APS/MBP
Silencer Series Booster Pumps
Operation and Maintenance Manual
Hale Products Inc. ◆ A Unit of IDEX Corporation
700 Spring Mill Avenue
Telephone: 610-825-6300
Web: www.haleproducts.com
◆ Conshohocken, PA 19428 U.S.A.
◆ FAX: 610-825-6440
Manual p/n: 029-0020-83-0
NOTICE !
Class1 cannot assume responsibility for product failure resulting from improper
maintenance or operation. Class1 is responsible only to the limits stated in the
product warranty. Product specifications contained in this manual are subject to
change without notice.
All Class1 products are quality components -- ruggedly designed, accurately
machined, precision inspected, carefully assembled and thoroughly tested. In
order to maintain the high quality of your unit, and to keep it in a ready condition, it
is important to follow the instructions on care and operation. Proper use and good
preventive maintenance will lengthen the life of your unit.
ALWAYS INCLUDE THE UNIT SERIAL NUMBER
IN YOUR CORRESPONDENCE.
ECO NO REV CHANGE FROM BY DATE APVD
05-019 A INITIAL RELEASE LwH 01/20/2005 MAL
Manual p/n: 029-0020-83-0, Rev. -B
Printed in U.S.A.
HALE PRODUCTS, INC.
A Unit of IDEX Corporation
Conshohocken, PA 19428 USA
DRAWN BY LwH ISSUE DATE
CHECKED BY PRW 01/20/2005
© Hale Products, Inc. 2005
NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY.
COPYRIGHT ©
All Rights Reserved
Table of Contents ❑
Contents Page
Silencer Series Booster Pumps
1 Safety Precautions.................................................................................11
1.1 Guidelines............................................................................................................. 11
2 Introduction...........................................................................................15
2.1 Overview ...............................................................................................................15
Table 2-1: Booster Pump Capacity.............................................................................. 15
2.2 Principles Of Operation ...................................................................................... 16
Centrifugal Force................................................................................................................ 16
Figure 2-2: Centrifugal Force, from Rotating Disk ....................................................... 16
Figure 2-3: Pump Water Flow, Cutwater .....................................................................17
2.3 BOOSTER Pump Components............................................................................17
Impeller and Shaft Assembly.............................................................................................. 17
Pump Body......................................................................................................................... 18
Figure 2-4: Overview of Hale Booster Pump and Gearbox ......................................... 18
Mechanical Seal.................................................................................................................18
Figure 2-5: Mechanical Seal Overview........................................................................ 18
Gearbox.............................................................................................................................. 19
2.4 Pump Drives .........................................................................................................19
Figure 2-6: Pump/Engine Rotation .............................................................................. 19
HALE Power Takeoff (PTO) Driven Pumps ....................................................................... 20
Hale Engine Mounted Pumps............................................................................................. 20
Hale Hydraulic-Drive Pumps .............................................................................................. 20
2.5 Accessories .......................................................................................................... 20
Priming Systems ................................................................................................................ 21
Figure 2-7: Rotary Vane and ESP Priming Pumps...................................................... 21
Priming Valves ................................................................................................................... 22
Figure 2-8: SPVR Priming Valves ............................................................................... 22
Figure 2-9: PVG Priming Valves.................................................................................. 23
Silencer Series Booster Pump, p/n: 029-0020-83-0
3
❑ Table of Contents
Contents - continued Page
2.5 Accessories - continued
Pressure Control ...............................................................................................................23
The P Relief Valve System .......................................................................................... 23
Figure 2-10: P Series Relief Valve System Arrangement ........................................... 23
How the Relief System Works ..................................................................................... 24
Thermal Relief Valve (TRV)......................................................................................... 24
Figure 2-11: Thermal Relief Valve, TRV ..................................................................... 24
TRV-L Kit ..................................................................................................................... 25
Anodes......................................................................................................................... 25
Figure 2-12: Hale Anode ............................................................................................. 25
Manifolds ..................................................................................................................... 26
Figure 2-13: Typical Manifold Assembly Option.......................................................... 26
3 Operation ...............................................................................................27
3.1 Stationary Pumping Operations..........................................................................27
Pumping from a Hydrant (General Operation).................................................................. 27
Figure 3-1: Driver’s Compartment Indicator Lights ..................................................... 28
Figure 3-2: Pump Operator’s Panel ............................................................................ 29
Draft Limiting Factors......................................................................................................... 30
Table 3-3: Base Line NFPA Ratings ........................................................................... 31
Pumping from Draft............................................................................................................ 31
Pumping from Onboard Water Tank.................................................................................. 33
3.2 Pump and Roll Operation ...................................................................................35
3.3 Relief Valve Procedures.......................................................................................35
Figure 3-4: TPM Relief Valve Control ......................................................................... 36
3.4 Cavitation ..............................................................................................................36
Figure 3-5: Sample, Cavitation Regions ..................................................................... 36
Process of Cavitation......................................................................................................... 37
Warning Signs of Cavitation (Discharge and Gauges) ...................................................... 37
Discharge Pressure ..................................................................................................... 37
Vacuum Compound Gauge ......................................................................................... 38
4
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table of Contents ❑
Contents - continued Page
3.4 Cavitation - continued
To Eliminate Cavitation ...................................................................................................... 38
During Operations ............................................................................................................. 38
Table 3-6: Lift Loss from Elevation .............................................................................. 38
