GORMAN-RUPP PUMPS S2D3A User manual

OM-01690---04

October 28, 2003

Rev. A 11-19-03

ACDEGH

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

www.gormanrupp.com

ECopyright by the Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SSERIESPUMP

MODEL

S2D3A 115V 1P

TABLE OF CONTENTS

INTRODUCTION PAGE I --- 1.................................................

SAFETY - SECTION A PAGE A --- 1............................................

INSTALLATION --- SE CTION B PAGE B --- 1....................................

GENERAL INFORMATION PAGE B --- 1..................................................

PREINSTALLATION INSPECTION PAGE B --- 1............................................

PUMP SEAL PAGE B --- 1..............................................................

LUBRICATION PAGE B --- 1.............................................................

PUMP INSTALLATION PAGE B --- 2......................................................

Pump Motor Specifications PAGE B --- 2..............................................

Pump Dimensions PAGE B --- 2.....................................................

Lifting PAGE B --- 2.................................................................

Positioning the Pump PAGE B --- 2...................................................

Piping PAGE B --- 3................................................................

ELECTRICAL CONNECTIONS PAGE B --- 3...............................................

Grounding Methods PAGE B --- 4....................................................

Pump Power Cable Connections PAGE B --- 5.........................................

OPERAT ION --- SECTION C PAGE C --- 1......................................

GENERAL INFORMATION PAGE C --- 1..................................................

Pump Performance PAGE C --- 1.....................................................

Pump Controls 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 And Stopping PAGE C --- 3..................................................

Operational Checks PAGE C --- 3....................................................

LIQUID LEVEL PAGE C --- 4............................................................

COLD WEATHER PRESERVATION PAGE C --- 4...........................................

LUBRICATION PAGE C --- 4.............................................................

Draining Oil PAGE C --- 4...........................................................

Condition Of Oil PAGE C --- 4........................................................

Adding Oil PAGE C --- 5............................................................

TROUBLESHOOTING --- SECTION D PAGE D --- 1..............................

ELECTRICAL TESTING PAGE D --- 2.....................................................

Test Equipment PAGE D --- 2........................................................

Voltage Imbalance PAGE D --- 3.....................................................

Motor And Motor Power Cable Continuity PAGE D --- 3.................................

Insulation Resistance PAGE D --- 3...................................................

Capacitor PAGE D --- 4.............................................................

Wiring Diagram PAGE D --- 4........................................................

PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E --- 1.................

STANDARD PERFORMANCE CURVE PAGE E --- 1........................................

PUMP MODEL S2D3A 115V 1P PARTS LIST PAGE E --- 3..................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 4.........................

TABLE OF CONTENTS

(continued)

PUMP END DISASSEMBLY PAGE E --- 4.................................................

Strainer And Impeller Cover Removal PAGE E --- 5.....................................

Draining Oil From Seal Cavity PAGE E --- 5............................................

Positioning Pump For Disassembly PAGE E --- 5.......................................

Impeller Removal PAGE E --- 5......................................................

Seal Removal PAGE E --- 5..........................................................

PUMP END REASSEMBLY PAGE E --- 6..................................................

Cleaning And Inspection Of Pump Parts PAGE E --- 6..................................

Seal Installation PAGE E --- 6........................................................

Impeller Installation PAGE E --- 8.....................................................

Impeller Clearance PAGE E --- 8.....................................................

Strainer Installation PAGE E --- 8....................................................

MOTOR DISASSEMBLY PAGE E --- 9....................................................

Head And Power Cable Removal PAGE E --- 9.........................................

Rotor And Shaft Removal PAGE E --- 10...............................................

Bearing Removal PAGE E --- 10.......................................................

Centrifugal Contact Switch Removal PAGE E --- 10......................................

Stator Removal PAGE E --- 10........................................................

MOTOR REASSEMBLY PAGE E --- 11.....................................................

Stator Installation PAGE E --- 11......................................................

Centrifugal Contact Switch Installation PAGE E --- 12....................................

Bearing Installation PAGE E --- 12.....................................................

Rotor And Shaft Installation PAGE E --- 13.............................................

Head And Power Cable Installation PAGE E --- 13.......................................

VACUUM/PRESSURE TESTING PAGE E --- 14.............................................

LUBRICATION PAGE E --- 15.............................................................

Seal Cavity PAGE E --- 15............................................................

Motor Cavity PAGE E --- 15...........................................................

SSERIESPUMP OM--01690

PAGE I -- 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman-Rupp pump.

Read this manual carefully to learn how to safely

install and operate your pump. Failure to do so

could result in personal injury or damage to the

pump. This Installation, Operation, and Mainte-

nance manual isdesigned tohelp you achievethe

best performance and longest life from your Gor-

man-Rupp pump.

