Gorman-Rupp Pumps SE1-1-2A3 User Manual

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Page 1

OM−06488−01

August 15, 2011

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SE SERIES PUMP

MODEL

SE1 1/2A3 115V 1P

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

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

www.grpumps.com

2011 The Gorman-Rupp Company

Page 2

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

INTRODUCTION PAGE I − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY − SECTION A PAGE A − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION − SECTION B PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Dimensions PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP SEAL PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP INSTALLATION PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Motor Specifications PAGE B − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Pump PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Cable Grounding Test PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Level Devices PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Performance PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Controls PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP OPERATION PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature and Overheating. PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding Oil PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4

TABLE OF CONTENTS

(continued)

TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Trouble Shooting Chart PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL TESTING PAGE D − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Equipment PAGE D − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Insulation Resistance PAGE D − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

PERFORMANCE CURVE PAGE E − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LISTS:

Pump Model PAGE E − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Removal PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Removal PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch Actuator Removal PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stator Removal PAGE E − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR REASSEMBLY PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stator Installation PAGE E − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch Actuator Installation PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Installation PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotor Installation PAGE E − 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

FINAL ASSEMBLY PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VACUUM/PRESSURE TESTING PAGE E − 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vacuum/Pressure Test Data PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Cavity PAGE E − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Cavity PAGE E − 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 5

SE SERIES OM−06488

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 is an SE 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, thermallyprotected electric motor which is not explosionproof. The pump may be operated fully or partially submerged. Do not operate the pump in a hazardous atmosphere.

All repairs to the pump motor must be performed by a Gorman-Rupp authorized submersible repair facility or the factory. Any repairs to the motor assembly performed by the customer or an unauthorized repair facility negates the warranty.

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 which WILL result in severe personal injury or death. These instructions describe the procedure required and the injury which will result from failure to follow the procedure.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for every aspect of each specific application. Therefore, it is the responsibility 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 compromised by the installation. Pumps and related equipment must be installed and operated according to all national, local and industry standards.

If there are any questions regarding the pump or its application which are not covered in this manual 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:

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 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 − 1INTRODUCTION

Page 6

SE SERIES OM−06488

SAFETY − SECTION A

This information applies to SE Series submersible motor driven pumps.

Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and precautions for each specific application. Therefore, it is the owner/installer’s responsibility to ensure that applications not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity are compromised by the installation.

Before attempting to open or service the pump:

1. Familiarize yourself with this manual.

2. Make certain the control box or switch is in the OFF or STOP position, or that the power supply to the control box has been otherwise cut off and locked out to ensure that the pump will remain inoperative.

3. Allow the pump to completely cool if overheated.

5. Close the discharge valve (if used).

If the power cable is wired into an optional manual starting switch or control box, make sure that the enclosure is grounded. See Section B for recommended grounds.

The electrical power used to operate this pump is high enough to cause injury or death. Make certain the control box or switch is in the OFF or STOP position, or that the power supply to the control box has been otherwise cut off and locked out. Tag electrical circuits to prevent accidental start-up.

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.

This pump is not designed to pump volatile, 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 endanger personnel as a result of pump failure. Consult the factory for specific application data.

SAFETY

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.

All electrical connections must be in accordance with The National Electric Code and all local codes. If there is a

PAGE A − 1

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OM−064988 SE SERIES

conflict between the instructions provided 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

Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of this pump.

applicable specifications, or substitution of electrical parts not supplied or approved by the manufacturer, can result in severe injury or death and void warranty.

Do not attempt to lift the pump by the motor power cable or discharge hose. Attach proper lifting equipment to the lifting device fitted to the pump.

After the pump has been installed, make certain that the pump and all piping or hose connections are secure before operation.

Pumps and related equipment must be installed and operated according to all national, local and industry standards.

PAGE A − 2 SAFETY

Page 8

OM−06488 SE SERIES

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 recommendations and practices required to inspect, position, and arrange the pump and piping. If there are any questions concerning your specific installation, contact your Gorman-Rupp distributor or the Gorman-Rupp Company.

Nuts, bolts and screws used on this pump

OUTLINE DRAWING

are metric and do not match standard SAE 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.

Pump Dimensions

See Figure B−1 for the approximate physical dimensions of this pump.

Figure B−1. Pump Model SE1 1/2A3 115V 1P

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested before shipment from the factory. Before installation, check for damage which may have occurred during shipment. Check as follows:

a. Inspect the pump assembly for cracks, dents,

damaged threads, and other obvious damage.

b. Check for and tighten loose attaching hard-

ware. Since gaskets tend to shrink after dry-

PAGE B − 1INSTALLATION

Page 9

SE SERIES

OM−06488

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 power.

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.

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

months, some of the components or lubricants may have exceeded their maximum shelf life. These must be inspected or re- placed to ensure maximum pump service.

If the maximum shelf life has been exceed, or if 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 appropriate action has been taken.

PUMP SEAL

The pump is equipped with one double-faced seal assembly. It is designed to prevent the liquid being

pumped from entering the lubrication cavity at the impeller end, and to prevent moisture or lubrication oil from entering the motor housing cavity at the motor end.

The seal is lubricated by premium quality submersible 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 oil which lubricates the pump seal. The motor operates in and is cooled by air, therefore it requires no lubrication.

The pump was fully lubricated when shipped from the factory. However, lubrication levels must be

checked before installing the pump (see LUBRICATION in Section E, MAINTENANCE AND REPAIR). If the oil level is abnormally low, deter-

mine the cause before putting the pump into service.

Refer to Table B-2 for oil capacity and position for filling the seal cavity in each pump. Refer to LU- BRICATION, Section E for lubrication specifications and intervals.

PUMP INSTALLATION

Pump Motor Specifications

See Table B-1 for pump specifications.

Table B-1. Pump Specifications

Model Voltage/

Phase

SE1 1/2A 115/1 NO 1/3 HP 3420 5.4 4.0 29.5

Pump

Model

PAGE B − 2 INSTALLATION

Voltage/

Phase

115/1SE1 1/2A 7 (0,2)50 (23) 6 (3) HORIZONTAL

Liquid

Level

Control

Pump

HP/ KW

Table B-2. Additional Specifications

Approximate

Weight − Lbs. (kg)

Motor Speed (RPM)

50 Ft. Cable

Full

Load

Amperes

Seal

Cavity

Load

Amperes

Oil Capacity

Ounces (Liters)

Locked

Amperes

Motor

Cavity

−−−

Rotor

Discharge

Size

(NPT)

1 1/2 INCH w/BARBED

ADAPTOR

Seal Cavity

Filling

Position

(H)orizontal

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OM−06488 SE SERIES

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 requirements. Failure to observe these requirements could result in injury or death to personnel.

NOTE

Refer to the performance curve in Section E when determining the most efficient piping installation.

The recommended maximum submergence depth is 23 feet. Greater depths could result in damage to the pump

Lifting

Use lifting equipment with a capacity of at least five times the weight of the pump, including the

weight of the cable, if applicable, and any options or customer-installed accessories. Discharge hose or piping must be removed before attempting to lift the pump.

Refer to Table B−2 for the approximate maximum weight for each pump.

Do not attempt to lift the pump by the 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 by a constant flow 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 torque could cause the pump to roll during operation.

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 suspending 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−2 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.

PAGE B − 3INSTALLATION

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SE SERIES

OM−06488

BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS

Figure B−2. Typical Pump Installations

Piping

No suction piping is required in a standard installation.

S Series pumps are 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, Pump Specifications. Either hose or rigid pipe may be used. To facilitate mobility and maintenance, it is recommended that the discharge line be fitted with a quick disconnect fitting near the pump. The discharge line must be independently supported to avoid strain and vibration on the pump.

Either hose or rigid pipe may be used to make discharge connections. For maximum pumping capacity, keep the line as short and straight as possible. 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 to control siphoning or back flow when the pump is shut off.

ELECTRICAL CONNECTIONS

Install and operate this pump in accordance with the National Electrical Code and all local codes. Have a qualified electrician perform all checks and connections 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 motor must be kept completely waterproof. 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 available at the motor must be within the indicated range in Table B−3.