Table 3-7: Lift Loss from Elevation .............................................................................. 39
Preventive Measures.......................................................................................................... 39
Table 3-8: Hose Size vs. Pump Rating Capacity......................................................... 39
3.5 Post Operation Procedure................................................................................... 40
4 Preventive Maintenance .......................................................................41
4.1 Overview ...............................................................................................................41
4.2 Post-Operation .....................................................................................................41
Drain Pump ........................................................................................................................41
4.3 Extreme Conditions ............................................................................................. 41
During Freezing Weather ...................................................................................................42
4.4 Weekly................................................................................................................... 42
Relief Valve Test ................................................................................................................ 42
Figure 4-1: TPM Relief Valve Control.......................................................................... 43
Priming System ..................................................................................................................43
Pump Shift Warning Indicator Lights.................................................................................. 43
Valve Maintenance............................................................................................................. 44
Intake Strainers ..................................................................................................................44
Auxiliary Engine.................................................................................................................. 44
Verify All Gauges are in Working Order ............................................................................. 44
Operate Pump Controls...................................................................................................... 44
Inspect Water and Foam Tanks .........................................................................................45
Check Roof and Bumper Turrets........................................................................................45
Silencer Series Booster Pump, p/n: 029-0020-83-0
5
❑ Table of Contents
Contents - continued Page
4.5 Monthly..................................................................................................................45
Gearbox Lubrication .......................................................................................................... 45
Figure 4-2: Gearbox Capacity / Recommended Lubricants ........................................ 45
Figure 4-3: Typical Drain, Fill and Level Plugs............................................................ 46
Drive Line and Flange Bolts............................................................................................... 46
Priming System Test (Dry Vacuum Test)........................................................................... 46
Figure 4-4: PVG Priming Valve Handle....................................................................... 47
4.6 Annually ................................................................................................................48
Replace Gearbox Oil.......................................................................................................... 48
Check Drain Lines to Multi-Drain ....................................................................................... 48
Tank-to-Pump Flow Rate Test........................................................................................... 49
Performance Testing Overview.......................................................................................... 50
Figure 4-5: Pump Ratings (GMP/LPM) ....................................................................... 50
Performance Testing Equipment and Materials........................................................... 50
Performance Testing ................................................................................................... 51
Table 4-6: Nozzle Flow and Pressure Ratings, Part 1 ................................................ 52
Table 4-7: Nozzle Flow and Pressure Ratings, Part 2 ................................................ 53
Worn Clearance Rings and Impeller Hubs......................................................................... 54
Anode Check .....................................................................................................................54
Figure 4-8: Hale Anode ............................................................................................... 54
5 Troubleshooting ....................................................................................55
Figure 5-1: Sample, Serial Nameplate ........................................................................ 55
Figure 5-2: Troubleshooting Charts ............................................................................ 55
PTO Will Not Engage ............................................................................................. 55
Pump Loses Prime or Will Not Prime..................................................................... 55
Insufficient Pump Capacity..................................................................................... 57
Insufficient Pressure............................................................................................... 57
Valve Remote Control Difficult to Operate ............................................................. 57
Engine Speeds Too HIGH for Required Capacity or Pressure .............................. 57
Cavitation ............................................................................................................... 58
Relief Valve Does Not relieve Pressure When Valves are Closed ........................ 59
6
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table of Contents ❑
Contents - continued Page
Figure 5-2: Troubleshooting Charts - continued
Relief Valve Does Not Recover and Return to Original
Pressure Setting After Opening Valves.................................................................. 59
Relief Valve Opens When Control Valve is Locked Out......................................... 59
Unable to Obtain Proper Setting on Relief Valve ................................................... 59
Discharge Valves Difficult to Operate..................................................................... 60
Water in Pump Gearbox ......................................................................................... 60
Rotation Symptoms ................................................................................................ 60
6 Repair.....................................................................................................61
Figure 6-1: Silencer Series Booster Pump .................................................................. 61
Figure 6-2: Gearbox Capacity / Recommended Lubricants ........................................62
Table 6-3: Torque Values Chart .................................................................................. 62
6.1 Overview ...............................................................................................................62
6.2 General Repair Guidelines ..................................................................................63
Before You Begin... ............................................................................................................ 63
Cleaning and Inspection Guidelines................................................................................... 65
Hale Recommended Cleaners ...........................................................................................66
Tools Required................................................................................................................... 66
6.3 Pump and Gearbox Assembly ............................................................................67
Installing the Assembly to Apparatus ................................................................................. 68
