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Original Issue
REV.
DESCRIPTION
19-FEB-08
KIDDE
RZ
JN
DATE
EXEC.
REV.
APPR.
REVISION:
SCALE
DOCUMENT Nr:
Revision
1155-01-90-T0-8015101-DM1
REPLACE:
A
Page 1 of 4
6. FLEXIBLE CONNECTORS
3.5.4.
3.5.5.
3.5.6.
6. FLEXIBLE CONNECTORS
SECTION 1:
NATIONAL FOAM
AER-O-LITE 3% AFFF
FOAM CONCENTRATE
SKZZ-66025
N a tio n a l F o a m
1.1
1.2
NMS#300
Page 2 of 8
10/01/07
NMS#300
Page 3 of 8
10/01/07
Not applicable
Vapor Pressure:
Not applicable
Vapor Density:
Not applicable
Melting Point:
Not applicable
Evaporation Rate:
Solubility in Water:
100%
NMS#300
Page 4 of 8
10/01/07
pH:
8.0
Specific Gravity:
1.03 @ 25C
Freezing Point:
12F (-11C)
Odor:
Mild, pleasant
Form:
Liquid
Color:
Straw yellow
NMS#300
Page 5 of 8
10/01/07
239,000 mg/kg
BOD5 3% solution
8,750 mg/kg
COD
400,000 mg/kg
Concentrate
NMS#300
Page 6 of 8
10/01/07
NMS#300
Page 7 of 8
10/01/07
WHMIS Rating
Health 0
Flammability 0
Reactivity 0
D2B
ADDITIONAL INFORMATION
Revision Summary
5/3/96 ........... Revised to ANSI format.
10/2/96 ......... Updated Section 12 - Environmental Fate.
2/5/99 ........... Added MSDS number, updated Sections 1,3,4,6,7,9,11,12,13,15.
08/10/00 ....... Revised Section 1 and 2.
09/10/03 ....... Updated Sections 2, 5, 9, 14, 15, 16.
05/03/05 ....... Updated Section 9.
10/01/07 ....... Updated Address.
For further information, see National Foam Product Data Sheet for Aer-O-Lite 3%.
NMS#300
Page 8 of 8
10/01/07
GFGV.EX1734
Foam Liquid Concentrates
Page Bottom
EX1734
SUITE 3600
180 SHEREE BLVD
PO BOX 695
EXTON, PA 19341 USA
Aer-O-Lite, nominal 3 percent Aqueous Film Forming Foam, +20 F minimum storage and use temperature. Hydrocarbon fuels only.
Foam concentrates for use with the following equipment:
AER-O-LITE, 3 PERCENT
PROPORTIONERS-BALANCED PRESSURE VALVES WITH CONTROLLERS
Controller
Size In.
Description
National, 1-1/2 in. Model 1.5 BPRV
Orifice
Size In.
Flow GPM
0.203
60-225
0.500
106-1564
0.703
106-2968
0.500
106-1564
0.703
106-2968
1.250
850-4209
0.203
60-225
0.500
106-1564
0.703
106-2968
0.500
106-1564
0.703
106-2968
1.250
850-4209
1.3.1
SECTION 2:
4BWC3-A-MOR ILBP
PROPORTIONING MODULE
SKZZ-66025
N a tio n a l F o a m
2.1
2.2
GFGV.EX1734
Foam Liquid Concentrates
Page Bottom
EX1734
SUITE 3600
180 SHEREE BLVD
PO BOX 695
EXTON, PA 19341 USA
Aer-O-Lite, nominal 3 percent Aqueous Film Forming Foam, +20 F minimum storage and use temperature. Hydrocarbon fuels only.
Foam concentrates for use with the following equipment:
AER-O-LITE, 3 PERCENT
PROPORTIONERS-BALANCED PRESSURE VALVES WITH CONTROLLERS
Controller
Size In.
Description
National, 1-1/2 in. Model 1.5 BPRV
Orifice
Size In.
Flow GPM
0.203
60-225
0.500
106-1564
0.703
106-2968
0.500
106-1564
0.703
106-2968
1.250
850-4209
0.203
60-225
0.500
106-1564
0.703
106-2968
0.500
106-1564
0.703
106-2968
1.250
850-4209
2.3.1
2.4
TABLE OF CONTENTS
Text
Page
CHAPTER 1 - INTRODUCTION
CHAPTER 2 - INSTALLATION
2-1.
2-2.
Cautions and Notes for In-Line Balanced Pressure Proportioning System ................................
Recommended Materials of Construction .....................................................................................
A. With Synthetic Based Polar Solvent/AFFF & Conventional AFFF Foam Concentrates .....
B. Protein Based Foam Concentrates .........................................................................................
Figure 2-1 In-Line Balanced Pressure Proportioner Module
3" to 8" Wafer Style with Manual Override ......................................................................
Figure 2-2 In-Line Balanced Pressure Proportioner Module
3" to 8" Wafer Style without Manual Override .................................................................
Figure 2-3 In-Line Balanced Pressure Proportioner Module
2" to 8" Flanged Style ........................................................................................................
Installation and Start-Up: ILBP Module .........................................................................................
A. Off Loading ...............................................................................................................................
B. Installation .................................................................................................................................
C. Operating Requirements ..........................................................................................................
2-1
2-2
2-2
2-2
2-3
2-4
2-5
2-6
2-6
2-6
2-7
3-1.
-i-
3-1
3-1
3-2
3-3
3-4
12/98
TABLE OF CONTENTS
Text
3-2.
3-3.
3-4.
Page
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-1
4-1
4-1
4-2
4-2
4-2
4-3
4-3
4-4
4-4
4-4
CHAPTER 5 - TROUBLESHOOTING
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
Troubleshooting ..............................................................................................................................
Table 5-1 Troubleshooting .......................................................................................................
No Proportioning .............................................................................................................................
Low Percent of Proportioning .........................................................................................................
High Percent of Proportioning ........................................................................................................
No Flow at Discharge Device(s) ....................................................................................................
Low Flow at Discharge Device(s) ..................................................................................................
No Operation ...................................................................................................................................
5-1
5-1
5-1
5-2
5-3
5-4
5-4
5-4
A-1.
A-2.
A-3.
12/98
- ii -
SAFETY INFORMATION
WARNING:
This manual has been prepared as an aid and guide for personnel involved in the installation, operation and
maintenance of a National Foam In-Line Balanced Pressure Proportioning Module and must be kept with the
module. All instructions must be read and understood thoroughly before attempting any installation, operation
or maintenance to this module. Failure to follow any instructions can result in personal injury and/or damage
to this equipment.
SAFETY INFORMATION
The International Safety Alert Symbol - is used with one of the following signal words to alert operating
personnel to the potential for death, personal injury or damage to equipment or property.
DANGER: indicates an extremely hazardous situation which, if not avoided, will result
in death or serious injury to the operator or major property damage.
WARNING: indicates a potentially hazardous situation which, if not avoided, can result
in serious injury, or death to the operator or major property damage.
CAUTION: indicates a potentially hazardous situation which, if not avoided, can result
in personal injury or property damage.
NOTE: indicates special instructions which are very important and must be followed.
It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully
understand the DANGER, WARNING, CAUTION and NOTE procedures by which hazards are to be reduced or
eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation
or maintenance of the equipment.
Operating and Maintenance Instructions and layouts shall be posted at control equipment with a second copy on file.
All persons who may be expected to inspect, test, maintain or operate foam-generating apparatus shall be thoroughly
trained and kept thoroughly trained in the functions they are expected to perform.
National Foam
Red Alert Fire Emergency Service
National Foams Red Alert Emergency Service is a system set up to respond to an emergency
situation requiring foam, equipment or service and is available 24 hours a day, 365 days a year.
- iii -
6/00
CHAPTER 1 - INTRODUCTION
The ILBP Module is a complete, self-contained unit,
assembled and tested at the factory. The unit is supplied
with no finish and is suitable for either horizontal or
vertical mounting.
The principle of operation of the ILBP Module is
based on the use of a modified venturi proportioner
called a ratio controller. With this type of proportioner,
water passes thru a jet (venturi) at the inlet of the ratio
controller, creating a reduced pressure area on the discharge side of the jet. This reduction in pressure creates
a pressure differential across the foam concentrate orifice and causes injection of foam concentrate into the
water stream at this reduced pressure area.
As the water flow thru the ratio controller increases, the
pressure reduction on the discharge side of the jet increases, thereby increasing the pressure differential across
the foam concentrate orifice. A proportionate increase in
foam concentrate injection will occur with an increase in
the water flow thru the ratio controller due to the increased pressure differential. As both the water and foam
concentrate flow into the common reduced pressure area,
it is necessary only to maintain identical water and foam
concentrate pressures at the inlets of the ratio controller.
A diaphragm valve (pressure control valve) automatically adjusts the foam concentrate inlet pressure to
correspond to the water inlet pressure. Pressure sensing
lines lead from the foam concentrate line upstream of the
ratio controller and from the water inlet to the ratio
Ratio Controller
1-1
The appropriate lengths of pipe and fittings to join these components into a single
package called an In-Line Balanced Pressure Proportioning Module.
12/98
CHAPTER 2 - INST
ALL
ATION
INSTALL
ALLA
CAUTION:
Install the In-Line Balanced Pressure Proportioning Module in accordance with instructions in this manual.
Variations may affect performance or cause system failure.
Customer modification or alteration of this equipment, or the use of replacement parts other than those
specified by NF, may affect the performance of this equipment and may void the warranty.
NOTE: National Foam recommends that those individuals charged with designing, installing, operating, testing and
maintaining a foam fire protection system, or the replacement of equipment and/or components of an existing
system, refer to the appropriate authority having jurisdiction for compliance with applicable standard(s), code(s)
and regulation(s) for that particular type of system and its components.
NOTE: The design requirements for the foam equipment provided may or may not be based on specific design
requirements provided to National Foam. Any changes to the area(s) of coverage or additions of other products
could exceed the design parameters of the foam equipment. Contact NF Engineering Dept. for questions regarding
changes to design.
12/98
2-1
INSTALLATION
2-1.
Brass or Bronze (Note: All foam concentrate lines on NF skid paks are Brass)
Stainless Steel 304L or 316 grades
High Density Polyethylene
PVC
Fiberglass with isophthalic based polyester
and an internal layer (50-100 mils minimum)
of vinyl ester resin in contact with foam
concentrate
1. Piping:
2. Valves:
2. Valves:
3. Storage Tanks:
2-2
3. Storage Tanks:
Steel
Same materials as Synthetic Based Polar
Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless
steel.
12/98
12/98
2-3
850(3218)
0.3(.02)
0.3(.02)
5000(18927)
*4000(15141)
0.3(.02)
0.3(.02)
0.3(.02)
0.3(.02)
MIN. FLOW
20(1.37)
20(1.37)
19.5(1.34)
19.5(1.34)
19.5(1.34)
10.5(.72)
MAX. FLOW
PRESSURE LOSS **
PSI (BAR)
Percent Proportioning
"B"
FOAM CONCENTRATE
INLET CONNECTION
"C"
PRESSURE GAUGE
FOAM CONCENTRATE
SUPPLY VALVE "V"
(NORMALLY CLOSED)
P/A/U
"E"
FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"
WATER FLUSH-OUT
VALVE "P"
2-1_2-2.P65 (2/98)
ILBP2-1.DSF
22-11/16(576)
"G"
(Ref.)
164(74)
MATERIALS OF CONSTRUCTION
Component Description
Material
Diaphragm Valve
Brass & Stainless Steel
Ratio Controller
Brass
Ball Valve
Brass & Stainless Steel
with Teflon Seals
Pipe and Fittings
Brass
Hose
Braided Stainless Steel
over Teflon Tube
DUPLEX GAUGE
WATER FLUSH-OUT
VALVE "M"
DUPLEX GAUGE
FOAM CONCENTRATE
FLUSH-OUT VALVE "N"
DUPLEX GAUGE
11(279)
FIGURE 2-1
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITH MANUAL OVERRIDE
Manual Override
Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF
MOR
"D"
"F"
SOLUTION
FLOW
BUSHING
CHECK VALVE
"A"
FLOW
WATER
BODY
DRAIN PLUG
DIAPHRAGM
BALANCING
VALVE
2-1/2(64)
164(74)
22-11/16(576)
11(279)
2-1/2(64)
1-3/4(44)
2(51)
12-1/4(311)
22(559)
1-3/4(44)
109(49)
21-15/16(557)
10-3/8(264)
2-3/8(60)
1-5/8(41)
2(51)
11-9/16(294)
21-7/8(556)
2(51)
94(43)
21-1/8(537)
10-3/8(264)
2-3/8(60)
1-5/8(41)
1-1/2(38)
11-1/8(283)
18-7/8(479)
12-9/16(319)
84(38)
20-1/8(511)
8-1/32(204)
1-31/32(50)
1-7/32(31)
1-1/2(38)
10-1/8(257)
19-1/4(489)
23-3/8(594)
74(34)
19-3/4(502)
4-13/16(122)
1-11/16(43)
1-3/16(30)
1-1/2(38)
APPROX.
WEIGHT
LBS (KGS)
9-3/4(248)
TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E
19-9/16(497)
6%
*8
2500(9463)
850(3218)
300(1136)
6%
1% & 3%
*8
2500(9463)
300(1136)
1% & 3%
1200(4542)
150 (568)
1%, 3% & 6%
450(1703)
70(265)
3% & 6%
3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM
NOMINAL
PERCENTAGE
PIPE
SIZE
SPECIFICATIONS
1-11/16(43)
4-13/16(122)
15-3/8(391)
74(34)
WEIGHT
LBS (KGS)
SPECIFICATIONS
1-3/16(30)
84(38)
TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E
B
1-1/2(38)
94(43)
70(265)
450(1703)
0.3(.02)
PRESSURE LOSS **
PSI (BAR)
3% & 6%
1200(4542)
NOMINAL
PERCENTAGE
PIPE
SIZE
9-3/4(248)
15-3/4(400)
109(49)
19-9/16(497)
16-3/4(425)
164(74)
10.5(.72)
8-1/32(204)
17-5/8(448)
MAX. FLOW
1-31/32(50)
10-3/8(264)
18-5/16(465)
0.3(.02)
1-7/32(31)
2-3/8(60)
11(279)
10-3/8(264)
MIN. FLOW
3
150 (568)
19.5(1.34)
3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM
1-1/2(38)
2-3/8(60)
10-1/8(257)
1-5/8(41)
2-1/2(64)
19-1/4(489)
1%, 3% & 6%
0.3(.02)
20(1.37)
19.5(1.34)
19.5(1.34)
4
2500(9463)
0.3(.02)
1-1/2(38)
300(1136)
0.3(.02)
11-1/8(283)
1% & 3%
2500(9463)
18-7/8(479)
5000(18927)
1-5/8(41)
300(1136)
1-3/4(44)
850(3218)
2(51)
6%
2(51)
1% & 3%
12-1/4(311)
11-9/16(294)
*8
22(559)
164(74)
21-7/8(556)
18-5/16(465)
2-1/2(64)
11(279)
1-3/4(44)
23-3/8(594)
2(51)
0.3(.02)
"F"
"D"
WATER FLUSH-OUT
VALVE "P"
FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"
Component Description
Diaphragm Valve
Ratio Controller
Ball Valve
Pipe and Fittings
Hose
"G"
(Ref.)
Material
Brass & Stainless Steel
Brass
Brass & Stainless Steel
with Teflon Seals
Brass
Braided Stainless Steel
over Teflon Tube
FIGURE 2-2
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITHOUT MANUAL OVERRIDE
SOLUTION
FLOW
"E"
P/A/U
Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF
2-1_2-2.P65 (2/98)
ILBP2-2.DSF
MATERIALS OF CONSTRUCTION
12-9/16(319)
*4000(15141)
20(1.37)
850(3218)
"A"
FLOW
WATER
BODY
DRAIN PLUG
6%
"B"
*8
PRESSURE GAUGE
"C"
FOAM CONCENTRATE
INLET CONNECTION
12/98
2-4
12/98
2-5
0.3(.02)
*5000(18927)
850(3218)
* 8*
3-1/2(89)
3-1/16(78)
3(76)
22(559)
23-3/4(603)
26-1/4(667)
6" 150#
FLAT FACE
8" 150#
FLAT FACE
13-1/2(343)
12-3/4(324)
F1/4
Brass
Brass
Brass
Braided Stainless Steel
Ratio Controller
Pipe
Pittings (Pipe)
Hose
Diaphragm Valve
Ball Valve
MATERIALS OF CONSTRUCTION
RCF2-3.DSF
RCF2-3.P65
FOAM CONCENTRATE
SUPPLY
"H"
PRESSURE GAUGE
A1/4
WATER
FLOW
B
C
"D" FLANGE
PER ANSI B16.5
DRAIN/FLUSH-OUT
VALVES - TYPICAL
5 PLACES
12(305)
12(305)
12(305)
12-3/4(324)
12-3/4(324)
G1/4
12-3/4(324)
11(279)
9-1/2(241)
8(203)
7-1/2(191)
2 NPT
2 NPT
1-1/2 NPT
1-1/2 NPT
1-1/2 NPT
220(100)
145(66)
110(50)
90(41)
75(34)
WEIGHT
LBS (KGS)
FIGURE 2-3
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
2" - 8" FLANGED STYLE
FLOW
SOLUTION
E1/4
20-1/2(521)
4" 150#
FLAT FACE
6-1/2(165)
10(254)
19-3/4(502)
3" 150#
FLAT FACE
D
2" 150#
FLAT FACE
TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
9-5/8(244)
18-1/4(464)
18-11/16(475)
19.5(1.34)
0.3(.02)
2500(9463)
300(1136)
6
20(1.37)
15-1/4(387)
0.3(.02)
2(51)
16-1/4(413)
10.5(.72)
19.5(1.34)
0.3(.02)
450(1703)
1200(4542)
70(265)
150 (568)
2-9/16(65)
15-11/16(398)
14(.97)
0.5 .03)
180(681)
PRESSURE LOSS**
PSI (BAR)
MINIMUM MAXIMUM
30(114)
SOLUTION CAPACITIES
PSI (BAR)
MINIMUM
MAXIMUM
NOMINAL
PIPE
SIZE
SPECIFICATIONS
INSTALLATION
2-2.
CAUTION:
For proper piping sizes contact NF Engineering Department.
WARNING:
In accordance with NFPA requirements for supervision of an Automated Foam Fire Protection System manually operated valve(s) in the foam solution line from the proportioner to the discharge device(s) must be
chained or locked in the open position or equipped with tamper alarm switch(es) which are monitored by a
supervisory panel alarm.
The major concern is the possibility that any manually operated valve(s) in the foam solution line to the
hazard(s) could inadvertently be left in the closed position during a fire condition, which would prevent the foam
solution from reaching the hazard(s) in the event of an automatic trip sequence.
A. Off Loading:
WARNING:
Be sure the module is properly secured and balanced
during any lifting or moving procedure. If the module
is not properly secured in the lifting device, damage to
the module or injury to personnel could result.
B. Installation:
NOTE: Refer to Operating Schematic Drawing Fig. 3-1, 3-2 or 3-3.
1. Mount the module on the water piping main and
connect the foam concentrate supply piping to
the module. ILBP modules can be mounted in
either a horizontal or vertical orientation.
2. All interconnecting piping to and from the ILBP
Module (that is - foam concentrate supply piping, watermain piping and foam solution piping)
must be self-supporting so as to eliminate any
load on the module itself.
3. To facilitate future service/removal of the ratio
controller, the installer should provide a spool
piece upstream of the ratio controller. See Chart
below for minimum spool piece lengths.
2-6
Ratio Controller
(203)
(254)
(305)
(356)
12/98
INSTALLATION
10. Hydrostatically test piping in accordance with procedures outlined in the latest edition of the applicable
section of NFPA.
11. Flush the foam concentrate piping before introducing foam concentrate into the foam system.
12. Follow the procedures outlined in Section 2-2., C.
Installation, Item Nos. 7 and 8. Refer to System
Flushing procedures outlined in Sect. 4-15.
13. Place all valves to their normal stand-by position.
See Normal Stand-By Valve Position Chart on Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
14. Perform the applicable testing after installation procedures as recommended by the latest edition of
NFPA 11.
C. Operating Requirements:
by position for automatic balancing. To place in
the normal stand-by position: rotate the
manual override handle in the counter-clockwise direction until fully open.
12/98
2-7
CHAPTER 3 - OPERA
TING PROCEDURES
OPERATING
3-1.
W A T E R IN L E T P R E S S U R E (P S I/B A R )
B A R /P S I
3 " R C F /R C W
2 " R C T
6 .9 /1 0 0
6 .2 /9 0
4 " R C F /R C W
6 " R C F /R C W
8 " R C F /R C W
5 .5 /8 0
4 .8 /7 0
4 .1 /6 0
3 .4 /5 0
2 .7 /4 0
2 .0 6 /3 0
G P M
L P M
1 .3 /2 0
6 0
2 2 7
8 0
3 0 3
1 0 0
3 7 9
2 0 0
7 5 7
4 0 0
1 5 1 4
6 0 0
2 2 7 1
S O L U T IO N F L O W
8 0 0
3 0 2 8
1 0 0 0
3 7 8 5
2 0 0 0
7 5 7 1
4 0 0 0
1 5 1 4 1
(G P M /L P M )
FIGURE 3-1
RATIO CONTROLLER MINIMUM INLET PRESSURE VS. SOLUTION FLOW CHART
12/98
3-1
LEGEND
FOAM CONCENTRATE LINE
VALVE DESCRIPTION
WATER SENSING LINE SHUT-OFF VALVE
TO DIAPHRAGM VALVE
DUPLEX GAUGE WATER FLUSH-OUT
DUPLEX GAUGE FOAM CONC. FLUSH-OUT
DIAPHRAGM VALVE WATER FLUSH-OUT
DIAPHRAGM VALVE CONC. FLUSH-OUT
FOAM CONCENTRATE SUPPLY VALVE
BODY DRAIN PLUG
SENSING LINE
WATER LINE
RCW RATIO CONTROLLER
BALL VALVE (N.O.)
