OM-06012-02
April 16, 2007
Rev. D 08‐10‐20
GORMAN‐RUPP PUMPS
www.grpumps.com
2002 Gorman‐Rupp Pumps
Printed in U.S.A.
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
ULTRA V PUMP
MODEL
VS3A60-B
INCLUDING: /WW
Страница 1: ... 02 April 16 2007 Rev D 08 10 20 GORMAN RUPP PUMPS www grpumps com 2002 Gorman Rupp Pumps Printed in U S A INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST ULTRA V PUMP MODEL VS3A60 B INCLUDING WW ...
Страница 2: ...erial number and e mail address required RECORD YOUR PUMP MODEL AND SERIAL NUMBER Please record your pump model and serial number in the spaces provided below Your Gorman Rupp distributor needs this information when you require parts or service Pump Model Serial Number ...
Страница 3: ... LINES PAGE B 4 Siphoning PAGE B 4 Valves PAGE B 4 Bypass Lines PAGE B 4 AUTOMATIC AIR RELEASE VALVE PAGE B 5 Air Release Valve Installation PAGE B 6 DRIVE ARRANGEMENTS PAGE B 7 Dual Motor Drives PAGE B 7 Single Motor Belt Drives PAGE B 7 Single Motor Combination Drives PAGE B 8 HIGH PUMP TEMPERATURE SHUTDOWN FOR STAGED APPLICATIONS PAGE B 9 ALIGNMENT PAGE B 9 Coupled Drives PAGE B 9 Drive Belts P...
Страница 4: ...E 10 Support Plate Removal PAGE E 11 Back Cover And Wear Plate Removal PAGE E 11 Rotating Assembly Removal PAGE E 11 Impeller Removal PAGE E 12 Seal Removal PAGE E 12 Shaft and Bearing Removal and Disassembly PAGE E 13 Pump Casing and Transition Chamber Removal PAGE E 14 Pump Casing and Transition Chamber Installation PAGE E 14 Shaft and Bearing Reassembly and Installation PAGE E 14 Seal Installat...
Страница 5: ...power source contact the power source manufac turer s local dealer or representative If there are any questions regarding the pump or its application which are not covered in this man ual or in other literature accompanying this unit please contact your Gorman Rupp distributor or The Gorman Rupp Company P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or Gorman Rupp of Canada Limited 70 B...
Страница 6: ...on and discharge valves 6 Vent the pump slowly and cau tiously 7 Drain the pump This pump is designed to handle liquids containing large entrained solids or slurries Do not attempt to pump vola tile corrosive or flammable materials which may damage the pump or endan ger personnel as a result of pump fail ure After the pump has been positioned make certain that the pump and all pip ing connections ...
Страница 7: ...nel away from suspended objects Do not install a suction check valve in the first stage of the VS Series pump model Installing a suction check valve in the first stage of the VS Series pump model can cause over pressurization of the first stage pump casing resulting in possible explosion of the pump and se rious injury or death to presonnel Do not attempt to disengage any part of an overheated pum...
Страница 8: ... 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 Only operate this pump in the...
Страница 9: ...es 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 ...
Страница 10: ... 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 suctio...
Страница 11: ...ne 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 Bypass Lines Self priming pumps are not air compressors D...
Страница 12: ...ation If the installation involves a flooded suction such as a below ground lift station a pipe union and manu al shut off valve may be installed in the bleed line to allow service of the valve without shutting down the station and to eliminate the possibility of flooding If a manual shut off valve is installed anywhere in the air release piping it must be a full opening ball type valve to prevent...
Страница 13: ...to escape through the Air Release Valve When air in the sys tem is purged pressure opens the second dis charge check valve for full operation When the liquid level in the sump lowers enough to de activate the automatic liquid level device and stop the pumps the first discharge check valve closes and creates an air tight seal thus maintain ing liquid in the pump casing and suction line to al low th...
Страница 14: ...arrangements for staged pumps Consult the factory for information regard ing your specific application Dual Motor Drives It is recommended that each pump be directly driv en by its own electric motor either through cou plings see Figure 3 or a belt arrangement see Figure 4 Each motor should be independently operated through a reduced voltage solid state RVSS start er a variable frequency drive VFD...
