Models : FGHC Series Horizontal split case Fire pumps

Installation & Operating Instructions

www.pumpsgp.com
Horizontal split case Fire pump
FGHC
Contents 1. Symbols used in this document

1. Symbols used in this document 1 Warning

If these safety instructions are not observed, it
2. General description 1 may result in personal injury!
3. Delivery & Handling 1 If these safety instructions are not observed, it
3.1 Delivery 1
3.2 Handling 2 Caution may result in malfunction or damage to the
3.3 Temporary storage 2 equipment!

4. Applications 2 Notes or instructions that make the job easier

Note
4.1 Pumped liquids 2 and ensure safe operation.
5. Operating conditions 3 2. General description
5.1 Ambient temperature 3
5.2 Liquid temperature 3 FGHC Horizontal split case Fire pumps are supplied either as
5.3 Maximum pressure 3 complete pump with motor, base frame, couple &
5.4 Minimum inlet pressure 3 coupling guard or as bare shaft pump.
5.5 Maximum inlet pressure 3
5.6 Minimum flow rate 3 These instructions apply to both types.
5.7 Maximum flow rate 3
The FGHC pump can be driven by an electric motor or
6. Mechanical installation 3 other type of driver. In the following we assume that the
6.1 Location 3 pump is driven by an electric motor.
6.2 Foundation 3
6.3 Vibration dampers 3
6.4 Expansion joints 3 3. Delivery and handling
6.5 Foundation and alignment procedure 4
3.1 Delivery
7. Piping 7 The pump is delivered from factory in a crate or wooden
7.1 System types 7 box specially designed for transport by a forklift truck.
7.2 General information 7
7.3 Suction piping 7 Upon a receipt, check the pump visually to check
7.4 Valves in suction piping 8 whether any damage has happened during transport or
7.5 Discharge piping 8
handling. Check especially for
8. Electrical connection 9
8.1 Frequency converter operation 9 1. Broken or cracked equipment, including base frame,
motor or pump feet and flanges.
9. Start-up 9 2. Broken motor fan cover, bent eye bolts or damaged
9.1 Pre-start checks 9 terminal box.
9.2 Starting 10 3. Missing parts.
9.3 Operating checks 10
9.4 Operating at reduced flow and/or head 10 Parts or accessories are sometimes wrapped individually
9.5 Frequency of start and stops 10
or fastened to the equipment.
10. Maintenance 11
10.1 General information 11 If any damage or losses have occurred, promptly notify
10.2 Frequency of inspections 11 General Pumps representative and the carrier’s agent.
10.3 Lubrication 11

11. Frost protection 11

12. Fault finding chart 12

13. Disposal 13

14. Spare parts list 14

Warning
Prior to installation, read these installation and
operating instructions. Installation and
operation must comply with local regulations
and accepted codes of good practice.

EN-1
Horizontal split case Fire pump
FGHC
3.2 Handling 3.3 Temporary storage
If the pump is not to be installed and operated soon after
When unloading the pump, lift equally at four or arrival, store it in a clean, dry place with slow, moderate
more points on the base frame. Do not lift by changes in ambient temperature. Protect the pump from
the motor or pump. Do not lift by the flanges or moisture, dust, dirt and foreign bodies. Prior to and
by the eye bolts on the motor. during storage we recommend these precautions:

1. Ensure that the bearings are filled with the

recommended grease to prevent moisture from
entering around the shaft, see section 10.3 lubrication.
2. Ensure that suction and discharge ports of the pump
and all other openings are covered with cardboard,
wood or masking tape to prevent foreign objects from
entering the pump.
3. Cover the unit with a tarpaulin or other suitable
covering if it is to be stored where there is no
protective covering.
4. Rotate the shaft 2 turns every 2 weeks to prevent
corrosion of the bearing surfaces and the stuffing box/
shaft seal faces due to moisture.

4. Applications
General Pumps FGHC Horizontal split case Fire pumps are
typically used for

• Community water supply.

• Circulation in heating, ventilating, air-conditioning and
cooling systems.
• Liquid transfer and pressure boosting in various
industrial systems.
• Liquid transfer in irrigation systems.
Fig. 1 How to lift and handle FGHC pumps.
Note Use shackles at all four corners. 4.1 Pumped liquids
Thin, clean and non-aggressive liquids, not containing
solid particles or fibers. Do not pump liquids that will
attack the pump materials chemically.

When pumping liquids with a density and/or viscosity

higher than that of water, use motors with
correspondingly higher outputs.

The stuffing box packing rings/mechanical shaft seal

O-rings chosen must be suitable for the liquid to be
pumped.

Special stuffing box packing rings/shaft seal O-rings may

be required if the pump is used for pumping treated water

• At temperatures above 80°C (176°F)

• Containing additives to prevent system corrosion,
calcareous deposits, etc. (This may be the case in
heating and ventilating systems).

When pumping water mixed with glycol, it may be

necessary to use another shaft seal. For further
information, pleas contact General Pumps.