BALL VALVE (N.C.)
DESIGNATION
L
M
N
P
R
V
POSITION
MANUAL
AUTO.
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
DUPLEX GAUGE
P
PRESSURE GAUGE
MANUAL OVERRIDE
HANDWHEEL
DIAPHRAGM VALVE
M
N
R
P
V
ILBP MODULE
SCHEMATIC
- TYPICAL -
BODY
DRAIN
PLUG
FO
A
LU M
TIO
N
SO
NOTES:
The schematics shown are typical installations and
may not reflect actual equipment furnished.
3-2
FO
AM
EN
SU TRA
T
PP
LY E
NC
WATER PUMP
(IF REQUIRED)
MAIN WATER
SUPPLY VALVE
WA
SU TER
PP
LY
MOD3-1.DSF
LGND3-1.DSF
12/98
LEGEND
FOAM CONCENTRATE LINE
POSITION
DESIGNATION MANUAL
AUTO.
P
CLOSED
CLOSED
R
CLOSED
OPEN
V
CLOSED
OPEN
CLOSED
CLOSED
VALVE DESCRIPTION
DIAPHRAGM VALVE WATER FLUSH-OUT
DIAPHRAGM VALVE CONC. FLUSH-OUT
FOAM CONCENTRATE SUPPLY VALVE
BODY DRAIN PLUG
SENSING LINE
WATER LINE
RCW RATIO CONTROLLER
BALL VALVE (N.O.)
BALL VALVE (N.C.)
AUTOMATED VALVE W/MANUAL
OVERRIDE
P
PRESSURE GAUGE
DIAPHRAGM VALVE
P
V
ILBP MODULE
SCHEMATIC
- TYPICAL -
BODY
DRAIN
PLUG
FO
A
LU M
TIO
N
SO
NOTES:
CO
SU
FO
AM
EN
TR
PP ATE
LY
NC
WATER PUMP
(IF REQUIRED)
MAIN WATER
SUPPLY VALVE
WA
SU TER
PP
LY
MOD3-2.DSF
LGND3-2.DSF
12/98
3-3
LEGEND
FOAM CONCENTRATE LINE
VALVE DESCRIPTION
WATER SENSING LINE SUPPLY VALVE
WATER SENSING LINE SHUT-OFF VALVE
TO DIAPHRAGM VALVE
FOAM CONCENTRATE SENSING LINE
SHUT-OFF VALVE TO DIAPHRAGM VALVE
DUPLEX GAUGE WATER FLUSH-OUT
DUPLEX GAUGE FOAM CONC. FLUSH-OUT
DIAPHRAGM VALVE WATER FLUSH-OUT
DIAPHRAGM VALVE CONC. FLUSH-OUT
FOAM CONCENTRATE SUPPLY VALVE
LOWER PETCOCK ON DIAPHRAGM VALVE
SENSING LINE
WATER LINE
RCF RATIO CONTROLLER
BALL VALVE (N.O.)
BALL VALVE (N.C.)
AUTOMATED VALVE W/MANUAL
OVERRIDE
POSITION
DESIGNATION MANUAL
AUTO.
J
OPEN
OPEN
L
OPEN
OPEN
K
OPEN
OPEN
M
N
P
R
V
W
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
CHECK VALVE
D
DUPLEX GAUGE
P
PRESSURE GAUGE
MANUAL OVERRIDE
HANDWHEEL
DIAPHRAGM VALVE
M
N
K
P
V
ILBP MODULE
SCHEMATIC
- TYPICAL SO
FO
A
LU M
TIO
N
NOTES:
SEE NOTE NO. 2
SU
MOD3-3.DSF
LGND3-3.DSF
3-4
FO
AM
EN
TR
PP ATE
LY
NC
WATER PUMP
(IF REQUIRED)
MAIN WATER
SUPPLY VALVE
WA
SU TER
PP
LY
12/98
OPERATING PROCEDURES
3-2.
NOTE: Refer to Operating Schematic Drawing Fig. 32, 3-3 or 3-4 for valve location, designation
and normal stand-by position.
1. Verify that all valves on the proportioning system
are in their normal stand-by position.
2. Start water pump (if required).
3. Start foam concentrate pump.
4. If applicable - Set the desired percentage on the
metering valve(s) at the appropriate ILBP Module(s).
NOTE: The metering valve is for regulating the
foam concentrate injection (percentage) into the system only , and does not have shut-off capability. For
positive foam concentrate shut-off, a separate valve
must be used along with the metering valve.
5. Open water supply valve to the desired ILBP
module(s).
3-3.
NOTE: The instructions below, apply only to ILBP Module Diaphragm Valves with manual
override capability. These instructions do not apply to Diaphragm Valves which do not
have manual overrride capability.
NOTE: Used only when system will not balance automatically.
4. Turn manual override knob clockwise until it contacts a stop and will not travel further.
12/98
3-5
OPERATING PROCEDURES
3-4.
SHUTDOWN
WARNING:
Only after the fire is out and the danger of reignition
has passed, shall consideration be given to flushing
and draining the system. Follow the appropriate
Flushing Instructions which follow in this manual
after it is determined that it would be safe to flush
and drain the system.
3-6
12/98
4-1.
4-2.
4-3.
ANNUAL TESTING
At least annually, all foam systems shall be thoroughly inspected and checked for proper operation.
This shall include performance evaluation of the foam concentrate or premix solution quality or both.
Deviation of results exceeding 10 percent from those recorded in acceptance testing shall be discussed
immediately with the manufacturer. Regular service contracts are recommended. The goal of this
inspection and testing shall be to ensure that the system is in full operating condition, and that it will
remain in that condition until the next inspection. The inspection report, with recommendations, shall
be filed with the owner. Between the regular service contract inspections or tests, the system shall
be inspected by competent personnel following an approved schedule.
6/00
4-1
WARNING:
The following recommendations are based on normal operating conditions. Due to environmental or
other conditions unique to your system, the frequency of some inspecton and maintenance procedures
may need to be adjusted. Additional inspection and maintenance procedures may also be required.
NOTE:
START
AFTER
UP
OPERATION WEEKLY MONTHLY
SEMIANNUAL ANNUAL
OTHER
4-4. GENERAL
1. Check all valves to insure that they are in the
normal stand-byposition. See Operating
Schematic Dwg. Fig. 3-2, 3-3 or 3-4.
2. Check that Manual Override Handwheel is in the
normal stand-by position for automatic
balancing. Refer to Sect. 2-2.C., item 3.
3. Inspect system for physical damage and repair.
4. Check the complete module, all valves, fittings
& connections for leakage.
5. Cycle manual valves where practical.
6. Check flange bolts for tightness.
7. Perform system testing after installation as
described in the latest edition of NFPA 11.
8. Check module for any external damage to the
paint surfaces.
AFTER
ALL
MAINT.
PROCEDURES
4-2
12/98
START
AFTER
UP
OPERATION WEEKLY MONTHLY
SEMIANNUAL ANNUAL
OTHER
WARNING:
When automated foam concentrate valves
are cycled, Valve "V" must be closed.
When automated valves are cycled, the
main water supply valve must be closed.
2. Cycle valve(s) from the control panel to insure
proper operation from control.
3. Check supervision of control circuit.
4. Check for leakage past valve seat.
4-7.
CONTROL SYSTEM
12/98
4-3
4-8.
Return all valves to their normal stand-by position (reinstall body drain plug). Refer to Normal
Stand-By Valve Position Chart on Operating
Schematic Dwg. Fig. 3-3.
8. Return all valves to their normal stand-by position (reinstall diaphragm valve body drain plug).
Refer to Normal Stand-By Valve Position Chart
on Operating Schematic Dwg. Fig. 3-2 or 3-4.
4-4
12/98
CHAPTER 5 - TROUBLESHOOTING
5-1.
TROUBLESHOOTING
See Table 5-1 for Troubleshooting Problems, Possible Causes and Corrective Actions. These procedures
cover problems that may be experienced during normal operations. Although these recommendations cover
most problems that are experienced there are some situations that may occur which are not covered in these
instructions. Please contact National Foam's Engineering Department for problems that cannot be resolved
thru the use of this manual.
NOTE: Refer to individual instruction manuals or sheets for additional information on system components
and discharge devices.
5-2. No
Proportioning
POSSIBLE CAUSE
CORRECTIVE ACTION
12/98
5-1
TROUBLESHOOTING
POSSIBLE CAUSE
No Proportioning
continued
5-3. Low
Percent of
Proportioning
CORRECTIVE ACTION
Check Drain/Vent valve on strainer for clogging which shuts off water supply to cylinder.
Open Drain/Vent valve on strainer, vent and
flush any debris blocking water supply.
Diaphragm Valve Foam Concentrate FlushOut Valve "R" open or partially open.
5-2
12/98
TROUBLESHOOTING
Low Percent of
Proportioning
continued
POSSIBLE CAUSE
CORRECTIVE ACTION
5-4. High
Percent of
Proportioning
12/98
TROUBLESHOOTING
High Percent of
Proportioning
continued
POSSIBLE CAUSE
CORRECTIVE ACTION
5-5. No Flow
at Discharge
Device(s)
Partial blockage in water or foam solution line. Find blockage and remove.
5-7. No
Operation
5-4
Power failure.
Fill tank.
12/98
APPENDIX - F
ACTOR
Y MUTU
AL APPRO
VALS
FACTOR
ACTORY
MUTUAL
APPROV
Factory Mutual Research and Engineering is a non-profit independent research and testing organization. FM tests
and approves a wide variety of equipment, materials and services related to fire safety.
Each year FM publishes an Approval Guide listing all approved equipment, materials and services. This guide gives
detailed information on the approved products, as well as the operational parameters of the approval. In the case of
foam proportioning systems, the parameters are the minimum and maximum foam solution flows and the foam
concentrates for which the proportioner is approved.
The following foam concentrates, along with the particular In-Line Balanced Pressure (ILBP) Proportioning System
components and discharge device(s) listed under the foam concentrate, constitute an FM Approved foam system. An
approved system must consist of a foam concentrate, ILBP Proportioning system and discharge device(s).
A-1.
d. Ethers
Viking Model M
17/32" Upright and Pendent
Viking Model M
1/2" Upright
Grinnell Model F950
1/2" Upright and Pendent
4" BWC3 - UG
4" BWC3 - UG-MOR
e. Hydrocarbons
6" BWC3 - UG
6" BWC3 - UG-MOR
Viking Model M
17/32" Large Orifice Upright
Viking Model M
1/2" Upright
a. Alcohols
Viking Model M
17/32" Upright
2. Nozzles
Viking Model M
1/2" Upright
Model JS-10
Model JS-10B
Model PC-31A
b. Ketones
Viking Model M
17/32" Upright
MCS-9 Type A
Viking Model M
1/2" Upright
MCS-33 Type A
MCS-55 Type A
12/98
3. Foam Chambers
MCS-17 Type A
A-2.
Aer-O-Lite - 3% AFFF
A. In-Line Balanced Pressure Proportioning Systems:
1. ILBP Proportioner Models - for flow ranges see
Factory Mutual Approval Guide:
4" BWC3 - A
4" BWC3 - A-MOR
6" BWC3 - A
6" BWC3 - A-MOR
A-1
APPENDIX
A-2
12/98
NOTES
Na
tional F
oam
National
Foam
SECTION 3:
SKID MOUNTED ILBP
PROPORTIONING SYSTEM
SKZZ-66025
N a tio n a l F o a m
3.1
3.2
TABLE OF CONTENTS
TABLE OF CONTENTS
Text
Page
CHAPTER 1 - INTRODUCTION
1-1.
1-2.
1-3.
1-1
1-2
1-1
1-2
1-3
CHAPTER 2 - INSTALLATION
2-1.
2-2.
2-3.
2-4.
2-5.
6/05
Cautions, Warning and Note for In-Line Balanced Pressure Proportioning System .................. 2-1
Recommended Materials of Construction ..................................................................................... 2-2
A. With Synthetic Based Polar Solvent/AFFF & Conventional AFFF Foam Concentrates ..... 2-2
B. Protein Based Foam Concentrates ......................................................................................... 2-2
Figure 2-1 In-Line Balanced Pressure Proportioner Module
3" to 8" Wafer Style with Manual Override ...................................................................... 2-3
Figure 2-2 In-Line Balanced Pressure Proportioner Module
3" to 8" Wafer Style without Manual Override ................................................................. 2-4
Figure 2-3 In-Line Balanced Pressure Proportioner Module
2" to 8" Flanged Style ........................................................................................................ 2-5
Installation and Start-Up: In-Line Balanced Pressure Proportioning Skid Pak .......................... 2-6
A. Site Selection ............................................................................................................................ 2-6
B. Off Loading ............................................................................................................................... 2-6
C. Installation ................................................................................................................................. 2-6
Installation and Start-Up: ILBP Module ......................................................................................... 2-8
A. Off Loading ............................................................................................................................... 2-8
B. Installation ................................................................................................................................. 2-9
C. Operating Requirements ........................................................................................................ 2-10
Installation and Start-Up: Pump and Pressure Sustaining Valve
Supplied as Loose Components ............................................................................................ 2-10
A. Foam Concentrate Pump ....................................................................................................... 2-10
B. Pressure Sustaining Valve ..................................................................................................... 2-11
C. General System ...................................................................................................................... 2-11
D. Foam Concentrate Jockey Pump .......................................................................................... 2-12
Testing After Installation .............................................................................................................. 2-12
-i-
TABLE OF CONTENTS
Text
Page
3-1.
3-2.
3-3.
3-4.
Figure 3-1 Operating Schematic Drawing ILBP Module With Manual Override and RCW Ratio Controller ....................................
Figure 3-2 Operating Schematic Drawing ILBP Module Without Manual Override and RCW Ratio Controller ...............................
Figure 3-3 Operating Schematic Drawing ILBP Module With Manual Override and RCF Ratio Controller .....................................
Minimum Inlet Pressure Requirements .........................................................................................
Figure 3-4 NF Ratio Controller Minimum Inlet Pressure vs. Solution Flow Chart ...............
Operation of System .......................................................................................................................
A. Manual System Operation .......................................................................................................
B. Automatic System Operation ...................................................................................................
Manual System Override (Manual Regulation) .............................................................................
A. ILBP Module .............................................................................................................................
B. Pump and Pressure Sustaining Valve Module .......................................................................
Shutdown .........................................................................................................................................
A. Manual System Shutdown .......................................................................................................
B. Automatic System Shutdown ...................................................................................................
3-1
3-2
3-3
3-4
3-4
3-5
3-5
3-5
3-6
3-6
3-6
3-6
3-6
3-7
6/00
4-1
4-1
4-1
4-2
4-2
4-3
4-3
4-4
4-4
4-4
4-5
4-5
4-5
4-5
4-6
4-7
4-7
4-7
- ii -
TABLE OF CONTENTS
Text
Page
CHAPTER 5 - TROUBLESHOOTING
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
Troubleshooting ..............................................................................................................................
Table 5-1 Troubleshooting .......................................................................................................
No Proportioning .............................................................................................................................
Low Percent of Proportioning .........................................................................................................
High Percent of Proportioning ........................................................................................................
No Flow at Discharge Device(s) ....................................................................................................
Low Flow at Discharge Device(s) ..................................................................................................
No Operation ...................................................................................................................................
5-1
5-1
5-1
5-3
5-5
5-6
5-6
5-6
ILBP SYSTEM_9936-2E.PMD
6/05
6/05
- iii -
CHAPTER 1 - INTRODUCTION
National Foam
Red Alert Fire Emergency Service
National Foams Red Alert Emergency Service is a system set up to respond to an emergency situation
requiring foam, equipment or service and is available 24 hours a day, 365 days a year.
WARNING:
This manual has been prepared as an aid and guide for personnel involved in the installation, operation and
maintenance of a NF In-Line Balanced Pressure Proportioning System. All instructions must be read and
understood thoroughly before attempting any installation, operation or maintenance to this equipment. Failure
to follow any instructions can result in personal injury and/or damage to this equipment.
1-1.
SAFETY INFORMATION
The International Safety Alert Symbol - is used with one of the following signal words to alert operating
personnel to the potential for death, personal injury or damage to equipment or property.
DANGER: indicates an extremely hazardous situation which, if not avoided, will result
in death or serious injury to the operator or major property damage.
WARNING: indicates a potentially hazardous situation which, if not avoided, can result
in serious injury, or death to the operator or major property damage.
CAUTION: indicates a potentially hazardous situation which, if not avoided, can result
in personal injury or property damage.
NOTE: indicates special instructions which are very important and must be followed.
It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully
understand the DANGER, WARNING, CAUTION and NOTE procedures by which hazards are to be reduced or
eliminated. Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation
or maintenance of the equipment.
Operating and Maintenance Instructions and layouts shall be posted at control equipment with a second copy on file.
All persons who may be expected to inspect, test, maintain or operate foam-generating apparatus shall be thoroughly
trained and kept thoroughly trained in the functions they are expected to perform.
6/00
1-1
INTRODUCTION
1-2.
GENERAL DESCRIPTION
The National foam In-Line Balanced Pressure Proportioning System is designed to inject foam concentrate
into the water supply at the correct percentage at multiple injection points. This type of foam proportioning
system consists of one or more In-Line Balanced Pressure Proportioning Modules (ILBP), a foam concentrate
pump, a pressure sustaining valve and a foam concentrate storage tank.
Ratio Controller
The appropriate lengths of pipe and fittings to join these components into a single
package called an In-Line Balanced Pressure Proportioning Module.
1-2
INTRODUCTION
1-3.
GENERAL NOTES
6/00
guidelines regarding these concentrates can compromise their effectiveness. Refer to NF Storage Tank
Installation, Cleaning & Filling Instruction Manual P/
N:1298-9933-7 for recommendations.
5. The foam system provided is based on specific design
requirements, that is, products(s) being protected and
area(s) of coverage. The design requirements may or
may not have been provided to National Foam. Any
changes to the area(s) of coverage or additions of other
products could exceed the design parameters of the
system. Contact NF Engineering Dept. for questions
regarding changes to design.
6. Before operating the system, the foam concentrate
pump should be serviced in accordance with the
manufacturers installation and maintenance sheets and
the recommended start-up procedures outlined in this
manual.
1-3
INTRODUCTION
6/00
1-4
CHAPTER 2 - INST
ALL
ATION
INSTALL
ALLA
CAUTION:
Install the In-Line Balanced Pressure Proportioning System in accordance with instructions in this manual.
Variations may affect performance or cause system failure.
Customer modification or alteration of this equipment, or the use of replacement parts other than those
specified by NF, may affect the performance of this equipment and may void the warranty.
WARNING:
National Foam, Inc. recommends the system be inspected and tested in accordance with applicable NFPA
standards
6/00
2-1
INSTALLATION
2-1.
Brass or Bronze (Note: All foam concentrate lines on NF skid paks are Brass)
Stainless Steel 304L or 316 grades
High Density Polyethylene
PVC
Fiberglass with isophthalic based polyester
and an internal layer (50-100 mils minimum)
of vinyl ester resin in contact with foam
concentrate
1. Piping:
2. Valves:
2. Valves:
6/00
3. Storage Tanks:
3. Storage Tanks:
Steel
Same materials as Synthetic Based Polar
Solvent/AFFF and Conventional AFFF Foam
Concentrate with the exception of stainless
steel.
2-2
6/00
2-3
850(3218)
850(3218)
0.3(.02)
0.3(.02)
5000(18927)
*4000(15141)
0.3(.02)
0.3(.02)
0.3(.02)
0.3(.02)
MIN. FLOW
20(1.37)
20(1.37)
19.5(1.34)
19.5(1.34)
19.5(1.34)
10.5(.72)
MAX. FLOW
PRESSURE LOSS **
PSI (BAR)
"B"
Percent Proportioning
FOAM CONCENTRATE
INLET CONNECTION
"C"
PRESSURE GAUGE
FOAM CONCENTRATE
SUPPLY VALVE "V"
(NORMALLY CLOSED)
P/A/U
"E"
FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"
WATER FLUSH-OUT
VALVE "P"
2-1_2-2.P65 (2/98)
ILBP2-1.DSF
22-11/16(576)
"G"
(Ref.)
