GORMAN-RUPP PUMPS S6A1-E60 460/3 User manual

OM‐06111‐02

March 10, 2020

GORMAN‐RUPP PUMPS

www.grpumps.com

2020 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUBMERSIBLE PUMPS

MODELS

S6A1-E60 460/3

and

S6A1-E60 575/3

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:

TABLE OF CONTENTS

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

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

INSTALLATION - SECTION B PAGE B - 1....................................

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

Pump Model Designation PAGE B - 1...............................................

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

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

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

PUMP INSTALLATION PAGE B - 1......................................................

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

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

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

Positioning the Pump PAGE B - 3...................................................

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

ELECTRICAL CONNECTIONS PAGE B - 4...............................................

Field Wiring Connections (Incoming Power) PAGE B - 4...............................

Grounding Methods PAGE B - 5....................................................

Pump Power Cable Connections PAGE B - 6.........................................

Control Box Specifications PAGE B - 7..............................................

Motor 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 C - 3..............................................................

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

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

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

Draining Oil PAGE C - 5...........................................................

Condition of Oil Oil PAGE C - 5.....................................................

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

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

PREVENTIVE MAINTENANCE PAGE D - 3...............................................

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

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

TABLE OF CONTENTS

(continued)

PARTS LISTS:

Pump Assemblies PAGE E - 3......................................................

Terminal Housing and Cable Assemblies PAGE E - 5..................................

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................

PUMP END DISASSEMBLY PAGE E - 7.................................................

Strainer Removal PAGE E - 7.......................................................

Draining Oil From Seal Cavity PAGE E - 7............................................

Draining Oil From Motor Cavity PAGE E - 7..........................................

Positioning Pump For Disassembly PAGE E - 7.......................................

Strainer Plate and Suction Head Removal PAGE E - 7.................................

Impeller Removal PAGE E - 8......................................................

Lower Seal Removal PAGE E - 8....................................................

Upper Seal Removal PAGE E - 8...................................................

PUMP END REASSEMBLY PAGE E - 8..................................................

Cleaning and Inspection of Pump Parts PAGE E - 8...................................

Upper Seal Installation PAGE E - 10..................................................

Lower Seal Installation PAGE E - 11..................................................

Impeller Installation PAGE E - 11.....................................................

Suction Head and Strainer Plate Installation PAGE E - 12...............................

Strainer Screen and Base Plate Installation PAGE E - 12................................

MOTOR DISASSEMBLY PAGE E - 12....................................................

Terminal Housing and Power Cable Removal and Disassembly PAGE E - 13..............

Intermediate and Motor Housing Disassembly PAGE E - 14.............................

Rotor and Bearing Removal PAGE E - 14.............................................

Stator Removal PAGE E - 15........................................................

Relief Valve PAGE E - 15............................................................

Hoisting Bail PAGE E - 15...........................................................

MOTOR REASSEMBLY PAGE E - 15.....................................................

Stator Installation PAGE E - 16......................................................

Bearing Installation PAGE E - 17.....................................................

Rotor and Intermediate Reassembly PAGE E - 18......................................

Terminal Housing and Power Cable Reassembly and Installation PAGE E - 19.............

Sealing Terminal Housing Connections With Silicone Adhesive PAGE E - 19..............

Sealing Terminal Housing Connections With Potting Compound PAGE E - 21.............

Terminal Housing Installation PAGE E - 22............................................

FINAL ASSEMBLY PAGE E - 22.........................................................

VACUUM TESTING PAGE E - 22........................................................

LUBRICATION PAGE E - 23.............................................................

Seal Cavity PAGE E - 23............................................................

Motor Housing Cavity PAGE E - 24...................................................

S SERIES PUMPS OM-06111

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 manual will alert personnel to known proce

dures which require special attention, to those

which could damage equipment, and to those

which could be dangerous to personnel. However,

this manual cannot possibly anticipate and provide

detailed precautions for every situation that might

occur during maintenance of the unit. Therefore, it

is the responsibility of the owner/maintenance per

sonnel to ensure that only safe, established main

tenance procedures are used, and that any proce

dures not addressed in this manual are performed

only after establishing that neither personal safety

nor pump integrity are compromised by such prac

tices.

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

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

For information or technical assistance on the pow

er source, contact the power source manufactur

er's local dealer or representative.

The following are used to alert maintenance per

sonnel to procedures which require special atten

tion, to those which could damage equipment, and

to those which could be dangerous to personnel:

Immediate hazards which WILL 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.

Hazards or unsafe practices which COULD

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.

OM-06111 S SERIES PUMPS

PAGE A - 1SAFETY

SAFETY - SECTION A

This information applies to the S Series

submersible motor driven pumps indi

cated on the front cover of this manual.

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.

Before attempting to open or service the

pump:

1. Familiarize yourself with this man

ual.

2. Lock out incoming power to the

control box to ensure that the

pump will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Close the discharge valve (if

used).

This pump is not designed to pump vol

atile, explosive, or flammable materials.

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.

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 power control.

Do not connect the pump motor directly

to the incoming power lines.

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 enclosure are properly

grounded; never use gas pipe as an

electrical ground. Be sure that the in

coming power matches the voltage and

phase of the pump and control before

connecting the power source. Do not

run the pump if the voltage is not within

the limits. If the overload unit is tripped

during pump operation, correct the

problem before restarting the pump.

The electrical power used to operate

this pump is high enough to cause inju

ry or death. Make certain that the control

handle on the control box is in the OFF

S SERIES PUMPS OM-06111

PAGE A-2 SAFETY

position and locked out, or that the pow

er supply to the control box has been

otherwise cut off and locked out, before

attempting to open or service the pump

assembly. Tag electrical circuits to pre

vent accidental start‐up.

