Fire Pump 8100 Series, 8200 Series, 8150 Series, 9100 Series Installation, Operation And Maintenance Manual

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Series 8100/8150/8200/9100 Fire Pump

3 AC6102 Rev 03

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Table of contents

1 Introduction …………………………………………………. 8

1.1 General …………………………………………… 8

1.2 Target Group ………………………………........... 8

1.3 Safety symbols used in this manual ……........... 8

1.4 Manufacturer ………………………………........... 8

1.5

2 Safety ………………………………………………………… 8

2.1 General …………………………………………… 8

2.2 Intended use …………………………………….. 8

2.3 Improper use ……………………………............ 8

2.4 Warning and Instruction Labels ……………….. 9

2.5 Personnel qualifications and training ………… 9

2.6 Safety awareness ………………………………… 9

2.7 Safety instruction for the user …………………. 9

2.8 Safety instructions for maintenance, inspection,

2.9 Noise Emissions ………………………………….. 9

2.10 Unauthorized modification and manufacture of

2.11 Product Warranty …………………………………. 10

2.11.1 Coverage ………………………………………….. 10

2.11.2 Limitations ……………………………………….... 10

2.11.3 Warranty Claim …………………………………… 10

3 Applications ………………………………………………... 10

4 Operational Limits …………………………………………. 10

4.1 Pumped liquids ……………………………………. 10

4.2 Liquid temperature ……………………………….. 10

4.3 Pressure limits ……………………………………. 10

4.4

4.5 Pump speed ………………………………………. 10

5 Delivery, handling, and storage ………………………… 11

5.1 Delivery ……………………………………….…. 11

5.2 Handling ………………………………………… 11

5.2.1 Bare shaft pump (Model 100) …….……………. 11

5.2.2 Complete pump unit (Model 150M) …………… 11

5.2.2.1 Bases supplied with lifting holes …….………… 11

5.2.2.2 Bases supplied without lifting holes …………… 11

5.2.3 Engine driven pump units (Model 150E) ……… 12

dditional technical documents ………………… 8

and installation ……………………………………. 9

spare parts ………………………………………… 9

mbient temperature …………………………….. 10

5.3 Storage ………………………….…………………. 12

5.3.1 Temporary storage ……………………………… 12

5.3.2 Long Term Storage ……….…………………… 12

6 Description ……………………………………………..…. 13

6.1 General …………………………………………… 13

6.2 Designation ………..……………………………. 13

6.3 Nameplate ………..……………………………… 13

6.3.1 Pump nameplate ………………………………… 13

6.3.2 Pump unit nameplate …………………………… 13

6.4 Design detail ……………………………………… 14

6.4.1 Casing …………..…………………………………. 14

6.4.2 Impeller …………………………………………….. 14

6.4.3 Shaft ……………………………………………… 14

6.4.4 Shaft sleeves ……………………………………… 14

6.4.5 Stuffing box ……………………………………… 14

6.4.6 Casing rings ……………………………………….. 14

6.4.7 Bearings ……………………………………..…….. 14

6.4.8 Bearing housings …….………………………..…. 14

6.4.9 Baseplate ………………………………………….. 14

6.4.10 Coupling ………………………………..………….. 14

6.4.11 Coupling Guard ………………….…….…………. 14

6.4.12 Rotation ……………………………………………. 14

6.5 Noise characteristics ……………………….……. 15

6.6 Scope of supply …………………….…………….. 15

6.7 Dimension and weights ………………………….. 15

7 Installation …………………….……..….…………………. 15

7.1 Location ……………………………………..…….. 15

7.2 Foundation ………………………………….…….. 15

7.3 Leveling the baseplate …………………….…….. 16

7.4 Grouting …………………………………..……….. 16

7.5 Initial Alignment ……………………………….….. 17

7.5.1 Straightedge method of alignment …………….. 17

7.5.1.1

7.5.1.2 Parallel Alignment ………………………….…….. 17

7.5.2 Dial indicator method of alignment …………….. 17

7.5.2.1

7.5.2.2 Parallel Alignment ………………………….…….. 18

7.5.3

7.5.3.1 Mount seal and hubs …………………….………. 18

ngular alignment ……………………….……….. 14

ngular alignment ……………………….……….. 18

lignment of grid couplings …….…………..….. 18

AC6102 Rev 03 4

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A

Series 8100/8150/8200/9100 Fire Pump

7.5.3.2 Gap and Angular alignment (X-Y) ……………… 18

7.5.3.3 Parallel Offset Alignment (P) …………...………. 18

7.5.3.4 Insert Grid …………………………………………. 18

7.5.3.5 Pack with grease and assemble covers ………. 18

7.6 Pipe connections …………………………………. 19

7.6.1 Suction and discharge piping general

7.6.2 Maximum forces and moments allowed on

7.6.2.1 8100 series Horizontal split case maximum

7.6.2.2 8200 series Horizontal split case maximum

7.6.2.3 9100 series Horizontal split case maximum

7.6.3 Suction piping …………………………………… 22

7.6.4 Discharge piping …….……………………………. 23

7.6.5 Bypass piping …………………………………… 23

7.6.6 Cooling system ……………………..…………… 23

7.6.7 Exhaust system …………………………….…… 23

7.6.8 Pressure gages ………………………….……… 24

7.6.9 Stuffing box lubrication ………………………… 24

7.6.9.1 General guidelines ……………………………… 24

7.6.9.2 Packing …………………………………………… 24

7.7 Final Alignment …………………………………… 24

7.8 Electrical Connection …………………………… 24

8 Start-up, operation and shutdown ……………...……… 25

8.1 Start-up …………………………………………… 25

8.1.1 Preparation for start-up ………………………… 25

8.1.2 Priming …………………………………………… 25

8.2 Coupling Guard ………………..………………… 25

8.2.1 Removing the coupling guard ……………….… 26

8.2.2 Installing the coupling guard ……………………. 26

8.3 Operation ………………………………………… 27

8.3.1 General procedure ……………………………… 27

8.3.2 Optional Checklist ………………………………… 27

8.4 Shutdown ………………………………………… 27

8.5 Returning to service ……..……………………… 27

8.6 Freeze protection ……………..………………… 27

8.7 Field testing ……………………………………… 27

9 Maintenance …….......................................................... 28

9.1 General …………………………………………… 28

9.2 Maintenance interval ……………………………. 28

9.3 Lubrication ……………………………………….. 28

precautions ……………………………………… 19

pump flange ……………………………………… 20

forces and moments allowed …………………… 20

9.3.1 Lubricating grease requirements ……………… 28

9.3.2 Grease lubrication ………………………………. 29

9.3.3 Lubrication procedure ……………………………. 29

9.4 Packed stuffing box …………..………………… 29

9.4.1 Packing specifications …………………………… 29

9.4.2 Packing maintenance ……………………………. 29

9.4.3 Removal of packing ………………………………. 29

9.4.4 Installing packing …………………………………. 29

9.4.5 Packing adjustment ………………………………. 30

10Service ……………………………………………………… 31

10.1 Tools required …………………………………….. 31

10.2 Dismantling ………………………………………... 31

10.2.1 Rotating Element …………………………………. 31

10.2.2 Bearing housing ………………………………….. 31

10.2.3 Shaft seal - gland packing ………………………. 31

10.2.4 Shaft sleeve ……………………………………….. 31

10.2.5 Impeller and casing wear rings …………………. 32

10.3 Examination of parts ……………………………... 32

10.3.1 Casing and impeller ……………………………… 32

10.3.2 Shaft and sleeve ………………………………….. 32

10.3.3 Gaskets and O-rings ……………………………... 32

10.3.4 Bearings …………………………………………… 32

10.3.5 Bearing isolators and lip seals …………………. 32

10.4

10.4.1 Wear Rings ……………………………………….. 32

10.4.2 Impeller …………………………………………….. 33

10.4.2.1 Series 8100, 8150 and 9100 …….……………… 33

10.4.2.2 Series 8200 ……………………………………….. 34

10.4.3 Bearings and bearing housings ………………… 34

10.4.3.1 Series 8100 ……………………………………….. 34

10.4.3.2 Series 8200 ……………………………………….. 35

10.4.3.3 Series 9100 ……………………………………….. 35

10.4.3.4 Series 8150 ……………………………………….. 35

10.4.4 Rotating Element …………………………………. 35

10.4.4.1 Series 8100 ……………………………………….. 35

10.4.4.2 Series 8200 ……………………………………….. 35

10.4.4.3 Series 9100 ……………………………………….. 35

10.4.4.4 Series 8150 ……………………………………….. 36

10.4.5 Casing Gaskets …………………………………… 36

10.4.6 Stuffing Box Assembly – Packing ……………… 36

10.5 Tightening torques ……………………………….. 36

10.5.1 Casing Bolts ………………………………………. 36

10.5.1.1 Tightening sequence …………………………….. 36

10.5.2 Other Bolt Locations …………………………… 37

ssembly ………………………………………….. 32

5 AC6102 Rev 03

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10.6 Spare Parts ………………………………………... 37

10.6.1 Ordering Spare Parts …………………………….. 37

10.6.2 Storage of spare parts …………………………… 37

11 Troubleshooting …………………………………………… 39

12 Replacement Parts ………………………………………… 41

12.1 Series 8100 Horizontal Split Case Fire Pump … 41

12.2 Series 8200 Horizontal Split Case Fire Pump … 43

12.3 Series 9100 Horizontal Split Case Fire Pump … 45

12.4 Series 8150 Horizontal Split Case Fire Pump … 47

A Appendix …………………………………………………..… 49

1 Coupling Guard Removal - non CE version …... 50

2 Changing pump rotation …………………………. 51

AC6102 Rev 03 6

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Series 8100/8150/8200/9100 Fire Pump

7 AC6102 Rev 03

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1 Introduction

1.1 General

The A-C Fire Pump product line of horizontal split case centrifugal fire pumps are the product of careful engineering and skilled workmanship and, if properly installed, maintained, and operated, should deliver efficient and trouble-free service.

This manual introduces the user to the pump unit and its intended uses. It is extremely important that the instructions for operating the pump safely are read, understood and followed prior to handling the pump.

These instructions do not consider local regulations. The user alone is responsible for ensuring that such regulations are observed, including by those who are installing the pump unit.

CAUTION

Read this manual carefully before installing,

1.2 Target Group

This manual is intended for use by personnel with qualified training and experience in the operation and maintenance of pumps used for fire suppression.

1.3 Safe ty symbols used in this

operating, using and maintaining the pump. Improper use of the pump can cause personal injury and damage to property, and may void the warranty.

NOTICE

Save this manual for future reference, and keep it readily available at the location of the unit.

manual

NOTICE

Instructions that are not safety related but pertain to the operation of the pump.

WARNING

The sound pressure is so high that hearing protection must be used.

NOTICE

Read the installation, operation and maintenance instructions.

1.4 Manufacturer

A-C Fire Pump Systems 8200 N. Austin Avenue Morton Grove, Illinois 60053 USA Tel.: +1-847-966-3700 Web: www.acfirepump.com

1.5 Additional technical documents

 Order-related documents.  Operating and maintenance instructions, motor, (if

applicable).

 Operating and maintenance instructions, engine, (if

applicable).

 Supplier documentation, (coupling, etc.).  Documentation on accessories, (if applicable).  General dimensional drawing of the pump unit.  Performance curve of the pump.

2 Safety

WARNING

AC6102 Rev 03 8



If these safety instructions are not followed, it could result in serious personal injury or death, or property damage.

CAUTION

If these safety instructions are not followed, it could result in equipment malfunction of damage.

WARNING

Electric Shock Hazard, failure to follow safety instructions could result in personal injury or death.

WARNING

The surface of the pump may be so hot that it may cause burns or personal injury.

2.1 General

This manual contains general installation, operating and maintenance instructions that must be observed to ensure safe pump operation and to prevent personal injury and damage to property.

2.2 Intended Use

The standard horizontal split case pump is designed for use in the fire suppression applications, with each pump being designed according to customer requirements.

The pump must only be operated with the operating limits described in this manual and other applicable documents listed in section 1.5, Additional technical documents.

2.3 Improper Use

The operational safety of the pump unit can only be guaranteed, if the pump is used in accordance with the specifications in the sections of this manual. The operational limits as stated on the pump unit’s nameplate must never be exceeded.

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WARNING

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WARNING

Eyebolts or lifti are for lifting o to which they Failure to follo result in prope

WARNING

Do not operat flow (closed s Explosion cou to follow thes could result in damage, seve or death.

CAUTION

Do not run pu damage may pump seal reg Replace as re lubrication req consult servic Failure to foll could result in damage.

CAUTION

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

C6102 Rev 03

2.11 Product Warranty

4 Operational Limits

2.11.1 Coverage

A-C Fire Pump undertakes to remedy defects in their products under these conditions:

 The faults are due to defects in design, materials, or

workmanship.

 The faults are reported to a local sales and service

representative within the warranty period, as described in the Terms and Conditions of Sale provided with the Sales Contract.

 The product is used only under the conditions that

are described in this manual.

 The monitoring equipment that is incorporated in the

product is correctly connected and in use.

 All service and repair work is performed by qualified

personnel.

2.11.2 Limitations

The warranty does not cover defects that are caused by these situations:

 Deficient maintenance.  Improper installation.  Modifications or changes to the product that are

made without consulting an A-C Fire Pump authorized representative.

 Incorrectly executing repair work.  Normal wear and tear.

A-C Fire Pump assumes no liability for these situations:

 Bodily injuries.  Material damages.  Economic losses.

2.11.3 Warranty Claim

A-C Fire Pump products are manufactured to the highest quality standards with expected reliable operation and long life. However, should the need for a warranty claim arise, contact your local sales and service representative.

3 Applications

A-C Fire Pump Horizontal Split Case Centrifugal Fire Pumps are designed to provide water to stand pipe, sprinkler, and hydrant systems for fire suppression in industrial and commercial facilities.

WARNING

Do not operate the pump at pressures, flow rate or liquid temperature other than those for

Pumps are not to be operated outside the operating limits as stated on the nameplate.

which the pump has been rated. Failure to follow these instructions could result in serious personal injury or death, or property damage.

