AURORA PRODUCTS 441 Water Pump User Manual
Contents
1. Packing Replacement Pump Disassembly CROSS SECTIONAL DRAWINGS AND PARTS LISTS PAGE i ND ND NO ONNOAAAARHR P P GO Ga PUMP IDENTIFICATION PAGE 1 PUMP IDENTIFICATION Congratulations You are the owner of one of the finest pumps commercially available If you give it the proper care as outlined and recommended by this manual it will provide you with reliable service and long life 441 amp 491 SPLIT CASE PUMPS Your Aurora Model 441 amp 491 is a Split Case Pump meaning the casing is split along the horizontal centerline This new compact design with its shorter bearing span has less deflection under hydraulic load which results in less wear on the sleeves bearings and packing It is ideally suited for applications such as water systems boosters liquid transfer irrigation and Fire Protection Systems These pumps are available with a wide variety of options including mechanical seals impeller wear rings oil lubricated and water cooled bearings Some options may not be available on Model 491 Fire Pumps This manual applies to X 441 XXX Horizontal Split Case Pumps X 491 XXX Horizontal Split Case Fire Pumps Example 4 491 11A Hydraulic design if applicable Maximum nominal impeller diameter Horizontal Fire Pump Discharge size Carefully record all the following data from your pump nameplate It will aid in obtaining the correct replacement p2. 8 Air in liquid 10 Insufficient suction line submergence OVERHEATING 11 Air in liquid 12 Impeller diameter too small 1 Bearings 13 Insufficient Net Positive Suction Head e Excessive grease e Shaft bent 4 Bien EE DURING OPERATION e Rotating element binds 2 Water seal line plugged e Pipe strain E 3 Suction lift too high e Insufficient bearing lubrication 4 Air or gases in liquid e Incorrect type grease 5 Airleaks into suction piping packing box or 2 Packing box gaskets e Packing gland too tight 6 Wrong direction of rotation e Water seal line plugged 7 Insufficient suction line submergence a Air acl v nted out of mechanical Seal EXCESSIVE POWER CONSUMPTION e Flushing water not circulating for mechanical 1 Speed too high seal 2 Head lower than rating pumping too much liquid 3 Specific gravity or viscosity of liquid too high 4 Mechanical defects e Shaft bent e Rotating element binds 5 Misalignment 6 System head lower than design 7 Incorrect impeller diameter MAINTENANCE PAGE 11 1 MAINTENANCE HISTORY SYMBOL DATE MAINTENANCE PERFORMED PARTS USED NUMBER S PAGE 12 MAINTENANCE continued 2 INSPECTIONS AND PREVENTIVE MAINTENANCE REQUIREMENTS To assure satisfactory operation of the pump daily inspections and periodic maintenance are required We suggest that an inspection and maintenance log be kept and that
3. Chevron SRI grease N L G I No 2 multi purpose with a mineral oil viscosity of 517 SUS at 100 F or equivalent Proceed as follows for bearing lubrication WARNING KEEP HANDS FINGERS CLOTHING AND ANY TOOLS AWAY FROM THE COUPLING FAILURE TO DO SO COULD RESULT IN SERIOUS PERSONAL INJURY Stop the pump and remove the pipe plug at the bottom of the bearing housing Comnect a grease gun to the lubrication fitting Inject grease until it relieves at the bearing housing cover and drain hole Remove the grease gun Start the pump NOTE Immediately after lubrication bearing temperatures may rise above the normal level Continue running the unit until bearing temperatures stabilize at the normal level 6 Stop the unit wipe off the relieved grease and replace the drain plug 7 Start the unit and resume normal operation NAON B Oil Lubricated Bearings Fill the constant level oiler and add additional oil as required Replace the old oil with new every 2000 hours but at least once a year Drain the oil by removing the plug at the bottom of the bearing housings C158 and D158 MAINTENANCE continued PAGE 13 3 BEARING LUBRICATION continued Check the oiler setting periodically to be sure it is correct Refer to the following table for the correct setting RECOMMENDED OILS The oil used should be non detergent type containing rust and oxidation inhibitors supplied by a reputable manufacturer Depending on bearing pump operatin
4. 441 18C 8 441 18A 6 441 12A 8 441 14A 10 441 20 Centerline of shaft to oil level 1 3 16 1 1 2 1 13 16 NOTE For Fire Pumps the Model designation changes from 441 to 491 Adjust the oil level if necessary by loosening the setscrews on the side of the dust cap raising the bottle and tightening the screws Refer to the oiler manufacturer s instructions for more specific details 11 FINAL COUPLING ALIGNMENT The alignment of the coupling must be carefully checked during installation and as the last step before starting the pump If realignment is required the piping should be disconnected first After aligning reconnect the piping in accordance with the previous instructions and again recheck the alignment A flexible coupling must not be used to compensate for misalignment resulting from poor installation or temperature changes Aurora Pumps are supplied with several different types of commercial couplings The following instructions apply to units supplied with Woods couplings If your unit has a different brand coupling the manufacturer s instructions should be obtained before proceeding NOTE FOR MAXIMUMLIFE KEEP MSALIGNVENT VALUES AS NEAR TO ZERO AS POSSIBLE MAXIMUM ALLOWABLE MISALIGNMENT WOODS COUPLINGS Dimensions in inches Sleeve an PE 4 021 028 035 The coupling Type is printed on the sleeve Type H sleeves SHOULD NOT be used as direct replacements for EPDM or Hytrel sleeves
