GORMAN-RUPP PUMPS JSV3A60-E2.7 200/3 Application guide

OM-03626−OM04

March 21, 1997

Rev. B 01/22/01

CDER

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

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

Copyright by the Gorman-Rupp Company

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUBMERSIBLE PUMPS

JSV3A60−E2.7 200/3 JSV3A60−E2.7 230/3 JSV3A60−E2.7 460/3 JSV3A60−E2.7 575/3

JSV3B60−E2.7 200/3 JSV3B60−E2.7 230/3 JSV3B60−E2.7 460/3 JSV3B60−E2.7 575/3

JSV3C60−E2.7 200/3 JSV3C60−E2.7 230/3 JSV3C60−E2.7 460/3 JSV3C60−E2.7 575/3

JSV3D60−E4 200/3 JSV3D60−E4 230/3 JSV3D60−E4 460/3 JSV3D60−E4 575/3

MODELS

OM−03626 JSV3A−B−C−D60 DV

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−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS PAGE B−4. . . . . . . . . . . . . . . . . . . . . . .

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

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

Dual Voltage PAGE B−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Conductor Identification PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . . .

Control Box Connections PAGE B−5. . . . . . . . . . . . . . . . . . . . . . . .

Liquid Level Devices PAGE B−6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

CONTROL BOX AND OPTIONAL CONTROLS PAGE C−5. . . . . . . . . .

PUMP OPERATION PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature and Overheating. PAGE C−5. . . . . . . . . . . . .

Impeller Rotation PAGE C−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−6.

Starting PAGE C−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping PAGE C−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operational Checks PAGE C−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C−7. . . . . . . . . . . . . . . . . . . . . . .

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−C−D60 DV OM−03626

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−03626 JSV3A−B−C−D60

PAGE I − 1INTRODUCTION

INTRODUCTION

This Installation, Operation, and Maintenance

Manual is designed to help you achieve the best

performance and longest life from your Gorman-

Rupp J Series submersible 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.

These J Series pumps are driven by a waterproof

submersible electric motor. The motor is dual volt-

age, but is shipped from the factory wired only for

the voltage shown on the nameplate. Contact the

factory before attempting to change to the alter-

native voltage.

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.

Pump construction is cast iron, with stainless steel

shaft and hardware. These pumps are equipped

with an integral guide shoe which engages an op-

tional base elbow with a 3−inch discharge; they

will handle solids up to 3−inches in diameter. The

pumps are designed to operate fully or partially

submerged mounted on guide rails installed in a

wet well, and to handle raw, unscreened sewage

and effluents. Installation of the guide rail system

and other wet well hardware is not covered in this

manual. Refer to other literature accompanying the

pump.

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 or Gorman-Rupp of Canada Limited

P.O. Box 1217 70 Burwell Road

Mansfield, Ohio 44901−1217 St. Thomas, Ontario N5P 3R7

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 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−03626 JSV3A−B−C−D60

PAGE A − 1SAFETY

SAFETY − SECTION A

This information is specific to the Gorman-Rupp J

Series Submersible pumps listed on the cover and

in MAINTENANCE AND REPAIR − SECTION E.

They apply throughout this manual to the in-

structions contained in the pages which follow.

In addition to this manual, see the separate litera-

ture covering the control box, control accessories,

guide rails and other installation hardware

shipped with this pump. This literature contains

essential information on installing and operating

the pump, and on making electrical 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 (70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.

This pump is dual voltage, 230/460−3

phase. Your pump was wired at the fac-

tory only for the voltage shown on the

nameplate. Do not attempt to change

the voltage in the field. If desired to

have the voltage changed, return the

pump to the factory or to an authorized

Gorman-Rupp repair facility only.

Otherwise, damage to the pump and in-

jury or death to personnel can result.

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

JSV3A−B−C−D60 OM−03626

PAGE A−2 SAFETY

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

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 pan-

el 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−03626 JSV3A−B−C−D60

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

or 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.

