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

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ACU
COM‐06098‐01
March 11, 2008
Rev. A 05‐15‐12
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMPS
MODELS
S4A1-E25 460/3
and
S4A1-E25 575/3
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
D
GORMAN‐RUPP OF CANADA LIMITED
ST. THOMAS, ONTARIO, CANADA
Printed in U.S.A.
e
2008 The Gorman‐Rupp Company

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  • Page 1 March 11, 2008 Rev. A 05‐15‐12 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST SUBMERSIBLE PUMPS MODELS S4A1-E25 460/3 S4A1-E25 575/3 THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A. 2008 The Gorman‐Rupp Company...
  • Page 2 Register your new Gorman‐Rupp pump online at www.grpumps.com Valid serial 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: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........PAGE I - 1 SAFETY ‐...
  • Page 4 TABLE OF CONTENTS (continued) PARTS LISTS: Pump Assemblies ............PAGE E - 3 Terminal Housing and Cable Assemblies .

  • Page 5: Introduction

    S SERIES PUMPS OM-06098 INTRODUCTION Thank You for purchasing a Gorman‐Rupp S Se­ RECORDING MODEL AND ries Pump. Read this manual carefully to learn SERIAL NUMBER how to safely install and operate your pump. Fail­ ure to do so could result in personal injury or dam­ Please record the pump model and serial number age to the pump.
  • Page 6 S SERIES PUMPS OM-06098 damage which could result from failure to follow the procedure. Hazards or unsafe practices which COULD NOTE result in minor personal injury or product or Instructions to aid in installation, operation, and property damage. These instructions de­ maintenance or which clarify a procedure.

  • Page 7: Safety - Section A

    OM-06098 S SERIES PUMPS SAFETY - SECTION A This information applies to the S Series submersible motor driven pumps indi­ cated on the front cover of this manual. Before connecting any cable to the con­ Because pump installations are seldom trol box, be sure to ground the control identical, this manual cannot possibly box.
  • Page 8 S SERIES PUMPS OM-06098 position and locked out, or that the pow­ trician to troubleshoot, test and/or ser­ er supply to the control box has been vice the electrical components of this otherwise cut off and locked out, before pump. attempting to open or service the pump assembly.

  • Page 9: Installation - Section B

    OM-06098 S SERIES PUMPS INSTALLATION - SECTION B GENERAL INFORMATION ratings on the control box and incoming pow­ Review all SAFETY information in Section A. e. Carefully read all tags, decals, and markings Since pump installations are seldom identical, this on the pump, and perform all duties indicated.

  • Page 10: Pump Motor Specifications

    OM-06098 S SERIES PUMPS equipment as outlined in the National to prevent liquid from wicking through the Electric Code. Follow all safety require­ cable and into the motor. ments. Failure to observe these require­ NOTE ments could result in injury or death to Refer to the performance curve in Maintenance personnel.

  • Page 11: Positioning The Pump

    OM-06098 S SERIES PUMPS Positioning the Pump The pump will operate if positioned on its side, but this is not recommended because the motor NOTE torque could cause the pump to roll during opera­ Before installing and operating the pump, check tion.

  • Page 12: Electrical Connections

    OM-06098 S SERIES PUMPS ting near the pump. The discharge line must be in­ sible to the operator, and located close enough to dependently supported to avoid strain and vibra­ the pump to avoid excessive voltage drop due to tion on the pump. cable length (see Pump Power Cable Connec­...

  • Page 13: Grounding Methods

    OM-06098 S SERIES PUMPS be of the proper size and type to ensure an ade­ Table B‐3. Pump Voltage Requirements quate voltage supply to the pump. Voltage avail­ MAXIMUM NOMINAL MINIMUM PHASE VOLTAGE able at the motor must be within the range indi­ VOLTAGE VOLTAGE cated in Table B‐3.

  • Page 14: Pump Power Cable Connections

    OM-06098 S SERIES PUMPS c. Buried electrode: If rock or stone prevents this pump is high enough to cause inju­ embedding the full 8 foot (2,4 m) length of the ry or death. Obtain the services of a ground rod, bury it horizontally in a trench. qualified electrician to make all electri­...

  • Page 15: Control Box Specifications

    OM-06098 S SERIES PUMPS Connect the pump power cable to the control box NOTE as shown in the wiring diagrams in the control box For reference, internal motor wiring connections manual. Use conduit or cable clamps to secure the are shown in Maintenance and Repair - Section power cable to the control box.

  • Page 16: Wiring Diagrams

    OM-06098 S SERIES PUMPS PUMP PUMP CONTROL BOX CONTROL BOX TO LEVEL CONTROL CIRCUIT TO LEVEL CONTROL CIRCUIT IN MAIN CONTROL BOX IN MAIN CONTROL BOX LIQUID LEVEL LIQUID LEVEL RANGE RANGE DEWATERING DEWATERING ON (FILLING) ON (FILLING) Figure B-4. Liquid Level Devices cluded with the option before making wir­...

  • Page 17: Operation - Section C

    S SERIES PUMPS OM-06098 OPERATION - SECTION C GENERAL INFORMATION Review all SAFETY information in Section A. 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 This pump is designed to handle most pump must be approved by the Gor­...

