ACDE OM-06406-01 June 1, 2011 Rev. E 01‐09‐14 INSTALLATION, OPERATION, AND MAINTENANCE MANUAL WITH PARTS LIST DRY PIT SUBMERSIBLE PUMP MODEL SFDV4A THE GORMAN‐RUPP COMPANY MANSFIELD, OHIO www.grpumps.com GORMAN‐RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA 2011 The Gorman‐Rupp Company Printed in U.S.A.
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TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1 SAFETY ‐ SECTION A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE A - 1 INSTALLATION - SECTION B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE B - 1 PREINSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP SEALS . . . . . . .
TABLE OF CONTENTS (continued) PARTS LISTS: Pump Model Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP AND SEAL DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . PUMP END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SF SERIES OM-06406 INTRODUCTION 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.
SF SERIES OM-06406 SAFETY - SECTION A This information applies to the SF Se ries dry pit submersible pump indicated on the front cover of this manual. In addition to this manual, see the sepa rate literature covering the control box, control accessories or other equipment shipped with this pump. Because pump installations are seldom identical, this manual cannot possibly provide detailed instructions and pre cautions for each specific application.
OM-06406 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.
SF SERIES After the pump has been installed, make certain that the pump and all piping or hose connections are secure before op eration. Approach the pump cautiously after it has been running. Although the motor is cooled by dispersing heat through the motor housing cooling fins into the liq uid being pumped, normal operating temperatures can still be high enough to cause burns. The temperature will be especially high if operated against a closed discharge valve.
SF SERIES OM-06406 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. Automatic liquid level controls are available from Gorman‐Rupp as options.
OM-06406 SF SERIES TABLE B-1. PUMP MOTOR SPECIFICATIONS MODEL VOLTAGE/ PHASE SIZE H.P. MOTOR RPM MAX LOAD AMPS LOCKED ROTOR AMPS SFDV4A 208/3 4” 5.0 1750 13.8 106.1 SFDV4A 230‐460‐575/3 4” 5.0 1750 Lifting 96.0/48.0/38.4 Piping 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.
SF SERIES OM-06406 or death to personnel can result from any alteration to the cable. Motor Cable Grounding Test 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.
OM-06406 Refer to Figure B-1 and connect the pump motor cable to the control box. SF SERIES 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. Liquid Level Devices Optional controls available from Gorman‐Rupp may provide a means to automatically regulate the liquid level.
SF SERIES OM-06406 PUMP CONTROL BOX PUMP CONTROL BOX TO LEVEL CONTROL CIRCUIT IN MAIN CONTROL BOX LIQUID LEVEL RANGE TO LEVEL CONTROL CIRCUIT IN MAIN CONTROL BOX LIQUID LEVEL RANGE OFF DEWATERING OFF DEWATERING ON (FILLING) ON (FILLING) BULB (FLOAT TYPE) DIAPHRAGM TYPE Figure B-3.
SF SERIES OM-06406 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.
OM-06406 SF SERIES SFDV4A 230/460/575V 3P PERFORMANCE CURVE PAGE C - 2 OPERATION
SF SERIES OM-06406 SFDV4A 208V 3P PERFORMANCE CURVE OPERATION PAGE C - 3
OM-06406 Control Box Control boxes are available as optional equipment from the factory. The control boxes contain con trols for starting and stopping the pump, and pro vide overload protection for the pump motor. The pump control may be equipped with an optional automatic liquid level sensing device, in which case those circuits are also contained within the control box.
SF SERIES burns and injuries. If overheating of the pump occurs: 1. Stop the pump immediately. 2. Ventilate the area. 3. Allow the pump to completely cool. 4. Check the temperature before ser vicing. 5. Vent the pump slowly and cau tiously 6. Refer to instructions in this manual before restarting the pump. OM-06406 ry or death. Make certain that incoming power is off and locked out before inter changing motor leads.
