GORMAN-RUPP SM SERIES Istruzioni operative

PUBLICATION NUMBER MR--05365

April 1, 2002

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

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

eCopyright by the Gorman-Rupp Company

SM SERIES PUMPS

SM4G’S AND SM4J’S

All Materials And Voltages

MR--05365 SM SERIES PUMPS

PAGE I -- 1

INTRODUCTION

Thank You for purchasing a Gorman-Rupp SM

Series Pump. Read this manual carefully to learn

howtosafelymaintainandserviceyourpump.Fail-

ure to do so could result in personal injury or dam-

age to the pump.

A set of three manuals accompanies your pump.

TheInstallation/OperationManualcontainsessen-

tial information on installing and operating the

pump, and on making electrical connections. The

Parts List Manualprovides a performance curve, a

pump model cross-section drawing, and parts list

foryourpump.

This Maintenance and Repair Manual provides

troubleshooting and maintenance instructions re-

quiredto properlydiagnose operationalproblems,

andtoservicethepumpcomponents.Pumpmotor

maintenance may be performed only by a Gor-

man-Rupp authorized Submersible repair facility,

orthefactory.Otherwise,thepumpwarrantywillbe

negated, and damage to the pump, and injury or

death to personnel can result. Contact the factory

for the authorized repair facility closest to you.

As described on the following page, this manual

willalert personnel toknown procedures which re-

quire specialattention, to those which could dam-

age equipment, and to those which could be dan-

gerous topersonnel. However,this manualcannot

possibly anticipate and provide detailed precau-

tions for every situation that might occur during

maintenanceoftheunit.Therefore,itistherespon-

sibilityof the owner/maintenance personnel to en-

sure that only safe, established maintenance pro-

ceduresareused,andthatanyproceduresnotad-

dressedinthismanualareperformedonlyafteres-

tablishingthatneitherpersonalsafetynorpumpin-

tegrity are compromised by such practices.

If there are any questions regarding the pump

which are not covered in this manual orin 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 --- 2........................................................

Test Equipment PAGE B --- 3...........................................................

Voltage Imbalance PAGE B --- 3........................................................

Motor and Power Cable Continuity PAGE B --- 3..........................................

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.................................

TYPICALTERMINALHOUSING&CABLEASSEMBLY PAGEC---4.............................

TERMINAL HOUSING & CABLE ASSEMBLY PARTS IDENTIFICATION LIST PAGE C --- 5..........

PUMP END DISASSEMBLY PAGE C --- 6....................................................

PUMP END REASSEMBLY PAGE C --- 8.....................................................

MOTOR DISASSEMBLY PAGE C --- 11......................................................

MOTOR REASSEMBLY PAGE C --- 15.......................................................

FINAL ASSEMBLY PAGE C --- 20...........................................................

VACUUM TESTING PAGE C --- 21..........................................................

LUBRICATION PAGE C --- 22...............................................................

MR--05365SM SERIES PUMPS

PAGE I -- 2 INTRODUCTION

RECORDING MODEL AND

SERIAL NUMBERS

Pleaserecordthepumpmodel,serialnumber,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

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 and approved by MSHA.

Please note that should the equipment be abused

ormodified tochange its performance beyondthe

originalfactory specifications, the warranty will be-

come 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 anunautho-

rized repair facility negates motor warranty.

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:

Immediate hazards whichWILL resultin

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.

HazardsorunsafepracticeswhichCOULD

resultinminorpersonalinjuryorproductor

property damage. These instructions de-

scribe 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.

SM SERIES PUMPSMR--05365

SAFETY PAGE A -- 1

SAFETY --- SECTION A

The following information applies

throughout this manual to Gorman-

Rupp SM Series submersible motor

driven 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,thismanualcannotpossiblyantici-

pate and provide detailed instructions

and precautions for every situation that

might occur during maintenance of the

unit.Therefore,itis the responsibilityof

the owner/maintenance personnel to

ensurethatonlysafe, 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.

