Molten Metal - Brochure

instruction manualinstruction manualMolten Metal PumpsInstallation, Operation & Maintenance ManualGUSHER PUMPS, INC.115 INDUSTRIAL DRIVEWILLIAMSTOWN, KY 41097PHONE: 859-824-3100FAX: 859-824-7428www.gusher.comMAINTENANCE • INSTALLATION • OPERATIONSTABLE OF CONTENTS Pump Safety Tips ....................................................................2Forward ....................................................................................3Precautions ..............................................................................4Nameplate Information, Receiving and Inspection .............5Operation and Maintenance ...................................................6Water Cooling Instructions .....................................................7Dimensional Drawing and Parts Breakdown ........8, 9, 10, 11Troubleshooting .....................................................................12Addresses, Phone Numbers .................................................132SAFETY APPAREL• Insulated work gloves when handling hot bearings or using bearing heater • Heavy work gloves when handling parts that have sharp edges, especially impellers • Safety glasses (with side shields) to protect eyes, especially in machine shop areas • Steel-toed shoes to protect feet when handling parts, heavy tools, etc. • Any other equipment needed to protect against hazardous/toxic fluids COUPLING GUARDS• Never operate a pump without coupling guards properly installedFLANGED CONNECTIONS• Never force piping to make connection with a pump• Use only fasteners of proper size and material• Ensure there are no missing fasteners• Beware of corroded or loose fastenersPUMP SAFETY TIPS OPERATION • Do not operate below minimum rated flow, or with suction/discharge valves closed• Do not open vent or drain valves, or remove plugs while the system is pressurizedMAINTENANCE SAFETY• Always lockout power • Ensure pump is isolated from the system and pressure is relived before disassembling pump, removing plugs, or disconnecting piping • Use proper lifting and supporting equipment to prevent serious injury • Observe proper decontamination procedures • Know and follow company safety regulations • Never apply heat to remove impeller3FOREWORDThe design, craftsmanship, and materials used in Gusher pumps provides for optimum performance and long, trouble-free service. As with any mechanical device, proper use and periodic maintenance will enhance the performance and life of your pump. This manual is provided as a guideline for proper installation, operation and maintenance. THIS MANUAL MUST BE READ AND UNDERSTOOD BEFORE INSTALLING AND OPERATING ANY PUMP. GUSHER PUMPS INC. SHALL NOT BE LIABLE FOR PHYSICAL INJURY, DAMAGE OR DELAYS CAUSED BY A FAILURE TO OBSERVE THE INSTRUCTIONS FOR INSTALLATION, OPERATION, AND MAINTENANCE CONTAINED IN THIS MANUAL. WARRANTYGusher Pumps, Inc. will replace or repair, within one year of shipment from our plant, anypump in our judgment that has failed due to defects in materials or workmanship, provided the pump has been properly installed and maintained and has not been subject to abuse. These pumps must return to Gusher Pumps, Inc. with complete history of service for inspection and warranty consideration. Gusher Pumps, Inc. does not accept the responsibility for transportation to and from our plant. Furthermore, we do not assume any responsibility for consequential damage or loss of production.WARRANTY IS ONLY VALID WHEN GENUINE GUSHER PARTS ARE USED. Supervision by an authorized Gusher representative is recommended to ensure proper installation.Additional manuals can be obtained by contacting your local Gusher representative or by calling (606) 824-5001.4• NEVER apply heat to remove impeller. It may explode due to trapped liquid.