Grundfos JP PS Series Betriebsanleitung

GRUNDFOS INSTRUCTIONS

JP-PS

Jet pumps with pressure switch, 115/230 V, 60 Hz

Service instructions

English (US)

English (US) Service instructions

CONTENTS

Page

1. General information

1.1 Hazard statements

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

The hazard statements are structured in the following way:

1.2 Notes

The symbols and notes below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

1. General information 2

1.1 Hazard statements 2

1.2 Notes 2

2. Safety information for working on the product 3

3. Maintenance 3

4. Dismantling the product 3

4.1 Before dismantling the product 3

4.2 Dismantling the pressure switch 3

4.3 Dismantling the pump housing 4

4.4 Replacing the plugs 4

4.5 Dismantling the hydraulic parts 4

4.6 Dismantling the motor housing 5

5. Disconnecting the power cable from the pressure

switch 6

5.1 Removing the motor fan 6

5.2 Removing the impeller 6

5.3 Removing the shaft seal 7

6. Assembling the product 8

6.1 Before assembling the product 8

6.2 Fitting the shaft seal 8

6.3 Fitting the impeller 9

6.4 Fitting the motor fan 9

6.5 Fitting the motor housing 9

6.6 Fitting the hydraulic parts 10

6.7 Fitting the pump housing 10

6.8 Connecting the power cable via the pressure switch 11

7. Additional information 13

7.1 Lubricant 13

7.2 Torques 13

7.3 Nameplate 13

7.4 Type key 14

7.5 Fault finding the product 14

7.6 Exploded view 15

Read this document before starting service work on

the product. Installation and service work must

comply with local regulations and accepted codes of

good practice.

Observe the safety instructions in the installation and

operating instructions for the product.

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

Observe these instructions for explosion-proof

products.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Tips and advice that make the work easier.

English (US)

2. Safety information for working on the product

3. Maintenance

The product is maintenance-free during normal operation. For

cleaning, use a dry and dust-free cloth.

4. Dismantling the product

4.1 Before dismantling the product

• Disconnect the power supply to the motor.

• Remove the power cable in accordance with local regulations.

• Gradually open a tap to release the pressure in the pump.

• Remove the drain plug (26) to drain the pump.

• Remove the pump from the plumbing.

Fig. 1 Plugs (25, 26), pressure switch (407), and pressure

switch connections (408)

4.2 Dismantling the pressure switch

1. Loosen the nut on the top cover of the pressure switch (407).

2. Lift up the pressure switch cover and set it aside.

3. Inside the pressure switch, use a large flat screw driver to turn

the locking ring counterclockwise to loosen it.

4. Use small pliers or a wrench to loosen the pressure

switch (407) and pressure switch connections (408).

5. Remove the pressure switch (407) and pressure switch

connections (408) from the pump.

WARNING

Electric shock

Death or serious personal injury

- Switch off the power supply before you start any

work on the product. Make sure that the power

supply cannot be switched on accidentally.

WARNING

Electric shock

Death or serious personal injury

- The product is supplied with a grounding

conductor and grounding-type attachment plug. To

reduce the risk of electric shock, be certain that the

product is connected only to a properly grounded,

grounding-type receptacle (protective earth).

WARNING

Electric shock

Death or serious personal injury

- Power cables without a plug must be connected to

a supply disconnecting device incorporated in the

fixed wiring according to the local wiring rules.

WARNING

Chemical hazard

Death or serious personal injury

- Make sure that the product has only been used for

water. If the product has been used for pumping

aggressive liquids, flush the system with clean

water before you start work on the product.

WARNING

Pressurized system

Death or serious personal injury

- Before dismantling the pump, drain the system or

close the isolating valves on both sides of the

pump. Slowly loosen the drain plug and

unpressurize the system.

CAUTION

Impurities in the water

Minor or moderate personal injury

- Before the pump is used for supplying drinking

water, flush the pump thoroughly with clean water.

CAUTION

Crushing of feet

Minor or moderate personal injury

- Wear safety shoes when handling the product.

CAUTION

Hot surface

Minor or moderate personal injury

- Use protective gloves if the liquid or ambient

temperature is higher than 104 °F (40 °C).

CAUTION

Hot or cold liquid

Minor or moderate personal injury

- Make sure that escaping hot or cold liquid does not

cause injury to persons or damage to the

equipment.

Only qualified persons are allowed to service the

pump.

Do not turn on the power supply until the pump has

been filled with liquid.

