Submersible Solids-Handling Pumps

OWNER’S MANUAL
Submersible Solids-Handling Pumps
4BSW4 Series
6191 0310
293 WRIGHT STREET, DELAVAN, WI 53115 WWW.berkeleypumps.COM
PH: 888-782-7483
© 2014 Pentair Ltd. All Rights Reserved.
BE889 (02/28/14)
PUMP/MOTOR IDENTIFICATION
Carefully record all of the following data from your pump/motor nameplate. It will aid in obtaining the correct replacement
parts for your pump. In addition to the nameplate, the pump serial number is also stamped on the discharge flange.
Pump:
Serial Number_______________________________________________________________________________________
Size__________________________________________ Model #_____________________________________________
GPM_________________________________________ Head___________________________________________ (feet)
BHP:_________________________________________ RPM:_______________________________________________
Pump ________________________________________ Weight (lbs.)__________________________________________
Motor:
Horsepower_________________________________________________________________________________________ Serial Number_______________________________________________________________________________________
Motor Frame________________________________________________________________________________________
Full Load Speed_____________________________________________________________________________________
Full Load Amps______________________________________________________________________________________
Phase/Hz/Volts___________________________ /_________________________ /______________________________
Motor Weight________________________________________________________________________________________
Motor Identification Number____________________________________________________________________________ Date Placed in Service________________________________________________________________________________
2
TABLE OF CONTENTS
PUMP/MOTOR IDENTIFICATION..................................................................................................2
INTRODUCTION.............................................................................................................................3
WARRANTY....................................................................................................................................4
PRESTART-UP AND START-UP CHECKLIST.............................................................................5
SAFETY INSTRUCTIONS..............................................................................................................6
STORAGE OF PUMPS...................................................................................................................6
GENERAL.......................................................................................................................................6
INSTALLATION..............................................................................................................................7
OPERATION...................................................................................................................................8
TROUBLESHOOTING..................................................................................................................10
MAINTENANCE............................................................................................................................11
ILLUSTRATIONS..........................................................................................................................13
Variations exist in both the equipment used with these
pumps and in the particular installation of the pump and
driver. Therefore, specific operating instructions are not
within the scope of this manual. The manual contains
general rules for installation, operation and maintenance
of the pump. If there are questions regarding the pump or
its application which are not covered in this manual, please
contact the factory as follows:
Berkeley
293 Wright Street
Delavan, WI 53115
To obtain additional data on hydraulics and pump selection
and operation, we suggest you purchase. “Hydraulic
Institute Standards” from the Hydraulic Institute, 9 Sylvan
Way, Parsippany, NJ 07054-3802.
California Proposition 65 Warning
This product and related accessories contain
chemicals known to the State of California to cause cancer,
birth defects or other reproductive harm.
INTRODUCTION
Congratulations! You are the new owner of the finest pump
commercially available. If you give it the proper care as
outlined and recommended by this manual, it will provide
you with reliable service and long life.
NOTE: Read this complete manual and manuals for all
component equipment before assembly or installation
is started. It contains information which is the result of
engineering and research efforts. It is designed to supply
adequate instructions for the installation, operation and
maintenance of your pump. Failure or neglect to properly
install, operate or maintain your pump may result in
personal injury, property damage or unnecessary damage to
the pump.
This manual applies to the pump installation, operation
and maintenance. They are intended to be general and
not specific. If your operating conditions ever change,
always refer to the factory for reapplication. Always refer
to the manuals provided by manufacturers of the accessory
equipment for their separate instructions.
This manual contains installation, operation and
maintenance instructions for Berkeley UL and CSA Listed
submersible pumps and motors. Instructions for non-UL
or non-CSA listed submersible pumps and motors may be
obtained by contacting the factory.
3
Limited Warranty
BERKELEY warrants to the original consumer purchaser (“Purchaser” or “You”) of the products listed below, that they will be
free from defects in material and workmanship for the Warranty Period shown below.
Product
Warranty Period
Water Systems:
Water Systems Products — jet pumps, small centrifugal pumps, submersible pumps and
related accessories
whichever occurs first:
12 months from date of original installation, or
18 months from date of manufacture
Pro-Source™ Composite Tanks
5 years from date of original installation
Pro-Source™ Steel Pressure Tanks
5 years from date of original installation
Pro-Source™ Epoxy-Lined Tanks
3 years from date of original installation
Sump/Sewage/Effluent Products
12 months from date of original installation, or
18 months from date of manufacture
Agricultural/Commercial:
Centrifugals – close-coupled motor drive, frame mount, SAE mount, engine drive, VMS, SSCX,
SSHM, solids handling, submersible solids handling
12 months from date of original installation, or
24 months from date of manufacture
Submersible Turbines, 6” diameter and larger
12 months from date of original installation, or
24 months from date of manufacture
Our limited warranty will not apply to any product that, in our sole judgement, has been subject to negligence, misapplication,
improper installation, or improper maintenance. Without limiting the foregoing, operating a three phase motor with single
phase power through a phase converter will void the warranty. Note also that three phase motors must be protected by threeleg, ambient compensated, extra-quick trip overload relays of the recommended size or the warranty is void.
Your only remedy, and BERKELEY’s only duty, is that BERKELEY repair or replace defective products (at BERKELEY’s choice). You
must pay all labor and shipping charges associated with this warranty and must request warranty service through the installing
dealer as soon as a problem is discovered. No request for service will be accepted if received after the Warranty Period has
expired. This warranty is not transferable.
BERKELEY SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT DAMAGES WHATSOEVER.
