GORMAN-RUPP PUMPS PA Series Anwendungshandbuch

OM-06440-01

April 11, 2011

Rev. A 04‐03‐15

GORMAN‐RUPP PUMPS

www.grpumps.com

2011 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

PA SERIESPUMPS

MODELS

PA4A60C‐B‐E30 460/575/3

PA4A60C-B-(E30)

Gorman‐Rupp pump online at

www.grpumps.com

Valid serial number and e‐mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

spaces provided below. Your Gorman‐Rupp distributor

needs this information when you require parts or service.

Pump Model:

Serial Number:

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.............................................................

SUCTION AND DISCHARGE PIPING PAGE B - 3.........................................

Materials PAGE B - 3..............................................................

Line Configuration PAGE B - 3......................................................

Connections to Pump PAGE B - 3..................................................

Gauges PAGE B - 3...............................................................

SUCTION LINES PAGE B - 3...........................................................

Fittings PAGE B - 3...............................................................

Strainers PAGE B - 3..............................................................

Sealing PAGE B - 4...............................................................

Suction Lines In Sumps PAGE B - 4.................................................

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

DISCHARGE LINES PAGE B - 5........................................................

Siphoning PAGE B - 5.............................................................

Valves PAGE B - 5................................................................

ELECTRICAL CONNECTIONS PAGE B - 5...............................................

Grouding Methods PAGE B - 6.....................................................

Field Wiring Connections (Incoming Power) PAGE B - 6...............................

Voltage Imbalance PAGE B - 7.....................................................

Power Cable Connections PAGE B - 7...............................................

Control Box Adjustment PAGE B - 7.................................................

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

AUTO‐START PAGE B - 8.............................................................

Float Switch Installation PAGE B - 8.................................................

Submersible Transducer Installation PAGE B - 9......................................

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

STARTING AND OPERATION PAGE C - 1...............................................

Control Box Function PAGE C - 1...................................................

Component Function PAGE C - 1...................................................

Rotation PAGE C - 2..............................................................

Priming PAGE C - 2...............................................................

Leakage PAGE C - 2..............................................................

Pump Vacuum Check PAGE C - 3..................................................

Priming Chamber Discharge Line PAGE C - 3........................................

Liquid Temperature And Overheating PAGE C - 3.....................................

Strainer Check PAGE C - 3.........................................................

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

Manual Stopping PAGE C - 3.......................................................

TABLE OF CONTENTS

(continued)

Automatic Stopping PAGE C - 3....................................................

PERIODIC CHECKS PAGE C - 3.......................................................

Seal Cavity and Bearing Lubrication PAGE C - 3......................................

Bearing Temperature Check PAGE C - 3.............................................

Air Compressor Drive Belt PAGE C - 4...............................................

COLD WEATHER PRESERVATION PAGE C - 4...........................................

TROUBLESHOOTING - SECTION D PAGE D - 1..............................

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

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

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

PARTS LISTS:

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

Pump End Assembly PAGE E - 5...................................................

Repair Rotating Assembly PAGE E - 9...............................................

Priming Chamber Kit PAGE E - 10...................................................

Priming Chamber Assembly PAGE E - 11.............................................

Air Compressor Assembly PAGE E - 12...............................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 13.........................

Priming Chamber Removal And Disassembly PAGE C - 14..............................

Discharge Check Valve Removal and Disassembly PAGE C - 14.........................

Back Cover Plate and Wear Plate Removal PAGE C - 14................................

Separating Pump And Drive Assembly From Engine PAGE C - 14........................

Draining Oil From Seal Cavity PAGE C - 15............................................

Loosening Impeller PAGE C - 15.....................................................

Pump Casing Removal PAGE C - 15.................................................

Impeller Removal PAGE C - 16......................................................

Seal Removal PAGE C - 16..........................................................

Shaft and Bearing Removal and Disassembly PAGE C - 16.............................

Shaft and Bearing Reassembly and Installation PAGE C - 17............................

Seal Reassembly and Installation PAGE C - 18........................................

Impeller Installation And Adjustment PAGE C - 20......................................

Pump Casing Installation PAGE C - 20................................................

Securing Pump End To Power Source PAGE C - 20....................................

Wear Plate and Back Cover Installation And Adjustment PAGE C - 20....................

Discharge Check Valve Reassembly And Installation PAGE C - 21.......................

Priming Chamber Assembly And Installation PAGE C - 22...............................

LUBRICATION PAGE C - 22.............................................................

Seal Assembly PAGE C - 22.........................................................

Bearings PAGE C - 22..............................................................

PA SERIES OM-06440

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.

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.

If there are any questions regarding the pump or

its application which are not covered in this man

ual or in other literature accompanying this unit,

please contact your Gorman‐Rupp distributor, or

The Gorman‐Rupp Company:

The 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

power source, contact the power source manufac

turer's local dealer or representative.

HAZARD AND INSTRUCTION

DEFINITIONS

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL result in

severe personal injury or death. These

instructions describe the procedure re

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

Hazards or unsafe practices which COULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi

ble damage which could result from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

PA SERIES OM-06440

PAGE A - 1SAFETY

SAFETY ‐ SECTION A

This information applies to Prime Airr

Series pumps. Refer to the manual ac

companying the engine or power

source before attempting to begin oper

ation.

