instruction, installation, maintenance and repair manual model 384

instruction, installation, maintenance and repair manual model 384
DATED JUNE 2011
INSTRUCTION, INSTALLATION, MAINTENANCE AND REPAIR MANUAL
MODEL 384
END SUCTION FIRE PUMPS
IMPORTANT NOTE TO INSTALLER:
This manual contains important information about the
installation, operation and safe use of this product. This
information should be given to the owner/operator of
this equipment.
ATTENTION: SAFETY WARNINGS:
Read and understand all warnings before installation or
servicing pump.
OPERATIONAL LIMITS: *
Maximum Operating Pressure:
Maximum Operating Temperature:
See UL Listings for max pressure by model.
150°F (66°C)
Pumps are not to be operated outside the operating envelope
as stated on the nameplate and the maximum case working
pressure as published in the product catalog for the relevant
model. Shaft couplings are selected for the maximum power
output of the driver, however, the pump is not to be operated
outside its normal limits.
All pumps are designed to allow 1/16" for corrosion. Should
this value be exceeded, the pump should be taken out of service.
The 384 Pumps are not designed for use in potentially
explosive atmospheres.
*See ASTM A126/ANSI B16.1 for pressure/temperature
ratings of flanges.
ELECTRICAL SAFETY:
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.
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.
Warning: Sudden Start-Up Hazard
Disconnect and lock out power source before servicing.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
HIGH TEMPERATURE SAFETY:
Warning: Hot Surface Hazard
If pumping hot water, ensure guards or proper insulation is
installed to protect against skin contact with hot piping or
pump components. Failure to follow these instructions could
result in serious personal injury, death or property damage.
HIGH PRESSURE SAFETY:
INSTALLATION
Warning: Hot Surface Hazard
Some pump surfaces may be subject to elevated
temperatures; there is no required operator contact necessary
while the pump is operating.
Warning: Spraying Water Hazard
When servicing pump replace all gaskets and seals. Do
not reuse old gaskets or seals. Failure to follow these
instructions could result in serious personal injury, death or
property damage.
Warning: High Pressure Hazard
Do not exceed the maximum pressure. Install properly sized
pressure relief valves in system. Failure to follow these
instructions could result in serious personal injury, death or
property damage.
MODEL 384
Warning: Expansion Hazard
PUMP
FLEXIBLE COUPLING
DRIVER
POWER FRAME
Water expands when heated. Install properly sized thermal
expansion tanks and relief valves. Failure to follow these
instructions could result in serious personal injury, death or
property damage.
PIPE
BASE PLATE
Read and understand all safety warnings at the beginning
of the manual before beginning installation or any
repair work.
PUMP LOCATION. You probably have spent considerable
time planning where your pump will be located. However,
you may have overlooked some factor that may affect pump
operation or efficiency.
CONCRETE
FOUNDATION
FOUNDATION BOLT
Figure 1. Foundation for Frame Mounted Pumps.
The pump should be located as close to the liquid source
as possible so that the suction line can be short and direct.
It should be located in a clean, open area, where it is easily
accessible for inspection, disassembly and repair. Pumps
installed in dark, dirty areas or in cramped locations are often
neglected, which can result in premature failure of both the
pump and the driver.
SOUPY GROUT
FOUNDATION BOLTS
ROLLED STEEL BASE
TWISTED TENSION WIRE
The Aurora pump must be installed horizontally. Install
isolating valves on each side of pump so pump maintenance can
be performed without draining the system. Special mounting
requirements may be required if the pump is to be mounted near
a noise or vibration sensitive area.
These pumps are intended for use in applications where the
water supply to the suction connection is permanently flooded.
Operation of these pumps under static suction lift condition is
prohibited.
The installation must be evaluated to ensure that the net positive
suction head available (NPSHA) meets or exceeds the net
positive suction head required (NPSHR), as stated by the pump
performance curve.
FOUNDATION. The foundation for your pump must
be sufficiently rigid to absorb any vibration and stress
encountered during pump operation. A raised foundation of
concrete is preferable for most floor mounted pumps. The
raised foundation assures a satisfactory base, protects against
flooding, simplifies moisture drainage, and facilitates keeping
the area clean.
SHIMS
GROUTING CLEARANCE
SHIMS
SHIMS TO LEVEL BASE PLATE
WOODEN DAM
ON BOTH ENDS
Figure 2. Grouting the Base for Frame Mounted Pumps.
Your pump should be firmly bolted to the foundation, whether
it is a raised concrete base, steelwork wall, or structural
member. The mounting bolts or lag screws should be accurately
located per the applicable Aurora dimension sheet. Refer to
Fig. 1.
LEVELING THE PUMP. Leveling the pump will require
enough shims to support the base plate near the foundation bolts
and at any points of the base plate carrying a substantial weight
load. The shims should be large enough to allow a gap of 3/4"
to 1-1/2" between the base plate and foundation for grouting.
STRAIGHT EDGE
WEDGE OR
THICKNESS GAUGE
PARALLEL MISALIGNMENT
ANGULAR MISALIGNMENT
Figure 3. Flexible Coupling Alignment.
2
PERFECT ALIGNMENT
MODEL 384
Warning: Lifting Hazard
GATE
VALVE
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.
