AC International 8200 Series Heat Pump User Manual
Contents
1. 9 DOWELING veda 11 SUCTION AND DISCHARGE 11 STUFFING BOX LUBR CAT ION 14 PACKING reiia 14 52 2 16 PRE START CHECKS 16 PRIMING o 16 STARTING 16 OPERATING CHECKS 16 FREEZING 1 17 FIELD TESTING aiaiai iaaa 17 57 2 17 GENERAL MAINTENANCE 17 MAINTENANCE OF PUMP DUE TO FLOOD DAMAGE AR sesh 17 BEARING LUBRICATION GREASE 18 PACKING SEAL 0 18 MAINTENANCE TIME TABLEF 19 TROUBLE SHOOTING 20 CHANGING ROTATION 23 SERVICE INSTRUCT IONS 24 DISASSEMBLY AND REASSEMBLY PROCEDURES 0 22 24 DISMANTLING PUMP WITH PACKING 24 ASSEMBLY PUMP WITH PACKING 27 APPENDIX A ENGINEERING DATA 30 APPENDIX 5 31 EXPLODED VIEW 8200 SERIES FIRE PUMBez 31 REPLACEMENT PARTS LI2. FIRE Instruction Manual PUMP AC2675 REVISION A 8200 Series Base Mounted Centrifugal Fire Pumps Installation Operation and Service Instructions INSTALLER PLEASE LEAVE THIS MANUAL FOR THE OWNER S USE ITT Engineered for life TABLE OF CONTENTS DESCRIPTION 3 OPERATIONAL LIMITS 3 MAXIMUM WORKING PRESSUR E 3 SEAL OPERATING LIMITS 3 PACKING sha gaat 3 PUMP IDENTIFICATION 3 SAFETY INSTRUCTIONS 4 ADDITIONAL SAFETY REQUIREMENTS 4 ADDITIONAL SAFETY REQUIREMENTS 5 ELECTRICAL SAFETY 5 THERMAL SAFETY L 5 MECHANICAL 5 INSTALLATIOQN 6 PUMP LOCA TO 6 RECEIVING PUMP 6 TEMPORARY STORAGE 7 LOCATION 7 FOUNDAT ON L l 7 BASE PLATE SETTING BEFORE PIPING 8 GROUTING PROCEDURE 8 SEE ANSI OSHA COUPLER GUARD REMOVAL INSTALLATION 8 ALIGNMENT PROCEDURE 8 ANSI OSHA COUPLER GUARD REMOVAL INSTALLATION
3. 20 Suction inlet not immersed deep enough If inlet cannot be lowered or if eddies through which air is sucked persist when it is lowered chain a board to suction pipe It will be drawn into eddies smothering the vortex 21 Wrong direction of rotation Symptoms are an overloaded driver and about one third rated capacity from pump Compare rotation of motor with directional arrow on pump casing f rotation is correct with arrow impeller may have to be turned 180 See CHANGING ROTATION 22 System head too high See item 4 23 Defective mechanical seal Repair or replace seal Not Enough Pressure 24 Speed too low See item 5 25 Air leaks in suction piping See item 11 or stuffing box 26 Mechanical defects See item 18 27 Vortex at suction inlet See item 20 28 Obstruction in liquid passages Check to see if suction and discharge valves are fully open Dismantle pump and inspect passages and casing Remove obstruction 29 Air or gases in liquid May be possible to over rate pump to a point where it will provide adequate pressure despite condition Better provide gas separation chamber on suction line near pump and periodically exhaust accumulated gas See item 17 21 TROUBLE SHOOTING CONT CAUSES CURES Pu mp Operates For Short Time Then Stops 30 Insufficient NPSHA See item 17 31 System head too high See items 4 a
4. Pumps and drivers normally are shipped from the factory mounted and painted with primer and one finish coat Couplings may be either completely assembled or have the coupling hubs mounted on the shafts and the connecting members removed When the connecting members are removed they will be packaged in a separate container and shipped with the pump or attached to the base plate Shafts are in alignment when the unit is shipped however due to shipping the pumps may arrive mis aligned and therefore alignment must be established during installation ITT AC Fire Pump Systems has determined that proper and correct alignment can only be made by accepted erection practices Refer to the following paragraphs on Foundation Base Plate Setting Grouting Procedure Alignment Procedure and Doweling TEMPORARY STORAGE If the pump is not to be installed and operated soon after arrival store it in a clean dry place having slow moderate changes in ambient temperature Rotate the shaft periodically to coat the bearings with lubricant and to retard oxidation corrosion and to reduce the possibility of false brinelling of the bearings LOCATION The pump should be installed as near the suction supply as possible but no less than five suction diameters refer to page 11 suction and discharge piping section with the shortest and most direct suction pipe practical The total dynamic suction lift static
5. 1 Head 2 TDH ft Total Dynamic Head ft Disch pressure gauge reading Suct pressure gauge reading Discharge velocity head Suction velocity head Elevation correction to disch gauge Elevation correction to suct gauge 3 PUMP INPUT HP BHP calculated Single Phase Motor Three Phase Motor BHP Amps x Volts x nm x p f BHP Avg Amps x Volts x 1 732 x nm x p f 746 746 where motor efficiency p f motor power factor Avg Amps 4 Pump Efficiency np GPMxTDH P 3960 x BHP 5 Affinity Lavvs for correcting GPM TDH and BHP for speed RPM GPM1 _ RPM1 gt GPM GPM x RPM GPM2 2 RPM2 TDH RPM RPM 1 or TDH x REM TDH2 RPM RPM2 BHP RPM RPM 1 or BHP BHP x BHP2 2 RPM2 6 NPSHA DETERMINATION NPSHA Net Positive Suction Head Available NPSHA Atmospheric pressure Vapor pressure of liquid Total suction head Total Suction Head Suction pressure gauge reading Suction velocity head Elevation correction to suction gauge NOTE NPSHA must always be greater than NPSHR NPSHA 2 NPSHR for the pump to operate without concern of cavitation NPSHR refers to Net Positive Suction Head Required by pump This is a published value obtained from the Pump Manufacturer s curve 2 of 2 35 1 Engineered for life COPYRIGHT 2005 BY ITT INDUSTRIES
6. WARNING Excessive Pressure Hazard Volumetric Expansion The heating of water and other fluids causes volumetric expansion The associated forces may cause failure of system components and release of high temperature fluids Installing properly sized and located compression tanks and pressure relief valves will prevent this Failure to follow these instructions could result in serious personal injury or death and property damage INSTALLATION PUMP LOCATION Locate the pump so there is sufficient room for inspection maintenance and service If the use of a hoist or tackle is needed allow ample head room A WARNING Falling Objects Hazard Eyebolts or lifting lugs if provided are for lifting only the components to which they are attached Failure to follow these instructions could result in serious personal injury or death or property damage If lifting base pump is required use a nylon string chain or wire rope hitch around both bearing supports If lifting of the entire pump is required do so with slings placed under the base rails as shown Care must be taken to size equipment for unbalanced loads which may exist if the motor is not mounted on the base at the time of lifting Motor may or may not be mounted at the factory Pump base and driver assemblies where the base length exceeds 100 inches may not be safe to lift as a complete assembly Damage to the baseplate may occur If the driver h
7. 2 375 2 375 2 375 2 375 2 375 2 375 Diameter at Coupling 2 125 2 125 2 125 2 125 2 125 2 125 Shaft Span Brg to Brg 33 45 33 45 33 45 33 45 33 45 33 45 Ball Bearings Inboard Brg No 5311 5311 5311 5311 5311 5311 Dia Thru Brg 2 1654 2 1654 2 1654 2 1654 2 1654 2 1654 Outboard Brg No 7311 BG 2 7311 BG 2 7311 BG 2 7311 BG 2 7311 BG 2 7311 BG 2 Dia Thru Brg 2 1654 2 1654 2 1654 2 1654 2 1654 2 1654 Frame Number F27 A1 F27 A1 F27 A1 F27 A1 F27 A1 F27 A1 Instruction Book Number AC2675 AC2675 AC2675 AC2675 AC2675 AC2675 o H Prefix indicates High Pressure Casing 30 APPENDIX 5 EXPLODED VIEW 8200 SERIES FIRE PUMP CLOCKWISE ROTATION CASTING BOTOM HALF 20088 31 REPLACEMENT PARTS LIST APPENDIX B 32 Part Number Part Name Quantity 1 952 0 Bleed Line 1 1 952 0 Flush Line 1 0 910 9 Pipe Plug 14 1 013 9 Seal Cage 2 1 014 9 Gland 2 1 901 9 Gland Bolt 4 1 909 9 Washer Gland Bolt 4 1 924 9 Packing Ring 10 2 001 7 Casing Upper Half 1 2 001 8 Casing Lower Half 1 2 123 5 Casing Joint Gasket Suction 1 2 123 5 Casing Joint Gasket Discharge 1 2 904 1 Cap Screw Casin Varies with size 1 439 0 Dowel 2 3 003 9 Casing Ring 2 3 007 0 Shaft 1 3 009 9 Shaft Sleeve 2 3 015 9 Shaft Sleeve Nut 2 5 018 0 Bearing Housing Cover 2 3 025 3 Bearing Ho
8. 2 910 9 on 24 suction and discharge nozzle See Exploded View on page 31 2 Remove coupling guard and separate the coupling to disconnect the pump form the driver 3 Remove seal lines 1 952 0 4 Remove gland bolts 1 904 9 washers 1 909 9 and gland 1 014 9 from each stuffing box 5 Remove all casing main joint cap screws 2 904 1 and dowels 2 916 0 Use slot in casing main joint and separate the casing halves with a pry bar Lift upper half casing 2 001 7 by castlugs NOTE Casings have jacking screws 6 Remove packing 1 924 9 and seal cage 1 013 9 from each stuffing box 7 Remove cap screws 3 904 9 which hold bearing housings 3 025 3 to the casing and lift rotating element out of lower casing 2 001 8 Rotating element may now be moved to suitable working location 8 Pull coupling half and key 3 911 2 off shaft 3 007 0 NOTE A spare rotating element can be installed at this point 9 Remove cap screws 5 904 9 from bearing covers 5 018 0 10 Remove bearing housings 3 025 3 locknut 3 516 4 and lockwasher 3 517 4 Mount bearing puller and remove bearings 3 026 2 Remove retaining collar and split ring on outboard side and snap ring on inboard side A CAUTION DO NOT REUSE THE BALL BEARINGS Failure to follow these instructions could result in injury or property damage NOTE Locknut and lockwasher are not used on inboard end bearing 11 Remo
