523D-95_IOM_Manual
Operating Instructions and Parts Manual
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
4020 thru 4022 & 5239 thru 523G
Please read and save this Repair Parts Manual. Read this manual and the General Operating Instructions carefully before attempting to assemble,
install, operate or maintain the product described. Protect yourself and others by observing all safety information. The Safety Instructions are contained
in the General Operating Instructions. Failure to comply with the safety instructions accompanying this product could result in personal injury and/or
property damage! Retain instructions for future reference. AMT reserves the right to discontinue any model or change specifications at any time without
incurring any obligation.
©2006 American Machine & Tool Co., Inc. of PA, A Subsidiary of The Gorman-Rupp Company, All Rights Reserved.
Periodic maintenance and inspection is required on all pumps to insure proper operation. Unit must be clear of debris and sediment. Inspect for leaks
and loose bolts. Failure to do so voids warranty.
Industrial/Commercial Sump
Pumps
Description
These upright sump pumps are used for drainage in industrial, residential and commercial settings. Units are completely assembled
(except for float assembly) and equipped with open type impellers, TEFC motor with switch and grounding-type power cord. Handles
liquids from 40º to 200º F (4º to 93º C). For use with non-flammable, non-abrasive liquids compatible with pump component materials.
Specifications
MOTOR
Model
Power Supply Req’d
4020-95, 4021-98
115VAC, 60 Hz
4022-95
Horsepower
Amps
Type
1/2
8
TEFC
115VAC, 60 Hz
1/2
8
TEFC
5239-98, 523A-98
115VAC, 60 Hz
1/3
6
TEFC
523C-98, 523D-98
115VAC, 60 Hz
1/2
8
TEFC
11
TEFC
523F-98, 523G-98
115VAC, 60 Hz
3/4
(TEFC) Totally Enclosed Fan Cooled
NOTE: Driver data is subject to change without notice, see label
on driver for actual specifications.
General Safety Information
1. Know the pump application,
limitations, and potential
hazards.
Do not use
to pump
flammable
or explosive fluids such as
gasoline, fuel oil, kerosene,
etc. Do not use in explosive
atmospheres. Pump should
only be used with liquids
compatible with pump
component materials. Failure
to follow this warning can
result in personal injury
and/or property damage.
PUMP
Model
Base
4020-95, CI
Impeller
Float
Shaft
Column
Bearing
Port
Size*
CI
304SS
303SS
304SS
CBN
2"
CI
304SS
303SS
304
CBN
2"
4022-95
CI
5239-98 thru 523F-98
304SS
304SS
304SS
303SS
304
CBN
1½
4021-98
304SS
304
304SS
303SS
304
CBN
2
5239-95 & 523A-95
CI
304
304SS
303SS
304
CBN
1½
5239-97 & 523A-97
BRZ
304
304SS 303SS
(CI) Cast Iron, (BRZ) Bronze, (SS) Stainless Steel, (CBN) Carbon
(*) NPT
304
CBN
1½
Unpacking
When unpacking the unit, inspect for any damage that may have occurred during transit. Check for
loose, missing or damaged parts.
4000-251-00
1
2. Make certain that the power
source conforms to the
requirements of your
equipment (115VAC).
3. Provide adequate protection
and guarding around moving
parts.
4. Disconnect power before
servicing. If the power
disconnect is out of sight,
lock in the open position and
tag it to prevent unexpected
application of power. Failure
to do so could result in fatal
electrical shock!
5. Release all pressure within
the system before servicing
any component.
6. Drain all liquids from the
system before servicing.
05/2011
Operating Instructions and Parts Manual
7. Secure the discharge line before
starting the pump. An unsecured
discharge line will whip, possibly
causing personal injury and/or
property damage.
8. Check hoses for weak or worn
condition before each use, making
certain that all connections are
secure.
9. Periodically inspect pump and
system components. Perform
routine maintenance as required
(See Maintenance section).