5. A Use a blunt screwdriver to slip the wire ring out of the groove and remove the two piece sleeve Check the G dimension If it is not as shown in the preceding table loosen one flange of the coupling and reposition it to achieve the specified G dimension NOTE On a sleeve bearing electric motor the armature should be at its electrical center when the G dimension is measured B Check parallel misalignment by placing a straightedge across the two coupling flanges and measuring the maximum offset at various points around the periphery of the coupling DO NOT ROTATE THE COUPLING If the maximum offset exceeds the figure shown under Parallel in the preceding table realign the coupling INSTALLATION continued PAGE 7 G PARALLEL ANGULAR DIMENSION MISALIGNMENT MISALIGNMENT Ir E FIGURE 3 COUPLING ALIGNMENT 11 FINAL COUPLING ALIGNMENT continued C Check the angular alignment with a micrometer or caliper Measure from the outside of one flange to the outside of the other at intervals around the periphery of the coupling Determine the maximum and minimum dimensions DO NOT ROTATE THE COUPLING The difference between the maximum and minimum dimensions should not exceed the figure shown under Angular in the preceding table If a correction is required you must always recheck the parallel alignment D Ifthe coupling employs a two piece sleeve with a wire ring force the ring into its groove in the center of
6. BE MADE WITH THE PIPING IN A FREE SUPPORTED STATE AND WITHOUT THE NEED TO APPLY VERTICAL OR SIDE PRESSURE TO OBTAIN ALIGNMENT OF THE PIPING WITH THE PUMP FLANGE CAUTION AFTER ALL THE PIPING IS CONNECTED THE PUMP AND DRIVER ALIGNMENT MUST BE RECHECKED All piping should be independently supported near the pump so that pipe strain will not be transmitted to the pump casing The suction and discharge piping should be one or two sizes larger than the pump flange sizes especially where the piping is of considerable length Any flexible joints installed in the piping must be equipped with tension rods to absorb piping axial thrust Care must be exercised in arranging elbows so as not to generate vortexing in the pump inlet The suction pipe must be air tight and sloped upward to the pump flange to avoid air pockets which will impair satisfactory pump operation The discharge pipe should be as direct as possible with a minimum of valves to reduce pipe friction losses A check valve and closing valve should be installed in the pump discharge line and a closing valve in the suction line The check valve between the pump and the closing valve protects the pump from water hammer and prevents reverse rotation in the event of power failure The closing valves are used in priming starting and when the pump is shut down The pump must never be throttled by the use of a valve in the suction line 9 AUXILIARY PIPING CONNECTIONS AND GAUGES In addition t
7. WHEN LOWERING THE ROTOR BE CAREFUL TO PROPERLY POSITION THE WEARING RINGS FAILURE TO DO SO COULD SERIOUSLY DAMAGE THE RINGS PAGE 18 MAINTENANCE continued 7 PUMP ASSEMBLY continued M Attach the bearing housings to the lower casing using the appropriate dowel pins 158A and capscrews 158B CAUTION BE SURE BEARING HOUSING CASING MATING SURFACES ARE CLEAN AND FREE FROM BURRS AS THIS WILL AFFECT THE ALIGNMENT OF THE ROTOR CASING N Inspect the upper casing 3 to assure that the water passage is clean and free from foreign material Apply a light coat of grease to the upper and lower casing mating surfaces and install a new casing gasket 157 on the lower casing making sure the holes are aligned Position the pins in the casing wearing rings to align with the slots in the lower casing Lower the upper casing into position Install the casing alignment pins 2B and securely bolt the upper and lower casing together using the capscrews 2A O Install the packing 212 lantern rings 10 split glands 19 and gland nuts 31B The pump assembly is now complete except for packing adjustment which should be accomplished after the pump is installed primed and started up Refer to the maintenance section of this manual for specific packing adjustment instructions REPAIR PARTS PAGE 19 ORDERING PARTS There are a variety of options available for this pump When ordering parts give the pump serial number size and figure number a
8. casing using a double rope sling WARNING BE CAREFUL WHEN POSITIONING THE ROPES TO AVOID THE ROTOR SLIPPING AND CAUSING POSSIBLE SERIOUS PERSONAL INJURY MAINTENANCE continued PAGE 15 6 PUMP DISASSEMBLY continued E F Remove the capscrews 159D that secure the bearing housing covers 159 to the bearing housings and remove the housings from the rotating assembly Remove the outer snap ring 345 from the outboard bearing end of the rotating assembly and use a wheel bearing puller to remove the outboard 168 and inboard 163 bearings WARNING TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY EXTREME CARE SHOULD BE EXERCISED TO SELECT THE PROPER PULLER AND APPROVED SAFETY GLASSES SHOULD BE WORN CAUTION BECAUSE OF POSSIBLE DAMAGE OR CONTAMINATION DURING REMOVAL BEARINGS SHOULD NOT BE REUSED AND NEW BEARINGS SHOULD ALWAYS BE INSTALLED Remove bearing housing covers 159 water slingers 126 casing wearing rings 16 lantern rings 10 and packing 212 If the pump is equipped with mechanical seals 456 refer to the seal manufacturer s instructions If the pump is equipped with an oil lubrication system remove the lip seals 158C from the inboard and outboard bearing housing covers and the inboard bearing housing Remove the shaft sleeves A14 or B14 Depending on the pump service shaft sleeves are supplied in two different configurations The removal procedure for each configuration differs Sleeves Affixed Wit
