GORMAN-RUPP PUMPS S2D3 115V 1P User manual

OM-01689---04
October 28, 2003
ACDEGH
THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO
GORMAN-RUPP OF CANADA LIMITED DST. THOMAS, ONTARIO, CANADA Printed in U.S.A.
www.gormanrupp.com
ECopyright by the Gorman-Rupp Company
INSTALLATION, OPERATION,
AND MAINTENANCE MANUAL
WITH PARTS LIST
SSERIESPUMP
MODEL
S2D3 115V 1P

TABLE OF CONTENTS
i
INTRODUCTION PAGE I --- 1.................................................
SAFETY - SECTION A PAGE A --- 1............................................
INSTALLATION --- SECTION B PAGE B --- 1....................................
GENERAL INFORMATION PAGE B --- 1..................................................
PREINSTALLATION INSPECTION PAGE B --- 1............................................
PUMP SEAL PAGE B --- 1..............................................................
LUBRICATION PAGE B --- 1.............................................................
PUMP INSTALLATION PAGE B --- 2......................................................
Pump Motor Specifications PAGE B --- 2..............................................
Pump Dimensions PAGE B --- 2.....................................................
Lifting PAGE B --- 2.................................................................
Positioning the Pump PAGE B --- 2...................................................
Piping PAGE B --- 3................................................................
ELECTRICAL CONNECTIONS PAGE B --- 3...............................................
Grounding Methods PAGE B --- 4....................................................
Pump Power Cable Connections PAGE B --- 5.........................................
Control Box PAGE B --- 5...........................................................
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........................................................
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............................................................
TROUBLESHOOTING --- SECTION D PAGE D --- 1..............................
ELECTRICAL TESTING PAGE D --- 2.....................................................
Test Equipment PAGE D --- 2........................................................
Voltage Imbalance PAGE D --- 3.....................................................
Motor And Motor Power Cable Continuity PAGE D --- 3.................................
Insulation Resistance PAGE D --- 3...................................................
Capacitor PAGE D --- 4.............................................................
Wiring Diagram PAGE D --- 4........................................................
PUMP MAINTENANCE AND REPAIR - SECTION E PAGE E --- 1.................
STANDARD PERFORMANCE CURVE PAGE E --- 1........................................
PUMP MODEL S2D3 115V 1P PARTS LIST PAGE E --- 3...................................
PUMP AND SEAL DISASSEMBLY AND REASSEMBLY PAGE E --- 4.........................

TABLE OF CONTENTS
(continued)
ii
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 --- 6........................................................
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 And Shaft Removal PAGE E --- 10...............................................
Bearing Removal PAGE E --- 10.......................................................
Centrifugal Contact Switch Removal PAGE E --- 10......................................
Stator Removal PAGE E --- 10........................................................
MOTOR REASSEMBLY PAGE E --- 11.....................................................
Stator Installation PAGE E --- 11......................................................
Centrifugal Contact Switch Installation PAGE E --- 12....................................
Bearing Installation PAGE E --- 12.....................................................
Rotor And Shaft Installation PAGE E --- 12.............................................
Head And Power Cable Installation PAGE E --- 12.......................................
VACUUM/PRESSURE TESTING PAGE E --- 14.............................................
LUBRICATION PAGE E --- 14.............................................................
Seal Cavity PAGE E --- 14............................................................
Motor Cavity PAGE E --- 15...........................................................

SSERIES OM--01689
PAGE I -- 1INTRODUCTION
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 Installation, Operation, and Mainte-
nance manual isdesigned tohelp you achieve the
best performance and longest life from your Gor-
man-Rupp pump.
This is an S 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, thermally-
protected electric motor which is not explosion-
proof. The pump may be operated fully or partially
submerged. Do not operate the pump in a hazard-
ous atmosphere.
Pump motor maintenance may be performedonly
by a Gorman-Rupp authorized repair facility, orthe
factory. Otherwise, the pump warranty will be ne-
gated, and damage to the pump, and injury or
death to personnel can result. Contact the factory
for the authorized repair facility closest to you.
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
neitheroperatorsafetynorpumpintegrityarecom-
promised by the installation. Pumps and related
equipment must be installed and operated ac-
cording to all national, local and industry stan-
dards.
If there are any questions regarding the pump or
its application which are not covered in this man-
ual or in other literature accompanying this unit,
please contact your Gorman-Rupp distributor, or
write:
The Gorman-Rupp Company
P.O. Box 1217
Mansfield, Ohio 44901--1217
Phone: [phone]
or:
Gorman-Rupp of Canada Limited
70 Burwell Road
St. Thomas, Ontario N5P 3R7
Phone: [phone]
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 whichWILL 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.
HazardsorunsafepracticeswhichCOULD
result in minor personal injury or product
or property damage. These instructions
describe the requirements and the possi-
ble damage which could result from failure
to follow the procedure.
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.

