GORMAN-RUPP PUMPS S, S2A Series Manual
PUBLICATION NUMBER MR--04301
July 10, 1995
SSERIESPUMPS
S2A’s
All Materials And Voltages
THE GORMAN-RUPP COMPANY D MANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
eCopyright by the Gorman-Rupp Company
MR--04301 SSERIESPUMPS
INTRODUCTION
Thank You for purchasing a Gorman-Rupp S
Series Pump. Read this manual carefully to learn
howt o safelymaintainand serviceyourpump. Failure to do so could resultin personal injury or damage to the pump.
A set of three manuals accompanies your pump.
TheInstallation/Operation Manual
tial information on installing and operating the
pump, and on making electrical connections. The
PartsList Manual
pump model cross-section drawing, and parts list
foryourpump.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions requiredtoproperlydiagnose operationalproblems,
andtoservicethepumpcomponents.Pumpmotor
maintenance may be performed only by a Gorman-Rupp authorized Submersible repair facility,
orthe factory.Otherwise,thepumpwarrantywillbe
negated, and damage to the pump, and injury or
death to personnel can result. Contact the factory
for the authorized repair facility closest to you.
As described on the following page, this manual
willalertpersonnel to knownprocedures which re-
provides a performance curve, a
containsessen-
CONTENTS
quire special attention, to those w hich could damage equipment, and to those which couldbe dangerousto personnel. However,this manual cannot
possibly anticipate and provide detailed precautions for every situation that might occur during
maintenanceoftheunit.Therefore,itistheresponsibilityof the owner/maintenance personnel to ensure that only safe, established maintenance proceduresareused, and that any procedures notaddressedinthismanualareperformedonlyafterestablishingthat neitherpersonalsafetynorpumpintegrity are compromised by such practices.
If there are any questions regarding the pump
which are not covered in this manual or in otherliterature accompanying the unit, please contact
your Gorman-Rupp distributor or the GormanRupp Company:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
SAFETY -- SECTION A
TROUBLESHOOTING -- SECTION B
ELECTRICAL TESTING PAGE B --- 3........................................................
Test Equ ipment PA GE B --- 3...........................................................
Volt age Imbalance PAGE B --- 3........................................................
Motor and Power Cable Continuity PAGE B --- 4..........................................
Insulation Resistance PAGE B --- 4......................................................
PUMP MAINTENANCE AND REPAIR -- SECTION C
GENERAL INFORMATION PAGE C --- 1.....................................................
Lifting PA GE C --- 1....................................................................
TYPICAL PUMP ASSEMBLY PA GE C --- 2....................................................
PUMP ASSEMBLY PARTS IDENTIFICATION LIST PAGE C --- 3.................................
TERMINAL HOUSING AND CABLE ASSEMBLY PAGE C --- 4...................................
TERMINAL HOUSING AND CABLE ASSEMBLY PARTS IDENTIFICATION LIST PAGE C --- 5.......
PUMP END DISASSEMBLY PAGE C --- 6....................................................
PUMP END REASSEMBLY PAGE C --- 8.....................................................
MOTOR DISASSEMBLY PAGE C --- 11......................................................
MOTOR REASSEMBLY PAGE C --- 14.......................................................
FINAL ASSEMBLY PA GE C --- 19...........................................................
VACUUM/PRESSURE TESTING PAGE C --- 20...............................................
LUBRICATION PA GE C --- 20...............................................................
INTRODUCTION
PAGE I -- 1
MR--04301SSERIESPUMPS
RECORDING MODEL AND
SERIAL NUMBERS
Pleaserecordthepumpmodel,serialnumber, voltage, and motor frame size in the spaces provided
below. Your Gorman-Rupp distributor needs this
information when you require parts or service.
Pump Model:
Serial Number:
Voltage:
Phase:
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman-Rupp’s support program for customers
The following are used to alert personnel to procedures which require special attention, to those which
could damage equipment, and to those which could be dangerous to personnel:
who operate and maintain their equipment as described in this and the other accompanying literature. The integral electric motor must be operated
through the control furnished with the pump as
standard equipment. Please note that should the
equipment be abused or modified to change its
performance beyondthe original factoryspecifications, the warrantywill become void and anyclaim
will be denied.
All repairs to the pump motor must be performed
bya Gorman-RuppauthorizedSubmersiblerepair
facility or the factory. Any repairs to the motor assemblyperformed by t he customeroran unauthorized repair facility negates motor warranty.
Immediate hazardswhichWILL resultin
severe personal injury or death. These
instructions describe the procedure required and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULDresult in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure tofollow
the procedure.
