FILE NO.

: DATE: SUPERSEDES: DATE:

F43.560IN July, 02 2012 New New

INSTALLATION AND OPERATING INSTRUCTIONS

HORIZONTAL SPLIT CASE FIRE PUMPS INSTALLATION AND OPERATING MANUAL

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INSTALLATION AND OPERATING MANUAL HORIZONTAL SPLIT CASE FIRE PUMPS

The Armstrongs innovative Series 4600 HSC pump is designed to allow easy maintenance. The pumps same level suction and discharge permits easy-piping layout and pump installation. Design features, such as bearing removal with no special tools, will make the reliable HSC pump a trouble-free pump for many years. Armstrong series 4600 HSC pumps are thoroughly tested and inspected before shipment, but should be carefully examined for possible damage during transit. Contact your Armstrong Darling representative and the Transport Company immediately if there is any evidence of mishandling.

INSTALLATION
1. LOCATION AND STORAGE
Locate the unit in a dry place as near the city water entrance as practical with a short, direct suction pipe Shaft should be rotated by hand 10 to 15 revolutions every one to three months depending on storage conditions

2. FOUNDATION FOR HSC PUMP

Foundation should be sufficiently substantial to absorb any vibration and to form a permanent, rigid support for the base plate Foundation bolts of suitable size should be embedded in the concrete located by a drawing or template Place pumping unit on foundation with wedges under base plate leaving approximately 3/4 space for grouting Carefully level the unit by adjusting the wedges until shafts of pump and driver are leveled, recreating factory alignment Check coupling faces as well as suction and discharge flanges of pump for horizontal or vertical position with a level Slight misalignment at this point may be corrected by adjusting the wedges

After unit has been in operation for about a week, check alignment. Any misalignment may be corrected by placing shims between base and driver or pump feet

Install foundation bolts Install grout forms Fill in base with grouting

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3. PUMP MOUNTING AND PIPING

Never connect a pump to piping, always start piping from pump Use as few bends as possible and preferably long radius piping Install good supports under suction and discharge piping with anchors near but independent of the pump Make sure piping exerts no strain on pump as this would throw the unit out of alignment or distort the casing Increase the size of both suction and discharge pipes at pump nozzle to suit pump capacity and particular conditions of installation Use eccentric reducers on suction

Lay out the suction line with a continual rise towards the pump without high points, thus eliminating possibility of air pockets Test suction line for air leaks before starting; this becomes essential with long suction line or high static lift Install, at pump suction, a straight pipe of a length equivalent to 4 or 6 times its diameter Install gate valve close to pump in both suction and discharge lines on flooded suction application; this is used mainly to isolate the pump for inspection or repair Install a check valve in discharge line between pump and gate valve

CAUTION: Discharge valve only must be used to reduce the flow or shutoff the pump

PRESSURE SENSING LINE CONNECTION FOR FIRE PUMP CONTROLLERS

Ref.: NFPA Pamphlet 20, Fig. A-7-5.2.1

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4. ALIGNMENT
The flexible coupling compensates for temperature changes and permits shafts end movement without interference; it will not compensate for misalignment. Faulty alignment will result in noisy pump operation, reduced bearing life, excessive coupling wear. Carefully verify the alignment after the foundation bolts have been properly tightened Alignment should be again verified after piping is installed and unit has operated under normal conditions at operating temperature To verify alignment, place a straight edge across the coupling as shown; this must rest evenly on both rims at top, bottom and both sides With a pair of inside calipers or thickness gauge, check distance between coupling halves at points where straight edge was used; distance must be equal at all points

CIRCULATION RELIEF VALVE (not supplied with diesel driven pumps) Install Circulation Relief Valve at the casing discharge (always before the check valve) Set pressure at the minimum suction pressure plus the pump rated pressure raised to the next higher 5 lb. increment Circulation relief valve and stuffing box should then be piped to drain

AUTOMATIC AIR RELEASE VALVE Install automatic air release valve on top of pump casing to vent casing and suction piping of air and vapor before start-up. SUCTION AND DISCHARGE GAUGES The following gauges are required to measure both suction and discharge pressures, and must be supplied with all fire pumps to ensure close check on pump performance: a. 3 " dial combination pressure and vacuum suction gauge b. 3 " dial discharge pressure gauge c. cocks with lever handle

