INSTRUCTION MANUAL AC2675 REVISION C INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
TABLE OF CONTENTS DESCRIPTION......................................................3 MAINTENANCE TIME TABLE........................... 21 OPERATIONAL LIMITS .......................................3 TROUBLE SHOOTING ...................................... 22 MAXIMUM WORKING PRESSURE .....................3 CHANGING ROTATION .................................... 25 SEAL OPERATING LIMITS .................................3 PACKING ......................................................
DESCRIPTION PUMP IDENTIFICATION 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. There are two identification plates on each pump. The pump rating plate gives identification and rating information. Figure 1 shows an example of a typical Rating Plate.
ADDITIONAL SAFETY REQUIREMENTS: 1. Electrical connections to be made by qualified Electrician in accordance with all national, state and local codes. SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS This safety alert symbol will be used in this manual and on the pump safety instruction decals to draw attention to safety related instructions. When used the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD. 2.
ADDITIONAL SAFETY REQUIREMENTS ELECTRICAL SAFETY: MECHANICAL SAFETY: WARNING: Electrical Shock Hazard Electrical connections to be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices. Failure to follow these instructions could result in serious personal injury or death, and property damage. WARNING: Unexpected Startup Hazard Disconnect and lockout power before servicing.
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. NYLON SLING, CHAIN OR WIRE ROPE 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.
“Foundation,” “Base Plate Setting,” “Grouting Procedure,” “Alignment Procedure” and “Doweling.” 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.
e. Check to make sure the piping can be aligned to the pump flanges without placing pipe strain on either flange. 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 rough aligned at the factory. If motor is to be field mounted, consult factory for recommendations.
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 runout. 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. d. Spread the inner guard and pull it over the coupler. Installation a. Check coupler alignment before proceeding. Correct if necessary. b.
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 LOCATE SUPPORT ARM BETWEEN OUTER GUARD ENDS. ALIGN THE ARM WITH HOLES IN THE OUTER GUARD AND HOLES IN THE SADDLE BRACKET.
Grid Couplings NOTE: The following procedure is intended for mounting and alignment of Rexnord Industries, LLC. and Clarke Fire Protection Products, Inc., Tapered Grid Couplings. Method 2 – For Orange Hytrel Insert, 3500 RPM Operation, or All Other Coupler Types Except as Noted Below (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. Adequate lubrication is essential for satisfactory operation.
FIGURE 7E – SEATING THE GRID FIGURE 7C – USING SPACER BAR 14. Pack the spaces between and around the grid with as much as coupling vendor supplied grease as possible and wipe off the excess until flush with the top of the grid. 9. Align so that a straight edge rests within the limits shown in Figure 7D on both hubs as shown below and also at 90° intervals without rotating the coupling. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in Figure 7H. 15.
17. Ensure the lube plugs are installed in the cover. WARNING: Coupling Failure Do not operate coupling without proper lubrication Failure to follow these instructions could result in serious personal injury or death and property damage. FIGURE 7G – COVER INSTALLATION, VERTICAL POSITION Fastener Tightening Torque Values Installation Limits Size 1040T 1050T 1060T 1070T 1080T Parallel Offset (P) Max Inch 0.006 0.008 0.008 0.008 0.008 Angular (x-y) Max Inch 0.003 0.004 0.005 0.005 0.
Where flanged joints are used, assure that inside diameters match properly. time and alignment is within the tolerance. See Doweling Section. Remove burrs and sharp edges when making up joints. CAUTION: Extreme Temperature and/or Flying Debris Hazard Eye protection and gloves required. Failure to follow these instructions could result in property damage and/or moderate personal injury. Do not “spring” piping when making any connections. Provide for pipe expansion when hot fluids are to be pumped.
SUCTION PIPE INSTALLED WITH A GRADUAL RISE TO PUMP 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.
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 “Valves in Discharge Piping”) 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.
1. Liquid is clean, free from sediment and chemical precipitation and is compatible with seal materials. 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. 2.
OPERATION 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. 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.
b. Keep fluid moving in the pump and insulate or heat the pump to prevent freezing. 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. 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. d. Check bearings for lubrication and temperature.
the bearing frame rise above 180°F, the pump should be shut down to determine the cause. 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. PACKING SEAL When a pump 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.
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 and 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.
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 prime. Check for leaks in suction pipe joints and fittings; vent casing to remove accumulated air. Check mechanical seal or packing. 3.