4.1 Pumped liquids

The pumps are suitable for clean water that does not contain solid particles or fibers.

4.2 Liquid temperature

Maximum permissible liquid temperature for motor driven pump units is 105°F [40°C].

Maximum permissible liquid temperature for engine driven pump units is dependent on the cooling water requirements as identified in the Engine Manufacturer’s Installation Manual.

The pump is designed to handle temperatures up to 250°F [120°C].

4.3 Pressure limits

The maximum working pressure for the horizontal splitcase series of pumps are as follows:

Type

8100

8150 Ductile Iron 325 [22]

8200

9100

Table 1 Maximum Working Pressure

Casing

Material

Cast Iron 225 [15]

Ductile Iron 375 [25]

Cast Iron 450 [30]

Ductile Iron 650 [45]

Cast Iron 250 [17]

Ductile Iron 375 [25]

Maximum

Working

Pressure

psi [bar]

WARNING

Using the pump in an application other than

AC6102 Rev 03 10



as described is considered improper use. A-C Fire Pump shall assume no liability for product that is used improperly.

4.4 Ambient temperature

Maximum ambient temperature for motor drive pump units is 105°F [40°C], based on the maximum ambient rating of the motor.

Maximum ambient temperature for engine driven pump units is identified in the engine manufacturer’s installation manual.

4.5 Pump Speed

The pump speed is listed on the nameplate on the pump unit.

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5.1

The pump i specially d similar veh determine transport o

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e Pump uni

pplied with li

lied with lifting h

hown in Fig. 2. he four corners

do not touch t gs, chains, or

ment for the loa

om the vertical.

(Model 15

fting holes

oles in the sides

lace lifting hoo

of the base. Be

e bottom of the ire rope to the li

, so that the lift

M)

or the

s in ure

ump

ting

ngle

5.2

5.2.1

The bare s Place a nyl pulled tight

andling

WARNING

Lifting devic must only b Eyebolts or for lifting th attached. D suspended l device or ri personal inj

NOTICE

Dispose of a with local re

are Shaft P

aft pump shoul

n sling around

choker hitches.

es must be suff

used by autho

lifting lugs, if pr

components t

not stand und

oads. A failure

ging can result

ry or death, or

l packing materi ulations.

mp (Model

be lifted as sh

both bearing s

ciently strong a

rized personnel

vided, are onl

which they are

rneath

n the lifting in serious property dama

ls in accordanc

100)

own in Fig. 1. pports using

nd .

e.

Fig. 2 How to

5.2.

.2 Bases su

Pum

units supplied

show

n in Fig. 3. Plac

housi

ng. Place the re

the m

otor as close to

sure the sling d

Make

it box. Join the

cond place

over the lifting

ning the sling u

positi

lift a Model 150

pplied witho

WAR

Do n

t use the lugs

casin

to lift the pum

ith bases witho

one sling arou

the mounting fe

es not damage ree ends of the ook. Use extre

nder the motor

ING

aining sling ar

pump unit larg

t lifting hole

n the pump up

unit.

ut lifting holes,

d the outboard und the back e t as possible. the housing cov

lings together a

e care when

o it cannot slip o

base

er

s

earing

d of

er or nd

ff.

Fig. 1 How t

11

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5.2.3 E

Before liftin manufactur

5.3

5.3.1 T

If the pump arrival, stor changes in covers in pl of the pum

Shaft exten should be preventativ

Rotate the the bearing corrosion,

How to lift a M

ngine drive

1

0E)

engine driven r’s instructions

torage

CAUTION

Damage du corrosion a unit.

NOTICE

For special engines, an manufacture storage proc

emporary S

is not to be ins

it in a clean, d ambient tempe ace to keep dirt

casing.

sions and other oated with an e

such as Valvo

ump shaft 10-1 with lubricant

nd to prevent f

del 150M pum

pump unit

pump unit, refe

.

to dirt and hu

d contaminatio

rotection of elec couplers, refer

r’s instruction for

dures.

orage

alled and oper ry place having ature. Leave pi

and other forei

exposed machi

sily removable

line Tectyl 502-

5 times twice a and to retard o

lse brinelling o

unit large bas

(Model

r to the engine

idity resulting i

of the pump

ric motors, dies

o the

their long term

ted soon after

slow moderate

ing connection n material out

ne surfaces rust

.

month to coat

idation,

the bearings.

n

l

5.3.2 L

Storage lon storage. Fol with the foll

Remove th

Apply a corr Corporation

AC61

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er than six mon

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gland and the p

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VpCI-329, to th

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long term

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tuffing box.

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6

6.1

The horizo stage [seri 8200] non

6.2

The fire pu on the nam represents:

Code

H

10

8

17

F-S

Ta

6.3

0/9100 Fire Pu

escriptio

eneral

tal split case c s 8100, 8150, elf-priming pu

esignatio

p can be ident plate; for exa

Description

No prefix=Ca H=Ductile iro

Suction inlet

Discharge ou

Nominal imp

S-small, M-m capacity imp

le 2 Key for s

ameplate

p

ntrifugal fire pu nd 9100] and t p.

fied by size de ple, H10 X 8 X

st iron A48;

A536

ize ANSI

tlet size ANSI

ller diameter

edium, L-large

ller

ize designation

mp is a single

o stage [series

ignation stated

17F-S

I

em Descript

1 Manufact

2 Approval

3 Size

4 Model Ty

5 Serial nu

6 Head [fe

7 Rated flo

8 Rated pr

9 Speed [

10 Number

11 Net pres

12 Net pres

13 Maximu

14 Maximu

15 Inboard

16 Outboard

17 Country

18 Impeller

on

urer

Agencies

pe

ber

t]

rate [GPM]

ssure [psi]

PM]

f stages

ure developed [

ure at 150% of

power [BHP]

suction pressu

earing number

bearing numbe

f origin

iameter [in]

si]

low [psi]

e [psi]

6.3.1 P

The namep attached to referenced used to ord digit of the orders of m

ump name

ate shows all i the upper casi

by the serial nu

r all spare and

erial number i

ore than one p

Fig. 4 Name

late

portant data o

g. Records for

ber and it mu

replacement p dicates the spe mp].

late of a Fire p

the pump. It is

he pump are

t, therefore, be rts. [The last

ific pump on

mp

6.3.

Pump u

The

ameplate sho

It is

ttached to the

Table 3 N

Fig. 5 N

meplate of a F

it namepla

s all important

pper casing.

meplate of a Fi

re-pump

e

ata of the pum

re pump unit

unit.

13



C6102 Rev 03

Item Description

1 Manufacturer

2 CE Mark

3 Type

4 Pump Size

5 Model series

6 Serial number

7 Engine type [engine driven pump units]

8 Motor voltage

9 Frequency

10 Impeller diameter [mm]

11 Rated flow rate [m3/hr]

12 Head [m]

13 Power [kW]

14 Speed [RPM]

15 Pump unit weight [kg] 16 Date of manufacture

17 Country of origin

Table 4 Nameplate of a Fire pump unit

6.4 Design detail

6.4.1 Casing

The pump casing is made from Cast Iron or Ductile Iron, and is an axially-split double suction volute design with the suction and discharge flanges and mounting feet cast integrally with the lower casing half.

Tapped and plugged holes are provided for priming, vent, drain, and gauge connections. The upper casing half can be removed without disturbing the suction or discharge piping. Pump flanges are made with ANSI Class 125 or 250 drillings, and come in the following combinations, [Suction/Discharge]: 125/125; 125/250; and 250/250.

The suction and discharge are on a common centerline in the vertical direction for all pump model types; and on a common horizontal centerline for model types 8100, 8150, and 9100.

6.4.2 Impeller

The impeller is an enclosed double suction type made of bronze, which is statically and hydraulically balanced. The impeller is firmly secured to the shaft by a key positioned by shaft sleeves and both locked in place by shaft sleeve lock nuts.

The shaft sleeves are made of bronze and protect the shaft from wear and from contact with the pumped liquid. Shaft sleeves are locked in place by threaded bronze shaft sleeve nuts. An O-ring is furnished under the sleeve to prevent leakage.

6.4.5 Stuffing Box

The stuffing box consists of die formed, graphite coated, synthetic fiber packing rings; and a split type gland to permit removal and access to the packing. The 8100 stuffing box housing is made of cast iron, and is separate from the pump casing. The stuffing box housing is drilled and tapped for drain connections.

6.4.6 Casing Rings

The casing rings are made of bronze and are installed with an anti-rotation device and designed to restrict leakage across the ring fit.

6.4.7 Bearings

The bearings are grease lubricated rolling type selected to carry radial and thrust loads. The outboard bearing is retained to handle the axial thrust.

6.4.8 Bearing Housings

The bearing housings are bolted to the pump and are piloted to positive alignment of the rotating element. The housings provide a fit for the inboard bearing that allows freedom for thermal expansion while the outboard bearing(s) are clamped in place in order to take all the thrust loads and keep the rotating element in its proper axial location. Openings for adding grease and draining grease are provided.

6.4.9 Baseplate

The baseplate is welded construction, manufactured from steel and is sufficiently rigid to support the pump and the driver.

6.4.10 Coupling

The coupling is of the flexible type. The coupling hubs are secured to the driver and the driven shafts by a setscrew located over the key.

6.4.11 Coupling Guard

The coupling guard is made of metal, and meets the requirements of EN ISO 13857.

6.4.12 Rotation

Pumps have a clockwise or counterclockwise rotation when viewed from its driven end.

6.4.3 Shaft

The shaft is made of AISI 1045 or 4140 steel and of ample size to operate under load with a minimum deflection.

6.4.4 Shaft sleeves

AC6102 Rev 03 14



Series 8100/8150/8200/9100 Fire Pump

6.5 Noise characteristics

The maximum measured A-weighted sound pressure level

] for the pump and motor, measured at a distance of

[L

pA

3.3 ft. [1m] from the pump, under full load, in accordance with EN ISO 3746 is 90dB.

The maximum measured A-weighted sound pressure level

] for the pump and diesel engine, measured at a

[L

pA

distance of 3.3 ft. [1m] from the pump, under full load, in accordance with EN ISO 3746 is 106dB.

6.6 Scope of supply

The pump unit includes the following items:

 Pump  Driver, (motor or engine)  Baseplate  Coupling  Coupling guard

6.7 Dimensions and weights

Refer to the general dimensional drawing supplied with the pump unit

7 Installation

This section describes the installation of a complete pump unit.

CAUTION

7.1 Location

Install the pump in a well-ventilated, dry place above the floor level wherever possible. Take care to prevent the pump from freezing during cold weather when not in operation.

The pump should be installed with sufficient space around it to facilitate ventilation and accessibility for inspection, maintenance and service. A clear space with ample head room should be allowed for the use of an overhead crane or hoist to lift the unit.

Install the pump as near to the suction supply as possible, with the shortest and most direct suction pipe practical. The total dynamic suction lift (static lift plus friction losses in suction line) should not exceed the limits for which the pump was sold.

When installing the pump, consider its location in relation to the system to assure that sufficient Net Positive Suction Head [NPSH] is available at the pump inlet connection. Available NPSH [NPSH NPSH [NPSH

The pump must be primed before starting. Whenever possible, the pump should be located below the fluid level to assure priming. This condition provides a positive suction head on the pump. It is also possible to prime the pump by pressurizing the suction vessel.

Installations should be performed by persons qualified in the setting up of pumping equipment.

WARNING

All electrical work should be carried out by qualified personnel.

WARNING

Engine-driven pump units: The engine must be provided with adequate ventilation to satisfy the requirements of the combustion system, and allow adequate dissipation of radiated heat and exhaust emissions.

] must always equal or exceed the required

A

] of the pump.

R

15 AC6102 Rev 03



7.2 Foundation

We recommend that the pump unit should be installed on a concrete foundation, sufficiently substantial to absorb vibration and to form a permanent, rigid support for the baseplate.

A base of concrete weighing 3 to 5 times the weight of the pump unit is recommended.

The foundation should be 3 to 6 inches [75 to 150mm] longer and wider than that of the baseplate that will be installed.

Foundation bolts must match those of the base plate. The foundation should be poured without interruption to within 1/2 to 1-1/2 inches [12.7 to 38.1mm] of the finished height. The top surface of the foundation should be well scored and

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6. An option the top of th alignment t bolt length f washers. T several day

In installati particularly mass of at

re the concrete

e grout.

bolts should be al 4 inch [102m

concrete will a

match the hole

r grout, shims, l

e foundation sh

before the bas

ns where lower

important, we r

east 5 times th

sets; this provid

et in concrete a

] long sleeve ar

low some flexibi

in the base plat

wer base plate

uld be allowed

plate is shimm

sound and vibr

commend a fo t of the compl

s a bonding

shown in Fig.

und the bolts a ity in bolt e. Allow enough flange, nuts and o cure for

d and grouted.

tion levels are

ndation with a

te pump unit.

remo

e coupling gua

chec

ing alignment.)

If alig

nment needs im

appr

priate positions

retigh

tening of the an

ent. Repeat thi

align align

ent” is reached

NOT

: Reasonable a

mutu

lly agreed upon

facilit

(final operator)

Chec

k to make sure t

pum

flanges without

Pour

grout in the bas

Grou

ing) and allow g

pipin

to pump. (24 h

grouti

ng procedure.)

d, see section 8

rovement, add

under the basep

hor nuts will shi

procedure until

.

lignment is defin by pump contra .

at the piping c

placing pipe str

plate completel

rout to dry thoro

s is sufficient

.2 Coupling Gua

hims or wedge

late, so that

t the shafts into

a “reasonable

d as that which

ctor and the acc

n be aligned to t

in on either flan

y (see section 7

ghly before atta

time with appro

rd, for

at

closer

is

pting

he

e.