THE FOREGOING LIMITED WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED
WARRANTIES, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE. THE FOREGOING LIMITED WARRANTIES SHALL NOT EXTEND BEYOND THE DURATION
PROVIDED HEREIN.
Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on the duration of an
implied warranty, so the above limitations or exclusions may not apply to You. This warranty gives You specific legal rights and
You may also have other rights which vary from state to state.
This Limited Warranty is effective June 1, 2011 and replaces all undated warranties and warranties dated before June 1, 2011.
In the U.S.: BERKELEY, 293 Wright St., Delavan, WI 53115
In Canada: 269 Trillium Dr., Kitchener, Ontario N2G 4W5
4
SUBMERSIBLE PUMP/MOTOR
PRESTART-UP AND START-UP CHECKLIST
Contractor_________________________________________ Pump Serial Number_________________________________
Project Name_______________________________________ Pump Model Number_________________________________
Date of Shipment____________________________________ Motor Serial Number_________________________________
Procedure
YesNoN/A
1.Shipment
Was there any damage in transit? (If so, has freight claim been filed?)
Were all items received?
2.Storage
Has equipment been protected from the elements?
Was equipment subject to flooding?
3.Installation
Have proper anchor bolts been used? Have the bolts been properly tightened? Has discharge been checked for pipe strain?
4.Rotation
Has the rotation of the drives been checked for correct rotation? Are moisture detectors wired into controls? Are thermostats wired into controls?
Is motor wired to a continuous meggaring device? Do controls have proper disconnect protection? Are heater coils correctly sized and installed properly? Are controls wired with an alarm that will promptly notify personnel
if a problem develops? 5.System
Has the system been checked to insure that it is free of foreign matter
which could be damaging to the pump? Is liquid available to the pump? Has assurance been obtained from responsible parties that all piping
is secure and that the routing of flow has been established and
is correct? Are liquid levels properly set? 6.Start-Up
Has flow been established? Flow rate:______________ GPM Have gauge readings been taken? Discharge pressure:_________PSI Is excessive vibration present? What is recorded line voltage? _____________ volts
What is motor amp draw on each leg? 1.)______ 2.)______ 3.)______ 7.Safety
Have all safety labels been read and understood? Name__________________________________________Date___________________
Name__________________________________________Date___________________
5
Comments
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
__________________________
READ AND FOLLOW SAFETY
INSTRUCTIONS!
properly supported prior to start-up and operation.
Burn hazard. Certain procedures in
disassembly and assembly require parts be heated to high
temperatures. Heated parts can cause severe burns. Wear
heat resistant gloves when handling heated parts.
NOTE: This manual contains general instructions for
installation and operation of Explosion-Proof Submersible
Pumps. Since pumping station designs and electrical
controls will vary significantly between various installations,
only general wiring diagrams for the motor and controls are
shown in this manual.
This is the safety alert symbol. When you see this
symbol on your pump or in this manual, look for one of
the following signal words and be alert to the potential for
personal injury.
warns about hazards that will cause serious
personal injury, death or major property
damage if ignored.
warns about hazards that will or can cause
serious personal injury, death or major property damage if
ignored.
STORAGE OF PUMPS
NOTE: If the equipment is not to be immediately installed
and operated, at least do the following:
Consider a unit in storage when:
1. It has been delivered to the jobsite and is awaiting
installation.
2. It has been installed but operation is delayed.
3. There are long (30 days or more) periods between
operation cycles.
4. The facility is shut down.
NOTE: Improper storage could result in product failures or
damage not covered by warranty.
If the pumps and motors are not immediately installed and
operated, store them vertically in a clean, dry, well-ventilated
area, free from vibration, moisture, and rapid or wide
variations in temperature. Rotate the motor shaft by hand
several revolutions every 4 weeks to ensure the bearing and
seal components are coated with oil for protection against
corrosion.
NOTE: Keep ends of power and control cables clean and
dry; do not submerge in water or sewage. Submergence
will result in permanent damage to the cables.
warns about hazards that will or can cause
minor personal injury or property damage if ignored.
The label NOTE indicates special instructions which are
important but not related to hazards.
The installation, use and operation of this type of equipment
is affected by various Federal, State and Local Laws,
Underwriters Laboratories (UL) and the regulations
concerning OSHA. Compliance with such laws relating to
the proper installation and safe operation of this type of
equipment is the responsibility of the equipment Owner and
all necessary steps should be taken by the Owner to assure
compliance with such laws before operating the equipment.
The Motor supplied on this order is UL and CSA Listed for
Hazardous Locations Class 1, Division 1, Group C and D,
when used with normal line current. When the motor is
built with inverter duty insulation, the pump may be used in
variable frequency drive applications.
Risk of serious eye injury from flying
chips, foreign matter on the pump, etc. Wear protective
eye glasses while working on this equipment.
GENERAL
Risk of sudden and unexpected starts.
Disconnect and lock out power and verify that pump
cannot start before servicing or working on equipment.
Many installations use automatic starting equipment, which
can cause the unit to start at any time without warning.
Proper precautions should be taken to avoid injury as a
result of automatic starting of the equipment.
NOTE: This product has been designed specifically for
operation in water or sewage. Consult the factory before
using it with other liquids.
The Model 4BSW4 pumps consist of several components.
The following is a list of those major parts (or component
assemblies) and a brief description of their design and
function.
Impellers
The impeller is a balanced solids-handling type made of
close-grained cast iron. The impeller is a one piece, single
suction, enclosed radial flow design with well-rounded
leading vanes and then tapered toward the trailing edge for
a circular flow pattern. The waterways through the impeller
have extremely smooth contours, devoid of sharp corners,
so as to minimize rags, stringy or fibrous material from
catching or clogging. The impeller is balanced and secured
to the shaft by means of a bolt and key. The arrangement
is such that the impeller cannot be loosened from torque in
either forward or reverse rotation.