164(74)
MATERIALS OF CONSTRUCTION
Component Description
Material
Diaphragm Valve
Brass & Stainless Steel
Ratio Controller
Brass
Ball Valve
Brass & Stainless Steel
with Teflon Seals
Pipe and Fittings
Brass
Hose
Braided Stainless Steel
over Teflon Tube
DUPLEX GAUGE
WATER FLUSH-OUT
VALVE "M"
DUPLEX GAUGE
FOAM CONCENTRATE
FLUSH-OUT VALVE "N"
DUPLEX GAUGE
11(279)
FIGURE 2-1
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITH MANUAL OVERRIDE
Manual Override
Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF
MOR
"D"
"F"
SOLUTION
FLOW
BUSHING
CHECK VALVE
"A"
WATER
FLOW
BODY
DRAIN PLUG
DIAPHRAGM
BALANCING
VALVE
2-1/2(64)
164(74)
22-11/16(576)
11(279)
2-1/2(64)
1-3/4(44)
2(51)
12-1/4(311)
22(559)
1-3/4(44)
109(49)
21-15/16(557)
10-3/8(264)
2-3/8(60)
1-5/8(41)
2(51)
11-9/16(294)
21-7/8(556)
2(51)
94(43)
21-1/8(537)
10-3/8(264)
2-3/8(60)
1-5/8(41)
1-1/2(38)
11-1/8(283)
18-7/8(479)
12-9/16(319)
84(38)
20-1/8(511)
8-1/32(204)
1-31/32(50)
1-7/32(31)
1-1/2(38)
10-1/8(257)
19-1/4(489)
23-3/8(594)
74(34)
19-3/4(502)
4-13/16(122)
1-11/16(43)
1-3/16(30)
1-1/2(38)
APPROX.
WEIGHT
LBS (KGS)
9-3/4(248)
TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E
19-9/16(497)
6%
*8
2500(9463)
300(1136)
6%
1% & 3%
*8
2500(9463)
300(1136)
1% & 3%
1200(4542)
150 (568)
1%, 3% & 6%
450(1703)
70(265)
3% & 6%
3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM
NOMINAL
PERCENTAGE
PIPE
SIZE
SPECIFICATIONS
6/00
2-4
"C" FOAM
CONCENTRATE
INLET
CONNECTION
"B"
0.3(.02)
*4000(15141)
Percent Proportioning
"A"
WATER
FLOW
BODY
DRAIN PLUG
P/A/U
"F"
"D"
SCH. 40 PIPING
BY OTHERS
(SAME NOMINAL
SIZE AS RATIO
CONTROLLER)
1-3/4(44)
18-5/16(465)
164(74)
"G"
Component Description
Diaphragm Valve
Ratio Controller
Ball Valve
Material
Brass & Stainless Steel
Brass
Brass & Stainless Steel
with Teflon Seals
Brass
Braided Stainless Steel
over Teflon Tube
MATERIALS OF CONSTRUCTION
(Ref.)
FIGURE 2-2
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
3" - 8" WAFER STYLE WITHOUT MANUAL OVERRIDE
FOAM
CONCENTRATE
FLUSH-OUT
VALVE "R"
WATER
FLUSH-OUT
VALVE "P"
SOLUTION
FLOW
2-1_2-2.P65 (2/98)
ILBP2-2.DSF
Foam Concentrate
- P - Protein
- U - Universal
- UG - Universal Gold
- A - AFFF
"E"
2(51)
12-9/16(319)
23-3/8(594)
11(279)
164(74)
11(279)
2-1/2(64)
1-3/4(44)
2(51)
2-1/2(64)
109(49)
17-5/8(448)
18-5/16(465)
10-3/8(264)
2-3/8(60)
1-5/8(41)
2(51)
12-1/4(311)
22(559)
11-9/16(294)
21-7/8(556)
94(43)
16-3/4(425)
10-3/8(264)
2-3/8(60)
1-5/8(41)
1-1/2(38)
11-1/8(283)
18-7/8(479)
84(38)
15-3/4(400)
8-1/32(204)
1-31/32(50)
1-7/32(31)
1-1/2(38)
10-1/8(257)
19-1/4(489)
74(34)
15-3/8(391)
4-13/16(122)
1-11/16(43)
1-3/16(30)
1-1/2(38)
9-3/4(248)
19-9/16(497)
WEIGHT
LBS (KGS)
G
TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
D
E
DIAPHRAGM
BALANCING VALVE
20(1.37)
20(1.37)
19.5(1.34)
19.5(1.34)
19.5(1.34)
10.5(.72)
0.3(.02)
5000(18927)
0.3(.02)
0.3(.02)
0.3(.02)
0.3(.02)
MAX. FLOW
PRESSURE LOSS **
PSI (BAR)
MIN. FLOW
850(3218)
850(3218)
PRESSURE
GAUGE
6%
*8
2500(9463)
300(1136)
6%
1% & 3%
*8
2500(9463)
300(1136)
1% & 3%
1200(4542)
150 (568)
1%, 3% & 6%
450(1703)
70(265)
3% & 6%
3% SYSTEM
SOLUTION CAPACITIES **
GPM (LPM)
MINIMUM
MAXIMUM
NOMINAL
PERCENTAGE
PIPE
SIZE
SPECIFICATIONS
6/00
2-5
0.3(.02)
*5000(18927)
850(3218)
* 8*
3-1/2(89)
3-1/16(78)
3(76)
22(559)
23-3/4(603)
26-1/4(667)
6" 150#
FLAT FACE
8" 150#
FLAT FACE
13-1/2(343)
12-3/4(324)
F1/4
Brass
Brass
Brass
Braided Stainless Steel
Ratio Controller
Pipe
Pittings (Pipe)
Hose
Diaphragm Valve
Ball Valve
MATERIALS OF CONSTRUCTION
RCF2-3.DSF
RCF2-3.P65
FOAM CONCENTRATE
SUPPLY
"H"
PRESSURE GAUGE
A1/4
WATER
FLOW
B
C
"D" FLANGE
PER ANSI B16.5
DRAIN/FLUSH-OUT
VALVES - TYPICAL
5 PLACES
G1/4
12-3/4(324)
11(279)
9-1/2(241)
8(203)
7-1/2(191)
12-3/4(324)
12-3/4(324)
12(305)
12(305)
12(305)
2 NPT
2 NPT
1-1/2 NPT
1-1/2 NPT
1-1/2 NPT
220(100)
145(66)
110(50)
90(41)
75(34)
WEIGHT
LBS (KGS)
FIGURE 2-3
IN-LINE BALANCED PRESSURE PROPORTIONER MODULE
2" - 8" FLANGED STYLE
FLOW
SOLUTION
E1/4
20-1/2(521)
4" 150#
FLAT FACE
6-1/2(165)
10(254)
19-3/4(502)
3" 150#
FLAT FACE
D
2" 150#
FLAT FACE
TABLE OF DIMENSIONS
INCHES (MILLIMETERS)
9-5/8(244)
18-1/4(464)
18-11/16(475)
19.5(1.34)
0.3(.02)
2500(9463)
300(1136)
6
20(1.37)
15-1/4(387)
0.3(.02)
2(51)
16-1/4(413)
10.5(.72)
19.5(1.34)
0.3(.02)
450(1703)
1200(4542)
70(265)
150 (568)
2-9/16(65)
15-11/16(398)
14(.97)
0.5 .03)
180(681)
PRESSURE LOSS**
PSI (BAR)
MINIMUM MAXIMUM
30(114)
SOLUTION CAPACITIES
PSI (BAR)
MINIMUM
MAXIMUM
NOMINAL
PIPE
SIZE
SPECIFICATIONS
INSTALLATION
2-2.
4. A relief valve has been installed in the foam concentrate discharge line downstream of the Foam Concentrate Discharge Valve "D" and discharge check
valve, with the relief valve discharge piped to the
foam concentrate return line downstream of the
pressure sustaining valve. This valve is intended to
relieve excess foam concentrate discharge line pressure. The relief valve is preset at the factory and
needs no adjustment.
5. Flush the foam concentrate piping before introducing foam concentrate into the foam system.
B. Off Loading:
1. Do not move the module using piping or installed
equipment as a lifting device. Use a crane or
other suitable lifting apparatus to move the module. Lift with a fork truck from the underside of
the module frame.
C. Installation:
1. The skid shall be suitably anchored to eliminate
vibration and movement. Level and shim as
necessary. NF recommends a clear distance of 2
ft. (0.6096 m) on the pump end and 3 ft. (0.9144
m) on the drive end be allowed by the installer to
facilitate service/removal of the pump and motor.
2. All interconnecting piping to and from the module must be self-supported. Plastic foam concentrate storage tanks must have flexible connection
fittings installed between the tank and proportioning equipment to eliminate stress imposed by
the piping and to eliminate vibration.
3. NF hydrostatically tests all skid units before
they leave our factory. However, due to vibration and handling experienced during transit, the
tightness of joints and connections on the skid
cannot be guaranteed. Therefore, NF recommends that the installer hydrostatically test the
skid piping in accordance with procedures outlined in the latest edition of the applicable section
of NFPA, before introducing foam concentrate
into the system.
6/05
2-6
INSTALLATION
6/05
2-7
INSTALLATION
2-3.
CAUTION:
For proper piping sizes contact NF Engineering Department.
WARNING:
In accordance with NFPA requirements for supervision of an Automated Foam Fire Protection System manually operated valve(s) in the foam solution line from the proportioner to the discharge device(s) must be
chained or locked in the open position or equipped with tamper alarm switch(es) which are monitored by a
supervisory panel alarm.
The major concern is the possibility that any manually operated valve(s) in the foam solution line to the
hazard(s) could inadvertently be left in the closed position during a fire condition, which would prevent the foam
solution from reaching the hazard(s) in the event of an automatic trip sequence.
A. Off Loading:
WARNING:
Be sure the module is properly secured and balanced during any lifting or moving procedure. If the module is
not properly secured in the lifting device, damage to the module or injury to personnel could result.
1. To avoid damage, the module should be left in
its shipping carton or crate until time of installation into foam system.
6/05
2-8
INSTALLATION
B. Installation:
6. Regarding only ILBP Module(s) that have a diaphragm valve with manual override capability:
If the module is used with an Automatic Zone Foam
Concentrate Supply Valve, the Manual Foam Concentrate Supply Valve "V" is still required for manual
override pressure regulation. Refer to Operating
Schematic Dwg. Fig. 3-1 or Fig. 3-3 for valve
locations and normal stand-by position.
7. Cycle all valves to insure freedom of movement and
that they open and close properly.
8. For NF recommended components - valves, strainers, gauges and connections, and their location in the
system, refer to the Operating Schematic Drawing
Fig. 3-1, 3-2 or 3-3.
9. Check that the system is properly installed according
to design with all necessary valves, correct pipe
sizes, discharge devices and discharge device locations, and is installed in compliance with local codes.
10. Hydrostatically test piping in accordance with procedures outlined in the latest edition of the applicable
section of NFPA.
11. Flush the foam concentrate piping before introducing foam concentrate into the foam system.
12. Follow the procedures outlined in Section 2-2., C.
Installation, Item Nos. 7 and 8. Refer to System
Flushing procedures outlined in Sect. 4-15.
6/05
2-9
INSTALLATION
C. Operating Requirements:
1. Foam concentrate pressure to the ILBP Module
inlet must exceed water pressure inlet by at least
30 psi (2.0 Bar) unless otherwise approved by
NF Engineering Department.
2. ILBP Module maximum working pressure - 200
psi(13.7 Bar).
3. Regarding only ILBP Module(s) that have a
diaphragm valve with manual override capability:
The Manual Override Handwheel on the diaphragm valve must be in the normal stand-by
6/05
4. The foam concentrate pump shall be suitably anchored to eliminate vibration and movement. Level
and shim as necessary.
5. Follow the procedures outlined in Section 2-2., C.
Installation, Item No. 10 thru 15.
6. If applicable, check the foam concentrate pump
relief valve for proper installation. See manufacturer's
instructions.
7. Run a foam concentrate pump relief valve pressure
setting check as described in Section 2-2., C. Installation, Item No. 22. NOTE: NF foam concentrate
pump relief valves are factory set at 200 psi (standard). For a relief valve pressure setting other than
standard, refer to the pump outline drawing or contact NF Engineering.
2-10
INSTALLATION
C. General System:
1. A check valve (customer supplied) must be
installed in the foam concentrate piping main
downstream of the Pump and Pressure Sustaining Module foam concentrate discharge connection. Refer to Operating Schematic Dwg. Fig.31 or 3-2 for location.
2. A 3/4" relief valve is required in the foam
concentrate piping main. The relief valve shall be
installed downstream of the check valve referred to
in item 1. The discharge from the relief valve shall
be piped to the foam concentrate return line downstream of the pressure sustaining valve. Refer to
Operating Schematic Dwg. Fig. 3-1, 3-2 or 3-3 for
location in the system.
3. All interconnecting piping to and from the components must be self-supported. Plastic foam
concentrate storage tanks must have flexible
connection fittings installed between the tank
and proportioning equipment to eliminate stress
imposed by the piping and to eliminate vibration.
4. Hydrostatically test piping in accordance with
procedures outlined in the latest edition of the
applicable section of NFPA.
5. Follow the procedures outlined in Section 2-2.,
C. Installation, Item Nos. 5 thru 9. Refer to
System Flushing procedures outlined in Sect. 414.
6/05
2-11
INSTALLATION
2-5.
CAUTION:
The pressure switch must have the high limit
jockey pump shutoff point set below the system
design discharge pressure.
1. The completed system shall be tested by qualified personnel to meet the approval of the authority having jurisdiction. These tests shall be adequate to determine that the system has been
properly installed, and will function as intended.
2. Foam systems shall be examined visually to
determine that they have been properly installed.
They shall be inspected for such items as conformity with installation plans; continuity of piping; removal of temporary blinds; accessibility
of valves; controls, and gages; and proper installation of vapor seals, where applicable. Devices
shall be checked for proper identification and
operating instructions.
3. Before acceptance, all operating devices and
equipment shall be tested for proper function.
4. A full scale test shall be run after the system is
6/05
2-12
6/00
3-1
DESIGNATION
MANUAL
FLUSH-OUT CONNECTION
STRAINER FLUSH-OUT
B2
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
WATER LINE
CHECK VALVE
OVERRIDE
SENSING LINE
COMPONENTS PROVIDED BY NF
LEGEND
TO DIAPHRAGM VALVE
CLOSED
OPEN
OPEN
CLOSED
CLOSED
CLOSED
OPEN
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
AUTO.
PRESSURE SWITCH
Closed
Open
Open
Wet
System
OU
ND
CO
MP
GA
UG
E
(M
AUXILIARY
FOAM CONCENTRATE
PUMP
(OPTIONAL)
ANTI-VIBRATION
FLEXIBLE COUPLING
BODY
DRAIN
PLUG
NT
OU
B2
B1
PRESSURE
GAUGE
FIG3-123.P65
FIG3-1.DSF
PRIMARY
FOAM CONCENTRATE
PUMP
WA
SU TER
PP
LY
MAIN WATER
SUPPLY VALVE
WATER PUMP
(IF REQUIRED)
PRESSURE
SUSTAINING
VALVE
MANUAL OVERRIDE
HANDWHEEL
JOCKEY PUMP
(OPTIONAL)
T)
RU
ST
NINU
O
D
R
TE
AR
ST
Closed
Closed
Closed
Dry
System
FIELD
CONNECTIONS
(Typical)
Field Piping
FLEXIBLE
EXPANSION JOINT
SO FOA
LU M
TIO
N
DRAIN CONNECTION
FILL CONNECTION
INSPECTION HATCH
ILBP MODULE
SCHEMATIC
- TYPICAL -
NOTES:
FLUSH-OUT CONNECTION
FLUSH-IN CONNECTION
DIAPHRAGM VALVE
COMPOUND GAUGE
PRESSURE GAUGE
DUPLEX GAUGE
STRAINER
RELIEF VALVE
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
(AUXILIARY PUMP)
(PRIMARY PUMP)
B1
DRAIN VALVES
FLUSH-IN CONNECTION
VALVE DESCRIPTION
POSITION
6/00
3-2
DESIGNATION
MANUAL
FLUSH-OUT CONNECTION
STRAINER FLUSH-OUT
B2
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
WATER LINE
CHECK VALVE
OVERRIDE
SENSING LINE
COMPONENTS PROVIDED BY NF
LEGEND
CLOSED
OPEN
CLOSED
CLOSED
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
AUTO.
PRESSURE SWITCH
Closed
Open
Open
Wet
System
B
S
AU
GE
MP
OU
ND
G
CO
AUXILIARY
FOAM CONCENTRATE
PUMP
(OPTIONAL)
BODY
DRAIN
PLUG
P
V
B2
B1
PRESSURE
GAUGE
FIG3-123.P65
FIG3-2.DSF
PRIMARY
FOAM CONCENTRATE
PUMP
WA
SU TER
PP
LY
MAIN WATER
SUPPLY VALVE
WATER PUMP
(IF REQUIRED)
PRESSURE
SUSTAINING
VALVE
JOCKEY PUMP
(OPTIONAL)
)
UT
TR
I-S
UN
ON
D
TE
R
TE
AR
ST
N
OU
(M
ANTI-VIBRATION
FLEXIBLE COUPLING
Closed
Closed
Closed
Dry
System
FIELD
CONNECTIONS
(Typical)
DRAIN CONNECTION
FILL CONNECTION
INSPECTION HATCH
Field Piping
FLEXIBLE
EXPANSION JOINT
SO FOA
LU M
TIO
N
ILBP MODULE
SCHEMATIC
- TYPICAL -
NOTES:
FLUSH-OUT CONNECTION
FLUSH-IN CONNECTION
DIAPHRAGM VALVE
COMPOUND GAUGE
PRESSURE GAUGE
DUPLEX GAUGE
STRAINER
RELIEF VALVE
CLOSED
CLOSED
CLOSED
CLOSED
(AUXILIARY PUMP)
(PRIMARY PUMP)
B1
DRAIN VALVES
FLUSH-IN CONNECTION
VALVE DESCRIPTION
POSITION
6/00
3-3
DESIGNATION
MANUAL
STRAINER FLUSH-OUT
B2
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
WATER LINE
CHECK VALVE
OVERRIDE
SENSING LINE
COMPONENTS PROVIDED BY NF
LEGEND
TO DIAPHRAGM VALVE
CLOSED
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
OPEN
OPEN
OPEN
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
CLOSED
OPEN
OPEN
AUTO.
PRESSURE SWITCH
Closed
Closed
Closed
Dry
System
Closed
Open
Open
Wet
System
FIELD
CONNECTIONS
(Typical)
CO
MP
OU
ND
GA
UG
E
AUXILIARY
FOAM CONCENTRATE
PUMP
(OPTIONAL)
JOCKEY PUMP
(OPTIONAL)
B2
B1
PRESSURE
GAUGE
FIG3-123.P65
FIG3-3.DSF
PRIMARY
FOAM CONCENTRATE
PUMP
WA
SU TER
PP
LY
MAIN WATER
SUPPLY VALVE
WATER PUMP
(IF REQUIRED)
PRESSURE
SUSTAINING
VALVE
MANUAL OVERRIDE
HANDWHEEL
T)
RU
ST
NINU
O
D
TE
R
TE
AR
ST
N
OU
(M
ANTI-VIBRATION
FLEXIBLE COUPLING
Field Piping
FLEXIBLE
EXPANSION JOINT
SO FOA
LU M
TIO
N
DRAIN CONNECTION
FILL CONNECTION
INSPECTION HATCH
ILBP MODULE
SCHEMATIC
- TYPICAL -
NOTES:
FLUSH-OUT CONNECTION
FLUSH-IN CONNECTION
DIAPHRAGM VALVE
COMPOUND GAUGE
PRESSURE GAUGE
DUPLEX GAUGE
STRAINER
RELIEF VALVE
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
CLOSED
OPEN
OPEN
OPEN
(AUXILIARY PUMP)
(PRIMARY PUMP)
B1
FLUSH-OUT CONNECTION
DRAIN VALVES
FLUSH-IN CONNECTION
VALVE DESCRIPTION
POSITION
CHAPTER 3 - OPERA
TING PROCEDURES
OPERATING
3-1.
BAR/PSI
3" RCF/RCW
2" RCT
6.9/100
6.2/90
4" RCF/RCW
6" RCF/RCW
8" RCF/RCW
5.5/80
4.8/70
4.1/60
3.4/50
2.7/40
2.06/30
1.3/20
60
GPM
227
LPM
80
303
100
379
200
757
400
1514
600
2271
800 1000
3028 3785
2000
7571
4000
15141
FIGURE 3-4
RATIO CONTROLLER MINIMUM INLET PRESSURE VS. SOLUTION FLOW CHART
6/00
3-4
OPERATING PROCEDURES
3-2.
OPERATION OF SYSTEM
8. Regarding only ILBP Module(s) that have a diaphragm valve with manual override capability:
6/00
3-5
OPERATING PROCEDURES
3-3.
NOTE: The instructions in sub-section A. below, apply only to ILBP Module Diaphragm Valves with manual
override capability. These instructions do not apply to Diaphragm Valves which do not have manual
overrride capability.
A. ILBP Module:
NOTE: Used only when system will not balance
automatically.
3. Slowly close Valve "C" until system design pressure is indicated on the discharge pressure gauge.
CAUTION:
An operator must remain stationed at the pump
and pressure sustaining module while the pressure is manually controlled to adjust for variations in pressure.
3-4.
SHUTDOWN
6/00
OPERATING PROCEDURES
CAUTION:
Only foam concentrate of the type listed on the
tank nameplate shall be used to replenish the tank.
Mixing of different types or brands of foam concentrate could cause failure of the system.
6. Replace all frangible components such as glass diaphragms, rupture discs, etc., in foam lines or foam
making devices.
6/00
3-7
4-1.
4-2.
4-3.