4 ching ed

7.3

Use blocks anchor bolt baseplate a foundation, plate, as sh

By adding o plumb the p have to be l

Draw ancho motor shaft

Fig. 6

eveling the

WARNING

Lifting devic must only b Eyebolts or l lifting the co attached. D loads. A fail can result in or property

NOTICE

This proced foundation h hold down b the pump un pump and d aligned at th mounted, co recommend assume res

nd shims unde

and midway be

proximately 1 i

ith studs exten

wn in Fig. 7.

removing shim

mp shaft and fl

vel.

nuts tight agai

or coupling hub

Foundation

baseplate

s must be suffi

used by author

ifting lugs, if pro

ponents to whi not stand unde re in the lifting serious person amage.

re assumes tha

s been prepare

lts extending u

t. It must be un

iver have been

factory. If the d sult AC Fire Pu

tions. AC Fire P

onsibility for fina

the baseplate f

ween bolts, so ch [25.4mm] ab

ing through hol

under the bas

nges. The base

st base, and ob

s for alignment.

iently strong an zed persons.

ided, are only f

h they are

neath suspend evice or rigging l injury or death,

a concrete

with anchor or ready to receiv erstood that the

ounted and rou

river is to be fiel

p for ump cannot l alignment.

r support at the

s to position the

ve the concrete

s in the base

, level and

late does not

erve pump and Temporarily

Fig.

Leveling of pu

r

d

h

7.4

Grou

compensates f

weig

t of the pump u

appr

ved, non-shrinki

unit,

see Fig. 7).

Build

a strong form ar Soak the top of

grout and t

en remove any

be co

mpletely filled wi

After

the grout has th

found

ation bolts and t

ent after the fo

align

Appr

ximately 14 day

when

the grout has th

exposed edges

to th from

oming in conta

Groutin

g

uneven found

it, and prevents

ng grout, after s

und the founda

the concrete fo

surface water. T

th grout.

roughly harden

ighten if necess

ndation bolts ar

s after the grout oroughly dried,

of the grout to p t with the grout.

p unit

tion, distributes

shifting. Use an

tting and levelin

ion to contain th

ndation thoroug

he base plate s

d, check the

ry. Check the

tightened.

has been poure

pply an oil base

revent air and m

the

g the

e

ly,

ould

or paint oisture

AC61

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8100/8150/820

7.5 I

0/9100 Fire Pu

itial Align

WARNING

Disconnect performing instructions injury.

NOTICE

The alignme motor driven for Engine-d the Engine

WARNING

Replace co alignment. could result

CAUTION

Misalignmen and bearing bearing failu

p

ent

nd lock out po

lignment. Failu

could result in

nt procedures th

pump units. Ali

iven pump units

anufacturer’s In

pler guard afte

ailure to follow

in serious pers

t causes excess

oads that result e and ultimate s

er before

e to follow the

erious persona

t follow are for

nment procedur

are available in

stallation Manua

performing

these instructio

nal injury.

ve wear, vibrati in premature

izing of the pu

7.5.

Straight

The

ost simple alig

calip

rs. This method

dial i

e

s

l.

s

n,

p.

dicator or laser i

7.5.1

.1 Angular

With

oupling hubs st

gap

etween the cou

shim

equipment until

the h

bs are within th

(see

ig. 8).

Fig. 8 A

dge metho

ment check is w is the least acc

s not available.

lignment

tionary, use cal

ling hubs at 90°

he gap differen

coupler manuf

gular Alignment

of alignme

ith a straight ed rate, but will ser

pers to measur intervals. Adjust

e at all points ar

cturers guidelin

t

e and

e if a

the

and/or

und

s,

When a co the factory, means of

The pump/ transport a parallel, or vertical plan

Proper align This should set and gro

Alignment s driver only recommend temperatur

All measure foot bolts tig

There are t flexible cou are not par are parallel

There are t misalignme

1.

2.

3.

NOTICE

Alignment s the pipes; if the pump, a driver.

NOTICE

Read Coupli supplied wit perform alig

plete pump uni

the coupling ha

s

ims inserted u

river could hav d installation.

combination of

s.

ment is essentia be performed af

t has dried thor

ould be made ntil the coupling ed tolerances, a s under normal

ents should be

htened.

o types of misa

lings: angular

llel, and parallel

ut not on the s

ree methods co

t:

Straight edg Dial indicato Laser Align manufacture

ould be made b

ot, it may not b

d it will be diffic

g Manufacturer the pump unit ment.

t comes pre-as

been accurat der the pump a

become misali

isalignment can hese, and in th

l for correct pum

er base plate h

ughly according

y moving and s

hubs are within

d should be m onditions.

taken with the

ignment encoun isalignment, in misalignment, me axis.

monly used to

and calipers.

ent Equipment ( ’s instructions f

fore connecting

possible to mo

lt to move the

instructions

efore attempting

embled from

ly aligned by

d driver.

ned during be angular, horizontal and

p operation.

s been properly

to instructions.

imming the

the

de at operating

ump and driver

tered with

hich the shafts

here the shafts

determine

see

r use).

e

to

7.5.1

.2 Parallel

With

oupling hubs st

the ri

of the couplin

vertic

al and horizontal

equip

ment until the st vertical and hori

rims, manu

facturer’s guidel

7.5.

Dial indi

The

ial indicator sho

accu

acy is required.

guide

line for accepta

lignment

tionary, lay stra

hub at 90° inte

alignment offse

aight edge lies f

ontal. Check th

ine for permissib

Fig

. 9 Parallel Align

ator metho

ld be used whe

heck the coupl

le alignment tol

F

ig. 10 Dial Indic

ight edge flat ag vals to determin

s. Adjust and/or

lat against both

coupler

le gap, (see Fig.

ment

of alignme

greater alignm

r manufacturer’

rances.

tor

inst

shim

ub

9).

t

nt

17



C6102 Rev 03

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d

7.5.2.1

To check a coupling hal face of the both couplin rotate both match; ens the same s for accepta

ngular Align

gular alignment,

(X), and positio

pposite couplin

g hubs as show

oupling halves t ring that the indi ot. Check the c

le alignment tol

ent

mount dial indic

n the dial indicat

half (Y). Scribe

in Fig. 10. Set

gether, so that ator button alw

upler manufactu

rances.

tor (A) to the

rs button on th index lines on he dial to zero,

he index lines

ys indicates off

rer’s guideline

specified in Tab

limits

stment is need

If adj remo

e an equal amo

align

he height. To c

of th

motor foot with

Tight

n the motor bol

in all

irections, if a c

until t

he desired resul

e 5.

d, loosen the m

unt of shims un

rrect side misali

a mallet.

s and check ag rrection is mad is obtained.

tor bolts and ad

er each motor f

nment, strike th

in. Re-check ali

. Repeat the pro

or

ot to

e side

nment

cess

7.5.2.2 P

To check p coupling hal outside dia

10). Set the so that the i button alwa manufactur

7.5.3

The followin alignment o Protection Couplings.

Alignment i which has b applications dial indicato

7.5.3.1

Clean all m seals lightly place on sh mount hubs Reposition specified in should be a the setscre

7.5.3.2

Use a spac Table 5. Ins intervals an face with fe maximum installation l

rallel Align

rallel alignment,

(X), and positio

eter of the opp

dial to zero, rota

dex lines match s indicates off t r’s guideline for

lignment of

procedure is i Rexnord Indust roducts, Inc., Ty

shown using a

en prove to be

However, for s

s is recommend

ount Seal an

tal parts using n

with coupling m

fts before moun with flange face ubs on shafts a able 5. The len

proximately eq

s.

ap and Angul

r bar equal to th

rt bar, as show

measure clear

ler gage. The di

easurements m

mits specified in

ent

mount dial indic

n the dial indicat

site coupling hal

e both coupling

; ensuring that t

e same spot. C

acceptable align

rid couplin

tended for mou

ies, LLC and Cl

e T10 Close C

pacer bar and s

ccurate for ma

perior final align

ed, per 7.5.2.

Hubs

on-flammable s

nufacturer supp

ting shaft hubs. I

flush with the s

required achie

th of engageme

al to the shaft di

ar Alignment

ckness to the g

above to the s nce between th ference in mini

st not exceed t Table 5.

tor (P) to the

rs button on th

(Y), (see Fig.

halves together,

e indicator eck the coupler

ment tolerances

s

ting and

rke Fire

upled Grid

raight edge,

y industrial

ment, the use of

lvent. Coat the lied grease and nstall keys and haft ends. ing the hub gap

t on each shaft

meter. Tighten

X-Y)

p specified in

me depth at 90°

bar and hub um and

e angular

Fig.

7.5.

.4 Insert Gri

Com

letely pack gap

suppl

ied grease befor hed in two or m

furnis

extend in the sa

ends

sure correct gri

will e halve

s.

Spre

d the grid slightl

seat

ith a soft mallet

12 Using Straig

and grooves wit e inserting grid.

re segments, in

e direction as

contact with n

Fi

. 13 Grids mag

y to pass over t , (see Fig. 14).

t edge

coupling manu

hen grids are

tall them so tha

hown in Fig. 13.

n-rotating pin in

ified

e coupling teeth

acturer

all cut This cover

and

Fig. 11 U

7.5.3.3 P

Align so tha limits specifi also at 90° i The clearan

AC61

2 Rev 03



rallel Offset

a straight edge

ed in Table 5 on

tervals, (see Fi e must not exc

ing Spacer Bar

lignment (P)

rests squarely, (

both hubs as sh

. 12). Check wit

ed the Parallel

r within the

own above and

feeler gages.

ffset installation

Fi

. 14 Seating th

7.5.

.5 Pack wit

Com

letely pack the

with

s much grease

with t

p of the grid. P

groo

es in the cover.

cover

half and assem

same side, (se

on th faste

ers tightening t

grease and

paces between

s possible and

sition seals on

Position gaskets

le covers so th

Fig. 15). Secu

torque specifie

grid

ssemble cov

and around the

ipe off excess f ubs to line up w on flange of low t the match mar

e cover halves

in Table 5.

rs

rid

lush

th the

er

s are

ith

18

Serie

s

P

O

AINC

m

r

a

t

n

l

g

x

h

e

F

a

%

d

F

Amm

3

5

3

1

n

w

P

D

a

U

Wtc

Isd

Iur

M

W

d

R

m

w

s

i

a

P

N

Aps

a

D

aft

e

a

e

o

FTiT

l

n

T

o

a

o

u

w

m

s

r

n

t

m

s

h

s

n

s

a

jo

n

z

t

a

r

v

d

p

t

p

u

s

c

8

o

u

0

n

c

e

g

uay

h

c

o

e

r

b

e

c

r

s

w

e

o

p

n

r

w

e

n

t

c

u

s

a

8

g

A

n

m

n

t

s

i

o

e

r

o

w

e

n

i

r

8100/8150/820

0/9100 Fire Pu

p

SIZE

1040T 10

1050T 20

1060T 20

1070T 20

1080T 20

Cover

astener ghtening Torque

in.

lb Nm

0 11.3 360

0 22.6 360

0 22.6 180

Table 5 Conti

Fig. 15 Cove

7.6

installation

Pipe co

CAU

ION

Do n

t draw piping in

at the

flanged conne

strain

adversely affe

pump

, which could r

dama

ge.

nections

Maxim

m

Allowa

ble

Spee

d

(rpm

)

1.90 54

2.40 68

3.00 86

4.00 114

6.10 172

ued

to place by usi

tions of the pu ts the operatio sult in serious i

Lube Wt.

oz g

g force

p. Pipe

of the

jury or

Size

1040T 0.0

1050T 0.0

1060T 0.0

1070T 0.0

1080T 0.0

WARNING

Do not oper lubrication.

CAUTION

Ensure that cover.

Fig. 16 Misalig

arallel

ffset (P)

M

X H MAX

mm

1 0.15 0

1 0.20 0

1 0.20 0.01

Table 5 Misal

te coupling wit

he lube plugs ar

ment and End

Insta

lation Limits

An

ular

(

-y)

MAX

INCH

mm

0.08 0.13

0.10 0.13

0.13 0.13

0.15 0.13

ignment and En

Hub G

MAX

INCH

± 10

out proper

installed in the

loat

End Float

p

(Min) 2 x

MAX

mm

INCH

3 0.21 5.

3 0.26 6.

3 0.29 7.

float

7.6.

Suction

precauti

Whe

installing the p

follo

ing precautions:

1.

iping should al

2.

o not move pu

lignment impos

3.

se pipe hange

i

ntervals to provi

hen expansio

4. hey must be ins

losest to the pu

5.

t is usually advi

uction and disc ecrease the los

6.

nstall piping as

nnecessary be

adius 90° fitting

7.

ake sure that

8.

here flanged

iameters match

9.

emove burrs a

Maxi

um forces and

vary

ith the pump si

force

and moments

misal

ignment, hot be

prem

M

X

6

8

5

8

2

ture pump failu

1.

revent excessi

2.

ever “spring” pi

3.

nchor indepen iping near the train is transmit re tightened.