IMPORTANT: The pump base must be set level to avoid
any mechanical difficulties with the pump or motor. The 384
pump was properly aligned, if supplied with a motor, at the
factory. However, since the pump base is flexible, it may
spring and twist during shipment. Do not pipe the pump until
it is realigned. Realign the base after piping is completed and
after the pump is grouted in and bolted down. NOTE: It may
be necessary to readjust the alignment from time to time while
the unit and foundation are new. Realignment will prevent
premature bearing failure, excessive vibration or shaft failure.
Ensure that proper hydronic accessories such as pressure relief
valves, thermal expansion tanks and flow/pressure control
devices are installed in the system. Consult the responsible
party for your system to ensure these devices are installed and
of the proper size.
GROUTING THE INSTALLATION. Grouting the base plate
prevents lateral movement of the base plate and improves
the vibration absorbing characteristics of the foundation by
increasing its mass. A wooden dam should be constructed
around the base plate to contain the grout while it is being
poured. The dam can be built tight against the base plate or
slightly removed from it as desired. Refer to Fig. 2. The entire
base plate should be completely filled with nonshrinkable type
grout. The grout should be puddled frequently to remove any air
bubbles from the grout.
ROTATION. Pump rotation is clockwise when viewed from
the back of the motor. An arrow is also located on the pump to
show the direction of rotation.
Warning: Sudden Start-Up Hazard
Disconnect and lock out power source before servicing.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
ECCENTRIC
TAPERED
REDUCER
DISCHARGE
SUCTION
ELBOW
CORRECT
ECCENTRIC
TAPERED
REDUCER
DISCHARGE
SUCTION
INCORRECT
Figure 4. Installation of Tapered Reducers.
AIR
POCKET
DISCHARGE
PIPING
CHECK
VALVE
SUCTION
Figure 5. Gate Valve and Check Valve.
INITIAL ALIGNMENT OF THE FLEXIBLE COUPLING.
The pump and driver were accurately aligned at the factory.
However, it is impossible to maintain this alignment during
shipping and handling. Therefore it will be necessary for you
to realign the pump and driver. Flexible couplings are not
universal joints. They should not be used to compensate for
misalignment of the pump and motor shafts. Their function is to
transmit power from the driver to the pump while compensating
for thermal expansion and shaft end movement. The coupling
faces should be far enough apart so that they do not make
contact when the motor shaft is forced to the limit of the bearing
clearance toward the pump shaft.
In order to properly align the coupling, you will need a taper
gauge or set of feeler gauges and a straight edge.
There are two types of misalignment encountered with flexible
couplings: angular misalignment, in which the shafts are not
parallel, and parallel misalignment where the shafts are parallel
but not on the same axis.
To check angular alignment, insert a feeler gauge or taper gauge
at any four places 90-degrees apart around the coupling halves.
Insert shims under the driver feet until the same reading is
obtained at all four check points. The pump and driver will then
be in angular alignment.
To check parallel alignment, a straight edge should be held
against the edges of the coupling halves at any four places 90°
apart around the coupling. The straight edge should be parallel
to the pump and driver shafts at all times. Insert shims until
the straight edge lies flat against both coupling halves at all
four checkpoints. The pump and driver will then be in proper
parallel alignment. Refer to Fig. 3.
For fine alignment, 3500 RPM operation, for all other
coupler types.
A dial indicator should be used when greater alignment
accuracy is required. Use the following alignment tolerances
unless specified otherwise by the coupling manufacturer. On
sleeve type couplings make sure there is at least 1/8" end
clearance between the sleeve and the two coupling halves.
To check angular misalignments, mount the dial indicator
base to the coupling half, and position the dial indicator button
on the front or rear face of the opposite coupling half. Set
the dial to zero, rotate both coupling halves together, making
sure the indicator button always indicates off the same spot.
Misalignment values within 0.004 inches TIR per inch of
coupler radius is permissible.
3
MODEL 384
Do not operate pump with coupling out of alignment.
Ensure final coupling alignment according to coupling
manufacturer’s instructions. Coupling, pump or driver
failure may occur. Failure to follow these instructions could
result in serious personal injury or death and property
damage.
Pumps are supplied by the manufacturer with adequate guards
for the coupling. The installer is to ensure that any additional
guarding required shall be compliant with EN 953.
PIPING:
SUCTION PIPING. The suction piping should be short, but
no less than ten pipe diameters in length, and direct with as
few elbows and fittings as possible to keep head loss, from
friction, at a minimum. However, the suction pipe should
provide a minimum uninterrupted length, equal to ten pipe
diameters, to the pump suction flange. A horizontal suction
line should have a gradual rise to the pump, and pass under any
interfering piping.
The suction pipe diameter should be at least the same diameter
as the suction nozzle on the pump, and preferably larger. Use
of a smaller diameter pipe will result in loss of head due to
friction. All joints must be tight to maintain prime on the pump.
REDUCERS. Eccentric reducers should be installed directly at
the suction nozzle, with the taper at the bottom to prevent air
pockets from forming. Straight taper reducers should never be
used in a horizontal suction line because of the air pocket that
is formed at the leg of the reducer and the pipe. Refer to Fig. 4.
DISCHARGE PIPING. Discharge piping should also be short
and direct as possible, with few elbows and fittings, to reduce
head loss from friction.
