Page 1
AC
OM−05169
October 18, 2000
Rev. H 01-30-12
INSTALLATION AND
OPERATION MANUAL
WITH PARTS LISTS
SINGLE PHASE CONTROL BOXES
MODELS
27511−101 27511−105
27511−102 27511−106
27511−103 27511−107
27511−104
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.
eCopyright by the Gorman-Rupp Company
Page 2
TABLE OF CONTENTS
INTRODUCTION PAGE I − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY INFORMATION 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX INSTALLATION PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27511−101, 102, 103, 104, 106 And 107 CONTROL BOX DIMENSIONS PAGE B − 1. . . . . . . . . . . . . . . .
27511−101, 102, 103, 104, 106 And 107 CONTROL BOX PARTS LIST PAGE B − 3. . . . . . . . . . . . . . . . . .
27511−105 CONTROL BOX DIMENSIONS PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27511−105 CONTROL BOX PARTS LIST PAGE B − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Methods PAGE B − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Wiring Connections (Incoming Power) PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Motor Voltage Limits PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cable Connections PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Box Specifications PAGE B − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27511−101, 102, 103, 104, 106 And 107 Control Box Pictorial Wiring Diagram PAGE B − 8. . . . . . . .
27511−101, 102, 103, 104, 106 And 107 Elementary Wiring Diagram PAGE B − 9. . . . . . . . . . . . . . . . .
27511−105 Control Box Pictorial Wiring Diagram PAGE B − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27511−105 Elementary Wiring Diagram PAGE B − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION − SECTION C PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX FUNCTION PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING − SECTION D PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING CHART PAGE D − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL TESTING PAGE D − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Equipment PAGE D − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Imbalance PAGE D − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitors PAGE D − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Relay PAGE D − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
Page 3
INTRODUCTION
OM−05169CONTROL BOXES
Read this manual carefully to learn how to safely
install and operate your control box. Failure to do
so could result in personal injury or damage to the
control box or the pump.
This manual does not include maintenance instructions. Have a qualified electrician perform all
maintenance. Be sure to follow all safety precautions as outlined by the National Electric Code and
all local codes.
These control boxes are Nema Type 3R rainproof
enclosures with padlockable front covers. The en-
closures are not designed to be watertight, and
should not be submerged. They are designed for
use with 110, 115, 220 and 230 volt, single phase
Gorman-Rupp submersible pumps. The integral
electric motor of the submersible pump must be
operated through the control box. The control box
is not explosion-proof and should not be operated
in a hazardous atmosphere.
Because pump installations are seldom identical,
this manual cannot possibly provide detailed instructions and precautions for every aspect of
each specific application. Therefore, it is the responsibility 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 compromised by the installation. Pumps and related
equipment must be installed and operated according to all national, local and industry standards.
If there are any questions regarding the control box
which are not covered in this manual or in other literature accompanying the unit, please contact
your Gorman-Rupp distributor or the GormanRupp Company:
RECORD CONTROL BOX NUMBER
Please record the control box number, voltage,
phase, and pump model in the spaces provided
below. Your Gorman-Rupp distributor needs this
information when you require parts or service.
Control Box:
Voltage:
Phase:
Pump Model:
WARRANTY INFORMATION
The warranty provided with your control box is part
of Gorman-Rupp’s support program for customers
who operate and maintain their equipment as described in this and the other accompanying literature. Please note that should the equipment be
abused or modified to change its performance beyond the original factory specifications, the warranty will become void and any claim will be denied.
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 which WILL result in
severe personal injury or death. These
instructions describe the procedure required and the injury which will result
from failure to follow the procedure.
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
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.
PAGE I − 1INTRODUCTION
Page 4
OM−05169 CONTROL BOXES
damage 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 describe the requirements and the possible
NOTE
Instructions to aid in installation, operation, and
maintenance or which clarify a procedure.
PAGE I − 2 INTRODUCTION
Page 5
CONTROL BOXES OM−05169
SAFETY − SECTION A
The following information applies
throughout this manual to GormanRupp Control Boxes.
Because pump installations are seldom
identical, this manual cannot possibly
provide detailed instructions and precautions for each specific application.