9. External sealing liquid should be adjusted to the point where the packing runs only slightly warm with a very slow drip from the stuffing box Excess pressure from an external source can be very destructive to packing More pressure is required however for abrasive slurries than for clear liquids Examination of the leakage will indicate whether to increase or decrease external pressure If slurry is present in the leakage increase the pressure until only clear liquid drips from the box If the drippage is corrosive or harmful to personnel it should be collected and piped away common error is to open the external piping valve wide and then control the drippage by tightening the packing gland A combination of both adjustments is essential to arrive at the optimum condition The life of packing and sleeve depends on careful control more than any other factor PRESSURE FLOWMETER 8 GAUGE PRESSURE REDUCING VALVE STUFFING BOX FIGURE 9 CONTROLLED PRESSURE SYSTEM 15 OPERATION WARNING Unexpected Startup Hazard Disconnect and lockout power before servicing Failure to follow these instructions could result in serious personal injury or death or property damage A WARNING Rotating Components Hazard Do not operate pump without all guards in place Failure to follow these instructions could result in serious personal injury or death and property dam
10. Replace when clearances become three 3 times their normal clearance or when a significant decrease in discharge pressure for the same flow rate is observed See Engineering Data Section for standard clearances Remove any deposit or scaling Clean out stuffing box piping Measure total dynamic suction and discharge head as a test of pump performance and pipe condition Record the figures and compare them with the figures of the last test This is important especially where the fluid being pumped tends to form a deposit on internal surfaces Inspect foot valves and check valves especially the check valve which safeguards against water hammer when the pump stops A faulty foot or check valve will reflect also in poor performance of the pump while in operation NOTE The above time table is based on the assumption that after start up the unit had been constantly monitored and such a schedule was found to be consistent with operation as shown by stable readings Extreme or unusual applications or conditions should be taken into consideration when establishing the maintenance intervals 19 TROUBLE SHOOTING Between regular maintenance inspections be alert for signs of motor or pump trouble Common symptoms are listed below Correct any trouble immediately and AVOID COSTLY REPAIR AND SHUTDOWN CAUSES CURES No Liquid Delivered 1 Lack of prime Fill pump and suction pipe completely with liquid 2 Loss of p
11. Valves in Discharge Piping b When foot valves are used or where there are other possibilities of water hammer close the discharge valve slowly before shutting down the pump c Where two or more pumps are connected to the same suction line install gate valves so that any pump can be isolated from the line Gate valves should be installed on the suction side of all pumps with a positive pressure for maintenance purposes Install gate valves with stems horizontal to avoid air pockets Globe valves should not be used particularly where NPSH is critical d The pump must never be throttled by the use of a valve on the suction side of the pump Suction valves should be used only to isolate the pump or maintenance purposes and should always be installed in positions to avoid air pockets e A pump drain valve should be installed in the suction piping between the isolation valve and the pump Discharge Piping If the discharge piping is short the pipe diameter can be the same as the discharge opening If the piping is long pipe diameter should be one or two sizes larger than the discharge opening On long horizontal runs it is desirable to maintain as even a grade as possible Avoid high spots such as loops which will collect air and throttle the system or lead to erratic pumping Valves in Discharge Piping A slow closing check valve and an isolating gate valve should be installed in the discharge line The che
12. and casing wear rings should be replaced with new parts during assembly All reusable parts should be cleaned of all foreign matter before reassembling The main casing joint gasket can be made using the upper or lower half as a template Lay the gasket material on the casing joint and mark it by pressing it against the edges of the casing Trim the gasket so that it is flush with the inside edges of the casing NOTE Precut casing gaskets 2 153 5 6 can be ordered to minimize the amount of trimming 1 Place impeller key 3 911 1 in shaft 3 007 0 2 Identify the first and second stage impellers 4 002 0 by the cast label For clockwise rotation locate the second stage impeller on the shaft per Figure 11 dimension A For counter clockwise rotation locate the first stage impeller per Figure 12 dimension A 3 Pre assemble interstage bushing 3 034 0 and diaphragm 3 231 0 assembly as follows a Install O rings 3 914 7 8 in the three grooves on the interstage bushing b Lightly press the bushing into the diaphragm locating the hole in the bushing over the pin in the diaphragm Install snap ring 3 915 0 to secure assembly 4 Slide interstage busing assembly over shaft and place over the rear hub of the impeller 5 Place the other impeller on the shaft and slide under the interstage bushing until it touches the impeller already installed Verify dimension A is mainta
13. are offset so the piping will need to be changed to accommodate the new flange locations 4 Reassemble the pump and realign the coupling as called for in the alignment instructions The rotation of the motor must be changed by switching the motor leads NOTE Unless the motor rotation is reversed the impeller will run backward SUCTION 1ST STAGE IMPELLER DISCHARGE CW ROTATION IMPELLER VANE ORIENTATION A A A CLOCKVVISE ROTATION VIEVVED FROM THE COUPLING END DISCHARGE _ 2ND STAGE IMPELLER SUCTION CCW ROTATION a A ye 5 A 33 ig PER IMPELLER VANE ORIENTATION A A DISCHARGE 5 COUNTERCLOCKWISE ROTATION VIEWED FROM THE COUPLING END FIGURE 10 CORRECT RELATIONSHIP OF THE IMPELLERS AND CASING 23 SERVICE INSTRUCTIONS DISASSEMBLY AND REASSEMBLY PROCEDURES The procedures outlined in this section cover the dismantling and reassembly of the 8200 Series Centrifugal Fire Pumps When working on the pump use accepted mechanical practices to avoid unnecessary damage to parts Check clearances and conditions of parts when pump is dismantled and replace if necessary Steps should usually be taken to restore impeller and casing ring clearance when it exceeds three times the original clearance DISMANTLING PUMP WITH PACKING WARNING Unexpected Startup Haz
14. cool First place the bearing lockwasher 3 517 4 on the shaft with the locking tabs away from bearing Install the locknut with the beveled edge facing the bearing Tighten it as much as possible with a spanner wrench turned by hand After the bearings have cooled to room temperature retighten the locknut as much as possible vvith a spanner vvrench turned by hand Then use a hammer on the vvrench to tighten the locknut an additional eighth to quarter turn Be sure a slot on the nut lines up vvith a tab on the lockvvasher Bend one of the lockvvasher tabs into matching slot on the bearing locknut o 16 Once bearings are cooled to room temperature coat vvith 2 to 3 ounces of a recommended grease 17 Slide bearing housings 3 025 3 4 onto shaft over bearings 18 Assemble bearing caps to bearing housings using cap screvvs 5 904 9 NOTE These are grade 8 screvvs 19 Assemble pipe plugs 2 910 9 and grease fittings 5 905 9 as required 20 Replace pump coupling half and key 21 Clean gasket surfaces of the casing Apply Scotch 3M 77 spray adhesive or equivalent to the lower half of the casing 2 001 8 22 Within one minute of spraying set the untrimmed gaskets 2 123 5 and 6 in place on the lower half casing align the 28 holes in the gaskets with the holes in the casing and press the gaskets firmly against the lower half casing face in the area coated by the adhesive 23 Trim the
15. in serious personal injury or death and property damage NOTE Do not spread the inner and outer guards more than necessary for guard removal or installation Over spreading the guards may alter their fit and appearance Removal a Remove the two capscrews that hold the outer motor side coupler guard to the support bracket s b Spread the outer guard and pull it off the inner guard c Remove the capscrew that holds the inner guard to the support bracket d Spread the inner guard and pull it over the coupler Installation a Check coupler alignment before proceeding Correct if necessary b Spread the inner guard and place it over the coupler c With the inner guard straddling the support bracket install a capscrew through the hole or slot in the support bracket and guard located closest to the pump Do not tighten the capscrew d Spread the outer guard and place it over the inner guard e Install the outer guard capscrews by following the step stated below which pertains to your particular pump i For pumps with a motor saddle support bracket Ensure the outer guard is straddling the support arm and install but do not tighten the two remaining capscrevvs li For pumps without a motor saddle support bracket Insert the spacer washer between the holes located closest to the motor in the outer guard and install but do not tighten the two remaining capscrews f Position the outer gu
