INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS FOR MODEL 442 HORIZONTAL SPLIT CASE & MODEL 492 SPLIT CASE FIRE PUMP
TABLE OF CONTENTS TOPIC PUMP IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STORAGE OF PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAUTION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP IDENTIFICATION PAGE 1 PUMP IDENTIFICATION Congratulations! You are the owner of one of the finest pumps commercially available. If you give it the proper care as outlined and recommended by this manual, it will provide you with reliable service and long life. 442 & 492 SPLIT CASE PUMPS Your Aurora Model 442 & 492 is a Split Case Pump, meaning the casing is split along the horizontal centerline.
PAGE 2 STORAGE OF PUMPS AND CAUTION NOTES THESE INSTRUCTIONS APPLY TO THE PUMP ONLY. THEY ARE INTENDED TO BE GENERAL AND NOT SPECIFIC. IF YOUR OPERATING CONDITIONS EVER CHANGE, ALWAYS REFER TO THE FACTORY FOR REAPPLICATION. ALWAYS REFER TO THE MANUALS PROVIDED BY MANUFACTURERS OF THE OTHER EQUIPMENT FOR THEIR SEPARATE INSTRUCTIONS.
INTRODUCTION AND INSTALLATION PAGE 3 INTRODUCTION This manual contains information that is the result of carefully conducted engineering and research efforts. It is designed to supply adequate instructions for the safe and efficient installation, operation maintenance of your pump. Failure or neglect to properly install, operate or maintain your pump may result in personal injury, property damage or unnecessary damage to the pump.
PAGE 4 3. INSTALLATION (continued) MINIMUM SUBMERGENCE OF SUCTION PIPE AND PIT DESIGN For installations where the pump draws fluid from a sump, the hydraulic characteristics of the pump, the suction inlet submergence and NPSH must be considered. Generally, it is required that an evenly distributed flow of non-aerated water be supplied to the suction bell.
INSTALLATION (continued) 7. PAGE 5 GROUTING When the alignment is correct, the unit should be grouted using high-grade non-shrinking grout. The entire base should be filled with grout. Be sure to fill all gaps and voids. Allow the grout to fully cure before firmly tightening the foundation bolts. Then recheck the alignment before connecting the piping. 8.
INSTALLATION (continued) PAGE 6 FIGURE 3 COUPLING ALIGNMENT FINAL COUPLING ALIGNMENT (continued) B. Check the angular alignment with a micrometer or caliper. Measure from the outside of one flange to the outside of the other at intervals around the periphery of the coupling. Determine the maximum and minimum dimensions. DO NOT ROTATE THE COUPLING. The difference between the maximum and minimum dimensions should not exceed manufacturer’s recommendations.
INSTALLATION continued) PAGE 7 13. MECHANICAL SEALS CAUTION: DRY OPERATION OF THE PUMP MAY CAUSE DAMAGE TO THE MECHANICAL SEAL AND IMPELLER. Model 442 pumps can be supplied with optional single face mechanical shaft seals. Mechanical seals are installed and adjusted in the factory and require no further adjustments in the field. For further information, refer to the seal manufacturer’s instructions.
PAGE 8 OPERATION Because variations exist in both the equipment used with these pumps and in the particular installation of the pump and driver, specific operating instructions are not within the scope of this manual. However, there are general rules and practices that apply to all pump installations and operation. CAUTION: BEFORE STARTING OR OPERATING THE PUMP, READ THIS ENTIRE MANUAL, ESPECIALLY THE FOLLOWING INSTRUCTIONS: A. BEFORE STARTING THE PUMP, INSTALL CLOSED GUARDS AROUND THE COUPLING. B.
OPERATION (continued) PAGE 9 3. STARTING THE PUMP A. After the pump is primed, and with the discharge valve closed and the suction valve open, start the driver according to the driver manufacturer’s instructions. Open the discharge valve slowly to prevent water hammer. After the pump has been started, check bearing temperatures, packing box lubrication and operation and pump noise level for a period of several hours. B. C.
MAINTENANCE PAGE 10 1.
MAINTENANCE (continued) PAGE 11 2. INSPECTIONS AND PREVENTIVE MAINTENANCE REQUIREMENTS To assure satisfactory operation of the pump, daily inspections and periodic maintenance are required. We suggest that an inspection and maintenance log be kept and that the inspector immediately report any problems. A guide for preventive maintenance for normal applications is given below. Unusual applications, with abnormal heat, moisture, dust, etc. may require more frequent inspections and service.