PIPE. The discharge pipe diameter should be the same as, or
larger than, the discharge nozzle diameter.
DISCHARGE VALVES. The discharge piping should include a
check valve and a gate valve. The check valve should be located
between the gate valve and the pump. If an increaser is used in
the discharge piping, the increaser should be installed between
the pump nozzle and the check valve. The check valve protects
against a reverse flow of the liquid if the driver fails. Refer to
Fig. 5.
PRESSURE RELIEF VALVE. All End Suction Fire Pump
Models are provided with a pressure relief valve by the pump
manufacturer to prevent an over pressure condition. For
rotodynamic pumps, these valves are to set in the field at a point
between the duty pressure and shut-off pressure to prevent a
no-flow condition. For rotary positive displacement pumps,
the pressure relief valve is factory set to 10% above the duty
pressure and sealed with a safety wire, and are not to be field
adjusted.
4
ENGINE FLUIDS. Many diesel engines are shipped dry and
must have lubricating oil and coolant added prior to start-up. It
is the installer’s responsibility to assure that all fluid levels are
correct to avoid damage to the engine.
DIESEL ENGINE WIRING. The End Suction Fire Pump
controller must be wired to the diesel engine’s junction box.
This is usually a simple matter of connecting like-numbered
terminals of each with the correct wire gauge size. Refer to
panel manufacturer’s wiring diagram.
The electric solenoid valve in the diesel engine cooling loop
piping must be wired to the engine junction box. Either red wire
goes to terminal 1; the other red wire goes to terminal 11; the
green wire is grounded to the engine block.
Engines may have 12-volt or 24-volt systems, but all batteries
furnished are 12-volt. Since dual battery sets are required by
N.F.P.A. 20, two batteries are furnished for 12-volt systems and
four batteries are furnished for 24-volt systems.
POS
P
+
P
+
12V
NEG
POS
N
Warning: Coupling Failure
SPECIAL CONSIDERATIONS FOR DIESEL ENGINES:
N
To check parallel misalignment, mount the dial indicator base
to one coupling half, or shaft, and position the dial indicator
button on the outside diameter of the opposite coupling half. Set
the dial to zero. Rotate both coupling halves together, making
sure the indicator button always indicates off the same spot.
Misalignment within 0.004 inches TIR is permissible.
-
NEG
}
12V
12 VOLT SYSTEM
POS
P
+
NEG
POS
N
-
P
+
NEG
POS
NEG
POS
N
NEG
-
}
}
24V
24V
24 VOLT SYSTEM
Figure 6. Battery Cable Arrangements.
Aurora’s standard battery racks are designed to keep the
batteries elevated off the floor for housekeeping purposes. They
must be placed on a suitable level surface as close to the diesel
engine as possible. Each rack holds two batteries; one rack is
required for 12-volt systems and two racks for 24-volt systems.
If two racks are used, they are to be placed side-by-side and not
stacked.
MODEL 384
Electrolyte is not furnished by Aurora Pump; it must be
procured locally (approximately 16 quarts per battery).
NEGATIVE (-) CABLES FROM BOTH
BATTERIES (SETS) TO GROUND ON
ENGINE BLOCK
STARTER
Electrolyte must be added and the batteries charged at a low
rate for at least 24 hours prior to start-up. It is recommended
for safety reasons that the batteries be filled with electrolyte
only after being placed in their permanent positions in the pump
room.
EXISTING STARTER WIRING
BY ENGINE MANUFACTURER
STARTER CONTACTOR
ON DIESEL ENGINE
Danger: Can Cause Blindness
or Severe Burns
Batteries contain sulphuric acid electrolyte. This is a highly
CORROSIVE POISON. They also produce a mixture
of hydrogen and oxygen gasses which will EXPLODE if
ignited.
WHEN WORKING ON OR NEAR BATTERIES,
MIXING OR POURING ACID SOLUTIONS,
ALWAYS WEAR PROTECTIVE CLOTHING AND
PROTECT EYES WITH SAFETY GOGGLES. KEEP
SPARKS, FLAMES AND CIGARETTES AWAY.
KEEP BATTERIES AND ACID OUT OF THE REACH
OF CHILDREN.
If acid contacts skin or eyes, flush affected parts with clean
water immediately and repeat for 15 minutes. Then seek
prompt medical attention.
If acid is taken internally, call medical help immediately.
Drink large quantities of water, milk or milk of magnesia,
beaten eggs or vegetable oil.
Acid spilled on clothing, workbench or floor may be
neutralized with baking soda or ammonia solutions, in
metallic containers.
Use only glass, ceramic or acid resisting plastic vessels.
Never discard used containers before they have been rinsed
clean, then puncture them to prevent further use.
When charging batteries, keep area well ventilated and
bar general access. Connect/disconnect batteries only
when charge is switched off. Make sure tools cannot short
circuit battery terminals. Keep vent caps on battery during
charging.
POSITIVE (+)
CABLE FROM
BATTERY No. 1
POSITIVE (+)
CABLE FROM
BATTERY No. 1
Figure 7. Starter and Contactor Connections.
The positive battery terminal of each battery (or pair of batteries
for 24-volt systems) is connected to one of the engine’s starter
contactors. The negative terminals are to be connected to the
engine block or other suitable ground. Aurora Pump’s standard
battery cable wire gauge sizes are selected for a maximum
10-foot circuit length (5-foot cables). Longer cables will require
heavier gauge wire to be used.