16. lift plus friction losses in suction line should not exceed the limits for which the pump was sold The pump must be primed before starting Whenever possible the pump should be located below the fluid level to facilitate priming and assure a steady flow of liquid This condition provides a positive suction head on the pump It is also possible to prime the pump by pressurizing the suction vessel When installing the pump consider its location in relation to the system to assure that sufficient Net Positive Suction Head NPSH at pump suction is provided Available NPSH must always equal or exceed the required NPSH of the pump The pump should be installed with sufficient accessibility for inspection and maintenance A clear space with ample head room should be allowed for the use of an overhead crane or hoist sufficiently strong to lift the unit NOTE Allow sufficient space to be able to dismantle pump without disturbing the pump inlet and discharge piping Select a dry place above the floor level wherever possible Take care to prevent pump from freezing during cold weather when not in operation Should the possibility of freezing exist during a shut down period the pump should be completely drained and all passages and pockets where liquid might OPTIONAL collect should be blown out with compressed air Make sure there is a suitable power source available for the pump driver If motor driven electrical characteri
17. to follow these instructions could result in property damage and or moderate personal injury PRIMING If the pump is installed with a positive head on the suction it can be primed by opening the suction and vent valve and allowing the liquid to enter the casing If the pump is installed with a suction lift priming must be done by other methods such as foot valves ejectors or by manually filling the casing and suction line A WARNING Rotating Components Hazard Do not operate pump without all guards in place Failure to follow these instructions could result in serious personal injury or death and property damage STARTING a Close drain valves and valve in discharge line b Open fully all valves in the suction line c Prime the pump NOTE If the pump does not prime properly or loses prime during start up it should be shutdown and the condition corrected before the procedure is repeated d When the pump is operating at full speed open the discharge valve slowly This should be done promptly after start up to prevent damage to pump by operating at zero flow OPERATING CHECKS a Check the pump and piping to assure that there are no leaks b Check and record pressure gauge readings for future reference c Check and record voltage amperage per phase and kw if an indicating wattmeter is available d Check bearings for lubrication and temperature Normal temperature is 180 m
18. with packing is first started it is advisable to have the packing slightly loose without causing an air leak As the pump runs in gradually tighten the gland bolts evenly The gland should never be drawn to the point where packing is compressed too tightly and no leakage occurs This will cause the packing to burn score the shaft sleeve and prevent liquid from circulating through the stuffing box cooling the package NOTE Eccentric run out of the shaft or sleeve through the packing could result in excessive leakage that cannot be compensated for Correction of this defect requires shaft and or sleeve replacement Packing should be checked frequently and replaced as service indicates Six months might be a reasonable expected life depending on the operating conditions CLEANING WITHOUT DISMANTLING PUMP A short section of pipe so designed that it can be readily dropped out of the line can be installed adjacent to the suction flange With this arrangement any matter clogging the impeller is accessible by removing the pipe section If the pump cannot be freed of clogging after the above methods have been tried dismantle the unit as previously described to locate the trouble MAINTENANCE TIME TABLE EVERY MONTH Check bearing temperature with a thermometer not by hand If bearings are running hot over 180 F it may be the result of too much lubricant If changing the lubricant does not correct the condition disassembly a
19. 00 1000 1000 1000 1000 1000 CASING DATA All Dimensions in Inches Flange Rating ASA Suction 125 or 250 125 or 250 125 or 250 125 or 250 125 250 Standard Discharge 250 800 250 800 250 250 Casing Material Cast Iron Ductile Iron Cast Iron Ductile Iron Cast Iron Ductile Iron ASTM A48 ASTM A536 ASTM A48 ASTM A536 ASTM A48 ASTM A536 Class 35 Gr 65 45 12 Class 35 Gr 65 45 12 Class 35 Gr 65 45 12 Max Working Pressure PSIG 500 800 500 800 375 500 Max Suction Pressure PSIG 100 300 100 300 100 200 Max Hydrostatic Pressure PSIG 750 1200 750 1200 563 750 Standard Hydrostatic Test 625 1000 625 1000 468 625 Pressure PSIG Casing Wall Thickness 75 75 75 75 75 75 STUFFING BOX DATA All Dimensions in Inches Bore 3 75 3 75 3 75 3 75 3 75 3 75 Depth 4 06 4 06 4 06 4 06 4 06 4 06 Packing No Rings Size Square 5 50 5 50 5 50 5 50 5 50 5 50 Seal Cage Width 94 94 94 94 94 94 Shaft Sleeve O D 2 75 2 75 2 75 2 75 2 75 2 75 IMPELLER DESIGN DATA All Dimensions in Inches No of Vanes 6 6 6 6 6 6 Inlet Area Sq Inches 26 75 26 75 33 14 33 14 28 72 28 72 Maximum Diameter 14 0 14 0 14 0 14 0 18 0 18 0 Minimum Diameter 9 0 9 0 9 0 9 0 13 5 13 5 Maximum Sphere 50 50 63 63 63 63 WR for Max Dia Lbs Ft 8 5 8 5 8 0 8 0 20 0 20 0 Wear Ring Clearance Diametral 015 017 015 017 015 017 015 017 015 017 015 017 SHAFT AND BEARING DATA All Dimensions in Inches Diameter Thru Impeller 2 437 2 437 2 437 2 437 2 437 2 437 Diameter Thru Sleeve
20. INC PRINTED IN U S A 11 05 A C Fire Pump 8200 N Austin Avenue VED Morton Grove IL 60053 DIN ISO 9001 Phone 847 966 3700 ISO 9001 Fax 847 966 1914 Certified www acfirepump com 36 In Canada Fluid Products Canada 55 Royal Road Guelph Ontario N1H 1T1 Canada Phone 519 821 1900 Fax 519 821 2569
21. ST 32 INSTRUCTIONS FOR ORDERING PARTS33 APPENDIX FIELD TEST REPORT 34 USEFUL 4 35 NOTE The information contained in this book is intended to assist operating personnel by providing information on the characteristics of the purchased equipment It does not relieve the user of their responsibility of using accepted engineering practices in the installation operation and maintenance of this equipment Any further questions contact ITT A C Pump 847 966 3700 DESCRIPTION The 8200 Series Centrifugal Fire Pumps are framed mounted pumps which feature high efficiency rugged construction compact design foot mounted volute and regreasable bearings These features along with the horizontal split case make installation operation and service easy to perform OPERATIONAL LIMITS Unless special provisions have been made for your pump by ITT A C Fire Pump Systems the operational limits for 8200 Series Centrifugal Fire Pumps are as follows MAXIMUM WORKING PRESSURE Listed on pump nameplate SEAL OPERATING LIMITS PACKING PH Limitations 7 9 Temperature Range 0 to 200 F For use on open or closed systems which require a large amount of makeup water as well as systems which are subjected to widely varying chemical conditions and solids buildup PUMP IDENTIFICATION There are two identificatio
22. URE 3 SAFETY INSTRUCTION DECALS 4 ADDITIONAL SAFETY REQUIREMENTS ELECTRICAL SAFETY MECHANICAL SAFETY A WARNING Electrical Shock Hazard Electrical connections to be made by a qualified electrician in accordance with all applicable codes ordinances and good practices Failure to follow these instructions could result in serious personal injury or death and property damage WARNING Unexpected Startup Hazard Disconnect and lockout power before servicing Failure to follow these instructions could result in serious personal injury or death and property damage A WARNING Electrical Overload Hazard Three phase motors must have properly sized heaters to provide overload and under voltage protection Single phase motors have built in overload protectors Failure to follow these instructions could result in serious personal injury or death and property damage A WARNING Excessive System Pressure Hazard The maximum working pressure of the pump is listed on the nameplate do not exceed this pressure Failure to follow these instructions could result in serious personal injury or death and property damage THERMAL SAFETY A WARNING Extreme Temperature Hazard If pump motor or piping is operating at extremely high or low temperature guarding or insulation is required Failure to follow these instructions could result in serious personal injury or death and property damage
