Gorman-Rupp Pumps 11-1-2A52-E2 User Manual

Page 1
ACDE OM‐04829‐02
November 27, 2001
Rev. B 10‐30‐2013
INSTALLATION, OPERATION,
WITH PARTS LIST
10 SERIES PUMPS
MODELS
11 1/2A52-E2 1P 11 1/2A52-E2 3P
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
2001 The Gorman‐Rupp Company
Page 2
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the spaces provided below. Your Gorman‐Rupp distributor needs this information when you require parts or service.
Pump Model:
Serial Number:
Page 3
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
Pump Dimensions PAGE B - 1.....................................................
PREINSTALLATION INSPECTION PAGE B - 2............................................
POSITIONING PUMP PAGE B - 2.......................................................
Lifting PAGE B - 2.................................................................
Mounting PAGE B - 2.............................................................
Clearance PAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................
Materials PAGE B - 3..............................................................
Line Configuration PAGE B - 3......................................................
Connections to Pump PAGE B - 3..................................................
Gauges PAGE B - 3...............................................................
SUCTION LINES PAGE B - 3...........................................................
Fittings PAGE B - 3...............................................................
Strainers PAGE B - 3..............................................................
Sealing PAGE B - 3...............................................................
Suction Lines In Sumps PAGE B - 4.................................................
Suction Line Positioning PAGE B - 4................................................
DISCHARGE LINES PAGE B - 5........................................................
Siphoning PAGE B - 5.............................................................
Valves PAGE B - 5................................................................
Bypass Lines PAGE B - 5..........................................................
AUTOMATIC AIR RELEASE VALVE PAGE B - 6...........................................
Air Release Valve Installation PAGE B - 6............................................
ELECTRICAL CONNECTIONS PAGE B - 7...............................................
OPERATION - SECTION C PAGE C - 1......................................
PRIMING PAGE C - 1.................................................................
STARTING PAGE C - 1................................................................
Rotation PAGE C - 1..............................................................
OPERATION PAGE C - 2..............................................................
Lines With a Bypass PAGE C - 2....................................................
Lines Without a Bypass PAGE C - 2.................................................
Leakage PAGE C - 2..............................................................
Liquid Temperature And Overheating PAGE C - 2.....................................
Strainer Check PAGE C - 2.........................................................
Pump Vacuum Check PAGE C - 2..................................................
STOPPING PAGE C - 3................................................................
Cold Weather Preservation PAGE C - 3..............................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
i
Page 4
TABLE OF CONTENTS
(continued)
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
STANDARD PERFORMANCE CURVE PAGE E - 1........................................
PARTS LISTS:
Pump Model PAGE E - 3..........................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 4.........................
Suction Check Valve Removal and Disassembly PAGE E - 4...........................
Back Cover Removal PAGE E - 4...................................................
Pump Casing Removal PAGE E - 5.................................................
Impeller Removal PAGE E - 5......................................................
Seal Removal and Disassembly PAGE E - 5..........................................
Seal Reassembly and Installation PAGE E - 5........................................
Impeller Installation and Adjustment PAGE E - 7......................................
Pump Casing Installation PAGE E - 7................................................
Back Cover Installation PAGE E - 7.................................................
Suction Check Valve Installation PAGE E - 7.........................................
Final Pump Assembly PAGE E - 7..................................................
LUBRICATION PAGE E - 8.............................................................
Seal Assembly PAGE E - 8.........................................................
Motor PAGE E - 8.................................................................
ii
Page 5
10 SERIES
OM-04829

INTRODUCTION

Thank You for purchasing a Gorman‐Rupp pump. Read this manual carefully to learn how to safely
install and operate your pump. Failure to do so could result in personal injury or damage to the pump.
This pump is a 10 Series, semi‐open impeller, self‐ priming centrifugal model with a suction check valve. It is close‐coupled to a 2 H.P., single phase or three phase, totally enclosed fan‐cooled electric motor. The basic material of construction for wetted parts is gray iron, with steel wearing parts and motor shaft. The pump is designed for handl ing most non‐volatile, nonflammable liquids con taining specified entrained solids.
For information or technical assistance on the mo tor, contact the motor manufacturer's local dealer or representative.
This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.
If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit, please contact your Gorman‐Rupp distributor, or The Gorman‐Rupp Company:
The following are used to alert maintenance per sonnel to procedures which require special atten tion, to those which could damage equipment, and to those which could be dangerous to personnel:
Immediate hazards which WILL result in severe personal injury or death. These instructions describe the procedure re quired and the injury which will result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in severe personal injury or death. These instructions describe the procedure required and the injury which could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. These instructions describe the requirements and the possi ble damage which could result from failure to follow the procedure.
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
NOTE
Instructions to aid in installation, operation, and maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
Page 6
10 SERIES
OM-04829