This is an S Series submersible pump. The basic

material of construction is cast iron, with stainless

steel hardware and fittings. The pump is light

weight and portable, making it ideally suited to

many domestic and industrial applications where

low capacity dewatering or irrigation is required.

The pump is powered by an integral, thermally-

protected electric motor which is not explosion-

proof. The pump may be operated fully or partially

submerged. Do not operate the pump in a hazard-

ous atmosphere.

Pump motor maintenance may be performedonly

by a Gorman-Rupp authorized repair facility, orthe

factory. Otherwise, the pump warranty will be ne-

gated, and damage to the pump, and injury or

death to personnel can result. Contact the factory

for the authorized repair facility closest to you.

Because pump installations are seldom identical,

this manual cannot possibly provide detailed in-

structions and precautions for every aspect of

each specific application. Therefore, it is the re-

sponsibility of the owner/installer of the pump to

ensure that applications not addressed in this

manual are performed only after establishing that

neitheroperatorsafetynorpumpintegrityarecom-

promised by the installation. Pumps and related

equipment must be installed and operated ac-

cording to all national, local and industry stan-

dards.

If there are any questions regarding the pump or

its application which are not covered in this man-

ual or in other literature accompanying this unit,

please contact your Gorman-Rupp distributor, or

write:

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

The following are used to alert maintenance personnel to procedures which require special attention, to

those which could damage equipment, and to those which could be dangerous to personnel:

Immediate hazards whichWILL result in

severe personal injury or death. These

instructions describe the procedure re-

quired and the injury which will result

from failure to follow the procedure.

Hazards or unsafe practices which

COULD result in severe personal injury

or death. These instructions describe

the procedure required and the injury

which could result from failure to follow

the procedure.

HazardsorunsafepracticeswhichCOULD

result in minor personal injury or product

or property damage. These instructions

describe the requirements and the possi-

ble damage which could result from failure

to follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

SSERIESPUMP OM--01690

SAFETY PAGE A -- 1

SAFETY --- SECTION A

This information applies to the S Series

submersible motor driven pumps.

Because pump installations are seldom

identical, this manual cannot possibly

provide detailed instructions and pre-

cautions for each specific application.

Therefore, it is the owner/installer’s re-

sponsibility to ensure that applications

not addressed in this manual are per-

formed only after establishing that nei-

ther operator safety nor pump integrity

are compromised by the installation.

Beforeattemptingtoopenorservicethe

pump:

1. Familiarize yourself with this man-

ual.

2. Unplugthepowercablefromitsre-

ceptacle to ensure that the pump

will remain inoperative.

3. Allow the pump to completely cool

if overheated.

5. Close the discharge valve (if

used).

This pump is not designed to pump vol-

atile,explosive,orflammablematerials.

Do not attempt to pump any liquids for

which you pump is not approved, or

which may damage the pump or endan-

ger personnel as a result of pump fail-

ure. Consult the factory for specific ap-

plication data.

The electrical power used to operate

this pump is high enough to cause inju-

ry or death. Make certain that the power

cable receptacle is properly grounded

before installation.

The electrical power used to operate

this pump is high enough to cause inju-

ry or death. Make certain that the plug

on the pump power cable is discon-

nected from its receptacle before ser-

vicing.

The electrical power used to operate

this pump is high enough to cause inju-

ry or death. Obtain the services of a

qualified electrician to make all electri-

cal connections.

Never attempt to alter the length or re-

pair any power cable with a splice. The

pump motor and cable must be com-

pletely waterproof. Injury or death may

result from alterations.

Allelectrical connectionsmustbe inac-

cordance with The National Electric

Code and all local codes. If there is a

conflict between the instructions pro-

vided and N.E.C. Specifications, N.E.C.

Specifications shall take precedence.

All electrical equipment supplied with

this pump was in conformance with

N.E.C. requirements in effect on the

OM--01690 SSERIESPUMP

PAGE A -- 2 SAFETY

date of manufacture. Failure to follow

applicable specifications, or substitu-

tion of electrical parts not supplied or

approved by the manufacturer, can re-

sult in severe injury or death and void

warranty.

Afterthepumphasbeeninstalled,make

certain that the pump and all piping or

hoseconnections are secure beforeop-

eration.

Obtain the services of a qualified elec-

trician to troubleshoot, test and/or ser-

vice the electrical components of this

pump.

Donotattempttoliftthepumpbythe

motor power cable or discharge hose.

Attach proper lifting equipment to the

lifting device fitted to the pump.

