Waterous S100 Series Installationsanleitung

S100 Series Centrifugal

Fire Pumps

Operation and Maintenance

Form No.

F-1031

Section

2117

Issue Date

02/22/02

Rev. Date

6/21/18

Table of Contents

Safety Information----------------------------------------------- 2, 3

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General Description . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . 4

Components.................................................................... 4

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Pump Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operating Instructions:

Transmission . . .. . . . . . . . .. . . . . .. . . . . .. . . . . .. . . . 6

Pumping from Water Tank................................................6

Pumping from Hydrant or in Relay .............................. 7

Pumping from Draft ..................................................... 8

Fire Hose Testing........................................................ 9

Maintenance:

Corrosion Protection:

Optional Zinc Intake Screens............................ 10

Optional Zinc Anodes ....................................... 10

Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 11

Overheat Protection Manager (OPM) . . . . . . . . . . . . 11

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 12

Read through the safety information and

operating instructions carefully before

using your Waterous Fire Pump.

Visit us at www.waterousco.com

Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450-5000

Instructions subject to change without notice.

F-1031, Section 2117

Page 2 of 12

Safety Information

Read through the safety information and operating instructions carefully before using

your Waterous Fire Pump.

! WARNING

Scalding Water Hazard. May result in serious burns.

When operating the pump, be sure to open at least one

discharge valve slightly to prevent the pump from over-

heating. If the pump runs for a few minutes completely

closed, it may heat the water enough to scald someone

when the valve is opened. Overheating can damage the

packing, seals and other pump parts. If the apparatus

builder has installed a by-pass system or other provision

designed to prevent overheating, opening a discharge

valve may be unnecessary.

! WARNING

Limit intake pressure to 75 psi (5.2 bar) if possible. Al-

though the pump will operate properly with higher intake

pressure, such operation will greatly accelerate me-

chanical seal wear.

! WARNING

Pressure Hazard. May result in personal injury.

Prior to connection or removal of hoses, caps or other

closures with pump intake or pump discharge connec-

tions, relieve pressure by opening drains or bleeder

valves. Bleeder valves should also be used while filling

a hose connected to an intake with water.

! WARNING

Unexpected Truck Movement. May result in serious

personal injury or death.

Failure to properly shift transmission in accordance to

the transmission operating instructions may result in

unexpected truck movement which may result in serious

personal injury or death.

! WARNING

Death or serious personal injury might occur if proper

operating procedures are not followed. The pump oper-

ator, as well as individuals connecting supply or dis-

charge hoses to the apparatus must be familiar with

these pump operating instructions as well as other op-

erating instructions and manuals for the apparatus, wa-

ter hydraulics and component limitation.

F-1031, Section 2117

Page 3 of 12

Safety Information

Read through the safety information and operating instructions carefully before using

your Waterous Fire Pump.

WARNING

Hose Testing Hazard. May result in serious personal injury.

Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to

prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be

used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.

WARNING

Pressure Hazard. May result in serious personal injury.

If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST

be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed

between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a

hose bursts during testing.

WARNING

Scalding Water Hazard. May result in serious burns.

If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be

circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be

used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be

heated enough to scald someone when a valve is opened.

F-1031, Section 2117

Page 4 of 12

Introduction

This instruction contains the information needed for operation and maintenance of S100 Series centrifugal pumps.

General Description

The S100 series pumps are single stage centrifug

al end suction pumps providing capacities up to 2000 GPM (7570 L/min).

S100 models are midship mounted with a Victaulic

Body Assembly

intake fitting, S101 models are midship mounted with an intake crosspipe.

Components

Mechanical Seal

This assembly includes a double stripping edge volute body

to minimize radial forces at all flow rates, intake adapter and

related parts. The body and adapters are ductile iron.

Impeller Shaft Assembly

This assembly consists of a bronze, flame-plated impeller

mounted on a stainless steel shaft, wear rings, mechanical

seal and related parts. The impeller is balanced and the im-

peller shaft is supported by ball bearings.

The mechanical seal consists of a flat, highly polished

(lapped), spring-fed carbon ring that is sealed to and rotates

with the impeller shaft. It presses against a highly polished

(lapped) silicon carbide mating ring that is sealed in the vo-

lute body. This seals the shaft and prevents air from entering

and water from leaving. A mechanical seal does not leak or

drip water, even when pumping.