• NEVER use heat to disassemble pump. Explosion could occur due to trapped liquid.• NEVER operate pump without coupling guard correctly installed.• NEVER operate pump beyond the rated conditions to which the pump was sold. • NEVER start pump without proper prime (sufficient liquid in pump casing). • NEVER operate pump below recommended minimum flow or when dry.• ALWAYS lock out power to the motor before performing pump maintenance. • NEVER operate pump without safety devices installed.• NEVER operate pump with discharge valve closed. • NEVER operate pump with suction valve closed. • DO NOT change conditions of service without approval of an authorized Gusher representative.WarningPersonal injury will result if procedures outlined in this manual are not followed.PRECAUTIONS5RECEIVING and INSPECTIONGusher Pumps, Inc. has taken great care in preparing your pump for shipment, however, due to circumstances beyond our control, your shipment may be received damaged. Therefore, we strongly recommend that you take a few minutes to check your pump upon receipt. Check for cracked, bent, severely misaligned (minor misalignments almost always occur during shipment), or even missing parts. If any such damage has occurred, you must report it to the delivering carrier and Gusher Pumps, Inc. immediately. We also recommend that you check the model number, horsepower, current characteristics, g.p.m., and ft. head of pump received to ensure that you have received the pump you ordered for your specific operating conditions. If you should find some discrepancy, report it to Gusher at once.NAMEPLATE INFORMATIONOn the casing of every Gusher pump is a nameplate that provides information about the pump’s hydraulic characteristics. This information will be used when ordering spare or replacement parts for your pump. If your pump is not going to be installed within six months, several precautions must be taken; 1. Preservative treatment of bearings and machined surfaces is required. 2. Remove packing on pumps with packed stuffing box, the stuffing box and shaft sleeve must be oil lubricated to also protect against moisture. 3. Units equipped with mechanical seals must also be oil lubricated with an oil can through the NPT port while rotating the shaft by hand. 4. Pump suction and discharge ports must be covered to prevent foreign material from getting into the pump and causing damage when pump is started at a later date. 5. Pump must be stored in a dry location. 6. Rotate pump shaft several times every other month. 