Installation, Operation, and

Maintenance Manual
Model 3296 EZMAG
 Table of Contents

Table of Contents
1 Introduction and Safety .................................................................................................................................... 4
1.1 Introduction................................................................................................................................................ 4
1.1.1 Requesting other information .......................................................................................................... 4
1.2 Safety ........................................................................................................................................................ 4
1.2.1 Safety terminology and symbols ..................................................................................................... 5
1.2.2 Environmental safety....................................................................................................................... 6
1.2.3 User safety ...................................................................................................................................... 6
1.2.4 Safety regulations for Ex-approved products in potentially explosive atmospheres ....................... 8
1.3 Product warranty ..................................................................................................................................... 10
1.3.1 Spare parts.................................................................................................................................... 11

2 Transportation and Storage............................................................................................................................ 12

2.1 Inspect the delivery ................................................................................................................................. 12
2.1.1 Inspect the package ...................................................................................................................... 12
2.1.2 Inspect the unit.............................................................................................................................. 12
2.2 Transportation guidelines ........................................................................................................................ 12
2.2.1 Pump handling .............................................................................................................................. 12
2.2.2 Lifting methods.............................................................................................................................. 12
2.3 Storage guidelines................................................................................................................................... 14
2.3.1 Pump storage requirements.......................................................................................................... 14

3 Product Description ........................................................................................................................................ 15

3.1 General description ................................................................................................................................. 15
3.2 Nameplate information ............................................................................................................................ 15

4 Installation........................................................................................................................................................ 18
4.1 Pre-installation......................................................................................................................................... 18
4.1.1 Pump location guidelines .............................................................................................................. 18
4.1.2 Foundation requirements .............................................................................................................. 19
4.2 Baseplate-mounting procedures ............................................................................................................. 20
4.2.1 Prepare the baseplate for mounting.............................................................................................. 20
4.2.2 Install the baseplate using shims or wedges................................................................................. 20
4.2.3 Install the baseplate using jackscrews .......................................................................................... 21
4.2.4 Baseplate-leveling worksheet ....................................................................................................... 24
4.3 Pump-to-driver alignment ........................................................................................................................ 25
4.3.1 Alignment checks .......................................................................................................................... 25
4.3.2 Permitted indicator values for alignment checks........................................................................... 26
4.3.3 Alignment measurement guidelines .............................................................................................. 26
4.3.4 Attach the dial indicators for alignment ......................................................................................... 26
4.3.5 Pump-to-driver alignment instructions........................................................................................... 27
4.4 Grout the baseplate................................................................................................................................. 30
4.5 Piping checklists...................................................................................................................................... 31
4.5.1 Fastening ...................................................................................................................................... 31
4.5.2 General piping checklist ................................................................................................................ 31
4.5.3 Suction-piping checklist................................................................................................................. 33
4.5.4 Discharge piping checklist............................................................................................................. 36
4.5.5 Final piping checklist ..................................................................................................................... 37

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 1

Table of Contents

5 Commissioning, Startup, Operation, and Shutdown ................................................................................... 38

5.1 Preparation for startup............................................................................................................................. 38
5.2 Remove the coupling guard .................................................................................................................... 39
5.3 Check the rotation ................................................................................................................................... 41
5.4 Check the rotation - Close Coupled ........................................................................................................ 41
5.5 Couple the pump and driver .................................................................................................................... 41
5.5.1 Install the coupling guard .............................................................................................................. 42
5.6 Bearing lubrication................................................................................................................................... 47
5.6.1 Lubricating-oil requirements.......................................................................................................... 47
5.6.2 Acceptable oil for lubricating bearings .......................................................................................... 48
5.6.3 Lubricate the bearings with oil....................................................................................................... 48
5.6.4 Greased-for-life bearing lubrication............................................................................................... 49
5.7 Pump priming .......................................................................................................................................... 49
5.7.1 Prime the pump with the suction supply above the pump............................................................. 49
5.7.2 Prime the pump with the suction supply below the pump ............................................................. 49
5.7.3 Other methods of priming the pump.............................................................................................. 50
5.8 Start the pump......................................................................................................................................... 50
5.8.1 Minimum continuous recommended flow...................................................................................... 51
5.9 Pump operation precautions ................................................................................................................... 52
5.10 Shut down the pump ............................................................................................................................. 53
5.11 Make the final alignment of the pump and driver................................................................................... 53

6 Maintenance..................................................................................................................................................... 55
6.1 Maintenance schedule ............................................................................................................................ 55
6.2 Bearing maintenance .............................................................................................................................. 56
6.3 Disassembly ............................................................................................................................................ 56
6.3.1 Disassembly precautions .............................................................................................................. 56
6.3.2 Required tools ............................................................................................................................... 57
6.3.3 Prepare the pump for disassembly ............................................................................................... 57
6.3.4 Remove the frame assembly and shaft (frame-mounted pump)................................................... 58
6.3.5 Remove the frame assembly and shaft (close-coupled pump) ..................................................... 60
6.3.6 Disassemble the liquid end ........................................................................................................... 61
6.4 Pre-assembly inspections ....................................................................................................................... 64
6.4.1 Replacement guidelines................................................................................................................ 64
6.4.2 Magnet inspections ....................................................................................................................... 66
6.4.3 Bearing-frame inspection .............................................................................................................. 66
6.4.4 Bearings inspection....................................................................................................................... 67
6.4.5 Minimum running clearances ........................................................................................................ 67
6.5 Reassembly............................................................................................................................................. 68
6.5.1 Reassemble the frame assembly and shaft (frame-mounted pumps) .......................................... 68
6.5.2 Reassemble the frame assembly and shaft (close-coupled pumps)............................................. 70
6.5.3 Reassemble the liquid end............................................................................................................ 71
6.5.4 Complete the pump reassembly ................................................................................................... 75
6.5.5 Bolt torque values ......................................................................................................................... 75

7 Troubleshooting .............................................................................................................................................. 77
7.1 Operation troubleshooting ....................................................................................................................... 77
7.2 Alignment troubleshooting....................................................................................................................... 78

8 Parts Listings and Cross-Sectionals ............................................................................................................. 79

8.1 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — stainless steel ........................................... 79

2 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 Table of Contents

8.2 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — Hastelloy-C ............................................... 81

8.3 S-group with bearing frame — stainless steel......................................................................................... 83
8.4 S-group with bearing frame — Hastelloy-C............................................................................................. 85
8.5 Frame cooling options ............................................................................................................................. 87
8.6 M-group with bearing frame — stainless steel ........................................................................................ 88
8.7 M-group with bearing frame — Hastelloy-C ............................................................................................ 90
8.8 Spare and repair parts............................................................................................................................. 92
8.9 Interchangeability drawings..................................................................................................................... 93

9 Other Relevant Documentation or Manuals.................................................................................................. 95

9.1 Condensed power monitor ...................................................................................................................... 95

10 Local ITT Contacts ........................................................................................................................................ 98

10.1 Regional offices..................................................................................................................................... 98

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 3

1 Introduction and Safety

1 Introduction and Safety

1.1 Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance

CAUTION:
Failure to observe the instructions contained in this manual could result in personal injury
and/or property damage, and may void the warranty. Read this manual carefully before instal-
ling and using the product.

NOTICE:
Save this manual for future reference and keep it readily available.

1.1.1 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 consid-
ered in this manual or in the sales documents, please contact the nearest ITT representative.
Always specify the exact product type and serial number when requesting technical information or spare
parts.

1.2 Safety
WARNING:
• Risk of serious 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 appropriate safety precautions to
prevent physical injury.
• Risk of serious injury or death. If any pressure-containing device is over-pressurized, it
can explode, rupture, or discharge its contents. It is critical to take all necessary meas-
ures to avoid over-pressurization.
• Risk of death, serious personal injury, and property damage. Installing, operating, or
maintaining the unit using any method not prescribed in this manual is prohibited. Prohib-
ited methods include any modification to the equipment or use of parts not provided by
ITT. If there is any uncertainty regarding the appropriate use of the equipment, please
contact an ITT representative before proceeding.

4 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 1.2 Safety

• If the pump or motor is damaged or leaking, electric shock, fire, explosion, liberation of
toxic fumes, physical harm, or environmental damage may result. Do not operate the unit
until the problem has been corrected or repaired.
• Risk of serious personal injury or property damage. Dry running may cause rotating parts
within the pump to seize to non-moving parts. Do not run dry.
• 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 (guards, etc.) are
properly installed. See specific information about safety devices in other sections of this
manual.

CAUTION:
• Risk of injury and/or property damage. Operating a pump in an inappropriate application
can cause over pressurization, overheating, 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 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 seri-
ous injury

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 unde-

sirable 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:

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 5

1.2 Safety

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

1.2.2 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 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 returning.

Electrical installation
For electrical installation recycling requirements, consult your local electric utility.

1.2.2.1 Recycling guidelines

Always follow local laws and regulations regarding recycling.

1.2.3 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:

6 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 1.2 Safety

• Hardhat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices

Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, nation-
al, state, and local regulations. For more information about requirements, see sections dealing specifical-
ly with electrical connections.

Noise

WARNING:
Sound pressure levels may exceed 80 dbA in operating process plants. Clear visual warnings
or other indicators should be available to those entering an area with unsafe noise levels. Per-
sonnel should wear appropriate hearing protection when working on or around any equipment,
including pumps. Consider limiting personnel’s exposure time to noise or, where possible, en-
closing equipment to reduce noise. Local law may provide specific guidance regarding expo-
sure of personnel to noise and when noise exposure reduction is required.

Temperature

WARNING:
Equipment and piping surfaces may exceed 130ºF (54ºC) in operating process plants. Clear
visual warnings or other indicators should alert personnel to surfaces that may reach a poten-
tially unsafe temperature. Do not touch hot surfaces. Allow pumps operating at a high tempera-
ture to cool sufficiently before performing maintenance. If touching a hot surface cannot be
avoided, personnel should wear appropriate gloves, clothing, and other protective gear as nec-
essary. Local law may provide specific guidance regarding exposure of personnel to unsafe
temperatures.

1.2.3.1 Magnetic precautions

WARNING:
Magnetic drive pumps contain very strong magnets that can pose health risks. Always observe
these guidelines:
• Avoid working with, being in proximity of, or handling the magnets contained in this pump
if you have any of these conditions:
• An artificial cardiac pacemaker
• An implanted defibrillator
• A metallic prosthetic heart valve
• Internal wound clips, from surgery
• Prosthetic joints
• Metallic wiring

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 7

1.2 Safety

• Any other type of metallic, prosthetic device

• Individuals who have had any surgery, especially to the chest or head, and do not know if
metallic clips were surgically implanted need to avoid work on this unit unless their physi-
cian can confirm that no metallic devices exist.

1.2.3.2 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 1. Hold your eyelids apart forcibly with your fingers.
in eyes 2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous fluids 1. Remove contaminated clothing.
on skin 2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.

1.2.4 Safety regulations for Ex-approved products in potentially explosive

atmospheres
Guidelines for compliance
Compliance is only fulfilled when the pump is operated within its intended use, for example within its in-
tended hydraulic range. The conditions of the service must not be changed without approval of an au-
thorized ITT representative. When installing or maintaining explosion-proof pumps, follow these guide-
lines:
• Always install ATEX-approved equipment in compliance with the directive and applicable stand-
ards.

WARNING:
Risk of serious 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 clear-
ly 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.

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.

8 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 1.2 Safety

• 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.

Product and product handling requirements

These are the product and product handling requirements for Ex-approved products in potentially explo-
sive 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.
• Never start a pump without the proper priming.
• See the dimensional drawings of the product for the minimum permitted water level according to
the ATEX approval. Level-sensing equipment must be installed if the product can be operated at
less than the minimum submersion depth.
• Move equipment to a safe/non ATEX environment for repairs/adjustments or use spark resistant
tools and work methods.
• Before you start working with the product, make sure that the product and the control panel are iso-
lated 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.
• Make sure that the equipment is properly maintained:
• Monitor the pump components and the end temperature of the liquid.
• Maintain proper bearing lubrication.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT 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 baseplate on which it is mount-
ed. A typical tag would look like this:

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 9

1.3 Product warranty

Figure 1: ATEX identification

Table 1: Temperature class definitions

Code Maximum permissible surface tem- Maximum permissible liquid tempera-

perature in °C | °F ture in °C | °F
T1 440 | 824 372 | 700
T2 290 | 554 267 | 513
T3 195 | 383 172 | 342
T4 130 | 266 107 | 225
T5 Option not available Option not available
T6 Option not available Option not available

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

1.3 Product warranty

Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and 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.

10 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 1.3 Product warranty

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 repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses

Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should
the need arise for a warranty claim, then contact your ITT representative.

1.3.1 Spare parts

ITT guarantees that spare parts will be available for 10 years after the manufacture of this product has
been discontinued.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 11

2 Transportation and Storage

2 Transportation and Storage

2.1 Inspect the delivery
2.1.1 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.

2.1.2 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.

2.2 Transportation guidelines

2.2.1 Pump handling

WARNING:
Dropping, rolling or tipping units, or applying other shock loads, can cause 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 lifting practices are critical
to safe transport of heavy equipment. Ensure that practices used are in compliance with
all applicable regulations and standards.
• Safe lifting points are specifically identified in this manual. It is critical to lift the equipment
only at these points. Integral lifting eyes or eye bolts on pump and motor components are
intended for use in lifting the individual components only.
• Lifting and handling heavy equipment poses 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.

12 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 2.2 Transportation guidelines

Table 2: Methods

Pump type Lifting method

Bare pump without lifting handles Use a suitable sling attached properly to solid points like the casing, the flang-
es, or the frames.
A base-mounted pump Use slings under the pump casing and the drive unit, or under the base rails.

Examples

Figure 2: Proper lifting method for a bare pump

Figure 3: Proper lifting method for a pump with a base and driver

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 13

2.3 Storage guidelines

NOTICE:

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.

Figure 4: Example of a proper lifting method

2.3 Storage guidelines

2.3.1 Pump storage requirements

Storage requirements depend on the amount of time that you store the unit. The normal packaging is
designed only to protect the unit during shipping.

Length of time in storage Storage requirements

Upon receipt/short-term (less than six • Store in a covered and dry location.
months) • 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 every three months.

