Gorman-Rupp Pumps S4C65-E10 User Manual
AC
OM-04136
January 21, 1998
Rev. C 09-03-03
INSTALLATION AND
OPERATION MANUAL
WITH P ARTS LISTS
CONTROL BOXES
MODELS
27515--503 27515--504 27515--505 27515--506
27515--507 27515--513 27515--514 27515--515
27515--516 27515--517 27515--524 27515--525
27515--534 27515--535 27515--543 27515--544
27515--545 27515--546 27515--554 27515--571
27515--572
THE GORMAN-RUPP COMPANY F MANSFIELD, OHIO
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.................................................
SA FE T Y --- SE C TIO N A PA G E A --- 1...........................................
IN STA L LAT ION --- SEC T IO N B PA G E B --- 1....................................
GENERAL INFORMATION PAGE B --- 1..................................................
PREINSTALLATION INSPECTION PAGE B --- 1............................................
CONTROL BOX INSTALLATION P AGE B --- 1.............................................
Enclosure PA GE B --- 1.............................................................
CONTROL BOX DIMENSIONS PAGE B --- 1..............................................
ELECTRICAL CONNECTIONS PAGE B --- 6...............................................
Grounding Methods PAGE B --- 6....................................................
Field Wiring Connections (Incoming Power) P AGE B --- 7...............................
Pump Motor Voltage Limits PAGE B --- 7..............................................
Power Cable Connections PA GE B --- 7...............................................
Control Box Adjustments PAGE B --- 7................................................
WIRING DIAGRAMS PAGE B --- 8.......................................................
Parts Lists:
Control Boxes 27515---503, 27515---513 And 27515---543 PAGE B --- 8...................
Control Boxes 27515---504, 27515---514 27515---544 And 27515---554 PAGE B --- 11........
Control Boxes 27515---505, 27515---515 And 27515---545 PAGE B --- 13...................
Control Boxes 27515---506, 27515---516 And 27515---546 PAGE B --- 15...................
Control Boxes 27515---507 And 27515---517 PAGE B --- 17...............................
Control Boxes 27515---524 And 27515---534 PAGE B --- 19...............................
Control Boxes 27515---525 And 27515---535 PAGE B --- 21...............................
Control Boxes 27515---571 And 27515---572 PAGE B --- 23...............................
Control Box Da ta Chart PAGE B --- 25.................................................
27515---571 And 27515---572 Control Box Data PAGE B --- 26............................
Control Box Torque Values PAGE B --- 26..............................................
OPER AT IO N --- SE C T IO N C PA G E C --- 1......................................
CONTROL BOX FUNCTION PAGE C --- 1.................................................
Component Function P AGE C --- 1...................................................
TR OUB LES HOO TI NG --- SE CTI ON D PA G E D --- 1..............................
ELECTRICAL TESTING PAGE D --- 2.....................................................
Test Equipment PA GE D --- 2........................................................
Voltage Imbalance PAGE D --- 2.....................................................
i
OM--04136 CONTROL BOXES
INTRODUCTION
Read this manual carefully to learn how to safely
install and operate your control box. Failure to do
so couldresult 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 precautionsas outlinedby the NationalElectric Codeand
all local codes.
Thecontrolboxis arainproof enclosure with apadlockable front cover. The enclosure is not de-
signed to be watertight, and should not be submerged. They are designed for use with 200, 230,
460, 575 or 380 volts, depending on your pump.
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 norpump integrity are compromised by the installation. Pumps and related
equipment must be installed and operated ac-
cording to all national, local and industry standards.
Ifthereareanyquestionsregardingthecontrolbox
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,
andphasein thespaces providedbelow.YourGorman-Ruppdistributor needs this informationwhen
you require parts or service.
Control Box:
Voltage:
Phase:
WARRANTY INFORMATION
The warrantyprovided with your control box ispart
ofGorman-Rupp’ssupportprogram 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 personnelto procedures which require special attention, to those
which could damage equipment, and to those
which could be dangerous to personnel:
Immediate hazards whichWILLresultin
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
INTRODUCTION
Hazards or unsafe practices which
COULDresult in severe personal injury
or death. These instructions describe
the procedure required and the injury
which could result fromfailure to follow
the procedure.
PAGE I -- 1
OM--04136CONTROL BOXES
damage which could result from failure to
follow the procedure.
HazardsorunsafepracticeswhichCOULD
resultinminor personalinjuryorproductor
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
SAFETY --- SECTION A
The following information applies
throughout this manual to GormanRupp Control Boxes.
CONTROL BOXESOM--04136
Because pump installationsare seldom
identical, this manual cannot possibly
provide detai led 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 destructionof equipment,inj ury,
or death to personnel.
Beforeconnectingany cable to thecontrol box, be sure to ground the control
box. See Section B for suggested
grounding methods.
The electrical power used to operate
thiscontrolbox is highenough tocause
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 ele ctrical 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
thiscontrolbox is highenough tocause
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,
beforeattempting toopen 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
breakeror overloadrelayis trippedduring operation, correct the problem before resetting or replacing.