OM-06406 between starts, it will over‐heat, resulting in damage to the motor windings. Stopping Follow the instructions accompanying the control box for stopping the pump. The integral thermal overload device will shut off the motor if the temperature rises above design limits. When the pump cools and the temperature falls below these limits, the motor will restart automatically.
SF SERIES COLD WEATHER PRESERVATION OM-06406 first two weeks of operation, and every month thereafter. Before installing or removing the lubrication plugs, always clean the area around the plugs to prevent contamination. Do not attempt to thaw the pump by us ing a torch or other source of flame. This could damage gaskets, O‐rings or heat the oil in the seal housing above critical temperatures, causing the pump to rup ture or explode.
SF SERIES OM-06406 TROUBLESHOOTING - SECTION D Review all SAFETY information in Section A. NOTE Many of the probable remedies listed in the TROU BLESHOOTING CHART require use of electrical test instruments; for specific procedures, see ELECTRICAL TESTING at the end of the chart. TROUBLESHOOTING CHART TROUBLE PUMP FAILS TO START, OVERLOAD UNIT NOT TRIPPED (MANUAL MODE). PUMP FAILS TO START, OVERLOAD UNIT NOT TRIPPED (AUTOMATIC MODE).
OM-06406 SF SERIES TROUBLESHOOTING CHART (cont'd) TROUBLE POSSIBLE CAUSE MOTOR RUNS, BUT Discharge head too high. PUMP FAILS TO DELIVER RATED DISCHARGE. Low or incorrect voltage. PUMP RUNS WITH EXCESSIVE NOISE OR VIBRATION PAGE D - 2 PROBABLE REMEDY 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 installed improp erly.
SF SERIES OM-06406 ELECTRICAL TESTING 3. The pump submerged and running under full load. Make the electrical checks which follow to deter mine if pump malfunctions are being caused by problems in the motor or in the motor cable. Test Equipment A volt/amp/ohmmeter and megohmmeter of ade quate range and quality are required to conduct the electrical tests which follow.
OM-06406 motor cable green/yellow ground lead. Touch the other test lead to each of the motor cable leads in turn. Note the readings. b. Readings will indicate resistance values in both the power cable and motor windings.If resistance reads infinity (1), insulation is good. If resistance reads between infinity (1), PAGE D - 4 SF SERIES and 1 megohm, insulation is acceptable but should be rechecked regularly.
SF SERIES OM-06406 PUMP MAINTENANCE AND REPAIR - SECTION E 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.
OM-06406 SF SERIES ILLUSTRATION PARTS PAGE Figure E-1.
SF SERIES OM-06406 SFDV4A Pump Model Assembly Parts List (From S/N 1476538 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 NO.
OM-06406 SF SERIES ILLUSTRATION Figure E-2.
SF SERIES OM-06406 47111-803, -808 and -809 Motor Assemblies Parts List ITEM PART NAME NO.
OM-06406 SF SERIES PUMP AND SEAL DISASSEMBLY AND REASSEMBLY Select a suitable location, preferably indoors, to perform required maintenance. All work must be performed by qualified personnel. Review all SAFETY information in Section A. Check the chart in TROUBLESHOOTING, Section D of this manual, to determine the nature of the pump problem. If the problem is mechanical in na ture, such as worn pump parts, seal replacement, lubrication, etc., refer to PUMP END DISASSEM BLY for instructions.
SF SERIES 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. It is not necessary to remove the guide shoe for most pump maintenance procedures.
OM-06406 SF SERIES Lower Seal Removal (Figures E-1 and E-3) Carefully remove the spring retainer (18) and seal spring. Lubricate the rotor shaft with light oil and work oil under the bellows assembly. Pull the rotat ing portion of the seal off the shaft. Work a pair of stiff wires with hooked ends between the rotor shaft and the stationary element and pull the stationary element and seat out of the seal plate (14).