ANNUAL TESTING
At least annually, all foam systems shall be thoroughly inspected and checked for proper operation. This shall
include performance evaluation of the foam concentrate or premix solution quality or both. Deviation of
results exceeding 10 percent from those recorded in acceptance testing shall be discussed immediately with
the manufacturer. Regular service contracts are recommended. The goal of this inspection and testing shall
be to ensure that the system is in full operating condition, and that it will remain in that condition until the
next inspection. The inspection report, with recommendations, shall be filed with the owner. Between the
regular service contract inspections or tests, the system shall be inspected by competent personnel following
an approved schedule.
6/00
4-1
WARNING:
The intervals in this chapter are a general recommendation; some environmental conditions may dictate
such inspections and maintenance be performed at more frequent intervals.
NOTE: The following recommendations are based on normal operating conditions. Due to environmental or other
conditions unique to your system, the frequency of some inspecton and maintenance procedures may need to be
adjusted. Additional inspection and maintenance procedures may also be required.
NOTE: When performing inspection and maintence procedures which:
a. require operation of the system or parts of the system,
b. cause the system to be non-operational during the procedure,
c. cause a trouble indication,
the system should be taken out of service and the proper authorities should be notified.
DESCRIPTION
4-4. TOTAL SYSTEM
1. Check all valves to insure that they are in the
normal stand-byposition. See Operating
Schematic Dwg. Fig. 3-1, 3-2 or 3-3.
2. Check that Manual Override Handwheel is in the
normal stand-by position for automatic
balancing. Refer to Sect. 2-3.C., item 3.
3. Inspect system for physical damage and repair.
4. Check the complete system, all valves, fittings &
connections for leakage.
5. Perform normal maintenance and inspection of the
fire water supply system to insure that the fire
pumps will be operational when required.
6. Perform the system testing after installation as
prescribed in Sect. 2-5 of this manual.
7. Perform annual system test as prescribed in
Sect. 4-3 of this manual.
8. Flush and drain the concentrate system. See
Flushing instructions Sect. 4-14 & 4-15 of this
manual.
9. Cycle manual valves where practical.
6/00
START
AFTER
UP
OPERATION WEEKLY MONTHLY
SEMIANNUAL ANNUAL
OTHER
AFTER
ALL
MAINT.
PROCEDURES
AFTER
MAINTENANCE
TO PIPING
4-2
6/00
START
AFTER
UP
OPERATION WEEKLY MONTHLY
SEMIANNUAL ANNUAL
AFTER
FLOW TEST
(PER NFPA)
AFTER
FLOW TEST
(PER NFPA)
MFR. RECOM.
OTHER
MFR. RECOM.
MFR. RECOM.
4-3
START
AFTER
UP
OPERATION WEEKLY MONTHLY
SEMIANNUAL ANNUAL
OTHER
WARNING:
When automated foam concentrate valves
are cycled, Valve "V"must be closed.
2.
3.
4.
4-8.
1.
WARNING:
When water powered ball valves are cycled,
Valve "V" must be closed.
2. If applicable, cycle the valve(s) using the solenoid
release.
WARNING:
3.
4.
5.
4-9.
1.
2.
3.
4.
5.
6.
6/00
4-4
START
AFTER
UP
OPERATION WEEKLY MONTHLY
6/00
SEMIANNUAL ANNUAL
OTHER
4-5
6/00
4-6
Return all valves to their normal stand-by position (reinstall body drain plug). Refer to Normal
Stand-By Valve Position Chart on Operating
Schematic Dwg. Fig. 3-2.
8. Return all valves to their normal stand-by position (reinstall diaphragm valve body drain plug).
Refer to Normal Stand-By Valve Position Chart
on Operating Schematic Dwg. Fig. 3-1 or 3-3.
6/00
4-7
TROUBLESHOOTING
See Table 5-1 for Troubleshooting Problems, Possible Causes and Corrective Actions. These procedures
cover problems that may be experienced during normal operations. Although these recommendations cover
most problems that are experienced there are some situations that may occur which are not covered in these
instructions. Please contact National Foam's Engineering Department for problems that cannot be resolved
thru the use of this manual.
5-2. No
Proportioning
POSSIBLE CAUSE
CORRECTIVE ACTION
6/00
5-1
TROUBLESHOOTING
No Proportioning
continued
POSSIBLE CAUSE
CORRECTIVE ACTION
6/00
Diaphragm Valve Foam Concentrate FlushOut Valve "R" open or partially open.
5-2
TROUBLESHOOTING
No Proportioning
continued
5-3. Low
Percent of
Proportioning
6/00
POSSIBLE CAUSE
CORRECTIVE ACTION
TROUBLESHOOTING
Low Percent of
Proportioning
continued
POSSIBLE CAUSE
CORRECTIVE ACTION
6/00
5-4
TROUBLESHOOTING
Low Percent of
Proportioning
continued
5-4. High
Percent of
Proportioning
6/00
POSSIBLE CAUSE
CORRECTIVE ACTION
TROUBLESHOOTING
High Percent of
Proportioning
continued
POSSIBLE CAUSE
CORRECTIVE ACTION
5-5. No Flow
at Discharge
Device(s)
Partial blockage in water or foam solution line. Find blockage and remove.
5-7. No
Operation
6/00
Power failure.
Fill tank.
5-6
Na
tional F
oam
National
Foam
3.3.1
3.3.2
3.3.3
Contents
1 - Introduction 03
2 - Basic Instructions ..........................................................05
2.1 Safety Instructions.......................................................05
2.2 Delivery .....................................................................05
2.3 Storage .....................................................................05
2.3.1 Drying the Windings ....................................06
3 - Installation 07
3.1 Mechanical Aspects..................................................07
3.1.1 Foundation...................................................07
3.1.2 Types of bases ............................................07
3.1.3 Alignment.....................................................08
3.1.4 Coupling ......................................................09
3.1.5 Bearing Load (Stresses on the bearings) ....10
3.2 Electrical Aspects......................................................16
3.2.1 Feed System ...............................................16
3.2.2 Starting of Electric Motors ...........................16
3.2.3 Motor Protection ..........................................18
3.3 Start-up19
3.3.1 Preliminary Inspection .................................19
3.3.2 The First Start-up.........................................21
3.3.3 Operation.....................................................21
3.3.4 Stopping ......................................................21
4 - Maintenance.....................................................................25
4.1 Cleanliness ...............................................................25
4.2 Lubrication ................................................................25
4.2.1 Periodical Lubrication ..................................25
4.2.2 Quality and Quantity of Grease ...................25
4.2.3 Lubricating Instructions................................25
4.2.4 Replacement of Bearings ............................26
4.3 Air Gap Checking......................................................26
4.4 Explosion Proof Motor Repair Steps.........................27
4.4.1 Objective......................................................27
4.4.2 Repair Procedure and Precautions .............27
4.4.3 Miscellaneous Recommendations...............27
5 - Malfunctioning ..............................................................28
5.1 Standard Three-phase Motor Failures......................28
5.1.1 Short Circuits Between Turns ......................28
5.1.2 Winding Failures..........................................28
5.1.3 Rotor Failures ..............................................29
5.1.4 Bearing Failures ..........................................29
5.1.5 Shaft Fractures ............................................29
5.1.6 Unbalanced V-Belt Drives............................29
5.1.7 Damage Arising from Poorly Fitted
Transmission Parts or
Improper Motor Alignment ...........................29
5.2 Troubleshooting Chart ..............................................30
6 - Spare Parts and Component Terminology ...................31
3
1. Introduction
2. Basic Instructions
2.2 Delivery
Prior to shipment, motors are factory-tested and balanced. They
are packed in boxes or bolted to a wooden base.
Upon receipt, we recommend careful handling and a physical
examination for damage which may have occurred during
transportation.
In the event of damage and in order to guaranty insurance
coverage, both the nearest WEG sales office and the carrier
should be notified without delay.
2.3 Storage
Motors should be raised by their eyebolts and never by their
shafts. It is important that high rating three-phase motors be
raised by their eyebolts. Raising and lowering must be steady
and joltless, otherwise bearings may be harmed.
When motors are not immediately installed, they should be
stored in their normal upright position in a dry even temperature
place, free of dust, gases and corrosive atmosphere.
Other objects should not be placed on or against them.
Motors stored over long periods are subject to loss of insulation
resistance and oxidation of bearings.
Bearings and lubricant deserve special attention during
prolonged periods of storage. Depending on the length
and conditions of storage it may be necessary to regrease
or change rusted bearings. The weight of the rotor in an
inactive motor tends to expel grease from between the
Example:
Ambient temperature = 50C
Motor winding resistence at 50C = 1.02 M W
Correction to 40C
R 40C = R 50C x K 50C
R 40 C = 1.02 x 1.3
R 40 C = 1.326 M W
The minimum resistence Rm will be:
Rm = Vn + 1
Rm = 0.440 + 1
Rm = 1.440 M W
On new motors, lower values are often attained due to solvents
present in the insulating varnishes that later evaporate during
normal operation. This does not necessarily mean that the motor
is not operational, since insulating resistance will increase after
a period of service.
On motors which have been in service for a period of time
much larger values are often attained. A comparison of the
values recorded in previous tests on the same motor under
similar load, temperature and humidity conditions, serves as a
better indication of insulation condition than that of the value
derived from a single test. Any substantial or sudden reduction is
suspect and the cause determined and corrective action taken.
Insulation resistance is usually measured with a MEGGER.
In the event that insulation resistance is inferior to the values
derived from the above formula, motors should be subjected to a
drying process.
Heat for drying can be obtained from outside sources (an oven),
energization of the space heater (optional), or introducing a
current through the actual winding of the motor being dried.
Winding Temperature (C)
R40 C = Rt x Kt 40 C
Figure 2.1.
3. Installation
Where:
F1 and F2
g
G
Tmax
A
3.1.1 Foundation
The motor base must be levelled and as far as possible free of
vibrations. A concrete foundation is recommended for motors
over 100 HP. The choice of base will depend upon the nature
of the soil at the place of erection or of the floor capacity in the
case of buildings.
When dimensioning the motor base, keep in mind that the motor
may occasionally be run at a torque above that of the rated full
load torque.
Based upon Figure 3.1, foundation stresses can be calculated
by using the following formula:
F1 = 0.2247 (0.009 x g x G - 213 Tmx/A)
b) Foundation Studs
Very often, particularly when drive is by flexible coupling the
motor is anchored directly to the base with foundation studs.
It is recommended that shim plates of approximately 0.8 inches
be used between the foundation studs and the feet of the motor
for replacement purposes. These shim plates are useful when
exchanging one motor for another of larger shaft height due to
variations allowed by standard tolerances.
Foundation studs should neither be painted nor rusted as both
interfere with to the adherence of the concrete, and bring about
loosening.
After accurate alignment and levelling of the motor, the
foundation studs are cemented and their screws tightened to
secure the motor.
3.1.4 Coupling
Figure 3.8a - Pulley extractor
a) Direct Coupling
Direct coupling is always preferable due to its lower cost, space
economy, no belt slippage and lower accident risk.
In the case of speed ratio drives, it is also common to use a
direct coupling with a reducer (gear box).
CAUTION: Carefully align the shaft ends using, whenever
feasible, a flexible coupling.
Figure 3.7 - A type of direct coupling
b) Gear Coupling
Bearing
6205-Z
6206-Z
6307-Z
6308-Z
6308-Z
6309 C3
6309 C3
6311 C3
6312 C3
6314 C3
Size X Inches
0.79
1.7
3.03
1.69
1.57
1.85
3.23
1.81
2.86
2.90
4.37
4.41
2.36
2
3.46
1.93
3.00
3.06
4.54
4.59
5.08
7.44
8.73
3.15
3.94
4.72
3.16
3.22
4.72
4.77
5.19
7.76
9.00
4.92
4.97
5.47
7.94
9.28
5.65
8.18
9.57
Ball Bearing
Frame
400
440
500
5008
580
Important:
Poles
Bearing
II
6314 C3
IV-VI-VII
6314 C3
II
6314 C3
IV-VI-VIII
6319 C3
II
6314 C3
IV-VI-VIII
6319 C3
II
6314 C3
IV-VI-VIII
6322 C3
II
6314 C3
IV-VI-VIII
6322 C3
Roller Bearing
Size X Inches
1.97
3.15
4.33
5.51
7.3
7.62
7.94
8.24
11.75
23.54
44.66
57
12.16
24.34
45.79
58
12.61
25.12
46.98
59
Bearing
Size X Inches
1.97
4.33
5.51
6.69
8.27
NU 316
4.13
4.31
4.49
4.67
4.85
NU 319
4.02
4.17
4.32
4.47
4.62
4.82
NU 319
6.52
6.73
6.95
7.17
7.39
7.67
NU 322
8.73
8.95
9.96
11.34
12.87
14.82
NU 322
10.72
10.91
11.11
11.31
11.50
11.76
13.08
25.87
48.23
60
1) Peripheral speeds for solid grey cast iron pulleys FC 200 is V = 115 ft/s
2) Use steel pulleys when peripheral speed is higher than 115 ft/s
3) V-belt speed should not exceed 115 ft/s.
Table 2 - Maximum acceptable radial load (Lbf)
10
3.15
Nema 56 Motors
Frame
Distance X
Poles
56A
56B
56D
1,18
II
88
59
IV
88
59
II
88
59
IV
86
59
II
127
70
IV
141
70
80 LMS
II
355
80 MMS
II
359
80 SMS
II
357
427
555
90 LMS
II
IV
F
R
A
M
E
140
W 180
180
W 210
210
W 250
250
280
320
360
400
440
500
5008
II
103
108
149
196
189
282
273
355
374
890
877
842
769
791
IV
141
145
207
264
257
372
368
480
498
1,181
1,148
1,303
1,250
1624
VI
167
180
249
326
315
443
436
551
588
1,144
1,347
1,563
1,481
1909
VIII
187
202
286
368
357
485
485
624
668
1,323
1,521
1,821
1,728
2137
II
112
154
269
329
324
471
463
621
703
890
877
842
769
791
IV
152
209
370
447
443
620
615
826
930
1,181
1,148
1,303
1,250
1624
VI
185
255
443
544
533
734
727
959
1,091
1,375
1,347
1,563
1,481
1909
VIII
207
286
500
610
599
811
813
1,082
1,232
1,552
1,521
1,821
1,728
2137
II
99
94
136
176
160
240
220
275
266
745
705
568
355
728
IV
132
130
189
238
220
317
310
388
366
985
890
884
721
1548
VI
158
165
229
297
275
394
379
427
432
1,144
1,060
1,109
844
1808
VIII
178
183
266
339
310
414
421
502
511
1,323
1,241
1,488
1,190
2029
II
105
141
253
310
295
430
410
540
597
745
705
568
355
728
IV
143
194
352
421
405
564
557
736
793
985
890
884
721
1548
VI
174
240
421
518
493
685
672
838
937
1,144
1,060
1,109
844
1808
VIII
198
269
480
582
553
743
749
961
1,078
1,323
1,241
1,488
1,109
2029
580
679
1,406
1,649
1,865
679
1,406
1,649
1,865
033
474
549
597
033
474
549
597
F
R
A
M
E
II
IV
II
IV
II
IV
II
IV
56 A
68
90
83
112
63
85
79
108
56 B
66
90
81
110
63
83
77
105
56 D
63
88
105
145
59
81
101
138
11
12
13
14
5min
15min
30 at
60min
Continuous
1.10
1.20
1.50
Intermittent (passenger or
freight elevators, tools,
pumps, rolling bridges etc)
0.85
0.85
0.90
1.40
0.85
0.90
0.95
1.40
Variable
1.10
1.20
1.50
2.00
Duty
Classification
16
b) Locate the rated voltage of the motor and the feed network
distance in the upper part of the corresponding table. The point
of intersection of the distance column and the line referring
to current will indicate the minimum required gauge of the
conductor.
Example:
Size the conductors for a 15 HP, three-phase, 230V, 42A,
motor located 200 feet from the main supply with cables laid in
conduits.
a) Current to be located: 1.25 x 42A = 52.5A
b) Closest value on table 6:55A
c) Minimum gauge: 6 AWG
Direct Starting
Whenever possible a three-phase motor with a squirrel cage
rotor should be started directly at full supply voltage by means of
a contactor (Connection diagram a). This method is called Directon-Line (DoL) starting.
51
102
204
250
69
138
276
338
85
170
340
420
102
204
408
501
137
274
548
670
14
14
12
12
10
8
6
4
2
14
14
12
12
10
8
6
4
2
14
14
12
12
10
8
6
4
2
14
14
12
10
8
8
6
4
2
14
12
12
10
8
6
6
4
2
14
12
10
8
6
6
4
2
2
Current (A)
5
10
15
20
30
40
55
70
95
171
342
684
840
205
410
820
1010
240
480
960
1181
273
546
1092
1342
308
616
1232
1515
342
684
1368
1680
428
856
1712
2105
514
1028
2056
2530
12
8
6
6
4
2
1/0
1/0
2/0
12
8
6
4
2
2
1/0
2/0
3/0
10
8
6
4
2
2
1/0
2/0
3/0
10
6
4
4
2
1/0
1/0
2/0
4/0
8
6
2
2
1/0
2/0
2/0
2/0
250M
12
10
8
6
6
4
2
2
1/0
12
10
6
6
4
2
2
1/0
1/0
Table 5 - Wire and cable gauges for three-phase motor installation - aerial conductors with 25cm spacing (voltage drop < 5%)
Supply Voltage
115
230
460
575
69
138
276
338
85
170
340
420
102
204
408
501
137
274
547
670
171
342
684
840
Current (A)
15
20
30
40
55
70
100
130
175
225
275
320
205
410
820
1010
240
480
960
1181
273
546
1092
1342
308
616
1232
1515
342
684
1368
1680
428
856
1712
2105
514
1028
2056
2530
685
1370
2740
3350
8
6
4
2
2
1/0
4/0
------
8
6
4
2
1/0
2/0
4/0
------
6
4
2
2
2/0
3/0
-------
6
4
2
1/0
3/0
--------
4
2
1/0
2/0
---------
14
14
12
10
10
8
6
4
2
1/0
2/0
3/0
14
12
10
10
8
6
4
4
2
1/0
2/0
3/0
12
12
8
8
8
6
4
2
1/0
2/0
4/0
4/0
12
10
8
8
6
4
2
1/0
2/0
3/0
---
10
10
8
6
4
2
2
1/0
3/0
----
10
8
6
4
4
2
1/0
2/0
-----
10
8
6
4
2
2
2/0
4/0
-----
8
8
4
4
2
1/0
3/0
------
Table 6 - Wire and cable gauges for three-phase motor installation (voltage drop < 5%) (in conduits)
Supply Voltage
115
230
460
575
102
204
408
501
120
240
480
590
137
274
548
670
171
342
684
840
Current (A)
15
20
30
40
55
70
95
125
145
165
195
215
240
265
280
320
205
410
820
1010
240
480
960
1181
273
546
1092
1342
308
616
1232
1515
342
684
1368
1680
428
856
1712
2105
514
1028
2056
2530
8
6
4
4
2
1/0
1/0
2/0
3/0
3/0
4/0
250M
300M
350M
400M
500M
6
6
4
2
2
1/0
1/0
3/0
3/0
4/0
250M
250M
300M
350M
400M
500M
6
6
4
2
1/0
1/0
2/0
3/0
4/0
4/0
250M
300M
300M
350M
400M
500M
6
4
2
2
1/0
2/0
3/0
4/0
250M
250M
300M
350M
400M
500M
400M
500M
4
4
2
1/0
1/0
2/0
4/0
250M
300M
350M
350M
400M
500M
500M
---
12
10
8
8
6
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M
12
10
8
6
6
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M
10
10
8
6
4
4
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M
10
8
6
6
4
2
2
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M
8
8
6
4
4
2
1/0
1/0
2/0
3/0
4/0
250M
300M
350M
400M
500M
8
6
6
4
2
2
1/0
2/0
2/0
3/0
4/0
250M
300M
350M
400M
500M
Note: The above indicated values are orientative. For guaranteed values, contact the Local Power Company.
17
There are DOL starter assemblies available combining a threepole contactor, a bimetal relay (overload protection device), and
a fuse (short circuit protection on branch circuit).
DOL starting is the simplest method, only feasible however,
when the locked rotor current (LRC) does not influence the main
electric supply lines.
Initial locked rotor current (LRC) in induction motors reach
values six to eight times the value of the full load current.
During starting by the DOL method, starting current can reach
these high levels. The main electrical supply should be rated
sufficiently, such that during the starting cycle no supply
disturbance to others on the power network is caused by the
voltage drop in the main supply.
This can be achieved under one of the following situations:
a) The rated main supply current is high enough for the locked
rotor current not to be proportionally high;
b) Motor locked rotor current is low with no effect on the
networks.
c) The motor is started under no-load conditions with a short
starting cycle and, consequently, a low locked rotor current
with a transient voltage drop tolerable to other consumers.
Star-Delta starting
It is fundamental to star-delta starting that the three-phase motor
has the necessary numbers of leads for both connections:
6 leads for Y/
or 12 leads for YY/
All the connections for the various voltages are made through
terminals in the terminal box in accordance with the wiring
diagram that accompanies the motor. This diagram may be
shown on the nameplate or in the terminal box.
The star-delta connection is usually used only in low-voltage
motors due to normally available control and protection
devices. In this method of starting the locked rotor current is
approximately 30% of the original LRC. The locked rotor torque
is reduced proportionally as well. For this reason, it is very
important before deciding to use star-delta starting to verify if the
reduced locked rotor torque in STAR connection is enough to
accelerate the load.
