REPAIR MANUAL

REPAIR MANUAL
MODEL 383
SINGLE STAGE INLINE FIRE PUMP
INSTRUCTION AND REPAIR MANUAL
NOTE! To the installer: Please make sure you provide this manual to the owner of the equip­ment or to the responsible
party who maintains the system.
Part # A-03-284 | © 2012 Pentair Ltd. | 12/03/12
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MODEL 383
DATED SEPTEMBER 2011
SUPERSEDES ITEM 383
DATED JULY 2001
SERVICE:
CALIFORNIA PROPOSITION 65 WARNING:
Read and understand all warnings before installing or servicing
pump.
Your Aurora pump requires little maintenance other than
periodic inspection, occasional cleaning, lubrication of bearings
and gland adjustments to minimize packing leakage. The intent
of inspection is to prevent breakdown, thus obtaining optimum
service life. The liquid end of the pump is lubricated by the
fluid being pumped and therefore does not require periodic
lubrication. The motor, however, may require lubrication, in
which case the motor manufacturer’s recommendation should
be followed.
OPERATIONAL LIMITS*:
REPAIRS:
Warning: This product and related accessories
contain chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
ATTENTION: SAFETY WARNINGS:
Maximum Operating Pressure:
175 psi at Temperatures
to l50ºF (66°C)
Before starting any work, ensure the electrical power is
locked out, the system pressure has been lowered to 0 psi and
temperature of the unit is at a safe level.
Maximum Operating Temperature: 225°F (107°C)
The pump may be disassembled using the illustrations and text
provided. Although complete disassembly is covered, it will
seldom be necessary to completely disassemble your Aurora
pump.
*See ASTM A126/ANSI B16.l for pressure/temperature ratings
of flanges.
ELECTRICAL SAFETY:
Inspect removed parts at disassembly to determine if they can
be reused. Ball bearings that turn roughly or show wear should
be replaced. Cracked casings should never be reused. Scored
or worn pump shafts should be replaced. Gaskets should be
replaced at reassembly simply as a matter of economy. They are
much less expensive to replace routinely than to replace as
the need arises. In general it is economical to return to the
manufacturer for repair of only the motor and motor controller.
Warning: Electrical Shock Hazard
All electrical connections are to be made by a qualified
electrician in accordance with all codes and ordinances.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
DISASSEMBLY:
Disassemble only what is needed to make repairs or to
accomplish inspection. Proceed to disassemble the pump as
follows:
Warning: Electrical Overload Hazard
Ensure all motors have properly sized overload protection.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
1.Break electrical connections to prevent any possibility of
pump starting during disassembly.
2.Remove plug (74) from casing (6) to drain pump.
Warning: Sudden Start-Up Hazard
3.Remove all relief, cooling, flushing, or drain lines from the
pump including compression connections (1 & 2), ball valve
(75) and tubing (3) if provided. Break suction and discharge
connections only if it is desired to remove casing (6).
Disconnect and lockout power source before servicing.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
4.Remove capscrews (5) and two opposite capscrews (41).
Thread two capscrews (5) into taps that held capscrews (41)
and turn alternately until cover (26) separates from casing.
This procedure may vary slightly for some pump sizes.
Lift pump assembly with motor from casing (6). Remove
gasket (8).
HIGH PRESSURE SAFETY:
Warning: High Pressure Hazard
The pump is rated at a maximum of 175 psi at 150°F. Do not
exceed this pressure. Install properly sized pressure relief
valves in system. Failure to follow these instructions could
result in serious personal injury, death or property damage.
3
MODEL 383
CAUTION
Warning: Lifting Hazard
There must be two (2) rings of packing in front of lantern
ring (29) to assure proper alignment between the lantern
ring and the sealing tube connection (1) in the cover (26).
Install remaining packing rings (28). Each ring should be
tapped firmly in place with a wood or metal bushing.
The motor and pump assembly may be very heavy. Use
extreme caution and safe lifting equipment during the lifting
procedure. Failure to follow these instructions could result
in serious personal injury, death or property damage.
5.Unscrew impeller screw (9) and remove washer (9A), gasket
(9B) and seal washer (9C).
4.Slide the sleeve (25) through the packing making sure the
pin end of the sleeve (25) is in the cover side opposite the
gland halves (23).
6.Slide impeller (11) and impeller key (12) from the shaft.
Remove O-ring (10).
5.Replace gland halves (23) and place gland clamps (22) over
capscrews (65). Tighten capscrews (65) finger tight into
cover assembly (26).
7.Wearing ring(s) (7 & 16) are pressed into their housings
with an interference fit and must be removed with a puller if
new rings are required.
NOTE:
The slots in gland halves (23) should be diagonal to pump
horizontal center line.
8.Remove capscrews (65), gland clamps (22), and gland
halves (23).
6.The cover assembly (26) as a unit may be replaced onto
the motor shaft. Align key groove to facilitate impeller
reassembly. The cover is held to motor bracket (35) by
capscrews (41). These should be installed and tightened at
this time.
