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.

10
The valvewill remainclosed,reducing the bypass
ofliquidto1to5gallons(3.8to19 liters)per
minute,until thepumplosesitsprimeorstops.
WARNING!
Someleakage(1to5gallons[3.8to19liters]per
minute)willoccurwhenthevalveisfullyclosed.
Besurethebypass lineisdirectedbacktothe
wetwellortanktopreventhazardousspills.
When thepumpshutsdown,thespring returnsthe
diaphragmtoitsoriginalposition.Anysolidsthat
mayhaveaccumulated inthe diaphragmchamber
settletothe bottomandareflushedoutduringthe
nextprimingcycle.
NOTE
Thevalvewill remainopenifthepumpdoesnot
reachitsdesignedcapacityorhead.Valve
closing pressureisdependentupon the
dischargeheadofthepumpatfullcapacity.The
rangeofthevalveclosing pressureis
establishedbythetension rateofthespring as
orderedfromthefactory.Valveclosing pressure
canbefurtheradjustedtotheexactsystem
requirementsbymoving thespring retaining pin
up ordowntheplungerrodtoincreaseor
decreasetension on thespring.Contactyour
Rotek distributororRotekFactoryfor
information aboutanAutomaticAirRelease
Valveforyourspecificapplication.
AirRelease Valveinstallation
The AutomaticAirReleaseValvemustbe
independentlymounted inahorizontalpositionand
connectedtothedischargelineoftheself-priming
centrifugalpump(seeFigure5).
NOTE
IftheAirReleaseValveistobeinstalledona
stagedpumpapplication,contactthefactoryfor
specificinstallation instructions.
AUTOMATICAIRRELEASE VALVE
Whenproperlyinstalled andcorrectlyadjustedtothe
specifichydraulicoperatingconditionsofthe
application, theRotekAutomaticAirReleaseValvewill
permitairtoescape throughthe bypass line,andthen
closeautomaticallywhen thepumpisfullyprimedand
pumpingat full capacity.
TheoryofOperation
Figures3and4showacross-sectionalviewofthe
AutomaticAirReleaseValve,andacorresponding
descriptionof operation.
Figure3. ValveinOpenPosition
During the priming cycle,airfromthepumpcasing
flowsthrough thebypass line,andpassesthroughthe
AirReleasevalvetothe wet well (Figure3).
Figure4. ValveinClosedPosition
Whenthepumpisfullyprimed, pressureresulting from
flowagainstthe valvediaphragmcompressesthe
spring and closesthevalve(Figure4).

11
Figure5.TypicalAutomaticAirRelease ValveInstallation
The valveinletmustbeinstalledbetweenthepump
dischargeportandthenon-pressurizedsideofthe
discharge check valve.The valveinletisitatthe
large endofthe valvebody,and isprovided with
standard1-inchNPTpipethreads.
The valveoutletislocatedatthe oppositeend ofthe
valve,andisalsoequippedwithstandard1-inchNPT
pipethreads.Theoutletshouldbe connectedtoa
bleedline whichslopesbacktothe wetwell orsump.
Thebleedline mustbethesamesizeastheinlet
piping,orlarger.Ifpipingisused forthebleedline,
avoidthe useof elbowswheneverpossible.
NOTE
ItisrecommendedthateachAirReleaseValvebe
fittedwithanindependentbleederlinedirected
backtothewetwell.However,ifmultipleair
ReleaseValvesareinstalledinasystem,the
bleederlinesmay bedirectedtoacommon
manifoldpipe.ContactyourRotekdistributoror
theRotekfactoryforinformationabout
installation ofanAutomaticAirReleaseValve for
yourspecificapplication.
ALIGNMENT
The alignmentofthe pumpand itspowersourceis
criticalfortrouble-freemechanicaloperation.In
eitheraflexiblecoupling orV-belt drivensystem, the
driverandpumpmustbemounted sothattheir
shaftsarealigned withandparalleltoeachother.It
isimperativethatalignmentbe checkedafterthe
pumpand piping areinstalled, andbeforeoperation.
NOTE
Check Rotation,SectionC,beforealignmentofthe
pump.
WhenmountedattheRotekfactory,driverand
pumparealignedbeforeshipment.Misalignment
will occurintransitandhandling.Pumpsmustbe
checkingalignment,tightenthefoundationbolts.
Thepumpcasingfeetand/orpedestalfeet,andthe
drivermounting boltsshouldalsobetightlysecured.
SUCTION
LINE
WETWELLORSUMP
BLEEDLINE1"
(25,4MM)DIA. MIN.
(CUSTOMER
FURNISHED)
EXTEND6"
(152,4MM)
BELOW LIQUID
LEVELSURFACE
90 LONG
RADIUS
ELBOW
°
INSTALL AIRRELEASE VALVE
INHORIZONTALPOSITION
CLEAN-OUT
COVER DISCHARGEPIPE
DISCHARGEPIPE
SUPPORT
BRACKET
SELF-PRINING
CENTRIFUGAL
PUMP
DRAINLINE