Intake Screens Options

Anodes

Zinc diecast screens are normallyused in the intakefit‐

tings, with brass screens available optionally. Although the

screensarechemicallytreated(coated)toinhibitcorro‐

sion, the water being pumped may still corrode the

screens. Such corrosion is ``sacrificial''; that is, it will help

prevent corrosion in the rest of the pump the same way

the magnesium anodes protect the metal parts of a water

heater.

As additional corrosion protection for iron body pumps,

Waterous has available zinc anodes to fit any unused

opening in the intake fitting. Anodes provide an additional

sacrificial zinc surface to the water to supplement the zinc

intake screens.

Overheat Protection Manager (OPM)

The Overheat Protection Manager (OPM) acts as a safety

device by releasing hot water to the ground or back to the

water tank from the discharge area of the pump.

F-1031, Section 2117

Page 5 of 12

S100C20 Series

Pump Models

S100PA Series

End Suction Intake

C20 Series Chain Drive Transmission End Suction Intake

PA Series Chain Drive Transmission

S101C20 Series S100D Series

Crosspipe Intake

C20 Series Chain Drive Transmission End Suction Intake Direct

Drive, Pedestal Mounted

F-1031, Section 2117

Page 6 of 12

! WARNING

Pressure Hazard. May result in personal injury or

death.

Prior to connection of hoses, caps or other closures

with pump intake or pump discharge connections, re-

lieve pressure by opening drains.

! WARNING

Scalding Water Hazard. May result in serious

burns.

When operating the pump, be sure to open at least

one discharge valve slightly to prevent the pump from

overheating. If the pump runs for a few minutes com-

pletely closed, it may heat the water enough to scald

someone when the valve is opened. Overheating can

damage the packing, seals and other pump parts. If

the apparatus builder has installed a by-pass system

or other provision designed to prevent overheating,

opening a discharge valve may be unnecessary.

Operating Instructions

Transmission Operation

Refer to the C20 Transmissions: Operation and Maintenance Instructions, See F-1031-2413

Refer to the PA Transmissions: Operation and Maintenance Instructions, See F-1031-2207

Pumping from Water Tank

6. Set relief valves or other pressure governing device to

desired pressure.

After Pumping

1. Open valve(s) in piping between water tank and pump

intake and at least one discharge valve.

2. Allow about 30 seconds for water to flow into pump.

NOTE: Priming the pump may be necessary due to air

trapped in piping.

3. S100D Only: Engage pump drive and accelerate en-

gine to obtain desired discharge pressure and capacity.

1. Disengage pump drive. If equipped with a C20 transmis-

sion (S100C20 or S101C20) disengage pump drive in

accordance with the transmission instructions.

2. If pumping anything but clean water, remove all intake

and discharge caps, open all valves and open all drains.

Flush entire system with clean, fresh water for several

minutes to remove all traces of impurities.

3. If pump is kept full of water when not in use, make sure

water is clean and non-corrosive. Make sure the pump

is completely full or completely drained - never partially

full.

4. S100C20 and S101C20 Only: Engage pump in accor-

dance with transmission instructions.

5. S100C20 and S101C20 Only: Open discharge valves

and accelerate engine to obtain desired discharge pres-

sure and capacity.

CAUTION

Freezing water hazard. May cause damage to

the pump.

If the pump is exposed to freezing temperatures,

drain all water from pump, lines and accessories.

4. Close all drains and install intake and discharge caps.

5. If truck is equipped with a priming pump, operate it until

fluid is discharged from priming pump discharge pipe.

If equipped with a priming tank, check fluid level and refill

if necessary.

! WARNING

Unexpected Truck Movement. May result in per-

sonal injury or death.

Failure to properly shift transmission in accordance

with the transmission operating instructions may result

in unexpected truck movement which may result in

serious personal injury or death.

! WARNING

Pressure Hazard. May result in personal injury or

death.

Prior to removal of hoses, caps or other closures with

pump intake or pump discharge connections, relieve

pressure by opening drains.

CAUTION

Do not attempt to pump more water than is avail-

able from the water tank. Always make sure the

intake pressure compound gage reading stays

above zero.

F-1031, Section 2117

Page 7 of 12

! WARNING

Pressure Hazard. May result in personal injury or

death.

Prior to connection of hoses, caps or other closures

with pump intake or pump discharge connections, re-

lieve pressure by opening drains or bleeder valves.

! WARNING

Scalding Water Hazard. May result in serious burns.

When operating the pump, be sure to open at least one

discharge valve slightly to prevent the pump from over-

heating. If the pump runs even for a few minutes com-

pletely closed it may heat the water enough to scald

someone when the valve is opened. Overheating can

damage the packing, seals and other pump parts.If the

apparatus builder has installed a by-pass system or oth-

er provision designed to prevent overheating, opening

a discharge valve may be unnecessary.