Treat bearing and machined surfaces so that they are well preserved. Refer to drive unit and coupling
manufacturers for their long-term storage procedures.
You can purchase long-term storage treatment with the initial unit order or you can purchase it and apply
it after the units are already in the field. Contact your local ITT sales representative.

14 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 3 Product Description

3 Product Description
3.1 General description
Model 3296 EZMAG
The Model 3296 EZMAG is a sealless centrifugal pump with an enclosed impeller that is driven by a syn-
chronous magnetic coupling. Model 3296 EZMAG meets the dimensional standards of ANSI B73.1.

Casing
The casing is top centerline discharge and is self-venting. It incorporates a fully-confined gasket with AN-
SI Class 150 flanges that are serrated and raised-faced. ANSI Class 300 flanges that are serrated and
raised-face are optional. The 3296 EZMAG is designed to have a metal-to-metal fit between the casing
and the backplate.

Magnetic coupling
The magnetic coupling is a coaxial synchronous type that uses rare earth magnets. This concept results
in a compact design and allows the impeller to turn at the same speed as the motor, which means that
there is no slip between the drive and the driven magnets.

Magnets
Two types of rare earth magnets are available:
• Neodymium Iron (NdFe) is used when pumped liquid temperatures are less than 180°C | 365°F.
• Samarium Cobalt (SmCo) is used when pumped liquid temperatures are between 180°C | 365°F
and 280°C | 536°F.

Containment shell
The containment shell isolates the pumped liquid from the atmosphere and is constructed from Hastel-
loy-C.

Sleeve bearings and thrust bearings

Goulds standard bearing material is Pure Sintered Alpha Grade Silicon Carbide. Dryguard™ bearings are
available for dry-run protection.

Impeller
The 3296 EZMAG uses an enclosed impeller that is hydraulically-balanced and keyed to the shaft.

Bearing frame
The standard configuration is cast iron with ball bearings that are flood oil–lubricated. Greased-for-life
bearings systems are available as an option. Bronze bearing isolators are provided for protection and re-
liability of the bearings and the lubricant.

3.2 Nameplate information

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.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 15

3.2 Nameplate information

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 information. See Parts List for item numbers.

Nameplate types

Nameplate Description
Pump
ATEX If applicable, your pump unit might have an ATEX nameplate affixed to the pump, the base-
plate, or the discharge head. The nameplate provides information about the ATEX specifica-
tions of this pump.

Nameplate on the pump casing using English units

Figure 5: Nameplate on the pump casing using English units

Nameplate on the pump casing using metric units

Figure 6: Metric units - nameplate on pump casing

ATEX nameplate
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 baseplate on which it is mount-
ed. A typical tag would look like this:

16 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 3.2 Nameplate information

Figure 7: ATEX pump nameplate

The code classification marked on the equipment should be in accordance with the specified area where
the equipment will be installed. If it is not, please contact your ITT/Goulds representative before proceed-
ing.

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.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 17

4 Installation

4 Installation
4.1 Pre-installation
Precautions

WARNING:
• When installing in a potentially explosive environment, ensure that the motor is properly
certified.
• All equipment being installed must be properly grounded to prevent unexpected dis-
charge. Discharge can cause equipment damage, electric shock, and result in serious in-
jury. Test the ground lead to verify it is connected correctly.

NOTICE:
• Electrical connections must be made by certified electricians in compliance with all inter-
national, national, state and local regulations.
• Supervision by an authorized ITT representative is recommended to ensure proper instal-
lation. Improper installation may result in equipment damage or decreased performance.

Evaluate the installation in order 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.

4.1.1 Pump location guidelines

Guideline Explanation/comment
Keep the pump as close to the liquid source as This minimizes the friction loss and keeps the suction piping as
practically possible. short as possible.
Make sure that the space around the pump is This facilitates ventilation, inspection, maintenance, and service.
sufficient.
If you require lifting equipment such as a hoist or This makes it easier to properly use the lifting equipment and
tackle, make sure that there is enough space safely remove and relocate the components to a safe location.
above the pump.
Protect the unit from weather and water damage This is applicable if nothing else is specified.
due to rain, flooding, and freezing temperatures.
Do not install and operate the equipment in Acceptable devices:
closed systems unless the system is constructed
• Pressure relief valves
with properly-sized safety devices and control
devices. • Compression tanks
• Pressure controls
• Temperature controls
• Flow controls
If the system does not include these devices, consult the engineer
or architect in charge before you operate the pump.
Take into consideration the occurrence of un- The best pump location for noise and vibration absorption is on a
wanted noise and vibration. concrete floor with subsoil underneath.

18 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.1 Pre-installation

4.1.2 Foundation requirements

Requirements
• The location and size of the foundation bolt holes must match those shown on the assembly draw-
ing provided with the pump data package.
• Provide a flat, substantial concrete foundation in order to prevent strain and distortion when you
tighten the foundation bolts.

Sleeve-type bolts

6 2
5

Item Description
1. Baseplate
2. Shims
3. Foundation
4. Sleeve
5. Dam
6. Bolt

Figure 8: Sleeve type bolts

J-type bolts

5
4
2
3

Item Description
1. Baseplate
2. Shims or wedges
3. Foundation
4. Dam
5. Bolt

Figure 9: J-type bolts

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 19

4.2 Baseplate-mounting procedures

4.2 Baseplate-mounting procedures

4.2.1 Prepare the baseplate for mounting
1. Remove all the attached equipment from the baseplate.
2. Clean the underside of the baseplate completely.
3. If applicable, coat the underside of the baseplate with an epoxy primer.
Use an epoxy primer only if using an epoxy-based grout.
4. Remove the rust-proofing coat from the machined mounting pads using an appropriate solvent.
5. Remove water and debris from the foundation-bolt holes.

4.2.2 Install the baseplate using shims or wedges

Required tools:
• Two sets of shims or wedges for each foundation bolt
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure is applicable to cast iron and fabricated steel baseplates.
1. Remove water and debris from the anchor bolt holes and sleeves.
2. If you use sleeve-type bolts, fill the bolt sleeves with packing material or rags to prevent grout from
entering the bolt holes.
3. Put the sets of wedges or shims on each side of each foundation bolt.
Make sure that the wedges extend 19 mm | 0.75 in. to 38 mm | 1.5 in. above the foundation to pro-
vide adequate space for grouting. The wedges will provide adequate support for the baseplate after
it is grouted.
1

1. Shims or wedges
Figure 10: Top view

1. Shims or wedges
Figure 11: Side view
4. Lower the baseplate carefully onto the foundation bolts.
5. Put the machinist's levels across the mounting pads of the driver and the mounting pads of the
pump.

20 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.2 Baseplate-mounting procedures

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 decreased performance.

6. Level the baseplate both lengthwise and across by adding or removing shims or moving the wedg-
es.
These are the leveling tolerances:
You can use the baseplate-leveling worksheet when you take the readings.
7. Hand-tighten the nuts for the foundation.

4.2.3 Install the baseplate using jackscrews

Tools required:
• Anti-seize compound
• Jackscrews
• Bar stock
• Two machinist's levels
• Baseplate-leveling worksheet
This procedure applies to the feature-fabricated steel baseplate and the advantage base baseplate.
1. Apply an anti-seize compound on the jackscrews.
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 baseplate above the foundation.
Make sure that the distance between the baseplate and the foundation surface is between 19 mm |
0.75 in. and 38 mm | 1.50 in.
d) Make sure that the center jackscrews do not touch the foundation surface yet.

2
1

4
3

Item Description
1. Jackscrew
2. Baseplate
3. Foundation
4. Plate

Figure 12: Jackscrews

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 21

4.2 Baseplate-mounting procedures

3. Level the driver 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 decreased performance.

a) Put one machinist's level lengthwise on one of the two pads.

b) Put the other machinist's level across the ends of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and
across.
Use the baseplate-leveling worksheet when you take the readings.

1 2

3 5 6
4

Item Description
1. Machinist's levels
2. Driver's mounting pads
3. Foundation bolts
4. Jackscrews
5. Grout hole
6. Pump's mounting pads

Figure 13: 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 decreased performance.

a) Put one machinist's level lengthwise on one of the two pads.

b) Put the other level across the center of the two pads.
c) Level the pads by adjusting the four jackscrews in the corners.
Make sure that the machinist's level readings are as close to zero as possible, both lengthwise and
across.

22 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.2 Baseplate-mounting procedures

2
1

3 5 6
4

Item Description
1. Driver's mounting pads
2. Machinist's levels
3. Foundation bolts
4. Jackscrews
5. Grout hole
6. Pump's mounting pads

Figure 14: Level pump mounting pads

6. Hand-tighten the nuts for the foundation bolts.
7. Check that the driver's mounting pads are level and adjust the jackscrews and the foundation bolts
if necessary.
The correct level measurement is a maximum of 0.167 mm/m | 0.002 in./ft .

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 23

4.2 Baseplate-mounting procedures

4.2.4 Baseplate-leveling worksheet

Level measurements

1)____________________

2)____________________
3
3)____________________
5 7
4)____________________
8 9
2 5)____________________

6)____________________
4 6
7)____________________
1 8)____________________

9)____________________

10)___________________

11)___________________
14
12)___________________
10
13)___________________
15 16 14)___________________
17 18
11 15)___________________
12
13 16)___________________

17)___________________

18)___________________

24 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.3 Pump-to-driver alignment

4.3 Pump-to-driver alignment

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 manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.

4.3.1 Alignment checks

When to perform alignment checks
You must perform alignment checks 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) Prior to operation when the pump and the driver are at ambient temperature.
check
Final alignment (hot alignment) check After operation when the pump and the driver are at operating temperature.

Initial alignment (cold alignment) checks

When Why
Before you grout the baseplate This ensures that alignment can be accomplished.
After you grout the baseplate This ensures that no changes have occurred during the grouting process.
After you connect the piping This ensures that pipe strains have not altered the alignment.
If changes have occurred, you must alter the piping to remove pipe strains
on the pump flanges.

Final alignment (hot alignment) checks

When Why
After the first run This ensures correct alignment when both the pump and the driver are at op-
erating temperature.
Periodically This follows the plant operating procedures.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 25

4.3 Pump-to-driver alignment

4.3.2 Permitted indicator values for alignment checks

NOTICE:
The specified permitted reading values are valid only at operating temperature. For cold set-
tings, other values are permitted. The correct tolerances must be used. Failure to do so can
result in misalignment. Contact ITT for further information.

When dial indicators are used to check the final alignment, the pump and drive unit are correctly aligned
when these conditions are true:
• The Total Indicated Reading (T.I.R.) is at 0.05 mm | 0.002 in. or less at operating temperature.
• The tolerance of the indicator is 0.0127 mm per mm | 0.0005 in. per in. of indicator separation for
the reverse dial indicator or laser method when the pump and driver are at operating temperature.

4.3.2.1 Cold settings for parallel vertical alignment

Introduction
This section shows the recommended preliminary (cold) settings for electric motor-driven pumps based
on different temperatures of pumped fluid. Consult driver manufacturers for recommended cold settings
for other types of drivers such as steam turbines and engines.

Recommended settings

Pumped fluid temperature Recommended setting for driver shaft

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
232°C | 450°F 0.33 mm | 0.013 in., high

4.3.3 Alignment measurement guidelines

Guideline Explanation
Rotate the pump coupling half and the driver coupling half together This prevents incorrect measurement.
so that the indicator rods have contact with the same points on the
driver coupling half.
Move or shim only the driver in order to make adjustments. This prevents strain on the piping installations.
Make sure that the hold-down bolts for the driver are tight when This keeps the driver stationary since move-
you take indicator measurements. ment causes incorrect measurement.
Make sure that the hold-down bolts for the driver are loose before This makes it possible to move the driver when
you make alignment corrections. you make alignment corrections.
Check the alignment again after any mechanical adjustments. This corrects any misalignments that an adjust-
ment may have caused.

4.3.4 Attach the dial indicators for alignment

You must have two dial indicators in order to complete this procedure.
1. Attach two dial indicators on the pump coupling half (X):
a) Attach one indicator (P) so that the indicator rod comes into contact with the perimeter of the
driver coupling half (Y).
This indicator is used to measure parallel misalignment.

26 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.3 Pump-to-driver alignment

b) Attach the other indicator (A) so that the indicator rod comes into contact with the inner end of
the driver coupling half.
This indicator is used to measure angular misalignment.

Y X

Figure 15: Dial indicator attachment

2. Rotate the pump coupling half (X) in order to check that the indicators are in contact with the driver
coupling half (Y) but do not bottom out.
3. Adjust the indicators if necessary.

4.3.5 Pump-to-driver alignment instructions

4.3.5.1 Perform angular alignment for a vertical correction

Before you start this procedure, make sure that the dial indicators are properly attached for measure-
ment.
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 Then...

reading val-
ue is...
Negative The coupling halves are farther apart at the bottom than at the top. Perform one of
these steps:
• Add shims in order to raise the feet of the driver at the shaft end.
• Remove shims in order to lower the feet of the driver at the other end.
Positive The coupling halves are closer at the bottom than at the top. Perform one of these
steps:
• Remove shims in order to lower the feet of the driver at the shaft end.
• Add shims in order to raise the feet of the driver at the other end.

X Y

Shims

Figure 16: Side view of an incorrect vertical alignment

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 27

4.3 Pump-to-driver alignment

4. Repeat the previous steps until the permitted reading value is achieved.

4.3.5.2 Perform angular alignment for a horizontal correction

Before you start this procedure, make sure that the dial indicators are properly attached for measure-
ment.
1. Set the angular alignment indicator (A) to zero on left side of the driver coupling half (Y), 90° from
the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start position
(3 o’clock).
3. Record the indicator reading.

When the reading value is... Then...

Negative The coupling halves are farther apart on the right side than
the left. Perform one of these steps:
• Slide the shaft end of the driver to the left.
• Slide the opposite end to the right.
Positive The coupling halves are closer together on the right side
than the left. Perform one of these steps:
• Slide the shaft end of the driver to the right.
• Slide the opposite end to the left.

