Gormann-Rupp Pumps JS4L60-E8.7 200/3 User manual

OM-03534-OM01

July 16, 1990

Rev. F 06‐23‐04

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

JS4L60‐E8.7 200/3, 230/3, 460/3, 575/3

JS4M60‐E11 200/3, 230/3, 460/3, 575/3

JS4N60‐E8.7 200/3, 230/3, 460/3, 575/3

JS4P60‐E11 200/3, 230/3, 460/3, 575/3

OM-03534 JS4L‐M‐N‐P

PAGE 1TOC

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-4..........................

PUMP INSTALLATION PAGE B-4...............................

Lifting PAGE B-4.........................................

Positioning the Pump PAGE B-4............................

Piping. PAGE B-4........................................

ELECTRICAL CONNECTIONS PAGE B-5.......................

Field Wiring Connections (Incoming Power) PAGE B-5........

Single Voltage PAGE B-5..................................

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

Conductor Identification PAGE B-5.........................

Control Box Connections PAGE B- 5........................

Wiring Diagrams PAGE B-6................................

Liquid Level Devices 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......................................

Operations Checks PAGE C-5.............................

Cold Weather Preservation PAGE C-6.......................

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

Insulation Resistance PAGE D-3............................

JS4L‐M‐N‐P OM-03534

PAGE 2 TOC

MAINTENANCE AND REPAIR - SECTION E PAGE E-1.

PUMP MODELS PAGE E-1....................................

PARTS LISTS:

Pump Model Assemblies PAGE E-3........................

Motor Assemblies PAGE E-5...............................

PUMP AND MOTOR DISASSEMBLY PAGE E-6..................

PUMP END DISASSEMBLY PAGE E-6..........................

Removing Volute Casing PAGE E-6........................

Removing Impeller PAGE E-6..............................

Lower Seal Removal PAGE E-7............................

Upper Seal Removal 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-9......................................

Other Reusable Parts (Except Seal Assemblies) PAGE E-9....

Cleaning Seal Assemblies 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-12..........................

Installing Upper Seal Assembly PAGE E-12...................

Installing Lower Seal Assembly PAGE E-13...................

Seal Testing PAGE E-13....................................

Installing Impeller PAGE E-14...............................

Installing Volute Casing PAGE E-14.........................

Impeller Clearance PAGE E-14..............................

Final Assembly PAGE E-15.................................

LUBRICATION PAGE E-15.....................................

Bearings PAGE E-15......................................

Draining Oil PAGE E-15....................................

Condition of Oil PAGE E-15.................................

Adding Oil PAGE E-15.....................................

OM-03534 JS4L‐M‐N‐P

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 single‐vol

tage, and is shipped from the factory wired only for

the voltage shown on the nameplate. Do not at

tempting to change the voltage.

The pump motor is designed to be operated

through an appropriate 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 will

handle solids up to 3 inches (76,2 mm) in diameter.

They are equipped with an integral guide shoe

which engages an optional base elbow with a 4‐

inch discharge. They 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 are not cov

ered in this manual. Refer to other literature accom

panying 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:

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.

JS4L‐M‐N‐POM-03534

SAFETY PAGE A - 1

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 versions of this pump are

dual‐voltage. Your pump was wired at

the factory for the voltage and phase

shown on the nameplate. Do not attempt

to change the voltage in the field. If de

sired to have the voltage changed, re

turn the pump to the factory or an autho

rized Gorman‐Rupp repair facility only;

otherwise, damage to the pump and in

jury 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

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.

OM-03534JS4L‐M‐N‐P

PAGE A - 2 SAFETY

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.

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 completely cool if

over heated.

3. Close the discharge valve (if used).

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.

OM-03534 JS4L‐M‐N‐P

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 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. (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 liquid being

pumped from entering the seal housing cavity from

the pump end. The upper seal prevents oil from es

caping from the seal housing into the motor hous

ing, and acts as back‐up 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 grease lubricated.

There is no other lubrication in the pump.

Pump Dimensions

See Figures B-1 and B-2 for the approximate

physical dimensions of this pump.

OM-03534

JS4L‐M‐N‐P

PAGE B - 2 INSTALLATION

FIGURE B-1. JS4L60-E8.7 And JS4M60-E11 (All Voltages)

PUMP DIMENSIONS

OM-03534 JS4L‐M‐N‐P

PAGE B - 3

INSTALLATION

FIGURE B-2. JS4N60-E8.7 And JS4P60-E11 (All Voltages)

PUMP DIMENSIONS

OM-03534

JS4L‐M‐N‐P

PAGE B - 4 INSTALLATION

Pump Motor Specifications

The motor furnished with this pump is a single volt

age, 60 Hz., Squirrel Cage, Induction Start, G‐R

Frame Size No. 3; 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

JS4L60-E8.7 230/3 4” 8.7 1750 27.6A 15.9A 160.1A

/PHASE

JS4L60-E8.7 460/3 4” 8.7 1750 13.2A 7.6A 76.6A

JS4M60-E11 230/3 4” 11 1750 27.6A 15.9A 160.1A

JS4M60-E11 460/3 4” 11 1750 13.2A 76.6A7.6A

JS4N60-E8.7 230/3 4” 8.7 1750 27.6A 15.9A 160.1A

JS4N60-E8.7 460/3 4” 8.7 1750 13.2A 76.6A7.6A

JS4P60-E11 230/3 4” 11 1750 31.8A 15.9A 159.0A

JS4P60-E11 460/3 4” 11 1750 15.2A 76.0A7.6A

JS4P60-E11 200/3 4” 11 1750 33.1A 17.5A 175.0A

JS4N60-E8.7 200/3 4” 8.7 1750 33.1A 17.5A 175.0A

JS4M60-E11 200/3 4” 11 1750 33.1A 17.5A 175.0A

JS4L60-E8.7 200/3 4” 8.7 1750 33.1A 17.5A 175.0A

JS4L60-E8.7 575/3 4” 8.7 1750 10.6A 6.1A 61.3A

JS4M60-E11 575/3 4” 11 1750 10.6A 61.3A6.1A

JS4N60-E8.7 575/3 4” 8.7 1750

JS4P60-E11 575/3 4” 11 1750

10.6A 61.3A6.1A

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 with an automatic sub

mersible connection which allows the pump to be

removed and/or installed without personnel enter

ing the wet well.

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