PAGE B − 4 INSTALLATION

Page 12

OM−06488 SE SERIES

To calculate the voltage available at the motor, proceed as follows:

a. Measure the voltage while the pump is oper-

ating at full capacity. See wiring diagrams at the end of this section.

b. Next, subtract the motor cable voltage drop

(see Table B-5, Pump Power Cable Specifi- cations).

c. Do not continue to operate the pump if this

voltage is not within the recommended limits. Obtain the services of a qualified electrician to determine the correct field wiring size and other details to ensure an adequate voltage supply to the pump.

Table B-3. Pump Voltage Requirements

NOMINAL

VOLTAGE

PHASE

1115 110 120

MINIMUM

VOLTAGE

MAXIMUM

VOLTAGE

Grounding Methods

The power cable will be wired into an optional manual switch or control box, ground the enclosure before installing the wiring. In any of these cases, the electrical circuit must be grounded to a properly imbedded electrode.

The material used for the electrode must be an excellent conductor of electricity, such as copper. If iron or steel is used, it must be galvanized or otherwise metal plated to resist corrosion. Do not coat the electrode with any material of poor conductivity, such as paint or plastic.

The electrode must conform to the recommendations of N.E.C. ARTICLE 250. Follow all installation requirements of the N.E.C., and all applicable local codes. See Figure B−3 for some suggested grounding methods.

a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE

SOIL

1/4 INCH (6,4 MM) STEEL PLATE 2 SQ. FEET (1858,1 SQ. CM) SURFACE AREA (MINIMUM)

Figure B−3. Suggested Grounding Methods

a. Plate Electrode: An iron or steel plate, 1/4

inch (6,4 mm) thick, completely impeded in the ground. The plate must present a surface area of at least 2 square feet (1858,1 sq. cm.).

b. Driven Electrode: A rod or pipe, 3/4 inch

(19,1 mm) in diameter minimum, 8 feet (2,4 m) long, completely driven into the ground.

c. Buried electrode: If rock or stone prevents

embedding the full 8 foot (2,4 m) length of the ground rod, bury it horizontally in a trench.

SOIL

3/4 INCH (19,1 MM) NOMINAL DIAMETER (MINIMUM)

8 FEET (2,4 M)

Space the ground rod or plates at least 6 feet (1,8) from any other electrode or ground rod, such as those used for signal circuits, radio grounds, lightning rods, etc.

The earth surrounding the ground rod or plate must contain enough moisture to make a good electrical connection. In dry or sandy areas, pour water around the rod, or consult qualified personnel to devise a method of improving the connections.

SOIL

3/4 INCH (19,1 MM) NOMINAL DIAMETER (MINIMUM) 8 FEET (2,4 M) LONG

ROCK

PAGE B − 5INSTALLATION

Page 13

SE SERIES

The electrical power used to operate this pump is high enough to cause injury or death. Make certain that the receptacle or optional enclosure is properly grounded after installation.

Pump Power Cable Connections

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 receptacle or optional enclosure are properly grounded.

The pump is provided with a 50 ft. (15,2 m) power cable (see Table B−5 for standard power cable specifications) with one end wired into the pump head. The other end terminates in separate leads

Table B-5. Pump Power Cable Specifications

OM−06488

which must be connected to a control box or switch box.

Optional rainproof starting switches are available from the factory (see the Parts List, Section E).

NOTE

The optional rainproof starting switch listed in the Parts List is not designed to be watertight and must not be used in submerged applications.

Splicing of the power cable is not recommended by the Gorman-Rupp Company due to safety and warranty considerations. If a longer power cable is required, it should be continuous length and should replace the existing cable. Any replacement cable must be to Gorman-Rupp standards, and must be approved by Gorman-Rupp.

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 alternations.

Amp

Cable

A.W.G

Pump

Model

* Applies only to SO type cable. Refer to manufacturer’s specifications for other cable.

When necessary to change or connect the pump power cable to a control box, make certain the incoming power is OFF and LOCKED OUT, Make certain the control box is PROPERLY GROUNDED and that the electrical data on the control matches the motor name plate data.

Connect the pump power cable to the control switch as shown in the wiring diagrams at the end

PAGE B − 6 INSTALLATION

Voltage/

Phase

115/1SE1 1/2A 16 0.43 (11) 0.06 (1,5)

Cable

Size

O.D.

Inches

(mm)

Conductor

Dia.

Inches

(mm)

Rating

(See Note

Below)

13*

of this section. Make certain that all connections are tight and that cable entry points are rainproof.

Control Box

Cable

Type

Any control box used to operate the

Resistance

(ohms) at

225_C (77_F)

per 1000 ft.

(305 m)

4.49 5.12

Voltage

Drop

per 100 ft. (30,5m) at Max. Load

Page 14

OM−06488 SE SERIES

pump must be approved by the Gorman-Rupp Company for the application.

Motor Cable Grounding Test

Do not connect the pump control cable incoming voltage before verifying the pump ground; otherwise, personnel will be exposed to serious injury or death.

Liquid Level Devices

The pump is not furnished with a means to auto-

PUMP

CONTROL BOX

TO LEVEL CONTROL CIRCUIT

IN MAIN CONTROL BOX

matically regulate liquid level. It may be controlled to perform filling and dewatering by using the float switch and liquid level control offered as options (see Figure B−5).

Overheating will occur if the liquid level falls below the level required to cool the pump motor (see LIQUID LEVEL in Operation, Section C).

PUMP

CONTROL BOX

TO LEVEL CONTROL CIRCUIT

IN MAIN CONTROL BOX

LIQUID LEVEL

RANGE

OFF

DEWATERING

ON (FILLING)

Figure B−5. Typical Float Switch Installation

LIQUID LEVEL

RANGE

DEWATERING

ON (FILLING)

OFF

PAGE B − 7INSTALLATION

Page 15

SE SERIES

OM−06488

WIRING DIAGRAM

Figure B−6. Pump Model SE1 1/2A3 115V 1P

PAGE B − 8 INSTALLATION

Page 16

OM−06488 SE SERIES

OPERATION − SECTION C

GENERAL INFORMATION

Review all SAFETY information in Section A.

This pump is designed to handle most non-volatile, non-flammable liquids. 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.

The pump motor and optional accessories are not designed to be explosionproof. Do not operate in an explosive atmosphere.

Follow the instructions on all tags, labels and decals attached to the pump.

Pump Controls

The pump is driven by an integral 115 VAC, 60 hertz, 1 phase motor equipped with thermal motor overheat protection.

If the pump is wired to an optional manual starting switch, the toggle switch within the rainproof enclosure will start and stop the pump.

If the pump power cable is wired into an optional automatic liquid level control box, pump operation is controlled by a selector switch. In the OFF posi- tion the switch prevents all operations of the pump. In the MAN position, it allows the pump to run continuously. In the AUTO position, it allows the pump to be controlled automatically by an optional liquid level device installed in the sump or wet well (see Liquid Level Devices in Section B).

Short circuit protection for the control box is provided by a customer-furnished fuse or breaker within the circuit. If the breaker trips repeatedly, operational problems exists. See TROUBLESHOOT-

ING in Section D.

Pump Performance

Since operation of the pump motor is dependent upon the quality and performance of the electrical controls, the pump warranty is valid only when controls have been specified or provided by The GormanRupp Company.

Refer to the performance curve in Section E for the specific performance for your pump.

The pump motor and control box are not designed to be explosion-proof. Do not operate in an explosive atmosphere. Improper location of a non-explosion proof control box could result in destruction of equipment, injury or death to personnel.

See the operating instructions furnished with the control box, and with other optional accessories and controls, before attempting to start the pump.

PAGE C − 1OPERATION

Page 17

SE SERIES OM−06488

PUMP OPERATION

Liquid Temperature and Overheating.

Do not start the pump more than 6 times per hour. If the motor does not cool between starts it will overheat, resulting in damage to the motor windings.

The maximum liquid temperature for this pump is 120F (490C). Do not apply it at a higher operating temperature.