3.3 Start-up
3.3.1 Preliminary Inspection
Before starting a motor for the first time, it will be necessary to:
a) Remove all locking devices and blocks used in transit and
check that the motor rotates freely;
b) Check that the motor is firmly secured and that coupling
elements are correctly mounted and aligned.;
Current-based
protection
Causes of
overheating
Fuse only
Fuse and
thermal
protector
Protection
with
probe
thermistor
in motor
Caption:
unprotected
partially protected
totally protected
19
CONNECTION DIAGRAMS
a) Direct starting
POWER NETWORK
c) Auto-transformer starting
POWER NETWORK
20
b) Star-Delta starting
POWER NETWORK
3.3.3 Operation
Drive the motor coupled to the load for a period of at least one
hour while watching for abnormal noises or signs of overheating.
Compare the line current with the value shown on the
nameplate.
Under continuous running conditions without load fluctuations
this should not exceed the rated current times the service factor,
also shown on the nameplate.
All measuring and control instruments and apparatus should
be continuously checked for anomalies, and any irregularities
corrected.
3.3.4 Stopping
Warning:
To touch any moving part of a running motor, even though
disconnected, is a danger to life and limb.
a) Three-phase motor with cage rotor:
Open the stator circuit switch. With the motor at a complete
stop, reset the auto-transformer, if any, to the start position;
21
143 T
145 T
182 T
184 T
W 182 T
W 184 T
213 T
215 T
W 213 T
W 215 T
254 T
256 T
W 254 T
W 256 T
284 T and TS
286 T and TS
324 T and TS
326 T and TS
364 T and TS
365 T and TS
404 T
404 TS
405 T
405 TS
444 T
444 TS
445 T
445 TS
447 T
447 TS
449 T
449 TS
504 T
504 TS
505 T
505 TS
5008 T
5008TS
586 T
586 TS
587 T
587 TS
Saw Arbor
motor
frame
80 S MS
80 M MS
80 L MS
90 L MS
22
Rear (O.D.E.)
6202 Z
6202 Z
6202 Z
6202 Z /
6203 Z
ALL FORMS
Front (D.E.)
Open drip proof motors
6203 Z
6203 Z
6203 Z
6204 Z
Frames
6204 ZZ
6204 ZZ
6206 ZZ
6206 ZZ
6205 ZZ
6205 ZZ
6207 ZZ
6207 ZZ
6207 ZZ
6207 ZZ
6209 Z-C3
6209 Z-C3
6209 Z-C3
6209 Z-C3
6211 Z-C3
6211 Z-C3
6212 Z-C3
6212 Z-C3
6314-C3
6314-C3
6314-C3
6314-C3
6314-C3
6414-C3
6316-C3
6314-C3
6316-C3
6314-C3
6316-C3
6314-C3
6319-C3
6314-C3
6316-C3
6314-C3
6316-C3
6314-C3
6319-C3
6314-C3
6319-C3
6314-C3
6319-C3
6314-C3
Bearings
ODP Motors
Nema-T
frames
E143/5T
F143/5T
182 T
184 T
213/5T
254 T
256 T
284 T
284 TS
286 T
286 TS
324 T
324 TS
326 T
326 TS
364 T
364 TS
365 T
365 TS
404 T
404 TS
405 T
405 TS
444 T
444 TS
445 T
445 TS
IEC
B3
Rear (O.D.E.)
6207 ZZ
6207 ZZ
6207 ZZ
6208 ZZ
Front (D.E.)
6205 ZZ
6205 ZZ
6206 ZZ
6202 ZZ
6208 ZZ
6309 Z-C3
6309 Z-C3
6311 Z-C3
6311 Z-C3
6311 Z-C3
6311 Z-C3
6312 Z-C3
6312 Z-C3
6312 Z-C3
6312 Z-C3
6314 C3
6314 C3
6314 C3
6314 C3
NU 316 C3
6314 C3
NU 316 C3
6314 C3
NU 319 C3
6314 C3
NU 319 C3
6314 C3
Rear (O.D.E.)
6204 ZZ
6204 ZZ
6205 ZZ
6205 ZZ
6206 ZZ
6209 Z-C3
6209 Z-C3
6211 Z-C3
6211 Z-C3
6211 Z-C3
6211 Z-C3
6212 Z-C3
6212 Z-C3
6212 Z-C3
6212 Z-C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6314 C3
6316 C3
6314 C3
6316 C3
6314 C3
Bearings
Mounting
frame
63
71
80
90 S - L
100 L
112 M
132 S - M
160 M - L
180 M - L
200 M - L
225 S/M
250 S/M
280 S/M
315 S/M
Mounting
Front (D.E.)
6307 ZZ
6307 ZZ
6307 ZZ
6308 ZZ
Bearings
Mounting
NEMA
355 M/L
Front (D.E.)
Rear (O.D.E.)
Totally enclosed fan cooled motors
6201 ZZ
6201 ZZ
6203 ZZ
6202 ZZ
6204 ZZ
6203 ZZ
6205 ZZ
6204 ZZ
6206 ZZ
6205 ZZ
6307 ZZ
6206 ZZ
6308 ZZ
6207 ZZ
6309-C3
6209 Z-C3
6211 Z-C3
B3
6311-C3
6312-C3
6212 Z-C3
6314-C3
6314-C3
6314-C3
6314-C3
6314-C3
6314-C3
6316-C3
6316-C3
6314-C3
6314-C3
6319-C3
6316-C3
6314-C3
6314-C3
NU 322-C3
6319-C3
II Pole
IV Pole
60Hz
1800
rpm
50Hz
1500
rpm
VI Pole
60Hz
1200
rpm
50Hz
1000
rpm
VIII Pole
60Hz
900
rpm
50Hz
750
rpm
X Pole
60Hz
720
rpm
50Hz
600
rpm
XII Pole
Characteristics
Ref.
60Hz
3600
rpm
50Hz
3000
rpm
60Hz
600
rpm
50Hz Amount
500 of grease
rpm
(oz)
6200
12500
13800
6201
11700
13000
16600
18400
6202
10500
11900
15400
17100
19500
0,07
6203
9800
11200
14500
16200
18500
0,11
6204
8700
10100
13300
14800
17100
19100
6205
8000
9400
12600
14100
16200
18200
19300
6206
7300
8700
12000
13400
15400
17200
18300
6207
6600
8100
11400
12700
14500
16300
17300
19200
0,25
0,07
0,07
0,14
> 20000
0,14
0,18
6208
5900
7400
10800
12000
13700
15300
16300
18200
0,29
6209
5300
6900
10400
11600
13400
15000
16000
17800
0,29
6210
4900
6400
9700
11000
12900
14600
15600
17300
0,32
6211
4300
5900
9500
10900
12700
14400
15300
17000
0,39
6212
3800
5400
9300
10300
12400
14300
15200
16500
0,46
6213
3100
4900
8900
10100
12200
14000
14800
16100
0,50
6214
1100
2000
4100
5000
5900
6500
6900
7600
0,54
6215
1000
1800
4400
5000
5600
6300
6700
7600
0,61
6216
700
1600
4100
4700
5700
6500
6800
7500
0,68
6304
8700
10100
13300
14800
17100
19100
6305
8000
9400
12600
14100
16200
18200
0,14
19300
0,21
0,25
6306
7300
8700
12000
13400
15400
17200
18300
6307
6600
8100
11400
12700
14500
16300
17300
19200
6308
5900
7400
10800
12000
13700
15300
16300
18200
18600
6309
5300
6900
10400
11600
13400
15000
16000
17800
18200
19900
6310
4900
6400
9700
11000
12900
14600
19500
17300
17700
19500
19500
0,54
6311
4300
5900
9500
10900
12700
14400
15300
17000
17400
19000
19000
0,64
6312
3800
5400
9300
10300
12400
14300
15200
16500
16800
18200
18200
0,75
6313
3100
4900
8900
10100
12200
14000
14800
16100
16400
17900
17900
19700
0,86
6314
1100
2000
4100
5000
5900
6500
6900
7600
7700
8600
8600
9600
0,96
> 20000
0,32
0,39
0,46
6315
1000
1800
4400
5000
5600
6300
6700
7600
7900
8900
8900
9900
1,07
6316
700
1600
4100
4700
5700
6500
6800
7500
7700
8500
8500
9500
1,22
6317
800
1300
3900
4700
5600
6300
6700
7400
7500
8300
8300
9300
1,32
6318
1000
3800
4600
5500
6200
6600
7200
7400
8200
8200
9100
1,47
6319
800
3700
4500
5400
6100
6500
7100
7300
8000
8000
8900
1,61
6320
3600
4300
5300
6000
6300
7000
7100
7900
7900
8800
1,82
6321
3400
4200
5100
5800
6200
6800
7000
7800
7800
8700
2,00
6322
3100
4000
5000
5700
6100
6700
6900
7700
7700
8600
2,14
1) Lubrication periodicity valid for NLG 1 and lithium based bearing lubricant.
2) Bearings for motors of X and XII poles - Lubrication Intervals > 20,000.
23
II Pole
IV Pole
VI Pole
X Pole
XII Pole
60Hz
3600
rpm
50Hz
3000
rpm
60Hz
1800
rpm
50Hz
1500
rpm
60Hz
1200
rpm
50Hz
1000
rpm
60Hz
900
rpm
50Hz
750
rpm
60Hz
720
rpm
50Hz
600
rpm
60Hz
600
rpm
50Hz Amount
500 of grease
rpm
(oz)
NU309
2800
4000
8300
9500
10700
11800
12500
14100
14500
16300
16300
18200
0,46
NU310
2400
3600
7900
9100
10300
11400
12200
13700
14000
15800
15800
17700
0,54
NU311
2000
3200
7400
8700
10000
11000
11800
13300
13600
15400
15400
17200
0,64
NU312
1600
2700
6900
8300
9600
10700
11400
12800
13200
14900
14900
16800
0,75
NU313
1500
2500
6600
8100
9400
10500
11200
12700
13000
14700
14700
16500
0,86
NU314
700
1100
3100
3900
4600
5200
5500
6200
6400
7200
7200
8100
0,96
Characteristics
Ref.
NU315
900
2900
3800
4500
5100
5500
6200
6300
7100
7100
7900
1,07
NU316
800
2800
3600
4400
5000
5400
6100
6200
7000
7000
7800
1,22
NU317
600
2600
3500
4300
4900
5300
6000
6100
6900
6900
7700
1,32
NU318
2100
3300
4300
4900
5300
5900
6000
6700
6700
7500
1,47
NU319
2300
3200
4100
4700
5100
5800
6000
6700
6700
7500
1,61
NU320
2000
3000
4000
4700
5000
5700
5900
6600
6600
7300
1,82
NU321
1900
2800
4000
4600
4900
5600
5700
6500
6500
7200
2,00
NU322
1900
2600
3900
4400
4800
5500
5600
6400
6400
7100
2,14
1) Lubrication periodicity valid for NLG 1 and 2 lithium based bearing lubricant.
24
VIII Pole
4. Maintenance
4.1 Cleanliness
Motors should be kept clean, free of dust, debris and oil. Soft
brushes or clean cotton rags should be used for cleaning. A jet
of compressed air should be used to remove non-abrasive dust
from the fan cover and any accumulated grime from the fan and
cooling fins.
Oil or damp impregnated impurities can be removed with rags
soaked in a suitable solvent.
Terminal boxes fitted to motors with IP55 protection should be
cleaned; their terminals should be free of oxidation, in perfect
mechanical condition, and all unused space dust-free.
Motors with IPW 55 protection are recommended for use under
unfavourable ambient conditions.
4.2 Lubrication
Proper lubrication extends bearing life.
Supplier
Grease
Temperature range
143T-215T
254T to 586/7
Esso
Shell
Alvania R3
Unirex N2
-20 to 130C
-30 to 165C
Substitutes
Supplier
Grease
Temperature Range
Mobil
ESSO
Atlantic
Texaco
Molikote
Inisilkon
Mobilith SHC100
Beacon 2
Litholine 2
Multifak 2
BG 20
L5012
-40 to 177C
-20 to 130C
-20 to 130C
-20 to 130C
-45 to 180C
-20 to 200C
26
4.3
4.4
4.4.1 Objective
In view of the heavy liability associated with burning of motors
of this type, this product has been designed and manufactured
to high technical standards, under rigid controls. In addition, in
many areas it is required that explosion proof motors ONLY be
repaired by licensed personnel or in licensed facilities authorized
to do this type of work.
The following general procedures, safeguards, and guidelines
must be followed in order to ensure repaired explosion proof
motors operate as intended.
4.4.2
IMPREGNATION
Protect all frame threads by inserting corresponding bolts, and
the joint between terminal box and frame, by coating it with a
non-adhesive varnish (ISO 287 - ISOLASIL).
Protective varnish on machined parts should be removed soon
after treating with impregnating varnish. This operation should
be carried out manually without using tools.
ASSEMBLY
Inspect all parts for defects, such as cracks, joint incrustations,
damaged threads and other potential problems.
Assemble using a rubber headed mallet and a bronze bushing
after ascertaining that all parts are perfectly fitted.
Bolts should be positioned with corresponding spring washers
and evenly tightened.
TESTING
Rotate the shaft by hand while examining for any drag problems
on covers or fastening rings.
Carry out running tests as for standard motors.
MOUNTING THE TERMINAL BOX
Prior to fitting the terminal box all cable outlets on the frame
should be sealed with a sealing compound (Ist layer) and an
Epoxy resin (ISO 340) mixed with ground quartz (2nd layer) in the
following proportions:
340A resin
340B resin
Ground quartz
50 parts
50 parts
100 parts
Drying time for this mixture is two hours during which the frame
should not be handled and cable outlets should be upwards.
When dry, see that the outlets and areas around the cables are
perfectly sealed.
Mount the terminal box and paint the motor.
4.4.3
Miscellaneous Recommendations
27
5. Malfunctioning
28
29
PROBABLE CAUSE
1.No voltage supply
2. Low voltage supply
3. Wrong control connections
4. Loose connection at some
terminal lug
5. Overload
1. Unbalance
2.
3.
4.
5.
6.
Distorted shaft
Incorrect alignment
Uneven air gap
Dirt in the air gap
Extraneous matter stuck between
fan and motor casing
7. Loose motor foundation
8. Worn bearings
Overheating of bearings
1. Excessive grease
2.
3.
4.
5.
1. Unbalanced rotor
2. Dirty or worn bearing
3. Bearing rings too tight on shaft
and/or bearing housing
4. Extraneous solid particles in
bearing
Overheating of motor
30
CORRECTIVE MEASURES
Check feed connections to control system and from this to motor.
Check voltage supply and ascertain that voltage remains
within 10% of the rated voltage shown on the motor nameplate.
Compare connections with the wiring diagram on the
motor nameplate.
Tighten all connections.
Try to start motor under no-load conditions. If it starts,
there may be an overload condition or a blocking of
the starting mechanism. Reduce load to rated load level
and increase torque.
Vibrations can be eliminated by balancing rotor. If load is
coupled directly to motor shaft, the load can be unbalanced.
Shaft key bent; check rotor balance and eccentricity.
Check motor aligment with machine running.
Check shaft for warping or bearing wear.
Dismantle motor and remove dirt or dust with jet of dry air.
Dismantle motor and clean. Remove trash or debris from
motor vicinity.
Tighten all foundation studs. If necessary, realign motor.
Check lubrication. Replace bearing if noise is excessive
and continuous.
Remove grease bleeder plug and run motor until excess
grease is expelled.
Reduce belt tension.
Have shaft straightened and check rotor balance.
Replace bearings before they damage shaft.
Check end shields for close fit and tightness around circumference.
Add grease to bearing.
Replace bearings.
Flush out housings and relubricate.
Balance rotor statically and dynamically.
If bearing rings are in perfect condition, clean and
relubricate the bearing, otherwise, replace bearing.
Before altering shaft or housing dimensions, it is advisable
to ascertain that bearing dimensions correspond to
manufacturers specifications.
Take bearing apart and clean. Reassemble only if rotating
and support surfaces are unharmed.
Clean and dry motor; inspect air vents and windings periodically.
Check application, measuring voltage and current under
normal running conditions.
Compare values on motor nameplate with those of mains
supply. Also check voltage at motor terminals under full load.
Exchange motor for another that meets needs.
Check bearing wear and shaft curvature.
Check for unbalanced voltages or operation under
single-phase condition.
THREE-PHASE MOTORS IP55 NEMA Frames 140T - W180T - 180T - 210T and W210T
Part Nr.
1
2
3
4
5
6
7
8
9
10
11
12
Description
Terminal box cover
Terminal box cover fixing bolt
Terminal box cover gasket
Terminal box fixing bolt
Terminal box fixing washer
Terminal box grounding lug
Terminal box
Frame grounding lug
Terminal box oring gasket
Fan cover
Fan cover fixing bolt
Fan
Part Nr.
Description
13
14
15
16
17
18
19
20
21
22
23
24
VRing
Non-drive end endshield fixing bolt
Non-drive end endshield washer
Non-drive endshield
Spring washer
Non-drive bearing
Fan fixing pin
Wound stator
Rotor / shaft assembly
Nameplate fixing rivet
Nameplate
Frame
Part Nr.
25
26
27
28
29
33
31
Description
Shaft key
Drive end bearing
Drive endshield
Drive endshield washer
Drive end endshield fixing bolt
VRing
Drain plug
THREE-PHASE MOTORS IP55 NEMA Frames 250T - W250T - 280T and 320T
Part Nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
Terminal box cover
Terminal box cover fixing bolt
Terminal box cover gasket
Terminal box fixing bolt
Terminal box fixing washer
Terminal box grounding lug
Terminal box
Frame grounding lug
Terminal box oring gasket
Fan cover
Fan cover washer
Fan cover fixing bolt
Fan
Non-drive end bearing cap bolt
VRing
Part Nr.
Description
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Part Nr.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
Description
Nameplate
Frame
Shaft key
Drive end bearing cap
Drive end bearing
Drive andshield
Drive end grease nipple cover
Drive endshield washer
Drive end endshield fixing bolt
Drive end bearing cap washer
VRing
Drive end bearing cap fixing bolt
Drain plug
Non-drive and grease relief
Drive end grease relief
31
THREE-PHASE MOTORS IP55 NEMA T Frames 360T - 400T - 440T - 500T and 580T
Part Nr.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
32
Description
Terminal box cover
Terminal box cover fixing bolt
Terminal box cover washer
Terminal box cover gasket
Terminal box fixing bolt
Terminal box fixing washer
Terminal box grounding lug
Terminal box
Frame grounding lug
Terminal box oring gasket
Nameplate fixing rivet
Nameplate
Eyebolt
Fan cover
Fan cover washer
Fan cover fixing bolt
Fan fixing ring
Part Nr.
Description
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Fan
Non-drive end bearing cap bolt
VRing
Non-drive end bearing cap washer
Non-drive end endshield fixing bolt
Non-drive end endshield washer
Non-drive end grease nipple
Non-drive end grease nipple cover
Non-drive enshield
Bearing cap
Non-drive bearing
Internal non-drive end bearing cap
Fan fixing key
Wound stator
Rotor / shaft assembly
Frame
Part Nr.
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Description
Shaft key
Internal drive end bearing cap
Drive end bearing
Drive endshield
Drive end grease nipple cover
Drive endshield washer
Pre-load spring
Drive end endshield fixing bolt
External drive end bearing cap
Drive end bearing cap washer
VRing
Drive end bearing cap fixing bolt
Drain plug
External non-drive end bearing cap
Non drive end grease relief
Non-drive end grease relief
THREE-PHASE MOTORS NEMA 56 Frames A56 - B56 - D56 - F56H and G56H
Part Nr.
1
2
3
4
5
6
7
Description
Sticker
Terminal box cover fixing bolt
Terminal box cover
Grounding lug
Through bolt fastening nut
Non-drive endshield
Spring washer
Part Nr.
8
9
10
11
12
13
Description
Non-drive end bearing
Wound stator
Rotor / shaft assembly
Frame
Through bolt
Shaft key
Part Nr.
Description
14
15
16
17
Fan
Drive end bearing fastening washer
Drive end bearing
Drive endshield
SINGLE-PHASE MOTORS NEMA 56 Frames B48 - C48 - C56 - A56 - B56 - D56 - F56H - G56H
Part Nr.
1
2
3
4
5
6
7
8
9
10
11
Note:
Description
Sticker
Capacitor cover fixing bolt
Terminal box cover fixing bolt
Terminal box cover
Grounding lug
Through bolt fastening nut
Non-drive endshield
Spring washer
Non-drive and bearing
Non-drive and bearing fastening
washer
Stationary switch
Part Nr.
Description
Part Nr.
12
13
14
23
24
25
26
27
15
16
17
18
19
20
21
22
Description
Drive end bearing fastening washer
Drive end bearing
Drive endshield
Overload thermal protector fixing ring
Overload thermal protector
For F56H and G56H frame motors: 1) Part nr. 2 = 3 pieces; 2) Part nr. 15 and 16 = 2 pieces
33
NOTES:
34
NOTES:
35
THE FOLLOWING
INSTALLATION AND
MAINTENANCE MANUALS
ARE AVAILABLE
3.4.1
Curvde # 80428SDF
Issue Date: August 1999
8.00
7.00
HORSEPOWER
6.00
5.00
4.00
3.00
2.00
1.00
0.00
5
50
100
150
200
50
40
30
20
1800 RPM
1500 RPM
1200 RPM
1000 RPM
10
0
5
50
100
150
200
PH: 503/659-4198
FX: 503/659-4696
EMAIL: edwards_info@pentairpump.com
WEBSITE: www.edwardsmfg.com
3.4.2
GKWT.EX5231
Pumps, Foam Concentrate
Page Bottom
EX5231
800 AIRPORT RD
NORTH AURORA, IL 60542 USA
Model
Size, In.