Fig. 2 How to lift and handle FGHC bare shaft pumps.

EN-2
Horizontal split case Fire pump
FGHC
5. Operating conditions
A A
5.1 Ambient temperature
Maximum +40°C.

5.2 Liquid temperature

The maximum liquid temperature marked on the pump
C C
nameplate depends on the mechanical shaft seal used.

Max. temperature for NBR: +80°C B

Max. temperature for Viton: +90°C.
Fig. 3 FGHC pump with base frame mounted on a
5.3 Maximum pressure concrete foundation (B) with expansion
The maximum pressure is stated on the nameplate. joints (A) and vibration dampers (C)
5.4 Minimum inlet pressure
The minimum inlet pressure must correspond to the 6.3 Vibration dampers
NPSH curve for the pump + a safety margin of minimum To prevent vibrations from being transmitted to the building
0.5 metres head. or the pipework, we recommend you to isolate the pump
NPSH curevs are available in data booklet. foundation from buildings by means of vibration dampers.
In order to select the right vibration damper, you need this
5.5 Maximum inlet pressure information:
Inlet pressure + pressure when the pump is running
against closed valve must never be higher than the • Forces transferred through the damper.
maximum pressure stated on the nameplate. • Motor speed. In the case of speed control, this must also
be taken into account.
5.6 Minimum flow rate • Desired dampening in % (recommended value: 70%).
A minimum flow rate equal to 30% of the flow rate at
maximum efficiency is needed at all times. Flow rate and The selection of vibration damper differs from installation to
head at maximum efficiency are stated on the nameplate. installation. In certain cases a wrong damper may increase
the vibration level. Vibration dampers should therefore be
5.7 Maximum flow rate sized by the supplier of the vibration dampers.
The maximum flow rate must not exceed 120% of the
value stated on the nameplate. If the maximum flow rate 6.4 Expansion joints
is exceeded, cavitation and overload may occur. Expansion joints provide these advantages:

6. Mechanical installation • Absorption of thermal expansion and contraction of

pipework caused by variations in liquid temperature.
6.1 Location • Reduction of mechanical influences in connection with
Install the pump as close as possible to the supply of pressure surges in the pipework.
pumped liquid, with the shortest and most direct suction • Isolation of structure-borne noise in the pipework (only
pipe practical. Install the pump with sufficient accessibility rubber bellows expansion joints).
for inspection and maintenance. Allow ample space and
headroom for the use of an overhead crane or hoist Do not fit expansion joints to make up for
sufficiently strong to lift the unit, when maintenance is Note inaccuracies in the pipework, e.g. centre
required. displacement or misalignment of flanges.

Make sure there is a suitable electricity supply available The expansion joints should be fitted at a minimum distance
for the motor. of 1 to 1.5 flange diameters away from the pump, both on
the suction and the discharge sides. This prevents
6.2 Foundation turbulence in the joints, thus ensuring optimum suction
We recommend that you install the pump on a concrete conditions and minimum pressure drop on the discharge
foundation which is heavy enough to provide permanent side.
and rigid support for the entire pump. The foundation
must be capable of absorbing any vibration, normal At high water velocities (> 2.5 m/s), we recommend you to
strain or shock. As a rule of thumb, the weight of the fit larger expansion joints & connection pipe.
concrete foundation should be 1.5 times the weight of the
pump or unit. For further information on the building of If the pump is installed on a foundation with
the foundation, see section 6.5 Foundation and alignment vibration dampers, fit expansion joints on both
procedure. sides of the pump. The pump must have these
flexible connections both at the discharge side
and the suction side to allow the pump to move
up and down.

EN-3
Horizontal split case Fire pump
FGHC
6.5 Foundation and alignment procedure 1. Lift/jack up the base frame to the final level, 15-25 mm
The foundation and alignment procedure has five steps: above the concrete foundation, and support the base
frame by means of blocks and shims both at the
1. Pouring of foundation foundation bolts and midway between bolts, see fig. 5.
2. Shimming of base frame
3. Preliminary alignment 2. Level the base frame by adding or removing shims under
4. Grouting the base frame, see fig. 5.
5. Final alignment
3. Tighten the foundation bolts nuts against the base frame.
6.5.1 Pouring of foundation Make sure the piping can be aligned to the pump flanges
We recommend the following procedure to ensure a without putting strain on pipes or flanges.
good foundation.
6.5.3 Preliminary alignment
1. Pour the foundation without interruptions to within
15-25 mm of the final level. Use compactors to ensure Before starting work on the pump, make sure
that the concrete is evenly distributed. The top that the electricity supply has been switched
surfaces should be well scored and grooved before the off and that it cannot be accidentally swithched
concrete sets. This provides a bonding surface for the on.
grout.
2. Embed foundation bolts in the concrete as shown in The pump and motor are correctly aligned on the base
fig. 4. Allow enough bolt length to reach through grout, frame from the factory. Some deformation of the base frame
shims, lower base frame, nuts and washers. may occur during transport and it is therefore essential to
check alignment at the installation site prior to final grouting.
Base frame or
vibration damper A flexible coupling will only compensate for minor
Thickness of misalignments and should not be used to compensate for
base frame or excessive misalignment of the pump and motor shafts.
vibration Inaccurate alignment results in vibration and excessive
damper flange
Leveling wedges
wear on the bearings, shaft or wear rings.
15 to 25 mm
allowance for Top of foundation Carry out alignment of motor and pump by placing shims of
grout left rough different thickness under motor and pump, respectively. If
possible, replace several thin shims with one thick shim.
Anchor 4 nos.

