BELL & GOSSETT INSTRUCTION MANUAL

P81773
REVISION B

Series 3540
Multistage Centrifugal Pump
Installation, Operation & Service Instructions
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

DESCRIPTION OPERATIONAL LIMITS

Series 3540 Multistage Centrifugal Pumps are specially de- Unless special provisions have been made for your pump by
signed for high pressure pump applications. The Series 3540 ITT Bell & Gossett, the operational limits of the Series 3540
pumps are of vertical in-line design and feature: stainless steel Pumps are as follows:
fitted construction, high efficiencies, wear and corrosion resis-
DO NOT EXCEED THESE VALUES
tant mechanical seals, and direct coupled pump to motor con-
figurations. The Series 3540 pump is designed for long life and MAXIMUM WORKING PRESSURE
maintenance-free operation.
Listed on the Nameplate

STANDARD SEAL OPERATING LIMITS

PUMP APPLICATION EPDM Elastomer Temperature range
Bell & Gossett Series 3540 Multistage Pumps may be used for
Models 20, 40, 80, 160 35¡F to 250¡F
Boiler Feed and Condensate Return, Irrigation, Fire Protection,
Models 300, 600 32¡F to 250¡F
Deaeration, Liquid Transfer, Water Supply as well as in other
heating, cooling, agricultural, industrial and general service Viton Elastomer Temperature range
operations. For other applications contact your local B&G
Models 20, 40, 80, 160 35¡F to 250¡F
Representative.
Models 300, 600 32¡F to 250¡F
.

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

Place this WARNING: EXTREME TEMPERATURE HAZARD.

caution label If the pump, motor, or piping are operating at extremely
below the
conduit box. high or low temperature, guarding or insulation is required.
The position Failure to follow these instructions could result in serious
should be 90°
from the personal injury, death and/or property damage.
Rotating
Components
warning

WARNING: HOT WATER HAZARD.

When disassembling a gasketed joint, always use a new
gasket upon reassembly. NEVER RE-USE OLD GAS-
KETS. 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 Ð DO NOT EXCEED THIS PRES-
SURE. Failure to follow these instructions could result in
serious personal injury, death and/or property damage.

WARNING: EXCESSIVE PRESSURE HAZARD Ð

Place this warning label below the
lifting lug. Not all Series 3540 motors
are equipped with a lifting lug.
VOLUMETRIC EXPANSION. The heating of water and
other fluids causes volumetric expansion. The associated
forces may cause failure of system components and re-
lease 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.

2
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 over-
heating 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.
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 weigh-
ing at least 21/2 times the weight of the pump (check the ship-
ping 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 spe-
cialist. 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. with-
out properly sized safety and control devices. Such devices
include properly sized and located pressure relief valves, com-
pression 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 suc-
tion 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.
Minimize strain on the pump by supporting the suction and dis-
charge 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 POSI-
TION. 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 sup-
ports 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 1" Nominal Diameter sch 40 pipe
Model 40 13/4" Nominal Diameter sch 40 pipe
Model 80/160 2" Nominal Diameter sch 40 pipe
Model 300 3" 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)
Model 600 4" Nominal Diameter sch 40 pipe
DISCHARGE: It is suggested that a check valve and isolation
valve be installed in the discharge pipe. Pipes, valves and fit-
tings 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 pres-
sure ratings equal to or greater than the maximum system
pressure.
Before the pump is installed it is recommended that the dis-
charge 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 sedi-
ment or if suspended particles are present, it is advisable to
use a strainer or filter.
3
SYSTEM PIPING (continued) WIRING INSTRUCTIONS
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 WARNING: ELECTRICAL GROUNDING HAZARD.
through the pump is required to ensure sufficient cooling and The safe operation of this pump requires that it be grounded
lubrication is maintained. The following is used for determining in accordance with the National Electrical Code and local
the minimum flow rates in each variation of the Series 3540: governing codes or regulations. Connect the ground wire
to the grounding screw in the terminal box and then to the
Pump Type Minimum Flow Rates acceptable grounding point. Failure to follow these instruc-
Model 20 21.2 GPM (0.25 M3/HR) tions could result in serious personal injury, death and/or
property damage.
Model 40 23.0 GPM (0.68 M3/HR)
Model 80 25.3 GPM (1.20 M3/HR) If it becomes necessary to change the motor, be sure to read
Motor Replacement (pp. 6) for proper coupler adjustment
Model 160 28.5 GPM (1.93 M3/HR) procedures.
Model 300 13.5 GPM (3.07 M3/HR) WIRING: All wiring and electrical component sizing and instal-
Model 600 27.0 GPM (6.14 M3/HR) lation is to be done by a qualified electrician in accordance
with all applicable codes, ordinances and good practices.
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 WARNING: ELECTRICAL SHOCK HAZARD.
should never be reused. Disconnect and lockout the power before making electrical
connections. Failure to follow these instructions could
result in serious personal injury or death.
WARNING: HOT WATER LEAKAGE HAZARD.
Make certain that the flange bolts have been adequately POSITION OF THE TERMINAL BOX: The motor terminal box
torqued. Failure to follow these instructions could result in can be turned to one of the four 90¡ positions. To rotate the ter-
serious personal injury and/or property damage. minal box, remove the four bolts securing the motor to the pump;
turn the motor to the desired location; replace and securely
TYPICAL PIPING SCHEMATIC tighten the four bolts. See diagram for standard positions:

