Gorman-Rupp Pumps SF4B User Manual
ACDE
OM-06460-01
March 22, 2012
Rev. C 01‐09‐14
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SUBMERSIBLE PUMP
MODEL
SF4B
THE GORMAN‐RUPP COMPANY D MANSFIELD, OHIO
www.grpumps.com
GORMAN‐RUPP OF CANADA LIMITED D ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
e2012 The Gorman‐Rupp Company
Register your new
Gorman‐Rupp pump online at
www.grpumps.com
Valid serial number and e‐mail address required.
RECORD YOUR PUMP MODEL AND SERIAL NUMBER
Please record your pump model and serial number in the
spaces provided below. Your Gorman‐Rupp distributor
needs this information when you require parts or service.
Pump Model:
Serial Number:
TABLE OF CONTENTS
INTRODUCTION PAGE I - 1.................................................
SAFETY ‐ SECTION A PAGE A - 1............................................
INSTALLATION - SECTION B PAGE B - 1....................................
PREINSTALLATION INSPECTION PAGE B - 1............................................
PUMP SEALS PAGE B - 1.............................................................
LUBRICATION PAGE B - 1.............................................................
PUMP INSTALLATION PAGE B - 1......................................................
Pump Dimensions PAGE B - 1.....................................................
Pump Motor Specifications PAGE B - 1..............................................
Lifting PAGE B - 2.................................................................
Positioning the Pump PAGE B - 2...................................................
Piping PAGE B - 2................................................................
ELECTRICAL CONNECTIONS PAGE B - 3...............................................
Field Wiring Connections (Incoming Power) PAGE B - 3...............................
Dual Vlotage PAGE B - 3..........................................................
Motor Cable Grounding Test PAGE B - 3.............................................
Control Box Connections PAGE B - 4...............................................
Liquid Level Devices PAGE B - 5....................................................
OPERATION - SECTION C PAGE C - 1......................................
GENERAL INFORMATION PAGE C - 1..................................................
Pump Performance PAGE C - 1.....................................................
Control Box PAGE C - 4...........................................................
PUMP OPERATION PAGE C - 4........................................................
Liquid Temperature And Overheating PAGE C - 4.....................................
Impeller Rotation PAGE C - 5.......................................................
STARTING, STOPPING AND OPERATIONAL CHECKS PAGE C - 5.........................
Starting PAGE C - 5...............................................................
Stopping PAGE C - 6..............................................................
Operational Checks PAGE C - 6....................................................
COLD WEATHER PRESERVATION PAGE C - 7...........................................
LUBRICATION PAGE C - 7.............................................................
Draining Oil PAGE C - 7...........................................................
Condition of Oil Oil PAGE C - 7.....................................................
Adding Oil PAGE C - 7............................................................
TROUBLESHOOTING - SECTION D PAGE D - 1..............................
PREVENTIVE MAINTENANCE PAGE D - 3...............................................
PUMP MAINTENANCE AND REPAIR ‐ SECTION E PAGE E - 1.................
GENERAL INFORMATION PAGE E - 1..................................................
Lifting PAGE E - 1.................................................................
i
TABLE OF CONTENTS
(continued)
PARTS LISTS:
Pump Model Assembly PAGE E - 3.................................................
Motor Assemblies PAGE E - 5......................................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E - 6.........................
PUMP END DISASSEMBLY PAGE E - 6.................................................
Preparing Pump for Disassembly PAGE E - 6........................................
Pump Casing Removal PAGE E - 7.................................................
Draining Oil From Seal Cavity PAGE E - 7............................................
Impeller Removal PAGE E - 7......................................................
Lower Seal Removal PAGE E - 8....................................................
Upper Seal Removal PAGE E - 8...................................................
PUMP END REASSEMBLY PAGE E - 8..................................................
Cleaning and Inspection of Pump Parts PAGE E - 8...................................
Upper Seal Installation PAGE E - 10..................................................
Lower Seal Installation PAGE E - 10..................................................
Impeller Installation PAGE E - 11.....................................................
Pump Casing Installation PAGE E - 11................................................
Final Assembly PAGE E - 11........................................................
MOTOR DISASSEMBLY PAGE E - 12....................................................