Overheating can occur if the pump is made to start and stop repeatedly without time to cool off between starts, the liquid level is allowed to fall too low to sufficiently cool the motor, or if the circuit breaker or fuse fails to provide adequate protection. Operating the pump against a closed discharge valve for an extended period will also cause the pump to overheat.

Overheated pumps can cause severe burns and injuries. If overheating of the pump occurs:

1. Stop the pump immediately. Switch off the power at the control box and lock it out to ensure that the pump will remain inoperative.

2. Ventilate the area.

3. Allow the pump to completely cool if overheated.

4. Check the temperature before servicing.

5. Close the discharge valve (if used).

6. Vent the pump slowly and cautiously

7. Refer to instructions in this manual before restarting the pump.

Impeller Rotation

Check impeller rotation as follows before operation to ensure that the impeller is rotating in the correct direction.

While checking impeller rotation, secure

Approach the pump cautiously after it has been running. Although the motor is

the pump to prevent the power cable from coiling.

cooled by the liquid being pumped, normal operating temperatures can 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

Suspend the pump from the lifting device fitted on the pump.

As viewed from the top, the pump should kick in a counterclockwise direction; this will indicate that impeller rotation is correct.

valve for long periods of time.

If the pump kicks in a clockwise direction, impeller

If overheating does occur, stop the pump immediately and allow it to completely cool before servicing it. Approach any overheated pump cautious-

ly.

PAGE C − 2 OPERATION

rotation is incorrect and the pump must be returned to the factory or a Gorman-Rupp authorized Submersible Repair Center. Since the pump is powered by a single-phase motor, the direction of

Page 18

OM−06488 SE SERIES

rotation can not be altered by interchanging motor leads at the control box.

DIRECTION OF

KICKBACK

AT STARTUP

Figure C−1. Checking Pump Rotation

If the pump is wired into an optional automatic liquid level control box, set the control box selector switch to MAN; the pump will continue to run until the switch returned to OFF, or reset to AUTO.

If desired to operate the pump in the automatic mode, set the selector switch to AUTO; pump operation will be controlled by the optional float switch. To terminate automatic mode, move the selector switch to OFF or HAND.

Moving the control box selector switch to OFF does not terminate incoming power through the field wiring connected to the control box.

It is recommended that a check valve or throttling valve be installed in the discharge line if there is any possibility of siphoning or back flow when the pump is shut off.

STARTING, STOPPING, AND OPERATIONAL CHECKS

Starting And Stopping

Do not attempt to operate the pump until impeller rotation has been checked; improper rotation will affect pump performance and may damage the pump.

If an optional control box is used, follow the instructions accompanying the control box, start the pump, and run any recommended checks.

After the pump and options have been installed in a wet well so that it is fully submerged, start the pump as follows.

Operational Checks

Check the pump for proper operation when first started and periodically thereafter to identify minor problems.

Check the pump for unusual noises or excessive vibration while it is operating. If noise or vibration is excessive, stop the pump and refer to the troubleshooting chart for possible causes.

Check the pump strainer screen for clogging caused by stones, sticks, or other debris. Clean the strainer screen when required. In some cases, stopping the pump momentarily may back flush the strainer screen, purging most of the debris from it. If this fails to clean the screen, remove the pump from the sump and remove the debris manually. See PUMP DISASSEMBLY in the Mainte- nance And Repair manual.

If wired into an optional manual switch, trip the switch within the rainproof enclosure to start or stop the pump.

Never introduce air or steam pressure into the pump casing to remove a block-

PAGE C − 3OPERATION

Page 19

SE SERIES OM−06488

age. This could result in personal injury or damage to the equipment. If backflushing is absolutely necessary, limit liquid pressure input to 50% of the maximum permissible operating pressure shown in the pump performance curve in Section E.

Check the pump for overheating. Overheating can occur if the pump is made to start and stop repeatedly without time to cool off between starts, the liquid level is allowed to fall too low to sufficiently cool the motor, or if the circuit breaker or fuse fails to provide adequate protection. Operating the pump against a closed discharge valve for an extended period will also cause the pump to overheat.

Check the oil level(s) as indicated in the following

LUBRICATION section.

LIQUID LEVEL

could damage gaskets, O-rings or heat the oil in the seal housing above critical temperatures, causing the pump to rupture or explode.

The pump will not freeze as long as the casing is submerged in liquid. If the casing is not submerged, or if the liquid begins to freeze, remove the pump from the sump or wet well and dry it thoroughly. Run the pump for two or three minutes to dry the inner walls.

If the pump does freeze while it is out of the liquid, submerge it until thawed; if the liquid is near freezing, the pump must be submerged for an extended period of time. Check thawing by starting the pump and checking that the shaft rotates freely. If the pump remains frozen, allow additional thawing time before attempting to restart.

If submerging does not thaw the pump, move it into a warm area until completely thawed.

Overheating will occur if the liquid falls below the level required to cool the pump motor.

The pump will operate fully or partially submerged. However, since the motor is cooled by the liquid being pumped, overheating will occur if the liquid is pumped below the required to cool the motor.

The pump operated manually or with an optional liquid level device must remain sufficiently submerged. Do not allow the liquid level to fall below the top of the barbed discharge adaptor in order to provide sufficient cooling to the motor.

COLD WEATHER PRESERVATION

LUBRICATION

Do not remove plates, covers, gauges, pipe plugs or fittings from an overheated pump. Vapor pressure within the pump can cause parts being disengaged to be ejected with great force. Allow the pump to completely cool before servicing.

On a new pump, check the oil level in the seal cavity before initial startup. Drain and replace the oil after the first 200 hours of operation. Following this, check the oil level in the seal cavity after the first two weeks of operation, and every month thereafter.

Before installing or removing the lubrication plug, always clean the area around the plug to prevent contamination.

Draining Oil

Do not attempt to thaw the pump by using a torch or other source of flame. This

PAGE C − 4 OPERATION

Refer to Section E for drain plug location.

Page 20

OM−06488 SE SERIES

It is not necessary to drain the oil from the seal cavity unless the pump casing will be separated from the motor housing.

Lay the pump horizontal on a flat work surface with the seal cavity drain plug facing up. Remove the drain plug slowly to release any pressure. Install a short pipe nipple in the hole. Place a clean container under the plug and roll the pump on its side to drain the seal housing.

Condition Of Oil

Check the condition of the oil drained from the pump. Clear oil indicates that the pump seal is functioning properly. If the oil is milky or contains a small amount of water, it must be changed.

If the oil contains a large amount of water, it must be changed, and the seal must be checked before

the pump is put back in operation (refer to the Maintenance and Repair Manual).

Adding Oil

Refer to Table B−2 in INSTALLATION for pump oil capacities.

The grade of lubricant used is critical to the operation of this pump. Use SAE No. 10 non-detergent oil. Oil must be stored in a clean, tightly closed container in a reasonably dry environment.

When lubricating the seal cavity, remove the lubrication plug as indicated in Draining Oil. Add the non-detergent oil through this plug hole. With the pump positioned horizontally, sight down the plug hole and check that the oil level is high enough to cover the seal spring.

Install and tighten the lubrication plug.

PAGE C − 5OPERATION

Page 21

OM−06488 SE SERIES

TROUBLESHOOTING − SECTION D

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 this manual and with all other literature shipped with the pump.

2. Shutdown and 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. 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 of electrical test instruments; for specific procedures, see ELECTRICAL TESTING following 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 with pump motor.

No voltage at line side of power cable connection.

Open circuit in motor windings or power cable.

Defective motor.

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 breaker, broken lead, or loose connection.

Check continuity.

Check for and replace defective unit.

Check wiring diagrams; correct or tighten connections.

Position device(s) at proper level.

Clean sensing device(s).

Float type sensing device(s) tangled or obstructed.

TROUBLESHOOTING PAGE D − 1

Check installation for free movement of float.

Page 22

SE SERIES OM−06488

Table 1. Trouble Shooting Chart (cont.)

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

(AUTOMATIC MODE) (CONT’D.)

OVERLOAD UNIT TRIPS Low or high voltage, or excessive

Defective liquid level sensing device(s) or control panel.

voltage drop between pump and control box.

Repair or replace defective unit(s).

