GORMAN-RUPP PUMPS SF4D Application guide

OM-06547-01

March 14, 2013

GORMAN‐RUPP PUMPS

www.grpumps.com

e2013 Gorman‐Rupp Pumps Printed in U.S.A.

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUBMERSIBLE PUMP

MODEL

SF4D

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....................................

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

PUMP SEALS PAGE B - 1.............................................................

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

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

Pump Dimensions PAGE B - 1.....................................................

Pump Motor Specifications PAGE B - 1..............................................

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

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

Piping PAGE B - 2................................................................

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

Field Wiring Connections (Incoming Power) PAGE B - 3...............................

Dual Vlotage PAGE B - 3..........................................................

Motor Cable Grounding Test PAGE B - 3.............................................

Control Box Connections PAGE B - 4...............................................

Liquid Level Devices PAGE B - 5....................................................

OPERATION - SECTION C PAGE C - 1......................................

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

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

Control Box PAGE C - 4...........................................................

PUMP OPERATION PAGE C - 4........................................................

Liquid Temperature And Overheating PAGE C - 4.....................................

Impeller Rotation PAGE C - 5.......................................................

STARTING, STOPPING AND OPERATIONAL CHECKS PAGE C - 5.........................

Starting PAGE C - 5...............................................................

Stopping PAGE C - 6..............................................................

Operational Checks PAGE C - 6....................................................

COLD WEATHER PRESERVATION PAGE C - 7...........................................

LUBRICATION PAGE C - 7.............................................................

Draining Oil PAGE C - 7...........................................................

Condition of Oil Oil PAGE C - 7.....................................................

Adding Oil PAGE C - 7............................................................

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

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

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

GENERAL INFORMATION PAGE E - 1..................................................

Lifting PAGE E - 1.................................................................

TABLE OF CONTENTS

(continued)

PARTS LISTS:

Pump Model Assembly PAGE E - 3.................................................

Motor Assemblies PAGE E - 5......................................................

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

PUMP END DISASSEMBLY PAGE E - 6.................................................

Preparing Pump for Disassembly PAGE E - 6........................................

Pump Casing Removal PAGE E - 7.................................................

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

Impeller Removal PAGE E - 7......................................................

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 - 10..................................................

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

Pump Casing Installation PAGE E - 11................................................

Final Assembly PAGE E - 11........................................................

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

Hoisting Bail Removal PAGE E - 12..................................................

Terminal Housing Assembly Removal PAGE E - 12.....................................

Rotor Shaft and Bearing Removal PAGE E - 12........................................

Stator Removal PAGE E - 13........................................................

MOTOR REASSEMBLY PAGE E - 14.....................................................

Stator Installation PAGE E - 14......................................................

Bearing and Rotor Shaft Installation PAGE E - 15......................................

Terminal Housing Assembly Installation PAGE E - 16...................................

Hoisting Bail Installation PAGE E - 17.................................................

VACUUM TESTING PAGE E - 17........................................................

Seal Cavity Testing PAGE E - 17.....................................................

Seal and Motor Cavity Testing PAGE E - 18...........................................

LUBRICATION PAGE E - 19.............................................................

Seal Cavity PAGE E - 19............................................................

Motor Bearings PAGE E - 19........................................................

SF SERIES OM-06547

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.

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

neither operator safety nor pump integrity are com

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

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

power source, contact the power source manufac

turer's local dealer or representative.

HAZARD AND INSTRUCTION

DEFINITIONS

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-06547SF SERIES

PAGE A - 1SAFETY

SAFETY - SECTION A

This information applies to the SF Se

ries submersible pump indicated on the

front cover of this manual.

In addition to this manual, see the sepa

rate literature covering the control box,

control accessories or other equipment

shipped with this pump.

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 install, operate, or

service this pump, familiarize yourself

with this manual, and with all other liter

ature shipped with the pump. Unfamil

iarity with all aspects of pump operation

covered in this manual could lead to de

struction of equipment, injury, or death.

This pump is designed to handle raw

sewage and industrial wastes at tem

peratures of 104_F (40_C); Do not apply

at higher temperatures. Do not attempt

to pump volatile, flammable, or corro

sive liquids which may damage the

pump or endanger personnel as a result

of pump failure.

The electrical power used to operate

this pump is high enough to cause inju

ry or death. Obtain the services of a qu

alified electrician to make all electrical

connections.

The following precautions should be

taken before attempting to open or ser

vice the pump; otherwise, injury or

death could result.

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).

Do not connect the pump motor directly

to the incoming power lines. The pump

motor is designed to operate through a

Gorman‐Rupp approved control box

which provides overload protection and

power control; otherwise, the pump

warranty will be voided. Make certain

that the pump and control box are prop

erly grounded and that the incoming

power matches the requirements of the

pump and controls. Install and operate

the control box in accordance with the

National Electric Code and all local

codes. Failure to follow the instructions

SF SERIESOM-06547

PAGE A-2 SAFETY

in this warning could result in injury or

death to personnel.