JSV3A−B−C−D60 OM−03626

PAGE B − 2 INSTALLATION

FIGURE B−1. PUMP DIMENSIONS 16020

OM−03626 JSV3A−B−C−D60

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.

575/3

JSV3C60−E2.7

TABLE B-1. PUMP MOTOR SPECIFICATIONS

MODEL VOLTAGE SIZE

RPM

MOTOR MAX NO LOCKEDH.P.

NUMBER LOAD LOAD ROTOR

JSV3A60−E2.7

200/3

460/3

2.7

1750

11.0A 6.0A 51.7A

/PHASE

3.8A 2.8A 22.5A

JSV3B60−E2.7

230/3

460/3

2.7

1750

8.4A 5.9A 47.0A

4.0A 2.8A 22.5A

JSV3C60−E2.7

230/3

460/3

2.7

1750

9.6A 5.9A 47.0A

4.6A 2.8A 22.5A

JSV3D60−E4

230/3

460/3

4.0

1750

12.8A 5.9A 48.1A

6.1A 2.8A 22.9A

JSV3A60−E2.7 575/3 3" 2.7 1750 3.0A 2.2A 18.0A

JSV3B60−E2.7 575/3 3" 2.7 1750 3.0A 2.2A 18.0A

3" 2.7 1750 3.0A 2.2A 18.0A

JSV3D60−E4 575/3 3" 4.0 1750 3.0A 2.2A 18.0A

JSV3D60−E4 200/3 3" 4.0 1750 11.1A 5.1A 41.8A

JSV3C60−E2.7 200/3 3" 2.7 1750 8.4A 5.1A 41.0A

JSV3B60−E2.7 200/3 3" 2.7 1750 7.3A 5.1A 41.0A

JSV3A60−E2.7 230/3 3" 2.7 1750 7.9A 5.9A 47.0A

PUMP INSTALLATION

Lifting

Use lifting equipment with a capacity of at least 660

lbs. (300 kg.). Each version of these pumps

weighs approximately 132 lbs. (60 kg.), including

the weight of standard cable, but not including the

weight of customer-installed accessories such as

the elbow/baseplate and discharge piping. Dis-

charge hose or piping must be removed before at-

tempting to lift the pump.

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 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

JSV3A−B−C−D60 OM−03626

PAGE B − 4 INSTALLATION

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-

ity, keep the line as short and straight as possible.

Elbows and fittings used in a discharge line in-

crease friction losses; minimize their use.

It is recommended that a check valve or throttling

valve be installed in the discharge line to control si-

phoning or back flow when the pump is shut off.

ELECTRICAL CONNECTIONS

Install and operate this pump in accor-

dance with the National Electrical Code

and all local codes. Have a qualified

electrician perform all checks and con-

nections in this section.

Never attempt to alter the length of the

pump motor cable or to repair it with a

splice. The power cable and pump mo-

tor must be kept completely waterproof.

Serious damage to the pump and injury

or death to personnel can result from

any alteration to the cable.

Field Wiring Connections (Incoming Power)

Field wiring is not provided with this pump, and

must be supplied by the user. The field wiring must

be of the proper size and type to ensure an ade-

quate voltage supply to the pump. Voltage avail-

able at the motor must be within the range indi-

cated in Table B-2.

TABLE B-2. MOTOR VOLTAGE LIMITS

NOMINAL

VOLTAGE

3230 210 250

PHASE MINIMUM

VOLTAGE

MAXIMUM

VOLTAGE

3460 420 500

3575 520 630

3200 180 220

Use conduit cable clamps to secure the incoming

field wiring to the control box. Make certain all con-

nections are tight. If necessary, support the cable

weight to prevent excessive strain on cable clamps

and cable.

Dual Voltage

230V and 460V versions of this pump are

dual-voltage; however, they are wired at

the factory only for the voltage shown on

the nameplate. Do not attempt to

change the voltage in the field. If de-

sired to have the voltage changed, re-

turn the pump to the factory or to an au-

thorized Gorman-Rupp repair facility

only. Otherwise, damage to the pump

and injury or death to personnel can re-

sult.

This manual suits for next models

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