GORMAN-RUPP PUMPS JSV3H60-E5 230/1 Application guide

OM−05229−OM01

February 22, 2001

Rev. C 05-30-03

CER

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

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

INSTALLATION, OPERATION,

AND MAINTENANCE MANUAL

WITH PARTS LIST

SUBMERSIBLE PUMPS

MODEL

JSV3H60−E5 230/1

OM−05229 JSV3H

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 Motor Specifications PAGE B−1. . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP INSTALLATION PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Positioning the Pump PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping. PAGE B−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS PAGE B−2. . . . . . . . . . . . . . . . . . . . . . .

Field Wiring Connections (Incoming Power) PAGE B−3. . . . . . . .

Motor Cable Grounding Test PAGE B−3. . . . . . . . . . . . . . . . . . . . .

Conductor Identification PAGE B−3. . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram and Control Box Connections PAGE B−3. . . . .

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

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

PERFORMANCE CURVE PAGE C−1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROLS PAGE C−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP OPERATION PAGE C−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature and Overheating. PAGE C−2. . . . . . . . . . . . .

Impeller Rotation PAGE C−2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−3.

Starting PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operational Checks PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Preservation PAGE C−4. . . . . . . . . . . . . . . . . . . . . . .

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

JSV3H OM−05229

PAGE 2 TOC

MAINTENANCE AND REPAIR − SECTION E PAGE E−1.

PARTS LISTS:

Pump Model PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Assembly PAGE E−5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND MOTOR DISASSEMBLY 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 Assemblies) 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−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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−05229 JSV3H

PAGE I − 1

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 shipped

from the factory wired only for the voltage shown

on the nameplate.

The pump motor is designed to be operated

through an appropriate 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. These J Series pumps are

equipped with an integral guide shoe which en-

gages an optional base elbow with a 3−inch dis-

charge; they will handle solids up to 3.15 inches

(80 mm) in diameter. They are designed to operate

fully or partially submerged mounted on guide rails

installed in a wet well, and to handle raw, un-

screened 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−05229 JSV3H

PAGE A − 1SAFETY

SAFETY − SECTION A

These warnings are 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 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.

This pump is wired at the factory only for

the voltage shown on the nameplate. Do

not attempt to run the pump on alternate

voltage. Otherwise, damage to the

pump and injury 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

the pump to lift it, make certain that they

are positioned so as not to damage the

OM−05229JSV3H

PAGE A − 2 SAFETY

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.

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.

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 completely cool if

over heated.

3. Close the discharge valve (if used).

JSV3HOM−05229

PAGE B − 1

INSTALLATION

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.

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 grease lubricated.

There is no other lubrication in the pump.

Pump Motor Specifications

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

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

2; 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

LOAD

AMPS

LOCKED

ROTOR

AMPS

H.P.

NUMBER

JSV3H60−E5 230/1 3" 5 1750 23.3A 5.8A 52.0A

/PHASE

LOAD

AMPS

OM−05229JSV3H

PAGE B − 2 INSTALLATION

PUMP INSTALLATION

Lifting

Use lifting equipment with a capacity of at least 990

lbs. (450 kg.). This pump weighs approximately

198 lbs. (90 kg.), including the weight of standard

cable, but not including the weight of customer-

installed accessories such as piping. Discharge

hose or piping must be removed before attempting

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 with an automatic sub-

mersible connection which allows the pump to be

removed and/or installed without personnel enter-

ing the wet well.

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. See Figure

B−1 for a typical elbow/baseplate installation. For

information on installing the guide rails, see the lit-

erature 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 discharge flange connection. Either hose

or rigid pipe may be used to make discharge con-

nections. The discharge line must be independ-

ently supported to avoid vibration and strain on the

pump. For maximum pumping capacity, keep the

line as short and straight as possible. Elbows and

fittings used in a discharge line increase 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.

JSV3HOM−05229

PAGE B − 3

INSTALLATION

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

3200 180 220

PHASE MINIMUM

VOLTAGE

MAXIMUM

VOLTAGE

3230 205 260

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.

Motor Cable Grounding Test

Do not connect the pump control cable

to the control box or incoming voltage

before verifying the pump ground;

otherwise, personnel will be exposed to

serious injury or death.

Connect one lead of lamp, bell or similar testing de-

vice to motor cable green/yellow ground lead.

Connect second test lead to an uninsulated point

on the pump body. The test circuit should close.

If the test circuit does not close there is a defect in

the cable or motor which must be corrected.

Conductor Identification

The conductors in the pump cable are labeled

when shipped from the factory. If the conductors

are shortened in the field, resulting in loss of identi-

fication markers, they can still be identified by their

location relative to the ground wire.

Refer to FIGURE B−1; as seen from the free end of

the cable, the conductor immediately adjacent to

and clockwise from ground (green/yellow) is as-

signed number T1. The second clockwise conduc-

tor is T2, etc.

The conductors labeled P1 and P2 are for thermal

and moisture sensor connections, respectively.

If the conductors are relabled, they should be iden-

tified with wire markers from the factory.

Wiring Diagram and Control Box Connections

The pump warranty is void if the motor is

not operated through a control box ap-

proved by Gorman-Rupp.

This pump is shipped completely wired for the volt-

age shown on the nameplate, and is ready for op-

eration through an approved control box.

Ground the control box in accordance with the in-

structions accompanying it.

Refer to FIGURE B−1, and wire the motor to a con-

trol which will provide the connections shown.

Control leads P1 and P2 provide the motor with

moisture and thermal protection. Note that thermal

protection is supplementary only; separate Class

10 overload relays are required for motor running

protection.

The thermal protection contacts will auto-

matically reclose when the motor cools to

the established safe operating tempera-

ture. Whenever automatic restarting is not

desirable, connect only to controls which

are wired for manual restart.

OM−05229JSV3H

PAGE B − 4 INSTALLATION

FIGURE B−1. INTERNAL MOTOR WIRING

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