Risk of puncture wounds and health
hazards from sharp objects. Do not try to clean the
pump with bare hands. Always wear heavy puncture
resistant gloves when cleaning the pump. The pumped
material may contain items that may present health hazards
such as needles and other sharp objects.
Before attempting to service this pump:
1. Familiarize yourself with this manual.
2. Disconnect or lock out the power source to
insure the pump will not start. Confirm power
source disconnect with appropriate electrical test
equipment.
3. Close the discharge valve, and if present, the suction
valve.
After the pump has been installed, make certain that
the pump and all piping connections are tight and are
Volute
The volute is matched to the impeller and made of closegrained cast iron. The volute is of one-piece constant
velocity, equalizing pressure design with smooth fluid
passage large enough to pass any size solid that can
pass through the impeller. The volute includes a flanged
discharge connection.
6
When the content of the pumpage includes large amounts
of fibrous solids which cannot be removed prior to the
pump, the sump design should be of the nature to allow
the pumps to be run at near full speed, drawing down the
sump and cycling the pumps on and off as required. This
is particularly true during low flow periods when solids tend
to settle out and accumulate at the bottom of the sump
and in the suction piping. Low speed and low velocity
pumping can even cause plugging in a vertical leg of the
discharge piping. Reduced pump speed and low suction
velocities must be avoided to reduce the tendency to clog.
The sump and suction piping design should be of the “selfcleaning” design to avoid the accumulation of solids at these
locations.
Fits and Hardware
The volute and fronthead are manufactured with concentric
shoulder fits to assure accurate alignment. All bolts, nuts
and capscrews are stainless steel and are of the hexheaded type.
Motor
The motors have a rated maximum operating skin
temperature of 160 degrees C.
Motors are designed for standard use with either 230V or
460V three phase service depending on the nameplate
rating. On special order other voltages are available. All
motor ratings are noted on the motor nameplate, and are
based on operating in a 40 degree C ambient temperature.
Insulation is Class F as noted on the motor nameplate.
The standard motors have duty ratings for any one of three
operating conditions: continuous duty in air, continuous
duty submerged, and one-hour duty in air. For a more
detailed discussion of these conditions, see the section on
“Operation.”
The motor is mounted directly on the pump volute, and
the pump impeller is installed on the motor shaft. All motor
housing joints are equipped with long rabbet fits and O-ring
seals. The housing is made of close grain cast iron. The
motor shaft and all external nuts and bolts are stainless
steel.
Motors have a single row, upper radial ball bearing and a
single row, lower thrust ball bearing. All bearings are oil
lubricated for life.
The motor shaft is sealed with two mechanical seals,
mounted in a tandem arrangement, and with an oil chamber
between them. The inner seal has a carbon rotating face
and a ceramic stationary face (optional seal faces are
available for the inner seal). The outer seal has a reaction
bonded silicone carbide stationary face and a tungsten
carbide rotating face. The o-rings for both the inner seal and
outer seal stationary faces are viton.
Since all mechanical seals must seep moisture to
provide lubrication to the sealing faces, two moisture
detector probes have been installed in the seal
chamber. This system monitors the quantity of water in
the oil chamber. When a mixture of 25 to 30% of water
to oil is reached, the moisture controller will signal that
it is time to change the oil. O-ring sealed fill and drain
plugs are included for ease of changing oil in the oil
chamber.
Thermostats in the motor windings are standard, and protect
the motor from excessive winding temperatures. Power and
control cables are epoxy-potted into the cover to prevent
moisture from intruding into the motor. For additional
protection of maintenance and operation personnel, it is
highly recommended that the motor power circuitry have
ground fault circuit interruption (GFCI) capabilities.
Non-Clog: Pumps referred to as non-clog are specially
designed to accommodate the pumping of solids by
providing larger than normal passage ways through the
impeller and volute, minimizing the number of impeller
vanes and volute cut-waters. In addition, the leading edges
of the impeller vanes and the volute cutwater are well
rounded to promote the shedding of long fibrous material.
These features make non-clog pumps more resistant to
plugging from the accumulation of solids in the pump than a
pump of conventional design. However, no pump can ever
be described as being completely resistant to clogging.
INSTALLATION
General
Carefully read all sections of this manual and all other
instruction manuals supplied by manufacturers of other
equipment supplied with this pump.
Upon receipt of this shipment, unpack and inspect the
pump/driver assembly and individual parts to ensure none
are missing or damaged. Carefully inspect all boxes and
packing material for loose parts before discarding them.
Report immediately to the factory, and the transportation
company involved, any missing parts or damage incurred
during shipment, and file your “damaged and/or lost in
shipment” claim with the carrier immediately.
Piping
NOTE: All piping connections must be made with the pipe
in a rigid supported state, and without the need to apply
vertical or side pressure to obtain alignment of the piping
with pump flange.
All piping should be independently supported so that neither
mechanical nor hydraulic pipe strain exists.
Discharge Piping
Discharge pipe should be as direct as possible with a
minimum of valves to reduce pipe friction losses. A check
valve and closing valve should be installed in the discharge
line. The check valve, between the pump and closing valve,
prevents reverse rotation in the event of power failure. The
closing valves are used to isolate the pump for repairs.
Crushing hazard if pump falls. Pump is
heavy (5 and 7.5 HP: 625 lbs.; 10 and 15 HP = 660 lbs.);
use appropriate lifting gear. Never stand under a
hanging load.