Hoisting Bail Removal PAGE E - 12..................................................
Terminal Housing Assembly Removal PAGE E - 12.....................................
Rotor Shaft and Bearing Removal PAGE E - 12........................................
Stator Removal PAGE E - 13........................................................
MOTOR REASSEMBLY PAGE E - 14.....................................................
Stator Installation PAGE E - 14......................................................
Bearing and Rotor Shaft Installation PAGE E - 15......................................
Terminal Housing Assembly Installation PAGE E - 16...................................
Hoisting Bail Installation PAGE E - 17.................................................
VACUUM TESTING PAGE E - 17........................................................
Seal Cavity Testing PAGE E - 17.....................................................
Seal and Motor Cavity Testing PAGE E - 18...........................................
LUBRICATION PAGE E - 19.............................................................
Seal Cavity PAGE E - 19............................................................
Motor Bearings PAGE E - 19........................................................
ii
INTRODUCTION
OM-06460SF SERIES
Thank You for purchasing a Gorman‐Rupp SF Se
ries Pump. Read this manual carefully to learn
how to safely install and operate your pump. Fail
ure to do so could result in personal injury or dam
age to the pump.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed in
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to
ensure that applications not addressed in this
manual are performed only after establishing that
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
The pump motor must be operated through an ap
propriate control box matching the voltage and
other characteristics of the motor. The control box
must also provide for proper operation of the motor
protection devices such as the integral moisture
and thermal switches. Control boxes and other
control devices other than those integral to the
pump motor are not covered in this manual.
Pump construction is cast iron, with ductile iron im
peller and stainless steel shaft and hardware. The
pump is designed to handle raw, unscreened sew
age and effluents. The pump may be equipped
with an integral guide shoe which, when mounted
on guide rails in a wet well, engages an optional
base elbow. The pump may also be equipped with
a trash stand for floor mounting in a wet well. Op
eration is the same for either installation.
If there are any questions regarding the pump
which are not covered in this manual or in other lit
erature accompanying the unit, please contact
your Gorman‐Rupp distributor or the Gorman‐
Rupp Company:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: (519) 631-2870
The following are used to alert personnel to proce
dures 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 re
quired and the injury which will result
from failure to follow the procedure.
Hazards or unsafe practices which
COULD result in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result from failure to follow
the procedure.
Hazards or unsafe practices which COULD
result in minor personal injury or product or
property damage. These instructions de
scribe the requirements and the possible
damage which could result from failure to
follow the procedure.
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
Phone: (419) 755-1011
or:
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I - 1INTRODUCTION
SAFETY - SECTION A
This information applies to the SF Se
ries submersible pump indicated on the
front cover of this manual.
OM-06460SF SERIES
In addition to this manual, see the sepa
rate literature covering the control box,
control accessories or other equipment
shipped with this pump.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and pre
cautions for each specific application.
Therefore, it is the owner/installer's re
sponsibility to ensure that applications
not addressed in this manual are per
formed only after establishing that nei
ther operator safety nor pump integrity
are compromised by the installation.
Before attempting to install, operate, or
service this pump, familiarize yourself
with this manual, and with all other liter
ature shipped with the pump. Unfamil
iarity with all aspects of pump operation
covered in this manual could lead to de
struction of equipment, injury, or death.
This pump is designed to handle raw
sewage and industrial wastes at tem
peratures of 104_F (40_C); Do not apply
at higher temperatures. Do not attempt
to pump volatile, flammable, or corro
sive liquids which may damage the
pump or endanger personnel as a result
of pump failure.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to make all electrical
connections.
The following precautions should be
taken before attempting to open or ser
vice the pump; otherwise, injury or
death could result.
1. Familiarize yourself with this man
ual.
2. Lock out incoming power to the
control box to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
4. Close the discharge valve (if
used).
Do not connect the pump motor directly
to the incoming power lines. The pump
motor is designed to operate through a
Gorman‐Rupp approved control box
which provides overload protection and
power control; otherwise, the pump
warranty will be voided. Make certain
that the pump and control box are prop
erly grounded and that the incoming
power matches the requirements of the
pump and controls. Install and operate
the control box in accordance with the
National Electric Code and all local
codes. Failure to follow the instructions
PAGE A - 1SAFETY
in this warning could result in injury or
death to personnel.