Measure voltage at control box. Check that wiring is correct type, size, and length. (See Field Wiring

Connections, Section B).

MOTOR RUNS, BUT PUMP FAILS TO DELIVER RATED DISCHARGE

Defective insulation in motor windings or power cable; defective windings.

Impeller jammed due to debris or insufficient clearance.

Bearing(s) frozen.

Discharge head too high.

Low or incorrect voltage.

Discharge throttling valve partially closed; check valve installed improperly.

Discharge line clogged or restricted; hose kinked.

Liquid being pumped too thick.

Strainer screen or impeller clogged.

Check insulation resistance; check continuity.

Disassemble pump and check impeller.

Disassemble pump and check bearing(s).

Reduce head.

Measure control box voltage, both when pump is running and when shut-off.

Open discharge valve fully; check piping installation.

Check discharge lines; straighten hose.

Dilute liquid if possible.

Clear clog(s). Stop pump; back flow may flush away debris.

PUMP RUNS WITH EXCESSIVE NOISE OR VIBRATION

Insufficient liquid in sump or tank.

Worn impeller vanes; excessive impeller clearance.

Pumping entrained air.

Damaged or unbalanced impeller.

Discharge piping not properly supported.

Impeller jammed or loose.

Motor shaft or bearings defective.

Pump cavitation.

Stop pump until liquid level rises.

Check impeller and clearance. See PUMP END REASSEMBLY.

Check liquid level in sump; check position of pump and liquid level sensing device(s).

Replace impeller.

Check piping installation.

Check impeller.

Disassemble pump and check motor and bearings.

Reduce discharge head, or restrict flow on low head applications.

TROUBLESHOOTINGPAGE D − 2

Page 23

OM−06488 SE SERIES

ELECTRICAL TESTING

If you suspect that pump malfunctions are caused by defects in the motor, power cable or control box, perform the following checks to help isolate the defective part.

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) in the Installation Operations manual before reconnecting any electrical components which have been disconnected.

Test Equipment

A volt/amp/ohmmeter and megohmeter of adequate range and quality will be required to conduct the following electrical tests. The suggested equipment indicated below is commercially available, or an equivalent substitute may be used.

Equipment Use

Ammeter To check AC Voltage

and current (amperage)

Ohmeter To measure resistance

(ohms) to ground

tional manual switch or automatic control box.

b. Connect the test leads to any two of three

power cable leads (not to the green ground lead). If the 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 connection between the motor and the power cable. Switch one test lead to the third power lead, and test again.

c. If an open or broken circuit is indicated,

check the power cable for obvious damage, and replace as necessary (see MAINTE- NANCE AND REPAIR). The entire motor power cable must be replaced; splicing or other means of repair are not recommended.

d. If the power cable appears undamaged, see

Head and Power Disassembly, separate the pump head from the motor housing, and disconnect the power cable Amp-lock cap from the Amp-lock plug. Separately test each of the cable leads, (including the green ground lead) for continuity through the Amp-Lock cap. If any of the power cable leads do not check out for continuity, replace the entire power cable.

e. If no break is found in the power cable, con-

nect the test leads to the power contacts (not to the ground wire contact) of the Amplock plug. If the test reading indicates an open or broken circuit, there is an open circuit in the motor.

NOTE

It is recommended that a pump with a defective motor be returned to Gorman-Rupp, or to one of the Gorman-Rupp authorized Submersible Repair Centers.

Motor And Motor Power Cable Continuity

f. Be certain to reconnect the Amp-lock plug

To check continuity, zero-balance the ohmmeter set at the RX1 scale, and test as follows:

a Disconnect the power cable plug from the

receptacle, or lock out incoming power and disconnect the power cable leads to the op-

TROUBLESHOOTING PAGE D − 3

and cap before reassembling the pump head to the motor housing.

If insulation resistance is to be checked, do not assemble the pump head to the motor housing at this time.

Page 24

SE SERIES OM−06488

Insulation Resistance

To check insulation, zero-balance the ohmmeter set at the RX100K scale, and test as follows:

a. Disconnect the power cable plug from its re-

ceptacle, or lock out incoming power and disconnect the power cable leads to the optional manual switch or automatic control box.

b. Connect one test lead to the power cable

plug grounding prong (or to the green ground lead), and touch the other test lead to each of the two power prongs (or power leads) in turn.

c. The reading obtained will indicate resis-

tance values in both the power cable and the motor windings. If the resistance reading is infinity (1), the insulation is in good condi-

tion. If the reading is between infinity (1) and 1 megohm, the insulation 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.

d. To determine whether the power cable or

the motor is grounded, separate the pump head from the motor housing (see Head

and power Cable Disassembly/Reassembly in MAINTENANCE AND REPAIR

section) and disconnect the Amp-lock plug and cap. Test the power cable leads and motor leads separately.

e. Be certain to reconnect the Amp-lock plug

and cap before reassembling the pump head on the motor housing.

TROUBLESHOOTINGPAGE D − 4

Page 25

SE SERIESOM−06488

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 MODEL SE1 1/2A3 115V 1P

Based on 70F (21C) clear water at sea level with minimum suction lift. Since pump installations are seldom identical, your performance may be different due to such factors as viscosity, specific gravity, elevation, temperature, and impeller trim.

Contact the Gorman-Rupp Company to verify performance or part numbers.

Pump speed and operating condition

If your pump serial number is followed by an N", your pump is NOT a standard production model.

MAINTENANCE AND REPAIR PAGE E − 1

points must be within the continuous performance range shown on the curve.

Page 26

PARTS PAGE

OM−06488SE SERIES

SECTION DRAWING

Figure E−1. SE1 1/2A3 115V 1P Pump Assembly

MAINTENANCE AND REPAIRPAGE E − 2

Page 27

SE SERIESOM−06488

PARTS LIST

Pump Model SE1 1/2A3 115V 1P

(From S/N 1483930 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.

ITEM

PART NAME PART

NO.

1 PUMP CASING 26815−033 −−− 1 2 IMPELLER 26815−045 −−− 1 3 SEAL ASSEMBLY 26815−115 −−− 1 4 DISCH FLANGE GSKT 26815−154 −−− 1

5 DISCHARGE FLANGE 26815−432 −−− 1 6 HEX HD CAPSCREW 26815−308 −−− 2 7 LOCKWASHER 26815−368 −−− 2 8 1 1/2" HOSE ADAPTOR 26815−421 −−− 1

9 PUMP SPEC DECAL 38814−037 −−− 1 10 MOTOR HOUSING 26815−821 −−− 1 11 TERMINAL 26815−560 −−− 2 12 RD HD PHL SCREW 26815−335 −−− 2 13 WITH LOCKWASHER −−− −−− 2 14 CENT SW CONTACT 26815−194 −−− 1 15 RD HD PHL SCREW 26815−340 −−− 2 16 WITH LOCKWASHER −−− −−− 2 17 FLAT WASHER 26815−374 −−− 2 18 MOUNTING PLATE 26815−163 −−− 1 19 HEX HD PHL SCREW 26815−356 −−− 4 20 WITH LOCKWASHER −−− −−− 4

21 GROMMET 26815−292 −−− 1 22 GROUND WIRE 26815−601 −−− 1 23 TERMINAL 26815−562 −−− 1 24 RD HD PHL SCREW 26815−340 −−− 1 25 WITH LOCKWASHER −−− −−− 1 26 FLAT WASHER 26815−374 −−− 1 27 HEAD 26815−008 −−− 1 28 CABLE LOCK 26815−441 −−− 1

29 POWER CABLE 26815−243 −−− 1 30 W/CABLE LOCK PLATE 26815−451 −−− 1 31 HEX HD PHL SCREW 26815−355 −−− 2 32 WITH LOCKWASHER −−− −−− 2 33 IDENT PLATE 2613EF 13990 1

34 LIFTING ROPE 26815−650 −−− 1 35 HANDLE 26815−082 −−− 1 36 HEX HD PHL SCREW 26815−355 −−− 2

NUMBER

INDICATES PARTS RECOMMENDED FOR STOCK

MAT’L CODE

QTY ITEM

NO.