Position numbers of parts (numbers in brackets) refer

to section 7.6 Exploded view.

TM07 4518 1419

26 32

408

25 407

English (US)

4.3 Dismantling the pump housing

Fig. 2 Dismantling the pump housing

1. Place the pump vertically with the inlet facing upwards.

2. Unscrew the clamp ring (92) by loosening screw (93) and nut

(94).

3. Remove the clamp ring (92) from the recess. Use two flat

screw drivers to lift the clamp ring from the recess.

Fig. 3 Removing the clamp ring

4. Remove the pump housing (1) including the hydraulic parts

(20 and 21).

5. Remove the O-ring (28).

4.4 Replacing the plugs

Fig. 4 Replacing the plugs

To replace the fill plug (25) and drain plug (26):

1. Remove the two plugs (25, 26) by turning each plug

counterclockwise with a big flat screwdriver.

2. Lubricate the O-ring seats on the pump housing (1). See

section 7.1 Lubricant.

3. Place the new plugs (25, 26) and O-rings (31, 32). Fasten the

plugs (25, 26) by turning the plug clockwise with a large flat

screwdriver.

4.5 Dismantling the hydraulic parts

Fig. 5 Hydraulic parts and pump housing

1. Place the pump housing (1) vertically with the inlet facing

upwards.

2. Use a suitable tool which fits inside the inlet and gently press

down on the venturi tube (21) to loosen the hydraulic parts

(20, 21, 21a and 13).

TM07 4514 1419TM07 4534 1419

TM07 4513 1419TM07 4530 1419

26 32

408

21a

English (US)

Fig. 6 Removal of hydraulic parts

Fig. 7 Incorrect way to remove the diffuser

4.6 Dismantling the motor housing

Fig. 8 Dismantling the motor housing

1. Remove the terminal box cover (51) and upper motor shell

housing (44) by loosening the screws (53).

2. Disconnect the power connections as required and follow the

instructions in section 5. Disconnecting the power cable from

the pressure switch.

3. Remove the motor housing grid (43).

4. Remove the base plate (56) by loosening the screw and nut

(56a).

5. Remove the lower motor housing (42).

TM07 4538 1419

Do not try to remove the diffuser (20) by using

screwdrivers or similar tools, as it might break.

TM07 3813 0519

TM07 3465 1319

56a

407

181

408

161

English (US)

5. Disconnecting the power cable from the

pressure switch

1. Locate the power-supply terminal and cable clamp inside the

pressure switch.

Fig. 9 Disconnecting the power cable

2. Loosen the three wires from the pressure switch.

3. Loosen the screw that holds the cable clamp.

4. Pull out the cable through the cable gland located on the side

of the pressure switch.

5.1 Removing the motor fan

Fig. 10 Removing the motor fan

1. Remove the motor fan (14) from the shaft with two large flat

screw drivers. Make sure to use sufficiently large screw

drivers. Place the screw drivers between motor flange and fan

at any two points.

5.2 Removing the impeller

1. Place the motor vertically with the impeller (19) facing

upwards.

2. Clamp the motor shaft end in a vice with soft copper or

aluminium jaw faces to protect the shaft end.

Fig. 11 Placing the motor shaft in a vice

3. Turn the impeller (19) counterclockwise by hand and

remove it.

Fig. 12 Removing the impeller

If you are replacing the motor housing (42, 44),

disconnect the power cable from the pressure switch

(407).

If you are replacing the impeller, remove the lower

motor housing (42) and the upper motor housing (44)

and disconnect the power cable from the pressure

switch (407).

TM07 4373 1319TM07 4329 1319

TM07 3817 0519TM07 3818 0519

English (US)

5.3 Removing the shaft seal

Fig. 13 Shaft seal and seal disc

Fig. 14 How to hold the shaft seal correctly

1. Remove the rotating part of the shaft seal (16) by inserting two

flat screw drivers in the shaft seal spring. Lever the screw

drivers against any two points at the edge of the seal disc.

Fig. 15 Removing the rotating part of the shaft seal

2. Remove the seal disc (15) including the stationary part of the

shaft seal (16a).

3. Remove the stationary shaft seal ring (16a) from the seal disc

(15) by pushing gently with a finger from below. Hold the seal

ring on the lower side and on the rubbery outer diameter. Do

not touch the seal face.

Fig. 16 Removing the stationary part of the shaft seal

Do not touch the seal faces.

TM07 4366 1319TM07 3820 0519

16a

TM07 3821 0519TM07 3822 0519

English (US)

6. Assembling the product

6.1 Before assembling the product

• Clean and check all parts.