This manual will alert personnel to

known procedures which require spe

cial attention, to those which could

damage equipment, and to those which

could be dangerous to personnel. How

ever, this manual cannot possibly antici

pate and provide detailed instructions

and precautions for every situation that

might occur during maintenance of the

unit. Therefore, it is the responsibility of

the owner/maintenance personnel to

ensure that only safe, established main

tenance procedures are used, and that

any procedures not addressed in this

manual are performed only after estab

lishing that neither personal safety nor

pump integrity are compromised by

such practices.

Before attempting to install, operate, or

wire the pump control box, familiarize

yourself with this manual, and with all

other literature shipped with the control

box. Unfamiliarity with all aspects of

control operation covered in this manu

al could lead to destruction of equip

ment, injury, or death to personnel.

Before connecting any cable to the con

trol box, be sure to ground the control

box. See Section B for suggested

grounding methods.

The control box provides overload pro

tection and power control. Do not con

nect the pump motor directly to the in

coming power lines. If the power circuit

breaker or overload relay is tripped dur

ing operation, correct the problem be

fore resetting or replacing.

The electrical power used to operate the

pump control box is high enough to

cause injury or death. Obtain the ser

vices of a qualified electrician to make

all electrical connections. Make certain

that the enclosure is properly

grounded; never use gas pipe as an

electrical ground. Be sure that the in

coming power matches the voltage and

phase of the control before connecting

the power source. Do not make electri

cal connections if the voltage is not

within the limits. If the overload unit is

tripped during operation, correct the

problem before restarting.

The electrical power used to operate the

pump control box is high enough to

cause injury or death. Make certain that

the control handle on the control box is

in the OFF position and locked out be

fore attempting to service the pump. Be

fore attempting to open or service the

control box, disconnect and/or lock out

the power supply to the control box. Tag

electrical circuits to prevent accidental

start‐up.

PA SERIESOM-06440

PAGE A - 2 SAFETY

Obtain the services of a qualified elec

trician to troubleshoot, test and/or ser

vice the electrical components of the

control box.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Lock out the power from the con

trol box to ensure that the pump

will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature before

opening any covers, plates, or

plugs.

5. Close the suction and discharge

valves.

6. Vent the pump slowly and cau

tiously.

7. Drain the pump.

This pump may be equipped with an op

tional automatic starting system, and

therefore subject to automatic restart.

Keep hands and clothing away from the

unit to prevent injury during automatic

operation. Lock out the power from the

control box to ensure that the pump will

remain inoperative. Failure to do so

may result in serious personal injury.

Do not attempt to disengage any part of

an overheated pump unit. Vapor pres

sure within the pump casing can eject

these parts with great force when they

are disengaged. Allow the pump to

completely cool before servicing it.

This pump is designed to handle most

non‐volatile, non‐flammable liquids

containing specified entrained solids.

Do not attempt to pump volatile, corro

sive, or flammable liquids which may

damage the pump or endanger person

nel as a result of pump failure.

Death or serious personal injury and

damage to the pump or components

can occur if proper lifting procedures

are not observed. Make certain that

hoists, chains, slings or cables are in

good working condition and of suffi

cient capacity and that they are posi

tioned so that loads will be balanced

and the pump or components will not be

damaged when lifting. Suction and dis

charge hoses and piping must be re

moved from the pump before lifting. Lift

the pump or component only as high as

necessary and keep personnel away

from suspended objects.

After the pump has been installed, make

certain that the pump and all piping or

hose connections are tight, properly

supported and secure before operation.

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

PA SERIES OM-06440

PAGE A - 3SAFETY

discharge valve is acceptable only

when required for startup or shutdown

procedures.

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.

Do not operate the pump without guards

in place over the rotating parts. Ex

posed rotating parts can catch clothing,

fingers or tools, causing severe injury to

personnel.

Pumps and related equipment must be in

stalled and operated according to all na

tional, local and industry standards.

Make sure the pump is level. Lower jack

stands and chock the wheels, if so

equipped.

PA SERIES OM-06440

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 positioned

above the free level of liquid to be pumped.

If installed in a flooded suction application where

the liquid is supplied to the pump under pressure,

some of the information such as mounting, line

configuration, and priming must be tailored to the

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.

Pump Dimensions

See Figure 1 for the approximate physical dimen

sions of this pump.

OUTLINE DRAWING

Figure 1. Pump Model PA4A60C-B-E30 460/575/3

OM-06440 PA SERIES

PAGE B - 2 INSTALLATION

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. Compare the amperes, phase, voltage and

hertz indicated on the pump motor nameplate

to the ratings indicated for the control box.

d. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated. Note that the pump shaft rotates in

the required direction.

Only operate this pump in the direction in

dicated by the arrow on the pump body

and on the accompanying decal. Other

wise, the impeller could become loosened

from the shaft and seriously damage the

pump.

e. Check levels and lubricate as necessary. Re

fer to LUBRICATION in the Maintenance and

Repair Manual and perform duties as in

structed.

f. If the pump has been stored for more than 12

months, some of the components or lubri

cants may have exceeded their maximum

shelf life. These must be inspected or re

placed to ensure maximum 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.

POSITIONING PUMP

Use lifting and moving equipment in

good repair and with adequate capacity

to prevent injuries to personnel or dam

age to equipment. Attach lifting equip

ment to the lifting device fitted to the

pump. If chains or cable are wrapped

around the pump to lift it, make certain

that they are positioned so as not to

damage the pump, and so that the load

will be balanced. The bail is intended for

use in lifting the pump assembly only.

Suction and discharge hoses and pip

ing must be removed from the pump be

fore lifting.

Lifting

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.

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.

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