9.U nscrew remaining capscrews (41) and remove cover
assembly (26).
10.Shaft sleeve (25) is slip fit on the shaft and should be easily
removed unless the pump has been in service for a long
time. In this case, it may be necessary to use a puller. Take
care to prevent damaging the surface of the sleeve. Replace
the sleeve if it is grooved from wear.
7.Carefully place O-ring (10) on motor end of impeller (11).
Assemble key (12) and impeller (11) to motor shaft. Secure
impeller with gasket (9B), washer (9A), seal washer (9C),
and impeller screw (9).
11.The packing (28) and lantern ring (29) (if used) must now be
removed from the packing box of cover (26), and the cavity
thoroughly cleaned to allow new packing to fit properly. The
throat of cover (26) should be checked for excessive wear.
8.Install the pipe plug (74) in the pump casing (6). Position
a new gasket (8) on casing (6). Lower bracket, cover, and
motor assembly onto casing and secure with capscrews (50).
12.If necessary, unscrew capscrews (32) and remove bracket
(35) from motor.
9.If provided, replace compression fittings (1 & 2), ball valve
(75), and tubing (3).
REASSEMBLY:
10.Secure suction and discharge piping to the pump. Make sure
to install gaskets on flanged connections.
Reassembly will generally be in reverse order of disassembly. If
disassembly was not complete, use only those steps related to
your particular repair program.
11.Connect electricity to the motor.
12.Read carefully the sections of the manual titled
INSTALLATION and OPERATION.
1.Replace wear ring(s) (7 & 16) in casing (6) and cover (26).
Rings should not be hammered into place. Use a press or
clamp the parts in a bench vice using wooden blocks to
protect the rings. It may be necessary to pin or dowel the
rings after assembly if the cover or casings has had rings
replaced before, since each reassembly can stretch or tear
metal and thereby loosen fits. If the facilities are available, it
is good practice to take a very light finish cut or to ream the
inside diameter of the casing rings after pressing to restore
roundness. When rings are pressed, they may get squeezed
out of shape.
STARTING PUMP AFTER REASSEMBLY:
Do not start pump until all air and vapor have been bled and
until making sure that there is liquid in the pump to provide the
necessary lubrication for the packing.
When the pump is returned to service, additional care must
be given to packing box to ensure a proper packing life. It is
necessary to allow 60–120 drops leakage per minute through the
packing for lubrication purposes. If the flow rate is other than
this, the capscrews should be either loosened or tightened
one quarter turn at a time to acquire the correct leakage (both
capscrews must be turned equally to prevent cocking of the
gland). It will take approximately ten minutes at anyone gland
setting before the leakage rate will stabilize. When in doubt,
choose the greater leakage rate since overly tight packing will
ruin not only the packing, but the sleeve as well.
2.If bracket (35) was removed, position the motor and secure
with capscrews (32). Tighten screws evenly to assure proper
alignment.
3.Place one ring of packing (28) into cover (26). On
successive rings of packing, stagger the packing joints to
prevent excessive leakage though the packing box. If lantern
ring (29) is used, place a second ring of packing (28) into the
cover before installing lantern ring.
4
MODEL 383
1. Compression Fitting
2. Compression Elbow
3. Tubing
4. Pipe Plug
5. Capscrew
6. Casing
7. Wear Ring
8. Gasket
9. Impeller Screw
9A.Washer
9B.Gasket
9C. Seal Washer
MODEL 383 LIST OF PARTS
10.Gasket
11.Impeller
12. Impeller Key
16. Wear Ring
22.Clamp
23.Gland
25.Sleeve
26.Cover
28.Packing
29. Lantern Ring
32.Capscrew
33.Screw
34.Nameplate
35.Bracket
39.Capscrew
40. Nameplate Holder
41.Capscrew
65.Capscrew
68. Pipe Plug
73.Base
74. Pipe Plug
75. Ball Valve
76.Nipple
AURORA PUMP RESERVES THE RIGHT TO SUBSTITUTE MATERIALS WITHOUT NOTICE.
NOTE: WHEN ORDERING SPARE PARTS ALWAYS INCLUDE THE PUMP TYPE, SIZE, SERIAL NUMBER, AND
THE PIECE NUMBER FROM THE EXPLODED VIEW IN THIS MANUAL. ORDER ALL PARTS FROM YOUR LOCAL
AUTHORIZED DISTRIBUTOR OR THE FACTORY AT NORTH AURORA, ILLINOIS.