6.4 Servicing the Booster Pump ............................................................................... 69
Volute (Pump Body) ........................................................................................................... 69
Figure 6-4: Booster Pump Parts Breakdown ............................................................... 69
Figure 6-5: Typical Water Cooling Lines ..................................................................... 70
Installation Notes – Volute ........................................................................................... 70
Impeller............................................................................................................................... 71
Inspection – Clearance Rings ...................................................................................... 72
Figure 6-6: Clearance Ring ID Measurement.............................................................. 72
Installation Notes – Clearance Rings ........................................................................... 72
Inspection – Impeller ....................................................................................................72
Figure 6-7: Impeller OD Measurement ........................................................................ 72
Installation Notes – Impeller........................................................................................ 73
Silencer Series Booster Pump, p/n: 029-0020-83-0
7
❑ Table of Contents
Contents - continued Page
6.5 Mechanical Seal Assembly..................................................................................74
Figure 6-8: Mechanical Seal Overview / Replacement ............................................... 74
Removing the Seal............................................................................................................. 74
Installing Seal..................................................................................................................... 75
6.6 Pump head ............................................................................................................77
Figure 6-9: Oil Seal Replacement / Pump Head Parts................................................ 77
Removing the Pump Head and Oil Seal ............................................................................ 78
Installation Notes – Pump Head and Oil seal .............................................................. 78
6.7 “B” Series Gearbox ..............................................................................................79
Oil Seal – Input Shaft......................................................................................................... 79
Figure 6-10: Oil Seal, Input Shaft................................................................................ 80
Installation Notes ......................................................................................................... 80
Figure 6-11: Typical Bearing and Seal Insertion Tools ............................................... 81
6.8 Dismantle the B Series Gearbox .........................................................................81
Figure 6-12: B Gearbox Parts Identification ................................................................ 82
Figure 6-13: Typical Angular Bearing Insertion Tool................................................... 84
Installation....................................................................................................................84
Figure 6-14: Angular Contact Bearing Orientation ...................................................... 85
6.9 Available options..................................................................................................87
Hydraulic Drive Option ....................................................................................................... 87
Figure 6-15: Hydraulic Drive Option............................................................................ 87
Installation Notes ......................................................................................................... 87
Tachometer Drive Option................................................................................................... 88
Figure 6-16: Tachometer Drive Option........................................................................ 88
Installation Notes ......................................................................................................... 88
7 Installation .............................................................................................89
7.1 OVERVIEW ............................................................................................................89
7.2 FRAME MOUNTING ..............................................................................................89
Mounting Holes..................................................................................................................89
8
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table of Contents ❑
Contents - continued Page
7.3 DRIVELINE ISSUES.............................................................................................. 90
Drive Line and Flange Bolts ............................................................................................... 90
Issues................................................................................................................................. 90
Table 7-1: Maximum Recommended Driveline Lengths.............................................. 91
7.4 PLUMBING CONNECTIONS.................................................................................91
8 Maintenance Kits ..................................................................................93
8.1 Recommended spare parts kits.......................................................................... 93
Level 1 ............................................................................................................................... 93
Figure 8-1: Typical Level 1 Basic Repair Kit................................................................ 93
Level 2................................................................................................................................ 93
Figure 8-2: Typical Level 2 Intermediate Repair Kit .................................................... 93
Table 8-3: Level 2 Kit Part Numbers ........................................................................... 94
Complete Overhaul ............................................................................................................94
Figure 8-4: Additional Booster Pump Maintenance Kits, Level 3 ................................ 94
Appendix A: Glossary.........................................................................95
Appendix A-1: Measurements .............................................................99
CONVERSIONS..................................................................................................... 99
Appendix C: Alternate Lubricant Manufacturers ..........................101
Table C-1: Alternate Lubricant Manufacturers........................................................... 101
Table C-2: Alternate Lubricant Manufacturers, continued ......................................... 102
Appendix D: Hose Friction Loss .......................................................103
Table D-1: Hose Friction Loss (PSI/Bar 100 Feet) .................................................... 103
Express Warranty...............................................................................105
Hale Products, Inc...................................................................................................... 106
Silencer Series Booster Pump, p/n: 029-0020-83-0
9
❑ Table of Contents
Contents - continued Page
Drawings ..........................................................................................Plate #
Installation / Parts
APS Silencer Series Booster Pump Installation and Identification...............................1027A
MBP Silencer Series Booster Pump Installation and Identification..............................1026A
Available Options
Anti-Corrosion Anode, Plate #869A...............................................................................869A
ESP Priming Pump........................................................................................................821A
P Series Relief Valve - Option.......................................................................................547C
PVG Priming Valve - Option................................................................................