Страница 15: ...n certain arrangements must be used in order to ensure proper operation Figure 6 shows a recommended alternate single motor combination drive arrangement where the first stage pump shaft is direct coupled to the motor and the second stage pump shaft is driven by belts and an idler located between the two shafts In this arrangement shaft and or bearing loads are shared between the two pumps Figure ...
Страница 16: ...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 must be ch...
Страница 17: ...LIGNED SHAFTS NOT IN LINE ALIGNED SHAFTS PARALLEL AND SHEAVES IN LINE Figure 11 Alignment of V Belt Driven Pumps Tighten the belts in accordance with the belt manu facturer s instructions If the belts are too loose they will slip if the belts are too tight there will be excessive power loss and possible bearing failure Select pulleys that will match the proper speed ra tio overspeeding the pump ma...
Страница 18: ...ime 2 The pump has not been used for a consider able length of time 3 The liquid in the pump casing has evapo rated Once the pump casing has been filled the pump will prime and reprime as necessary After filling the pump casing reinstall and tighten the fill plug Do not attempt to operate the pump unless all connect ing piping is securely installed Other wise liquid in the pump forced out under pr...
Страница 19: ... flow rate Do not operate the pump against a closed discharge throttling valve for long periods of time If operated against a closed discharge throttling valve pump components will deteriorate and the liquid could come to a boil build pressure and cause the pump casing to rupture or explode Leakage No leakage should be visible at pump mating sur faces or at pump connections or fittings Keep all li...
Страница 20: ...n air leak exists Before checking for the source of the leak check the point of installation of the vacuum gauge STOPPING Never halt the flow of liquid suddenly If the liquid being pumped is stopped abruptly damaging shock waves can be transmitted to the pump and piping system Close all connecting valves slowly If the application involves a high discharge head gradually close the discharge throttl...
Страница 21: ...g temperature is a warning that the bearings are at the point of failing to operate properly Make certain that the bearing lubricant is of the proper viscosity and at the cor rect level see LUBRICATION in MAINTENANCE AND REPAIR Bearing overheating can also be caused by shaft misalignment and or excessive vi bration When pumps are first started the bearings may seem to run at temperatures above nor...
Страница 22: ...MP FAILS TO PRIME Suction check valve contaminated or damaged Clean or replace check valve Air leak in suction line Lining of suction hose collapsed Correct leak Replace suction hose Leaking or worn seal or pump gasket Check pump vacuum Replace leaking or worn seal or gasket Suction lift or discharge head too high Check piping installation and in stall bypass line if needed See INSTALLATION Strain...
Страница 23: ...ck Dilute if possible Bearing s frozen Disassemble pump and check bearing s Liquid solution too thick Dilute if possible Discharge flow too slow Open discharge valve fully to in crease flow rate and run power source at maximum governed speed Suction check valve or foot valve clogged or binding Clean valve PUMP STOPS OR FAILS TO DELIVER RATED FLOW OR PRESSURE Strainer clogged Check strainer and cle...
Страница 24: ...duty cycle the part can be checked and replaced before failure occurs reducing unscheduled down time For new applications a first inspection of wearing parts at 250 hours will give insight into the wear rate for your particular application Subsequent inspec tions should be performed at the intervals shown on the chart below Critical applications should be inspected more frequently General Conditio...
Страница 25: ...e seldom identical your performance may be differ ent due to such factors as viscosity specific gravity elevation temperature and impeller trim If your pump serial number is followed by an N your pump is NOT a standard production model Contact the Gorman Rupp Company to verify per formance or part numbers Pump speed and operating condition points must be within the continuous per formance range sh...
Страница 26: ...OM 06012 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 2 PARTSPAGE ILLUSTRATION Figure 1 Pump Model VS3A60 B Including WW ...
Страница 27: ... 38687 060 1 8 LOCK WASHER J10 15991 4 9 HEX HD CAPSCREW B1007 15991 4 NOT SHOWN LUBRICATION DECAL 38817 084 2 G R DECAL GR 03 1 ULTRA V DECAL 38816 342 1 ROTATION DECAL 2613M 2 INSTRUCTION TAG 38817 023 1 WARNING DECAL 2613FE 2 DISCHARGE STICKER 6588BJ 1 PRIMING STICKER 6588AH 1 SUCTION STICKER 6588AG 1 INSTRUCTION TAG 38817 011 1 SMART SCROLL DECAL 38816 251 1 OPTIONAL STAGED FLANGE KITS 4 X 3 N...
