GORMAN-RUPP PUMPS J Series Application guide

OM-03690-06

October 28, 2009

CER

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

www.grpumps.com

GORMAN-RUPP OF CANADA LIMITED ST. THOMAS, ONTARIO, CANADA Printed in U.S.A.

2009 The Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

J SERIES PUMPS

MODEL

JSV3A60−E2.7 230/1 JSV3B60−E2.7 230/1

JSV3C60−E2.7 230/1

SINGLE PHASE

Gorman-Rupp pump online at

www.grpumps.com

Valid serial number and e-mail address required.

RECORD YOUR PUMP MODEL AND SERIAL NUMBER

Please record your pump model and serial number in the

spaces provided below. Your Gorman-Rupp distributor

needs this information when you require parts or service.

Pump Model:

Serial Number:

OM−03690 JSV3A−B−C60 230/1

PAGE−1TOC

TABLE OF CONTENTS

INTRODUCTION PAGE I−1. . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY − SECTION A PAGE A−1. . . . . . . . . . . . . . . . . . . . .

INSTALLATION − SECTION B PAGE B−1. . . . . . . . . . . . . .

PREINSTALLATION INSPECTION PAGE B−1. . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Dimensions PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Motor Specifications PAGE B−3. . . . . . . . . . . . . . . . . . . . . . .

PUMP INSTALLATION PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Pump PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS PAGE B−3. . . . . . . . . . . . . . . . . . . . . . .

Field Wiring Connections (Incoming Power) PAGE B−4. . . . . . . .

Voltage Limits PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Cable Grounding Test PAGE B−4. . . . . . . . . . . . . . . . . . . . .

Conductor Identification PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Connections PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . .

Liquid Level Devices PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram PAGE B−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION − SECTION C PAGE C−1. . . . . . . . . . . . . . . .

PERFORMANCE CURVES PAGE C−1. . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROLS PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP OPERATION PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature and Overheating. PAGE C−4. . . . . . . . . . . . .

Impeller Rotation PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−5.

Starting PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operational Checks PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C−6. . . . . . . . . . . . . . . . . . . . . . .

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−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor and Power Cable Continuity PAGE D−3. . . . . . . . . . . . . . . .

Insulation Resistance PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

JSV3A−B−C60 230/1 OM−03690

TOCPAGE−2

MAINTENANCE & REPAIR − SECTION E PAGE E−1. . . .

PARTS LISTS:

Pump Models PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Assemblies PAGE E−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND MOTOR DISASSEMBLY AND REASSEMBLY PAGE E−6

PUMP END DISASSEMBLY PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Volute Casing PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . .

Removing Impeller PAGE E−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Seal Assembly PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . .

MOTOR DISASSEMBLY PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Motor Cover PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . .

Removing Rotor and Shaft Assembly PAGE E−8. . . . . . . . . . . . . .

Removing Bearings PAGE E−8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION AND CLEANING PAGE E−8. . . . . . . . . . . . . . . . . . . . . . .

Bearings PAGE E−8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Reusable Parts (Except Seal Assembly) PAGE E−8. . . . . .

Cleaning Seal Assembly PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND MOTOR REASSEMBLY PAGE E−9. . . . . . . . . . . . . . . . . . .

MOTOR REASSEMBLY PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Bearings PAGE E−9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Shaft and Rotor Assembly PAGE E−10. . . . . . . . . . . . . . .

Installing Motor Cover PAGE E−10. . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP END REASSEMBLY PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Seal Assembly PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . .

Seal Testing PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Impeller PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Volute Casing PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition Of Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding Oil PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM−03690 J SERIES

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.

The manual applies only to the submersible pump

models listed on the cover and in MAINTENANCE

AND REPAIR − SECTION E. Refer to the name-

plate on your pump to determine the specific

model, voltage, and horsepower.

The pump is driven by a waterproof electric motor.

The pump motor must be operated through an ap-

propriate control box matching the voltage and

other characteristics of the motor. The control box

must also provide for proper operation of the motor

protection devices such as the integral moisture

and thermal switches. Control boxes and other

control devices other than those integral to the

pump motor are not covered in this manual. Refer

to other literature accompanying the pump.