  • Page 18: Impeller Rotation

    OM-06098 S SERIES PUMPS or thermal protection, or if the pump is operated 4. Check the temperature before ser­ against a closed discharge valve for an extended vicing. period of time. 5. Vent the pump slowly and cau­ tiously 6. Refer to instructions in this manual before restarting the pump.

  • Page 19: Starting, Stopping And Operational Checks

    S SERIES PUMPS OM-06098 this pump is high enough to cause inju­ ry or death. Make certain that incoming power is off and locked out before inter­ changing motor leads. Never start the pump more than 6 times per hour. If the pump motor does not cool be­ tween starts, it will over‐heat, resulting in damage to the motor windings.

  • Page 20: Cold Weather Preservation

    OM-06098 S SERIES PUMPS COLD WEATHER PRESERVATION To avoid serious damage to the pump, check for unusual noises or excessive vi­ Do not attempt to thaw the pump by us­ bration while the pump is running. If noise ing a torch or other source of flame. This or vibration is excessive, stop operation could damage gaskets, O‐rings or heat and refer to the troubleshooting chart in the...

  • Page 21: Draining Oil

    S SERIES PUMPS OM-06098 month thereafter. Check the motor lubrication level Adding Oil any time the pressure relief valve is activated, and Refer to Table B-2 in INSTALLATION for oil ca­ replace the oil annually. pacities and positions for filling the seal cavity in your pump.
  • Page 22 OM-06098 S SERIES PUMPS Table C-1. Pump Oil Specifications Specifications: Type ......Premium high viscosity index, anti‐wear hydraulic oil Viscosity @ 100_F (38_C) .

  • Page 23: Troubleshooting - Section D

    OM-06098 S SERIES PUMPS TROUBLESHOOTING - SECTION D Review all SAFETY information in Section A. NOTE Many of the probable remedies listed in the TROU­ BLESHOOTING CHART require use of electrical test instruments; for specific procedures, see ELECTRICAL TESTING at the end of the chart. TROUBLESHOOTING CHART TROUBLE POSSIBLE CAUSE...
  • Page 24 S SERIES PUMPS OM-06098 TROUBLESHOOTING CHART (cont'd) TROUBLE POSSIBLE CAUSE PROBABLE REMEDY Discharge head too high. Reduce discharge head or install MOTOR RUNS, BUT PUMP FAILS staging adaptor and additional TO DELIVER pump. RATED DIS­ Low or incorrect voltage. Measure control box voltage, both CHARGE.
  • Page 25 OM-06098 S SERIES PUMPS ELECTRICAL TESTING 3. The pump submerged and running under full load. Make the electrical checks which follow to deter­ The voltage measured under each condition mine if pump malfunctions are being caused by must be the same. problems in the motor or in the motor cable.
  • Page 26 S SERIES PUMPS OM-06098 the other test lead to each of the motor cable should be rechecked regularly. If resistance leads in turn. Note the readings. reads less than 1 megohm, insulation should be checked more closely and frequently. b. Readings will indicate resistance values in both the power cable and motor windings.If resistance reads infinity (1), insulation is c.

