5600Type1IOM

5600Type1IOM
07/31/2003
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL FOR ROPER®
5600 SERIES TYPE 1
PUMPS:
5638
5658
Roper Pump Company
PO Box 269
Commerce, Georgia 30529
USA
Telephone: (706) 335-5551
TeleFAX: (706) 335-5490
Email: [email protected]
Web: www.roperpumps.com
2003 Roper Pump Company
PART NO. G12-405
Section 1.0
TABLE OF CONTENTS
Section
Page
1.1
Nameplate Data ………………………………………………………… 1 - 1
1.2
Maximum Pump Ratings..…...………………………………………... 1 - 2
Page 1 – i
1.1
•
NAMEPLATE DATA
Roper Pump Company identifies each pump
manufactured by a metal nameplate
attached to the pump. This nameplate
describes the pump as built at the factory.
Copy the nameplate data from your pump in
the area provided below. Use this for ready
reference when ordering repair parts or when
consulting with Roper Pump Company or an
authorized distributor about this pump.
The second digit (6) indicates shaft
sealing.
6 − Packing
•
The third and fourth digits (58) indicate
the approximate theoretical displacement in US gallons per 100 revolutions.
Gallons/100 Rev. [Liters/100 Rev.]
38 [143.8]
58 [219.6]
FIGURE NUMBER:
•
SPEC NUMBER:
TYPE:
H
SERIAL NUMBER:
•
PUMP NOMENCLATURE
Pump with inboard bushing
The letter (F) indicates port style.
No letter − Pump with threaded ports
Example: 5658 HFL SPEC XXX
TYPE 1 SERIAL NO. ZZZ
F − Pump with ROPER® standard
flange ports
1. The FIGURE number consists of a
seven digit number.
•
The letter (H) indicates the pump
head arrangement.
•
The first digit (5) indicates the series.
The letter (L) indicates shaft position.
No letter − High Drive
L − Low Drive
Example:
5658*HFL SPEC XXX TY 1 S/N XXX
5
6
58
*
H
F
L
Shaft position
Port style
Pump head arrangement
Motor mounted unit *
Theoretical displacement
Shaft Sealing
Port arrangement
* The letter (M) may be used in this space indicating the pump is mounted with motor.
The letter (E) may be used in this space indicating the pump is mounted on a base
with or without engine.
Page 1 – 1
As stated in the explanation of the pump
nomenclature, all characters may not
appear on every pump nameplate.
1.2 MAXIMUM PUMP
RATINGS
NOTE: The preceding description of the
figure number is to assist in identifying your
ROPER® 5600 series pump only. DO NOT
attempt to derive any ratings or
performance from the figure number. DO
NOT use the explanation of the figure
number to construct your own pump. Not all
combinations are possible. For assistance
in pump selection, it is recommended that
you consult Roper Pump Company or an
authorized distributor.
The maximum pressure and speed limits for
this pump SERIES are shown below.
2. Occasionally, special pumps or
configurations are required which are
unique for a particular application.
These modifications are clarified by a
SPECification number. Identification of
any items different than a standard
pump can be made by consulting Roper
Pump Company or an authorized
distributor.
100 psi [689 kPa] Maximum Discharge
Pressure
3. The TYPE number is a number used by
Roper Pump Company for in-house
identification of construction and
hydraulics. Always include the type
number in any references to the pump.
4. The SERIAL number is a unique
number assigned to each pump built by
Roper Pump Company.
In any communication concerning this
pump, always by sure to include the Figure,
Spec, Type, and Serial numbers so proper
identification of the pump can be assured.
Page 1 – 2
The maximum rating of a pump with a
SPEC number may be lower depending on
the materials of construction.
Maximum limits for this SERIES:
100 psi [689 kPa] Maximum Inlet
Pressure
99 psi [683 kPa] Maximum
Differential Pressure
420 rpm Maximum Speed
Maximum Temperature Limits for standard
pumps (no spec number) are:
Packed Box Pumps: 160°F [71°C]
Section 2.0
TABLE OF CONTENTS
Section
2. 1
2. 2
Page
Introduction ……………………….……..…………………………….. 2 - 1
Safety Precautions …..………...……………………………………… 2 - 2
2. 3
Preoperation Checks…..………….…..…………..…………………… 2 - 3
2. 4
Preparation of Foundation…..………….……..……………………… 2 - 4
2. 5
Aligning Driver and Pump….………….……………………………… 2 - 5
2. 6
Additional Important Warnings and Information..….……..……… 2 - 9
2. 7
Installation of Pipes…..……….….……………………..…..………… 2 - 10
2. 8
Threaded Port Connections………………………..………………….2 - 11
2. 9
Checking Pump Performance…………………..……………………..2 - 12
2. 10
Replacement Parts…………………………………………….………...2 - 13
2. 11
Index ……………………….……………..………...……………..………2 - 14
Page 2 – i
2.1
INTRODUCTION
!
IMPORTANT
THIS MANUAL MUST ACCOMPANY THE
PUMP UPON ALL TRANSFERALS. MAKE
SURE THE OPERATOR OF THE
EQUIPMENT HAS READ AND
UNDERSTANDS THIS MANUAL BEFORE
OPERATING THE PUMP OR ANY RELATED
EQUIPMENT.
When properly selected, installed, operated,
and maintained, ROPER® pumps will provide
long, dependable service. Remember, faulty
selection and installation form the basis of
more pump troubles than all other causes
combined. No amount of maintenance can
compensate for selection and installation
mistakes. Read this manual carefully and
understand it totally before installing or
operating the pump which it accompanies.
This pump is satisfactory for its rated
conditions. Its operation beyond these
conditions may subject it to stresses and
strains that it is not designed to withstand.
Install ample coupling or belt guards for the
protection of personnel.
This manual will cover standard pumps and
most SPECification number pumps.
Appearance may vary among pumps and
construction may vary on spec. number
pumps. Specification numbers are assigned to
pumps with other than standard features.
Roper Pump Company produces specific
manuals for most standard line pump models.
Contact Roper Pump Company to find out if
the pump model you have has a specific
manual and to request a copy.
If there is any question concerning the ratings,
instructions, or compatibility of the pump with
the pumped liquid, consult an authorized
distributor or:
Roper Pump Company
PO Box 269
Commerce, Georgia 30529 USA
Telephone: (706) 335−5551
TeleFAX: (706) 335-5490
Email: [email protected]
Web: www.roperpumps.com
!
IMPORTANT
Read the following before starting the pump!
Failure to heed these warnings may result in
an accident causing physical damage, serious
personal injury, or death!
•
Read and understand all tags and
installation and operating instructions.
•
WARNING! Install proper guard(s). DO
NOT operate pump without guard(s)
installed, always use caution near rotating
parts including the drive system for the
pump. Serious injuries and death have
occurred from becoming entangled in
rotating shafts.
•
WARNING! DO NOT operate this
equipment in excess of its rated capacity,
pressure, speed, and temperature, or
other than according to the instructions
contained in this manual.
•
WARNING! Install and properly set
devices into the system to prevent the
chance of too much pressure, high
temperature, and driver overload. The
pump is not provided with these devices.
•
WARNING! Proper measures and
safeguards must be taken to avoid spillage
and overflow from overfilling or putting too
much pressure on any component of the
system. This includes the receiver and
lines.
•
Know the operating conditions.
•
Open all lines before starting pump.
This manual contains general information
concerning the use, inspection, adjustment,
and test of the pump furnished. For certain
applications and installations, other
precautions and safety measures may be
appropriate and are the responsibility of the
product installer and user. Users of this
pump must have ample knowledge and
training to apply sound safety and operating
practices that may not be mentioned in the
manual, and the sale of this pump is in
reliance on such user knowledge and
training.
Page 2 – 1
2.2
SAFETY PRECAUTIONS
WHEN LIQUID BEING PUMPED IS
HAZARDOUS OR VOLATILE, ALWAYS
TAKE FULL PRECAUTIONS. THIS
INCLUDES THE RUN-IN PERIOD AND
DURING DISASSEMBLY AND ASSEMBLY
OF PUMP.
Controls, guards, walkways, machine
arrangement, crew training, etc., are all
necessary factors in the creation of a safe,
practical installation and are generally not a
part of our services. It is the responsibility of
the contractor, installer, owner, and user to
add to the materials furnished by Roper Pump
Company to result in a safe installation and to
comply with OSHA, state and local laws, and
the ANSI/NFPA Life Safety Code.
There are many kinds of devices for pumps
and systems such that if one component in a
system is stopped, other equipment feeding or
following it also can be automatically stopped.
Serious thought should be given to the
installation of these types of devices in every
pump system.
•
•
•
DO NOT attempt to install, operate, or
perform maintenance on this equipment
without first reading and understanding the
material in this manual. Also, read and
understand all tags and any other
documentation accompanying the pump.
DO NOT operate this equipment in excess
of its rated capacity, pressure, speed, and
temperature, or other than according to the
instructions contained in this manual.
