Rotek U-3 User manual

INSTALLATION, OPERATION
ANDMAINTENANCEMANUAL
WITHPARTSLIST
SPP -UPUMP
MODEL
U-3

1
TABLEOFCONTENTS
INTRODUCTION............................................................................... Pg. 03
WARNING –SECTION.................................................................... Pg. 04
INSTALLATION–SECTIONB......................................................... Pg. 05
PumpDimensions............................................................ Pg. 05
PREINSTALLATIONINSPECTION........................................
Pg. 06
POSITIONING PUMP............................................................ Pg. 06
Lifting................................................................................ Pg. 06
Mounting...........................................................................
Pg. 06
Clearance......................................................................... Pg. 06
SUCTIONAND DISCHARGEPIPING.................................. Pg. 06
Materials........................................................................... Pg. 06
LineConfiguration............................................................ Pg. 07
ConnectionstoPump....................................................... Pg. 07
Gauges............................................................................. Pg. 07
SUCTIONLINES................................................................... Pg. 07
Fittings.............................................................................. Pg. 07
Strainers........................................................................... Pg. 07
Sealing..............................................................................
Pg. 07
Suction LinesinSumps.................................................... Pg. 07
Suction LinesPositioning................................................. Pg. 08
DISCHARGELINES.............................................................. Pg. 08
Siphoning..........................................................................
Pg. 08
Valves...............................................................................
Pg. 08
Bypass Lines.....................................................................
Pg. 09
AUTOMATICAIRRELEASE VALVE..................................... Pg. 10
Theoryof Operation..........................................................
Pg. 10
AirReleaseValveInstallation...........................................
Pg. 10
ALIGNMENT.......................................................................... Pg. 11
Coupled Drivers................................................................
Pg. 12
V-Belt Drives.....................................................................
Pg. 12
OPERATION–SECTIONC............................................................... Pg. 14
PRIMING................................................................................ Pg. 14
STARTING............................................................................. Pg. 14
Rotation............................................................................ Pg. 14
OPERATION.......................................................................... Pg. 15
LinesWithaBypass......................................................... Pg. 15
LinesWithout aBypass.................................................... Pg. 15
Leakage............................................................................
Pg. 15
LiquidsTemperatureand Overheating............................. Pg. 15
StrainerCheck..................................................................
Pg. 16
PumpVacuumCheck.......................................................
Pg. 16
STOPPING............................................................................. Pg. 16
ColdWeatherPreservation...............................................
Pg. 16
BEARING TEMPERATURECHECK......................................
Pg. 16

2
TABLEOFCONTENTS
(Continued)
TROUBLESHOOTING –SECTIOND……………………….. Pg. 18
PUMPMAINTENANCEAND REPAIR–SECTIONE……… Pg. 21
PERFORMANCECURVE……………………………………… Pg. 21
PumpModel…………………………………………………...... Pg. 22
PARTSLISTS..................................................................
Pg. 23
RepairRotating Assembly………………………………….......
Pg. 24
PARTSLISTS..................................................................
Pg. 25
PUMPAND SEALDISASSEMBLYAND REASSEMBLY…. Pg. 26
Back Coverand WearPlateRemoval…………………….Pg. 26
Suction Check ValveRemoval……………………………..
Pg. 26
Rotating AssemblyRemoval………………………………..
Pg. 26
ImpellerRemoval…………………………………………….
Pg. 27
SealRemoval……………………………………………… Pg. 28
Shaft and Bearing RemovalandDisassembly……………
Pg. 28
Shaft and Bearing ReassemblyandInstallation………….
Pg. 29
SealandInstallation…………………………..................... Pg. 30
ImpellerInstallation………………………………………….Pg. 32
Rotating AssemblyInstallation……….…………………… Pg. 32
Suction Check ValveInstallation………………………….. Pg. 33
Back CoverInstallation……………………………………...
Pg. 33
PRESSURERELIEFVALVE MAINTENANCEPg. 33
FinalPumpAssemblyPg. 34
LUBRIFICATION Pg. 34
SealAssemblyPg. 34
Bearings Pg. 34
PowerSource Pg. 34