A.Attach one end of a suitable lifting cable or chain to the
metal motor bale or lifting harness. Attach the other end
to a suitable lift or hoist that will bear the weight of the
pump.
NOTE the following: Prior to lifting the unit, check to
make sure that all hooks, cables, chains and hoists are
of adequate strength and size. The approximate weight
of pump plus motor is 625–660 pounds.
Lifting mechanism sheave shall have a diameter large
enough so as to not crimp or severely bend the lifting
cable. Small diameter or angle type sheaves could
cause cable failure.
Do not lift by the power or control cable. Damage to the
cables and connections will result and you may drop the
pump.
B. With an adequate hoist, lower the pump into the wet pit.
7
of 125 feet or less. The detectors can be wired to
shutdown the motor or to activate an indicator or alarm
device, or to do both. (Sample moisture detection
controllers are located in the drawing section of this
manual.) A compatible controller must be connected
to properly protect the motor. A controller rated for 500
volts A/C with a triggering resistance across the probes
of
25,000 Ohms is required.
NOTE: Moisture detectors must be connected and
functional. Operation of the pump without operative
moisture detectors will void the motor warranty.
F. The direction of rotation should be checked before the
pump is put in operation. Raise the pump back out of
the wet-well and carefully lay it horizontally. The correct
rotation of the pump is indicated by an arrow cast on the
volute. While looking into the pump section, “bump” start
the motor to observe rotation.
C. Connect the discharge piping. Tighten all bolts and
eliminate any pipe strain.
D. Install the controls per the control manufacturer’s
recommendations.
E. Wire the motor and motor protection devices.
The motors are supplied with one 4-lead power cable.
Lead color codes and terminal connections are outlined
in Tables 1 and 2.
Table 1: Power Cable Terminal Connections (1)
Frame
210
Black
T3
Lead Color Code
White
Red
T1
T2
Green
Ground
Table 2: Control Cable Terminal Connections (2)
Control
Lead Color Code
Device
Black White Red Orng
Grn
Thermostats
P2
P1
N/A N/A
Grd
Moisture Detector N/A
N/A
W2
W1 Grd
Risk of loss of fingers or serious hand
injury. Do not put hands or any item in
the volute suction to determine direction of rotation, as
doing so will cause serious personal injury.
Bump start is generally accomplished on three-phase
motors by engaging and immediately disengaging the
power switch. It is seldom necessary to engage the
power source for more than one second to determine
motor rotation.
Note the direction of impeller rotation. It the impeller
rotates opposite the arrow on the pump volute, reverse
any two of the three power leads and motor rotation will
be reversed
Both motor mechanical seals are lubricated and cooled by
the oil in the oil chamber. Oil chamber is filled at the factory
prior to shipment.
(1) Power leads connect the motor to the power supply.
(2) Control leads connect thermostats, moisture detectors and
optional thrust bearing RTD controls.
Possible explosion hazard. UL
requirements do not permit splicing the cable. Make
all connections at the terminal ends of the cable.
Figure 4 (later in this manual) shows the simplified
schematic wiring diagram for 210 frame motors. The
thermostats should be wired in series with the stop
button. Provision for manual reset of the motor after
the thermostats trip is recommended. The thermostats
themselves will reset automatically after the motor
windings cool down.
Risk of explosion. All electric controls
and motor starting equipment must be located outside
the hazardous area unless they are approved for
hazardous locations.
Hazardous voltage and risk of
unexpected motor starts. Can burn or kill. Open and
lock out the disconnect switch before doing any work on
the motor-pump unit.
The current through the thermostat shall not exceed the
OPERATION
General
NOTE: This section contains general rules for operation.
Because variations may exist in a particular installation
between the pumps, the drivers and the accessory
equipment, specific operating instructions are not within the
scope of this manual.
Hazardous voltage. Can shock, burn, or
kill. Before starting or operating the pump, read this entire
manual and the control manufacturer’s instructions for
proper operation of the system, especially complying with
the following instructions:
1. Duty Cycles:
It is important that the motor be operated within the limits
of its rating. Carefully note the “Duty” block on the motor
nameplate.
A Duty cycle of “Short Time in Air 1 Hour” requires the
following:
The capacity of the pump should be selected to be
greater than the maximum flow into the wet well. Under
maximum flow conditions, the pump should draw down
the sump from the top of the motor, Level A, to the
bottom flange on the motor, Level B, within 1 hour. See
Figure 1.
The power frequency shall not vary by more than +/-5%,
Table 3: Thermostat Current Limits
Volts
220-240
440-480
Continuous Inrush
Amps
Amps
1.5
15.0
0.75
7.5
limits in the following table:
NOTE: Thermostats must be connected in the circuit and
must be operative. Running the motor with inoperative
thermostats will void the warranty. Thermostat contact
rating 120-600 VAC, 360 VA maximum.
Figure 4 (later in this manual) shows a typical wiring
diagram for the moisture detectors for cable lengths
8
2.
3.
4.
5.
6.
and the voltage by more than +/-10% of the nameplate
data. Voltage deviation from the nameplate ratings will
have an effect on the pump speed and, therefore, on
pump performance. The pump will deliver the rated
head and capacity only when running at the rated speed.
Note: Voltage should not vary from phase to phase by
more than 2% without derating the motor’s horsepower
rating. Damage may occur to the motor if operated with
more variation.
NOTE: Check to make sure that input voltage is the
same as the motor rated voltage. Proper voltage is
required or permanent damage to the motor may occur.
Make sure the moisture detection system is operational
at all times. Note that all mechanical seals must seep
to provide lubrication to the rotating faces. The seep is
trapped in the oil chamber between the inner and outer
seals. During the initial run-in period, new seals may
seep enough to cause the moisture alarm to go off.