Speed Range
rpm
Pressure Range
psi
Max Working
Pressure psi
20-412SDF
1-1/2
1000-1800
40-200
400
20-414SDF
1-1/2
1000-1800
40-200
400
20-416SDF
1-1/2
1000-1800
40-200
400
20-418SDF
1-1/2
1000-1800
40-200
400
20-420SDF
1-1/2
1000-1800
40-200
400
20-412HDF
1-1/2
1000-1800
200-300
550
20-414HDF
1-1/2
1000-1800
200-300
550
20-416HDF
1-1/2
1000-1800
200-300
550
20-418HDF
1-1/2
1000-1800
200-300
550
20-420HDF
1-1/2
1000-1800
200-300
550
80-424SDF
1-1/2
1000-1800
40-200
400
80-428SDF
1-1/2
1000-1800
40-200
400
80-432SDF
1-1/2
1000-1800
40-200
400
80-440SDF
1-1/2
1000-1800
40-200
400
80-424HDF
1-1/2
1000-1800
200-300
550
80-428HDF
1-1/2
1000-1800
200-300
550
80-432HDF
1-1/2
1000-1800
200-300
550
80-440HDF
1-1/2
1000-1800
200-300
550
150-324SDF
1000-1800
40-200
400
150-332SDF
1000-1800
40-200
400
150-338SDF
1000-1800
40-200
400
150-344SDF
1000-1800
40-200
400
150-348SDF
1000-1800
40-200
400
160-324HDF
1000-1800
200-300
550
3.4.3.1
160-332HDF
1000-1800
200-300
550
160-338HDF
1000-1800
200-300
550
160-344HDF
1000-1800
200-300
550
160-348HDF
1000-1800
200-300
550
300-360SDF
1000-1800
40-200
400
300-368SDF
1000-1800
40-200
400
300-372SDF
1000-1800
40-200
400
300-388SDF
1000-1800
40-200
400
300-360HDF
1000-1800
200-300
550
300-368HDF
1000-1800
200-300
550
300-372HDF
1000-1800
200-300
550
300-388HDF
1000-1800
200-300
550
300-388HDF-AG
1000-1800
200-300
550
400-092HDF
1000-1800
40-300
550
400-112HDF
1000-1800
40-300
550
400-128HDF
1000-1800
40-200
400
400-140HDF
1000-1800
40-200
400
The maximum viscosity of foam concentrate intended for use with these pumps is 2700 cps.
Last Updated on 2006-02-14
Questions?
Notice of Disclaimer
Page Top
3.4.4
Contents
Safety
Inspection . . . . . . . . . . . . . . . . . . . . . . 3-1
Unpacking . . . . . . . . . . . . . . . . . . . . . . 3-1
Repacking . . . . . . . . . . . . . . . . . . . . . . 3-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Installation. . . . . . . . . . . . . . . . . . . . . . 3-2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . iii
Cautions . . . . . . . . . . . . . . . . . . . . . . . . . iv
General
Introduction . . . . . . . . . . . . . . . . . . . . 1-1
Pump Specifications . . . . . . . . . . . . . 1-2
Maintenance
Consumable Materials . . . . . . . . . . . . 2-1
Lubrication . . . . . . . . . . . . . . . . . . . . . 2-2
Troubleshooting . . . . . . . . . . . . . . . . . 2-2
Removal . . . . . . . . . . . . . . . . . . . . . . . 2-3
Disassembly . . . . . . . . . . . . . . . . . . . . 2-4
General Practice . . . . . . . . . . . . . . . . . 2-4
Disassembly Procedure . . . . . . . . . . . . 2-4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 2-6
Inspection . . . . . . . . . . . . . . . . . . . . . . 2-7
Repair and Replacement . . . . . . . . . . 2-7
Assembly . . . . . . . . . . . . . . . . . . . . . . 2-8
Installation
Parts
Warranty
Replacement. . . . . . . . . . . . . . . . . . . 2-12
Safety
General Precautions
The following are general safety precautions not related to any specific procedure. Personnel must understand and apply these precautions during both operation and maintenance of the pump.
Do Not Operate Pump Without Ear Protection. The pump has heat-treated steel
timing gears, which can be very noisy when operated above 900 rpm.
Be Aware of High Heat When Unit Is Running. Both operating and maintenance
personnel must observe all safety precautions at all times. To avoid injury, always deenergize the input power sources and lock-out or red-tag the controller. Let the pump
cool before handling.
Be Aware of Chemical Hazards. Maintenance personnel must observe all safety precautions while working with the chemicals used in cleaning agents.
Warnings
Do not perform maintenance using this manual if the model number on the
pump is not 80-428 or the serial number is not ________________. Performing
maintenance using the wrong manual could result in pump failure or personal
injury.
To avoid injury, always de-energize the input driver and lock-out or red-tag the
controller. Let the pump cool before removing.
To avoid injury, always use suitable protective gear. The timing gear is hot!
Overpressurization of the pump can cause equipment failure, resulting in personal injury.
iii
Do not order parts using this manual if the model number on the pump is not
80-428 or the serial number is not ________________. Using parts ordered from
the wrong manual could result in pump failure or personal injury.
Cautions
Do not hammer on pump endcase. This will cause gasket sealing surface damage, resulting in leaks.
Use shaft protector between puller tip and shaft face to prevent distortion of
shaft center.
Never hammer directly on pump drive shaft. This will cause the rotor assembly to become misaligned, resulting in incorrect internal clearances. Also,
hammering on the shaft ends may damage the shaft centers.
Never dip or soak packings, rubber, plastic, or teflon parts in dry cleaning
solvent. Wipe with clean, lint-free cloth. Solvent can react with material and
result in severe damage or destruction of parts.
Do not use excessive force when installing seals. This could damage the seals,
causing them to leak. Use approved tools available from EMI.
Do not rotate rotor assemblies until bearings have been installed and adjusted.
Damage to rotors and liners may occur.
Make sure liners fit into counterbore on endcase, and that they can be fully
seated into the endcase counterbore without using excessive force. Damage to
endcases and liners could occur.
Support ends of shafts axially with a jaw puller on the endcase when installing ball bearings to avoid damaging liners and rotors. The jaw puller should
be used on the shaft end opposite the end where the bearing is being installed.
Use a shaft protector to avoid damaging shaft center.
Do not overtighten bearing adjusting nut setscrews. Excessive bearing preload
may result, causing bearing damage.
Rotary pumps have close running clearances. Thus, clean piping is a must.
Dirt, grit, weld bead or scale, flushed from an unclean piping system, will
damage and may stall the pump. Flush the system thoroughly before connecting piping to pump.
iv
General
Introduction
pump
(Figure
a standard-duty
high-speed
gearThe Edwards Model
Model 80-428
80 pump
(Figure
1-1)1-1)
is a is
standard-duty
high-speed
gear-driven
driven positive-displacement
with gear-type
The casing,
liners, and
positive-displacement
rotary rotary
pump pump
with gear-type
rotors.rotors.
The pump
is self-priming.
rotors arerotary
bronze.
The drive
and idler rotor
shafts
are stainless steel.
pump
fitted
Edwards
pumps
are available
in many
configurations.
WhileThe
they
mayislook
with lip
seals,
andbeissignificant
self-priming.
alike,
there
may
differences from one pump to another. Differences
include construction material, sealing method, rotor type, etc.
Edwards rotary pumps are available in many configurations. While they may look alike,
there may be significant differences from one pump to another. Differences include construction material, sealing method, rotor type, etc. This manual covers only one configuration, which is defined by a model number and a serial number. Check the name plate
on the pump to make sure the model number is 80-428 and the serial number is
________________. If the numbers do not match, contact EMI
1070_0001c.cdr
Figure
Edwards
Model
80 Pump
Figure
1-1. 1-1.
Edwards
Model
80-428
Pump
1-1
Maintenance
Do not perform maintenance using this manual if the model number on the
pump is not 80-428 or the serial number is not ________________. Performing
maintenance using the wrong manual could result in pump failure or personal
injury.
Edwards rotary pumps are available in many configurations. While they may look alike,
there may be significant differences from one pump to another. Differences include construction material, sealing method, rotor type, etc. This manual covers only one configuration, which is defined by a model number and a serial number. Check the name plate
on the pump to make certain the model number is 80-428 and the serial number is
________________. If the numbers do not match, contact EMI.
Most pump repairs can be performed by maintenance personnel using normally available tools.
Consumable Materials
Cleaning materials, lubricants, and other products needed during pump maintenance
are listed in Table 2-1.
Table 2-1. Consumable Materials
Item
Nomenclature
Specification
Common Name
Lint-Free Cloth
MIL-C-85043
Emery Cloth
Anti-Seize Compound
Nevr Seize
Red Loctite
PermaLoc HH-120
Loctite, Permatex
Acetone, Brake
Cleaner
220 Grit
3M, Anderson,
Sandvik, Mirka
2-1
Nomenclature
Lapping Compound
Specification
MIL-G-18709
Common Name
NLGI #2
Chevron Ulti-Plex,
Shell Retina LC
Felpro Clover
Brand
Lubrication
To ensure a long service life, the pump should be lubricated routinely with approved
grease (7, Table 2-1). If the pump is operating under normal loads and temperatures,
use the intervals defined in Table 2-2. If the pump is operating at over 180F, contact
EMI
for for
recommended
lubrication
interval
for your
application.
Pentair
recommended
lubrication
interval
for your
application.
Table 2-2.
2-2. Model
Model 80-428
80 Lubrication
Schedule
Table
Lubrication
Schedule
Item
Interval
Amount of Grease
Bearings
6,000 Hours
0.25 Ounce
Timing Gears
6,000 Hours
1.00 Ounce
Troubleshooting
Table 2-3 provides assistance in diagnosing and correcting malfunctions that may occur
during normal operation.
Table 2-3. Troubleshooting
Trouble
1.
2-2
2.
Pump does
not turn
Excessive
Noise
Probable Cause
Remedial Action
2b. Cavitation.
Maintenance
3.
4.
Excessive
vibration
Reduced flow
Probable Cause
Remedial Action
3b. Cavitation.
4b. Cavitation.
Removal
To avoid injury, always de-energize the input driver and lock-out or red-tag the
controller. Let the pump cool before removing.
1. Before removing pump, refer to troubleshooting chart (Table 2-3) to determine if
the problem is actually the pump.
2. Ensure adequate clearance exists for removal of pump. Disassemble adjacent components as required for adequate working clearance.
3. Before removal, clean exterior parts to remove accumulated dirt, grease, or foreign
material.
4. Apply tags to identify parts of similar configuration to ensure correct installation.
2-3
Disassembly
General Practice
1. Keep work area as clean as possible to avoid contamination of internal parts.
2. Replace gaskets, packings, and seals removed during repair. Replace all keys, spring
washers, and like items during assembly.
3. When removing gaskets, packings, or seals, do not use a metal tool to pry, pick, or
scrape. Doing this could scratch sealing surfaces. Use wood or plastic scrapers to
remove gasket material.
4. Before disassembly of any component, study exploded view illustration (Figure 4-1).
Pay particular attention to relationship of internal parts. Being familiar with construction will speed up disassembly and help avoid improper assembly.
5. To prevent moisture or foreign material from entering open components, install
protective plugs or covers as soon as practical after disassembly. Wrap parts in clean
paper or clean lint-free cloths (1, Table 2-1).
6. Remove only the parts requiring repair or replacement. Do not disassemble pump
any further than necessary to complete needed repairs.
Disassembly Procedure
The pump can be
reassembled into
several configurations as shown in
Figure 2-1. Before
disassembling the
pump, circle the
configuration that
matches the pump
being repaired.
This will be an
invaluable aid during reassembly.
2-4
Remove machine
four machine
screws
(4, Figure
nuts (3),
timing
gear
1. Remove
screws
(4, Figure
4-1), 4-1),
nuts four
(3), timing
gear
cover
(2),cover
and (2),
and cover
gasket
Discard
gasket.
cover
gasket
(5). (5).
Discard
gasket.
2. Remove idler timing gear locknut (9).
3. Fabricate timing gear puller plate as shown in Figure 2-2.
.
Use shaft protector between puller tip and shaft face to prevent distortion of
shaft center.
Install timing gear puller
NCon
x 1-3/4-in.
Grade
8 cap
4. Install
puller plate
plate with
with two
cap 5/16
screws
idler timing
gear
(12,screws
Figureon
idler timing
gear (12, puller,
Figure pull
4-1).on
Using
jaw-type
puller,
on the gear
puller
4-1).
Using jaw-type
the gear
puller
platepull
to remove
the idler
timing
plate to
remove
idler timing
gear.
Repeat
procedure
for drive timing gear (11).
gear.
Repeat
procedure
for the
drive
timing
gear (11).
5. Remove Woodruff key (10) from drive shaft.
Remove machine
four machine
screws
(7), four
nuts (3),
front
(6), and
cover(5).
gasket
(5).
6. Remove
screws
(7), nuts
(3), front
cover
(6),cover
and cover
gasket
Discard
Discard gasket.
gasket.
7. Remove front cover seal (8) from front cover (6). Discard seal.
8. Remove
(13) from
endcases
(17).
Remove setscrews
four setscrews
(13) from
two endcases
(17).
9. Remove
bearing
adjusting
nuts
(14)
from
endcases
(17).
Remove four bearing adjusting nuts (14) from two endcases
(17).
10. Remove
cap screws
screws (18),
(18), nuts
2 nuts
(3),
andwashers
10 washers
timing
endcase
Remove8cap
(3),
and
(19) (19)
fromfrom
timing
geargear
endcase
(17).
(17).
Do not hammer on pump endcase. This will cause gasket sealing surface damage, resulting in leaks.
Use shaft protector between puller tip and shaft face to prevent distortion of
shaft center.
11. Using jaw-type puller, remove timing gear endcase (17) and pump body gasket (21).
Discard gasket.
Maintenance
UPPER DRIVE
SUCTION
PORT
DISCHARGE
PORT
DISCHARGE
PORT
RIGHT HAND
ROTATION
LEFT HAND
ROTATION
LOWER DRIVE
SUCTION
PORT
SUCTION
PORT
DISCHARGE
PORT
LEFT HAND
ROTATION
RIGHT HAND
ROTATION
1070_0002a.cdr
2-5
1
THRU
3/8 HOLES
(2 PLACES)
1-5/8
3/4
4
1-1/2
1070_0003b.cdr
12. Remove
Remove8cap
(3),
and
washers
(19) (19)
fromfrom
timing
geargear
endcase
(17).
capscrews
screws (18),
(18), nuts
2 nuts
(3),
and
10 washers
timing
endcase
(17).
13. Using jaw-type puller, remove drive endcase (17) and pump body gasket (21). Discard gasket.
Never hammer directly on pump drive shaft. This will cause the rotor assembly to become misaligned, resulting in incorrect internal clearances. Also,
hammering on the shaft ends may damage the shaft centers.
and hardwood
hardwoodblock,
block,tap
tappump
pumpdrive
driveshaft
shafttotoremove
removeidler
idler
and
14. Using hammer and
and
drive
drive
assemblies
(2324)
and
24)two
and
liners
(22).
rotor rotor
assemblies
(23 and
and
liners
(22).
15. Using hammer and hardwood
liners
pump
body
hardwood block,
block, remove
remove other
other two
liners
(22)(22)
fromfrom
pump
body
(27).
(27).
If damaged,
damaged, remove four
(26) from
pump
16. If
studsstuds
(26) from
pump
bodybody
(27).(27).
Using hammer and brass
bearings
fourseals
grease
seals
17. Using
brass drift,
drift, remove
removefour
ball ball
bearings
(15)(15)
andand
grease
(16)
from
(16) from(17).
two endcases (17).
endcases
18. Using hammer and brass
lip seals
two endcases
(17).
brass drift,
drift, remove
remove four
lip seals
(20)(20)
fromfrom
endcases
(17).
19. If damaged or plugged,
grease
fittings
(1) from
two endcases
plugged, remove
remove two
grease
fittings
(1) from
endcases
(17). (17).
20. If damaged or plugged, remove grease fittings (1) from timing gear cover (2).
Cleaning
Never dip or soak packings, rubber, plastic, or teflon parts in dry cleaning
solvent. Wipe with clean, lint-free cloth. Solvent can react with material and
result in severe damage or destruction of parts.
1. Use dry cleaning solvent (2, Table 2-1) to clean parts. Do not use gasoline for
cleaning parts.
2-6
Maintenance
2. After soaking parts in dry cleaning solvent, deposits may be washed away by
flushing or spraying. Where necessary, use soft-bristled, non-metallic brush moistened in solvent.
3. Except for bearings, dry parts using filtered, compressed air after cleaning.
4. Unless otherwise noted, do not use metal scrapers, wire brushes, abrasive wheels,
or compounds when cleaning parts.
5. Place ball or roller bearings in basket and suspend in container of dry cleaning
solvent overnight. If necessary, use soft-bristled brush to remove caked grease and
chips. Avoid rotating bearing before solid particles are removed to prevent damaging balls and races. After cleaning, dry bearings with low-pressure compressed air.
6. Check all passages and cavities for cleanliness and freedom from foreign material.
Use wire brush or pressurized spray gun and dry cleaning solvent to clean individual passages.
7. Buff bearing adjusting nut threads (14, Figure 4-1) with a wire brush.
Always replace
bearings whenever
possible. If new
bearings are not
available you may
clean and inspect
the bearings. The
bearings may be
reused if they are
not damaged.
Inspection
1. Check that rotor assemblies and liners are free of radial scoring and heat damage
(usually indicated by blue discoloration).
2. Check all surfaces in contact with gaskets, packings, or seals for nicks, burrs, or
scratches that may damage new parts during assembly.
3. Visually check castings or weldments for cracks.
4. Check bearings for rusted or pitted balls, races, or cage. Check balls and races for
brinelling, abrasions, and discoloration. Excluding defects that may cause bearing
binding or misalignment, nicks or gouges outside race load areas are not cause for
rejection. Bearings shall be rejected for cuts or grooves parallel to ball or roller rotation, or for fatigue pits (not minor machine marks or scratches).
5. Check all screws, nuts, fittings, and tapped holes for distortion and for stripped or
corroded threads.
3. Using 220 grit emery cloth or flat file, deburr all edges of pump parts, especially the
end covers (2 and 6) and endcases (17).
4. Repair of cracked castings and weldments is not authorized. Replace cracked or
damaged parts.
5. Replace all damaged screws, nuts, and fittings. Repair minor damage to tapped
holes with same size tap. Do not change size or thread type. Replace all self-locking
fasteners.
2-7
Assembly
General Practice
1. Remove any protective coatings from new parts.
2. Lubricate bearings with same type of lubricant normally used in pump or as
directed in specific repair procedure.
3. Lubricate lip of oil seals with lubricant specified in specific procedure. Install oil
seals, with lip facing out, by applying an even force to outer edge of seal. We recommend using an arbor press to seat the seals.
4. Coat both sides of gaskets with high-tack spray (6, Table 2-1). Be sure all old gaskets and sealant are removed from parts before installing new ones.
5. Hand-thread cap screws into parts until snug, then tighten in criss-cross pattern to
final torque. Install all cap screws, nuts, and fasteners using anti-seize compound
(4, Table 2-1) unless otherwise indicated in specific procedure.
If rotors are worn,
replace both rotor
assemblies.
Assembly Procedure
Assemble Rotors and Liners
If removed,
removed, install
install studs
four studs
(26, Figure
in pump
using
red Loctite
1. If
(26, Figure
4-1) 4-1)
in pump
bodybody
(27) (27)
using
red Loctite
(5,
Table
2-1).
Remove
all all
traces
of of
redred
Loctite
after
installing
studs.
(5, Table
2-1).
Remove
traces
Loctite
after
installing
studs.
2. Install
Install liners
two liners
in pump
Make
liner
suction
faces
pump
2.
(22) (22)
in pump
bodybody
(27).(27).
Make
suresure
liner
suction
holehole
faces
pump
body suction
suction port
port as
as shown
shown in
in Figure 2-3.
body
DISCHARGE
SIDE
SUCTION
HOLES
SUCTION
SIDE
1070_0017b.cdr
2-8
Maintenance
3. Install idler rotor assembly (23, ) in pump body (27) and into liner (22). Make sure
threaded end of rotor shaft is away from drive end of pump.
4. Install drive rotor assembly (24) in pump body (27) and into liner (22). Make sure
drive rotor shaft is in correct position (Figure 2-1) and short end of rotor shaft is
away from drive end of pump.
5. Install second set of liners (22, Figure 4-1) in pump body (27). Make sure suction
holes face pump body suction port.
InstallSeals
Seals(if pump has lip seals)
Install
and outside
outside diameters
diametersof
offour
lip seals
(20,(20,
Figure
4-1)4-1)
withwith
red red
1. Lightly coat bores and
lip seals
Figure
Loctite (5, Table 2-1).
Do not use excessive force when installing seals. This could damage the seals,
causing them to leak. Use approved tools available from Pentair.
EMI.
