Self Priming Pump

PUBLICATION NUMBER OM--04760December 2, 1998Rev. A 11-20-03

THE GORMAN-RUPP COMPANY D MANSFIELD, OHIOGORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

eCopyright by the Gorman-Rupp Company

SELF-PRIMINGCENTRIFUGAL PUMPS

OM--04760 SELF-PRIMING CENTRIFUGAL PUMPS

PAGE I -- 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman-Rupp Self-Priming Centrifugal Pump. Read this manualcarefully to learn how to safely install and operateyour pump. Failure todosocould result inpersonalinjury or damage to the pump.

A set of three manuals accompanies your pump.Each set consists of three parts; the Installation/Operation Manual contains essential informationon installing and operating the pumps. However,since pump installations are seldom identical,some of the information only summarizes generalrecommendations and practices required to in-spect, position, and arrange the pump and piping.

The Parts List Manual provides performancecurve(s), a pump model cross-section drawing,and parts list for your pump.

The Maintenance and Repair Manual providestroubleshooting and maintenance instructions re-quired to properly diagnose operational problems,and to service the pump components.

Because pump installations are seldom identical,this manual cannot possibly provide detailed in-

structions and precautions for every aspect ofeach specific application. Therefore, it is the re-sponsibility of the owner/installer of the pump toensure that applications not addressed in thismanual are performed only after establishing thatneither operator safety nor pump integrity are com-promised by the installation. Pumps and relatedequipment must be installed and operated ac-cording to all national, local and industry stan-dards.

If there are any questions regarding the pumpwhich are not covered in this manual or in other lit-erature accompanying the unit, please contactyour Gorman-Rupp distributor or the Gorman-Rupp Company:

The Gorman-Rupp CompanyP.O. Box 1217

Mansfield, Ohio 44901--1217or:

Gorman-Rupp of Canada Limited70 Burwell Road

St. Thomas, Ontario N5P 3R7

CONTENTSSAFETY -- SECTION AINSTALLATION -- SECTION B

GENERAL INFORMATION PAGE B --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PREINSTALLATION INSPECTION PAGE B --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .POSITIONING PUMP PAGE B --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SUCTION AND DISCHARGE PIPING PAGE B --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AUTOMATIC AIR RELEASE VALVE PAGE B --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ALIGNMENT PAGE B --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ELECTRICAL CONNECTIONS PAGE B --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION -- SECTION CPRIMING PAGE C --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING PAGE C --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OPERATION PAGE C --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STOPPING PAGE C --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BEARING TEMPERATURE CHECK PAGE C --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .LUBRICATION PAGE C --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM--04760SELF-PRIMING CENTRIFUGAL PUMPS

PAGE I -- 2 INTRODUCTION

RECORDING MODEL ANDSERIAL NUMBERS

Please record the pump model and serial numberin the spaces provided below. Your Gorman-Ruppdistributor needs this informationwhen you requireparts or service.

Pump Model:

Serial Number:

WARRANTY INFORMATION

The warranty provided with your pump is part ofGorman-Rupps support program for customerswho operate and maintain their equipment as de-scribed in this and the other accompanying litera-ture. Please note that should the equipment beabused or modified to change its performance be-yond the original factory specifications, the war-ranty will become void and any claim will be de-nied.

The following are used to alert personnel to procedures which require special attention, to those whichcould damage equipment, and to those which could be dangerous to personnel:

Immediate hazardswhichWILL result insevere personal injury or death. Theseinstructions describe the procedure re-quired and the injury which will resultfrom failure to follow the procedure.

Hazards or unsafe practices whichCOULD result in severe personal injuryor death. These instructions describethe procedure required and the injurywhich could result from failure to followthe procedure.

Hazards or unsafepractices whichCOULDresult inminor personal injuryor productorproperty damage. These instructions de-scribe the requirements and the possibledamage which could result from failure tofollow the procedure.

NOTEInstructions to aid in installation, operation, andmaintenance or which clarify a procedure.

SELF-PRIMING CENTRIFUGAL PUMPS OM--04760

PAGE A -- 1SAFETY

SAFETY - SECTION A

This information applies to G-R Self-Priming Centrifugal pumps. Thesepumps are available as basic, pedestal-mounted models or as close-coupledmodels driven by either an electric mo-tor, gasoline or diesel engine. Refer tothe manual accompanying the powersource before attempting to begin oper-ation.

This manual will alert personnel toknown procedures which require spe-cial attention, to those which coulddamage equipment, and to those whichcould be dangerous to personnel. How-ever, thismanual cannot possibly antici-pate and provide detailed instructionsand precautions for every situation thatmight occur during maintenance of theunit. Therefore, it is the responsibility ofthe owner/maintenance personnel toensure that only safe, establishedmain-tenance procedures are used, and thatany procedures not addressed in thismanual are performed only after estab-lishing that neither personal safety norpump integrity are compromised bysuch practices.

In addition to this manual, see the sepa-rate literature covering maintenanceand repair, pumpparts, and anyoptionalequipment shipped with the pump.

Before attempting toopenor service thepump:

1. Familiarize yourself with this man-ual.

2. Disconnect or shut down the pow-er source and take necessary pre-cautions to ensure that the pumpwill remain inoperative.