23. age A WARNING Electrical Shock Hazard Electrical connections to be made by a qualified electrician in accordance with all applicable codes ordinances and good practices Failure to follow these instructions could result in serious personal injury or death or property damage PRE START CHECKS Before initial start of the pump make the following inspections a Check alignment between pump and motor b Check all connections to motor and starting device with wiring diagram Check voltage phase and frequency on motor nameplate with line circuit c Check suction and discharge piping and pressure gauges for proper operation d Check impeller adjustment see specific section for proper adjustment e Turn rotating element by hand to assure that it rotates freely f Check driver lubrication g Assure that pump bearings are properly lubricated h Assure that coupling is properly lubricated if required i Assure that pump is full of liquid See Priming and all valves are properly set and operational with the discharge valve closed and the suction valve open Check rotation Be sure that the drive operates in the direction indicated by the arrow on the pump casing as serious damage can result if the pump is operated with incorrect rotation Check rotation each time the motor leads have been disconnected A CAUTION Seal Damage Hazard Do not run pump dry seal damage may occur Failure
24. ard Disconnect and lockout power before servicing Failure to follow these instructions could result in serious personal injury or death or property damage A WARNING Electrical Shock Hazard Electrical connections to be made by a qualified electrician in accordance with all applicable codes ordinances and good practices Failure to follow these instructions could result in serious personal injury or death or property damage WARNING Prior to working on pump the power source should be disconnected with lockout provisions so power cannot be re energized to the motor Close isolating suction and discharge valves Failure to follow these instructions could result in property damage severe personal injury or death A CAUTION Extreme Temperature Hazard Allow pump temperatures to reach acceptable levels before proceeding Open drain valve do not proceed until liquid stops coming out of drain valve If liquid does not stop flowing from drain valve isolation valves are not sealing and should be repaired before proceeding After liquid stops flowing from drain valve leave valve open and continue Remove the drain plug located on the bottom of the pump housing Do not reinstall plug or close drain valve until reassembly is completed Failure to follow these instructions could result in property damage and or moderate personal injury 1 Drain pump by opening vent plug 2 910 9 and removing drain plugs
25. ard so it is centered around the shaft and so there is less than a 1 4 of the motor shaft exposed On guards that utilize a slotted support bracket the inner guard will have to be positioned so there is only a 1 4 of the pump shaft exposed g Holding the guard in this position tighten the three capscrews ANSI OSHA Coupling Guard Exploded View For Typical 8200 Series Fire Pump Installation INNER GUARD OUTER GUARD ATTACH SUPPORT BRACKET TO BEARING HOUSING SUPPORT BRACKET SUPPORT ARM ALIGN THE ARM WITH HOLES IN THE OUTER GUARD AND HOLES IN THE SADDLE BRACKET BRACKET SUPPORT BRACKET ATTACHED INSIDE HERE SUPPORT IN LINE WITH BOLT MOTOR SADDLE BRACKET ATTACH TO MOTOR SADDLE THIS OPTION USED IN PLACE OF SPACER WHERE OVERALL LENGTH OF GUARD EXCEEDS 12 INCHES OR GUARD WITH IS OVER 10 INCHES ACROSS THE FLATS Method 1 Straight Edge Alignment for Standard Sleeve Type Coupler with Black Rubber Insert STRAIGHT EDGE See Figure 7A Proceed with this method only if satisfied that face and outside diameters of the coupling ANGULAR ALIGNMENT PARALLEL ALIGNMENT halves are square and concentric with the coupling borers If this condition does not INCORRECT ALIGNMENT exist or elastomeric couplings do not make STRAIGHT EDGE this method convenient use Method 2 1 Check angular misalignment using a micrometer or caliper Measure from the outside of one flan
26. are not recommended When operating on a suction lift the suction pipe should slope upward to the pump nozzle A horizontal suction line must have a gradual rise to the pump Any high point in the pipe can become filled with air and prevent proper operation of the pump When reducing the piping to the suction opening diameter use an eccentric reducer with the eccentric side down to avoid air pockets NOTE When operating on suction lift never use a concentric reducer in a horizontal suction line as it tends to form an air pocket in the top of the re ducer and the pipe To facilitate cleaning pump liquid passage without dismantling pump a short section of pipe Dutchman or spool piece so designed that it can be readily dropped out of the line can be installed adjacent to the suction flange With this arrangement any matter clogging the impeller is accessible by removing the nozzle or pipe section Valves in Suction Piping When installing valves in the suction piping observe the following precautions a If the pump is operating under static suction lift conditions a foot valve may be installed in the suction line to avoid the necessity of priming each time the pump is started This valve should be of the flapper type rather than the multiple 13 spring type sized to avoid excessive friction in the suction line Under all other conditions a check valve if used should be installed in the discharge line See
27. as been mounted on the baseplate at the factory itis safe to lift the entire assembly If the driver has not been mounted at the factory and the overall baseplate length exceeds 100 inches do not lift the entire assembly consisting of pump base and driver Instead lift the pump and baseplate to its final location without the driver Then mount the driver The best pump location for sound and vibration ab sorption is on a concrete floor with subsoil underneath If the pump location is overhead special precautions should be undertaken to reduce possible sound transmission Consult a sound specialist NYLON SLING CHAIN OR WIRE 4 CHOKER 9 HITCH AROUND 5 ok BEARING FIGURE 4 If the pump is not on a closed system it should be placed as near as possible to the source of the liquid supply and located to permit installation with the fewest number of bends or elbows in the suction pipe The installation must be evaluated to determine that the Net Positive Suction Head Available NPSHA meets or exceeds the Net Positive Suction Head Required NPSHR as stated by the pump performance curve See page 11 for more details on proper suction piping installation RECEIVING PUMP Check pump for shortages and damage immediately upon arrival An absolute must Prompt reporting to the carrier s agent with notations made on the freight bill will expedite satisfactory adjustment by the carrier
28. aximum e Make all pump output adjustments with the discharge line A CAUTION Cavitation Damage Hazard Do not throttle the suction line to adjust the pump output Failure to follow these instructions could result in property damage and or moderate personal injury FREEZING PROTECTION Pumps that are shut down during freezing conditions should be protected by one of the following methods A CAUTION Bearing Seal Damage Hazard Do not let heated pump temperature rise above 150 F Failure to follow these instructions could result in property damage and or moderate personal injury FIELD TESTING A typical performance curve for a specific pump can be obtained from ITT A C Fire Pump Systems This can be used in conjunction with a field test if one is required All ITT A C Fire Pump Systems tests and curves are based on the Hydraulic Institute Standards Any field test must be conducted according to these Standards Unless otherwise specifically agreed all capacity head and efficiencies are based on shop tests when handling clear cold fresh water at a temperature not over 85 F Appendix C Pages 34 35 contains a field test report sheet and some useful equations which can be used when conducting a field a Drain the pump remove all liquids from test the casing b Keep fluid moving in the pump and insulate or heat the pump to prevent freezing MAINTENANCE GENERAL MAINTENANCE Operating
29. ck valve triple duty valve placed between pump and gate valve protects the pump from excessive back pressure and prevents liquid from running back through the pump in case of power failure The gate valve is used in priming and starting and when shutting the pump down Pressure Gauges Properly sized pressure gauges should be installed in both the suction and discharge nozzles in the gauge taps provided The gauges will enable the operator to easily observe the operation of the pump and also determine if the pump is operating in conformance with the performance curve If cavitation vapor binding or other unstable operation should occur widely fluctuating discharge pressure will be noted Pump Insulation On chilled water applications most pumps are insulated As part of this practice the pump bearing housings should not be insulated since this would tend to trap heat inside the housing This could lead to increased bearing temperatures and premature bearing failures STUFFING BOX LUBRICATION Contaminants in the pumped liquid must not enter the stuffing box These contaminants may cause severe abrasion or corrosion of the shaft or shaft sleeve and rapid packing deterioration they can even plug the stuffing box flushing and lubrication system The stuffing box must be supplied at all times with a source of clean clear liquid to flush and lubricate the packing or seal It is important to establish the optimum flus
