GORMAN-RUPP PUMPS JSV4F60-E8.7 230/3 Anwendungshandbuch

OM−03592−OM01CER

NOVEMBER 30, 1990

Rev. B

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

MODELS

JSV4F60−E8.7 230/3

DUAL VOLTAGE

JSV4F60−E8.7 460/3

JSV4G60−E11 230/3 JSV4G60−E11 460/3

OM−03592−OM01 JSV4F−G60 DV

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

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

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

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

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

Motor Cable Grounding Test PAGE B−5. . . . . . . . . . . . . . . . . . . . . .

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

Wiring Diagrams PAGE B−6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIQUID LEVEL DEVICES PAGE B−6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

CONTROL BOX AND OPTIONAL CONTROLS PAGE C−3. . . . . . . . . .

PUMP OPERATION PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Liquid Temperature and Overheating. PAGE C−3. . . . . . . . . . . . . .

Impeller Rotation PAGE C−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING, STOPPING, AND OPERATIONAL CHECKS PAGE C−4.

Starting PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operations Checks PAGE C−4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING − SECTION D PAGE D−1. . . . . . . .

TROUBLESHOOTING CHART PAGE D−1. . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL TESTING PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Equipment PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Imbalance PAGE D−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Insulation Resistance PAGE D−4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

JSV4F−G60 DV OM−03592−OM01

TOCPAGE−2

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

PARTS LIST − FIGURE E−1 PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS PAGE E−3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST − FIGURE E−2 PAGE E−5. . . . . . . . . . . . . . . . . . . . . . . . .

PUMP AND MOTOR DISASSEMBLY AND REASSEMBLY PAGE E−6

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

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

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

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

Junction Box Cover Disassembly PAGE E−7. . . . . . . . . . . . . . . . . .

Removing the Stator/Motor Housing PAGE E−7. . . . . . . . . . . . . . .

Seal Disassembly PAGE E−7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

INSPECTION AND CLEANING PAGE E−9. . . . . . . . . . . . . . . . . . . . . . .

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

Other Reusable Parts (Except Seal Assembly) PAGE E−9. . . . . .

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

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

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

Junction Box Cover Reassembly PAGE E−9. . . . . . . . . . . . . . . . . .

Installing Bearings PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating Assembly PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Reassembly PAGE E−11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seal Testing PAGE E−12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP END REASSEMBLY PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installing The Volute Casing PAGE E−13. . . . . . . . . . . . . . . . . . . . . .

Impeller Clearance PAGE E−13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

JSV4F−G60 DV

OM−03592−OM01

INTRODUCTION 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 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. 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 4−inch dis-

charge; they will handle solids up to 3−inches in

diameter. The pumps are designed to operate fully

or partially submerged mounted on guide rails in-

stalled 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 accompa-

nying 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:

NOTE

Instructions to aid in installation, operation, and maintenance, or which clarify a procedure.

ÉÉÉÉÉÉ

CAUTION

INSTRUCTIONS WHICH MUST BE FOLLOWED TO AVOID CAUSING DAMAGE TO THE PRODUCT OR

OTHER EQUIPMENT INCIDENTAL TO THE INSTALLATION. THESE INSTRUCTIONS DESCRIBE THE

REQUIREMENTS AND THE POSSIBLE DAMAGE WHICH COULD RESULT FROM FAILURE TO FOL-

LOW THE PROCEDURE.

ÍÍÍÍÍÍ

WARNING

INSTRUCTIONS WHICH MUST BE FOLLOWED TO AVOID CAUSING INJURY OR DEATH TO PER-

SONNEL. THESE INSTRUCTIONS DESCRIBE THE PROCEDURE REQUIRED AND THE INJURY

WHICH COULD RESULT FROM FAILURE TO FOLLOW THE PROCEDURE.

JSV4F−G60 DV OM−03592−OM01

INTRODUCTIONPAGE I−2

This page intentionally blank.

OM−03592−OM01 JSV4F−G60 DV

SAFETY PAGE A−1

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, 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.

ÍÍÍÍÍÍ

WARNING

BEFORE ATTEMPTING TO INSTALL, OPERATE,

OR SERVICE THIS PUMP, FAMILIARIZE YOUR-

SELF WITH THIS MANUAL, AND WITH ALL

OTHER LITERATURE SHIPPED WITH THE

PUMP. UNFAMILIARITY WITH ALL ASPECTS OF

PUMP OPERATION COVERED IN THIS MAN-

UAL COULD LEAD TO DESTRUCTION OF

EQUIPMENT, INJURY, OR DEATH.

ÍÍÍÍÍÍ

WARNING

THIS PUMP IS DESIGNED TO HANDLE RAW

SEWAGE AND INDUSTRIAL WASTES AT TEM-

PERATURES OF 104_F; DO NOT APPLY AT

HIGHER TEMPERATURES. DO NOT ATTEMPT

TO PUMP VOLATILE, FLAMMABLE, OR COR-

ROSIVE LIQUIDS WHICH MAY DAMAGE THE

PUMP OR ENDANGER PERSONNEL AS A RE-

SULT OF PUMP FAILURE.

ÍÍÍÍÍÍ

WARNING

THE ELECTRICAL POWER USED TO OPERATE

THIS PUMP IS HIGH ENOUGH TO CAUSE IN-

JURY OR DEATH. OBTAIN THE SERVICES OF A

QUALIFIED ELECTRICIAN TO MAKE ALL ELEC-

TRICAL CONNECTIONS.