Therefore, it is the owner/installer’s responsibility to ensure that applications
not addressed in this manual are performed only after establishing that neither operator safety nor pump integrity
are compromised by the installation.
Before attempting to install, operate, or
wire this control box, familiarize yourself with this manual, and with all other
literature shipped with the control box.
Unfamiliarity with all aspects of control
operation covered in this manual could
lead to destruction of equipment, injury,
or death to personnel.
Before connecting any cable to the control box, be sure to ground the control
box. See Section B for suggested
grounding methods.
ing operation, correct the problem before resetting or replacing.
The electrical power used to operate
this control box is high enough to cause
injury or death. Obtain the services of a
qualified electrician to make all electrical connections. Make certain that the
enclosure is properly grounded; never
use gas pipe as an electrical ground. Be
sure that the incoming power matches
the voltage and phase of the control before connecting the power source. Do
not make electrical connections if the
voltage is not within the limits. If the
overload unit is tripped during operation, correct the problem before restarting.
The electrical power used to operate
this control box is high enough to cause
injury or death. Make certain that the
control handle on the control box is in
the OFF position 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
control box. Tag electrical circuits to
prevent accidental start-up.
The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines. If the power circuit
breaker or overload relay is tripped dur-
SAFETY PAGE A − 1
Obtain the services of a qualified electrician to troubleshoot, test and/or service the electrical components of this
control box.
Page 6
OM−05169 CONTROL BOXES
Do not attempt to repair individual components of the control box. Any component which fails should be replaced.
PAGE A − 2 SAFETY
Page 7
CONTROL BOXES OM−05169
INSTALLATION − SECTION B
GENERAL INFORMATION
Review all SAFETY information in Section A.
This section is intended only to summarize recommended installation practices for the control box. If
there are any questions concerning your specific
application, contact your Gorman-Rupp distributor
or the Gorman-Rupp Company.
PREINSTALLATION INSPECTION
The control box was inspected before shipment
from the factory. Before installation, inspect the
control for damage which may have occurred during shipment. Check as follows:
a. Inspect the control box for cracks, dents, and
other obvious damage.
b. Check that all control box components are se-
curely attached to their mounting surfaces,
and that the electrical connections are tight
and free of corrosion.
c. Compare the amperes, phase, voltage and
hertz indicated on the pump motor nameplate
to the ratings indicated for the control box.
d. Carefully read all tags, decals, and markings
on the control box.
Enclosure
The control box is a NEMA Type 3R rainproof enclosure with a padlockable front cover. The enclosure
is not designed to be watertight, and should not
be submerged.
No mounting hardware is furnished with the control box. Secure the control box vertically on a level
surface, above flood level. The control should be
mounted on a flat surface. If the mounting surface
is not perfectly flat, it may be necessary to use
shims (not supplied) with the enclosure.The box
should be easily accessible to the operator, and located close enough to the pump to avoid excessive voltage drop due to cable length.
Failure to mount the control box vertically
on a level surface may affect operation of
the pump controls.
After the box is securely installed, make certain the
front cover latches properly before installing any
electrical lines.
If anything appears to be abnormal, contact your
Gorman-Rupp distributor or the factory to determine the repair policy. Do not put the control box
into service until appropriate action has been
taken.
CONTROL BOX INSTALLATION
The control box furnished with the
pump is designed to operate the pump.
The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines.
CONTROL BOX DIMENSIONS
For the approximate physical dimensions of your
control box, refer to Figure B−1.