SAFETY ‐ SECTION A

This information applies to 10 Series electric motor driven pumps. Refer to the manual accompanying the motor before attempting to begin operation.
This manual will alert personnel to known procedures which require spe cial attention, to those which could damage equipment, and to those which could be dangerous to personnel. How ever, this manual cannot possibly antici pate and provide detailed instructions and precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance personnel to ensure that only safe, established main tenance procedures are used, and that any procedures not addressed in this manual are performed only after estab lishing that neither personal safety nor pump integrity are compromised by such practices.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inopera tive.
3. Allow the pump to completely cool if overheated.
4. Check the temperature before opening any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cau tiously.
7. Drain the pump.
This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids. Do not attempt to pump volatile, corro sive, or flammable liquids which may damage the pump or endanger person nel as a result of pump failure.
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
After the pump has been installed, make certain that the pump and all piping or hose connections are tight, properly supported and secure before operation.
PAGE A - 1SAFETY
Page 7
10 SERIESOM-04829
Do not operate the pump against a closed discharge valve for long periods of time. If operated against a closed dis charge valve, pump components will deteriorate, and the liquid could come to a boil, build pressure, and cause the pump casing to rupture or explode.
Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:
1. Stop the pump immediately.
2. Ventilate the area.
3. Allow the pump to completely cool.
4. Check the temperature before opening any covers, plates, gauges, or plugs.
5. Vent the pump slowly and cau tiously.
6. Refer to instructions in this manual before restarting the pump.
Do not install and operate a non‐explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with the Na tional Electric Code and all local codes. If there is a conflict between the instruc tions in the manual accompanying the unit and the National Electric Code or the applicable local code, the National or local code shall take precedence.
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to troubleshoot, test and/or service the electrical compo nents of this pump.
Do not remove plates, covers, gauges, pipe plugs, or fittings from an over heated pump. Vapor pressure within the pump can cause parts being disen gaged to be ejected with great force. Al low the pump to completely cool before servicing.
Never run this pump backwards. Be cer tain that rotation is correct before fully engaging the pump.
Pumps and related equipment must be in stalled and operated according to all na tional, local and industry standards.
PAGE A - 2 SAFETY
Page 8
10 SERIES OM-04829

INSTALLATION - SECTION B

Review all SAFETY information in Section A.
Since pump installations are seldom identical, this section offers only general recommendations and practices required to inspect, position, and ar range the pump and piping.
Most of the information pertains to a standard static lift application where the pump is positioned above the free level of liquid to be pumped.
If installed in a flooded suction application where the liquid is supplied to the pump under pressure, some of the information such as mounting, line configuration, and priming must be tailored to the
OUTLINE DRAWING
specific application. Since the pressure supplied to the pump is critical to performance and safety, be sure to limit the incoming pressure to 50% of the maximum permissible operating pressure as shown on the pump performance curve (see Sec tion E, Page 1).
For further assistance, contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company.
Pump Dimensions
See Figure 1 for the approximate physical dimen sions of this pump.
Figure 1. Pump Model 11 1/2A52-E2 1P and 11 1/2A52-E2 3P
PAGE B - 1INSTALLATION
Page 9
OM-04829 10 SERIES
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be fore shipment from the factory. Before installation, inspect the pump for damage which may have oc curred during shipment. Check as follows:
a. Inspect the pump and motor for cracks,
dents, damaged threads, and other obvious damage.
b. Check for and tighten loose attaching hard
ware. Since gaskets tend to shrink after dry ing, check for loose hardware at mating sur faces.
c. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties indicated. Note that the pump shaft rotates in the required direction.
The impeller of the pump is threaded onto the pump shaft. Reverse rotation of the shaft can cause the impeller to unscrew and break the suction head or casing. Dis connect the power before checking for proper direction of rotation.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCE AND REPAIR section of this manual and per form duties as instructed.
e. If the pump and motor have been stored for
more than 12 months, some of the compo nents or lubricants may have exceeded their maximum shelf life. These must be inspected or replaced to ensure maximum pump serv ice.
If the maximum shelf life has been exceeded, or if anything appears to be abnormal, contact your Gorman‐Rupp distributor or the factory to deter mine the repair or updating policy. Do not put the pump into service until appropriate action has been taken.
POSITIONING PUMP
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
Lifting
Pump unit weights will vary depending on the mounting and drive provided. Check the shipping tag on the unit packaging for the actual weight, and use lifting equipment with appropriate capacity. Drain the pump and remove all customer‐installed equipment such as suction and discharge hoses or piping before attempting to lift existing, installed units.
Mounting
Locate the pump in an accessible place as close as practical to the liquid being pumped. Level mount ing is essential for proper operation.
The pump may have to be supported or shimmed to provide for level operation or to eliminate vibra tion.
Clearance
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to troubleshoot, test and/or service the electrical compo nents of this pump.
PAGE B - 2 INSTALLATION
It is recommended that 18 inches (457 mm) of clearance be provided in front of the back cover to permit removal of the cover and easy access to the pump interior. A minimum clearance of 6 inches (152,4 mm) must be maintained to permit removal of the cover.
Page 10
10 SERIES OM-04829
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in creased suction lift, discharge elevation, and fric tion losses. See the performance curve on Page E‐1 to be sure your overall application allows pump to operate within the safe operation range.
Materials
Either pipe or hose maybe used for suction and discharge lines; however, the materials must be compatible with the liquid being pumped. If hose is used in suction lines, it must be the rigid‐wall, rein forced type to prevent collapse under suction. Us ing piping couplings in suction lines is not recom mended.
Line Configuration
Keep suction and discharge lines as straight as possible to minimize friction losses. Make mini mum use of elbows and fittings, which substan tially increase friction loss. If elbows are necessary, use the long‐radius type to minimize friction loss.
Connections to Pump
Before tightening a connecting flange, align it ex actly with the pump port. Never pull a pipe line into place by tightening the flange bolts and/or cou plings.
Lines near the pump must be independently sup ported to avoid strain on the pump which could cause excessive vibration, decreased bearing life, and increased shaft and seal wear. If hose‐type lines are used, they should have adequate support to secure them when filled with liquid and under pressure.
Installation closer to the pump may result in erratic readings.
SUCTION LINES
To avoid air pockets which could affect pump prim ing, the suction line must be as short and direct as possible. When operation involves a suction lift, the line must always slope upward to the pump from the source of the liquid being pumped; if the line slopes down to the pump at any point along the suction run, air pockets will be created.
Fittings
Suction lines should be the same size as the pump inlet. If reducers are used in suction lines, they should be the eccentric type, and should be in stalled with the flat part of the reducers uppermost to avoid creating air pockets. Valves are not nor mally used in suction lines, but if a valve is used, install it with the stem horizontal to avoid air pock ets.
Strainers
If a strainer is furnished with the pump, be certain to use it; any spherical solids which pass through a strainer furnished with the pump will also pass through the pump itself.
If a strainer is not furnished with the pump, but is installed by the pump user, make certain that the total area of the openings in the strainer is at least three or four times the cross section of the suction line, and that the openings will not permit passage of solids larger than the solids handling capability of the pump.
This pump is designed to handle up to 1 inch (25,4 mm) diameter spherical solids.
Sealing
Gauges
Most pumps are drilled and tapped for installing discharge pressure and vacuum suction gauges. If these gauges are desired for pumps that are not tapped, drill and tap the suction and discharge lines not less than 18 inches (457,2 mm) from the suction and discharge ports and install the lines.
Since even a slight leak will affect priming, head, and capacity, especially when operating with a high suction lift, all connections in the suction line should be sealed with pipe dope to ensure an air tight seal. Follow the sealant manufacturer's rec ommendations when selecting and applying the pipe dope. The pipe dope should be compatible with the liquid being pumped.
PAGE B - 3INSTALLATION
Page 11
OM-04829 10 SERIES
Suction Lines In Sumps
If a single suction line is installed in a sump, it should be positioned away from the wall of the sump at a distance equal to 1‐1/2 times the diame ter of the suction line
If there is a liquid flow from an open pipe into the sump, the flow should be kept away from the suc tion inlet because the inflow will carry air down into the sump, and air entering the suction line will re duce pump efficiency.
If it is necessary to position inflow close to the suc tion inlet, install a baffle between the inflow and the suction inlet at a distance 1‐1/2 times the diameter of the suction pipe. The baffle will allow entrained air to escape from the liquid before it is drawn into the suction inlet.
If two suction lines are installed in a single sump, the flow paths may interact, reducing the efficiency
of one or both pumps. To avoid this, position the suction inlets so that they are separated by a dis tance equal to at least 3 times the diameter of the suction pipe.
Suction Line Positioning
The depth of submergence of the suction line is
critical to efficient pump operation. recommended minimum submergence vs. veloc ity.
Figure 2 shows
NOTE
The pipe submergence required may be reduced by installing a standard pipe increaser fitting at the end of the suction line. The larger opening size will reduce the inlet velocity. Calculate the required submergence using the following formula based on the increased opening size (area or diameter).
Figure 2. Recommended Minimum Suction Line Submergence vs. Velocity
PAGE B - 4 INSTALLATION
Page 12
10 SERIES OM-04829
DISCHARGE LINES
Siphoning
Do not terminate the discharge line at a level lower than that of the liquid being pumped unless a si phon breaker is used in the line. Otherwise, a si phoning action causing damage to the pump could result.
Valves
If a throttling valve is desired in the discharge line, use a valve as large as the largest pipe to minimize friction losses. Never install a throttling valve in a suction line.
A check valve in the discharge line is normally rec ommended, but it is not necessary in low dis charge head applications.
With high discharge heads, it is recommended that a throttling valve and a system check valve be in stalled in the discharge line to protect the pump from excessive shock pressure and reverse rota tion when it is stopped.
air from the top of the pump during the priming process. This may be accomplished by installing a bypass line from the top of the pump, back to the source of liquid. The end of the bypass line must be submerged. The line must be large enough to pre vent clogging, but not so large as to affect pump discharge capacity.
AUTOMATIC AIR RELEASE VALVE
When properly installed, a Gorman‐Rupp Auto matic Air Release Valve will permit air to escape through the bypass line and then close automati cally when the pump is fully primed and pumping at full capacity.
Some leakage (1 to 5 gallons [3.8 to 19 liters] per minute) will occur when the valve is fully closed. Be sure the bypass line is directed back to the wet well or tank to prevent hazardous spills.
Consult the manual accompanying the Air Release Valve for additional information on valve installation and performance.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
Bypass Lines
If a system check valve is used due to high dis charge head, it may be necessary to vent trapped
Air Release Valve Installation
The Automatic Air Release Valve must be inde pendently mounted in a horizontal position be tween the pump discharge port and the inlet side of the discharge check valve (see Figure 3). The inlet opening in the Air Release Valve is equipped with standard 1‐inch NPT pipe threads.
PAGE B - 5INSTALLATION
Page 13
OM-04829 10 SERIES
INSTALL AIR RELEASE VALVE IN HORIZONTAL POSITION
90 LONG
RADIUS ELBOW
BLEED LINE 1” (25,4 MM) DIA. MIN. (CUSTOMER FUR NISHED) DO NOT EX TEND BELOW PUMP OFF LIQUID LEVEL
SUPPORT BRACKET
CLEAN‐OUT COVER
SUCTION LINE
WET WELL OR SUMP
DISCHARGE PIPE
DISCHARGE CHECK VALVE
PUMP DISCHARGE
SELF‐PRIMING CENTRIFUGAL
PUMP
Figure 3. Typical Automatic Air Release Valve Installation
Connect the valve outlet to a bleed line which slopes back to the wet well or sump. The bleed line must be the same size as the outlet opening or larger, depending on which Air Release Valve is be ing used. If piping is used for the bleed line, avoid the use of elbows whenever possible.
NOTE
For multiple pump installations, it is recommended
that each Air Release Valve be fitted with an inde pendent bleeder line directed back to the wet well. If multiple Air Release Valves are installed in a sys tem, do not direct bleeder lines to a common mani fold pipe. Contact your Gorman‐Rupp distributor or the Gorman‐Rupp Company for information about installation of an Automatic Air Release Valve for your specific application.
PAGE B - 6 INSTALLATION
Page 14
10 SERIES OM-04829
ELECTRICAL CONNECTIONS
Before connecting the motor to the incoming power, check that the electrical service available matches the pump motor requirements stamped on the motor nameplate.
Do not install and operate a non‐explo sion proof motor in an explosive atmo sphere. Install, connect, and operate the motor in accordance with The Na tional Electric Code and all local codes. If there is a conflict between the instruc tions in the manual accompanying the
The electrical power used to operate this pump is high enough to cause inju ry or death. Obtain the services of a qu alified electrician to make all electrical connections.
VOLTAGE PHASE HP Hz RPM THERMAL
unit and The National Electric Code or the applicable local code, The National or local code shall take precedence.
Refer to the following motor data before making electrical connections.
OVERLOAD
115/230
230/460
1
3
2
2
60
60
3450
3450
20 AMPS
N/A
PAGE B - 7INSTALLATION
Page 15
10 SERIES
OM-04829

OPERATION - SECTION C

Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and decals attached to the pump.
This pump is designed to handle most non‐volatile, non‐flammable liquids containing specified entrained solids. Do not attempt to pump volatile, corro sive, or flammable liquids which may damage the pump or endanger person nel as a result of pump failure.
Pump speed and operating condition points must be within the continuous per formance range shown on the curve (see Section E, Page 1).
Add liquid to the pump casing when:
1. The pump is being put into service for the first time.
2. The pump has not been used for a consider able length of time.
3. The liquid in the pump casing has evapo rated.
Once the pump casing has been filled, the pump will prime and reprime as necessary.
After filling the pump casing, reinstall and tighten the fill plug. Do not attempt to operate the pump unless all connect ing piping is securely installed. Other wise, liquid in the pump forced out un der pressure could cause injury to per sonnel.
To fill the pump, remove the pump casing fill cover or fill plug in the top of the casing, and add clean liquid until the casing is filled. Replace the fill cover or fill plug before operating the pump.
PRIMING
Install the pump and piping as described in IN STALLATION. Make sure that the piping connec
tions are tight, and that the pump is securely mounted. Check that the pump is properly lubri cated (see LUBRICATION in MAINTENANCE AND REPAIR).
This pump is self‐priming, but the pump should never be operated unless there is liquid in the pump casing.
STARTING
Consult the operations manual furnished with the motor.
Rotation
The correct direction of pump rotation is indicated by an arrow on the pump body or accompanying decals. If the pump is operated in the wrong direc tion, the impeller could become loosened from the shaft and seriously damage the pump.
The pump must operate in the direction in Never operate this pump unless there is liquid in the pump casing. The pump will not prime when dry. Extended operation of a dry pump will destroy the seal assembly.
OPERATION PAGE C - 1
dicated by the arrow on the pump, or ac
companying decals. Reverse rotation
could loosen the impeller and seriously
damage the pump.
Page 16
OM-04829 10 SERIES
Consult the operating manual furnished with the pump motor before attempting to start the motor.
If rotation is incorrect on a three‐phase motor, have a qualified electrician interchange any two of the three phase wires to change direction. If rotation is incorrect on a single‐phase motor, consult the lit erature supplied with the motor for specific instruc tions.
OPERATION
Lines With a Bypass
Close the discharge throttling valve (if so equipped) so that the pump will not have to prime against the weight of the liquid in the discharge line. Air from the suction line will be discharged through the bypass line back to the wet well during the priming cycle. When the pump is fully primed and liquid is flowing steadily from the bypass line, open the discharge throttling valve. Liquid will then continue to circulate through the bypass line while the pump is in operation.
Liquid Temperature And Overheating
The maximum liquid temperature for this pump is
160 F (71C). Do not apply it at a higher operating
temperature.
Overheating can occur if operated with the valves
in the suction or discharge lines closed. Operating
against closed valves could bring the liquid to a
boil, build pressure, and cause the pump to rup
ture or explode. If overheating occurs, stop the
pump and allow it to completely cool before servic
ing it. Refill the pump casing with cool liquid.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to completely cool before
servicing.
Strainer Check
Lines Without a Bypass
Open all valves in the discharge line and start the motor. Priming is indicated by a positive reading on the discharge pressure gauge or by a quieter op eration. The pump may not prime immediately be cause the suction line must first fill with liquid. If the pump fails to prime within five minutes, stop it and check the suction line for leaks.
After the pump has been primed, partially close the discharge line throttling valve in order to fill the line slowly and guard against excessive shock pres sure which could damage pipe ends, gaskets, sprinkler heads, and any other fixtures connected to the line. When the discharge line is completely filled, adjust the throttling valve to the required flow rate.
Leakage
No leakage should be visible at pump mating sur faces, or at pump connections or fittings. Keep all line connections and fittings tight to maintain maxi mum pump efficiency.
If a suction strainer has been shipped with the
pump or installed by the user, check the strainer
regularly, and clean it as necessary. The strainer
should also be checked if pump flow rate begins to
drop. If a vacuum suction gauge has been in
stalled, monitor and record the readings regularly
to detect strainer blockage.
Never introduce air or steam pressure into the
pump casing or piping to remove a blockage. This
could result in personal injury or damage to the
equipment. If backflushing is absolutely neces
sary, liquid pressure must be limited to 50% of the
maximum permissible operating pressure shown
on the pump performance curve (see Section E,
Page 1).
Pump Vacuum Check
With the pump inoperative, install a vacuum gauge
in the system, using pipe dope on the threads.
Block the suction line and start the pump. At oper
ating speed the pump should pull a vacuum of 20
inches (508 mm) or more of mercury. If it does not,
check for air leaks in the seal, gasket, or discharge
valve.
OPERATIONPAGE C - 2
Page 17
10 SERIES
OM-04829
Open the suction line, and read the vacuum gauge with the pump primed and at operation speed. Shut off the pump. The vacuum gauge reading will immediately drop proportionate to static suction lift, and should then stabilize. If the vacuum reading falls off rapidly after stabilization, an air leak exists. Before checking for the source of the leak, check the point of installation of the vacuum gauge.
STOPPING
Never halt the flow of liquid suddenly. If the liquid being pumped is stopped abruptly, damaging shock waves can be transmitted to the pump and piping system. Close all connecting valves slowly.
If the application involves a high discharge head, gradually close the discharge throttling valve before stopping the pump.
After stopping the pump, disconnect the incoming
power to the motor and lock it out to ensure that the
pump will remain inoperative.
Cold Weather Preservation
In below freezing conditions, drain the pump to
prevent damage from freezing. Also, clean out any
solids by flushing with a hose. Operate the pump
for approximately one minute; this will remove any
remaining liquid that could freeze the pump rotat
ing parts. If the pump will be idle for more than a
few hours, or if it has been pumping liquids con
taining a large amount of solids, drain the pump,
and flush it thoroughly with clean water. To prevent
large solids from clogging the drain port and pre
venting the pump from completely draining, insert
a rod or stiff wire in the drain port, and agitate the
liquid during the draining process. Clean out any
remaining solids by flushing with a hose.
OPERATION PAGE C - 3
Page 18

TROUBLESHOOTING - SECTION D

Review all SAFETY information in Section A.
Before attempting to open or service the pump:
1. Familiarize yourself with this manual.
2. Disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inoperative.
3. Allow the pump to completely cool if overheated.
4. Check the temperature before open ing any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cautiously.
7. Drain the pump.
OM-0482910 SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO PRIME
PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE
Not enough liquid in casing. Add liquid to casing. See
PRIMING.
Suction check valve contaminated or damaged.
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
Suction lift or discharge head too high. Check piping installation and install
Strainer clogged. Check strainer and clean if neces
Air leak in suction line. Correct leak.
Lining of suction hose collapsed. Replace suction hose.
Suction intake not submerged at proper level or sump too small.
Impeller or other wearing parts worn or damaged.
Clean or replace check valve.
leaking or worn seal or gasket.
bypass line if needed. See INSTAL LATION.
sary.
Check installation and correct submergence as needed.
Replace worn or damaged parts. Check that impeller is properly centered and rotates freely.
TROUBLESHOOTING PAGE D - 1
Page 19
OM-04829 10 SERIES
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE (cont.)
PUMP REQUIRES TOO MUCH POWER
Leaking or worn seal or pump gasket. Check pump vacuum. Replace
leaking or worn seal or gasket.
Free impeller of debris.Impeller clogged.
Low or incorrect voltage. Measure control box voltage, both
when pump is running and when shut off.
No voltage at line side of circuit breaker.
Pump running back wards.
Suction lift or discharge head too high. Check piping installation and install
Motor shaft or bearings defective. Disassemble pump and check mo
Discharge head too low.
Check power source for blown fuse, open circuit breaker or control box, broken lead, or loose connection.
Check direction of rotation and correct by interchanging any two motor leads at control box. (See Pump Rotation, Section C).
bypass line if needed. See INSTAL LATION.
tor and bearings.
Adjust discharge valve.
Dilute if possible.Liquid solution too thick.
PUMP CLOGS FREQUENTLY
EXCESSIVE NOISE Cavitation in pump. Reduce suction lift and/or friction
Discharge flow too slow.
Suction check valve or foot valve clogged or binding.
Pumping entrained air.
Impeller clogged or damaged. Clean out debris; replace damaged
Open discharge valve fully to in crease flow rate, and run motor at maximum governed speed.
Clean valve.
losses in suction line. Record vac uum and pressure gauge readings and consult local representative or factory.
Locate and eliminate source of air bubble.
Secure mounting hardware.Pump or drive not securely mounted.
parts.
TROUBLESHOOTINGPAGE D - 2
Page 20
OM-0482910 SERIES
PREVENTIVE MAINTENANCE
Since pump applications are seldom identical, and pump wear is directly affected by such things as the abrasive qualities, pressure and temperature of the liquid being pumped, this section is intended only to provide general recommendations and practices for preventive maintenance. Regardless of the application however, following a routine pre ventive maintenance schedule will help assure trouble‐free performance and long life from your Gorman‐Rupp pump. For specific questions con cerning your application, contact your Gorman‐ Rupp distributor or the Gorman‐Rupp Company.
Record keeping is an essential component of a good preventive maintenance program. Changes in suction and discharge gauge readings (if so
equipped) between regularly scheduled inspec tions can indicate problems that can be corrected before system damage or catastrophic failure oc curs. The appearance of wearing parts should also be documented at each inspection for comparison as well. Also, if records indicate that a certain part (such as the seal) fails at approximately the same duty cycle, the part can be checked and replaced before failure occurs, reducing unscheduled down time.
For new applications, a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application. Subsequent inspec tions should be performed at the intervals shown on the chart below. Critical applications should be inspected more frequently.
Preventive Maintenance Schedule
Service Interval*
Item
General Condition (Temperature, Unusual
Noises or Vibrations, Cracks, Leaks,
Loose Hardware, Etc.) I Pump Performance (Gauges, Speed, Flow) I Bearing Lubrication I R Seal Lubrication (And Packing Adjustment,
If So Equipped) I R V‐Belts (If So Equipped) I Air Release Valve Plunger Rod (If So Equipped) I C Front Impeller Clearance (Wear Plate) I Rear Impeller Clearance (Seal Plate) I Check Valve I Pressure Relief Valve (If So Equipped) C Pump and Driver Alignment I Shaft Deflection I Bearings I Bearing Housing I Piping I Driver Lubrication - See Mfgr's Literature
Daily Weekly Monthly Semi‐
Annually
Annually
Legend: I = Inspect, Clean, Adjust, Repair or Replace as Necessary C = Clean R = Replace
* Service interval based on an intermittent duty cycle equal to approximately 4000 hours annually.
Adjust schedule as required for lower or higher duty cycles or extreme operating conditions.
TROUBLESHOOTING PAGE D - 3
Page 21
10 SERIES OM-04829
PUMP MAINTENANCE AND REPAIR ‐ SECTION E
MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE.
STANDARD PERFORMANCE FOR PUMP MODEL 11 1/2A52-E2 1P AND 11 1/2A52-E2 3P
Based on 70F (21C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be dif ferent due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.
Contact the Gorman‐Rupp Company to verify per formance or part numbers.
Pump speed and operating condition
If your pump serial number is followed by an “N”, your pump is NOT a standard production model.
MAINTENANCE & REPAIR PAGE E - 1
points must be within the continuous per formance range shown on the curve.
Page 22

PARTS PAGE

10 SERIESOM-04829
SECTION DRAWING
Figure 1. Pump Model 11 1/2A52-E2 1P And 11 1/2A52-E2 3P
MAINTENANCE & REPAIRPAGE E - 2
Page 23
10 SERIES OM-04829
PARTS LIST
Pump Model 11 1/2A52-E2 1P And 11 1/2A52-E2 3P
(From S/N 1235018 Up)
If your pump serial number is followed by an “N”, your pump is NOT a standard production model. Contact the Gorman‐Rupp Company to verify part numbers.
ITEM
PART NAME PART
NO.
NUMBER
MAT'L CODE
QTY ITEM
NO.
PART NAME PART
NUMBER
MAT'L CODE
QTY
1 PUMP CASING SEE NOTE BELOW
2 IMPELLER 12368A 10010 1 3 SEAL ASSY 25285-853 --- 1
4 SUCTION FLANGE 8599 10010 1
5 PIPE PLUG P04 15079 16 FILL PLUG ASSY 48271-067 --- 1
7 NAME PLATE 38818-021 13990 1 8 DRIVE SCREW BM#04-03 17000 4
9 WARNING PLATE 2613EV 13990 110 DRIVE SCREW BM#04-03 17000 4
11 SPRING RETAINER 31161-041 17000 1 12 IMP ADJUSTING SHIMS 513A 17090 1
13 STUD C0605 1/2 15991 4
14 HEX NUT D06 15991 4 15 ROTATION DECAL 2613M --- 1 16 SHAFT SLEEVE 2353 17020 1
17 SLINGER RING 14049 19140 1 18 ELECTRIC MOTOR
-2 HP 1P 28156-550 --- 1
-2 HP 3P 28196-550 --- 1 19 WARNING DECAL 2613FF --- 1 20 HEX HD CAPSCREW B0503S 15991 4 21 LOCKWASHER J05 15991 4 22 INTERMEDIATE 6732A 10010 1
23 CASING GASKET SET 504G 18000 1 24 WEAR PLATE ASSY 2643 15990 1
25 CASING DRAIN PLUG P06 15079 1
26 BACK COVER GSKT 12369G 20000 1 27 BACK COVER PLATE 12369 10010 1
28 HEX HD CAPSCREW B0808 15991 2
29 CLAMP BAR SCREW 8618 24000 1 30 CLAMP BAR 12370 11010 1 31 HEX NUT D04 15991 2 32 LOCKWASHER J04 15991 2 33 CHECK VALVE ASSY 1352 --- 1
34 -CHECK VALVE 1352G 19070 1 35 -SM VALVE WEIGHT 1354 15160 1 36 -RD HD MACH SCREW X0403 17090 1 37 -LOCKWASHER J04 17090 1 38 -LG VALVE WEIGHT 1353 10010 1
39 STUD C0606 15991 4
40 HEX NUT D06 15991 4
NOT SHOWN:
1P WARNING DECAL 2613FE --- 1 STRAINER 12383 24000 1 SUCTION STICKER 6588AG --- 1 PRIMING STICKER 6588AH --- 1 DISCHARGE STICKER 6588BJ --- 1 INSTRUCTION DECAL 2613DK --- 1 INSTRUCTION TAG 38817-013 --- 1 G‐R DECAL GR-03 --- 1
INDICATES PARTS RECOMMENDED FOR STOCK
INCLUDED WITH 46471-556 --- 1
REPAIR PUMP CASING ASSY
MAINTENANCE & REPAIR PAGE E - 3
Page 24
10 SERIESOM-04829

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

Review all SAFETY information in Section A.
Follow the instructions on all tags, label and de cals attached to the pump.
This pump requires little service due to its rugged, minimum‐maintenance design. However, if it be comes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional view (see Figure 1) and the accompa nying parts list.
This manual will alert personnel to known proce dures which require special attention, to those which could damage equipment, and to those which could be dangerous to personnel. However, this manual cannot possibly anticipate and provide detailed precautions for every situation that might occur during maintenance of the unit. Therefore, it is the responsibility of the owner/maintenance per sonnel to ensure that only safe, established main tenance procedures are used, and that any proce dures not addressed in this manual are performed only after establishing that neither personal safety nor pump integrity are compromised by such prac tices.
that the pump will remain inopera tive.
3. Allow the pump to completely cool if overheated.
4. Check the temperature before opening any covers, plates, or plugs.
5. Close the suction and discharge valves.
6. Vent the pump slowly and cau tiously.
7. Drain the pump.
Suction Check Valve Removal and Disassembly
Before attempting to service the pump, remove the pump casing drain plug (25) and drain the pump. Clean and reinstall the drain plug.
To service the suction check valve assembly (33), remove the suction piping. Remove the nuts (40) securing the suction flange (4) to the pump casing (1). Pull the check valve assembly from the suction port.
Inspect the check valve parts for wear or damage. If replacement is required, remove the hardware (36 and 37), and separate the check valve gasket (34) and weights (35 and 38).
Before attempting to service the pump, disconnect the incoming power to the motor and lock it out to ensure that the pump will remain inoperative. Close all valves in the suction and discharge lines.
For motor disassembly and repair, consult the lit erature supplied with the motor, or contact your lo cal motor representative.
Before attempting to open or service the pump:
1. Familiarize yourself with this man ual.
2. Disconnect the incoming power to the motor and lock it out to ensure
If no further disassembly is required, see Suction Check Valve Installation.
Back Cover Removal
The wear plate (24) is easily accessible and may be serviced by removing the back cover plate (27). Loosen the clamp bar screw (29) and remove the clamp bar (30). Pull the back cover and wear plate from the pump casing. Remove the back cover gasket (26). Clean the mating surfaces of the back cover plate and pump casing.
Inspect the wear plate (24) and replace it if badly scored or worn. To remove the wear plate, disen gage the hardware (31 and 32) securing it to the back cover.
If no further disassembly is required, see Back
Cover Installation.
MAINTENANCE & REPAIRPAGE E - 4
Page 25
OM-0482910 SERIES
Pump Casing Removal
Death or serious personal injury and damage to the pump or components can occur if proper lifting procedures are not observed. Make certain that hoists, chains, slings or cables are in good working condition and of suffi cient capacity and that they are posi tioned so that loads will be balanced and the pump or components will not be damaged when lifting. Suction and dis charge hoses and piping must be re moved from the pump before lifting. Lift the pump or component only as high as necessary and keep personnel away from suspended objects.
To service the impeller or seal assembly, discon nect the discharge piping. Remove the hardware securing the pump casing (1) to the base.
rotating portion of the seal off the shaft as a unit. Apply oil to the sleeve and work it under the bel lows. Slide the rotating portion of the seal off the sleeve.
To remove the stationary seat, remove the hard ware (20 and 21), and slide the stationary portion of the seal and intermediate (22) off the shaft as a unit. Position the intermediate on a flat surface with the impeller side down. Use thumb pressure to press the stationary seat from the intermediate.
Remove the slinger ring (17) from the shaft.
If no further disassembly is required, see Seal
Reassembly and Installation.
Seal Reassembly and Installation
Clean the seal cavity and shaft with a cloth soaked in fresh cleaning solvent.
Tie and tag any leveling shims used under the cas ing mounting feet to ease reassembly.
Remove the nuts (14), and separate the pump cas ing and gasket set (23) from the intermediate (22). Tie and tag the gaskets, or measure and record their thickness for ease of reassembly.
Clean the mating surfaces of the intermediate and pump casing.
Impeller Removal
To loosen the impeller (2), immobilize the motor shaft, and tap the vanes of the impeller in a coun terclockwise direction (when facing the impeller) with a block of wood or a soft‐faced mallet. Be careful not to damage the impeller vanes. Use caution when removing the impeller; tension on the seal spring will be released as the impeller is unscrewed.
Inspect the impeller and replace it if cracked or badly worn. Tie and tag the shims or measure and record their thickness for ease of reassembly.
Seal Removal and Disassembly
Remove the impeller shims and spring retainer (11 and 12) and seal spring. Slide shaft sleeve (16) and
Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers.
Inspect the motor shaft for damage. Small scratches or nicks may be removed with a fine file or emery cloth. If excessive wear exists, the shaft will have to be replaced (refer to the motor service manual).
The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an old seal in an emer gency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.
Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non‐oil based solvent and a clean, lint‐free tissue. Wipe lightly in a concentric pattern to avoid scratching the faces.
MAINTENANCE & REPAIR PAGE E - 5
Page 26
10 SERIESOM-04829
Inspect the seal components for wear, scoring, grooves, and other damage that might cause leak age. Clean and polish the shaft sleeve, or replace it if there are nicks or cuts on either end. If any com ponents are worn, replace the complete seal; never mix old and new seal parts.
If a replacement seal is being used, remove it from the container and inspect the precision finished
RETAINER
SPRING
IMPELLER
IMPELLER
SHIMS
IMPELLER
SHAFT
BELLOWS
faces to ensure that they are free of any foreign matter. Discard the spring centering washer in cluded with the seal. It is not used in this applica tion.
To ease installation of the seal, lubricate the shaft sleeve with water or a very small amount of oil, and apply a drop of light lubricating oil on the finished faces. Assemble the seal as follows, (see Figure 2).
INTERMEDIATE
SHAFT
SLEEVE
SPRING
RETAINER
ROTATING
ELEMENT
Figure 2. Seal Assembly
This seal is not designed for operation at temperatures above 160F (71C). Do not use at higher operating temperatures.
Slide the slinger ring (17) onto the shaft. Install the stationary seat and press this stationary subas sembly into the intermediate until fully seated. After installation, wipe the sealing face lightly in a con centric pattern with a clean, lint‐free tissue.
Position the intermediate (22) and stationary sub assembly over the shaft and against the motor. Se
SLINGER
RING
STATIONARY
SEAT
cure the intermediate to the motor with the hard ware (20 and 21).
Slide the rotating subassembly (consisting of the element, bellows and retainer) over the lubricated shaft sleeve until the rotating element is just flush with the chamfered end of the sleeve. Slide the sleeve over the shaft until the sealing faces con tact. Continue to press the shaft sleeve through the seal assembly until it seats squarely against the shaft shoulder.
Install the seal spring and spring retainer (11 and
12).
MAINTENANCE & REPAIRPAGE E - 6
Page 27
OM-0482910 SERIES
Impeller Installation and Adjustment
Inspect the impeller, and replace it if cracked or badly worn. Install the same thickness of impeller shims (12) as previously removed, and screw the impeller onto the shaft until tight.
A clearance of .010 to .012 inch (0,25 to 0,30 mm) between the impeller and the intermediate is nec essary for maximum pump efficiency. Measure this clearance and add or remove impeller shims until this clearance is reached.
Pump Casing Installation
Install the same thickness of pump casing gaskets (23) as previously removed, and secure the pump casing to the intermediate (22) with the nuts (14).
Do not fully tighten the nuts at this time.
NOTE
The back cover assembly must be in place to adjust the impeller face clearance.
A clearance of .008 to .015 inch (0,20 to 0,38 mm) between the impeller and the wear plate is also rec ommended for maximum pump efficiency. Set this clearance by adding or removing gaskets in the pump casing gasket set (23) until the impeller scrapes against the wear plate when the shaft is turned. After the impeller binds, add approximately .008 inch (0,20 mm) of gaskets.
After the face clearance has been set, tighten the nuts (14) securing the pump casing to the interme diate.
Clean any scales or debris from the contacting sur faces on the pump casing that might prevent a good seal with the back cover. Replace the back cover gasket (26) and slide the back cover assem bly into the pump casing. Be sure the wear plate does not bind against the impeller.
NOTE
To ease future disassembly, apply a film of grease or `Never‐Seez' on the back cover shoulder, or any surface that contacts the pump casing. This action will reduce rust and scale build‐up.
Secure the back cover assembly by installing the clamp bar (30) and tightening the clamp bar screw (29). Do not over‐tighten the clamp bar screw; it should be just tight enough to seal the back cover shoulder.
Suction Check Valve Installation
Inspect the check valve components and replace as required. Subassemble the check valve weights (35 and 38) and check valve (34) using the attach ing hardware (36 and 37).
Position the check valve assembly (33) in the suc tion port with the large weight toward the inside of the pump casing. Install the suction flange (4), and secure with the nuts (40). Check the operation of the check valve to ensure proper seating and free movement.
Final Pump Assembly
Be sure the pump and motor are securely
mounted to the base.
Secure the pump casing to the base with the pre viously removed hardware. Be sure to reinstall any leveling shims used under the casing mounting feet.
Back Cover Installation
If the wear plate (24) was removed for replace ment, secure it to the cover plate (27) using the at taching hardware (31 and 32) at this time. The wear plate must be concentric to prevent binding when the back cover is installed.
MAINTENANCE & REPAIR PAGE E - 7
Install the suction and discharge lines and open all valves. Make certain that all piping connections are tight, properly supported and secure.
Be sure the pump and motor have been properly lubricated, see LUBRICATION.
Remove the fill plug assembly (6) and fill the pump casing with clean liquid. Reinstall the fill plug and tighten it.
Refer to OPERATION, Section C, before putting the pump back into service.
Page 28
10 SERIESOM-04829
LUBRICATION
Seal Assembly
The seal assembly is lubricated by the medium be ing pumped, and no additional lubrication is re quired.
Motor
Consult the literature supplied with the motor, or contact your local motor representative.
MAINTENANCE & REPAIRPAGE E - 8
Page 29
For U.S. and International Warranty Information,
Please Visit www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
International: +1-419-755-1352
For Canadian Warranty Information,
Please Visit www.grcanada.com/warranty
or call:
519-631-2870
THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO
GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA
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