Washer Lug Pipe sleeve

The preliminary alignment procedure has three steps:

1. Checking coupling clearance.

Fig. 4 Typical foundation bolt design 2. Checking parallel alignment.
Let the foundation cure for several days before the base 3. Checking angular alignment.
frame is shimmed and grouted.
1. Checking coupling clearance
6.5.2 Shimming of base frame Check that the gap between the coupling halves is equal to
the values in the table and that the key ways are 180°
displaced.
For a coupling The coupling clearance
with an outside [mm] must to be:
diameter of Ø [mm]
25 mm

Spirit level Nominal Tolerance

Ø90 to 180 3 + 0/-1
Ø200 to Ø315 4 + 0/-1
Ø355 to Ø630 5 + 0/-1
2. Checking parallel alignment
Place a straight edge across both coupling rims at the top
the bottom and both sides, see fig. 6. After each
adjustment, recheck all features of alignment. Parallel
alignment is correct when the measurements show that
all points of the coupling faces are within ±0.2 mm of
each other.

Fig. 5 Shimming of base frame and leveling of pump

EN-4
Horizontal split case Fire pump
FGHC
Base frame
or vibration
damper

Grout

Leveling
wedges
15 to 25 mm or shims
Fig. 6 Checking parallel alignment grout
Top of
foundation
Form work
(rough)
3. Checking angular alignment
Insert a pair of inside calipers or a taper gauge at four
points at 90° intervals around the coupling, see fig. 7.
Angular alignment is correct when the measurements Fig. 8 Sectional view of foundation with foundation
show that all points of the coupling faces are within bolt, grouting and base frame
±0.2 mm of each other.

6.5.5 Final alignment

Make final alignment after the base frame has been
properly fastened and the grout has dried throughly
according to instructions.

Make final alignment by shimming the motor

only.

Proceed like this:

Fig. 7 Checking angular alignment 1. Check direction of rotation, see section 9.1.5 Direction
of rotation.
2. Let the pump run until it has reached its operating
Recheck coupling clearance and tighten the set screws temperature under normal operating conditions (approx.
on the couplings. 1 hour).
3. Check alignment on the coupling by means of a dial
6.5.4 Grouting gauges, see below.
Grouting compensates for uneven foundation, distributes
weight of unit and prevents shifting. Use an approved, Checking coupling alignment by means of dial gauges
non-shrinking grout and proceed as follows: Start the procedure by removing coupling pins and checking
that the motor shaft and pump shaft can turn freely.
1. Build a strong form work around the foundation to
contain the grout.
2. Soak top of concrete foundation throughly, then Dial gauge (2) for
parallel alignment
remove surface water.
3. Fill the form work with grout up to a thickness of 15-25
mm. Allow grout to dry throughly before attaching 0°
piping to pump (24 hours is sufficient time with
Index
approved grouting procedure). line
4. When the grout has throughly hardened, check the
foundation bolts nuts and tighten if necessary. 270° 90°
5. Approximately two weeks after the grout has been
poured, or when the grout has throughly dried, apply
an oil base paint to the exposed edges of the grout to
prevent air and moisture from getting in contact with 180°
the grout.
Dial gauge (1) for
angular alignment

Fig. 9 Dial gauge arrangements;

the end view of the coupling is seen from the
motor

EN-5
Horizontal split case Fire pump
FGHC
The coupling alignment procedure has four steps: 1. Mount dial gauge (1) in position 90° (3 o’clock) see fig. 9.
2. Make index lines on the two coupling halves, see fig. 9.
1. Parallel alignment - vertically 3. Set the dial gauge pointer to zero, turn motor and pump
2. Parallel alignment - horizontally shaft simultaneously until dial gauge is in position 270°
3. Angular alignment - horizontally (9 o’clock) and check that the index lines are still in line.
4. Angular alignment - vertically. 4. Read dial gauge (1). If the dial gauge shows a deflection
exceeding ±0.2 mm, move the motor sideways until the
1. Parallel alignment - vertically deflection is halves.
5. Set the dial gauge point to zero, turn motor and pump
shaft simultaneously until dial gauge is in position 90°
(3 o’clock) and read dial gauge (1) again.
6. Now the reading should be within the allowable tolerance
of ±0.2 mm. If not - repeat the procedure.