HazardsorunsafepracticeswhichCOULD
resultinminorpersonalinjuryorproductor
property damage. These instructions describe 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 I -- 2
INTRODUCTION
SSERIESPUMPS MR--04301
SAFETY --- SECTION A
The following information applies
throughout this manual to GormanRupp S Series submersible motor driven pumps.
This manual will alert personnel to
known procedures which require special attention, to those whic h could
damage equipment,and to thosewhich
could be dangerous to personnel.However,thismanualcannotpossiblyanticipate and provide detailed instructions
and precautionsfor every situationthat
might occur during maintenance of the
unit.Therefore,itis the responsibilityof
the owner/maintenance personnel to
ensurethat onlysafe,established maintenance procedures are used, and that
any procedures not addressed in this
manual are performed only after establishing that neither personal safety nor
pump integrity are compromised by
such practices.
4. Close the discharge valve (if
used).
This pump is not designedto pump volatile,explosive,orflammable materials.
Do not
attempt to pump any liquids for
which your pump is not approved, or
which may damage the pump or endanger personnel as a result of pump failure. Consult the factory for specific
application data.
Beforeconnectinganycable tothe control box, be sure to ground the control
box.Refer tothe ControlBox manualfor
the suggested grounding methods.
Thismanual containsessentialinformation on troubleshooting and maintainingthe pump.In additionto thismanual,
see the separate literature covering installation and operation, pump parts,
and any optional equipment shipped
with the pump.
Beforeattemptingtoopen orservicethe
pump:
1. Familiarize yourself with thismanual.
2. Lock out incoming power to the
control box to ensure that the
pump will remain inoperative.
3. Allow the pump tocompletely cool
if overheated.
The pump motor isdesignedto be operated through the control box furnished
withthepump. Thecontrolboxprovides
overload protection and power control.
Do not connect the pump motordirectly
to the incoming power lines.
The electrical power used to operate
this pump is high enough to cause injury or death. Obtain the services of a qualified electrician to make all electrical
connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electricalground.Besurethatthein-
SAFETY
PAGE A --1
MR--04301 SSERIESPUMPS
coming powermatches 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 injuryordeath.Makecertainthat thecontrol
handle on the control box is in the OFF
position and locked out, orthat the power 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 prevent accidental start-up.
Never attempt to alter the length or repair any power cable with a splice. The
pump motor and cable must be completely 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
date of manufacture. Failure to follow
applicable specifications, or substitu-
tion of electrical parts not supplied or
approved by the manufacturer, can result in severe injury or death and void
warranty.
Afterthepumphasbeeninstalled,make
certain that the pump and all piping or
hoseconnections aresecure before operation.
Approach the pump cauti ously after it
hasbeen running.Although the motoris
cooledbytheliquidbeing pumped,normaloperating temperaturescan be high
enough to cause burns. The tempe rature will be especially high if operated
againsta closeddischargevalve.Never
operate against a closed discharge
valve for long periods of time.
Donotattempttoliftthepumpbythe
motorpower cable orthe 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 positioned so as not to damage the pump,
and so that the load will be balanced.
Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of this
pump.
PAGE A -- 2
SAFETY
MR--04301 SSERIESPUMPS
TROUBLESHOOTING --- SECTION B
Review all SAFETY information in Section A.
The following precautions should be
taken before attempting to service the
pump; otherwise, injury or death could
result.
1. Familiarize yourself with thismanual and with all other literature
shipped with the pump.
2. Lock out incoming power to the
pump or control box to ensure that
the pump will remain inoperative.
3. Allow the pump tocompletely cool
if overheated.
4. Check the temperature before
opening any covers, plates or
plugs.
5. Close the discharge valve (if
used).
The electrical power used to operate
this pump is high enough to cause injury or death. Obtain the services of a qualified electrician to troubleshoot, test
and/or service the electrical components of this pump.
NOTE
Many of the probable remedies listed below require use ofelectricaltestinstruments;for specific
procedures, seeELECTRICALTESTINGfollowing
the chart.
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO START,
OVERLOAD UNIT NOT
TRIPPED
(MANUAL MODE)
(AUTOMATIC MODE)
Table 1. Trouble Shooting Chart
Power source incompatible withcontrol box.
No voltage at line side of circuit
breaker.
Open circuit in motor windings or
power cable.
Defective motor power cable.
Motor defective.
Liquid level device or control circuits
improperly connected to main control box.
Level sensing device(s) improperly
positioned.
Level sensing device(s) fouled with
mud or foreign material.
Correct power source.
Check power source for blown fuse,
open overload unit, broken lead, or
loose connection.
Check continuity.
Replace cable.
Check for and replacedefective unit.
Check wiring diagrams; correct or
tighten connections.
Position device(s) at proper level.
Clean sensing device(s).