Thismanualcontainsessentialinforma-

tion on troubleshooting and maintain-

ing the pump.In additionto thismanual,

see the separate literature covering in-

stallation and operation, pump parts,

and any optional equipment shipped

with the pump.

Beforeattemptingtoopenorservicethe

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.

4.Closethedischargevalve(if

used).

This pump is not designed to pump vol-

atile,explosive,orflammablematerials.

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 anycable tothe con-

trol box, be sure to ground the control

box. Refer tothe ControlBox manualfor

the suggested grounding methods.

The pump is designed to be operated

through the control box furnished with

thepump.Thecontrolboxprovides

overload protection and power control.

Do not connect the pump motordirectly

to the incoming power lines.

When installing or servicing the pump

or controls, follow all requirements for

the installation of wiring or electrical

equipment as outlined by MSHA

SCHEDULE 2G. Follow all MSHA safety

requirements. Failure to observe these

requirements could result in injury or

death to personnel.

MR--05365SM SERIES PUMPS

PAGE A -- 2 SAFETY

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-

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-

ryordeath.Makecertainthatthecontrol

handle on the control box is in the OFF

positionand lockedout,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.

Any control box used to operate the

pump must be approved by the MSHA

and the Gorman-Rupp Company for the

application.

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.

Allelectrical connections mustbe in ac-

cordance with MSHA Schedule 2G. If

there is a conflict between the instruc-

tions provided and MSHA specifica-

tions, MSHA specifications shall take

precedence. All electrical equipment

supplied with this pump was in confor-

mance with MSHA requirements in ef-

fect on the date of manufacture. Failure

to follow applicable specifications, or

substitution of electrical parts not

supplied or approved by the manufac-

turer, can result in severe injury or

death.

Afterthepumphasbeeninstalled,make

certain that the pump and all piping or

hoseconnections are secure beforeop-

eration.

Approach the pump cautiously after it

hasbeenrunning.Althoughthemotoris

cooledbytheliquidbeing pumped,nor-

maloperatingtemperaturescanbehigh

enough to cause burns. The tempera-

ture will be especially high if operated

againsta closeddischarge valve.Never

SM SERIES PUMPSMR--05365

SAFETY PAGE A -- 3

operate against a closed discharge

valve for long periods of time.

Donotattempttoliftthepumpbythe

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.

MR--05365 SM SERIES PUMPS

TROUBLESHOOTING PAGE B -- 1

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.Closethedischargevalve(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, seeELECTRICAL TESTINGfollowing

the chart.

Table B-1 Troubleshooting Chart

TROUBLE CAUSE REMEDY

PUMP FAILS TO

START, CIRCUIT

BREAKER NOT

TRIPPED

Power source incompatible

with control box.

Novoltageatlinesideofcir-

cuit breaker.

Open circuit in motor wind-

ings or power cable.

Defective motor power cable.

Correct power source.

Check power source for blown fuse, open

overload unit, broken lead, or loose connec-

tion.

Check continuity.

Check for and replace defective unit.

CIRCUIT BREAKER

TRIPS Loworhighvoltage,orexces-

sive voltage drop between

pump and control box.

Defective insulation in motor

windings.

Impeller jammed due to de-

bris or insufficient clearance.

Bearing(s) frozen.

Measure voltage at control box. Check that

wiring is correct type, size, and length. (See

Field Wiring Connections,OperationsAnd

Maintenance Manual.

Check insulation resistance; check continuity.

Disassemble pump and check impeller.

Disassemble pump and check bearing(s).

SM SERIES PUMPS MR--05365

TROUBLESHOOTINGPAGE B -- 2

Table B-1 Troubleshooting Chart (continued)

TROUBLE CAUSE REMEDY

MOTOR RUNS, BUT

PUMP FAILS TO DE-

LIVER RATED DIS-

CHARGE

Discharge head too high.

Low or incorrect voltage.

Discharge throttling valve par-

tially closed; check that valve

is installed improperly.

Dischargelinecloggedorre-

stricted; hose kinked.

Liquid being pumped too

thick.