PAGE B − 1INSTALLATION
Page 8
OM−05169 CONTROL BOXES
Figure 1. 27511−101, 27511−102, 27511−103, 27511−104, 27511−106 And 27511−107 NEMA
Type 3R Control Box Dimension
PAGE B − 2 INSTALLATION
Page 9
CONTROL BOXES OM−05169
27511−101, 27511−102, 27511−103, 27511−104, 27511−106 And 27511−107
CONTROL BOX PARTS LIST
ITEM
NO. PART NAME
1 PANEL −−− 81−26110 1
2 ENCLOSURE WELDMENT −−− 39−45727 1
3 EXTERIOR DOOR ASM −−− 47−47184 1
4 INTERIOR COVER PLATE −−− 47−47186 1
5 MAIN BREAKER SEE TABLE 1 −−− 1
6 START CAPACITOR SEE TABLE 1 −−− 1
7 RUN CAPACITOR SEE TABLE 1 −−− 1
8 TERMINAL BLOCK −−− 80−5821 2
9 GROUND LUG −−− 80−3132 2
10 CABLE GRIPS −−− 3303TBCF 2
11 PAD LOCKING LATCH −−− 52−3182−4 1
12 1/4 TURN LATCH −−− 2092A24G05 1
13 GASKET −−− 45301AFBR3
14 OPTIONAL LIQUID LEVEL CONTROL SEE TABLE 1 −−− 1
15 G-R LOGO DECAL GR06 −−− 1
16 G-R WARNING LABEL 38816−066 −−− 1
17 G-R WARNING DECAL 38816−067 −−− 1
18 START RELAY SEE TABLE 1 −−− 1
19 PUB SHEET 1 PH −−− 25883 1
20 DIN RAIL −−− 800612−113−19 1
21 END STOP FOR DIN RAIL −−− C383ES35 2
22 BREAKER BRACKET −−− 47−47188 1
G-R PART
NUMBER QTY
C-H PART
NUMBER
Table 1. Repair Parts
G-R
Control Box
27511−101 S2F 115 60 9483A 9482B 27571−303 SPHM2RM0015 27521−323
27511−101 S2F 110 50 9483A 9482B 27571−303 SPMH2RM0015 27521−323
27511−102 S2F 230 60 9483 9482A 27571−302 SPMH2RM07R5 27521−324
27511−102 S2F 220 50 9483 9482A 27571−302 SPHM2RM07R5 27521−324
27511−103 S2A 230 60 9483 9482A 27571−323 SPHM2RM0015 27521−324
27511−104 S2A/S2B 115 60 9483A 9482B 27571−304 SPHM2RM0030 27521−323
27511−106 S3A/S3D 230 60 9483 11343 27571−304 SPHM2RM0030 27521−324
27511−107 S3B/S3C 230 60 9483 11343 27571−306 SPHM2RM0035 27521−324
G-R
Pump Model
Volts Hz Start
Relay
G-R P/N
Start
Capacitor
G-R P/N
Run
Capacitor
G-R P/N
Circuit
Breaker
C-H P/N
Liq. Level
Option
G-R P/N
PAGE B − 3INSTALLATION
Page 10
OM−05169 CONTROL BOXES
Figure 2. 27511−105 NEMA Type 3R Control Box Dimension
PAGE B − 4 INSTALLATION
Page 11
CONTROL BOXES OM−05169
27511−105 CONTROL BOX PARTS LIST
ITEM
NO.
1 PANEL −−− 81−26110 1
2 ENCLOSURE WELDMENT −−− 39−45727 1
3 EXTERIOR DOOR ASM −−− 47−47184 1
4 INTERIOR COVER PLATE −−− 47−47186 1
5 MAIN BREAKER −−− SPHM2RM0015 1
6 STARTER CAPACITOR 27581−015 −−− 1
7 RUN CAPACITOR 47883−002 −−− 1
8 TERMINAL BLOCK −−− 80−5820 2
9 GROUND LUG −−− 80−3132 2
10 CABLE GRIPS −−− 3303TBCF 2
11 PAD LOCKING LATCH −−− 52−3182−4 1
12 1/4 TURN LATCH −−− 2092A24G05 1
13 GASKET −−− 45301AFBR3
14 OPTIONAL LIQUID LEVEL CONTROL 27521−324 −−− 1
15 G-R LOGO DECAL GR06 −−− 1
16 G-R WARNING LABEL 38816−066 −−− 1
17 G-R WARNING DECAL 38816−067 −−− 1
18 START RELAY 27547−015 −−− 1
19 PUB SHEET 1 PH (SP RELAY) 25885 1
20 DIN RAIL −−− 800612−113−1 1
21 END STOP FOR DIN RAIL −−− C383ES35 2
22 BREAKER BRACKET −−− 47−47188 1
PART NAME
G-R PART
NUMBER
C-H PART
NUMBER
QTY
PAGE B − 5INSTALLATION
Page 12
OM−05169 CONTROL BOXES
ELECTRICAL CONNECTIONS
Obtain the services of a qualified electrician to make all electrical connections and to service the control box.