3
INTRODUCTION
If thereareanyquestionsregardingthepumporitsapplicationswhicha
renotcovered inthismanualorinother
literatureaccompanyingthisunit, pleasecontact yourRotekdistributor, orwrite:
ROTEKHANDELSGMBH
Handelsstrasse4
2201 Hagenbrunn, Austria
[e-mail] http://www.rotek.at
Tel.:[phone]Fax.:[phone]
Forinformationortechnicalassistanceonthepowersource,contactthepowersourcemanufacture’sl
ocal
dealerorrepresentative.
Thefollowingareusedtoalertmaintenancepersonneltoprocedureswhichrequirespecialattention,tothose
whichcoulddamageequipment, andtothosewhichcouldbedangeroustopersonnel:
ThisInstallation,Operation,and
Maintenancemanualisdesignedtohelp
yougetthebestperformanceand longest
lifefromRotek.
ThispumpisaUSeries,semi-open
impeller,selfprimingcentrifugalmodelwith
asuctioncheck valve.
The pumpisdesignedforhandlingmild
industrialcorrosives,mudorslurries
containinglargeentrainedsolids.Thebasic
materialofconstructionisgrayiron,with
ductileironimpellerand steelwearingparts.
DANGER!
ImmediatehazardswhichWILL resultin
severepersonalinjuryordeath.These
instructionsdescribetheprocedurerequired
and theinjurywhichwillresultfromfailure
tofollowprocedure.
CAUTION!
HazardsorunsafepracticeswhichCOULD
resultinminorpersonalinjuryorproductor
propertydamage.These instructionsdescribe
therequirementsandthepossibledamage
whichcouldresultfromfailuretofollowthe
procedure
.
NOTE
Instructionstoaidininstallation,operation,
and maintenanceorwhichclarifyaprocedure.

4
SAFETY–SECTIONA
ThesewarningsapplytoUseriesbasicpumps.
Rotekhasnocontroloverorparticularknowledge
ofthepowersourcewhichwill beused.Referto
themanualaccompanying thepowersource
beforeattemptingtobeginoperation.
WARNING!
Afterthepumphasbeenpositioned,make
certainthatthepumpandall piping
connectionsaretight,properlysupportedand
securebeforeoperation.
WARNING!
Donotoperatethepumpwithouttheguardsin
place overtherotating parts.
Exposedrotating partscancatchclothing,
fingers,ortools,causing severeinjuryto
personnel.
WARNING!
Donotoperatethepumpagainstaclosed
dischargevalveforlong periodsoftime.If
operatedagainstacloseddischargevalve,pump
componentswill deteriorate,and theliquidcould
cometoaboil,pressure,and causethepump
casing toruptureorexplode.
WARNING!
Beforeattemptingtoopenorservice the
pump:
1.Familiarizeyourselfwiththismanual.
1.
2.Disconnectorlockoutthepowersourceto
ensurethatthepumpwillremaininoperative.
2.
3. Allowthepumptocoolifoverheated.
3.
4.Checkthetemperaturebeforeopening any
covers, plates, orplugs.
4.
5. Closethesuction and dischargevalves.
5.
6. Ventthepumpslowlyand cautiously.
6.
7. Drainthepump
WARNING!
Thispumpisdesignedtohandlemild
industrialcorrosives,mud orslurries
containing largeentrainedsolids.Donot
attempttopumpvolatile,corrosive,or
flammablematerialswihchmaydamagethe
pumporendangerpersonnelasresultof
pumpfailure.
WARNING!
Donotremoveplates,covers,gauges,pipe
plugs,orfittingsfromanoverheatedpump.
Vaporpressurewithinthepumpcancauseparts
being disengagedtobeejectedwithgreatforce.
Allowthepumptocoolbeforeservicing.
WARNING!
Uselifting and moving equipmentingood repair
and withadequatecapacitytopreventinjuriesto
personnelordamagetoequipment.Suction and
dischargehosesand piping mustberemoved
formthebeforelifting

5
INSTALLATION–SECCTIONB
OUTLINEDRAWING
DIMENSIONS:INCHES
(MILIMETERS)
Figure1. PumpModel U-3
Reviewall SAFETYinformationinSectionA.
Sincepumpinstallationsareseldomidentical,this
sectionoffersonlygeneralrecommendationsand
practicesrequiredtoinspect, position andarrange
thepumpandpiping.
Mostoftheinformationpertainstoastandard
staticlift application wherethepumpis
positioned abovethe levelofliquidtobepumped.
Ifinstalledina floodedsuction application
wheretheliquidissupplied tothe pumpunder
pressure,someofthe information suchas
mounting,lineconfiguration,and primingmustbe
tailoredtothespecificapplication.
Sincethepressuresuppliedtothepumpiscriticalto
performanceand safety, be sure tolimitincoming
pressureto 50% ofthemaximpermissibleoperating
pressureasshownonthepumpperformancecurve.
Forfurtherassistance,contactyourRotek
distributorortheRotekfactory.
PumpDimensions
SeeFigure1fortheapproximatephysical
dimensionsof thispump.

