Om 04136
Om 04136
INSTALLATION AND
OPERATION MANUAL
WITH PARTS 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
GORMAN‐RUPP PUMPS
www.grpumps.com
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE I - 1
i
OM-04136 CONTROL BOXES
INTRODUCTION
Read this manual carefully to learn how to safely RECORD CONTROL BOX NUMBER
install and operate your control box. Failure to do
so could result in personal injury or damage to the Please record the control box number, voltage,
control box or the pump. and phase in the spaces provided below. Your Gor
man‐Rupp distributor needs this information when
This manual does not include maintenance in you require parts or service.
structions. Have a qualified electrician perform all
maintenance. Be sure to follow all safety precau Control Box:
tions as outlined by the National Electric Code and
Voltage:
all local codes.
Phase:
The control box is a rainproof enclosure with a pad
lockable front cover. The enclosure is not de
signed to be watertight, and should not be sub
WARRANTY INFORMATION
merged. They are designed for use with 200, 230,
460, 575 or 380 volts, depending on your pump. The warranty provided with your control box is part
The integral electric motor of the submersible of Gorman‐Rupp's support program for customers
pump must be operated through the control box. who operate and maintain their equipment as de
The control box is not explosion‐proof and should scribed in this and the other accompanying litera
not be operated in a hazardous atmosphere. ture. Please note that should the equipment be
abused or modified to change its performance be
Because pump installations are seldom identical, yond the original factory specifications, the war
ranty will become void and any claim will be de
this manual cannot possibly provide detailed in
nied.
structions and precautions for every aspect of
each specific application. Therefore, it is the re
sponsibility of the owner/installer of the pump to The following are used to alert personnel to proce
dures which require special attention, to those
ensure that applications not addressed in this
which could damage equipment, and to those
manual are performed only after establishing that
which could be dangerous to personnel:
neither operator safety nor pump integrity are com
promised by the installation. Pumps and related
equipment must be installed and operated ac
cording to all national, local and industry stan
dards.
Immediate hazards which WILL result in
If there are any questions regarding the control box
severe personal injury or death. These
which are not covered in this manual or in other lit
erature accompanying the unit, please contact instructions describe the procedure re
your Gorman‐Rupp distributor or the Gorman‐ quired and the injury which will result
Rupp Company: from failure to follow the procedure.
INTRODUCTION PAGE I - 1
CONTROL BOXES OM-04136
PAGE I - 2 INTRODUCTION
OM-04136 CONTROL BOXES
SAFETY - SECTION A
The following information applies
throughout this manual to Gorman‐
Rupp Control Boxes.
Because pump installations are seldom The electrical power used to operate
identical, this manual cannot possibly this control box is high enough to cause
provide detailed instructions and pre injury or death. Obtain the services of a
cautions for each specific application. qualified electrician to make all electri
Therefore, it is the owner/installer's re cal connections. Make certain that the
sponsibility to ensure that applications enclosure is properly grounded; never
not addressed in this manual are per use gas pipe as an electrical ground. Be
formed only after establishing that nei sure that the incoming power matches
ther operator safety nor pump integrity the voltage and phase of the control be
are compromised by the installation. fore connecting the power source. Do
not make electrical connections if the
voltage is not within the limits. If the
overload unit is tripped during opera
tion, correct the problem before restart
Before attempting to install, operate, or ing.
wire this control box, familiarize your
self 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 The electrical power used to operate
lead to destruction of equipment, injury, this control box is high enough to cause
or death to personnel. 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,
Before connecting any cable to the con before attempting to open or service the
trol box, be sure to ground the control control box. Tag electrical circuits to
box. See Section B for suggested prevent accidental start‐up.
grounding methods.
SAFETY PAGE A - 1
CONTROL BOXES OM-04136
trical equipment supplied with this con vice the electrical components of this
trol box conformed to applicable federal control box.
regulations and national codes in effect
on the date of manufacture.
PAGE A - 2 SAFETY
OM-04136 CONTROL BOXES
INSTALLATION - SECTION B
GENERAL INFORMATION
This section is intended only to summarize recom The control box furnished with the
mended installation practices for the control box. If pump is designed to operate the pump.
there are any questions concerning your specific The control box provides overload pro
application, contact your Gorman‐Rupp distributor tection and power control. Do not con
or the Gorman‐Rupp Company.
nect the pump motor directly to the in
coming power lines.