The electrical power used in this control
box is high enough to cause injury or
death. Make certain that the control box
is properly grounded after installation.
Make certain that the power source
phase and voltage matches the data on
the control box. Complete all electrical
connections before connecting the
power supply to the control box. Make
certain to ground the appropriate lead
a) PLATE ELECTRODE b) DRIVEN ELECTRODE c) BURIED ELECTRODE
of the power source before connecting
power to the control. Make certain that
the control box is properly grounded after installation.
Grounding Methods
Electrically ground the installation before connecting the field wiring to the control box. Install a
grounding terminal to the enclosure and connect it
to a properly embedded electrode.
The material used for the electrode must be an excellent conductor of electricity, such as copper. If
iron or steel is used, it must be galvanized or otherwise metal plated to resist corrosion. Do not coat
the electrode with any material of poor conductivity, such as paint or plastic.
The electrode must conform to the recommendations of N.E.C. ARTICLE 250. Follow all installation
requirements of the N.E.C., and all applicable
codes. See Figure B−2 for some suggested
grounding methods.
SOIL
1/4 INCH STEEL
PLATE 2 SQ. FEET
(1858,1 SQ. CM)
SURFACE AREA
(MINIMUM)
Figure B−2. 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 a surface
area of at least 2 square feet (1858,1 sq. cm).
b. Driven Electrode: A rod or pipe, 3/4 inch
(19,1 mm) in diameter minimum, 8 feet (2,4 m)
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.
PAGE B − 6 INSTALLATION
SOIL
3/4 INCH (19,1
MM) NOMINAL
DIAMETER
(MINIMUM)
8 FEET
(2,4 M)
Space the ground rod or plates at least 6 feet
(1,8 m) from any other electrode or ground
rod, such as those used for signal circuits, radio grounds, lightning rods, etc.
The earth surrounding the ground rod or plate
must contain enough moisture to make a
good electrical connection. In dry or sandy areas, pour water around the rod, or consult
qualified personnel to devise a method of improving the connection.
SOIL
ROCK
3/4 INCH (19,1 MM)
NOMINAL DIAMETER
(MINIMUM) 8 FEET
(2,4 M) LONG
Page 13
CONTROL BOXES OM−05169
Field Wiring Connections (Incoming Power)
The electrical power used to operate
this pump is high enough to cause injury or death. Obtain the services of a qualified 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 incoming 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.
The control is designed to regulate the power supply. The field wiring must be properly sized to ensure an adequate voltage supply. The voltage
available at the pump motor must be within the in-
dicated range.
Table 3. Pump Motor Voltage Limits
Power Cable Connections
The electrical power used to operate the
control box is high enough to cause injury or death. Obtain the services of a
qualified electrician to make all electrical connections. Make certain that incoming power to the control box is in the
off position and locked out, or that the
power supply to the control box has
been otherwise cut off and locked out,
before connecting power or accessory
cables.
When necessary to change or connect power
cables to the control box, make certain the incoming power is OFF and LOCKED OUT. Make certain
the control box is properly grounded and that the
electrical data on the control matches the pump
motor name plate data.
Nominal
Voltage
115 1 110 120
200 1 190 210
220 (50 Hz) 1 209 230
230 1 220 240
If the voltage is not within the recommended limits,
obtain the services of a qualified electrician to determine the correct field wiring size and other details to ensure an adequate voltage supply.
Make certain all connections are tight and that cable entry points are rainproof. Support the cable
weight, if required, to prevent excessive strain on
cable clamps and cable.
Phase
Minimum
Voltage
Maximum
Voltage
NOTE
After the power cables have been connected to the
control box, make certain the connection is waterproof.
Connect the power cable to the control box as
shown in the wiring diagrams in this section. Use
conduit or cable clamps to secure the power and
accessory cables to the control box. Make certain
that all connections are tight and that cable entry
points are rainproof.
