Preface:

The purpose of this manual is to provide relevant information and instructions regarding:
Installation, operation and maintenance aspects of your pump set.
Accurate implementation of the informati on and instructions given will opti mise the use of
purchased equipment.
A properl y designed installation ensure maxi mum reliabili ty and durabili ty in the long run.
Maintenance activities lie repairs and overhauls are not included in this manual.
These activities are preferabl y performed by specific dealers with trained personal and required
tools and spare parts.
!uestions related to your "i#huis product can be addressed to our service department. In case of
ordering spare parts please always state pump serialnumber on your enquiries to be able to serve
you quicer and better.
Guarant ee:
$ur responsibili ty is limited to the terms described in our sales conditions and amended by
contractual agreements.
%e emphaticall y reset any responsibili ty regarding claimes as a result from: incorrect installati on,
improper use, inadequate maintenance and any other application contrary with the instructions
described in this manual.
&ismantling of the pump within the guarantee period without written approval will immediatel y
invalidate applicable guarantee.
Manufacturers address :
NIJHUIS FIRE PROTECTION
Parallelweg 4
!"#$C %&ntersw&'(
P)O) *+, !"#
!"" -C %&ntersw&'( . H+lland
Tele, : 44!/0
P1+ne : 23!. 043. 0444
Telefa, : 23!. 043. 0444
S1&55&ng address :
Freule 6an $+rt1straat !#
!"# $C %&ntersw&'( . H+lland
Nijhuis Fire Protection
1 of '(
C+ntent:
)reface, guarantee, manual, address
* + ,eneral
+.+ -ocating the pump. unit
+./ )re installation
* / Transport
/.+ ,eneral
/.+.+ 0pecial hoisting instructions
/./ )ump sid
* 1 Inspection
1.+ Inspection of the pump. unit
* ' 0torage
'.+ ,eneral
'./ )ump
'.1 2ire pump controllers
'.' 3lectric motors
* 4 Installation
4.+ 0id foundation with anchor bolts
4.+.+ ,eneral
4.+./ ,uidelines for contructing a concrete foundation
4.+.1 3rection
* ( 5ustomers connections
(.+ 5onnecting piping
(.+.+ ,eneral
(.+./ 0uction piping for hori6ontal pumps
(.+.1 &ischarge piping according "2)A
(./ 5onnecting sensingli ne pr.sw.
(./.+ ,eneral
(.1 3lectrical supply 7direct online8
(.1.+ ,eneral
(.1./ Main 7A.5.8 power
(.1.1 5onnection between controller and electricmotor
* 9 Aligning hori6ontal pump units
9.+ Aligning the pump unit
9.+.+ ,eneral
9.+./ &eviations
9.+.1 5oupling data
9.+.' )ump ad#ustment with ad#usting bolts
9.+.'.+ ,eneral
9./ &river alignment with ad#usting :#acs;
* < 0ystem description
<.+ ,eneral
<./ 3ledyne controller
Nijhuis Fire Protection
1 of '(
* = )utting the pump. unit into operation for the +
st
time
=.+ >efore putti ng into operation for the +
st
time
=./ 2irst starting 7on site8
=.1 After first operation
=.' )ossible causes of fire pump troubles
* +? Maintenance
+?.+ )reventi ve maintenance programme
+?.+.+ ,eneral
+?.+./ %eely: >efore taling into operation
+?.+./.+ 3.motor
+?.+././ )ump
+?.+.1 %eely: &uring operation
+?.+.1.+ 3.motor
+?.+.1./ )ump
+?.+.' Monthl y
+?.+.'.+ 5ontroller
+?.+.4 @early: >efore taling into operation
+?.+.4.+. 3.motor
+?.+.4./ )ump
+?.+.( @early: &uring operation
+?.+.(.+ 3.motor
+?.+.(./ )ump
+?.+.9 3very three years: >efore taling into operation
+?.+.9.+ 3.motor
+?.+.9./ )ump
+?.+.< 3very three years: &uring operation
+?.+.<.+ 3.motor
+?.+.<./ )ump
+?./ ,land pacing directions
+?./.+ ,eneral
+?././ Aemoving old pacing. rings
+?./.1 "ew pacing. rings
+?./.' Mounting the new pacing. rings
+?./.4 Ad#usting B running in of the pacing
* ++ 7&is8Assembling the pump:
++.+ ,eneral
++./ &isassembling the pump
++.1 After disassembli ng
++.' >efore re.assembli ng
++.4 Aeassembli ng the pump
Nijhuis Fire Protection
1 of '(
7 ! GENER-87 ! GENER-87 ! GENER-8
7 !)! 8+cat&ng t1e 5u95. un&t :7 !)! 8+cat&ng t1e 5u95.
un&t :7 !)! 8+cat&ng t1e 5u95. un&t :
A careful chosen location for the pump. unit is of the utmost impor tance for maintenance as well
as for operation of the pump. unit. %hen choosing a location for your pump. unit the following
factors should be taen into consideration :
. -ocate the pump as close as possible to the source of the water. supply.
. If possible, locate the pumpC s centre. line under the level of the water. supply source so
that gravi tati on will help to push the water into the pump.
. Tae care that both suction and discharge lines are ept as short and straight as
possible to eep friction. losses as small as possible. >ends in suction as well as in
discharge line should have the largest 7practicable8 possible radius.
. )lace the pump. unit in such a way that the unit is easily accessible for maintenance,
inspection and possible repair activi ti es. Therefore tae care of good illumination and
ventilation in the pumproom to simplify these activi ties.
. Mae sure there is enough space beyond the pump for a hois ting device such as a
crane or a winch with enough capacity to hoist the complete unit.
. -ocate the unit, where possible, in a dry, dustfree and well ventilated space.
. %henever possible, do not locate the pump. unit on locations with a high damage ris.
Therefore do not place the unit on locations with extensive traffic 7human as well as
vehicles8. %hen the unit is placed on a location with extensi ve traffic however, mae
sure there is ample space for human as well as for vehicle traffic.
7 !)# Pre &nstall at&+n :7 !)# Pre &nstall at&+n :7 !)# Pre
&nstallat& +n :
$ne of the most important factors to successful operation and mainte nance of your pump. unit is
a correctly performed installation of the unit. A pump. unit that has been installed correctl y will
remain aligned better in the long run, will show less leaages of casing as well as flanges, will
show less vibrations and will demand less servicing. Another aspect that will be influenced by the
instal lation of your pump. unit is itCs service. life. A correctl y performed installation will prolong the
pumpCs service. life and diminish the ris of failures in emergency situations. A badly performed
installation may damage a new pump. unit severely within a relativel y short time D
7 # TR-NSPORT7 # TR-NSPORT7 #
TR-NSPORT
7 #)! General :7 #)! General :7 #)! General :
)ump. unit andBor components may only be hoisted at the suitable hoisting supports. Always use
all hoist. supports when hoisting D Eoisting of each component should always be performed in
accordance with the following general instructions regarding hoisting B transporting :
. The capacity of the hoisting. device and all other auxiliary components should be
enough to carry the component safely.
. Eoisting of each component has to be performed in accordance with all applicable local
laws B directions .
. Eoisting and transporti ng should be performed by authorised personnel with the utmost
care.
7 #)!)! S5ec&al 1+&st&ng &nstruct&+ns :
Apart from the above mentioned general instructions it is necessary to pay extra attention to
hoisting instructions given for auxiliary components.
7 #)# Pu95 s(&d :7 #)# Pu95 s(&d :7 #)# Pu95 s(&d :
&epen .
ding on
the execu .
tion of the
sid the
engine is
assembled onto, / different executions regarding the hois ting supports at the sid are possi ble
7see figures + F / 8.
If the driver is assembled on a sid lie is setched in the left figure, the unit is to be hoisted by
putti ng a chain through the open space between the sid and the plates welded on it.Mae sure
the hoos are fitted properl y around the chain. If the driver is assembled on a sid, lie setched
in the right figure, the unit is to be hoisted by attaching the hoisting. hoos around / pipes or bars.
These pipesBbars are not part of "i#huisC delivery. The pipesBbars should be stuc through the
hollow. pipes that are welded in the sid for this purpo se.The pipesBbars are to be a considerabl y
longer than the sidCs width in order to prevent the hoos slipping of the pipesBbars andBor to
prevent damages to the driver. "aturally, the pipesBbars should have sufficient capacity to carry
the weight of the unit.
Figure 1
Figure 2
%hen the driver is not assembled on a sid it must be hoisted by putti ng a chain through the
available eyebolts. ItCs not allowed to hoist the engine anywhere else because
it may damage the driver.
NOTES : . %hen hoisting, always all 7generall y '8 hoisting supports have to be used.
. EoistingBlifti ng should always be performed in accordance with the applicable legal
laws B directions.
7 3 INSPECTION7 3 INSPECTION7 3
INSPECTION
7 3)! Ins5ect&+n +f t1e 5u95. un&t :7 3)!
Ins5ect&+n +f t1e 5u95. un&t :7 3)!