6
PREINSTALLATIONINSPECTION POSITIONING PUMP
Thepumpassemblywasinspectedand tested
beforefromthe factory. Beforeinstallation, inspect
thepumpfordamage whichmayhaveoccurred
duringshipment.Check asfollows:
a.inspectthepumpforcracks,dents,
damagedthreads,andotherobvious
damage.
b.Checkforandtighten looseattaching
hardware.Sincegasketstendtoshrink
afterdrying,check forloosehardwareat
matingsurfaces.
c.Carefullyread all warningsandcautions
contained inthismanualoraffixedtothe
pump,andperform all dutiesindicated.
Notethe directionofrotationindicatedon
the pump.Check thatthe pumpshaft
rotatescounterclockwisewhenfacingthe
back coverplateassembly/impellerendof
thepump.
Lifting
Useliftingequipmentwithacapacityofatleast
2500pounds(1134Kg).Thispumpweighs
approximately 500 pounds(222Kg), notincluding
the weightofaccessoriesand base.Customer
installedequipmentsuchassuctionand discharge
piping must be removedbeforeattemptingtolift.
CAUTION!
Thepumpassemblycanbeseriously
damagedifthecablesorchainsusedtolift
and movetheunitareimproperlywrapped
around thepump.
CAUTION!
Onlyoperatethispumpinthedirection
indicatebythearrowonthepumpbodyand
on theaccompanying decal.Referto
ROTATION inOPERATION, Section C.
d.Checklevelsand lubricateas
necessary.RefertoLUBRICATION inthe
MAINTENANCEANDREPAIR section of
thismanualandperformdutiesas
instructed.
e.Ifthepumpand powersource have
beenstoredformorethan12months,
someofthecomponentsorlubricantsmay
haveexceededtheirmaximumshelflife.
Thesemustbeinspectedorreplaced to
ensuremaximumpumpservice.
Ifthemaximumshelflifehasbeenexceeded,
orifanything appearstobeabnormal,contact
yourRotek distributororthefactoryto
determinetherepairorupdating policy. Donot
putthepumpintoservice untilappropriate
action hasbeentaken.
Mounting
Locatethepumpinan accessibleplaceascloseas
practicaltotheliquidbeing pumped. Levelmounting
isessentialforproperoperation.
The pumpmayhavetobe supportedorshimmed to
provideforleveloperationortoeliminatevibration.
Clearance
When positioningthepump,allowaminimum
clearanceof 31inches(800mm) infrontoftheback
covertopermitremovalofthecoverandeasy
accesstothepumpinterior.
SUCTIONAND DISCHARGEPIPING
Pumpperformanceisadverselyeffected by
increasesuctionlift, discharge elevation.Andfriction
losses.Seetheperformancecurveandoperating
rangeshownon Page21tobesureyouroverall
applicationallowspumptooperatewithinthesafe
operationrange.
Materials
Eitherpipeorhosemaybeusedforsuctionand
discharge lines:however,the materialsmustbe
compatiblewithliquidbeingpumped.