  • Page 27: Pump Maintenance And Repair - Section E

    MAINTENANCE AND REPAIR OF THE WEARING PARTS OF THE PUMP WILL MAINTAIN PEAK OPERATING PERFORMANCE. STANDARD PERFORMANCE FOR PUMP MODELS S4A1-E25 460/3 AND S4A1-E25 575/3 Based on 70_F (21_C) clear water at sea level Contact the Gorman‐Rupp Company to verify per­...
  • Page 28 S SERIES PUMPS OM-06098 SECTION DRAWING PARTS PAGE Figure E-1. S4A1-E25 460/3 And S4A1-E25 575/3 Pump Assemblies PAGE E - 2 MAINTENANCE AND REPAIR...
  • Page 29 OM-06098 S SERIES PUMPS S4A1-E25 460/3 And S4A1-E25 575/3 Pump Assemblies Parts List (From S/N 1396115 Up) 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 part numbers.
  • Page 30 S SERIES PUMPS OM-06098 SECTION DRAWING Figure E-2. Terminal Housing And Cable Assembly PAGE E - 4 MAINTENANCE AND REPAIR...
  • Page 31 OM-06098 S SERIES PUMPS Terminal Housing And Cable Assembly Parts List ITEM PART MAT'L PART NAME NUMBER CODE TERMINAL GLAND 11367 13040 POWER CABLE 10325S CABLE GRIP 11227L STUD C0808 17000 HEX NUT 17000 GLAND BUSHING 10758K 19100 TERMINAL WASHER 10659 15991 TERMINAL HOUSING...
  • Page 32 S SERIES PUMPS OM-06098 used, disconnect the piping before attempting to PUMP AND SEAL DISASSEMBLY AND move the pump. REASSEMBLY Review all SAFETY information in Section A. Do not attempt to lift the pump by the motor power cable or the piping. Attach proper lifting equipment to the lifting Do not attempt to service the pump as­...
  • Page 33 OM-06098 S SERIES PUMPS disturbed. Repair gaskets and O‐rings are listed in could indicate a breakdown in the waterproof in­ the Parts List. tegrity of the motor cavity, probably due to poor gaskets or seals. PUMP END DISASSEMBLY Positioning Pump For Disassembly Strainer Removal (Figure E-1) (Figure E-1)
  • Page 34 S SERIES PUMPS OM-06098 Lower Seal Removal If no further disassembly is required, proceed to the appropriate areas in PUMP END REASSEMB­ (Figures E-1 and E-3) Carefully remove the seal spring. Lubricate the ro­ NOTE tor shaft (40) and work oil under the bellows as­ Do not disassemble the motor unless it is neces­...
  • Page 35 OM-06098 S SERIES PUMPS Inspect the rotor shaft (40) for damaged threads, Handle the seal parts with extreme care to prevent scoring, or nicks. Remove nicks and burrs with a damage. Be careful not to contaminate the preci­ fine file or hand honing stone to restore original sion finished faces;...
  • Page 36 S SERIES PUMPS OM-06098 Clean the rotor shaft (40) and seal cavity area of the Slide the seal spring over the shaft and bellows re­ intermediate (51). Be sure the area is dry and free tainer, and install the spring retainer. Install the seal of lint and dirt.
  • Page 37 OM-06098 S SERIES PUMPS surface damage. Because the rotating element moval. If this occurs, the lower bearing must be may not stay in the bellows retainer when turned pressed back into place (see MOTOR DISASSEM­ upside down, place a small amount of grease at BLY and MOTOR REASSEMBLY).
  • Page 38 S SERIES PUMPS OM-06098 Apply `Never‐Seez' or equivalent compound to the assembly. Tag electrical circuits to pre­ threads of the capscrews (5). Install the hardware vent accidental start‐up. (5, 6 and 7) and torque evenly in a cross sequence Carefully inspect any O‐rings or gaskets before re­ to 60 ft.
  • Page 39 OM-06098 S SERIES PUMPS Quite often, pressure exerted on the bushing will Remove the hardware (18 and 19) securing the deform the cable jacket. If such happens, addition­ green and yellow ground leads to the terminal al oil and effort will be required to remove the bush­ housing.
  • Page 40 S SERIES PUMPS OM-06098 Position an expandable tool, such as a split disc, be cleaned and inspected in place. It is approximately 2 inches (51 mm) inside the stator, strongly recommended that the bearings and expand it tightly and squarely on the I.D. At­ be replaced any time the shaft and rotor tach a lifting device to the lifting eye of the tool, and assembly is removed.
  • Page 41 OM-06098 S SERIES PUMPS ple is removed, apply `Loctite Retaining Com­ Clean all gasket and O‐ring surfaces of the motor pound No. 680 or No. 620' or equivalent com­ housing (16), completely removing any old gasket pound on both ends of the nipple only. and cement material.
  • Page 42 S SERIES PUMPS OM-06098 Heat the motor housing (16) with a torch to expand hot plate may be used to heat the bearings. Bear­ it enough for the stator (39) to be installed; when ings should never be heated with a direct flame or heating the motor housing, make sure that the sta­...
  • Page 43 OM-06098 S SERIES PUMPS 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 When installing the bearing onto the shaft, threads of the capscrews (49). Use two of the caps­ crews and lockwashers (50) to draw the intermedi­...
  • Page 44 S SERIES PUMPS OM-06098 Before resealing the power and control cables, re­ pump motor and cable must be com­ move all the old adhesive material (or potting com­ pletely waterproof. Injury or death may pound) from the leads, terminal collars, and termi­ result from alterations.
  • Page 45 OM-06098 S SERIES PUMPS adhesive. See Figure E-5 and check terminal locations. Ap­ ply a 1/4 to 3/8 in. (6,4 to 9,7 mm) thick layer (maxi­ All air pockets, voids or gaps in the sili­ mum) of silicone adhesive around each of the ter­ cone sealant must be removed to en­...
  • Page 46 S SERIES PUMPS OM-06098 up over the leads of the power cable and control Terminal Housing Installation cable. (Figure E-2) After the terminal plate has been sealed, slide the terminal housing down the cable. Untape the Secure each cable lead as described in the pre­ ground lead(s) and secure them to the terminal vious section.
  • Page 47 OM-06098 S SERIES PUMPS ket (19). Apply `Never‐Seez' or equivalent com­ It is recommended that a vacuum pump be used to pound on the flange studs (21), and secure the draw the vacuum on the cavities. If a vacuum pump flange with the nuts (22).
  • Page 48 S SERIES PUMPS OM-06098 mally low, or the color milky or dark, refer to Drain­ LUBRICATION ing Oil From Seal Cavity in this section for instruc­ tions and troubleshooting tips. If the oil is clear, ap­ Seal Cavity ply `Loctite Pipe Sealant With Teflon No. 592.' or equivalent to the threads of the pipe plug, before Check the oil level in the seal cavity before initial reinstalling the plug.
  • Page 49 OM-06098 S SERIES PUMPS 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.
  • 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...

This manual is also suitable for:

S4a1-e25 575/3

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