Ins5ect&+n +f t1e 5u95. un&t :
,enerally hori6ontal fire fighting pump units will be delivered in an almost complete assembled
condition
with smaller components such as connecti ng materials gauges etc. separatel y paced.
A pump. set generall y contains the following components :
. 5omplete electr+9+t+r +n s(&d
. H+r&:+ntal 5u95
At receipt of the material it has to be inspected accuratel y for damages andBor the presence of all
components. Also chec the pacing. list. Any damaged or missing parts should be reported
immedia tely to the local agent of the company that is responsible for the transport of the unit.
&amages B missing parts should also be mared on the freight bill.
7 4 STOR-GE7 4 STOR-GE7 4 STOR-GE
7 4)! General :7 4)! General :7 4)! General :
)umpunits are usually delivered and paced in condition for immedia te installati on. The way of
pacing in which the pump. units are shipped depends on the method of trans port, distance and
durati on. Gnits that are to be shipped within 3urope are usually delivered without special storage
provisions. 2or units to be shipped out of 3urope generall y special storage provisions have been
made for the duration of the transport. If, for whatever reason, the pump is not to be installed for
a considerable time special storage provisions should be made. "i#huis 2ire )rotection provides
this, on special request only.
F+ll+w&ng general d&rect&+ns s1all *e 9et :
. All components should be stored in the proper position. 3ngine and all other non .
"i#huis manufac tured components should be stored in accordan ce with the directions
given by the respecti ve manufacturers H these are generall y mentioned in the
appendices of the operating and maintenance manuals of the components.
. &o not store components in a place with a high damage ris 7places with intensive
traffic 7human as well as vehicle88.
. 0tore the components in a dry, dust. and frostfree and well ventilated room.
. In order to avoid bearing damage owing to vibration during storage, e.g. due to
machines operated in close vicini ty, components should only be stored in rooms free of
vibration.
. If components are paced in undamaged seaworthy pacagings and provisions have
already been taen for long term stora ge, these pacagings should not be removed
until installa ti on. 5omponents paced in seaworthy pacagings that have not been
protected for long term storage, should be removed and protected for long term
storage at the moment of arrival. If possible pacagings should be applied again after
having protected the compo nents.
. If components are not suitably, paced they should be covered entirely. If the room in
which the components are stored isnC t waterproof the components should be covered
with a waterproof protectant.
. Inspect and clean the components regularl y 7only if not thoroughl y pacaged in dust.
and waterproof closed paca gings8. If pacaged, chec the pacagings regularl y for
damage and general condition.
. If components are to be stored for a long term 7more than 1 months8 before installation
and provisions for this stora ge have not been made 7provisions for long term storage
are only being made on your special request8 these should be made at the time of
arrival. The most important provision to be made for this purpose is the protecting of
corrodible parts of all components. )rotection can be made by greasing these parts
+
or,
better, by applyi ng a special preser vation oil. &epending on the provisions taen,
storage cir cumstances and the component, it can be necessary to regrease or re.apply
preserva tion. oil periodicall y.
. F+r au,&l&ar; c+95+nents alwa;s c+nsult t1e d&rect&+ns g&6en *; t1e
9anufacturers) T1ese d&rect&+ns s1+uld alwa;s *e a55l&ed &n add&t&+n t+ +r
&nstead +f t1e d&rect&+ns t1at are 9ent&+ned &n t1&s 9anual
1
If possible
7 4)# Pu95 :7 4)# Pu95 :7 4)# Pu95 :
. All applicable general directions mentioned should be met with.
. All pump components are to be stored in hori6ontal position.
. )rotection of the corrodible pump. parts can be made by greasing these parts 7shorter
periods8 or, better, by apply ing a special preservation. oil
/
. If storage is going to last
longer than ( months, or will tae place under severe envi ronmen tal circumstances the
corrodible pump. parts should always be treated with preservation oil. ,reasing will not
satisfy in these cases. 2or extended storage periods the preservation. oil must be
changed periodicall y. The period after which re.application of the preservation. liquid
becomes necessary depends on the storage circumstancesH when stored indoors in
accordance with the directions mentioned in * './.+ the preservation. oil should be re.
applied every +< months, when stored outdoors under a cover the preserva tion. oil
should be re.applied every +/ months.
. %hen the pump is to be stored for more than ( months the soft shaftseal pacing. rings
should be removed.
7 4)3 F&re 5u95 c+ntr+llers : * '.1 2ire pump controllers : * '.1 2ire pump
controllers :
. All applicable general directions mentioned should be met with.
. 2ire )ump controllers should always be stored under cover in a dry, temperature
regulated non. corrosive atmosphere, with each enclosure protected against the effects
of condensation by either one of both the following precautions being obser ved :
I Introduction of desiccant substance such as 0ilica. ,el, contained within a suitable
receptacle, into each enclosure. It is recommended that such a desiccant is
replaced on a regular basis 7e.g. every ( . < wees8, since itCs effecti veness is
nown to deteriorate with time.
I The connection of auxiliary A5 power feeds to the panel anticondensation heaters
7when fitted8 to main tain the interior of each enclosure at a constant temperature
7"ote : the auxiliary A5 power feed must correspond to the rated voltage of each
item of equip ment, otherwise damage may occur8.
. It is recommended that a suitable polythene covering is employed with protecti ve
pacaging as necessary to prevent damage to paintwor and exterior mounted
components.
. 2or protracted storage periods it is advisable to utilise hermeticall y sealed polythene
wrapping 7evacuated8 and then enclose each unit in an export quality pacing case
lined with tar. paper or equivalent.
2
Shell ENSIS liquid G, or equivalent.
7 4)4 Electr&c9+t+r :7 4)4 Electr&c9+t+r :7 4)4
Electr&c9+t+r :
. All applicable general directions mentioned should be met with.
. If electromotors are stored in a dry, dust. free and tempera ture regulated room, special
pacing is not necessary. In all other cases of storage the motors have to be paced in
plastic foil containi ng humidi ty. absorbing material 7e.g. 0ilicagel
1
8 or have to be sealed
in hermetic foil, whereby they also have to be protected against sunshine and rain.
. >igger motors are equipped with an interlocing device at the driving end for transport
purposes. This interlocing device should be ept bloced until the motors are put into
opera tion, or it has to be remounted after inspection or trial run. An interlocing device
is not necessary and not availa ble in case of axiall y biased bearings.
. In case the motors are equipped with sealed drainage holes condensation water inside
the motor may occur which has to be removed. Then the holes have to be sealed again.
. M+t+rs w&t1 slee6e *ear&ngs are delivered and to be stored without oil. filling in the
bearings. In order to protect the sleeve bearings, including bearing #ournal, against
corrosi on the followi ng has to be done :
I All openings should be sealed .
I All threads are to be fitted with plugs.
I All connection flanges are to be fitted with dead flanges.
I ,aps between sealing and winding respecti vel y sealing and housing have to be
covered 7with self. adhesive stable strips8.
Aemove cover at bearing housing and 7if possible8 through this opening spray in, by
means of pneumatic in#ection, a corrosion protecti ve paste which has not to be
removed in case of putti ng the motor into operation 7e.g. T35T@- 4++ M from
Jalvoline8
+
.
Insert a bag with humidi ty. filling 7e.g. 0ilica. gel8
+
below the plexi. glass cover in order to
avoid building of conden sation water. Then the bearings have to be screwed up tight
again.
In case a 5er&+d +f < ;ear &s e,ceeded fr+9 t1e date +f c+nser6at&+n unt&l t1e
date +f 5utt& ng &nt+ +5erat&+n t1e a*+6e 9ent&+ned c+nser6at&+n ste5s 1a6e
t+ *e re5eated)
. If st+rage &n t1e +5en is unavoidable the following has to be regarded at least :
I )rotecti ve cover against sunshine and rain has to be provided whereby there must
be the possibility of air inlet and outlet in order to avoid con densation.
. If motors are to be stored for an extended period 7K / years8, further provisions have to
be made. 2or these provi sions the motor manufacturer should be consulted.
. 2or motors equipped with a special temperature regulated ant&. c+ndensat&+n 1eater ,
this heater should be connected. %hen using an anti. condensation heater the
provisions, for preventi ng condensation, that were mentioned before may be cancelled.
3
Or equivalent
7 0 INST-88-TION :7 0 INST-88-TION :7 0
INST-88-TION :
7 0)! S(&d F+undat&+n w&t1 anc1+r *+lts :7 0)! S(&d
F+undat&+n w&t1 anc1+r *+lts :7 0)! S(&d F+undat&+n w&t1
anc1+r *+lts :
7 0)!)! General :To achieve a proper long. term functioning of the pump. unit, the pump. unit
should be placed on a solid foundation of sufficient capacity made out of, for instance, concrete.
The founda tionCs si6es should be chosen so that it will be able to carry the weight of the entire
pump. unit, as well as absorbing vibration, generated by the pump. unit, sufficientl y. A solid
foundation will guarantee a better unit. alignment in the long. term, which will result in a longer
service. life and less wear.
