Gorman-Rupp Pumps S3B65-E6 User Manual

AC

OM-05170

August 28, 2000

Rev. D 06-04-07

INSTALLATION AND

OPERATION MANUAL

WITH PARTS LISTS

CONTROL BOXES

MODELS

27515−561 27515−564
27515−562 27515−565
27515−563

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

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

CONTROL BOX DIMENSIONS

27515−561, 27515−562, 27515−563 And 27515−564 PAGE B − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST - CONTROL BOX PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL BOX DIMENSIONS 27515−565 PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST - CONTROL BOX 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAMS − 27515−561, 27515−562, 27515−563, 27515−564 CONTROL BOXES

Pictorial Wiring Diagram PAGE B − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Elementary Wiring Diagram PAGE B − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAMS − 27515−565 CONTROL BOX

Pictorial Wiring Diagram PAGE B − 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

i

INTRODUCTION

OM−05170CONTROL 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 230, 460, 575 and 380 volts, 3 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

OM−05170 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

CONTROL BOXES OM−05170

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.

OM−05170 CONTROL BOXES

Do not attempt to repair individual com­ponents of the control box. Any compo­nent which fails should be replaced.

PAGE A − 2 SAFETY

CONTROL BOXES OM−05170

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.

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.

d. Carefully read all tags, decals, and markings

on the control box.

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.

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.

CONTROL BOX DIMENSIONS

For the approximate physical dimensions of your
control box, refer to Figure B−1.

PAGE B − 1INSTALLATION