DO NOT continue to operate this
equipment if there is a failure of any part of
the equipment or system. Correct the
failure before operating the equipment.
•
DO NOT bypass safety controls or guards.
Their purpose is to protect and they must
be in proper working order.
•
DO NOT operate equipment without
proper guards in place.
•
DO NOT walk, stand, sit, or lean on
guards.
Page 2 – 2
•
DO NOT work on a pump while it is
operating or if there is a chance of the
driver becoming energized except to
adjust the relief valve.
•
DO NOT adjust packing while the pump is
operating or if there is a chance of the
driver becoming energized.
•
DO NOT adjust the integral relief valve
without coupling guards in place.
•
DO NOT place hands, feet, head, or any
other part of your body in any pump
opening while the pump can be operated.
•
DO NOT poke or prod material in the
pump.
•
DO NOT start to disassemble the pump if
there is the slightest chance of it becoming
energized by accident. Lock out the
energy source to the driver and disconnect
the coupling before performing
maintenance to the equipment.
•
DO NOT wear loose or dangling clothing
or jewelry near the equipment. It could
become caught and possibly cause
serious injury or death.
•
DO NOT use metallic or hard faced
striking tools when the need for tapping
parts into position arises. Hard faced
striking tools may damage parts or they
may fracture or chip and send particles
flying that could cause possible injury.
•
DO NOT allow spills to remain in the work
area. Clean up spills immediately. Oils,
greases, and other fluids used in the
equipment may create hazards if not
cleaned up immediately after a spill.
•
DO NOT spin bearings with compressed
air. This is highly dangerous and can
cause the bearing to fragment with
explosive force, possibly causing serious
injury or death.
•
DO NOT attempt to install, use, or repair
this equipment while under the influence of
any substance that may impair physical or
mental abilities. This includes, but is not
limited to, alcohol and prescription and
nonprescription drugs.
•
DO be aware of your location relative to
the equipment.
•
DO NOT dispose of fluoroelastomers by
burning. Toxic vapors are released by this
compound upon combustion.
•
•
DO NOT suspend pumps from the ports
unless they have been specifically
designed for this type of mounting.
DO wear proper clothing near the
equipment. Safety glasses or goggles, and
safety shoes are recommended. They will
help reduce the chance of injury.
•
DO use soft faced striking tools when the
need for tapping parts into position arises.
Rubber or plastic faced striking tools are
recommended.
•
DO practice good housekeeping. Clean up
spills immediately. Keep the work area
clean to avoid hazards. Always be sure of
your footing around the equipment to avoid
a possible fall and injury.
•
DO use proper tools. Avoid cheater bars
as they are a source for serious injury
should they slip or break.
•
DO mount pumps in the manner they were
designed to be mounted.
•
DO completely read and understand the
information contained in this manual. The
operator of the equipment must be familiar
with these instructions.
•
DO stop the pump in a manner that there
is no chance of the driver becoming
energized while any kind of work is being
performed on the pump or system.
•
DO always keep safety in mind.
•
DO know the operating conditions of the
equipment.
•
DO take proper measures and precautions
to avoid spillage and overflow from
overfilling or putting too much pressure on
any component of the system.
2.3 PREOPERATION CHECKS
DO identify all possible hazards and
decide what controls are needed.
Remember, only you understand your
product and system characteristics fully.
The ultimate responsibility for the
application and safety is with you.
Disconnect the coupling between the driver
and pump.
•
•
DO install and properly set devices into the
system to prevent the chance of dry
operation, overpressure, excessive
temperature, and driver overload.
•
DO provide guards for all exposed rotating
parts, including all parts of the drive
system, to prevent possible injury.
•
DO be careful when working near an
operating pump. Contacting or getting
caught in rotating parts may cause serious
or fatal injury.
•
DO keep equipment in good working
order, especially safety devices and
guards.
Read and understand the instructions and
recommendations contained in this manual.
Test the rotation of the driver to make sure it
will operate the pump in the desired direction
of rotation. Rotation is shown on the pump in
relation to the integral relief valve. When an
integral relief valve is used, make sure it is
positioned and adjusted as discussed in the
section titled, DIRECTION OF ROTATION
AND RELIEF VALVES. After the unit is
mounted and the piping is connected, the
pump should be checked to be sure it
operates freely without binding. After
operation is proved satisfactory, both pump
and driver should be tightly secured and the
alignment rechecked before operation.
Before starting, make sure all guards are in
place and the inlet and discharge valves are
opened. After starting the unit, check to see
that the pump is delivering liquid. If not, stop
Page 2 – 3
the driver immediately and refer to Section
2.9, CHECKING PUMP PERFORMANCE.
After the pump is delivering liquid, check the
unit for excessive vibration, localized heating,
and excessive shaft seal leakage. Check the
pressure or vacuum by installing gauges at
both the inlet and discharge sides of the pump
to make sure the pressure or vacuum conform
to specifications.
If there is no pressure relief device in the
system, NEVER block the discharge line. If
there is a relief valve in the system, NEVER
block the discharge line between the relief
valve and pump. High pressure will occur,
resulting in possible damage or breakage
to the pump or system parts and possible
injury to personnel. DO NOT operate the
pump for more than one minute with the
discharge line blocked downstream of the
relief valve. Rapid heating and possible
damage will occur. Even an open
discharge line does not prevent the
possibility of high pressure. Discharge line
length, diameter, and arrangement along
with fluid viscosity and velocity also can
create a high pressure situation at the
pump.
WARNING! DO NOT overpressurize pump or
system.
Page 2 – 4
2.4 PREPARATION OF
FOUNDATION
Locate the pump so that it is as low and as
close to the fluid source as practical and so
that piping to and from the pump will be as
short and simple as practical. The pump and
its driver must be accessible for inspection
and maintenance. Accessibility to the unit and
adequate clearance should be a major thought
in any installation. The driver must be suitable
for the environment (for example; open,
splash proof, totally enclosed, or explosion
proof electric motor). If the driver is not
suitable, choose a different location or obtain
another driver.
For best pump-driver unit life, mount each unit
on a strong, fabricated, structural steel
baseplate with a proper foundation. A good
foundation is of major importance to the total
installation. A thick, heavy concrete foundation
is best since it is heavy enough to support the
baseplate rigidly and absorb strain and shock.
Locate anchor bolts for the baseplate in the
foundation. Use a pipe sleeve, two to three
times as large as the anchor bolts, around the
anchor bolts to allow some lateral bolt
movement during final positioning of the unit.
Place the unit, with the pump and driver
mounted on the baseplate, on the foundation
and disconnect the coupling (flexible coupling,
belts, and sheaves, etc.). DO NOT reconnect
the coupling unit until all alignment operations
are complete. Support the baseplate on
rectangular metal blocks and shims or on
metal wedges having a small taper. Place the
support pieces close to the anchor bolts and
directly under the part of the baseplate
carrying the greatest weight. Space the
support pieces close enough to give uniform
support. Allow a gap of about 3/4 inch [19 mm]
to 1-1/2 inches [38mm] between the
foundation and baseplate for grouting. Refer
to Fig. 2.4.1.
Adjust the metal supports or wedges until the
shafts of the pump and driver are level. At this
time, check the faces of the inlet and
discharge connections of the pump for
horizontal or vertical position using a level.
Correct the positions, if necessary, by
adjusting the supports or wedges under the
baseplate as required.
For maximum rigidity and lower noise levels,
grout the baseplate to the foundation. Use a
good grade of nonshrink grout. When all
alignments are correct (refer to Section 2.5,
ALIGNING DRIVER AND PUMP), tighten the
anchor bolts evenly but not too firmly. Then
grout the unit to the foundation. Completely fill
the baseplate with grout. It is desirable to
grout the leveling pieces, shims, or wedges in
place. Fill the spaces between the anchor
bolts and sleeves with grout, also. Allow the
grout to dry according to the manufacturer's
instructions. DO NOT fully tighten the anchor
bolts until the grout has hardened.
Normal mounting for this pump is horizontal
with the pump above the baseplate, properly
grouted to a concrete foundation placed in or
on solid earth. Mountings other than described
above (such as vertical mounting, wall
mounting, ceiling mounting, etc.) may require
special components and precautions. Extra
pump supports, special drivers, and extra
anchor bolts may be necessary in unusual
mountings. If your application requires other
than normal mounting, as described above,
you are urged to consult Roper Pump
Company for assistance in determining any
special needs that may be required.
2.5 ALIGNING DRIVER AND
PUMP
The flexible coupling or belts and sheaves
must be accurately realigned during and after
installation. Refer to the flexible coupling or
belt and sheave manufacturer's
recommendations and instructions for the
requirements for proper alignment. Also refer
to Section 2.4, PREPARATION OF
FOUNDATION, for additional information.
FLEXIBLE COUPLING
Fig. 2.4.1: Typical Baseplate Anchoring
After the grout has hardened and the anchor
bolts have been properly tightened, check the
unit for parallel and angular misalignment, and
if necessary, take corrective measures. After
the piping to the unit has been connected,
check the alignment again.
