Instruction/ maintenance manual of the product 8200 Series AC International
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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 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 R.
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.
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.
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.
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) 500/7.
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-.
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 buto.
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.
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.
An important point after buying a device AC International 8200 Series (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought AC International 8200 Series yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data AC International 8200 Series - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, AC International 8200 Series you will learn all the available features of the product, as well as information on its operation. The information that you get AC International 8200 Series will certainly help you make a decision on the purchase.
If you already are a holder of AC International 8200 Series, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime AC International 8200 Series.
However, one of the most important roles played by the user manual is to help in solving problems with AC International 8200 Series. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device AC International 8200 Series along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