12
Figure6A. AligningSpider–TypeCouplings
F
Figure6B. AligningNon-SpiderTypeCouplings
WARNING!
When checkingalignment,disconnect thepowersource
toensurethat thepumpwill remaininoperative.
CAUTION!
Adjustingthealignmentinone directionmayalterthe
alignmentinanotherdirection.Check eachprocedure
afteralteringalignment.
CoupledDrives
Whenusingcouplings, theaxisofthepowersource
mustbealignedtheaxisofthe pumpshaft inboth
the horizontalandverticalplanes.Mostcouplings
requireaspecificgap orclearancebetweenthe
driving andthedrivensh
afts.Refertothecoupling
manufacturer’sserviceliterature.
Align spiderinserttype couplingsbyusing calipers
tomeasurethedimensionsonthecircumferenceof
theouterendsofthecouplinghub every90
degrees.Thecouplingisinalignmentwhenth
ehub
endsarethesamedistanceapartatall points(see
Figure6A).
Align non-spidertype couplingsbyusingafeeler
gaugeortapergaugebetweenthecouplinghalves
every90degrees.Thecouplingisinalignmentwhen
thehubsarethe samedistanceapartatall points
(see Figure6B).
Checkparalleladjustmentbylayingastraightedge
acrossbothcouplingrimsatthetop,bottom,and
side.Whenthe straightedge restsevenlyonboth
halvesofthecoupling,thecouplingisinhorizontal
parallelalignment. Ifthe couplingismisaligned usea
feelergaugebetweenthecouplingandthe
straightedgetomeasuretheamountofmisalignment.
V-BeltDrives
WhenusingV-beltdrives,the powersourceandthe
pumpmustbeparallel.Useastraightedgealongthe
sidesofthepulleys toensurethatthe pulleysare
properlyaligned(seeFigure6C).Indrivesystems
using twoprmorebelts,makecertainthatthe belts
areamatched set;unmatchedsetswill cause
accelerated belt wear.

13
MISALIGNED:SHAFTSMISALIGNED:SHAFTSALIGNED:SHAFTSPARALLEL
NOTPARALLELNOTINLINEANDSHEAVES INLINE
Figure6C. AlignmentofV-BeltDrivenPumps
F
Tighten the beltsinaccordancewiththe belt
manufacturer’sinstructions.Ifthebeltsaretoo loose,
theywill slip;ifthebeltsaretootight,therewill be
excessivepowerloss and
possiblebearing failure.
Selectpulleysthatwill matchthe properspeedratio;
overspeedingthepumpmaydamagebothpumpand
powersource.
DANGER!
Donotoperatethepumpwithouttheguardin
place overtherotating parts.Exposedrotating
partscancatchclothing,fingers,ortools,
causing severeinjurytopersonnel.