6• OPERATIONBefore starting the pump the reservoir should be filled to the minimum level so as to completely submerge the bottom pump impeller housing in the liquid which assures priming of the pump.Upon initial start up we recommend that you check and maintain the minimum liquid level in your reservoir, it is also advisable to check your piping for leaks at this time. We also recommend that you check and record the pump discharge pressure, line voltage and amperage being drawn by the motor and operating temperature of the bearings.Temperature should be checked with a pyrometer, do not check by touch.Temperatures that are hot to the touch are often well within the maximum operating temperature of 2250 F.If a problem develops check the trouble shooting list on page 10. If you are unable to solve your problem please feel free to contact the factory.OPERATION & MAINTENANCE• MAINTENANCE Normally after proper installation and under normal operating conditions (8 hours daily duty in clean liquid with SG of 1) the pump requires very little attention. Before shipment all Gusher pumps have been tested and greased at the plant, therefore lubrication is not necessary for approximately six to eight months. Remember, when lubricating ball bearings that too much grease will cause bearings to run hot, so grease bearings sparingly when it is necessary. We recommend the use of Chevron SRI #2 grease. Because of the vast range of operating con-ditions it is difficult to recommend one set schedule for periodic maintenance.The more severe the application the more attention the pump will require. When a pump operates in a high temperature application (over 1500F) it is recommended to grease the ball bearings sparingly once a month (approx. 1 gram).In hostile environments where abrasives are present the pump may need to be inspected for wear quarterly. This should include inspection of the impellers, bushings and seals. 7WATER COOLING INSTRUCTIONS FOR15028XE & XEB MOLTEN METAL PUMPS.IF THE ABOVE INSTRUCTIONS ARE FOLLOWED, SATISFACTORY RESULTS SHOULD BE OBTAINED. UNLESS THESE INSTRUCTIONS ARE COMPLIED WITH, THE MANUFACTURER IS NOT RESPONSABLE FOR PUMP WARRANTY. CONNECT WATER SUPPLY FOR COOLING AT THIS POINT3 TO 5 G.P.M. SHOULD PROVIDE ADEQUATE CIRCULATION FORCOOLING. CONTROL FLOW BY USE OF VALVE IN WATER SUPPLY LINE DO NOT CONTROL FLOW OF WATER OUTLET BY USE OF VALVE IN OUTLET PIPING. (C)O N L Y .O N LY.1/4” N.P.T. WATER INLETATHE PURPOSE OF THE SAFETY DRAIN IS TO PIPE AWAY ANY POSSIBLELEAKAGE FROM SEAL OR PACKING WITHIN COOLING SYSTEM.1” SAFETY DRAINIT IS IMPORTANT THAT THIS OUTLET BE PIPEDSEPARATELY TO DRAIN.THE WATER OUTLET CARRIES ALL THE WATER WITHIN THE CIRCULATING COOLING SYSTEM. THIS OUTLET SHOULD BE PIPED SEPARATELY TO DRAIN.1” N.P.T. WATER OUTLETDO NOT USE ANY VALVES IN PIPINGFROM OUTLET TO DRAIN.BCC A U T I O N :WATER CIRCULATION SHOULD CONTINUE BEFORE AND AFTER CYCLEOF OPERATION OR UNTIL PUMP PARTS HAVE COOLED TO ATEMPERATURE OF 2000 F. THIS APPLIES TO BOTH PORTABLE AND PERMANENT INSTALLATIONS.{8 FEATURESBALL BEARING T.E.F.C. MOTOR,WATER COOLED SHAFT, BALLBEARINGS AND MOTOR,QUICK MAKE-AND-BREAK SELF-LOCKING WEDGE,DISCHARGE CONNECTIONS,HANDLES MATERIALS UP TO 12000 FAHRENHEIT. M O D E L15028-XEMOLTEN METAL PUMP, FOR MOLTEN LEAD, BABBIT, SOLDERS, TIN AND ALLOYS AT TEMPERATURES UP TO12000 F. FOR SPELTER OR ZINC, RECOMMENDEDTEMPERATURE 8750 F.WHEN ORDERING SPECIFY:• MODEL 15028-E OR 15028-XE (IF MOUNTING FLANGE IS DESIRED ADD SUFFIX “MF” TO MODEL DESIRED (15028-EMF OR 15028-XEMF).• DISCHARGE CONFIGURATIONS: A MACHINED WEDGE, B DISCHARGE FLANGE,• IMPELLER NUMBER.