5. MINIMUM FITTINGS
If minimum fittings recommended by N.F.P.A. 20 are supplied loose, they should be installed as follows:

TESTING ALIGNMENT

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TYPICAL FIRE PUMP & CONTROLLER ARRANGEMENT

HORIZONTAL SPLIT CASE - ELECTRIC DRIVEN

TYPICAL FIRE PUMP & CONTROLLER ARRANGEMENT

HORIZONTAL SPLIT CASE - DIESEL DRIVEN

NOTE: ALL VALVES SHALL BE LISTED FOR FIRE APPLICATION These drawings are a suggested arrangement and are issued for information purposes only.

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OPERATION-ELECTRIC DRIVEN
Set pressure switches to the following setting values: Fire Pump Stop Point (FSP) FSP Jockey Pump Stop Point (JSP) JSP Jockey Pump Start Point (JSTRT) JSTRT Fire Pump Start Point (FSTRT) FSTRT = = = = Fire Pump Shut Off Pressure + MIN. Static Suction Pressure FSP JSP - 10 PSI JSTRT - 5 PSI

1. PRESTART-UP
Fill out PRESTART-UP CHECK LIST

Allow Jockey Pump to stop automatically at pressure switch setting

2. PRESSURE SWITCH SETTING

The pressure switch to start the fire pump is normally located in the lower left-hand side of fire pump controller. Similarly the pressure switch to start the Jockey pump is located in the Jockey pump controller. Make sure that pump shutoff + MAX. suction pressure does not exceed system rated pressure or its components. If it does, a main relief valve should be installed at the pump discharge.

START-UP PROCEDURE - (FLOW TEST PROCEDURE IF REQUIRED BY AUTHORITIES)

Close system butterfly valve. Open gate valve to hose outside header for flow test or flow meter discharge valve Press start button to start pump Adjust flow by the quantity of hose valves opened or with pump discharge valve if using flow meter Take gauge and ammeter readings at 150% of rated flow, shutoff and other intermediate flows When test is finished, close gate valve REMINDER Leave the disconnect switch ON and the circuit breaker ON (The Power On light must be lit) Bring timer setting back to required value one) minute for each 10HP, maximum 10 minutes

3. CIRCULATION RELIEF VALVE

The circulation relief valve should be set in the field at pressure to the lowest suction pressure, plus the rated pressure of the unit raised to the next higher 5 lbs increment.

4. START-UP PROCEDURE - (PUMP SEQUENCE)

CAUTION: In case of electrical control circuit problem use the emergency disconnect lever to bypass control circuits

DIESEL ENGINE DRIVEN

Open suction gate valves Check that pump is full of water and that all air contained in pump has been allowed to escape through the air release valve Compress packing evenly with gland (Gland nut should be finger tight) Close the Main Relief Valve using the maximum spring pressure Bring the timer setting down to one minute for automatic start test purpose Start engine manually on either battery Adjust Main Relief Valve (MRV) spring to allow valve to fully open Stop engine and open system butterfly valve Bleed the system by opening a valve on the pressure sensing line to create a pressure drop As soon as fire pump starts check engine speed and adjust to pump rated speed with throttle Check packing adjustment to obtain slight leak of approximately 1 drops per second After running for one minute (time set on the running period timer), stop pump with stop button. If you try stopping it before the time set on the timer, the pump will not stop Bleed again until desired start-up pressure is attained Allow Jockey Pump to run to stop pressure setting