Power wiring to the engine’s jacket water heater must be
completed only after it has been assured that there is sufficient
coolant in the engine. Most heaters are continuously energized
when wiring is connected and will burn out the heating element
if no water is present. This failure is not covered by warranty.
Refer to engine manufacturer’s data sheet for correct voltage of
the heater.
DIESEL ENGINE COOLING LOOP PIPING. The cooling
loop system diverts a small amount of water from the pump
discharge through the engine’s heat exchanger to help control
the operating temperature of the engine. Prior to start-up, it
is recommended that this piping be checked for damage or
displacement that might have occurred during shipment.
During normal operation, the top two valves of the cooling
loop (in the by-pass line) are to be closed, and the lower two
valves (in the pressure regulated line) are to be open. Failure
to observe this may result in overpressurization of the heat
exchanger when the pump is started, causing damage to the
engine.
Piping from the engine’s heat exchanger to a drain
is to be provided by the installer. It is important to use the
recommended size piping to reduce back pressure and avoid
overpressurizing the heat exchanger.
5
MODEL 384
GAUGE
BYPASS VALVES
NORMALLY CLOSED
TO
ENGINE
REGULATOR VALVE
STRAINERS
SOLENOID
VALVE
FROM
PUMP
VALVE OPEN
VALVE OPEN
Figure 8. Cooling Loop Showing Normal Position Of Valves.
A length of PVC tubing is provided by Aurora to be connected
to the petcock in the cooling loop piping in order to vent the
system and visually verify the flow of water through the heat
exchanger.
DIESEL ENGINE FUEL SYSTEM. The fuel tank should be
installed so that the supply outlet is at the same elevation as the
engine’s fuel pump. Since the unit base is usually elevated as
described earlier, this may require that the fuel tank is likewise
elevated. The means of elevating the tank is the responsibility
of the installer. Substituting the legs furnished with the tank
with pipes of greater length is not a recommended method of
elevating the tank.
All fuel fittings shown in Figure 9 are shipped loose for field
installation. They are to be assembled as shown in Figure 9
to be consistent with Figure A-8-4.6 of N.F.P.A. Pamphlet
20. Installation may vary at the discretion of the installer with
the approval of the local authority having jurisdiction. Note
that some sections of common piping needed to complete this
installation are not furnished by Aurora and must be procured
locally.
Tube fittings are provided to allow the use of 5/8" O.D. tubing
for the fuel supply and return lines (the tubing itself is NOT
furnished by Aurora). If hard piping is used, these tube fittings
are simply to be discarded.
Diesel fuel is not furnished by Aurora and must be procured
locally prior to start-up.
DIESEL MUFFLER AND EXHAUST SYSTEM. A
commercial grade muffler and flexible connector are furnished
as standard on diesel End Suction Fire Pumps. If necessary,
additional fittings needed for connecting these to the engine are
also provided.
Commercial grade mufflers have NPT connections on 3" and
3-1/2" sizes, slip-on (automotive type) connectors for 4", 5" and
6" sizes, and 125# ANSI flanged connections for larger sizes.
Optional residential grade mufflers have NPT connections on 3"
and 3-1/2" sizes; ANSI 125# flanges on 4" and larger sizes.
Piping, elbows and other components required to route
the exhaust to the outside are not provided by Aurora. It is
suggested that the building contractor or on-site engineers
design and install the remainder of the exhaust system.
Mufflers are sized by Aurora to allow the engine to operate
at its rated speed with nominal back pressure. However, if
more than 25 feet of additional piping and/or more than four
90-degree elbows are required to complete the system, it is
6
important to contact the factory for re-evaluation of the system
with respect to back pressure. A larger muffler and piping may
be required to allow the engine to operate properly.
The flexible connectors furnished by Aurora are intended for
use as a vibration control device and cannot be substituted for
elbows in the piping system. It is recommended that the flexible
connector be placed as close to the engine’s exhaust outlet as
possible. The muffler and piping must be supported to prevent
strain on any diesel engine component.
START-UP AND FIELD ACCEPTANCE TEST:
GENERAL. The following is a general outline for starting and
field testing End Suction Fire Pump systems. It is recognized
that requirements and methods may vary depending on local
customs and practices. Those involved in End Suction Fire
Pump sales MUST fully understand all local requirements and
N.F.P.A. Pamphlet 20. A general method to follow is outlined
below.
Be specific and complete when ordering End Suction Fire
Pumps and accessories so that all necessary and correct items
are on hand for the start-up. Trouble cannot be tolerated on the
day of the field acceptance test.
Visit the jobsite after delivery of the equipment to verify that all
components ordered have been received and are correct for the
installation.
Visit the jobsite again after installation to assure that the
components have been correctly assembled and installed.
After the installation is complete and the End Suction Fire
Pump system is pressurized and checked by the contractor, the
following items must be verified:
1.Coupling has been properly aligned.
2.Motor has been “bumped” to check for proper rotation.
3.Diesel engine (where applicable) has been properly
serviced, necessary fluids added, batteries filled and
charged, jacket water heater operating.
INITIAL TEST. The following steps are basic for an initial test
of the End Suction Fire Pump system:
1.Close the valves on all discharge outlets.
2.Open the suction valve.