4. Angular alignment - vertically

1. Mount dial gauge (2) in position 0° (12 o’clock),

see fig. 9.
2. Make index lines on the two coupling halves,
see fig. 9.
3. Set the dial gauge pointer to zero, turn motor and
pump shaft simultaneously until dial gauges is in
position 180° (6 o’clock) and check that the index
lines are still in line.
4. Read dial gauge (2). If dial gauge shows a deflection
exceeding ±0.2 mm, add or remove shims under the 1. Turn motor and pump shaft until dial gauge (1) in position
motor until the reading of the dial gauge is within the 0° (12 o’clock).
allowable tolerance of ±0.2 mm. 2. Set the dial gauge pointer to zero, turn motor and pump
shaft simultaneously until dial gauge is in position 180°
2. Parallel alignment - horizontally (6 o’clock) and check that the index lines are still in line.
3. Read dial gauge (1). If dial gauge shows a deflection
exceeding ±0.2 mm, add or remove shims under the
motor until the deflection is halved.
4. Set the dial gauge pointer to zero, turn motor and pump
shaft until dial gauge is in position 0° (12 o’clock) and
read dial gauge (1) again.
5. Now the reading should be within the allowable tolerance
of ±0.2 mm. If not - repeat the procedure.
6. Remove dial gauge (1).
1. Turn motor and pump shaft 90°.
2. Set the dial gauge pointer to zero, turn motor and Coupling tolerances may differ from coupling
pump shaft 180° and check that the index lines are still make to coupling make. For the standard
in line. mounted pin and bush coupling the allowable
3. Read dial gauge. If dial gauge shows a deflection Note tolerance is ±0.2 mm. For other coupling types,
exceeding ±0.2 mm, move the motor sideways until please see the coupling data supplied with the
the reading of the dial gauge is within the allowable pump.
tolerance of ±0.2 mm.
4. Remove dial gauge (2). Finish the alignment procedure by refitting and tightening
the coupling pins.
3. Angular alignment - horizontally
Do not operate unit without ensuring that all
guards are in place.

EN-6
Horizontal split case Fire pump
FGHC
7. Piping
Air pocket
7.1 System types
The General Pumps FGHC Horizontal split case Fire pumps
can be installed in two types of system:

1. Closed system or open systems where the liquid level

is above the pump inlet, meaning that a certain suction
head will be available.
2. Open systems where the liquid level is below the
pump inlet, meaning that the pump will be operating
with a suction lift.

7.2 General information Turbulent flow

When installing the piping, observe these precautions:
Fig. 10 NOT recommended suction pipe installations
• Always run the piping to the pump.
• Do not move pump to the piping. This could make final
alignment impossible. • Install the suction pipe sloping upwards toward the
• Make sure that both suction and discharge piping are suction port. Any high point in the pipe will be filled
independently supported near the pump so that no with air and thus prevent proper operation of the pump.
strain is transmitted to the pump when the flange bolts When reducing the piping to the suction port diameter,
are tightened. Use pipe hangers or other supports with use an eccentric reducer with the eccentric side down
necessary spacing to provide support. to avoid air pockets, see fig. 11.
• When expansion joints are used in the piping system,
fit the joints at a minimum distance of 1 to 1.5 flange
diameters away from the pump, both on the suction
and the discharge sides. This prevents turbulence in
the joints, thus ensuring optimum suction conditions
and minimum pressure drop on the discharge side.
• Install piping as straight as possible and avoid
unnecessary bends. Where necessary, use 45° or long
sweep 90° fittings to reduce friction loss, see fig. 17.
• Make sure that all piping joints are tight. Fig. 11 Upward sloping suction pipe
• Where flanged joints are used, ensure that inside
diameters match properly.
• Remove burrs and sharp edges when making up joints. • Never use a straight, concentric reducer in a horizontal
• Make sure that the piping does not cause stress or suction pipe, as it tends to cause the formation of air
strain in the pump. pockets at the top of the reducer and the pipe, see
• Provide for expansion of pipe material when hot liquids fig. 12.
are to be pumped.

7.3 Suction piping Air pocket

The sizing and installation of the suction piping

is extremely important.
The following procedure applies to

• Closed systems and open systems where the liquid

level is above the pump inlet. Fig. 12 A concentric reducer will cause an air pocket
• Open systems where the liquid level is below the to be formed at the top of the reducer.
pump inlet.

Many NPSH (Net Positive Suction Head) problems can • Make sure that liquid flow is evenly distributed to both
be avoided if the suction piping is properly installed. sides of the double suction impellers.
There is always an uneven, turbulent flow through an
• Ensure that pressure losses are minimized and elbow. So if an elbow is installed in the suction pipe
sufficient liquid will flow into the pump. near the pump in a position other than vertical, more
• Make the suction piping is as short in length and as liquid will enter one side of the impeller than the other,
direct as possible, and never smaller in diameter than
see fig. 13. This will result in heavy, unbalanced thrust
the pump suction port.
• Avoid air pockets or turbulence in the suction pipe, loads overheating the bearings, causing rapid wear
see fig. 10. and reducing the hydraulic performance.