9. head energy that causes liquid to flow through the suction pipe and enter the eye of the impeller NPSH is expressed in two values 1 NPSH required NPSHg and 2 NPSH available NPSH It is essential that NPSHa be always greater than NPSHp to prevent cavitation vibration wear and unstable operation NPSHR is a function of the pump design and therefore varies with the model size capacity and speed of the pump The value for your pump can be obtained from your pump performance curve or from the factory A When the source of the liquid is above the pump NPSHa barometric pressure feet static suction head feet friction losses in suction piping feet vapor pressure of liquid feet B When the source of the liquid is below the pump NPSHa barometric pressure feet static suction lift feet friction losses in suction piping feet vapor pressure of liquid feet PAGE 4 INSTALLATION continued 3 MINIMUM SUBMERGENCE OF SICTION PIPE AND PIT DESIGN For installations where the pump draws fluid from a sump the hydraulic characteristics of the pump the suction inlet submergence and NPSH must be considered Generally it is required that an evenly distributed flow of non aerated water be supplied to the suction bell Improper pit design or insufficient suction pipe submergence can result in intake vortexing which reduces the pump s performance and can result in severe damage to the pump We recommend that y
10. 159 and the lip seal and the lip seal 158C in the inboard bearing housing C158 Assemble the O rings 159A on the bearing housing covers prior to installing the bearings F If your pump is equipped with mechanical seals or solid packing glands install the seals 456 and mechanical seal glands B31 or solid packing glands before proceeding Refer to the seal manufacturer s instructions for installation G Install the water slingers 126 on each end of the shaft H Install the outboard and inboard bearing covers A159 or B159 on the shaft I Install the outboard 168 and inboard bearings 163 WARNING TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY AND DAMAGE TO THE BEARINGS PRESSURE SHOULD BE APPLIED TO THE INNER BEARING RACE ONLY Note The pump is designed to have a 000 to 001 interference fit between the bearings and the shaft J Install the snap ring 345 on the outboard end of the shaft Pack both bearings approximately one half full of lithium base NGLI2 all purpose bearing grease K Install bearing housings A158 and B158 if grease lubricated or C158 and D158 or E158 and F158 over the bearings and securely bolt the bearing covers to the bearing housings using the appropriate capscrews 159D L Using a double rope sling carefully lower the rotor assembly into the lower casing 2 WARNING BE CAREFUL WHEN POSITIONING THE ROPES TO AVOID THE ROTOR SLIPPING AND CAUSING POSSIBLE SERIOUS PERSONAL INJURY CAUTION
11. AFT SLEEVE SHAFT WEARING RING CASING WEARING RING IMPELLER IF ON ORIGINAL CONSTRUCTION BEARING INBOARD BEARING OUTBOARD PACKING OR MECHANICAL SEAL 456 GASKETS COMPLETE SET For Severe Duty Add The Following REF NO DESCRIPTION COMPLETE ROTATING ASSEMBLY PAGE 20 NOTES NOTES PAGE 21 PAGE 22 NOTES SECTIONAL DRAWING PAGE 23 P158 A159 A31 10 212 20 3 16 1 102 P14 157 213 126 M58 4 272 Figure 6 STANDARD CONSTRUCTION PAGE 24 SECTIONAL DRAWINGS Figure 7 DESCRIPTION EN DESCRIPTION BEARING HOUSING INBOARD OIL LUBE BEARING HOUSING OUTBOARD OIL LUBE BEARING HOUSING INBOARD WATER COOLED BEARING BEARING HOUSING OUTBOARD WATER COOLED BEARING PIN BEARING HOUSING ALIGNMENT CAPSCREW HOUSING LIPSEAL PIPE PLUG HOUSING BEARING HOUSING COVER GREASE LUBE SHAFT SLEEVE KEYED BEARING HOUSING COVER OIL LUBE WEARING RING CASING BEARING HOUSING COVER WATER COOLED BEARING WEARING RING IMPELLER O RING OIL LUBE COVER SETSCREW O RING WATER COOLED COVER PACKING GLAND SPLIT LIPSEAL WASHER PACKING BOX CAPSCREW HOUSING COVER PACKING GLAND SOLID GLAND MECHANICAL SEAL GLAND STUD GLAND NUT KEY IMPELLER WATER SLINGER GASKET CASING BEARING HOUSING INBOARD GREASE LUBE O RING SHAFT SLEEVE BEARING HOUSING OUTBOARD GREASE LUBE SEAL MECHANICAL Not Shown
12. EASE ONCE EVERY TWO WEEKS TO 1 COAT THE BEARING WITH LUBRICANT 2 RETARD OXIDATION OR CORROSION AND 3 PREVENT POSSIBLE FALSE BRINELLING CONSIDER A UNIT IN STORAGE WHEN 1 IT HAS BEEN DELIVERED TO THE JOBSITE AND IS AWAITING INSTALLATION 2 IT HAS BEEN INSTALLED BUT OPERATION IS DELAYED PENDING COMPLETION OF CONSTRUCTION 3 THERE ARE LONG PERIODS 30 DAYS OR MORE BETWEEN OPERATION CYCLES 4 THE PLANT OR DEPARTMENT IS SHUT DOWN FOR PERIODS OF LONGER THAN 30 DAYS NOTE STORAGE REQUIREMENTS VARY DEPENDING ON THE LENGTH OF STORAGE THE CLIMATIC ENVIRONMENT AND THE EQUIPMENT FOR STORAGE PERIODS OF THREE MONTHS OR LONGER CONTACT THE MANUFACTURER FOR SPECIFIC INSTRUCTIONS IMPROPER STORAGE COULD DAMAGE THE EQUIPMENT WHICH WOULD RESULT IN NON WARRANTY COVERED RESTORATION REQUIREMENTS OR NON WARRANTY COVERED PRODUCT FAILURES INTRODUCTION AND INSTALLATION PAGE 3 INTRODUCTION This manual contains information which is the result of carefully conducted engineering and research efforts lt is designed to supply adequate instructions for the safe and efficient installation operation maintenance of your pump Failure or neglect to properly install operate or maintain your pump may result in personal injury property damage or unnecessary damage to the pump Variations exist in both the equipment used with these pumps and the particular installation of the pump and driver Therefore specific operating instructions are not within t