Y X

Figure 17: Top view of an incorrect horizontal alignment

4. Repeat the previous steps until the permitted reading value is achieved.

4.3.5.3 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 alignment value based on the motor temperature rise and the
pump operating temperature.
Before you start this procedure, make sure that the dial indicators are correctly set up.
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.
When aligning a cold unit, see the Cold settings for vertical parallel alignment table.
1. Set the parallel alignment indicator (P) to zero at the top-center position (12 o’clock) of the driver
coupling half (Y).
2. Rotate the indicator to the bottom-center position (6 o’clock).
3. Record the indicator reading.

When the read- Then...

ing value is...
Negative The pump coupling half (X) is lower than the driver coupling half (Y). Remove
shims of a thickness equal to half of the indicator reading value under each driver
foot.

28 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.3 Pump-to-driver alignment

When the read- Then...

ing value is...
Positive The pump coupling half (X) is higher than the driver coupling half (Y). Add shims of
a thickness equal to half of the indicator reading value to each driver foot.

Y X

Shims

Figure 18: Side view of an incorrect vertical alignment

4. Repeat the previous steps until the permitted reading value is achieved.

NOTICE:
The specified permitted reading values are valid only at operating temperature. For cold set-
tings, other values are permitted. The correct tolerances must be used. Failure to do so can
result in misalignment. Contact ITT for further information.

4.3.5.4 Perform parallel alignment for a horizontal 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 alignment value based on the motor temperature rise and the
pump operating temperature.
Before you start this procedure, make sure that the dial indicators are properly attached for measure-
ment.
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 zero on the left side of the driver coupling half (Y), 90°
from the top-center position (9 o’clock).
2. Rotate the indicator through the top-center position to the right side, 180° from the start position
(3 o’clock).
3. Record the indicator reading.

When the reading value is... Then...

Negative The driver coupling half (Y) is to the left of the pump coupling half (X).
Positive The driver coupling half (Y) is to the right of the pump coupling half (X).
4. Slide the driver carefully in the appropriate direction.

NOTICE:
Make sure to slide the driver evenly. Failure to do so can negatively affect horizontal angular
correction.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 29

4.4 Grout the baseplate

Y X

Figure 19: Top view of an incorrect horizontal alignment

5. Repeat the previous steps until the permitted reading value is achieved.

4.3.5.5 Perform complete alignment for a vertical correction

Before you start this procedure, make sure that the dial indicators are properly attached for measure-
ment.
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 indicators to zero at the top-center position (12 o’clock) of the driver
coupling half (Y).
2. Rotate the indicators to the bottom-center position (6 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment until you
obtain the permitted reading values.
When the procedure is complete, both the angular and parallel alignment must meet the permitted toler-
ances.

4.3.5.6 Perform complete alignment for a horizontal correction

Before you start this procedure, make sure that the dial indicators are properly attached for measure-
ment.
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 indicators to zero at the left side of the driver coupling half (Y), 90°
from the top-center position (9 o’clock).
2. Rotate the indicators through the top-center position to the right side, 180° from the start position
(3 o’clock).
3. Record the indicator readings.
4. Make corrections according to the separate instructions for angular and parallel alignment until you
obtain the permitted reading values.
When the procedure is complete, both the angular and parallel alignment must meet the permitted toler-
ances.

4.4 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 the grout.
2. Build a dam around the foundation.
3. Thoroughly wet the foundation that will come into contact with the grout.

30 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.5 Piping checklists

4. Pour grout through the grout hole into the baseplate up to the level of the dam.
When you pour the grout, remove air bubbles from it by using one of these methods:
• Puddle with a vibrator.
• Pump the grout into place.
5. Allow the grout to set.
6. Fill the remainder of the baseplate with grout, and allow the grout to set for at least 48 hours.

5
4 2

Item Description
1. Baseplate
2. Grout
3. Foundation
4. Dam
5. Bolt

Figure 20: Fill remainder of baseplate with grout

7. Tighten the foundation bolts.
8. Recheck the alignment.

4.5 Piping checklists

4.5.1 Fastening

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 all corroded fasteners.
• Ensure that all fasteners are properly tightened and that there are no missing fasteners.

4.5.2 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
system, including those from the thermal expansion of the piping, must not exceed the
limits of the pump.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 31

4.5 Piping checklists

• Risk of serious personal injury or property damage. Fasteners such as bolts and nuts are
critical to the safe and reliable operation of the product. Ensure appropriate use of fasten-
ers during installation or reassembly of the unit.
• Use fasteners of the proper size and material only.
• Replace all corroded fasteners.
• Ensure that all fasteners are properly tightened and that there are no missing fas-
teners.

CAUTION:
Do not move the pump to the pipe. This could make final alignment impossible.

CAUTION:
Never draw piping into place at the flanged connections of the pump. This can impose danger-
ous strains on the unit and cause misalignment between the pump and driver. Pipe strain ad-
versely affects the operation of the pump, which results in physical injury and damage to the
equipment.
Flange loads from the piping system, including those from the thermal expansion of the piping,
must not exceed the limits of the pump. Deformation can result in contact with rotating parts,
which can result in excess heat generation, sparks, and premature failure.

NOTICE:
Vary the capacity with the regulating valve in the discharge line. Never throttle the flow from the
suction side. This action can result in decreased performance, unexpected heat generation,
and equipment damage.

Piping guidelines
Guidelines for piping are 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- • Strain on the pump
dependently of, and lined up naturally • Misalignment between the pump and the drive unit
with, the pump flange.
Keep the piping as short as possible. This helps to minimize friction losses.
Check that only necessary fittings are This helps to minimize friction losses.
used.
Do not connect the piping to the —
pump until:
• The grout for the baseplate or
sub-base becomes hard.
• The grout for the pit cover be-
comes hard.
• The hold-down bolts for the
pump and the driver are tight-
ened.

32 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.5 Piping checklists

Check Explanation/comment Checked

This helps to prevent misalignment due to linear expansion of
the piping.

Example: Installation for expansion

Correct Incorrect
This illustration shows a correct installation for expan- This illustration shows an incorrect installation for expan-
sion: sion:

1. Expansion loop/joint

4.5.3 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.
Refer to the Hydraulic Institute for NPSH and pipe friction values needed in order to evaluate suction pip-
ing.

Suction-piping checks

Check Explanation/comment Checked

Flush all suction piping before you connect This reduces the risk of pump operation problems.
it to the pump.
Check that the suction piping fittings and —
joints are airtight and have no leaks.
Check that the distance between the inlet This minimizes the risk of cavitation in the suction in-
flange of the pump and the closest elbow let of the pump due to turbulence.
is at least two pipe diameters.
See the Example sections for illustrations.
Check that elbows in general do not have See the Example sections for illustrations.
sharp bends.
—

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 33

4.5 Piping checklists

Check Explanation/comment Checked

Check that the suction piping is one or two The suction piping must never have a smaller diame-
sizes larger than the suction inlet of the ter than the suction inlet of the pump.
pump.
See the Example sections for illustrations.
Install an eccentric reducer between the
pump inlet and the suction piping.
Check that the eccentric reducer at the See the example illustrations.
suction flange of the pump has the follow-
ing properties:
• Sloping side down
• Horizontal side at the top
Suggested suction strainers are used. Suction strainers help to prevent debris from entering
Check that they are at least three times the the pump.
area of the suction piping.
Mesh holes with a minimum diameter of 1.6 mm |
Monitor the pressure drop across the suc- 1/16 in. are recommended.
tion strainer.
Liquids with specific gravity less than 0.60 a pressure
An increased pressure drop across the drop across the suction strainer may be due to ice
strainer of 34.5 kPa | 5 psi indicates that buildup. Ice buildup can cause turbulence, low pres-
the strainer should be removed and sure areas and pumpage vaporization.
cleaned.
After a period of time (24 hours minimum)
system flushing should be complete and
the suction strainer can be removed.
If more than one pump operates from the This recommendation helps you to achieve a higher
same liquid source, check that separate pump performance and prevent vapor locking espe-
suction-piping lines are used for each cially with specific gravity of liquid less than 0.60.
pump.
If necessary, make sure that the suction —
piping includes a drain valve and that it is
correctly installed.
Assure adequate insulation is applied for To assure sufficient NPSHa.
liquids with specific gravity less than 0.60.

Liquid source below the pump

Check Explanation/comment Checked

Make sure that the suction piping is free This helps to prevent the occurrence of air and cavita-
from air pockets. tion in the pump inlet.

Check that the suction piping slopes up- —

wards from the liquid source to the pump
inlet.
If the pump is not self-priming, check that a Use a foot valve with a diameter that is at least equiva-
device for priming the pump is installed. lent to the diameter of the suction piping.

34 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.5 Piping checklists

Liquid source above the pump

Check Explanation/comment Checked

Check that an isolation valve is installed in This permits you to close the line during pump inspec-
the suction piping at a distance of at least tion and maintenance.
two times the pipe diameter from the suc-
Do not use the isolation valve to throttle the pump.
tion inlet.
Throttling can cause these problems:
• Loss of priming
• Excessive temperatures
• Damage to the pump
• Voiding the warranty
Make sure that the suction piping is free This helps to prevent the occurrence of air and cavita-
from air pockets. 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 size of the entrance —
from the supply is one or two sizes larger
than the suction pipe.
Make sure that the suction piping is ade- This prevents air from entering the pump through a
quately submerged below the surface of suction vortex.
the liquid source.

Correct Incorrect
The correct distance between the inlet flange of the
pump and the closest elbow is at least two pipe diame-
ters.

1. Enough distance to prevent cavitation

2. Eccentric reducer with a level top

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 35

4.5 Piping checklists

Example: Suction piping equipment

Correct Incorrect

1
1

4
3
1. Suction pipe sloping upwards from liquid source 1. Air pocket, because the eccentric reducer is not
2. Long-radius elbow used and because the suction piping does not
slope gradually upward from the liquid source
3. Strainer
4. Foot valve
5. Eccentric reducer with a level top

4.5.4 Discharge piping checklist

Checklist

Check Explanation/comment Checked

Check that an isolation valve is installed in The isolation valve is required for:
the discharge line. For specific gravity less
• Priming
than 0.60, minimize distance from pump
discharge. • Regulation of flow
• Inspection and maintenance of the 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 The location between the isolation valve and the pump
discharge line, between the isolation valve allows inspection of the check valve.
and the pump discharge outlet.
The check valve prevents damage to the pump and seal
due to the back flow through the pump, when the drive
unit is shut off. It is also used to restrain the liquid flow.
See Example: Discharge piping equipment for illustra-
tions.
If increasers are used, check that they are See Example: Discharge piping equipment for illustra-
installed between the pump and the check tions.
valve.

36 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 4.5 Piping checklists

Check Explanation/comment Checked

If quick-closing valves are installed in the This protects the pump from surges and water hammer.
system, check that cushioning devices are
used.

Example: Discharge piping equipment

Correct Incorrect

1 1
4
2
2
3

1. Bypass line 1. Check valve (incorrect position)

2. Shut-off valve 2. The isolation valve should not be positioned be-
tween the check valve and the pump.
3. Check valve
4. Discharge isolation valve

4.5.5 Final piping checklist

WARNING:

A build-up of gases within the pump, sealing system, or process piping system may
result in an explosive environment. Make sure the process piping system, pump and sealing
system are properly vented prior to operation.

Check Explanation/comment Checked

Check that the shaft rotates smoothly. Rotate the shaft by hand. Make sure there is no rubbing that
can lead to excess heat generation or sparks.
Re-check the alignment to make sure that If pipe strain exists, then correct the piping.
pipe strain has not caused any misalign-
ment.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 37

5 Commissioning, Startup, Operation, and Shutdown

5 Commissioning, Startup, Operation, and

Shutdown
5.1 Preparation for startup
WARNING:
• Risk of serious physical injury or death. Exceeding any of the pump operating limits (e.g. -
pressure, temperature, power, etc.) could result in equipment failure, such as explosion,
seizure, or breach of containment. Assure that the system operating conditions are within
the capabilities of the pump.
• Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Ensure all open-
ings are sealed prior to filling the pump.
• Breach of containment can cause fire, burns, and other serious injury. Failure to follow
these precautions before starting the unit may lead to dangerous operating conditions,
equipment failure, and breach of containment.
• Risk of explosion and serious physical injury. Do not operate pump with blocked system
piping or with suction or discharge valves closed. This can result in rapid heating and va-
porization of pumpage.
• Risk of breach of containment and equipment damage. Ensure the pump operates only
between minimum and maximum rated flows. Operation outside of these limits can cause
high vibration, mechanical seal and/or shaft 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 (guards, etc.) are
properly installed.
• 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 manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.
• Risk of seizure, breach of containment, or explosion. Ensure balance line is installed and
piped back to either the pump suction or suction vessel. This prevents rapid vaporization
of the pumped fluid.

Precautions

WARNING:
The mechanical seal used in an Ex-classified environment must be properly certified.

38 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.2 Remove the coupling guard

CAUTION:
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 or shaft sleeve damage by ensuring that the seal is properly installed and centered on the
sleeve.

NOTICE:
• Verify the driver settings before you start any pump. Refer to the applicable drive equip-
ment IOMs and operating procedures.
• Excessive warm-up rates can cause equipment damage. Ensure the warm-up rate does
not exceed 1.4°C | 2.5°F per minute.

NOTICE:
You must follow these precautions before you start the pump:
• Flush and clean the system thoroughly to remove dirt or debris in the pipe system in order
to prevent premature failure at initial startup.
• Bring variable-speed drivers to the rated speed as quickly as possible.
• If temperatures of the pumped fluid will exceed 93°C | 200°F, then warm up the pump pri-
or to operation. Circulate 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 over-speed trip
settings while the variable-speed driver is coupled to the pump. If the settings have not been verified,
then uncouple the unit and refer to instructions supplied by the driver manufacturer.

5.2 Remove the coupling guard

1. Remove the nut, bolt, and washers from the slotted hole in the center of the coupling guard.
2. Slide the driver half of the coupling guard toward the pump.

Driver
Slide to fit

3. Remove the nut, bolt, and washers from the driver half of the coupling guard.
4. Remove the driver half of the coupling guard:
a) Slightly spread the bottom apart.
b) Lift upwards.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 39

5.2 Remove the coupling guard

2
1

Item Description
1. Annular groove
2. Driver half of the coupling guard
3. Driver

5. Remove the remaining nut, bolt, and washers from the pump half of the coupling guard.
It is not necessary to remove the end plate from the pump side of the bearing housing. 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.