PREINSTALLATION INSPECTION
Enclosure
The control box was inspected before shipment
from the factory. Before installation, inspect the The control box is a NEMA Type 3R rainproof enclo
control for damage which may have occurred dur sure with a padlockable front cover. The enclosure
ing shipment. Check as follows: is not designed to be watertight, and should not
be submerged.
a. Inspect the control box for cracks, dents, and
other obvious damage. No mounting hardware is furnished with the con
trol box. Secure the control box vertically on a level
b. Check that all control box components are se
surface, above flood level. The control should be
curely attached to their mounting surfaces,
mounted on a flat surface. If the mounting surface
and that the electrical connections are tight
is not perfecting flat, it may be necessary to use
and free of corrosion.
shims (not supplied) with the enclosure.The box
c. Compare the amperes, phase, voltage and should be easily accessible to the operator, and lo
hertz indicated on the pump motor nameplate cated close enough to the pump to avoid exces
to the ratings indicated for the control box. sive voltage drop due to cable length.
The control box provides protection for the pump CONTROL BOX DIMENSIONS
motor against excessive heat due to motor over
loads and failure to start, as well as short circuit For the approximate physical dimensions of your
protection for incoming power lines. control box, refer to Figures B-1 thru B-4.
INSTALLATION PAGE B - 1
CONTROL BOXES OM-04136
PAGE B - 2 INSTALLATION
OM-04136 CONTROL BOXES
INSTALLATION PAGE B - 3
CONTROL BOXES OM-04136
PAGE B - 4 INSTALLATION
OM-04136 CONTROL BOXES
INSTALLATION PAGE B - 5
CONTROL BOXES OM-04136
8 FEET ROCK
1/4 INCH (6,4 MM)
3/4 INCH (19,1 (2,4 M)
STEEL PLATE 2 SQ.
MM) NOMINAL
FEET (1858,1 SQ. CM) 3/4 INCH (19,1 MM)
DIAMETER
SURFACE AREA NOMINAL DIAMETER
(MINIMUM)
(MINIMUM) (MINIMUM) 8 FEET
(2,4 M) LONG
Figure B-5. Suggested Grounding Methods
a. Plate Electrode: An iron or steel plate, 1/4 Space the ground rod or plates at least 6 feet
inch (6,4 mm) thick, completely impeded in (1,8 m) from any other electrode or ground
the ground. The plate must present a surface rod, such as those used for signal circuits, ra
area of at least 2 square feet (1858,1 sq. cm). dio grounds, lightning rods, etc.
b. Driven Electrode: A rod or pipe, 3/4 inch
The earth surrounding the ground rod or plate
(19,1 mm) in diameter minimum, 8 feet (2,4 m)
must contain enough moisture to make a
long, completely driven into the ground.
good electrical connection. In dry or sandy ar
c. Buried electrode: If rock or stone prevents eas, pour water around the rod, or consult
embedding the full 8 foot (2,4 m) length of the qualified personnel to devise a method of im
ground rod, bury it horizontally in a trench. proving the connection.
PAGE B - 6 INSTALLATION
OM-04136 CONTROL BOXES
The electrical power used to operate The electrical power used to operate the
this pump is high enough to cause inju control box is high enough to cause in
ry or death. Obtain the services of a qu jury or death. Obtain the services of a
alified electrician to make all electrical qualified electrician to make all electri
connections. Make certain that the cal connections. Make certain that in
pump and enclosure are properly coming power to the control box is in the
grounded; never use gas pipe as an off position and locked out, or that the
electrical ground. Be sure that the in power supply to the control box has
coming power matches the voltage and been otherwise cut off and locked out,
phase of the pump and control before before connecting power or accessory
connecting the power source. Do not cables.
run the pump if the voltage is not within When necessary to change or connect power
the limits. cables to the control box, make certain the incom
ing power is OFF and LOCKED OUT. Make certain
The control is designed to regulate the power sup the control box is properly grounded and that the
ply. The field wiring must be properly sized to en electrical data on the control matches the pump
sure an adequate voltage supply. The voltage motor name plate data.
available at the pump motor must be within the in
dicated range. Connect the power cable to the control box as
shown in the wiring diagrams in this section or in
Table 1. Pump Motor Voltage Limits side the control box door. Use conduit or cable
clamps to secure the power and accessory cables
Nominal Minimum Maximum
Voltage Phase Voltage Voltage to the control box. Make certain that all connec
tions are tight and that cable entry points are
200 3 180 220
rainproof.
