GORMAN-RUPP PUMPS U Series Application guide

CJuly 20, 1990

OM-01864-OB02

Rev. D 10/14/02

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

ECopyright by the Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

U-SERIES PUMP

MODELS

U6B60 --- B

INCLUDING: /F, /FM

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 --- 2.........................................

Materials PAGE B --- 2..............................................................

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 --- 3.................................................

Suction Line Positioning PAGE B --- 4................................................

DISCHARGE LINES PAGE B --- 4........................................................

Siphoning PAGE B --- 4.............................................................

Valves PAGE B --- 4................................................................

Bypass Lines PAGE B --- 5..........................................................

AUTOMATIC AIR RELEASE VALVE PAGE B --- 6...........................................

Theory of Operation PAGE B --- 6....................................................

Air Release Valve Installation PAGE B --- 6............................................

ALIGNMENT PAGE B --- 7..............................................................

Coupled Drives PAGE B --- 8........................................................

V-Belt Drives PAGE B --- 8...........................................................

OPERATION --- SECTION C PAGE C --- 1......................................

PRIMING PAGE C --- 1.................................................................

STARTING PAGE C --- 1................................................................

Rotation PAGE C --- 1..............................................................

OPERATION PAGE C --- 1..............................................................

Lines With a Bypass PAGE C --- 1....................................................

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 --- 3..................................................

STOPPING PAGE C --- 3................................................................

Cold Weather Preservation PAGE C --- 3..............................................

BEARING TEMPERATURE CHECK PAGE C --- 3..........................................

TABLE OF CONTENTS

(continued)

TROUBLESHOOT ING --- SECTION D PAGE D --- 1..............................

PREVENTIVE MAINTENANCE PAGE D --- 3...............................................

PUMP MAINTENANCE AND REPAIR --- SECTION E PAGE E --- 1................

PERFORMANCE CURVE PAGE E --- 1...................................................

PARTS LISTS:

Pump Model PAGE E --- 3..........................................................

Repair Rotating Assembly PAGE E --- 5...............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 6.........................

Back Cover And Wear Plate Removal PAGE E --- 6.....................................

Suction Check Valve Removal PAGE E --- 6...........................................

Rotating Assembly Removal PAGE E --- 7.............................................

Impeller Removal PAGE E --- 8......................................................

Seal Removal and Disassembly PAGE E --- 8..........................................

Shaft and Bearing Removal and Disassembly PAGE E --- 8.............................

Shaft and Bearing Reassembly and Installation PAGE E --- 9............................

Seal Reassembly and Installation PAGE E --- 10........................................

Impeller Installation and Adjustment. PAGE E --- 13.....................................

Rotating Assembly Installation PAGE E --- 13...........................................

Suction Check Valve Installation PAGE E --- 14.........................................

Back Cover Installation PAGE E --- 14.................................................

PRESSURE RELIEF VALVE MAINTENANCE PAGE E --- 14..................................

LUBRICATION PAGE E --- 14.............................................................

Seal Assembly PAGE E --- 14.........................................................

Bearings PAGE E --- 15..............................................................

Power Source PAGE E --- 15.........................................................

USERIES OM--01864

PAGE I -- 1INTRODUCTION

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 Installation, Operation, and Maintenance

manual is designed to help you achieve the best

performance and longest life from your Gorman-

Rupp pump.

This pump is a U Series, semi---open impeller, self-

priming centrifugal model with a suction check

valve. It is designed for high-efficiency distribution

of liquids containing specified entrained solids.

The basic material of construction of wetted parts

iscast iron, with ductileironimpellerand alloysteel

impeller shaft.

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

write:

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

For information or technical assistance on the

powersource, contactthe power sourcemanufac-

turer’s local dealer or representative.

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

neitheroperatorsafetynorpumpintegrityarecom-

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 maintenance per-

sonnel to procedures which require specialatten-

tion,tothosewhichcoulddamageequipment,and

to those which could be dangerous to personnel:

Immediate hazards whichWILL 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.

HazardsorunsafepracticeswhichCOULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi-

ble damage which couldresult from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation,and

maintenance, or which clarify a procedure.

USERIES OM--01864

PAGE A -- 1SAFETY

SAFETY --- SECTION A

This information applies toU Seriesba-

sic pumps. Gorman-Rupp has no con-

trol over or particular knowledge of the

power source which will be used. Refer

to the manual accompanying the power

source before attempting to begin

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.

Beforeattemptingtoopenorservicethe

pump:

1. Familiarize yourself with this man-

ual.

2. Disconnect or lock out the power

sourcetoensurethatthepumpwill

remain inoperative.

3. Allow the pump to cool if over-

heated.

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.