Death or serious personal injury and

damage to the pump or components

can occur if proper lifting procedures

are not observed. Make certain that

hoists, chains, slings or cables are in

good working condition and of suffi

cient capacity and that they are posi

tioned so that loads will be balanced

and the pump or components will not be

damaged when lifting. Do not attempt to

lift this pump by the motor or control

cables, or the piping. Attach proper lift

ing equipment to the lifting bail fitted on

the pump. Lift the pump or component

only as high as necessary and keep per

sonnel away from suspended objects.

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

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.

OM-06547SF SERIES

PAGE A - 3SAFETY

After the pump has been installed, make

certain that the pump and all piping or

hose connections are secure before op

eration.

Approach the pump cautiously after it

has been running. Although the motor is

cooled by dispersing heat through the

motor housing cooling fins into the liq

uid being pumped, normal operating

temperatures can still be high enough

to cause burns. The temperature 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.

If this pump is used to handle sewage,

take necessary precautions during

maintenance and repair to prevent per

sonal contamination which could result

in illness.

Pumps and related equipment must be

installed and operated according to all na

tional, local and industry standards.

SF SERIES OM-06547

PAGE B - 1

INSTALLATION

INSTALLATION - SECTION B

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.

The motor in these pumps is not designed

to be operated in air for more than 10 min

utes without overheating. The pumps must

be operated through liquid level controls to

maintain the level of liquid in the wet well so

that power to the motor is cut off when liq

uid falls below the midpoint of the motor

housing.

Automatic liquid level controls are available from

Gorman‐Rupp as options. For information on in

stalling and operating these controls, see the tech

nical data accompanying them.

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 and tighten loose attaching hard

ware.

c. Inspect the power cable for cuts or any other

obvious damage.

d. Check that amperes, phase, voltage, and

hertz indicated on the motor name plate

match the ratings on the control box and in

coming power.

e. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

f. Check for any oil leaks. If there is any indica

tion of an oil leak, see LUBRICATION in

MAINTENANCE AND REPAIR - SECTION

PUMP SEALS

This pump is equipped with two mechanical seals.

The lower seal is lubricated by the liquid being

pumped and prevents the liquid from entering the

seal housing cavity from the pump end. The upper

seal prevents oil from escaping from the seal hous

ing into the motor housing and acts as backup pro

tection in the event of lower seal failure.

LUBRICATION

The seal cavity is fully lubricated when shipped

from the factory. However, the lubrication level

must be checked before installing the pump (see

LUBRICATION in MAINTENANCE AND REPAIR

- SECTION E). If the oil level is abnormally low, de

termine the cause before putting the pump into

service.

The shaft bearings are permanently lubricated.

There is no other lubrication in the pump.

PUMP INSTALLATION

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.

Pump Motor Specifications

The motor furnished with this pump is a 60 Hz.,

Squirrel Cage, Induction Start, Class H Insulation

Rated 365_F (180_C).

OM-06547 SF SERIES

PAGE B - 2 INSTALLATION

See Table B-1 for motor specifications.

TABLE B-1. PUMP MOTOR SPECIFICATIONS

MODEL VOLTAGE/

PHASE

SIZE MOTOR

RPM

MAX

LOAD

AMPS

H.P. LOCKED

ROTOR

AMPS

SF4D 460/575 4” 75.0 1750 86.0/69.0 542.0/434.0

Lifting

Death or serious personal injury and

damage to the pump or components

can occur if proper lifting procedures

are not observed. Make certain that

hoists, chains, slings or cables are in

good working condition and of suffi

cient capacity and that they are posi

tioned so that loads will be balanced

and the pump or components will not be

damaged when lifting. Do not attempt to

lift this pump by the motor or control

cables, or the piping. Attach proper lift

ing equipment to the lifting bail fitted on

the pump. Lift the pump or component

only as high as necessary and keep per

sonnel away from suspended objects.

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.

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.

This pump may be mounted on guide rails or

cables for use with optional discharge elbow/base

plate kits, or it may be mounted on a trash stand

with an optional discharge elbow.

If the pump is configured for a guide rail/guide

cable application, the pump will be equipped with

a rail guide shoe which connects to the discharge

optional elbow/baseplate. When lowered into

place, the pump is automatically and securely con

nected to the elbow/baseplate and the piping sys

tem. For information on installing the guide rails,

see the literature accompanying them.

NOTE

When engaging the guide shoe and elbow/base

plate, make sure that the connection is not impeded

by mounting hardware, and that the guide shoe is

fully seated in the baseplate.

To install a pump configured for a guide rail/guide

cable application, engage the guide shoe at the

top of the guide rails and use a suitable lifting de

vice attached to the lifting handle to lower the

pump into the wet well. When the pump and guide

shoe engages the discharge elbow/baseplate, it

will form an automatic seal.

If the pump is mounted on a trash stand, secure a

discharge hose or pipe to the optional discharge

elbow and use a suitable lifting device attached to

the lifting handle to lower the pump into the wet

well.

Make certain that the pump and stand sit level in

the wet well.

Regardless of the installation configuration, the

maximum recommended submergence depth

is 65 feet (20 meters).

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