30. conditions vary so widely that to recommend one schedule of preventative maintenance for all centrifugal pumps is not possible Yet some sort of regular inspection must be planned and followed We suggest a permanent record be kept of the periodic inspections and maintenance performed on your pump This recognition of maintenance procedure will keep your pump in good working condition and prevent costly breakdown One of the best rules to follow in the proper maintenance of your centrifugal pump is to keep a record of actual operating hours Then after a predetermined period of operation has elapsed the pump should be given a thorough inspection The length of this operating period will vary with different applications and can only be determined from experience New equipment however should be examined after a relatively short period of operation The next inspection period can be lengthened somewhat This 17 system can be followed until a maximum period of operation is reached which should be considered the operating schedule between inspections MAINTENANCE OF PUMP DUE TO FLOOD DAMAGE WARNING Unexpected Startup Hazard Disconnect and lockout power before servicing Failure to follow these instructions could result in serious personal injury or death or property damage A WARNING Electrical Shock Hazard Electrical connections to be made by a qualified electrician in accordance will all applicable codes o
31. de deflectors toward bearing covers Allow rotating clearance of approximately 1 16 29 Rotate shaft by hand to assure that it turns smoothly and is free from rubbing and binding 30 Cut full rings packing 1 924 9 so that ends butt leaving no gap between packing and casing Install three rings of packing and tap fully to bottom of both stuffing boxes Stagger joints of each ring of packing at least 90 Install seal cage 1 013 9 and be sure that it will line up with seal water inlet when packing is compressed Install remaining two rings of packing with joints staggered Assemble glands 1 014 9 square with stuffing box and pull up tight Then loosen gland bolts 1 904 9 to permit packing to expand and retighten finger tight Final adjustment of gland bolts must be done when pump is running Allow 30 minutes between adjustments 29 31 Assemble seal water flush and bleed lines 1 952 0 a Clockvvise Figure 11 b Counter clockvvise Figure 12 32 Check coupling alignment and realign if necessary APPENDIX ENGINEERING DATA Pump Size o 8x6x14F S H8x6x14F S 8x6x14F L H8x6x14F L 8x6x18 H8x6x18 8200 8200 8200 8200 8200 8200 Number of Stages 2 2 2 2 2 2 Approval Flovv Rate GPM 500 750 500 750 500 750 500 750 500 750 500 750 710
32. ds adjustment See paragraph i below h Assemble coupling Tighten all bolts and set screw s It may be necessary to repeat steps c through f for a final check i For single element couplings a satisfactory parallel misalignment is 004 T 1 R while a satisfactory angular misalignment is 004 T 1 R per inch of radius R See Figure 7B DIAL INDICATOR PARALLEL ALIGNMENT INDEX LINE __ RESILIENT SEPARATOR ANGULAR ALIGNMENT DIAL INDICATOR FIGURE 7B CHECKING ALIGNMENT METHOD 2 11 Final Alignment Final alignment cannot be accomplished until the pump has been operated initially for a sufficient length of time to attain operating temperature When normal operating temperature has been attained secure the pump to re check alignment and compensate for temperature accordingly See Alignment Section A WARNING Rotating Components Hazard Do not operate pump without all guards in place Failure to follow these instructions could result in serious personal injury or death and property damage OPTIONAL Alignment Procedure If desired the pump and motor feet can be doweled to the base after final alignment is complete This should not be done until the unit has been run for a sufficient length of time and alignment is within the tolerance See Doweling Section A CAUTION Extreme Temperature and or Flying Debris Hazard Eye protection and gloves required Failure to fo
33. e CAUTION These are precision high quality bearings Exercise care at all times to keep them clean and free from foreign matter Failure to follow these instructions could result in injury or property damage 12 Assemble lip seal 3 177 9 in each bearing cap 5 018 0 Seal lip or pressure side of seal must point away from the end of the shaft the lip seal is assembled on 13 Slide deflectors 3 136 9 and bearing caps on the shaft Install snap ring 5 915 3 on the inboard side of shaft Install the split ring 5 050 4 and retaining collar 5 421 4 on the outboard side of shaft 14 Using gloves install the double row ball bearing on the inboard side and locate against snap ring 15 Using gloves install the two angular contact bearings on the outboard end of shaft These bearings must be installed back to back wide shoulders of outer race contacting as shown on assembly section a Remove the preservative from the outside diameter and faces of the bearings Heat both bearings to 200 F at the same time Place the first bearing on the shaft Very quickly place the second bearing on the shaft When installing the second bearing push against the inner race to remove all clearance between the inner races of the two bearings and between the inner race of the first bearing and the retaining collar Use locknut 3 516 4 to hold the bearings together against the retaining ring while they
34. efects The voltage and frequency of the electrical current may be lower than that for this motor was built or there may be defects in motor The motor may not be ventilated properly due to a poor location 45 Mechanical defects in turbine engine or other type of drive exclusive of motor If trouble cannot be located consult factory 22 CHANGING ROTATION A WARNING Rotating Components Hazard Do not operate pump without all guards in place Failure to follow these instructions could result in serious personal injury or death and property damage 3 Set the rotating element back in the casing and reassemble the pump NOTE The impeller and casing are in the same relationship to each other as they were originally The shaft and motor are also in the 8200 Series centrifugal pumps can be operated clockwise or counterclockwise when viewed from the coupling end of the pump If you wish to reverse the suction and discharge nozzles i e change rotation this can be accomplished with the same pump as follows 1 Remove the impeller from the shaft and relocate the two impellers per Figure 10 for the desired rotation Follow the disassembly procedures given in this manual With the rotating element out of the casing remove the casing from the base and turn 180 Factory bases are drilled for both rotations same relationship to each other as they were originally The suction and discharge
35. gaskets flush with the lower casing bores if this has not been done yet A CAUTION Machined casing bores must remain sharp at the casing parting line Gaskets must be flush with bore in order to contact O rings Leakage can result around stuff box O ring if this step is not properly followed Failure to follow these instructions could result in injury or property damage 350 FT LBS MIN TORQUE REQUIRED FIGURE 13 TORQUE PATTERN FOR CASING MAIN JOINT 24 Assemble rotating element in lower half casing Correctly locate casing ring pins stuff box bushing pins and interstage diaphragm pins in casing main joint slots Sliding the inboard bearing housing towards the coupling slightly will ease assembly 25 Bolt outboard bearing housing in place Be sure that both housings are seated properly in lower half casing 26 Bolt inboard bearing housing in place Rotating element should now turn freely A CAUTION Double check rotation of pump before installing the upper half casing Failure to follow these instructions could result in injury or property damage 27 Lower the upper half casing 2 001 7 into place locate using the dowels 2 916 0 and install casing main joint bolts 2 904 1 The casing joint bolts should be tightened to the torque specified in Figure 16 NOTE Torque values are essential in obtaining proper gasket compression so no leakage can occur at main joint 28 Sli
36. ge to the outside of the opposite flange at four points 90 apart DO NOT ROTATE COUPLER CORRECT ALIGNMENT Misalignment up to 1 64 per inch of coupler radius is permissible FIGURE 7A CHECKING ALIGNMENT METHOD 1 2 At four points 90 apart DO NOT ROTATE COUPLER measure the parallel coupler misalignment by laying a straight edge across one coupler half and measuring the gap between the straight edge and opposite coupler half Up to a 1 64 gap is permissible 10 Method 2 For Orange Hytrel Insert 3500 RPM Operation or All Other Coupler Types See Figure 7B a Make sure each hub is secured to its respective shaft and that all connecting and or spacing elements are removed at this time b The gap between the coupling hubs is set by the manufacturer before the units are shipped However this dimension should be checked Refer to the coupling manufacturer s specifications supplied with the unit c Scribe index lines on coupling halves as shown in Figure 7B d Mount dial indicator on one hub as shown for parallel alignment Set dial to zero e Turn both coupling halves so that index lines remain matched Observe dial reading to see whether driver needs adjustment See paragraph i below f Mount dial indicator on one hub as shown for angular alignment Set dial to zero g Turn both coupling halves so that index lines remain matched Observe dial reading to see whether driver nee