Thispumpisdesignedtohandleliquids

containing specified entrained solids.

Do not attempt to pump volatile, corro-

sive, or flammable materials, or any liq-

uidswhichmaydamagethepumporen-

danger personnel as a result of pump

failure.

After the pump has been positioned,

make certain that the pump and all pip-

ing connections are tight, properly sup-

ported and secure before operation.

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-

heatedpump. Vaporpressure withinthe

pump can cause parts being disen-

gaged tobe ejected withgreat force. al-

low the pump to cool before servicing.

Do not operate the pump against a

closed discharge valve for long periods

oftime.Ifoperatedagainstacloseddis-

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.

USERIES

OM--01864

PAGE A -- 2 SAFETY

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam-

age to equipment. Suction and dis-

charge hoses and piping must be re-

moved from the pump before lifting.

OM--01864USERIES

PAGE B -- 1INSTALLATION

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-

tionedabovethefreelevelofliquidtobepumped.

If installedinaflooded suctionapplicationwhere

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 furtherassistance, contact yourGorman-Rupp

distributor or the Gorman-Rupp Company.

Pump Dimensions

SeeFigure1fortheapproximatephysicaldimen-

sionsofthispump.

OUTLINE DRAWING

U6B60A---B 3.00 2.50 11.52 19.49 31.5

5(76,5) (63,5) (292,6) (495,0) (801,

DIMENSIONS

MODEL “A” “B” “C” “D” “E

”

U6B60 --- B 4.50 3.56 13.02 20.96 33.0

0(114,3) (90,4) (330,7) (532,4) (838,

“A”

“B”

“E”

“C”

“D”

NOTE: OPTIONAL ASA OR DIN SUCTION & DISCHARGE SPOOL FLANGES AVAILABLE

Figure 1. Pump Model U6B60-B

OM--01864 USERIES

PAGE B -- 2 INSTALLATION

PREINSTALLATION INSPECTION

The pump assemblywasinspected and testedbe-

fore shipment from the factory. Before installation,

inspect the pump for damage which may haveoc-

curred during shipment. Check as follows:

a. Inspectthepump forcracks,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 allwarnings 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.

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,SectionC.

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.Ifthepumpandpowersourcehavebeen

stored for more than 12 months, some of the

components or lubricants may have ex-

ceeded their maximum shelf life. These must

be 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-

minethe repairor updating policy. Donotputthe

pump into service until appropriate action has

been taken.

POSITIONING PUMP

Lifting

Use lifting equipment with a capacity of at least

4,920 pounds (2231,7 kg). Thispump weighs ap-

proximately984 pounds (446,3 kg), not including

the weight of accessories and base. Customer in-

stalled equipment such as suction and discharge

piping must be removed before attempting to lift.

Thepumpassemblycanbeseriously

damagedifthecablesorchainsusedtolift

andmovetheunitareimproperlywrapped

around the pump.

Mounting

Locatethepumpinanaccessibleplaceascloseas

practical tothe 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

When positioning the pump, allow a minimum

clearance of 20 inches (508,0 mm) in front of the

backcovertopermitremovalofthecoverandeasy

access to the pump interior.

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

thesafeoperationrange.

Materials

Either pipe or hose maybe used for suction and

discharge lines; however, the materials must be

compatiblewiththeliquidbeingpumped.Ifhoseis

OM--01864USERIES

PAGE B -- 3INSTALLATION

used insuction lines, it must be the rigid-wall, rein-

forced type to prevent collapseunder 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-

tiallyincreasefriction loss.Ifelbowsarenecessary,

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 pulla 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

linesareused,theyshouldhaveadequatesupport

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 arenot

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 tothe pump may result in erratic

readings.

SUCTION LINES

Toavoidairpockets whichcouldaffect pumpprim-

ing, the suction line must be as short and direct as

possible.Whenoperationinvolvesasuctionlift,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 linesshouldbe 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 withthe flatpart ofthe reducersuppermost

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

touseit;anysphericalsolidswhichpassthrougha

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 1/4 inch

(31,8 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 to1 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 carryair down into

the sump, and air entering the suction line will re-

duce pump efficiency.

OM--01864 USERIES

PAGE B -- 4 INSTALLATION

If it is necessary to position inflow close to the suc-

tioninlet, install a bafflebetween theinflow 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,

theflowpathsmayinteract,reducingtheefficiency

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. Figure 2 shows

recommended minimum submergence vs. veloc-

ity.

NOTE

The pipe submergence required may be reduced

by installing a standard pipe increaser fitting at the

end of thesuction 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

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,

useavalveaslargeasthelargestpipetominimize

friction losses. Never install a throttling valve in a

suction line.

Withhighdischargeheads,itisrecommendedthat

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.

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