ELECTRIC DRIVEN
Open suction gate valves Check that pump is full of water and that all air contained in pump has been allowed to escape through the air release valve Compress packing evenly with gland (Gland nut should be finger tight) Lower setting of pressure switch (senses discharge pressure) to prevent pump from starting Place the main disconnect switch in the ON position Place circuitry breaker in the ON position and check if POWER ON light is illuminated Check direction of driver rotation by pressing momentarily the Start and then Stop push buttons on the controller (proper direction is indicated by arrow on pump casing); for in-line pump use a light on shaft to see rotation (this is clockwise looking down from top of motor). If rotation is wrong interchange motor leads in panel per instructions in panel Bring the timer setting down to one (1) minute for automatic start test purpose Open system butterfly valve Bleed the system by opening a valve on the pressure sensing line to create a pressure drop As soon as fire pump starts check if full load current value is within the electric motor nameplate rating with service factor taken into account Check packing adjustment to obtain slight leak of approximately 1 drop per second After running for one minute (time set on the running period timer), stop pump with stop button. If you try stopping it before the time set on the timer, the pump will not stop Bleed again until desired start-up pressure is attained

START-UP PROCEDURE - (FLOW TEST PROCEDURE IF REQUIRED BY AUTHORITIES)

Close system butterfly valve. Open gate valve to hose outside header for flow test or flow meter discharge valve Press start button to start pump Adjust flow by the quantity of hose valves opened or with pump discharge valve if using flow meter

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Take gauge and ammeter readings at 150% of rated flow, shutoff and other intermediate flows When test is finished, close gate valve

5. AUTOMATIC OPERATION
Open system butterfly valve and turn all the isolating valves to the fully open position Place the main disconnect switch on the ON position Switch fire pump circuit breaker to the ON position Switch the jockey pump to AUTO (the Power On light must be lit)

NOTE
When the operating differential of pressure switches do not permit these settings, the settings should be as close as equipment will permit The settings should be established by pressures observed on test gauges All devices are preset at the factory and should normally require no further adjustment A final adjustment may be made on any control to match the exact system requirements

When removing old packing, make sure bottom rings are completely removed Clean thoroughly the stuffing box and check condition of shaft sleeve (A badly worn or corroded shaft sleeve will never seal properly) Cut packing into lengths allowing 1/8 between ends when installed Place first ring around shaft and press firmly and evenly into stuffing box Continue in the same manner staggering ring joints one quarter of a turn until stuffing box is filled Make certain lantern ring is in correct position under pipe connection STUFFING BOX ASSEMBLY Install back stuffing box extension Install flush line connection on stuffing box extension Install gland plate and compress evenly leaving it finger tight Compress packing evenly with gland and leave gland nut finger tight With pump running adjust gland with recommended leakage rate CAUTION: Packing should not be pressed too tight, as this may result in burning the packing and scoring the shaft sleeve.

AFTER START-UP, MAKE SURE ... To open system butterfly valve To bring minimum run timer back to 30 minutes Valve on pump suction must be fully open as throttling on suction side is harmful to the pump Pump will not run dry. Most centrifugal pumps have close clearances and cannot run dry without serious damage resulting

PUMP DISASSEMBLY
WARNING!! Whenever any disassembly work is to be done on pump, disconnect power source to driver to eliminate any possibility of starting unit TO REMOVE ROTATING ASSEMBLY
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Remove coupling guard and disconnect coupling halves Disconnect flush line from upper half casing Remove bolting from bearing covers and jack the (2) screws to help remove bearing covers Remove bearing locknut on opposite side of motor Remove bearing by holding shaft in place and turning nut behind bearing; bearing with slide out Remove gland plate and split gland Remove stuffing box extension Remove packing, lantern ring and bushing Remove top casing bolting Screw (2) jack screws down to separate upper and lower case Turn jack screws back after separation to prevent interference at reassembly Lift upper casing straight up until clear of impeller Place slings around shaft near the bearing housings and lift shaft assembly Place shaft assembly in a clean, dry work area for necessary disassembly

MAINTENANCE HSC pumps are built to operate without periodic maintenance. A systematic inspection made at regular intervals, giving special attention to the following, will ensure years of trouble-free operation. 1. GENERAL CARE
Keep unit clean Provide the motor with adequate overload protection Keep flying chips or other loose particles away from the ventilating openings of the motor Avoid operating the unit in overheated surroundings SEALED GREASED FOR LIFE BEARINGS are fitted on your pump. No particular attention is required No need for greasing since the bearings are greased for the entire bearing life If abnormal noises come from the bearing during normal operation, replace bearings