EN-7
Horizontal split case Fire pump
FGHC
Water pressure increases here causing Generally recommended suction pipe installations
a greater flow to one side of the
impeller than to the other

Fig. 13 Unbalanced loading of a double suction impeller

due to uneven flow through an elbow close to
the pump

Uneven flow

Fig. 14 NOT recommended suction pipe installation Concentric

reducer
The problems of uneven suction flow to the pump may be
solved in two different ways:

• Install a length of straight pipe of at least 10 times the

diameter of the suction pipe, see fig. 15.

Eccentric
reducer
10 x DN

DN Fig. 17 Generally recommended suction pipe installations

7.4 Valves in suction piping

If the pump is operating under static suction lift conditions, a
non-return valve may be installed in the suction pipe to
avoid having to prime the pump each time it is started. The
non-return valve should be of the flap type or a foot-vlave.
Fig. 15 Recommended suction pipe installation with a
length of straight pipe 7.5 Discharge piping
The discharge pipe is usually preceded by a non-return
valve and a discharge isolating valve. The non-return valve
• or install a suction diffuser direct on the suction port of protects the pump against excessive back pressure and
the pump, see fig. 16. reverse rotation of the pump and prevents back flow
through the pump in case of stoppage or failure of the
motor.

1 If the discharge piping is short, the pipe diameter can be the

same as the discharge port. If the piping is long, the pipe
diameter should be one or two sizes larger than that of the
discharge port. On long horizontal runs, it is desirable to
keep the piping as level as possible.

Avoid high spots, such as loops, as they will collect air and
Fig. 16 Pump installation with suction diffuser (1) throttle the system or lead to uneven pumping.

EN-8
Horizontal split case Fire pump
FGHC
8. Electrical connection 9. Start-up
The electrical connections should be carried out by an The start-up procedure for FGHC pumps has three steps:
authorised electrician in accordance with local
regulations. 1. Pre-start checks, see section 9.1 Pre-start checks.
Before removing the terminal box cover and 2. Starting, see section 9.2 Starting
before any removal/dismantling of the pump, 3. Operating checks, see section 9.3 Operating checks.
make sure that the electricity supply has been
switched off and that it can not be accidently Do not start the pump until you have gone
switched on. through all the pre-start checks.

The operating voltage and frequency are marked on the 9.1 Pre-start checks
nameplate. Pre-start checks has six steps:

Make sure that the motor is suitable for the electricity 1. Bearings
supply of the installation site. 2. Stuffing boxes
3. Pressure gauge
The electrician connections should be carried out as 4. Priming
shown on the motor nameplate or in the wiring diagram 5. Direction of rotation
on the back of the terminal box cover. 6. Operating of valves
Whenever powered equipment is being used in
9.1.1 Bearings
explosive surroundings, the rules and
Check that all bearings are properly lubricated, see
regulations generally or specifically imposed by
section 10.3 Lubrication.
the relevant responsible authorities or trade
organizations must be observed.
9.1.2 Stuffing boxes
8.1 Frequency converter operation Check that the stuffing boxes have been properly
All three-phase motors can be connected to a frequency tightened.
converter.
Does not apply to pumps with mechanical
Note
Frequency converter operation will often expose the shaft seal.
motor insulation system to a heavier load and cause the
motor to be more noisy than usual due to eddy currents 9.1.3 Pressure gauge
caused by voltage peaks. Check that the pressure gauge connection is closed.

In addition, large motors driven via a frequency converter 9.1.4 Priming

will be loaded by bearing currents.
Closed systems or open systems where the liquid
When your pump is operated via a frequency converter, level is above the pump inlet:
check the following operating conditions:
The suction pipe and the pump must be filled with liquid
Operating and vented before the pump is started. Proceed as
Action
conditions follows:
2- and 4-pole motors Check that one of the motor bearing is
of 110 kW and up electrically isolated. 1. Close the discharge isolating valve and loosen the air
and 6-pole motors of vent screw.
75 kW and up
Noise critical Fit a dU/dt filter between the motor and
applications
Pay attention to the direction of the vent hole
the frequency converter (reduce the
voltage peaks and thus the noise). and ensure that the escaping water does not
Particularly noise Fit a sinusoidal filter. cause injury to persons or damage to the
critical applications motor or other components.
Cable length Fit a cable that meets the specifications In hot-water installations, pay special attention
laid down by the frequency converter to the risk of injury caused by scalding hot
supplier. (The length of the cable water.
between motor and frequency converter
affects the motor load). 2. Slowly open the isolating valve in the suction pipe until
Supply voltage up to Check that the motor is suitable for
500 V frequency converter operation.
a steady flow of liquid runs out of the vent hole.
Supply voltage • Fit a dU/dt filter (reduce the voltage 3. Tighten the air vent screw and completely open the
between 500 V and peaks and thus the noise) or isolating valve(s).
690 V • Check that the motor has reinforced
insulation.
Supply voltage of • Fit a dU/dt filter and
690 V and upwards • Check that the motor has reinforced
insulation.