3.Having read the controller manual and gained an
understanding of its operation, set the End Suction Fire
Pump controller to “manual”. The Jockey pump panel
should be set to the “off’ position.
4.With the controller door closed, start the End Suction
Fire Pump.
5.Adjust the packing to allow approximately 60 drops per
minute to flow from each packing box. Further adjustment
may be required later, so a recheck upon completion of the
test is advised.
MODEL 384
13
7
15
16
6
Item
Number
1
2
3
4
5
6
7
8
9
2
14
11
3
1
5
7
10
8
10
11
9
PIPE LEGS &
FLOOR FLANGES
4
FUEL RETURN FROM ENGINE
FUEL SUPPLY TO ENGINE
7
10
9
Item
Number
13
14
15
16
Components Furnished By Aurora Pump
Quantity
Description
Required
1
2" NPT Lockable Fuel Cap
1
“Z” Npt Vent/Flash Arrestor
1
Fuel Gauge – 2" NPT
1
1" NPT Drain Plug
1
Fuel Fill Tube – 2" NPT
1
Fuel Return Tube – 1/2" NPT
6
Tube Fitting
1
1/2" NPT Lockable Fuel Valve
2
Fuel Hoses For Supply and Return
(Furnished By Engine Manufacturer)
2
Tube Fitting Adaptor (If Required)
1
2" NPT Pipe Plug
Components To Be Furnished By Others
Quantity
Description
Required
1
“Z” x “Z” x 1/2" Pipe Tee
2
"Z" Diameter Piping For Vent
1
1/2" Pipe Tee
1
5/8" O.D. Tubing
Figure 9. Diesel Fuel Tank and Fittings.
6.Close the relief valve completely for a brief period to verify
that the shut-off pressure agrees with that on the certified
factory test curve.
7.Adjust the casing relief valve (electric-driven units only) to
allow enough flow to keep the pump cool.
8.Stop the End Suction Fire Pump.
9.Set the End Suction Fire Pump controller to the “automatic”
position.
10.Slowly lower the system pressure with the control valve.
The End Suction Fire Pump should start. Observe this
starting pressure and adjust if necessary. (Adjustment
procedure varies with controller manufacturer.) Stop the
End Suction Fire Pump.
FIELD ACCEPTANCE TEST. Personnel on hand for the End
Suction Fire Pump field acceptance test should include the
controller representative, diesel engine service technician (if
applicable), representatives of the insuring agency and local fire
authority, as well as those responsible for building maintenance
and supervision.
5.Calibrated suction and discharge gauges with 1/4%
accuracy. (Gauges furnished with the pump are 2%-3%
accurate and could be troublesome for the field acceptance
test.)
6.50 feet of 2-1/2" hose for each connection on the hose
manifold.
7.Play pipe with suitable nozzle for each hose.
While field acceptance tests vary by location, the following
steps are usually taken. Additional operations may be required
depending on the special needs in some territories.
1.A hose and play pipe are connected to each valve on the
hose manifold.
2.The discharge valve leading to the building’s fire system is
closed.
3.The discharge valve leading to the hose manifold (or “test
header”) is opened.
4.The suction valve is opened.
Equipment needed for the field acceptance test includes:
5.All relief valves are closed.
1.Calibrated ammeter.
6.One hose valve on the hose manifold is opened.
2.Volt meter.
7.With the End Suction Fire Pump operating, the hose valve is
adjusted for a flow of 500 GPM at the play pipe as indicated
by the pitot tube. Refer to Table 1 to determine the pressure
vs. flow for the size play pipe used for this test.
3.Tachometer.
4.Pitot tube & gauge.
7
MODEL 384
Nozzle
Pressure
10
20
30
35
40
45
50
55
60
62
64
66
68
70
72
74
76
78
80
85
90
95
100
105
110
115
120
1-1/8
100
160
206
222
238
252
266
279
291
296
301
305
310
315
319
323
328
332
336
347
357
355
376
385
394
403
412
GPM At Various Nozzle Sizes
1-1/4 1-3/8 1-1/2 1-5/8
130
160
195
235
203
245
290
348
254
308
366
430
275
332
395
464
294
355
423
496
311
377
448
525
328
397
473
555
344
417
496
582
360
435
518
608
366
442
526
618
371
449
535
628
377
456
543
637
383
463
551
647
388
470
559
656
394
477
567
666
399
483
575
675
405
490
583
684
410
496
590
693
415
502
598
702
428
518
616
723
440
533
634
744
452
547
651
765
464
562
668
784
476
575
685
804
487
589
701
823
498
602
717
841
509
615
732
859
1-3/4
285
410
498
538
575
610
643
675
716
728
732
739
750
761
772
783
793
803
814
839
863
887
910
932
954
976
997
Table 1. GPM At Various Nozzle Sizes.
8.By opening additional valves and measuring the flow equal
to 500 GPM, readings of 1000 GPM, 1500 GPM, 2000
GPM, etc. can be determined.
9.Open the necessary hose valves to obtain the total rated
flow. When this flow is assured, check and record the
following data:
a. Suction gauge pressure
b. Discharge gauge pressure
c. RPM with tachometer
d.Voltage
e. Amps (on all legs)
10.Verify that the flow remained constant during the above
data readings.