Pump construction is cast iron, with stainless steel

shaft and hardware. This pump is equipped with

an integral guide shoe which engages an optional

base elbow with a 3-inch discharge. The pump is

designed to handle raw, unscreened sewage and

effluents with solids up to 3.15 inches (80 mm) in

diameter.

If there are any questions regarding the pump or

motor which are not covered in this manual or in

other literature accompanying this unit, please

contact your Gorman-Rupp distributor or the Gor-

man-Rupp Company:

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

Phone: (419) 755−1011

or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

Phone: (519) 631−2870

The following are used to alert personnel to proce-

dures 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 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.

Hazards or unsafe practices which COULD

result in minor personal injury or product or

property damage. These instructions de-

scribe the requirements and the possible

damage which could result from failure to

follow the procedure.

NOTE

Instructions to aid in installation, operation, and

maintenance or which clarify a procedure.

OM−03690 J SERIES

PAGE A − 1SAFETY

SAFETY − SECTION A

This information is specific to the Gorman-Rupp J

Series Submersible pump listed on the cover and

in MAINTENANCE AND REPAIR − SECTION E.

It applies throughout this manual to the instruc-

tions contained in the pages which follow.

In addition to this manual, see the separate litera-

ture covering the control box and other control ac-

cessories which will be used with this pump. This

literature contains essential information on install-

ing and operating the pump, and on making elec-

trical connections.

Before attempting to install, operate, or

service this pump, familiarize yourself

with this manual, and with all other liter-

ature shipped with the pump. Unfamil-

iarity with all aspects of pump operation

covered in this manual could lead to de-

struction of equipment, injury, or death.

This pump is designed to handle raw

sewage and industrial wastes at tem-

peratures of 104F (40C); do not apply

at higher temperatures. Do not attempt

to pump volatile, flammable, or corro-

sive liquids which may damage the

pump or endanger personnel as a result

of pump failure.

The electrical power used to operate

this pump is high enough to cause inju-

ry or death. Obtain the services of a qu-

alified electrician to make all electrical

connections.

Do not connect the pump motor directly

to the incoming power lines. The pump

motor is designed to operate through a

Gorman-Rupp approved control box

which provides overload protection and

power control; otherwise, the pump

warranty will be voided. Make certain

that the pump and control box are prop-

erly grounded and that the incoming

power matches the requirements of the

pump and controls. Install and operate

the control box in accordance with the

National Electric Code and all local

codes. Failure to follow the instructions

in this warning could result in injury or

death to personnel.

Do not attempt to lift this pump by the

motor power cable or the piping. Attach

proper lifting equipment to the lifting

handle, and make certain that the hook

of the lifting device is securely posi-

tioned in the apex of the handle. If

chains or cables are wrapped around

the pump to lift it, make certain that they

are positioned so as not to damage the

pump, and so that the load will be bal-

anced.

After the pump has been installed, make

certain that the pump and all piping or

hose connections are secure before op-

eration. Loose connections can result in

J SERIES OM−03690

SAFETYPAGE A − 2

damage to equipment and serious inju-

ry to personnel.

The following precautions should be

taken before attempting to open or ser-

vice the pump; otherwise, injury or

death could result.

1. Lock out the power to the control

panel to ensure that the pump will

remain inoperative.

2. Allow the pump to cool if over-

heated.

3. Close the discharge valve (if

used).

If this pump is used to handle sewage,

take necessary precautions during

maintenance and repair to prevent per-

sonal contamination which could result

in illness.

OM−03690 J SERIES

PAGE B − 1INSTALLATION

INSTALLATION − SECTION B

Review all SAFETY information in Section A.

This section is intended only to summarize recom-

mended installation practices for this pump. If

there are any questions concerning your specific

installation, contact your Gorman-Rupp distributor

of the Gorman-Rupp Company.

The motor in these pumps is not designed

to be operated in air for more than 10 min-

utes without overheating. The pumps must

be operated through liquid level controls to

maintain the level of liquid in the wet well so

that power to the motor is cut off when liq-

uid falls below the midpoint of the motor

housing in single pump operation, and be-

low the level of the discharge flange in du-

plex pump operation.