Страница 28: ...TRA V SERIES MAINTENANCE REPAIR PAGE E 4 ILLUSTRATION 9 32 12 33 2 6 13 31 30 11 17 28 28 8 20 20 34 34 4 27 16 14 3 26 7 7 12 21 10 29 1 25 24 5 15 23 9 18 19 6 22 Figure 2 Pump Assemblies 46146 037 and 46146 038 ...
Страница 29: ...46 621 17040 1 26 LOCK WASHER J05 15991 4 27 HEX HEAD CAP SCREW B0504 15991 4 28 SQUARE HEAD BOLT A1014 15991 2 29 FILL PORT COVER ASSY 42111 437 1 FILL PORT GASKET 50G 19210 1 WARNING PLATE 38816 097 13990 1 DRIVE SCREW BM 04 03 17000 2 30 CLAMP BAR 38111 004 11010 1 31 HEX HEAD CAP SCREW B1010S 15991 1 32 HEX HEAD CAP SCREW B0806 15991 4 33 SPACER 33221 022 17040 4 34 PIPE PLUG P08 15079 2 NOT S...
Страница 30: ...OM 06012 ULTRA V SERIES MAINTENANCE REPAIR PAGE E 6 ILLUSTRATION 3 4 3 4 3 4 21 25 20 7 10 24 1 5 6 9 23 22 2 3 16 13 12 11 7 9 17 19 14 18 10 8 7 15 Figure 3 46146 065 Ultra Mate Pump Assembly ...
Страница 31: ... 15000 4 15 LOCK COLLAR 38115 551 15001 4 16 ADJUSTING SCREW 31871 070 1500G 4 17 HIGH PRESS CPLATE ASSY 42111 831 1 WARNING PLATE 2613EV 13990 1 DRIVE SCREW BM 04 03 17000 4 PRESS RELIEF VALVE 26662 007 1 WARNING DECAL 38816 302 1 18 O RING 25152 273 1 19 WEAR PLATE ASSEMBLY 46451 758 24150 1 20 STUD C1213 15991 4 21 HEX HEAD CAP SCREW B0606 15991 11 22 O RING 25152 277 1 23 O RING 25152 273 1 24...
Страница 32: ...14 13 15 28 1 2 3 4 5 31 26 27 3 SEAL AREA DETAIL Ç ÇÇ ÇÇ ÇÇ ÇÇ Ç ÇÇ ÇÇ ÇÇ ÇÇ Ç Ç Ç ÇÇ ÇÇ ÇÇÇÇÇÇ ÇÇ Ç Ç Ç Ç Ç ÇÇ ÇÇ ÇÇÇÇÇÇ ÇÇÇ Ç ÇÇ ÇÇ ÇÇ ÇÇ Ç Ç Ç Ç Ç Ç ÇÇ ÇÇ ÇÇ ÇÇ Ç Ç Ï Ï ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÏÏÏÏÏ ÇÇ ÇÇ ÇÇ ÇÇ Ì Ì 2 ÑÑÑ ÑÑÑ ÑÑÑ ÏÏÏ ÏÏÏ ÏÏÏ ÌÌÌÌÌÌ ÌÌÌÌÌÌ ÌÌÌÌÌÌ Ñ Ñ Ï Ï ÑÑÑ ÑÑÑ ÑÑÑ ÇÇÇÇ ÇÇÇÇ 7 Figure 4 Repair Rotating Assemblies ...
Страница 33: ...79 1 14 SIGHT GAUGE S1471 2 15 PIPE PLUG P04 15079 2 16 HEX HEAD CAP SCREW B0605 15991 4 17 LOCK WASHER J06 15991 4 18 BEARING CAP 38322 220 10000 1 19 GASKET 38683 271 18000 1 20 RETAINING RING S442 1 21 BALL BEARING S375 1 22 SHAFT KEY N0608 15990 1 23 IMPELLER SHAFT 38514 827 1706H 1 24 BALL BEARING S1088 1 25 O RING 25154 022 REF 26 IMPELLER WASHER 31167 029 16000 1 27 IMPELLER SCREW F1004S 15...
Страница 34: ...tions assume complete disassem bly is required Before attempting to service the pump disconnect or lock out the power source and take precautions to ensure that it will remain inoperative Close all valves in the suction and discharge lines For power source disassembly and repair consult the literature supplied with the power source or contact your local power source representative Before attemptin...