! WARNING

Unexpected Truck Movement. May result in person-

al injury or death.

Failure to properly shift transmission in accordance with

the transmission operating instructions may result in

unexpected truck movement which may result in serious

personal injury or death.

! WARNING

Pressure Hazard. May result in personal injury or

death.

Prior to removal of hoses, caps or other closures with

pump intake or pump discharge connections, relieve

pressure by opening drains or bleeder valves.

CAUTION

Limit intake pressure to 75 psi (5.2 bar) if possible.

Although the pump will operate properly with higher

intake pressure, such operation will greatly acceler-

ate mechanical seal wear.

Pumping from Hydrant or in Relay

4. S100C20 and S101C20 Only: Open discharge valves

and accelerate engine to obtain desired discharge pres-

sure and capacity.

5. Set relief valves or other pressure governing device to

desired pressure.

NOTE: Some fire departments operate at a minimum

intake pressure of 10 psi (.7 bar) when pumping

from hydrant or in relay to prevent a •soft" intake

hose from collapsing.

After Pumping

1. S100D Only: Engage pump drive and accelerate en-

gine to obtain desired discharge pressure and capacity.

2. S100C20 and S101C20 Only: Engage pump in accor-

dance with transmission instructions.

3. Open intake, hydrant and other valves as necessary to

allow water to enter the pump.

NOTE: Bleeder valves should be used while filling a

hose connected to an intake with water.

1. Disengage pump drive. If equipped with a C20 transmis-

sion (S100C20 and S101C20) disengage pump drive in

accordance with the transmission instructions.

2. If pumping anything but clean water, remove all intake

and discharge caps, open all valves and open all drains.

Flush entire system with clean, fresh water for several

minutes to remove all traces of impurities.

3. If pump is kept full of water when not in use, make sure

water is clean and non-corrosive. Make sure the pump

is completely full or completely drained (never partially

full).

4. Close all drains and install intake and discharge caps.

5. If truck is equipped with a priming pump, operate it until

fluid is discharged from priming pump discharge pipe. If

equipped with a priming tank, check fluid level and refill

if necessary.

CAUTION

Do not attempt to pump more water than is available

from the hydrant or relaying pumper. Always make

sure the intake pressure compound gage reading

stays above zero.

F-1031, Section 2117

Page 8 of 12

! WARNING

Pressure Hazard. May result in personal injury or

death.

Prior to connection of hoses, caps or other closures with

pump intake or pump discharge connections, relieve

pressure by opening drains.

! WARNING

Scalding Water Hazard. May result in serious burns.

When operating the pump, be sure to open at least one

discharge valve slightly to prevent the pump from over-

heating. If the pump runs even for a few minutes com-

pletely closed it may heat the water enough to scald

someone when the valve is opened. Overheating can

damage the packing, seals and other pump parts. If the

apparatus builder has installed a by-pass system or oth-

er provision designed to prevent overheating, opening a

discharge valve may be unnecessary.

! WARNING

Unexpected Truck Movement. May result in person-

al injury or death.

Failure to properly shift transmission in accordance with

the transmission operating instructions may result in

unexpected truck movement which may result in serious

personal injury or death.

Pumping from Draft

1. Prime the pump (see separate instructions supplied with

primer).

2. S100D Only: Engage pump drive and accelerate en-

gine to obtain desired discharge pressure and capacity.

3. S100C20 and S101C20 Only: Engage pump in accor-

dance with transmission instructions.

4. S100C20 and S101C20 Only: Open discharge valves

and accelerate engine to obtain desired discharge pres-

sure and capacity.

5. Set relief valves or other pressure governing device to

desired pressure.

After Pumping

NOTE: To get full capacity, quick prime and maintain

pump efficiency:

a) Position vehicle as near as possible to water supply.

b) Avoid humps and sharp bends in intake hose. Make

sure no part of hose is higher than pump inlet. (Air pock-

ets in intake hose may cause loss of prime or erratic

pump action, and may reduce pump capacity.)

c) Make sure all intake connections are tight and discharge

valves are closed.

d) Immerse intake strainer at least two feet below water

surface to prevent pump from drawing air. (Whirlpools

forming above intake strainer indicate that strainer is too

close to surface of water.)

e) Make sure intake strainer is far enough from bottom to

prevent sand, gravel and other foreign matter from be-

ing drawn into the pump.