4
1

Item Description
1. Annular groove
2. Pump-side end plate
3. Driver
4. Pump half of the coupling guard

40 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.3 Check the rotation

5.3 Check the rotation

WARNING:
• Starting the pump in reverse rotation can result in the contact of metal parts, heat genera-
tion, and breach of containment. Ensure correct driver settings prior to starting any pump.
• 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 manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.

1. Lock out power to the driver.

2. Make sure that the coupling hubs are fastened securely to the shafts.
3. Make sure that the coupling spacer is removed.
The pump ships with the coupling spacer removed.
4. Unlock power to the driver.
5. Make sure that everyone is clear, and then 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 Check the rotation - Close Coupled

WARNING:
• Starting the pump in reverse rotation can result in the contact of metal parts, heat genera-
tion, and breach of containment. Ensure correct driver settings prior to starting any pump.
• 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 manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.

1. Lock out power to the driver.

2. Make sure that everyone is clear. Jog the driver momentarily, about a half a second. You should be
able to check motor rotation by observing the motor fan direction. The direction should be the same
as the arrow on the close coupled frame.
3. Lock out power to the driver.

5.5 Couple the pump and driver

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.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 41

5.5 Couple the pump and driver

• Electrical connections must be made by certified electricians in compliance with all inter-
national, national, state, and local rules.
• Refer to driver/coupling/gear manufacturer's installation and operation manuals (IOM) for
specific instructions and recommendations.

Couplings must have proper certification to be used in an ATEX classified environment. Use
the instructions from the coupling manufacturer in order to lubricate and install the coupling. Refer to
driver/coupling/gear manufacturers IOM for specific instructions and recommendations.

5.5.1 Install the coupling guard

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 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 manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.

WARNING:
The coupling guard used in an ATEX classified environment must be properly certified and
constructed from a spark resistant material.

Required parts:

42 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.5 Couple the pump and driver

1 2 3

4 5

Item Description Item Description

1. End plate, drive end 4 3/8-16 nut, 3 required
2. End plate, pump end 5 3/8 in. washer
3. Guard half, 2 required 6 3/8-16 x 2 in. hex head bolt, 3 required

Figure 21: Required parts

1. De-energize the motor, place the motor in a locked-out position, and place a caution tag at the start-
er that indicates the disconnect.
2. Put the pump-side end plate in place.
If the pump-side end plate is already in place, make any necessary coupling adjustments and then
proceed to the next step.

If the pump size is... Then...

STX, MTX, LTX Align the pump-side end plate to the bearing frame. You do not need to
adjust the impeller.
XLT-X 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 slots align with the impeller adjusting bolts.
2. Fasten the end plate to the bearing housing using the jam nuts on the im-
peller adjusting bolts.
3. Check the impeller clearance. Refer to the impeller clearance table for the
correct impeller clearance.

STX, MTX, LTX

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 43

5.5 Couple the pump and driver

XLT-X
2
1

Ite Description
m
1. Driver
2. Pump end plate
3. Bearing housing
4. Jam nut

3. Put the pump-half of the coupling guard in place:

a) Slightly spread the bottom apart.
b) Place the coupling guard half over the pump-side end plate.

4
1

Item Description
1. Annular groove
2. Pump-side end plate
3. Driver
4. Pump half of the coupling guard

Figure 22: Guard half installation

The annular groove in the coupling guard half must fit around the end plate.

44 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.5 Couple the pump and driver

Item Description
1. Annular groove
2. End plate (pump end)
2. Guard half

Figure 23: Annular groove in coupling guard

4. Use a bolt, a nut, and two washers to secure the coupling guard half to the end plate. Tighten se-
curely.

1 2 3

Item Description
1. Nut
2. Washer
3. Bolt

Figure 24: 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.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 45

5.5 Couple the pump and driver

2
1

Item Description
1. Annular groove
2. Driver half of the coupling guard
3. Driver

6. Place the driver-side end plate over the motor shaft.

Driver

234B

Figure 25: Placement of driver half of coupling guard

7. Place the driver-side end plate in the annular 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.

46 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.6 Bearing lubrication

Driver
Slide to fit

Figure 26: Slide driver-half of coupling guard towards motor

10. Use a nut, a bolt, and two washers to secure the coupling guard halves together.
11. Tighten all nuts on the guard assembly.

5.6 Bearing lubrication

WARNING:
Pumps are shipped without oil. Oil-lubricated anti-friction bearings must be lubricated at the job
site.

Risk of explosive hazard and premature failure from sparks and heat generation.
Ensure bearings are properly lubricated prior to startup.

Lubrication requirements

Pump type Requirements

Close coupled Close-coupled pumps do not have bearings that require lubrication.
Frame mounted • The oil level is measured through the sight glass.
• The oil level must not fall below the center of the sight glass.
• An increase in oil level may be noted after startup due to oil circulation within the bearing
frame.

5.6.1 Lubricating-oil requirements

Oil quality requirements
Use a high-quality turbine oil with rust and oxidation inhibitors with rated viscosity shown below at 38°C |
100°F.

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 requirements.

Temperature Oil requirement

Bearing temperatures exceed 82°C | 180°F Use ISO viscosity grade 100. Bearing temperatures are generally
about 11°C | 20°F higher than bearing-housing outer surface tempera-
tures.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 47

5.6 Bearing lubrication

Temperature Oil requirement

Pumped-fluid temperatures exceed 177°C | Use synthetic lubrication.
350°F

5.6.2 Acceptable oil for lubricating bearings

Acceptable lubricants

Table 3: Acceptable lubricants

Brand Lubricant type

Chevron GST Oil 68
Exxon Teresstic EP 68
Mobil DTE Heavy Medium
Phillips 66 Turbine Oil VG68
Shell Turbo T 68
Royal Purple SYNFILM ISO VG 68 Synthetic Oil
Gulf Harmony 68

5.6.3 Lubricate the bearings with oil

WARNING:
Risk of explosive hazard and premature failure from sparks and heat generation. Ensure bear-
ings are properly lubricated prior to startup.

Use a high-quality turbine oil with rust and oxidation inhibitors.

1. Remove the fill plug.
2. Fill the bearing frame with oil through the filler connection, which is located on top of the bearing
frame.
Fill the bearing frame with oil until the oil level reaches the middle of the sight glass (319). The cor-
rect volume of oil required for each size of bearing frame can be found in the ‘Oil Volume Require-
ments’ section in the ‘Bearing Maintenance’ / ‘Maintenance’ portion of the IOM.

Oil lubricated
bearings
113A

319
Correct
level

Figure 27: Oil filler connection

3. Replace the fill plug.

48 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.7 Pump priming

5.6.4 Greased-for-life bearing lubrication

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. Refer to the Maintenance chapter for re-greasing and main-
tenance procedures for these bearings.

5.7 Pump priming

Potential for leaks or flooding. Make sure that you reinstall the drain plugs, check all joints for tightness,
and flange bolts for the proper torque. Failure to follow these instructions can result in property damage
and/or moderate personal injury.
Prior to filling the pump, install all plugs and blind flanges on casing and auxiliary piping. Make sure all
openings are sealed off prior to priming pump.

5.7.1 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 flows out.
3. Close the air vents.

1
2

Item Description
1. Discharge isolation valve
2. Check valve
3. Suction isolation valve

Figure 28: Suction supply above pump

5.7.2 Prime the pump with the suction supply below the pump
Use a foot valve and an outside source of liquid in order to prime the pump. The liquid can come from
one of these sources:
• A priming pump
• A pressurized discharge line
• Another outside supply
1. Close the discharge isolation valve.
2. Open the air vent valves in the casing.
3. Open the valve in the outside supply line until only liquid escapes from the vent valves.
4. Close the vent valves.
5. Close the outside supply line.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 49

5.8 Start the pump

1 1
5
2
2

5 3 4

3
4

Item Description
Item Description 1. By-pass line
1. Discharge isolation valve 2. Shutoff valve
2. Shutoff valve 3. Foot valve
3. From outside supply 4. Check valve
4. Foot valve 5. Discharge isolation valve
5. Check valve
Figure 30: Pump priming with suction supply
Figure 29: Pump priming with suction supply below pump with foot valve using bypass
below pump with foot valve and an outside sup- around check valve
ply

5.7.3 Other methods of priming the pump

You can also use these methods in order to prime the pump:
• Prime by ejector
• Prime by automatic priming pump

5.8 Start the pump

WARNING:
Continuous operation against a closed discharge valve can vaporize liquid. This condition can
cause an explosion due to confined vapor that is under high pressure and temperature.

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.

50 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.8 Start the 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 attempt to restart the pump.
• On frame mounted units, ensure that the oil level is correct prior to starting pump. Close
coupled pumps do not have oil lubricated bearings.
• Continuous operation against a closed discharge valve will cause the pump to overheat.
Overheating the magnetic drive assembly will weaken or ruin the magnets.

NOTICE:
Risk of equipment damage on pure or purge-oil mist-lubricated units. Remove the viewing port
plugs to verify that oil mist is flowing properly. Reinstall the plugs after confirming.

Before you start the pump, you must perform these tasks:
• Open the suction valve.
• Open any recirculation or cooling lines.
1. Fully close or partially open the discharge valve, depending on system conditions.
2. Start the driver.
3. Slowly open the discharge valve until the pump reaches the desired flow.
4. Immediately check the pressure gauge to ensure that the pump quickly reaches the correct dis-
charge pressure.
5. If the pump fails to reach the correct pressure, perform these steps:
a) Stop the driver.
b) Prime the pump again.
c) Restart the driver.
6. Monitor the pump while it is operating:
a) Check the pump for bearing temperature, excessive vibration, and noise.
b) If the pump exceeds normal levels, then shut down the 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.

5.8.1 Minimum continuous recommended flow

Table 4: Minimum flow in GPM (m3/hr)

NOTICE:
These measurements are based on water with a Specific Gravity of 1.0 and a Specific
Heat of 1.0.

Group Size 3500 rpm 2900 rpm 1750 rpm 1450 rpm
S 1 x 1½ - 6 23 (5) 15 (4) 11 (3) 8 (2)
1 x 1½ - 6G 7.0 (1.6) 4.9 (1.1) 1.8 (0.4) 1.2 (0.27)
1½ x 3 - 6 30 (7) 25 (6) 15 (4) 13 (3)
2x3-6 56 (12.5) 47 (11) 28 (6) 23 (5)
1 x 1½ - 8 10 (2.5) 7 (2) 3 (1) 2 (1)

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 51

5.9 Pump operation precautions

Group Size 3500 rpm 2900 rpm 1750 rpm 1450 rpm
1 x 1½ - 8H 22 (5) 18 (4) 11 (2.5) 9 (2)
1½ x 3 - 8 34 (8) 29 (7) 17 (4) 14 (3)
S/M 2x3-8 74 (17) 61 (14) 37 (9) 20 (5)
M (8 in.) 3x4-7 157 (36) 127 (29) 78 (18) 64 (15)
3 x 4 - 8G 159 (36) 129 (30) 79 (18) 65 (15)
M (10 in.) 1 x 2 - 10 21 (5) 13 (3) 9 (2) 7 (2)
1½ x 3 - 10 41.5 (9) 35 (8) 21 (5) 17.5 (4)
2 x 3 - 10 78 (18) 65 (15) 38 (9) 31 (7)
3 x 4 - 10 173 (40) 144 (33) 86 (20) 72 (16)
M (13 in.) 1½ x 3 - 13 53 (12) 44 (10) 26 (6) 22 (5)

5.9 Pump operation precautions

General considerations

WARNING:
• Risk of serious personal injury or property damage. Dry running may cause rotating parts
within the pump to seize to non-moving parts. Do not run dry.
• Risk of explosion and serious physical injury. Do not operate pump with blocked system
piping or with suction or discharge valves closed. This can result in rapid heating and va-
porization of pumpage.
• Starting the pump in reverse rotation can result in the contact of metal parts, heat genera-
tion, and breach of containment. Ensure correct driver settings prior to starting any pump.

NOTICE:
Operation at reduced capacity

WARNING:
• Risk of breach of containment and equipment damage. Excessive vibration levels can
cause damage to bearings, stuffing box, seal chamber, and/or mechanical seal. Observe
pump for vibration levels, bearing temperature, and excessive noise. If normal levels are
exceeded, shut down and resolve.
• Risk of explosion and serious physical injury. Do not operate pump with blocked system
piping or with suction or discharge valves closed. This can result in rapid heating and va-
porization of pumpage.
• Risk of equipment damage and serious physical injury. Heat build-up can cause rotating
parts to score or seize. Observe pump for excessive 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.

52 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 5.10 Shut down the pump

Operation under freezing conditions

NOTICE:
Do not expose an idle pump to freezing conditions. Drain all liquid that will freeze that is inside
the pump and any auxiliary equipment. Failure to do so can cause liquid to freeze and damage
the pump. Note that different liquids freeze at different temperatures. Some pump designs do
not drain completely and may require flushing with a liquid that doesn't freeze.

Temperature ratings

CAUTION:
Do not operate the pump above the rated temperature range of the magnets. This will weaken
or ruin the magnets. The rated temperature is 121°C | 250°F for all sizes.

Magnetic types Drive destination Rated temperature

Neodymium iron (NdFe) A, B, C, D, E, F, G, H, I, J, K 180°C | 356°F
Samarium Cobalt (SmCo) AA, BB, CC, DD, EE, FF, GG, HH, II, JJ, KK 280°C | 536°F

5.10 Shut down the pump

WARNING:
Precautions must be taken to prevent physical injury. The pump may handle hazardous and/or
toxic fluids. Proper personal protective equipment should be worn. Pumpage must be handled
and disposed of in conformance with applicable environmental regulations.

1. Slowly close the discharge valve.

2. Shut down and lock out the driver to prevent accidental rotation.

5.11 Make the final alignment of the pump and driver

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 manufacturer's installation and operation manuals
(IOM) for specific instructions and recommendations.
• Misalignment can cause decreased performance, equipment damage, and even cata-
strophic failure of frame-mounted units leading to serious injury. Proper alignment is the
responsibility of 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.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 53

5.11 Make the final alignment of the pump and driver

1. Run the unit under actual operating conditions for enough time to bring the pump, driver, and asso-
ciated system to operating temperature.
2. Shut down the pump and the driver.
3. Remove the coupling guard.
See Remove the coupling guard in the Maintenance chapter.
4. Check the alignment while the unit is still hot.
See Pump-to-driver alignment in the Installation chapter.
5. Reinstall the coupling guard.
6. Restart the pump and driver.