Control Box Specifications
Overload relays are provided to protect the pump
motor.
If burnout of the overload protection occurs, the complete overload protection
must be replaced.
PAGE B − 7INSTALLATION
Page 14
OM−05169 CONTROL BOXES
WIRING DIAGRAM
Figure B−3. Control Boxes 27511−101, 27511−102, 27511−103, 27511−104, 27511−106 And
27511−107 Pictorial Wiring Diagram
PAGE B − 8 INSTALLATION
Page 15
CONTROL BOXES OM−05169
Figure B−4. Control Boxes 27511−101, 27511−102, 27511−103, 27511−104, 27511−106
And 27511−107 Elementary Wiring Diagram
PAGE B − 9INSTALLATION
Page 16
OM−05169 CONTROL BOXES
WIRING DIAGRAM
Figure B−5. Control Box 27511−105 Pictorial Wiring Diagram
PAGE B − 10 INSTALLATION
Page 17
CONTROL BOXES OM−05169
Figure B−6. Control Box 27511−105 Elementary Wiring Diagram
PAGE B − 11INSTALLATION
Page 18
CONTROL BOXES
OPERATION − SECTION C
Review all SAFETY information in Section A.
Follow the instructions on all tags, labels and
decals attached to the control box.
The electrical power used to operate
this control box is high enough to cause
injury or death. Make certain that the tie
handle in the control box is in the OFF
position 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 control box. Tag electrical circuits to prevent accidental start-up.
OM−05169
The control box provides overload protection and power control. Do not connect the pump motor directly to the incoming power lines.
Since operation of the pump motor is dependent upon the quality and performance
of the electrical controls, the pump warranty is valid only when controls have been
specified or provided by The GormanRupp Company.
Component Function
Obtain the services of a qualified electrician to make all electrical connections, and to troubleshoot, test and/or
service the electrical components of the
control box.
CONTROL BOX FUNCTION
The control box is not designed to be explosion-proof. Do not operate in an explosive atmosphere.
The control box is provided to facilitate operation of
the pump. It contains controls for starting and stopping the pump, and provides overload protection
for the pump motor. The pump control may be
equipped with an optional automatic liquid level
sensing device, in which case the circuits are also
contained within the control box.
The control box contains the following hand-operated switches and controls:
D The tie handle operates the control box cir-
cuit breakers. In the OFF position, the tie
handle opens the circuit breakers to interrupt incoming power through the control
box and prevent pump operation. In the ON
position, it closes the circuit breakers to permit pump operation. The circuit breakers will
open or trip" automatically in the event of a
short circuit overload current. When tripped,
move the tie handle to OFF and back to ON
to reset the circuit breakers.
D The overload unit is also the ON and OFF
switch. The overload relay will trip automatically if the current drawn by the motor exceeds design specifications. Allow 10 seconds for the unit to cool after tripping before
resetting.
NOTE
If the circuit breaker trips, do not reset it immediately. Wait at least ten minutes before resetting the
tie handle back to the ON position. If the overload
unit continues to trip, operational problems exist.
OPERATION PAGE C − 1
Page 19
OM−05169
CONTROL BOXES
D The liquid level devices (optional equip-
ment) operate in conjunction with the 3-position switch (HAND-OFF-AUTO) supplied
as part of that option. After the level sensors
and circuitry have been installed, pump operation may be automatically controlled for
filling or dewatering functions. In the HAND
position, the switch closes the circuit to permit pump operation until the switch is
moved to the OFF position. In the OFF position, the switch interrupts incoming power
through the control box and prevents pump
operation. In the AUTO position, sensors will
automatically turn the pump on or off depending on the level of the liquid being
pumped.
Always terminate incoming power to the control
box before investigating control box circuitry problems.
Always terminate power to the control
box before performing service functions.
Power through the control box may be terminated
by moving the tie handle to the OFF position, thereby opening the circuit breakers. This stops the
pump, but does not terminate incoming power
through the field wiring connected to the control
box.