10. Provide a means of pressure relief
for pumps whose discharge line
can be shut off or obstructed.
11. Personal Safety:
a. Keep work area clean,
uncluttered and properly lighted
- replace all unused tools and
equipment.
b. Keep visitors at a safe.
c. Make workshop childproof with padlocks, master switches,
and by removing starter keys.
12. Do not handle the pump with wet
hands or when standing in water
as fatal electrical shock could
occur. Disconnect main power
before handling unit for any
reason.
13. Do not touch an operating motor.
Modern motors are designed to
operate at high temperatures.
14. It is strongly recommended that
this unit is plugged into a Ground
Fault Circuit Interrupter (GFCI).
Consult a local electrician for
installation and availability.
15. All wiring should be performed by
a qualified electrician.
16. When wiring an electrically driven
pump, follow all electrical and
safety codes as well as the most
recent United States National
Electrical Code (NEC) and the
Occupational Safety and Health
Act (OSHA).
Risk of Electric
Shock! Never
connect the green (or green and
yellow) wire to a live terminal!
17. This equipment is only for use on
115 volt (single phase) and is
equipped with an approved 3conductor cord and 3-prong,
grounding-type plug (See Figure
1). To reduce the risk of electric
shock, the motor must be securely
4000 thru 4022 & 5230 thru 523G
and adequately grounded. This
can be accomplished by either: 1)
Inserting plug directly into a
properly installed and grounded 3prong grounding-type receptacle
(See Figure 1); 2) Permanently
wiring the unit with a grounded,
metal raceway system; 3) Using a
separate ground wire connected
to the bar metal of the frame; or 4)
Other suitable means.
Figure 1 - Grounding
Where a 2-prong wall receptacle
is encountered, it must be
replaced with a properly grounded
3-prong receptacle installed in
accordance with the National
Electrical Code and local codes
and ordinances. To ensure a
proper ground, the grounding
means must be tested by a
qualified electrician.
Use only 3-wire extension cords
that have 3-prong, grounding-type
plug and 3-pole receptacles that
accept the equipment plug.
18. Use wire of adequate size to
minimize voltage drop at the
motor.
19. Protect electrical cord from sharp
objects, hot surfaces, oil and
chemicals. Avoid kinking the cord.
Replace or repair damaged or
worn cords immediately.
20. Keep fingers and foreign objects
away from ventilation and other
openings. Do not insert any
objects into the motor.
The pump motor
is equipped with
an automatic resetting thermal
protector and may restart
unexpectedly. Protector tripping is
an indication of motor overloading
as a result of operating the pump at
low heads (low discharge
restriction), excessively high or low
voltage, inadequate wiring,
2
incorrect motor connections, or a
defective motor or pump.
Pre-installation
SUMP PIT AND GENERAL
INFORMATION
This unit can be installed in a pit with a
minimum diameter of 18" and a depth
of 24". (Pit dimensions less than these
will cause rapid cycling and shortened
pump life). A pit may be constructed of
tile, concrete, steel or plastic. Check
local codes for approved materials. The
pit should have a hard bottom. Do not
place pump directly on clay, earth or
sand surface. Make sure there are no
small stones, gravel, sand, dirt, silt, etc.
that may clog or damage the pump
and/or seal and cause pump failure. If
there are stones or gravel, clean these
out as deep as possible by hand; do
not damage or move any drain tiles
below. Fill the pit to the same level as
before with 3/4" to 1" stones and place
either a round or square patio block
(slightly smaller than pit, e.g., 18"
diameter pit should have a 14" round
patio block). The patio block will form a
solid foundation for the pump and still
allow seepage water to enter the pit
from below. Test pump for proper
operation (See Operation) before
installing pit cover. A pit cover will
prevent debris from possibly clogging
or damaging the pump, it will also
prevent persons from falling in and
causing injury.