54 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6 Maintenance

6 Maintenance
6.1 Maintenance schedule
Maintenance inspections
A maintenance schedule includes these types of inspections:
• Routine maintenance
• Routine inspections
• Three-month inspections
• Annual inspections
Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the envi-
ronment is classified as potentially explosive.

Routine maintenance
Perform these tasks whenever you perform routine maintenance:
• Lubricate the bearings.
• Inspect the seal.
• Perform a vibration analysis.
• Monitor the discharge pressure.
• Monitor the temperature.

Routine inspections
Perform these tasks whenever you check the pump during routine inspections:
• Check the level and condition of the oil through the sight glass on the bearing frame.
• Check for unusual noise vibration, and bearing temperatures.
• Check the pump and piping for leaks.
• Analyze the vibration.*

NOTICE:
*If equipped, temperature and vibration levels can be retrieved by using your i-ALERT monitor-
ing sensor and app.

Three-month inspections
Perform these tasks every three months:
• Check that the foundation and the hold-down bolts are tight.
• Change the oil every three months (2000 operating hours) at minimum.
• Check the shaft alignment, and realign as required.

Annual inspections
Perform these inspections one time each year:
• Check the pump capacity.
• Check the pump pressure.
• Check the pump power.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 55

6.2 Bearing maintenance

If the pump performance does not satisfy your process requirements, and the process requirements
have not changed, then perform these steps:
1. Disassemble the pump.
2. Inspect it.
3. Replace worn parts.

6.2 Bearing maintenance

Lubrication schedule

Type of bearing First lubrication Lubrication intervals

Oil lubricated Change the oil after 200 hours for After the first 200 hours, change the oil every 4000 operat-
new bearings. ing hours or every six months.

For ATEX applications bearing replacement (all) is recommended after 17,500 hours of oper-
ation.

These bearing lubrication sections list different temperatures of the pumped fluid. If the pump
is ATEX-certified and the temperature of the pumped fluid exceeds the permitted temperature values,
then consult your ITT representative.

6.3 Disassembly
6.3.1 Disassembly precautions

WARNING:
• Chemical hazard. You must individually decontaminate each component according to all
federal, state, local, and company environmental regulations.
• A build up of gases within the pump, sealing system, or process-piping system can result
in an explosive environment within the pump. Make sure that the process piping system,
pump, and sealing system are properly vented prior to operation.
• Burn Hazard. Coupling may be hot. Use proper protection when handling.
• Burn Hazard. use proper protection when handling bearings.
• Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves
while handling these parts.
• Risk of serious personal injury from exposure to hazardous or toxic liquids. A small
amount of liquid will be present in certain areas like the seal chamber upon disassembly.
• Process fluid leaks can result in an explosive atmosphere. Follow all pump and seal as-
sembly procedures.
• Risk of serious 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.

56 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.3 Disassembly

• Risk of serious physical injury or death from rapid depressurization. Ensure pump is iso-
lated from system and pressure is relieved before disassembling pump, removing plugs,
opening vent or drain valves, or disconnecting piping.
• Lifting and handling heavy equipment poses 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.
• Precautions must be taken to prevent physical injury. The pump may handle hazardous
and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must
be handled and disposed of in conformance with applicable environmental regulations.

CAUTION:
• You must keep the shop area clean and free of any substances that can contaminate the
magnets, such as ferrous metals.
• The magnets in this unit are extremely powerful. Beware of serious injury to fingers and
hands. Keep magnetic drive components and magnetic tools apart by a minimum of 1 m |
3 ft.

NOTICE:
Use a bench with a non-magnetic work surface such as wood or brass when you work on the
pump.

6.3.2 Required tools

WARNING:
This pump contains extremely strong magnets. You must use non-magnetic tools and work sur-
faces.

Tools
• Assorted metric open-end or socket sizes 13 mm, 17 mm, 18 mm, 19 mm, and 24 mm
• Hex wrenches, sizes 2.5 mm, 3 mm, 5 mm, and 6 mm with a 12.07 cm | 4.75 in. minimum reach
• Hex wrench, size 8 mm with 15 cm | 6 in. minimum reach
• Torque wrench
• Strap wrench
• 3/8 in. eyebolt

6.3.3 Prepare the pump for disassembly

1. Lock out power to the driver.

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 in-
ternational, national, state, and local rules.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 57

6.3 Disassembly

• Refer to driver/coupling/gear manufacturer's installation and operation manuals (IOM)

for specific instructions and recommendations.

2. Shut off all valves that control flow to and from the pump.
3. Drain and flush the pump before you remove it from the piping.
4. Isolate the pump from the system and then flush the pump using a compatible liquid.
5. Disconnect all piping and auxiliary equipment.
6. For the frame-mounted pump, remove the coupling guard and coupling.
7. Remove the casing foot and frame and C-face motor-support foot bolts.
8. Remove the pump from the baseplate.
9. For the frame-mounted pump, drain the oil.
10. Decontaminate the pump:
a) Connect a clean-flush liquid supply to the discharge nozzle.
b) Collect the flushed liquid as it drains out of the drain connection.
c) Flush the pump in order to remove residue.

6.3.4 Remove the frame assembly and shaft (frame-mounted pump)

1. Secure the pump on a workbench or worktop with the suction nozzle facing down.
2. Screw the 3/8 in. eyebolt into the drive shaft.
3. Remove the screws (370B) holding the bearing frame to the frame adapter.

1. Frame-to-adapter hex screw (370B)

2. Frame assembly
3. Mag drive carrier
4. Frame-to-adapter gasket (360W)
5. Adapter
4. If required, use jackscrews to separate the parts using the two threaded holes in the bearing frame.

Pump size Screw type

S-Group M12
M-Group M14
5. Lift the bearing frame assembly off the adapter.
Use a crane, if available.
6. Remove the frame-to-adapter gasket (360W).

58 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.3 Disassembly

7. Secure the drive shaft so that it cannot rotate.

8. Remove the capscrew (791D) and the lockwasher (382) from the drive shaft.
1
2

1. Frame assembly
2. Drive carrier assembly (740B)
3. Internal tooth lockwasher (382)
4. Drive-to-shaft capscrew (791D)
9. Remove the drive magnet assembly (740B).
10. Remove the bearing-end cover screws (370C) and the bearing-end cover (109A).
1
2
3
4
5

1. Frame
2. End cover gasket (360A)
3. Wave washer (529)
4. Frame end cover (109A)
5. End cover hex screw (370C)
6. Labyrinth oil seal (332A)
11. Remove the wavy spring washer (529) and end-cover gasket (360A).
12. Remove the drive shaft with both bearings attached.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 59

6.3 Disassembly

2
1 3

1. Labyrinth oil seal (333D)

2. Bearing frame (228)
3. Drive with shaft bearings
13. Remove the labyrinth oil seals (332A and 333D).
14. Remove both radial ball bearings using a press.
The radial ball bearings lie against the shaft collar.

6.3.5 Remove the frame assembly and shaft (close-coupled pump)

1. Secure the complete pump on a workbench in either a horizontal or a vertical position.
2. Remove the hex screws (370B) that hold the motor adapter (503) to the frame adapter (108).

1
2

1. Frame-to-adapter hex screw (370B)

2. Close-coupled adapter (503)
3. Frame-to-adapter gasket (360W)
3. If necessary, remove the motor adapter (503) from the frame adapter (108) using two levers or pry-
bars.
There are also two threaded holes (size M12) in the close-coupled motor adapter (503) for jack-
screws.
4. Lift the motor and motor adapter assembly off the frame adapter.
Use a crane, if necessary.
5. Remove the gasket (360W).
6. Remove the hex screw (791D) and lockwasher (382) from the drive magnet (740B).
7. Remove the drive magnet (740B) from the stub shaft (122A).

60 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.3 Disassembly

8
5 6
4 7
3

1. Stub shaft–to-motor setscrew (222L)

2. Shaft (122A)
3. Motor-to-adapter hex screw (371)
4. Frame-to-adapter hex screw (370B)
5. Close-coupled adapter (503)
6. Frame-to-adapter gasket (360W)
7. Drive carrier assembly (740B)
8. Drive-to-adapter capscrew (791D), internal tooth lockwasher (382)
8. Remove the hex screws (371) that hold the motor to the motor adapter (503).
9. Pull the motor adapter (503) off the motor flange.
10. Loosen the setscrew (222L) that holds the stub shaft onto the motor shaft.
11. Remove the stub shaft (122A) from the motor.

6.3.6 Disassemble the liquid end

1. Remove the hex screws (370) that hold the adapter to the case.

1. Adapter-to-case hex screw (370)

2. Frame adapter (108)
3. Backplate-to-case gasket (351)
4. Casing (100)

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 61

6.3 Disassembly

NOTICE:
Do not remove the three setscrews (222E on the 6 in. S-group, 3 x 4-7, and 3 x 4-8G) or two
hex screws (370V on all other sizes). These setscrews hold the adapter (108), backplate (444),
and containment shell (750).

2
3

1. Adapter-to-backplate setscrew 222E (6 in. S-group, 3 x 4-7, and 3 x 4-8G)

2. Containment shell gasket (540N)
3. Containment shell (750)
4. Frame adapter (108)
5. Adapter-to-backplate hex screw (370V)
2. Remove the entire assembly from the casing (100).
3. If you need to remove the assembly from the casing, insert jackscrews through the threaded holes
in the adapter (108).
S- and M-groups use M8 screws.
4. Place the adapter, backplate, and impeller assembly on a bench with the impeller facing upwards.
5. Remove the three setscrews, (222E for 6 in. S-group, 3x4-7, and 3x4-8G) or two hex screws (370V
for all other sizes).
6. Remove the adapter (108) and the containment shell (750).
7. Place the remaining part of the unit on a workbench with the driven magnet facing downwards.

62 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.3 Disassembly

1
2

4
5
6

1. Impeller nut (304)

2. Impeller nut O-ring (412A)
3. Impeller (101)
4. Distance washer (199)
5. Intermediate ring spacer (351X)
6. Impeller key (178)
8. Place the strap wrench on the impeller and remove the impeller nut (304) and O-ring (412A).
9. Slide the impeller (101) off the shaft.
10. Remove the impeller key (178), distance washer (199), and gasket (351X).
11. Pull the backplate (444) and bearing cartridge (849) from the shaft.
1
2 3 4

5 6

1. Backplate (444)
2. Cartridge-to-backplate hex screw (791E)
3. Parallel pin (445A)
4. Driven carrier assembly (740A)
5. Bearing cartridge assembly (849)
6. Intermediate ring spacer (351X)
12. Remove the second gasket (351X).
13. Undo the screws (791E) and remove the bearing cartridge (849) from the backplate (444).
The driven magnet assembly (740A) is a two-piece assembly on S-group pumps held with a drive-
key. Item 740A is a single-piece component on M-group pumps with a parallel pin (445A) to drive
the bearing cartridge.
The bearing cartridge (849) is one unit that is replaced completely.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 63

6.4 Pre-assembly inspections

6.4 Pre-assembly inspections

Guidelines
Before you assemble the pump parts, make sure you follow these guidelines:
• Inspect the pump parts according to the information in these pre-assembly topics before you reas-
semble your pump. Replace any part that does not meet the required 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.

6.4.1 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 surfaces are not damaged and repair or replace as necessary.

Inspect the casing for cracks and excessive wear or pitting. Thoroughly clean gasket surfaces and align-
ment fits in order to remove rust and debris.
Repair or replace the casing if you notice any of these conditions:
• Localized wear or grooving that is greater than 3.2 mm | 1/8 in. deep
• Pitting that is greater than 3.2 mm | 1/8 in. deep
• Irregularities in the casing-gasket seat surface

Casing areas to inspect

The arrows point to the areas to inspect for wear on the casing:

64 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.4 Pre-assembly inspections

100

Figure 31: 3296 EZMAG casing

Impeller replacement

This table shows the criteria for replacing the impeller:

Impeller parts When to replace

Vane edges When you see cracks, pitting, or corrosion damage
Wear ring surfaces When the clearance to the casing wear ring has increased by 50% over the values in the Mini-
mum running clearances table

Gaskets, O-rings, and seats replacement

WARNING:
Risk of death or serious injury. Leaking fluid can cause fire and/or burns. Replace all gaskets
and O-rings at each overhaul or disassembly.

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 all corroded fasteners.
• Ensure that all fasteners are properly tightened and that there are no missing fasteners.

Frame adapter
• Check the frame adapter (108) for cracks or excessive corrosion damage. Replace if any of these
conditions exist.
• Make sure that the gasket surface is clean.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 65

6.4 Pre-assembly inspections

Silicon carbide bearings, bearing cartridge

Inspect the bearings (849) for cracks, chips, or excessive wear. Replace the cartridge if any of these con-
ditions exist.

Containment shell
• Make sure that the wall thickness of the containment shell (750) is a minimum of 0.991 mm | 0.039
in.
• Make sure that the containment shell is free from pitting or cracks.
• Replace the containment shell if there are any grooves in excess of 0.127 mm | 0.005 in.

6.4.2 Magnet inspections

WARNING:
The magnets contained in this unit are extremely powerful. Keep magnetic drive components
and magnetic tools apart from each other by a minimum of 2 m | 6 ft. Serious injury to fingers
and hands will result if you do not follow this precaution.

Driven magnet assembly inspections

Perform these checks on the driven magnet assembly (740A):
• Check that the assembly is free from bulges.
• Check that the assembly is free from pits and scratches that exceed 0.127 mm | 0.005 in. deep.
• Check that the assembly is free from erosion or corrosion that exceeds 0.127 mm | 0.005 in. deep.
• Check the pump-out vanes for cracks and corrosion.
• Check that the circulation holes are open.

