Aurora of America 442, 492 User Manual
INSTALLATION,
OPERATION AND
MAINTENANCE
INSTRUCTIONS
FOR
MODEL 442
HORIZONTAL SPLIT CASE
&
MODEL 492
SPLIT CASE FIRE PUMP
TABLE OF CONTENTS PAGE i
TOPIC PAGE
PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STORAGE OF PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CAUTION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Net Positive Suction Head (NPSH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Minimum Submergence of Suction Pipe and Pit Design . . . . . . . . . . . . . . . . . . 4
4. Location and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Leveling of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7. Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9. Auxiliary Piping Connections and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . 5
10. Final Coupling Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
11. Flexible Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
12. Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
13. Mechanical Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION
1. Operating at Reduced Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Starting the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Bearing Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Troubleshooting Operating Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
MAINTENANCE
1. Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Inspections and Preventive Maintenance Requirements . . . . . . . . . . . . . . . . . 11
3. Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Packing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Packing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
6. Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14
7. Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17
REPAIR PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
RECOMMENDED SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-21
CROSS-SECTIONAL DRAWINGS AND PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . 22-23
PUMP IDENTIFICATION PAGE 1
PUMP IDENTIFICATION
Congratulations! You are the owner of one of the finest pumps commercially available. If you give it
the proper care as outlined and recommended by this manual, it will provide you with reliable service
and long life.
442 & 492 SPLIT CASE PUMPS
Your Aurora Model 442 & 492 is a Split Case Pump, meaning the casing is split along the horizontal
centerline. This new compact design, with its shorter bearing span, has less deflection under
hydraulic load which results in less wear on the sleeves, bearings and packing. It is ideally suited for
applications such as water systems, boosters, liquid transfer, irrigation and Fire Protection Systems.
These pumps are available with a wide variety of options including mechanical seals and impeller
wear rings. Some options may not be available on Model 492 Fire Pumps.
This manual applies to:
X-442-XX Horizontal Split Case Pumps
X-492-XX Horizontal Split Case Fire Pumps
Example: 5-492-10
Maximum nominal impeller diameter
Carefully record all the following data from your pump nameplate. It will aid in obtaining the correct
replacement parts in the future.
FIGURE (MODEL): __________________ SERIAL NUMBER: __________________
IMPELLER DIAMETER:_______________ SIZE: _____________________________
CAPACITY: _____________ GPM ______ TOTAL HEAD ____________ FT/PSI
RPM: __________________
MANUFACTURER: __________________
HORSEPOWER: _______________ SERIAL NUMBER: _______________________
SPEED: ____________ RPM ______ VOLTAGE: _____________________________
MANUFACTURER: _____________________ FRAME: ________________________
Horizontal Fire Pump
Discharge size
DRIVER
PAGE 2 STORAGE OF PUMPS AND CAUTION NOTES
THESE INSTRUCTIONS APPLY TO THE PUMP ONLY. THEY ARE INTENDED TO BE GENERAL
AND NOT SPECIFIC. IF YOUR OPERATING CONDITIONS EVER CHANGE, ALWAYS REFER TO
THE FACTORY FOR REAPPLICATION. ALWAYS REFER TO THE MANUALS PROVIDED BY
MANUFACTURERS OF THE OTHER EQUIPMENT FOR THEIR SEPARATE INSTRUCTIONS.
CAUTION
IMPORTANT SAFETY NOTICE
THE INSTALLATION, USE AND OPERATION OF THIS TYPE OF EQUIPMENT IS AFFECTED BY
VARIOUS FEDERAL, STATE AND LOCAL LAWS AND THE REGULATIONS CONCERNING
OSHA. COMPLIANCE WITH SUCH LAWS RELATING TO PROPER INSTALLATION AND SAFE
OPERATION OF THIS TYPE OF EQUIPMENT IS THE RESPONSIBILITY OF THE EQUIPMENT
OWNER AND ALL NECESSARY STEPS SHOULD BE TAKEN BY THE OWNER TO ASSURE
COMPLIANCE WITH SUCH LAWS BEFORE OPERATING THE EQUIPMENT.
STORAGE OF PUMPS
IF THE EQUIPMENT IS NOT TO BE IMMEDIATELY INSTALLED AND OPERATED, STORE IT IN
A CLEAN, DRY, WELL-VENTILATED PLACE, FREE FROM VIBRATION, MOISTURE AND RAPID
OR WIDE VARIATIONS IN TEMPERATURE.