Do not attempt to lift this pump by the
motor or control cables, or the piping.
Attach proper lifting equipment to the
lifting bail fitted on the pump.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a
qualified electrician to make all electri
cal connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. If the overload unit is tripped
during pump operation, correct the
problem before restarting the pump.
SF SERIESOM-06460
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com
pletely waterproof. Injury or death may
result from alterations.
All electrical connections must be in ac
cordance with The National Electric
Code and all local codes. If there is a
conflict between the instructions pro
vided and N.E.C. Specifications, N.E.C.
Specifications shall take precedence.
All electrical equipment supplied with
this pump was in conformance with
N.E.C. requirements in effect on the
date of manufacture. Failure to follow
applicable specifications, or substitu
tion of electrical parts not supplied or
approved by the manufacturer, can re
sult in severe injury or death and void
warranty.
After the pump has been installed, make
certain that the pump and all piping or
hose connections are secure before op
eration.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the OFF
position and locked out, or that the pow
er supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
PAGE A-2 SAFETY
Approach the pump cautiously after it
has been running. Although the motor is
cooled by dispersing heat through the
motor housing cooling fins into the liq
uid being pumped, normal operating
temperatures can still be high enough
to cause burns. The temperature will be
especially high if operated against a
closed discharge valve. Never operate
against a closed discharge valve for
long periods of time.
Do not remove plates, covers, gauges,
pipe plugs, or fittings from an over
heated pump. Vapor pressure within the
pump can cause parts being disen
gaged to be ejected with great force. Al
low the pump to completely cool before
servicing.
OM-06460SF SERIES
If this pump is used to handle sewage,
take necessary precautions during
maintenance and repair to prevent per
sonal contamination which could result
in illness.
Pumps and related equipment must be
installed and operated according to all na
tional, local and industry standards.
PAGE A - 3SAFETY
SF SERIES OM-06460
INSTALLATION - SECTION B
Review all SAFETY information in Section A.
Since pump installations are seldom identical, this
section is intended only to summarize general rec
ommendations and practices required to inspect,
position, and arrange the pump and piping. If there
are any questions concerning your specific instal
lation, contact your Gorman‐Rupp distributor or
the Gorman‐Rupp Company.
The motor in these pumps is not designed
to be operated in air for more than 10 min
utes without overheating. The pumps must
be operated through liquid level controls to
maintain the level of liquid in the wet well so
that power to the motor is cut off when liq
uid falls below the midpoint of the motor
housing.
match the ratings on the control box and in
coming power.
e. Carefully read all tags, decals, and markings
on the pump assembly, and perform all duties
indicated.
f. Check for any oil leaks. If there is any indica
tion of an oil leak, see LUBRICATION in
MAINTENANCE AND REPAIR - SECTION
E.
PUMP SEALS
This pump is equipped with two mechanical seals.
The lower seal is lubricated by the liquid being
pumped and prevents the liquid from entering the
seal housing cavity from the pump end. The upper
seal prevents oil from escaping from the seal hous
ing into the motor housing and acts as backup pro
tection in the event of lower seal failure.
LUBRICATION
Automatic liquid level controls are available from
Gorman‐Rupp as options. For information on in
stalling and operating these controls, see the tech
nical data accompanying them.
PREINSTALLATION INSPECTION
The pump assembly was inspected and tested be
fore shipment from the factory. Before installation,
check for damage which may have occurred dur
ing shipment. Check as follows:
a. Inspect the pump assembly for cracks, dents,
damaged threads, and other obvious dam
age.
b. Check for and tighten loose attaching hard
ware.
c. Inspect the power cable for cuts or any other
obvious damage.
d. Check that amperes, phase, voltage, and
hertz indicated on the motor name plate
The seal cavity is fully lubricated when shipped
from the factory. However, the lubrication level
must be checked before installing the pump (see
LUBRICATION in MAINTENANCE AND REPAIR
- SECTION E). If the oil level is abnormally low, de
termine the cause before putting the pump into
service.
The shaft bearings are permanently lubricated.
There is no other lubrication in the pump.