NEW SUMP
If you are installing a new sump:
1. Locate pump approximately 6"
from basement wall in lowest point
of basement floor.
2. With chalk, mark out diameter on
floor.
3. Cut through floor with masonry drill
or other concrete cutting tool and
excavate below the floor to
required depth.
4. Level bottom and set sump tile in
place. Tie in any sub-floor drains.
Backfill and mortar tile or sump pit
in place. The top should be flush
with floor for surface drainage.
5. It is recommended that bottom of
tile be provided with a concrete
base. However, a concrete block
or bricks may be used to provide a
support for the sump pump.
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
Installation
In installations
where property
damage might
result because of an inoperative
pump due to power outages,
discharge line freezing, or any other
reason, backup system(s) should be
used.
These pumps should never be used
in hazardous or explosive locations,
nor in swimming pool applications.
PUMP LOCATIONS AND
CONNECTIONS
1. Pump should be located and
should rest on a level solid
foundation. Do not suspend pump
by means of a discharge pipe or
power cord. Keep pump inlet clear.
Do not install pump directly on
clay, earth or sand surfaces. Clean
sump pit of small stones, gravel,
sand, dirt, silt, etc. which could
clog or damage pump, or seal, and
cause pump failure. Keep pump
inlet clear.
2. Locate pump in center of pit so
that pump housing and any float
control will not come in contact
with side of pit and create
operational problems. Installation
should be with motor and all
electrical components above the
top grade level of the sump. This
motor is not submersible.
3. Protect pump from extreme heat,
cold and dampness. This unit is
not waterproof and is not intended
to be used in showers, saunas, or
other potentially wet locations. The
motor is designed to be used in a
clean, dry location with access to
an adequate supply of cooling air.
Ambient temperature around the
motor should not exceed 104º (40º
C). For outdoor installations, motor
must be protected by a cover that
does not block airflow to and
around the motor. This unit is not
weatherproof nor is it able to be
submersed in water or any other
liquid.
4. Connect discharge piping and run
it to nearest sewer or surface
outlet. Sump pumps can be piped
to discharge into the house
drainage system to a dry well,
splash block, or to a storm drain
depending on local plumbing
codes. The discharge piping
5.
6.
7.
8.
should be as short as possible to
reduce pipe friction losses. It is
recommended that the discharge
pipe diameter should be equal to
or larger than the discharge size
of the pump. Smaller pipe
diameters will restrict the capacity
of the pump and reduce
performance. These sump pumps
are provided with an NPT
discharge connection. Assure
airtight pipe connections with the
use of a pipe joint sealant.
It is recommended that a 12"
nipple be installed in the discharge
outlet first and the balance of the
piping attached to the nipple.
Install a union in the discharge
line, preferably just above the
sump pit, to allow easy removal of
the pump for cleaning or repair. To
reduce motor noise and vibration
transmission to the building
structure, a short length of rubber
hose (e.g., radiator hose) can be
connected into the discharge line
using suitable clamps. A
discharge line check valve should
not be used unless needed to
prevent pump from recycling when
the water level drops and pump
shuts off.
In installations where the piping is
long, the vertical discharge is
above 7 or 8 feet, or a small sump
has been provided, use of a check
valve is recommended to prevent
back flow of water into the sump.
Where a check valve is used, drill
a relief hole (1/8" or 3/16"
diameter) in the discharge pipe.
This hole should be located below
the floor line between the pump
discharge and the check valve.
Unless such a relief hole is
provided, the pump could "air
lock" and will not pump water even
though it will run.
It is strongly recommended that
this pump motor be electrically
connected to a ground fault
interrupter. Consult your local
electrician for availability and
installation.
Power Supply: Pump is designed
for 115V, 60 Hz operation and
requires a circuit of 15 amperes or
more capacity. Wire unit on a
separate line (power). Pump is
supplied with a 3-wire cord set
with ground-type plug for use in a
3-wire, grounded outlet. Three-
3
wire extension cord of at least 14
AWG size is suggested; larger
sizes for runs over 25 feet.