• MOTOR HORSE POWER AND• CURRENT CHARACTERISTICS.Standard Materials: STAINLESS STEEL SHAFT, CAST IRON HOUSING, CARBON STEEL SCREWS.NOTE: OTHER MATERIALS AVAILABLE, QUOTATION UPON REQUEST.SEE PAGE 7WHEN MOUNTING FLANGE DESIRED, GUIDEBARS ARE REMOVED.SEE PAGE 92OR‡*HORSE POWER RECOMMENDATION CHARTFOR DIFFERENT WEIGHT MATERIALS POUNDS PER GALLON IMPELLER NUMBERR.P.M. H.P. 6125-3.000 6125-3.500 6125-3.625 1725 _____ _____ 81 to 120 1140 _____ _____ _____71/2DIMENSION15028-XFHORSEPOWER7 1/2 A B C ____ ____ ____ * * 12 3/4CURRENTVOLTSPHASECYCLER. P. M.FUL LOAD60 114050 95060 172550 1425A.C.220440OR5502OR3MOTOR DIMENSIONS MAY VARYACCORDING TO FRAME SIZE.GALLONS PER MINUTE — TIN AT 8500F.HEAD AND G.P.M. MEASURED AT DISCHARGE.TO APPROXIMATE CAPACITY IN POUNDSAND FOR DIFFERENT WEIGHT MATERIALS. ?0 10 20 30 40 50 60IMPELLER? 6125-3. 625 6125-3. 500 6125-3. 0001412108642HEAD IN FEETDISCHARGE2” N.P.T.? 1800 R.P.M. 1800 R.P.M.? 1500 R.P.M. 1800 R.P.M. ? 1200 R.P.M. 1200 R.P.M. 1500 R.P.M. 1500 R.P.M.DRAWN BY SCALE MATERIAL WEIGHTDATE 15028-XE 7.5HP 3 PH 1750RPMDINSER 8/5/98 REV: 0.1 AK971022-191 SEAL GLAND2 PACKING GLAND COVER3 SEAL HEAD SUPPORT4 UPPER ENDBELL5 #209 BEARING6 LOWER ENDBELL7 #207 BEARING8 LARGE WATER JACKET9 GUILD BARS10 IMPELLER HOUSING11 IMPELLER12 SHAFT13 SLINGER14 BAFFLE16 LIFT LOOP17 STEM18 MOTOR19 MECHANICAL SEAL20 SEAL COLLAR21 .25” BRASS TUBE22 IMP. RETAINING NUTBOTTOM VIEWOF HOUSING* VARIES WITH MOTOR MANUFACTURERTITLECAN NOT READ THISDIVISION OF RUTHMAN PUMP AND ENGINEERING,INC.RUTHMAN DRIVE-DRY RIDGE, KENTUCKY 41035GUSHER PUMPSMODEL 9075-M 9075M-AM 9075M-BD 9075M-PD AVAILABLE WITH 4 - AM AVAILABLE WITH 5” OR 7” AIR MOTOR PITCH DIAMETER PULLEY A SIZE V-BELT. MODELS 9075-M, 9075-MAM, 9075-MBD and 9075-MPD are without water jacket which allows handling of liquids up to 700 F. Models 9075-MW, 9075-MWAM, 9075-MWBD and 9075-MWPD are equipped with a water jacket (as shown in photo) these models will handle liquids up to 800 F.GALLONS PER MINUTE—SOLUBLE COOLANTHEAD & G.P.M.MEASURED AT DISCHARGE.TO APPROXIMATE CAPACITY IN POUNDSSEE PAGE 2.NOTE: 208/ 230/ 460 VOLT 60 CYCLES — 220 / 380 VOLTS 50 CYCLE — 575 VOLTS 60 CYCLE SAME DIMENSIONS AS 230/ 460 VOLTS 60 CYCLE. EXCEPT SINGLE PHASE. (OTHER CURRENT CHARACTERISTICS AVAILABLE).Standard Material:STAINLESS STEEL SHAFT,CAST IRON HOUSING,CARBON STEEL SCREWS.Note:OTHER MATERIALSAVAILABLE, QUOTATIONUPON REQUEST. M O D E L9075 — MMOLTEN METAL AND HOT LIQUIDS PUMPWHEN ORDERING SPECIFY:• MODEL 9075-M, 9075-MAM, 9075-MBD, 9075-MPD, 9075-MW, 9075-MWAM, 9075-MWBD, OR 9075-MWPD (SHORT OR LONG)• IMPELLER NUMBER,• MOTOR HORSE POWER AND• CURRENT CHARACTERISTICS.VOLTSCYCLEPHASER. P. M.MODEL DIMENSION IN INCHES HORSE POWER OF MOTORA (long) A (short) B 1/4 1/2 3/4 1/4 1/2 3/4 1/4 1/2 3/4230 60 3 1725 9075-M 23 1/4 24 5/8 24 7/16 18 7/16 19 13/16 19 5/8 12 5/8 14 13 13/16460 WITH ELECTRIC230 60 3 1140 MOTOR 23 1/4 24 1/8 — 18 7/16 19 5/16 — 12 5/8 13 1/2 —460 NOTE:WHEN WATER JACKET IS NEEDED FOR HIGHER TEM-PERATURES, ADD 3-1/2” TO A AND B DIMENSIONS.4AM AIRMOTOR9075-MAMBELT DRIVE9075-MBDPLAIN DRIVE9075-MPD 23 3/8 18 9/16 12 3/4 21 5/16 16 1/2 10 11/16 21 9/16 16 3/4 10 15/16MUST BE T. E. F. C.HORSE POWER RECOMMENDATION CHARTFOR DIFFERENT WEIGHT MATERIALSPOUNDS PER GALLON IMPELLER NUMBER 6172-MSEE TABLE ON PAGE 2 FOR DIFFERENT WEIGHTMATERIALS.R.P.M H.P.1725 1/4 1 UP TO 301140 1 UP TO 601725 1/2 31 UP TO 801140 61 UP TO 1201725 3/4 81 UP TO 1200 2 4 6 8 10 12 14IMPELLER NO.6172-M7531HEAD IN FEETDISCHARGE3/4” N.P.T.1725 R.P.M.1425 R.P.M.10 M O D E L1 5 0 2 8MOLTEN METAL AND HOT LIQUIDS PUMPWHEN ORDERING SPECIFY:• MODEL 15028, 15028-AM, 15028-BD, 15028-PD, 15028-W, 15028-WAM, 15028-WBD OR 15028-WPD (WHEN MOUNTING FLANGE IS DESIRED ADD SUFFIX “MF” TO MODEL DESIRED (15028-MF, 15028-WMF ECT.).