MAINTENANCE (continued) PAGE 12 4. PACKING BOX CAUTION: DO NOT TIGHTEN THE GLAND TO STOP ALL LEAKAGE. LEAKAGE IS NECESSARY TO ENSURE THE COOLING, FLUSHING AND LUBRICATION OF THE PACKING AND TO PREVENT SHAFT SLEEVE DAMAGE. The packing boxes on Aurora Pumps are packed at the factory. All packing is subject to wear and should be given regular inspections and, if necessary, periodic adjustments.
MAINTENANCE (continued) PAGE 13 5. PACKING REPLACEMENT (continued) PUMP MODEL (PUMP SIZE) 5-442-18 4-442-10 5-442-10 6-442-15 3-442-10A 4-442-14 8-442-18 10-442-18 8-442-24 6-442-10 6-442-18 4-442-18 8-442-15 PACKING BOX Sleeve O.D. Packing Box I.D. Packing Box Depth PACKING SIZE Qty.
MAINTENANCE (continued) PAGE 14 6. PUMP DISASSEMBLY (continued) E. Remove the capscrews that secure the bearing cartridge covers (159) to the bearing cartridges and remove the cartridges from the rotating assembly. WARNING: CAUTION: TO PREVENT POSSIBLE SERIOUS PERSONAL INJURY, EXTREME CARE SHOULD BE EXERCISED TO SELECT THE PROPER PULLER, AND APPROVED SAFETY GLASSES SHOULD BE WORN.
MAINTENANCE (continued) PAGE 15 7. PUMP ASSEMBLY CAUTION: READ THIS ENTIRE PROCEDURE BEFORE CONTINUING. Following are step-by-step instructions for assembly of the pump and are essentially the reverse order of the instructions for disassembly. A. Thoroughly clean all parts to remove oil, grease and foreign material. Inspect for wear or damage and replace if required. Remove all parts to a clean and dust-free location for assembly.
MAINTENANCE (continued) PAGE 16 7. PUMP ASSEMBLY (continued) CAUTION: THIS PUMP MAY BE SUPPLIED IN SEVERAL DIFFERENT CONFIGURATIONS. EACH USES DIFFERENT BEARING COVERS AND HOUSINGS WITH DIFFERENT DRAWING REFERENCE NUMBERS. DESPITE THE FOLLOWING INSTRUCTIONS, ALWAYS REFER TO THE SECTIONAL DRAWINGS CONTAINED IN THIS MANUAL BEFORE PROCEEDING, TO INSURE THAT YOU HAVE INSTALLED ALL REQUIRED LIP SEALS, O-RINGS, ETC. D.
MAINTENANCE (continued) PAGE 17 7. PUMP ASSEMBLY (continued) CAUTION: BE SURE BEARING HOUSING/CASING MATING SURFACES ARE CLEAN AND FREE FROM BURRS, AS THIS WILL AFFECT THE ALIGNMENT OF THE ROTOR/CASING. L. Attach the bearing cartridges to the lower casing using the appropriate dowel pins (158B). M. Inspect the upper casing (3) to assure that the water passage is clean and free from foreign material.
REPAIR PARTS PAGE 18 ORDERING PARTS There are a variety of options available for this pump. When ordering parts, give the pump serial number, size and figure number and a complete description and item number of each part. Refer to the drawings and parts list in the back of this manual. You should order parts from your local Aurora Pump distributor. Consult your local telephone yellow pages for the office nearest you.
NOTES PAGE 19
PAGE 20 NOTES
NOTES PAGE 21
PAGE 22 SECTIONAL DRAWING Figure 6 STANDARD CONSTRUCTION
SECTIONAL DRAWINGS PAGE 23 Figure 7 REF. NO. 1 2 3 4 6 10 14 B14 16 17 17A 19 B31 95 102 DESCRIPTION IMPELLER CASING, LOWER HALF CASING, UPPER HALF SHAFT BEARING HOUSING LANTERN RING SHAFT SLEEVE SHAFT SLEEVE- KEY DRIVEN WEARING RING, CASING WEARING RING, IMPELLER SETSCREW PACKING GLAND, SPLIT GLAND, MECHANICAL SEAL STUFFING BOX BUSHING KEY, IMPELLER REF. NO. 118 126 157 158A A158 B158 161 162 163 168 212 213 272 452 456 DESCRIPTION CLOSURE WATER SLINGER GASKET, CASING GREASE SEAL BEARING CART.
