GORMAN-RUPP PUMPS JS Series Operating instructions

PUBLICATION NUMBER MR−03955

August 9, 1993

THE GORMAN-RUPP COMPANY DMANSFIELD, OHIO

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

eCopyright by the Gorman-Rupp Company

JS SERIES PUMPS

MOTOR FRAME SIZE 4

APPROVED

X-PROOF MOTORS FOR CLASS 1,

DIV. 1, GROUPS C & D LOCATIONS

MR−03955 JS SERIES PUMPS

APPROVED

PAGE I − 1INTRODUCTION

INTRODUCTION

Thank You for purchasing a Gorman-Rupp JS

Series FM-Approved Pump. Read this manual

carefully to learn how to safely maintain and ser-

vice your pump. Failure to do so could result in per-

sonal injury or damage to the pump.

A set of three manuals accompanies your pump.

The Installation/Operation Manual contains essen-

tial information on installing and operating the

pump, and on making electrical connections. The

Parts List Manual provides performance curve(s),

a pump model cross-section drawing, and parts

list for your pump.

This Maintenance and Repair Manual provides

troubleshooting and maintenance instructions re-

quired to properly diagnose operational problems,

and to service the pump hydraulic components.

Pump motor maintenance may be performed only

by a Gorman-Rupp authorized FM-Approved re-

pair facility, or the factory. Otherwise, the pump

warranty will be negated, and damage to the

pump, and injury or death to personnel can result.

Contact the factory for the authorized repair facility

closest to you.

The pump is driven by a water-proof, explosion-

proof, submersible electric motor that is FM-ap-

proved for Class 1, Division 1, Group C and D loca-

tions.

If there are any questions regarding the pump

which are not covered in this manual or in other lit-

erature accompanying the unit, please contact

your Gorman-Rupp distributor or the Gorman-

Rupp Company:

The Gorman-Rupp Company

P.O. Box 1217

Mansfield, Ohio 44901−1217

or:

Gorman-Rupp of Canada Limited

70 Burwell Road

St. Thomas, Ontario N5P 3R7

CONTENTS

SAFETY − SECTION A

TROUBLESHOOTING − SECTION B

ELECTRICAL TESTING PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Equipment PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Imbalance PAGE B − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Insulation Resistance PAGE B − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP MAINTENANCE AND REPAIR − SECTION C

GENERAL INFORMATION PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting PAGE C − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TYPICAL PUMP ASSEMBLY PAGE C − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PART IDENTIFICATION LIST PAGE C − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAL AREA DETAIL PAGE C − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAL AREA DETAIL PART IDENTIFICATION LIST PAGE C − 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP END DISASSEMBLY PAGE C − 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION AND CLEANING PAGE C − 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PUMP END REASSEMBLY PAGE C − 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAL TESTING PAGE C − 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION PAGE C − 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MR−03955JS SERIES PUMPS

APPROVED

PAGE I − 2 INTRODUCTION

RECORDING MODEL AND

SERIAL NUMBERS

Please record the pump model, serial number, volt-

age, and motor frame size in the spaces provided

in the separate Installation/Operation Manual ac-

companying your pump. Your Gorman-Rupp dis-

tributor needs this information when you require

parts or service.

WARRANTY INFORMATION

The warranty provided with your pump is part of

Gorman-Rupp’s support program for customers

who operate and maintain their equipment as de-

scribed in this and the other accompanying litera-

ture. Please note that should the equipment be

abused or modified to change its performance be-

yond the original factory specifications, the war-

ranty will become void and any claim will be de-

nied.

The motor powering this pump is FM-Approved for

Class 1, Division 1, Groups C and D environments.

All repairs to the pump, other than seal, impeller

and other hydraulic components, must be per-

formed by a Gorman-Rupp authorized repair facil-

ity or the factory. Any repairs to the motor assembly

performed by the customer or an unauthorized re-

pair facility negates the FM Approval and the motor

warranty.

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.

MR−03955 JS SERIES PUMPS

APPROVED

PAGE A − 1SAFETY

SAFETY − SECTION A

The following information applies

throughout this manual to Gorman-

Rupp JS Series FM-Approved Submers-

ible pumps.

This manual contains essential informa-

tion on troubleshooting and maintain-

ing the pump. In addition to this manual,

see the separate literature covering in-

stallation and operation, pump parts,

and any optional equipment shipped

with the pump.

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

to personnel.

When installing or servicing the pump

or controls, follow all requirements for

the installation of wiring or electrical

equipment in hazardous locations as

outlined in the National Electric Code.

When entering the pump wet well for in-

stallation or service, follow all safety re-

quirements for confined space entry.

Failure to observe these requirements

could result in injury or death to person-

nel.

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.

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 these could re-

sult in injury or death to personnel.

This pump is not designed to pump vol-

atile, flammable, or corrosive liquids.

The maximum temperature of the liquid

being pumped should not exceed 104_F

(40_C); do not apply the pump at higher

temperatures. Do not attempt to pump

any liquids which may damage the

pump or endanger personnel as a result

of pump failure.