2.
seals
(20, Figure
4-1) in
seal
boresbores
of endcases
(17). Press
allseals
the
2. Install
Install lip
four
lip seals
(20, Figure
4-1)
in seal
of two endcases
(17).seals
Press
way
to
the
bottom
of
the
bore
as
shown
in
Figure
2-4.
We
recommend
using
an
all the way to the bottom of the bore as shown in Figure 2-4. We recommend using
arbor
press
to seat
thethe
seals.
Installation
tools
are
available
an arbor
press
to seat
seals.
Installation
tools
are
availablefrom
fromPentair.
EMI.
Pre-lubricate grease
four grease
(16) with
approved
grease
(7, Table
3. Pre-lubricate
sealsseals
(16) with
approved
grease
(7, Table
2-1).2-1).
Install grease
four grease
Figure
in two endcases
(17)
with sealing
lip facing
4. Install
sealsseals
(16, (16,
Figure
4-1) 4-1)
in endcases
(17) with
sealing
lip facing
toward counterbore
counterbore in
in endcase.
toward
CAP SCREW
BODY GASKET
BODY
ENDCASE
LINER
SEAL
INSTALLATION
CONE
ROTOR
ASSEMBLY
SEAL
1070_0004a.cdr
2-9
Install Endcases
1. Install new pump body gasket (21) to each side of the body (27).
Seals must be
installed in endcases before installing endcases.
2. Install large flat washer and nut (3) on one of the studs (26) on timing-gear end of
pump body (27). The outside diameter of the washer must overlap the liners (22) to
prevent the liners and rotors from being displaced during installation of the drive
endcase. Make sure liners are protruding at least 0.2 in. from the body before running the nut and washer up against liners.
3. Check that seals (20) have been installed in endcases (17) before proceeding with
endcase installation.
Make sure liners fit into counterbore on endcase, and that they can be fully
seated into the endcase counterbore without using excessive force. Damage to
endcases and liners could occur.
We highly
highly recomrecommend
you seal
use
mend you use
seal
installation
installation
cones
cones
on thefrom
rotor
(available
shafts
EMI) during
on the rotor
installation
of the
shafts during
endcases.
installation of the
endcases.
4. Starting with the drive end, carefully install endcase over idler and drive rotor
assemblies (23 and 24). Use caution not to damage seals (20).
5.
5.
6.
7.
Install cap
8 cap
screws
(18),
10 washers
and 2(3)
nuts
and tighten
finger-tight.
Install
screws
(18),
washers
(19), (19),
and nuts
and(3)
tighten
finger-tight.
Remove large washer and nut (3) from timing-gear end of pump body (27).
Carefully install other endcase (17) over idler and drive rotor assemblies (23 and
24). Use caution not to damage seals (20).
Install cap
8 cap
screws
(18),
10 washers
and 2(3)
nuts
and tighten
finger-tight.
8. Install
screws
(18),
washers
(19),(19),
and nuts
and(3)
tighten
finger-tight.
Install Bearings
1. Pack
(15) with
approved
grease
(7, Table
2-1).2-1).
Pack ball
four bearings
ball bearings
(15) with
approved
grease
(7, Table
Support ends of shafts axially with a jaw puller on the endcase when installing ball bearings to avoid damaging liners and rotors. The jaw puller should
be used on the shaft end opposite the end where the bearing is being installed.
Use a shaft protector to avoid damaging shaft center.
Bearing
Bearinginstallation
installatools
are available
tion tools
are availfrom
able Pentair.
from EMI.
2. Using
Using aa bearing
bearing seating sleeve,
bearings
Figure
on both
2.
sleeve, install
install two
ballball
bearings
(15,(15,
Figure
4-1)4-1)
on both
ends of
of idler
idler and
and drive rotor assemblies (23
ends
(23 and
and 24).
24). Make
Makesure
sureball
ballbearings
bearingsare
seated
on shoulders
of shafts
withwith
loading
grooves
facing
center
of pump.
are
seated
on shoulders
of shafts
loading
grooves
facing
center
of the pump.
Using criss-cross
criss-cross pattern, tighten
screws
(18)
lb-ft.
3. Using
tighten 16
capcap
screws
(18)
to to
12 12
to to
1515
lb-ft.
4.
Using
criss-cross
pattern,
tighten
nuts
(3)
to
8
to
10
lb-ft.
4. Using criss-cross pattern, tighten four nuts (3) to 8 to 10 lb-ft.
Adjust Rotor Clearance
2-10
1. Install
adjusting
nutsnuts
(14)(14)
on endcases
(17), leaving
about 1/2-turn
short
Install bearing
four bearing
adjusting
on two endcases
(17), leaving
about 1/2-turn
of
bearing
contact.
short
of bearing
contact.
2. On idler rotor assembly (23) tighten one bearing adjusting nut (14) until rotor contacts liner (22). Install dial indicator on opposite end of shaft as shown in Figure 25 and zero indicator.
3. Loosen previously tightened bearing adjusting nut (14). Tighten opposing bearing
adjusting nut until rotor just contacts the other liner and note reading. This is the
total clearance.
4. Loosen adjusting nut tightened in step 3 and tighten opposing adjusting nut until
dial indicator reading is half the total clearance reading obtained in step 3. (for
example, if the total clearance is 0.006 in., adjust for reading of 0.003 in.)
Maintenance
5. Slowly tighten adjusting nut opposing adjusting nut tightened during step 4 until
slight opposite dial indicator needle movement is observed. Do not overtighten.
.
ENDCASE
SECURE TO BOLT
DIAL INDICATOR
ROTOR SHAFT
1070_0018a.cdr
2. If possible, preheat drive timing gear (11, Figure 4-1) to 450F and install with Woodruff key (10) on drive rotor shaft (24). Position gear about 0.175 to 0.200 inch from
face of endcase (17). We recommend using shims for accurate positioning.
3. Cool drive timing gear (11) with compressed air. Do not quench gear with liquid.
4. After drive timing gear has cooled to ambient temperature, insert piece of 0.004- to
0.006-in. shim stock between rotors from the discharge port for lash adjustment.
Shim should feed into pump between rotors when drive rotor is turned in normal
direction of rotation.
5. Install idler timing gear (12) on idler shaft (23). Remove all lash between timing
gears in direction of rotation by turning idler timing gear until gear meshes fully
with drive timing gear (11).
2-11
6. After all lash has been removed, hold idler timing gear (11) in place while seating
gear by lightly tapping it with a bearing seating sleeve.
7. Apply anti-seize compound (4, Table 2-10) to timing gear locknut (9, Figure 4-1)
threads and install locknut on idler shaft. Wedge a piece of nylon or rawhide
between rotors to prevent rotation, and tighten locknut .to 90 lb-ft.
8. Remove shim stock and rotate drive rotor (24) in direction of rotation. The drive
rotor should rotate idler rotor (23) freely with no contact between rotors.
Install End Covers
1. Apply light coat of approved grease (7, Table 2-1) to rubber surface of new front
cover seal (8, Figure 4-1).
2. Install front cover seal (8) in front cover (6) with seal lips pointed toward inside of
cover. We recommend using an arbor press to seat the seal.
3. Apply
Apply light coat of approved grease
grease (7,
(7, Table
Table 2-1)
2-1) to
to front
front cover
cover gasket
gasketsurface
surfaceand
and
install
new
gasket
(5,
Figure
4-1),
front
cover
(6),
four
machine
screws
(7),
four
install
gasket (5, Figure 4-1), front cover (6), machine screws (7), andand
nuts
(3).
nuts (3).machine
Tighten screws
machine
to lb-ft.
12 to 15 lb-ft.
Tighten
toscrews
12 to 15
4. Fill timing gear cover (2) with about three 1/2-in. beads of approved grease (7, Table
2-1) around inside perimeter of cover.
5. Apply
Apply light
light coat
coat of
of approved
approved grease (7, Table
5.
Table 2-1)
2-1) to
to timing
timing gear
gearcover
coversealing
sealingsurface andand
install
newnew
gasket
(5, Figure
4-1),4-1),
timing
geargear
cover
(2), (2),
fourmachine
machine
surface
install
gasket
(5, Figure
timing
cover
screws (4),
(3). Tighten
screws
to 15 lb-ft.
screws,
andand
nutsfour
(3).nuts
Tighten
machinemachine
screws to
12 toto
1512
lb-ft.
Lubricate Bearings
If removed,
removed, install two
grease
fittings
(1)each
in each
endcase
twofittings
grease fit1. If
grease
fittings
(1) in
endcase
(17)(17)
andand
grease
(1)
tings
(1) in
timing
gear
in
timing
gear
cover
(2).cover (2).
2. Using grease gun, lubricate pump bearings with approved grease (7, Table 2-1)
through endcase grease fittings. Usually five to six pumps is sufficient when bearings have been previously packed.
Replacement
1. Be sure pump is oriented in same position as removed.
2. Check all identifying tags for correct connection of all lines and hoses.
3. Operate pump and inspect for proper adjustment, leaks, vibration, noise, or misalignment. Correct any problems.
2-12
Installation
Inspection
EMI pumps
are are
shipped
suitably
protected
to prevent
damage
in transit
fromfrom
normal
Pentair
pumps
shipped
suitable
protected
to prevent
damage
in transit
normal
handling. When
Whenreceived,
received,inspect
inspectthe
theshipment
shipmentimmediately:
immediately:
1. Check for damage to the packaging or crating and note it on the bill of lading.
2. Check for shipment shortages against the bill of lading.
3. Report shortages to the carrier and note them on the bill of lading.
4. Notify Pentair
EMI of damage
to contents
not not
a fault
of the
carrier,
or inorthe
of shortof damage
to contents
a fault
of the
carrier,
in event
the event
of
ages.
shortages.
Unpacking
Care must be taken when removing the pump from the shipping pallet. Remove pump
as follows:
1. Remove all protective material.
2. Remove all bolts securing pump to pallet.
3. Using suitable lifting device, lift pump from packing case.
4. Inspect equipment for proper lubrication prior to entering service.
Repacking
1. Using suitable lifting device, lift pump and place on pallet.
2. Secure pump to pallet.
3. Install protective material.
Storage
If the pump will not be installed immediately after receipt and inspection, the pump
should be repackaged and placed in suitable storage:
1. Inspect protective coatings on unpainted surfaces. (Do not disturb coatings.)
2. If protective coatings are damaged or if unpainted surfaces are not coated, apply
rust inhibiting protective coating to surfaces.
3-1
Installation
The pump can be installed wherever adequate space exists to connect piping and perform maintenance. The pump must be installed in compliance with regulatory body
codes (national, state, and local) in effect at the time of installation. In cases where a
code conflicts with the following instructions, the code shall prevail.
Clean Pump
To ensure that test fluids and/or preservatives do not contaminate the fluid to be
pumped, do the following:
1. Flush pump thoroughly before it is placed in service. The flushing media must be
compatible with the pump and seal materials.
2. Remove rust-inhibiting coatings on unpainted exterior surfaces with dry-cleaning
solvent (2, Table 2-3).
3. Cover ports and other openings until ready to install piping.
Mount Pump
Install pump on skid base along with the driver as shown in Figure 3-1. See Figure 3-2
for pump dimensions. and Figure 3-3 for mounting bolt locations.
.
PUMP
DRIVER
SKID BASE
1070_0019a.cdr
3-2
Installation
NOTES
14.375
7.75
8
5.0
3.75
2.75
2.25
0.625
4.5
5.9375
1070_0006d.cdr
6.25
3.13
2.50
2.50
CL PUMP
CL PUMP
0.38 HOLES
1.14
2.28
1070_0007c.cdr
3-3
Prepare Foundation
The foundation absorbs any vibration, strains, or shock, while providing a permanent,
rigid support for the pump skid.
1. Construct a foundation form that is 4 to 6 inches longer and wider than the skid
base. The foundation form height should be about twenty times the diameter of the
foundation bolts. See Figure 3-4 for a typical foundation form.
2. Make templates to position and hold foundation bolts in place while pouring concrete.
3. Fasten templates to foundation form.
4. Place form where pump is to be located.
5. Cut four 1.5-inch inside-diameter pipe sleeves 5 inches long.
Allow a cure time
for the concrete of
at least 14 days
prior to operation
of the pump. A cure
time of 28 days is
preferred.
6. Assemble foundation bolts as shown in Figure 3-5 and attach them to template.
Foundation bolts should extend about 2 to 2.5 inches above top of form.
7. Pour a concrete mix of 1:2:4 ratio by volume (cement, fine aggregate, coarse aggregate) into form. Leave surface rough for anchoring grout.
FOUNDATION
FORM
4 - 6'' LONGER
THAN PUMP
SKID BASE
4 - 6'' WIDER
THAN PUMP
SKID BASE
1070_0010a.cdr
3-4
Installation
PUT WASTE
AROUND BOLT
BEFORE POURING
CONCRETE
1/2
TEMPLATE
LEAVE SURFACE
ROUGH TO
ANCHOR GROUT
SLEEVE
5
1.5
WASHER
1/4
2
3
1070_0011a.cdr
2. Prepare grout mix of 1:2 ratio by volume (Portland cement and fine sand) with just
enough water to obtain creamy consistency and allow free flow under base.
3-5
FINISH
GROUTING
1/4
BASE
ALLOW
1/2 TO 3/4
FOR LEVELING
GROUT
LEAVE
LEVELING
WEDGES OR
SHIMS IN
PLACE
WOOD
FRAME
CLEAN AND
WET DOWN
TOP OF
FOUNDATION
1070_0012a.cdr
3-6
Installation
4. Start and stop the driver while observing driver shaft rotation. Driver rotation
must be same as pump rotation.
Align Couplings
The alignment of the pump and motor or engine driver must be checked before startup.
Maximum angular offset in the two coupling halves is 1 degree; maximum parallel offset is 0.015 inch. To align the pump and motor, loosen the mounting bolts, align the two
components, and tighten the bolts.
Couplings are intended to provide a mechanically flexible connection for two shaft ends.
Additionally, they provide limited shaft end float (for mechanical movement or thermal
expansion) and, within prescribed limits, angular and parallel misalignment of shafts.
Couplings are not intended to compensate for major angular or parallel misalignment.
The allowable misalignment varies with the type of coupling. Refer to the coupling
manufacturers literature for specific allowable limits. Any improvement in alignment
beyond the coupling manufacturers minimum specification will extend pump, mechanical seal or packing, coupling, and driver service life by reducing bearing loads and wear.
Misalignment of the pump and driver shafts may be angular (shaft axes concentric but
not parallel), parallel (shaft axes parallel but not concentric), or a combination of the
two, as shown in Figure 3-7.
Flexible coupling types in general use are chain, gear, steel grid, and flex member. For
aligning the pump and driver shafts, remove the coupling cover, then remove chain,
gear, steel grid, or flex member connecting the coupling halves.
ANGULAR
PARALLEL
For applications
where pumps are
operated at elevated
temperatures, final
alignment may not
be possible at operating temperature.
In this instance,
proper allowance
should be made for
the increase in
pump shaft height
due to thermal
expansion. As a
rule of thumb
(for cast iron or
steel pumps), a vertical allowance of
0.001 inch per inch
of pump shaft
height above the
base per 150F
(65C) should be
added to the height
of the driver shaft.
3-7
FEELER
GAUGE
1070_0014a.cdr
STRAIGHT
EDGE
SECURE
TO SHAFT
DIAL
INDICATOR
OR
1070_0015a.cdr
3-8
Installation
USE DIAL
INDICATOR
FOR PARALLEL
ALIGNMENT
SECURE BRACKET
TO COUPLING HALF
1070_0016a.cdr
Piping
Rotary pumps have close running clearances. Thus, clean piping is a must.
Dirt, grit, weld bead or scale, flushed from an unclean piping system, will
damage and may stall the pump. Flush the system thoroughly before connecting piping to pump.
Piping should be installed on supports independent of the pump. Supports must be
capable of carrying the mass of the pipe, insulation, and the fluid carried. Supports may
be hangers or stands that respectively carry the mass from above or below. Clamps or
brackets may be used to secure piping to existing columns. Supports must allow for free
movement of the piping caused by thermal expansion or contraction. Supports should
be installed at intervals such that piping load is uniformly and amply supported, precluding contact with adjacent piping and equipment. Pipe strains or stresses transmitted to the pump by improper piping support systems may cause pump distortion, wear
or binding of the rotary members, and excessive power requirements.
Piping systems containing expansion joints must be so designed that the expansion
joint is not exposed to motion greater than that for which the joint is designed. Expansion joints or flexible connectors should not be used to compensate for misaligned
piping.
Threaded joints should be coated with compounds compatible with but not soluble in
the liquid handled. Care must be taken with Teflon-taped joints to prevent shredded
pieces of Teflon from entering the piping system. Piping should start at the pump,
working toward the source of supply and the point of discharge. Shutoff valves and
unions are recommended to facilitate future inspection and repair. Reducers are preferred to bushings when a change in pipe size is necessary. Unnecessary restrictions in
the pipeline should be avoided, including elbows, sharp bends, globe or angle valves,
and restricted-type plug valves.
Pipe size must take into account the required capacity, minimum or maximum velocities, the fluid viscosity at the lowest pumping temperature, the length of the piping sys-
3-9
tem including valves, strainers, and other restrictions, and the elevation of the pump
with reference to supply and discharge points. Friction or line losses may be calculated
by referring to the manufacturers Engineering Manual or the Hydraulic Institutes
Engineering Data Book.
Do not install 45or 90-degree fittings at the pump
suction port. When
possible, provide 10
pipe diameters of
straight pipe at the
suction port.
Inlet Piping. Inlet piping should normally be equal to or one size larger than the pump
inlet port connection. Viscous liquids may require larger inlet piping. Absolute air
tightness of the inlet line is a must. Pumps operating with a static suction lift should
have the inlet piping sloping gradually upward to the pump. On a long, horizontal run,
keep the horizontal piping below the liquid level when possible. Piping should go
around obstacles that are encountered rather than over them. Piping over an obstacle
creates an air pocket, thereby making priming difficult.
Outlet Piping. Outlet piping should be sized to produce the desired discharge pressure.
At the outlet port, the piping should have a vertical rise of about five pipe diameters to
prevent gas or air pockets in the pump and act as a fluid seal within the pump on highvacuum starting.
Strainers
With but a few exceptions, a pump should not be installed without strainer protection.
Foreign matter may be large enough or of sufficient volume to jam a pump with probable damage to both pump and drive equipment. Smaller matter passing through the
pump will cause rapid pump wear and premature pump failure.
Strainers should be of ample size to prevent an excessive vacuum condition at the
pump. Generally, the net area of the strainer screen should be three to five times the
area of the inlet pipe. The required net area is dependent on the flow rate and the liquid
viscosity. Strainer basket design must include capability of operation under high vacuum without collapsing.
Install the strainer in the inlet piping near the pump, making certain it is located where
it may be readily serviced. The strainer must be installed according to arrows or notation designating direction of flow. Provide a vacuum or compound gauge before and
after the strainer to determine when cleaning is required.
For continuous pumping, a bypass (including valving) should be piped around the
strainer to permit cleaning. Alternately, two strainers in parallel or a duplex strainer
may be used.
Check the strainer frequently when the pump is first started. This is the time that foreign material in the system is most likely to collect in the strainer.
Overpressure Protection
Overpressurization of the pump can cause equipment failure, resulting in personal injury.
The pump is capable of building infinite pressure. A pressure relief valve should be
installed in the discharge side of the piping as shown in Figure 3-11. The relief valve
discharge should be piped back to the supply tank. If it is routed directly to the suction
side of the pump, the recirculation will cause excessive heat buildup. This will cause
expansion between close-tolerance parts, which will result in galling or binding in the
pump.
3-10
Installation
RECOMMENDED
BYPASS FLOW
SUPPLY
TANK
PRESSURE
RELIEF
VALVE
NPT
BUSHING
NOT RECOMMENDED
PIPE TEE
TO SYSTEM
SUCTION PORT
DISCHARGE PORT
ROTARY GEAR PUMP
1070_0005a.cdr
Pre-Startup Checks
Inspection checks are essential to avoid operational difficulties and ensure trouble-free
startup. Listed below are several items that need to be checked before the pump is
started:
1. Inspect all piping for undue stress and strain on the pump.
2. Flush and leak test all piping before connecting to pump.
3. Fully open inlet and outlet valves. Pump must not be started with throttled or
closed inlet or outlet valves.
4. Close all drain valves.
5. Check wiring diagrams for proper connections for voltage and rotation. Proper
rotation is indicated by an arrow on the pump. Disconnect driver coupling and start
driver momentarily to ensure correct rotation.
6. Before reconnecting driver coupling, turn pump shaft to be sure it rotates freely.
7. Reconnect driver coupling and replace guard. Make certain all other guards are in
place.
8. For relief valves that can be installed for either direction of rotation, make certain
that valve is installed properly for desired rotation.
9. Install pressure and vacuum gauges for checking startup conditions.
3-11
Parts
Do not order parts using this manual if the model number on the pump is not
80-428 or the serial number is not ________________. Using parts ordered from
the wrong manual could result in pump failure or personal injury.
Edwards rotary pumps are available in many configurations. While they may look alike,
there may be significant differences from one pump to another. Differences include construction material, sealing method, rotor type, etc. This manual covers only one configuration, which is defined by a model number and a serial number. Check the name plate
on the pump to make certain the model number is 80-428 and the serial number is
________________. If the numbers do not match, contact EMI.
When ordering parts, please provide:
1. Model number from pump name plate.
2. Serial number from pump name plate.
3. Part number of part from parts list.
4. Name of part from parts list.
3.