Shift Indicator Lights, Wiring Schematic, PTO...............................................................825A
SPV Priming Valve - Option...........................................................................................828A
TRV/TRVM Relief Valve System - Option......................................................................729A
..........480G
10
Silencer Series Booster Pump, p/n: 029-0020-83-0
1 Safety Precautions
THE HALE SILENCER SERIES BOOSTER PUMPS ARE DESIGNED FOR OPTIMUM SAFETY OF ITS OPERATORS. FOR ADDED PROTECTION, PLEASE
FOLLOW THE SAFETY GUIDELINES LISTED IN THIS SECTION AND ADHERE
TO ALL WARNING, DANGER, CAUTION AND IMPORTANT NOTES FOUND
WITHIN THIS MANUAL.
ALL SUPPLIED DOCUMENTATION MUST BE CAREFULLY READ, UNDERSTOOD AND ADHERED TO STRICTLY BY ALL INSTALLERS AND OPERATORS
BEFORE ATTEMPTING TO INSTALL OR OPERATE THE SILENCER SERIES
BOOSTER PUMP.
Hale is a registered trademark of Hale Products, Incorporated. All other brand and product
names are the trademarks of their respective holders.
Safety Precautions ❑
IMPORTANT !
1.1 GUIDELINES
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES, GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO
THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED
IN THE APPARATUS MANUFACTURER'S MANUAL.
REFER TO PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS.
❑ Use care when removing the Booster Pump assembly from its packaging
to prevent personal injury and/or damage to the system.
❑ To fully support the booster pump assembly, use all mounting bolt holes
provided on the gearbox and/or the booster pump.
❑ Installation should be performed by a trained and qualified installer, such
as your authorized Hale service representative. Be sure the installer has
sufficient knowledge, experience and the proper tools before attempting
any installation.
NOTICE !
Silencer Series Booster Pump, p/n: 029-0020-83-0
11
❑ Safety Precautions
THE BOOSTER PUMP AND GEARBOX ASSEMBLY IS HEAVY AND BULKY,
WEIGHING UP TO 145 LBS. (54 KGS.). ADDING ACCESSORIES INCREASES
THE WEIGHT. BE CERTAIN TO USE PROPER LIFTING SUPPORT DEVICES
CAPABLE OF HANDLING THE LOAD WHEN REMOVING OR INSTALLING THE
SILENCER SERIES BOOSTER PUMP AND GEARBOX ASSEMBLIES.
❑ The installer is responsible for observing all instructions and safety pre-
cautions in his or her daily routine as dictated by regional safety ordinances or departmental procedures.
❑ DO NOT permanently remove or alter any protective feature, guard or
insulating devices, or attempt to operate the system when these guards
are removed.
Doing so voids the Silencer Booster Pump warranty.
❑ Any of the above could affect system capacity and/or safe operation of
the system and is a serious safety violation which could cause personal
injury or could affect safe operation of the pump.
WARNING !
WARNING!
NO MODIFICATIONS OR ADDITIONS MAY BE MADE TO THE SILENCER
SERIES BOOSTER PUMP ASSEMBLY WITHOUT PRIOR WRITTEN PERMIS
SION FROM:
-
Hale Products, Incorporated
Fire Suppression Division
700 Spring Mill Avenue
Conshohocken, PA 19428 U.S.A.
Telephone .......... 610-825-6300
Fax..................... 610-825-6440
Web ................... www.haleproducts.com
❑ Rotating drive line parts can cause injury. Be extremely careful that NO
part of your body (head, feet, arms, legs, fingers, hair) is in an area of
rotating parts where you could be subject to injury.
❑ Make sure everyone is clear of the apparatus. Verify the parking brake is
set and the wheels are chocked to prevent any movement of the
apparatus.
12
Silencer Series Booster Pump, p/n: 029-0020-83-0
Safety Precautions ❑
❑ DO NOT operate the system at pressures higher than the maximum
rated pressure. (Also see Table 2-1: “Booster Pump Capacity” on page
13.)
❑ Relieve all system pressure, then drain all water from the system before
servicing any of its component parts.
❑ Use only pipe, hose and fittings which are rated at or above the maxi-
mum pressure rating at which the water pump system operates.
❑ If a pump is operated without water for extended periods, or without dis-
charging water, it could overheat. This can damage the mechanical seal
or the drive mechanism.
❑ DO NOT attempt to pump until all the “GREEN” pump indicators in the
cab and panel are ON. (Also see Figure 3-2: “Pump Operator’s Panel”
on page 27.)
❑ DO NOT advance the throttle unless the "OK TO PUMP" indicator is ON.
❑ DO NOT reduce the pressure on the INTAKE gauge below zero (0).
Serious damage to the water main could result.