11.Adjust hose valves to achieve 150% of rated flow. Proceed
as before and record the necessary data.
12.Repeat these steps as required by supervising authorities to
obtain the desired number of points on the test curve.
8
13.Finally, close all valves and record the above readings in
Step 9 at shut-off (zero GPM) condition.
If a number of automatic and/or manual starts are to be
demonstrated, this series of tests can now be conducted.
The Jockey Pump controller must be set to start the Jockey
Pump at a pressure greater than that of the main End Suction
Fire Pump. The following procedure may be used to accomplish
this.
1.The main End Suction Fire Pump controller is set to the
“off’ position.
2.The Jockey Pump controller is set to the “automatic”
position.
3.The system pressure is slowly reduced by opening the test
valve until the Jockey Pump starts. Observe the pressure at
which the Jockey Pump starts.
4.Allow the Jockey Pump to continue running until the system
pressure rises enough to stop the pump automatically.
Typically, there is a minimum of 10 psi between the “pump
start” and “pump stop” pressure readings.
5.Adjust the set points in the Jockey Pump controller as
necessary to achieve the desired results. As with the main
End Suction Fire Pump controller, adjustment methods vary
with controller manufacturer.
IMPORTANT:
Upon successful completion of the field acceptance test, the
following points must be verified:
1.The discharge valve leading to the outside hose manifold
should be closed.
2.The discharge valve leading to the building fire protection
system should be opened.
3.The casing relief valve should be set to a pressure just
below the shut-off pressure of the pump.
4.The main relief valve (if applicable) should be set to a
pressure just above the maximum system pressure.
5.Both the End Suction Fire Pump and Jockey Pump
controllers should be set to the “automatic” position.
6.Any alarm systems disabled during the tests should be
reactivated.
7.The individual or authority responsible for maintaining the
building’s fire protection system must be made aware of all
settings and the operational condition of the system before
leaving the site.
MAINTENANCE:
Your Aurora pump requires no maintenance other than periodic
inspection, occasional cleaning and lubrication of bearings. 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.
MODEL 384
LUBRICATION OF IMPELLER SHAFT BEARINGS:
Regreaseable bearings will require periodic lubrication and can
be accomplished by using the zerk or lubrication fittings in the
cartridge cap and power frame. Lubricate the bearings at regular
intervals using a grease of high quality. Mixing of different
brands of grease should be avoided due to possible chemical
reactions between the brands which could damage the bearings.
Accordingly, avoid grease of vegetable or animal base which
can develop acids, as well as grease containing rosin, graphite,
talc and other impurities. Under no circumstances should used
grease be reused.
Overlubrication should be avoided as it may result in
overheating and possible bearing failure. Under normal
application, adequate lubrication is assured if the amount of
grease is maintained at 1/3 to 1/2 the capacity of the bearing
and space surrounding it.
In dry locations, each bearing will need lubrication at least
every 4,000 hours of running time or every 6 to 12 months,
whichever is more frequent. In wet locations (exposed to
dripping water, to the weather, or to heavy condensation such
as is found in unheated and poorly ventilated underground
locations) the bearings should be lubricated at least after every
2,000 hours of running time or every 4 to 6 months, whichever
is more frequent.
Use Chevron SRI, NLGI2.
Lubricate motor per motor manufacturer’s instructions.
GENERAL INSTRUCTIONS:
1.Keep this pump and motor properly lubricated.
2.Inspect the pump regularly for leaky seals of gaskets
and loose or damaged components. Replace or repair
as required.
ELECTRICAL WIRING. Normally, your pump will be
supplied with an attached drive motor. The motor should be
wired in accordance with the wiring diagram found on the
motor nameplate. Be sure the voltage, frequency, and phase of
your power supply corresponds with the nameplate data. It is
advisable to provide a separate switch and overload protection
for your pump motor to protect against power failure in some
other area. Conversely, if the pump motor develops electrical
problems, it will be isolated from other equipment.
PRESTARTING INSTRUCTION. The coupling halves
should be connected. Prior to connection, however, the drive
motor should be started to make sure the direction of rotation
is the same as the direction indicated by the arrow on the
pump casing.
When the pump is used in conjunction with electric motors
and controls, these components must be in accordance with
EN 60529 IP 22. Electrical equipment applied is to conform
to the requirements of EN 50081 parts I or 2, and to EN
50082 parts 1 or 2, and the relevant parts of EN 6100 with
regard to electromagnetic compatibility. Protection of the
electrical assembly against electrostatic phenomena shall be
per paragraph 5.2.2.2 of EN 809. General compliance of the
CAPSCREW TORQUE FOR COMMON BOLT DIAMETERS
IN-POUNDS
FOOT-POUNDS
1/4" 5/16" 3/8" 7/16" 1/2" 5/8" 3/4"
85
180
27
43
65
130
230
Table 2. Torque Chart.
electrical assembly shall be per EN 60204-1. The installer shall
ensure that any displays and control actuators are designed and
installed in accordance with EN 894. The nature of the pumped
liquid precludes the need for an emergency stop device; the
pump can be shut down by normal means. Any electrical
equipment shall be properly earthed.
Overall assembly shall be shown to comply with 98/37/EC
Annex 1 paragraph 1.7.4 (f) by the final assembler with respect
to noise and vibration.