ÍÍÍÍÍÍ

WARNING

THIS IS A DUAL−VOLTAGE PUMP. ANY

CHANGE IN VOLTAGE SHOULD BE PER-

FORMED BY YOUR GORMAN−RUPP DISTRIB-

UTOR, AUTHORIZED SERVICE CENTER, OR

THE FACTORY. DO NOT CHAGE VOLTAGE IN

THE FIELD WITHOUT CONTACTING THESE

SOURCES. OTHERWISE, THE PUMP MAY BE

DAMAGED, AND PERSOONEL MAY SUFFER

INJURY OR DEATH.

ÍÍÍÍÍÍ

WARNING

DO NOT CONNECT THE PUMP MOTOR DI-

RECTLY 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; OTH-

ERWISE, THE PUMP WARRANTY WILL BE

VOIDED. MAKE CERTAIN THAT THE PUMP AND

CONTROL BOX ARE PROPERLY 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 INSTRUC-

TIONS IN THIS WARNING COULD RESULT IN

INJURY OR DEATH TO PERSONNEL.

ÍÍÍÍÍÍ

WARNING

DO NOT ATTEMPT TO LIFT THIS PUMP BY THE

MOTOR POWER CABLE OR THE PIPING. AT-

TACH PROPER LIFTING EQUIPMENT TO THE

LIFTING HANDLE, AND MAKE CERTAIN THAT

THE HOOK OF THE LIFTING DEVICE IS SE-

CURELY POSITIONED 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 BALANCED.

OM−03592−OM01JSV4F−G60 DV

SAFETYPAGE A−2

ÍÍÍÍÍÍ

WARNING

THE FOLLOWING PRECAUTIONS SHOULD BE

TAKEN BEFORE ATTEMPTING TO OPEN OR

SERVICE THE PUMP; OTHERWISE, INJURY OR

DEATH COULD RESULT.

1. LOCK OUT THE POWER TO THE

CONTROL PANEL TO ENSURE THAT

THE PUMP WILL REMAIN INOPERA−

TIVE.

2. ALLOW THE PUMP TO COOL IF OVER-

HEATED.

3. CLOSE THE DISCHARGE VALVE (IF

USED).

ÍÍÍÍÍÍ

WARNING

IF THIS PUMP IS USED TO HANDLE SEWAGE,

TAKE NECESSARY PRECAUTIONS DURING

MAINTENANCE AND REPAIR TO PREVENT

PERSONAL CONTAMINATION WHICH COULD

RESULT IN ILLNESS.

OM−03592−OM01 JSV4F−G60 DV

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 these pumps. If

there are any questions concerning your specific

installation, contact your Gorman−Rupp distribu-

tor or the Gorman−Rupp Company.

ÉÉÉÉÉÉ

CAUTION

THE MOTOR IN THESE PUMPS IS NOT DE-

SIGNED TO BE OPERATED IN AIR FOR MORE

THAN 10 MINUTES 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 MO-

TOR HOUSING IN SINGLE PUMP OPERATION,

AND BELOW THE LEVEL OF THE DISCHARGE

FLANGE IN DUPLEX 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. Check the pump assembly for cracks,

dents, damaged threads, and other obvi−

ous damage.

b. Check for loose attaching hardware. Since

gaskets tend to shrink after drying, check

for loose hardware at mating surfaces.

c. The standard pump is provided with 26 ft.

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 mark−

ings on the pump assembly, and perform all

duties indicated.

f. Check for any oil leaks. If there is any indi−

cation of an oil leak, see LUBRICATION in

MAINTENANCE AND REPAIR − SECTION

LUBRICATION

The shaft seal I is lubricated by oil in the seal hous-

ing (see LUBRICATION in MAINTENANCE AND

REPAIR − SECTION E).

The shaft bearings are grease 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−03592−OM01JSV4F−G60 DV

PAGE B−2 INSTALLATION

FIGURE B−1. PUMP DIMENSIONS

OM−03592−OM01 JSV4F−G60 DV

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. 3 model; 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 for each

pump model.

TABLE B-1. PUMP MOTOR SPECIFICATIONS

MODEL VOLTAGE SIZE

RPM

MOTOR MAX NO LOCKEDH.P.

NUMBER LOAD LOAD ROTOR

JSV4E60−E8.7

230/3

460/3

8.7

1750

27.6A 15.9A 160.1A

/PHASE

13.2A 7.6A 76.6A

JSV4F60−E11

230/3

460/3

1750

31.8A 15.9A 159.0A

15.2A 7.6A 76.0A

PUMP INSTALLATION

Lifting

Use lifting equipment with a capacity of at least

1,850 lbs. Each version of these pumps weighs

approximately 369 lbs., not including the weight of

customer−installed accessories such as the el-

bow/baseplate and piping. Discharge hose or pip-

ing 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 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 optional discharge elbow/base−

plate. When lowered into place, the pump is auto-

matically and securely connected to the elbow/

baseplate and the piping system; the pump can be

removed or installed without personnel entering

the wet well.

For information on installing the guide rails, see the

literature accompanying them.

NOTE

When engaging the guide shoe and elbow/base-

plate, make sure that the connection is not imped-

ed 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 guide shoe engages the discharge elbow/

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 OPERATION

− SECTION C when determining the most efficient

piping installation. The recommended maximum

submergence depth is 65 feet.

No suction piping is required in a standard sub-

merged operation.

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