3. Allow the pump to completely coolif overheated.

4. Check the temperature beforeopening any covers, plates, orplugs.

5. Close the suction and dischargevalves.

6. Vent the pump slowly and cau-tiously.

7. Drain the pump.

Do not attempt to pump any liquids thepump has not been designed for, andwhich may damage the pump or endan-ger personnel as a result of pump fail-ure. Consult the factory to determinecompatibility between thepumpand liq-uid.

Use lifting and moving equipment ingood repair and with adequate capacityto 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.

After the pump has been positioned,make certain that the pump and all pip-ing or hose connections are tight, prop-erly supported and secure before oper-ation.

Do not operate the pump against aclosed discharge valve for long periodsof time. If operated against a closed dis-charge valve, pump components willdeteriorate, and the liquid could come

SELF-PRIMING CENTRIFUAL PUMPSOM--04760

PAGE A -- 2 SAFETY

to a boil, build pressure, and cause thepump casing to rupture or explode.

Do not remove plates, covers, gauges,pipe plugs, or fittings from an over-heated pump. Vapor pressure within thepump can cause parts being disen-gaged to be ejected with great force. Al-low the pump to cool before servicing.

These pumps may be used to handleproductswhich if overheated could pro-duce dangerous fumes. Use extremecaution when venting the pump, orwhen removing covers, plates, plugs, orfittings.

Never run this pumpbackwards. Be cer-tain that rotation is correct before fullyengaging the pump.

If the pump is used to pump materialswhich could cause serious illness or in-jury through direct exposure or emittedfumes, wear protective clothing, suchas rubbergloves, facemask, and rubberapron, as necessary before disassem-bling the pump or piping.

Do not operate the pump withoutshields and/or guards in place over thedrive shafts, belts, and/or couplings, orother rotating parts. Exposed rotating

parts can catch clothing, fingers, ortools, causing severe injury to person-nel.

If the pump is powered by an electricmotor, do not operate a non-explosionproof motor in an explosive atmo-sphere. An explosion, which may causesevere personal injury or death, couldresult. Install, connect and operate themotor in accordance with the NationalElectric Code and all local codes. Ifthere is a conflict between the instruc-tions in the manual accompanying theunit and the National Electric Code orapplicable local code, the National orLocal code shall take precedence. Allelectrical equipment supplied with thepump conforms to applicable federalregulations and national codes in effecton the date of manufacture.

If the pump is electric motor driven, theelectrical power used to operate thispump is high enough to cause injury ordeath. Obtain the services of a qualifiedelectrician to troubleshoot, test and/orservice the electrical components ofthis pump.

If the pump is powered by an internalcombustion engine, do not operate inan explosive atmosphere.When operat-ing internal combustion engines in anenclosed area, make certain that ex-haust fumes are piped to the outside.These fumes contain carbon monoxide,a deadly gas that is colorless, tasteless,and odorless.


PAGE A -- 3SAFETY

Fuel used by internal combustion en-gines presents an extreme explosionand fire hazard. Make certain that allfuel lines are securely connected andfree of leaks. Never refuel a hot or run-ning engine. Avoid overfilling the fueltank.Always use the correct type of fuel.

Never tamper with the engine governorto gain more power. The governor esta-blishes safe operating limits that shouldnot be exceeded. The maximum contin-

uous operating speed for the pump isshown on the performance curve (seethe Parts List Manual).

If the pump ispowered byan engine, theengine exhaust from this product con-tains chemicals known to the State ofCalifornia to cause cancer, birth defectsor other reproductive harm.

Pumps and related equipment must be in-stalled and operated according to all na-tional, local and industry standards.


PAGE B -- 1INSTALLATION

INSTALLATION --- SECTION B

Review all SAFETY information in Section A.

Since pump installations are seldom identical, thissection offers only general recommendations andpractices required to inspect, position, and ar-range the pump and piping.

Most of the information pertains to a standardstatic lift applicationwhere the pump is positionedabove the free level of liquid to be pumped.

If installed in a flooded suction applicationwherethe liquid is supplied to the pump under pressure,some of the information such as mounting, lineconfiguration, and priming must be tailored to thespecific application. Since the pressure suppliedto the pump is critical to performance and safety,besure to limit the incomingpressure to50%of themaximum permissible operating pressure asshown on the pump performance curve (see PartsList Manual). If the pump is fittedwith a Gorman-Rupp double grease lubricated seal, the maxi-mum incoming pressure must be reduced to 10p.s.i.

For further assistance, contact your Gorman-Ruppdistributor or the Gorman-Rupp Company.

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 power source (if soequipped) for cracks, dents, damagedthreads, 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 markingson the pump assembly, and perform all dutiesindicated. Note that the pump shaft rotates inthe required direction.

d. Check levels and lubricate as necessary. Re-fer to LUBRICATION in the MAINTENANCEAND REPAIR section of this manual and anyother literature accompanying the unit andperform duties as instructed.

e. If the pump and power source have beenstored for more than 12 months, some of thecomponents or lubricants may have ex-ceeded their maximum shelf life. Thesemustbe inspected or replaced to ensure maxi-mum pump service.