2. BEARINGS

3. STUFFING BOX WITH PACKING

STUFFING BOX DISMANTLING Adjust pressure of packing gland to obtain a slight leak of 6 to 8 drops per minute for suction pressures up to 20 PSIG (The increase in suction pressure causes proportional increase in leakage through the stuffing box) Remove flush line connection from stuffing box extension Remove gland plate from stuffing box Remove stuffing box extension PACKING REPLACEMENT

DISASSEMBLY OF ROTATING ELEMENT

Remove pump half coupling Unscrew sleeve on right side of the pump when facing suction flange 3. Slide impeller on shaft and remove NOTE DIRECTION OF VANES, IMPELLER MUST BE INSTALLED IN SAME DIRECTION 4. Remove impeller key 5. Unscrew other sleeve 1. 2.

REMOVAL OF IMPELLER RING

It is not necessary to remove impeller from shaft to replace impeller rings 1. Remove rotating element 2. Remove locking set screws from rings

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3. 4.

Rings may now be pulled from impeller, cut off with a chisel, or turned off if a suitable lathe is available using original shaft centers - DO NOT CUT INTO BODY OF IMPELLER When new rings are installed, drill and tap new holes for locking set screws - do not attempt to use old half holes in impeller hub

ASSEMBLY IS THE REVERSE OF THE DISASSEMBLY PROCEDURE

1. 2. 3. 1. 2. 3. 4. 5. 6. 7. All parts, inside and out, should be clean since dirt and grit will cause excessive wear, plus needless shutdown Reinstall sleeve in correct position - 8 1/2 from bearing face to sleeve face (see drawing PUMP ASSEMBLY) Reinstall impeller with vanes in right direction - Impeller vanes slope must be opposite to pump rotation Do not lock sleeve shaft with impeller key until impeller has been positioned in center of volute; this may be accomplished by moving sleeve Make certain that casing rings are in proper position; the half raised ring should be on the outside and completely in the lower half casing and ensure ring is fully seated Install casing gasket and do not cut overlap before casing cover is in place and bolted Install upper half, cut gasket on each side of the stuffing box and bore after all cap screws are tightened Install stuffing box bracket and packing afterwards. Insure that packing does not block seal water inlet Install packing flush line Reinstall bearings and bearing covers

INSPECTION
Visually inspect parts for damage affecting serviceability Check O rings and gaskets for cracks, nicks or tears Check packing rings for excessive compression, fraying or shredding and embedded particles 4. Replace if defective in any way 5. Mount shaft between the lathe centers to check eccentricity throughout the entire length, runoff should not exceed .002 in. 6. Bearing surface should be smooth and shoulders square and free of nicks 7. Measure OD of impeller hub or impeller wear rings and ID of casing wear ring 8. Compute diametrical clearance (ID minus OD) and compare with original (.0075 to .0085) radial clearance 9. Surfaces must be smooth and concentric 10. Examine impeller passages for cracks, dents or embedded material 11. Examine shaft sleeves for wear 1. 2. 3.

Pump rotation is defined viewed from the drivers end

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TROUBLE SHOOTING CAUSES

PUMP WILL NOT START
Faulty electrical circuit Make sure both circuit breaker and disconnect switch are in the ON position If the circuit breaker trips when the pump tries to start check horsepower and voltage specified on the schematic and wiring diagram inside the starter door with the pump motor nameplate Ensure that the pressure switch is working properly and is responding to changes in pressure Loosen gland swing bolts and remove stuffing box gland halves; replace packing Remove obstruction Remove bearings and clean, lubricate, or replace as necessary

REMEDY

Stuffing box too tight or packing improperly installed Impeller locked Excess bearing friction due to wear and dirt

PUMP IS NOISY OR VIBRATES

Stuffing box too tight or packing improperly installed Impeller obstructed Excess bearing friction due to wear and dirt Foundation not rigid Loosen gland swing bolts and remove stuffing box gland halves; replace packing Pressures fall off rapidly when an attempt is made to draw a large amount of water, remove obstruction from impeller Remove bearings and clean, lubricate, or replace as necessary Tighten foundation bolts or replace foundation if necessary