PUMP INSTALLATION
Pump Dimensions
For the approximate physical dimensions of your
pump, refer to the pump specification data sheet
or contact your Gorman‐Rupp distributor or the
Gorman‐Rupp Company.
Pump Motor Specifications
The motor furnished with this pump is a 60 Hz.,
Squirrel Cage, Induction Start, Class H Insulation
Rated 365_F (180_C).
INSTALLATION
PAGE B - 1
OM-06460 SF SERIES
See Table B-1 for motor specifications.
TABLE B-1. PUMP MOTOR SPECIFICATIONS
MODEL VOLTAGE/
PHASE
SF4B 460/575 4” 30.0 1750 36.6/29.3 246.0/197.0
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tag on the unit packaging for the actual weight, and
use lifting equipment with appropriate capacity.
Drain the pump and remove all customer‐installed
equipment such as suction and discharge hoses
or piping before attempting to lift existing, installed
units.
Positioning the Pump
SIZE MOTOR
H.P. LOCKED
NOTE
Before installing and operating the pump, check
the direction of impeller rotation to ensure that the
pump is properly wired at the control box. See IM
PELLER ROTATION, SECTION C.
This pump may be mounted on guide rails or
cables for use with optional discharge elbow/base
plate kits, or it may be mounted on a trash stand
with an optional discharge elbow.
MAX
RPM
fully seated in the baseplate.
To install a pump configured for a guide rail/guide
cable application, engage the guide shoe at the
top of the guide rails and use a suitable lifting de
vice attached to the lifting handle to lower the
pump into the wet well. When the pump and guide
shoe engages the discharge elbow/baseplate, it
will form an automatic seal.
If the pump is mounted on a trash stand, secure a
discharge hose or pipe to the optional discharge
elbow and use a suitable lifting device attached to
the lifting handle to lower the pump into the wet
well.
Make certain that the pump and stand sit level in
the wet well.
Regardless of the installation configuration, the
maximum recommended submergence depth
is 65 feet (20 meters).
After installation in the wet well, reel in any slack in
the cables so that they are not dragged into the
pump suction.
LOAD
AMPS
ROTOR
AMPS
If the pump is configured for a guide rail/guide
cable application, the pump will be equipped with
a rail guide shoe which connects to the discharge
optional elbow/baseplate. When lowered into
place, the pump is automatically and securely con
nected to the elbow/baseplate and the piping sys
tem. For information on installing the guide rails,
see the literature accompanying them.
NOTE
When engaging the guide shoe and elbow/base
plate, make sure that the connection is not impeded
by mounting hardware, and that the guide shoe is
PAGE B - 2 INSTALLATION
Piping
NOTE
Refer to Pump Performance in OPERATION -
SECTION C when determining the most efficient
piping installation.
No suction piping is required in a standard sub
merged operation.
Either hose or rigid pipe may be used to make dis
charge connections. The discharge line must be
independently supported to avoid vibration and
strain on the pump. For maximum pumping capac
SF SERIES OM-06460
ity, keep the line as short and straight as possible.
Elbows and fittings used in a discharge line in
crease friction losses; minimize their use.
It is recommended that a check valve or throttling
valve be installed in the discharge line to control si
phoning or back flow when the pump is shut off.
ELECTRICAL CONNECTIONS
Install and operate this pump in accor
dance with the National Electrical Code
and all local codes. Have a qualified
electrician perform all checks and con
nections in this section.
Never attempt to alter the length of the
pump motor cable or to repair it with a
splice. The power cable and pump mo
tor 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)
Field wiring is not provided with this pump, and
must be supplied by the user. The field wiring must
be of the proper size and type to ensure an ade
quate voltage supply to the pump. Voltage avail
able at the motor must be within the range indi
cated in Table B-2.
TABLE B-2. MOTOR VOLTAGE LIMITS
NOMINAL
VOLTAGE
PHASE MINIMUM
VOLTAGE
MAXIMUM
VOLTAGE
Motor Cable Grounding Test
Do not connect the pump power or con
trol cables to the control box or incom
ing voltage before verifying the pump
ground. Otherwise, personnel will be
exposed to serious injury or death.