If the maximum shelf life has been exceeded, or ifanything appears to be abnormal, contact yourGorman-Rupp distributor or the factory to deter-mine the repair or updating policy. Do not put thepump into service until appropriate action hasbeen taken.

Battery Installation

If the pump is engine driven, the engine battery isnot included with the unit unless otherwise speci-fied on the pump order. See the battery tag in-cluded with the battery box assembly for batteryspecifications. Refer to information accompanyingthe battery and/or electrolyte solution for activationand charging instructions.

Before installing the battery, clean the positive andnegative cable connectors, and the battery termi-nals. Secure the battery by tightening the hold-down brackets. The terminals and clamps may becoated with petroleum jelly to retard corrosion.Connect and tighten the positive cable first, thenthe negative cable.

POSITIONING PUMP

Lifting

Use lifting equipment with a capacity of at least 5times the weight of the pump, not including theweight of accessories, wheel kit or optional equip-ment. Customer installed equipment such as suc-tion and dischargepipingmust be removedbeforeattempting to lift.


PAGE B -- 2 INSTALLATION

The pump assembly can be seriouslydamaged if the chains or cables used to liftandmove the unit are improperly wrappedaround the pump.

Mounting

Locate the pump in an accessible place as close aspractical to the liquid being pumped. Level mount-ing is essential for proper operation.

The pump may have to be supported or shimmedto provide for level operation or to eliminate vibra-tion.

If the pump has been mounted on a moveablebase,make certain the base is stationary bysettingthe brake and blocking the wheels before attempt-ing to operate the pump.

If the pump is engine driven, do not position thepump and engine more than 15_ off horizontal forcontinuous operation in order to ensure sufficientlubrication and fuel supply to the engine. Thepump and engine may be positioned up to 30_ offhorizontal for intermittent operation only; how-ever, the enginemanufacturer should beconsultedfor continuous operation at angles greater than15_.

Clearance

When positioning the pump, allow clearance infront of the back cover to permit removal of thecover and easy access to the pump interior. Con-sult the factory or the Specification Data sheet forrecommended clearance.

SUCTION AND DISCHARGE PIPING

Pump performance is adversely effected by in-creased suction lift, discharge elevation, and fric-tion losses. See the performance curve in the PartsList manual to be sure your overall application al-lows the pump to operate within the safe operationrange.

Materials

Either pipe or hose maybe used for suction anddischarge lines; however, the materials must becompatible with the liquid being pumped. If hose isused 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 aspossible 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 intoplace 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 couldcause excessive vibration, decreased bearing life,and increased shaft and seal wear. If hose-typelines are used, they should have adequate supportto secure them when filled with liquid and underpressure.

Gauges

Most pumps are drilled and tapped for installingdischargepressure and vacuumsuction gauges. Ifthese gauges are desired for pumps that are nottapped, drill and tap the suction and dischargelines not less than 18 inches (457,2 mm) from thesuction and discharge ports and install the lines.Installation closer to the pumpmay result in erraticreadings.

SUCTION LINES

To avoid air pockets which could affect pumpprim-ing, the suction line must be as short and direct aspossible.Whenoperation involves a suction lift, theline must always slope upward to the pump fromthe source of the liquid being pumped; if the line



slopes down to the pump at any point along thesuction run, air pockets will be created.

Fittings

Suction lines should be the same size as the pumpinlet. If reducers are used in suction lines, theyshould be the eccentric type, and should be in-stalled with the flat part of the reducers uppermostto 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 certainto use it; any spherical solids which pass through astrainer furnished with the pump will also passthrough the pump itself.

If a strainer is not furnished with the pump, but isinstalled by the pump user, make certain that thetotal area of the openings in the strainer is at leastthree or four times the cross section of the suctionline, and that the openings will not permit passageof solids larger than the solids handling capabilityof the pump.

Refer to the Specification Data sheet for the spheri-cal solids handling capability of your specific pumpmodel.

Sealing

Since even a slight leak will affect priming, head,and capacity, especially when operating with ahigh suction lift, all connections in the suction lineshould be sealed with pipe dope to ensure an air-tight seal. Follow the sealant manufacturers rec-ommendations when selecting and applying thepipe dope. The pipe dope should be compatiblewith the liquid being pumped.

Suction Lines In Sumps

If a single suction line is installed in a sump, itshould be positioned away from the wall of thesump 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 thesump, the flow should be kept away from the suc-tion inlet because the inflow will carry air down intothe 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 thesuction inlet at a distance 1-1/2 times the diameterof the suction pipe. The baffle will allow entrainedair to escape from the liquid before it is drawn intothe suction inlet.

If two suction lines are installed in a single sump,the flow pathsmay interact, reducing the efficiencyof one or both pumps. To avoid this, position thesuction inlets so that they are separated by a dis-tance equal to at least 3 times the diameter of thesuction pipe.

Suction Line Positioning

The depth of submergence of the suction line iscritical to efficient pump operation. Figure 1 showsrecommended minimum submergence vs. veloc-ity.