Страница 35: ...Removal Figure 2 The wear plate 5 is easily accessible and may be serviced by removing the back cover assembly 10 Before attempting to service the pump re move the pump casing drain plug 4 and drain the pump Clean and reinstall the drain plug Remove the back cover nuts 15 and pry the back cover and assembled wear plate from the pump casing 1 NOTE An alternate method of removing the back cover from...
Страница 36: ... inch pipe schedule 80 steel or malleable iron and a standard tee see Figure 6 All threads are 1 2 inch NPT Do not pre assemble the tool TEE APPROX 6 IN 152 MM LONG APPROX 14 IN 356 MM LONG Figure 6 Rotating Assembly Tool To install the tool remove the vented plug 10 Fig ure 4 from the bearing housing and screw the longest length of pipe into the vent hole until fully engaged Install the tee and s...
Страница 37: ...seals 6 from the bearing hous ing After removing the shaft and bearings clean and inspect the bearings in place as follows To prevent damage during removal from the shaft it is recommended that bearings be cleaned and inspected in place It is strongly recommended that the bearings be replaced any time the shaft and bear ings are removed Clean the bearing housing shaft and all compo nent parts exce...
Страница 38: ...g and O ring 22 from the transi tion chamber If the transition chamber requires removal from the Ultra V first stage pump support the chamber us ing a suitable hoist and sling See Figure 1 and re move the mounting hardware 8 and 9 Use the hoist and sling to remove the transition chamber Remove the gasket 7 Pump Casing and Transition Chamber Installa tion Ultra Mate Second Stage Model Only Figure 1...
Страница 39: ...d to cool check to ensure that they have not moved away from the shaft shoulders in shrinking If movement has occurred use a suitably sized sleeve and a press to reposition the bearings against the shaft shoulders If heating the bearings is not practical use a suit ably sized sleeve and an arbor or hydraulic press to install the bearings on the shaft When installing the bearings onto the shaft nev...
Страница 40: ...realigned during reassembly Reusing an old seal could result in prema ture failure The seal is not normally reused because wear pat terns on the finished faces cannot be realigned during reassembly This could result in premature failure If necessary to reuse an old seal in an emer gency carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly Inspect the seal compone...
Страница 41: ...an the O D of the shaft Slide the tube over the shaft threads then slide the O ring off the tube and onto the shaft Remove the tube and continue to slide the O ring down the shaft until it seats against the shaft shoulder When installing a new cartridge seal assembly remove the seal from the container and remove the mylar storage tabs if so equipped from be tween the seal faces Some cartridge seal...
Страница 42: ...nd Adjustment If necessary to reuse an old seal in an emer gency carefully separate the rotating and station ary seal faces from the bellows retainer and sta tionary seat A new seal assembly should be installed any time the old seal is removed from the pump Wear patterns on the finished faces cannot be realigned during reassembly Reusing an old seal could result in prema ture failure Handle the se...
Страница 43: ... to 1 02 mm between the impeller and the seal plate is recom mended for maximum pump efficiency Measure this clearance and add or remove impeller adjust ing shims as required Proceed with Rotating Assembly Installation be fore installing the impeller capscrew and washer 26 and 27 The rotating assembly must be in stalled in the pump casing in order to torque the im peller capscrew After the rotatin...
Страница 44: ...screws Use the collars to turn the adjusting screws clockwise until the holes in the locking collars realign with the tapped screw holes in the back cover plate Secure the locking collars to the back cover plate with the hardware 12 and 14 Install the two remaining back cover nuts snugly against the adjusting screws Remove the first two back cover nuts from their studs Turn the adjusting screws cl...
Страница 45: ...in it at the middle of the gauge Clean and reinstall the vented plug Maintain the oil at this level NOTE The white reflector in the sight gauge must be posi tioned horizontally to provide proper drainage Bearings Figure 4 The bearing housing was fully lubricated when shipped from the factory Check the oil level regu larly through the bearing cavity oil level sight gauge 14 and maintain it at the m...
Страница 46: ...For Warranty Information Please Visit www grpumps com warranty or call U S 419 755 1280 Canada 519 631 2870 International 1 419 755 1352 GORMAN RUPP PUMPS ...