37 WITH LOCKWASHER −−− −−− 2 38 M CONNECTOR SLEEVE 26815−927 −−− 3 39 PLUG 26815−925 −−− 3 40 F CONNECTOR SLEEVE 26815−926 −−− 3 41 RECEPTACLE 26815−924 −−− 3 42 PRESSURE TEST PLUG 26815−406 −−− 1

43 BEARING SHIM 26815−134 −−− 1 44 BALL BEARING 23253−003 −−− 1

45 OVERLOAD PROTECTOR 26815−202 −−− 1 46 RD HD PHL SCREW 26815−342 −−− 2 47 FLAT WASHER 26815−374 −−− 2

48 HEAD GSKT 26815−156 −−− 1 49 CENT SW ACTUATOR 26815−184 −−− 1

50 ROTOR W/SHAFT 26815−851 −−− 1 51 DUST SEAL 26815−123 −−− 1 52 SHAFT SLEEVE 26815−271 −−− 1 53 STATOR 26815−841 −−− 1 54 IMPELLER KEY 26815−054 −−− 1 55 BALL BEARING 23253−006 −−− 1 56 HEX HD PLUG 26815−400 −−− 1 57 CASING O-RING 26815−146 −−− 1 58 COVER GSKT 26815−155 −−− 1

59 HEX HD PHL SCREW 26815−350 −−− 4 60 WITH LOCKWASHER −−− −−− 4

61 IMPELLER COVER 26815−062 −−− 1 62 IMPELLER WASHER 26815−052 −−− 1 63 IMPELLER LOCKWASHER 26815−368 −−− 1 64 IMPELLER LOCK NUT 26815−053 −−− 1 65 STRAINER 26815−073 −−− 1 66 HEX HD PHL SCREW 26815−350 −−− 3 67 WITH LOCKWASHER −−− −−− 3 68 HEX HD PHL SCREW 26815−356 −−− 3 69 WITH LOCKWASHER −−− −−− 3

OPTIONAL:

PART NAME PART

NUMBER

FF ADAPTOR CONV KIT 48224−003 −−− 1

MAT’L CODE

QTY

MAINTENANCE AND REPAIR PAGE E − 3

Page 28

PUMP AND SEAL DISASSEMBLY AND REASSEMBLY

OM−06488SE SERIES

Review all SAFETY information in Section A.

Follow the instructions on all tags, label and decals attached to the pump.

This pump requires little service due to its rugged, minimum-maintenance design. However, if it becomes necessary to inspect or replace the wearing parts, follow these instructions which are keyed to the sectional view (see Figure E-1) and the accompanying parts list.

This manual will alert personnel to known procedures 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 personnel to ensure that only safe, established main- tenance 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.

Before attempting to service the pump, disconnect or lock out incoming power and take precautions to ensure that it will remain inoperative. Close any valves in the discharge line.

Nuts, bolts, and screws used on this pump are metric and do not match standard English-measurement threads. If any threaded hardware is replaced, it must be replaced with metric type. Attempting to force in a fastener with English threads will damage the mating threads. An optional discharge adaptor is available to convert the metric pipe threads in the discharge flange to American pipe threads.

Use the lifting rope (34) to remove the pump from the wet well or sump, and move it to a location where the discharge line can be removed. It is not necessary to disconnect a flexible discharge hose before removing the pump. If rigid discharge piping is used, disconnect the piping before attempting to move the pump.

Pump motor maintenance may be performed only by a Gorman-Rupp authorized repair facility or the factory. Otherwise, the pump warranty will be 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.

PUMP END DISASSEMBLY

Follow the instructions on all tags, label and decals attached to the pump.

To remove the discharge flange (5), disengage the hardware (6 and 7) and remove the flange and gasket (4).

Do not attempt to lift the pump by the motor power cable or the piping. Use the lifting rope 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.

MAINTENANCE AND REPAIRPAGE E − 4

Page 29

SE SERIESOM−06488

Select a suitable location, preferably indoors, to perform the degree of maintenance required. If the motor housing is to be opened, the work must be done in a clean, well-equipped shop. All maintenance functions must be done by qualified personnel.

Check the chart in TROUBLESHOOTING, Section D of this manual, to determine the nature of the pump problem. If the problem is mechanical in nature, such as worn pump parts, seal replacement, lubrication, etc., refer to PUMP END DISASSEM- BLY for instructions.

If the problem is electrical, complete disassembly may not be required. Refer to Electrical Testing in TROUBLESHOOTING, Section D, and have a qualified electrician check the control box, cable and head. If the problem is determined to be in the motor, proceed with PUMP END DISASSEMBLY, followed by MOTOR DISASSEMBLY. Otherwise, see Head And Power Cable Disassembly.

Carefully inspect any O-rings or gaskets before removal and cleaning to determine if a proper seal and compression existed prior to disassembly. If sealing was faulty or questionable, the cause must be determined and corrected before reassembly. All gaskets and most O-rings must be replaced if disturbed. Repair gaskets and O-rings are listed in the Parts List.

PUMP END DISASSEMBLY

Strainer And Impeller Cover Removal

If the impeller (2) is clogged, the debris can usually be removed without further disassembly.

Draining Oil From Seal Cavity

The oil should be drained from the seal cavity before performing any further disassembly.

Let the pump cool before removing the seal cavity drain/fill plug. Pressure built up within a hot pump could cause the oil to spray out when the plug is removed. Remove the plug slowly and permit pressure to vent to atmosphere.

Lay the pump on its side with the drain/fill plug (56) facing up. Clean any dirt from around the plug. Remove the plug and install a short nipple in the hole. Tip the pump and drain the seal oil into a clean container. Inspect the oil for water, dirt, or cloudy condition which could indicate lower seal failure or poor gasket seal. Remove the nipple and reinstall the plug.

Positioning Pump For Disassembly

It is recommended that the pump be positioned upside-down during disassembly. To hold the pump in the inverted position, rest the pump securely on blocks. Be careful not to damage the head (27) and power cable (29) while in this position.

To remove the strainer assembly (65), disengage the hardware (66 and 67) securing the strainer to the impeller cover (61). To remove the impeller cover, remove the hardware (59 and 60) securing it to the pump casing (1). Remove the cover gasket (58).

NOTE

Carefully inspect any O-rings or gaskets before removal and cleaning to determine if a proper seal and compression existed prior to removal. If sealing was faulty or questionable, determine the cause and correct it before reassembly. Replace any parts as required.

MAINTENANCE AND REPAIR PAGE E − 5

Impeller Removal

Wedge a piece of wood between the vanes of the impeller (2) and the pump casing to prevent shaft rotation. Remove the hardware (62, 63 and 64) securing the impeller.

Remove the wood and use a suitable puller to pull the impeller off the shaft. Retain the impeller key (54).

Seal Removal

The seal contains two rotating elements, two stationary elements and two bellows assemblies.

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OM−06488SE SERIES

Remove the hardware (68 and 69) securing the pump casing to the motor housing (10). Use caution when removing the hardware, tension on the seal spring will be release.

Carefully slide the pump casing off the shaft. The shaft sleeve (52) will be removed with the pump casing. Lubricate the sleeve and press it out of the dust seal (51). Remove the casing O-ring (57).

Use a screwdriver or other suitable tool to pry the dust seal out of the pump casing from the back side.

To remove the stationary portion of the seal, place the pump casing on a clean cloth with the impeller side up. Use a drift pin or dowel to press on alternate sides of the stationary seat until the stationary element and seat are removed.

Lubricate the rotor shaft (50) and work oil under the bellows assembly. Pull the bellows assembly off the shaft.

PUMP END REASSEMBLY

NOTE

Reuse of old O-rings, gaskets, or shaft seal parts will result in premature leakage or reduced pump performance. It is strongly recommended that new gaskets and shaft seal assemblies be used during reassembly (see the parts lists for numbers).

Cleaning And Inspection Of Pump Parts

With the pump inverted, stuff a clean tissue into the stationary seal seat bore of the motor housing (10) or wrap a small rag around the shaft to prevent foreign material from entering the motor cavity.

Remove the seal spring.

Lubricate the rotor shaft and work oil under the upper bellows assembly. Pull the bellows assembly and the rotating element off the shaft.