JS SERIES PUMPS MR−03955

APPROVED

PAGE A−2 SAFETY

The following precautions should be

taken before attempting to service the

pump; otherwise, injury or death could

result.

1. Familiarize yourself with this man-

ual and with all other literature

shipped with the pump.

2. Lock out incoming power to the

pump or control box to ensure that

the pump will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Close the discharge valve (if

used).

Do not attempt to lift this pump by the

motor power cable or the piping. Attach

proper lifting equipment to the lifting

device fitted to the pump, and make cer-

tain that the hook of the lifting device is

securely positioned in the center of the

pump lifting device. 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.

If this pump is used to handle liquids

which may cause illness or disease

through direct exposure, take neces-

sary precautions during maintenance

and repair to prevent personal contami-

nation.

The motor powering this pump is FM-Ap-

proved for Class 1, Division 1, Groups C

and D environments. All repairs to the

pump, other than seal, impeller and other

hydraulic components, must be per-

formed by a Gorman-Rupp authorized re-

pair facility or the factory. Any repairs to the

motor assembly performed by the custom-

er or an unauthorized repair facility ne-

gates the FM Approval and the motor war-

ranty.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

PUMP FAILS TO

START

MR−03955 JS SERIES PUMPS

APPROVED

TROUBLESHOOTING PAGE B − 1

TROUBLESHOOTING − SECTION B

Review all SAFETY information in Section A.

The following precautions should be

taken before attempting to service the

pump; otherwise, injury or death could

result.

1. Familiarize yourself with this man-

ual and with all other literature

shipped with the pump.

2. Lock out incoming power to the

pump or control box to ensure that

the pump will remain inoperative.

3. Allow the pump to completely cool

if overheated.

4. Check the temperature before

opening any covers, plates or

plugs.

4. Close the discharge valve (if

used).

NOTE

Many of the probable remedies listed below re-

quire use of electrical test instruments; for specific

procedures, see ELECTRICAL TESTING following

the chart.

No power to motor. Check for blown fuse or open

circuit breaker.

Impeller jammed. Check Impeller; disassemble and

repair as necessary.

Motor, voltage or control box incompat- Check ratings on pump nameplate

ible; defective connections. and control box; check incoming

voltage; check connections.

Motor cable damaged. Check (see Electrical Testing).

Control box current interrupting or Check control box; check for leaking

moisture-sensing devices tripped. shaft seals, cut O-rings, or moisture

wicking through cable.

Open circuit in motor windings or cable. Check continuity (see Electrical

Testing).

Motor overheated, thermal switches Allow motor to cool.

tripped.

TROUBLE POSSIBLE CAUSE PROBABLE REMEDY

MOTOR RUNS BUT

FAILS TO DELIVER

RATED FLOW OR

PRESSURE

PUMP STARTS

THEN SHUTS OFF

EXCESSIVE

NOISE OR VIBRA-

TION

JS SERIES PUMPS MR−03955

APPROVED

TROUBLESHOOTINGPAGE B − 2

Pump running backwards. Check and correct impeller rotation

(see Rotation in Installation and

Operation Manual).

Voltage too low or too high; excessive Check incoming voltage; check

voltage drop between pump and control. cable length.

Discharge head too high. Reduce discharge head, or install

staging adaptor and additional pump.

Discharge throttling valve partially Open discharge valve; check piping

closed; check valve improperly installed. installation.

Impeller or discharge line clogged. Check and clear as necessary.

Liquid being pumped too thick. Dilute liquid if possible.

Impeller worn or damaged. Replace.

Insufficient liquid in wet well. Stop pump until liquid level rises;

install liquid level devices.

Clogged suction port or impeller Clear blockage; reset overload

causing motor to overload. device in control box.

Motor overheated; thermal switch Allow pump to cool.

tripped.

Moisture sensing device tripped. Return pump to factory or authorized

repair facility.

Motor bearings defective. Return pump to factory or authorized

repair facility.

Motor cable damaged. Check (see Electrical Testing).

Insufficient liquid in wet well. Stop pump until liquid level rises;

install liquid level devices.

Pump operating outside designed Check discharge head and flow;

operating range. adjust as required to meet perform-

ance specifications.

Impeller clogged. Clear blockage.

Impeller loose or damaged. Check impeller; replace if necessary.

Motor shaft or bearings defective. Replace.

Pumping entrained air. Check wet well liquid level; install

baffles if required.

MR−03955 JS SERIES PUMPS

APPROVED

TROUBLESHOOTING PAGE B − 3

ELECTRICAL TESTING

Make the electrical checks which follow to deter-

mine if pump malfunctions are being caused by

problems in the motor or in the power cable.

Test Equipment

A volt/amp/ohmmeter and megohmmeter of ade-

quate range and quality are required to conduct

the electrical tests which follow. Use commercially

available equipment as listed below.