4.

o not install ex ny way that wo om system pre

ie bolts and spa

xpansion joints

The t

bles in 7.6.2 su

mom

nts allowed on

Horiz

ntal Split Case

nd dischar ns

mp piping, be s

s be run to t

p to pipe. This

ible. s or other supp de support.

joints are used

alled beyond th

mp.

able to increase

arge pipes at th s of head from f

traight as possi ds. Where nec to decrease fri

ll piping joints a

ints are used, a

properly.

d sharp edges

moments allow

e and series. T

hat may, if exce

rings, worn cou

re, the following

e external pipe l

ping when maki

ently both the s

ump and prope

ed to the pump

ansion joints n

ld cause a strai

sure changes. I

er sleeves sho

to prevent pipe

mmarize the m

100, 8150, 820

fire pump casin

e piping ge

e to observe th

e pump.

ould make final

rts at necessary

in the piping sys

piping support

the size of both e pump connect iction.

le, avoiding

ssary, use 45°

tion losses.

e air-tight.

sure that inside

hen making up

d on the pump f

minimize thes ssive, cause plings, vibration

should be obse

oading.

g any connecti uction and disch ly aligned so tha

hen the flange

xt to the pump o

on the pump r

is recommend ld be used with train.

ximum forces a

0, and 9100 ser

.

neral

e

em

ons to

r long

joints.

langes

and ved:

ns.

ge

a t no

bolts

r in

sulting

d that

d

es

19



C6102 Rev 03

y

7.6.2 Maximum forces and moments allowed on pump flange

7.6.2.1

8100 series Horizontal Split Case maximum forces and moments allowed

Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)

Size

3X2X11

6X4X9

6X4X10

6X4X11

6X4X12

6X6X9

8X6X9

8X6X10

8X6X12

8X6X13

8X6X18

8X8X12

8X8X17

10X8X17

10X8X20

12X10X18

Fx F

F

37 46 40 20 25 51 28 30 38 24 25 30

(165) (205) (178) (27) (34) (69) (125) (133) (169) (33) (34) (41)

143 178 102 103 129 258 32 40 47 20 25 51

(636) (792) (454) (140) (175) (350) (142) (178) (209) (27) (34) (69)

143 178 102 103 129 258 32 40 47 20 25 51

(636) (792) (454) (140) (175) (350) (142) (178) (209) (27) (34) (69)

143 178 102 103 129 258 32 40 47 20 25 51

(636) (792) (454) (140) (175) (350) (142) (178) (209) (27) (34) (69)

124 155 88 89 112 224 33 42 44 21 26 54

(552) (689) (391) (121) (152) (304) (147) (187) (196) (28) (35) (73)

143 178 102 103 129 258 117 147 89 91 114 229

(636) (792) (454) (140) (175) (350) (520) (654) (396) (123) (155) (311)

143 178 102 103 129 258 117 147 89 91 114 229

(636) (792) (454) (140) (175) (350) (520) (654) (396) (123) (155) (311)

201 251 116 156 195 390 117 147 89 91 114 229

(894) (1116) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)

201 251 116 156 195 390 117 147 89 91 114 229

(894) (1116) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)

181 227 116 156 195 390 80 100 71 57 72 144

(805) (1010) (516) (212) (264) (529) (356) (445) (316) (77) (98) (195)

227 284 150 202 253 506 68 85 78 53 66 132

(1010) (1263) (667) (274) (343) (686) (302) (378) (347) (72) (89) (179)

170 213 116 156 195 390 117 147 89 91 114 229

(756) (947) (516) (212) (264) (529) (520) (654) (396) (123) (155) (311)

195 244 133 179 223 447 90 112 92 75 93 187

(867) (1085) (592) (243) (302) (606) (400) (498) (409) (102) (126) (254)

463 579 274 463 579 1158 150 187 129 133 166 333

(2059) (2575) (1219) (628) (785) (1570) (667) (832) (574) (180) (225) (452)

514 643 304 514 643 1287 167 208 143 148 184 370

(2286) (2860) (1352) (697) (872) (1745) (743) (925) (636) (201) (250) (502)

490 613 270 544 680 1361 169 211 153 168 211 422

(2180) (2727) (1201) (738) (922) (1846) (752) (939) (681) (228) (286) (572)

Suction M

z

M

x

M

F

z

F

x

Discharge

F

M

z

M

x

M

z

7.6.2.2 8200 series Horizontal Split Case maximum forces and moments allowed

Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)

Size

8X6X14

8X6X18

Fx F

F

454 568 300 404 506 1012 136 170 156 106 132 264

(2019) (2526) (1334) (548) (686) (1372) (605) (756) (694) (144) (179) (358)

454 568 300 404 506 1012 136 170 156 106 132 264

(2019) (2526) (1334) (548) (686) (1372) (605) 756 (694) (144) (179) (358)

Suction M

z

M

x

M

F

z

F

x

F

Discharge

M

z

M

x

M

z

7.6.2.3 9100 series Horizontal Split Case maximum forces and moments allowed

Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)

Size

12X8X21

12X8X22

14X10X20

16X12X23

Fx F

193 242 167 226 282 565 79 98 108 92 115 230

(858) (1076) (743) (306) (382) (766) (351) (436) (480) (125) (156) (312)

193 242 167 226 282 565 79 98 108 92 115 230

(858) (1076) (743) (306) (382) (766) (351) (436) (480) (125) (156) (312)

571 714 284 666 833 1666 196 245 160 207 259 518

(2540) (3176) (1263) (903) (1130) (2259) (872) (1090) (712) (281) (351) (702)

623 779 323 865 1081 2163 215 268 192 298 373 746

(2771) (3465) (1437) (1173) (1466) (2933) (956) (1192) (854) (404) (506) (1012)

F

AC6102 Rev 03 20

Suction M

z

M

x

M

F

z

F

x

F

Discharge

M

z

M

x

M

z



y

Series 8100/8150/8200/9100 Fire Pump

7.6.2.4 8150 series Horizontal Split Case maximum forces and moments allowed

Size

Fx F

16X10X22

623 779 323 865 1081 2163 196 245 160 207 259 518

(2771) (3465) (1437) (1173) (1466) (2933) (872) (1090) (712) (281) (351) (702)

Maximum forces (F) in lbf (N) and moments (M) in lbf.ft (Nm)

Suction Discharge

F

M

z

M

x

M

F

z

F

x

F

M

z

M

x

M

z

21 AC6102 Rev 03



0

o

e

=

o

F

M

hmu

a+ ocano

2

a

h

o

d

p

H

p

2

a

2

l

m

3

s

r

s

p

o

b

o

n

r

n

c

m

s

p

c

E

c

e

n

w

o

p

v

p

o

n

b

y

e

o

e

p

l

e

a

s ar

n

m

)

o

T

b

u

e

b

w

etr

w

n

p

oer

n

a

p

s

h

o

g

h

u

t

e

h

n

o

t

u

n

l

t

e

a

p

s

e

o

b

o

s

p

g

b

u

m

h

p

y

c

s

a

g

t

.

c

e

a

e

s

t

o

m

p

b

p

s

y

p

S

v

e

s

a

u

e

h

c

e

c

a

o

i

h

t

h

e

n

c

b

a

s

P

e

Fig. 17 L

Notes:

1) F

2)

3) ∑

4) ∑

5)

6)

ad and moment

fir

pump casings

External force

M

= External mom

cl

ckwise) =√ F

+ F

x

=√ M

+ M

T

x

e nozzle loads

st not exceed t

V

lues given are f

r – direction. In

n be increased

t exceeded.

orientation for

(tension or com ent (clockwise o

+ F

, (∑F = result

y

z

+

M

y

z

pplied to the pu e values given i

r loads applied ividual forces a

rovided that ∑F

, (∑M = resu

orizontal Split C

ression (+/-))

counter-

nt force). tant moment).

p flanges

n the tables. concurrently in

nd moments

and ∑M are

ase

7.6.

Suction

The

izing and install

impo

tant. It must be losse pum Sucti sucti

Sucti possi sucti

A mi tee a requi openi

Ecce redu They reco pipe

A hor pum and the pi redu

NOT

redu pock and i

e minimized

when started a

n Head) proble

n piping system

n piping should

ble, and never s

n opening.

imum of ten (10

d the pump sh

ed, it should be

ng, depending o

ic reducers sh

tion each to avo

should be of the

mended. When

hould slope up

izontal suction li

. Any high point

revent proper o

ping to the sucti

with the ecce

: When operati

er in a horizont

t in the top of th

correct suction

18.

installing valve

Whe follo

ing precautions: sucti

n lift conditions, sucti

n line to avoid t pum

is started.

This

alve should be

multi

le spring type, s

sucti

n line. (Under al

should be instal

used,

Discharge Pipin

7.6.4

foot valves are

Whe possi

ilities of “water

slowl

before shutting

Wher

e two or more p

sucti

n line, install ga isolat

d from the line.

Gate

valves should b

s with a positive

pum Instal

l gate valves wit

Glob

valves should

piping

tion of the sucti

elected and ins

and sufficient liq

d operated. Ma

s can be direct

s.

be short in leng

aller in diamet

pipe diameters uld be allowed. I one or two sizes n its length.

CAU

ION

An el

ow should not

the s

ction of a doub

plane

is parallel to th

caus

an excessive

probl

ms in the pum

distri

ution. If there i

elbo

should have st

help

venly distribut

ould be limited t id excessive tur

conical type. C

operating on a

ard to the pum

e must have a

in the pipe can

eration of the p

n opening dia

ntric side down t

g on suction lift

l suction line, as

e reducer and t

piping arrangem

in the suction

If the pump is o

a foot valve ma

e necessity of p

f the flapper typ ized to avoid ex l other condition led in the disch

).

used, or where

ammer,” close

down the pump

mps are conne

e valves so that

installed on th

pressure for ma

stems horizont

ot be used, part

n piping is extr

alled so that pre

id will flow into

y NPSH (Net P

y attributed to i

h, as direct as

r than the pum

between any el f a long suction larger than the

be used directl le suction pum

pump shaft. T xial load or NP due to an une no other choic

raightening van

the flow.

one pipe size ulence and noi ntour reducers uction lift, the s

nozzle.

radual rise to th

ecome filled wit

mp. When redu

eter, use an ec

o avoid air pock

never use a con it tends to form

e pipe. Some c

ents are shown

iping, observe t

erating under s be installed in t

riming each tim

e, rather than th

essive friction i

, a check valve,

rge line, see se

here are other

he discharge va

ted to the same

any pump can

suction side of intenance purpo

l to avoid air po

icularly where N

mely

sure

he

sitive

proper

ow or

ipe is

uction

before if its

his can

H

en flow

, the

es to

e.

re not

ction

air ing

entric

ts.

entric

n air rrect n Fig.

e atic

e the

the

if

tion

lve

e

ll

es.

ckets.

SH is

AC61

2 Rev 03



22

Serie

s

m

s

t

y

m

.

m

n

o

e

s

r

o

4

e

a

o

a

w

s

)

p

r

g

n

5

e

r

a

b

a

6

c

b

p

c

e

7

m

e

g

e

n

r

o

v

c

o

d

w

P

p

t

m

t

S

C

s

n

e

p

h

k

w

m

C

s

n

N

u

p

n

a

u

N

u

p

g

a

o

e

a

n

e

a

x

m

s

b

u

p

s

e

p

e

A

b

h

a

s

o

u

e

g

o

m

g

d

r

u

q

e

s

8100/8150/820

critical.

The pump the suction only to isola should alwa

0/9100 Fire Pu

ust never be thr ide of the pump e the pump for

s be installed i

p

ttled by the us

Suction valves

aintenance pu

positions to av

of a valve on

hould be used

poses, and

id air pockets.

7.6.

Dischar

If the

discharge pipin

as the discharg

same

ter should be o

diam disch

rge opening. O

maint

ain an even a g

ps, which will c

as lo to err

tic pumping.

A slo

closing check

be in

talled in the dis

valve

, placed betwee

pum

from excessive

from

unning back thr

The

ate valve is use

shutti

ng the pump do

7.6.

Bypass

Wher

e the suction su

mate

ial value withou

with

bypass.

The

ypass pipe dia

disch

rge pipe diame

e piping

is short, the pip

opening. If the

e or two sizes l

long horizontal

ade as possible.

llect air and thr

alve and an iso

harge line. The

n pump and gat

back pressure,

ugh the pump i in priming and n.

iping

ply is of sufficie

the pump, the p

eter shall be at l er.

e diameter can

piping is long, t

ger than the runs, it is desir Avoid high spot

ttle the system

lating gate valve check valve (trip

valve, protects nd prevents liq

case of power

starting, and wh

t pressure to b

ump shall be ins

east as large as

e the

e pipe

ble to

, such

r lead

should le duty

the id

failure.

n

of

talled

the

7.6.

Cooling

The

ooling water su

shall

e from the disc

pum

discharge chec

The

ooling water flo

ambi

nt cooling para

Manu

facturer.

7.6.

Exhaust

System

NOTI

E

This

ection is only a

drive

pump units th

heat

xchangers.

ply for a heat e

arge of the pu valve.

shall be set ba

eters provided

system

NOTI

E

This

ection is only a

drive

pump units.

WAR

ING

Exha

st emissions m

safe

oint outside the

shall

ot affect person

Oper

tion of an engin

exha

st system can r

injury.

pplicable to en

t have water c

changer-type en

p taken off prior

ed on the maxi y the Engine

pplicable to en

st be discharge

ump room whe or endanger b without an ade

sult in serious p

ineoled

gine

to the

um

ine-

to a

e they

ildings.

uate rsonal

23



Fig. 18 Suction

piping arrangem

ents

Each

pump engine sh

. The exhaust

syste diam

ter than the en

as po

ssible.

WAR

ING

Exha

st pipes are hot

injury

if touched.

all have an inde

ipe shall not be

ine exhaust outl

and will cause s

endent exhaust

any smaller in

t and shall be a

rious

short

C6102 Rev 03

The exhaust pipe shall be covered with high-temperature insulation or otherwise guarded to protect from personal injury.

The exhaust pipe and muffler, if used, shall be suitable for the use intended, and the exhaust back-pressure shall not exceed the engine manufacturer’s recommendations.

Exhaust pipes shall be installed with clearances of at least 9 inch [229mm] to combustible materials.

7.6.8 Pressure Gages

Properly sized pressure gages 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.

7.7 Final alignment

WARNING

Do not operate pump with coupling out of alignment. Ensure final coupling alignment is within the values according to the coupling manufacturer’s instructions. Coupling, pump, or driver failure may occur. Failure to follow these instructions could result in serious personal injury.

After connecting piping to the pump, rotate the shaft several times by hand to ensure that there is no binding and all parts are free. Recheck the coupling alignment, as previously described, to ensure that there is no pipe strain. Correct, if necessary, by adjusting the motor only.

7.6.9 Stuffing box lubrication

7.6.9.1 General guidelines

Contaminants in the pumped liquid must not enter the stuffing box. These contaminants may cause severe abrasion or corrosion of the shaft, or shaft sleeve, and rapid packing deterioration; even plugging the stuffing box flushing and lubrication system.

The stuffing box must be supplied at all times with a source of clean, clear liquid to flush and lubricate the packing.

This is normally achieved with a supply from the pump discharge volute to the stuffing box. A control valve may be fitted into the supply line to control the pressure to the stuffing box.

7.6.9.2 Packing

Pumps are normally packed before shipment. If the pump is installed within 60 days after shipment, the packing will be in good condition with a sufficient supply of lubrication.

If the pump is stored for a longer period, it may be necessary to repack the stuffing box. In all cases, however, inspect the packing before the pump is started.