This is normal, change the oil and put the unit back into
service.
Make sure both the suction (if required) and discharge
valves are open.
Observe all caution, warning and danger tags that may
be attached to the equipment.
Never run the pump longer than 15 minutes without
liquid in the volute as close running fits within the pump
are lubricated by the liquid. This condition may result in
pump seizure, and/or seal damage.
Because of tight internal clearances these pumps should
not run against a closed valve, unless approved by the
factory.
Pump stations are usually designed to have the pumps
started and stopped automatically. Since this is a function
of station design, the operators should be familiar with the
system’s operating parameters. The general procedure to
shut down the pump is as follows:
A. Disconnect the electrical motor.
B. If the pump is to be removed for repair, close the suction
and discharge valves.
Seasonal Operating Instructions
If the pump is located in an area that is subject to below
freezing temperatures and will not be operated enough to
prevent freezing, the sump and pump should be drained to
prevent damage to the casing caused by freezing.
Emergency Procedures
Many installations are equipped with emergency shut off
switches near the pump location. These locations should be
plainly marked and be readily accessible at all times.
The control panel (if used) may be equipped with an
emergency start/stop button or switch.
NOTE: The operator or persons working around the
equipment should be familiar with locations of emergency
start-up and shut-off points.
Starting the Pump
A. Be sure the pump is submerged properly and that
the liquid level exceeds the minimum operating level
recommended.
B. Refer to the motor nameplate for operation limits before
proceeding.
C. The pump requires no special procedures or adjustments
before starting, except to check for rotation. The control
system should be set to ensure no more than 10 across
the line starts per hour.
Risk of explosion and fire. Pump water
or sewage only with this pump. NEVER pump
flammable liquids with this pump.
D. Start the unit.
E. Immediately after the pump has been started, check the
following:
1) Observe the unit for any unusual noise or vibration.
2) The voltage should be within +/- 10% of the rated
nameplate voltage across each phase. There should
be no more than 2% variation between the average
voltage and each leg.
3) The amp reading of each phase should be less than
the rated nameplate amps.
4) Observe the unit for proper pressure and flow output.
5) Continue to observe the unit’s operation for at least
the next four hours.
F. For any problems, consult the “Troubleshooting” section
of this manual.
LEVEL A
LEVEL B
Figure 1: Typical Installation
Stopping the Pump
9
6155 0201
Symptom
Probable Cause
Corrective Actions
Insufficient Wrong direction of rotation.
Pressure
or Flow
Impeller running clearance too great.
Speed too low.
Impeller passage partially plugged.
Insufficient net positive suction head.
Air in liquid.
Impeller damaged.
Impeller diameter too small.
Insufficient submergence.
Excessive Pumping too much liquid.
Power Consumption
Speed too high.
Improper line voltage or frequency.
Incorrect diameter impeller.
Internal rubbing.
Shaft bent.
Rotating element binds.
Specific gravity or viscosity of liquid pumped is too high.
Vibration Pipe strain.
or Noise
Wrong rotation.
Pumps too much liquid and exceeds NPSHR.
Shaft bent.
Vortexing
Pump running at shut-off. Restricted discharge,
internal recirculation.
Air in liquid.
Impeller passages plugged.
Overheating
Shaft bent.
Insufficient submergence.
Rotating element binds.
Excessive load.
Excessive cycles.
Excessively high or low voltage.
Loss of internal oil.
Liquid Level Excessive flow to wet well.
Above High Solids collecting around the pump suction Limit
reducing pump capacity.
Controls improperly set on the high level.
Improper sump design.
Pump has been inoperative temporarily and excess water has accumulated in wet well.
10
Reverse any two motor lead connections.
Check O&M manual.
Reset impeller clearance per O&M manual.
Check driver voltage and electrical source.
Clean impeller passages.
Raise wet well level.
De-aerate liquid. Increase submergence to prevent vortexing.
Check and repair or replace.
Replace impeller with larger diameter. Check driver HP.
Increase submergence.
Change system. Reduce pump speed. Trim
impeller.
Check driver speed and voltage.
Check driver voltage. Change power source or driver.
Determine correct impeller diameter and replace or trim impeller.
Replace shaft.
Determine cause and correct.
Reduce pump capacity.
Improperly supported or aligned. Check pipe supports; adjust or realign.
Reverse any two motor lead connections. Check O&M manual.
Increase system head. Reduce pump speed.
Trim impeller.
Replace shaft.
Increase suction head.
Open discharge valve. Check for obstructions.
Increase submergence.
Clean impeller passages.
Replace shaft.
Increase submergence.
Determine cause and correct.
Increase system head. Check for mechanical interference.
Change level controls, change system.
Correct voltage source.
Check oil level, check for bearing and seal damage.
Reduce influent. Increase pump capacity.
Remove solids accumulation.
Reset controls.
Correct sump design.
Operate pump to reduce level. (If a higher than normal water level has existed and was not witnessed, it can easily be detected by examining
the sump for a scum line above the normal high
level limit.)
4. If pump/motor inspection, maintenance or repair must
be performed at another location, disconnect the
motor leads at the controller.
B. Remove the capscrews holding the motor to the volute.
Remove the motor and impeller assembly from the
volute.
C. Remove the impeller capscrew (9) and impeller washer
(9A). Because the impeller capscrew (9) is installed
with Loctite, it may be necessary to heat the capscrew
to break the bond. Excessive heating may damage the
lower seal.
TROUBLESHOOTING
If you have followed the installation and start up procedures
outlined in this manual, your pump should provide reliable
service and long life. However, if operating problems occur,
significant time and expense can be saved if you use the
following checklist to eliminate the most common causes of
those problems.