EN-9
Horizontal split case Fire pump
FGHC
Open systems where the liquid is below the pump overloaded.
inlet: 4. Measure motor current consumption and compare the
result with the rated current stated on the motor
The suction pipe and the pump must be filled with liquid nameplate. In the event of motor overload, throttle the
and vented before the pump is started. Proceed as discharge isolating valve until the motor is no longer
follows: overloaded.
5. Check bearings for lubrication and temperature.
1. Close the discharge isolating valve and open the Normal temperature is 80°C (176°F). Maximum
isolating valve in the suction pipe. temperature depends on the type of lubrication, see
2. Remove the air vent screw. the lubrication nameplate on the pump.
3. Pour liquid through the vent hole until the suction pipe Stop the pump immediately if any defects are
and the pump are completely filled with liquid. noticed. Do not start the pump unless defects
4. Refit the air vent screw and tighten securely. Caution have been corrected, see section 12. Fault
finding. Report immediately to the supplier if
The suction pipe can to some extent be filled with liquid it is not possible to remedy the defects.
and vented before it is connected to the pump. A priming
device can also be installed before the pump. The operating checks apply not only to the
Note start-up procedure, but should be used when
9.1.5 Direction of rotation checking the pump during normal operation.
Direction of rotation is checked in the following way:
9.4 Operating at reduced flow and/or head
1. Remove coupling pins and check that the motor shaft
can turn freely. Do not operate the pump at a flow below 30% of flow at
2. Start motor briefly to check direction of rotation. The best efficiency point or with the discharge isolating valve
correct direction of rotation is indicated by arrows on closed. Operating the pump in such condition may
the pump housing. involve the risk of the pump being overheated.

The direction of rotation of the pump is not If a pump is operated at reduced head, the flow will
Note increase and the motor will consume more current than
always the same as the flow direction.
normal; this will result in overheating of the motor. In
If direction of rotation is wrong, correct it by such situations, throttle the valve on the discharge side
interchanging two phases in the motor. Check direction either manually or automatically.
of rotation again
3. Reassemble coupling with pins and guards. 9.5 Frequency of starts and stops

9.1.6 Opening of valves Excessive number of starts in a short time will

Completely open the isolating valve on the suction side increase the temperature rise of the motor
of the pump and leave the discharge isolating valve Caution causing burnout. Please ensure that maximum
closed or almost closed. number of start / stops does not exceed the
number shown in the table.
9.2 Starting
1. Start the pump. The recommended maximum number of starts and stops
2. Vent the pump during starting by loosening the air vent per hour appearing from this table apply to complete
screw until a steady stream of liquid runs out of the pumps with motor supplied by General Pumps.
vent hole.
Frame Max. starts/stops per hour
Pay attention to the direction of the vent hole size 2-pole 4-pole 6-pole
and ensure that the escaping water does not
56-71 100 250 350
cause injury to persons or damage to the
motor or other components. 80-100 60 140 160
In hot-water installations, pay special attention 112-132 30 60 80
to the risk of injury caused by scalding hot 160-180 15 30 50
water.
200-225 8 15 30
3. When the piping system has been filled with liquid, 250-315 4 8 12
slowly open the discharge isolating valve unit it is
completely open.

9.3 Operating checks

1. Check pump and piping for leaks.
2. Check and record pressure gauge readings for future
reference.
3. Check the differential pressure. If the differential
pressure is lower than anticipated, the motor may be

EN-10
Horizontal split case Fire pump
FGHC
10. Maintenance For every 10,000 operating hours or every two years,

Before starting work on the pump, make sure • Remove bearing housing from pump.
that the electricity supply has been switched • Remove old grease.
off and that it cannot be accidently switched • Throughly clean bearing housings.
on. • Refill bearings with fresh grease.
• Refit bearing housings in accordance with assembly
10.1 General information instructions.
Routine maintenance is essential to maintain the pump in
a good condition. Ball bearing grease
Use Lithium based grease suitable for temperature from
A high degree of cleanliness should be maintained during -30°C to +140°C.
all maintenance procedures.
11. Frost protection
10.2 Frequency of inspections Pumps which are not being used during periods of frost
Inspections should be carried out in accordance with the should be drained to avoid damage.
routine maintenance chart below.
Drain the pump by loosening the air vent screw at the top
Depending on operation and environmental conditions of the pump housing and by removing the drain plugs
together with a comparison of previous inspections, the from the bottom of the pump housing, see fig. 18.
frequency of inspections may be altered to maintain
satisfactory operation of the pump. Ensure that the escaping water does not cause
injury to persons or damage to the motor or
Every week a. Visually check for leaks.
b. Check for vibrations.
other components.
c. Hand test bearing housing for any In hot-water installations, pay special attention
sign of temperature rise. to the risk of injury caused by scalding hot
water.
Every month Check bearing temperature.
Every 3 months Check whether the grease in the
bearings has hardened.
Every 6 months a. Check shaft for scoring.
b. Check alignment of pump and motor.
c. Check fixing bolts and tighten, if
necessary
d. Check coupling for wear.
Every year a. Check rotating assembly for wear.
b. Check wear ring clearances.
Between regular maintenance inspections, be aware of
signs of motor or pump trouble.