It is important to establish the optimum flushing pressure that will keep contaminants from the stuffing box cavity. If this pressure is too low, fluid being pumped may enter the stuffing box. If the pressure is too high, excessive packing wear may result; and extreme heat may develop in the shaft causing higher bearing temperatures.

The most desirable condition, therefore, is to apply seal water at a flow rate of approximately 0.25 gpm [0.95 lpm] at a pressure approximately 15-20 psig [1 bar] above the maximum stuffing box pressure. [Approximately one [1] drop per second.]

NOTE: Packing adjustment is covered in section 9, Maintenance.

7.8 Electrical Connection

WARNING

Risk of electric shock. All electrical connections shall be performed by a qualified

The operating voltage and frequency are marked on the motor nameplate.

The motor must be suitable for the power supply at the installation site.

The electrical connections should be carried out as shown on the motor nameplate and/or the terminal box.

electrician in accordance with all applicable codes, ordinances and good practices. Failure to follow these instructions could result in serious injury, death and/or property damage.

WARNING

Risk of injury due to rotating parts. Isolate the motor from its supply voltage and keep it locked out when performing any work on the pump.

NOTICE

Follow the instructions of the motor manufacturer.

NOTICE

Engine-driven pump units: The requirement for the electrical connection of the engine unit is covered in the engine manufacturer’s Installation Manual.

AC6102 Rev 03 24



Series 8100/8150/8200/9100 Fire Pump

8 Start-up, operation and

shutdown

8.1 Start-up

WARNING

Start-up should be carried out by authorized personnel. Do not start the pump until all prestart-up checks have been performed

11. Assure that coupling is properly lubricated, if required.

12. Assure that pump is full of liquid and all valves are

properly set and operational, with the discharge valve closed and the suction valve open. Purge all air from top of casing.

13. Check rotation. Be sure that the driver operates in the

direction indicated by the arrow on the pump casing as serious damage can result if pump is operated with incorrect rotation.

8.1.2 Priming

CAUTION

Do not start the pump until it has been completely filled with liquid and vented. The pump must not run dry as this will result in serious damage to the pump.

WARNING

Electric Shock Hazard: Electrical connections are to be made by qualified personnel, in accordance with applicable codes, ordinances, and good practices.

NOTICE

See also installation and operating instructions for the electric motor, if applicable.

NOTICE

See also installation and operating instructions for the diesel engine, if applicable. We recommend that you register the diesel engine with the manufacturer before start-up. Otherwise, the engine manufacturer cannot provide any warranty if the engine is faulty.

8.1.1 Preparation for startup

WARNING

Unexpected Start-up Hazard: Disconnect and

Before the initial start of the pump, perform the following inspections:

1. Remove all corrosion protection materials, referenced in section 5.3 Storage, in accordance with the manufacturer’s recommendations.

2. Check alignment between pump and driver, (motor or

engine). See section 7.5 Initial Alignment.

3. Check that all pipes and hoses are installed correctly.

4. Check all electrical connections. Check voltage, phase,

and frequency.

5. Check suction and discharge piping and pressure

gauges for proper operation.

6. Check that all safety devices are installed.

7. Turn rotating element by hand to assure that it rotates

freely.

8. Check stuffing box adjustment, lubrication, and piping.

9. Check driver lubrication.

10. Assure that pump bearings are properly lubricated.

lockout power before performing pre-start-up checks. Failure to follow these instructions could result in serious personal injury or death.

NOTICE

Flushing: New and old systems should be flushed to eliminate all foreign matter. Heavy scale, welding splatter and wire or other large foreign matter can clog the pump impeller.

If the pump is installed with a positive head on the suction, it can be primed by opening the suction valve, and loosening the vent plug on top of the casing (Do not remove), allowing air to be purged from the casing.

If the pump is installed with a suction lift, priming must be done by other methods such as foot valves, ejectors, or by manually filling the casing and suction line.

All drains should be closed when filling the system. Filling should be done slowly so that excessive velocities do not cause rotation of the pumping elements which may cause damage to the pump or its driver. The adequacy of the piping anchors and hangers may be checked at this time by mounting a dial indicator off of any rigid structure not tied to the piping and setting the indicator button on the pump flange in the axial direction of the nozzle.

If the indicator moves, as the filling proceeds, the anchors and supports are not adequate or set properly and should be corrected.

8.2 Coupling Guard

WARNING

Unexpected Start-up Hazard: Disconnect and lockout power before performing pre-start-up checks. Failure to follow these instructions could result in serious personal injury or death.

NOTICE

The coupling guarding described herein refers to guarding that is supplied by A-C Fire Pump for pumps that have a motor driver. For pumps with an engine driver refer to the engine manufacturers instructions, supplied with the pump unit.

NOTE: The coupling guard fasteners have devices that keep them from completely detaching from the guard or the pump. Do not remove these devices or separate the fasteners from the guard or the pump.

NOTE: Do not spread the inner and outer guards more than necessary for guard removal or installation. Over-spreading the guards may alter their fit and appearance.

25 AC6102 Rev 03



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9 Coupling Gu

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2

AC61

2 Rev 03



26

Series 8100/8150/8200/9100 Fire Pump

8.3 Operation

8.4 Shutdown

WARNING

Pump units have a sound pressure level higher than 85 dB(A). Hearing protection must be worn when the pump is running.

WARNING

Do not operate the pump at or near zero flow, i.e. closed discharge valve. Explosion could result. Failure to follow these instructions could result in serious personal injury and part damage.

WARNING

Do not operate the pump unless all guarding are in place.

8.3.1 General Procedure

1. Close drain valves and valve in discharge line.

2. Open fully all valves in the suction line.

3. Slowly turn on seal water to the stuffing box. (If pumped fluid is dirty or if leakage of air is to be prevented, these lines should be always left open.)

4. Prime the pump. [NOTE: If the pump does not prime properly, or loses prime during start-up, it should be shut down and the condition corrected before the procedure is repeated.]

5. Start the pump driver (Engines may require warming up; consult the manufacturer’s instructions).

6. When the pump is operating at full speed, open the discharge valve slowly. This should be done promptly after start-up to prevent damage to pump by operating at zero flow.

7. Adjust the liquid seal valves to produce the recommended pressure for the packed stuff box.

8.3.2 Optional Checklist

NOTICE

This section applies to parameters that contribute to assessing the performance of the pump unit.

WARNING

Escaping pressurized liquids. Liquid draining from the pump could result in personal injury and equipment damage.

NOTICE

This section applies to the complete pump unit. See also installation and operating instructions for the driver, (electric motor or diesel engine), and controller.

The following steps will take care of most normal shutdowns of the pump, i.e. maintenance or to make any further adjustments of process piping, valves, etc., as required.

1. Shut off power supply to the driver.

2. Close suction and discharge valves.

3. Close seal liquid valves. (If pumped liquid is dirty, or if leakage is to be prevented, these lines should always be left open, except when the pump is completely drained.)

4. Open drain valves as required.

8.5 Returning to service

After long-term storage and before commissioning, check seals, bearings, and lubrication.

8.6 Freeze Protection

CAUTION

If heat is used to keep the pump from freezing, do not let the temperature rise above 150°F [66°C].

Pumps that are shut down during freezing conditions should be protected by one of the following methods:

1. Drain the pump; remove all liquid from the casing.

2. Keep fluid moving in the pump and insulate or heat the pump to prevent freezing.

1. Driver/Pump Rotation: Check the rotation each time that the motor leads have been disconnected. Be sure that the driver operated in the direction indicated by the arrow on the pump casing.

2. Flow: An accurate measurement of the flow rate is difficult to in the field. Venturi meters, flow nozzles, orifice plates, or timing the draw down in a wet well are all possible methods. Record any reading for future reference.

3. Pressure: Check and record both suction and discharge pressure gauge readings for future reference.

4. Power: Record voltage, amperage per phase, kilowatts if an indicating wattmeter is available, and the pump speed.

5. Temperature: Check and record the bearing temperature using a thermometer. Temperature should not exceed 225°F [107°C] for polyurea-greased bearings and180°F [82°C] for lithium-greased bearings.

27 AC6102 Rev 03



8.7 Field testing

A performance curve for the pump-unit is included in the document package shipped with the pump unit or it can be obtained from A-C Fire Pump. This can be used in conjunction with a field test, if one is required.

All A-C Fire Pump tests and curves are based on the Hydraulic Institute Standards. Any field tests must be conducted according to these standards.

Unless otherwise specifically agreed, all capacity, head, and efficiencies are based on factory tests using clear water at a temperature not greater than 85°F [29°C].

9 Maintenance

WARNING

Rotating parts. Disconnect and lock out power before performing maintenance. Failure to follow these instructions could result in serious personal injury.

9.2 Maintenance Interval

Inspection intervals should be carried out in accordance with the maintenance table, Table 6.

WARNING

Electrical Shock Hazard. Disconnect and lock out power before performing maintenance. Failure to follow these instructions could result in serious personal injury.

NOTICE

It is the operator’s responsibility to ensure that all maintenance work is performed by authorized and qualified personnel.

NOTICE

Read the installation and operation instructions for the driver and coupling for maintenance requirements not covered in this instruction.

9.1 General

A regular inspection and maintenance program must be planned and followed in order to keep the pump in good working condition. We suggest a permanent record be kept of the periodic inspections and maintenance performed on your pump. This recognition of maintenance procedure will keep your pump in good working conditions, and prevent costly breakdowns.

Action

Test run the pump X

Check pump/driver alignment

Check bearing housing temperature

Check bearing grease

Check the stuffing box leak rate

Lubricate bearings

Check anchor bolts and tighten

Check coupling guard bolts and tighten

Check for unusual noise and vibration

Check the pump and piping for leaks

Check pump shaft end play

Check impeller assembly for wear

Test pump against performance curve

Weekly

Monthly

Every six months

X

X X X

Table 6 Maintenance Interval

9.3 Lubrication

9.3.1 Lubricating grease requirements

Use a high-quality grease lubricant corresponding to NLGI Grade 2. The recommended grease lubricants are shown in Table 7.

Annually

X

X X X

AC6102 Rev 03 28



Polyurea-based grease

(pumps built after December 2014)

Manufacturer Brand Name

Exxon Mobil Polyrex EM

Chevron SRI NLGI 2

Shell Gadus S5 T100 2

Lithium-based grease

(pumps built before December 2014)

Manufacturer Brand Name

Exxon Mobil Mobilux EP 2

Chevron Multifak EP2

Shell Gadus S2 V100 2

Table 7 Recommended Grease Lubricants

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8100/8150/820

0/9100 Fire Pu

9.3.2

Grease lubr factory and provided th to its first o

The bearing should nev grease, and checked m frame rise a determine t

9.3.3 L

Add grease

Adequate lu maintained of the cavity greater am vent and be

To lubricate

1. Remo

2. Fill the

3. Wipe

4. Run th

The bearing grease due return to no grease from

9.4

9.4.1 P

Pumps are fiber packin equivalent.

rease Lubri

cated ball beari

pump has bee

eration.

temperature, m

r exceed 225°F

180°F [82°C] fo

nthly. Should th

bove the limit, t

e cause.

ubrication p

while the pump i

brication is assu

t about the cap

between the be

unt will, as a rul

wasted.

the bearings wi

e dirt from the g grease cavities

recom

ff any excess gr

temperature us

o an excess su

mal as the pum

the bearings.

acked Stuf

acking spe

upplied with a as standard, u

WARNING Never chec frame by ha device.

CAUTION Greases of etc.) may n Mixing grea lubricant lif

rdinarily will req

CAUTION

Over-greasi overheating

CAUTION

Use only ma may damag unnecessar overheating unsightly co

ended grease.

pump to distri

p

ation

the temperatur

d, use a tempe

ifferent bases

t be compatibl

es can result i

and premature

gs are packed uire no attention stored in a clea

asured at the b

[107°C] for poly

r lithium-based

temperature o

e pump should

ocedure

g is the most

and premature

ual grease gun

the bearings or loss of grease,

ue to over-grea

ditions around t

s stopped to av

red if the level o

city of the beari

ring and greas

, be discharged

h grease, proce

rease fitting.

hrough the fittin

ase.

ute the grease.

ally increases ply of grease. runs and purg

ing Box

ifications

raphite-coated

ing John Crane

of the bearing

ature measurin

lithium, polyure when mixed.

reduced bearing failure.

ith grease at th before starting,

, dry place prio

earing frame,

rea-based rease when

the bearing

e shut down to

ommon cause bearing failure.

High pressure seals, cause

reate a danger

ing, and produ

e bearing.

id overloading.

grease is

g and 1/3 to 1/ fitting. Any by the seal or

d as follows:

gs with the

fter you re-

emperatures

s the excess

eneral service

style 1340, or

a,

e

9.4.

Packing

In ac

ordance with th

shoul

d be visually ins

rate

hecked. If the le

nuts

ay be tightene

whic

should be least

Whe

the gland follo

move

ment and the p

r, all of the pac

furth Neve

reuse old and l

new

ings.

9.4.

Remova

9.4.

Installin

New

f

acking may be

speci

ied dimensions

Whe

supplied as a

off le

gths of material

Usua

lly 5 or 6 rings a

If mol

ded rings are us

ays and the join

side

If coil

packing is used the cutting positi

mark

6mm] over size.

in. [3 exce

s length is requi

unde

sized. Cut one r

miter

d (45°) joint. (A

poor

itting mitered joi

Fit th

ring over the s

remo

e and cut all ot

rings

are placed arou

d.

form

Plac

the first packin

butt

r mitered joint b

the st

uffing box. Push

the jo

int, and then the

o packing ends

the t

Push

the ring to the b nable pressure

reas but it

is not over com

The r

ngs are installe

and t

e joints stagger

prec

ding joint. For 3

o’clo

k positions.

maintenanc

maintenance s ected once a m

kage rate is ex , until the requir 40 to 60 drops

er has reached cking cannot be ing should be r feless packing

of Packing

WAR

ING

Ensu

e that the pump

allow

safe handling of

packi

g tool should b

packi

g from the stuffi

stuffin

g box is thoroug

packi

g is installed. A

the s

aft or sleeve for

eccen

tricity. Any part

shoul

be replaced.