Pumps and related equipment must be

installed and operated according to all na-

tional, local and industry standards.

OM--01690 SSERIESPUMP

PAGE B -- 1

INSTALLATION

INSTALLATION --- SECTION B

GENERAL INFORMATION

Review all SAFETY information in Section A.

Since pump installations are seldom identical, this

section is intended only to summarize generalrec-

ommendations and practices required to inspect,

position,andarrangethepumpandpiping.Ifthere

are any questions concerning your specific instal-

lation, contact your Gorman-Rupp distributor or

the Gorman-Rupp Company.

Nuts, bolts and screws used on this pump

are metric and do not matchstandardSAE

measurement threads. If any threaded

hardware is replaced, it must be replaced

with metric type. Attempting to force in a

fastener with SAE threads will damage the

mating threads. An optional discharge

adaptor is available to convert the metric

pipe threads in the discharge flange to the

SAE threads.

PREINSTALLATION INSPECTION

The pump assemblywas inspectedand tested be-

fore shipment from the factory. Before installation,

check for damage which may have occurred dur-

ing shipment. Check as follows:

a. Inspectthepumpassemblyforcracks,dents,

damaged threads, and other obvious dam-

age.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry-

ing, check for and tighten loose hardware at

the mating surfaces.

c. Inspect the power cable for cuts or any other

obvious damage.

d. Check that amperes, phase, voltage and

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

onthepump,andperformalldutiesindicated.

f. Check for oil leaks. If there is any indication of

an oil leak, see LUBRICATION at the end of

this manual.

g. If the pump has been stored for more than 12

months, some of the components or lubri-

cants may have exceeded their maximum

shelf life. These must be inspected or re-

placed to ensure maximum pump service.

Ifthemaximumshelflifehasbeenexceed,orif

anything appears to be abnormal, contact

your Gorman-Rupp distributor or the factory

to determine the repair or updating policy. Do

not put the pump into service until appropri-

ate action has been taken.

PUMP SEAL

Thepumpisequippedwithasinglefacedsealas-

sembly. It is designed to prevent the liquid being

pumped from entering the lubrication cavity at the

impeller end. A lip seal is used to prevent moisture

or lubrication oil from entering the motor housing

cavity at the motor end.

Thesealislubricatedbypremiumqualitysubmers-

ible pump oil.

LUBRICATION

The pump utilizes one lubrication cavity, located

between the pump casing and the motor housing.

It is filled with premium quality submersible pump

oilwhichlubricatesthepumpseal.Themotoroper-

ates in and is cooled by air, therefore it requires no

lubrication.

This pump was fullylubricated when shipped from

the factory. However, lubrication levels must be

checked before installing the pump (see LU-

BRICATION in the MAINTENANCE AND REPAIR

MANUAL). If the oil level is abnormally low, deter-

mine the cause before putting the pump into ser-

vice.

Refer to Table B-2 for the oil capacity and position

for filling the seal cavity in the pump. Refer to LU-

BRICATION, Section C for lubrication specifica-

tions and intervals.

SSERIESPUMPS OM--01690

PAGE B -- 2 INSTALLATION

PUMP INSTALLATION

Pump Motor Specifications

See Tables B-1 and B-2 for pump specifications.

Table B-1. Pump Specifications

Liquid

Level

Control

Locked

Rotor

Amperes

Pump

HP/

Motor

Speed

(RPM)

Full

Load

Amperes

Load

Amperes

Discharge

Size

(NPT)

Model Voltage/

Phase

S2D3A 115/1 YES 8.6 1.0 50.61 HP 3450 2INCH

w/BARBED

ADAPTOR

Table B-2. Additional Specifications

Pump

Model Voltage/

Phase

115/1S2D3A

Approximate

Weight -- Lbs. (kg) Oil Capacity

Ounces (Liters) Seal Cavity

Filling

Position

(H)orizontal

Pump 50 Ft. Cable Seal

Cavity Motor

Cavity

78 (42) 6 (3) 7 (0,2) H

--- --- ---

When installing or servicing the pump

or controls, follow all requirements for

the installation of wiring or electrical

equipment as outlined in the National

Electric Code. Follow all safety require-

ments.Failuretoobservetheserequire-

ments could result in injury or death to

personnel. NOTE

Refer to the performance curve in Section E, Main-

tenance and Repair when determining the most

efficient piping installation. The recommended

maximum submergence depth is 23 feet. Great-

er depths could result in damage to the pump

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 unit weights will vary depending on the

mounting and drive provided. Check the shipping

tagontheunitpackagingfortheactualweight,and

use lifting equipment with appropriate capacity.

