GORMAN-RUPP PUMPS S4A1-E25 460/3, Installation, Operation And Maintenance Manual

Page 1: ...P COMPANY MANSFIELD OHIO www grpumps com GORMAN RUPP OF CANADA LIMITED ST THOMAS ONTARIO CANADA Printed in U S A 2008 The Gorman Rupp Company INSTALLATION OPERATION AND MAINTENANCE MANUAL WITH PARTS LIST SUBMERSIBLE PUMPS MODELS S4A1 E25 460 3 and S4A1 E25 575 3 ...

Page 2: ...erial number and e mail address required RECORD YOUR PUMP MODEL AND SERIAL NUMBER Please record your pump model and serial number in the spaces provided below Your Gorman Rupp distributor needs this information when you require parts or service Pump Model Serial Number ...

Page 3: ...Cable Grounding Test PAGE B 7 Control Box Connections PAGE B 7 Liquid Level Devices PAGE B 7 WIRING DIAGRAMS PAGE B 8 OPERATION SECTION C PAGE C 1 GENERAL INFORMATION PAGE C 1 Pump Performance PAGE C 1 Control Box PAGE C 1 PUMP OPERATION PAGE C 1 Liquid Temperature And Overheating PAGE C 1 Impeller Rotation PAGE C 2 STARTING STOPPING AND OPERATIONAL CHECKS PAGE C 3 Starting PAGE C 3 Stopping PAGE ...

Page 4: ...d and Strainer Plate Installation PAGE E 11 Strainer Screen and Base Plate Installation PAGE E 12 MOTOR DISASSEMBLY PAGE E 12 Terminal Housing and Power Cable Removal and Disassembly PAGE E 12 Intermediate and Motor Housing Disassembly PAGE E 13 Rotor and Bearing Removal PAGE E 13 Stator Removal PAGE E 14 Relief Valve PAGE E 14 Hoisting Bail PAGE E 15 MOTOR REASSEMBLY PAGE E 15 Stator Installation...

Page 5: ...or in other lit erature accompanying the unit please contact your Gorman Rupp distributor or the Gorman Rupp Company The Gorman Rupp Company P O Box 1217 Mansfield Ohio 44901 1217 Phone 419 755 1011 or Gorman Rupp of Canada Limited 70 Burwell Road St Thomas Ontario N5P 3R7 Phone 519 631 2870 RECORDING MODEL AND SERIAL NUMBER Please record the pump model and serial number in the spaces provided on ...

Page 6: ...D result in minor personal injury or product or property damage These instructions de scribe the requirements and the possible damage which could result from failure to follow the procedure NOTE Instructions to aid in installation operation and maintenance or which clarify a procedure ...

Page 7: ...e pump or endan ger personnel as a result of pump fail ure Consult the factory for specific ap plication data Before connecting any cable to the con trol box be sure to ground the control box Refer to the Control Box Manual for the suggested grounding methods The pump motor is designed to be oper ated through the control box furnished with the pump The control box provides overload protection and ...

Page 8: ...lled make certain that the pump and all piping or hose connections are secure before op eration Obtain the services of a qualified elec trician to troubleshoot test and or ser vice the electrical components of this pump Approach the pump cautiously after it has been running Although the motor is cooled by the liquid being pumped nor mal operating temperatures can be high enough to cause burns The ...

Page 9: ...nd hertz indicated on the name plate match the ratings on the control box and incoming pow er e Carefully read all tags decals and markings on the pump and perform all duties indicated f Check for oil leaks If there is any indication of an oil leak see LUBRICATION at the end of this manual PUMP SEAL There are two shaft seals in the pump The lower seal prevents liquid from entering the intermediate...

Page 10: ...oltage Phase 460 3 575 3 S4A Approximate Weight Lbs kg Oil Capacity Ounces Liters Seal Cavity Filling Position H orizontal V ertical Pump 50 Ft Cable Seal Cavity Motor Cavity 423 192 43 20 96 2 8 352 10 4 V Pump Dimensions For the approximate physical dimensions of your pump refer to the pump specification data sheet or contact your Gorman Rupp distributor or the Gorman Rupp Company Lifting Pump u...

Page 11: ...volves a lot of debris protect the pump from excessive wear and clogging by sus pending it in a perforated barrel or culvert pipe If the bottom is heavily sludge covered rest the pump on support blocks or suspend it from a raft or similar device near the surface of the liquid See Figure B 1 for typical pump installations All liquid entering the pump must pass through a strainer screen Any spherica...