SPECIAL INSTRUCTIONS FOR:
CONSIDER A UNIT IN STORAGE WHEN:
1. IT HAS BEEN DELIVERED TO THE JOBSITE AND IS AWAITING INSTALLATION.
2. IT HAS BEEN INSTALLED BUT OPERATION IS DELAYED PENDING COMPLETION OF
3. THERE ARE LONG PERIODS (30 DAYS OR MORE) BETWEEN OPERATION CYCLES.
4. THE PLANT (OR DEPARTMENT) IS SHUT D OWN FOR PERIODS OF LONGER THAN 30
NOTE: STORAGE REQUIREMENTS VARY DEPENDING ON THE LENGTH OF STORAGE,
GREASE-LUBRICATED PUMPS: ROTATE THE SHAFT FOR SE VERAL REVOLUTIONS
AT LEASE ONCE EVERY TWO WEEKS TO:
1. COAT THE BEARING WITH LUBRICANT.
2. RETARD OXIDATION OR CORROSION AND,
3. PREVENT POSSIBLE FALSE BRINELLING.
CONSTRUCTION.
DAYS.
THE CLIMATIC ENVIRONMENT AND THE EQUIPMENT. FOR STORAGE
PERIODS OF THREE MONTHS OR LONGER, CONTACT THE MANUFACTURER
FOR SPECIFIC INSTRUCTIONS. IMPROPER STORAGE COULD DAMAGE THE
EQUIPMENT WHICH WOULD RESULT IN NON-WARRANTY COVERED
RESTORATION REQUIREMENTS OR NON-WARRANTY COVERED PRODUCT
FAILURES.
INTRODUCTION AND INSTALLATION PAGE 3
INTRODUCTION
This manual contains information that is the result of carefully conducted engineering and research efforts. It is
designed to supply adequate instructions for the safe and efficient installation, operation maintenance of your
pump. Failure or neglect to properly install, operate or maintain your pump may result in personal injury,
property damage or unnecessary damage to the pump.
Variations exist in both the equipment used with these pumps and the particular installation of the pump and
driver. Therefore, specific operating instructions are not within the scope of this manual. The manual contains
general rules for installation, operation and maintenance of the pump.
Observe all caution or danger tags attached to the pump or included in this manual.
INSTALLATION
1. GENERAL
CAUTION: CAREFULLY READ ALL SECTIONS OF THIS MANUAL AND ALL OTHER
INSTRUCTION MANUALS PROVIDED BY MANUFACTURERS OF OTHER
Upon receipt of the shipment, unpack and inspect the pump and driver assembli es and individual parts to
ensure that none are missing or damaged. Carefully inspect all boxes and packing material for loose parts
before discarding them. Report immediately to the transportation company involved, and to the factory, any
missing parts or damage incurred during shipment, and file your “damaged and/or lost-in-shipment” cl aim with
the carrier.
Horizontal pump and driver assemblies mounted on a common base are accurately aligned at the factory.
However, alignment may be disturbed in transit or during installation. It must be checked after the unit is
leveled on its foundation, after the grouting has set and the foundation bolts are tightened, and after the piping
is completed.
When the pump and driver are mounted on separate base structures, the pump should be leveled and aligned
first, then the driver leveled and aligned with the pump. With separate bases, a flexible shaft between the pump
and driver must be used.
2. NET POSITIVE SUCTION HEAD (NPSH)
NPSH can be defined as the head (energy) that causes liquid to flow through the suction pipe and enter the eye
of the impeller.
NPSH is expressed in two values: (1) NPSH required (NPSHR) and (2) NPSH available (NPSHA). It is essential
that NPSH
NPSHR is a function of the pump design and therefore varies with the model, size, capacity and speed of the
pump. The value for your pump can be obtained from your pump performance curve or from the factory.
A. When the source of the liquid is above the pump:
NPSH
B. When the source of the liquid is below the pump:
NPSH
EQUIPMENT SUPPLIED WITH THIS PUMP.
be always greater than NPSHR to prevent cavitation, vibration, wear and unstable operation.
A
= barometric pressure (feet) + static suction head (feet) – friction losses in suction piping
A
(feet) – vapor pressure of liquid (feet)
= barometric pressure (feet) - static suction lift (feet) – friction losses in suction piping (feet)
A
– vapor pressure of liquid (feet)
PAGE 4 INSTALLATION (continued)
3. MINIMUM SUBMERGENCE OF SUCTION PIPE AND PIT DESIGN
For installations where the pump draws fluid from a sump, the hydraulic characteristics of the pump, the suction
inlet submergence and NPSH must be considered. Generally, it is required that an evenly distributed flow of
non-aerated water be supplied to the suction bell. Improper pit design or insufficient suction pipe submergence
can result in intake vortexing that reduces the pump’s performance and can result in severe damage to the
pump.
We recommend that you secure the advice of a qualified Consulting Engineer for the analysis of the suction pit.
Significant engineering data on design is provided in the Hydraulic Institute Standards.
4. LOCATION AND HAN D LING
The pump should be located as near the fluid as possible so a short direct suction pipe can be used to keep
suction losses at a minimum. If possible, locate the pump so the fluid will flow to the suction opening by gravity.
