AC International 8200 Series manual

1 Instruction Manual 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.[...]

2 TABLE OF CONTENTS DESCRIPTION ...................................................... 3 OPERATIONAL LIMITS ....................................... 3 MAXIMUM WORKIN G PRESSURE ..................... 3 SEAL OPERATING LIMITS ................................. 3 PACKING ...................................................... 3 PUMP IDENTIFICATION .......[...]

3 DESCRIPTION The 8200 Series Centrifugal Fire Pumps are framed mounted pumps which feature – high efficiency, rugged construction, co mpact design, foot mounted volute and regre asable bearings. These features, along with the horizontal split case, make installatio n, operation and service easy to perform. OPERATIONAL LIMITS Unless special provi[...]

4 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS This safety alert symbol will be used in this manual and on the pump safety instruction de cals 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. Your 8[...]

5 ADDITIONAL SAFETY REQUIREMENTS: ELECTRICAL SAFETY: WARNING: Electrical Shock Hazard Electrical connections to be made by a qualified electrician in acco rdance with all applicable codes, ordin ances, and good pra ctices. Failure to follow these inst ructions could re sult in serious personal inju ry or death, and property damage. WARNING: Electri[...]

6 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, all ow ample head room. 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 inst ructi[...]

7 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 o[...]

8 BASE PLATE SETTING (BEFORE PIPING) NOTE: This procedure assume s that a concrete foundation has be en prepared with anchor or hold down bolts extending up rea dy to receive unit. It must be understood that pump and motor have been mounted a nd rough aligned at the factory. If motor is to be field mounted, consult factory for recommendations. ITT [...]

9 vibration, and bearing load s that result in premature bearing failure and ultimate seizin g of the pump. Misalignment can be angular, parallel, or a combination of these, and in the horizontal and vertical planes. Fin al alignment should be made by moving and shi mming the motor on the base plate, until the coupling hubs are within the recommend[...]

10 Method 1 – Straight Edge Alignment for Standard Sleeve Type Coupler with Black Rubber Insert (See Figure 7A) 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 d o not make this method con[...]

11 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 eleme nts are removed at this time. b. The gap between the coupling hubs is se t by the manufacturer before the units ar e shipped. However, this dim[...]

12 and properly aligned, so that no strain is transmitted to the pump when the flange bolts are tightened. Use pipe ha ngers or other supports at necessary intervals to provide support. W hen 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[...]

13 Suction piping should be short in len gth, as direct as possible, and never small er in diameter than the pump suction opening . A minimum of ten (10) pipe diameters between any elbow or tee and the pump should b e allowed. If a long suction pipe is required, it should be one or two sizes large r than the suction opening, dependin g on its lengt[...]

14 Pressure Gauges Properly sized pre ssure gauges should be installed in both the suction and disch arge nozzles in the gauge taps provided. The gauges will enable the ope rator 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 [...]

15 box. Excess pressure from an external source can be very destructive to packing. More pressure is required, however, for abrasive slurries than for clear liquid s. Examination of the leakage will indicate whether to increase or decrease externa l pressure. If slurry is present in the leaka ge, increase the pressure until only clear liquid drips [...]

16 OPERATION WARNING: Unexpected Startup Hazard Disconnect and lockout po wer before servicing. Failure to follow these inst ructions could result in serious person al injury or death, or property damage. WARNING: Electrical Shock Hazard Electrical connections to be made by a qualified electrician in acco rdance with all applicable codes, ordin anc[...]

17 b. Check and reco rd pressure gauge readings for future reference. c. Check and reco rd voltage, amperage per phase, and kw if an indicating wattmeter is available. d. Check bearings for lu brication and temperature. Normal temperature is 180° maximum. e. Make all pump output adjustments with the discharge line. CAUTION: Cav itation Damage Haza[...]

18 Bearings are a primary con cern 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 relu bricate them with one of the recommended pump lubricant s. Depending on the length of time the pump has remained in the flooded are a, it is un[...]

19 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 lu bricant. If changing the lubricant does not correct the co ndition, disassembly and inspect the bea rings. Lip seals bearing on the shaft may also cause the housing to run h[...]

20 TROUBLE SHOOTING Between regular maintenance in spections, be alert for signs of mot or or pump trouble. Common symptoms are listed below. Correct any troubl e immediately and AV OID 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 lea ks[...]