SF SERIES OM-06406 burrs with a fine file or hand honing stone 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). Neither of the shaft seal assemblies should be re used because wear patterns on the finished faces cannot be realigned during reassembly. This could result in premature failure.
OM-06406 SF SERIES lint and dirt. Check the seal bore for burrs or nicks that might prevent a good seal. Remove them with a fine file or emery cloth to restore original con tours. If the shaft is bent or damaged, the complete rotor and shaft must be replaced as an assembly. Apply a light coating of oil to the bore of the inter mediate. Slide the seal spring over the shaft and bellows re tainer and install the spring centering washer. In stall the seal retaining ring (10).
SF SERIES OM-06406 Unpack the rotating portion of the seal. Be certain the seal face of the rotating element is free of grit or surface damage. Because the rotating element may not stay in the bellows retainer when turned upside down, place a small amount of grease at equal spaces on the back of the element and posi tion it in the bellows retainer. The grease should hold the element in position until the seal is in stalled.
OM-06406 SF SERIES move the terminal housing assembly from 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 po sition and locked out, or that the power supply to the control box has been otherwise cut off and locked out, before attempting to open or service the pump assembly. Tag electrical circuits to pre vent accidental start‐up.
SF SERIES OM-06406 removed, position the motor housing upside down on a flat work surface. Most cleaning solvents are toxic and flammable. Use them only in a well ven tilated area; free from excessive heat, sparks, and flame. Read and follow all precautions printed on solvent contain ers. Rotate the bearings by hand to check for rough ness or binding. If rotation is rough, replace the bearings.
OM-06406 SF SERIES is strongly recommended that new O‐rings and shaft seal assemblies be used during reassembly (see the parts list for numbers). Stator Installation (Figure E-2) NOTE Stator installation involves heating the motor hous ing. This process must be done quickly; therefore it is recommended that these steps be performed by at least two people to promote efficient installation of the stator. height when assembled. The O.D.
SF SERIES OM-06406 the intermediate until fully seated. If removed, install a new male terminal (15) on the sensor and position it so the moisture sensor female terminal (14) can be easily attached. Inspect the rotor shaft (3) 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.
OM-06406 With the motor housing and stator positioned up side down, carefully lower the assembled inter mediate, rotor shaft and bearings into the motor housing until the female terminal (14) can be se curely attached to the male terminal (15) on the moisture sensor. Position the intermediate so the holes for the mounting hardware in the intermediate align with those in the motor housing and press the inter mediate into the motor housing until fully seated.
SF SERIES OM-06406 Hoisting Bail Installation motor and seal cavities must be vacuum tested any time the seal(s) and/or motor are serviced. (Figure E-1) If the hoisting bail (13) was removed in order to re move the terminal housing assembly (10) position the bail over the motor housing so the holes for the mounting hardware align. Apply “Never‐Seez” or equivalent compound to the threads of the caps crews (8) and secure the bail to the motor housing with the hardware (8 and 12).
OM-06406 SF SERIES ential between the vacuum readings shown in the table. To vacuum test the motor cavity, the terminal hous ing assembly must be replaced with a test plate. Make the test plate as shown in Figure E-5 below, install the terminal housing O‐ring under the test plate, then proceed with vacuum testing. Make from commercially available steel plate. 1.5 in. (38,1 mm) 45_ x 1/8” (3,1 mm) Chamfer .438” (11,1 mm) dia. drill thru. Tap .250‐18 NPT. 5.5 in. (139,7 mm) 12 mm dia.
SF SERIES OM-06406 The grade of lubricant used is critical to the opera tion of this pump. Use premium quality hydraulic oil as specified in Table E-2. Table E-2. Pump Oil Specifications Specifications: Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Premium high viscosity index, anti‐wear hydraulic oil Viscosity (SSU @ 104 F [40 C]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 to 155 Viscosity (SSU @ 210 F [100 C]) . . . . . . . . . . . . . . . .
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.