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.
TROUBLE SHOOTING (CONT.) CAUSES CURES Pump Operates For Short Time, Then Stops 30. Insufficient NPSHA. See item 17. 31. System head too high. See items 4 and 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 immersed. See item 20. 36.
CHANGING ROTATION 3. Set the rotating element back in the casing and reassemble the pump. 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. 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 same relationship to each other as they were originally.
SERVICE INSTRUCTIONS suction and discharge nozzle. (See Exploded View on page 33). DISASSEMBLY AND REASSEMBLY PROCEDURES The procedures outlined in this section cover the dismantling and reassembly of the 8200 Series Centrifugal Fire Pumps. 2. Remove coupling guard and separate the coupling to disconnect the pump form the driver. 3. Remove seal lines (1-952-0). When working on the pump, use accepted mechanical practices to avoid unnecessary damage to parts.
12. Remove casing rings (3-003-9) from impeller (4-002-0). CAUTION: DO NOT EXCEED 275°F. Failure to follow these instructions could result in injury or property damage. 13. Remove set screw (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). To further assist in removing the sleeves, hold the shaft vertically and drop it on a block of wood.
2ND STAGE IMPELLER 1ST STAGE IMPELLER Dimension “A” = 12.06” FIGURE 11 – ASSEMBLY SECTION: PUMP WITH PACKING CLOCKWISE ROTATION 2ND STAGE IMPELLER 1ST STAGE IMPELLER Dimension “A” = 12.
until the sleeve is flush against the face. Wipe off any excess sealant. ASSEMBLY (PUMP WITH PACKING) All bearings, O-rings, seals, gaskets, impeller rings, 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.
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. against the lower half casing face in the area coated by the adhesive. 23.
. Assemble seal water flush and bleed lines (1-952-0). 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. a) Clockwise – Figure 11 b) Counter-clockwise – Figure 12 32. Check coupling alignment and realign if necessary. 25. Bolt outboard bearing housing in place.
APPENDIX “A” ENGINEERING DATA Pump Size A Number of Stages Approval Flow Rate (GPM) 8x6x14F-S 8200 H8x6x14F-S 8200 8x6x14F-L 8200 H8x6x14F-L 8200 8x6x18 8200 H8x6x18 8200 2 2 2 2 2 2 500/750 /1000 500/750 /1000 500/750 /1000 500/750 /1000 500/750 /1000 500/750 /1000 CASING DATA (All Dimensions in Inches) Suction 125 or 250 125 or 250 125 or 250 125 or 250 125 250 250 800 250 800 250 250 Cast Iron ASTM A48 Class 35 Ductile Iron ASTM A536 Gr.
APPENDIX “B” EXPLODED VIEW – 8200 SERIES FIRE PUMP CLOCKWISE ROTATION 33
APPENDIX “B” REPLACEMENT PARTS LIST Part Number 1-952-0 1-952-0 0-910-9 1-013-9 1-014-9 1-901-9 1-909-9 1-924-9 2-001-7 2-001-8 2-123-5 2-123-5 2-904-1 1-439-0 3-003-9 3-007-0 3-009-9 3-015-9 5-018-0 3-025-3 3-026-3 3-026-4 5-050-4 5-421-4 3-169-9 3-177-9 3-516-4 3-514-4 3-902-9 5-904-9 3-911-1 3-911-2 3-914-9 6-914-9 6-008-0 3-034-0 3-231-0 3-914-7 5-915-0 3-915-0 4-002-0 Part Name Bleed Line Flush Line Pipe Plug Seal Cage Gland Gland Bolt Washer, Gland Bolt Packing Ring Casing, Upper Half Casing, Lower H
APPENDIX “B” INSTRUCTIONS FOR ORDERING PARTS When ordering parts for 8200 Series Fire Pumps, be sure to furnish the following information to the AC Fire Pump Systems stocking distributor in your area: – Serial Number – Pump Size & 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 34 for a complete parts list and recommended spare parts.
APPENDIX “C” FIELD TEST REPORT 36
APPENDIX “C” FIELD TEST REPORT USEFUL FORMULAS 1) Head (ft.) = Pressure (psig.) x 2.31 S.G. S.G. = specific gravity; S.G. of water = 1.0 at 70°F 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 BHP = Three Phase Motor Amps x Volts x nm x p.f. 746 BHP = Avg.
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