21 TROUBLE SHOOTING (CONT.) CAUSES CURES 16. Impeller partially plugged. See item 9. a. Increase positive suction head on p ump by lowering pump or increasing suction pipe an d fittings size. b. Sub-cool suction piping at inlet to lower entering liqui d temperature. 17. Cavitation; insufficient NPSHA (Net Positive Suction Head Available). c. Pressu[...]

22 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 advi sed by factory or reduce speed. 33. Cavitation See item 17.[...]

23 CHANGING ROTATION WARNING: Rotating Components Hazard Do not opera te pump withou t all guards in plac e. Failure to follow these instr uctions could result in serious personal inju ry or death and property damage. 8200 Series centrifugal pumps can b e operated clockwi se or counterclockwise when viewed from the coupling end of the pump. If you [...]

24 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 a ccepted mechanical practices to avoid unnecessary damage to parts. Check cle arances and conditions of parts when pump is di smantled an[...]

25 12. Remove casing rings (3-0 03-9) from impeller (4-002-0 ). 13. Remove set screw (3-902-9) from shaft nuts. Remove shaft nuts (3-015-9), O-rings (3-91 4-9), 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. CAUTION: DO NOT[...]

26 Dimension “A” = 12.06” FIGURE 11 – ASSEMBLY SECTION: PUMP WITH PACKING CLOCKWISE ROTATION Dimension “A” = 12.06” FIGURE 12 – ASSEMBLY SECTION: PUMP WITH PACKING COUNTER-CL OCKWISE ROTATION 2ND STAGE IMPELLER 1ST STAGE IMPELLER 2ND STAGE IMPELLER 1ST STAGE IMPELLER[...]

27 ASSEMBLY (PUMP WITH PACKING ) All bearings, O-rings, seal s, gaskets, impeller rings, and casing wea r rings should be replaced with new parts du ring assembly. All reusable parts should b e cleaned of all foreign matter before reassembling. The main casing joint gasket can be made u sing the upper or lower half as a template. Lay the gasket mat[...]

28 race contacting, as shown on assembly section). a) Remove the preservative from the outside diameter and faces of the bearings. Heat both bearin gs 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 secon d bearing, push against the inner race to remove all cl[...]

29 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 hou sing towards the coupling slightly will ease assembly. 25. Bolt outboard bearing housing in place. Be sure that both housings are seated properly [...]

30 APPENDIX “A” ENGINEERING DATA Pump Size A 8x6x14F-S 8200 H8x6 x14F- S 8200 8x6x14F-L 8200 H8x6 x14F- L 8200 8x6x18 8200 H8x6 x18 8200 Number of Stages 2 2 2 2 2 2 Approval Flow Rate (GPM) 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 12[...]

31 APPENDIX “B” EXPLODED VIEW – 8200 SERIES FIRE PUMP CLOCKWISE ROTATION[...]

32 APPENDIX “B” REPLACEMENT PARTS LIST 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[...]

33 APPENDIX “B” INSTRUCTIONS FOR ORDERING PARTS When ordering parts for 82 00 Series Fire Pumps, be sure to furnish the followin g information to the ITT A-C Fire Pump Systems stocking distri butor in your area: – Serial Number – Pump Size & Type – Pump Model Number – Pump Frame Number – Description of Part – Catalog Code – Qu[...]

34 APPENDIX “C” FIELD TEST REPORT[...]

35 APPENDIX “C” FIELD TEST REPORT USEFUL FORMULAS 1) Head (ft.) = S.G. 2.31 x (psig.) Pressure S.G. = specific gravity; S.G. of water = 1.0 at 70°F 2) TDH (ft.) = Total Dynamic Head (ft.) = (Disch. pressure gauge readi ng - Suct. pressure gauge reading) + (Discharge velocity hea d - Suction velocity head) + (Elevation correction to disch. gaug[...]

36 © COPYRIGHT 2005 BY ITT INDUSTRIES, INC. PRINTED IN U .S.A. 11-05 A-C Fir e Pu mp 8200 N. Austin Avenue Morton Grove, IL 60053 Phone: (847) 966-3700 Fax: (847) 966-1914 www.acfirepump.com In Canada Fluid Products Canada 55 Royal Road Guelph, Ontario, N1H 1T1, Canada Phone: (519) 821-1900 Fax (519) 821-2569[...]