Common symptoms are listed in the fault finding chart,

see section 12. Fault finding.
Drain plug
Correct any trouble immediately and avoid
Caution
costly repairs and shutdowns.
Fig. 18 Position of drain plug
10.3 Lubrication

Pump Bearing Do not tighten the air vent screw and refit the drain plug
Pump bearings are lubricated during manufacture and until the pump is to be used again.
prior to delivery.

To refill the bearings with fresh grease, use a grease gun

and press grease through the two lubricating nipples
provided.

Do not apply grease while pump is running.

EN-11
Horizontal split case Fire pump
FGHC
12. Fault finding chart
Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the
electricity supply has been switched off that it cannot be accidently switched on.
Faults Causes
The pump does not create

Pump operates for a short

The pump consumes too
running for a short time
Pump loses liquid after

Reference numbers to
The pump delivers no

deliver enough liquid

time and then stops

The pump does not

Motor overloaded
enough pressure

Cavitation noise

Pump bearings
much power

overheated

remedies
Vibration
liquid

Pump not primed, lack of priming liquid,

X X incomplete priming. 1

X Loss of priming liquid. 2

X X X X Suction lift/static lift too high. 3
Discharge pressure too high (measured at
X X discharge port). 4

X X X Speed too low. 5

X X Wrong direction of rotation. 6
X X Impeller completely clogged. 7
X Suction pipe partially blocked. 8
X X X X X Air leak in suction pipe or flange. 9
Air leak in stuffing box (flushing channel may be
X X X blocked). 10

Cavitation; insufficient NPSH (depending on

X X X X installation). 11

X X X Impeller or wear rings worn. 12

X X Defective packing rings. 13
Non-return valve too small or partially obstructed
X (cross section of non-return valve port should be 14
at least as large as cross section of suction pipe).
X X X Suction pipe not immersed deeply enough. 15
Impeller diameter too small (probable cause if
X none of above causes can be established). 16

X Obstruction in pimp housing. 17

X X X X Air or gases in liquid. 18
The actual duty point of the pump lies to the right
X X of the specified duty point on the pump curve. The 19
result is lower head, higher flow and higher power
consumption.
Viscosity or specific gravity of pumped liquid is
X X 20
higher than that of water.
X X X X Shaft bent due to damage. 21
X X X X Mechanical failure of bearing. 22
X X X Misalignment. 23
X X Electrical defects. 24
X X X Speed too high. 25
X Foundation not rigid enough. 26
X Lubricating oil/grease dirty or contaminated. 27

EN-12
Horizontal split case Fire pump
FGHC
No. Causes Remedy
1. Pump not primed, lack of priming liquid, Fill pump and suction pipe completely with pumped liquid.
incomplete priming.
2. Loss of priming liquid. Mend possible leaks in suction pipe, joints and fittings; vent pump
housing to remove accumulated air.
3. Suction lift/static lift too high. Reduce the difference in height between the water reservoir/water
supply and the pump.
4. Discharge pressure too high. Make sure that valves in discharge pipe are fully open.
5. Speed too low. 1. Make sure the motor receives full voltage.
2. Make sure the frequency is correct.
3. Make sure all phases are connected.
6. Wrong direction of rotation. Compare direction of rotation with directional arrow on pump housing. If
required, change direction of rotation by interchanging two phases in the
motor.
7. Impeller completely clogged. Dismantle pump and clean impeller.
8. Suction pipe partially blocked. Remove any obstructions in the suction pipe.
9. Air leak in suction pipe or flange. Replace or repair defective pipe section or flange.
10. Air leak in stuffing box. Clean flushing channel. Replace stuffing box packing rings, if necessary.
11. Cavitation; insufficient NPSH 1. Increase net positive suction head by placing the pump in a lower
(depending on installation). position.
2. Pressurize suction vessel.
12. Impeller or wear ring worn. Replace impeller and/or wear rings. If necessary, also replace bearings
and shaft.
13. Defective packing rings. Replace packing rings.
14. Non-return valve too small or partially obstructed. Replace or clean non-return valve.
15. Suction pipe not immersed deeply enough. Extend the suction pipe so that the risk of sucking air is eliminated.
16. Impeller diameter too small. Check with factory if a larger impeller can be used; if not, reduce
discharge pipe friction losses. But be careful not to seriously overload
motor.
17. Obstruction in pump housing. Dismantle pump and remove obstruction.
18. Air or gases in liquid. Remove gas or air from pumped liquid. Possibly, see 11 above.
19. The actual duty point of the pump lies to the right Install an orifice plate immediately after the discharge flange. The orifice
of the specified duty point on the pump curve. The plate will raise the system characteristic/increase the counter pressure
result is lower head, higher flow and higher power thus increasing the head and lowering the flow. The size of the orifice
consumption. plate must be adapted so that the pressure corresponds to the required
duty point.
20. Viscosity or specific gravity of pumped liquid is Use larger motor. Consult factory for recommended size. Test liquid for
higher than that of water. viscosity and specific gravity.
21. Shaft bent due to damage. Check deflection of shaft by turning on bearing journals. Total indicator
runout should not exceed 0.05 mm on shaft and 0.1 mm on impeller
wearing surface. Possibly replace shaft.
22. Mechanical failure of bearing and/or impeller. Check bearings and impeller for damage.
Possibly replace bearing or impeller.
23. Misalignment. Realign pump and motor.
24. Electrical defects. Check that volatge and frequency of the electricity supply are correct.
Check for possible defects in the motor.
Check that the motor is properly ventilated.
25. Speed too high. Check that frequency of electricity supply corresponds to frequency
stated on motor nameplate.
26. Foundation not rigid enough. Retighten foundation bolt nuts. Check that foundation was made
according to installation and operating instructions.
27. Lubricating oil/grease dirty or contaminated. 1. Clean bearings and bearing housings according to instruction and
relubricate bearings.
2. Check that the V-ring (extended and two-stage, through-bore versions)
is working properly.
13. Disposal
This product or parts of it must be disposed of in an
environmentally sound way:
1. Use the public or private waste collection service.