7 0)!)# Gu&del&nes f+r c+nstruct&ng a c+ncrete f+undat&+n :
5onstructi ng a foundation should be done in accordance with the guidelines that are mentioned
hereafter. Eowever, it should be pointed out that these guidelines should only be seen as being
guidelines, and no more than that. Therefore, if directions from e.g. concrete. manufacturer are
available 7for instance regarding hardeni ng. times, mix. compositions8 these should be read and
applied carefully. "i#huis 2ire )rotection is not responsible for the pump. unit foundation D
NOTE : F+r f+undat&+ns= +ut +f a 9ater& al +t1er t1an c+ncrete= c+ntact N&'1u&s>
Ser6&ce
$e 5art9ent )
7 0)!)3 Erect&+n :
. %hen placing the sid onto the foundation, the sid should be hoisted accor ding to the
directions given in * LTrans portL.
. )lace the sid on a number 7at least '8 of wedges or stacs of shims, thus that the
space between floor and pump. sid is about /? . '? milli metres.
. Tae care that the floor on which the sid is to be placed, is sufficientl y strong to carry
the weight of the unit and is sufficientl y rough so that the concrete that is poured
afterwards will be able to obtain a proper bond with the floor.
. Ad#ust the unit to level by ad#usting the wedges, or , in case the unit was placed on
stacs of shims, by adding B removing shims at the several places. Ad#usting the unit to
waterlevel should be done with respect to the wored up planes of driver. sup ports on
the sid 7these are the hig hest flat planes from the sid8, and not with respect to the
sid itself, as the sid isnC t necessarily +?? M straight at all places.
. >efore pouring concrete to fill the space between sid and floor, the floor should be
ept moist during a consi derable period, in order to saturate the floor with water so that
it will soa as less water as possible from the concre te that is to be poured, which would
affect the final result. The period during which the floor is to be ept wet varies,
depending on the age of the floor, between +/ . /' hours. As a guideline it can be taen
that a floor that is less than one month old should be ept wet for about +/ hours H a
floor that is older than one month should be ept wet for about /' hours.
. >efore the concrete can be poured, the anchor. bolts have to be placed. %hen placing
the anchor. bolts mae sure the bolts are placed far enough under the frame 7into the
concrete that is to be poured8 so that a sufficientl y thic layer of concrete will be able to
fill the space above the hoo of the anchor. bolts.
2urther there has to be taen care that the nuts can be tightened far enough after the
concrete has hardened. Therefore tae care that the nuts 7and possible inclined plates8
are tightened #ust that far that the screw. thread rises #ust a couple of threads above the
nut.
. %hen pouring concrete special care has to be taen that the concrete can spread itself
well around the anchor. bolts so that a good hole. less connection between bolts and
concrete can arise and the bolts will be clamped firml y in the con crete.
. After the concrete has been poured it should harden out. Eardening time depends on
environmental circumstances and the exact composition of the concrete and will vary
from days to over a month. 2urther informati on concerning the hardening time should
be obtained from the concrete manufacturer.
. After the hardeni ng. process has been accomplished the an chor. bolts can be tightened
and suction B discharge lines and other connections to the unit can be made. Tighteni ng
should be accomplished crosswise and in equal steps.
. The tighteni ng torqueNs the anchor bolts are to be tightened with, depend on bolt.
quality as well as on the quality of the concrete. If required "i#huis can deliver complete
sets of foundation bolts including, if necessary, inclined plates that fulfil &I" 4/=.
3Piping
7 4 CUSTOMERS CONNECTIONS7 4
CUSTOMERS CONNECTIONS7 4 CUSTOMERS
CONNECTIONS
7 4)! C+nnect&ng 5&5&ng :7 4)! C+nnect&ng 5&5&ng :7 4)!
C+nnect&ng 5&5&ng :
7 4)!)! General :
0uction as well as discharge piping may not be connected until concrete has hardened entirely
and anchor. bolts have been tightened. %hen connecting suction. and discharge piping the
following guidelines should be applied to increase pump efficiency and to prevent future trouble.
Aead and apply the following advice carefull y.
. >efore connecting suction and discharge piping mae sure that both lines are free of
debris and other foreign ob#ects that might damage pump and line system.
. Inside diameters of suction and discharge piping are to be selected in accordance with
the applicable standard 7e.g. "2)A./?8 and should be at least as large as the inside.
diameters of the respecti ve pump flanges.
. )acing between all flanges and other connections should, in order to prevent reducing
the pipingC s culvert, have an inside diameter that is about 4 . +? mm larger than the
inside diameter of the respective flanges.
. 0election of the materials that are to be applied for the piping 7and all other piping.
properties8 ought to be in accordance with the applicable standard 7e.g. "2)A./?8.
. 0uction and discharge lines should both be equipped with a compound. gauge
respecti ve a pressure gauge. >oth compound and pressure gauges should fulfil the
applicable conditions of the applicable standards.
. 0uction as well as discharge piping should be suppor ted as close to the pump flanges
as possible in order to reduceBmi ni mise the forces on the pump7flanges8 7see figure 8.
. )ump. and pipingflanges should lay perfectl y parallel and centre on centre. "3J3A use
the bolts of the flange. connections to achieve this. &oing so will cause high tension on
pump and flanges.
. Tighten the bolts of the flange. connections crosswise and in more equal steps.
Tighteni ng torqueNs with which this is to be performed can be found in appendi x +.
7 4)!)# Suct&+n 5&5&ng f+r 1+r&:+ntal 5u95s:
. 0uction. piping acc. "2)A shall be equipped with a listed $.0. F @. gate. valve. A butterfl y
valve shall not be installed in the suction pipe.
. %hen the suction pipe and pump suction flange are not of the same si6e 7suction pipe
K suction flange8, suction pipe and flange shall be connected with an eccentric tapered
reducer in such a way to avoid air pocets 7see figure suction piping8.
. Avoid the use of bends in the suction pipe which rise 7partially8 above the pump.
centreline. &oing thus will dimi nish the ris of air in the piping. system considerabl y.
. %hen pump and suction pipe support are mounted on different foundations and are
connec ted by a rigid connecti on, the connection pump. suction pipe should be equipped
with a flexible connection. The flexible connection must naturall y fulfil the same stand .
ards the rest of the piping has to fulfil.
. 0uction piping must be hydrostaticall y tested for tightness according to the applicable
test procedure mentioned in the applicable standard 7e.g. "2)A./?8.
. %hen the water supply can be expec ted to contain foreign materials, the sucti on pipe
should be equipped with sucti on screening. 3xecution of the scree ning should be
according to the appli cable standard.
7 4)!)3 $&sc1arge 5&5&ng acc NFP- :
Suction piping
. %hen the inside diameter of the di scharge piping is larger than the inside diameter of
the discharge flange, pipe and flange should be connected with a concen tric reducer
7see figure discharge piping8.
. &ischarge piping should be equipped with a c1ec(. 6al6e which should protect the
pump against damages caused by bac. flowing water and should also maintain the pressure in
the discharge system during the time the pump isnC t operating. 7see figure discharge piping8.
&ischarge piping should be equipped with a c+ntr+l 6al6e which is to be used by the weely
performed tests. The control valve should be mounted after the chec valve.7see figure discharge
piping8.
1 2 3 4
&ischarge piping
+ O 3xcentrisch reducer
/ O 5oncentrisch reducer
1 O 5hec valve
' O ,ate valve
. In between chec valve and control valve a Tee should be mounted on which a branch
pipe can be mounted that can be used for more duties. An example for the duty of this
branch pipe is the use of it as a measuring pipe by which the generated flow can be
measured 7control valve should be closed when measuring8. The branch can also be
used for fire. extinguishing dutiesH water can be pumped out through this pipe as well as
pumped into the system through this pipe.
. &ischarge pipe should also be equip ped 7only for pump. units driven by a diesel. engine8
with a 5ressure rel&ef 6al6e which is to be located directly after the pump 7before the
chec valve8. %hen a concentric reducer between pumpflange and pipe is mounted the
pressure relief valve should be mounted directl y after this reducer. Aim of the pressure
relief valve is to protect the discharge piping, and all components that are connected to
it, against damages caused by too high a pressure 7caused by an overspeed of the
dieselengi ne8.
. 0i6es, construction and materials of pressure relief valve, chec valve, tee and control
valve should be in accordance with the demands of the applicable standard 7e.g. "2)A.
/?8.
. &ischarge pipe should be equipped with a branch. pipe for the engine cooling system
7diesel engines only8. 3xecution and location of this branch should compl y with the
demands according to the applicable standard 7e.g. "2)A./?8 and are discussed further
in * C5onnec ting cooling water systemC .
. The discharge pipe should also be equipped with necessary branches for connecting
the pressure switches for both the main fire pump and #ocey pump. 3xecution and
location of these pressure switches should comply with the demands to this according
to the applicable standard and are discussed further in a separate *.
. These pump. units, driven by an air. cooled electromotor, the discharge pipe is to be
equipped with a circulation relief valve 7delivered with pumpset8. It shall provide
sufficient water to prevent the pump from overheating when operating with no
discharge. )rovision shall be made for a discharge to a drain.