NOTE: Attempts to correct alignment in one
direction may alter the alignment in the other
direction. Therefore, it is necessary to check
alignment in all directions after making any
adjustments.
Schedule semiannual inspections and checks
of the foundation anchor bolts as part of a
preventive maintenance program. If loose
foundation bolts are found, tighten them and
check the unit alignment.
DO NOT use a flexible coupling to
compensate for misalignment of the driver and
pump shafts. The purpose of the flexible
coupling is to compensate for temperature
changes and to permit end movement of the
shafts without interference with each other
while transmitting power from the driver to the
pump.
The faces of the coupling halves should be
spaced far enough apart so that they cannot
strike each other when the driver rotor is
moved hard over toward the pump. The
necessary tools for approximate checking of
the alignment of a flexible coupling are a
straight edge and a taper gauge or a set of
feeler gauges.
Page 2 – 5
Make sure there is no chance of the driver
becoming energized while aligning driver
and pump. Getting caught in rotating parts
of the drive system will cause serious
personal injury or death. DO NOT start or
operate pump without guards in place.
WARNING! DO NOT operate without guards in
place.
There are two forms of misalignment between
the driver shaft and the pump shaft. The first is
angular misalignment, where the axes of the
shafts are concentric but not parallel. The
other is parallel misalignment, where the axes
of the shafts are parallel but not concentric.
Refer to Fig. 2.5.1.
Make the check for angular alignment by
inserting the taper gauge or feeler gauges
between the coupling faces and comparing
the distance between the faces at four points
spaced at 90° intervals around the coupling.
The unit will be in angular alignment when the
measurements show that the coupling faces
are the same distance apart at all points.
Page 2 – 6
Fig. 2.5.1 Misalignments: Top, Angular; Center,
Parallel; Bottom, Both.
Make the check for parallel alignment by
placing a straight edge across both coupling
halves at the top, bottom, and at both sides.
The unit will be in parallel alignment when the
straight edge rests evenly on the coupling
halves at all positions. Allowance may be
necessary for temperature changes and for
coupling halves that DO NOT have the same
outside diameter. Take care to have the
straight edge parallel to the axes of the shafts.
Correct angular and parallel misalignment by
placing shims under the mounting feet of the
equipment. After each change, it is necessary
to recheck the alignment of the coupling
halves. Adjustment in one direction may
disturb adjustments already made in another
direction.
BELTS AND SHEAVES
Some applications on gear pumps involving
low discharge pressure and slow speeds may
permit the mounting of the driven sheave
directly on the pump shaft. However, it is
recommended that all belt drive assemblies be
designed with a separate jackshaft mounted
on pillow blocks to carry the side loads of the
sheaves and belts and a flexible coupling
connecting the jackshaft to the pump shaft.
Make sure there is no chance of the driver
becoming energized while aligning and
adjusting the belts. Getting caught in
rotating parts of the drive system will
cause serious personal injury or death. DO
NOT start or operate pump without guards
in place.
Misalignment will cause undue belt wear, or
turn-over in the grooves. Approximate
alignment should be checked by placing a
long straight edge evenly across the rims of
both sheaves. If the faces of the sheaves are
not of equal width, the alignment may be
checked by resting the straight edge across
the rim of the widest sheave and measuring
the distance from the straight edge to the
nearest belt groove with a scale. Adjust either
sheave on the shaft to equalize these
dimensions.
The driver should be mounted with adequate
provision for belt center distance adjustment.
Provide a minus adjustment to permit belt
installation without stretching and a plus
allowance to provide belt take-up.
DO NOT pry, twist, or force the belts over the
sheave grooves. This will damage the belts
and greatly reduce the belt life. Shorten the
drive by moving the driver enough to permit
fitting the belts in the proper grooves. When
the belts are in place, increase the center
distance until proper belt tension is obtained.
Adjust take-up until only a slight bow appears
on the slack side of the drive when it is
operating. All the belts must be pulling evenly.
Belt tension should be reasonable. It is not
necessary to have belts excessively tight.
During the first few days of operation, the belts
will seat themselves in the sheave grooves.
After that, the drive must be adjusted to take
up the slack. Slipping belts will result in
lowered capacity. Squealing or smoking belts
are sometimes a clue to the slipping of belts.
WARNING! DO NOT operate without guards in
place.
The driver and pump shafts must be parallel,
and the belts at right angles to these shafts.
Keep belts clean and free from oil. Stop drive
to clean belts. DO NOT attempt to clean belts
while the drive is operating. Clean oily belts
with a cloth dampened with soap and water.
Never install new belts on the same drive with
used belts. DO NOT use sheaves with
chipped or worn grooves. For hazardous
locations, check to see if an antistatic belt
should be used. When purchasing
replacement belts, the same size and type
should be ordered as furnished originally.
Page 2 – 7
POWER TAKE-OFF DRIVE SYSTEMS
When mounting a pump on a vehicle with a
PTO drive, always check with the
manufacturer of the PTO equipment to
determine the alignment required for proper
operation of the PTO. The mount for the pump
must be rigid. The pump must be mounted the
way it was designed to be mounted. Pumps
with feet must be mounted by the feet. DO
NOT use the pump ports to mount a pump
that has feet. It is acceptable to mount a foot
mounted pump in the three, nine, or twelve
o'clock position as well as the standard six
o'clock position as long as proper shaft
alignment is maintained.
Make sure there is no chance of the driver
becoming energized while aligning the power
take-off shafting. Getting caught in a power
take-off drive system will cause serious
injury or death. Proper guarding must be
provided for all power take-off drive systems.
Unless properly designed, guarded, and
maintained, all drive systems are dangerous.
•
DO be careful near rotating PTO drive
systems. Contacting a PTO drive system
may cause serious injury or death.
•
DO install and maintain proper guard(s) for
PTO drive systems.
•
DO NOT operate PTO drive systems
without proper guards in place.
•
DO NOT work on or adjust a pump driven
by a PTO drive system while it is operating
or has a chance of the driver becoming
energized except as specified in the
section titled, DIRECTION OF ROTATION
AND RELIEF VALVES.
•
DO NOT work on a PTO drive system
while it may become energized.
•
DO NOT wear loose or dangling clothing
or jewelry near the equipment. It could
become caught and possible cause
serious injury or death.
GUARDING PTO DRIVE SHAFTS
PTO drive systems can be dangerous and
when used, additional safety precautions,
including guarding, may be required and must
be provided by the drive system installer.
Roper Pump Company has no responsibility
for recommending or providing proper
guarding or other safety measures in any
particular application.
WARNING! DO NOT operate without guards in
place.
Serious injuries and deaths have resulted from
persons becoming caught in power take-off
(PTO) drive systems. Loose or dangling
clothing and slippery or unsure footing are
factors in many PTO accidents. DO NOT work
on or adjust a pump driven by a PTO drive
system while it is operating or has a chance of
the driver becoming energized except as
specified in the section titled, DIRECTION OF
ROTATION and RELIEF VALVES.
Page 2 – 8
The installation of proper guards for the power
take-off and its associated equipment is the
responsibility of the drive system designer and
the installer who know the particular product
application and the user's exposure to danger.
The ultimate responsibility for the safe
application and installation is the user's.
SPECIAL PRECAUTIONS FOR HYDRAULIC
DRIVES
Avoid contact with high pressure fluids.
Check all hydraulic hoses.
Hydraulic hoses can fail due to physical
damage, kinks, age, and exposure. Check
hoses regularly. Replace damaged hoses.
2.6 ADDITIONAL
IMPORTANT WARNINGS AND
INFORMATION
•
This manual contains general information
concerning the use, inspection, adjustment,
testing, and safety considerations of the
pump furnished. Other precautions and
safety measures may be appropriate
depending on the particular application and
installation and are the responsibility of the
product installer and user. Installers and
users of this pump must have sufficient
knowledge and training to apply sound
safety and operating practices that may not
be mentioned in the manual, and the sale of
this pump is in reliance on such installer and
user knowledge and training.
•
ROPER® pumps are general purpose
pumps for a wide range of uses; yet, they
are not designed nor intended for use with
every known substance. Maximum ratings
are shown in the section titled, MAXIMUM
PUMP RATINGS. ROPER® sales
brochures contain standard ratings.
Ratings for SPECification number pumps
or standard pumps may be obtained by
contacting Roper Pump Company or an
authorized distributor.
•
Review this manual to determine the
proper union of the pump into the total
plant or system operating programs.
•
Roper Pump Company does not supply,
recommend, or approve the systems in
which its pumps are or may be used.
Unless designed, built, and used properly,
systems may be unsafe or dangerous.
Installers and users should check and
comply with all applicable federal, state,
local, and other regulations and
recommendations such as: NFPA, UL,
OSHA, API, etc.
WARNING! AVOID CONTACT with high
pressure fluids.
Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
lines. Tighten all connections before
applying pressure. Search for leaks with a
piece of cardboard. Protect hands and
body from high pressure fluids.