For safety, pump should always be
electrically grounded to a suitable
electrical ground such as a
grounded water pipe or a properly
grounded metallic raceway or
ground wire system.
DO NOT CUT OFF THE ROUND
GROUNDING PRONG. Cutting
cord or plug will void warranty. Do
not bend, kink or cut power cord.
Protect cord from sharp objects,
hot surfaces, oil and chemicals.
Replace damaged cord.
9. Float rod stop setting:
a. ON high water level stop
setting: With the switch arm in
the OFF position, slide float rod
assembly up until float is at
desired high water level
position.
b. Position lower rod stop "A": it
must trip the switch arm into
the ON position when float
reaches high water mark.
NOTE: Care must be taken to
ensure that rod stop "A" trips the
switch arm before the float hits
standoff bracket. Pump will not
turn ON if float makes contact
against standoff bracket before
stop "A" activates motor switch.
c. OFF low water setting: with
switch arm in ON position, slide
float rod assembly down until
float is at desired low water
level.
d. Position upper rod stop "B" so
that it trips switch arm into OFF
position when float reaches low
water level.
NOTE: Care must be taken to
ensure that upper rod stop "B"
trips the switch arm before lower
rod stop "A" contacts standoff
bracket. Pump will not turn off if
lower rod stop "A" contacts the
bracket before upper rod stop "B"
activates motor switch.
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
with the float control motion or to
drape over the pump motor. With
electrician’s tape, secure the cord
to the discharge pipe. This will
provide protection for the cord and
make a neat installation.
11. Install any auxiliary components
(e.g., back-up pumps, warning
systems, timer, etc.).
12. After all piping and controls have
been installed, connect the pump
cord cap to the electrical outlet
and run water into the sump to
test the pump.
13. Unit is ready for operation.
Operation
e. After setting all stops as
described above, the sump
should be filled with water. The
pump should be checked for
correct operation and desired
ON/OFF water levels.
Disconnect the
power supply
before attempting
any servicing or adjustments to the
pump.
10. Do not allow the cord to interfere
Do not touch
sump pump,
pump motor,
water, or discharge piping when the
pump is connected to electrical
power. Do not handle a pump or
pump motor with wet hands or
when standing on wet or damp
surface, or in water. Never tough
the sump pump or discharge piping
when unit is operating or fails to
operate. Always disconnect the
pump cord (power) before handling.
Do not attempt to operate pump
without water! Bearings could be
damaged if pump is run dry.
1. Plug unit into 115V outlet.
2. Fill the sump with water to the
normal turn-on level and allow
pump to remove water to normal
control turn-off point.
3. If necessary, readjust the cutin/cut-out differential. See Step 9
under Installation for guidance.
4. The float must not touch pit walls
or discharge pipe and must be
able to move freely.
4
5. Install a sump cover. A cover will
prevent matter from falling into
sump, prevent odors, and guard
against accidental injury.
6. While the unit is draining the
sump, verify that the discharge
piping is carrying the water to a
point several feet away from the
foundation.
Maintenance
Make certain that
the pump is
unplugged before
attempting to service or remove any
component. This is a difficult pump
to repair, therefore, only qualified
electricians or service personnel
should attempt to repair this unit.
Improper repair and/or assembly
can cause an electrical shock
hazard.
1. Pump and motor bearings require
NO lubrication.
2. Pump should be checked for
proper operation weekly or
monthly by filling the sump pit with
water and watching the operation
of the pump, the on and off locks,
etc. If anything has changed since
the pump was new, the pump
should be removed from the pit,
examined and repaired.
3. Inlet should be kept clean and free
of all foreign objects and
periodically inspected. Sump pit
should be kept free of small
stones, gravel, sand, dirt, silt, etc.
These items can clog and/or
damage pump and pump bearings,
eventually causing pump failure.