7
Ifhoseisusedinsuctionlines,itmustbethe
rigid-wall,reinforced typetopreventcollapse
undersuction.Usingpipingcouplingsinsuction
linesisnot recommended.
LineConfiguration
Keepsuctionanddischarge linesasstraightas
possibletominimizefrictionlosses.Make
minimumuseofelbowsandfittings,which
substantiallyincreasefrictionloss.Ifelbowsare
necessary,usethe longradiustypetominimize
friction loss.
ConnectionstoPump
Beforetighteningaconnectingflange,alignit
exactlywiththepumpport.Neverpull apipeline
intoplacebytightening the flange boltsand/or
couplings.
Linesnearthepumpmustbeindependently
supportedtoavoidstrainonthepumpwhich
couldcauseexcessivevibration,decrease
bearinglife,andincreasedshaftandsealwear.
Ifhose-typelinesareused,theyshouldhave
adequatesupporttosecurethemwhen filled
withliquidandunderpressure.
Gauges
Mostpumpsaredrilled andtapped forinstalling
discharge pressureandvacuumsuction gauges.
Ifthesegaugesaredesiredforpumpsthatare
nottapped,drill andtapthesuctionand
discharge linesnotless than18inches
(457,2mm) fromthesuction and dischargeports
andinstall thelines.Installationclosertothe
pumpmayresultinerraticreadings.
SUCTIONLINES
Toavoidairpocketswhichcouldaffectpump
priming,thesuctionlinemustbeasshortand
directaspossible.When operation involvesa
suctionlift,thelinemustalways slopeupwardto
thepumpfromthesourceofthe liquidbeing
pumped:ifthelineslopesdowntothe pumpat
anypointalongthe suctionrun,airpocketswill
be created.
Fittings
Suctionlinesshouldbethesamesizeasthepump
inlet. If reducersareusedinsuctionlines, theyshould
bethe eccentrictype,andshouldbeinstalledwiththe
flatpartofthe reducersuppermosttoavoidcreating
airpockets.Valvesarenotnormallyusedinsuction
lines,butifavalveisused,installitwiththehorizontal
toavoidairpockets.
Strainers
Ifastrainerisfurnishedwiththepump,becertainto
useit;anysphericalsolidswhichpassthrougha
strainerfurnished withthepumpwill alsopass
throughthe pumpitself.
Ifastrainerisnotfurnished withthe pump,butis
installed bythepumpuser,makecertainthatthetotal
areaof theopeningsinthestrainerisatleastthreeor
fourtimesthe cross sectionofthesuctionline,and
thattheopeningswill notpermitpassage ofsolids
largerthanthesolidshandlingcapabilityofthepump.
Thispumpisdesigned tohandleupto3/4inch(19
mm) diametersphericalsolids.
Sealing
Sinceeven aslightleakwill affectpriming,head,and
capacity,especiallywhen operatingwithahigh
suctionlift,all connectionsinthesuctionlineshould
besealedwithpipe dopetoensureanairtightseal.
Followthe sealantmanufacturer’srecommendations
whenselectingandapplying thepipe dope.The pipe
dope shouldbecompatiblewiththe liquidbeing
pumped.
SuctionLines inSumps
Ifasinglesuctionline isinstalledinasump,itshould
bepositionedawayfromthewallofthesumpata
distanceequalto1½timesthe diameterofthe
suctionline.
Ifthereisaliquidflowfromanopen pipe intothe
sump,theflowshouldbe keptawayfromthesuction
inletbecausetheinflowwill carryairdownintothe
sump,andairenteringthe suctionlinewill reduce
pumpefficiency.

8
VELOCITY(FT./SEC.)=QUANT. (G.P.M)x.321 ORG.P.M. x4085
AREAD²
VELOCITY(M./SEC.)=FLOW(M./MIN)x21.22 ORFLOW(M³/SEC.)
DIAMETERINMM²AREAINM²
Figure2. RecommendedMinimumSuction LineSubmergencevs. Velocity
If itisnecessarytopositioninflowclosetothe suction
inlet, install abafflebetween theinflowandthein
suctionlines,itmustbetherigid-wall,reinforced type
topreventcollapseundersuction.Usingpiping
couplingsinsuctionlinesisnotrecommended.
Suctioninletatadistance1½timesthediameterof
the suction pipe.The bafflewill allowentrainedairto
escape fromtheliquidbeforeitisdrawnintothe
suctioninlet.
Iftwosuctionlinesareinstalled asinglesump,the
flowpathsmayinteract, reducingthe efficiency ofone
orbothpumps.Toavoidthis,positionthesuction
inletssothattheyareseparatedbyadistanceequal
toat least3timesthediameterof the suction pipe.
Suction LinePositionin
g
The depthofsubmergenceofthesuction lineis
criticaltoefficientpumpoperation.Figure2shows
Recommendedminimumsubmergencevs. velocity.
NOTE
Thepipesubmergencerequiredmaybereduced
byinstallingastandardpipeincreaserfittingat
theend ofthesuction line.Thelargeropening
sizewill reducetheinletvelocity.Calculatethe
requiredsubmergence using thefollowing
formulabasedon theincreasedopening size
(areaordiameter).
DISCHARGELINES
Siphoning
Donotterminatethedischargelineatalevellower
thanofthe liquidbeingpumped unless asiphon
breakerisusedintheline.Otherwise,asiphoning
actioncausing damagetothepumpcouldresult.
Valves
Ifathrottlingvalveisdesiredinthe discharge line,
useavalveaslarge asthelargestpipetominimize
frictionlosses.Neverinstall athrottlingvalveina
suctionline.
Withhighdischargeheads,itisrecommendedthata
throttling valveand asystemcheck valvebeinstalled
inthe dischargelinetoprotectthepumpfrom
excessiveshockpressureandreverserotationwhen
it isstopped.