❑ Use only PAC-EASE Rubber Lubricant Emulsion (or equal) on the rubber
mechanical seal parts to ease installation. DO NOT use other lubricant
types as damage to the mechanical seal and seat could occur.
Silencer Series Booster Pump, p/n: 029-0020-83-0
13
❑ Safety Precautions
Notes
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
14
Silencer Series Booster Pump, p/n: 029-0020-83-0
2 Introduction
2.1 OVERVIEW
Hale Products currently offers the Silencer Series Booster Pumps in two
models:
❑ APS – Single-Stage, Centrifugal Attack Pump (250-500 GPM/1,000-
2,000 LPM), with three primary drive options: truck transmission PTO,
hydraulic drive or direct engine mount.
❑ MBP – Single-Stage, Centrifugal, “High Volume” Attack Pump (500-
1,000 GPM/2,000-4,000 LPM), also with three primary drive options:
truck transmission PTO, hydraulic drive or direct engine mount.
Unless otherwise indicated, these procedures apply to all models of Hale
Silencer Series Booster Pumps.
Introduction ❑
The Hale line of booster pumps are the favorites of fire fighters throughout
the world. Booster pumps can be used as initial attack pumps or as auxil
iary pumps in conjunction with the apparatus main pump. They offer the
versatility, dependability, reliability, ease of operation and reduced mainte
nance that is so necessary to effective fire fighting.
Hale booster pumps are compact in size and lightweight for easy mounting.
The apparatus builder must supply the transmission PTO (power takeoff)
and connecting shaft.
Hale offers two models of the silencer series booster pumps. The anticipated use and position on the apparatus determines the model selected as
well as the drive unit. Flow capacities are shown in Table 2-1: “Booster
Pump Capacity.”
Model Type Capacity
APS Single-Stage Silencer Series
HIGH Volume Attack Pump.
MBP Single-Stage Silencer Series
HIGH Volume Attack Pump
Up to 500 GPM (1,893LPM). NFPA Rated at 250 to 500
GPM (946 to 1,893LPM), per Standard 1901.
Up to 1,000 GPM (3,785LPM). NFPA Rated at 500 to
1,000 GPM (1,983 to 3,785LPM), per Standard 1901.
-
-
Silencer Series Booster Pump, p/n: 029-0020-83-0
Table 2-1: Booster Pump Capacity
15
❑ Introduction
2.2 PRINCIPLES OF OPERATION
Centrifugal Force
Hale booster pumps are centrifugal pumps that operate on the principle of
centrifugal force created by a rapidly spinning disk.
trifugal Force, from Rotating Disk.”)
As the disk is rotated, it throws water from the center toward the outer circumference of the disk. The
velocity at which the water travels from the center
directly relates to the diameter of the disk and the
speed of rotation.
When water is confined in a closed container, such
as the volute (pump body), the velocity of the water
is converted to pressure that rises to a level depen
dent on the speed of rotation.
(See Figure 2-2: “Cen-
-
There are three interrelated factors that regulate
the performance of a centrifugal pump:
❑ SPEED (RPM) If the speed of rotation
Figure 2-2: Centrifugal
Force, from Rotating
Disk
increases with flow held constant, fluid pressure
increases.
❑ PRESSURE If pressure changes with speed held constant, the flow,
measured in gallons or liters per minute (GPM/LPM), changes inversely;
if pressure increases, flow decreases.
Pressure is usually measured in pounds per square inch (PSI) or BAR.
❑ FLOW If the pressure is held constant, the flow increases with an
increase in the speed of rotation. Flow is measured in the number of gal
lons of fluid per minute (GPM or LPM) that a pump can deliver when supplied from draft.
A centrifugal pump is preferred by the fire protection service due to its ability
to fully utilize any positive suction inlet pressure, reducing the amount of
work done by the pump.
For example, if the required discharge pressure is 120 PSI (8.3 BAR), and
the inlet pressure is 45 PSI (3.1 BAR), the pump must only produce the dif
ference in pressure or 75 PSI (5.2 BAR). This contributes to improved performance with reduced maintenance. Decreased maintenance is aided by
the fact a centrifugal pump has few moving parts.
-
-
16
Silencer Series Booster Pump, p/n: 029-0020-83-0
As the impeller rotates, the
water moving outward in the
impeller creates reduced pres
sure or a vacuum in the suction
eye allowing atmospheric pres
sure to push water into the
pump impeller, replacing the
water discharged.
During operation water enters
the suction eye of the impel
ler. The rotating impeller
vanes develop discharge pres
sure and direct the water to the
discharge opening.
The cutwater is a wedge that
divides the water between the
volute (pump body) and the
pump discharge.
Introduction ❑
-
-
-
Figure 2-3: Pump Water Flow, Cutwater
2.3 BOOSTER PUMP COMPONENTS
(See Figure 2-4: “Overview of Hale Booster Pump and Gearbox,” on page
18.)
