Installation and Care
Installation and Care
CORNELL GENERAL
PURPOSE PUMPS
AGRICULTURE FOOD INDUSTRIAL MINING MUNICIPAL OIL & GAS REFRIGERATION RENTAL
ISO9001:2008 CERTIFICATION
Cornell Pump Company proudly maintains its ISO9001:2008 certification which validates that
Cornell is in compliance with all necessary processes to meet customer requirements.
The elements associated with ISO 9001:2008 certification include such areas as contract
review, design and development, production, purchasing, quality control and service.
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION Priming Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
II Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION Air Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
III Bearing Lubrication and Temperature . . . . . . . . . . . . . . . . 19
Packing and Wear Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pump Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . 21
Cornell Features Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
This booklet is a general guide only for general purpose pumps. Applications
and field conditions vary. If you have questions about a specific application,
ask us or a qualified engineer. The suggestions in this booklet are not
intended as engineering specifications for individual applications. Cornell
Pump Company makes no performance warranty of the information
contained herein with respect to any particular application.
Base-Coupling-Guard Mounted
Horizontal Frame Unit.
Can be mounted with a motor or other
driver on a common base.
INSTALLATION
SLIGHTLY INCLINED
TOWARD PUMP FLOW STRAIGHTENER
4 DIAMETERS APPROXIMATELY 4
PIPE DIAMETERS
LONG ters
iame
4D
i a .
2D
SMOOTH,
GENTLE
TURN
USE SUCTION
BELL TO REDUCE
ENTRANCE LOSSES
SLIGHTLY INCLINED
TOWARD PUMP
ECCENTRIC
TAPER
SHUT-OFF
VALVE
SUCTION GAGE
AND STOP COCK
CONTOURED ENTRANCE
TO REDUCE
ENTRANCE LOSSES STRAIGHT PIPE SECTION PROVIDE
BEFORE ENTRANCE A FLOOR
(USE FLOW STRAIGHTENER HERE*) DRAIN
Do not use a concentric reducer. Air remains Do not restrict the flow. This may cause
in pipe, and the pump may cavitate or lose cavitation, reduce performance, and add
prime. friction losses.
TRAPPED AIR
Do not slope piping down toward the pump. Do not use many fittings. This creates high
Trapped air may cause the pump to cavitate friction losses and may cause cavitation,
or lose prime. Avoid the use of 90° miters. trapped air and reduced performance.
UNSUPPORTED
DIAMETER
PREFERRED
Do not discharge 'in-flow' above DISCHARGE
the surface. Entrained air can POSITION
be carried to a nearby suction
pipe. The pump will lose ENTRAINED
performance, efficiency, and AIR BUBBLES
possibly prime. Extend the pipe ADDING A
below the minimum pumpage BAFFLE
level (shown by dashed line). MAY HELP
Adding a baffle may help if the
'in-flow' already contains air
bubbles. Do not let the flow
cascade over the baffle.
SUBMERGENCE (d)
70
SUBMERGENCE (d), INCHES
60
PE IPE
50
Suction . PI
.P
I.D I.D . PIP
E
IP
E
E
40 H H . P PIP PE
Pipe
C C I .D I. D . I PE
N
4
I
6
IN
CH C H I. .D. P . PI
D
IN IN C H I I.D
8 H
10 2 IN INC NCH
Submergence
30
1 I
14 16
20
10
0
100 200 400 600 800 1000 2000 4000 6000
FLOW, GPM
DIAMETER
PUMP
INLET
15ϒMAXIMUM
SIDE VIEW
PUMP
INLET
15ϒPREFERRED
45ϒMAXIMUM TOP VIEW
GROUT DRAINAGE
DAM TACK TACK
WELD SHIMS WELD
WEDGES
3/4 TO 1 1/2 INCHES GROUT DRAINAGE
HIGH
CONCRETE
FOUNDATION
Alternate
SHAFTS PARALLEL
Tighten the take-up until the belts If the belts slip, they are too loose
are snug. Run drive at full speed or overloaded. Never use belt
and adjust take-up until only slight dressings.
bow appears in back side of belts.
Vertical drives must be operated
tighter than other configurations.
Reinstall belt guard before start-up.
PLACE ELECTRICAL
CONTROL
NEAR DOOR
USE ADEQUATE VENTILATION
WITH SCREENS
AND SHADES
(FORCED AIR IS BEST)
SECURITY LOCK
PROVIDE EQUIPMENT
SERVING SPACE
PROPER SITE
DRAINAGE
USE LARGE, CONCRETE
THRUST BLOCKS, EVEN
ON SUBSURFACE PIPING
SUBSURFACE
PIPING IS PREFERED
FOR FREEZE
INFLOW
PROTECTION
OUTFLOW
PUMP SHELTER
Protect the pump from moisture, piping movement,
dust, standing water, sun, heat, freezing, high humidity,
electrical problems, and flooding. Also check for rodents
and nests in temporarily unused piping.
VENTILATION
PROTECTION
FROM
BLOWING
DUST
DRAINAGE
GOOD SUPPORT
PROVIDED MOTOR PLACED AT PROFESSIONALLY INSTALLED,
LEAST 4 INCHES ABOVE WEATHER PROTECTED, ELECTRICAL SYSTEM
FLOOR LEVEL
START-UP
VACUUM
PUMP
FLOAT
CORNELL REDI-PRIME® VALVE
Cornell Redi-Prime, fully automated, FLOAT
self-priming pumps are ideal for unattended SWITCH
CHAMBER
operation. Our postitive sealing float box
and diaphram vacuum pump configurration
insures that there is no water carry-over.