SSERIESPUMP OM--01689
SAFETY PAGE A -- 1
SAFETY --- SECTION A
This information applies to the S Series
submersible motor driven pumps.
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.
Beforeattemptingtoopenorservicethe
pump:
1. Familiarize yourself with this man-
ual.
2. Lock out incoming power to the
controlboxorswitchtoensurethat
the pump will remain inoperative.
3. Allow the pump to completely cool
if overheated.
5. Close the discharge valve (if
used).
This pump is not designed to pump vol-
atile,explosive,orflammablematerials.
Do not attempt to pump any liquids for
which you 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.
Ifthepowercableiswiredintoanop-
tional manual starting switch or control
box, make sure that the enclosure is
grounded. See Section B for recom-
mended grounds.
The electrical power used to operate
this pump is high enough to cause inju-
ryordeath.Make certainthe controlbox
orswitchisinthe OFForSTOPposition,
or that the power supply to the control
box has been otherwise cut off and
lockedout.Tagelectricalcircuitstopre-
vent accidental start-up.
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.
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 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

OM--01689 SSERIESPUMP
PAGE A -- 2 SAFETY
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.
Afterthepumphasbeeninstalled,make
certain that the pump and all piping or
hoseconnections are secure beforeop-
eration.
Obtain the services of a qualified elec-
trician to troubleshoot, test and/or ser-
vice the electrical components of this
pump.
Donotattempttoliftthepumpbythe
motor power cable or discharge hose.
Attach proper lifting equipment to the
lifting device fitted to the pump.
Pumps and related equipment must be
installed and operated according to all na-
tional, local and industry standards.

OM--01689 SSERIESPUMP
PAGE B -- 1
INSTALLATION
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 generalrec-
ommendations and practices required to inspect,
position,andarrangethepumpandpiping.Ifthere
are any questions concerning your specific instal-
lation, contact your Gorman-Rupp distributor or
the Gorman-Rupp Company.
Nuts, bolts and screws used on this pump
are metric and do not matchstandardSAE
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.
PREINSTALLATION INSPECTION
The pump assemblywas inspectedand tested be-
fore shipment from the factory. Before installation,
check for damage which may have occurred dur-
ing shipment. Check as follows:
a. Inspectthepumpassemblyforcracks,dents,
damaged threads, and other obvious dam-
age.
b. Check for and tighten loose attaching hard-
ware. Since gaskets tend to shrink after dry-
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 pow-
er.
e. Carefully read all tags, decals, and markings
onthepump,andperformalldutiesindicated.
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 lubri-
cants may have exceeded their maximum
shelf life. These must be inspected or re-
placed to ensure maximum pump service.
Ifthemaximumshelflifehasbeenexceed,orif
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 appropri-
ate action has been taken.
PUMP SEAL
Thepumpisequippedwithasinglefacedsealas-
sembly. It is designed to prevent the liquid being
pumped from entering the lubrication cavity at the
impeller end. A lip seal is used to prevent moisture
or lubrication oil from entering the motor housing
cavity at the motor end.
Thesealislubricatedbypremiumqualitysubmers-
ible 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
oilwhichlubricatesthepumpseal.Themotoroper-
ates in and is cooled by air, therefore it requires no
lubrication.
This pump was fullylubricated when shipped from
the factory. However, lubrication levels must be
checked before installing the pump (see LU-
BRICATION in the MAINTENANCE AND REPAIR
MANUAL). If the oil level is abnormally low, deter-
mine the cause before putting the pump into ser-
vice.
Refer to Table B-2 for the oil capacity and position
for filling the seal cavity in the pump. Refer to LU-
BRICATION, Section C for lubrication specifica-
tions and intervals.

