GORMAN-RUPP PUMPS S Series, S2E, S2F, S2B Maintenance And Repair Manual
PUBLICATION NUMBER MR-04280
June 29, 1995
Rev. D 05‐15‐12
S SERIES PUMPS
S2B, S2E and S2F
All Materials And Voltages
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.
e1995 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:
MR-04280 S SERIES PUMPS
INTRODUCTION
Thank You for purchasing a Gorman‐Rupp S
Series Pump. Read this manual carefully to learn
how to safely maintain and service your pump. Fail
ure to do so could result in personal injury or dam
age to the pump.
A set of three manuals accompanies your pump.
The Installation/Operation Manual contains essen
tial information on installing and operating the
pump, and on making electrical connections. The
Parts List Manual provides a performance curve, a
pump model cross‐section drawing, and parts list
for your pump.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re
quired to properly diagnose operational problems,
and to service the pump components. Pump motor
maintenance may be performed only by a Gor
man‐Rupp authorized Submersible 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.
As described on the following page, this manual
will alert personnel to known procedures which re
quire special attention, to those which could dam
age equipment, and to those which could be dan
gerous to personnel. However, this manual cannot
possibly anticipate and provide detailed precau
tions for every situation that might occur during
maintenance of the unit. Therefore, it is the respon
sibility of the owner/maintenance personnel to en
sure that only safe, established maintenance pro
cedures are used, and that any procedures not ad
dressed in this manual are performed only after es
tablishing that neither personal safety nor pump in
tegrity are compromised by such practices.
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:
The Gorman‐Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901-1217
or:
Gorman‐Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
CONTENTS
SAFETY - SECTION A
TROUBLESHOOTING - SECTION B
ELECTRICAL TESTING PAGE B - 3........................................................
Test Equipment PAGE B - 3...........................................................
Voltage Imbalance PAGE B - 3........................................................
Motor and Power Cable Continuity PAGE B - 4..........................................
Insulation Resistance PAGE B - 4......................................................
PUMP MAINTENANCE AND REPAIR - SECTION C
GENERAL INFORMATION PAGE C - 1.....................................................
Lifting PAGE C - 1....................................................................
TYPICAL PUMP ASSEMBLY PAGE C - 2....................................................
PUMP ASSEMBLY PARTS IDENTIFICATION LIST PAGE C - 3.................................
TERMINAL HOUSING AND CABLE ASSEMBLY PAGE C - 4...................................
TERMINAL HOUSING AND CABLE ASSEMBLY PARTS IDENTIFICATION LIST PAGE C - 5.......
TERMINAL HOUSING AND CABLE ASSEMBLY PAGE C - 6...................................
TERMINAL HOUSING AND CABLE ASSEMBLY PARTS IDENTIFICATION LIST PAGE C - 7.......
PUMP END DISASSEMBLY PAGE C - 8....................................................
PUMP END REASSEMBLY PAGE C - 10....................................................
MOTOR DISASSEMBLY PAGE C - 13......................................................
MOTOR REASSEMBLY PAGE C - 16.......................................................
PAGE I - 1INTRODUCTION
FINAL ASSEMBLY PAGE C - 23...........................................................
VACUUM TESTING PAGE C - 23..........................................................
LUBRICATION PAGE C - 24...............................................................
MR-04280S SERIES PUMPS
RECORDING MODEL AND
SERIAL NUMBERS
Please record the pump model, serial number, volt
age, and motor frame size in the spaces provided
below. Your Gorman‐Rupp distributor needs this
information when you require parts or service.
Pump Model:
Serial Number:
Voltage:
Phase:
WARRANTY INFORMATION
The warranty provided with your pump is part of
Gorman‐Rupp's support program for customers
The following are used to alert personnel to procedures which require special attention, to those which
could damage equipment, and to those which could be dangerous to personnel:
who operate and maintain their equipment as de
scribed in this and the other accompanying litera
ture. The integral electric motor must be operated
through the control furnished with the pump as
standard equipment. Please note that should the
equipment be abused or modified to change its
performance beyond the original factory specifica
tions, the warranty will become void and any claim
will be denied.
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 as
sembly performed by the customer or an unautho
rized repair facility negates motor warranty.
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 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.
NOTE
Hazards or unsafe practices which
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
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.