4.
5. Quantity needed.
Order replacement parts from:
Pentair
WaterNorth Aurora Operations
Edwards
Manufacturing
Inc.
800
Airport
Rd.
2441 SE Stubb St.
North
Aurora,
60542
Milwaukie,
ORIL,
97222
Phone: (630)
(503) 859-7000
659-4198
Phone:
FAX:
(503)
659-4696
FAX: (630) 859-7060
Internet: www.aurorapump.com
www.edwardsmfg.com
Internet:
E-Mail: parts@edwardsmfg.com
4-1
1
9
5
12
14
15
17
16
3
18
19
1
11
20
21
13
3
19
13
22
23
27
24
10
26
21
19
22
18
20
10
5
6
7
19
3
8
13
17
16
15
14
4-2
1070_0008e.cdr
Parts
Figure &
Index No.
Part
Number
4-1-1
-2
-3
-4
-5
-6
-7
-8
-9
-10
-11
-12
-13
-14
-15
-16
-17
-18
-19
-20
-21
-22a
-22b
-23
1080428BBBS40S
0200032
0120022
0200038
0200070
0200082
0120002
0200072
0160004
0200002
0200057
0180004
0180002
0200034
0190002
0170004
0160006
0110004
0200006
0200020
0160050
0200080
0130202
0130202L
No Number
-23a
0140200
-23b
0150216
-24
No Number
-24a
0140200
-24b
0150018
-26
-27
0200014
0100012
Description
Units
Per
Assy
REF
5
1
12
4
2
1
4
1
1
2
1
1
4
4
4
4
2
16
20
4
2
2
2
1
1
1
1
1
1
4
1
4-3
WARRANTY
WARRANTY: Seller warrants equipment (and its component parts) of its own manufacture against defects in
materials and workmanship under normal use and service for one (1) year from the date of installation or startup, or for eighteen (18) months after the date of shipment, whichever occurs first. Seller does not warrant
accessories or components that are not manufactured by Seller; however, to the extent possible, Seller agrees
to assign to Buyer its rights under the original manufacturer's warranty, without recourse to Seller. Buyer must
give Seller notice in writing of any alleged defect covered by this warranty (together with all identifying
details, including the serial number, the type of equipment, and the date of purchase) within thirty (30) days of
the discovery of such defect during the warranty period. No claim made more than 30 days after the expiration
of the warranty period shall be valid.
Guarantees of performance and warranties are based on the use of original equipment manufactured (OEM)
replacement parts. Seller assumes no responsibility or liability if alterations, non-authorized design
modifications and/or non-OEM replacement parts are incorporated If requested by Seller, any equipment (or
its component parts) must be promptly returned to Seller prior to any attempted repair, or sent to an authorized
service station designated by Seller, and Buyer shall prepay all shipping expenses. Seller shall not be liable for
any loss or damage to goods in transit, nor will any warranty claim be valid unless the returned goods are
received intact and undamaged as a result of shipment. Repaired or replaced material returned to customer will
be shipped F.O.B., Seller's factory. Seller will not give Buyer credit for parts or equipment returned to Seller,
and will not accept delivery of any such parts or equipment, unless Buyer has obtained Seller's approval in
writing.
The warranty extends to repaired or replaced parts of Seller's manufacture for ninety (90) days or for the
remainder of the original warranty period applicable to the equipment or parts being repaired or replaced,
whichever is greater. This warranty applies to the repaired or replaced part and is not extended to the product
or any other component of the product being repaired.
Repair parts of its own manufacture sold after the original warranty period are warranted for a period of one
(1) year from shipment against defects in materials and workmanship under normal use and service. This
warranty applies to the replacement part only and is not extended to the product or any other component of the
product being repaired.
Seller may substitute new equipment or improve part(s) of any equipment judged defective without further
liability. All repairs or services performed by Seller, which are not covered by this warranty, will be charged
in accordance with Seller's standard prices then in effect.
THIS WARRANTY IS THE SOLE WARRANTY OF SELLER AND SELLER HEREBY EXPRESSLY
DISCLAIMS AND BUYER WAIVES ALL OTHER WARRANTIES EXPRESSED, IMPLIED IN LAW OR
IMPLIED IN FACT, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. Seller's sole obligation under this warranty shall be, at its option, to repair or
replace any equipment (or its component parts) which has a defect covered by this warranty, or to refund the
purchase price of such equipment or part. Under the terms of this warranty, Seller shall not be liable for (a)
consequential, collateral, special or liquidated losses or damages; (b) equipment conditions caused by normal
wear and tear, abnormal conditions of use, accident, neglect, or misuse of said equipment; (c) the expense of,
and loss or damage caused by, repairs or alterations made by anyone other than the Seller; (d) damage caused
by abrasive materials, chemicals, scale deposits, corrosion, lightning, improper voltage, mishandling, or other
similar conditions; (e) any loss, damage, or expense relating to or resulting from installation, removal or
reinstallation of equipment; (f) any labor costs or charges incurred in repairing or replacing defective
equipment or parts, including the cost of reinstalling parts that are repaired or replaced by Seller; (g) any
expense of shipment of equipment or repaired or replacement parts; or (h) any other loss, damage or expense
of any nature.
Warranty (8/99)
3.5.1
-CTS
SPECIAL ENCLOSURES
-T
NEMA Type 3R (IEC IP14), Painted Steel
-E
NEMA Type 4 (IEC IP56), Painted Steel
-F
NEMA Type 4X (IEC IP56), #304 Stainless Steel,
Natural Finish**
-FXP NEMA Type 4X (IEC IP56), #304 Stainless Steel,
Painted Finish
-FD
NEMA Type 4X (IEC IP56), #316 Stainless Steel,
Natural Finish**
-FDB NEMA Type 4X (IEC IP56), 12 Gauge, Seam
Welded, #316 Stainless Steel, Polished and
Brushed Finish
-FDP NEMA Type 4X (IEC IP56), #316 Stainless Steel
Painted Finish
-G
NEMA Type 12 (IEC IP52), Painted Steel
** Natural Finish (Visible surface blemishes, weld
burns and grinding marks).
-EG
-EH
-EJ
-EK
-KH
-JR
-JT
-P
-PB
-PE
-PT
-HV
-LVA
-LW
-LY
PRESSURE TRANSDUCERS
-B
0-600 psi (0-42.25 bar) Pressure Transducer for
Fresh Water Service
-C
0-300 psi (0-21.1 bar) Pressure Transducer for Sea
Water, Foam or Copper Corrosive Service
-D
0-600 psi (0-42.25 bar) Pressure Transducer for Sea
Water, Foam or Copper Corrosive Service
AUTOMATIC POWER TRANSFER SWITCHES
FTA975 - generator set emergency supply
FTA976 - second utility emergency supply
(Refer to publication SD975-20)
ALARMS
-AC
Extra contacts (normally open & normally closed) for
remote indication, pump operating
-AF
Audible and Visible low pump room temperature alarm
-AG
Built-in reservoir low alarm
-AH
Audible low suction pressure alarm
-AM
Contacts for remote indication, pump fail to start
-AV
Contacts for remote indication, low pump room
temperature
-AW Contacts for remote indication, reservoir low
-AY
Contacts for remote indication, low suction pressure
-AZ
Low pump room temperature switch, mounted and wired
-BW
Extra contacts for remote indication,
phase failure/phase reversal
-BY
Contacts for remote indication, pump overload
-COM Visible low suction pressure alarm, Manual
reset only (Includes reset push-button,
initiating pressure switch not included)
MISCELLANEOUS
-DZ
Test push-button and solenoid valve*
-ED
Load shed circuits
-PY
Motor space heater output contacts
-S
Tropicalization
-ZPA Customized, annual service display message (when
factory programmed or programmed by Firetrol
representative during start-up)
-ZPN 5150 Ethernet Connectivity Module (Allows users
to monitor limited controller status via a single
computer or over a computer network)
-ZPM Serial Modbus RTU Communications Protocol
(Allows users to monitor all aspects of the controller
status via a RS485 communications network
(system integration required). (Includes RS485
to twisted pair breakout module, optical isolation
module (4000 ft. range), DC power supply and
customer connection terminal blocks).
Export packaging (Wooden crating to conform
to IPPC Standards)
*Weekly Test Timer - Standard
XXXGJSFUSPMDPN4BMFT0GGJDF$BSZ
/$64"
PD750-20 (07-05-06)
$6&2
Specifications
Limited Service Fire Pump Controllers
FTA750
3.5.2
Event Recording
Memory - The controller shall record all operational and alarm events to system memory. All events
shall be time and date stamped and include an index
number. The system memory shall have the capability
of storing 3000 events and allow the user access to
the event log via the user interface. The user shall
have the ability to scroll through the stored messages
in groups of 1, 10, or 100.
USB Host Controller - The controller shall have a
built-in USB Host Controller. A USB port capable of
accepting a USB Flash Memory Disk (aka: flash drive,
thumb drive, memory stick, etc..) shall be provided.
The controller shall save all operational and alarm
events to the flash memory on a daily basis. Each
saved event shall be time and date stamped. The total
amount of historical data saved shall solely depend
on the size of the flash disk utilized. The controller
shall have the capability to save settings and values
to the flash disk via the user interface.
Communications - The controller shall feature two
independent communications ports to allow connectivity to computers, modems, or building management
systems.
Solid State Pressure Transducer
The controller shall be supplied with a solid state
pressure transducer with a range of 0-300 psi (0-20.7
bar) 1 psi. The solid state pressure switch shall be
used for both display of the system pressure and control of the fire pump controller. Systems using analog
pressure devices or mercury switches for operational
control will not be accepted.
The START, STOP and SYSTEM PRESSURE
shall be digitally displayed and adjustable through
the user interface. The pressure transducer shall be
mounted inside the controller to prevent accidental
damage. The pressure transducer shall be directly
pipe mounted to a bulkhead pipe coupling without
any other supporting members. Field connections
shall be made externally at the controller coupling to
prevent distortion of the pressure switch element and
mechanism.
Operation
A digitally set On Delay (Sequential Start) timer
shall be provided as standard. Upon a call to start,
the user interface shall display a message indicating
the remaining time value of the On Delay timer.
The controller shall be field programmable for
manual stop automatic stop. If set for automatic
stopping, the controller shall allow the user to select
either a Minimum Run Timer or an Off Delay Timer.
Both timers shall be programmable through the user
interface.
3.5.3
XXXGJSFUSPMDPN4BMFT0GGJDF$BSZ
/$64"
SQ750-20 (04-12-07)
$6&2
3.5.4
3.5.5
QYZS.EX2662
Pump Controllers, Fire
Page Bottom
EX2662
5625 DILLARD DR
CARY, NC 27511 USA
Combined manual and automatic type controllers for internal combustion engines driving centrifugal fire pumps, Model
FTA-1100 followed by A or B, followed by -A, followed by 12 or 24, followed by L or N, followed by N or P, may be followed by one or
more suffix letters. Model FTA-1100 followed by A, F or R, followed by L or N, followed by 12 or 24, followed by N or P, may be
followed by one or more suffix letters.
Cat. No. FTA-1100 followed by D or M, followed by L or N, followed by 12 or 24, followed by N or P.
Cat. No. FTA1100 followed by E, followed by L or N, followed by 12 or 24, followed by N or P, with or without modification or
optional suffix letters.
Model FTA-1100 followed by J, -HW or -HX, followed by L or N, followed by 12 or 24, followed by P or N.
Manual controller-wound rotor type, Cat. No. FTA-1750 followed by A, B, C, D, E, F, G, H, J or K, followed by 15-400, followed by A,
B, C, F or H, followed by additional suffixes.
Cat. No. FTA1100-P followed by L or N, followed by 12 or 24, followed by N or P.
Manual controllers, Cat. No. FTA1000 (across the line), FTA1250 (part winding*), FTA1300, (wye-delta open transition*), FTA1350
(wye-delta closed transition*), FTA1500 (primary resistor*), FTA1800 (autotransformer*) and FTA1900 (electronic soft start*),
followed C, followed by D, E, F, G or K, followed by 2 or 3 digit number 15 to 700, followed by A, B, C, F or H, may be followed by
additional suffixes. (*Emergency manual operator provides full voltage across the line starting).
Automatic controllers, Cat. No FTA1000 (across the line), FTA1250 (part winding*), FTA1300 (wye-delta open transition*), FTA1350
(wye-delta closed transition*), FTA1500 (primary resistor*), FTA1800 (autotransformer*) and FTA1900 (electronic soft start*),
followed by A or B, followed by D, E, F, G or K, followed by 2 or 3 digit number 15 to 700, followed by A, B, C, F or H, may be
followed by additional suffixes. (*Emergency manual operator provides full voltage across the line starting).
Variable Speed Pressure Limiting Fire Pump Controllers Cat. No. FTA followed by 3100, 3110, 3120, followed by A, B or C, followed
by M, N, P, Q or R, followed by two or three numbers from 15 to 400 followed by A, AZ, B, BZ, C, F, FZ, H or HH, maybe followed by
additional suffixes.
Controllers are suitable for use as service equipment on circuits capable of delivering high fault currents: maximum ratings are
42,000 amps at 200-600 v (D), 200,000 aperes at 200-600 v (E, F, G) or 200,000 amps at 200-600 v (K) with current limiting (K).
Controllers rated 15-250 hp, 200-800 v (H); 15-300 hp, 220-240 v (A), 15-500 hp, 380-415 v (F); 15-600 hp, 440-480 v (B); and
15-700 hp, 550-600 v (C), three-phase, 50/60 hz (cps).
Controllers may be provided with a power transfer switch compartment, Cat. No. FTA900 (generator alternate source) or FTA901
(generator alternate source with bypass-isolation switch, followed by BL or Cat. No FTA950 (utility alternate source) or FTA951
(utility alternate source with bypass-isolation switch), followed by B, followed by D, E, F, G or K; either catalog number followed by
100, 150, 260, 400, 600, 800 or 1000 (amp rating) followed by A, B, C, F or H, may be followed by additional suffixes. Fault current
rating on normal side is same as fire pump controller. Fault current rating on emergency side is dependent upon the external circuit
breaker (FTA900, FTA901) or the same as the fire pump controller rating D, E, F, G or K (FTA950, FTA951 ).
Foam concentrate fire pump controller, Cat. No. FTA followed by 1000, 1250, 1300, 1350, 1500, 1800 or 1900, followed by A, B or
C, followed by D, E, F, G, K, M, N, P, Q or R, followed by 03 through 700, followed by A, AZ, B, BZ, C, F, FZ, H or HZ, may be
3.5.6
followed by KL or LL.
The above foam concentrate fire pump controllers may be provided with transfer switch assembly, Cat. No. FTA900, FTA901,
FTA950 or FTA951, followed by suffix letters and numbers.
All of the above controllers are suitable for use on circuits capable of delivering high fault currents. The withstand ratings are as
follows:
Circuit
Breaker
Rated
V
240
42,000
480
30,000
600
22,000
240
42,000
480
30,000
600
22,000
480
150,000
600
22,000
600
200,000
switches
Same as above when
provided with current
limiting devices (PCL)
Those controllers provided with transfer switches have withstand ratings on the normal side equal to those shown above at 240 and
480 v. The emergency side of the transfer switch, if protected by an additional circuit located within the controller, has withstand
ratings shown above at 240 and 480 v. If the circuit breaker protecting the emergency side is not supplied with the controller, the
withstand rating for the emergency side will be dependent upon the ratings of the transfer switch and external circuit breaker
provided.
Foam concentrate fire pump controller, Cat. No. FTA-740 or -750 followed by A, B or C, followed by A, B or H, followed by 10 or 30,
followed by A, B, C, E, F, H or T, followed by **, LK, LKA, LL or LLA. The above foam concentrate controllers may be provided with
transfer switch assembly. Cat. No. FTA-975 or -976 followed by suffix letters and numbers.
All of the above controllers are suitable for use on circuits capable of delivering high fault currents. The withstand ratings are as
follows:
Circuit
Breaker
Rated
V
SEL
480
65,000
SED
600
14,000
600
150,000
SEH
240
65,000
SEL
480
65,000
SEH
600
18,000
limiting device)
Above limited service controllers may be provided with transfer switch assembly, Cat. Nos. FTA-975 or -976; followed by suffix
letters and numbers.
Circuit
Breaker
For operation with diesel generator (FTA-475).
Rated
V
200-600 v
10,000
SED 3-20 HP
220-240
10,000
25-30 HP
220-240
18,000
SED All HP
480
14,000
SEL All HP
480
14,000
All HP
200-240
18,000
200-480
150,000
limiters - All HP
Cat. No. FTA-975 transfer switch assembly has the following short circuit rating:
Molded Case
Switch
Short Circuit
Current + RMS
Symmetrical A
Max
Rated V
SED
200-480
10,000
SED
550-600
10,000
Circuit
Breaker
Rated
V
SED 3-20 HP
200-240
10,000
SED 25-30 HP
200-240
18,000
SED
380-600
14,000
SEL++
600
150,000
SEH
550-600
18,000
additional suffixes.
Cat. Nos. FTA followed by 750, followed by A, B or C, followed by D or E, followed by two numbers from 03 to 30, followed by A, AZ,
B, BZ, C, F, FZ, H or HH, may be followed by additional suffixes.
Cat. Nos. FTA followed by 740, followed by A, B or C, followed by D or E, followed by two numbers from 03 to 10, followed by E, EZ,
T, or TT, may be followed by additional suffixes.
Cat. Nos. FTA followed by 975 or 976, followed by A followed by L, D or E, followed by two numbers from 100 to 150, followed by A,
AZ, B, BZ, C, F, FZ, H or HH, may be followed by additional suffixes.
These controllers are suitable for use on circuits capable of delivering high fault currents. The withstand ratings are determined by
the circuit breaker used except for those controllers provided with transfer switches in which case the ratings are determined by the
circuit breaker and transfer switch.
Withstand ratings of the controller are dependent upon the circuit breaker as indicated below:
FTA750 Standard short-circuit rating
Isolation
Voltage
Range
Withstand
Maximum
Rating RMS
Symmetrical
A
Circuit Breaker
MFR
Frame
Rating A
Rating
Code
200 240
ABB
S3NT
15-150
65,000
380 480
ABB
S3NT
15-150
25,000
550-600
ABB
S3NT
15-150
14,000
Isolation
Voltage
Range
Withstand
Maximum
Rating RMS
Symmetrical
A
Circuit Breaker
MFR
Frame
Rating A
Rating
Code
200 240
ABB
S3LT
15-150
85,000
380 480
ABB
S3LT
15-150
65,000
550-600
ABB
S3LT
15-150
25,000
Isolation
Voltage
Range
200 240
Circuit Breaker
MFR
ABB
Frame
S3LT-2
Rating A
15-150
Withstand
Maximum
Rating RMS
Symmetrical
A
10,000
Rating
Code
D
Isolation
Voltage
Range
200 240
Circuit Breaker
MFR
ABB
Frame
S3LT-2
Rating A
15-150
Withstand
Maximum
Rating RMS
Symmetrical
A
65,000
Rating
Code
E
The above ratings also apply to the normal side of the transfer switch. They also apply to the emergency side when it is protected by
a circuit breaker of the same type. If the emergency side is not protected by an additional circuit breaker within the power transfer
switch compartment, the following ratings apply to the emergency side. The external circuit breaker must have an interrupting
rating at least equal to those shown.
WITHSTAND RATINGS EMERGENCY SIDE (UNITS WITH FIRE PUMP POWER TRANSFER SWITCH)
Cat. No.
200-480 V ac
550-600 V ac
100
as described
22,000
10,000
150
104
as described
22,000
10,000
150
150
as described
22,000
10,000
225
Notice of Disclaimer
Page Top
SECTION 4:
1000 GAL. FIBERGLASS
FOAM LIQUID STORAGE TANK
SKZZ-66025
N a tio n a l F o a m
4.1
SECTION 5:
2 IN. PRESSURE VACUUM VENT
SKZZ-66025
N a tio n a l F o a m
5.1
SECTION 6:
FLEXIBLE CONNECTORS
SKZZ-66025
N a tio n a l F o a m
6.1
SECTION 7:
NATIONAL FOAM SEALER OIL
SKZZ-66025
N a tio n a l F o a m
7.1
7.2
NMS#950
Page 2 of 7
10/01/07
NMS#950
Page 3 of 7
10/01/07
6000F
Vapor Pressure:
Vapor Density:
Not applicable
Melting Point:
Not applicable
Evaporation Rate:
Solubility in Water:
Negligible
NMS#950
Page 4 of 7
10/01/07
pH:
7.0
Specific Gravity:
0.88 @ 60oF
Odor:
Odorless
Form:
Liquid
Color:
Colorless
No data available
COD
No data available
Page 5 of 7
10/01/07
NOTE: As a service to our customers, National Foam has approvals in place with disposal
facilities throughout the U.S. for waste water treatment of our foam liquid concentrates and foam
solutions. If required, National Foam, Inc. can also provide information on the disposal of drums
used for shipping our concentrates. Please contact National Foams Risk Management
Administrator at (610) 363-1400 for additional information.
NMS#950
Page 6 of 7
10/01/07
STATE REGULATIONS
PENNSYLVANIA RIGHT-TO-KNOW HAZARDOUS SUBSTANCES LIST
PA Hazardous Substances present at levels greater than 1%:
None
NMS#950
Page 7 of 7
10/01/07