230 3 210 250
380 (50 Hz) 3 350 420 Control Box Adjustments
460 3 420 500 For control adjustments and settings, refer to the
575 3 520 630 information inside the control box door.
INSTALLATION PAGE B - 7
CONTROL BOXES OM-04136
PAGE B - 8 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-9. Control Boxes 27515-503, 27515-513 And 27515-543 Elementary Wiring Diagram
REPAIR PARTS LIST
ITEM PART NAME C H PART QTY ITEM PART NAME C H PART QTY
NO. NUMBER NO. NUMBER
1 CIRCUIT BREAKER 30 AMPS HMCP030H1C 1 11 TERMINAL BLOCK 80-5817 2
2 MOTOR STARTER AN16DNOAB 1 12 H-O-A SELECTOR SWITCH 10250T21KB 1
3 CONTACTOR - 3 POLE CN15DN3AB 1 13 “HAND‐OFF‐AUTO” LGND PLT 10250TM51 1
4 RENEWAL CONTACT SET 6-65-2 1 14 OPT LIQ LVL CONTROL RELAY A999AY574 1
5 COIL 9-2703-1 1 15 SECONDARY FUSE 44-796-5 1
6 OVERLOAD RELAY C306GN3B 1 16 PRIMARY FUSE - 380V 44-2144-17 2
7 HEATER PACK SEE CHART AT END OF THIS SECTION 17 PRIMARY FUSE - 460V 44-2144-13 2
8 CONTROL TRANSFORMER C0100G6UFB 1 18 PRIMARY FUSE - 575V 44-2144-12 2
9 “MOTOR RUN” PILOT LIGHT 10250T34G 1 19 RESET BOOT 35-524 2
10 “MOTOR RUN” LEGEND PLATE 10250TM81 1 20 PUB SHEET 25762 2
INSTALLATION PAGE B - 9
CONTROL BOXES OM-04136
Figure B-10. Control Boxes 27515-503, 27515-513 And 27515-543 Pictorial Diagram
For specific control box data information, refer to
the chart at the end of this section.
PAGE B - 10 INSTALLATION
OM-04136 CONTROL BOXES
INSTALLATION PAGE B - 11
CONTROL BOXES OM-04136
Figure B-12. Control Boxes 27515-504, 27515-514, 27515-544 And 27515-554 Pictorial Diagram
PAGE B - 12 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-13. Control Boxes 27515-505, 27515-515 And 27515-545 Elementary Wiring Diagram
INSTALLATION PAGE B - 13
CONTROL BOXES OM-04136
Figure B-14. Control Boxes 27515-505, 27515-515 And 27515-545 Pictorial Diagram
For specific control box data information, refer to
the chart at the end of this section.
PAGE B - 14 INSTALLATION
OM-04136 CONTROL BOXES
INSTALLATION PAGE B - 15
CONTROL BOXES OM-04136
Figure B-16. Control Boxes 27515-506, 27515-516 And 27515-546 Pictorial Diagram
For specific control box data information, refer to
the chart at the end of this section.