Packing

supplied as mol or, more usuall ontinuous lengt to make the re

e required per

ed, the rings sh ts pushed into t

wrap the packi on. The packing

The larger the s red. The packin ing to accurate

accurately cut

t).

aft to assure pr

er rings to the fi

d the shaft a tig

ring around the

tween the two the joint first, th two remaining s

are pushed tight

ttom of the stuf

o ensure that th

ressed.

NOTI

E

The p

acking rings m

and u

nder no circum

sets

e fitted as a un

one at a time,

d at about 90°

adjacent rings,

e

hedule, the pa

onth and the lea

essive then the

d leak rate is o

er minute.

the limit of its

compressed an

moved and repl r merely add so

has cooled suffi the stuffing box.

used to remov ng box. Make s hly cleaned bef

so check the co possible scorin

with significant

ed rings made

, as a length of

, it is necessar

uired number o tuffing box.

uld be opened

e stuffing box fir

g around the sh

should be cut 1 haft diameter, th

must not be cu ize with either a

utt joint is supe

per length. The

st sample. Whe ht joint should b

shaft, and form

nds. Push the ri

n the side oppo ides. It is essent ly together.

ing box, applyin

ring is seated

st be fitted indi tances should

t.

ach ring seated otation from ea se the 4, 8 and

king

age

gland

tained,

y

ced.

e

iently to

A

all old re the

re new

dition of

or

damage

o

oil. to cut rings.

st.

ft and

8-1/4

more

butt or

ior to a

the

neat

g into

ite to

ial that

roperly

idually omplete

firmly h

2

29



C6102 Rev 03

Check the shaft to ensure that it can be rotated after fitting each packing ring.

Fit as many rings as possible into the stuffing box without having any packing protruding, and without over-compressing the packing

NOTE: The last ring in each box may not be required until after the pump has operated for a period of time.

NOTE: When supplied, the seal cage will replace the third packing ring from the bottom of the stuffing box. The seal cage must be aligned with the seal water inlet when the packing is compressed.

Bring the gland follower up squarely against the last packing ring and tighten the nuts evenly to finger pressure.

9.4.5 Packing Adjustment

Install the proper flush set up.

Start the pump and allow the packing to leak freely at startup. During the break-in period, adjustments should be made gradually (tightening the gland nuts one 1/4 revolution at a time), allowing 5 to 10 minutes between adjustments.

After the break-in period, the leakage rate can be controlled to 40 to 60 drops per minute.

AC6102 Rev 03 30



Series 8100/8150/8200/9100 Fire Pump

10 Service

The procedures outlined in this section cover the dismantling and reassembly of four different model types of Horizontal Split Case fire pumps:

1. 8100

2. 8150

3. 8200

4. 9100

When working on the pump, use accepted mechanical practices to avoid unnecessary damage to parts. Check clearances and conditions of parts when pump is dismantled and replace if necessary. Steps should usually be taken to restore impeller and casing ring clearance when it exceeds three times the original clearance.

WARNING

Rotating parts. Disconnect and lock out power before servicing. Failure to follow these instructions could result in serious personal injury.

WARNING

Electrical Shock Hazard.

10.1 Tools required

In order to assemble and disassemble the pump, the following tools are required:

 Hex wrenches  Open end wrenches  Spanner wrench  Torque wrench with sockets  Feeler gauges  Range of screwdrivers  Soft mallet  Bearing pullers  Bearing induction heater  Allen wrenches  Dial indicators  Lifting sling

10.2 Dismantling

Refer to section 12, Replacement Parts, for exploded drawings and parts lists. Part numbers listed in this procedure refer to the 8100 series pumps; corresponding part numbers for 8150, 8200, and 9100 can be identified by the description in the parts lists.

Disconnect and lock out power before servicing. Failure to follow these instructions could result in serious personal injury.

WARNING

During dismantling/assembly of the pump, ensure that lifting devices are sufficiently strong and that the pump-unit and parts are secured to prevent tipping over. Failure to follow these instructions could result in serious personal injury and part damage.

CAUTION

Before dismantling the pump, ensure that genuine AC-Fire Pump parts are available.

10.2.1 Rotating Element

1. Isolate driver and lock out power supply in accordance with local regulations.

2. Isolate suction and discharge valves.

3. Remove coupling guards and separate the coupling to disconnect the pump from the driver.

4. Drain the pump by opening the vent plug [0-910-0] and removing the drain plugs [0-910-0] on the suction and discharge nozzles.

5. Remove flushlines [0-952-0], if supplied.

6. Series 8150, 8200, and 9100: Remove gland bolts [1-

904-9], washers [1-909-9], and slide gland [1-014-9] away from the lower casing [2-001-8].

7. Remove all casing main joint cap screws [2-904-1] and dowels [2-916-1].

8. Using the slot in the casing main joint, separate the casing halves with a pry bar. Lift the upper half casing [2-001-0] by the cast lugs.

NOTE: Some casings have jacking screws.

9. Series 8100 only: Tap the stuffing boxes [3-073-9] with

a soft-headed hammer to break the seal between the stuffing box and the lower casing [2-001-0].

10. Series 8200 and 9100: Remove packing [1-924-9] and

seal cage [1-013-9] from each stuffing box.

11. Series 8150, 8200, and 9100: Remove cap screws [3-

904-9] which hold the bearing housings [3-025-3] to the lower casing.

12. The rotating element may now be removed. Carefully lift the complete rotating element, protecting the packing surface on the outside diameter of the shaft sleeve [3009-9] from damage and place on two support blocks.

10.2.2 Bearing Housing

1. Remove four cap screws [3-904-9] from each bearing housing [3-025-3, 3-025-4] and remove the bearing housings from the shaft [3-007-0].

2. Bend back the lock-washer tab and remove locknut [3516-4] and lock-washer [3-517-4] from the outboard end of the shaft and, using a bearing puller, remove the bearing [3-026-4] from the shaft. Remove the inboard end bearing [3-026-3] in the same manner.

NOTE: Locknut and lock-washer are not used on inboard end bearings.

3. Series 8200 and 9100: Remove bearing covers [5-018-

0] out of bearing housings. Pull deflectors [3-136-9] off the shaft. Slide stuffing box bushings [6-008-0] off the shaft.

4. Series 8150 Remove the four capscrews [3-904-9] from

each bearing housing and remove the housings from the bearing brackets. Remove the snap ring [3-177-3] (outboard side only), bearings [3-026-2] and backing snap rings [0-915-0]. Remove the bearing brackets from the shaft.

10.2.3 Shaft seal – gland packing

1. Series 8100 Slide both stuffing boxes [3-073-9] off the shaft, working deflector rings [3-136-9] off the shaft at the same time.

2. Remove the lip seals [3-177-9] from the stuffing box.

3. Remove the gland bolts [1-904-9], gland halves [1-0149], packing [1-924-9] and, if supplied, seal cage [1-0139] from each stuffing box. Remove the O-rings [3-914-1]

31 AC6102 Rev 03



from the stuffing boxes.

10.2.4 Shaft sleeve

1. Loosen set screws [3-902-3] in shaft nuts [3-015-9] and then remove shaft nuts using pin spanner wrench. Remove O-rings [3-914-9] from the counter-bore in shaft sleeve. Remove the shaft sleeves [3-009-2] from the shaft.

10.2.5 Impeller and casing wear rings

1. The impeller and casing rings can now be removed if required.

2. When removing the rotating element, the casing wear rings [3-003-9] will be attached to the impeller [4-002-0] by locking pins [3-943-9] inserted into the casing ring and located in grooves in the lower half casing.

3. If impeller rings [0-004-0] are also fitted, they are shrunk onto the impeller, and can be removed by cutting with a cold chisel.

10.4 Assembly

Refer to section 12, Replacement Parts, for exploded drawings and parts lists. Part numbers listed in this procedure refer to the 8100 series pumps; corresponding part numbers for 8200 and 9100 can be identified by the description in the parts lists.

10.4.1 Wear Rings

1. Impeller rings [0-004-0] (when fitted) should be heated up to approximately 300°F - 400°F [150°C - 200°C] and then slipped onto the impeller. Using gloves hold rings against the impeller shoulder until they cool.

2. Slide the casing rings [3-003-9] over the impeller hubs before mounting the rotating element into the lower casing, ensuring that the locking pins in the rings locate into the grooves in the casing.

3. Check the wear ring clearance against the appropriate pump size in Table 8.

10.3 Examination of parts

CAUTION

10.3.1 Casing and impeller

Inspect for excessive wear, pitting, corrosion, erosion or damage and any sealing surface irregularities. Replace as necessary.

10.3.2 Shaft and sleeve

Replace if grooved, pitted or worn.

10.3.3 Gaskets and O-rings

After dismantling, discard and replace.

10.3.4 Bearings

It is recommended that bearings are not reused after removal from the shaft.

10.3.5 Bearing isolators and lip seals

1. The lubricant, bearings and bearing housing seals are to be inspected for contamination and damage. Damaged parts should be replaced.

2. If bearing damage is not due to normal wear and the lubricant contains adverse contaminants, the cause should be corrected before the pump is returned to service.

3. Bearing isolators (if used) should be inspected for damage but are normally non-wearing parts and can be usually reused.

Used parts must be inspected before assembly to ensure that the pump will operate correctly.

CAUTION

Do not reuse the ball bearings.

Pump Size Series/Type

3X2X11F-S

6X4X9F

6X4X10F-M

6X4X11F

6X4X12F

6X6X9F

8X6X9F

8X6X10F

8X6X12F

8X6X12F-M

8X6X13F

8X6X18F

8X8X12F

8X8X17F

10X8X17F

10X8X20F

12X10X18F

8x6x14F-S

8X6X14F-L

8x6x18F

12X8X21F

12X8X22F-M

14X10X20F

16X12X23F

14X10X20F-L

16X10X22F 8150

Table 8 Wear ring clearance

8100

8200

9100

Wear Ring

Clearance in

[mm]

0.015 - 0.017 [0.38 – 0.43]

.019-.021

[.48-.53]

AC6102 Rev 03 32



Serie

s

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8100/8150/820

10.4.2 I

10.4.2.1 S

1. Assem 0].

2. Check the co the sh Tables

3. Startin bead o equiva up the

4. Slide t sleeve

NOTE:

impell

5. Place t sleeve 015-9]

6. Repea and nu

0/9100 Fire Pu

peller

ries 8100, 81

le the impeller

he impeller [4-0

rect impeller rot

ft in accordanc 9 and 10. with the outbo

f RTV silicone s

ent), at the imp

keyway.

e sleeve [3-009 to evenly distrib

The pin in each

r key slot. (not

e sleeve O-ring

-bore. A

counte

steps (3)-(5) fo t. Wipe off exce

p

50, and 9100

ey [3-911-1] in

2-0] and casin

tion, and locate

with Figs. 20 a

rd end, apply a

alant, (Dow Co

ller hub face, m

9] onto the shaf

te the silicone

shaft sleeve m sed on 8150)

[3-914-9] onto t

semble the sha

the inboard sh

s RTV silicone

he shaft [3-007-

to determine the impeller on d 21 and

.4mm [1/4 inch

ning or

king sure to fill

, rotating the ealant.

st seat in the

he shaft, into th

t sleeve nut [3-

ft sleeve, O-ring

ealant.

Pump Size

3X2X11F-S

6X4X9F

6X4X10F-M

6X4X11F

6X4X12F

6X6X9F

8X6X9F

8X6X10F

8X6X12F

8X6X12F-M

8X6X13F

8X6X18F

8X8X12F

8X8X17F

10X8X17F

10X8X20F

12X10X18F

A

8.755

9.312

10.625

10.750

9.755

9.312

9.755

10.625

9.755

10.625

11.495

11.620

11.495

Packing Siz

0.375

0.500

0.375

0.500

0.375

0.500

ig. 20 Series

100 Impeller lo

ation

Table 9

Fig. 21

eries 8100 Imp

eries 9100 Imp

ller Location

ller location

33

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C6102 Rev 03

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Pump

12X8X

12X8X2

14X10X

16X12X

14X10X2

Table

10.4.2.2 S

1. Assem 0].

2. Identif the ca on the

3. Pre-as diaphr

i. I

ii.

4. Slide t and pl

5. Place t interst install

6. Apply (Dow sleeve about sleeve

7. Slide t distrib engag sleeve flush a sealan

8. Place t sleeve 015-9].

ize A

1F

F-M

0F

3F

0F-L 16.6

0 Series 910

ries 8200

le the impeller

the first and se

ted label, and l

shaft in accorda

emble the inter

gm [3-231-0] a

stall O-rings [3 rooves of the in ightly press the

cating the hole

iaphragm. Insta

t

e assembly.

e interstage bu

ce over the rea

e other impelle

ge bushing unti

d.

1/4 in. [6.4mm]

orning or equiv

[3-009-9] inside

/2 in. [12.8mm] Also apply seal e shaft sleeves te the sealant.

s into the keyw

against the im

ainst the face.

.

e sleeve O-ring

counterbore. As

13.5

15.8

Packing

Impeller Locati

ey [3-911-1] in

ond stage impe

cate the second

ce with Fig. 22

tage bushing [3 follows: 914-7, 3-914-8] erstage bushin

bushing into the in the bushing o

l snap ring [3-91

hing assembly

hub of the imp

on the shaft an

it touches the i

bead of RTV sil

lent), uniformly diameter, cover

at each impeller

nt to the face o

nto the shaft to otate until the p y of the impelle eller face until t

ipe off excess

[3-914-9] onto t semble the shaf

Size

0.62

n

he shaft [3-007-

lers [4-002-0] b

stage impeller

and Table 11.

034-1] and the

in the three

.

diaphragm,

er the pin in th

5-0] to secure

ver the shaft

ller.

slide over the peller already

cone sealant, about the shaft

ng an area of

end of the the impellers. evenly

in in the sleeve

s and push the

e sleeve is

RTV silicone

he shaft, into th

sleeve nut [3-

Fig. 22

Pump Size

8x6x14F-S

8X6X14F-L

8x6x18F

Table 11 Se

10.4

.3 Bearing

10.4

3.1 Series 81

1.

ress a new lip 73-9]. Before i

l

ightweight oil.