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 cur-
rent 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.

4
OPERATIONAL INSTRUCTIONS
LUBRICATION
Series 3540 pump bearings are system lubricated and there-
fore do not require lubrication. However, the motor should be lubri-
cated in accordance with the manufacturerÕs recommendations.
DO NOT OVER-GREASE THE MOTOR BEARINGS. Exces-
sive 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 direc-
tion. 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.
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 name-
plate 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.
CAUTION: SEAL DAMAGE HAZARD.
Do not run the pump dry Ð seal damage may occur. Failure
to follow these instructions could result in moderate per-
sonal 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 pumpÕs iso-
lation valve(s) and removing the priming plug from the pump
head. Gradually open the isolation valve in the suction line until
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, fol-
low 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: 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 hammer-
ing 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
The Series 3540 pump is manufactured entirely with metric fas-
teners. 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.
5
 REPLACING THE MOTOR
The following instructions are for replacing the motor. Re-
placement is required when damage to the motor is caused by
bearing failure, burning or electrical failure. It is strongly rec-
ommended that any motor used as a replacement should
meet the rigid specifications set forth by B&G. REPLACE-
MENT 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 FAC-
TOR. It is not necessary to drain the system before removing
the motor.
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 re-
move 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 re-
placing, the position of the terminal box should be to this
position.
DEALER SERVICING
If your pump requires further repair, contact your local B&G
Representative. Having the following information at hand will
facilitate your representativeÕs ability to assist you:
1. Complete data from nameplate.
2. Suction and discharge pipe pressure gauge readings.
3. Ampere draw of motor.
Ensure Quality and Performance with É
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.
PRINTED IN U.S.A. 1-96
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 cou-
pling and then the other. Torque the coupler to the follow-
ing specifications:
Minimum Torque
Coupling Bolt Size Specifications
M6 10 ft.-lbs.
M8 23 ft.-lbs.
M10 46 ft.-lbs.
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.
YOUR BELL & GOSSETT REPRESENTATIVE ISÉ
Bell & Gossett
Morton Grove, IL, U.S.A.
Note: Suction Diffusers & Triple PRIMING/
duty valves are designed for VENT PLUG
standard 125# FF and 175# MWP
SUCTION
Note: Suction
Diffusers & Triple DISCHARGE
duty valves are
designed for DRAIN PLUG
standard
125# FF and PRIMING/
175# MWP VENT PLUG

B&G TRIPLE DUTY DRAIN

VALVE PLUG

ECCENTRIC SUCTION
REDUCER
DISCHARGE
FOOT
VALVE Models: 20, 40

B&G TRIPLE Models: 80, 160,

DUTY VALVE 300, 600

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