13. ION 4 BEARING OPERATING TEMPERATURE These pumps are designed to operate over a wide ambient temperature range The bearing temperature when measured at the outside surface of the bearing housing should not exceed 190 F Temperatures in excess of 190 F may indicate lack of lubricant bearing overload or insipient bearing failure If the temperature exceeds this limit the pump should be stopped and the cause investigated and corrected 5 TROUBLESHOOTING OPERATING PROBLEMS If you have followed the installation and start up procedures outlined in this manual your pump should provide reliable service and long life However if operating problems do occur significant time and expense can be saved if you use the following checklist to eliminate the most common causes of those problems INSUFFICIENT DISCHARGE VIBRATION OR NOISE RE OR FLOW ESOO i Misalignment between driver and pump 1 E SU idu ed driver 2 Loose foundation bolts or defective grouting 3 Discharge head too high 3 Mechanical defects 4 Suction lift too high e Shaft bent 5 Wrong direction of rotation e Rotating element binds BE 6 Air leaks into suction piping packing box or 4 Head lower than rating pumping too much liquid gaskets 5 Pipe strain improperly supported or aligned 7 Impeller passage partially plugged 6 Pump running at shut off condition 8 Impeller damaged 7 Insufficient suction line submergence 9 Impeller running clearance too large
14. SECTIONAL DRAWINGS IN THIS MANUAL BEFORE PROCEEDING Major maintenance will require disassembly of the pump Following are step by step instructions A Lock out the power to the driver and close the suction and discharge valves Drain the pump disconnect and remove the coupling or flexible shafting Disconnect and remove all auxiliary piping to the upper casing 3 and bearing housings C158 and D158 packing box flush line lubricators on oil lubricated pumps cooling water lines on pumps with water cooled bearings etc B Remove the capscrews 2A securing the upper casing half 3 to the lower half 2 Remove the gland nuts 31B and slide the glands A31 or B31 off the gland studs 31A Install jack screws in the tapped holes in the upper casing half and use them to separate the flanges Carefully lift the upper casing half using the long shank eyebolts in the tapped holes in the upper casing half CAUTION USE OF A CRANE OR HOIST OF ADEQUATE CAPACITY IS RECOMMENDED THE LIFTING HOOK SHOULD BE NO LESS THAN 3 4 FEET ABOVE THE EYE OF THE EYEBOLTS TO AVOID BENDING OF THE BOLTS THE USE OF THE SHORT EYEBOLTS IS NOT RECOMMENDED SINCE THE UPPER CASING HALF WILL TEND TO TIP WHILE BEING LIFTED RESULTING IN POSSIBLE DAMAGE OR PERSONAL INJURY C Remove the capscrews 158B and pins 158A that secure the bearing housings 158 to the lower casing The pins may be removed using the threaded holes in the pins D Lift the rotor assembly from the
15. aaas MODEL 441 MAINTENANCE HORIZONTAL SPLIT CASE INSTRUCTIONS S h MODEL 491 SPLIT CASE FIRE PUMP CI AURORA Pentair Water PUMP IDENTIFICATION CAUTION NOTES INTRODUCTION INSTALLATION General TABLE OF CONTENTS STORAGE OF PUMPS Net Positive Suction Head NPSH 1 2 3 Minimum Submergence of 4 Location and Handling 5 Foundation 6 7 8 9 Leveling of Unit Grouting Piping oia sees Suction Pipe and Pit Design Auxiliary Piping Connections and Gauges 10 Constant Level Oiler Oil Lubricated Pumps 11 Final Coupling Alignment 12 Flexible Shaft Alignment 13 Rotation 14 Mechanical Seals OPERATION 1 Operating at Reduced Capacity 2 Priming 3 Starting the Pump 4 Bearing Operating Temperature 5 Troubleshooting Operating Problems MAINTENANCE 1 Maintenance History 2 Inspections and Preventive Maintenance Requirements 3 Bearing Lubrication Grease Lubricated Bearings Oil Lubricated Bearings Packing Box noon Pump Assembly REPAIR PARTS RECOMMENDED SPARE PARTS NOTES ce eae as
16. aft shoulders as shown in Figure 5 FIGURE 5 CAUTION IF THE SHAFT SLEEVES ON YOUR PUMP ARE SECURED WITH LOCTITE ONLY REFER TO THE SHAFT SLEEVE INSTALLATION INSTRUCTIONS BEFORE INSTALLING THE IMPELLER D Install the shaft sleeves A14 or B14 shaft sleeve nuts 213 and O rings 452 if your pump uses them on the shaft The shaft sleeves will be secured by one of three methods and you should proceed as follows Sleeves Secured With Loctite And Sleeve Nuts Apply two beads of Loctite No 601 around the shaft on the shaft shaft sleeve fit one approximately 2 inches from the impeller hub and the second at the threaded end Slide the shaft sleeves part way onto the shaft and rotate them at least one full revolution to evenly spread the Loctite then slide the sleeves over the shaft until they butt firmly against the impeller hub Install and tighten the shaft sleeve nuts 213 and the set screws 213A MAINTENANCE continued PAGE 17 7 PUMP ASSEMBLY continued Sleeves Secured With Loctite Only Clean the shaft the bore of the sleeves and the bore of the impeller with Loctite Safety Solvent 75559 Install the impeller key in the shaft and coat the impeller area on the shaft with Loctite 601 Press the impeller onto the shaft centering it between the shoulders as shown in Figure 5 Coat the shaft on the shaft sleeve fit and the bore of the sleeves with Loctite 601 Slide the sleeves part way onto the shaft and rotate them at