• IMPELLER NUMBER,• MOTOR HORSE POWER AND• CURRENT CHARACTERISTICS.Standard Materials: STAINLESS STEEL SHAFT, CAST IRON HOUSING, CARBON STEEL SCREWS.NOTE: OTHER MATERIALS AVAILABLE, QUOTATION UPON REQUEST.NOTE: 208/ 220/440 VOLTS 50/60 CYCLES — 220/380 VOLTS 50 CYCLES —550 VOLTS 50/60 CYCLES SAME DIMENSIONS AS 2230/460 VOLTS 60 CYCLES.EXCEPT SINGLE PHASE. OTHER CURRENT CHARACTERISTICS AVAILABLE. Models 15028, 15028-AM, 15028-BD and 15028-PD are without water jacket which allows handling of liquids up to 7000F. Mod-els 15028-W, 15028-WAM, 15028-WBD and 15028-WPD are equipped with a water jacket (as shown in photo) these models can handle liquids up to 8000F.GALLONS PER MINUTE — SOLUBLE COOLANT. HEAD & GPM MEASURE AT DISCHARGE. TO APPROXIMATE CAPACITY IN POUNDS SEE PAGE 2.*15028-AM . . . AVAILABLE WITH 4AM AND 8AM AIR MOTORS. 15028-BD. . . AVAILABLE WITH 5” & 7” PITCH DIAMETER PULLEY A SIZE V-BELT.0 10 20 30 40 50IMPELLER NO.6125A-3.62512108642HEAD IN FEETDISCHARGE SIZE1-1/4” N.P.T. 1725 R.P.M. 1425 R.P.M. HORSE POWER RECOMMENDED FOR DIFFERENT WEIGHT MATERIALSSEE TABLE ON PAGE 2 FOR DIFFERENT WEIGHT MATERIALS.POUNDS PER GALLON OF MATERIAL PUMPEDH.P. RECOMMENDED FOR 1725 R. P. M. 1 to 20 21 to 40 41 to 50 51 to 80 81 to 120 3/4 1-1/2 2 3 5HORSE FRAME VOLTS R.P.M. CYCLE PHASE POWER 3/4 5 611/2 & 145T 230 1725 6 0 3 2 460 3 182T 5 184TDIMENSIONS IN INCHESOTHER MEANS OF DRIVING PUMP A ? B G H J 291/2 185/8 45/16 25/8 11/16 327/16 219/16 53/4 49/16 61/4 3215/16 221/16 71/4 53/4 613/16 3315/16 231/16 71/4 53/4 75/16? ALL “B” DIMENSIONS GO TO BOTTOM OF MOUNTING FLANGE. PUMPS WITH WATER JACKET HAVE THE SAME DIMENSIONS.AIR MOTOR15028-AM,4 AM AIRMOTOR8 AM AIRMOTORBELT DRIVE15028-BDPLAIN DRIVE15028-PDDIMENSIONS A B 2715/16 171/16 3315/16 231/16 271/4 163/8 281/16 173/161112No liquid delivered • Pump not primed • Speed too low * • Discharge head too high • Suction line or suction strainer is clogged • Impeller completely clogged • Wrong direction of rotation. • Too much clearance between impeller and intake flange. Not enough water delivered • Air leaks in suction or stuffing boxes • Speed too low * • Discharge head higher than anticipated • Too much clearance between impeller and intake flange • Impeller partially clogged • Not enough suction head for hot water • Mechanical defects: Wear ring is worn Impeller damaged • Impeller diameter is too small • Foot valve is too small • Foot valve or suction opening not submerged deep enoughTROUBLE SHOOTINGVibration • Bent shaft • Pipe strain • Impeller clogged • Coupling alignment offNot enough pressure • Speed too low * • Air in water • Mechanical defects: Wear ring is worn Impeller damaged • Impeller diameter too smallPump works for a while then loses suction • Leaky suction line • Water seal plugged • Impeller clogged • Air or gasses in liquidPump takes too much power • Speed too high * • Head lower than rating, pumps too much water • Specific gravity or viscosity too high • Mechanical defects: Shaft bent Power frame in bind Wear ring is worn • Impeller