Slide the hooked ends of the two wires along the shaft and under the upper stationary element and seat. Hook the back side of the seat and pull them from the motor housing bore.

Stuff a clean tissue into the stationary seal seat bore of the motor housing (10) or wrap a small rag around the shaft to prevent foreign material from entering the motor cavity.

If no further disassembly is required, proceed to the appropriate areas in PUMP END REASSEMB-

LY.

NOTE

Do not disassemble the motor unless it is necessary and a clean, well-equipped shop is available. If the motor housing components are to be serviced, see MOTOR DISASSEMBLY in this section. Do not reassemble the pump end components at this time.

Thoroughly clean all reuseable parts with a soft cloth soaked in cleaning solvent. Remove all Orings and gaskets, and clean the sealing surfaces of dirt or gasket material. Be careful not to scratch gasket surfaces.

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Inspect the rotor shaft (50) for damaged threads, scoring, or nicks. Remove nicks and burrs with a fine file or emery cloth to restore original contours. If the shaft is bent or severely damaged, the rotor and shaft must be replaced as an assembly (see MOTOR DISASSEMBLY).

The shaft seal assembly (3) should not be reused because wear patterns on the finished faces cannot be realigned during reassembly. This could result in premature failure. If necessary to reuse an

MAINTENANCE AND REPAIRPAGE E − 6

Page 31

SE SERIESOM−06488

old seal in an emergency, carefully wash all metallic parts in fresh cleaning solvent and allow to dry thoroughly.

Handle the seal parts with extreme care to prevent damage. Be careful not to contaminate the precision finished faces; even fingerprints on the faces can shorten seal life. If necessary, clean the faces with a non-oil based solvent and a clean, lint-free

ROTOR SHAFT

STATIONARY ELEMENT

ROTATING ELEMENT

SPRING

STATIONARY SEAT

tissue. Wipe lightly in a concentric pattern to avoid scratching the faces.

Inspect the seal components for wear, scoring, grooves, and other damage that might cause leakage. If any components are worn, replace the complete seal; never mix old and new seal parts.

Install the shaft seal as illustrated in Figure E−2.

STATIONARY SEAT

MOTOR HOUSING

BELLOWS AND RETAINING ASSY

ROTATING ELEMENT

PUMP CASING

DUST SEAL

IMPELLER KEY

Figure E−2. 26815−115 Seal Assembly

This seal is not designed for operation at temperatures above 120 F (49 C). Do not use at higher operating temperatures.

Seal Installation

Do not unwrap a new seal assembly until time of

installation. Cleanliness of seal components is critical, especially the seal faces.

Clean the rotor shaft (50) and seal cavity area of the motor housing (10). Be sure the area is dry and free

STATIONARY ELEMENT

SHAFT SLEEVE

IMPELLER SHIMS

IMPELLER

of lint and dirt. Check the seal bore for burrs or nicks that might prevent a good seal. Apply a light coating of oil to the bore.

Carefully remove the material stuffed into the seat bore (or unwrap the shaft). Be sure no debris stopped by the material falls into the motor cavity.

NOTE

When pressing seal components onto the shaft, use hand pressure only. A push tube cut from a length of plastic pipe will aid in installing seal components. The I.D. of the push tube should be approximately the same as the I.D. of the seal spring.

MAINTENANCE AND REPAIR PAGE E − 7

Page 32

OM−06488SE SERIES

Subassemble the upper stationary element into the stationary seat. Position this subassembly in the motor housing bore with the sealing face up and cover the seal face with a clean tissue. Use your thumbs to press the assembly into the bore. Apply equal pressure on opposite sides until the seat contacts the bore shoulder. Remove the tissue and inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use clean tissue to wipe lightly in a concentric pattern.

Unpack the rotating portion of the upper seal. Be certain the seal face of the rotating element is free of grit or surface damage.

Apply a light coating of oil to the seal seating sur- face on the shaft and I.D. of the bellows. Inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use a clean tissue to wipe in a circular pattern. Slide the seal rotating portion onto the lubricated shaft as shown in Figure E−2. Apply firm, steady pressure on the seal retainer until it slides down the shaft and the seal faces contact.

Slide the seal spring over the shaft and bellows retainer. The seal spring will be compressed and held in place when the pump casing (1) is installed.

Unpack the lower rotating portion of the seal. Be certain the seal face of the rotating element is free of grit or surface damage. Apply a light coating of oil on the shaft and the I.D. of the bellows.

Position the rotating subassembly on the shaft with the sealing face up, and cover it with a clean tissue. Use your thumbs to press the subassembly onto the shaft. Apply equal pressure on opposite sides of the retainer until it contacts the seal spring. Remove the tissue and inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use clean tissue to wipe lightly in a concentric pattern. After cleaning, apply a drop of light oil to the seal face.

Unpack the lower stationary seat and element. Subassemble the stationary element into the stationary seat. Apply a light coating of oil to the pump casing (1) bore and the O.D. of the seal seat. Apply equal pressure on opposite sides until the seat contacts the bore shoulder. Remove the tissue and inspect the seal face to ensure that it is clean and dry. If cleaning is necessary, use clean tissue to wipe lightly in a concentric pattern.

Install the pump casing O-ring (57) on the casing shoulder and lubricate with light oil. Carefully position the pump casing and stationary seal components over the rotor shaft. Align the holes for the capscrews (68) and press the casing into the lower motor housing until fully seated. Be careful not to damage the stationary element or casing O-ring already installed.

Secure the pump casing to the motor housing (10) with the hardware (68 and 69).

Impeller Installation

Inspect the impeller (2) for cracks, broken vanes, or wear from erosion, and replace it if damaged. Clean the threads on the rotor shaft to remove any old thread locking material.

Lubricate the casing bore and lip of the dust seal (51). Press the dust seal into the pump casing until fully seated. Install the shaft sleeve (52).

Install the impeller key (54) in the shaft keyway, align the impeller keyway, and press the impeller onto the shaft until it seats firmly against the shaft sleeve.

Install the impeller hardware (62, 63 and 64). Place a block of wood between the vanes of the impeller and pump casing to prevent shaft rotation and tighten the impeller lock nut (64).

Remove the block of wood and turn the impeller to check for free rotation. Check the front clearance after installing the impeller cover (61).

Impeller Clearance

Install the impeller cover gasket (58). Position the impeller cover over the pump casing and secure the cover with the hardware (59 and 60).

There should be a clearance of .010 to .020 inch (0,25 and 0,51 mm) between the impeller cover (61) and the face of the impeller. Use a feeler gauge to measure this clearance.

If the impeller clearance is not within specified limits, remove the impeller cover, impeller and one of the impeller shims. Reinstall the impeller and impeller cover, and recheck clearance.

Strainer Installation

Inspect the strainer assembly (65) for cracks, distortion or erosion, and replace it if defective.

MAINTENANCE AND REPAIRPAGE E − 8

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SE SERIESOM−06488

Position the strainer squarely on the shoulder of the impeller cover (61) and secure with the hardware (66 and 67). Make certain that the strainer seats properly against the shoulder of the impeller cover.

See LUBRICATION and FINAL ASSEMBLY before putting the pump back into service.

MOTOR DISASSEMBLY

Disassembly of the motor is rarely required except to replace the motor rotor, stator, bearings or motor housing. The rotor and shaft assembly (50) and the stator (53) cannot be removed from the motor housing without disassembling the pump end and removing the head (27). Do not disassemble the motor unless it is necessary and a clean, wellequipped shop is available.

NOTE

It is recommended that a pump with a defective motor be returned to Gorman-Rupp, or to one of the Gorman-Rupp authorized Submersible Repair Centers.

Head And Power Cable Removal

Total disassembly of the head (27) and power cable (29) is not always required. The head and power cable may be serviced without disassembling the motor housing or pump end. Disassemble and replace only the parts proven defective by inspection or testing. See Electrical Testing in TROUBLESHOOTING.

The oil must be drained, however, before attempting to disassemble the motor housing and components see Draining Oil in PUMP END DISASSEM-

BLY.