9
In
high dischargeheadapplications
(morethan
30 feet),anexcessiveamountofliquidmaybe
bypassedandforcedback tothewetwell under
the full working pressureofthepump;thiswill
reduceoverall pumpingefficiency. Therefore,itis
recommendedthataRotekAutomaticAir
ReleaseValvebeinstalledinthebypass line.
RotekAutomaticAirReleaseValvesarereliable,
andrequireminimummaintenance.See
AUTOMATICAIRRELEASE VALVE inthis
sectionforinstallationand theoryofoperationof
the AutomaticAirReleaseValve. Contact Rotekfor
selectionofanAutomaticAirReleaseValvetofit
yourapplication.
Iftheinstallationinvolvesafloodedsuctionsuchas
below-ground liftstation.Apipeunionandmanual
shut-offvalvemaybe installed inthebleed lineto
allowserviceof thevalvewithout shuttingdownthe
station,andtoeliminatethepossibilityofflooding.
Ifamanualshut-off valveisinstalledanywherein
the airreleasepiping,itmustbeafull-openingball
typevalvetopreventplugging bysolids.
DANGER!
Ifamanualshut-off valveisinstalledina
bypass line,itmustnotbeleft closedduring
operation.Aclosedmanualshut-offvalvemay
causeapumpwhichhaslostprimetocontinue
tooperatewithoutreaching prime,causing
dangerousoverheating andpossibleexplosive
ruptureofthepumpcasing.Personnelcould
beseverelyinjured.
Allowanover-heatedpumptocoolbefore
servicing.Donotremoveplates,covers,
gauges,orfittingsfromanoverheatedpump.
Liquidwithinthepumpcanreachboiling
temperatures,andvaporpressurewithinthe
pumpcancausepartsbeing disengagedtobe
ejectedwithgreatforce.Afterthepumpcools,
draintheliquidfromthepumpbyremoving the
casing drainplug.Usecaution whenremoving
theplug topreventinjurytopersonnelfromhot
liquid.
CAUTION!
Iftheapplication involvesahighdischargehead,
graduallyclosethe dischargethrottlingvalvebefore
stoppingthepump.
Bypass Lines
Self-primingpumpsarenotaircompressors.During
theprimingcycle,airfromthesuctionlinemustbe
vented toatmosphereon the dischargeside.Ifthe
dischargelineisopen,thisairacheck valvehas
been installedinthedischargeline,thedischarge
sideofthepumpmustbe openedtoatmospheric
pressurethrough abypass lineinstalledbetween
thepumpdischargeanthecheckvalve.Aself-
priming centrifugalpump willnotprime ifthereis
sufficientstaticliquidheadtoholdthedischarge
checkvalveclosed.
NOTE
Thebypass lineshouldbesizedsothatitdoes
notaffectpumpdischargecapacity;however,
thebypass lineshouldbeatleast1inchin
diametertominimizethechance ofplugging.
In lowdischargeheadapplications (less than30
feet or9meters), it isrecommendedthat the bypass
line berun back tothe wetwell, andlocate6inches
belowthe waterlevelorcut-offpointofthelevel
pump.Insomeinstallations,thisbypasslinemaybe
terminatedwithasix-to-eight footlengthof1¼inch
ID. smooth-bore hose;airand liquidventedduring
theprimingprocesswill then agitatethehoseand
breakup anysolids,grease,orothersubstances
likelytocauseclogging.
CAUTION!
Abypasslinethatisreturnedtoawetwell must
besecuredagainstbeing drawnintothepump
suction inlet.
Itisalsorecommended thatpipeunionsbe installed
ateac
h90ºelbowinabypass linetoease
disassemblyandmaintenance.