14
OPERATION –SECTIONC
ReviewallSAFETYinformation inSection A.
Followinstructionsonalltags,labelsanddecals
attached tothepump.
WARNING!
Thispumpisdesignedtohandlemild
industrialcorrosives,mud orslurries
containing largeentrainedsolids.Donot
attempttopumpvolatile;corrosive,or
flammableliquidswhichmaydamagethe
pumporendangerpersonnelasaresultof
pumpfailure.
CAUTION!
Pumpspeedandoperating conditionsmustbe
withintheperformance rangeshownon page
21.
PRIMING
Install thepumpandpipingasdescribe in
INSTALLATION.Makesurethatthepiping
connectionsaretight,andthatthepumpis
securelymounted.Check thatthe pumpis
properlylubricated(see LUBRICATION in
MAINTENANCEAND REPAIR).
Thispumpisself-priming,butthepumpshould
neverbe operated unlessthereisliquidinthe
pumpcasing.
CAUTION!
Neveroperatethispumpunless thereisliquid
inthepumpcasing.Thepumpwillnotprime
whendry.Extendoperation ofadrypumpwill
destroythesealassembly.
Add liquidtothepumpcasing when:
1.The pumpisbeing putintoserviceforthe
firsttime.
2.The pumphasnotbeenused fora
considerablelengthof time.
3.Theliquidinthepumpcasinghas
evaporated.
Oncethe pumpcasinghasbeenfilled, the pump
will primeandreprimeasnecessary.
WARNING!
Afterfilling thepumpcasing,reinstalland
tightenthefill plug.Donotattempttooperate
thepumpunless all connecting piping is
securelyinstalled.Otherwise,liquidinthe
pumpforcedoutunderpressurecouldcause
injurytopersonnel.
Tofill thepump,removethepumpcasingfill cover
orfill pluginthe topofthecasing,and addclean
liquiduntil the casingisfilled.Replacethefill cover
orfill plugbeforeoperatingthe pump.
STARTING
Consulttheoperationsmanualfurnishedwiththe
powersource.
Rotation
The correctdirectionofpumprotationis
counterclockwisewhenfacingthe impeller.The
pumpcouldbedamaged andperformance
adverselyaffectedbyincorrectrotation.Ifpump
performanceisnotwithinthe specifiedlimits(see
thecurveonpage 21),check thedirectionof
powersourcerotationbeforefurther
troubleshooting.
Ifanelectricmotorisused todrivethepump,
removeV-belts,couplings,orotherwisedisconnect
the pumpfromthemotorbeforecheckingmotor
rotation.Operatethemotorindependentlywhile
observingthedirection ofthemotorshaft,or
coolingfan.

15
Ifrotation isincorrectonathree-phasemotor,
haveaqualified electricianinterchangeanyofthe
Phasewirestochange direction.Ifrotationis
incorrecton asingle-phasemotor,consultthe
literaturesuppliedwiththemotorforspecific
instructions.
OPERATION
LinesWithaBypass
IfaRotekAutomaticAirReleaseValvehasbeen
installed, thevalvewill automaticallyopen toallow
thepumptoprime,andautomaticallycloseafter
priming iscomplete(see INSTALLATION forAir
ReleaseValveoperation.
Lines WithoutaBypass
Open all valvesinthedischargeline andstartthe
powersource.Priming isindicatedbyapositive
readingon the othedischargepressuregauge or
byaquieteroperation.Thepumpmaynotprime
immediatelybecausethesuctionlinemustfirstfill
withliquid.Ifthe pumpfailstoprimewithinfive
minutes,stopitandcheckthesuctionlinefor
leaks.
Afterthepumphasbeenprimed,partiallyclose
thedischargelinethrottlingvalveinordertofill the
line slowlyandguardagainstexcessiveshock
pressurewhichcoulddamage pipeends,gaskets,
sprinklerheads,andanyotherfixturesconnected
totheline.Whenthedischargeline iscompletely
filled,adjustthethrottlingvalvetotherequired
flowrate.
WARNING!
Donotoperatethepumpagainstaclosed
dischargethrottling valveforlong periodsof
time.Ifoperatedagainstacloseddischarge
throttling valve,pumpcomponentswill
deteriorate,and theliquidcouldcometoa
boil,buildpressure,and causethepump
casing toruptureorexplode.
Leakage
Noleakageshouldbevisibleatpumpmating
surfaces,oratpumpconnectionsorfittings.Keep
all lineconnectionsandfittingstighttomaintain
maximumpumpefficiency.
LiquidTemperatureAndOverheating
The maximum liquidtemperatureforthispumpis
160ºF(71ºC).Donot applyit at ahigheroperating
temperature.
Overheating canoccurifoperatedwiththe valves
inthesuctionordischargelinesclosed.Operating
againstclosedvalvescouldbring the liquidtoa
boil, buildpressure,andcausethepumptorupture
orexplode.Ifoverheatingoccurs,stopthepump
andallowittocoolbeforeservicingit.Refill the
pumpcasing withcoolliquid.
DANGER!
Allowanover-heathpumptocoolbefore
servicing.Donotremoveplates,covers,
gauges,orfittingsfromanoverheatedpump.
Liquidwithinthepumpcanreachboiling
temperatures,andvaporpressurewithinthe
pumpcancausepartsbeing disengagedtobe
ejected,withgreatforce.Afterthepumpcools,
draintheliquidfromthepumpbyremoving the
casing drainplug.Usecaution whenremoving
theplug topreventinjurytopersonnelfromhot
liquid.
Assafeguardagainstruptureorexplosiondueto
heat,thispumpisequippedwithapressurerelief
valvewhichwill openifvaporpressurewithinthe
pumpcasingreachesacriticalpoint. If overheating
doesoccur, stopthepumpimmediatelyandallowit
tocoolbeforeservicingit.Approachany
overheatedpumpcautiously.Itisrecommended
thatthepressurereliefvalveassemblybereplaced
ateachoverhaul,oranytimethepumpcasing
overheatsand activatesthevalve.Neverreplace
thisvalvewithasubstitutewhichhasnotbeen
specified orprovided byRotek.