PAGE B - 16 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-17. Control Boxes 27515-507 And 27515-517 Elementary Wiring Diagram
REPAIR PARTS LIST
ITEM PART NAME C H PART QTY ITEM PART NAME C H PART QTY
NO. NUMBER NO. NUMBER
1 CIRCUIT BREAKER, 250 AMPS HMCP250W5C 1 12 H-O-A SELECTOR SWITCH 10250T21KB 1
2 MOTOR STARTER AN16SNOAB 1 13 “H‐O‐A” LEGEND PLATE 10250TM51 1
3 CONTACTOR - 3 POLE CN15SN3AB 1 14 CURRENT TRANSFORMER 42-3564-2 1
4 RENEWAL CONTACT SET 6-45-2 1 15 RESET BOOT 32-524 1
5 COIL (ON COIL) 1 16 OPT'L FLOAT CNTROL RELAY A999AY574 1
6 OVERLOAD RELAY C306DN3 1 17 PRIMARY FUSE, 460V 44-2144-23 2
7 HEATER PACK SEE CHART AT END OF THIS SECTION 18 PRIMARY FUSE, 575V 44-2144-21 2
8 CONTROL TRANSFORMER C0250G6UFB 1 19 SECONDARY FUSE 44-796-10 2
9 “MOTOR RUN” PILOT LIGHT 10250T34G 1 20 PUB SHEET 25775 2
10 “MOTOR RUN” LEGEND PLATE 10250TM81 1 21 OVERLOAD RELAY ADAPTER 10-6380-2 1
11 TERMINAL BLOCK 80-5817 2
INSTALLATION PAGE B - 17
CONTROL BOXES OM-04136
PAGE B - 18 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-19. Control Boxes 27515-524 And 27515-534 Elementary Wiring Diagram
INSTALLATION PAGE B - 19
CONTROL BOXES OM-04136
PAGE B - 20 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-21. Control Boxes 27515-525 And 27515-535 Elementary Wiring Diagram
INSTALLATION PAGE B - 21
CONTROL BOXES OM-04136
PAGE B - 22 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-23. Control Boxes 27515-571 And 27515-572 Elementary Wiring Diagram
INSTALLATION PAGE B - 23
CONTROL BOXES OM-04136
Figure B-24. Control Boxes 27515-571 And 27515-572 (With S801 Starter) Pictorial Diagram
For specific control box data information, refer to
the chart at the end of this section.
PAGE B - 24 INSTALLATION
OM-04136 CONTROL BOXES
Figure B-25. Control Boxes 27515-571 And 27515-572 (With S811 Starter) Pictorial Diagram
For specific control box data information, refer to
the chart at the end of this section.
INSTALLATION PAGE B - 25
CONTROL BOXES OM-04136
PAGE B - 26 INSTALLATION
OM-04136 CONTROL BOXES
POWER TERMINATIONS
HEATER PACK
MOUNTING SCREW LINE SIDE LOAD SIDE
NEMA
SIZE RECOMMENDED TORQUE Terminal Terminal
In. lbs. (m. kg.) Wire Size Torque Wire Size Torque
(AWG) In. lbs. (m. kg.) (AWG) In. lbs. (m. kg.)
Use 60/75_C Al or Use 60/75_C Al or
Cu Conductors Cu Conductors
1&2 9 (0,10) 14 - 10 35 (0,40) 14 - 10 35 (0,40)
8 40 (0,46) 8 40 (0,46)
6-4 45 (0,52) 6-4 45 (0,52)
3-2 50 (0,58)
Use 75_C Al or Use 75_C Al or
Cu Conductors Cu Conductors
14 - 10 35 (0,40) 14 - 10 35 (0,40)
3 24 - 30 (0,28 - 0,35) 8 40 (0,46) 8 40 (0,46)
6-4 45 (0,52) 6-4 45 (0,52)
3 - 1/0 50 (0,58) 3 - 1/0 50 (0,58)
Use 75_C Cu Use 75_C Cu
Conductors Only Conductors Only
Socket Size
In. (mm)
4 24 - 30 (0,28 - 0,35) 14 - 10 35 (0,40) 3/16 (4,76) 120 (1,38)
8 40 (0,46) 1/4 (6,35) 200 (2,30)
6-4 45 (0,52) 5/16 (7,94) 250 (2,88)
3 - 1/0 50 (0,58) 3/8 (9,53) 550 (6,34)
Use 75_C Copper or Alumi Use 75_C Copper or Alumi
num Conductors only. num Conductors only.
5 9 (0,10) Torque terminals to values
given on HMCP nameplate. 550 (6,34)
INSTALLATION PAGE B - 27
OM-04136 CONTROL BOXES
OPERATION - SECTION C
Obtain the services of a qualified elec D The control handle operates the control
trician to make all electrical connec box circuit breakers. In the OFF position, the
tions, and to troubleshoot, test and/or control handle opens the circuit breakers to
service the electrical components of the interrupt incoming power through the con
control box. trol box and prevent pump operation. In the
ON position, it closes the circuit breakers to
permit pump operation. The circuit breakers
CONTROL BOX FUNCTION
will open or “trip” automatically in the event
of a short circuit overload current. When
tripped, move the control handle to OFF and
back to ON to reset the circuit breakers.
D The selector switch controls the mode of
The control box is not designed to be ex operation. In the OFF position, it prevents all
plosion‐proof. Do not operate in an ex operation of the pump. In the HAND posi
plosive atmosphere. tion, it allows the pump to run continuously.