OTE: Lip seal

houlder in the

OTE: The seal

oint away from

2.

ubricate and rol

ach stuffing bo

3.

lide the outboa

haft end exten

ot enter the lip

he deflector [3-

4.

lide the deflect ush the shaft e

tuffing box fully

5.

eat the ball be r a 10-15% sol

OTE: Do not e

6.

sing gloves sli gainst the shaf

7. I

nstall the lock w

n the outboard

l

ocknut is secur ock washer.

l

OTE: A lock w

he inboard end

eries 8200 Imp

A

12.06

ies 8200 Impell

and bearin

0

eal [3-177-9] int

stalling the seal

should seat ag racket.

lip or pressure

the bearings [3-

l O-ring [3-914-

.

d stuffing box o

s through the p

eal. This will p

36-9].

r over the shaft

d through the li onto the shaft. ring [3-026-4],

ble oil and wat

ceed 275°F [1

e the heated be shoulder.

asher [3-517-4]

end of the shaft.

d and then ben

sher and lockn

of the shaft.

ller location

Packing Size

0.500

r Location

housings

o each stuffing

, lubricate it with

inst the machin

ide of the seal

26-3, 3-026-4].

] into the groov

the shaft so th

cking area, but

rmit the installat

end then carefu

seal and slide

sing either a dr r solution.

5°C].

ring onto the s

nd locknut [3-5

Ensure that the

over the tabs o

t are not install

ox [3-

d

hould

of

t the

oes

ion of

ly

the

heat,

aft

6-4]

n the

d on

AC61

2 Rev 03



34

Series 8100/8150/8200/9100 Fire Pump

8. Allow the bearing to cool to room temperature. Coat the exposed sides with 2 to 3 oz. [55 to 85 g] of the recommended grease.

9. Coat the inside of the bearing housing [3-025-4] with grease and slide into place over the bearing. Attach the bearing housing to the stuffing box with four cap screws [3-909-9].

10. Repeat steps for the inboard end.

10.4.3.2 Series 8200

1. Press a new lip seal [3-177-9] into each bearing cap [5018-0].

NOTE: Seal lip or pressure side of seal must point away from the end of the shaft the lip seal is assembled on.

2. Place two O-rings [6-914-9] on each stuffing box bushing [6-008-0], and then slide over the shaft sleeve with the beveled end facing the impeller.

3. Slide the deflectors [3-136-9] and bearing caps onto the shaft. Install snap ring [5-915-3] on the inboard side of the shaft. Install the split ring [5-050-4] and retaining collar [5-421-4] on the outboard side of the shaft.

4. Heat the ball bearings [3-026-3-026-4], using either a dry heat, or a 10-15% soluble oil and water solution.

NOTE: Do not exceed 275°F [135°C].

5. Using gloves slide the heated ball bearing [3-026-3] onto the inboard end of the shaft against the snap ring.

6. Using gloves slide the two heated ball bearing [3-026-4] onto the outboard end of the shaft. These bearings must be installed back to back. Place the first 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.

7. Install the lock washer [3-517-4] and locknut [3-516-4] on the outboard end of the shaft. Ensure that the locknut is secured and then bend over the tabs on the lock washer.

8. Allow the bearings to cool to room temperature. Coat the exposed sides with 2 to 3 oz. [55 to 85 g] of the recommended grease.

9. Slide the bearing housings [3-025-3, 3-025-4] into place over the bearing. Attach the bearing caps to the bearing housing with four cap screws [5-904-9].

10.4.3.3 Series 9100

1. Press bearing isolators [1-333-1] in each bearing cover [3-018-3, 3-018-4]. Install gaskets [3-409-9] on each bearing cover.

NOTE: Inboard bearing cover [3-018-3] is 1/4 in. [6.4mm] less in width than outboard [3-018-4].

2. Slide bearing covers onto the shaft. Install the snap rings [3-915-9]. Install thrust washer on the outboard end.

3. Heat the ball bearings [3-026-2], using either a dry heat, or a 10-15% soluble oil and water solution.

NOTE: Do not exceed 275°F [135°C].

4. Using gloves slide the heated ball bearing [3-026-2] onto the shaft against the snap ring on the inboard end and the thrust washer on the outboard end.

5. Install the lock washer [3-517-4] and locknut [3-516-4] on the outboard end of the shaft. Ensure that the locknut is secured and then bend over the tabs on the lock washer.

6. Allow the bearings to cool to room temperature. Coat the exposed sides with 2 to 3 oz. [55 to 85g] of the recommended grease.

7. Press a bearing isolator [1-333-1] in the inboard bearing housing and an oil seal [3-177-4] in the outboard bearing housing.

8. Slide the bearing housings [3-025-2] into place over the bearings. Attach the bearing covers to the bearing housing with two cap screws [3-904-9].

10.4.3.4 Series 8150

1. Install slingers onto shaft

2. Press new lip seals into the bearing brackets. Note: Seal lip or pressure side of seal must point away from bearing

3. Place brackets onto shaft. Install backing snap rings into the shaft grooves.

4. Heat the bearings using a dry heat. Note: Do not exceed 275°F [135°C].

5. Using gloves slide the bearing onto the shaft. The shielded side goes on first.

6. Install the beveled snap ring into the groove in the shaft, outboard side only.

7. Install both bearing housings.

10.4.4 Rotating element

After completion of the preceding steps, carefully place the shaft assembly into the lower half pump casing.

10.4.4.1 Series 8100

1. Set the rotating element in the pump casing [2-001-0], assuring correct rotation. Locate both stuffing box tongues in their respective casing grooves.

2. Locate pins [3-943-9] in the stuffing box and the casing wear rings in their respective slots at the casing parting line. Correct any O-ring bulging.

10.4.4.2 Series 8200

1. Set the rotating element in the pump casing [2-001-8], assuring correct rotation. Correctly locate casing ring pins, stuffing box bushing pins, and interstage diaphragm pins in the casing main joint slots. (Sliding the inboard bearing housing towards the coupling slightly will ease assembly).

2. Bolt the outboard bearing housing in place. Ensure that both housings are seated properly in the lower half casing.

3. Bolt inboard bearing housing in place. Rotating element should now turn freely.

10.4.4.3 Series 9100

1. Set the rotating element in the pump casing [2-001-8], assuring correct rotation. Correctly locate casing ring pins in the casing main slot. (Sliding the inboard bearing housing towards the coupling slightly will ease assembly).

35 AC6102 Rev 03



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2. Bolt th both h casing

3. Bolt in should

10.4.4.4 S

1. Set the assuri pins in bearin assem

2. Bolt th both h casing

3.

Bolt in

should

4.

Adjust

in the

5.

Tighte

10.4.5

1. The m upper materi agains lightly

apping with a b

with th

2. Precut

3. Clean t

4. Within

5. Machin

6. The ga

7. Lower

8. Tighte

casing gaskets

ordere

he gasket surfa multip equiva

gasket casing gasket area c

ed casing bores parting

line.

contac stuffin

the tap

ered dowel pins box an

torque.

outboard beari

usings are seat

oard bearing ho now turn freely.

ries 8150

rotating elemen g correct rotatio the casing main

housing towar

ly).

outboard beari

usings are seat

oard bearing br now turn freely. he shaft sleeve asing water pas the sleeve nut

asing Gask

in casing joint g

nd lower half a l on the casing

the edges of th

inside edges o

to minimize th

rpose spray ad ent) to the lowe

ne minute of s [2-123-5, 2-12

align the holes

firmly against t

ated by the adh

kets must be fl the O-rings so box (8100 only he upper half c

bearing housi

the upper half

g housing in pl d properly in th

using in place.

ce. Ensure that

lower half

otating element

t in the pump ca

n. Correctly loc

slot. (Sliding th

s the coupling s

g bracket in pla d properly in th

cket in place.

ing [2-001-0],

te casing ring

inboard

lightly will ease

ce. Ensure that

lower half

otating element

nuts to get the i sage.

etscrews.

peller centered

ts

sket can be m

a template. La

oint and mark it

casing. Trim t

ll peen hammer

the casing.

2-123-5, 2-123-

amount of trim es of the casing esive, (3M Sup half of the casi raying, set the

-6] in place on in the casing an he lower half ca

esive.

must remain sh

sh with the bor

s to prevent le . sing [2-001-0] i [2-916-1], ensu g are correctly asing joint bolts

de using the the gasket

by pressing it

e gasket by

so that it is flus

] can be

ing.

. Apply a

r 77, or

g. ntrimmed he lower half

press the

ing face in the

rp at the casin

in order to kage around th

to place using

ing the stuffing

ligned.

to the correct

CAU

ION

Gask

t compression:

incur

10.5

1.1 Tightenin

Tight

n the casing bo

tighte

ning pattern, se

ighten the four

1.

2.

orking outwar oxes in opposit .

3.

orking outwar uadrants, tight

4.

epeat sequenc

Tight

n the casing bo

1.

ighten bolts loo

ccording to the

t

ighten evenly.

sing a torque

2. t

he full torque fir ightening patter

t

ompressing the

3.

orque to a max

ccording to the

4.

orque to the ful

attern.

5.

erform final pa

n adjacent bolt

creep relaxatio

pump

ensure that th

tighte

ned to the corr

NOTI

E

Tight

ning sequence:

corre

t values in acco

bolt ti

htening pattern

the pr

per gasket co

leaka

e can occur at t

a torq

e wrench when

g sequence

lts in accordanc

Fig. 23:

orner bolts ma

along the shaft

e quadrants, tig

along the flang

n bolts in zones

1 - 3.

lts in five steps:

sely by hand in

bolt tightening p

rench, torque to

t time around, . Check that th

gasket evenly.

mum of 60% of

bolt tightening p

torque, accordi

s at full torque, .

Non-metallic g

, before startin casing bolts ar ct torque.

Torqueing bolts

dance with the

is essential for o

pression so that

e main joint. Al

tightening casin

with the followi

ked 1 - 4.

axis toward the

ten bolts in regi

s and in opposi

9 - 12.

he first instance

ttern, then han

a maximum of ccording to the

casing flange i

the full torque,

ttern.

g to the bolt tig

n a clockwise di

skets the

e

o the orrect

btaining

no

ays use

g bolts.

ng bolt

stuffing

ns 5 -

e

,

0% of

olt

tening

rection

10.4.6 S

Install two ri boxes. Inst up with the Install the r square with

10.5

10.5.1

The standa lubricated t be applied

AC61

2 Rev 03



tuffing Box

ngs of packing

ll seal cage [1-0

eal water inlet maining rings. the stuffing box

ightening

asing Bolts

d bolt class is S

read. The torqu n the pump casi

ssembly –

nd tap fully to b

13-9] and ensur

hen the packin oosely fit the gl and connect the

orques

E J429 or high

values listed i ng bolts.

Packing

ttom of stuffing

that it will line

is compressed.

nd [1-014-9]

flush lines.

r with a non-

Table 12 shall

Fig. 2

Bolt tightenin

pattern

36

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S

O

m

c

e

C

o

m

12345

6

7

p

e

p

a

m

e

s

v

C

a

e

q

S

e

d

w

p

e

m

r

t

e

r

m

r

a

(

t

A

g

u

o

t

g

t

Serie

8100/8150/820

Bolt Siz

5/8-11

3/4-10

7/8-9

1-8

16X10X2

10.5.2

0/9100 Fire Pu

Tabl

12 Torque re

ther bolt lo

Grade

SAE

G5

B8

G8

p

Head

Identification

12pt

quirements for

ations

Torque

Min. Value

ft-lb [N.m]

140 [190]

75 [100]

300 [405]

350 [475]

400 [540]

900 [1220]

asing bolts

infor

ation to the A-

) Pump Seri ) Pump Size ) Description ) Part numb ) Quantity re ) Billing and ) Date requir

The

ump size and s

nam

plate; refer to s

The

art numbers an

Repl

cement Parts,

reco

mended spare

10.6

.2 Storage

Spar

parts should b

and r

-treatment of

corro

ion inhibitor is

inter

als.

Fire Pump dist

l Number

and Type

of Part

uired

hipping instruc

d

rial number are

ction 6, Descrip

descriptions a hich also indica

parts for the pu

of spare pa

stored in a cle

etallic surfaces

ecommended a

ibutor in your re

ions

shown on the p

tion.

e shown in secti tes a list of

p.

ts

n dry area. Insp if necessary) wi

six (6) month

ion:

mp

on 12,

ection

h a

Bolt Size

5/16-18

3/8-16

7/16-14

1/2-13

5/8-11

3/4-10

1-8

3/8-16

½-13

5/8-11

5/16-18

1/2-13

Tab

Grade

SAE

G2

G5

B8

e 13 Torque r

Head

Identification

quirements for

Torque Max Value ft-lb [N.m]

11 [15]

20 [27]

32 [43]

49 [66]

97 [132]

172 [230]

250 [340]

31 [42]

90 [122]

150 [203]

11 [15]

45 [61]

ther bolts

10.6

10.6.1

When order

37



pare Parts

rdering Spa

ng parts always

re Parts

provide the foll

wing

C6102 Rev 03

AC6102 Rev 03 38



Serie

s

T

a

m

o

n

G

n

s

o

g

e

m

p

o

C

A

8100/8150/820

11

0/9100 Fire Pu

roublesh

p

oting

Between re symptoms

gular maintena

re listed below

WARNIN

Disconnec before tryi follow the serious pe

ce inspections

. Correct any tr

t and lock out p

g to determine

e instructions c

rsonal injury.

, be alert for si

uble immediat

wer to the pu

a failure. Failur

uld result in

ns of driver or

ly and avoid c

p

e to

ump trouble.

stly repair and

ommon shutdown.