7 4)# C+nnect&ng sens&ngl&ne 5ressure sw&tc1 :7 4)#
C+nnect&ng sens&ngl&ne 5ressure sw&tc1 :7 4)# C+nnect&ng
sens&ngl&ne 5ressure sw&tc1 :
7 4)#)! General :
The pressure switch to initiate automatic starting in case of pressure drop in the system, is
mounted on the side of the controller and already electricall y connected. The only connection to
be made is the sensing line to the pump discharge. This connection should be in accordance with
the applicable standard.
. The pr essure. switchline should be made out of a corro si on.proof metal.
. The nominal inside diameter should be at least PL.

. The pressure switchline should be connected to the pump di schar ge pipe.
The connec tion to this pipe should be loca ted between chec. valve and shut. off valve.
All connections, and pi ping should be lea. tight, thoroughl y con structed, and resistant
to the maxi mum system pres sure.
Pressure Transducer:
2or this pro#ect a pressure transducer has been selected and installed at the right hand side
exterior of the controller. 7 operating range ? . 1??)0I8
This pressure transducer shall be connected to the main system as described in section
:5onnecti ng sensingline pressure switch;.
The purpose of this pressure transducer is to continuously monitor the fire water pressure in the
main system and to feed a volt signal ranging from + volt equal to 19,4 )0I and ',4 volt equal to
1?? )0I to signal conditioni ng module )5+/9. The actual measured system pressure can be read
from display module )5+4+ at mode A.
The set pressure at which the pump set shall start can be selected by pressing green setBreset
push button to appraise mode.
5onsult applicable section of controller manual for ad#usting procedures when required. There are
no maintenance activi ties required for this pressure transducer.
5omplete transducer shall be replaced when, suspected, malfunctioni ng or the pump set when
pressure transducer andBor setting are changed.
7 4)3 Electr&cal su55l; ?d&rect +n l&ne@ :7 4)3 Electr&cal
su55l; ?d&rect +n l&ne@ :7 4)3 Electr&cal su55l; ?d&rect +n
l&ne@ :
7 4)3)! General :
The controller is delivered separatel y with the pump. unit, it should be connected at the moment
of installation. The following connection have to be made H
+8 Mains 7 A.5. 8 power supply
/8 5onnection between controller and electromotor
18 5onnecting electromotor heater to controller7if mounted8
4)3)# Ma&n ?-)C)@ 5+wer :
5onnecting the controller to the mains should be done in accordance with the control lerCs
connecti ng. schedule, that is delivered with7in8 the controller 7usually within the controller
enclosure8. The controllerCs operating volta ge, depending on the execution and the
country the controller has to operate in, is indicated on the controller. identification plate.
5onnecting should be done in accordan ce with the applica ble legal safety. regulations as
well as with respect to the maxi mum mains. power needed by the controller.
4)3)3 C+nnect&+n *etween c+ntr+ller and electr&c9+t+r :
"ormall y electromotors have windings for 5.5.%. rotation 7 facing shaftend8 when phases
are in positive sequence. 5able si6e has to be calculated regarding nominal motor current
ambient and cable length.
7 -8IGNING HOR)PUMP UNITS 7
-8IGNING HOR)PUMP UNITS 7 -8IGNING
HOR)PUMP UNITS
7 )! -l&gn&ng t1e 5u95. un&t :7 )! -l&gn&ng t1e 5u95. un&t
:
7 )! -l&gn&ng t1e 5u95. un&t :
7 )!)! General :
After the unit is fastened on the foundation and piping is connected, the pump. unit has to be
aligned. Although pump. units are already aligned when manufactured, it remains necessary to
chec and, if necessary, ad#ust the unitCs alignment when installing, because it is possible that the
unitCs alignment is disturbed by forces that could occur during the transport and the connection of
suction. and discharge pi ping.
7 )!)# $e6&at&+ns :
The alignment of a pump. unit is determi ned by the position of the coupling halves with respect to
another, therefore alignment should be performed by checing 7and if necessary ad#usting8 the
coupling half positions with respect to another. %hen aligning the coupling half positions, the
following 1 possible inds of deviation should be taen into account :
!@ N+n. 5arallel&s9 +f t1e s1afts ?c+u5l&ng 1al6es@
#@ N+n. c+ncentr&c&t; +f t1e s1afts ?c+u5l&ng. 1al6es@
3@ Clearance &n a,&al d&rect&+n *etween t1e c+u5l&ng 1al6es
ad !@ N+n. 5arallel&s9 +f t1e s1afts :
5hecing the mutual angle between two shaft parts 7coupling halves8 can be done a.o. with
the help of feeler gauges. These are to be positi oned at ' places equally divided 7every
=?8 around the circum ference of the circle. The angle between the two shafts can be esti .
mated by comparing the distances 7in axial direc tion8 between the coupling halves. The
allowable deviati ons 7Qw 7mm88 between the largest mea sured axial distance 70max 8 and
the smal lest distance 70min 8, depended on the coupling si6e, are to be found in table +.
-lwa;s chec the angular devia tion in both the hori 6ontal and the vertical plane D
ad #@ N+n. c+ncentr&c&t; +f t1e s1afts :
5hecing the deviation in the posi tion of the cent res of the shafts 7coupling halves8 in
relation to each other, can be done with the help of a straight edge. This should be
positioned over both the coupling halves 7see figure non. concentricity8. Rust as when
checing the deviations in non. alignment of the shafts, checing of the deviation in non.
concentrici ty should always be performed in both the hori6ontal and the vertical plane. 2or
pump. units driven by a diesel. engine the coupling. halves should be positioned exactl y
concentric in the hori 6ontal plane ideally H in the vertical plane though, the coupling halves
ideally should NOT be positio ned exactl y concentric D Ideally, the coupling halve on
engine. side should lay about ?,+ mm lower than the coupling halve on pump side, when
not opera ting.
At the moment the engine is star ted and oil
pressu re rises, an oil. film will exist between
crans haft and bearing sleeves, as a result of
which cranshaft and flywheel will rise about ?,+
mm. >y ad#usting the vertical engine halve cou .
pling positi on thus that it is about ?,+ mm lower
in stationary conditi on, will be archived that the
coupling hal ves will be properly aligned when
opera ting. The allowable deviations 7Qr8
depended on the coup ling si6e, are to be found
in table +.
ad 3@ Clearance &n a,&al d&rec t&+n *etween t1e c+u5l&ng 1al6es :
The 1
th
magnitu de that is of impor tance when align ing
the unit is the distance in axial direction between the
coupling. hal ves. This distance shouldnC t be too small
in order to permi t axial move ments of the shafts in
relation to another 7these move ments are caused by
expansion of the shafts due to tem pera ture chan ges,
or are as a result of bearing wear8. $n the other hand,
the axial distance shouldnC t be too large.If the
clearance between the two cou pling halves gets too
large, the forces the cou pling has to transmi t will be
trans mitted on a too a small part of the coupling pins
and rubbers. This will cause prematu re wear and
decrease the service. life of the coup ling. The axial
clearance can be esti mated easily by measu ring the
distan ce with a venire calliper. )ermissible clearan ces
70+8 7mini mum as well as maxi mum8 are to be found in
table +.
S&9ultane+us n+n. c+ncentr&c&t; and n+n. 5arallel&s9 :
In practice, there never will be a situation in which only a deviation in concentri city +r in
paralleli ty will occur. These deviations shall always occur simul tane ously. Therefore, the
absolute sum of both the deviations together may not be larger than the maxi mal
allowable deviation for one of the deviations 7 Qw F Qr8 separatel y. As can be seen in the
table the allowable deviations 7mm8 for Qw and Qr are identical. Therefore it is not
important which deviation is taen as criterion for both the deviations together.
Non-concentricity
Clearance in axial direction
7 )!)3 C+u5l&ng data
Ta*le ! : General data regard&ng fle,&*le N. Eu5e, c+u5l&ngs
C+u5l&ng
s&:e ?99@
S!
?99@
P
?99@
T-
?N9@
Sw
?99@
Aw
?99@
Ar
?99@
/4? 1...< (= +'4 +' ?,'/ ?,'/
E,5lanat&+n used a**re6&at&+ns :
. 0+ : The distance 7mm8 between the two coupling halves in axial direction, whereby the
+
st
number states the mini mum demanded clearance and the /
nd
number
represents the maxi mum allowable clearance.
. ) : The mini mum clearance 7mm8 needed for the 1
th
part of the coupling to be able to
move freely in order to be able to disconnect the two coupling halves without
having to remove more than only the 1
rd
coupling. part for this purpose.
. TA : The tightening torque 7"m8 with which the bolts, with which coupling part 1 is
attached to part / 7see figure ".eupex
coupling8 are to be tightened.
. 0w : The spanner width 7mm8 of the bolts with which part 1 is attached to part /.
. Qw: The maxi mal allowable deviation 7mm8 in 7non8 paralle lity of the shafts, measured
as suggested in figure "on.parallity. Qw O 0max . 0min .
. Qr : The maxi mal allowable deviation 7mm8 in 7non8 con centricity of the shafts, measu .
red as sugge sted in figure "on.concentricity.