MAINTENANCE
General
A. With proper application of the pump/motor unit and
proper installation of all the protective devices, no
periodic maintenance of the equipment is necessary.
B. Should the moisture detector indicate intrusion of
moisture, the pump should be shut-down as soon as
possible. Oil should be drained from the motor by
removing the oil cavity inspection plug. Dispose of oil
in accordance with local ordinances. With the motor in
position with the inspection plug hole at the top, refill the
seal chamber with the recommended oil (one port: 19
oz.; two or three ports: 28 oz.) and place the unit back in
service. (In some cases, the seal faces require time to
seal properly and some water may have passed by the
seal faces into the seal oil chamber causing an alarm to
signal.)
Note that all mechanical seals must seep to provide
lubrication to the rotating faces. The seep is trapped
in the oil chamber between the inner and outer seals.
During the initial run-in period, new seals may seep
enough to cause the moisture alarm to go off. This is
normal, change the oil and put the unit back into service.
C. Should a malfunction be indicated by the motor
protection devices or observed in the operation of the
pump, the pump should be removed, serviced, and the
cause of the problem corrected. Refer to the REPAIR
PARTS section of this manual for instructions on
ordering.
D. Motor overheating may be caused by an accumulation
of foreign material collecting on the outside of the motor
housing. The outside of the motor housing should be
cleaned.
Burn hazard. Wear heat resistant
gloves when handling heated parts.
D. Remove the impeller (1) and the impeller key (102) from
the motor shaft.
1. The impeller (1) has a straight bore fit, with a close
tolerance. It may be necessary to use a wheel puller
or similar device.
2. Note the location and number of shims placed
between the impeller hub and the shaft shoulder.
NOTE: Care should be taken not to damage the impeller
when using a puller or similar device. Attach the puller
or other equipment behind the impeller vane area only.
Do not try to pull against the unsupported impeller
shroud.
NOTE: Do not try to remove the shaft from the motor or
disassemble any part of the motor.
3. Store the motor in a clean, dry place if no motor
repair is required.
E. If the impeller or fronthead wear rings require
replacement, or if the pump is to be retrofitted for wear
rings, refer to the “WEAR RINGS” section of this manual.
Always use original manufacturer’s parts.
Note: It is not necessary to remove the volute (30) from
the fronthead (33) unless those items require service.
F. If the fronthead (33) must be removed, remove the
capscrews and remove from the volute (30). Remove
the cleanout over (202) and gasket (203), if provided.
Motor Disassembly
NOTE: The motor requires no periodic service, with the
exception of changing the mechanical seal oil every 4000
hours of operation, not to exceed one year. Motor bearings
are lubricated for life.
Pump Disassembly
NOTE: Read this entire disassembly procedure and refer to
the sectional drawings in this manual before starting.
A. Prepare the pump for disassembly according to the
following procedures:
1. Disconnect and lock out the power to the motor.
UL Listing requirements do not permit
disassembly or repairs of the motor by the
owner, except for the replacement of the outer seal or
the cable assembly. Motors must be returned to the
factory or an authorized UL Listed Qualified Service
Center.
A. Cover/Cable Removal
1. With the motor in a vertical position remove the cover
capscrews, loosening slowly to allow any pressure to
escape.
2. Break the seal between the cover and the housing.
3. Lift cover, turn over, and secure to housing with one
cover capscrew.
4. Remove the terminal board nuts and lead wires.
B. Lower Mechanical Seal Removal
1. Drain oil from seal chamber through the inspection
plug (34G), and properly dispose of oil in accordance
Risk of electrical shock and
unexpected starts. Lock out and tag out all
circuits connected to the motor before beginning
to work on the pump or motor. Check with
appropriate electrical test equipment to make sure
that the motor cannot be accidentally started.
2. Remove the pump and motor from the sump.
3. Place the pump in an area where it can be cleaned
and decontaminated thoroughly. Remove all scale
and deposits on the pump. Submerge the complete
pump in a disinfectant solution (chlorox or chlorine
bleach) for at least one hour before disassembling
the pump. Dispose of the bleach solution in
accordance with local ordinances.
11
with local ordinances.
2. Remove the rotary seal body clamp by removing the
two locking screws.
3. Remove the rotating portion of the seal.
4. Remove the gland capscrews (31A).
5. Remove the gland (31).
6. Remove the stationary portion of seal from the gland.
Registered
fit area
O-Ring
90
6239 0810
Burn hazard. Allow the motor to cool
before attempting to disassemble it. Residual heat in
the motor windings can cause high temperatures and
pressures within the motor. Escaping hot gas or oil may
cause serious burns.
NOTE: Normal maintenance does not require removal of the
upper seal. Removal of the upper seal is not recommended
as it requires draining and refilling the motor oil—also not
recommended.
Motor Assembly
NOTE: Read this entire assembly procedure before starting.
A. Outer Mechanical Seal and Gland Installation
1. Inspect the shaft.
2. Buff out all nicks that could cut the seal elastomer.
NOTE: Exercise caution while buffing to avoid
creating flat spots on the shaft under the elastomer.
Wipe the shaft clean with a soft cloth. Keep the cloth
out of the oil cavity.
3. Clean the machined surfaces.
4. Clean the oil cavity.
5. Install the gland O-ring (31B) on the gland (31).
6. Run a small bead of 515 Loctite® Form-a-Gasket
around the face of the lower bearing housing (34).
7. Install the gland (31) and install the gland capscrews
(31A).