OPERATIONPAGE C − 2
Page 20
CONTROL BOXES OM−05169
TROUBLESHOOTING − SECTION D
Review all SAFETY information in Section A.
The electrical power used to operate
this control box is high enough to cause
injury or death. Obtain the services of a
qualified electrician to troubleshoot,
test and/or service the electrical components.
Many of the probable remedies listed in the troubleshooting chart below require use of electrical test instruments; for specific procedures, see Electrical Testing at the end of the troubleshooting chart.
When troubleshooting, also refer to the technical information accompanying the pump and optional equipment.
TROUBLESHOOTING CHART
TROUBLE POSSIBLE CAUSE PROBABLE REMEDY
PUMP FAILS TO
START, OVERLOAD
UNIT NOT TRIPPED
(MANUAL MODE)
OVERLOAD UNIT
TRIPS
Power source incompatible
with control box.
No voltage at line side of circuit breaker.
No voltage at line terminals
on bottom of overload unit in
control box.
Low or high voltage, or excessive voltage drop between
pump and control box.
Power input phases not balanced.
Control box not compatible
with pump.
Foreign object locking impeller or bearing frozen.
Correct power source.
Check power source for blown fuse, open
overload unit, broken lead, or loose connection.
Check power source for blown fuse, open
disconnect, broken wire, or loose connection.
Measure voltage at control box. Check that
wiring is correct type, size, and length. (See
Field Wiring Connections, Section B).
If imbalance exceeds 1 percent, notify power
company.
Electrical data on control box and pump
name plate must agree. Replace control box if
not in agreement.
Remove foreign material or replace damaged
bearing. If bearing is damaged, check for water in motor housing.
Motor windings short-circuited.
TROUBLESHOOTING PAGE D − 1
Check motor windings with ohmmeter.
Page 21
OM−05169
ELECTRICAL TESTING
Be certain to refer to the wiring diagram(s)
in the Installation Section of this manual before reconnecting any electrical components which have been disconnected.
CONTROL BOXES
Before disconnecting the capacitor leads,
discharge the capacitors; use a screwdriver with an insulated handle, and place the
blade across the two terminals of each capacitor to short the terminals.
Zero-balance the ohmmeter set to read RX100K,
and test the capacitors as follows:
Test Equipment
A volt/amp/ohmmeter and megohmeter of adequate range and quality will be required to conduct
the electrical tests. The suggested equipment indicated below is commercially available, or an equivalent substitute may be used.
Equipment Use
Ammeter/
Voltmeter
Ohmmeter To measure resistance
Voltage Imbalance
To check AC Voltage
and current (amperage)
(ohms) to ground
a. Disconnect the capacitor leads, and remove
the resistor from the start capacitor.
b. Place a test lead against each of the termi-
nals of the start capacitor for a few seconds.
If the ohmmeter needle moves toward zero
then slowly drifts back to the left, the capacitor is good. If the needle remains at infinity
(∞) the capacitor is open; if the needle remains at zero, the capacitor is shorted. In either case, the capacitor must be replaced.
c. Test the run capacitor as in b. In addition,
test the metal run capacitor for shorts to
ground by touching one test lead to the capacitor case and the other lead to each of
the capacitor terminals in turn. The ohmmeter should read infinity (∞); if it does not, the
capacitor is grounded and must be replaced.
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 out of balance, contact your power company
and request that they correct the condition.
Capacitors
The start capacitor is designed to split the electrical
phase during the initial power surge at motor startup. The start capacitor is controlled by the start
relay at motor startup. When the motor reaches
load speed, the start relay cuts out and permits the
run capacitor to maintain operation. Both the start
and run capacitors are located in the control box.
Start Relay
The start relay is located in the control box.
Disconnect the two wires from relay terminal 2. Use
a zero-balanced ohmmeter set to read RX100K,
and touch one lead to relay terminal 2 and the other
to relay terminal 5. The resistance reading should
be between 4000 to 6000 ohms; if the reading is
not in this range, the start relay is defective and
should be replaced.
NOTE
Repair of individual electrical components is not
recommended. Replace defective and/or malfunctioning components.
TROUBLESHOOTINGPAGE D − 2
Page 22
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