• Replace defective parts.

6.2 Fitting the shaft seal

Fig. 17 Shaft seal and seal disc

Fig. 18 How to correctly hold the shaft seal

1. Clamp the motor shaft end in a vice with soft copper or

aluminium jaw faces to protect the shaft end. See fig. 11.

2. Lubricate the seal disc opening. See section 7.1 Lubricant.

Fig. 19 Lubricating the seal disc

3. Fit the stationary part of the shaft seal (16a) inside the seal

disc (15).

Fig. 20 Fitting the stationary part of the shaft seal

4. Lubricate the shaft. See section 7.1 Lubricant.

5. Place the seal disc (15) with the stationary part of the shaft

seal (16a) on the shaft and make sure the seal disc (15)

centers on the motor flange.

Fig. 21 Lubricating the shaft and placing the rotating part of

the shaft seal.

6. Place the rotating part of the shaft seal (16) on the shaft and

press it down with two fingers.

Position numbers of parts (numbers in brackets) refer

to section 7.6 Exploded view.

Do not touch the seal faces.

TM07 4366 1319TM07 3820 0519

16a

TM07 3823 0519TM07 3824 0519TM07 3825 0519

English (US)

Fig. 22 Fitting the rotating part of the shaft seal

6.3 Fitting the impeller

1. Fit the impeller (19) on the shaft.

2. Spin the impeller (19) clockwise and tighten by hand until you

feel the resistance of the mechanical stop.

Fig. 23 Fitting the impeller

6.4 Fitting the motor fan

1. Place the pump in a vertical position with the shaft end facing

upwards. The surface must be smooth or soft to protect the

impeller (15) facing downwards.

2. Fit the motor fan (14) on the shaft by hand.

Fig. 24 Fitting the motor fan

6.5 Fitting the motor housing

Fig. 25 Fitting the motor housing

1. Place the pump in a vertical position with the motor fan (14)

facing upwards.

Fig. 26 Fitting the nut and the lower motor housing

2. Place the nut (56a) in the groove on the motor flange.

3. Fit the lower motor housing (42). Align the guides on the

inside of the lower motor housing (42) with the metal cooling

ribs on the stator housing. Click the motor housing in place.

4. Mount the foot (56) and tighten the screw (56a).

Torque: 12 ± 1 Nm.

5. Fit the motor housing grid (43) in the groove in the motor shell

(42).

TM07 3826 0519TM07 3827 0519TM07 4369 1319

TM07 3465 1319TM07 3829 0519

56a

407

181

408

161

English (US)

6. Fit the upper motor housing (44).

7. Fasten the screws (53) that hold the motor housing together.

Torque: 1.5 ± 0.1 Nm.

8. Fit the terminal box lid (51) and fasten the screws (53) that

hold it in place.

9. Follow the instructions below on how to connect the power

cable in section 6.6 Fitting the hydraulic parts.

6.6 Fitting the hydraulic parts

Fig. 27 Exploded view of hydraulic parts and pump housing

1. Lubricate the O-ring seat on the diffuser (20).See section

7.1 Lubricant.

2. Fit the two O-rings (13, 21a) on the venturi tube (21).

3. Assemble the venturi tube (21) and diffuser (20) by hand.

4. Lubricate the O-ring seat inside the inlet on the pump housing

(1). See section 7.1 Lubricant.

5. Fit by hand the venturi tube (21) and diffuser (20) inside the

pump housing (1).

Fig. 28 Fitting the hydraulic parts in the pump housing

6.7 Fitting the pump housing

Fig. 29 Exploded view of the pump housing

1. Place the pump in a vertical position with the motor housing

grid (43) facing downwards.

2. Fit the O-ring (28) on the seal disc (15). No lubrication is

needed. Run a screw driver along the ring to remove any

twisting.

Fig. 30 Fitting the O-ring on the seal disc

3. Fit the pump housing (1) so that the cut-out on the edge of the

pump housing is aligned with the marker on the edge of the

motor flange.

Fig. 31 Aligning the pump housing on the motor flange

4. Fit the clamp ring (92) on the recess. Use two flat screw

drivers to widen the clamp.

Verification of assembly:

Turn the shaft by rotating the impeller (19) clockwise

and check that the motor fan (14) does not touch the

motor housing (42 and 44).

TM07 4531 1419TM07 4532 1419

21a

TM07 4533 1419TM07 3835 0919TM07 3833 0519

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