8. Lubricate the viton O-ring on the stationary seal face
with a water based rubber lubricant (P-80 or equal)
and install it in the gland. Be sure the correct side
(polished side) is facing up. Extreme care is to be
taken not to damage the stationary seal face, and
when installed, it is level and perpendicular to the
shaft. It is recommended to measure down to at least
three points on the seal face, at 120 degrees from
each other. These dimensions should not vary more
than 0.003”.
9. Lubricate the inner diameter of the elastomer body of
the rotating seal with a water based rubber lubricant
(P-80 or equal).
10.Install the rotating portion of the seal. Be sure not to
damage the seal when it passes over the step on the
shaft. Take care as the seal body is sliding down the
shaft. Try to keep the seal straight (not cocked) to
the shaft and the ridge inside the seal body will seat
in the groove in the shaft.
11.Install the retaining clamp, secure with the two locking
screws.
12.Through the fill port on the side of the housing, fill the
oil cavity (one port: 19 oz.; two or three ports: 28 oz.).
Replace plug.
12
shaft and the impeller (1) exceeds 0.003” anywhere
along the length of the impeller bore, contact the
factory for instructions for rework or replacement of
the components.
3. Install the impeller key (102) in the motor shaft.
Replace the shaft shims and if provided the circulator.
Slide the impeller (1) in place, making sure it butts
firmly against the shaft shims or circulator.
4. With the impeller washer (9A) in place, install the
impeller capscrew (9) and tighten it to 60 ft.-lbs torque.
D. If the volute (30) and fronthead (33) have been removed
proceed as follows:
1. Use new cleanout cover gaskets (203) and install the
cleanout cover (202), if provided.
B. Cover/Cable Assembly
1. Install the cover O-Ring (32A) onto the cover.
2. Connect the control and power cable lead wires to
the terminal board as shown on the drawings in the
Auxiliary Diagrams section of this manual.
3. Run a small bead of 525 Loctite™ Form-a-Gasket
around the motor housing (90) to seal it to the cover.
525 Loctite™ must be applied so
as to keep it away from the o-ring and
registered fit area.
4. Place the cover onto the motor housing or top motor
housing and bolt up.
Pump Assembly
NOTE: Read this entire assembly procedure before starting.
The following step-by-step instructions for assembly of the
pump are essentially the reverse order of the instructions for
disassembly.
A. Prepare the pump for assembly according to the
following procedures:
1. Thoroughly clean all parts to remove all oil, grease
and any foreign material.
2. Inspect all parts including the motor shaft for wear or
damage and replace if required.
3. Gaskets should not be reused and should always be
replaced.
B. If the impeller or fronthead wear rings are being
replaced, or if the pump is to be retrofitted for wear rings,
refer to the “Wear Rings” section of this manual. Always
use original manufacturer’s parts.
C. Thoroughly clean the impeller bore, the end of the shaft,
the shaft and keyway.
1. Inspect and measure the impeller bore, the shaft fit
diameter, the key and the keyway for wear.
NOTE: Measure in several locations along the length of
the fit.
2. If wear is noticed and the clearance between the
Seal Oil
3-PHASE MOTOR LEAD SIDE CONNECTIONS
RED
POWER LEAD
BLACK
POWER
LEAD
T2
T3
W2
WHITE
POWER
LEAD
T1
W1
P2
P1
WHITE
CONTROL
LEAD
RED
CONTROL
LEAD
A.C. Supply
Line
BLACK
CONTROL LEAD
ORANGE
CONTROL LEAD
1
2
3
4
5
6
7
8
9
10
460 V #2
Controller Wiring
Wiring by Other
Control Enclosure
460 V #1
230 V
#2
#8
230 V #1
#7
460 V
#3
T2
Load contacts
T3
T1
P1
P2
W1
230 V
#3
#9
W2
500 Volts AC
25,000 Ohms
Triggering
Resistance
Y
THERMOSTAT
Moisture Detector
Continuity Test Pushbutton
& Indicator Light
#4
#7
460 V
W1
W2
MOISTURE
DETECTOR
#6
#5
#8
#9
460 V 460 V
#4
#5
#6
230 V
3-PHASE CABLE LEAD
SIDE CONNECTIONS
Motor
6142 0110
Figure 2: Moisture Detection Controller Wiring Diagram
6144 0110
Figure 3: Dual Voltage Terminal Board Connections
13
14
Item
Engineering Number (230V)
Engineering Number (460V)
Motor (230Volt)
Motor (460 Volt)
Lifting Bail
Lifting Bail Capscrews
Impeller
Impeller Capscrew
Impeller Washer
Vertical Base
Base Capscrews
Base Capscrew Nuts
Volute Wear Ring
Fronthead Wear Ring
Volute
Volute Capscrews
Pipe Plug
Fronthead
Fronthead Capscrews
Impeller Key
Volute Gasket
Impeller Hub Shim (.015”)
Impeller Hub Shim (.005”)
Handhole Cover
Handhole Cover Capscrews
Handhole Cover Gasket
4” D5431W-5HP
B85654
B85658
U005C2214A1X
U005D2214A1X
CP8984AA 2280 F
(2) 11FM7A0111 0005 F
T4A1FG675
11FM7A0113 0003 F
CP5855AN 9660 F
T4A15J 0220 F
(8) 11FM7A0174 0005 F
(8) 11FM25A10007 0005 F
T4A16A 9630 F
N/A
T4A30AG 0220 F
(8) 11FM7A0056 0005 F
N/A
N/A
N/A
16FM104S0194 4780 F
T3A155A 8380 F
(2) CP5819AA 2280 F
(4) CP5819AB 2280 F
N/A
N/A
N/A
* Replaceable only by an Authorized Motor Repair Station.