NOTEThe pipe submergence required may be reducedby installing a standard pipe increaser fitting at theend of the suction line. The larger opening size willreduce the inlet velocity. Calculate the requiredsubmergence using the following formula basedon the increased opening size (area or diameter).



Figure 1. Recommended Minimum Suction Line Submergence vs. Velocity

DISCHARGE LINES

Siphoning

Do not terminate the discharge line at a level lowerthan 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 pumpcould result.

Valves

If a throttling valve is desired in the discharge line,use a valve as large as the largest pipe tominimizefriction losses. Never install a throttling valve in asuction 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 thata throttling valve and a system check valve be in-stalled in the discharge line to protect the pumpfrom excessive shock pressure and reverse rota-tion when it is stopped.

If the application involves a high dischargehead, gradually close the dischargethrottling valve before stopping the pump.

Bypass Lines

Self-priming pumps are not air compressors. Dur-ing the priming cycle, air from the suction linemustbe vented to atmosphere on the discharge side. Ifthe discharge line is open, this air will be ventedthrough the discharge. However, if a check valvehas been installed in the discharge line, the dis-charge side of the pumpmust be opened toatmos-pheric pressure through a bypass line installed be-tween the pump discharge and the check valve. Aself-priming centrifugal pump will not prime ifthere is sufficient static liquid head to hold the dis-charge check valve closed.

NOTEThe bypass line should be sized so that it does notaffect pump discharge capacity; however, the by-pass line should be at least 1 inch in diameter to



minimize the chance of plugging.

In low discharge head applications (less than 30feet or 9 meters), it is recommended that the by-pass line be run back to the wet well, and located 6inches below the water level or cut-off point of thelow level pump. In some installations, this bypassline may be terminated with a six-to-eight footlength of 1 1/4 inch I.D. smooth-bore hose; air andliquid vented during the priming process will thenagitate the hose and break up any solids, grease,or other substances likely to cause clogging.

A bypass line that is returned to a wet wellmust be secured against being drawn intothe pump suction inlet.

It is also recommended that pipe unions be in-stalled at each 90_ elbow in a bypass line to easedisassembly and maintenance.

In high discharge head applications (more than30 feet), an excessive amount of liquid may be by-passed and forced back to the wet well under thefull working pressure of the pump; this will reduceoverall pumping efficiency. Therefore, it is recom-mended that a Gorman-Rupp Automatic Air Re-lease Valve be installed in the bypass line.

Gorman-Rupp Automatic Air Release Valves arereliable, and require minimum maintenance. SeeAUTOMATICAIRRELEASE VALVE in this sectionfor installation and theory of operation of the Auto-matic Air Release Valve. Consult your Gorman-Rupp distributor, or contact the Gorman-RuppCompany for selection of an Automatic Air ReleaseValve to fit your application.

If the installation involves a flooded suction such asa below-ground lift station, a pipe union andmanu-al shut-off valvemay be installed in the bleed line toallow service of the valve without shutting down thestation, and to eliminate the possibility of flooding.If a manual shut-off valve is installed anywhere in

the air release piping, itmust be a full-openingballtype valve to prevent plugging by solids.

If a manual shut-off valve is installed ina bypass line, it must not be left closedduringoperation. Aclosedmanual shut-off valve may cause a pump which haslost prime to continue to operate with-out reaching prime, causing dangerousoverheating and possible explosiverupture of the pump casing. Personnelcould be severely injured.

Allow an over-heated pump to cool be-fore servicing. Do not remove plates,covers, gauges, or fittings from an over-heated pump. Liquid within the pumpcan reach boiling temperatures, and va-por pressurewithin the pump cancauseparts being disengaged to be ejectedwith great force. After the pump cools,drain the liquid from the pump by re-moving the casing drain plug. Use cau-tion when removing the plug to preventinjury to personnel from hot liquid.

AUTOMATIC AIR RELEASE VALVE

When properly installed and correctly adjusted tothe specific hydraulic operating conditions of theapplication, the Gorman-Rupp Automatic Air Re-leaseValvewill permit air to escape through the by-pass line, and then close automatically when thepump is fully primed and pumping at full capacity.

Theory of Operation

Figures 2 and 3 show a cross-sectional view of theAutomatic Air Release Valve, and a correspondingdescription of operation.



Figure 2. Valve in Open Position

During the priming cycle, air from the pump casingflows through the bypass line, and passes throughthe Air Release Valve to the wet well (Figure 2).

Figure 3. Valve in Closed Position

When the pump is fully primed, pressure resultingfrom flow against the valve diaphragm com-presses the spring and closes the valve (Figure 3).The valve will remain closed, reducing the bypassof liquid to 1 to 5 gallons (3.8 to 19 liters) per min-ute, until the pump loses its prime or stops.

Some leakage (1 to 5 gallons or 3.8 to 19

liters per minute) will occur when thevalve is fully closed. Be sure the bypassline is directed back to the wet well ortank to prevent hazardous spills.

When the pump shuts down, the spring returns thediaphragm to its original position. Any solids thatmay have accumulated in the diaphragm chambersettle to the bottom and are flushed out during thenext priming cycle.