Drive magnet assembly

The magnets are extremely brittle. It is normal to have chips that amount to 10% of the magnet surface
per MMPA Standard No. 0100-90.
Perform these checks on the drive magnet assembly (740B):
• Check that the magnets are free of major cracks and extent over 50% of the surface and are free of
imperfections that create loose particles.
• Replace the magnets if the magnets and drive magnet carrier were exposed to any pumped fluid.
• Check the drive magnet carrier for cracks and replace if any cracks are found.
• Check the drive magnet carrier hub OD is free from grooves and scratches that are greater than
0.127 mm | 0.005 in.
• Check the magnets for proper bonding to the metal carrier.

6.4.3 Bearing-frame inspection

Checklist
Check the bearing frame for these conditions:
• Visually inspect the bearing frame and frame foot for cracks.
• Check the inside surfaces of the frame for rust, scale, or debris. Remove all loose and foreign ma-
terial.
• Make sure that all lubrication passages are clear.

66 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.4 Pre-assembly inspections

• Inspect the inboard-bearing bores.

The maximum acceptable bore is 7.203 cm | 2.836 in. for S-group pumps and 9.002 cm | 3.544 in.
for M-group pumps.
• Inspect the labyrinth seal O-rings for cuts and cracks.
• Inspect the ball bearings for containment and damage.
• Make sure the gasket surfaces are clean.
• Visually inspect the bearing end cover for cracks and pits.

6.4.4 Bearings inspection

Condition of bearings
Do not reuse bearings. The condition of the bearings provides useful information on operating conditions
in the bearing frame.

Checklist
Perform these checks when you inspect the bearings:
• Inspect the ball bearings for contamination and damage.
• Note any lubricant condition and residue.
• Inspect the ball bearings to see if they are loose, rough, or noisy when you rotate them.
• Inspect the silicon carbide bearings for cracks, chips, or excessive wear. If any of these conditions
exist, replace the bearing cartridge.
• Investigate any bearing damage to determine the cause. If the cause is not normal wear, correct
the issue before you return the pump to service.

6.4.5 Minimum running clearances

This table provides the radial wear ring clearances:

Group Size New, mm | inches Replace, mm | inches

S 1 x 1½ - 6 0.51–0.61 | 0.020–0.024 0.74 | 0.029
1 x 1½ - 6G
1½ x 3 - 6
2x3-6
1 x 1½ - 8
1 x 1½ - 8H
1½ x 3 - 8
2x3-8
M 1½ x 3 - 10 0.71–0.79 | 0.028–0.031 0.91 | 0.036
3x4-7
4 x 4 - 8G
3 x 4 - 10
1 x 2 - 10
2 x 3 - 10
1½ x 3 - 13

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 67

6.5 Reassembly

6.5 Reassembly
6.5.1 Reassemble the frame assembly and shaft (frame-mounted pumps)
1. Press both radial ball bearings (112) onto the drive shaft (122B).

NOTICE:
There are several methods you can use to install bearings. The recommended method is to
use an induction heater that heats and demagnetizes the bearings.
Only use original spare parts to replace any worn or faulty components. The use of unsuitable
spare parts may cause malfunctions, damage, and injuries as well as void the guarantee.
Do not use a flame to heat bearings. This will damage the bearing surfaces. Do not heat the
bearings above 135°C | 275°F.

1
2
3
4

|
1. Bearing frame (228)
2. Ball bearing (112)
3. Drive shaft (122B)
4. Ball bearing (112)
2. Install the pre-assembled drive shaft in the bearing frame (228) from the motor side.
3. Insert the wave washer (529).

68 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.5 Reassembly

2
3 5
4
1 6

1. Labyrinth oil seal (333)

2. Bearing frame (228)
3. End cover gasket (360A)
4. Wave washer (529)
5. Frame end cover (109A)
6. End cover hex screw (370C)
7. Labyrinth oil seal (332A)
Figure 32: Bearing frame cover and seals

1. Foot-to-frame hex screw (370F)

2. Frame foot (241)
Figure 33: Frame foot (M-group only)
4. Insert the end-cover gasket (360A) into the bearing frame.
5. Mount the bearing-end cover (109A) using the hex screws (370C).
6. Press the inboard labyrinth seal (333D) and the outboard labyrinth seal (332A) into the correspond-
ing bores on the bearing frame.
Press the seals until they are fully-seated in the bore. Make sure to keep the oil return slot on the
inside of the seal at the 6 o’clock position.
7. Mount the bearing frame foot (241) with hex screws (370F) and lockwashers (M-group only).
8. Clamp the pre-assembled bearing frame assembly in a vice with the motor end of the shaft facing
downwards.

9. Mount the drive magnet assembly (740B) onto the drive shaft so that the driver cams engage. Se-
cure the drive magnet assembly using the lockwasher (382) and capscrew (791D).

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 69

6.5 Reassembly

1. Drive-to-shaft capscrew (791D)

2. Internal tooth lockwasher (382)
3. Drive carrier assembly (740B)
4. Bearing frame (228)

6.5.2 Reassemble the frame assembly and shaft (close-coupled pumps)

1. Slide the stub shaft (122A) onto the motor shaft and secure it with the setscrew (222L).

1
2 3 4

1. Setscrew (122L)
2. Stub shaft (380)
3. Motor-to-adapter hex screw (371)
4. Close-coupled adapter (503)
2. Mount the motor adapter (503) onto the motor using hex screws (371).
3. Mount the drive magnet (740B) onto the stub shaft (122A) so that the driver cams are fully-engag-
ed.

70 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.5 Reassembly

8
5 6
4 7
3

1. Stub shaft–to-motor setscrew (222L)

2. Stub shaft (380)
3. Motor-to-adapter hex screw (371)
4. Frame-to-adapter hex screw (370B)
5. Close-coupled adapter (503)
6. Frame-to-adapter gasket (360W)
7. Drive carrier assembly (740B)
8. Drive-to-shaft capscrew (791D), internal tooth lockwasher (382)
4. Insert the lockwasher (382) and capscrew (791D) in order to secure the magnet to the shaft.

1
2

1. Frame-to-adapter hex screw (370B)

2. Close-coupled adapter (503)
3. Frame-to-adapter gasket (360W)
Figure 34: Close-coupled pump assembly

6.5.3 Reassemble the liquid end

1. Insert the bearing cartridge (849) into the backplate (444).

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 71

6.5 Reassembly

2
3

1. Backplate (444)
2. Cartridge-to-backplate hex screw (791E)
3. Bearing cartridge assembly (849)
2. Rotate the bearing cartridge until all three holes line up and secure with hex screws (791E).
See 6.5.5 Bolt torque values on page 75.
3. For M-group pumps, if the driven carrier pin (445A) in the driven magnet assembly (740A) must be
replaced, then drive in the carrier pin carefully until it protrudes approximately 3.05 mm | 0.12 in.
towards the impeller.
The S-group has a drive key, which is automatically placed into position during installation when in-
stalled.

4. Cut out a small notch on the inside diameter of the intermediate ring gasket (351X) in order to cre-
ate a recess for the driven carrier pin (445A) or key, depending on size.
1
2 3

1. Driven carrier assembly (740A)

2. Driven carrier pin (445A)
3. Notch
4. Intermediate ring spacer (351X)
5. Apply anti-seizing compound to the shaft and shaft threads.
6. Mount the intermediate ring gasket (351X) onto the shaft of the driven magnet assembly (740A).

72 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.5 Reassembly

Intermediate ring gasket mounting Driven pin aligned with the slot in the cartridge

2
1

1. Driven carrier pin (445A)

1. Intermediate ring spacer (351X)

2. Driven carrier assembly (740A)
7. Place the driven magnet assembly (740A) on the workbench, and then mount the pre-assembled
bearing cartridge (849) and backplate (444) assembly onto the driven magnet assembly from
above. Make sure the driven carrier pin or key (445A) engages the carrier groove in the bearing car-
tridge (849).
If the pin or key at the bottom of the shaft does not properly engage the slot in the bearing cartridge,
then the impeller key in step 9 will not fit.
You can turn the backplate slightly in order to help with alignment.
8. Mount the second intermediate ring gasket (351X) and distance washer (199) onto the drive shaft.

1. Impeller key (178)

2. Impeller nut (304)
3. Impeller nut O-ring (412A)
4. Impeller (101)
5. Distance washer (199)
6. Intermediate ring spacer (351X)
9. Install the impeller:
a) Insert the impeller key (178) into the key-slot on the shaft.
If the impeller key does not fit into the keyway due to interference with the distance washer, then go
back to step 7 and re-assemble the bearing cartridge to the shaft.
b) Mount the impeller (101) onto the shaft.
c) Insert the impeller nut O-ring (412A) into the groove on the rear side of the impeller nut (304).

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 73

6.5 Reassembly

d) Secure the driven magnet assembly with a strap wrench and tighten the impeller nut to the ap-
propriate torque value.
See 6.5.5 Bolt torque values on page 75.

NOTICE:
Check that you can rotate the backplate freely by hand. When you raise the backplate, make
sure that the axial play is approximately 1.02 mm | 0.040 in. in order to ensure proper assem-
bly. The axial play of the plain bearings is automatically set during assembly.

10. Place the containment shell gasket (540N) and containment shell (750) onto the backplate (444).

2
3

1. Adapter-to-backplate setscrew (222E, 6 in. S-group, 3 x 4-7, and 3 x 4-8G)

2. Containment shell gasket (540N)
3. Containment shell (750)
4. Frame adapter (108)
5. Adapter-to-backplate hex screw (370V)
11. Screw the three setscrews (222E for the 6 in. S-group, 3 x 4-7, and 3 x 4-8G pumps) or two connec-
tion screws (370V for M-group pumps) of the adapter (108) into the backplate and tighten.
This holds the containment shell in place.
12. Secure the casing (100) to the workbench with the suction flange facing downwards.

1. Adapter-to-case hex screw (370)

2. Frame adapter (108)
3. Backplate-to-case gasket (351)
4. Casing (100)
13. Insert the casing gasket (351) into the casing.

74 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 6.5 Reassembly

14. Insert the pre-assembled unit into the casing so that the crane hook of the adapter (108) faces the
center of the discharge nozzle.
15. Secure the adapter to the casing using hex screws (370) to the appropriate torque value.
See 6.5.5 Bolt torque values on page 75.

6.5.4 Complete the pump reassembly

1. Insert the gasket (360W) into the adapter. Check that all plugs, labyrinth seals and lip seals are in-
stalled.

1. Frame-to-adapter hex screw (370B)

2. Frame assembly
3. Mag drive carrier
4. Frame-to-adapter gasket (360W)
5. Adapter
2. Secure the bearing frame and drive magnet assembly:
a) Place the bearing frame and drive magnet assembly already assembled on the workbench with
the drive magnet facing downwards.
b) Screw a 3/8 in. eyebolt into the end of the drive shaft.
c) Place the bearing frame assembly onto the adapter using a crane.
d) Screw in the hex screws (370B) in order to secure the bearing frame to the adapter.
e) Turn the drive shaft by hand to make sure that the shaft can rotate freely.
Check by looking into the suction nozzle to make sure the impeller is rotating.

6.5.5 Bolt torque values

NOTICE:
Make sure to tighten in a diametrically opposite sequence.

Description Group Dry, ft-lbs (Nm) Standard lube, ft-lbs (Nm)

Adapter to casing screws (370) S/M (M12) 65 (88) 49 (66)
10 in. & 13 in. M (M16) 161 (219) 120 (164)

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 75

6.5 Reassembly

Description Group Dry, ft-lbs (Nm) Standard lube, ft-lbs (Nm)

Impeller nut (304) S 47 (64) 26 (35)
M 116 (158) 52 (70)
Cartridge to backplate screws (791E) S/M 12 (16) 9 (12)

76 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 7 Troubleshooting

7 Troubleshooting
7.1 Operation troubleshooting
Symptom Cause Remedy
The pump is not delivering liq- The pump is not primed. Reprime the pump and check that the pump and
uid. suction line are full of liquid.
The suction line is clogged. Check the suction line pressure. If it is low, locate
and remove any obstructions.
The impeller is clogged. Disassemble the impeller and remove the block-
age.
The magnet is de-coupling. Shut down the pump and check the temperature
and viscosity of the pumped fluid. Check the mag-
nets with a breakaway torque test.
The pump is not producing There is an air leak in the suc- Check for leaks and repair the lines.
rated flow or head. tion line.
The impeller is partly clogged. Back flush the pump to clean the impeller.
The impeller rings are worn. Replace the defective ring as required.
There is insufficient suction Make sure that the suction line shutoff valve is
head. fully open and the line is unobstructed. Check the
suction pressure.
The impeller is either worn or Inspect and replace the impeller if necessary.
broken.
The rotation is wrong. Correct the wiring.
Pump starts and then stops The pump is not primed correct- Reprime the pump.
pumping. ly.
There is an air leak in the suc- Check for leaks and correct.
tion line.
The magnet is de-coupling. Shut down the pump. Check the temperature and
viscosity of the pumped fluid. Check the magnets
with a breakaway torque test.
There are either air or vapor Rearrange the piping to eliminate air pockets.
pockets in the suction line.
The bearings run hot. The bearings are not lubricated Check the suitability and level of the lubricant.
properly.
The lubricant is cooling. Check the cooling system.
The pump is not aligned proper- Check the pump alignment.
ly.
Pump is noisy or vibrates. The pump or driver is not aligned Align the shafts.
properly.
There is a partially-clogged im- Disassemble the impeller and remove the block-
peller causing the imbalance. age.
There is a broken or bent impel- Replace as required.
ler or shaft.
The base is not rigid enough. Tighten the pump and motor hold-down bolts or
adjust the stilts. Then check the grout.
The suction or discharge piping Anchor the piping per the Hydraulic Institute
is not anchored or properly sup- Standards recommendations (Edition 14, centrifu-
ported. gal pump section).
The pump is cavitating. Increase the NPSH available.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 77

7.2 Alignment troubleshooting

Symptom Cause Remedy

The motor requires excessive The head is lower than the rating Install a throttle valve.
power. and the pump has too much liq-
uid.
The liquid is heavier than ex- Check the specific gravity and viscosity.
pected.
The head is higher than the rat- Check the impeller diameter.
ing, which is at capacity.
The rotating parts are binding or Check the internal wearing parts for proper clear-
are severely worn. ances.
The motor rotation is incorrect. Correct the wiring.
The condition monitoring de- The sleeve and thrust bearings Replace as required.
vice shuts down the pump. are damaged.
There is a plugged recirculation Disassemble and remove the blockage. Then de-
circuit. termine and correct the cause of the blockage.
There is recirculation liquid va- Correct all of these as necessary:
porization.
• Check the actual liquid temperature versus
the design temperature.
• Check the actual NPSH available versus the
design.
• Check the minimum flow requirement for the
pump size.
The containment shell is dam- Replace as required.
aged.
The magnets are de-coupling. Check the temperature and viscosity of the pump-
ed fluid. Check the magnets with a breakaway tor-
que test.
The pump is running dry. • Check the control device for proper opera-
tion.
• Check the suction line for blockage.
• Reprime the pump.
There is excessive motor power. The system head is lower than the rating and
pumps too much liquid.
Check the rotating parts for binding and wear. The
liquid is heavier than expected.