Page 12: ...t be sub merged Refer to the control box manual for enclo sure dimensions and parts Secure the control vertically on a level surface above flood level The box should be easily acces sible to the operator and located close enough to the pump to avoid excessive voltage drop due to cable length see Pump Power Cable Connec tion After the box is installed make certain the front cover latches properly F...

Page 13: ...n on cable clamps and cable Grounding Methods Electrically ground the installation before connect ing the field wiring to the control box Install a grounding terminal to the enclosure and connect it to a properly embedded electrode The material used for the electrode must be an ex cellent conductor of electricity such as copper If iron or steel is used it must be galvanized or other wise metal pla...

Page 14: ... position and locked out or that the power supply to the control box has been otherwise cut off and locked out before connecting power or accessory cables The pump is provided with a 50 ft 15 2 m power cable see Table B 4 for standard power cable specifications If a longer cable is required an op tional cable assembly must be ordered from the factory Splicing of the power cable is not recom mended...

Page 15: ...ation through an approved control box Ground and wire the control box in accordance with the instructions accompanying it NOTE For reference internal motor wiring connections are shown in Maintenance and Repair Section E Liquid Level Devices The standard pump is not furnished with a means to automatically regulate liquid level However the pump may be controlled to perform filling or dewa tering fu...

Page 16: ...L BOX LIQUID LEVEL RANGE OFF DEWATERING ON FILLING Figure B 4 Liquid Level Devices The internal wiring of the sensing devices are different for filling and dewatering func tions Be sure to follow the instructions in cluded with the option before making wir ing connections WIRING DIAGRAMS Refer to the appropriate wiring diagram in the liter ature accompanying the control box when making electrical ...

Page 17: ...l automatic liquid level sensing device in which case those circuits are also contained within the control box The pump motor and control box are not designed to be explosion proof Do not operate in an explosive atmosphere Any control box used to operate the pump must be approved by the Gor man Rupp Company for the application Improper location of a non explosion proof control box could result in ...

Page 18: ...e pump immediately 2 Ventilate the area 3 Allow the pump to completely cool 4 Check the temperature before ser vicing 5 Vent the pump slowly and cau tiously 6 Refer to instructions in this manual before restarting the pump It is recommended that the pressure relief valve as sembly be replaced at each overhaul or any time the pump motor overheats and activates the valve Never replace this valve wit...

Page 19: ... the integral thermal over load device will shut off the motor if the temperature rises above design limits When the pump cools and the tempera ture falls below these limits the motor will restart automatically To avoid the hazards of an unexpected motor start up do not attempt to handle or service the pump unless all power to the motor has been shut off and locked out at the control box otherwise...

Page 20: ...k the oil level s as indicated in the following LUBRICATION section COLD WEATHER PRESERVATION Do not attempt to thaw the pump by us ing a torch or other source of flame This could damage gaskets O rings or heat the oil in the seal housing above critical temperatures causing the pump to rup ture or explode The pump will not freeze as long as the casing is submerged in liquid If the casing is not su...

Page 21: ...dding Oil Refer to Table B 2 in INSTALLATION for oil ca pacities and positions for filling the seal cavity in your pump Motor cavities requiring lubrication should always be positioned vertically for filling The grade of lubricant used is critical to the opera tion of this pump Use premium quality submers ible pump oil as specified in the following table Oil must be stored in a clean tightly close...

Page 22: ... 26 000 volts min Acceptable alternate suppliers Gulf Oil Company Gulf Harmony HVI AW 26 Texas Oil Company Rando HD 32 or HD AZ 32 Sun Oil Company Sunvis 816 or 916 BP Also Boron Energol HLP 32 Shell Oil Company Tellus 32 Tellus T 23 or T32 Viscosity 210 F 99 C 40 to 50 Recommended supplier Gulf Oil Company Gulf Harmony 32 AW ARCO Duro 32 Exxon Also Esso Nuto H 32 Petro Canada Harmony HVI 22 ...

Page 23: ...nsing device s Float type sensing device s tangled or obstructed Check installation for free movement of float Defective liquid level sensing de vice s or control panel Repair or replace defective unit s OVERLOAD UNIT TRIPS Low or high voltage or excessive voltage drop between pump and control box Measure voltage at control box Check that wiring is correct type size and length see Field Wiring Con...

Page 24: ...p or tank Stop pump until liquid level rises Worn impeller vanes excessive im peller clearance Check impeller and clearance see PUMP END REASSEMBLY in Maintenance and Repair Section E Pump running backwards Check direction of rotation If incor rect interchange any two motor leads at the control box see Pump Rotation Section C PUMP RUNS WITH EXCES SIVE NOISE OR VIBRATION Pumping entrained air Check...