37. ging Special care in furnishing the above information with the original order for parts will facilitate shipment 33 FIELD TEST REPORT APPENDIX Aq u ym sBulpeay XlA p 1 5 MOL 40 99 1 SS wa Ae Ss Se Slee SS SS n 3 0 Splnuuo iny sn Z JO Z 199 5 995 ayejdaweu Jo OW Uaye 8 0 JONON anund yooq 2 5 9 1 8 8 WO UIJL YHSdN a Saran pz SS hake me Kugy JDM O S aeq 1612 x 150 1 x 6H ul Y azis did 8 03 8888 bipu siq ul ul 3 dwng 23 53 sduiy SUA waa 4 6 soon dwnd sdwy aunssaid zoden pinbry aunjyesoduuay seyd pedwnd 13 Td dwya ainssaud 3 8 syon 401 0 HO uonenaja 8686 uon ns oo 8 9886 abseyosiq ON AND 56 138 8 1 8215 adid uon uuo 8886 uon ns 777 ul eig dw ON euas dung pe H Wd d lduna gt gt gt 8 5 ding Hod u 1591 14 34 APPENDIX FIELD TEST REPORT USEFUL FORMULAS Pressure psig x 2 31 ft 9 S G specific gravity S G of water 1 0 at 70 F
38. hafts or coupling hubs for alignment Temporarily remove coupling guard for checking alignment d If alignment needs improvement add shims or wedges at appropriate positions under base so that retightening of anchor nuts will shift shafts into closer alignment Repeat this procedure until a reasonable alignment is reached NOTE Reasonable alignment is defined as that which is mutually agreed upon by pump contractor and the accepting facility final grout after setting and leveling unit See Figure 6 a Build strong form around the foundation to contain grout b Soak top of concrete foundation thoroughly then remove surface water c Base plate should be completely filled with grout d After the grout has thoroughly hardened check the foundation bolts and tighten if necessary e Check the alignment after the foundation bolts are tightened f Approximately 14 days after the grout has been poured or when the grout has thoroughly dried apply an oil base paint to the exposed edges of the grout to prevent air and moisture from coming in contact with the grout SEE ANSI OSHA COUPLER GUARD REMOVAL INSTALLATION SEE BELOW ALIGNMENT PROCEDURE NOTE A flexible coupling will only compensate for small amounts of misalignment Permissible misalignment will vary with the make of coupling Consult coupling manufacturer s data when in doubt Allowances are to be made for thermal expansion during cold alig
39. he bearings should be watched the first hour or so after the pump has been started to see that they are operating properly The importance of proper lubrication cannot be over emphasized It is difficult to say how often a bearing should be greased since that depends on the conditions of operation It is well to add one ounce of grease at regular intervals but it is equally important to avoid adding too much grease For average operating conditions it is recommended that 1 oz of grease be added at intervals of three to six months and only clean grease be used It is always best if unit can be stopped while grease is added to avoid overloading NOTE Excess grease is the most common cause of over heating A lithium based NLGI 2 grade grease should be used for lubricating bearings where the ambient temperature is above 20 F Grease lubricated bearings are packed at the factory with Shell Alvania No 2 Other recommended 18 greases are Texaco Multifak No 2 and Mobilux No 2 grease Greases made from animal or vegetable oils are not recommended due to the danger of deterioration and forming of acid Do not use graphite Use of an ISO VG 100 mineral base oil with rust and oxidation inhabitors is recommended The maximum desirable operating temperature for ball bearings is 180 F Should the temperature of the bearing frame rise above 180 F the pump should be shut down to determine the cause PACKING SEAL When a pump
40. hing pressure that will keep contaminants from the stuffing box cavity If this pressure is too low fluid being pumped may enter the stuffing box If the pressure is too high excessive packing wear may result and extreme heat may develop in the shaft causing higher bearing temperatures The most desirable condition therefore is to use a seal water pressure 15 20 psig above the maximum stuffing box pressure PACKING Standard pumps are normally packed before shipment If the pump is installed within 60 days after shipment the packing will be in good condition with a sufficient supply of lubrication If the pump is stored for a longer period it may be necessary to repack the stuffing box In all cases however inspect the packing before the pump is started NOTE Packing adjustment is covered in the MAINTENANCE section of this manual On some applications it is possible to use internal liquid lubrication pumped liquid to 14 lubricate packing Only when all of the following conditions prevail can this be done 1 Liquid is clean free from sediment and chemical precipitation and is compatible with seal materials 2 Temperature is above 32 F and below 160 F 3 Suction pressure is below 75 psig 4 Lubrication pumped liquid has lubricating qualities 5 Liquid is non toxic and non volatile When the liquid being pumped contains solids or is otherwise not compatible with packing materials an outside su
41. ined See Figure 11 or 12 6 Apply RTV Dow Corning Silicone Sealant or equivalent uniformly about shaft sleeve 3 009 9 inside diameter covering an area of about 1 2 inch at each impeller end of sleeve Also apply sealant to the face of the impellers 7 Slide shaft sleeves onto shaft rotating the sleeves to evenly distribute the sealant applied in above step Rotate until pin in 27 sleeve engages into keyway of impellers and push sleeves against impeller face until the sleeve is flush against the face Wipe off any excess sealant 8 Place the sleeve O ring 3 914 9 onto shaft and place in sleeve counterbore Verify that dimension A is maintained then using a pin spanner wrench and hammer securely tighten the shaft sleeve nuts 3 015 9 Drill a shallow recess in the shaft through the set screw hole in each of the shaft sleeve nuts Stake each shaft sleeve nut in position with cup point set screws 3 902 9 9 Slide casing rings 3 003 9 onto the impellers 10 Place two O rings 6 914 9 on each stuffbox bushing 6 008 0 then slide over shaft sleeve with the beveled end facing the impeller 11 Start heating bearings 3 026 3 4 so they will be ready to use in a later step Use dry heat from induction heat lamps or electric furnace or a 10 15 soluble oil and water solution CAUTION DO NOT EXCEED 275 F Failure to follow these instructions could result in injury or property damag
42. ipes at the pump connections to decrease the loss of head from friction Install piping as straight as possible avoiding unnecessary bends Where necessary use 45 degree or long sweep 90 degree fitting to decrease friction losses Make sure that all piping joints are air tight Where flanged joints are used assure that inside diameters match properly Remove burrs and sharp edges when making up joints Do not spring piping when making any connections Provide for pipe expansion when hot fluids are to be pumped Suction Piping When installing the suction piping observe the following precautions Figure 8 shows some correct and incorrect suction piping arrangements The sizing and installation of the suction piping is extremely important It must be selected and installed so that pressure losses are minimized and sufficient liquid will flow into the pump when started and operated Many NPSH Net Positive Suction Head problems can be attributed directly to improper suction piping systems Friction losses caused by undersized suction piping can increase the fluid s velocity into the pump As recommended by the Hydraulic Institute Standard ANSI HI 1 1 1 5 1994 suction pipe velocity should not exceed the velocity in the pump suction nozzle In some situations pipe velocity may need to be further reduced to satisfy pump NPSH requirements and to control suction line losses Pipe friction can be reduced by using pi
43. llow these instructions could result in property damage and or moderate personal injury NOTE Pump may have been doweled to base at factory DOWELING Dowel the pump and driving unit as follows a Drill holes through diagonally opposite feet and into the base Holes must be of a diameter 1 64 inch less than the diameter of the dowel pins Clean out the chips b Ream the holes in feet and base to the proper diameter for the pins light push fit Clean out the chips c Insert pins to be approximately flush with feet SUCTION AND DISCHARGE PIPING General When installing the pump piping be sure to observe the following precautions Piping should always be run to the pump Do not move pump to pipe This could make final alignment impossible Both the suction and discharge piping should be supported independently near the pump and properly aligned so that no strain is transmitted to the pump when the flange bolts are tightened Use pipe hangers or other supports at necessary intervals to provide support When expansion joints are used in the piping system they must be installed beyond the piping supports closest to the pump Tie bolts should be used with expansion joints to prevent pipe strain Do not install expansion joints next to the pump or in any way that would cause a strain on the pump resulting from system pressure changes It is usually advisable to increase the size of both suction and discharge p