Installation must comply with the Machinery Directive 98/37/
EC as well as any other applicable national regulations in the
member state of the installation. The final installation must not
be put into service until it has been declared in conformity with
the provisions of the Machinery Directive.
PUMP DISASSEMBLY: For frame mounted pumps, model
384.
Any disassembly/assembly procedures performed
will require testing per NFPA 20 Table 14.5.2.3 after
re-assembly has been completed prior to the pump being
returned to service.
Warning: Sudden Start-Up Hazard
Disconnect and lock out power source before servicing.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
Read and understand all safety warnings at the beginning
of the manual before beginning installation or any
repair work.
1.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 before beginning any disassembly of
the pump.
2.Isolate the pump from the system by closing the valves that
should be located on both the suction and discharge of the
pump. Loosen the drain plug at the bottom of the casing and
drain the pump. The flush line assembly (optional 1, 3, 2
and 75) should be removed at this time.
Inspect removed parts at disassembly to determine if they can
be reused. Ball bearings that turn roughly or show wear should
be replaced. Cracked castings 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 singly
as the need arises.
Warning: Hot Surface Hazard
If pumping hot water, ensure guards or proper insulation is
installed to protect against skin contact with hot piping or
pump components. Failure to follow these instructions could
result in serious personal injury, death or property damage.
9
MODEL 384
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.
Warning: Spraying Water Hazard
When servicing pump replace all gaskets and seals. Do
not reuse old gaskets or seals. Failure to follow these
instructions could result in serious personal injury, death or
property damage.
PACKING REMOVAL/REPLACEMENT ONLY:
a. Remove capscrews (65), gland lamps (22) and gland
halves (23).
b. Use a flexible Packing Tool* with a hook attachment for
removal of the packing, and a wood screw attachment
for removal of the lantern ring. The lantern ring contains
several holes for the packing tool.
*The Packing Tool can be purchased from industrial supply,
or hardware stores. It is not considered a special tool.
c. Thoroughly clean the shaft sleeve (25) and packing
cover (26) seal cavity. Thoroughly inspect the bore of
the Pump Packing Cover (26) and the Shaft Sleeve (25)
for wear or signs that replacement is needed.
d. Place one ring of packing (28) into the packing cover
(26). On successive rings of packing stagger the packing
joints to prevent excessive leakage through the packing
box. If a lantern ring (29) is used, place a second ring
of packing (28) into the cover before installing lantern
ring. Refer to Fig. 10.
CAUTION
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 (3) in the cover (26).
Install remaining packing rings (28). Each ring should be
tapped firmly into place with a wood or metal bushing.
e. Replace gland halves (23) and place gland clamps (22)
over capscrews (65). Tighten capscrews (65) finger tight
into either cover assembly (26).
NOTE: The slots in gland halves (23) should be
diagonal to pump horizontal center line.
Proceed to Step 17 to return the pump to service.
Warning: High Pressure Hazard
Make certain that the internal pressure of the pump
is relieved before continuing. Failure to follow the
instructions could result in serious person injury, death, or
property damage.
5.Remove the two foot support capscrews from the
powerframe. Loosen, but do not remove the volute
capscrews (5). Use capscrew in the jack screw holes to
loosen the impeller subassembly from the volute.
6.Now remove the volute capscrews (5) and remove the
impeller subassembly from the volute.
Warning: Lifting Hazard
The motor and pump assemblies may be very heavy. Use
extreme caution and safe lifting equipment during the
removal and assembly procedures. Failure to follow these
instructions could result in serious personal injury, death or
property damage.
7.Remove the impeller capscrew (9), washer (9A), gasket
(9B), and capscrew seal (9C). Remove impeller (11).
8. Remove impeller key (12).
9.Remove the O-ring (10).
Remove the packing (and optional lantern ring)
10.Remove capscrews (65), gland lamps (22) and gland
halves (23).
11.Unscrew capscrews (5) and remove cover assembly (26).
The bore of the pump packing cover (26) should be checked
for excessive wear.
12.Shaft sleeve (25) is a 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.
13.All packing (28) and lantern ring (29) (if used) must now be
removed from the packing box, and the cavity thoroughly
cleaned to allow new packing to fit properly.
14.Thoroughly clean the shaft sleeve (25) and packing cover
(26) seal cavity.
15.Wear 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.
PUMP REASSEMBLY:
3.Remove the coupling guard.
1.Replace the shaft sleeve (25) or packing cover (26) if there
is evidence of surface damage like pitting, corrosion, nicks
or scratches.
4.Loosen the set screws in both coupling halves and slide each
half back as far as possible on its shaft. Then, remove the
coupling insert.
2.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
10
MODEL 384
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.
3.Place one ring of packing (28) into the packing cover (26).
On successive rings of packing stagger the packing joints
to prevent excessive leakage through the packing box. If a
lantern ring (29) is used, place a second ring of packing (28)
into the cover before installing lantern ring. Refer to Fig. 10.
CAUTION
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 (3) in the cover (26).
Install remaining packing rings (28). Each ring should be
tapped firmly into place with a wood or metal bushing.
Warning: Lifting Hazard
The motor and pump assemblies may be very heavy. Use
extreme caution and safe lifting equipment during the
removal and assembly procedures. Failure to follow these
instructions could result in serious personal injury, death or
property damage.