PAGE I - 2 INTRODUCTION
MR-04280 S SERIES PUMPS
SAFETY - SECTION A
The following information applies
throughout this manual to Gorman‐
Rupp S Series submersible motor driv
en pumps.
This manual will alert personnel to
known procedures which require spe
cial attention, to those which could
damage equipment, and to those which
could be dangerous to personnel. How
ever, this manual cannot possibly antici
pate and provide detailed instructions
and 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 estab
lishing that neither personal safety nor
pump integrity are compromised by
such practices.
4. Close the discharge valve (if
used).
This pump is not designed to pump vol
atile, explosive, or flammable materials.
Do not attempt to pump any liquids for
which 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
application data.
Before connecting any cable to the con
trol box, be sure to ground the control
box. Refer to the Control Box manual for
the suggested grounding methods.
This manual contains essential informa
tion on troubleshooting and maintain
ing the pump. In addition to this manual,
see the separate literature covering in
stallation and operation, pump parts,
and any optional equipment shipped
with the pump.
Before attempting to open or service the
pump:
1. Familiarize yourself with this man
ual.
2. Lock out incoming power to the
control box to ensure that the
pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
The pump motor is designed to be oper
ated through the control box furnished
with the pump. The control box provides
overload protection and power control.
Do not connect the pump motor directly
to the incoming power lines.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Obtain the services of a qu
alified electrician to make all electrical
connections. Make certain that the
pump and enclosure are properly
grounded; never use gas pipe as an
electrical ground. Be sure that the in
PAGE A - 1SAFETY
S SERIES PUMPS MR-04280
coming power matches the voltage and
phase of the pump and control before
connecting the power source. Do not
run the pump if the voltage is not within
the limits. If the overload unit is tripped
during pump operation, correct the
problem before restarting the pump.
The electrical power used to operate
this pump is high enough to cause inju
ry or death. Make certain that the control
handle on the control box is in the OFF
position and locked out, or that the pow
er supply to the control box has been
otherwise cut off and locked out, before
attempting to open or service the pump
assembly. Tag electrical circuits to pre
vent accidental start‐up.
Never attempt to alter the length or re
pair any power cable with a splice. The
pump motor and cable must be com
pletely waterproof. Injury or death may
result from alterations.
All electrical connections must be in ac
cordance with The National Electric
Code and all local codes. If there is a
conflict between the instructions pro
vided and N.E.C. Specifications, N.E.C.
Specifications shall take precedence.
All electrical equipment supplied with
this pump was in conformance with
N.E.C. requirements in effect on the
date of manufacture. Failure to follow
applicable specifications, or substitu
tion of electrical parts not supplied or
approved by the manufacturer, can re
sult in severe injury or death and void
warranty.
After the pump has been installed, make
certain that the pump and all piping or
hose connections are secure before op
eration.
Approach the pump cautiously after it
has been running. Although the motor is
cooled by the liquid being pumped, nor
mal operating temperatures can be high
enough to cause burns. The tempera
ture will be especially high if operated
against a closed discharge valve. Never
operate against a closed discharge
valve for long periods of time.
Do not attempt to lift the pump by the
motor power cable or the piping. Attach
proper lifting equipment to the lifting
device fitted to the pump. If chains or
cable are wrapped around the pump to
lift it, make certain that they are posi
tioned so as not to damage the pump,
and so that the load will be balanced.
Obtain the services of a qualified elec
trician to troubleshoot, test and/or ser
vice the electrical components of this
pump.
PAGE A-2 SAFETY
MR-04280 S SERIES PUMPS
TROUBLESHOOTING - SECTION B
Review all SAFETY information in Section A.
The following precautions should be
taken before attempting to service the
pump; otherwise, injury or death could
result.
1. Familiarize yourself with this man
ual and with all other literature
shipped with the pump.
2. Lock out incoming power to the
pump or control box to ensure that
the pump will remain inoperative.
3. Allow the pump 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 inju
ry or death. Obtain the services of a qu
alified electrician to troubleshoot, test
and/or service the electrical compo
nents of this pump.
NOTE
Many of the probable remedies listed below re
quire 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 con
trol box.
No voltage at line side of circuit
breaker.
Open circuit in motor windings or
power cable.
Defective motor power cable.
Motor defective.
Liquid level device or control circuits
improperly connected to main con
trol box.
Level sensing device(s) improperly
positioned.
Level sensing device(s) fouled with
mud or foreign material.