Connect one lead of a lamp, bell or similar testing
device to the motor cable green/yellow ground
lead (s). Connect the second test lead to an unin
sulated point on the pump body. The test circuit
should close.
If the test circuit does not close, there is a defect in
the cable or motor which must be corrected.
Control Box Connections
The pump warranty is void if the motor is
not operated through a control box ap
proved by Gorman‐Rupp.
This pump is shipped completely wired for the volt
age shown on the nameplate and is ready for op
eration through an approved control box.
Ground the control box in accordance with the in
structions accompanying it.
Ground the pump to the control box using the pow
er cable ground(s) and ground check wire (if so
equipped). Secure the ground wire(s) and ground
check wire (if so equipped) to the grounding lug(s)
inside the control box to ensure a thorough ground
for the pump.
3460 414 506
Use conduit cable clamps to secure the incoming
field wiring to the control box. Make certain all con
nections are tight. If necessary, support the cable
weight to prevent excessive strain on cable clamps
and cable.
INSTALLATION
3575 517 632
Ground the pump using the power cable
ground wire(s) before applying line po
tential. Failure to properly ground the
pump could result in damage to the
pump or control and/or injury or death to
personnel.
PAGE B - 3
OM-06460 SF SERIES
Refer to Figures B-1 and connect the pump motor
cable to the control box.
Figure B-1. Three Phase Power
Cable Connections
Control leads P1 and P2 provide the motor with
thermal protection. Control leads W1 and W2 pro
vide the motor with moisture protection. Refer to
Figure B-3 and connect the pump control cable to
the control box.
Liquid Level Devices
Optional controls available from Gorman‐Rupp
may provide a means to automatically regulate the
liquid level. These control boxes may be con
nected to the following sensing devices which per
form either filling or dewatering functions (see Fi
gure B-3).
The internal wiring of the sensing devices
are different for filling and dewatering func
tions. Be sure to follow the instructions in
cluded with the option before making con
nections.
S Diaphragm Type: two fixed‐position sen
sors (upper and lower) each contain a dia
phragm which flexes with changes in liquid
level, thus activating an enclosed miniature
switch.
Figure B-2. Control Cable Connections
The thermal protection contacts will auto
matically reclose when the motor cools to
the established safe operating tempera
ture. Whenever automatic restarting is not
desirable, connect only to controls which
are wired for manual restart.
Refer to the appropriate wiring diagram accompa
nying the control box when making electrical con
nections.
S Bulb (Float) Type: a bulb raises or lowers
(floats) with the liquid level, thus activating
an enclosed miniature switch.
Other types of liquid level devices may also be
used. Consult the factory for the liquid level device
best suited for your application.
Liquid level devices must be positioned far
enough to allow 6 minutes between starts.
If the pump motor cycles more than 10
starts per hour, it will over‐heat, resulting in
damage to the motor windings or control
box components.
PAGE B - 4 INSTALLATION
SF SERIES OM-06460
PUMP
CONTROL BOX
TO LEVEL CONTROL CIRCUIT
IN MAIN CONTROL
BOX
LIQUID LEVEL
RANGE
OFF
DEWATERING
ON (FILLING)
BULB (FLOAT TYPE)
Figure B-3. Liquid Level Devices
TO LEVEL CONTROL CIRCUIT
IN MAIN CONTROL
BOX
LIQUID LEVEL
RANGE
DEWATERING
ON (FILLING)
DIAPHRAGM TYPE
PUMP
CONTROL BOX
OFF
INSTALLATION
PAGE B - 5
SF SERIES OM-06460
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 endan
ger personnel as a result of pump fail
ure. Consult the factory for specific ap
plication data.
Follow the instructions on all tags, labels and de
cals attached to the pump.
Pump Performance
pendent upon the quality and performance
of the electrical controls, the pump warran
ty is valid only when controls have been
specified or provided by The Gorman‐
Rupp Company.
In the performance curve which follows, perform
ance is based on 70_F (21_C) clear water at sea
level. The performance of your pump may be differ
ent due to such factors as viscosity, specific grav
ity, elevation, temperature and impeller trim.
NOTE
The curve applies to standard production models.
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 per
formance.
Since operation of the pump motor is de
PAGE C - 1OPERATION
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