17. arts in the future FIGURE MODEL SERIAL NUMBER IMPELLER DIAMETER SIZE CAPACITY 2 TOTAL HEAD RPM DRIVER HORSEPOWER SERIAL NUMBER SPEED VOLTAGE MANUFACTURER FRAME PAGE 2 STORAGE OF PUMPS AND CAUTION NOTES THESE INSTRUCTIONS APPLY TO THE PUMP ONLY THEY ARE INTENDED TO BE GENERAL AND NOT SPECIFIC IF YOUR OPERATING CONDITIONS EVER CHANGE ALWAYS REFER TO THE FACTORY FOR REAPPLICATION ALWAYS REFER TO THE MANUALS PROVIDED BY MANUFACTURERS OF THE OTHER EQUIPMENT FOR THEIR SEPARATE INSTRUCTIONS CAUTION IMPORTANT SAFETY NOTICE THE INSTALLATION USE AND OPERATION OF THIS TYPE OF EQUIPMENT IS AFFECTED BY VARIOUS FEDERAL STATE AND LOCAL LAWS AND THE REGULATIONS CONCERNING OSHA COMPLIANCE WITH SUCH LAWS RELATING TO PROPER INSTALLATION AND SAFE OPERATION OF THIS TYPE OF EQUIPMENT IS THE RESPONSIBILITY OF THE EQUIPMENT OWNER AND ALL NECESSARY STEPS SHOULD BE TAKEN BY THE OWNER TO ASSURE COMPLIANCE WITH SUCH LAWS BEFORE OPERATING THE EQUIPMENT STORAGE OF PUMPS IF THE EQUIPMENT IS NOT TO BE IMMEDIATELY INSTALLED AND OPERATED STORE IT IN A CLEAN DRY WELL VENTILATED PLACE FREE FROM VIBRATION MOISTURE AND RAPID OR WIDE VARIATIONS IN TEMPERATURE SPECIAL INSTRUCTIONS FOR OIL LUBRICATED PUMPS FILL THE BEARING RESERVOIRS WITH OIL PRIOR TO START UP DRAIN THE STORAGE OIL AND FILL THE RESERVOIRS WITH NEW OIL GREASE LUBRICATED PUMPS ROTATE THE SHAFT FOR SEVERAL REVOLUTIONS AT L
18. ation CAUTION BEFORE STARTING OR OPERATING THE PUMP READ THIS ENTIRE MANUAL ESPECIALLY THE FOLLOWING INSTRUCTIONS A BEFORE STARTING THE PUMP INSTALL CLOSED GUARDS AROUND THE COUPLING B BEFORE STARTING THE PUMP ROTATE THE UNIT OR ASSEMBLY BY HAND TO ASSURE ALL MOVING PARTS ARE FREE C OBSERVE ALL CAUTION AND DANGER TAGS ATTACHED TO THE EQUIPMENT D NEVER RUN THE PUMP DRY AS THE CLOSE RUNNING FITS WITHIN THE PUMP ARE WATER LUBRICATED RUNNING DRY MAY RESULT IN PUMP SEIZURE E BEFORE STARTING THE PUMP FILL THE CASING AND SUCTION LINE WITH LIQUID THE PUMP MAY BE PRIMED USING AN EJECTOR OR VACUUM PUMP F BEFORE STARTING A PACKED BOX PUMP ADJUST THE PACKING GLAND SO THERE IS SUFFICIENT LEAKAGE TO LUBRICATE THE PACKING AND ASSURE A COOL PACKING BOX SEE MAINTENANCE INSTRUCTIONS G IF EXCESSIVE VIBRATION OR NOISE OCCURS DURING OPERATION SHUT THE PUMP DOWN AND CONSULT AN AURORA PUMP REPRESENTATIVE 1 OPERATING AT REDUCED CAPACITY Although these pumps are applicable over a wide range of operating conditions care should be exercised when doing so especially when the actual conditions differ from the sold for conditions You should always contact your nearest Aurora Pump sales office before operating the pumps for any condition other than that for which it was sold 2 PRIMING Since the pump medium is used to lubricate various internal parts running a centrifugal pump dry can result in extensive damage and possible s
19. eizing It is therefore imperative that the pump be primed prior to initial start up and that prime be maintained through subsequent start stop cycles The priming method is different for positive and negative suction head systems and the following procedures should be followed A Positive Suction Head 1 Open the vent on the highest point on the pump casing 2 Open all suction valves 3 Allow the pumped liquid to flow from the vent hole until all air bubbles are vented then close the vent 4 The pump is now primed B Negative Suction Head Install an ejector or vacuum pump on the vent at the highest point on the pump casing Close the discharge valve Open the suction valve Start ejector or vacuum pump Allow the liquid to flow until a continuous flow is exhausted from the ejector then close the valve to the vent The pump is now primed Oe co fonce o PAGE 10 OPERATION continued 3 STARTING THE PUMP A After the pump is primed and with the discharge valve closed and the suction valve open start the driver according to the driver manufacturer s instructions B Open the discharge valve slowly to prevent water hammer C After the pump has been started check bearing temperatures packing box lubrication and operation and pump noise level for a period of several hours CAUTION BEGIN THESE CHECKS IMMEDIATELY UPON STARTING THE PUMP AND MONITOR THEM CONTINUOUSLY FOR THE FIRST SEVERAL HOURS OF OPERAT
20. g temperature the grade and viscosity should be as follows Below 120 F ISO Vg Grade 40 70 SAE 20 120F to 250 F ISO Vg Grade 70 100 SAE 20 Above 250 F Consult the factory for a recommendation 4 PACKING BOX CAUTION DO NOT TIGHTEN THE GLAND TO STOP ALL LEAKAGE LEAKAGE IS NECESSARY TO ENSURE THE COOLING FLUSHING AND LUBRICATION OF THE PACKING AND TO PREVENT SHAFT SLEEVE DAMAGE The packing boxes on Aurora Pumps are packed at he factory All packing is subject to wear and should be given regular inspections and if necessary periodic adjustments Generally packed box pumps require inspection of the packing and adjustments to the glands after each 150 hours of operation Adjustment is made by lightly tightening the gland nuts then loosening them so that they can be adjusted with finger pressure to allow a small flow of liquid to lubricate the packing If the flow of liquid has increased and cannot be reduced by a slight tightening of the gland add one ring of packing to the packing box and readjust the gland If this fails to reduce the flow replace the packing and or shaft sleeve The packing boxes may be fitted with lantern rings When a lantern ring is furnished the sealing chamber should be connected to a source of clear fresh water 5 PACKING REPLACEMENT Use a good grade of soft square long fiber packing thoroughly graphited The replacement procedure should be as follows A Stop the pump B Unbolt and