If an accident occurs, see a doctor
immediately. Any fluid injected into the
skin must be surgically removed within a
few hours or gangrene may result. Doctors
unfamiliar with this type injury should
reference a knowledgeable source.
An overload or kickdown valve in a
hydraulic drive system is NOT a safe
substitute for a pressure relief valve
correctly installed in the pump piping
system.
In particular, installers and users must check
the pumped liquid properties and take proper
precautions. Among other things, consider the
following:
•
Decide the results of spillage or leakage
(all pumps or systems may fail sometime).
Page 2 – 9
__Explosion
•
Install a pressure relieving device in the
system discharge piping to protect the
equipment and crew from accident due to
too much pressure. NEVER place a
shutoff valve between the pump and
system relief valve. Read Section 2.3,
PREOPERATION CHECKS.
•
Spillage or overflow, from overfilling or
putting too much pressure on any
component of a system incorporating this
pump, may result in an accident. Proper
measures and precautions must be taken
to avoid spillage or overflow from
overfilling or putting too much pressure on
any component of the system. This
includes the receiver and lines.
__Corrosion
__Chemical Burns
__High Pressure Spray
__Toxic Exposure
__Fire
__Exposure to Extreme Temperatures
__Environmental Impact
__System Impact
__Other
•
Are proper safeguards being used?
__Temperature Controls
__Pressure Controls
__Leak Detectors
__Shutoff Devices
__High or Low Pressure Safeguards
__Alarm Devices
__Overfill or Overflow Detection
__Driver Overload Controls
2.7 INSTALLATION OF PIPES
__Consider all possible methods and
series of failure.
•
__Are any other methods needed to
control a hazard?
DO NOT connect raised face flanges to
the ports of a cast iron pump.
•
DO use flat faced flanges with cast iron
pumps.
__Regular scheduled inspection for the
wear and tear of parts.
•
Prior to starting pump, read sections on
PREPARATION OF FOUNDATION;
ALIGNING DRIVER AND PUMP;
INSTALLATION OF PIPES; THREADED
PORT CONNECTIONS; and
PREOPERATION CHECKS.
Identify all possible hazards. Decide upon
and install the required controls. Only the
installer and user can fully understand the
product and system characteristics. The
ultimate responsibility for the safety of the
application and the system characteristics
is with the installer and user.
•
Particularly note the chance of fire and
burns from flammable or hot liquid spillage
from burst hoses and take proper
precautions.
•
Properly guard all exposed rotating parts
of the drive to the pump.
Page 2 – 10
Piping must be installed and checked
carefully. Allow for any expansion or
contraction.
Any external force or moment (torque or twist)
applied on the pump ports by the piping will
cause stresses in the pump and its foundation.
This may cause misalignment that could result
in hot bearings, worn couplings, or excessive
vibration. Such forces or moments may be
caused by improperly aligned piping or by
thermal expansion of the piping when
pumping hot or cold fluids. The piping should
be supported independently. Use flexible
piping connectors and insure that they are
properly anchored.
If an expansion joint is installed in the piping
between the pump and the nearest point of
anchor in the piping, a force equal to the area
of the expansion joint (which may be
considerably larger than the normal pipe size)
times the pressure in the pipe will be
transmitted directly to the pump. Pipe
couplings that DO NOT provide an axially rigid
connection have the same effect. This
reaction force can be so large that it would be
impractical to design suitable components to
withstand the force. If an expansion joint or
nonrigid coupling is used, install a pipe anchor
between it and the pump. If properly installed,
this will eliminate the forces mentioned above.
The pump port size does not necessarily
establish the correct pipe size. Piping must be
sized and arranged to provide ample inlet
pressure at the pump and to insure that the
discharge pressure will be at least as low as
the rated pressure of the pump. If the fluid to
be pumped is viscous, or the piping long, or
the suction lift or static discharge head
somewhat high, piping one or two sizes larger
may be required. Friction losses should be
carefully calculated (see Hydraulic Institute
Engineering Data Book or similar authority for
friction loss data) and compared to the pump
ratings before the installation is made. Where
valves are used in the piping system, gate,
ball, or butterfly valves are preferable to globe
or angle valves. 90° long radius elbows or 45°
elbows are preferable to standard short radius
elbows. NEVER place a valve between the
pump and system relief valve.
2.8 THREADED PORT
CONNECTIONS
American National Standard Taper Pipe
Threads (NPT) are standard for pipe plugs
and threaded ports of the pump ports. British
Standard Pipe Threads (BSP) are available on
request for most sizes.
To produce a pressure tight joint, a thread
sealant must be used. TFE tape is generally
not recommended where cast iron is used as
one or more parts of the joint. The use of TFE
tape for installing cast iron fillings may cause
damage to the pump or fittings.
The following is a partial list of sealants that
may be used when making up joints on the
pump:
•
PST Pipe Sealant No. 567 − Loctite Crop.
•
Rectorseal No. 5 − The Rectorseal Corp.
•
Leak Lock − Highside Chemical, Inc.
Follow the sealant manufacturer's instructions
when making up a joint.
Page 2 – 11
2.9
CHECKING PUMP PERFORMANCE
A summary of the causes of common malfunctions.
PROBLEM
NO LIQUID DELIVERED
RAPID WEAR
EXCESSIVE NOISE
PUMP TAKES TOO
MUCH POWER
INSUFFICIENT LIQUID
DELIVERED
Page 2 – 12
POSSIBLE CAUSES
Pump rotating in wrong direction.
Pump not primed.
Inlet lift too high. Check this with gauge at pump inlet.
Clogged inlet line.
Inlet pipe not submerged.
Air leaks in inlet line.
Faulty pressure relief device in system.
Pump Worn.
Excessive pressure.
Nonlubricating liquid.
Pump runs dry.
Incompatibility of liquid and pump materials.
Pipe strain on pump. See Section 2.7, Installation of Pipes.
Excessive abrasives in liquid.
Starved Pump.
Air leaks in inlet line.
Air or gases in liquid.
Pump speed too high.
Relief valve chatter. Check pressure setting.
Improper mounting. Check alignment thoroughly.
See Section 2.4, Preparation of Foundation
and Section 2.5, Aligning Driver and Pump.
Speed too high.
Liquid more viscous than previously anticipated.
Operating pressure higher than specified. Check this with
gauge at pump discharge.
Discharge line obstructed.
Mechanical defect, such as bent shaft.
Pipe strain on pump. See Section 2.7, Installation of Pipes.
Pressure relief device not operating properly.
Air leaks in inlet line.
Air leaks through mechanical seal.
Speed too slow.
Excessive lift at inlet. Check this with gauge at pump inlet.
Viscosity of liquid too high for size and length of inlet pipe.
Foot valve, if used, too small, stuck, or not working properly.
Foot valve or end of inlet pipe not immersed deeply enough in
liquid.
Excessive clearance in pump caused by wear or corrosion.
Faulty pressure relief device.
2.10 REPLACEMENT PARTS
Repair parts can be ordered from your nearest authorized distributor. For the location of a
distributor near you, contact Roper Pump Company. DO NOT order repair parts by their key
number. Order by ROPER® part number only and include the nameplate data for aid in
identification. Repair parts lists depicting ROPER® part numbers are available for most pumps.
•
Roper Pump Company assumes no responsibility for parts other than those supplied by Roper
Pump Company. The use of substitutes may result in poor performance or in an accident
causing physical damage or injury to personnel.
•
WARNING! Only use genuine ROPER® gaskets. Gasket thickness determines proper
clearances. Always check quantity of gaskets removed and replace with exact quantity. Proper
material must be used based on application.
SERVICE NOTES
Page 2 – 13
2.11 INDEX
A
Aligning Shafts
Belts and Sheaves, 2 - 7
Flexible Coupling, 2 - 5 through 2 - 7
Power Take-Off, 2 - 8
Pump and Driver, 2 - 5 through 2 - 8
F
Foundation, 2 - 4 through 2 - 5
G
Guarding Power Take-Off Shafts, 2 - 8
I
Installation of Pipes, 2 - 10 through 2 - 11
P
Pipe Installation, 2 - 10 through 2 - 11
Pipe Threads - Threaded Port Connections, 2 - 11
Preoperation Checks, 2 - 3 through 2 - 4
Problems and Causes, 2 - 12
R
Replacement Parts, 2 - 13
S
Safety Precautions, 2 - 2 through 2 - 3, 2 - 9 through 2 - 10
T
Threaded Port Connections, 2 - 11
Page 2 – 14
Section 3.0
TABLE OF CONTENTS
Section
Page
3.1
Safety Signal Words and Symbols ................................................. 3 - 1
3.2
Recommended Tool List ................................................................. 3 - 1
3.3
Truck Mounting................................................................................ 3 - 1
3.4
Direction of Rotation ....................................................................... 3 - 3
3.5
High Drive to Low Drive .................................................................. 3 - 4
3.6
Instructions for Draining Pump ...................................................... 3 - 5
3.7
Instructions for Pump Disassembly............................................... 3 - 5
3.8
Bearing Removal and Installation .................................................. 3 - 6
3.9
Instructions for Pump Assembly.................................................... 3 - 7
3.10
Pump Sectional Drawing................................................................. 3 - 8
3.11
Parts List .......................................................................................... 3 - 9
3.12
Shaft Sealing .................................................................................. 3 - 11
3.13
Lubrication ..................................................................................... 3 - 11
3.14
Common Maintenance Questions ................................................ 3 - 12
3.15
Index ...............................................................................................3 – 13
Page 3 – i
3.1 SAFETY SIGNAL
WORDS AND SYMBOLS
SAFETY SIGNAL WORDS
The safety signal words CAUTION!,
WARNING!, DANGER!, and TOXIC! Have
specific meanings in this manual.