39



C6102 Rev 03

0

r

Table 14 T

AC61

2 Rev 03



oubleshooting List

40

Serie

s

R

S

m

e

d

0

p

t

p

A

8100/8150/820

12

0/9100 Fire Pu

eplacem

p

nt Parts

12.1

eries 8100

Horizontal

Split Case

Fire pum

Fig. 23 Explo

41



ed view of 810

Horizontal Spli

Case Fire Pum

C6102 Rev 03

Table 15 List of components 8100 Horizontal Split Case Fire pump Cat. No. Description Qty Cat. No. Description Qty

0-910-0 Pipe Plug (Casing) 5 3-025-3 Housing, Inboard Bearing 1

0-912-0 Pipe Fitting 3 3-025-4 Housing, Outboard Bearing 1 0-944-0 Spirol Pin (Shaft Sleeve) 2 3-026-3 Bearing, Inboard 1 0-950-0 Pipe Nipple 2 3-026-4 Bearing, Outboard 1

0-952-0 Tubing & Connectors 2 3-073-9 Stuffing Box 2

1-013-9 Seal Cage 2 3-136-9 Deflector 2 1-014-9 Gland, Packing 2 3-177-9 Lip Seal 2

1-904-9 Cap Screw (Gland) 4 3-516-4 Locknut, bearing 1 1-909-9 Washer (Gland) 4 3-517-4 Lockwasher, bearing 1 1-924-9 Packing 12 3-902-3 Shaft Nut Set Screw 2

2-001-0 Casing, Lower Half 1 3-904-9 Cap Screw (Bearing Housing) 8

2-001-0 Casing, Upper Half 1 3-910-9 Pipe Plug (Bearing Housing) 4

2-123-5 Gasket, Casing (Suction) 1 3-911-1 Impeller Key 1 2-123-6 Gasket, Casing (Discharge) 1 3-911-2 Coupling Key 1

2-904-1 Cap Screw (Casing) VARIES 3-914-1 O-Ring (Stuffing Box) 2 2-916-1 Casing Taper Pin 2 3-914-2 O-Ring (Casing Ring) 2

3-003-9 Casing Ring Assembly 2 3-914-9 O-Ring (Shaft Sleeve) 2

3-007-0 Shaft 1 3-943-9 Spirol Pin 4 3-009-9 Shaft Sleeve 2 4-002-0 Impeller 1

3-015-9 Nut, Shaft Sleeve 2

Bold Face: Recommended spare parts.12.2 Series 8200 Horizontal Split Case Fire pump

AC6102 Rev 03 42



Serie

s

d

p

A

8100/8150/820

0/9100 Fire Pump

Fig. 24 Explo

43



ed view of 8200 Horizontal Split Case Fire Pum

C6102 Rev 03

Table 16 List of components 8200 Horizontal Split Case Fire pump Cat. No. Description Qty Cat. No. Description Qty

1-952-0 Bleed Line 1 3-026-4 Bearing, Outboard 2

1-952-0 Flush Line 1 5-050-4 Split Ring 1

0-910-9 Pipe Plug 14 5-421-4 Retaining Collar 1

1-013-9 Seal Cage 2 3-169-9 Deflector 2 1-014-9 Gland 2 3-177-9 Lip Seal 2

1-901-9 Gland Bolt 4 3-516-4 Locknut 1 1-909-9 Washer, Gland Bolt 4 3-514-4 Lockwasher 1 1-924-9 Packing Ring 10 3-902-9 Set Screw 2

2-001-7 Casing, Upper Half 1 5-904-9 Bearing Cover Bolt 8

2-001-8 Casing, Lower Half 1 3-911-1 Key (Impeller) 1

2-123-5 Gasket, Casing (Suction) 1 3-911-2 Key (Coupling) 1 2-123-6 Gasket, Casing (Discharge) 1 3-914-9 O-Ring (Shaft Sleeve) 2

2-904-1 Cap Screw (Casing) VARIES 3-914-9 O-Ring (Stuffbox Bushing) 4

1-439-0 Dowel 2 6-008-0 Stuffbox Bushing 2 3-003-9 Casing Ring Assembly 2 3-034-0 Interstage Bushing 1

3-007-0 Shaft 1 3-231-0 Interstage Diaphragm 1 3-009-9 Shaft Sleeve 2 3-914-7 O-Ring (Interstage Bushing) 3

3-015-9 Shaft Sleeve Nut 2 5-915-0 Snap Ring (Bearing) 1

5-018-0 Bearing Housing Cover 2 3-915-0 Snap Ring (Interstage Bushing) 1

3-025-3 Bearing Housing 1 4-002-0 Impeller 2

3-026-3 Bearing, Inboard 1

Bold Face: Recommended spare parts

AC6102 Rev 03 44



Serie

s

S

m

d

0

p

t

p

A

8100/8150/820

12.3

0/9100 Fire Pu

eries 9100 p Horizontal

Split Case

Fire pum

Fig. 25 Explo

45



ed view of 910

Horizontal Spli

Case Fire Pum

C6102 Rev 03

Table 17 List of components 9100 Horizontal Split Case Fire pump

Cat. No. Description Qty Cat. No. Description Qty

0-901-0 Valve 2 3-015-9 Shaft Sleeve Nut 2

0-910-0 Pipe Plug 20 3-018-3 Bearing Housing Cover (Inboard) 1

0-950-0 Pipe Nipple 2 3-018-4 Bearing Cover (Outboard) 1

0-952-0 Tubing 2 3-025-2 Bearing Housing 2 1-013-2 Seal Cage 2 3-026-2 Bearing 2

1-014-2 Gland 2 3-078-9 Thrust Washer (Outboard) 1

1-333-1 Bearing Isolator 3 3-177-4 Lip Seal (Outboard Bearing) 1 1-904-9 Gland and Housing Bolt 12 3-409-9 Gasket (Bearing Housing Cover) 2 1-909-9 Washer, Gland Bolt 4 3-516-4 Locknut 1 1-924-9 Packing Ring 12 3-517-4 Lockwasher 1

2-001-7 Casing, Upper Half 1 3-902-9 Set Screw (Shaft Sleeve Nut) 2

2-001-8 Casing, Lower Half 1 3-904-9 Gland and Cover Bolt 4

2-123-5 Gasket, Casing (Suction) 1 3-911-1 Key (Impeller) 1 2-123-6 Gasket, Casing (Discharge) 1 3-911-2 Key (Coupling) 1

2-904-1 Cap Screw (Casing) VARIES 3-911-3 Key (Shaft Sleeve) 2 2-916-9 Taper Pin 2 3-914-9 O-Ring (Shaft Sleeve) 2 3-003-9 Casing Wear Ring 2 3-915-9 Snap Ring 2

3-007-0 Shaft 1 3-943-9 Spirol Ring 2

3-009-9 Shaft Sleeve 2 4-002-0 Impeller 1

Bold Face: Recommended spare parts

AC6102 Rev 03 46



Serie

s

S

m

d

0

p

t

A

8100/8150/820

12.4

0/9100 Fire Pu

eries 8150 p Horizontal

Split Case

Fire pum

Fig. 23 Explo

47



ed view of 815

Horizontal Spli

Case Fire Pump

C6102 Rev 03

Table 18 List of components 8150 Horizontal Split Case Fire pump

Cat. No. Description Qty Cat. No. Description Qty

2-001-0 Casing Asm 125Flg DI 1 3-025-3 Housing Bearing Inboard 1

2-001-0 Casing Asm 250Flg DI 1 3-025-4 Housing Bearing Outboard 1

2-001-0 Casing Asm 125-250Flg DI 1 3-904-9 CAPSCREW 3/8-16UNCX3-1/2 8

0-905-0 Grease Fitting 2

0-910-9 Pipe Plug 1/2NPT Brass 2 3-904-8 CAPSCREW 1/2-13NCX1-1/2 8

0-910-8 Pipe Plug 1NPT SS 2

0-910-7 Pipe Plug 1/4NPT SS 8 2-904-1 BOLT, CASING 1-8UNCx2.75 12Pt 42

2-904-2 BOLT, CASING 1-8UNCx7 12Pt 4

2-123-5 Gasket: Suction, Casing 1 2-916-1 PIN, TAPER 2 2-123-6 Gasket: Discharge, Casing 1

6-924-0 Packing 5/8 10 3-007-0 Shaft 1 6-013-2 Lantern Ring 2 4-002-0 Impeller Brz w/o rings 1 6-014-0 Gland 4 3-911-1 Impeller Key 1/2x5-3/4 1 6-902-2 Capscrew 1/2-13UNCx2-1/2 SS 4

3-009-2 Shaft Sleeve 2 0-909-0 Washer 1/2 4 3-914-9 O-Ring Sleeve 2-153 (3.500x.103) 2

3-015-9 Shaft Sleeve Nut 2 0-952-1 HEX BUSHING 1/2NPT x 1/4NPT 1

3-902-3 Setscrew 1/4-28UNFx3/16 SS 4 0-952-2 NIPPLE 1/4NPT x 1-1/2 1

3-136-9 Slinger 2 0-952-3 TEE 1/4NPT 1

3-003-2 Ring Casing: Brz 2 0-952-4 NEEDLE VALVE 1/4NPT-1/4TUBE 2 3-943-9 Pin W/R 2 0-952-5 TUBING 1/4 COPPER 4

0-952-6 3-177-2 Lip Seal 2

3-025-5 Bearing Bracket 2 3-911-2 Coupler Key 3/4x3/4x4.5 1

0-915-0 Snap Ring Bearing 2 3-026-2 Bearing 6316 w/Shield 2

3-177-3 Snap Ring Beveled 1

Bold Face: Recommended spare parts.

CONNECTOR MALE COMP

1/4ODX1/4NPT

2

AC6102 Rev 03 48



Series 8100/8150/8200/9100 Fire Pump

A. Appendix

49 AC6102 Rev 03



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A1

oupling

uard Re

oval and

nstallatio

(Non C

version)

NOTE: Do

spreading t

A1.1

1. R

2. S

3. R

4. S

A1.2 I

1. A

2.

3. S

4. I

5. P

6. H

ot spread the i e guards may

emoval

move the two

acket(s), (item

read the outer move the cap read the inner

stallation

tach the Suppo

S

read the inner

ith the inner gu

e support brac

read the outer

stall the outer g

mp:

4.

1 For pumps

support arm Locate the s the outer gu

4.

2 For pumps

holes locate cap screws.

sition the oute

m

otor shaft expo

sitioned so the

p

lding the guar

ner and outer lter their fit an

2) cap screws 3 (and item 6)) guard and pull i

crew that hold

guard and pull i

rt Brackets, (ite guard, (item 2);

rd straddling t et and guard lo guard, (item 1);

uard cap screw

ith a motor sad

(item 6); and i

upport arm, (ite

rd and the hol

ithout a motor

closest to the

guard so it is

ed. On guards e is only a 1/4 in this position

uards more th

appearance.

hat hold the ou . t off the inner g

the inner guar

t over the coupl

s 3 and 4 pre and place it ov e support brac

ated closest to

and place it ov

by following t

dle support bra

stall but do not

6) between t

s in the motor

addle support

motor in the ou

entered on the that utilize a sl

n. (6.35mm) of

, tighten the thr

n necessary fo

er (motor side)

ard, (item 2). to the support

er.

ssembled); to t

r the coupler.

et, (item 3); in

the pump. Do

r the inner gua

e step stated b

ket, (item 5): E tighten the two e outer guard addle support

racket: Insert t

er guard, and i

haft, and so th

tted support br

the pump shaft

e (3) cap scre

guard removal

coupler guard,

bracket, (item

he bearing hou

tall a cap scre

ot tighten the c

rd.

elow which pert

nsure the outer

remaining cap nds, align the s

racket, (item 5

e spacer wash

stall, but do no

re is less than

cket, the inner

exposed.

s.

or installation.

item 1); to the

).

ing, (if a new i

through the ho

apscrew.

ains to your pa

guard is stradd

upport arm with

. er, (item 7); bet t tighten, the tw

a 1/4 in. (6.35 guard will have

crews.

ver-

upport

stallation).

le (or slot) in

ticular

ling the

the holes in

een the

remaining

m) of the

to be

F

G A1 Couple

Guard Explod

d View for typi

al Motor Drive

HSC Fire pum

AC61

2 Rev 03



50

Serie

s

C

s

u

e

P

e

W

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h

e

m

P

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m

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A

8100/8150/820

A2

0/9100 Fire Pu

hanging

p

ump Rot

tion

Every serie from the co the same p

NOTE: Ref assembly te

A2.1

1. R

2.

3. S NOTE: The

motor are a

4. R

5. T NOTE: Unl

Horizontal Split

pling end of the

mp as follows:

r to the disasse

hniques.

rocedure

move the impelle

m

anual.)

ith the rotating

t the rotating el

impeller and th

lso in the same

assemble pum

e rotation of th

ss the motor rot

case Centrifuga

pump. If you wi

bly and assem

from t he shaft, tu

lement out of th

ment back in th

casing are in

relationship to

and realign the

motor must be

tion is reversed

Fire Pumps ca

h to reverse the

ly procedures in

n it 180° and repla

casing, remov

casing and rea

he same relati

ach other as t

coupling as call

hanged by swit

the impeller will

be operated cl

suction and disc

section 10 of th

ce it on the shaft. (

the casing from

ssemble the pu

nship to each ey were origina

d for in the alig

hing the motor l

run backwards.

ckwise or count

harge nozzles, t

s manual for pr

Follow the disass

the baseplate a

p.

ther as they we lly.

ment instructio ads.

-clockwise wh

is can be acco

per disassembl

mbly procedures

d turn 180°.

re originally. Th

s in section 7.

n viewed plished with

and

iven in this

e shaft and

51

IG A2 Correc

relationship of i

peller and casi

g HSC Fire pu

p

C6102 Rev 03



AC6102 Rev 03 52

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efficiently, in th

long-standing r

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you, go to ww

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innovative soluti the way water is

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customers who

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Xylem Inc. 8200 N. Austin Morton Grove, USA Tel: (847) 966Fax: (847) 966www.xyleminc.

Avenue

llinois 60053

700

1914

om/brands/acfi

epump

The o

riginal instruction is i

tions are translation

instru © 201

4 Xylem Inc.

AC Fi

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subsi

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English. All non-Eng

of the original instru

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AC610

ish

tion.

e of its

_3_en

Fire Pump 8100 Series, 8200 Series, 8150 Series, 9100 Series Installation, Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual