GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A
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2012 The Gorman‐Rupp Company
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TABLE OF CONTENTS
INTRODUCTIONPAGE I - 1.................................................
SAFETY ‐ SECTION APAGE A - 1............................................
INSTALLATION - SECTION BPAGE B - 1....................................
PREINSTALLATION INSPECTIONPAGE B - 1............................................
POSITIONING PUMPPAGE B - 1.......................................................
LiftingPAGE B - 1.................................................................
MountingPAGE B - 2.............................................................
SUCTION AND DISCHARGE PIPINGPAGE B - 2.........................................
MaterialsPAGE B - 2..............................................................
Line ConfigurationPAGE B - 2......................................................
Connections to PumpPAGE B - 2..................................................
GaugesPAGE B - 2...............................................................
SUCTION LINESPAGE B - 2...........................................................
FittingsPAGE B - 2...............................................................
StrainersPAGE B - 2..............................................................
SealingPAGE B - 3...............................................................
Suction Lines In SumpsPAGE B - 3.................................................
Suction Line PositioningPAGE B - 3................................................
DISCHARGE LINESPAGE B - 4........................................................
SiphoningPAGE B - 4.............................................................
ValvesPAGE B - 4................................................................
ALIGNMENTPAGE B - 4..............................................................
Coupled DrivesPAGE B - 4........................................................
Drive BeltsPAGE B - 5............................................................
DRIVE BELT TENSIONINGPAGE B - 5..................................................
General Rules of TensioningPAGE B - 5.............................................
OPERATION - SECTION CPAGE C - 1......................................
PRIMINGPAGE C - 1.................................................................
STARTINGPAGE C - 1................................................................
RotationPAGE C - 1..............................................................
OPERATIONPAGE C - 1..............................................................
LeakagePAGE C - 1..............................................................
Liquid Temperature And OverheatingPAGE C - 1.....................................
Strainer CheckPAGE C - 2.........................................................
Pump Vacuum CheckPAGE C - 2..................................................
STOPPINGPAGE C - 2................................................................
PERIODIC CHECKSPAGE C - 3.......................................................
Seal Cavity and Bearing LubricationPAGE C - 3......................................
Bearing Temperature CheckPAGE C - 3.............................................
Air CompressorPAGE C - 3........................................................
COLD WEATHER PRESERVATIONPAGE C - 3...........................................
TROUBLESHOOTING - SECTION DPAGE D - 1..............................
PREVENTIVE MAINTENANCEPAGE D - 3...............................................
i
TABLE OF CONTENTS
(continued)
PUMP MAINTENANCE AND REPAIR ‐ SECTION EPAGE E - 1.................
STANDARD PERFORMANCE CURVEPAGE E - 1........................................
PARTS LISTS:
Pump ModelPAGE E - 3..........................................................
Pump End AssemblyPAGE E - 5...................................................
Repair Rotating AssemblyPAGE E - 7...............................................
Priming Chamber KitPAGE E - 8...................................................
Priming Chamber AssemblyPAGE E - 9.............................................
Air Compressor AssemblyPAGE E - 10...............................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLYPAGE E - 11.........................
Priming Chamber Removal And DisassemblyPAGE E - 11..............................
Discharge Check Valve Removal and DisassemblyPAGE E - 12.........................
Suction Head and Wear Ring RemovalPAGE E - 12....................................
Pump Casing RemovalPAGE E - 12.................................................
Air Compressor RemovalPAGE E - 12................................................
Draining Oil From Seal CavityPAGE E - 13............................................
Impeller RemovalPAGE E - 13......................................................
Seal RemovalPAGE E - 13..........................................................
Separating Rotating Assembly From Power SourcePAGE E - 13........................
Shaft and Bearing Removal and DisassemblyPAGE E - 13.............................
Shaft and Bearing Reassembly and InstallationPAGE E - 14............................
Securing Rotating Assembly to Power SourcePAGE E - 16.............................
Seal Reassembly and InstallationPAGE E - 16........................................
Impeller Installation and AdjustmentPAGE E - 17......................................
Pump Casing InstallationPAGE E - 18................................................
Suction Head and Wear Ring Installation and AdjustmentPAGE E - 18...................
Discharge Check Valve Assembly and InstallationPAGE E - 18..........................
Priming Chamber Assembly And InstallationPAGE E - 19...............................
LUBRICATIONPAGE E - 19.............................................................
Seal AssemblyPAGE E - 19.........................................................
BearingsPAGE E - 19..............................................................
Power SourcePAGE E - 19.........................................................
ii
PAH SERIES
OM-06455
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 PAH Series, priming‐assisted cen
trifugal model. The unit is designed for handling
non‐volatile, non‐flammable liquids containing
specified entrained solids. The basic material of
construction is ductile iron, with alloy steel shaft
and ductile iron wear ring.
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,
because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
The following are used to alert personnel to proce
dures which require special attention, 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.
If there are any questions regarding the pump
which are not covered in this manual or in other lit
erature accompanying the unit, please contact
your Gorman‐Rupp distributor or the Gorman‐
Rupp Company:
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
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions de
scribe the requirements and the possible
damage which could result from failure to
follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
PAH SERIES
OM-06455
SAFETY ‐ SECTION A
This information applies to Prime Aire
Series basic pumps. Gorman‐Rupp has
no control over or particular knowledge
of the power source which will be used.
Refer to the manual accompanying the
power source before attempting to be
gin operation.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
Before attempting to open or service the
pump:
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.
1. Familiarize yourself with this man
ual.
2. Disconnect or lock out the power
source to ensure that the pump will
remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Check the temperature and make
sure the pump is cool before open
ing 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
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.
Do not operate the pump against a
closed discharge valve. If operated
against a closed discharge valve, pump
components will deteriorate, and the
liquid could come to a boil, build pres
sure, and cause the pump casing to rup
ture or explode. Momentary closure of a
discharge valve is acceptable only
PAGE A - 1SAFETY
PAH SERIESOM-06455
when required for startup or shutdown
procedures.
Do not operate the pump without the
guards in place over the rotating parts.
Exposed rotating parts can catch cloth
ing, fingers, or tools, causing severe in
jury to personnel.
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 cool completely before
servicing.
This pump may be used to handle mate
rials which could cause illness through
direct exposure or emitted fumes. Wear
adequate protective clothing when
working on the pump or piping.
Pumps and related equipment must be in
stalled and operated according to all na
tional, local and industry standards.
PAGE A - 2SAFETY
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 posi
tioned 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
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.
For further assistance, contact your Gorman‐Rupp
distributor or the Gorman‐Rupp Company.
OM-06455PAH SERIES
Only operate this pump in the direction in
dicated by the arrow on the pump body
and on the accompanying decal. Refer to
ROTATION in OPERATION, Section C.
d. Check levels and lubricate as necessary. Re
fer to LUBRICATION in the MAINTENANCEAND REPAIR section of this manual and per
form duties as instructed.
e. If the pump and power source have been
stored for more than 12 months, some of the
components or lubricants may have ex
ceeded their maximum shelf life. These mustbe inspected or replaced to ensure maxi
mum pump service.
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.
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 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 warnings and cautions con
tained in this manual or affixed to the pump,
and perform all duties indicated. Note the di
rection of rotation indicated on the pump.
Check that the pump shaft rotates counter
clockwise when facing the impeller.
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
PAGE B - 1INSTALLATION
OM-06455PAH SERIES
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.
SUCTION AND DISCHARGE PIPING
Pump performance is adversely effected by in
creased suction lift, discharge elevation, and fric
tion losses. See the performance curve and oper
ating range shown 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.
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.
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.
PAGE B - 2INSTALLATION
OM-06455PAH SERIES
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 3‐inch (76,2
mm) diameter spherical solids.
Sealing
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.
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).
PAGE B - 3INSTALLATION
OM-06455PAH SERIES
Figure 1. Recommended Minimum Suction Line Submergence vs. Velocity
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
This pump is designed with a check valve in the
discharge line.
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.
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.
If the application involves a high discharge
head, gradually close the discharge
throttling valve before stopping the pump.
ALIGNMENT
The alignment of the pump and its power source is
critical for trouble‐free mechanical operation. In
either a flexible coupling or V‐belt driven system,
the driver and pump must be mounted so that their
shafts are aligned with and parallel to each other. It
is imperative that alignment be checked after the
pump and piping are installed, and before opera
tion.
NOTE
Check Rotation, Section C, before final alignment
of the pump.
When mounted at the Gorman‐Rupp factory, driver
and pump are aligned before shipment. Misalign
ment will occur in transit and handling. Pumps
PAGE B - 4INSTALLATION
must be checked and realigned before operation.
Before checking alignment, tighten the foundation
bolts. The pump casing feet and/or pedestal feet,
and the driver mounting bolts should also be tightly
secured.
When checking alignment, disconnect
the power source to ensure that the
pump will remain inoperative.
Adjusting the alignment in one direction
may alter the alignment in another direc
tion. check each procedure after altering
alignment.
Coupled Drives
When using couplings, the axis of the power
source must be aligned to the axis of the pump
shaft in both the horizontal and vertical planes.
Most couplings require a specific gap or clearance
between the driving and the driven shafts. Refer to
the coupling manufacturer's service literature.
Align spider insert type couplings by using calipers
to measure the dimensions on the circumference
of the outer ends of the coupling hub every 90.
The coupling is in alignment when the hub ends
are the same distance apart at all points (see Fig
ure 2).
OM-06455PAH SERIES
Figure 3. Aligning Non‐Spider Type Couplings
Align non‐spider type couplings by using a feeler
gauge or taper gauge between the coupling halves
every 90. The coupling is in alignment when the
hubs are the same distance apart at all points (see
Figure 3).
Check parallel adjustment by laying a straightedge
across both coupling rims at the top, bottom, and
side. When the straightedge rests evenly on both
halves of the coupling, the coupling is in horizontal
parallel alignment. If the coupling is misaligned,
use a feeler gauge between the coupling and the
straightedge to measure the amount of misalign
ment.
Drive Belts
When using drive belts, the power source and the
pump must be parallel. Use a straightedge along
the sides of the pulleys to ensure that the pulleys
are properly aligned (see Figure 4). In drive sys
tems using two or more belts, make certain that the
belts are a matched set; unmatched sets will cause
accelerated belt wear.
Figure 2. Aligning Spider‐Type Couplings
MISALIGNED:
SHAFTS
NOT PARALLEL
MISALIGNED:
SHAFTS
NOT IN LINE
ALIGNED: SHAFTS
PARALLEL AND
SHEAVES IN LINE
Figure 4. Alignment of V‐Belt Driven Pumps
PAGE B - 5INSTALLATION
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