Equipment Use

Ammeter To check AC Voltage

and current (amperage)

Ohmeter To measure resistance

(ohms) to ground

Refer to the wiring diagram(s) accompany-

ing the motor and control box before re-

connecting any electrical leads which have

been disconnected. Connections to the

wrong terminals may damage the motor

and/or control devices.

Voltage Imbalance

Use a voltmeter to read each phase of the incom-

ing 3-phase power. Each phase must balance with

the other two as closely as can be measured with a

commercial instrument. If the phases are out of

balance, contact your power company. If the

phases are balanced, check out the motor as de-

scribed in the following steps:

a. Use a voltmeter, Amprobe, or equivalent in-

strument to read the voltage of incoming

power lines 1 and 2, 2 and 3, and 1 and 3 at the

control box. Voltage must match as closely as

can be measured. If possible, measure the

voltage at the control box with:

1. The pump off.

2. The pump running in air.

3. The pump submerged and running under

full load.

The voltage measured under each condition must

be the same.

b. If voltage is balanced when the pump is off but

is imbalanced when the pump is running,

thoroughly check the power source, all inter-

connecting cables, and the pump motor to

isolate the defect.

c. Use an Amprobe or equivalent instrument to

measure the current draw (amperage) of

each phase while the pump is running under

full load, and with no load. In each condition,

the amperage readings for all three phases

must match as closely as can be measured.

Normal amperage values are listed in Table 1,

Section B; these values apply only when the

voltage at the site is the normal voltage listed.

Motor and Power Cable Continuity

Set the megohmmeter at R x 1 scale and zero-

balance it. Test as follows:

a. Shut off incoming power to the control box,

and disconnect the motor power cable leads.

Connect the megohmmeter test leads to any

two power cable leads, and note the megohm

meter reading. A high resistance reading indi-

cates an open or broken circuit in the power

cable or motor windings, or a bad connection

between the motor and cable.

b. Repeat Step a. with each set of leads. The

three readings should be as close as can be

measured.

c. If readings indicate that continuity problems

exist in the motor or power cable, the motor

must be returned to the factory or to a Gor-

man-Rupp authorized repair facility.

JS SERIES PUMPS MR−03955

APPROVED

TROUBLESHOOTINGPAGE B − 4

Insulation Resistance

Set the megohmmeter at R x 100, and zero-ba-

lance it. Test as follows:

a. Shut off incoming power to the control box,

and disconnect the motor power cable leads.

Connect one megohmmeter test lead to the

motor cable green/yellow ground lead. Touch

the other test lead to each of the motor cable

leads in turn. Note the readings.

b. Readings will indicate resistance values in

both the power cable and motor windings.If

resistance reads infinity (1), insulation is

good. If resistance reads between infinity (1),

and 1 megohm, insulation is acceptable but

should be rechecked regularly. If resistance

reads less than 1 megohm, insulation should

be checked more closely and frequently.

c. If readings indicate that a ground exists, the

motor must be returned to the factory or to a

Gorman-Rupp authorized repair facility.

MR−03955 JS SERIES PUMPS

APPROVED

PAGE C − 1MAINTENANCE AND REPAIR

PUMP MAINTENANCE AND REPAIR − SECTION C

GENERAL INFORMATION

Review all SAFETY information in Section A.

Do not attempt to service the pump end

assembly unless all power to the motor

has been shut off at the control box;

otherwise, injury or death could result.

Use a lifting device with sufficient ca-

pacity. If slings or chains are used to

move the pump or components, make

sure that the load is balanced; other-

wise serious personal injury or death

could result.

The maintenance and repair instructions in this

manual are keyed to the sectional views, Figures

1 and 2, and the corresponding parts identification

lists. Refer to the separate Parts List Manual for re-

placement parts.

Select a suitable location, preferably indoors, to

perform required maintenance. All work must be

performed by qualified personnel.

The motor powering this pump is FM-Ap-

proved for Class 1, Division 1, Groups C

and D environments. All repairs to the

pump, other than seal, impeller and other

hydraulic components, must be per-

formed by a Gorman-Rupp authorized re-

pair facility or the factory. Any repairs to the

motor assembly performed by the custom-

er or an unauthorized repair facility ne-

gates the FM Approval and the motor war-

ranty.

This Maintenance and Repair Manual provides

troubleshooting and maintenance instructions re-

quired to properly diagnose operational problems,

and to service the pump hydraulic components.

Pump motor maintenance may be performed only

by a Gorman-Rupp authorized repair facility, or the

factory. Otherwise, the pump warranty will be ne-

gated, and damage to the pump, and injury or

death to personnel can result. Contact the factory

for the authorized repair facility closest to you.

Check TROUBLESHOOTING, Section B to deter-

mine causes and remedies of pump problems.

Disassemble the pump only as far as required.

Lifting

Use lifting equipment with a capacity of at least

five times the weight of the pump, including the

weight of any options or customer-installed acces-

sories. The approximate maximum weight for this

pump is 441 lbs. (200 kg.). Discharge hose or pip-

ing must be removed before attempting to lift the

pump.

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