Strainer screen or impeller

clogged.

Insufficient liquid in sump or

tank.

Worn impeller vanes; exces-

sive impeller clearance.

Pump running backwards.

Reduce discharge head, or install staging

adaptor and additional pump.

Measure control box voltage, both when

pump is running and when shut off.

Open discharge valve fully; check piping in-

stallation.

Check discharge lines; straighten hose.

Dilute liquid 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 correct by in-

terchanging any two motor leads at control

box. (See Pump Rotation,SectionC).

PUMP RUNS WITH

EXCESSIVE NOISE

OR VIBRATION

Pumping entrained air.

Damaged or unbalanced im-

peller.

Discharge piping not properly

supported.

Impellerjammedorloose.

Pump cavitation.

Motor shaft or bearings defec-

tive.

Check liquid level in sump; check position of

pump and liquid level sensing device(s).

Replace impeller.

Check piping installation.

Check impeller.

Reduce discharge head, or restrict flow on

low head applications.

Disassemble pump and check motor and

bearings.

ELECTRICAL TESTING

If you suspect that pump malfunctions arecaused

bydefectsinthemotor,powercableorcontrolbox,

performthefollowingcheckstohelpisolatethede-

fective part.

Obtain the services of a qualified elec-

trician to troubleshoot, test and/or ser-

vice the electrical components of this

pump.

MR--05365 SM SERIES PUMPS

TROUBLESHOOTING PAGE B -- 3

Be certain to refer to the wiring diagram(s)

before reconnecting any electrical compo-

nents which have been disconnected.

Test Equipment

A volt/amp/ohmmeter and megohmeter of ade-

quaterangeandqualitywillberequiredtoconduct

thefollowingelectricaltests.Thesuggestedequip-

ment indicated below is commercially available, or

an equivalent substitute may be used.

Equipment Use

Ammeter/

Voltmeter To check AC Voltage

and current (amperage)

Ohmmeter To measure resistance

(ohms) to ground

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

yourpowercompanyandrequestthattheycorrect

the condition.

a. Useavoltmeter,amprobe,orequivalentme-

ter to read the voltage across terminals 1 &

2,2&3,and1&3inthe controlbox. Allthree

measured voltages must be the same, as

accuratelyasthemeterwillread.Ifpossible,

measure the voltage with the pump off, with

the pump running but out of the water, and

with the pump running in the water at full

load.Allthemeasured voltagesateachcon-

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 fullload and at

no load. All three amperage readings must

be the same at each condition, as accurate-

ly as the meter will read. Nominalamperage

values are listed in Table 1, but these apply

onlywhentheactualvoltageatthesiteisthe

nominal voltage listed.

c. If the voltages are balanced with the pump

off, but are unbalanced when the pump is

running, a thorough check of the power

source, all interconnecting cables, and the

pumpmotorisrequiredtoisolatethedefect.

Motor And Motor Power Cable Continuity

To check continuity, zero-balance the ohmmeter

set at the RX1 scale, and test as follows:

a Disconnect the motor power cable leads

from the control box and connect the test

leadstoanytwoofthethreepowercable

leads(nottothegreengroundleadoryellow

ground check lead). If there is a high resis-

tance reading on the ohmmeter, there is an

open or broken circuit cause a break in the

power cable or motor windings, orby a bad

connectionbetweenthemotorandthepow-

er 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 cablefor 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

eachpowercableleadattheterminalposts.

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

testreadingindicatesanopenorbrokencir-

cuit, there is an open circuit in the motor.

NOTE

Itisrecommendedthatapumpwithadefectivemo-

tor be returned to Gorman-Rupp, or to one of the

Gorman-Rupp authorized Submersible Repair en-

ters.

SM SERIES PUMPS MR--05365

TROUBLESHOOTINGPAGE B -- 4

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 othertest lead toeach of thethree

power leads in turn.

b. The reading obtained will indicate resis-

tancevaluesinboththepowercableandthe

motor windings. If the resistance reading is

infinity (1), the insulation is in good 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.

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