All electrical connections and disconnections must be made by qualified personnel. Refer to Figure 1 in this section, and to the Electrical Wiring Diagram,in Section B, Installation.

Secure the pump in an upright position. Remove the hardware (19 and 20) securing the head to the motor housing (10). Raise the head for access to the sleeves (38 and 40), plugs and receptacles (39 and 41). Separate the male and female sleeves (38 and 40), and slide them over the power cable and stator leads. Pull the plugs out of the receptacles. Remove the head and power cable from the pump.

Remove the hardware (31 and 32) securing the handle (34) and cable lock (28) to the head. To sep-

The electrical power used to operate this pump is high enough to cause injury or death. If the pump power cable is wired into an optional control box make certain the switch is in the OFF or STOP position and locked out, or that the power supply to the control box has been otherwise cut off and locked out. Tag electrical circuits to prevent accidental start-up.

MAINTENANCE AND REPAIR PAGE E − 9

arate the power cable (29) from the head, remove the hardware (36 and 37) securing the cable lock plate (30) to the head. Pull the cable and lock plate out of the head. Slide the lock plate off the cable.

Remove the head gasket (48).

NOTE

The mounting plate (18) must be removed if the rotor and shaft (50), bearings (44 and 55), and/or stator (53) are to be disassembled.

Disconnect the white lead from the stator (53) at its point of connection to the overload protector (45).

Using caution not to strain any electrical leads, lift the mounting plate (18) from the upper bearing (44); the bearing shim (43) will become a free part.

Page 34

OM−06488SE SERIES

Turn the mounting plate over and remove the hardware (12 and 13) securing the terminals (11) of the blue stator leads to the centrifugal switch contact (14). Lift the mounting plate off the motor housing, using caution to feed the stator leads down through the grommet (21).

To remove the green ground wire (22), remove the hardware (24, 25 and 26) securing the terminal (23) of the green ground wire to the mounting plate (18).

To remove the overload protector (45), remove the hardware (46 and 47) securing the protector to the mounting plate.

Remove the hardware (15, 16 and 17) securing the centrifugal switch contact to the mounting plate.

NOTE

The centrifugal switch actuator (49) is a press fit onto the rotor shaft and cannot be removed until the rotor is removed.

To replace the grommet (21), press it from the mounting plate.

See Head And Power Cable Installation if no fur- ther disassembly is required.

Rotor Removal

See PUMP END DISASSEMBLY and remove all pump end components and Head And Power Cable Removal and remove the head (27) and mounting plate (18).

From the impeller end of the shaft, use a block of wood or soft-faced mallet to tap the rotor, switch actuator (49) and assembled ball bearings (44 and

55) out of the motor housing and through the stator (53). Use caution to prevent the rotor (50) from falling on the stator windings.

be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and rotor assembly is removed.

Before removing the bearings from the rotor shaft, clean and inspect the bearings in place as follows.

Clean the bearings thoroughly in fresh cleaning solvent. Dry the bearings with filtered compressed air and coat with light oil.

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area; free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Rotate the bearings by hand to check for roughness or binding. If rotation is rough, replace the bearings.

The bearing tolerances provide a tight press fit onto the shaft and a snug slip fit into the motor housing and bearing bore. Replace the shaft and rotor (as an assembly) or the motor housing if the proper bearing fit is not achieved.

If replacement is required, use a bearing puller to remove the ball bearings from the rotor shaft.

Switch Actuator Removal

Remove the snap ring securing the switch actuator to the shaft. Use a felt tip ink marker to scribe the location of the actuator on the shaft. Use a suitable puller to remove the switch actuator from the shaft.

Stator Removal

Bearing Removal

To prevent damage during removal from the shaft, it is recommended that bearings

Do not remove the stator (53) unless it is defective (open windings, insulation resistance low, or stator core damaged). If the stator must be removed, remove the head as indicated in Head And Power

Cable Removal.

Position an expandable tool, such as a split disc, approximately 2 inches (51 mm) inside the stator, and expand it tightly and squarely on the I.D. At-

MAINTENANCE AND REPAIRPAGE E − 10

Page 35

SE SERIESOM−06488

tach a lifting device to the lifting eye of the tool, and raise the assembly approximately 1 inch (25 mm) off the work surface. Take care not to damage the stator end turns.

The motor housing (10) must be heated with a torch to expand it enough for the stator to be removed. Apply heat evenly to the outside of the motor housing; excessive heat is not required. When the motor housing is sufficiently heated, use a softfaced mallet to rap alternate edges of the motor housing, and walk" the stator out. Continue this process until the stator clears the motor housing.

Take care not to damage the stator end turns during removal from the motor housing.

Clean all gasket and O-ring surfaces, completely removing any old gasket and cement material. Inspect the sealing surfaces for burrs, nicks and pits which could cause a poor seal. Replace defective parts as required.

Thoroughly clean the inside of the motor housing (10) with fresh solvent. The interior must be dry and free of dirt or lint.

Most cleaning solvents are toxic and flammable. Use them only in a well ventilated area; free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent containers.

Stator Installation

After the stator has been removed, wrap it in clean, dry rags or other suitable material until reassembly. The stator must be kept clean and dry. When handling the stator, do not set it on the end windings; lay it on its side.

Do not attempt to rewind the stator. Winding tolerances and materials are closely controlled by the manufacturer, and any deviation can cause damage or operating problems. Replace the stator, or return it to one of The Gorman-Rupp Authorized Submersible Repair Centers or The GormanRupp factory, if defective.

MOTOR REASSEMBLY

NOTE

Reuse of old O-rings, gaskets, shaft seal parts will result in premature leakage or reduce pump performance. It is strongly recommended that new gaskets and shaft seal assemblies be used during reassembly (see the parts lists for numbers).

NOTE

Stator installation involves heating the motor housing. This process must be done quickly. Therefore it is recommended that these steps be performed by two people to promote efficient installation of the stator.

Do not unwrap the stator (53) until the motor housing has been prepared for stator installation. The stator must be kept clean and dry. When handling the stator, do not set it on the end windings; lay it on its side and block it from rolling.

Test the new stator as indicated in Electrical Test- ing in TROUBLESHOOTING, Section D, to ensure that no damage has occurred during transit or handling.

NOTE

Remove any drops of varnish from the ends of the stator before installation to ensure proper stack-up height when assembled.

Stand the motor housing (10) upright. Position an expandable tool, such as a split disc, approximately 2 inches (51 mm) down inside the stator (opposite the lead wire end), and expand it tightly and squarely on the I.D. Attach a lifting device to

MAINTENANCE AND REPAIR PAGE E − 11

Page 36

OM−06488SE SERIES

the lifting eye of the tool, and carefully lift the assembly. Take care not to damage the stator end turns. Slip a sleeve over the stator leads, or tape them together to protect them during installation.

NOTE

Stator installation involves heating the motor housing. This process must be done quickly to allow the stator to slide into the motor housing before the housing cools.

Heat the motor housing (10) with a torch to expand it enough for the stator (53) to be installed; when heating the motor housing, make sure that the stator is clear to avoid a fire hazard, or damage to the windings. Apply heat evenly to the outside of the housing; excessive heat is not required.

When the motor housing is sufficiently heated, position the stator so that the leads are in line with the terminal opening. Carefully lower the stator into the motor housing until fully seated against the housing shoulder. Be careful not to damage the stator leads and switch actuator during reassembly. If the stator cocks" in the motor housing, remove it and try again.

the previously scribed mark on the shaft. Secure the switch actuator to the shaft using the snap ring.

Bearing Installation

To prevent damage during removal from the shaft, it is recommended that bearings be cleaned and inspected in place. It is strongly recommended that the bearings be replaced any time the shaft and rotor assembly is removed.

The bearings may be heated to ease installation. An induction heater, hot oil bath, electric oven, or hot plate may be used to heat the bearings. Bearings should never be heated with a direct flame or directly on a hot plate.

NOTE

If a hot oil bath is used to heat the bearings, both the oil and the container must be absolutely clean. If the oil has been previously used, it must be thor- oughly filtered.

After the stator is fully and squarely seated on the motor housing shoulder, remove the expandable disc tool. Untape or remove the protective sleeve from the electrical leads.