Page 25: ... under each condition must be the same b If voltage is balanced when the pump is off but is imbalanced when the pump is running thoroughly check the power source all inter connecting cables and the pump motor to isolate the defect c Use an Amprobe or equivalent instrument to measure the current draw amperage of each phase while the pump is running under full load and with no load In each condition...

Page 26: ...ble and motor windings If resistance reads infinity 1 insulation is good If resistance reads between infinity 1 and 1 megohm insulation is acceptable but should be rechecked regularly If resistance reads less than 1 megohm insulation should be checked more closely and frequently c If readings indicate that a ground exists test the stator and motor power cable separately Replace as required ...

Page 27: ...water at sea level with minimum suction lift Since pump installations are seldom identical your performance may be dif ferent due to such factors as viscosity specific gravity elevation temperature and impeller trim If your pump serial number is followed by an N your pump is NOT a standard production model Contact the Gorman Rupp Company to verify per formance or part numbers Pump speed and operat...

Page 28: ...S SERIES PUMPS OM 06098 MAINTENANCE AND REPAIR PAGE E 2 SECTION DRAWING PARTSPAGE Figure E 1 S4A1 E25 460 3 And S4A1 E25 575 3 Pump Assemblies ...

Page 29: ...NING RING S245 1 35 UPPER IMP WASHER 10047A 17000 1 36 ADJ SHIM SET 37J 17090 REF 37 DEFORM LOCKNUT DD06 17000 6 38 STUD C0607 17000 6 39 STATOR 460V 47113 081 1 575V 47113 082 1 40 ROTOR SHAFT ASSY 47112 080 1 41 NAME PLATE 2613CY 17020 1 42 DRIVE SCREW BM 04 03 17000 6 43 BEARING CAP 10111 10010 1 44 MOTOR BUSHING 10108 14000 1 45 BEARING CAP GSKT 10111G 20000 1 46 STUD C0810 17000 6 47 LOCKWASH...

Page 30: ...S SERIES PUMPS OM 06098 MAINTENANCE AND REPAIR PAGE E 4 SECTION DRAWING Figure E 2 Terminal Housing And Cable Assembly ...

Page 31: ... 1 8 TERMINAL HOUSING 11366 13040 1 9 TERMINAL S1949 1 10 HEAT SHRINK TUBE 31413 014 19530 3 11 AL HD SETSCREW GA0501 1 2 14990 3 12 TERMINAL COLLAR 10144 14100 3 13 TERMINAL PLT ASSY 11163 24010 1 14 TERMINAL POST 38724 009 14100 3 15 AL HD SETSCREW GA0501 1 2 14990 3 16 DYNA SEAL WASHER S1586 3 17 TERMINAL S1550 1 18 RD HD MACH SCREW X0603 14990 2 19 T TYPE LOCKWASHER AK06 15991 2 20 DRIVE SCREW...

Page 32: ...nect a flexible discharge hose before removing the pump If rigid discharge piping is used disconnect the piping before attempting to move the pump Do not attempt to lift the pump by the motor power cable or the piping Attach proper lifting equipment to the lifting device fitted to the pump If chains or cable are wrapped around the pump to lift it make certain that they are posi tioned so as not to...

Page 33: ...or water could indicate a breakdown in the waterproof in tegrity of the motor cavity probably due to poor gaskets or seals Positioning Pump For Disassembly Figure E 1 It is recommended that the pump be positioned upside down during disassembly To hold the pump in the inverted position rest the pump se curely on blocks Be careful not to damage the pressure relief valve 28 and the terminal housing a...

Page 34: ...tating portion of the seal off the shaft Slide the hooked ends of two wires along the shaft and under the stationary seal seat Hook the back side of the seat and pull it from the intermediate bore If no further disassembly is required proceed to the appropriate areas in PUMP END REASSEMB LY NOTE Do not disassemble the motor unless it is neces sary and a clean well equipped shop is available If the...

Page 35: ...life If necessary clean the faces with a non oil based solvent and a clean lint free tissue Wipe lightly in a circular pattern to avoid scratching the faces Inspect the seal components for wear scoring grooves and other damage that might cause leak age If any components are worn replace the com plete seal never mix old and new seal parts Install the shaft seals as illustrated in Figure E 3 STATION...

Page 36: ...ng 34 and I D of the bellows Position the seal rotat ing portion on the shaft with the seal face down Apply firm steady pressure on the bellows retainer until it slides down the shaft and the seal faces con tact This step should be done in one continuous motion to prevent the bellows from sticking or roll ing as it passes over the retaining ring groove Slide the seal spring over the shaft and bell...