Correct power source.
Check power source for blown fuse,
open overload unit, broken lead, or
loose connection.
Check continuity.
Replace cable.
Check for and replace defective unit.
Check wiring diagrams; correct or
tighten connections.
Position device(s) at proper level.
Clean sensing device(s).
TROUBLESHOOTING PAGE B - 1
S SERIES PUMPS MR-04280
Table 1. Trouble Shooting Chart (cont.)
TROUBLE
(AUTOMATIC MODE)
(CONT'D.)
OVERLOAD UNIT TRIPS Low or high voltage, or excessive
MOTOR RUNS, BUT
PUMP FAILS TO
DELIVER RATED
DISCHARGE
POSSIBLE CAUSE PROBABLE REMEDY
Float type sensing device(s) tangled
or obstructed.
Defective liquid level sensing de
vice(s) or control panel.
voltage drop between pump and
control box.
Defective insulation in motor wind
ings or power cable; defective wind
ings.
Impeller jammed due to debris or
insufficient clearance.
Bearing(s) frozen.
Discharge head too high.
Low or incorrect voltage.
Check installation for free move
ment of float.
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).
Check insulation resistance; check
continuity.
Disassemble pump and check im
peller.
Disassemble pump and check
bearing(s).
Reduce discharge head, or install
staging adaptor and additional
pump.
Measure control box voltage, both
when pump is running and when
shut‐off.
Discharge throttling valve partially
closed; check valve is installed im
properly.
Discharge line clogged or re
stricted; hose kinked.
Liquid being pumped too thick.
Strainer screen or impeller clogged.
Insufficient liquid in sump or tank.
Worn impeller vanes; excessive im
peller clearance.
Pump running backwards.
Open discharge valve fully; check
piping installation.
Check discharge lines; straighten
hose.
Dilute liquid by heating if possible.
Clear clog(s). Stop pump; back flow
may flush away debris.
Stop pump until liquid level rises.
Check impeller and clearance. See
PUMP END REASSEMBLY.
Check direction of rotation and cor
rect by interchanging any two motor
leads at control box. (See Pump
Rotation, Section C).
TROUBLESHOOTINGPAGE B - 2
MR-04280 S SERIES PUMPS
Table 1. Trouble Shooting Chart (cont.)
TROUBLE
PUMP RUNS WITH
EXCESSIVE NOISE OR
VIBRATION
POSSIBLE CAUSE PROBABLE REMEDY
Pumping entrained air.
Damaged or unbalanced impeller.
Discharge piping not properly sup
ported.
Impeller jammed or loose.
Motor shaft or bearings defective.
Pump cavitation.
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 de
fective part.
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 mo
tor and bearings.
Reduce discharge head, or restrict
flow on low head applications.
Equipment Use
Ammeter To check AC Voltage
and current (amperage)
Ohmeter To measure resistance
(ohms) to ground
Obtain the services of a qualified elec
trician to troubleshoot, test and/or ser
vice the electrical components of this
pump.
Be certain to refer to the wiring diagram(s)
in the Installation Section of this manual be
fore reconnecting any electrical compo
nents which have been disconnected.
Test Equipment
A volt/amp/ohmmeter and megohmeter of ade
quate range and quality will be required to conduct
the following electrical tests. The suggested equip
ment indicated below is commercially available, or
an equivalent substitute may be used.
Voltage Imbalance
Each phase of the incoming three‐phase power
must be balanced with the other two as accurately
as a commercial voltmeter will read. If the phases
are balanced, check out the motor as described
below. If the phases are out of balance, contact
your power company and request that they correct
the condition.
a. Use a voltmeter, amprobe, or equivalent me
ter to read the voltage across terminals 1 &
2, 2 & 3, and 1 & 3 in the control box. All three
measured voltages must be the same, as
accurately as the meter will read. If possible,
measure the voltage with the pump off, with
the pump running but out of the water, and
with the pump running in the water at full
load. All the measured voltages at each con
dition must be the same.
b. Use an amprobe or equivalent meter to
measure the current draw of each phase
while the pump is running at full load and at
no load. All three amperage readings must
TROUBLESHOOTING PAGE B - 3
S SERIES PUMPS MR-04280
be the same at each condition, as accurate
ly as the meter will read. Nominal amperage
values are listed in Table 1, but these apply
only when the actual voltage at the site is the
nominal voltage listed.
c. If the voltages are balanced with the pump
off, but are unbalanced when the pump is
running, a thorough check of the power
source, all interconnecting cables, and the
pump motor is required to isolate the defect.
