GORMAN-RUPP PUMPS JDV4A60-E2.7 200/3 Bedienungsanleitung

OM−03500−OM06

December 14, 2006

THE GORMAN-RUPP COMPANY MANSFIELD, OHIO

www.grpumps.com

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

MODELS

JDV4A60−E2.7 200/3 JDV4A60−E2.7 230/3 JDV4A60−E2.7 460/3

JDV4B60−E2.7 200/3 JDV4B60−E2.7 230/3 JDV4B60−E2.7 460/3

JDV4C60−E2.7 200/3 JDV4C60−E2.7 230/3 JDV4C60−E2.7 460/3

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:

JDV4A−B−COM−03500

TOC PAGE−1

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−5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram PAGE B−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

CONTROL BOX AND OPTIONAL 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−5. . . . . . . . . . . . . . . . . . . . . . .

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

OM−03500JDV4A−B−C

TOC

PAGE−2

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

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 Pump From Stand 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. . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Pump on Stand PAGE E−14. . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

OM−03500JDV SERIES

PAGE I − 1

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. This Installation, Operation, and Mainte-

nance Manual is designed to help you achieve the

best performance and longest life from your Gor-

man-Rupp J Series submersible pump.

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. On dual voltage models, con-

tact the factory before attempting to change to

the alternative 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. Refer

to other literature accompanying the pump.

Pump construction is cast iron, with stainless steel

shaft and hardware. These pumps have a 4−inch

discharge, and will handle solids up to 3 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.

JDV SERIES OM−03500

PAGE A − 1

SAFETY

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 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.

230/460 volt models are dual-voltage;

however, they are wired at the factory

only for the voltage shown on the name-

plate. Do not attempt to change the volt-

age 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 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

OM−03500 JDV SERIES

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.

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 cool if over heated.

3. Close the discharge valve (if used).

JDV SERIES OM−03500

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 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.

OM−03500 JDV SERIES

PAGE B − 2 INSTALLATION

FIGURE B−1. PUMP DIMENSIONS

JDV SERIES OM−03500

PAGE B − 3

INSTALLATION

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

JDV4A60−E2.7

230/3

460/3

2.7

1750

9.0A 4.8A 55.8A

/PHASE

4.5A 2.4A 27.9A

JDV4B60−E2.7

230/3

460/3

2.7

1750

JDV4C60−E2.7

230/3

460/3

2.7

1750

9.0A 4.8A 55.8A

4.5A 2.4A 27.9A

9.0A 4.8A 55.8A

4.5A 2.4A 27.9A

JDV4C60−E2.7 200/3 4" 2.7 1750

JDV4B60−E2.7 200/3 4" 2.7 1750

JDV4A60−E2.7 200/3 4" 2.7 1750 10.3A 5.5A 64.2A

10.3A 5.5A 64.2A

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 designed to be mounted on a stand in

a dry pit with an optional 4 x 6 inch suction elbow.

See Figure B−1 for a typical stand/elbow installa-

tion.

Refer to Section E, Figure E−1. Install and secure

the stand in the floor of the dry pit. Install the upper

seal (79) on the stand, and position the pump on

the stand. Install the lower seal on the suction el-

bow, and secure the elbow to the stand and pump

with the screws (21).

Align the elbow with the system suction piping, and

secure. Align the volute casing flange with the sys-

tem discharge piping, and secure.

Reel in any slack control cable, and wire the motor

as indicated in the wiring diagrams in this section.

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