Maintenance
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0623
3
Pre-Start — Before initial start of the pump,
check as follows:
1. The rotation must be checked upon
installation. Close, then break the contacts
quickly and observe the rotation of the
exposed portion of the rotating parts. Rotation
must agree with the rotation arrow on the
motor. For all pumps, the standard rotation
is counterclockwise when viewed from the
suction end. Motor wiring is easily changed
in the eld. Observe the wiring diagram on
the inside of the terminal box cover, or on the
motor nameplate.
2. Check voltage, phase and frequency of line
circuit with motor nameplate.
3. Check suction and discharge piping and
pressure gauges for proper operation.
4. Assure that the pump is full of liquid (primed).
Operation 2. Record pressure gauge readings for future
reference.
3. Record voltage, amperage per phase, and kW
(if an indicating wattmeter is available).
4. Adjust pump output capacity with discharge
valve. DO NOT throttle suction line.
Freezing Protection — Protect pumps shut down
during freezing conditions by one of the following
methods:
1. Drain pump; remove all liquid from the casing.
2. Keep uid moving in pump and insulate or
heat the pump to prevent freezing. If heated,
do not let temperature go above 100 to 150
degrees F.
3. Fill pump completely with antifreeze solution.

Mechanical Seal Replacement
9. Remove motor shaft end cap at the back of
motor (opposite the pump end).
10. Insert a screwdriver in slot of motor shaft
end. While holding screwdriver against
rotation, use a strap wrench around impeller
outer diameter to unscrew the impeller
counterclockwise from the motor shaft.
(Figure 3)
4
Figure 1
Figure 2
Figure 4
IOM482EGB
0623
B.) Reassembly:
1. Clean ange faces, seal seat cavity, and
shaft- especially the face tting against
impeller.
2. Place adapter on a at surface with motor
side facing down. Position the stationary
seat with the silver dot down (away from
you) and the lapped face (shiny side) fac-
ing you. Lubricate the seal seat cavity of
the adapter and the rubber cup or O-ring
of stationary seal seat with the lubricating
uid that comes with the mechanical seal
or repair kit. Press the stationary seat in
seal seat cavity of the adapter squarely
and evenly using an arbor press (if possi-
ble) and the cardboard disc supplied with
the seal. Be certain that the lapped face
(shiny side) is facing you.
11. Remove bolts holding adapter to motor.
Lightly tap the adapter from side to side
away from the motor using a rawhide or
hard rubber hammer to achieve a large
enough gap to insert screwdrivers between
the adapter face and the motor face. Using
two screwdrivers 180 degrees apart, evenly
pry the adapter with the seal assembly
away from the motor until rotary seal is
free of motor shaft. Be careful not to insert
screwdrivers too far to prevent contacting
and damaging the motor shaft. (Figure 4)
Figure 3
12. Place adapter on a at surface with case
rabbet facing down, and push out stationary
part of mechanical seal.
8. Place a strap wrench around the impeller
outer diameter. While holding strap wrench
against rotation, unscrew the impeller locking
nut in eye using a 1/4-inch Allen wrench or
Allen socket. (Figure 2)
A.) Disassembly:
1. Turn o power.
2. Close suction and discharge valves.
3. Drain pump.
4. Remove bolts holding base to foundation
5. Remove casing bolts.
6. Remove motor and rotating element
from casing, leaving casing and piping
undisturbed.
7. Remove drip cover from motor end.
(Figure 1)

Reassembly, cont...
IOM482EGB
0623
5
The approved lubricating uid for seal installation is
included with the mechanical seal or repair kit.
DO NOT USE OTHER LUBRICATING LIQUIDS!
WE RECOMMEND STOCKING A SPARE MECHANICAL
SEAL OR REPAIR KIT TO ELIMINATE DOWN TIME.
3. Remount the adapter on motor, making
sure the motor shaft does not dislocate or
chip the stationary seat of the seal.
4. Apply the lubricating uid that comes with
the mechanical seal or repair kit to the
motor shaft and the rubber bellows of the
rotary seal. Slide the seal head on the
shaft, press the rubber drive band on the
rotary head until the lapped face on the
head seats rmly against the lapped face of
the stationary seat. Do not chip or scratch
faces during installation. Take extra care
to make sure the lapped faces are clean.
Install spring on seal head (only applies to
Type 21 seal).
5. Hold shaft against rotation as described in
paragraph 10 of disassembly procedure,
and thread impeller on shaft until it is tight
against the shaft shoulder. The impeller
will compress the seal spring to the proper
length assuring correct pressure on lapped
faces.
6. Replace impeller locking nut while holding
impeller against rotation as indicated in
paragraph 8 of disassembly procedure (2 &
3 HP 1PH, and all 3PH motors only).
7. Replace protective motor shaft end cap.
8. Replace drip cover on motor end.
9. Replace motor and rotating element in cas-
ing. Be sure that any damaged O-ring or
gasket is replaced.
10. Apply thread sealant to case bolt ends and
inside case threads (Figure 5). Thread seal-
ant is not supplied with repair kits.
11. Tighten casing bolts alternately and evenly.
12. Replace hold-down bolts.
13. Check for free rotation after assembly is
completed.
14. Seal all drain openings using pipe sealant on
threads.
15. Reprime before starting. Do not start until
pump is completely lled with water.
Figure 5
Pressure and Temperature Limitation
Standard Fitted Pumps
Pump No. Pressure Temperature
482 EGB 75 PSI 150 PSI 220⁰F 275 ⁰F
CAUTION
DO NOT ALLOW EITHER THE DISCHARGE PRESSURE OR THE TEMPERATURE OF THE LIQUID TO
EXCEED THE LIMITATIONS LISTED ABOVE.

American-Marsh Pumps
T [phone]
www.american-marsh.com
[email protected] A WILO BRAND