EN-13
Horizontal split case Fire pump
FGHC
14. Spare parts list 3032 3016
3014 3033
3031 3001 3006
3011
3007 3004
3017 3002 3013
3012 3010
3003 3020
3018
3005
3029
3009
3028

3008 3023
3015
3021 3024
3022
3026 3027
3025
3030
3019

Sectional drawing
Spare parts list
Part nos. Parts name Part nos. Parts name
3001 Split casing 3018 Water thrower
3002 Impeller 3019 Water plug with 'O' ring
3003 Bearing housing 3020 'O’ ring
3004 Back cover 3021 Cap screw with spring washer
3005 Shaft 3022 Cap screw
3006 Wear ring 3023 Cap screw
3007 Gland 3024 Ball bearing
3008 Internal bearing cover 3025 Key
3009 External bearing cover 3026 Graphite packing
3010 External bearing cover(drive) 3026.1 Mechanical seal
3011 R.H. Nut 3027 Hex nut
3012 L.H. Nut 3028 Key
3013 Shaft sleeve 3029 Grease nipple
3014 Shaft sleeve 3030 Dowel pin
3015 Stud 3031 Hose pipe
3016 Key 3032 Nipple 1/4”-1/8” BSP
3017 Lantern ring 3033 Air cock with ‘O’ ring
Ordering note: While ordering spare parts kindly mention pump type, sr. no., part no, part name, material specification
& quantity in the order. While ordering impeller kindly mention the impeller diameter.

Example: Pump type Sr. No. Part no. Part name Material Impeller dia. Qty.
FGHC 80 300 31012001 3002 Impeller Bronze 300 mm 1 No.

EN-14
Note

EN-15
Note

EN-16
 Warranty Certificate

General Pumps warrants this product to be free from any defects in material and
workmanship under normal use and service for twelve (12) months from the date of
purchase by the end user, or 18 months from date of invoice whichever is earlier.

Products that fail during this period will be repaired or replaced at General Pumps’s discretion,
with the same or a functionally equivalent product, provided that;

(A) The product is returned freight paid to our factory or any General Pumps Authorized Service
Station.
(B) A copy of sales invoice indicating the date of sale to the end user is provided.

This warranty does not apply to products that are found by us to be damaged;

(A) During shipment, handling or storage.

(B) Due to improper selection, installation or use.
(C) Due to single phasing or improper voltage operation of the product.
(D) Due to usage of pump for pumping liquid other than what is compatible with it's
material of construction.
(E) Due to usage of pump for pumping liquids at higher temperature than as mentioned
on the name plate.
(F) Due to installation, start up, operation that is not carried out in accrodance with this
manual or when acceptable code of good practice is not followed.
(G) Due to motor getting exposed to strike of lightning.
(H) Due to pump running dry or being operated with intermittent flow of water.

The maximum liability of this warranty is limited to the purchase price of this product.
In no event, regardless of the cause shall General Pumps be liable;

(A) For labour in removing or reinstalling the product.

(B) For any damages caused due to use of product, delay, or loss of profits.
(C) For any incidental indirect or consequential damages even if advised of the possibility
of such damages.

The original purchaser of the product from General Pumps must obtain a Return Material
Authorisation (RMA) number from General Pumps prior to returning any defective product to the
factory. In case of an end user wanting to return a defective product he must obtain
an RMA number by contacting our dealer or distributor from whom he purchased the
product, General Pumps will not accept any defective product sent to it’s factory without an RMA
number.

GENERAL PUMPS, S.L.

Pol. Ind. El Oliveral (U.E.7, Nave n°1) - Calle W 46394 Ribarroja del Turia - Valencia Spain
Tel. : +34 96 1665200 / Fax :+34 96 1665052 • E-mail: [email protected]
Website : www.pumpsgp.com