-d'ust9ent :
If the alignment of the unit doesnC t fulfil the stand ards that it is to comply with, the
alignment has to be ad#u sted. >y moving pump in hor. plane with the ad#usting bolts
andBor moving driver in vert.plane with installed ad#usting#acs 7engine8 or shims 7e.
motor8
Technical data:
Model: A./4?
"ominal torque: /<?? "m
Max. allowable speed: /94? rpm.
7 )!)4 Pu95 ad'ust9ent w&t1 ad'ust&ng*+l ts
7 )!)4) ! General
2our ad#usting bolts are positioned around the pump pedestal. -oosing two bolts and tightening
the two opposite bolts causes pump movement. 2irst loosen the pump foundation bolts. %ith this
feature it is possible to correct coupling "$" concentricity in hori6ontal plane. After ad#usting, all
four ad#usting bolts and pump foundation bolts have to be re.tightened.
7 )# $r&6er al&gn9ent w&t1 ad'ust&ng 'ac(s :7 )# $r&6er
al&gn9ent w&t1 ad'ust&ng 'ac(s :7 )# $r&6er al&gn9ent
w&t1 ad'ust&ng 'ac(s :
An ad#us ting #ac is setched in figure ad#us ting supports. %hen ad#usting the engine, proceed as
fol lows :
.-oosen the bolts 7+8 of all the supports somewhat, so that
the engi ne can be moved easi ly to some extent.
.After having loosened the bolts 7+8, the threa ded loc
washers 718 of all supports should also be loos ened. These
loc washers should be loosened as far as needed for the
ad#us ting. #ac7s8 7/8 to be able to be turned freely 7in both
direc tions8 for as far as needed to achieve proper engine.
alignm ent. 2or loosening and tighteni ng the loc. washers 718
a hoo ed spanner should be used suitable for loc. was hers
in the range from S <? . S =? mm.
.The actual ad#usting is to be done by turning the ad#usting
#acs 7/8 into 7or out of8 the sid support.
.After the alignment has been ad#usted within the applicable
tolerances, the threaded loc was hers 718 and bolts 7+8
Figure 13
should be tightened.
.Always chec the shaft alignment in both the vertical and
the hori6ontal plane H even if the engineCs position has only
be ad#u sted in one of these planes. An ad#ust ment in the hori6on tal 7verti cal8 plane may also
influen ce the
engineCs position in the vertical 7hori 6ontal8 plane D
If the unitCs alignment is checed 7and if necessary ad#usted8, without suction. and discharge pi .
ping mounted, the unitCs alignment should always be checed 7and ad#usted, if necessary8 after
having mounted suction. and discharge piping.
After the alignment procedure has been finished, the tightening torqueNs of the engineBpump
connections to the sid as well as of the coupling bolts should be checed. The proper tightening
torqueNs for the engineBpump . sid bolts are to be found in appendi x +.
7 / SBSTEM $ESCRIPTION7 / SBSTEM
$ESCRIPTION7 / SBSTEM $ESCRIPTION
7 /)! General7 /)! General7 /)! General
The fire pump controller is designed for automatic starting at loss of water pressure in the main
and complies with the "2)A /? requirements.
7 /)# Eled;ne c+ntr+ller7 /)# Eled;ne c+ntr+ller7 /)#
Eled;ne c+ntr+ller
Motor contactors are fitted on the bac panel and in the event of control circuit failure they can be
operated Ldirect on lineL, externall y by a manual mechanical lever fitted on the side of the
controller. Aemote moni tor volt free change over contacts are provided for :
)EA03 03!G3"53 2AG-T
MAI"0 2AI-GA3
)GM) AG""I",
)GM) $" &3MA"&
$nly if specially ordered, the controller will be equipped with an auxiliary supply circuit for
winding heaters electromotor andBor supply circuits for #ocey pump and engine controller.
3ach controller will have his own operati ng instruction manual related to the controller serial nr..
It>s 6er; &95+rtant t+ read t1&s 9anual carefull; *ef+re +5erat&ng)
7 C PUTTING THE PUMP. UNIT INTO OPE.
R-TION FOR THE !
st
TIME :7 C PUTTING
THE PUMP. UNIT INTO OPER-TION FOR
THE !
st
TIME :7 C PUTTING THE PUMP. UNIT
INTO OPER-TION FOR THE !
st
TIME :
7 C)! Def+re 5utt& ng &nt+ +5erat&+n f+r t1e !
st
t&9e :7 C)!
Def+re 5utt&ng &nt+ +5erat&+n f+r t1e !
st
t&9e :7 C)! Def+re
5utt&ng &nt+ +5erat&+n f+r t1e !
st
t&9e :
I5hec the complete installation carefull y.
IMae sure all bolts and nuts have been properly tightened.
IIf not already done, install a pressure gauge so that the result of pump. operation can be
monitored and checed properly.
I5hec suction valve is open and water level is sufficient for operating.
I5hec discharge valve and B or testline valves are closed.
I5hec circulation relief valve 7"2)A /? /.(8 is properl y mounted.
I5hec that the impellers have been ad#usted properl y so that the pumpshaft can rotate freely
I0witch on main isolator and circuit breaer of the controller and chec the mains phases have no
phase sequence fault.
CAUT!N
-6+&d un&ntent& +nal 5u95 start& ng w1en cl+s&ng 9a&n c&rcu&t *rea(er)
Precaut& +nar; 9easures t+ *e ta(en)
Ma(e sure t1at re9+te st+5 ?energ&sed t+ st+5@ +r 5ressure sw&tc1 ?5ressure &n f&re
s;ste9 1ealt1;@ are +5erat& 6e *ef+re cl+s&ng 9a&n c&rcu&t *rea(er)
Negl&gence w&t1 t1ese reEu&re9ents 9a; result &n 5ers+nal &n'ur; and w&ll cause
se6ere da9age t+ 5u95 and anc&llar; eEu&59ent
7 C)# F&rst start&ng ?+n s&te@ :7 C)# F&rst start& ng ?+n
s&te@ :7 C)# F&rst start& ng ?+n s&te@ :
I0tart the pump by initiati ng a manual start
I$bserve that the pump starts easily and runs without exces sive vibration. If there is any starting
difficulty or excessive vibration, then stop the engine immediatel y and determi ne the probable
cause.
I0lowl y open the discharge valve until the discharge pressure reaches the desired value.
IAd#ust 7tighten8 the gland nuts graduall y over an extended period. 2or the proper ad#ustment
procedure : see * / of the maintenance part of this manual : Cgland pacing directi onsC.
I&uring the +
st
operation period, chec and note all gauge readings and compare them to the
respective values in the pump manual. If considerable deviations from the guidelines in these
manuals are met with, the cause of this should be located and corrected if necessary.
I -oc engine control lever after speed ad#ustment is made.
7 C)3 -fter f&rst +5erat&+n :7 C)3 -fter f&rst +5erat&+n :7 C)3
-fter f&rst +5erat&+n :
IAfter the +
st
running period it is recommended to chec and, if necessary, to correct the
alignment of pump and driver.
7 C)4 P+ss&*le causes +f F&re Pu95 Tr+u*les :7 C)3 -fter
f&rst +5erat&+n :7 C)3 -fter f&rst +5erat&+n :
In this section a guide for locating pump troubles and their possible causes are given. The causes
listed are in addition to possible mechanical breaage that would be obvious on visual inspection.
In case of trouble it is suggested that those troubles which can can be checed easily should be
corrected first ore eliminated as possibilities )
Rec+99endat& +n
It is recommended that trouble shooting procedures are carried out by qualified personnel
familair with equipment and safety procedures. Always investigate problems completel y. "ever
compromise on problem solutions, avoid RGAI.AI,,I",.
%-RNING
$e energ&se c+ntr+ller and el&9&nate an; 5+ss&*le un&ntent& +nal start) S1+rt c&rcu&t&ng
+f start&ng *atter&es
cause ser&+us s5ar(s and 5+ss&*le f&re)
7 !" M-INTEN-NCE :7 !" M-INTEN-NCE :7
!" M-INTEN-NCE :
7 !") ! Pre6ent& 6e 9a&ntenance 5r+gra99e :7 !") !
Pre6ent& 6e 9a&ntenance 5r+gra99e :7 !") ! Pre6ent& 6e
9a&ntenance 5r+gra99e :
7 !")!) ! General :
Ma&ntenance sc1edule
This chapter provides the mini mum inspection and maintenance requirements to be a part of a
total preventi ve maintenance program. A preventi ve maintenance program is essential to ensure
proper functioning of the complete pump set and reduce maintenance costs to a mini mum. This
program shall be initiated after the pump set has passed acceptance test.
Aeports shall be made from each inspection, maintenance and testing activity. These reports shall
be filed for future review while latest inspection B maintenance report shall be stored in the wiring
diagram carrier located at the bac side of controller panel door.