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.

All electrical connections must be in ac

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

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.

After the pump has been installed, 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 tempera

ture will be especially high if operated

against a closed discharge valve. Never

operate against a closed discharge

valve for long periods of time.

Do not remove plates, covers, gauges,

pipe plugs, or fittings from an over

heated pump. Vapor pressure within the

pump can cause parts being disen

gaged to be ejected with great force. Al

low the pump to completely cool before

servicing.

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 damage the pump,

and so that the load will be balanced.

Pumps and related equipment must be

installed and operated according to all na

tional, local and industry standards.

S SERIES PUMPS OM-06111

PAGE B - 1INSTALLATION

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 general rec

ommendations and practices required to inspect,

position, and arrange the pump and piping. If there

are any questions concerning your specific instal

lation, contact your Gorman‐Rupp distributor or

the Gorman‐Rupp Company.

Liquid level devices are available from Gorman‐

Rupp as optional equipment. For information on

installing and operating these items, refer to the lit

erature accompanying them.

Pump Model Designation

Following is a description of the model numbering

system for S Series pumps. These submersible

pumps are available in a range of sizes. Refer to the

following chart to identify the size of your specific

pump model.

Series

Discharge Size

Pump Hydraulics

Pump Construction

H.P.

Voltage/Phase

3 C 1 E 230/3- 6.2

Pump Model

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be

fore shipment from the factory. Before installation,

check for damage which may have occurred dur

ing shipment. Check as follows:

a. Inspect the pump assembly for cracks, dents,

damaged threads, and other obvious dam

age.

b. Check for loose attaching hardware. Since

gaskets tend to shrink after drying, check for

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

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

cavity at the impeller end. The upper seal prevents

oil leakage from the motor housing cavity and acts

as back‐up protection in the event of lower seal fail

ure.

LUBRICATION

These pumps utilize two lubrication cavities. The

motor housing cavity provides lubrication to the

motor assembly and bearings, while the intermedi

ate cavity provides lubrication to the pump seal.

The pumps are fully lubricated when shipped from

the factory. However, lubrication levels must be

checked before installing the pump (see LU

BRICATION in MAINTENANCE AND REPAIR -

SECTION E). An additional quart (0,9 liter) of oil is

provided to “top off” the oil level in the pump motor

cavity. If the oil level is abnormally low, determine

the cause before putting the pump into service.

Due to differences in pump design, the quantity of

oil and manner in which oil is to be added to the

seal cavity varies between pump models. Refer to

Table B‐2 for oil capacities and positions for filling

the seal cavity in each pump. Motor cavities requir

ing lubrication should always be positioned verti

cally for filling. Refer to LUBRICATION, Section C

for lubrication specifications and intervals.

PUMP INSTALLATION

When installing or servicing the pump

or controls, follow all requirements for

the installation of wiring or electrical

OM-06111 S SERIES PUMPS

PAGE B - 2 INSTALLATION

equipment as outlined in the National

Electric Code. Follow all safety require

ments. Failure to observe these require

ments could result in injury or death to

personnel.

Do not allow the free end of the power

cable to enter the liquid being pumped.

The free end of the cable must be kept dry

to prevent liquid from wicking through the

cable and into the motor.

NOTE

Refer to the performance curve in Maintenance

and Repair - Section E when determining the

most efficient piping installation. The recom

mended maximum submergence depth is 65

feet.

Pump Motor Specifications

See Table B‐1 for pump specifications.

Table B‐1. Pump Specifications

Dual

Voltage

Locked

Rotor

Amperes

Pump

HP/

Motor

Speed

(RPM)

Full

Load

Amperes

Load

Amperes

Discharge

Size

(NPT)

Model Voltage/

Phase

S6A

460/3

575/3 NO 6 INCH60 HP 1750

427

329

Table B‐2. Additional Specifications

Pump

Model

Voltage/

Phase

460/3

575/3

S6A

Approximate

Weight - Lbs. (kg) Oil Capacity

Ounces (Liters)

Seal Cavity

Filling

Position

(H)orizontal

(V)ertical

Pump 50 Ft. Cable Seal

Cavity

Motor

Cavity

743 (337) 80 (36,3) 176 (5,2) 832 (24,6) V

56.5 (25,6)

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

tag on the unit packaging for the actual weight, 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.

Refer to Table B-2 for the approximate maximum

weight for your 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 damage the pump,

and so that the load will be balanced.

S SERIES PUMPS OM-06111

PAGE B - 3INSTALLATION

Positioning the Pump

NOTE

Before installing and operating the pump, check

the direction of impeller rotation to ensure that the

pump is properly wired at the control box. See IM

PELLER ROTATION, Section C.

The pump is designed to operate fully or partially

submerged. The rotating parts are oil lubricated,

and the motor is cooled by a constant flow of liquid

or air discharged through internal passages.

As a safeguard against rupture or explosion due to

heat, models equipped with oil‐lubricated motors

are fitted with a pressure relief valve which will open

if vapor pressure within the pump motor reaches a

critical point.

The pump will operate if positioned on its side, but

this is not recommended because the motor

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.

If the application involves 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 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

No suction piping is required in a standard installa

tion.

These pumps are provided with a suction strainer

to prevent large solids from clogging the impeller.

If required, the strainer can be removed and the

pump suction “staged” to the discharge of another

pump, allowing one pump to feed the other on high

discharge head applications.

To determine the size of the discharge connection,

see Table B-1, Pump Specifications. Either

hose or rigid pipe may be used. To facilitate mobil

ity and maintenance, it is recommended that the

discharge line be fitted with a quick disconnect fit

This manual suits for next models

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