NOTEThe valve will remain open if the pump does notreach its designed capacity or head. Valve closingpressure is dependent upon the discharge head ofthe pump at full capacity. The range of the valveclosing pressure is established by the tension rateof the spring as ordered from the factory. Valve clos-ing pressure can be further adjusted to the exactsystem requirements by moving the spring retain-ing pin up or down the plunger rod to increase ordecrease tension on the spring. Contact your Gor-man-Rupp distributor or the Gorman-Rupp Com-pany for information about an Automatic Air Re-lease Valve for your specific application.

Air Release Valve Installation

The Automatic Air Release Valve must be inde-pendently mounted in a horizontal position andconnected to the discharge line of the self-primingcentrifugal pump (see Figure 4).

NOTEIf theAir ReleaseValve is to be installed on a stagedpump application, contact the factory for specificinstallation instructions.



DISCHARGE PIPE

DISCHARGECHECK VALVE

PUMP DISCHARGE

SELF-PRIMINGCENTRIFUGALPUMP

SUCTIONLINE

SUPPORTBRACKET

CLEAN-OUTCOVER

INSTALL AIR RELEASE VALVEIN HORIZONTAL POSITION

90_ LONGRADIUSELBOW

BLEED LINE 1(25,4 MM) DIA. MIN.(CUSTOMERFURNISHED)EXTEND 6(152,4 MM)BELOW LIQUID

WET WELLOR SUMP

LEVEL SURFACE

Figure 4. Typical Automatic Air Release Valve Installation

The valve inlet line must be installed between thepumpdischargeport and the non-pressurizedsideof the discharge check valve. The valve inlet is atthe large end of the valve body, and is providedwith standard 1-inch NPT pipe threads.

The valve outlet is located at the opposite end ofthe valve, and is also equipped with standard1-inch NPT pipe threads. The outlet should be con-nected to a bleed line which slopes back to the wetwell or sump. The bleed linemust be the same sizeas the inlet piping, or larger. Ifpiping is used for thebleed line, avoid the use of elbows whenever pos-sible.

NOTEIt is recommended that each Air Release Valve befitted with an independent bleeder line directedback to the wet well. If multiple Air Release Valvesare installed in a system, theymust be fitted with in-dependent bleeder lines; never use a commonmanifold pipe. Contact your Gorman-Rupp dis-tributor or the Gorman-Rupp Company for informa-tion about installation of an Automatic Air ReleaseValve for your specific application.

ALIGNMENT

The alignment of the pump and its power source iscritical for trouble-free mechanical operation. Ineither a flexible coupling or V-belt driven system,the driver and pumpmust bemounted so that theirshafts are alignedwith and parallel to each other. Itis imperative that alignment be checked after thepump and piping are installed, and before opera-tion.

NOTECheck Rotation, Section C, before final alignmentof the pump.

Whenmounted at theGorman-Rupp factory, driverand pump are aligned before shipment. Misalign-ment will occur in transit and handling. Pumpsmust be checked and realigned before operation.Before checking alignment, tighten the foundationbolts. The pump casing feet and/or pedestal feet,and the drivermountingbolts should alsobe tightlysecured.



When checking alignment, disconnectthe power source to ensure that thepump will remain inoperative.

Adjusting the alignment in one directionmay alter the alignment in another direc-tion. check each procedure after alteringalignment.

Coupled Drives

When using couplings, the axis of the powersource must be aligned to the axis of the pumpshaft in both the horizontal and vertical planes.Most couplings require a specific gap or clearancebetween the driving and the driven shafts. Refer tothe coupling manufacturers service literature.

Align spider insert type couplings by using calipersto measure the dimensions on the circumferenceof the outer ends of the coupling hub every 90 de-grees. The coupling is in alignment when the hubends are the same distance apart at all points (seeFigure 5).

Figure 5. Aligning Spider-Type Couplings

Align non-spider type couplings by using a feelergaugeor taper gaugebetween the couplinghalvesevery 90 degrees. The coupling is in alignmentwhen the hubs are the same distance apart at allpoints (see Figure 6).

Figure 6. Aligning Non-Spider Type Couplings

Check parallel adjustment by laying a straightedgeacross both coupling rims at the top, bottom, andside. When the straightedge rests evenly on bothhalves of the coupling, the coupling is in horizontalparallel alignment. If the coupling is misaligned,use a feeler gauge between the coupling and thestraightedge to measure the amount of misalign-ment.

V-Belt Drives

When using V-belt drives, the power source andthe pump must be parallel. Use a straightedgealong the sides of the pulleys to ensure that the pul-leys are properly aligned (see Figure 7). In drivesystems using two ormore belts,make certain thatthe belts are a matched set; unmatched sets willcause accelerated belt wear.

MISALIGNED:SHAFTS

NOT PARALLEL

MISALIGNED:SHAFTS

NOT IN LINE

ALIGNED: SHAFTSPARALLEL ANDSHEAVES IN LINE

Figure 7. Alignment of V-Belt Driven Pumps

Tighten the belts in accordancewith the beltmanu-facturers instructions. If the belts are too loose,they will slip; if the belts are too tight, there will beexcessive power loss and possible bearing failure.



Select pulleys that will match the proper speed ra-tio; overspeeding the pump may damage bothpump and power source.