44. n plates on each pump The pump rating plate gives identification and rating information Figure 1 shows an example of a typical Rating Plate Permanent records for this pump are referenced by the Serial Number and it must therefore be used with all correspondence to order all spare parts and replacement parts The fourth digit indicates the specific pump on orders for more than one pump For example if an order called for six pumps all pumps would have the same first three sets of digits and the last digit will change to identify each of the six e g 03 123456 01 01 03 123456 01 02 etc The frame plate shown below in Figure 2 gives information concerning the bearings and their lubrication The inboard and outboard bearing numbers refer to the bearing manufacturer s numbers O A C Fire Pump Systems ITT Industries W Centrifugal Fire Pump r Size Splitcase Type 8X6X14 F S 8200 Serial Number 961 234567 01 02 GPM Head PS 750 670 290 RPM Imp Dia in No Stages 3550 9 40 2 Max Net Pressure Developed 331 PSI Net Pressure at 150 Capacity 230 PSI Max B H P 223 Max Positive Suction Pressure 169 PSI Inb Brg 5311 Out Brg 7311BG 2 Q MORTON GROVE IL USA 52 128 074 001 FIGURE 1 RATING PLATE Frame Inb Brg F 27 A1 5311 Lubrication Out Brg GREASE 7311BG Part No 0685 FIGURE 2 FRAME PLATE ADDITIONAL SAFETY REQUIREMENTS 1 Electrical connection
45. nd 10 Pump Takes Too Much Power 32 Head lower than rating thereby pumping too much liquid Machine impeller s O D to size advised by factory or reduce speed 33 Cavitation See item 17 34 Mechanical defects See items 18 19 21 and 23 35 Suction inlet not See item 20 immersed 36 Liquid heavier in either viscosity or specific gravity than allowed for Use larger driver Consult factory for recommended size Test liquid for viscosity and specific gravity 37 Wrong direction of rotation 38 Stuffing box glands too tight See item 6 Release gland pressure Tighten reasonably If sealing liquid does not flow while pump operates replace packing 39 Casing distorted by excessive strains from suction or discharge piping Check alignment Examine pump for rubbing between impeller and casing Replace damaged parts Repipe pump 40 Shaft bent due to damage through shipment operation or overhaul Check deflection of rotor by turning on bearing journals Total indicator run out should not exceed 002 on shaft and 004 on impeller wearing surface 41 Mechanical failure of critical pump parts Check wear rings and impeller for damage Any irregularity in these parts will cause a drag on shaft 42 Misalignment Realign pump and driver 43 Speed may be too high Check voltage on motor Check speed versus pump nameplate rating 44 Electrical d
46. nd inspect the bearings Lip seals bearing on the shaft may also cause the housing to run hot Lubricate lip seals to correct EVERY 3 MONTHS Check grease lubricated bearings for saponification This condition is usually caused by the infiltration of water or other fluid past the bearing shaft seals and can be noticed immediately upon inspection since it gives the grease a whitish color Wash out the bearings with a clean industrial solvent and replace the grease with the proper type as recommended EVERY 6 MONTHS Check the packing and replace if necessary Use the grade recommended Be sure the seal cages are centered in the stuffing box at the entrance of the stuffing box piping connection Take vibration readings on the bearing housings Compare the readings with the last set of readings to check for possible pump component failure e g bearings Check shaft or shaft sleeve for scoring Scoring accelerates packing wear Check alignment of pump and motor Shim up units if necessary If misalignment reoccurs frequently inspect the entire piping system Unbolt piping at suction and discharge flanges to see if it springs away thereby indicating strain on the casing Inspect all piping supports for soundness and effective support of load Correct as necessary EVERY YEAR Remove the upper half of the casing Inspect the pump thoroughly for wear and order replacement parts if necessary Check wear ring clearances
47. nment so that the coupling will be aligned at operating temperature In all cases a coupling must be in alignment for continuous operation Even though the coupling may be lubricated misalignment causes excessive wear vibration and bearing loads that result in premature bearing failure and ultimate seizing of the pump Misalignment can be angular parallel or a combination of these and in the horizontal and vertical planes Final alignment should be made by moving and shimming the motor on the base plate until the coupling hubs are within the recommended tolerances measured in total run out All measurements should be taken with the pump and motor foot bolts tightened The shaft of sleeve bearing motors should be in the center of its mechanical float NOTE Proper alignment is essential for correct pump operation This should be performed after base plate has been properly set and grout has dried thoroughly according to instructions Final alignment should be made by shimming driver only Alignment should be made at operating temperatures WARNING Unexpected Start up Hazard Disconnect and lock out power before servicing Failure to follow these instructions could result in serious personal injury or death and property damage ANSI OSHA COUPLER GUARD REMOVAL INSTALLATION A WARNING Unexpected Start up Hazard Disconnect and lock out power before servicing Failure to follow these instructions could result
48. ough aligned at the factory If motor is to be field mounted consult factory for recommendations ITT AC Fire Pump Systems cannot assume responsibility for final alignment operator Final alignment procedures are covered under Alignment Procedures e Check to make sure the piping can be aligned to the pump flanges without placing pipe strain on either flange f Grout in base plate completely See Grouting Procedure and allow grout to dry thoroughly before attaching piping to pump 24 hours is sufficient time with approved grouting procedure GROUTING PROCEDURE NO Eep SeN Grout compensates for uneven foundation ALLOW 1 FOR di 1 i 1 PLACE ALLOW GROUT istributes weight of unit and prevents SHIMS PLACE ON TO FLOW AROUND BOTH SIDES OF shifting Use an approved non shrinking GROUT ONLY TO TOP OF BASE RAIL HOLD DOVVN LUGS PUMP BASE RAIL APPROX 1 gt FOUNDATION LEVELING OF PUMP BASE ON CONCRETE FOUNDATION FIGURE 6 SETTING BASE PLATE AND GROUTING a Use blocks and shims under base for support at anchor bolts and midway between bolts to position base approximately 1 above the concrete foundation with studs extending through holes in the base plate b By adding or removing shims under the base level and plumb the pump shaft and flanges The base plate does not have to be level c Draw anchor nuts tight against base and observe pump and motor s
49. pes that are one to two sizes larger than the pump suction nozzle in order to maintain pipe velocities less than 5 feet second 12 CHECK VALVE SUCTION PIPE INSTALLED WITH A Pec GATE VALVE GRADUAL RISE TO PUMP GRADUAL RISE TO PUMP NO AIR GRADUAL RISE POCKETS TO PUMP ECCENTRIC REDUCER CORRECT D STANCE PLUS ECCENTRIC REDUCER STRAIGNTENS FLOW m lE INCORRECT 1 d U PATH OF WATER FIGURE 8 SUCTION INSTALLATIONS PIPING SUPPORTS NOT SHOWN Suction piping should be short in length as direct as possible and never smaller in diameter than the pump suction opening A minimum of ten 10 pipe diameters between any elbow or tee and the pump should be allowed If a long suction pipe is required it should be one or two sizes larger than the suction opening depending on its length CAUTION An elbow should not be used directly before the suction of a double suction pump if its plane is parallel to the pump shaft This can cause an excessive axial load or NPSH problems in the pump due to an uneven flow distribution If there is no other choice the elbow should have straightening vanes to help evenly distribute the flow Failure to follow these instructions could result in injury or property damage Eccentric reducers should be limited to one pipe size reduction each to avoid excessive turbulence and noise They should be of the conical type Contour reducers
50. pply of seal liquid should be furnished In general external injection liquid from an outside source is required when any of the above conditions cannot be met The standard stuffing box consists of rings of packing see assembly section for number of rings a seal cage a bushing and a gland A shaft sleeve which extends through the box and under the gland is provided to protect the shaft A tapped hole is supplied in the stuffing box directly over the seal cage to introduce a clean clear sealing medium The stuffing box must at all times be supplied with sealing liquid at a high enough pressure to keep the box free from foreign matter which would quickly destroy the packing and score the shaft sleeve Only a sufficient volume of sealing liquid to create a definite direction of flow from the stuffing box inward to the pump casing is required but the pressure is important Apply seal water at a rate of approximately 25 GPM at a pressure approximately 15 to 20 psig above the suction pressure Approximately one 1 drop per second One recommended method to minimize error in regulating flushing water is a Controlled Pressure System Figure 9 It is important to set the pressure reducing valve adjusted to a value slightly exceeding the maximum stuffing box operating pressure assuming it is reasonably constant A flow indicating device will detect a failing of the bottom packing rings allowing leakage in the pump