Automatic liquid level controls are available from

Gorman-Rupp as options. For information on in-

stalling and operating these controls, see the tech-

nical data accompanying them.

PREINSTALLATION INSPECTION

The pump assembly was inspected and tested be-

fore shipment from the factory. Before installation,

check for damage which may have occurred dur-

ing shipment. Check as follows:

a. Inspect the pump assembly for cracks, 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 loose hardware at mating sur-

faces.

c. The standard pump is provided with 26 ft. (8

m.) of power cable. Inspect the cable for cuts

or damage.

d. Check that amperes, phase, voltage, and

Hertz indicated on the motor name plate

match the ratings on the control box.

e. Carefully read all tags, decals, and markings

on the pump assembly, and perform all duties

indicated.

f. Check for any oil leaks. If there is any indica-

tion of an oil leak, see LUBRICATION in

MAINTENANCE AND REPAIR − SECTION

LUBRICATION

These pumps are equipped with a mechanical

double seal. The lower seal prevents the liquid be-

ing pumped from entering the seal housing cavity

from the pump end. The upper seal prevents oil

from escaping from the seal housing into the motor

housing, and acts as backup protection in the

event of lower seal failure.

Both ends of the shaft seal are lubricated by oil in

the seal housing (see LUBRICATION in MAINTE-

NANCE AND REPAIR − SECTION E).

The shaft bearings are permanently lubricated.

There is no other lubrication in the pump.

Pump Dimensions

See Figure B-1 for the approximate physical di-

mensions of this pump.

J SERIES OM−03690

PAGE B − 2 INSTALLATION

FIGURE B−1. PUMP DIMENSIONS

OM−03690 J SERIES

PAGE B − 3INSTALLATION

Pump Motor Specifications

The motor furnished with this pump is a 60 Hz.,

Squirrel Cage, Induction Start, G-R Frame Size No.

1; Class F Insulation Rated 155C (311F), 40C

(104F) ambient, plus 115C (239F) temperature

rise.

See Table B−1 for motor specifications.

TABLE B-1. PUMP MOTOR SPECIFICATIONS

MODEL VOLTAGE SIZE

RPM

MOTOR MAX NO LOCKEDH.P.

NUMBER LOAD LOAD ROTOR

JSV3A60−E2.7 230/1 3" 2.7 1750 11.9A

/PHASE

JSV3B60−E2.7 230/1 3" 2.7 1750

JSV3C60−E2.7 230/1 3" 2.7 1750

N/A 39.3

39.3

11.9A

N/A

PUMP INSTALLATION

Lifting

Pump unit weights will vary depending on the

mounting and drive provided. Check the shipping

tag on the unit packaging for the actual weight, 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.

Positioning the Pump

NOTE

Before installing and operating the pump, check

the direction of impeller rotation to ensure that the

pump is properly wired at the control box. See IM-

PELLER ROTATION, SECTION C.

This pump is provided with a 3-inch discharge

hose connection.

This pump is designed to be operated mounted on

guide rails and a discharge elbow/baseplate of-

fered as an option. See Figure B−1 for a typical el-

bow/baseplate installation.

The pump is equipped with a rail guide shoe which

connects to the discharge optional elbow/

baseplate. When lowered into place, the pump is

automatically and securely connected to the el-

bow/baseplate and the piping system. For infor-

mation on installing the guide rails, see the litera-

ture accompanying them.

NOTE

When engaging the guide shoe and elbow/base-

plate, make sure that the connection is not impeded

by mounting hardware, and that the guide shoe is

fully seated in the baseplate.

Engage the guide shoe at the top of the guide rails,

and lower the pump into the sump. When the

pump and guide shoe engages the discharge el-

bow/baseplate, it will form an automatic seal.

Reel in any slack control cable so that it is not

dragged into the pump suction.

Piping

NOTE

Refer to PERFORMANCE CURVES in OPERA-

TION − SECTION C when determining the most ef-

ficient piping installation.

No suction piping is required in a standard sub-

merged operation.

The optional elbow/baseplate is drilled for a

3−inch or 4−inch discharge flange connection.

Either hose or rigid pipe may be used to make dis-

charge connections. The discharge line must be

independently supported to avoid vibration and

strain on the pump. For maximum pumping capac-

This manual suits for next models

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