Cover the motor housing with a clean, lint-free cloth while the rotor is being assembled.

Switch Actuator Installation

Inspect the rotor shaft (50) for damaged threads, scoring in the seal area, and a nicked or damaged keyway. If the bearings were removed, inspect the bearing areas for scoring or galling. Remove nicks and burrs with a fine file or emery cloth. Inspect the rotor area for separated laminations. If the shaft is bent or damaged, or if the laminations are separated, replace the shaft and rotor (a single assembly).

Using a sleeve with an I.D. a little larger than the O.D. of the shaft, press the switch actuator onto the shaft. The actuator flange sits just flush with the snap ring groove. The lower side should align with

Heat the bearings (44 and 55) to a uniform temperature no higher than 250F (120C). Slide the bearings onto the shaft one at a time until they are fully seated against the shaft shoulder. This should be done quickly, in one continuous motion, to prevent the bearings from cooling and sticking on the shaft.

Use caution when handling hot bearings to prevent burns.

After the bearings have been installed and allowed to cool, check to ensure that they have not moved out of position in shrinking. If movement has occurred, use a suitably sized sleeve and a press to reposition the bearings. Make certain that they are seated squarely against the shaft shoulders.

If heating the bearings is not practical, use a suitably sized sleeve and an arbor (or hydraulic) press to install the bearings on the shaft.

MAINTENANCE AND REPAIRPAGE E − 12

Page 37

SE SERIESOM−06488

When installing the bearings onto the shaft, never press or hit against the outer race, balls, or ball cage. Press only on the inner race.

Rotor Installation

With the stator (53) installed and the motor housing (10) upright, carefully ease the rotor, switch actuator and assembled bearings (44 and 55) into the motor housing and through the stator until the bearing (55) seats squarely into the motor housing bore.

Wrap the impeller end of the shaft in a clean cloth to protect it during installation of the head and power cable.

Head And Power Cable Installation

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.

Inspect the mounting plate grommet (21) and replace as required. Press the grommet into the mounting plate (18). Be sure that it seats on both sides of the plate.

Install the centrifugal switch contact (14) on the mounting plate with the hardware (15, 16 and 17).

Secure the blue stator wire terminals to the centrifugal switch contact with the hardware (12 and 13) as shown in the wiring diagram, Figure B-6.

Secure the overload protector (45) to the mounting plate with the hardware (46 and 47).

Feed the white and red stator leads through the grommet.

Position the bearing shim (43) on the upper bearing (44). Carefully press the mounting plate bore over the bearing shim and upper bearing. Make certain that the bearing seats squarely into the bore.

The electrical power used to operate this pump is high enough to cause inju-

As shown in the wiring diagram, Figure B-6, secure the white stator lead to the overload protector.

ry or death. If the pump power cable is wired into an optional control box make certain the switch is in the OFF or STOP position and locked out, or that the power supply to the control box has been

Install the cable lock (28) and lock plate (30) on the power cable (29). Lubricate the bore of the head (27) and install the power cable through the bore. Secure the lock plate to the head (27) using the hardware (36 and 37).

otherwise cut off and locked out. Tag electrical circuits to prevent accidental start-up.

Clean the exterior of the power cable with warm water and mild detergent. Check for obvious physical damage. Check the cable for continuity and insulation resistance (see Electrical Testing in TROUBLESHOOTING). Do not attempt repairs except to cut off either end of the cable; splicing is not recommended. Reinstall any wire tags or terminals which may have been removed.

MAINTENANCE AND REPAIR PAGE E − 13

Using the hardware (31 and 32) secure the handle (34) to the head.

Replace the head gasket (48).

Connect the male and female sleeves (38 and 40) over the plugs and receptacles. Install the plugs (39) in the receptacles (41) as shown in the wiring diagram, Figure B−6.

Connect the green ground wire (22) to the mounting plate using the hardware (24, 25 and 26). Make

Page 38

OM−06488SE SERIES

certain the terminal makes good contact with the plate.

Position the head (27) on the motor housing (10) and secure with the hardware (19 and 20).

See PUMP END REASSEMBLY to reassemble the pump end components.

FINAL ASSEMBLY

If the discharge flange (5) was removed from the pump casing, replace the discharge flange gasket (4). Secure the flange with the hardware (6 and 7).

VACUUM/PRESSURE TESTING

To ensure the water-tight integrity of the pump, it is recommended that the motor and seal cavities be vacuum and pressure tested any time the seal and/ or motor are serviced. The seal cavity must be pressurized to prevent separation of the seal faces or unseating the stationary seal seat between the seal and motor cavities. Use a manometer with a range up to 30 inches of mercury to perform the vacuum test. Do not use a vacuum gauge. Vacu-

um gauges are not sensitive enough to detect minor leaks.

Drain all of the oil from both the seal and motor cavities before performing the test. Oil within the motor cavity will be drawn into the system, resulting in damage to the vacuum pump or manometer.

It is recommended that a vacuum pump be used to draw the vacuum on the motor cavity. If a vacuum pump is not available, a compressor/venturi system may be used. If the compressor/venturi cannot draw the vacuum level shown in Table E−1, draw the motor cavity vacuum down as far as the system will allow, then pressurize the seal cavity so the differential between the two cavities is the same as the differential between the readings shown in the table.

If a compressor/venturi system is used, install fullclosing ball-type shutoff valves with quick-disconnect fittings in the pipe plug holes in both the motor and seal cavities. This will allow the pressure (or vacuum) to be maintained while using the compressor to perform the second portion of the test.

Figure E−3 shows a simple schematic for setting up either a vacuum pump or a venturi/compressor test system.

Vacuum Pump

Venturi

Air Compressor

Manometer

Tee

Quick Disconnect Fitting

Figure E−3. Vacuum/Pressure Test System

Table E−1 shows the motor cavity vacuum and seal cavity pressure readings for the test, and the duration to maintain each reading. Any change in

Table E−1. Vacuum/Pressure Test Data

Quick Disconnect Fitting

Full-Closing Ball-Type Shutoff Valve

Use Compressor to Pressure Test Seal Cavity

the readings during the test indicates a leak which must be identified and corrected before putting the pump back into service.

MAINTENANCE AND REPAIRPAGE E − 14

Vacuum Test Motor Cavity

Submersible Pump

Page 39

SE SERIESOM−06488

Pump

Model

SE1 1/2A 30 1 15 1

Motor Cavity

Vacuum

(In. Hg.)

(Minutes)

LUBRICATION

Seal Cavity

Check the oil level in the seal cavity before initial startup, after the first two weeks of operation, and every month thereafter.

Check the oil level only when the pump is cool. If the oil level plug is removed when the pump is hot, pressure in the seal cavity can cause hot oil to be ejected as the plug is removed.

Duration

housing. Tip the pump and drain off a small amount of oil into a transparent cup. If the oil level is abnormally low, or the color milky or dark, refer to Draining Oil From Seal Cavity in this section for instructions and troubleshooting tips.

To fill the seal cavity, remove the seal cavity drain/fill plug (56) and add 7 ounces (0,2 liter) of SAE No. 10 non-detergent oil. Refer to the Section B, Installa- tion and Section C, Operations or positioning of the pump during filling of the seal cavity. Apply ‘Loctite Pipe Sealant With Teflon No. 592.’ or equivalent to the threads of the pipe plug, before reinstalling the plug.

Motor Cavity

Seal Cavity

Pressure

(PSI)

Duration

(Minutes)

To check the seal cavity oil, lay the pump on its side and remove the seal cavity plug (56) in the motor

The motor cavity is cooled by the liquid being pumped. No further lubrication is required.

MAINTENANCE AND REPAIR PAGE E − 15

Page 40

For U.S. and International Warranty Information,

Please Visit www.grpumps.com/warranty

or call:

U.S.: 419−755−1280

International: +1−419−755−1352

For Canadian Warranty Information,

Please Visit www.grcanada.com/warranty

or call:

519−631−2870

THE GORMAN-RUPP COMPANY  MANSFIELD, OHIO

GORMAN-RUPP OF CANADA LIMITED  ST. THOMAS, ONTARIO, CANADA