SSERIESPUMPS OM--01689
PAGE B -- 2 INSTALLATION
PUMP INSTALLATION
Pump Motor Specifications
See Tables B-1 and B-2 for pump specifications.
Table B-1. Pump Specifications
Liquid
Level
Control
Locked
Rotor
Amperes
Pump
HP/
KW
Motor
Speed
(RPM)
Full
Load
Amperes
No
Load
Amperes
Discharge
Size
(NPT)
Model Voltage/
Phase
S2D3 115/1 NO 8.6 1.0 50.61 HP 3450 2INCH
w/BARBED
ADAPTOR
Table B-2. Additional Specifications
Pump
Model Voltage/ Phase
115/1S2D3
Approximate
Weight -- Lbs. (kg) Oil Capacity
Ounces (Liters) Seal Cavity Filling
Position
(H)orizontal
Pump 50 Ft. Cable Seal
Cavity Motor
Cavity
78 (42) 6 (3) 7 (0,2) H
--- --- ---
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 require-
ments.Failuretoobservetheserequire-
ments could result in injury or death to
personnel.
NOTE
Refer to the performance curve in Section E, Main-
tenance and Repair when determining the most
efficient piping installation. The recommended
maximum submergence depth is 23 feet. Great-
er depths could result in damage to the pump
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.
Lifting
Pump unit weights will vary depending on the
mounting and drive provided. Check the shipping
tagontheunitpackagingfortheactualweight,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.
Donotattempttoliftthepumpbythe
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 bya constant flow ofliquid
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 opera-
tion.

OM--01689 SSERIESPUMP
PAGE B -- 3
INSTALLATION
The pump should be independently secured and
supported by the lifting device fitted on the pump.
Iftheapplicationinvolvesalotofdebris,protectthe
pump from excessive wear and clogging by sus-
pending 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-1 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.
BY BAIL IN PERFORATED CULVERT PIPE ON SUPPORTS
Figure B-1. Typical Pump Installations
Piping
Nosuctionpipingis required ina standard installa-
tion. This pump is 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. Either hose or rigid pipe may be
used. To facilitate mobility and maintenance, it is
recommendedthatthedischargelinebefittedwith
a quick disconnect fitting near the pump. The dis-
charge line must be independently supported to
avoid strain and vibration on the pump.
Either hose or rigid pipe may be used to make dis-
charge connections. For maximum pumping ca-
pacity, keep the line as short and straight as pos-
sible. 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 tocontrolsi-
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-
tormust bekeptcompletelywaterproof.
Serious damage to the pump and injury

SSERIESPUMPS OM--01689
PAGE B -- 4 INSTALLATION
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 avail-
able at the motor must be within the range indi-
cated in Table B-3.
Tocalculate the voltage available atthe motor, pro-
ceed as follows:
a. Measurethevoltagewhile the pump is oper-
ating atfull 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 recommendedlimits.
Obtaintheservices ofa qualifiedelectrician to
determinethecorrectfieldwiringsizeandoth-
er details toensure an adequate voltagesup-
ply to the pump.
Table B-3. Pump Voltage Requirements
NOMINAL
VOLTAGE PHASE MINIMUM
VOLTAGE MAXIMUM
VOLTAGE
1115 110 120
Grounding Methods
Ifthepowercablewillbewiredintoanoptional
manual switch or control box, ground the enclo-
sure before installing the wiring. In any of these
cases, the electrical circuit must be grounded to a
properly imbedded electrode.
Thematerialusedfortheelectrodemust be an ex-
cellent conductor of electricity, such as copper. If
ironor steelis used,itmust be galvanized orother-
wise metal plated to resist corrosion. Do not coat
the electrode with any material of poor conductiv-
ity, such as paint or plastic.
The electrode must conform to the recommenda-
tions of N.E.C. ARTICLE 250. Follow all installation
requirementsoftheN.E.C.,andallapplicablelocal
codes.SeeFigureB-3forsomesuggested
grounding methods.
ROCK
8 FEET
(2,4 M)
3/4 INCH (19,1
MM) NOMINAL
DIAMETER
(MINIMUM)
3/4 INCH (19,1 MM)
NOMINAL DIAMETER
(MINIMUM) 8 FEET
(2,4 M) LONG
SOIL
SOIL
SOIL
1/4 INCH (6,4 MM)
STEEL PLATE 2 SQ.
FEET (1858,1 SQ. CM)
SURFACE AREA
(MINIMUM)
a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE
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 asurface
area of at least 2square feet (1858,1 sq. cm.).
b. Driven Electrode: A rod or pipe, 3/4 inch
(19,1mm)indiameterminimum,8feet(2,4m)
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.
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.