NO WATER DISCHARGE
Air pocket or air leakage in suction line Suction connection obstructed Impeller obstructed Pump not primed Uncover suction pipe and locate and re-arrange Examine suction intake, screen, and suction pipe and remove obstruction Pressures fall off rapidly when an attempt is made to draw a large amount of water, remove obstruction from impeller First warning is a change in pitch of the sound of the driver; shut down the pump

DISCHARGE PRESSURE TOO LOW

Air leakage in suction line Suction connection obstructed Stuffing box too tight or packing improperly installed Water seal or pipe to seal obstructed or air leak into pump through stuffing boxes Uncover suction pipe and locate and re-arrange Examine suction intake, screen, and suction pipe and remove obstruction Loosen gland swing bolts and remove stuffing box gland halves; replace packing Loosen gland swing bolt and remove stuffing box gland halves along with the water-seal ring and packing. Clean the water passage to and in the water seal-ring. Replace water sealring, packing gland and packing in accordance with manufacturers instructions Pressures fall off rapidly when an attempt is made to draw a large amount of water, remove obstruction from impeller Check that rated motor speed corresponds to rated speed of pump, voltage is correct, and starting equipment is operating properly With polyphase electric motor drive two wires must be reversed; where two sources of electrical current are available, the direction of rotation produced by each should be checked Obtain motor of correct rated voltage or larger size motor

Impeller obstructed Speed too low Wrong direction of rotation

Rated motor voltage different from line voltage i.e., 220 or 440 volt motor on 208 or 416 volt line

PUMP WILL NOT STOP

* Faulty electrical circuit Is the pressure switch inside the starter properly piped up to the water system? (system side) Is the stop valve in the piping to the pressure switch open? Check that pressure switch is working properly by disconnecting one of the pressure switch leads to simulate open contact position Ensure that pressure switch connection lines have been flushed to clear dirt in piping Make sure that pressure switch set point is correct according to suction and working pressure Change manual start handle to automatic Remove jumper if applicable Verify pressure switch setting compared to system pressure

Run period timer defective Pressure too low

* Note: Refer to control panel manufactures installation instructions for other controller related problems.

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WARRANTY
Armstrong Darling pumps are guaranteed against defective workmanship and material for a period of twelve months from date of shipment. Should the Armstrong Darling pump fail within the warranty period, our responsibility is limited to the repair or replacement of defective parts provided such are returned to our Plant, transportation prepaid. We do not accept liability for damage or break-down from causes beyond our control, or the result of reasonable wear nor for repair made, or date attempted to be made without prior sanction, nor for any consequential damage resulting from the failure of a pump. The customer will assume all labor charges incurred in our making the replacement of adjustment of the part.

SERIES 4600 HORIZONTAL SPLIT CASE

FOR 1" SHAFT CONSTRUCTION

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SERIES 4600F HORIZONTAL SPLIT CASE PUMP PARTS LIST

No. PART LIST 1 2* 3 4* 5 6 7 8* CASING - LOWER STUFFING BOX BUSHING LANTERN RING PACKING GLAND NUT GLAND STUDBOLT RETAINER BEARING SHAFT MATERIAL CAST IRON BRONZE TEFLON GRAPHITE STAINLESS STEEL STAINLESS STEEL STAINLESS STEEL CARBON STEEL NSK CAST IRON BRONZE CARBON STEEL STAINLESS STEEL BRONZE BRONZE BRONZE CAST IRON BUNA N 80 DURO CAST IRON CARBON STEEL BRONZE BRONZE CAST IRON BRASS BRASS STAINLESS STEEL BRASS CAST IRON NEOPRENE CARBON STEEL CARBON STEEL NSK CARBON STEEL CAST IRON CARBON STEEL BRONZE STAINLESS STEEL CAST IRON STAINLESS STEEL VELOTHERM 4 4 2 1 1 1 2 6 2 2 2 2 2 2 1 1 2 1 1 2 2 4 2 1 2 1 1 1 4 2 16 2 2 1 1 1 QTY 1 2 2