Do not operate the pump without theguard in place over the rotating parts.exposed rotating parts can catch cloth-ing, fingers, or tools, causing severe in-jury to personnel.

ELECTRICAL CONNECTIONS

If the pump is driven by an electric motor, checkthat the electrical service available matches themotor requirements stamped on the motor name-plate before connecting a motor to the incomingpower. Check that the motor speed meets pumpspecifications.

If rotation is incorrect on a three-phasemotor, havea qualified electrician interchange any two of thethree phase wires to change direction. If rotation isincorrect on a single-phase motor, consult the lit-erature supplied with themotor for specific instruc-tions.

Theelectrical power used to operate thepump is high enough to cause injury ordeath. Obtain the services of a qualifiedelectrician to make all electrical con-nections.

If the pump is powered by an electricmotor, do not operate a non-explosionproof motor in an explosive atmo-sphere. An explosion, which may causesevere personal injury or death, couldresult. Install, connect and operate themotor in accordance with the NationalElectric Code and all local codes. Ifthere is a conflict between the instruc-tions in the manual accompanying theunit and the National Electric Code orapplicable local code, the National orLocal code shall take precedence. Allelectrical equipment supplied with thepump conforms to applicable federalregulations and national codes in effecton the date of manufacture.


OPERATION PAGE C -- 1

OPERATION --- SECTION C

Review all SAFETY information in Section A.

Follow the instructions on all tags, labels and de-cals attached to the pump.

Do not attempt to pump any liquids thepump has not been designed for, andwhich may damage the pump or endan-ger personnel as a result of pump fail-ure.

Pump speed and operating conditionsmust be within the performance rangeshown on the curve in Parts Lists manual.

Refer to the pump Specification Data Sheet or theaccompanying Parts List Manual for the specificperformance for your 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 securelymounted. Check that the pump is properly lubri-cated (see LUBRICATION in theMAINTENANCEAND REPAIR manual).

Thepump is self-priming, but it shouldnever beop-erated unless there is liquid in the pump casing.

Never operate the pump unless there is liq-uid in the pump casing. The pump will notprime when dry. Extended operation of adry pump will destroy the seal assembly.

Add liquid to the pump casing when:

1. The pump is being put into service for thefirst 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 pumpwill prime and reprime as necessary.

After filling the pump casing, reinstalland tighten the fill plug. Do not attemptto operate the pump unless all connect-ing piping is securely installed. Other-wise, liquid in the pump forced outunder pressure could cause injury topersonnel.

To fill the pump, remove the pump casing fill coveror fill plug in the top of the casing, and add cleanliquid until the casing is filled. Replace the fill coveror fill plug before operating the pump.

STARTING

Starting procedures will vary slightly dependingonthe pump application, type of priming device, andtype of drive. Consult the operations manual fur-nished with the power source.

Rotation

The correct direction of pump rotation is indicatedby an arrow on the pump body or accompanyingdecals. If the pump is operated in the wrong direc-tion, the impeller could become loosened from theshaft and seriously damage the pump.

The pumpmust operate in the direction in-dicated by the arrow on the pump, or ac-

SELF-PRIMING CENTRIFUGAL PUMPSOM--04760

OPERATIONPAGE C -- 2

companying decals. Reverse rotationcould loosen the impeller and seriouslydamage the pump.

If the pump is driven by an electric motor, consultthe operating manual furnished with the motor be-fore attempting to start the motor.

If rotation is incorrect on a three-phasemotor, havea qualified electrician interchange any two of thethree phase wires to change direction. If rotation isincorrect on a single-phase motor, consult the lit-erature supplied with themotor for specific instruc-tions.

OPERATION

Pump speedand operatingpointsmust bewithin the continuous performance rangeshown on the pump curve. (See the PartsList Manual accompanying the pump.)

Lines With a Bypass

Close the discharge throttling valve (if soequipped) so that the pump will not have to primeagainst the weight of the liquid in the dischargeline. Air from the suction line will be dischargedthrough the bypass line back to the wet well duringthe priming cycle. When the pump is fully primedand liquid is flowing steadily from the bypass line,open the discharge throttling valve. Liquid will thencontinue to circulate through the bypass line whilethe pump is in operation.

Lines Without a Bypass

Open all valves in the discharge line and start thepower source. Priming is indicated by a positivereading on the discharge pressure gauge or by aquieter operation. The pumpmay not prime imme-diately because the suction line must first fill withliquid. If the pump fails to primewithin fiveminutes,stop it and check the suction line for leaks.

After the pump has been primed, partially close thedischarge line throttling valve in order to fill the lineslowly and guard against excessive shock pres-

sure which could damage pipe ends, gaskets,sprinkler heads, and any other fixtures connectedto the line. When the discharge line is completelyfilled, adjust the throttling valve to the required flowrate.

Do not operate the pump against aclosed discharge throttling valve forlong periods of time. If operated againsta closed discharge throttling valve,pump components will deteriorate, andthe liquid could come to a boil, buildpressure, and cause the pump casing torupture or explode.