21. h Loctite Remove the shaft sleeve nuts 213 if they are provided heat the sleeves to approximately 450 F to break the bond then tap them with a brass or copper mallet WARNING TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY HEAT RESISTANT GLOVES MUST BE WORN WHEN HANDLING HEATED PARTS Sleeves Keyed To Shaft Remove the shaft sleeve nuts 213 shaft sleeves B14 and the shaft sleeve O rings 452 CAUTION BECAUSE OF POSSIBLE DAMAGE DURING DISASSEMBLY O RINGS SHOULD NOT BE REUSED AND NEW O RINGS SHOULD ALWAYS BE INSTALLED Slide the impeller 1 off the shaft 4 and remove the impeller key 102 If your pump has impeller wear rings and they require replacement they will be secured by one of two methods and you should proceed as follows Wearing Rings Secured With Loctite Heat the sleeves to approximately 450 F to break the bond then tap them with a brass or copper mallet If heating fails to affect removal the rings may be ground off Wearing Rings Secured With Setscrews Remove the setscrews 17A and chisel cut or grind the rings in two at the setscrew location WARNING TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY HEAT RESISTANT GLOVES MUST BE WORN WHEN HANDLING HEATED PARTS WARNING TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY EXTREME CARE SHOULD BE EXERCISED TO SELECT THE PROPER GRINDING EQUIPMENT AND APPROVED SAFETY GLASSES SHOULD BE WORN WHEN GRINDING The pump disassembly is now complete All parts should be tho
22. he scope of this manual The manual contains general rules for installation operation and maintenance of the pump Observe all caution or danger tags attached to the pump or included in this manual INSTALLATION 1 GENERAL CAUTION CAREFULLY READ ALL SECTIONS OF THIS MANUALAND ALL OTHER INSTRUCTION MANUALS PROVIDED BY MANUFACTURERS OF OTHER EQUIPMENT SUPPLIED WITH THIS PUMP Upon receipt of the shipment unpack and inspect the pump and driver assemblies and individual parts to ensure that none are missing or damaged Carefully inspect al boxes and packing material for loose parts before discarding them Report immediately to the transportation company involved and to the factory any missing parts or damage incurred during shipment and file your damaged and or lost in shipment claim with the carrier Horizontal pump and driver assemblies mounted on a common base are accurately aligned at the factory However alignment may be disturbed in transit or during installation It must be checked after the unit is leveled on its foundation after the grouting has set and the foundation bolts are tightened and after the piping is completed When the pump and driver are mounted on separate base structures the pump should be leveled and aligned first then the driver leveled and aligned with the pump With separate bases a flexible shaft between the pump and driver must be used 2 NET POSITIVE SUCTION HEAD NPSH NPSH can be defined as the
23. least one full revolution to evenly spread the Loctite then slide the sleeves over the shaft until they butt firmly against the impeller hub Check the sleeve location again and let the Loctite cure for 8 hours before completing the pump assembly Sleeves Installed With O rings Slide the shaft sleeves over the shaft until they engage the key and butt firmly against the impeller hub Install the O rings in the outboard shaft sleeve nut end of the sleeve and tighten the shaft sleeve nuts and setscrews CAUTION THE LINEAR POSITION OF THE IMPELLER MUST BE OBTAINED AND THE SHAFT SLEEVES MUST BE PROPERLY LOCATED REFER TO FIGURE 5 ON THE PREVIOUS PAGE OF THIS MANUAL IF PROVIDED THE SHAFT SLEEVE NUST MUST BE TIGHTENED WITHIN 10 MINUTES AFTER THE LOCTITE IS APPLIED TO ACCOMPLISH LINEAR POSITIONING OF THE IMPELLER LEAVE AN EQUAL AMOUNT OF SHAFT OR SHAFT THREADS EXPOSED ON EACH END OF THE SHAFT AFTER ASSEMBLY IS COMPLETED ALLOW 4 HOURS FOR THE LOCTITE TO CURE BEFORE COMPLETING THE PUMP ASSEMBLY CAUTION THIS PUMP MAY BE SUPPLIED IN SEVERAL DIFFERENT CONFIGURATIONS EACH USES DIFFERENT BEARING COVERS AND HOUSINGS WITH DIFFERENT DRAWING REFERENCE NUMBERS DESPITE THE FOLLOWING INSTRUCTIONS ALWAYS REFER TO THE SECTIONAL DRAWINGS CONTAINED IN THIS MANUAL BEFORE PROCEEDING TO INSURE THAT YOU HAVE INSTALLED ALL REQUIRED LIP SEALS O RINGS ETC E If your pump is oil lubricated install the lip seals 159C in the outboard and inboard bearing covers B