7 !")!) # %ee(l; : *ef+re ta(&ng &nt+ +5erat&+n
7 !")!) #) ! E.9+t+r :
,eneral : 3lectro motors do not need a special maintenance programme. Eowever to
avoid and locate possible failures at an early stage it is recommen ded that
electromotors are inspected weely. %hen chec ing the motors the
following ob#ects should be paid attention to :
%al. around
inspection : 5hec the motor for cleanliness, presence of moisture, loose bolts. -ocate
the cause of possible failures and correct it as soon as possi ble. %hen
cleaning the motor mae sure this is done dry. 2or drip. proof motors tae
special care the presen ce of dust on the windings. Qeep electro motors
free from contami nating fluids or gases which could damage the windings.
3lectric motor: 2or this pro#ect a squirrel cage electric motor mae -eroy 0omer
2-0 144-A', nominal speed +4?? rpm., suitable for direct starting has been
selected.
The construction of this 2-0 cast iron motor include I)44 protection a class
2 insulation and suitable to operate at 4?T5 ambient temperatures. A +4?
watt space heater has been installed to eliminate problems caused by
condensation. 7loss of Insulation8
The heater supply wires arebrought out to a termi nal bloc in the motor
#unction box. The heaters will be switched off, by the controller, while the
machine is in operation. 7see cross sectional drawing e.motor8
Maintenance: The rotor has been provided with two ball bearings number
1//51.
,rease is used for lubricati ng purposes and shall be replaced at '4??
running hour intervals or in accordance with other maintenance schedules.
3ach bearing shall be provided with (?cmU lithium based grease.
73sso Gnirex "1 or equivalent8
5hec annually all cable connections for damage and tighten all
connections.
>earing arrangement
7 !")!) #) # Pu95 :
%al. around
inspection )erform a visual chec for leaageNs, loose bolts, corrosion and filthi ness,
presence of debris or foreign ob#ects.
7 !")!) 3 %ee(l; : dur&ng +5erat&+n
7 !")!) 3) ! E.9+t+r :
"oises B
vibrations : 5hec vibration and noise level. Any unusual vibrations or noises should
be located and corrected immediatel y.
7 !")!) 3) # Pu95 :
"oises B
vibrations 5hec the pump for unusual noises and vibrations.
0tuffing box 5hec leaage from stuffing. box. -eaage must be somewhere in between
'? to (? drops B minute. -eaage may only occur between shaft. sleeve
and soft pacing. ringsH no leaage may occur between stuffing. box and
soft pacing rings. Ad#ust stuf fing. box leaage if necessary. Ad#ustment of
stuffing. box leaage has to be performed in accordance with gland
pacing instructi ons 7pages 4' to 4< of this manual8.
0tuffing box
drain 5hec stuffing. box waste. pipes for free flow.
>earings 5hec bearing temperature. >earing temperature may not exceed '4 5
above ambient and may also not exceed =4 5.
7 !")!) 4 M+nt1l; :
7 !")!) 4) ! C+ntr+ller :
0ignal. lamp
bulbs Aeplace those signal. lamp bulbs that are illumi nated continuously 7A.5.
mains $",
7%hen Applicable8 battery A healthy, battery > healthy8 .
7 !")!) 0 Bearl; : *ef+re ta(&ng &nt+ +5erat&+n
7 !")!) 0) ! E.9+t+r :
Inspections : 0ame as all inspections that are to be performed weely.
>earings : Aeplace bearing grease. !uality and quanti ty of the grease are gene rally
mentioned on an identification plate that is attached to the motor.
Aegreasing should be done in accordance with the applicable regreasing
directions from the motor. manufactu rer.
Technical data bearings:
&riven end: (1//51 grease quant. (?cmU
"on &riven end: (1//51 grease quant. (?cmU
,rease quality: 3sso unirex "1 or equal
7 !")!) 0) # Pu95 :
%al. around
inspection )erform a visual chec for leaageNs, loose bolts, corrosion and filthi ness,
presence of debris or foreign ob#ects.
>earings 5hec bearings and change bearing grease. 2or this purpose the old
grease must be removed and bearings have to be cleaned .
>earings may not be filled for more than 4? M with new grease. Gse
Texaco Multi )urpose "o. / Marfa or equi valent. 5hec general operation
of the bearings and, if necessary, replace them.
Technical data bearings:
&riven end: 0Q2 (/+( grease quant. +<cmU
"on &riven end: 0Q2(/+( grease quant. +<cmU
7 !")!) 4 Bearl; : dur&ng +5erat&+n
7 !")!) 4) ! E.9+t+r :
,eneral 0ame as all %eely during operation )ump inspections.
7 !")!) 4) # Pu95 :
,eneral 0ame as all %eely during operation )ump inspections.
7 !")!) E6er; t1ree ;ears : *ef+re ta(&ng &nt+ +5erat&+n
7 !")!) ) ! E.9+t+r :
,eneral : 0ame as all @early before Taing Into $peration )reventi ve Mainte nance
operations.
7 !")!) ) # Pu95 :
,eneral The 1 yearly or /?.??? hours inspection must contain the same inspecti .
onsBchecs that are to be performed yearly.
>earings Aeplace bearings.
0tuffing box Aeplace all soft pacing rings at this time. 5hec casing 7and impel ler if
equip ped8 for wear. Max imum permissible diametrical clearan ce between
impeller and casing depends on impeller si6e and can be found in figure +.
C8E-R-NCES IMPE88ER. C-SING %E-RRING
s&ngle stage and tw+ stages centr&fugal 5u95s ? T9a,F/" C @
F&gure !
0haft sleeves 5hec shaft sleeves for damage and wear. If neces sary, replace them. )ermissible
wear andBor damage should be con sidered for each case sepa rately. It
may not be neces sary to replace shaft sleeves in cases where small
damage or minor wear is established. &amage or wear that does 7or may8
influence pump performance considerabl y is not permissible. In cases
where small damage or small wear is established, and shaftslee ves are not
replaced, a more frequent inspection of the damaged or worn parts should
to be per formed.

$il seal 5hec the oil seal ring in the bearing housing on the coupling side and
replace it, if necessary.
2elt rings 5hec the feltrings in both bearing housings and replace them, if neces sary.
Miscel laneous 5lean the entire pump thoroughl y 7inside as well as outside8 and mae sure the old
flange sealant between the two casing halves is removed entirel y before
new sealant is applied. 2lange sealant between the two casing halves
should be -octite 0uperfast 491. Mae sure all casing bolts are tightened
crosswise with the proper tighteni ng torque 7tighteni ng torqueNs : table +
,appendi x +8.
7 !")!) / E6er; t1ree ;ears : dur&ng +5erat&+n
7 !")!) /) ! E.9+t+r :
,eneral : 0ame as all @early during $peration )reventi ve Maintenance operati ons.
7 !")!) /) # Pu95 :
,eneral 0ame as all @early during operation )GM) inspections.
7 !") # Gland 5ac(&ng d&rect&+ns :7 !") # Gland 5ac(&ng
d&rect&+ns :7 !") # Gland 5ac(&ng d&rect&+ns :
7 !")#) ! General : If a large leaage flow, or a leaage in the wrong location
'
, should
occur and the gland has already been ad#usted several times 7or in
case ad#usting doesnC t result in an improvement8, the pacing. rings
most liely are worn or damaged so that a replacement of the rings
becomes necessary. %hen removing and assembli ng the rings the
following procedure should be followed :
Technical data pacing material:
Mae: >urgmand
0i6e: +/,9mm square
7 !")#) # Re9+6&ng +ld 5ac(&ng. r&ngs :
+?././.+ Mae sure the stuffing. box is not under pressure. 2or this purpose chec :
. Aeadings discharge pressure gauge
. %ater supply to lantern. rings
4
If possible, drain the water that is in the pump, until the water level has at least dropped below
the lowest
stuffing. box level. &raining can be done by removi ng one of the plugs that are placed in the
discharge
flange.
+?./././ After having checed the points mentioned in the mainte nance, the gland should be
removed. 2or this purpose the gland. nuts should be removed, wherefore the gland
should be pulled bac as far as possible 7figure +8 .
+?././.1 After the gland has been removed, the old pacing. rings and the lantern. ring can be
removed. -lwa;s re5lace all 5ac(&ng. r&ngs G Aeplacing only one or two rings will not
result enough effect. Aemoving the pacing. rings should be done with the help of a
pacing. extractor 7see figure /8 and should be performed with ample care, in order to
prevent damages to stuffing. box andBor shaft7sleeve8.
Mae sure the pacing. extractorC s sharp side is pointed to wards the stuf fing. box and
not towards the shaft 7sleeve8, so that in case of shooting out the shaft 7sleeve8 will not
4
Leaa!e should o""ur bet#een shaft$sleeve% and pa"in!&rin!s, NO leaa!e should o""ur on other lo"ations,
su"h as bet#een pa"in!&rin!s and stuffin!&bo'.
(
)he"in! #hether the #ater&suppl* to the lantern&rin!s is "losed is onl* to be done in "ase the lantern&
rin!s are supplied #ith #ater that is not "o+in! fro+ the pu+p,s dis"har!e.
F&gure !
F&gure #
be damaged.