The discharge piping should be direct and with as few elbows and fittings as possible. The total net positive
suction head available (NPSH
positive suction head required (NPSH
), which includes suction lift and pipe friction losses, must be greater than the net
A
) by the pump.
R
The pump and driver should be located in an area that will permit periodic inspection and maintenance. Headroom and access should be provided and all units should be installed in a dry location with adequate drainage.
WARNING: DO NOT LIFT THE COMPLETE UNIT BY THE DRIVER OR PUMP SHAFTS OR EYE BOLTS.
To lift a horizontal mounted unit, a chain or suitable lifting device should be attached to each corner of the unit
base. The driver by itself may be lifted using the proper eyebolts provided by the manufacturer, but these
should not be used to lift the entire assembled unit.
5. FOUNDATION
The foundation should have a level surface and have sufficient mass to prevent vibration and form a pe rmanent
rigid support for the unit. The most satisfactory foundations are concrete with anchor bolts of adequate size
embedded in the foundation in pipe sleeves with an inside diameter 2½ times larger than the bolt diameter.
This will allow final accurate positioning of the unit.
6. LEVELING OF THE UNIT
Lower the unit onto the foundation, positioning it so the anchor bolts are aligned with the center of the mounting
holes in the base. On all units, always disconnect the coupling halves and never reconnect them until all the
alignment operations are complete.
The base should be supported on metal shims or metal wedges placed directly under the part of the base
carrying the greatest weight, and spaced close enough to give uniform support and stability (see Figure 1).
Adjust the metal shims or wedges until the shafts of the pump and driver are level. Alignment adjustments can
be accomplished by adjusting the supports under the base. When proper alignment is obtained, tighten the
foundation bolts snugly, but not too firmly, and recheck the alignment before grouting.
Figure 1
BASEPLATE INSTALLATION
INSTALLATION (continued) PAGE 5
7. GROUTING
When the alignment is correct, the unit should be grouted using high-grade non-shrinking g rout. The entire
base should be filled with grout. Be sure to fill all gaps and voids. Allow the grout to fully cure before firmly
tightening the foundation bolts. Then recheck the alignment before connecting the piping.
8. PIPING
CAUTION: ALL PIPING CONNECTIONS MUST BE MADE WITH THE PIPING IN A FREE
SUPPORTED STATE, AND WITHOUT THE NEED TO APPLY VERTICAL OR
SIDE PRESSURE TO OBTAIN ALIGNMENT OF THE PIPING WITH THE
CAUTION: AFTER ALL THE PIPING IS CONNECTED, THE PUMP AND DRIVER
All piping should be independently supported near the pump so that pipe strain will not be transmitted to the
pump casing. The suction and discharge piping should be one or two size s larger than the pump flange sizes,
especially where the piping is of considerable length. Any flexible joints installed in the piping must be equipped
with tension rods to absorb piping axial thrust. Care must be exercised in arranging elbows so as not to
generate vortexing in the pump inlet.
The suction pipe must be air tight and sloped upward to the pump flange to avoid air pockets that will impair
satisfactory pump operation. The discharge pipe should be as direct as possible with a minimum of valves to
reduce pipe friction losses.
A check valve and closing valve should be installed in the pump discharge line and a closing valve in the
suction line. The check valve, between the pump and the closing valve, protects the pump from water ham mer
and prevents reverse rotation in the event of power failure. The closing valves are used in priming, starting and
when the pump is shut down. The pump must never be throttled by the use of a valve in the suction line.
9. AUXILIARY PIPING CONNECTIONS AND GAUGES
In addition to the primary piping connections, your pump may require mechanical seal and seal water filter
connections, connections to the lantern ring (see the “Packing Box” and “Mechanical Seal” sections of this
manual), stuffing box drain, discharge and suction flange gauges, casing relief valve drain or baseplate drain
connections. All these lines and gauges should now be installed.
10. FINAL COUPLING ALIGNMENT
The alignment of the coupling must be carefully checked during installation and as the last step before starting
the pump. If realignment is required, the piping should be disconnected first. After aligning, reconnect the
piping in accordance with the previous instructions and again recheck the align ment.
A flexible coupling must not be used to compensate for misalignment resulting from poor installation or
temperature changes.
Aurora Pumps are supplied with several different types of commercial couplings. Refer to the coupling
manufacturer’s installation instructions for maximum allowable misalignment.
NOTE: FOR MAXIMUM LIFE, KEEP MISALIGNMENT VALUES AS NEAR TO ZERO AS POSSIBLE.
A. Check parallel misalign ment by placing a straightedge across the two coupling flanges and
measuring the maximum offset at various points around the periphery of the coupling. DO NOT
ROTATE THE COUPLING. If the maximum offset exceeds manufacturer’s recommendations,
realign the coupling.
PUMP FLANGE.
ALIGNMENT MUST BE RECHECKED.
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