SAFETY
Do not install and operate a non-explosion proof control box in an explosive
atmosphere. Install, connect, and operate the control box in accordance with
MSHA Schedule 2G. If there is a conflict
between the instructions in the manual
accompanying the unit and MSHA,
MSHA shall take precedence. All elec-
PAGE A -- 1
OM--04136CONTROL BOXES
tricalequipment supplied with this controlboxconformedtoapplicablefederal
regulations and national codes in effect
on the date of manufacture.
Obtain the services of a qualified electrician to troubleshoot, test and/or ser-
vice the electrical components of this
control box.
Do not attempt to repair individual components of the control box. Any component which fails should be replaced.
PAGE A -- 2
SAFETY
INSTALLATION --- SECTION B
GENERAL INFORMATION
Review all SAFETY information in Section A.
CONTROL BOXESOM--04136
Thissection is intended only to summarizerecommendedinstallationpracticesfor the controlbox.If
there are any questions concerning your specific
application,contact your Gorman-Ruppdistributor
or the Gorman-Rupp Company.
PREINSTALLATION INSPECTION
The control box was inspected before shipment
from the factory. Before installation, inspect the
controlfor damage which may have occurred during shipment. Check as follows:
a. Inspect thecontrolbox for cracks, dents, and
other obvious damage.
b. Checkthat allcontrolboxcomponentsarese-
curely attached to their mounting surfaces,
and that the electrical connections are tight
and free of corrosion.
c. Compare the amperes, phase, voltage and
hertzindicatedonthepump motornameplate
to the ratings indicated for the control box.
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.
Enclosure
Thecontrolboxis a NEMA Type3Rrainproofenclosurewithapadlockablefrontcover.Theenclosure
is not designed to be watertight, and should not
be submerged.
No mounting hardware is furnished with the controlbox. Securethe controlbox verticallyon alevel
surface, above flood level. The control should be
mounted on a flat surface. If the mounting surface
is not perfecting flat, it may be necessary to use
shims (not supplied) w ith the enclosure.The box
shouldbeeasilyaccessibleto theoperator, 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 determinethe repair policy. Do not put the controlbox
into service until appropriate action has been
taken.
CONTROL BOX INSTALLATION
The control box provides protection for the pump
motor against excessive heat due to motor overloads and failure to start, as well as short circuit
protection for incoming power lines.
INSTALLATION
Failure to mount the control box vertically
on a level surface may affect operation of
the pump controls.
Afterthe box issecurely installed, make certain t he
front cover latches properly before installing any
electrical lines.
CONTROL BOX DIMENSIONS
For the approximate physical dimensions of your
control box, refer to Figures B --- 1 t hru B --- 4.
PAGE B -- 1
OM--04136CONTROL BOXES
Figure B--1. 27515--503, 27515--504, 27515--513, 27515--514, 27515--524, 27515--534,
27515--543, 27515--544 And 27515--554 Control Box Dimensions
PAGE B -- 2
INSTALLATION
CONTROL BOXESOM--04136
Figure B--2. 27515--505, 27515--506, 27515--515, 27515--516, 27515--525, 27515--535,
27515--545 And 27515--546 Control Box Dimensions
INSTALLATION
PAGE B -- 3
OM--04136CONTROL BOXES
PAGE B -- 4
Figure B--3. 27515--507 And 27515--517 Control Box Dimensions
INSTALLATION
CONTROL BOXESOM--04136
INSTALLATION
Figure B--4. 27515--571 And 27515--572 Control Box Dimensions
PAGE B -- 5
OM--04136CONTROL BOXES
ELECTRICAL CONNECTIONS
Obtain the services of a qualified electrician to make all electrical connections and to service the control box.
Theelectricalpowerused in thiscontrol
box is high enough to c ause injury or
death. Make certain that the controlbox
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
Electricallygroundthe installationbefore connecting the field w iring to the control box. I nstall a
groundingterminaltothe enclosureand connect it
to a properly embedded electrode.
Thematerialusedfortheelectrodemustbe anexcellent conductor of electricity, such as copper. If
ironorsteelis used, it must be galvanizedorotherwise 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 recommendationsof N.E.C. ARTICLE 250. Followall installation
requirements of the N.E.C., and all applicable
codes. See Figure B---5 for some suggested
grounding methods.
SOIL
1/4 INCH (6,4 MM)
STEEL PLATE 2 SQ.
FEET (1858,1 SQ. CM)
SURFACE AREA
(MINIMUM)
Figure B--5. 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
(19,1mm)indiameterminimum,8feet (2,4m)
long, completely driven into the ground.
c. Buried electrode: If rock or stone prevents
embeddingthe full8 foot (2,4m) length ofthe
ground rod, bury it horizontally in a trench.
PAGE B -- 6
SOIL
3/4 INCH (19,1
MM) NOMINAL
DIAMETER
(MINIMUM)
8 FEET
(2,4 M)
SOIL
ROCK
3/4 INCH ( 19,1 MM)
NOMINAL DIAMETER
(MINIMUM) 8 FEET
(2,4 M) LONG
Space the ground rod or plates at least 6 feet
(1,8 m) from any other electrode or ground
rod, such as those usedfor signal circuits,radio grounds, lightning rods, etc.
Theearthsurroundingthegroundrod or plate
must contain enough moisture to make a
goodelectricalconnection.Indryorsandyareas, pour water around the rod, or consult
qualified personnel to devise a method of improving the connection.
INSTALLATION
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