10* INBOARD BEARING 11 INBOARD BEARING HOUSING 12* BEARING REMOVAL NUT 13 BEARING HOUSING CAP SCREW 14* SHAFT SLEEVE PACKING 15 SPLIT RING 16 PACKING GLAND 17 STUFFING BOX EXTENSION 18 STUFFING BOX 19* STUFFING BOX "O" RING 20 CASING - UPPER 21* IMPELLER KEY 22* CASING RING 23* IMPELLER 24* PLUG 25 NEEDLE VALVE 26 SEAL PIPING 27 SET SCREW 29 TUBE CONNECTOR 34 OUTBOARD BEARING HOUSING 35* DEFLECTOR 37 BEARING LOCK NUT 38 BEARING LOCK WASHER 39* OUTBOARD BEARING 40 CAP SCREW 46 CONNECTION TO DRAIN 47 CAP SCREW 49* IMPELLER RING (OPTIONAL) 50 LOCKING PIN 51 PIPE PLUG 52 BEARING COLLAR *CASING GASKET (NOT SHOWN) * RECOMMENDED SPARES

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PRE START-UP / POST START-UP CHECK LIST

CENTRIFUGAL PUMPS
START-UP DATE:
PUMP SIZE MIN. SUCT.PRESS.

ORDER No.:
FLOW HEAD

SERIAL No.:
VOLT________ PHASE _____ Hz_____

CHECK THE FOLLOWING AT PRESTART-UP 1. STORAGE

Verify equipment for improper storage or mishandling.

OK

REMARKS / CORRECTIVE ACTIONS

2. INSTALLATION
Compare electrical supply to one indicated on motor nameplate. Compare current rating of overload relays and fuses in controller against full load current value on motor nameplate.

3. ALIGNMENT
Verify the alignment of driver to pump. (Horizontal Pumps Only) Verify suction and discharge for pipe strain. Do the flanges meet squarely? Indicate alignment reading

___________________

4. ROTATION
Manually turn coupling to assure free rotation of pump and motor.

5. SYSTEM
Insure system is free of foreign matter which could damage the pump. Responsible parties present when equipment is energized.

6. DIESEL DRIVEN FIRE PUMP ONLY

Engine coolant filled to the proper level? Engine oil filled to proper level? Fuel line from the tank connected to engine (supply and return)? Fuel tank filled with proper diesel fuel? Silencer properly connected to engine and outside? Engine controller wiring connected to engine junction box? Is engine jacket water heater connected to AC power? Batteries charged (MIN.24 HRS PRIOR TO START-UP) and connected to engine?

CHECK THE FOLLOWING AT POST START-UP 6. VIBRATION

Upon the occurrence of excessive vibration or noise, was equipment immediately shut down?

OK

REMARKS / CORRECTIVE ACTIONS

7. FLOW
Has flow been established? Take gauge and amperage readings (if motor driven) ? Packing been adjusted to a slight leakage? If pumps are equipped with mechanical seals, has the establishment of a clear source of water to lubricate the seals been made? Is the lubricating seal water pressure a constant 10 to 15 PSI above the discharge of the pump?

8. READINGS
Flow, pressure and amperage readings taken immediately after correction of all problems and restart.

CUSTOMERS REPRESENTATIVE(S) WITNESSING TESTS: WITNESS _________________________________________ DATE: ____________________________________________

ARMSTRONG PUMP DIV., REPRESENTATIVE CONDUCTING TESTS: WITNESS ____________________________________________ DATE: _______________________________________________

S. A. Armstrong Limited 23 Bertrand Avenue Toronto, Ontario Canada, M1L 2P3 T: 416 755 2291 F: 416 759 9101

Armstrong Integrated Limited Wenlock Way Manchester United Kingdom, M12 5JL T: +44 (0) 8444 145 145 F: +44 (0) 8444 145 146

Armstrong Design Private Limited

(Unit 1- Armstrong Manufacturing Center)

490-L, 4th Phase, Peenya Industrial Area, Bangalore, India 560 058 T: +91 (80) 4906 3555 F: +91 (80) 2334 3535

S.A. Armstrong Limited 2011

For Armstrong locations worldwide, please Page 12 of 12 visit www.armstrongintegrated.com