The silencer series booster pump consist of:
❑ Impeller and Shaft Assembly
❑ Volute (Pump Body)
❑ Mechanical Seal
❑ B Series Gearbox
Impeller and Shaft Assembly
Power is transmitted through the B Series gearbox to a high-quality, bronze
impeller.
on page 18.)
(See Figure 2-4: “Overview of Hale Booster Pump and Gearbox,”
Silencer Series Booster Pump, p/n: 029-0020-83-0
17
❑ Introduction
Pump Body
(See Figure 2-4: “Overview of Hale Booster
Pump and Gearbox.”)
As water discharges
from the impeller, it
enters the volute (pump
body). The volute is
shaped so that its area
increases from the cut
water to its full capacity
at the volute throat. This
gradual increase in size
maintains a constant
average velocity through
the volute.
Standard APS and MBP
volutes are constructed
from fine-grain cast iron. For areas where salt water is commonly used, a
bronze version of the Model APS is available.
-
Figure 2-4: Overview of Hale Booster Pump and
Gearbox
The volute is a single piece, and must be removed to service the impeller,
clearance rings, and mechanical seal. Removal of the volute can often be
accomplished without removing the pump and gearbox assembly from the
apparatus.
Mechanical Seal
The mechanical seal is
common to Hale booster
pumps.
“Mechanical Seal Overview.”)
The stationary seat is in
constant contact with a
rotating seal ring to pre
vent leakage. The sealing diaphragm is made of
a rubber elastomer spe
cifically designed for hightemperature operations.
(See Figure 2-5:
-
-
Figure 2-5: Mechanical Seal Overview
18
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
Note: Mechanical seals do not drip like older pump packing. A Hale Booster
Pump with a drip from the seal requires service.
WARNING !
IF A PUMP IS OPERATED WITHOUT WATER FOR EXTENDED PERIODS, OR
WITHOUT DISCHARGING WATER, IT COULD OVERHEAT. THIS CAN DAM
AGE THE MECHANICAL SEAL OR THE DRIVE MECHANISM.
-
Gearbox
Hale Silencer Series Pumps are equipped with a B Series Gearbox that utilizes helical gears to reduce operating noise. To accommodate a wide
range of engines, transmissions, and PTOs, this speed increasing gearbox
is available in a variety of ratios. All Silencer series pumps feature a stan
dard water cooler that uses water flowing through the pump to lower gearbox temperatures when required.
-
2.4 PUMP DRIVES
Three common booster pump drives are used on fire fighting apparatus:
❑ Operation from a
Power Take-Off
(PTO) from the truck
transmission or drive
train
❑ A stand-alone drive
with separate engine
(auxiliary engine)
❑ Hydraulic motor
Hale booster pumps
produce the volumes
and pressures shown
on their performance
curves. However, max
imum pump performance is sometimes
limited by the power
capacity and speed limits of the engine, transmission, and PTO.
-
Figure 2-6: Pump/Engine Rotation
Silencer Series Booster Pump, p/n: 029-0020-83-0
19
❑ Introduction
Hale booster pumps are available for either engine rotation (clockwise), or
opposite engine rotation (counterclockwise) PTO operation.
5: “Mechanical Seal Overview,” on page 18.)
NEVER OPERATE A BOOSTER PUMP ABOVE THE DERATED CONTINUOUS
TORQUE RATING FOR ITS TRANSMISSION OR PTO, OR ABOVE THE REC
OMMENDED PTO OUTPUT SPEED AS RECOMMENDED BY THE PTO
MANUFACTURER.
HALE Power Takeoff (PTO) Driven Pumps
Silencer series booster pumps feature a 1-1/2” (38mm) input shaft for connection to a PTO driveline. An optional 1410 companion flange is also
available.
(See Figure 2-
WARNING !
-
Hale Engine Mounted Pumps
Silencer series booster pumps are available with an adapter to accept #3
and #4 SAE bell housings. Elastomeric couplings are also available for 61/5” (165mm), 10” (254mm) and 11.5” (292mm) clutch discs.
Hale Hydraulic-Drive Pumps
Silencer series boosters pumps are available with an adapter to accept
SAE “C” two and four bolt hydraulic motors with SAE “C” splined output
shafts.
2.5 ACCESSORIES
In addition to the basic Hale booster pump, the following options are available to complete system installation:
❑ Priming Systems
20
❑ Pressure Control Devices (Relief Valves or Governors)
❑ Manifolds
❑ Anodes
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
Priming Systems
Priming pumps are used to evacuate air in the suction hose and pump.
`The vacuum created allows atmospheric pressure to push water from the
static source through the suction hose and into the pump.
Hale booster pumps use Rotary Vane Positive Displacement type pumps for
priming.
(See Figure 2-7: “Rotary Vane and ESP Priming Pumps.”)