24. nd a complete description and item number of each part Refer to the drawings and parts list in the back of this manual You should order parts from your local Aurora Pump distributor Consult your local telephone yellow pages for the office nearest you RETURNING PARTS Unnecessary delays and wasted effort will be avoided if you use the proper procedure to return parts or equipment All materials or parts returned to the factory must have prior approval and a Returned Goods Tag Contact your nearest Aurora Pump distributor listing the material to be returned and the reason for the return He will contact the factory to obtain the required approval and Returned Goods Tag All materials to be returned should be carefully packaged to avoid damage in route from rough handling or exposure to weather The Returned Goods Tag will give shipping instructions All material is to be returned freight prepaid Aurora Pump makes improvements on its products from time to time and reserves the right to furnish improved parts for repairs A part that is received and is not identical in appearance or has a different symbol from the original part may still be interchangeable Examine the part carefully before contacting your Aurora Pump distributor The parts should never be returned to the factory without first obtaining proper authorization from your Aurora Pump distributor RECOMMENDED SPARE PARTS For Normal Duty DESCRIPTION SLEEVE SH
25. o the primary piping connections your pump may require mechanical seal and seal water filter connections connections to the lantern ring see the Packing Box and Mechanical Seal sections of this manual stuffing box drain discharge and suction flange gauges casing relief valve drain or baseplate drain connections All these lines and gauges should now be installed 10 CONSTANT LEVEL OILERS If your pump has oil lubricated bearings it will be equipped with constant level oilers which will be shipped loose to prevent damage in shipment The oilers must be installed in the tapped holes in the side of the beating housings To provide proper lubrication the pipe connection the oiler to the bearing housing must be level see Figure 2 CONSTANT LEVEL OILER BEARING HOUSING C158 amp D158 LEVEL o 7 o CONNECTING PIPE 4 FIGURE 2 When the oiler is level fill the bottle and screw it onto the lower reservoir of the oiler Allow the oil to flow into the bearing reservoir Several fillings of the bottle may be required before the oil level for which the oiler is set is reached and the oil stops flowing After filling the oil reservoir check the oil level to make sure it is as specified in the following table see Page 6 PAGE 6 INSTALLATION continued BEARING HOUSING OIL LEVEL CHART 4 441 11A C 5 441 18A 5 441 11A PUMP MODEL 3 441 9A C 4 441 14C 6 441 14A C 6 441 19A PUMP SIZE 4 441 8A 5 441 14A 6
26. ou secure the advice of a qualified Consulting Engineer for the analysis of the suction pit Significant engineering data on design is provided in the Hydraulic Institute Standards 4 LOCATION AND HANDLING The pump should be located as near the fluid as possible so a short direct suction pipe can be used to keep suction losses at a minimum If possible locate the pump so the fluid will flow to the suction opening by gravity The discharge piping should be direct and with as few elbows and fittings as possible The total net positive suction head available NPSH which includes suction lift and pipe friction losses must be equal to or greater than the net positive suction head required NPSHg by the pump The pump and driver should be located in an area that will permit periodic inspection and maintenance Head room and access should be provided and all units should be installed in a dry location with adequate drainage WARNING DO NOT LIFT THE COMPLETE UNIT BY THE DRIVER OR PUIVP SHAFTS OR EYE BOLTS To lift a horizontal mounted unit a chain or suitable lifting device should be attached to each corner of the unit base The driver by itself may be lifted using the proper eyebolts provided by the manufacturer but these should not be used to lift the entire assembled unit 5 FOUNDATION The foundation should have a level surface and have sufficient mass to prevent vibration and form a permanent rigid support for the unit The most satisfacto
27. remove the glands away from the packing C Use a packing hook to remove the worn rings of packing and lantern rings Note the location of the lantern rings relative to the amount of packing on each side of the lantern rings See sectional drawings on pages 23 amp 24 Clean the packing boxes and shaft sleeves Inspect the shaft sleeves for wear or rough finish and replace if necessary Install new packing and lantern rings CAUTION STAGGER THE PACKING END JOINTS 180 AND FIRMLY SEAT THE PACKING THE FOLLOWING TABLE GIVES THE PERTINENT PACKING BOX LANTERN RING AND PACKING DIMENSIONS see page 14 G Reinstall the glands and tighten the gland nuts H Loosen the gland nuts so they can be adjusted with finger pressure to obtain correct leakage for lubrication after start up mm PAGE 14 MAINTENANCE continued 5 PACKING REPLACEMENT continued PUMP MODEL PUMP SIZE 4 441 11A 5 441 18A 3 441 9A C 4 441 14C 6 441 14A C 6 441 19A 4 441 8 5 441 14A 6 441 18A 10 441 20 6 441 12A 8 441 14A PACKING BOX Sleeve O D 2 Packing Box LD Packing Box Depth Qty of Rings per Box Without Lantern Ring Lantern Ring Width PACKING ARRANGEMENT WITH LANTERN RING Packing Rings Lantern See Sectional Drawings on pages 23 amp 24 NOTE For Fire Pumps the Model designation changes from 441 to 491 6 PUMP DISASSEMBLY CAUTION READ THIS ENTIRE DISASSEMBLY PROCEDURE AND REFER TO THE