16
StrainerCheck
Ifssuctionstrainerhasbeenshippedwiththe
pumporinstalledbythe user,check thestrainer
regularly,and cleanitasnecessary.Thestrainer
shouldalsobecheckedifpumpflowratebegins
todrop.Ifavacuumsuction gauge hasbeen
installed,monitorandrecordthereadings
regularlytodetect strainerblockage.
Never introduceairorsteampressureintothe
pumpcasingorpipingtoremoveablockage.This
couldresultinpersonalinjuryordamage tothe
equipment.Ifback flushingisabsolutely
necessary,liquidpressure must be limitedto50%
ofthemaximumpermissibleoperatingpressure
showonthepumpperformancecurve.
PumpVacuumCheck
Withthepumpinoperative,install avacuum
gaugeinthesystem,usingpipedopeonthe
threads.Block thesuctionlineand startthepump.
Atoperatingspeed thepumpshouldpull a
vacuumof20inches(508,0mm) ormoreof
mercury.Ifitdoesnot, check forairleaks inthe
seal,gasket,ordischargevalve.
Openthesuctionline,andreadthevacuum
gaugewiththepumpprimedandatoperation
speed.Shutoff thepump.The vacuumgauge
reading will immediatelydropproportionateto
staticsuctionlift, and shouldthenstabilize.Ifthe
vacuumreading fallsoff rapidlyafterstabilization,
an airleakexists.Beforechecking forthesource
oftheleak,checkthe pointofinstallation ofthe
vacuumgauge.
STOPPING
Neverhalttheflowofliquidsuddenly.Iftheliquid
beingpumpedisstopped abruptly,damaging
shockwavescan be transmitted tothepumpand
pipingsystem. Closeall connectingvalvesslowly.
Onenginedrivenpumps,reducethethrottle
speed slowlyandallowthe enginetoidlebriefly
beforestopping.
CAUTION!
Iftheapplication involvesahigh discharge head,
graduallyclosethedischargethrottlingvalve
beforestopping thepump.
Afterstopping thepump,lock outordisconnectthe
powersourcetoensurethatthepumpwill remain
inoperative.
WARNING!
Donotoperatethepumpagainstaclosed
dischargethrottling valveforlong periodsof
time.Ifoperatedagainstacloseddischarge
throttling valve,pumpcomponentswill
deteriorate, and theliquidcouldcometoaboil,
buildpressure,and causethepumpcasing to
ruptureorexplode.
ColdWeatherPreservation
Inbelowfreezing conditions,drainthe pumpto
preventdamagefromfreezing.Also,clean outany
solidsbyflushingwithahose.Operatethepump
forapproximatelyone minute;thiswill removeany
remainingliquidthatcouldfreezethe pump
rotatingparts.If thepumpwill beidleformorethan
afewhours,orifithasbeenpumpingliquids
containing alargeamountofsolids,drainthe
pump,andflushitthoroughlywithcleanwater.To
preventlarge solidsfromclogging thedrainport
andpreventing the pumpfromcompletelydraining,
insertarodorstiff wireinthedrainport, and
agitatetheliquidduringthe drainingprocess.
Clean outanyremainingsolidsbyflushing witha
hose.
BEARING TEMPERATURECHECK
Bearingsnormallyrunathigherthanambient
temperaturesbecauseofheatgeneratedby
friction.Temperaturesupto160ºF(71ºC)are
considerednormalforbearings,andtheycan
operatesafelytoatleast180º F(82º C).