The lantern. ring also should be removed in order to be able to remove the pacing.
rings that are placed on the other side of the ring. 2or this purpose the lantern. ring is
executed with, generally /, savings through which hoos can be inserted. )ull the
lantern. ring out with one hoo in both the savings simultane ously so that the ring can
be pulled out of the stuffing. box straight. $bviously, removing the lantern. ring should
be performed with the same care as is required when removi ng the pacing. rings.
+?././.' After having removed pacing. and lantern. ring7s8 the
shaft 7sleeve8 and stuffing box should be clea ned and
checed for damage or wear thoroughl y. If shaft 7sleeve8
andBor stuffing. box show considera ble
(
wearBdamage
these failures should be correc ted.
In case abnormal pacing. wear seems to occur, it is recom mended to also chec
whether shaft7sleeve8 and stuffing. box are positioned concentric 7see figure 18 and
aligned, apart from wear and damage to shaft7sleeve8 and stuffing. box. Also chec the
shaft run. out.
Also chec the glandCs dimensions 7see figure '8. 2or this purpose place the gland into
the stuffing. box and measure the clearance on the inside. diameter 7with the shaft .
7sleeve88 as well as on the outside. diameter 7with the stuffing. box8. These clearances
should 7diametrical8 not be more than +,( mm respective +,? mm, to prevent that the
gland will be able to contact the shaft or shaftsleeve.
5hec the clearance between the bottom of the shaft 7slee ve8 and the stuf fing. box 7see
figure 48. In case this clearan ce should be larger than ?,< mm 7radial8 than mount a
necring with the proper dimensi ons. %hen using such a ring itCs not possible that
pacing. rings are pressed between shaft7sleeve8 and stuffing. box, what would cause
dama ge to the rings.
-
.e!ardin! allo#able da+a!es and/or #ear to shaft$sleeve% and/or stuffin!&bo' it is not eas* to appl* "on"rete
+a'i+. 0u+ps that are applied for 1ire 1i!htin! 2ut* !enerall* #ill operate onl* little3 therefore,
da+a!es/#ear that effe"t pu+p&effi"ien"* and perfor+an"e of the pu+p onl* li+ited "an be
allo#ed for e"ono+i" reasons. 4o#ever, #ear and/or da+a!es that +i!ht effe"t pu+p&reliabilit* in #hatever
#a* should not be allo#ed. 5ear and/or da+a!es that "ould "ause to drop the pu+p&"apa"it* belo# the
required "apa"it* should also not be allo#ed.
F&gure 3
F&gure 4
7 !")#) 3 New 5ac(&ng. r&ngs :
+?./.1.+ $nly apply original pacing. rings of the proper material and manufacture.
+?./.1./ )acing usually is delivered in pre. formed rings of the
proper si6es or in one spiral. formed length.
In case pacing is not delivered in one of the forms mentio ned above, but in one length
7non. spiral formed8 it is neces sary to cut off the proper length that is needed for one
ring. In these cases proceed as follows :
I %ind the pacing. length tightl y around a shaft with the same diameter as the
shaft7slee ve8 is 7see figure (8 .
I &raw two lines on the pacing. CspiralC parallel to each other in axial direction with a
space that is equal to the pacing. width 7or pacing. height, as the pacing. width is
generall y equal to the pacing. height8.
"ow cut rings out of the spiral
9
, between the two parallel lines in
an angle of '4, in the
hori6ontal plane, with the axial direction 7see figure 98.
I )acing. rings made out of a stiff material should be cut in 7see figure <8 , over about
/B1 of the pacing. height, on the inside. diameter on one or more spots so that the rings
can be bent open somewhat when mounti ng onto the shaft7sleeve8.
I 5hec whether all pacing. rings are the proper dimensions, before mounti ng them
into the stuffing. box.
6
7his should also be done in "ase the pa"in! is delivered in one spiral&for+ed len!th.
F&gure 0
F&gure 4
F&gure
F&gure /
7 !")#) 4 M+unt&ng t1e new 5ac(&ng. r&ngs :
+?./.'.+ >efore mounting the new pacing. rings first chec whether stuffing. box and
shaft7sleeve8 are clean H also chec whe ther the old pacing. rings are completel y remo .
ved. Also chec that the pump. shaft can rotate freely.
+?./.'./ Always place only one pacing. ring at a time and mount each pacing. ring about +/?
rotated with respect to the previousl y mounted ring.
After the mounti ng of each ring, always chec whether the shaft can still rotate freely.
+?./.'.1 &o not forget to replace the lantern. ring 7if equip ped8 D
>efore replacing the lantern. ring chec the ring for
cleanli ness and damage.
Mae sure the lantern. ring is mounted so that the ring will be placed straight under the
lantern. ring water. supply con nections 7see figure =8, after the gland. nuts have been
tightened again .
+?./.'.' After having placed the lantern. ring, the rest of the pacing. rings can be placed.
)lacing these rings should be done in accordance with the directions given in the
maintenance.
+?./.'.4 After having placed the last pacing. ring, the gland has to be mounted again. %1en
re5lac&ng t1e gland= t1e gland. nuts s1+uld eEuall; *e t&g1tened unt&l t1e; are
1and. t&g1t t+ l++se ) 5hec again that the shaft can still be rotated freely.
+?./.'.( After having checed and approved that the shaft can be rotated freely, the gland. nuts
should be equall y and firml y tightened.
7 !")#) 0 -d'ust&ng H runn&ng &n +f t1e 5ac(&ng :
+?./.4.+ Gntighten the gland. nuts until they are 1and. t&g1t t+ l++se again.
+?./.4./ 0tart the pump.
NOTE : NEIER COMP8ETE8B 8OOSEN THE G8-N$. NUTS %HEN THE PUMP IS RUNNING G
+?./.4.1 After having started the pump 7almost8 immediatel y a leaage should occur between
pacing. rings and shaft7sleeve8
<
. In case no leaage should occur read and apply the
maintenan ce.
+?./.4.' 8ea(age d+es +ccur : If leaage does occur between pacing and shaft7sleeve8, the
pacing. rings have been mounted properl y H the pacing should now be ad#usted.
%hen ad#usting, proceed as follows :
a8 -eaage should ideally be about '? to (? drops per minute. ,enerally, the leaage with
8
No leaa!e +a* o""ur bet#een pa"in! and stuffin!&bo' 9
F&gure C
the gland. nuts hand. tight to loose will be 7much8 more than the mentioned '? . (?
drops B minute. In these cases the gland has to be ad#usted.
b8 >efore the gland may be ad#usted the pump should first have operated about +?
minutes with a constant leaage, so that leaage will be able to stabilise itself and
therefore can be esti mated more correctl y.
c8 After having let the pump operate for about +? minutes the gland. nuts can be
tightened. The gland. nuts should never be tightened more than +B+( turn at a time.
After each time the gland. nuts have been ad#usted the pump should be operated for
about +? minutes again before further ad#ustment may be performed.
d8 Aepeat the steps mentioned under point c8 until leaage has stabilised to the mentioned '? .
(? dropsBminute.
e8
+?./.4.4 N+ lea(age
C
+ccurs : If no leaage 7or a leaage on the wrong place8 should occur the
pacing is liely to become overheated rapidly. Therefore, if leaage does not occur
7almost8 immediatel y, stop the pump and let it cool down.
5hec whether the gland. nuts are still hand. tight to loose.
a8 T1e nuts are st&ll 1and. t&g1t t+ l++se :
If the nuts are still hand. tight to loose, after having stopped, tighten the nuts slightl y
7about + complete turn8.
b8 T1e nuts are n+t 1and. t&g1t t+ l++se an;9+re :
If the nuts are not placed hand. tight to loose anymore the pacing will most liely have
been tightened to much when the gland was mounted, this has probabl y caused an
expansion of the pacing during pump. test operation. Therefore undo the nuts slightl y
until they are hand. tight to loose again.
After having executed one of these procedures a8 or b8, the pump can be started again.
After starting leaage should occur 7almost8 immediatel y. If still no leaage occurs, or a
leaage on the wrong place occurs, then immediatel y stop the pump again.
-et the pump cool down again and disassemble the gland and pacing. rings again.
-ocate and correct the cause of the failure.
:
Or leaa!e at the #ron! pla"e.
7 !! ?$IS@ -SSEMD8ING THE PUMP :7 !!
?$IS@ -SSEMD8ING THE PUMP :7 !!
?$IS@ -SSEMD8ING THE PUMP :
7 !!) ! General :7 !!) ! General :7 !!) ! General :
2or some checs that are to be performed during the maintenan ce programme as well as for
possible repairs it will be necessary to disas semble the pump 7partiall y8. &isassembli ng, and re.
assembli ng, the pump should be performed carefully in order to prevent damage due to an
incorrect 7dis8. assembling process. Therefore, disassembli ng and re.assembling of the pump are
discussed in detail further in this paragraph. Aead these directi ons carefull y before you start
disassembling the pumpD
NOTES :
. As already mentioned, "i#huis 2ire protectionCs written permission should be obtained,
in case the pump should be disassembled within the duration of the guarantee. peri od.