7.2 Alignment troubleshooting

Symptom Cause Remedy
Horizontal (side-to-side) align- The driver feet are bolt- Loosen the pump's hold-down bolts, and slide the pump
ment cannot be obtained (angu- bound. and driver until you achieve horizontal alignment.
lar or parallel). The baseplate is not 1. Determine which corners of the baseplate are
leveled properly and is high or low.
probably twisted. 2. Remove or add shims at the appropriate cor-
ners.
3. Realign the pump and driver.
Vertical (top-to-bottom) align- The baseplate is not 1. Determine if the center of the baseplate should
ment cannot be obtained (angu- leveled properly and is be raised or lowered.
lar or parallel). probably bowed. 2. Level screws equally at the center of the base-
plate.
3. Realign the pump and driver.

78 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8 Parts Listings and Cross-Sectionals

8 Parts Listings and Cross-Sectionals

8.1 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) —
stainless steel
Cross-sectional drawing
371 492A 503 791D 178X 122A 108 370V 791E 222E
100

199

178

412A
222L
304

101
380
351X
382

750

740A 360W 351X 740B 849 370 444 351 540N

Parts list

Item Quantity Part name Material

100 1 Casing Stainless steel (1.4408)
101 1 Impeller Stainless steel (1.4408)
108 1 Frame adapter Ductile iron
122A* 1 Driven shaft Duplex SS (1.4462)
178 1 Impeller key 303SS
178X* 1 Driven carrier key Stainless steel (1.4571)
199 1 Distance washer Stainless steel (1.4571)
222E 3 Adapter-to-backplate setscrew (6 in. Steel
size pumps)
222L 2 Stub shaft–to-motor setscrew Steel
304 1 Impeller nut Duplex SS (1.4517)
351 1 Backplate-to-case gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 79

8.1 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — stainless steel

Item Quantity Part name Material

• Fawn gylon (optional)
351X 2 Intermediate ring spacer Optional spacer material:
• TFM1600 (PTFE) (standard)
• Viton B (optional)
360W 1 Frame-to-adapter gasket Aramid fiber/EPDM
370 12 for 7 in. and 8 Adapter-to-case hex capscrew Steel
in. pumps, 8 for
10 in. pumps, 16
for 13 in. pumps
370B 4 Frame-to-adapter hex capscrew (not Steel
illustrated)
370V 2 Adapter-to-backplate hex capscrew Steel
(8 in. pumps)
371 4 Motor-to-adapter hex capscrew Steel
380 1 Stub shaft Steel
382 1 Internal tooth lockwasher Steel
412A 1 Impeller nut O-ring PTFE
444 1 Backplate Stainless steel (1.4408)
492A 1 Frame plug, setscrew access Steel
503 1 Close-coupled adapter Cast iron
540N 1 Containment shell gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
740A 1 Driven carrier assembly Duplex SS/NdFeB (1.4517)
740B 1 Drive carrier assembly Ductile iron/NdFeB (0.7043)
750 1 Containment shell Hastelloy-C (2.4610)
791D 1 Drive-to-shaft capscrew socket head Steel
791E 3 Cartridge-to-backplate hex capscrew Stainless steel
849 1 Bearing cartridge assembly Duplex SS/SSiC
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
High temperature optional components
351 1 Backplate-to-case gasket Grafoil
540N 1 Containment shell gasket Grafoil
740A 1 Driven carrier assembly Duplex SS/SmCo (1.4517)
740B 1 Drive carrier assembly Ductile iron/SmCo (0.7043)
849 1 High temperature bearing cartridge Duplex SS/SSiC
assembly
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
*Included in 740A driven carrier assembly.

80 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.2 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — Hastelloy-C

8.2 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) —

Hastelloy-C
Cross-sectional drawing
371 492A 503 791D 178X 122A 108 370V 791E 222E
100

199

178

412A
222L
304

101
380
351X
382

750

740A 360W 351X 740B 849 370 444 351 540N

Parts list

Item Quantity Part name Material

100 1 Casing Hastelloy-C (2.4686)
101 1 Impeller Hastelloy-C (2.4686)
108 1 Frame adapter Ductile iron
122A* 1 Driven shaft Hastelloy-C (2.4610)
178 1 Impeller key Hastelloy-C
178X* 1 Driven carrier key Hastelloy-C (2.4610)
199 1 Distance washer Hastelloy-C (2.4610)
222E 3 Adapter-to-backplate setscrew (6 in. Steel
pumps)
222L 2 Stub shaft-to-motor setscrew Steel
304 1 Impeller nut Hastelloy-C (2.4610)
351 1 Backplate-to-case gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
351X 2 Intermediate ring spacer Optional spacer material:
• TFM1600 (PTFE) (standard)

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 81

8.2 Close-coupled S-group (all) and M-group (2 x 3 - 8 only) — Hastelloy-C

Item Quantity Part name Material

• Viton B (optional)
360W 1 Frame-to-adapter gasket Aramid fiber/EPDM
370 8 for 6 in. pumps, Adapter-to-case hex capscrew Steel
12 for 8 in. pumps
370B 4 Frame-to-adapter hex capscrew (not Steel
illustrated)
370V 2 Adapter-to-backplate hex capscrew Steel
(8 in. pumps)
371 4 Motor-to-adapter hex capscrew Steel
380 1 Stub shaft Steel
382 1 Internal tooth lockwasher Stainless steel
412A 1 Impeller nut O-ring PTFE
444 1 Backplate Hastelloy-C (2.4686)
492A 1 Frame plug, setscrew access Steel
503 1 Close-coupled adapter Cast iron
540N 1 Containment shell gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
740A 1 Driven carrier assembly Hastelloy-C/NdFeB (2.4686)
740B 1 Drive carrier assembly Ductile iron/NdFeB (0.7043)
750 1 Containment shell Hastelloy-C (2.4610)
791D 1 Drive-to-shaft capscrew socket head Steel
791E 3 Cartridge-to-backplate hex capscrew Hastelloy-C
849 1 Bearing cartridge assembly Hastelloy-C/SSiC
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
High temperature optional components
351 1 Backplate-to-case gasket Grafoil
540N 1 Containment shell gasket Grafoil
740A 1 Driven carrier assembly Hastelloy-C/SmCo (2.4686)
740B 1 Drive carrier assembly Ductile iron/SmCo (0.7043)
849 1 High temperature bearing cartridge Hastelloy-C/SSiC
assembly
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
*Included in 740A driven carrier assembly.

82 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.3 S-group with bearing frame — stainless steel

8.3 S-group with bearing frame — stainless steel

Cross-sectional drawing
113A 333D 382 370B 791D 740B 108 370V 791E 222E 351 540N
178X 122A
100

199

228 178

412A
304
109A

332A

122B

400

370C
529 101
360A 351X
112
319

408A 750 360W 740A 351X 849 370 444

Parts list

Item Quantity Part name Material

100 1 Casing Stainless steel (1.4408)
101 1 Impeller Stainless steel (1.4408)
108 1 Frame adapter Ductile iron
109A 1 Frame end cover Ductile iron
112 2 Ball bearing Steel
113A 1 Fill plug Steel
122A* 1 Driven shaft Duplex SS (1.4462)
122B 1 Drive shaft Steel 4140
178 1 Impeller key 303SS
178* 1 Driven carrier key Stainless steel (1.4571)
199 1 Distance washer Stainless steel (1.4571)
222E 3 Adapter-to-backplate setscrew (6 in. Steel
pumps)
228 1 Bearing frame Cast iron
304 1 Impeller nut Duplex SS (1.4517)
319 1 Sight window Steel/glass
332A 1 Labyrinth oil seal (coupling end) Bronze/SS
333D 1 Labyrinth oil seal (radial end) Carbon-filled PTFE

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 83

8.3 S-group with bearing frame — stainless steel

Item Quantity Part name Material

351 1 Backplate-to-case gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
351X 2 Intermediate ring spacer Optional spacer material:
• TFM1600 (PTFE) (standard)
• Viton B (optional)
360A 1 End cover gasket Vellumiod
360W 1 Frame-to-adapter gasket Aramid fiber/EPDM
370 8 for 6 in. pumps, Adapter-to-case hex capscrew Steel
12 for 8 in. pumps
370B 4 Frame-to-adapter hex capcrew Steel
370C 1 End cover hex capscrew Steel
370V 2 Adapter-to-backplate hex capscrew Steel
(8 in. pumps)
382 1 Internal tooth lockwasher Stainless steel
370C 4 End cover hex capscrew Steel
400 1 Coupling key Steel
408A 1 Drain plug Steel
412A 1 Impeller nut O-ring PTFE
444 1 Backplate Stainless steel (1.4408)
529 1 Wave washer Steel
540N 1 Containment shell gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
740A 1 Driven carrier assembly Duplex SS/NdFeB (1.4517)
740B 1 Drive carrier assembly Ductile iron/NdFeB (0.7043)
750 1 Containment shell Hastelloy-C (2.4610)
791D 1 Drive-to-shaft capscrew socket head Steel
791E 3 Cartridge-to-backplate hex capscrew Stainless steel
849 1 Bearing cartridge assembly Duplex SS/SSiC
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
High temperature optional components
351 1 Backplate-to-case gasket Grafoil
540N 1 Containment shell gasket Grafoil
740A 1 Driven carrier assembly Duplex SS/SmCo (1.4517)
740B 1 Drive carrier assembly Ductile iron/SmCo (0.7043)
849 1 High temperature bearing cartridge Duplex SS/SSiC
assembly
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
*Included in 740A driven carrier assembly.

84 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.4 S-group with bearing frame — Hastelloy-C

8.4 S-group with bearing frame — Hastelloy-C

Cross-sectional drawing
113A 333D 382 370B 791D 740B 108 370V 791E 222E 351 540N
178X 122A 100

199

228 178

412A
304
109A

332A

122B

400

370C
529 101
360A 351X
112
319

408A 750 360W 740A 351X 849 370 444

Parts list

Item Quantity Part name Material

100 1 Casing Hastelloy-C (2.4686)
101 1 Impeller Hastelloy-C (2.4686)
108 1 Frame adapter Ductile iron
109A 1 Frame end cover Ductile iron
112 2 Ball bearing Steel
113A 1 Fill plug Steel
122A* 1 Driven shaft Hastelloy-C (2.4610)
122B 1 Drive shaft Steel 4140
178 1 Impeller key Hastelloy-C
178* 1 Driven carrier key Hastelloy-C (2.4610)
199 1 Distance washer Hastelloy-C (2.4610)
222E 3 Adapter-to-backplate setscrew (6 in. Steel
pumps)
228 1 Bearing frame Cast iron
304 1 Impeller nut Hastelloy-C (2.4610)
319 1 Sight window Steel/glass
332A 1 Labyrinth oil seal (coupling end) Bronze/SS
333D 1 Labyrinth oil seal (radial end) Carbon-filled PTFE

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 85

8.4 S-group with bearing frame — Hastelloy-C

Item Quantity Part name Material

351 1 Backplate-to-case gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
351X 2 Intermediate ring spacer Optional spacer material:
• TFM1600 (PTFE) (standard)
• Viton B (optional)
360A 1 End cover gasket Vellumiod
360W 1 Frame-to-adapter gasket Aramid fiber/EPDM
370 8 for 6 in. pumps, Adapter-to-case hex capscrew Steel
12 for 8 in. pumps
370B 4 Frame-to-adapter hex capscrew Steel
370C 4 End cover hex capscrew Steel
370V 2 Adapter-to-backplate hex capscrew Steel
(8 in. pumps)
382 1 Internal tooth lockwasher Stainless steel
400 1 Coupling key Steel
408A 1 Drain plug Steel
412A 1 Impeller nut O-ring PTFE
444 1 Backplate Hastelloy-C (2.4686)
529 1 Wave washer Steel
540N 1 Containment shell gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
740A 1 Driven carrier assembly Hastelloy/NdFeB (1.4517)
740B 1 Drive carrier assembly Ductile iron/NdFeB (0.7043)
750 1 Containment shell Hastelloy-C (2.4610)
791D 1 Drive-to-shaft capscrew socket head Steel
791E 3 Cartridge-to-backplate hex capscrew Hastelloy-C
849 1 Bearing cartridge assembly Hastelloy-C/SSiC
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
High temperature optional components
351 1 Backplate-to-case gasket Grafoil
540N 1 Containment shell gasket Grafoil
740A 1 Driven carrier assembly Hastelloy-C/SmCo (2.4686)
740B 1 Drive carrier assembly Ductile iron/SmCo (0.7043)
849 1 High temperature bearing cartridge Hastelloy-C/SSiC
assembly
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
*Included in 740A driven carrier assembly.