28. roughly cleaned and inspected for wear or damage and replaced if required PAGE 16 MAINTENANCE continued 7 PUMP ASSEMBLY CAUTION READ THIS ENTIRE PROCEDURE BEFORE CONTINUING Following are step by step instructions for assembly of the pump and are essentially the reverse order of the instructions for disassembly A Thoroughly clean all parts to remove oil grease and foreign material Inspect for wear or damage and replace if required Remove all parts to a clean and dust free location for assembly Gaskets grease seals and bearings should not be reused and should always be replaced with new parts B Ifthe impeller wear rings 17 require replacement they are a light press fit and will be secured by one of the following methods You should proceed as follows Rings Secured With Loctite Apply a light film of Loctite No 290 to the impeller part of the impeller wear ring fit and install the rings Rings Secured With Set Screws Press the rings in place and drill and tap them using the same size and number of setscrews as originally provided The new holes should be 15 to 20 from the old holes Install and tighten the set screws CAUTION BE CAREFUL NOT TO DRILL THROUGH THE IMPELLER AND BE SURE TO PRESS THE WEAR RING COMPLETELY IN PLACE THEY SHOULD BE FIRMLY BUTTED AGAINST THE CORRESPONDING IMPELLER SHOULDER C Install the impeller key 102 in the shaft 4 and slide the impeller 1 over the key centering it between the sh
29. ry foundations are concrete with anchor bolts of adequate size embedded in the foundation in pipe sleeves with an inside diameter 212 times larger than the bolt diameter This will allow final accurate positioning of the unit 6 LEVELING OF THE UNIT Lower the unit onto the foundation positioning it so the anchor bolts are aligned with the center of the mounting holes in the base On all units always disconnect the coupling halves and never reconnect them until all the alignment operations are complete The base should be supported on metal shims or metal wedges placed directly under the part of the base carrying the greatest weight and spaced close enough to give uniform support and stability see Figure 1 Adjust the metal shims or wedges until the shafts of the pump and driver are level Alignment adjustments can be accomplished by adjusting the supports under the base When proper alignment is obtained tighten the foundation bolts snugly but not too firmly and recheck the alignment before grouting Figure 1 BASEPLATE INSTALLATION INSTALLATION continued PAGE 5 7 GROUTING When the alignment is correct the unit should be grouted using high grade non shrinking grout The entire base should be filled with grout Be sure to fill all gaps and voids Allow the grout to fully cure before firmly tightening the foundation bolts Then recheck the alignment before connecting the piping 8 PIPING CAUTION ALL PIPING CONNECTIONS MUST
30. the inspector immediately report any problems A guide for preventive maintenance for normal applications is given below Unusual applications with abnormal heat moisture dust etc may require more frequent inspections and service ITEM ACTION REQUIRED FREQUENCY HOURS OF OPERATION Packing Box Adjust gland inspect packing for 150 Hours possible replacement Pump Alignment Check for change in alignment ANNUALLY Vibration Check for change in vibration ANNUALLY Bearings Lubricate Grease lubricated Every 2000 hours of operation but at least once a year Oil lubricated As required to maintain proper oil level drain and replace oil every 2000 hours of operation but at least once a year 3 BEARING LUBRICATION A Grease Lubricated Bearings Under normal operating conditions the bearings must be lubricated after every 2000 hours of running time but at least once a year regardless of total operating hours CAUTION ANY APPLICATION WITH ABNORMAL HEAT MOISTURE DUST ETC MAY REQUIRE A CHANGE IN THIS SCHEDULE AND YOU SHOULD REFER TO A LUBRICATION ENGIEER OR THE FACTORY FOR SPECIFIC INSTRUCTIONS CAUTION THE GREASES RECOMMENDED IN THIS MANUAL WILL PROVIDE SATISFACTORY LUBRICATION OVER A WIDE TEMPERATURE RANGE THERE IS HOWEVER A PRACTICAL LIMIT AND OPERATION OF THE PUMP SHOULD BE DISCONTINUED AND THE FACTORY CONSULTED IF THE TEMPERATURE WHEN MEASURED ON THE OUTSIDE OF THE BEARING HOUSING EXCEEDS 190 F RECOMMENDED GREASE
31. the sleeve It may be necessary to pry the ring into position with a blunt screwdriver WARNING CHECK SAFETY CODES AND ALWAYS INSTALL PROTECTIVE GUARD OR SHIELD AS REQUIRED BY VARIOUS FEDERAL STATE AND LOCAL LAWS AND REGULATIONS CONCERNING OSHA WARNING COUPLING SLEEVES MAY BE THROWN FROM THE ASSEMBLY WHEN SUBJECTED TO A SEVERE SHOCK LOAD 12 FLEXIBLE SHAFTING ALIGNMENT For installation and alignment of intermediate flexible shafting refer to the manufacturer s instructions 13 ROTATION Before connecting the coupling halves bump start the driver to verify rotation is in the proper direction The correct pump rotation is indicated by a directional arrow on the pump casing PAGE 8 INSTALLATION continued 14 MECHANICAL SEALS CAUTION DRY OPERATION OF THE PUMP MAY CAUSE DAMAGE TO THE MECHANICAL SEAL AND IMPELLER Model 441 pumps can be supplied with optional single face mechanical shaft seals Mechanical seals are installed and adjusted in the factory and require no further adjustments in the field For further information refer to the seal manufacturer s instructions 456 B31 FIGURE 4 TYPICAL MECHANICAL SEAL OPERATION PAGE 9 Because variations exist in both the equipment used with these pumps and in the particular installation of the pump and driver specific operating instructions are not within the scope of this manual However there are general rules and practices that apply to all pump installations and oper
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