Page 37: ...against the diffuser the shaft and lower bearing have been driven out of position during impeller re moval If this occurs the lower bearing must be pressed back into place see MOTOR DISASSEM BLY and MOTOR REASSEMBLY Suction Head And Strainer Plate Installation Figure E 1 Inspect and thoroughly clean the suction head 62 and its O ring groove It must be clean and free of any flaws which could cut th...

Page 38: ...Carefully inspect any O rings or gaskets before re moval and cleaning to determine if a proper seal and compression existed prior to disassembly If sealing was faulty or questionable the cause must be determined and corrected before reassembly Replace any parts as required Terminal Housing And Power Cable Removal And Disassembly Figure E 1 Total disassembly of the terminal housing and power cable ...

Page 39: ...away the tubing and adhesive Disconnect the power cable leads from the termi nal posts and separate the terminal plate 13 from the terminal housing 8 Unscrew the terminal posts 14 and remove the terminal collars 12 posts and dyna seal washers 16 from the terminal plate Remove the hardware 18 and 19 securing the green and yellow ground leads to the terminal housing Reinstall the hardware See Termin...

Page 40: ...emoved re move the terminal housing as indicated in Termi nal Housing And Power Cable Disassembly Position an expandable tool such as a split disc approximately 2 inches 51 mm inside the stator and expand it tightly and squarely on the I D At tach a lifting device to the lifting eye of the tool and raise the assembly approximately 1 inch 25 mm off the work surface The motor housing 16 must be heat...

Page 41: ...motor housing 16 completely removing any old gasket and cement material Inspect the sealing surfaces for burrs nicks and pits which could cause a poor seal and replace defective parts as required Thoroughly clean the inside of the motor housing with fresh solvent The interior must be dry and free of dirt or lint Most cleaning solvents are toxic and flammable Use them only in a well ven tilated are...

Page 42: ...gs be cleaned and inspected in place It is strongly recommended that the bearings be replaced any time the shaft and rotor assembly is removed The bearings may be heated to ease installation An induction heater hot oil bath electric oven or hot plate may be used to heat the bearings Bear ings should never be heated with a direct flame or directly on a hot plate NOTE If a hot oil bath is used to he...

Page 43: ...efully lower the intermedi ate over the shaft and lower bearing guiding the studs in the bearing cap through the holes in the intermediate as it is lowered into place Apply Never Seez or equivalent compound to the threads of the capscrews 49 Use two of the caps crews and lockwashers 50 to draw the intermedi ate and bearing cap together Remove the studs temporarily installed in the bearing cap and ...

Page 44: ...nstructions in Seal ing Terminal Plate Connections With Potting Compound Use only materials and heating equip ment approved by Gorman Rupp for field repairs Before resealing the power and control cables re move all the old adhesive material or potting com pound from the leads terminal collars and termi nal plate Inspect all parts for damage and replace as required If the rubber bonding material on...

Page 45: ...INSIDE TERMINAL HOUSING RED T3 WHITE T1 BLACK T2 Figure E 5 Terminal Housing Wiring Connections Sealing Terminal Housing Connections With Potting Compound Figure E 2 Potting compound and silicone adhesive have the same electrical properties when correctly applied Silicone adhesive is used at the factory to facilitate production A commercially available potting kit Products Research Corp part numbe...

Page 46: ...er tacky to the touch it has cured Terminal Housing Installation Figure E 2 After the terminal plate has been sealed slide the terminal housing down the cable Untape the ground lead s and secure them to the terminal housing with the hardware 18 and 19 Be sure the lead s make good contact with the housing Pull gently on the cable to remove any excess length from within the terminal housing The term...

Page 47: ...the system will allow then draw the seal cavity down so the dif ferential between the two cavities is the same as the differential between the vacuum readings shown in the table Install full closing ball type shutoff valves with quick disconnect fittings in the pipe plug holes in both the motor and seal cavities Test the motor cavity for its full duration first then use the shutoff valve to mainta...

Page 48: ...quantity of lubricant when lubri cating a dry overhauled pump See Table E 3 for lubricant specifications The grade of lubricant used is critical to the opera tion of this pump Use premium quality hydraulic oil as specified in the following table Oil must be stored in a clean tightly closed container in a rea sonably dry environment Table E 2 Oil Quantity Pump Model Seal Cavity Motor Cavity S4A 352...

Page 49: ... REPAIR street tee assembly 29 Reinstall and tighten the cap Never attempt to fill the motor cavity through the drain plug 11 opening or the oil level plug 17 A volume of air must be trapped above the motor to permit thermal expansion of the motor oil ...

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Page 52: ...For Warranty Information Please Visit www grpumps com warranty or call U S 419 755 1280 Canada 519 631 2870 International 1 419 755 1352 GORMAN RUPP PUMPS ...