CAUTION! Is used to identify hazards that
may cause damage to property or equipment.
WARNING! Is used to identify hazards that
may cause personal injury.
DANGER! Identifies the most serious hazards.
DANGER! Is used to identify hazards that will
cause personal injury or death.
3.3
TRUCK MOUNTING
The mounting pads for truck mounted pumps
must be rigid and properly aligned with the
driver. When PTO drives are used, always
check with the manufacturer of the PTO
equipment to determine the alignment
required for proper operation of the PTO and
the type of guarding that must be used. See
Section 2.5, ALIGNING DRIVER AND PUMP.
The GHB, HB, H, BHB, and BH pumps are
designed to be mounted by the feet. These
pumps may be mounted with the feet in the
three, nine, or twelve o'clock position as
well as the standard six o'clock position.
TOXIC! Identifies hazards that involve
materials that may cause death by contact,
ingestion, or inhalation. TOXIC! Will always be
used with the safety signal word DANGER!
3.2 RECOMMENDED TOOL
LIST
NOTE: Tools not furnished with pump.
Tools for all Pumps:
(1) Safety Glasses
(1) 3/4" Combination Wrench
(1) 7/16" Combination Wrench
(1) Pliers
(1) 18" Pipe Wrench
Additional Tools for Pumps with
Flanges:
(1) 5/8" Combination Wrench
Page 3 – 1
MOUNTING POSITIONS
Page 3 – 2
3.4
DIRECTION OF ROTATION
DIRECTION OF ROTATION FOR HIGH DRIVE AND LOW DRIVE PUMP CONFIGURATIONS
FIGURE 3.4.1
Page 3 – 3
3.5 HIGH DRIVE TO LOW
DRIVE
Prior to operating pump, make sure that the
shaft rotation and pipe connections are in
accordance with the appropriate illustrations
(Figure 3.4.1). In order to change the rotation
and/or piping orientation, it may be
necessary to remove the piping from the
pump or the pump from the mounting.
(Fittings (3) and flange gaskets (2), when
provided, can be removed from pump.)
Whenever changing rotation, inspect all parts
before reassembly. Replace all worn parts
and install new gaskets in appropriate
numbers as removed.
1. Remove coupling or universal joint and
drive key (70) from drive shaft (72).
Remove all burrs and sharp edges from
drive shaft and keyway.
2. To reverse pump rotation and keep
piping arrangement the same, drive shaft
(72) position must be changed. Follow
steps 3 - 10.
To reverse pump rotation and leave drive
shaft (72) in same position; liquid flow
through pump will be reversed. Follow
steps 11 - 12.
REVERSE ROTATION, SAME PIPING
ARRANGEMENT
3. To reverse pump rotation and keep
piping arrangement the same, it is
necessary to change from high drive to
low drive or low drive to high drive.
4. Remove ten hex head cap screws (22)
and two nuts (85) securing backplate (20)
to case (1) and separate backplate
assembly from case assembly. The drive
gear and shaft assembly (71) will pull out
with backplate assembly.
Page 3 – 4
5. Switch drive gear and shaft assembly
(71) and idler gear/shaft (73) position in
case (1).
6. Position appropriate number of case
gaskets (5) on case (1) (oil or grease
may be used to hold gaskets in place).
7. Rotate backplate (20) assembly 180°.
8. Slide backplate (20) assembly with drive
gear/shaft (72) assembly into position
and secure.
REVERSE ROTATION, SAME DRIVE
SHAFT AND CASE ARRANGEMENT
9. To reverse flow of liquid through pump
ports, reverse rotation of drive gear and
shaft (72), maintain the original positions
of the drive gear/shaft and case (1).
CHANGE PORT AND DRIVE SHAFT
LOCATION, SAME ROTATION
10. To change the port to the opposite side
and maintain same pump rotation,
change drive gear and shaft (72) from
high drive to low drive or vice versa.
11. Remove ten hex head cap screws (22) and
two nuts (85) securing backplate (20) to
case (1) and separate backplate assembly
from case assembly. The drive gear and
shaft (72) will pull out with backplate
assembly.
12. Switch drive gear and shaft (72) and idler
gear/shaft (73) positions in case (1).
13. Rotate backplate (20) assembly 180° and
remount on case (1).
3.6 INSTRUCTIONS FOR
DRAINING PUMP
Refer to Section 3.10, PUMP SECTIONAL
DRAWING.
3. Rotate drive shaft very slowly by hand.
Each time that flow from drain increases,
stop turning shaft until flow stops; then
resume until flow increases again. Be
sure to rotate shaft several complete
revolutions in each direction until all flow
from drain has stopped.
4. Reinstall and tighten pipe plug (8A).
•
WARNING! Relieve all internal fluid and
air pressure inside the pump before
attempting to drain the pump.
•
WARNING! Take necessary precautions
to prevent the pump from becoming
energized while draining the pump.
•
WARNING! Take necessary precautions
to prevent injury or physical damage that
could be caused by any loss of the
product being pumped while draining the
pump.
The extent to which a pump can be drained
is dependent upon the product being
pumped. Low viscosity products such as
solvents will drain quickly and easily. High
viscosity products such as molasses and tar
will drain very slowly. Also, the draining of
high viscosity products will be less complete.
Regardless of the product pumped, the areas
at the blind end of the bearing bores and the
mechanical seal chamber will not drain.
3.7 INSTRUCTIONS FOR
PUMP DISASSEMBLY
Refer to Section 3.10, PUMP SECTIONAL
DRAWING.
1. Read section 2.0 on SAFETY
PRECAUTIONS and ADDITIONAL
IMPORTANT WARNINGS AND
INFORMATION before starting to
disassemble pump. While disassembling
pump, always inspect disassembled
parts and adjacent parts to see if further
disassembly is needed. Replace worn or
damaged parts as required. Read
Section 2.0, REPLACEMENT PARTS.
2. If you do not know which pump
arrangement you have, collect nameplate
data and refer to Section 1.0,
NAMEPLATE DATA, to determine what
you have. Consult a Roper Pump
Company or an authorized distributor if
you have any questions.
FOR PUMPS EQUIPPED WITH DRAIN
PLUGS;
3. When cleaning or lubricating, use only
cleaning solutions and lubricants that are
compatible with products being pumped
and with pump elastomers.
1. Refer to Section 2.0 and read sections on
SAFETY PRECAUTIONS and
ADDITIONAL IMPORTANT WARNINGS
AND INFORMATION before starting
draining procedure.
4. Turn off pump and lock out energy
source to driver. DO NOT proceed further
with disassembly of pump it there is the
slightest possibility that driver may be
started.
2. There are two pipe plugs (8A) in the
faceplate (45). Remove one that is in
lowest position.
5. Close inlet and discharge valves.
6. Remove guard and disconnect coupling
between driver and pump.
Page 3 – 5
7. Drain inlet and discharge lines. Disconnect lines from pump inlet and
discharge.
8. Follow the procedure in Section 3.6,
INSTRUCTIONS FOR DRAINING PUMP.
9. Remove ten hex head cap screws (22)
and two nuts (85) securing faceplate (20)
to case (1).
10. By screwing two long 3/8 - 16 thread bolts
in jack holes, remove faceplate (45).
11. Remove case gaskets (5).
12. Remove idler gear/shaft (73).
13. Remove packing nut (87) from end of
backplate (20).
14. Remove drive gear/shaft (72).
15. Remove ten hex head cap screws (22)
and two nuts (85) securing backplate (20)
to case (1).
16. By screwing two long 3/8 - 16 thread
bolts in jack holes, remove backplate(20).
17. Remove case gaskets (5) from opposite
side of case (1).
18. Remove four dowel pins (4) from case
(1), backplate (20), and faceplate (45).
19. Visually inspect all parts. Replace all
worn or damaged parts before
reassembling pump. It is recommended
that new gaskets (2, 5, if applicable) be
installed each time pump is
disassembled and reassembled.
3.8 BEARING REMOVAL
AND INSTALLATION
BEARING REMOVAL
1. Remove NPT plugs (8B) from ends of
bearing areas in faceplate (45) and
backplate (20).