diameter too large • Pump delivering too many gallons* When directly connected to electric motors, check for full voltage across all electrical leadsRuthman...Another Word for InnovationIt began in 1913, servicing me-chanical components of the steamboats on the Ohio River. The company founder, Alois Ruthman, was a man of vision and saw part of the future of the company was in the development of a reliable in-dustrial pump.In 1924, with the conception of the first vertical ball bearing seal-less centrifugal pump, Ruthman Pump and Engineering furthered the design on a unit with a one piece motor driven shaft. The pump was called “Gusher”, giving birth to the trade name Gush-er Pumps, and the coining of the term “coolant pump”.Wanting to carry on the tradition of quality and reliability started by his father, Thomas R. Ruthman joined the company in 1949. In the early 1990’s Thomas R. Ruthman’s son, Thomas G. Ruthman joined the company, continuing this same tradition. Maintaining the reputation of Gusher Pumps by innovation and customer ser-vice, the company has grown to service companies worldwide.Gusher Pumps is a Division ofRuthman CompaniesCorporate Headquarters1212 Streng StreetCincinnati, OH 45233Phone: 513-559-1901Fax: 513-559-0035Web: www.ruthmancompanies.comGusher Pumps of Dry Ridge22 Ruthman DriveDry Ridge, KY 41035Phone: 859-824-5001Fax: 859-824-3011Web: www.gusher.comGusher Pumps of Williamstown115 Industrial DriveWilliamstown, KY 41097Phone: 859-824-3100Fax: 859-824-7248Web: www.gusher.comGusher Pumps of Cincinnati1212 Streng StreetCincinnati, OH 45233Phone: 513-559-1901Fax: 513-559-0035Web: www.gusher.comGusher Pumps of California8226 Salt Lake AvenueCudahy, CA 90201Phone: 323-773-0847Fax: 323-773-0958Email: www.gusherca@aol.comGusher Pumps of New Castle403 North Ninth StreetNew Castle, IN 47362Phone: 765-529-5624Fax: 765-521-0008Email: www.gusherpump@insightbb.comBSM Pump Corp.180 Frenchtown RoadNorth Kingstown, RI 02852Phone: 401-471-6350Fax: 401-471-6370Web: www.bsmpump.comNagle Pumps1249 Center AvenueChicago Heights, IL 60411Phone: 708-754-2940Fax: 708-754-2944Web: www.naglepumps.comWagner Processing – Bay Area23510 Bernhardt StreetHayward, CA 94545Phone: 510-786-3929Fax: 510-786-3722Web: www.wagnerprocess.comWagner Processing – Central Valley3675 N. Wilcox Street #CStockton, CA 95215Phone: 209-931-0100Fax: 209-931-7910Web: www.wagnerprocess.comGreat Lakes Pump & Supply Co.1075 NaughtonTroy, MI 48083Phone: 248-528-9100Fax: 248-528-9015Web: www.greatlakespump.comProcess Systems, Inc.Michigan, Main Headquarters23633 PinewoodWarren, MI 48091Phone: 586-757-5711Fax: 586-758-6996Web: www.INFOatpsi4pumps.comIndiana485 N State Route 3431 SouthMellott, IN 47958Phone: 765-295-2206Fax: 765-295-2243Web: www.process-systems-inc.comWorldwide:Ruthmann PumpenNorthberger Strabe 60Eschweiler Germany D-52249Phone: +49 (0) 2403 5595 0Fax: +49 (0) 2403 5595 20Web: www.ruthmannpumpen.deBirmingham PumpUnit 7 Network ParkDuddeston Mill RoadSaltley, Birmingham England B81AUPhone: +44 (0) 121 503 3000Fax: +44 (0) 121 503 3002Web: www.birminghampumps.co.ukGuan Shen Industrial Pumps(Shanghai) CompanyGusher Pumps (Shanghai) Co., Ltd.Building D, Room 416No. 188 East Jiagwan RoadShanghai, 200081P.R. CHINAPhone: 86-21-33872056Phone: 86-21-33872058Fax: 86-21-33872057 86-21-33872056 86-21-33872058 86-21-33872057