INSTRUCTION MANUAL AC8585 REVISION C INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
TABLE OF CONTENTS 1. GENERAL MAINTENANCE.................... 25 2. MAINTENANCE OF PUMP DUE TO FLOOD DAMAGE ............................... 25 3. BEARING LUBRICATION – GREASE ... 25 4. PACKING SEAL...................................... 26 5. CLEANING WITHOUT DISMANTLING PUMP .................................................. 26 DESCRIPTION......................................................3 OPERATIONAL LIMITS .......................................3 MAXIMUM WORKING PRESSURE .....................
SEAL OPERATING LIMITS DESCRIPTION PACKING PH Limitations 7-9; Temperature Range 0 to +200°F The 9100 Series Centrifugal Fire Pumps are frame 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.
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. Additional Safety Requirements: 1. Electrical connections to be made by qualified Electrician in accordance with all national, state and local codes. 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.
PUMP LOCATION Locate the pump so there is sufficient room for inspection, main-tenance 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.
INTRODUCTION 6. 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. 1. PURPOSE OF MANUAL This manual is furnished to acquaint you with some of the practical ways to install, operate, and maintain this pump.
. 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. ALLOW 1" FOR SHIMS. PLACE ON BOTH SIDES OF ANCHOR BOLTS. GROUT ONLY TO TOP OF BASE RAIL.
motors should be in the center of its mechanical float. 10. GROUTING PROCEDURE Grout compensates for uneven foundation, distributes weight of unit, and prevents shifting. Use an approved, non-shrinking grout, after setting and leveling unit (See Figure 5). 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.
e. Install the outer guard capscrews by following the step stated below which pertains to your particular pump: and install, but do not tighten, the two remaining capscrews. f. Position the outer guard 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. i.
Method 1 – Straight Edge Alignment for Standard Sleeve Type Coupler with Black Rubber Insert (See Figure 6A) PARALLEL ALIGNMENT INDEX LINE Proceed with this method only if satisfied that face and outside diameters of the coupling halves are square and concentric with the coupling borers. If this condition does not exist or elastomeric couplings do not make this method convenient, use Method 2. RESILIENT SEPARATOR ANGULAR ALIGNMENT 1. Check angular misalignment using a micrometer or caliper.
misalignment is .004"T.I.R. per inch of radius R (See Figure 6B). 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. Adequate lubrication is essential for satisfactory operation. Grease supplied by the coupling manufacturer is highly recommended. Other greases to be used should be approved by the coupling manufacturer. FIGURE 6C – USING SPACER BAR 9.
16. If the shafts are not horizontal, or coupling is to be used vertically, assemble cover halves with the lug and match mark UP or on the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tightening to torque specified in Figure 6H. Ensure gaskets stay in position during fastener tightening. FIGURE 6E – SEATING THE GRID 14.
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 0.006 End Float Physical Cover Fastener Hub Gap Limit (Min) Tightening Torque +/- 10% 2xF Values Inch 0.125 0.125 0.125 0.125 0.125 Inch 0.211 0.212 0.258 0.259 0.288 In. Series Fasteners (lb*in) 100 200 200 200 200 Flange Type 31 & 35 In.
Provide for pipe expansion when hot fluids are to be pumped. 14. 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. 15.
Suction Piping When installing the suction piping, observe the following precautions (See Figure 7). CHECK VALVE SUCTION PIPE INSTALLED WITH A GRADUAL RISE TO PUMP GATE VALVE INCREASER LEVEL 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.
There is always an uneven turbulent flow around an elbow and when it is in a position other than the vertical it causes more liquid to enter one side of the impeller than the other (See Figure 8). This results in high unequalized thrust loads that will overheat the bearings and cause rapid wear in addition to affecting hydraulic performance. 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.
2. Temperature is above 32°F and below 160°F. 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. 3. Suction pressure is below 75 psig. 4. Lubrication (pumped liquid) has lubricating qualities. Pump Insulation On chilled water applications most pumps are insulated.
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. A 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.
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.
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° maximum. e. Make all pump output adjustments with the discharge line. 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. 5.