1. Disengage pump drive. If equipped with a C20 transmis-

sion (S100C20 and S101C20) disengage pump drive in

accordance with the transmission instructions.

2. If pumping anything but clean water, remove all intake

and discharge caps, open all valves and open all drains.

Flush entire system with clean, fresh water for several

minutes to remove all traces of impurities.

3. If pump is kept full of water when not in use, make sure

water is clean and non-corrosive. Make sure the pump

is completely full or completely drained (never partially

full).

4. Close all drains and install intake and discharge caps.

5. If truck is equipped with a priming pump, operate it until

fluid is discharged from priming pump discharge pipe.

If equipped with a priming tank, check fluid level and refill

if necessary.

CAUTION

Freezing water hazard.

May cause damage to the pump.

If the pump is exposed to freezing temperatures,

drain all water from pump, lines and accessories.

! WARNING

Pressure Hazard. May result in personal injury or

death.

Prior to removal of hoses, caps or other closures with

pump intake or pump discharge connections, relieve

pressure by opening drains.

F-1031, Section 2117

Page 9 of 12

Fire Hose Testing

WARNING

Hose Testing Hazard. May result in serious personal injury.

Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to

prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be

used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.

NFPA 1962 Standard for the Inspection, Care, and use of Fire Hose, Couplings, and Nozzles and the Service Testing of Fire

Hose provides requirements and testing procedures for service-testing fire hose at least annually. NFPA 1962 includes

procedures for service testing with either a hose testing machine or with a pump on a fire department fire apparatus.

WARNING

Pressure Hazard. May result in serious personal injury.

If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST

be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed

between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a

hose bursts during testing.

During fire hose testing with a fire pump on a fire department fire apparatus, the fire pump is required to be operated at high

discharge pressure with little or no flow out of the apparatus.

WARNING

Scalding Water Hazard. May result in serious burns.

If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be

circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be

used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be

heated enough to scald someone when a valve is opened.

CAUTION

If a fire pump on a fire department apparatus is used for service testing of fire hoses, operating the pump at high discharge

pressure with little or no flow may result in severe damage to the pump.

F-1031, Section 2117

Page 10 of 12

Threaded Anodes

Zinc Intake Screen

Threaded Anodes

Optional Zinc Intake Screens

Maintenance

Corrosion Protection

Once per month check to make sure the intake screens

are not clogged or damaged. Also check for corrosion,

and replace screens if damage is severe. For the zinc

screen to adequately control corrosion, there must be a

strong electrical contact between the screen and the

fitting. Remove any corrosion, debris or paint from the

counter bore that will insulate the screen from the intake

fitting. If the screen does not fit tightly, adjust the gap of

the slot on the outside diameter of the screen to ensure a

tight fit.

NOTE: These screens are die-cast which results in a

slight taper from one side to the other. Install the

screen with the thinner cross-section facing out to

minimize flow restriction.

Optional Zinc Anodes

Twice per year, remove the anodes and check for erosion

of the zinc elements. Replace the zinc elements if more

than half of either of the zinc elements has eroded.

Anodes are normally mounted on the pump intake piping,

but they may also be installed in the discharge piping if no

intake mounting locations were available. Physical

mounting of the anode may be via an NPT tap or bolt-on

flange as described below.

NOTE: The zinc must make contact with water to be

effective. Do not paint or use any other coating on the

zinc elements.

Bolt-on Anodes

Unscrew the (4) hex head screws from the pump. If zinc

elements require replacement, unscrew the hex head cap

screw.

NOTE: There is no need to remove the threaded

anode adapter from the anode flange for zinc element

replacement. The screw was installed using thread

sealant so higher force than normal may be neces-

sary to remove.

Replace one or both elements as necessary. Install the

hex head screw using Loctite 242 (blue) on the screw

threads. Mount the anode assembly back on the fitting.

Threaded Anodes

NOTE: The 2-1/2 in. hex is threaded into a bushing

that should remain on the pump. Be sure to restrain

the bushing when removing the 2-1/2 in. hex.

Unscrew the 2-1/2 in. hex from the pump. If the zinc

elements require replacement, unscrew the hex head cap

screw.

NOTE: The screw was installed using thread sealant

so higher force than normal may be necessary to

remove.

Replace one or both elements as necessary. Install the

hex head screw using Loctite 242 (blue) on the screw

threads. Remove any paint or corrosion from the face

around the NPT tap on the pump. Apply thread sealant to

the threads and screw the 2-1/2 in. hex into the pipe tap

until tight.

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