51. rdinances and good practices Failure to follow these instructions could result in serious personal injury or death or property damage The servicing of centrifugal pumps after a flooded condition is a comparatively simple matter under normal conditions Bearings are a primary concern on pumping units First dismantle the bearings clean and inspect them for any rusted or badly worn surfaces If bearings are free from rust and wear reassemble and relubricate them with one of the recommended pump lubricants Depending on the length of time the pump has remained in the flooded area it is unlikely that bearing replacement is necessary however in the event that rust or worn surfaces appear it may be necessary to replace the bearings Next inspect the stuffing box and clean out any foreign matter that might clog the box Mechanical seals should be cleaned and thoroughly flushed Couplings should be dismantled and thoroughly cleaned Any pump that is properly sealed at all joints and connected to both the suction and discharge should exclude outside liquid Therefore it should not be necessary to go beyond the bearings stuffing box and coupling when servicing the pump BEARING LUBRICATION GREASE Grease lubricated ball bearings are packed with grease at the factory and ordinarily will require no attention before starting provided the pump has been stored in a clean dry place prior to its first operation T
52. rime 3 Suction lift too high a negative suction gauge reading Check for leaks in suction pipe joints and fittings vent casing to remove accumulated air Check mechanical seal or packing If there is no obstruction at inlet and suction valves are open check for pipe friction losses However static lift may be too great Measure with mercury column or vacuum gauge while pump operates If static lift is too high liquid to be pumped must be raised or pump lowered 4 System static head too high Check with factory to see if a larger impeller can be used otherwise cut pipe losses or increase speed or both as needed But be careful not to overload driver by more than the service factor 5 Speed too low Check whether motor is directly across the line and receiving full voltage Frequency may be too low Motor may have an open phase 6 Wrong direction of rotation 7 No rotation Check motor rotation with directional arrow on pump casing If rotation is correct with arrow check the relationship of the impeller with casing This will require removing casing upper half See Figure 10 on page 23 Check power coupling line shaft and shaft keys 8 Impeller loose on shaft Check key locknut and set screws 9 Impeller completely plugged Dismantle pump and clean impeller 10 System head or required discharge head too high Check pipe friction losses Large piping may correc
53. s to be made by SAFETY INSTRUCTIONS T qualified Electrician in accordance with all SAFETY INSTRUCTIONS national state and local codes This safety alert symbol will be used in this manual and on the pump safety instruction decals 2 Motor must have properly sized starter to draw attention to safety related instructions with properly sized heaters to provide When used the safety alert symbol means overload and undervoltage protection ATTENTION BECOME ALERT YOUR SAFETY 3 If pump motor or piping are operating at IS INVOLVED FAILURE TO FOLLOW THE extremely high or low temperatures eee MAY RESULT IN A SAFETY guarding or insulation is required 4 The maximum working pressure of the Your 8200 Series Centrifugal Fire Pump should pump is listed on the pump nameplate do have the following safety instruction decals not exceed this pressure displayed If the decals are missing or illegible contact your local ITT A C Fire Pump Systems representative for a replacement A WARNING ROTATING COMPONENTS DISCONNECT AND LOCKOUT POWER BEFORE SERVICING DO NOT OPERATE WITHOUT ALL GUARDS IN PLACE CONSULT INSTALLATION ANDSERMCE INSTRUCTION SHEET BEFORE OPERATING OR SERVICING RESULT ININ URY OR DEATH COUPLER ALIGNIVENT IS REQUIRED LEVEL AND GROUT BEFORE USE 15 FILLED AFTER SERMCING PUM ANDAS REQUIRED RESULT ININ URY OR PROPERTY DAMAGE RESULT ININ URY OR PROPERTY DAMAGE FIG
54. stics should be identical to those shown on motor data plate FOUNDATION A substantial foundation and footing should be built to suit local conditions The foundation must be substantial enough to absorb vibration Hydraulic Institute Standards recommends the foundation weigh at least five 5 times the weight of the pump unit It must form a permanent and rigid support for the baseplate This is important in maintaining the alignment of the flexibly coupled unit The foundation should be poured without interruption to within 1 2 to 1 1 2 inches of the finished height The top surface of the foundation should be well scored and grooved before the concrete sets this provides a bonding surface for the grout Foundation bolts should be set in concrete as shown in Figure 5 An optional 4 inch long tube around the bolts at the top of the concrete will allow some flexibility in bolt alignment to match the holes in the base plate Allow enough bolt length for grout shims lower base plate flange nuts and washers The foundation should be allowed to cure for several days before the base plate is shimmed and grouted FOUNDATION BOLT BUILT UP CONCRETE FOUNDATION FIGURE 5 FOUNDATION BASE PLATE SETTING BEFORE PIPING NOTE This procedure assumes that a concrete foundation has been prepared with anchor or hold down bolts extending up ready to receive unit It must be understood that pump and motor have been mounted and r
55. t condition Check that valves are wide open Not Enough Liquid Delivered 11 Air leaks in suction piping 12 Air leaks in stuffing box If liquid pumped is water or other non explosive and explosive gas or dust is not present test flanges for leakage with flame or match For such liquids as gasoline suction line can be tested by shutting off or plugging inlet and putting line under pressure A gauge will indicate a leak with a drop of pressure Replace packing and sleeves if appropriate or increase seal lubricant pressure to above atmosphere 13 Speed too low See item 5 14 Discharge head too high See item 10 15 Suction lift too large See item 3 20 TROUBLE SHOOTING CONT CAUSES CURES 16 Impeller partially plugged See item 9 17 Cavitation insufficient NPSHA Net Positive Suction Head Available a Increase positive suction head on pump by lowering pump or increasing suction pipe and fittings size b Sub cool suction piping at inlet to lower entering liquid temperature c Pressurize suction vessel 18 Defective impeller Inspect impeller bearings and shaft Replace if damaged or vane sections badly eroded 19 Foot valve too small or partially obstructed Area through ports of valve should be at least as large as area of suction pipe preferably 1 5 times If strainer is used net clear area should be 3 to 4 times area of suction pipe
56. using 1 3 026 3 Bearing Inboard 1 3 026 4 Bearing Outboard 2 5 050 4 Split Ring 1 5 421 4 Retaining Collar 1 3 169 9 Deflector 2 3 177 9 Lip Seal 2 3 516 4 Locknut 1 3 514 4 Lockwasher 1 3 902 9 Set Screw 2 5 904 9 Bearing Cover Bolt 8 3 911 1 Key Impeller 1 3 911 2 Key Coupling 1 3 914 9 O Ring Shaft Sleeve 2 6 914 9 O Ring Stuffbox Bushing 4 6 008 0 Stuffbox Bushing 2 3 034 0 Interstage Bushing 1 3 231 0 Interstage Diaphragm 1 3 914 7 O Ring Interstage Bushing 3 5 915 0 Snap Ring Bearing 1 3 915 0 Snap Ring Interstage Bushing 1 4 002 0 Impeller 2 APPENDIX B INSTRUCTIONS FOR ORDERING PARTS When ordering parts for 8200 Series Fire Pumps be sure to furnish the following information to the ITT A C Fire Pump Systems stocking distributor in your area Serial Number Pump Size amp Type Pump Model Number Pump Frame Number Description of Part Catalog Code Quantity Required Definite Billing and Shipping Instructions Date Required Refer to parts list on page 32 for a complete parts list and recommended spare parts Parts should be ordered as far in advance of their need as possible since circumstances beyond the control of ITT A C Fire Pump Systems may reduce existing stock All parts are not carried in stock Some are made for each order If replacement parts required are to be made of different materials than originally specified give exact requirements and the reason for chan
57. ve bearing covers 5 018 0 and push oil seals 3 177 9 out of bearing covers Pull deflectors 3 136 9 off shaft Slide stuff box bushings 6 008 0 off of shaft 12 Remove casing rings 3 003 9 from impeller 4 002 0 13 Remove set screvv 3 902 9 from shaft nuts Remove shaft nuts 3 015 9 O rings 3 914 9 sleeves 3 009 9 interstage bushing 3 231 0 and impellers 4 002 0 NOTE Apply heat uniformly to the shaft sleeve to loosen the sealant between the shaft and sleeve 25 CAUTION DO NOT EXCEED 275 F Failure to follow these instructions could result in injury or property damage To further assist in removing the sleeves hold the shaft vertically and drop it on a block of wood The impeller weight should force both the impellers and sleeves from the shaft 2ND STAGE 1ST STAGE IMPELLER IMPELLER Dimension A 12 06 FIGURE 11 ASSEMBLY SECTION PUMP WITH PACKING CLOCKWISE ROTATION EIZ pe U C 5 A SG R 2 oe 2230 TS 4 rs Kat kx 4 272 1ST STAGE AN homes TEN 2ND STAGE IMPELLER fo A IMPELLER TS oe Dimension 12 06 FIGURE 12 ASSEMBLY SECTION PUMP WITH PACKING COUNTER CLOCKWISE ROTATION 26 ASSEMBLY PUMP WITH PACKING All bearings O rings seals gaskets impeller rings
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