CHANGING ROTATION 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. 9100 Series Centrifugal Fire Pumps can be operated clockwise or counter-clockwise when viewed from the coupling end of the pump. If you wish to reverse the suction and discharge nozzles, this can be accomplished with the same pump as follows: 4.
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 1. Lack of prime. 2. Loss of prime. CURES No Liquid Delivered Fill pump and suction pipe completely with liquid. 6. Wrong direction of rotation. Check for leaks in suction pipe joints and fittings; vent casing to remove accumulated air.
CAUSES CURES Not Enough Pressure See item 14 and 15. 21. Mechanical defects. 22. Obstruction in liquid passages. Dismantle pump and inspect passages of impeller and casing. Remove obstruction. 23. Air or gases in liquid. (Test in May be possible to over rate pump to point where it will provide laboratory, reducing pressure adequate pressure despite condition. Better to provide gas separation on liquid to pressure in suction chamber on suction line near pump, and periodically exhaust line.
MAINTENANCE 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. 1. GENERAL MAINTENANCE Operating 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.
4. 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. 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.
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 the oil on oil lubricated units. Check grease lubricated bearings for saponification.
SERVICE INSTRUCTIONS 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. DISASSEMBLY AND REASSEMBLY PROCEDURES The procedures outlined in this section cover the dismantling and reassembly of the 9100 Series Centrifugal Fire Pumps.
10. Pull coupling half and key (3-911-2) off shaft (3-007-0). 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.
ASSEMBLY (PUMP WITH PACKING) All bearings, O-rings, bearing isolators, 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. Trim the gasket, so that it is flush with the inside edges of the casing.
18. Bolt outboard bearing housing in place. Be sure that both housing are seated properly in lower half casing. CAUTION: DO NOT EXCEED 275°F. CAUTION: These are precision, high quality bearings. Excercise care at all times to keep them clean and free from foreign matter. 19. Bolt inboard bearing housing in place. 20. Clean the gasket surfaces of the casing. Apply Scotch 3M-77 spray adhesive or equivalent to the lower half of the casing. 9. Press bearing isolators (1-333-1) in each bearing cover.
packing and casing. Install three rings of packing (1-924-9) and tap fully to bottom of both stuffing boxes. (See Figure 18) Stagger joints of each ring of packing t least 90°. Install seal cage (1-013-2) and be sure that it will line up with seal water inlet when packing is compressed. Install remaining three rings of packing with joints staggered. Assemble glands (1-0142) square with stuffing box and pull up tight. Then loosen gland bolts (1-904-9) to permit packing to expand, and retighten finger tight.
APPENDIX “A” EXPLODED VIEW 33
APPENDIX “A” REPLACEMENT PARTS LIST PART NUMBER PART NAME 0-901-0 0-910-0 0-950-0 0-952-0 1-013-2 0-014-2 1-333-1* 1-904-9 1-909-9 1-924-9* 2-001-7 2-001-8 2-123-5* 2-123-6* 2-904-1 2-916-9 3-003-9* 3-007-0 3-009-9* 3-015-9 3-018-3 3-018-4 3-025-2 3-026-2* 3-078-9 3-177-4* 3-409-9 3-516-4 3-517-4 3-902-9 3-904-9 3-911-1 3-911-2 3-911-3 3-914-9* 3-915-9 3-943-9 4-002-0 Valve Pipe Plug Pipe Nipple Tubing Seal Cage Gland (Packing) Bearing Isolator Gland and Housing Bolt Washer, Gland Bolt Packing Ring Casin
LIMITED END FLOAT COUPLINGS For units with drivers having sleeve bearings the coupling halves are set to limit total shaft axial movement to less than one-half of he motor rotor assembly end float. This is accomplished by inserting a phenolic disc, or equivalent, of a specified thickness between the motor and pump shaft (See Figure 20). ORDERING PARTS The pumps covered by this manual have been designed and built with certain replaceable wearing parts.
2. Suction and discharge pipe pressure gauge readings. DEALER SERVICING If trouble occurs that cannot be rectified, contact your local A-C Fire Pump Systems Representative. They will need the following information in order to give you assistance. 3. Ampere draw of the motor. 4. A sketch of the pumping hook-up and piping. 1. Complete nameplate data of pump and motor.
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