86 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.5 Frame cooling options

8.5 Frame cooling options

Cross-sectional drawing

551D 494
551D
555B 555B

555C 555C

Parts list

Item Quantity Part name Material

494 2 Cooling tube Stainless steel
555B 2 Thermocouple fitting tube Stainless steel
555C 2 Tube fitting str Brass
551D 1 Hex bushing Iron

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 87

8.6 M-group with bearing frame — stainless steel

8.6 M-group with bearing frame — stainless steel

Cross-sectional drawing
113A 333D 382 791D 178X 740B 108 122A 370V 540N 222E 100

791E

228 199
178
412A
109A 304
332A

122B

400

370C
529
360A 101
112
319 351X

360W
408A 370F 241 750 740A 351X 849 370 444 351

Parts list

Item Quantity Part name Material

100 1 Casing Stainless steel (1.4408)
101 1 Impeller Stainless steel (1.4408)
108 1 Frame adapter Ductile iron
109A 1 Frame end cover Ductile iron
112 2 Ball bearing Steel
113A 1 Fill plug Steel
122A* 1 Driven shaft Duplex SS (1.4462)
122B 1 Drive shaft Steel 4140
178 1 Impeller key 303SS
178X* 1 Driven carrier key Stainless steel (1.4571)
199 1 Distance washer Stainless steel (1.4571)
222E** 3 Adapter-to-backplate setscrew Steel
228 1 Bearing frame Cast iron
241 1 Frame foot Cast iron
304 1 Impeller nut Duplex SS (1.4517)
319 1 Sight window Steel/glass
332A 1 Labyrinth oil seal (coupling end) Bronze/SS
333D 1 Labyrinth oil seal (radial end) Bronze/SS
351 1 Backplate-to-case gasket Optional gasket material:
• Aramid fiber/EPDM (standard)

88 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.6 M-group with bearing frame — stainless steel

Item Quantity Part name Material

• White gylon (optional)
• Fawn gylon (optional)
351X 2 Intermediate ring spacer Optional spacer material:
• TFM1600 (PTFE) (standard)
• Viton B (optional)
360A 1 End cover gasket Vellumoid
360W 1 Frame-to-adapter gasket Aramid fiber/EPDM
370 12 for 7 in. and 8 Adapter-to-case hex capscrew Steel
in. pumps, 8 for
10in. pumps, 16
for 13 in. pumps
370B 4 Frame-to-adapter hex capscrew Steel
370C 4 End cover hex capscrew Steel
370F 2 Foot-to-frame hex capscrew Steel
370V 2 Adapter-to-backplate hex capscrew Steel
(8 in. pumps)
382 1 Internal tooth lockwasher Stainless steel
400 1 Coupling key Steel
408A 1 Drain plug Steel
412A 1 Impeller nut O-ring PTFE
444 1 Backplate Stainless steel (1.4408)
529 1 Wave washer Steel
540N 1 Containment shell gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
740A 1 Driven carrier assembly Duplex SS/NdFeB (1.4517)
740B 1 Drive carrier assembly Ductile iron/NdFeB (0.7043)
750 1 Containment shell Hastelloy C (2.4610)
791D 1 Drive-to-shaft capscrew socket head Steel
791E 3 Cartridge-to-backplate hex capscrew Stainless steel
849 1 Bearing cartridge assembly Duplex SS/SSiC
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
High temperature optional components
351 1 Backplate-to-case gasket Grafoil
540N 1 Containment shell gasket Grafoil
740A 1 Driven carrier assembly Duplex SS/SmCo (1.4517)
740B 1 Drive carrier assembly Ductile iron/SmCo (0.7043)
849 1 High temperature bearing cartridge Duplex SS/SSiC
assembly
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
*Included in 740A driven carrier assembly.
**Used on 3x4-7 and 3x4-8G pumps only.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 89

8.7 M-group with bearing frame — Hastelloy-C

8.7 M-group with bearing frame — Hastelloy-C

Cross-sectional drawing
113A 333D 382 791D 178X 740B 108 122A 370V 540N 222E 100

791E

228 199
178
412A
109A 304
332A

122B

400

370C
529
360A 101
112
319 351X

360W
408A 370F 241 750 740A 351X 849 370 444 351

Parts list

Item Quantity Part name Material

100 1 Casing Hastelloy-C (2.4686)
101 1 Impeller Hastelloy-C (2.4686)
108 1 Frame adapter Ductile iron
109A 1 Frame end cover Ductile iron
112 2 Ball bearing Steel
113A 1 Fill plug Steel
122A* 1 Driven shaft Hastelloy-C (2.4610)
122B 1 Drive shaft Steel 4140
178 1 Impeller key Hastelloy-C
178X* 1 Driven carrier key Hastelloy-C (2.4610)
199 1 Distance washer Hastelloy-C (2.4610)
222E 3 Adapter-to-backplate setscrew (6 in. Steel
pumps)
228 1 Bearing frame Cast iron
241 1 Frame foot Cast iron
304 1 Impeller nut Hastelloy-C (2.4610)
319 1 Sight window Steel/glass
332A 1 Labyrinth oil seal (coupling end) Bronze/SS
333D 1 Labyrinth oil seal (radial end) Bronze/SS
351 1 Backplate-to-case gasket Optional gasket material:

90 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.7 M-group with bearing frame — Hastelloy-C

Item Quantity Part name Material

• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
351X 2 Intermediate ring spacer Optional spacer material:
• TFM1600 (PTFE) (standard)
• Viton B (optional)
360A 1 End cover gasket Vellumiod
360W 1 Frame-to-adapter gasket Aramid fiber/EPDM
370 12 for 7 in. and 8 Adapter-to-case hex capscrew Steel
in. pumps, 8 for
10 in. pumps, 16
for 13 in. pumps
370B 4 Frame-to-adapter hex capscrew Steel
370C 4 End cover hex capscrew Steel
370F 2 Foot-to-frame hex capscrew Steel
370V 2 Adapter-to-backplate hex capscrew Steel
(except on 3x4-7 and 3x4-8G)
382 1 Internal tooth lockwasher Stainless steel
400 1 Coupling key Steel
408A 1 Drain plug Steel
412A 1 Impeller nut O-ring PTFE
444 1 Backplate Hastelloy-C (2.4686)
529 1 Wave washer Steel
540N 1 Containment shell gasket Optional gasket material:
• Aramid fiber/EPDM (standard)
• White gylon (optional)
• Fawn gylon (optional)
740A 1 Driven carrier assembly Hastelloy-C/NdFeB (2.4686)
740B 1 Drive carrier assembly Ductile iron/NdFeB (0.7043)
750 1 Containment shell Hastelloy-C (2.4610)
791D 1 Drive-to-shaft capscrew socket head Steel
791E 3 Cartridge-to-backplate hex capscrew Hastelloy-C
849 1 Bearing cartridge assembly Hastelloy-C/SSiC
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
High temperature optional components
351 1 Backplate-to-case gasket Grafoil
540N 1 Containment shell gasket Grafoil
740A 1 Driven carrier assembly Hastelloy-C/SmCo (2.4686)
740B 1 Drive carrier assembly Ductile iron/SmCo (0.7043)
849 1 High temperature bearing cartridge Hastelloy-C/SSiC
assembly
Silicon Carbide (standard)
Dryguard Silicon Carbide (optional)
*Included in 740A driven carrier assembly.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 91

8.8 Spare and repair parts

8.8 Spare and repair parts

Recommended spare parts

Item Quantity Part Material

351 1 Backplate to case gasket Aramid fiber with EPDM rubber
112 2 Ball bearing Steel
351X 2 Intermediate ring spacer Grafoil
360A 1 End-cover gasket Vellumoid
360W 1 Frame-to-adapter gasket Aramid fiber with EPDM rubber
740A 1 Driven carrier assembly Duplex SS/NdFeB
740B 1 Drive carrier assembly Ductile iron/NdFeB
750 1 Containment shell Hastelloy-C
849 1 Bearing cartridge assembly Duplex SS/SSiC

Repair parts
• Impeller (101)
• Impeller nut and O-ring (304 and 412A)
• Impeller key (178)
• Driven magnet assembly (740A)
• Drive magnet assembly (740B)
• Containment shell (750)
• Driven shaft (122B)
• Labyrinth oil seals (332A and 333D)

92 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 8.9 Interchangeability drawings

8.9 Interchangeability drawings

Figure 35: Frame-mounted 3296 EZMAG

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 93

8.9 Interchangeability drawings

Figure 36: Close-coupled 3296 EZMAG

Interchangeability drawings parts list

1. Size 6. Frame adapter 11. Bearing frame

2. Casing 7. Driven magnet 12. Stub shaft
3. Impeller 8. Shell 13. Motor adapter
4. Backplate 9. Drive magnet 14. Adapter plate
5. Bearing cartridge 10. Drive shaft —

94 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 9 Other Relevant Documentation or Manuals

9 Other Relevant Documentation or

Manuals
9.1 Condensed power monitor
Description
ITT offers various power-monitoring devices for specific pump sizes, speeds, and impeller diameters.
Power-monitoring devices are designed to protect pumps from:
• Dry-running
• Running against a closed discharge valve
• Running outside of the recommended operating region
Power monitors were designed to detect power relative to load, which is a linear function, as opposed to
measuring amperage relative to load, which is a parabolic function. The linear characteristic of measur-
ing power vs. load enhances sensitivity at low-power conditions where increments in power are critical.
This figure shows a comparison of power measurements vs. amperage measurements. A properly ad-
justed and installed power monitor is an insurance policy for securing extended pump life.

Power

i P

Current

Load

Figure 37: Power vs. amperage measurements

Since the current curve is so flat, load changes are difficult to detect when you measure only the current
in this range. If you misread these changes, then nuisance tripping or a dry running pump can result. If
you measure power as well, then this problem is eliminated.

Power draw measuring

Power monitors can be strategically calibrated to protect your pump by measuring the power draw from
any of these conditions:
• Dry running
• Closed discharge valve
• No prime
• Inadequate suction conditions/plugged suction
• Cavitation
• Air lock
• Decoupled magnets
• Solidified, plugged, or frozen discharge line
• Fluctuating viscosities, precipitation, or coagulation

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 95

9.1 Condensed power monitor

• Broken or damaged shaft

• Broken or damaged coupling
• Jammed impeller
• Bad bearings
• Rapid cycling
The power draw at each of these conditions can be simulated in a plant test or estimated through calcu-
lations or interpolations from the pump performance curve. By defining these dangerous power fluctua-
tions, appropriate calibration of the power-monitoring unit prevents avoidable pump failures. This figure
shows a typical power evaluation recorded from a common centrifugal pump electric motor.
1 2 3 4
0

0
20

20
0

0
1. The pump is in operation.
2. The valve is closing.
3. The valve is opening.
4. There is no fluid being pumped.
Figure 38: Typical power evaluation
Contact your ITT representative for assistance and power analysis for your specific system. For further
details and evaluation of power monitoring units, a comprehensive power monitor user guide is available
from ITT.

Calibration tips
Use these tips to assist you when you select and calibrate power monitors:
• Read your power monitor installation instructions and wiring diagram before you attempt to cali-
brate the unit.
• Understand the recommended operating envelope of your pump provided by ITT.
• Understand the requirements and limitations of your system.
• Understand the full range of your operating duty, including power requirements at the rated mini-
mum and maximum flow conditions.
• Identify potential failures that would be characteristic of your specific process and pump type.
• Understand the power scope and torque scope of the selected electric motor.
• When feasible, further define your operating range to run as close to best efficiency point (BEP) as
practical.
• Select either a single trip unit or dual trip unit as practical for your specific system. A dual trip unit is
recommended for the 3296 EZMAG. Always use a low setting in order to protect against dry run. A
high setting detects if an upset condition has occurred. This results in bearing damage.
• Set a low-power trip point at the required power draw when operation is at the recommended mini-
mum flow of the manufacturer or higher, but less that the normal operating point.
• Set a high-power trip point at the required power draw when operation is at the recommended max-
imum flow of the manufacturer or lower, or at the flow rate that will prevent cavitation.
• When using dual trip power monitors, select high and low trip points designed to protect your spe-
cific system within the recommended pump operating region that is defined by ITT. This method
creates boundaries for a safe pump operating envelope.

96 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

 9.1 Condensed power monitor

• Set the nuisance trip feature for each power trip. Set the nuisance trip device to an interval that al-
lows the system to experience momentary fluctuations in power draw. Set it during an appropriate
time-frame that prevents the pump from experiencing excessive heat or dangerous operating condi-
tions.
• Set the delay timer for start-up conditions that allow the system to come to normal operating power
within a time-frame that maximizes protection of your pump.
• For variable speed operation, consult ITT or the power monitor manufacturer for appropriate auxili-
ary devices that are designed for operating at multiple speeds or fluctuating frequencies.
• Select an electrical enclosure that is suitable for the operating environment, or install the unit in an
appropriate electrical panel.
• Do not activate the manual override of the power monitor until a thorough examination of the
source of the problem is defined and corrected.
• Investigate and select power monitor features that are most suitable for your particular application
and plant safety.

Model 3296 EZMAG Installation, Operation, and Maintenance Manual 97

10 Local ITT Contacts

10 Local ITT Contacts

10.1 Regional offices
Region Address Telephone Fax
North America ITT - Goulds Pumps +1 315-568-2811 +1 315-568-2418
(Headquarters) 240 Fall Street
Seneca Falls, NY 13148
USA
Houston office 12510 Sugar Ridge Boulevard +1 281-504-6300 +1 281-504-6399
Stafford, TX 77477
USA
Los Angeles Vertical Products Operation +1 562-949-2113 +1 562-695-8523
3951 Capitol Avenue
City of Industry, CA 90601-1734
USA
Asia Pacific ITT Fluid Technology Asia Pte Ltd +65 627-63693 +65 627-63685
1 Jalan Kilang Timor
#04-06 Singapore 159303
Asia Pacific ITT Goulds Pumps Ltd +82 234444202
35, Oksansandan-ro
Oksan-myeon, Heungdeok-gu,
Cheongju-si, Chungcheongbuk-do
28101, Rep. of KOREA
Europe ITT - Goulds Pumps +44 1297-639100 +44 1297-630476
Millwey Rise Industrial Estate
Axminster, Devon, England
EX13 5HU
Latin America ITT - Goulds Pumps +562 544-7000 +562 544-7001
Camino La Colina # 1448
Condominio Industrial El Rosal
Huechuraba Santiago
8580000
Chile
Middle East and Africa ITT - Goulds Pumps +30 210-677-0770 +30 210-677-5642
Achileos Kyrou 4
Neo Psychiko 115 25 Athens
Greece

98 Model 3296 EZMAG Installation, Operation, and Maintenance Manual

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ITT Goulds Pumps, Inc.

240 Fall Street
Seneca Falls, NY 13148
USA
Form IOM.3296EZMag.en-US.2021-09

©2021 ITT Inc.

The original instruction is in English. All non-English instructions are translations of the original instruction.