TROUBLESHOOTING PAGE B -- 1
SSERIESPUMPS MR--04301
Table 1. Trouble Shooting Chart (cont.)
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
(AUTOMATIC MODE)
(CONT’D.)
Float type sensing device(s) tangled
or obstructed.
Check installation for free movement of float.
Defective liquid level sensing device(s) or control panel.
OVERLOAD UNIT TRIPS Loworhighvoltage,orexcessive
voltage drop between pump and
control box.
Defective insulation in motor windings or power cable; defective windings.
Impeller jammed due to debris or
insufficient clearance.
Bearing(s) frozen.
MOTOR RUNS, BUT
PUMP FAILS TO
DELIVER RATED
DISCHARGE
Discharge head too high.
Low or incorrect voltage.
Discharge throttling valve partially
closed; check valve is installed improperly.
Repair or replace defective unit(s).
Measure voltage at control box.
Check that wiring is correct type,
size, and length. (See Field Wiring
Connections,SectionB).
Check insulation resistance; check
continuity.
Disassemble pump and check impeller.
Disassemble pump and check
bearing(s).
Reduce discharge head, or install
staging adaptor and additional
pump.
Measure control box voltage, both
when pump is running and when
shut-off.
Open discharge valve fully; check
piping installation.
Dischargelinecloggedorrestricted; hose kinked.
Liquid being pumped too thick.
Strainer screen or impeller clogged.
Insufficient liquid in sump or tank.
Worn impeller vanes; excessive im-
peller clearance.
Pump running backwards.
Check discharge lines; straighten
hose.
Dilute liquid by heating if possible.
Clear clog(s). Stop pump; back flow
may flush away debris.
Stop pump until liquid level rises.
Check impeller and clearance. See
PUMP END DISASSEMBLY.
Check direction of rotation and cor-
rect by interchanging any two motor
leads at control box. (See Pump
Rotation,SectionC).
TROUBLESHOOTINGPAGE B -- 2
MR--04301 SSERIESPUMPS
Table 1. Trouble Shooting Chart (cont.)
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP RUNS WITH
EXCESSIVE NOISE OR
VIBRATION
Pumping entrained air.
Check liquid level in sump; check
position of pump and liquid level
sensing device(s).
Damagedorunbalancedimpeller.
Discharge piping not properly sup-
ported.
Impellerjammedorloose.
Motor shaft or bearings defective.
Pump cavitation.
ELECTRICAL TESTING
If you suspect that pump malfunctions are caused
bydefects inthemotor, power cableorcontrolbox,
performthefollowingchecks to helpisolatethedefective part.
Replace impeller.
Check piping installation.
Check impeller.
Disassemble pump and check mo-
tor and bearings.
Reduce discharge head, or restrict
flow on low head applications.
Equipment Use
Ammeter To check AC Voltage
and current (amperage)
Ohmeter To measure resistance
(ohms) to ground
Voltage Imbalance
Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of this
pump.
Be certain to refer to the wiring diagram(s)
intheInstallationSectionofthismanualbefore reconnecting any electrical components which have been disconnected.
Test Equipment
A volt/amp/ohmmeter and megohmeter of adequaterangeandqualitywillberequired toconduct
thefollowingelectricaltests.The suggestedequipment indicated below is commercially available, or
an equivalent substitute may be used.
Each phas e of the incoming three-phase power
must be balancedwiththe othertwo a s accurately
as a commercial voltmeter w ill read. If the phases
are balanced, check out the motor as described
below. If the phases are out of balance, contact
yourpowercompanyand requestthat theycorrect
the condition.
a. Useavoltmeter,amprobe,or equivalentme-
ter to read the voltage across terminals 1 &
2,2&3,and1 & 3 inthe controlbox.Allthree
measured voltages must be the same, as
accuratelyasthemeterwillread.Ifpossible,
measure the voltage with the pump off,with
the pump running but out of the water, and
with the pump running in the water at full
load. All themeasuredvoltagesateach condition must be the same.
b. Use an amprobe or equivalent meter to
measure the current draw of each phase
while the pump isrunning at full loadand at
no load. All three amperage readings must
TROUBLESHOOTING PAGE B -- 3
SSERIESPUMPS MR--04301
bethe sameat each condition,as accuratelyas the meterwillread. Nominalamperage
values are listed in Table 1, but these apply
onlywhen theactualvoltageatthesiteisthe
nominal voltage listed.
c. If the voltages are balanced with the pump
off, but are unbalanced when the pump is
running, a thorough check of the power
source, all interconnecting cables, and the
pumpmotorisrequiredtoisolatethedefect.
Motor And Motor Power Cable Continuity
placethetubingorpottingandallowadequatedrying timebefore putting the pump back into service.