In the AUTO position, it allows the pump to
The control box is provided to facilitate operation of be controlled automatically by the optional
the pump. It contains controls for starting and stop liquid level control system, if used.
ping the pump, and provides overload protection D The reset pushbutton resets the motor over
for the pump motor. The pump control may be load after it has been TRIPPED by an over
equipped with an optional automatic liquid level load. The overload relay will trip automatical
sensing device, in which case the low voltage cir ly if the current drawn by the motor exceeds
cuits are also contained within the control box. design specifications. Allow 10 seconds for
OPERATION PAGE C - 1
CONTROL BOXES OM-04136
the relay to cool after tripping before press The green run light is standard equipment
ing the reset. on all the controls and indicates the pump is
If replacing the heater pack press the reset running. The light will be energized when
button to set relay. the 3‐position switch is in the HAND position
or when the pump is running with the switch
NOTE in the AUTO position.
If the circuit breaker trips, do not reset it immedi The red motor overheat light (standard
ately. Wait at least ten minutes before resetting the equipment only on some controls) works in
control handle back to the ON position. If the over conjunction with a thermostat embedded in
load unit continues to trip, operational problems ex the motor windings. In event of a high tem
ist. perature condition, the motor is shut‐down.
After the motor cools, the device is automati
cally reset.
The amber seal failure light (standard equip
ment only on some controls) works in con
junction with a sensor probe located in the
seal oil cavity of the pump and detects an in
The pump motor will restart as soon as flux of moisture into the cavity. Should this
the RESET pushbutton is pressed, un condition occur, the pump motor should re
less the selector switch is in the OFF po main inoperative until the problem is cor
sition. Turn the selector switch to OFF rected.
and move the control handle to OFF be Always terminate incoming power to the control
fore approaching the pump. box before investigating control box circuitry prob
D The liquid level devices (optional equip lems.
ment) operate in conjunction with the 3‐po
sition switch (HAND‐OFF‐AUTO) supplied
as part of that option. After the level sensors
and circuitry have been installed, pump op
eration may be automatically controlled for Always terminate power to the control
filling or dewatering functions (see LIQUID
box before performing service func
LEVEL DEVICES, Section B).
tions.
D The operational warning lights operate in
conjunction with the 3‐position switch Power through the control box may be terminated
(HAND‐OFF‐AUTO) supplied as a part of by moving the control handle to the OFF position,
that option. After the level sensors and cir thereby opening the circuit breakers. This stops
cuitry have been installed, pump operations the pump, but does not terminate incoming power
may be automatically controlled for filling or through the field wiring connected to the control
dewatering functions. box.
PAGE C - 2 OPERATION
OM-04136 CONTROL BOXES
TROUBLESHOOTING - SECTION D
Review all SAFETY information in Section A.
When troubleshooting, also refer to the technical information accompanying the pump and optional equip
ment.
PUMP FAILS TO Power source incompatible with control Correct power source.
START, OVERLOAD box.
UNIT NOT TRIPPED
(MANUAL MODE) No voltage at line side of circuit beaker. Check power source for blown fuse,
open overload unit, broken lead, or
loose connection.
No voltage at line terminals on bottom Check power source for blown fuse,
of overload unit in control box. open disconnect, broken wire, or
loose connection.
OVERLOAD UNIT Low or high voltage, or excessive volt‐ Measure voltage at control box.
TRIPS age drop between pump and control Check that wiring is correct type, size,
box. and length. (See Field Wiring
Connections,Section B).
Control box not compatible with pump. Electrical data on control box and
pump name plate must agree. Re‐
place control box if not in agreement.
TROUBLESHOOTING PAGE D - 1
CONTROL BOXES OM-04136
ELECTRICAL TESTING
Equipment Use
A volt/amp/ohmmeter and megohmeter of ade Each phase of the incoming three‐phase power
quate range and quality will be required to conduct must be balanced with the other two as accurately
the electrical tests. The suggested equipment indi as a commercial voltmeter will read. If the phases
cated below is commercially available, or an equiv are out of balance, contact your power company
alent substitute may be used. and request that they correct the condition.
PAGE D - 2 TROUBLESHOOTING
1
For Warranty Information, Please Visit
www.grpumps.com/warranty
or call:
U.S.: 419-755-1280
Canada: 519-631-2870
International: +1-419-755-1352
GORMAN‐RUPP PUMPS