Drain the pump and remove all customer-installed

equipment such as suction and discharge hoses

or piping before attempting to lift existing, installed

units.

Donotattempttoliftthepumpbythe

motor power cable or the piping. Attach

proper lifting equipment or a rope to the

lifting device fitted to the pump.

Positioning the Pump

The pump is designed to operate fully or partially

submerged. The rotating parts are oil lubricated,

and the motor is cooled bya constantflow of liquid

or air discharged through internal passages.

The pump will operate if positioned on its side, but

this is not recommended because the motor

OM--01690 SSERIESPUMP

PAGE B -- 3

INSTALLATION

torque could cause the pump to roll during opera-

tion.

The pump should be independently secured and

supported by the lifting device fitted on the pump.

Iftheapplicationinvolvesalotofdebris,protectthe

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 spherical solids which pass

through the screen will pass through the pump.

BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS

Figure B-1. Typical Pump Installations

Piping

Nosuctionpipingis required ina standard installa-

tion. This pump is provided with a suction strainer

to prevent large solids from clogging the impeller.

To determine the size of the discharge connection,

see Table B-1. Either hose or rigid pipe may be

used. To facilitate mobility and maintenance, it is

recommendedthatthedischargelinebefittedwith

a quick disconnect fitting near the pump. The dis-

charge line must be independently supported to

avoid strain and vibration on the pump.

Either hose or rigid pipe may be used to make dis-

charge connections. For maximum pumping ca-

pacity, keep the line as short and straight as pos-

sible. Elbows and fittings used in discharge lines

increase friction loss, minimize their use.

It is recommended that a check valve or throttling

valve be installed in the discharge line tocontrolsi-

phoning or back flow when the pump is shut off.

ELECTRICAL CONNECTIONS

Install and operate this pump in accor-

dance with the National Electrical Code

and all local codes. Have a qualified

electrician perform all checks and con-

nections in this section.

Never attempt to alter the length of the

pump motor cable or to repair it with a

splice. The power cable and pump mo-

tormustbekeptcompletelywaterproof.

SSERIESPUMPS OM--01690

PAGE B -- 4 INSTALLATION

Serious damage to the pump and injury

or death to personnel can result from

any alteration to the cable.

Field Wiring Connections (Incoming Power)

The pump is designed to operate with a 115 volt,

1 phase, 60 hertz power supply. The voltage avail-

able at the motor must be within the range indi-

cated in Table B-3.

To calculate the voltageavailable at the motor, pro-

ceed as follows:

a. Measurethevoltagewhile the pump is oper-

ating atfull capacity. See wiring diagrams at

the end of this section.

b. Next, subtract the motor cable voltage drop

(see Table B-4, Pump Power Cable Specifi-

cations).

c. Do not continue to operate the pump if this

voltage is not within the recommendedlimits.

Obtaintheservices ofa qualifiedelectrician to

determinethecorrectfieldwiringsizeandoth-

er details toensure an adequate voltagesup-

ply to the pump.

Table B-3. Pump Voltage Requirements

NOMINAL

VOLTAGE PHASE MINIMUM

VOLTAGE MAXIMUM

VOLTAGE

1115 110 120

Pump Power Cable Connections

The electrical power used to operate

this pump is high enough to cause inju-

ry or death. Obtain the services of a

qualified electrician to make all electri-

cal connections. Make certain that the

pump and receptacle are properly

grounded.

The pump is provided with a 50 ft. (15,2 m) power

cable (see Table B-4 for standard power cable

specifications) with one end wired into the pump

head. The other end terminates in a grounded

power plug. Power to the receptacle must be di-

rected through a fused circuit, and the receptacle

must be controlled by a positive ON/OFF switch.

The use of extension cords is not recommended.

If extension cords are used, they must have three-

wiresinglephase construction and have adequate

carrying capacity for their length.

Never attempt to alter the length or re-

pair any power cable with a splice. The

pump motor and cable must be com-

pletely waterproof. Injury or death may

result from alternations.

Table B-4. Pump Power Cable Specifications

Pump

Model Voltage/

Phase

115/1

A.W.G

Cable

Size

Conductor

Dia.

Inches

(mm)

Resistance

(ohms) at

225_

_C(77_

_F)

per 1000 ft.

(305 m)

Cable

O.D.

Inches

(mm)

Amp

Rating

(See

Note

Below) Cable

Type

Voltage

Drop

per 100 ft.

(30,5m) at

Max. Load

16 13* SO 7.72S2D3A 0.43 (11) 0.06 (1,5) 4.49

When necessary to service the pump, make cer-

tain the power cable is unplugged from the recep-

tacle.

This manual suits for next models

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