If the pump is disassembled within this period without "i# huis fire protecti onCs
permission, the guarantee may be invalidatedD
. $nly use original spare parts of the proper manu facture. 2or questions concerning
spare parts as well as general infor mation regar ding the pump, always quote pump ty .
pe and serial. number with all your enquiries. This will help us to deal with them
efficientl y.
7 !!) # $&sasse9*l& ng t1e 5u95 :7 !!) # $&sasse9*l&ng t1e
5u95 :7 !!) # $&sasse9*l& ng t1e 5u95 :
This paragraph is to be read in con#unction with
figures + to 4.
2igure +
F&gure ! :
Aemove the gland. nuts 7A8 and with draw the gland 7>8 as far as possi ble. Aemove the dowels 758
and nuts 7&8 from the cap 7,8, and turn the forcing screws 738 until the cap gets loose from the
pump housing 7E8. "ow remove cap 7,8 from the pump housing 7E8.
F&gure # :
Aemove bearing. housing bolts 7I8 from both the bearing. hou sings. After having accomplished this,
the complete pump. shaft 7Q8 inclu ding the wear rings 7R8 can be removed from the pum phou sing.
F&gure 3 :
Aemove the bolts 7-8 and bearing. covers 7M8 and 7$8. Aemove bearing. nut 7)8 and loc. washer
7!8. Mae sure the l ocwasher. lip is pressed bac before removi ng the bearing. nutD "ow remove
bearing. housings 7A8.
Technical data ball bearings:
mae: 0Q2 (/+( 7 driven end . non driven end 8
F&gure #
F&gure 3
F&gure 4 :
The wear rings 7R8 can now be remo ved from the impeller. -oosen the ad#us ting screws 708 and
thereaf ter remo ve shoulder. ring 7T8, thrower 7G8, spacer 7J8, gland 7>8, pac ing. rings 7%8, lantern.
ring 7V8 and impel lerey 7&&8.
F&gure 0 :
Aemove shaft sleeves 7AA8 and 7>>8. These shaftslee ves should al ways be loosened in the same
direc tions as the pumpC s direc ti on of rotation. 2or remo ving the shaftsleeves use always the pro .
per tools 7shaft sleeves. spanner8 on the right place. "ow remove impeller 7558 and impel lerey
7&&8.
7 !!) 3 -fter d&sasse9*l& ng :7 !!) 3 -fter d&sasse9*l& ng :7
F&gure 4
F&gure 0
!!) 3 -fter d&sasse9*l&ng :
. After having disassembled the pump 7partiall y8, all parts that are liely to be damaged
7due to weather as well as to mechanical causes8 should be protected in order to
prevent this. If the pump, or parts of it, are to be stored : pro ceed in accordance with
the directions mentioned in * /, in the pre. instal lation part of this manual.
. 5lean the bearings with white spirit or erosene and dry them with dry, compressed air.
Inspected the bearings for wear, frac ture, corrosion and other damage. If necessary,
renew them. &$ "$T 0)I" &A@ >3AAI",0 7at high speed during a longer period8 D After
having inspec ted the bearings, they should be greased or oiled immediatel y in order to
prevent corrosion.
. 3xamine the shaftsleeves for damage and wear. If scoring is not heavy, the
shaftsleeves can be reground to provide a new surfa ce. 0haftsleeves can be reduced
up to maxi mum ?,94 mm below the initial diameter for this purpose. If this is not suffi .
cient to elimina te scoring the sleeves should be renewed.
. 5hec pacing. rings, C$C. rings and felt rings for damage and we ar and, if necessary,
renew them.
7 !!) 4 Def+re re. asse9*l& ng :7 !!) 4 Def+re re.
asse9*l&ng :7 !!) 4 Def+re re. asse9*l& ng :
. 5lean the entire pump thoroughl y. 3specially both pumphou sing separati ng flanges to
mae sure all old pacing 7locti te8 and other foreign materials are removed. 5hec
these flanges accuratel y for damage and, if neces sary flatten the flange surfaces.
7 !!) 0 Reasse9*l& ng t1e 5u95 :7 !!) 0 Reasse9*l&ng t1e
5u95 :7 !!) 0 Reasse9*l&ng t1e 5u95 :
This paragraph is to be read in con#unction with
figures ( to +1 .
F&gure 4 :
Mae sure the impeller 7558 is mounted cor rectly so that the impellerCs direction of rotation is in
F&gure 4
accordance with the dri verCs direc ti on of rota tion.
F&gure :
2irst mount ey 7&&8 and impeller 7558 onto the shaft 7Q8. $nce again : atten tion for the direc tion
of rotati on D "ow mount the shaftsleeves 7AA8 and 7>>8. $ne of the shaft sleeves has left. handed
screw. thread, the other right. handed. Therefore mae sure the pro persleeve is mounted on the
propershaft si de. &o not forget to assemble the rubber C$C. rings 7338 onto the shaft. sleeves.
F&gure / :
"ow mount the follo wing parts : "ecbush 7@8, lantern. ring 7V8, gland 7>8 spacer 7J8, thrower 7G8
and shoul der. ring 7T8. &o not forget to tigh ten the ad#us ting scr ews 708. "ow assemble the wear
rings over the impeller 7558.
F&gure
F&gure /
F&gure C :
Mount the bearing. hou sings 7A8 and place new fel trings 7228 when they are worn. Mount the
spacers 7,,8, 7EE8 and 7II8. "ow assemble the bearings 7RR8 and 7QQ8 onto the pump shaft 7Q8 and
loc them with loc. was her 7!8 and bearing. nut 7)8. After the bearings have been pla ced properl y
and the nut is tigh tened far enough, press one of loc washer. lips into the nut so that the nutCs
position will be fixed. %hen moun ting the bearings it is to be recommended to heat the inner. ring
of the bearings to about <? 5 7"$T >@ &IA35T 2IA38. 2ill the bearings for only 4? M with new
grease 7Texaco Multi. purpose / mar fa8. "ow place bearings. covers 7M8 and 7$8.
F&gure !" :
5hec that the stuf fing. box chambers and separa ting flanges 7A8 of upper and under halves are
clean. If these compo nents are clean the complete pumpshaft can be assembled into the
pumpbody. Mae sure that lantern ring water. supply con nections 7>8 are open. Also chec
whether the water. discharge holes that are placed opposite to it are open too.
F&gure C
F&gure !"
F&gure !! :
The casing flanges should be sealed with sealant. %e recommend -octite 0uper fast 491. Apply
the loctite to the pump body 7E8H mae sure it is also applied around the studsD
F&gure !# :
"ow mount cap 7,8 onto the pump body 7E8H eep the lantern rings 7V8 and necbushs 7@8 outside
the pumphousing. Ad#ust the cap 7,8 by the two dowels 758. "ow fasten the cap onto the body by
tighte ning nuts 7&8. The nuts 7&8 should be tighte ned in a sequence as shown in figure +1.
Tighteni ng torqueNs with which the nuts are to be tightened depend on pumpsi6e and materi al
and can be found in table +, appen dix + of this manual.
F&gure !!
2igure +/
Also fasten the bearings. housings 7A8 by the hexagon screws 7I8. "ow it should be possible to
rotate the pumpshaft 7Q8 easily. After having checed and approved the shaftCs ability to rotate
the pacing rings should be inser ted. Inserting the pac ing rings is to be done in accor dance with
the directi ons given in * +?./.
F&gure !3
-PPEN$IJ-PPEN$IJ-PPEN$IJ
7 T&g1ten& ng t+rEueKs :
A. Tighten the ' LcornerL nuts mared LVL .+,/,1 and ' 7see figure +8
>. %or outward along shaft axis toward the sealhouses in opposite quarters tighteni ng nuts in
regions 4, (, 9 and <.
5. %or outward along the branch and in opposite quarters tightening nuts in regions =, +?, ++
and +/.
&. Aepeat the whole sequence.
0crew Tighteni ng torqueNs
2igure +
si6e
5asing Materials
Irons,
>ron6es
0teels,
0tainless steels, Eigh
&uty Irons
lbfBft "m lbfBft "m
M +( (4 << +?? +14
M /? +1? +9< +=4 /(4
M /' //? 1?? 11? '4?
M-JI MUM -$IISE$ TIGHTENI NG TORLUES
FOR ST-N$-R$ METRIC DO8TS -N$ NUTS
-CCOR$ING TO ISO M-TERI-8 GR-$ES)
!uality. (:( <:< =:< +?:= +/:=
Torque. "m "m "m "m
"m
"ominal thread
diameter, mm.
< +( 1? 11 '+ 4?
+? 11 4< (( </ =<
+/ 49 +?/ ++' +'1 +9+
+' =+ +(/ +</ //9 /91
+( +'/ /4/ /<+ 144 '/(
+< +=4 1'9 1=+ '<< 4<(
/? /99 '=/ 44+ (=1 <1?
// 199 (9? 941 ='+ ++1?
/' '9= <4+ =49 ++=( +'1(
/9 9?? +/'4 +'?+ +94? /+??
These torque settings are for general purpose use only. Torque settings may alter depending on the
material used on the nuts and bolts, 3.,. stainless steel, or the machine application. %hen in doubt
please consult "IREGI0 )GM)0.