Page 3 – 6
2. Place backplate or faceplate face down
on press.
3. Using proper size arbor press bearings
out.
BEARING INSTALLATION
1. Remove all burrs and raised edges from
bores for bearings.
2. Place faceplate or backplate on a press
base with milled face upward. Support
endplate so that milled face is
perpendicular (square) with press ram.
3. Position endplate so that one bearing
bore is located directly under press ram.
4. Lubricate endplate bores with a light oil
that is compatible with product to be
pumped.
5. Place end of new bearing at entrance of
bore in endplate, taking care to align
grooves in bearing with the grooves in
face of endplate.
6. Press bearing into endplate bore. It is
best to use a stepped arbor with a few
thousandths of an inch clearance
between arbor and bore of bearing. Be
sure to press bearings in until they are
flush to .005 of an inch [.127 mm] below
milled face of endplate.
7. Repeat procedure for second bearing.
8. Using a three square file, file shallow
grooves in ends of bearings to connect
grooves inside bearings with groove on
milled face of endplate. If your bearings
or endplates DO NOT have grooves, omit
this step.
3.9 INSTRUCTIONS FOR
PUMP ASSEMBLY
Refer to Section 3.10, PUMP SECTIONAL
DRAWING.
Refer to Section 3.4, DIRECTION OF
ROTATION, to assure proper configuration
for pump rotation, port location, and relief
valve position prior to assembling pump.
1. Refer to Section 2.0 and read instructions
on REPLACEMENT PARTS,
THREADED PORT CONNECTIONS,
SHAFT SEALING, and SAFETY
PRECAUTIONS before assembling
pump. Visually inspect all parts during
assembly. Replace all worn or damaged
parts. Although they may appear
reusable, it is recommended that new
gaskets (5) and packing rings (91) be
installed when pump is being
reassembled.
•
WARNING! Only use genuine
ROPER® gaskets. Gasket thickness
determines proper clearances.
Always check quantity of gaskets
removed and replace with exact
quantity. Proper material must be
used based on application.
4. Place drive gear/shaft (72) and idler
gear/shaft (73) into case bore.
5. Place appropriate number of case
gaskets (5) on backplate side of case.
Slide backplate over shafts and up to
case. Drive in two dowels (4). Secure
backplate to case with ten hex head cap
screws and two nuts.
6. Install three packing rings (91) in packing
nut (87) bore. Stagger joints on each
packing ring 180° apart. Rings must not
be tamped or seated.
7. Slide packing nut (87) with rings over end
of drive shaft.
8. Screw packing nut (87) on backplate (20)
finger tight. Tighten 1/2 to 3/4 of one
round then loosen to finger tight.
9. Screw hex head cap screw (10) into
backplate adjacent to packing nut (87).
10. Attach lockwire (9) to packing nut and
hex head cap screw (10). Be sure to
wrap lockwire in a clockwise direction
facing drive shaft end.
2. When cleaning or lubricating, only use
products that are compatible with product
being pumped and elastomers within
pump. Clean and lubricate parts with
bearing grease.
3. Place appropriate number of case
gaskets (5) on faceplate side of case.
Align faceplate on two finger tight hex
head cap screws (22) at top and bottom
of faceplate. Drive in two dowels (4).
Secure faceplate to case with ten hex
head cap screws (22) and two nuts (85).
Page 3 – 7
3.10 PUMP SECTIONAL DRAWING
FIGURE 3.10.1
Page 3 – 8
3.11 PARTS LIST
1. Case Assembly
21. Stud
2. Flange Gasket
22. Hex Head Cap Screw
3. Flange
25. Lube Fitting
4. Dowel Pin
45. Faceplate Assembly
5. Case Gasket
70. Drive Key
6. Hex Head Cap Screw
72. Drive Gear, Shaft, & Key
8A. Pipe Plug (small)
73. Idler Gear & Shaft
8B. Pipe Plug (large)
85. Nut
9. Lockwire
87. Packing Nut
10. Hex Head Cap Screw
91. Packing Rings
20. Backplate Assembly
Page 3 – 9
3.12
SHAFT SEALING
STANDARD COMPRESSION PACKING
One type of shaft sealing used in these
pumps is formed ring packing with or
without a lantern ring. When using a packed
box pump, use formed packing rings. DO
NOT use a one piece spiral wrap of
packing. Packing rings are available in a
wide selection of materials for various
applications and temperatures. Previous
experience with the pumped fluid is the best
guide in selecting the proper packing ring
material for your particular application.
CARE OF PACKING
DO NOT work on or adjust packing while
the pump is running.
If truck mounted, disengage the PTO or
hydraulic drive and shut off the engine.
If motor driven, TURN OFF motor and
lock out the energy source.
CLOSE VALVES on the inlet and
discharge while working on the pump.
It is generally not recommended to reuse old
packing rings. When installing packing, use
formed packing rings. DO NOT use a one
piece spiral wrap of packing. Before installing
packing, carefully clean the stuffing box and
shaft.
Packing rings should be installed one ring at
a time, with the joints of adjacent rings
staggered approximately 180°.
The packing gland nut should be tightened
with a wrench to seat the packing firmly in
the stuffing box and against the shaft. DO
NOT over-tighten the packing. The gland
nut should then be backed off until fingertight. Connect the lock wire from the
packing nut to the hex head cap screw
adjacent to the packing nut and twist ends
together.
Page 3 – 10
Note: The wire should be wrapped in a
clockwise direction from the packing nut to
the hex head cap screw.
After the pump is started, note the stuffing
box. If the packing leakage exceeds ten
drops per minute, stop the pump and adjust
the gland nut. The gland nut should be
adjusted evenly in 1/6 to 1/3 turn (1 to 2
flats on the nut) increments. Start the pump
and allow it to operate for several minutes.
Again, visually examine the stuffing box for
excessive leakage. Repeat the above
procedure until the stuffing box leakage is
between five to ten drops per minute.
DO NOT over-tighten the packing. Slight
leakage is a necessary requirement for
proper packing operation. Leakage of five to
ten drops per minute when the pump is
operating is desirable, as it will preserve the
packing and avoid scoring of the shaft.
Over-tight packing may score shafts,
increase torque requirements of the pump,
damage couplings and drivers, and
generate excessive heat.
The pump should be stopped and the
packing gland adjusted whenever leakage
exceeds ten drops per minute. The
condition of the packing should be checked
at regular intervals, the frequency
depending on the type of service.
Experience will dictate how frequently the
inspections should be made.
3.13
LUBRICATION
Pumps are fitted with lube fittings to all four
bearings. Lubricate the bearing on a regular
basis with any good quality bearing grease
that is compatible with the product being
pumped.
3.14 COMMON
MAINTENANCE QUESTIONS
Question:
At what point do I need to overhaul my
pump?
Answer:
As with all rotating equipment, your pump
will eventually wear to a point where the
pump's performance is diminished. The
pump's performance is dependent upon the
application. For instance, a very worn pump
may work at an acceptable level in an
application involving a high viscosity (thick)
liquid when combined with low discharge
pressure. This same pump would most
likely be unsatisfactory in a low viscosity,
high pressure application. The best answer
to the above question is the following: You
need to overhaul your pump when you feel
that the performance has dropped to an
unacceptable level for your application.
If you have set up your own test procedure
to check your used pumps, it will be helpful
to test at least one new pump of each size
to use as a benchmark for setting your own
acceptance levels.
Question:
What parts will I need to replace to get my
pump back to “like-new” condition?
Answer:
As a general rule, replace all gaskets and
packing seals at each servicing regardless
of their apparent condition. These parts are
usually less expensive than the labor costs
and downtime incurred if the pump has to
be serviced a second time to stop a leak.
The parts subject to wear should be
examined for obvious wear and corrosion.
This includes bearings, shafts, gears,
cases, and endplates. Measurements
should be made and compared to the
dimensions shown in Section 3.9. Replace
any parts that are worn beyond the limit
shown.
If the pump is used exclusively in an
abrasive application or high viscosity
application, you may be able to extend the
life of the gears or case. If a case with
straight through ports is worn on the inlet
side only, the case can be turned around
and used again.
Question:
What do I look for to determine excessive
wear?
• Gears
The gears are serviceable if there is no
degradation of the teeth or end faces.
Check for uniform wear. There should be no
burrs or gouges on any of the gear's
surfaces.
• Endplates
Excessive wear is usually the result of
pumping products containing abrasives. If
the endplates are damaged in the area that
the ends of gears rub, they should be
replaced. If a bearing has turned or spun in
the bore, the endplate must be replaced.
• Cases
Excessive case wear is usually the result of
worn bearings or shafts allowing gears to
contact the case bores. Minor rubbing of the
case bore is normal.
• Bearings
If bearings appear worn, the bearings
should be replaced. See Section 3.8 for
proper bearing removal and installation.
• Shafts
Replace the shaft if it is scored in the
packing, seal, or bearing area.