Leakage

No leakage should be visible at pump mating sur-faces, or at pump connections or fittings. Keep allline connections and fittings tight to maintainmaxi-mum pump efficiency.

Liquid Temperature And Overheating

Refer to the Specification Data sheet for themaxi-mum liquid temperature for your specific pump.Do not apply the pump at a higher operating tem-perature.

Overheating can occur if operated with the valvesin the suction or discharge lines closed. Operatingagainst closed valves could bring the liquid to aboil, build pressure, and cause the pump to rup-ture or explode. If overheating occurs, stop thepump and allow it to cool before servicing it. Refillthe pump casing with cool liquid.

Allow an over-heated pump to com-pletely cool before servicing. Do not re-move plates, covers, gauges, or fittingsfrom an over-heated pump. Liquid with-in the pump can reach boiling tempera-tures, and vapor pressure within thepump can cause parts being disen-gaged to be ejected with great force. Af-



ter the pump cools, drain the liquid fromthe pump by removing the casing drainplug. Use caution when removing theplug to prevent injury to personnel fromhot liquid.

If overheating does occur, stop the pump immedi-ately and allow it to cool before servicing it. Ap-proach any overheated pump cautiously.

As a safeguard against rupture or explosion due toheat, some pumps are equipped with a pressurerelief valve which will open if vapor pressure withinthe pump casing reaches a critical point. It is rec-ommended that the pressure relief valve assemblybe replaced at each overhaul, or any time thepump casing overheats and activates the valve.Never replace this valve with a substitute whichhas not been specified or providedby theGorman-Rupp Company.

Strainer Check

If a suction strainer has been shipped with thepump or installed by the user, check the strainerregularly, and clean it as necessary. The strainershould also be checked if pump flow rate begins todrop. If a vacuum suction gauge has been in-stalled, monitor and record the readings regularlyto detect strainer blockage.

Never introduce air or steam pressure into thepump casing or piping to remove a blockage. Thiscould result in personal injury or damage to theequipment. If backflushing is absolutely neces-sary, liquid pressuremust be limited to 50% of themaximum permissible operating pressure shownon thepumpperformance curve. If thepump is fit-ted with a Gorman-Rupp double grease lubri-cated seal, the maximum incoming pressuremust be reduced to 10 p.s.i.

Pump Vacuum Check

With the pump inoperative, install a vacuumgaugein 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 20inches (508 mm) or more of mercury. If it does not,

check for air leaks in the seal, gasket, or dischargevalve.

Open the suction line, and read the vacuumgaugewith the pump primed and at operation speed.Shut off the pump. The vacuumgauge reading willimmediately drop proportionate to static suctionlift, and should then stabilize. If the vacuumreadingfalls off rapidly after stabilization, an air leak exists.Before checking for the source of the leak, checkthe point of installation of the vacuum gauge.

Operational Checks

Check the pump for proper operationwhen it is firststarted and periodically thereafter to identify minorproblems.

Check the pump for unusual noises or excessivevibration while it is operating. If noise or vibration isexcessive, stop the pump and refer to Trouble-shooting in the Maintenance And Repair Manualfor possible causes.

To avoid serious damage to the pump,check for unusual noises or excessive vi-bration while the pump is running. If noiseor vibration is excessive, stop operationand refer to the troubleshooting chart in theMaintenance and Repair manual.

STOPPING

Never halt the flow of liquid suddenly. If the liquidbeing pumped is stopped abruptly, damagingshock waves can be transmitted to the pump andpiping system. Close all connecting valves slowly.

On engine driven pumps, reduce the throttlespeed slowly and allow the engine to idle briefly be-fore stopping.

If the application involves a high dischargehead, gradually close the dischargethrottling valve before stopping the pump.

SELF-PRIMING CENTRIFUGAL PUMPSOM--04760

OPERATIONPAGE C -- 4

After stopping the pump, lock out or disconnectthe power source to ensure that the pump will re-main inoperative.

Cold Weather Preservation

In below freezing conditions, drain the pump toprevent damage from freezing. Also, clean out anysolids by flushing with a hose. Operate the pumpfor approximately one minute; this will remove anyremaining liquid that could freeze the pump rotat-ing parts. If the pump will be idle for more than afew 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 preventlarge solids from clogging the drain port and pre-venting the pump from completely draining, inserta rod or stiff wire in the drain port, and agitate theliquid during the draining process. Clean out anyremaining solids by flushing with a hose.

BEARING TEMPERATURE CHECK

Bearings normally run at higher than ambient tem-peratures because of heat generated by friction.Temperatures up to 160_F (71_ C) are considerednormal for bearings, and they canoperate safely toat least 180_F (82_ C).

Checkingbearing temperatures byhand is inaccu-rate. Bearing temperatures can be measured ac-curately by placing a contact-type thermometeragainst the housing. Record this temperature forfuture reference.

A sudden increase in bearing temperature is awarning that the bearings are at the point of failingto operate properly. Make certain that the bearinglubricant is of the proper viscosity and at the cor-rect level (see LUBRICATION in theMaintenanceAnd Repair manual). Bearing overheating canalso be caused by shaft misalignment and/or ex-cessive vibration.