The priming pump has a rotor mounted off-center (eccentric) to the pump
body housing. The rotor vanes slide in grooves and are held against the
body housing by centrifugal force. As a vane turns toward the discharge, it
recedes into the rotor compressing the air.
As the rotor continues past the discharge, the vane advances outward from
the groove and against the body housing. During this cycle, the space
between the rotor and housing case fills with air. The vanes, acting as wip
ers, force air out of the discharge, creating a vacuum in the main pump
allowing atmospheric pressure to push water into the hose and suction side
of the pump.
The Hale ESP series priming pump is an environmentally friendly primer
that does not require a separate lubricant reservoir. The vanes and pump
body are self-lubricating for maintenance free operation.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 2-7: Rotary Vane and ESP Priming Pumps
-
21
❑ Introduction
An ESP series priming pump also uses a single control to open the priming
valve between the booster and the priming pumps, and start the priming
motor.
(See Figure 2-7: “Rotary Vane and ESP Priming Pumps,” on page
21.)
Priming Valves
Hale priming valves open when the priming pump is operated to allow the
air to escape from the pump.
Two priming valves are offered:
❑ Hale Semi-Automatic Priming Valve for Remote Mounting (SPVR)
22
Figure 2-8: SPVR Priming Valves
A hose is connected from the SPVR to the priming tap on the booster
pump body. A single push-button on the operator’s panel starts the
priming pump motor. When a vacuum is created, the SPVR opens.
(See Figure 2-8: “SPVR Priming Valves.”)
Releasing the push-button stops the priming pump and the SPVR
closes.
❑ The Hale PVG Priming Valve
The PVG is mounted on the pump operator’s panel. The PVG is a combination valve and switch.
When the handle on the PVG is pulled out, the valve opens and the
switch energizes the primer motor.
(See Figure 2-9: “PVG Priming
Valves,” on page 23.) Pushing the handle in de-energizes the motor and
closes the valve.
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
Figure 2-9: PVG Priming Valves
Pressure Control
The P Series relief valve system is a bronze, variable-pressure setting relief
valve that prevents undue pressure per the requirements of NFPA Standard
1901. An indicator light on the operator control panel signals when the
valve is open.
The P Relief Valve System
The P relief valve system consists of a panel mounted control valve (PM)
and a P25, P30 or P30V relief valve.
(See Figure 2-10: “P Series Relief
Valve System Arrangement.”)
Silencer Series Booster Pump, p/n: 029-0020-83-0
Figure 2-10: P Series Relief Valve System Arrangement
23
❑ Introduction
The valve is mounted in the discharge piping and plumbed back to the
pump suction. Valve connections are either flanged or Victaulic
ure 2-10: “P Series Relief Valve System Arrangement,” on page 23.)
How the Relief System Works
A pressure line mounted in the pump discharge pressure tap provides pressure to the diaphragm in the PM control valve. The handwheel on the PM
control either increases or decreases the spring tension on the diaphragm.
The seat of the P series relief valve is kept closed by pump discharge pres
sure. Also see Figure 2-10: “P Series Relief Valve System Arrangement” on
page 23.
As the pump pressure increases, more pressure is applied to the diaphragm
in the PM control valve.
As the pressure on the diaphragm increases beyond the set point, the stem
moves off its seat, allowing pump pressure to push on the piston in the relief
valve. This causes the relief valve seat to lift, allowing excess pressure to
dump back to the pump suction side.
™
. (See Fig-
-
After the pressure equalizes, the piston returns to the closed position as the
pressure in the relief valve bleeds off through an orifice.
An Amber indicator light on the PM control illuminates when the relief valve
is OPEN.
Thermal Relief Valve (TRV)
The Thermal Relief Valve
protects the pump from over
heating. (See Figure 2-11:
“Thermal Relief Valve, TRV.”)
The optional TRV unit is
attached to the discharge pip
ing either by flange mounting
or 1-1/4” NPT threaded con
nection (38mm for the Model
TRVM).
The valve monitors the temperature of the water in the
pump. When the tempera
ture exceeds 120°F (48.9°C),
-
Figure 2-11: Thermal Relief Valve, TRV
the valve automatically opens
and depending on the instal
lation, discharges a small amount of water either to the ground or into the
water tank allowing cooler water to enter.
24
Silencer Series Booster Pump, p/n: 029-0020-83-0
Introduction ❑
After the temperature returns to a safe level, the valve closes.
TRV-L Kit
(See Figure 2-11: “Thermal Relief Valve, TRV,” on page 24.)
The TRV-L kit includes a chrome panel placard with a warning lamp, a lamp
test button, and a pre-assembled wire harness. The light illuminates when
the TRV is open and discharging water.
An optional buzzer provides audible warning. The buzzer mounts on the
operator panel.
Anodes
(See Figure 2-12: “Hale Anode.”)