• Packing
Replace packing if it cannot be properly
adjusted to control leakage as described in
Section 3.12, SHAFT SEALING. It is normal
and necessary for packing to drip slightly.
Never rebuild a pump with used packing.
Page 3 – 11
Question:
Do I need special tools to disassemble and
reassemble my pump?
Answer:
The only special tools required are for
removal and installation of the bearings. A
list of all tools required can be found in
Section 3.2, TOOL LIST.
Question:
Is it okay to reface worn endplates?
Answer:
No. Roper Pump Company does not
recommend this procedure. Refacing
reduces the face flange thickness and
increases the possibility of interference
between the internal parts.
Question:
How long can my 5600 Series pump run
dry?
Answer:
One minute is a practical maximum for
running a pump dry. Anything longer could
cause the pump to overheat resulting in
possible pump damage or failure.
Page 3 – 12
Question:
At what point should I buy a new pump?
Answer:
A new pump should be purchased when the
old pump cannot be economically repaired.
Question:
Are there service centers where I can get
my pump repaired?
Answer:
Most Roper Pump Company distributors are
able to repair pumps. Consult the factory to
find your nearest distributor. Also, Roper
Pump Company has a repair department.
Any pump repaired at the factory is rebuilt to
like-new condition and carries a new pump
warranty. Pumps may be returned to the
factory by an authorized ROPER® pump
distributor.
3.15
INDEX
A
M
Assembly Instructions
Maintenance Questions, 3 - 12 through 3 - 13
All, 3 - 6 through 3 - 7
P
B
Packing, 3 - 10
Bearing
R
Removal, 3 - 6
Installation, 3 - 6
Rotation
Direction of Rotation, 3 - 3
Reversing, 3 - 3, 3 - 4
D
Disassembly Instructions
All, 3 - 5 through 3 - 6
Draining Pump, 3 - 5
L
Lubrication, 3 - 11
T
Tools, 3 - 1
Truck Mounting, 3 - 1, 3 - 2
Page 3 – 13
TERMS & CONDITIONS AND LIMITED WARRANTY
This agreement (this “Agreement”), consisting of these Terms and Conditions, and the associated Order Acknowledgement is binding upon Roper Pump
Company, hereinafter “SELLER,” and the customer, hereinafter “BUYER.” By placing an order for a product with the Seller, the Buyer agrees to these
Terms and Conditions of sale and acknowledges that the person placing the order has the authority to enter into the Order Acknowledgement on Buyer’s
behalf.
LEGAL EFFECT: Except as expressly otherwise agreed to in writing by an
authorized representative of Seller, the following terms and conditions shall
apply to and form a part of any Order Acknowledgement. Seller may
suspend its performance of any Order Acknowledgement if Buyer defaults
in the performance of its duties under the Order Acknowledgement or
under any other agreement between the Buyer and Seller.
ACCEPTANCE: The sale of goods and services is expressly conditional
on Buyer’s acceptance of Seller’s terms and conditions as stated herein.
Provided that Seller’s terms and conditions have not been previously
accepted by Buyer, Buyer’s receipt of goods or services shipped under this
Agreement constitutes acceptance of these terms and conditions. No
additional, different or conflicting provisions proposed by Buyer are
acceptable to Seller and are hereby specifically rejected, Seller being
unwilling to sell goods on any terms conflicting with, limiting or modifying
the terms hereof. Buyer shall not sell, transfer or otherwise provide any
goods to another for resale without the prior, written authorization of Seller.
Seller reserves the right to sell and to authorize other entities to sell such
goods through all means and channels of distribution and in competition
with Buyer. Buyer acknowledges that it has no authority to bind or contract
in the name or for the account of Seller, to create any liability against Seller
or to exert any direction or control over Seller’s personnel.
PAYMENTS: Standard terms for customers who qualify for credit net 30. A
monthly service charge of 1.5% may be charged on amounts owed by
Buyer to Seller that have not been paid within by the due date, subject to
the maximum amount permitted by law.
TAXES: Buyer assumes exclusive liability for any and all taxes, tariffs,
fees, duties, withholdings or like charges, whether domestic or foreign, now
imposed or hereafter becoming effective (“Taxes”) related to the goods and
its purchases from Seller, including without limitation, federal, provincial,
state and local taxes, value-added taxes, goods and services taxes, stamp,
documentary, excise or property taxes, duties and other governmental
charges.
TITLE AND LIEN RIGHTS: The equipment will remain personal property,
regardless of how it is installed or affixed to any realty or structure. After
delivery to Buyer, Seller will have all such rights, including security
interests and liens, in the equipment as lawfully may be conferred upon
Seller by contract under any applicable provision of law. Buyer agrees to
cooperate fully with Seller in the filing of any financing statements,
including Uniform Commercial Code (UCC) filings or other documents
necessary to perfect such interests and liens. If Buyer defaults in its
obligations under the Order Acknowledgement before the price (including
any notes given therefore) of the equipment has been fully paid in cash,
CHANGES: This Agreement and the associated Order Acknowledgement Seller may take any and all actions permitted by law to protect its interests
constitutes the entire agreement between Seller and Buyer with respect to including, where permissible, repossession of such equipment.
the subject matter thereof, and supersedes all prior oral or written
agreements. This Agreement and the associated Order Acknowledgement SHIPMENTS: All sales are Ex-Works Factory (as such term is defined by
may not be amended or modified, except by a further written agreement the International Chamber of Commerce as of the date hereof). Shipping
signed by an authorized representative of Seller. Seller reserves the right contracts made by Seller shall be to Buyer’s account. All claims for loss or
to make reasonable changes to an Order Acknowledgement, including damage after risk of loss has passed to Buyer shall be filed by Buyer with
changes as to packaging, testing, specifications, designs and delivery the carrier. Buyer shall be liable to Seller for the full price of the goods,
schedules. The terms and conditions of any purchase order or other irrespective of loss or damage in transit. Seller shall not be required to
instrument issued by Buyer or its agent in connection with this Agreement provide freight cost receipts to Buyer at the time of invoice. Buyer shall
and the associated Order Acknowledgement or any goods sold thereunder bear all risk and expense for delivery of goods, including without limitation,
that is in addition to or inconsistent with the terms and conditions of this shipping, loading, unloading, storage, freight, and insurance. Goods may
Agreement or the associated Order Acknowledgement are null and void be shipped to Buyer in whole or in part. Title to goods shall pass to Buyer
and shall not be binding on Seller. Buyer’s changes made after formation when delivered to the carrier or the Buyer, whichever occurs first, even if
of this Agreement that affect the schedule or requirements for services or the goods are shipped freight prepaid. Among other things, a signed
otherwise affect the scope of this Agreement shall be submitted in writing delivery receipt or bill of lading will constitute proof of delivery. The choice
by Buyer and shall become binding only if approved in writing by Seller’s of carrier is made solely at the discretion of Seller, and Seller makes no
cognizant representative. All charges and delays resulting from such representation as to the acceptability of a particular carrier. Except when
changes shall be solely determined by Seller and shall be binding upon Seller expressly agrees in writing, Seller does not guarantee shipment or
Buyer.
delivery by a certain date or time, although Seller will strive to deliver
TERMINATION, SUSPENSION, AND CANCELED ORDERS: Provided
that Seller receives adequate written notice from Buyer, Buyer may
terminate or suspend performance at Buyer’s convenience subject to all
reasonable charges, which charges shall be solely determined by Seller.
Buyer cannot cancel or alter Orders without the Seller’s written consent. If
Seller grants such consent, Buyer will reimburse Seller for all of Seller’s
losses and expense caused by such cancellation or alteration, including
without limitation all of Sellers additional costs caused by changes in
design or specifications, or by product revisions, and all incidental and
consequential damages incurred by Seller as a result of such cancellation
or alteration. No goods may be returned to Seller except with Seller’s
written consent. Title in a returned good will pass when Seller takes
possession of the returned goods.
CREDIT: The amount of credit offered by Seller to Buyer is contingent
upon Seller’s opinion of Buyer’s capacity, ability, and willingness to
promptly pay for goods and services received under the terms of this
Agreement. Provided that, in Seller’s opinion, there is a material adverse
change in Buyer’s financial condition and/or Buyer has not, within the
agreed time, fully paid for goods and services previously supplied under
this and/or another Agreement(s) with Seller, Seller reserves the right to
revoke Buyer’s credit and/or suspend performance on this and/or other
orders for goods and services.
goods by the date that it may communicate to Buyer. Seller shall not be
liable to Buyer, or any other person, for any loss or damage of any kind
which results from delay in shipment, delivery, or failure to give notice of
delay, whether or not such delay was caused by Seller or otherwise. Seller
reserves the right to backorder any goods and to ship from backorder in
such order as Seller determines.