17
Checking bearingtemperaturesbyhandis
inaccurate.Bearing temperaturescanbe
measuredaccuratelybyplacingacontact-type
Thermometeragainstthe housing.Recordthis
temperatureforfuturereference.
Asuddenincreaseinbearingtemperatureisa
warningthatthebearingsareatthepoint offailing
tooperateproperly.Makecertainthatthebearing
lubricantisoftheproperviscosityandatthe
correctlevel(see LUBRICATION in
MAINTENANCEAND REPAIR).
Bearingoverheatingcanalsobecausedbyshaft
misalignmentand/orexcessivevibration.
Whenpumpsarefirststarted,the bearingsmay
seemtorun attemperaturesabovenormal.
Continuedoperationshouldbringthe temperatures
downtonormallevels.

18
TROUBLESHOOTING -SECTIOND
ReviewallSAFETYinformation inSection A.
TROUBLE POSSIBLECAUSE PROBABLEREMEDY
PUMPFAILS
TO PRIME Not enough liquidincasing.
Suction check valvecontaminated or
damaged.
Airleakinsuctionline.
Liningofsuctionhosecollapsed.
Leakingorwornsealorpumpgasket.
Suction lift ordischargehead toohigh.
Strainerclogged.
Addliquidtocasing.See PRIMING.
Cleanorreplacecheckvalve.
Correct leak.
ReplacesuctionHose.
Check pumpvacuum. Replaceleaking
Orwornsealorgasket.
Check piping installationandinstall bypass lineif
needed.See INSTALLATION.
Check strainerandclean if necessary.
WARNING!
Beforeattempting toopenorservice the
pump:
1.Familiarizeyourselfwiththismanual.
2.Lock outordisconnectthepower
source toensurethatthepumpwill
remaininoperative.
3.Allowthepumptocoolifoverheated.
4.Checkthetemperaturebeforeopening
anycovers, plates, orplugs.
5.Closethesuction and dischargevalves.
6.Ventthepumpslowlyand cautiously.
7.Drainthepump.

19
TROUBLE POSSIBLECAUSE PROBABLEREMEDY
PUMPSTOPSOR
FAILSTODELIVER
RATEDFLOWOR
PRESSURE
Airleakinsuctionline.
Liningofsuctionhosecollapsed.
Leakingorwornsealorpumpgasket.
Strainerclogged.
Suction intakenot submergedat
properlevelorsumptoosmall.
Impellerorotherwearing partswornor
damaged.
Impellerclogged.
Pumpspeedtooslow.
Dischargehead toohigh.
Suction lift too high.
Correct leak.
Replacesuctionhose.
Check pumpvacuum. Replaceleaking or
wornsealorgasket.
Check strainerandclean if necessary.
Check installationandcorrect submergence
asneeded.
Replacewornordamagedparts.Check
that impellerisproperlycenteredand
rotates.
Free impellerof debris.
Check driveroutput; checkbeltsorcouplings
forslippage.
Install bypassline.
Measurelift w/vacuumgauge.Reducelift
and/orfrictionlossesinsuctionline.
PUMPREQUIRES
TOO MUCH POWER Pumpspeedtoohigh
Dischargehead toolow.
Liquidsolution toothick.
Bearing(s)frozen.
Check driveroutput; check that sheavesor
motorrpmarecorrectlysized.
Adjust dischargevalve.
Diluteifpossible.
Disassemblepumpand check bearing(s).
PUMPCLOGS
FREQUENTLY Liquidsolution toothick.
Dischargeflowtoo slow.
Suction check valveorfootvalve
Cloggedorbinding.
Diluteifpossible.
Opendischargevalvefullytoincreaseflow
rate,and run powersourceatmaximum
governedspeed.
Cleanvalve.