Motor And Motor Power Cable Continuity
To check continuity, zero‐balance the ohmmeter
set at the RX1 scale, and test as follows:
a Disconnect the motor power cable leads
from the control box and connect the test
leads to any two of the three power cable
leads (not to the green ground lead or yellow
ground check lead). If there is a high resis
tance 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.
b. If an open or broken circuit is indicated,
check the power cable for obvious damage,
and replace as necessary (see MAINTE
NANCE AND REPAIR). If there is no appar
ent damage to the motor cable, remove the
terminal housing (see MAINTENANCE
AND REPAIR) and check the continuity of
each power cable lead at the terminal posts.
NOTE
When shipped from the factory, the connections be
tween the power cable leads and the terminal posts
were encapsulated in heat shrink tubing and
bonded to the terminal plate to provide a water tight
seal. In service, these connections may have been
potted by the pump operator. Do not cut the tubing
or potting away unless absolutely necessary.
Check the continuity of each lead from the motor
side of the terminal plate. If the continuity is good,
there is no need to remove the tubing or potting ma
terial. If there is no continuity through the lead, re
move the tubing or potting from only that terminal,
and check for a loose connection. Be sure to re
place the tubing or potting and allow adequate dry
ing time before putting the pump back into service.
(See Power Cable Reassembly, Section E).
c. If an open circuit still exists after each lead
(terminal) has been tested and tightened,
then the entire motor power cable must be
replaced. Splicing or other means of repair
are not recommended.
d. If no break is found in the power cable,
check the motor leads for continuity. If the
test reading indicates an open or broken cir
cuit, there is an open circuit in the motor.
NOTE
It is recommended that a pump with a defective mo
tor be returned to Gorman‐Rupp, or to one of the
Gorman‐Rupp authorized Submersible Repair
Centers.
Insulation Resistance
To check insulation, zero‐balance the ohmmeter
set at the RX100K scale, and test as follows:
a. Disconnect the motor power cable leads
from the control box. Connect one test lead
to the power cable green ground lead, and
touch the other test lead to each of the three
power leads in turn.
b. 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 insula
tion should be checked more closely; a
reading of zero indicates that the power
cable or the motor is grounded.
c. To determine whether the power cable or
the motor is grounded, remove the terminal
housing (see MAINTENANCE AND RE
PAIR), disconnect the motor leads from the
motor terminals, and test the power cable
leads and motor leads separately.
TROUBLESHOOTINGPAGE B - 4
MR-04280 S SERIES PUMPS
PUMP MAINTENANCE AND REPAIR - SECTION C
GENERAL INFORMATION
Review all SAFETY information in Section A.
Do not attempt to service the pump as
sembly unless all power to the motor
has been shut off at the control box;
otherwise, injury or death could result.
Use a lifting device with sufficient ca
pacity. If slings or chains are used to
move the pump or components, make
sure that the load is balanced; other
wise serious personal injury or death
could result.
The maintenance and repair instructions in this
manual are keyed to the sectional views, Figures
C-1, C-2 or C-3, and the corresponding parts
identification lists. Refer to the separate Parts List
Manual for replacement parts.
formed by a Gorman‐Rupp authorized
Submersible repair facility or the factory.
Any repairs to the motor assembly per
formed by the customer or an unautho
rized repair facility negates the warranty.
This Maintenance and Repair Manual provides
troubleshooting and maintenance instructions re
quired to properly diagnose operational problems,
and to service the pump components. Pump motor
maintenance may be performed only by a Gor
man‐Rupp authorized Submersible 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.
Check TROUBLESHOOTING, Section B to deter
mine causes and remedies of pump problems.
Disassemble the pump only as far as required.
Lifting
Select a suitable location, preferably indoors, to
perform required maintenance. All work must be
performed by qualified personnel.
All repairs to the pump motor must be per
Use lifting equipment with a capacity of at least
five times the weight of the pump, including the
weight of any options or customer‐installed acces
sories. The approximate maximum weight for this
group of pumps is 73 lbs. (33 kg.). Discharge
hose or piping must be removed before attempt
ing to lift the pump.
PAGE C - 1MAINTENANCE AND REPAIR
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