5
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WARRANTY
Seller warrants equipment (and its component parts) of its own manufacture against defects in materials and workmanship under normal use
and service for one (1) year from the date of installation or start-up, or for eighteen (18) months after the date of shipment , whichever occurs
first. Seller does not warrant accessories or components that are not manufactured by Seller; however, to the extent possible, Seller agrees to
assign to Buyer its rights under the original manufacturer's warranty, without recourse to Seller. Buyer must give Seller notice in writing of
any alleged defect covered by this warranty (together with all identifying details, including the serial number, the type of equipment, and the
date of purchase) within thirty (30) days of the discovery of such defect during the warranty period. No claim made more than 30 days after
the expiration of the warranty period shall be valid. Guarantees of performance and warranties are based on the use of original equipment
manufactured (OEM) replacement parts. Seller assumes no responsibility or liability if alterations, non-authorized design modifications
and/or non-OEM replacement parts are incorporated If requested by Seller, any equipment (or its component parts) must be promptly
returned to Seller prior to any attempted repair, or sent to an authorized service station designated by Seller, and Buyer shall prepay all
shipping expenses. Seller shall not be liable for any loss or damage to goods in transit, nor will any warranty claim be valid unless the
returned goods are received intact and undamaged as a result of shipment. Repaired or replaced material returned to customer will be
shipped F.O.B., Seller's factory. Seller will not give Buyer credit for parts or equipment returned to Seller, and will not accept delivery of
any such parts or equipment, unless Buyer has obtained Seller's approval in writing. The warranty extends to repaired or replaced parts of
Seller's manufacture for ninety (90) days or for the remainder of the original warranty period applicable to the equipment or parts being
repaired or replaced, whichever is greater. This warranty applies to the repaired or replaced part and is not extended to the product or any
other component of the product being repaired. Repair parts of its own manufacture sold after the original warranty period are warranted for
a period of one (1) year from shipment against defects in materials and workmanship under normal use and service. This warranty applies to
the replacement part only and is not extended to the product or any other component of the product being repaired. Seller may substitute
new equipment or improve part(s) of any equipment judged defective without further liability. All repairs or services performed by Seller,
which are not covered by this warranty, will be charged in accordance with Seller's standard prices then in effect.
THIS WARRANTY IS THE SOLE WARRANTY OF SELLER AND SELLER HEREBY EXPRESSLY DISCLAIMS AND BUYER
WAIVES ALL OTHER WARRANTIES EXPRESSED, IMPLIED IN LAW OR IMPLIED IN FACT, INCLUDING ANY WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Seller's sole obligation under this warranty shall be, at its
option, to repair or replace any equipment (or its component parts) which has a defect covered by this warranty, or to refund the purchase
price of such equipment or part. Under the terms of this warranty, Seller shall not be liable for (a) consequential, collateral, special or
liquidated losses or damages; (b) equipment conditions caused by normal wear and tear, abnormal conditions of use, accident, neglect, or
misuse of said equipment; (c) the expense of, and loss or damage caused by, repairs or alterations made by anyone other than the Seller; (d)
damage caused by abrasive materials, chemicals, scale deposits, corrosion, lightning, improper voltage, mishandling, or other similar
conditions; (e) any loss, damage, or expense relating to or resulting from installation, removal or reinstallation of equipment; (f) any labor
costs or charges incurred in repairing or replacing defective equipment or parts, including the cost of reinstalling parts that are repaired or
replaced by Seller; (g) any expense of shipment of equipment or repaired or replacement parts; or (h) any other loss, damage or expense of
any nature.
The above warranty shall not apply to any equipment which may be separately covered by any alternate or special warranties.
PERFORMANCE: In the absence of Certified Pump Performance Tests, equipment performance is not warranted or guaranteed.
Performance curves and other information submitted to Buyer are approximate and no warranty or guarantee shall be deemed to arise as a
result of such submittal. All testing shall be done in accordance with Seller's standard policy under Hydraulic Institute procedures.
LIABILITY LIMITATIONS: Under no circumstances shall the Seller have any liability under the Order or otherwise for liquidated
damages or for collateral, consequential or special damages or for loss of profits, or for actual losses or for loss of production or progress of
construction, regardless of the cause of such damages or losses. In any event, Seller's aggregate total liability under the Order or otherwise
shall not exceed the contract price.
ACTS OF GOD: Seller shall in no event be liable for delays in delivery of the equipment or other failures to perform caused by fires, acts of
God, strikes, labor difficulties, acts of governmental or military authorities, delays in transportation or procuring materials, or causes of any
kind beyond Seller's control.
COMPLIANCE WITH LAW: Seller agrees to comply with all United States laws and regulations applicable to the manufacturing of the
subject equipment. Such compliance shall include: The Fair Labor Standards Acts of 1938, as amended; Equal Employment Opportunity
clauses of Executive Order 11246, as amended; Occupational Safety and Health Act of 1970 and the standards promulgated thereunder, if
applicable. Since compliance with the various Federal, State, and Local laws and regulations concerning occupational health and safety,
pollution or local codes are affected by the use, installation and operation of the equipment and other matters over which Seller has no
control, Seller assumes no responsibility for compliance with those laws and regulations, whether by way of indemnity, warranty, or
otherwise. It is incumbent upon the Buyer to specify equipment which complies with local codes and ordinances.
800 Airport Road
North Aurora, Illinois 60542
630-859-7000
www.aurorapump.com
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