Gorman-Rupp Pumps S3A1-460V User Manual

Page 1
AC
OM−05169
October 18, 2000
Rev. H 01-30-12
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
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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
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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
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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
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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
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OM−05169 CONTROL BOXES
Figure 2. 27511−105 NEMA Type 3R Control Box Dimension
PAGE B − 4 INSTALLATION
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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
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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
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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.
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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
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