LIMITED WARRANTY: Seller warrants, to its original Buyer, that goods
manufactured by Seller are free from defects in material and workmanship
for 12 months from date of shipment (except for specified products with
warranties that supercede this limited warranty. Please consult factory for
these products). The Buyer hereby acknowledges and agrees, though free
from defects in material and workmanship at the time of shipment, that the
useful life of goods manufactured by Seller will vary depending upon the
Buyer’s frequency of use, application, and other factors, with regard to
such goods. In that respect, notwithstanding any other provision to the
contrary in the Agreement, these Terms and Conditions, or the Order
Acknowledgement, the Seller specifically does not warrant the useful life of
any product. If a failure to conform to specifications or a defect in materials
or workmanship is discovered within this period, Seller must promptly be
notified in writing within thirty (30) days, which notification, in any event
must be received no later than 12 months from the date of shipment.
Within a reasonable time after such notification, Seller will correct any
failure to conform to specifications or any defect in materials or
workmanship, or in lieu of such repair, and at its sole option, shall replace
the equipment.
THE ABOVE ARE THE BUYER’S EXCLUSIVE
REMEDIES FOR BREACH OF WARRANTY. Seller does not warrant: (a)
defects caused by failure to provide suitable installation environment for
the product, (b) damage caused by use of the product for purposes other
than those for which it was purchased, (c) damage caused by disasters
such as fire, flood, wind, and lightning, (d) damage caused by unauthorized
attachments, or modification, (e) any other abuse or misuse by the Buyer,
including improper installation; or (f) goods which have been damaged or
altered by Buyer or its customers.
Each good sold by Seller to Buyer shall be deemed to be without defect
and in conformity with its specifications and the terms of this Agreement
and the associated Order Acknowledgement even though reasonable
variances may exist. As a result, Seller cannot and does not guarantee
that goods sold hereunder, whether in whole or in part, will exactly match in
specification or otherwise, and Buyer acknowledges that reasonable
variance is permissible. Additionally, Seller shall have no liability if a good
does not conform to any applicable state, county or local ordinance, as the
conformity of a good to each state, county and local ordinance is the sole
responsibility of the Buyer. Seller reserves the right to change its goods
and the components of its goods without prior notice to Buyer, although in
circumstances where an order from Buyer has been accepted by Seller,
Seller will use commercially reasonable efforts to ensure that such change
will not affect performance of the good in a materially adverse manner.
EXCEPT AS SET FORTH ABOVE AND TO THE MAXIMUM EXTENT
PERMITTED BY LAW, SELLER MAKES NO OTHER WARRANTIES
FOR A PRODUCT OR UNDER THIS AGREEMENT OR ANY ORDER
ACKNOWLEDGEMENT AND HEREBY DISCLAIMS ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR
USE, AND INCLUDING THE WARRANTY OF MERCHANTABILITY. IN
NO CASE SHALL SELLER BE LIABLE FOR ANY SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES BASED UPON ANY
LEGAL THEORY, INCLUDING BUT NOT LIMITED TO LOSS OF
PROFITS, LOSS OF SAVINGS OR REVENUE, LOSS OF USE OF THE
PRODUCT OR ANY ASSOCIATED EQUIPMENT, COST OF CAPITAL,
COST OF ANY SUBSTITUTE EQUIPMENT, FACILITIES OR SERVICES,
DOWNTIME, THE CLAIMS OF THIRD PARTIES INCLUDING
CUSTOMERS, INJURY TO PROPERTY AND, UNLESS PRECLUDED
UNDER APPLICABLE STATE LAW, BODILY AND PERSONAL INJURY.
CONFIDENTIAL INFORMATION: During the term of this Agreement and
the associated Order Acknowledgement and for the longer of (a) three (3)
years following its termination and (b) for such Confidential Information of
Seller that is a Trade Secret of Seller as defined by applicable law, for the
life of such Seller Trade Secret, Buyer agrees to receive and hold
Confidential Information of Seller in trust and in strictest confidence and
shall not use, reproduce, distribute, disclose or otherwise disseminate any
Confidential Information except as necessary to perform its obligations
hereunder. Disclosures of the Confidential Information may be made only
to Buyer’s employees and agents who have a specific need to know and
are subject to confidentiality restrictions at least as restrictive as those
contained herein. “Confidential Information” means confidential information
relating to the business, products and services of Seller which is or has
been disclosed to Buyer, and which has value to Seller and is not generally
known to Seller’s competitors, including (without limitation), information
regarding the specifications provided to Buyer by Seller and Seller’s
product plans, designs, costs, prices, finances, marketing plans, business
opportunities, personnel, R&D activities and know-how.
CONTROLLING LAW:
This Agreement and the associated Order
Acknowledgement entered into hereunder shall be governed and
construed in accordance with the laws of the State of Georgia and of the
United States of America without reference to any conflicts of law
principles; the parties submit themselves to the jurisdiction of the federal
and state courts located in Jackson County, Georgia, which shall have
exclusive jurisdiction of any disputes arising hereunder, and the parties
waive any objection to venue therein. The United Nations Convention on
Contracts for the International Sale of Goods, the Uniform Law on the
Formation of Contracts for the International Sale of Goods, and any
applicable international discovery and service of process conventions shall
not be applicable. In the event legal action is undertaken by Seller to
collect any amounts due to Seller by Buyer hereunder and if Seller prevails
in such action, then Buyer shall reimburse Seller for its reasonable attorney
fees and costs incurred in conjunction with such action, which amount shall
not exceed the maximum amount allowed by law of the forum in which
such action is brought.
ASSIGNMENT:
Neither this Agreement nor any associated Order
Acknowledgement may be assigned by the Buyer, or its contents
publicized by the Buyer, without the written consent of Seller. Seller shall
have the right to assign, transfer or sublicense all or any part of this
Agreement or any associated Order Acknowledgement to another at any
INDEMNITY; LIABILITY LIMITATION: Buyer hereby agrees to indemnify, time and without the consent of Buyer.
reimburse in full, defend and hold harmless Seller, its subsidiaries,
affiliates, officers, directors, personnel and agents from and against any MISCELLANEOUS: The various provisions of this Agreement and any
and all liability, claims, suits, actions, losses, costs or expenses including associated Order Acknowledgement are severable, and any determination
(without limitation) reasonable attorneys’ fees relating to or arising out of of invalidity or unenforceability of any one provision hereof shall no bearing
any claim or demand (a) for any Taxes or related penalties and interest, (b) on the continuing force and effect of the remaining provisions hereof. This
due to Buyer’s breach of the Order Acknowledgement; (c) that Buyer’s Agreement and any associated Order Acknowledgement and the terms
customers or a third party may make against Seller based upon or arising and conditions contained herein constitute the entire understanding of the
from damage due to the acts and/or omissions of Buyer or due to the parties with respect to the purchase and sale of the goods, and any prior
installation of the goods; (d) for infringement or misappropriation of a third agreements, with respect thereto, whether written or oral, are superseded
party’s intellectual property rights based upon Seller’s incorporation of any hereby. This Agreement and any associated Order Acknowledgement
designs, formulas or specifications in any goods where such designs, shall be binding on the parties and their respective successors and any
formulas or specifications have been specifically ordered or requested by permitted assigns.
Buyer. To the maximum extent allowable under applicable law and
excluding those liabilities that by law Seller cannot limit or disclaim, (i) ELECTRONIC DATA INTERCHANGE: The parties may execute a Order
Seller’s aggregate liability arising from or relating to this Order Acknowledgement by transmitting and receiving the data contained in the
Acknowledgement or goods, regardless of the cause of action asserted, is Order Acknowledgement electronically rather than in paper form. To
limited to the amount paid by Buyer to Seller for the applicable goods and provide the legal validity and enforceability of such Order
(ii) Seller shall not be liable for any special, incidental, consequential, Acknowledgement, the parties further agree that the data transmitted
indirect, or punitive damages, including without limitation, lost revenues, herein will be considered “in writing” and to have been “signed.” The
loss of use of the goods, loss resulting from improper storage, processing, parties agree not to contest the validity or enforceability of a Order
padding/cushion, delay in delivery or shipment or errors in shipment or Acknowledgement because of the electronic origination, transmission,
labeling, loss of data, or the cost of any substitute goods or related storage or handling of such Order Acknowledgement. Any computer
equipment, even if Seller has been advised of the possibility of such printout of the data contained in the Order Acknowledgement will be
damages.
considered an “original” when maintained in the ordinary course of
business and will be admissible as between the parties to the same extent
EXPORT RESTRICTIONS: Buyer shall not export or re-export goods in and under the same conditions as other business records maintained in
violation of any applicable laws or regulations of the United States or the documentary form. The parties agree to properly use those security
country in which Buyer obtained them.
procedures which are reasonably sufficient to ensure that a transmission of
the data contained in a Order Acknowledgement is authorized and to
protect its business records and data from improper sources.
Additional copies of the installation and operation manual may be obtained by contacting a Roper
Pump Company distributor or:
Roper Pump Company
PO Box 269
Commerce, Georgia 30529 USA
Telephone: (706) 335-5551
TeleFAX: (706) 335-5490
Email: [email protected]
Web: www.roperpumps.com
Your Roper Pump Company distributor is:
PART NO. G12-405
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