When pumps are first started, the bearings mayseem to run at temperatures above normal. Con-tinued operation should bring the temperaturesdown to normal levels.

LUBRICATION

Do not remove plates, covers, gauges,pipe plugs or fittings from an over-heated pump. Vapor pressure within thepump can cause parts being disen-gaged to be ejected with great force. Al-low the pump to completely cool beforeservicing.

On a new pump, check the oil level in the seal andbearing cavities before initial startup, after the firsttwo weeks of operation, and every month thereaf-ter.

Before installing or removing the lubrication plug,always clean the area around the plug to preventcontamination.

Self Lubricated Seal Assembly

The self lubricated seal assembly is lubricated bythemediumbeingpumped, or by a flow of fresh liq-uid from an external source. Flushing liquid maybe taken from the pump discharge and suppliedthrough auxiliary piping.

When handling abrasive or tacky liquids, supplyfresh lubricating liquid from an external source. Besure the liquid supplied to the seal is compatiblewith the liquid being pumped, and that its flow iscontrolled to prevent dilution. Consult the factory ifflushing is required.

Oil Lubricated Seal Assembly

Before starting the pump, remove the vented plugand fill the seal cavity with SAE No. 30 non-deter-gent oil. Clean and reinstall the vented plug. Referto the Maintenance And Repair Manual for theseal cavity oil capacity.

Grease Lubricated Seal Assembly

Fill the automatic grease cup through the greasefitting with No. 2 lithium base grease until greaseescapes from the relief hole. Turn the grease cuparm counterclockwise until it is at the top of the



stem; this will release the spring to apply grease tothe seal.

Oil Lubricated Bearings

Bearing housings are fully lubricated whenshipped from the factory. Check the oil level regu-larly andmaintain it at the desired level.When lubri-cation is required, add SAE No. 30 non-detergentoil. Do not over-lubricate. Over-lubrication cancause the bearings to over-heat, resulting in pre-mature bearing failure.

Under normal conditions, drain the bearing hous-ing once each year and refill with clean oil. Changethe oil more frequently if the pump is operated con-tinuously or installed in an environment with rapidtemperature change.

Monitor the condition of the bearing lubri-cant regularly for evidence of rust or mois-ture condensation. This is especially im-portant in areas where variable hot andcold temperatures are common.

For cold weather operation, consult the factory or alubricant supplier for the recommended grade ofoil.

Grease Lubricated Bearings

Bearing housings are fully lubricated whenshipped from the factory. Under normalconditions,add No. 0 lithium base grease from a grease gunthrough the grease fitting after each 250 hours ofoperation or once each month, whichever comesfirst. Do not over-lubricate. Over-lubrication cancause the bearings to over-heat, resulting in pre-mature bearing failure.

If there is no provision in the bearing cavity to drainor flush the lubricant, the pump and bearing hous-ingmust bedisassembled to completely clean andmaintain this cavity.

Under normal conditions, change the grease aftereach 5000 hours of operation, or at 12 month inter-vals, whichever comes first. Change the greasemore frequently if the pump is operated continu-ously or installed in an environment where variablehot and cold temperatures are common.

Refer to theMaintenance And Repair Manual forgrease capacity of the bearing housing for thepump.

For cold weather operation, consult the factory or alubricant supplier for the recommended grade oflubricant.

Power Source

Consult the literature supplied with the powersource, or contact your local power source repre-sentative.

THE GORMAN-RUPP COMPANY FMANSFIELD, OHIOGORMAN-RUPPOF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

July 18, 1979

WARRANTY

Pumping units manufactured by The Gorman-Rupp Company,Mansfield, Ohio are guaranteed to be free from defects in mate-rial and workmanship for one year from date of shipment fromfactory in Mansfield, Ohio. The obligation under this Warranty,statutory or otherwise, is limited to replacement or repair atMansfield, Ohio factory or at a point designated by Gorman-Rupp, of such part as shall appear to us upon inspection at suchpoint, to have been defective in material or workmanship.

ThisWarranty does not obligate TheGorman-Rupp Company tobear the cost of labor or transportation charges in connectionwith replacement or repair of defective parts; nor shall it apply toa pump upon which repairs or alterations have been made un-less authorized by Gorman-Rupp.

No warranty is made in respect to engines, motors, or trade ac-cessories, such being subject to warranties of their respectivemanufacturers.

In Submersible Pumps, pump and motor are integral and Sub-mersibles are warranted as a unit. Since motor is subject to animportant degree upon quality and performance of electricalcontrols, unit warranty is valid only when controls have beenspecified and provided by Gorman-Rupp.

No express implied or statutory warranty, other than herein setforth is made or authorized to be made by Gorman-Rupp.

In no event shall The Gorman-Rupp Company be liable for con-sequential damages or contingent liabilities arising out of the fail-ure of any Gorman-Rupp pump or parts thereof to operate prop-erly.

THE GORMAN-RUPP COMPANY

Mansfield, Ohio

NOTE: In Canada, all above references to The Gorman-RuppCompany, Mansfield, Ohio is understood to mean Gorman-Rupp of Canada Limited, St. Thomas, Ontario.

ECopyright by the Gorman-Rupp Company

Self Priming Pump

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