Cornell Redi-Prime pumps handle air/water
mixtures with ease.
SUMP
LEVEL HIGH
CONTROL WATER
ALARM
PUMP "ON"
FLOAT
VENTURI SWITCH
COMPRESSED AIR PUMP "OFF"
FLOAT
SWITCH
EXHAUST AIR
COMPRESSOR
FLOAT
ASSEMBLY
VOLUTE VENTURI PRIME
Specially constructed engine-
driven pumps can be primed
with an exhaust operated
vacuum producing device.
EVACUATED
AIR
PRIMING SUPPLY
LIQUID VALVE
SUPPLY
FOOT VALVE
AND SCREEN
VACUUM PRIMING
External vacuum pump creates
a vacuum that pulls water into
the volute. System shuts off
when prime is established.
Generally, allows for automatic
DISCHARGE LINE
priming and re-priming.
CHECK VALVE
AUTOMATIC AIR
DISCHARGE SPOOL RELEASE VALVE
RETURN LINE
PUMP
SELF-PRIMING
During the priming cycle, air mixes with
water retained inside the pump and is
discharged out of the casing. The air
SUCTION LINE will rise and water will fall down to the
bottom of the casing. This will repeat
until all air is evacuated from the suction
line and is full of water. The pump is
essentially creating a vacuum in the
suction line which is lifting the water into
the pump. Once air has been removed
from the pump and suction line, flow will
begin to happen.
Cornell Pump Company Clackamas, Oregon 15
START-UP CHECK LIST
Before the start-up of any pump, a careful check must be made to insure that all is in order.
1. Re-read all instructions and check for 11. Check pump rotational direction.
compliance on each point. (VERY SHORT on/off power pulse).
2. Piping must be clean and free of 12. Comply with all seal or packing
debris and obstructions, gaskets in operation and start-up instructions.
place and all joints secure.
13. Monitor the motor temperature.
3. Are all thrust blocks and supports
adequate? 14. Note the operating temperature of
frame bearings (if any).
4. Are screens in place?
15. The pump may be checked for
5. Check the valves and blow-offs for shut-off pressure with the pump
proper position. performance curve.
6. Make sure support systems are in 16. Fill the system slowly.
place and functioning, such as special
lubrication, frame oil, etc. 17. Do not operate any pump without
properly priming it, unless it has
7. Check the power supply voltage with been specifically designed for such
the motor name plate. operation.
8. Are belts and shaft couplings properly 18. New pumps must not be started
adjusted and aligned and guards in and stopped frequently. If possible,
place? permit the unit to run until operating
temperature is reached.
9. Does the pump rotate freely? NOTE: Large motors must not be
10. Prime the pump. started and stopped more than five
times per hour.
A pump must not be started until compliance is reached on all the applicable points above and any others
specified in the Operation and Maintenance Manual supplied with the pump. Failure to do so may cause severe
damage to equipment and/or personal injury. It may also void the warranty.
OPERATION
AIR
LIQUID
PUMPAGE
INJECTION FLOW FROM LARGE LEVEL SUCTION
THE PUMP DISCHARGE BUBBLES LIFT
FLOW
STOPS AIR
Bearing temperatures to 160°F (71°C) are normal. Temperatures over 200°F (93°C) are too high. The human
hand can not estimate high temperatures. Use a thermometer or other device for temperature measurement.
IMPORTANT
A. Oil level must be correct before unit is started.
C. Grease lubricated motors and frames must be maintained per instructions accompanying
the pump. Grease code EP-2 is recommended for most applications. Added grease must
be the same type as recommended in the O&M manual.
RUNNING
CLEARANCE
GLAND
NUTS
PACKING PULLER
Packing puller used when
PACKING replacing packing
GLAND PACKING
GLAND
LEAKAGE
Running clearance on most new general purpose water pumps is about .010 inch on a side. (check with the
factory for specifications on for your model). If wear increases this to .032 inch, the wear ring should be replaced
and the impeller repaired or replaced. Wear may be caused by abrasives in the pumpage, unsupported piping
loads, or other causes.
Tighten the gland nuts 1/4 turn every ten minutes until a leakage of only 40–60 drops per minutes is achieved. If
the packing must be replaced, a packing puller may be needed.
DISHED BACKPLATE
QUALITY
MECHANICAL SEAL
VOLUMINOUS SPACE
BEHIND IMPELLER
OPTIONAL RUN-DRY
GLAND™
SPECIFICALLY-CALIBRATED
IMPELLER
IMPELLER
BACK VANES
Shown is patented Cycloseal® mechanical seal configuration. Allows for longer bearing and seal life, reduces
stuffing box pressure, reduces maintenance costs, and minimizes axial thrust loads.
Cornell’s position of leadership has been maintained through the years by sound engineering and continuing
research and development. This attention to detail provides features allowing Cornell pumps to provide the
lowest cost of ownership. The quality and serviceability built into each pump permits Cornell to proudly offer a
full two-year warranty against defects in material and workmanship.