The Hale Anode System helps prevent damage caused by galvanic corrosion in the pump. Galvanic action pits the pump and pump shaft material
through the electrolysis of water in the pump. The popularity of noncorro
sive water tanks and piping has increased this type of corrosion in today’s
fire pumps.
The Hale Anode System is a sacrificial metal, which helps to
diminish or prevent corrosion.
The anode fits on any Hale truck
mounted pump, regardless of
age or model.
The Anode kit is designed for
installation in the standard Hale
115 series flange opening. On
fabricated manifolds and similar
applications, the installer is to
provide 1-1/4” NPT openings and
install anodes directly. It is rec
-
Figure 2-12: Hale Anode
ommended that one anode be
installed on each suction manifold and one on the discharge side. Typically,
three are used. Anodes can be mounted in any position, horizontal or
vertical.
Zinc anodes should be inspected every twelve (12) months. Replace when
over 75% of the zinc has been consumed. Performance of the anode varies
with water quality and PH. Anodes conform to Mil Spec. A18001.
Silencer Series Booster Pump, p/n: 029-0020-83-0
25
❑ Introduction
Manifolds
(See Figure 2-13: “Typical Manifold Assembly Option.”)
26
Figure 2-13: Typical Manifold Assembly Option
Silencer Series Booster Pump, p/n: 029-0020-83-0
3 Operation
This section provides information and procedures for the operation of Hale
silencer series booster pumps. Included are post-operation procedures and
procedures for pumping from:
❑ a hydrant
❑ draft
❑ an onboard tank
THE PROCEDURES IN THIS MANUAL ARE GENERAL OPERATING PROCEDURES. THEY DO NOT REPLACE THE PROCEDURES, POLICIES, GUIDELINES ESTABLISHED BY THE AUTHORITY HAVING JURISDICTION, NOR DO
THEY REPLACE THE RECOMMENDATIONS AND PROCEDURES PROVIDED
IN THE APPARATUS MANUFACTURER'S MANUAL.
Operation ❑
NOTICE !
REFER TO PROCEDURES PROVIDED BY THE AUTHORITY HAVING JURISDICTION ON SETTING WHEEL CHOCKS AS WELL AS LAYOUT AND CONNECTION OF HOSES, VALVES AND DRAIN COCKS.
3.1 STATIONARY PUMPING OPERATIONS
Pumping from a Hydrant (General Operation)
1. Bring the truck to a complete stop and apply the truck parking brake.
CAUTION !
REFER TO DEPARTMENT PROCEDURES FOR SETTING WHEEL CHOCKS
AND LAYING OUT SUCTION AND DISCHARGE HOSES.
ALL VALVES, DRAIN COCKS, AND CAPS SHOULD BE CLOSED.
2. Shift the truck transmission to the NEUTRAL position.
Silencer Series Booster Pump, p/n: 029-0020-83-0
27
❑ Operation
Figure 3-1: Driver’s Compartment Indicator Lights
3. Engage the PTO (power take-off) per the PTO manufacturer’s instructions.
The GREEN shift warning indicator light illuminates, indicating a complete
shift.
(See Figure 3-1: “Driver’s Compartment Indicator Lights.”)
WARNING !
DO NOT LEAVE THE CAB OR ATTEMPT TO PUMP UNTIL ALL THE GREEN
PUMP LIGHTS IN THE CAB ARE ON.
4. Exit the driving compartment only after all the above steps are completed and
you are sure that the appropriate lights in the cab and panel are ON.
CAUTION !
DO NOT OPEN THE THROTTLE UNLESS THE GREEN INDICATOR LIGHT IS
ALSO SEE FIGURE 3-2: “PUMP OPERATOR’S PANEL” ON PAGE 29.)
ON.
5. Verify that the pump panel shift indicator green “OK TO PUMP” light is ON
and that all hose connections are complete.
6. Open the hydrant. Bleed off the air from the suction hose.
28
Silencer Series Booster Pump, p/n: 029-0020-83-0
Operation ❑
Figure 3-2: Pump Operator’s Panel
7. If necessary, open the suction valve to allow water to flow into the pump.
8. To eliminate air pockets, open appropriate valve to expel air or prime the pump,
if so equipped.
Also see heading “Pumping from Draft” on page 31.
9. Note the discharge pressures and intake pressures as applicable, then open
the engine throttle gradually until the master discharge gauge indicates the
desired pressure.
10. Set the automatic relief valve or governor control system according to your
company policy, if so equipped.
CAUTION !
DO NOT REDUCE THE PRESSURE ON THE INTAKE GAUGE BELOW
DEPARTMENT LIMITS. SERIOUS DAMAGE TO THE WATER MAIN COULD
RESULT.
11. If the master intake gauge shows a vacuum before the desired discharge
pressure or flow is reached, it indicates that you are receiving all the water the
suction piping (hydrant) can supply.
Silencer Series Booster Pump, p/n: 029-0020-83-0
29
Loading...