(See Power Cable Reassembly,SectionE).
c. If an open circuit still exists after each lead
(terminal) has been tested and tightened,
then the entire motor power cable must be
replaced. Splicing or other means of repair
are not recommended.
d. If no break is found in the power cable,
check the motor leads for continuity. I f the
test reading indicates an openor brokencircuit, there is an open circuit in the motor.
To check continuity, zero-balance the ohmmeter
set at the RX1 scale, and test as follows:
a Disconnect the motor power cable leads
from the control box and connect the test
leadstoanytwoofthethreepowercable
leads(nottothegreengroundleadoryellow
ground check lead). If there is a high resistance reading on the ohmmeter, there is an
open or broken circuit caused by a break in
the power cable or motor windings, or by a
bad connectionbetween the motor and the
power cable. Switch one test lead to the
third power lead, and test again.
b. If an open or broken circuit is indicated,
check the power cableforobviousdamage,
and replace as necessary (see MAINTE-
NANCE AND REPAIR).If thereis no apparent damage to the motorcable, removethe
terminal housing (see MAINTENANCE
AND REPAIR) and check the continuity of
each power cablelead atthe terminalposts.
NOTE
Whenshippedfrom thefactory,theconnections betweenthepowercable leadsandtheterminal posts
were encapsulated in heat shrink tubing and
bonded to the terminalplate to provideawater tight
seal. In service, these connections may have been
potted by the pump operator .Do not cut the tubing
or potting away unless absolutely necessary.
Check the continuity of each lead from the motor
side of the terminal plate. If the continuity is good,
thereisno need to removethe tubingor pottingmaterial. If there is no continuity through the lead, remove the tubing or potting from only that terminal,
and check for a loose connection. Be sure to re-
NOTE
Itis recommendedthatapump withadefectivemotor be returned to Gorman-Rupp, or to one of the
Gorman-Rupp authorized Submersible Repair
Centers.
Insulation Resistance
To check insulation, zero-balance the ohmmeter
set at the RX100K scale, and test as follows:
a. Disconnect the motor power cable leads
from the control box. Connect one test lead
to the power cable green ground lead, and
touchthe other t est leadtoeach of t he three
power leads in turn.
b. The reading obtained will indicate resis-
tancevaluesinboththepowercableandthe
motor windings. If the resistance reading is
infinity (1), the insulation is in good condition. If the reading is between infinity (1)
and 1 megohm,theinsulation is acceptable
but should be rechecked periodically. If the
reading is less than 1 megohm, the insulation should be checked more closely; a
reading of zero indicates that the power
cable or the motor is grounded.
c. To determine whether the power cable or
the motor is grounded, remove the terminal
housing (see MAINTENANCE AND RE-
PAIR), disconnect the motor leads from the
motor terminals, and test the power cable
leads and motor leads separately.
Capacitors
Thestartcapacitoris designedtosplittheelectrical
phase during the initialpower surge at motor star-
TROUBLESHOOTINGPAGE B -- 4
MR--04301 SSERIESPUMPS
tup. The start capacitor is controlled by the start
relay at motor startup. When the motor reaches
loadspeed, thestartrelaycuts out and permitsthe
run capacitor to maintain operation. Both the start
and run capacitors are located in the control box.
Before disconnecting the capacitor leads,
discharge the capacitors using a screwdriver with an insulated handle, and place
the blade across the two terminals of each
capacitor to short the terminals.
Zero-balance the ohmmeter set to read RX100K,
and test the capa citors as follows:
a. Disconnect the capacitorleads and remove
the resistor from the start capacitor.
b. Place a test lead against each of the termi-
nalsof the startcapacitorforafew seconds.
If the ohmmeter needle moves toward zero
thenslowlydrifts back tothe left, thecapacitor is good. If the needle remains at infinity
(1) the capacitor is open; if the needle remains atzero, thecapacitoris shorted. Ineither case, the capacitor must be replaced.
c. Test the run capacitor as in b. In addition,
test the metal run capacitor for shorts to
ground by touching on etest leadto thecapacitor case and the other lead to each of
the capacitor terminals in turn. The ohmmeter should read infinity(1);if it does not,the
capacitor is grounded and must be replaced.
Start Relay
The start relay is located in the control box.
Disconnect the two wires from relay terminals 2.
Use a zero-balanced ohmmeter set to read
RX100K,andtouchoneleadtorelayterminal2and
the other to relay terminal 5. The resistance readingshould be between 1000 and1500 ohms; if the
readingis not in this range, the start relay isdefective and should be replaced.
NOTE
With the exception of the motor assembly, repair of
individual electrical components is not recommended. Replace defective and/or malfunctioning
components.
TROUBLESHOOTING PAGE B -- 5
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