• Not illustrated.
Parts below are a part of the motor cost above:
32
Cover/Cable Assembly
CP8986H25
(Includes Key Nos. 32A, 90E)
32A Cover/Cable Assembly O-Ring
HYD6E114
(Included with Cover/Cable
Assembly, Key No. 32)
34D Water Sensor Probe
*
34G/H Drain/Fill Plugs
(2) HYD42U1 9906 F
90E Terminal Board Assembly
CP9003J 1111A
90F Terminal Board Retaining Ring
HYD37A11 9906F
•
Inner Mechanical Seal
*
456
Outer Mechanical Seal
HYD1EW1 9906 F
F
Key
No.
M
M
B
BA
1
9
9A
15
15A
15B
16
16
30
30A
33
33A
102
156
186
186
202
•202A
•203
CP8986K25
HYD6E114
*
(2) HYD42U1 9906 F
CP9003J 1111A
HYD37A11 9906F
*
HYD1EW1 9906 F
HYD6E114
*
(2) HYD42U1 9906 F
CP9003J 1111A
HYD37A11 9906F
*
HYD1EW1 9906 F
4” D5432W-10HP
B85656
B85660
U010C2214B1X
U010D2214B1X
CP8984AA 2280 F
(2) 11FM7A0111 0005 F
T4B1MG770
11FM7A0114 0003 F
CP5855AN 9660 F
T4A15J 0220 F
(8) 11FM7A0174 0005 F
(8) 11FM25A10007 0005 F
N/A
T4C16AF 9630 F
T4B30AK 0220 F
(8) 11FM7A0112 0005 F
(5) 20FM7D0004 0008 F
T4B33AZ 0220 F
(8) 11FM7A0112 0005 F
16FM104S0194 4780 F
(2) CP2930 8380 F
(4) CP5819AA 2280 F
(2) CP5819AB 2280 F
T4C202A 3980 F
(4) 11FM7A0112 0005 F
TBGA467A 7880 F
CP8986H25
4” D5431W-7.5HP
B85655
B85659
U007C2214A1X
U007D2214A1X
CP8984AA 2280 F
(2) 11FM7A0111 0005 F
T4A1FG760
11FM7A0113 0003 F
CP5855AN 9660 F
T4A15J 0220 F
(8) 11FM7A0174 0005 F
(8) 11FM25A10007 0005 F
T4A16A 9630 F
N/A
T4A30AG 0220 F
(8) 11FM7A0056 0005 F
N/A
N/A
N/A
16FM104S0194 4780 F
T3A155A 8380 F
(2) CP5819AA 2280 F
(4) CP5819AB 2280 F
N/A
N/A
N/A
4BSW4 Parts List
*
(2) HYD42U1 9906 F
CP9003J 1111A
HYD37A11 9906F
*
HYD1EW1 9906
HYD6E114
CP8986L25
4” D5432W-15HP
B85657
B85661
U015C2214B1X
U015D2214B1X
CP8984AA 2280 F
(2) 11FM7A0111 0005 F
T4B1MG865
11FM 7A0114 0003 F
CP5855AN 9660 F
T4A15J 0220 F
(8) 11FM7A0174 0005 F
(8) 11FM25A10007 0005 F
N/A
T4C16AF 9630 F
T4B30AK 0220 F
(8) 11FM7A0112 0005 F
(5) 20FM7D0004 0008 F
T4B33AZ 0220 F
(8) 11FM7A0112 0005 F
16FM104S0194 4780 F
(2) CP2930 8380 F
(4) CP5819AA 2280 F
(2) CP5819AB 2280 F
T4C202A 3980 F
(4) 11FM7A0112 0005 F
TBGA467A 7880 F
GND
MOTOR CONTROL
O.L.
BLACK
C
FUSE
L2
RED
C
FUSE
L3
WHITE
C
Aux. Control
Power Circuit
O.L.
T1
WHITE P1
STOP
START
BLACK
T2
MOTOR
THERMOSTATS
C
TO: WARRICK
CONTROL
500 Volts AC
T3
W1
RED
FUSE
ORANGE
DISCONNECT
L1
W2
P2
MOISTURE
PROBES
Submersible Motor Wiring Diagram
for 210T and 220T Frame Motors
6141 0110
Figure 4: Submersible 210T Frame Motor Wiring Diagram.
32B
32
32A
B
90E
90F
BA
M
30A
186
156
102
9A
1
30
33A
16
15
34H
202
202A
203
9
33
34D
34G
15A 15B
456
Figure 5: Submersible Solids Pump Assembly Drawing.
6140 0110
Figure 6: Submersible Solids 210 Frame Motor Assembly
Drawing.
6139 0510
15
1-1/8
Mfg. Holes For No. 10 Screw
6-1/4
A.C.
Power
Supply
Outer Seal Leakage
Indicator Light
A
2
3
4
5
6
7
8
9
10
4
1
6-1/4
A
1-1/8
Y
Load
Contacts
4
1-1/8
3-1/8
4
1-1/8
Y
7/8
Sensor Probe,
Continuity Test Pushbutton, and
Indicator Light
Dimension Diagram
NEMA Type 4
Watertight
1-1/4 1-1/4
1/2” NPT Tappings
Wiring by Warrick
Wiring by Others
Control Enxlosure
W1
W2
6181 0310
Figure 9: Dimension drawing, NGMA Type 4 Watertight
Control Housing
Motor
6182 0310
Figure 7: Connections for Warrick Moisture Detection
Controls
A
Load
Contact
Load
Contact
Y
Contact
Configuration
6183 0310
Figure 8: Contact configuration for Warrick Moisture
Detection Controls
16
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