10.I nstall new casing gasket (8). Then install the pump
assembly into the volute.
11.Tighten volute capscrews (5) per torque chart (see Table 2).
12.Install foot support capscrews (62) and tighten per torque
chart (see Table 2).
13.Install coupling and align.
14.Install drain plugs, close drain valve.
4.Slide the shaft sleeve (25) through the packing. Proceed to
next step if only replacing packing.
15.Replace all relief, cooling, flush lines (1, 3, 2, 75), or drain
lines from the pump including compression connections
(1 and 2) and tubing (3).
16.Reinstall the coupling guard.
17.Open isolation valves and inspect pump for leaks.
18. Return pump to service.
Warning: Sudden Start-Up Hazard
Disconnect and lock out power source before servicing.
Failure to follow these instructions could result in serious
personal injury, death or property damage.
CAPSCREW
CLAMP
GLAND
Warning: Rotating Component Hazard
PACKING
LANTERN
RING
PACKING
Figure 10. Packing.
5.Replace gland halves (23) and place capscrews (65) through
gland clamps (22). Tighten capscrews (65) finger tight into
either cover assembly (26).
6.Slide Packing Cover Assembly onto shaft.
NOTE: The slots in gland halves (23) should be diagonal to
pump horizontal center line.
7.Install O-ring (10).
8.Install a new impeller key (12).
9.Install impeller, impeller washer (9A), new impeller washer
gasket (9B), capscrew seal and capscrew (9). Tighten
capscrew per torque chart (see Table 2).
Do not operate pump without all guards in place. Failure
to follow these instructions could result in serious personal
injury or death and property damage.
STARTING PUMP AFTER REASSEMBLY:
Do not start pump until all air and vapor has 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 any one 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.
11
MODEL 384
POWER FRAME OR PUMP SHAFT
DISASSEMBLY/REPLACEMENT:
Read and understand all safety warnings at the beginning
of the manual before beginning installation or any
repair work.
Follow steps 1 – 14 from main pump disassembly procedure.
15.Remove the power frame capscrews and bearing/shaft
assembly from the packing cover. If replacing the shaft,
continue to Step 16.
16.Remove the grease fittings (43) from the power frame.
17.Unscrew capscrews (48) and remove bearing cap (49).
Remove O-ring (oil lubed only) and retainer ring (52).
18.Slide out shaft (55) and bearings (53 and 54). Since bearings
(53 and 54) are press fitted on the shaft, they will have to
be pulled or pressed off the shaft. Remove grease seals (51)
from frame (57) and bearing cap (49).
19.Thoroughly clean the shaft (55), removing any oil or dirt.
POWER FRAME REASSEMBLY:
Reassembly will generally be in reverse order of disassembly.
If disassembly was not complete, use only those steps related to
your particular repair program.
1.Press grease seals (51/51A) into frame (57), and bearing
cap (49).
2.Press bearings (53 and 54) onto shaft (55). Snap retainer
ring (52) into place.
12
3.Slide shaft (55) and bearings (53 and 54) into frame (57).
4.Fasten bearing cap (49) in position with capscrews (48).
Position slingers (47) on the shaft.
5.Position bracket (35) on the frame (57) and secure with
capscrews (5A). Tighten screws evenly to assure proper
alignment.
Follow steps 1 through 18 from Pump Reassembly procedure to
complete pump assembly.
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 any one 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.
MODEL 384
65 22 23
28 29 28
25
5
26
8
10 12 16
11 9B 9A
9C 9
2
5C
42
43 48
49
52 53
65
22 23 28 29
28
55
4B
7
54
3
57
1
75
34
33
43 51
47
5B
4C
35
26
25
5C
4A
4A
51A
5
6
4C
2
63
62
64
5A
4A
Figure 11. Model 384.
1.
Compression Fitting
2.
Compression Fitting
3.
Tubing
4A/4B/4C. Pipe Plug
5/5A/B/C.Capscrew
6.
Casing
7.
Wear Ring
8.
Gasket
9.
Impeller Screw
9A.
Washer
9B.
Gasket
9C.
Capscrew Seal
10.
O-Ring
11.
Impeller
MODEL 384 LIST OF PARTS
12.
Impeller Key
16.
Back Wear Ring
22.
Gland Clamp
23.
Packing Gland
25.
Shaft Sleeve
26.
Pump Packing Cover
28.
Packing
29.
Lantern Ring
33.
Nameplate Screw
34.
Nameplate
35.
Motor Bracket
42.
Key
43.
Grease Fitting
47.
Water Slinger
48.
Capscrew
49.
51/51A.
52.
53.
54.
55.
57.
62.
63.
64.
65.
75.
Bearing Cap
Lip Seal
Retaining Ring
Bearing
Bearing
Shaft
Frame
Capscrew
Washer
Foot Support
Capscrew
Ball Valve
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.
13
MODEL 384
NOTES
14
MODEL 384
NOTES
15
MODEL 384
NOTE: Aurora Pump reserves the right to make revisions to its products and their specifications, and to this manual and related information, without notice.
800 Airport Road • North Aurora, Illinois 60542 • Phone: 888-987-8680
3601 Fairbanks Avenue • Kansas City, Kansas 66106 • Phone: 888-416-9510
www.aurorapump.com
AF-03-342 09/11 © 2011 Pentair Pump Group, Inc.
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