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
Troubleshooting Chart
Symptom
Pump won’t start or run
Possible Cause(s)
Corrective Action
1. Water level too low
2. Blown fuse
3. Low line voltage
4. Defective motor
5. Defective float switch
6. Impeller clogged or jammed
(pump filled with debris)
7. Float water-logged
8. Float touching or jammed up against
side of pit
Pump starts and stops
too often
1.
2.
3.
4.
Backflow of water from piping
Improper positioning of float rod collars
Long extension cord
Low line voltage
5. Very low discharge head or pit too
small
1. Pump will not turn on unless float pushes collar
to activate switch.
2. If blown, replace with fuse of proper size.
3. If voltage under recommended minimum, check
size of wiring from main switch on property. If OK,
contact power company.
4. Replace motor
5. Replace switch
6. Disassemble and clean out. If impeller won’t
turn, remove housing and locate source of
binding.
7. Replace float
8. Reposition pump, move away from side of pit
1.
2.
3.
4.
Install check-valve
Reposition
Shorten extension cord
Check for proper wire size. If okay, call
power company.
5. Increase discharge head or restrict discharge
by use of gate valve (1/2 open), make pit
larger.
Pump won’t shut off
1. Defective switch
2. Restricted discharge (rag or obstacle
in piping)
3. Float rod jammed or defective
4. Float touching or jammed up
against side of pit
1. Replace switch
2. Remove pump and clean pump and
piping
3. Repair or replace
4. Reposition pump, move away from side of
pit
Pump operates, but delivers
little or no water
1. Low line voltage
1. If voltage under recommended minimum,
check size of wiring from main switch on
property. If OK, contact power company.
2. Remove and clean out
3. Replace worn parts or entire pump.
Clean parts if required.
4. Drill 1/8" hole in discharge piping
between pump and check valve
2. Debris caught in impeller
3. Worn or defective pump parts
plugged impeller.
4. Pump air locked
5
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
For replacement parts, please provide the following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
Figure 2 - Repair Parts Illustration
6
402X SERIES
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
For replacement parts, please provide the following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
Figure 3 - Repair Parts Illustration
7
523X SERIES
Operating Instructions and Parts Manual
4000 thru 4022 & 5230 thru 523G
Repair Parts List
Ref.
No.
Description
4020-95
1/2HP
32" C.I.
4021-98
1/2HP
32" S.S.
4022-95
1/2HP
42"
5239-9x
1/3HP
29"
523A-9x
1/3HP
41"
523C-9x
1/2HP
29"
523D-9x
1/2HP
41"
523F-9x
3/4HP
29"
523G-9x
3/4HP
41"
Qty.
8
1
Motor
523C-350-90 523C-350-90 523C-350-90 5239-350-90 5239-350-90 523C-350-90 523C-350-90 523F-350-90 523F-350-90
1
2
Switch
5460-000-00 5460-000-00 5460-000-00 5460-000-00 5460-000-00 5460-000-00 5460-000-00 5460-000-00 5460-000-00
1
3
Switch Bracket Kit
5230-106-90 5230-106-90 5230-106-90 5230-106-90 5230-106-90 5230-106-90 5230-106-90 5230-106-90 5230-106-90
1
4
Strain Relief Bushing
5230-353-00 5230-353-00 5230-353-00 5230-353-00 5230-353-00 5230-353-00 5230-353-00 5230-353-00 5230-353-00
2
5
Rod Stops (Pkg of 2)
5230-105-90 5230-105-90 5230-105-90 5230-105-90 5230-105-90 5230-105-90 5230-105-90 5230-105-90 5230-105-90
2
6
Power Cord
1639-077-00 1639-077-00 1639-077-00 1639-077-00 1639-077-00 1639-077-00 1639-077-00 1639-077-00 1639-077-00
1
7
Rod
5230-104-00 5230-104-00 5231-104-00 5230-104-00 5231-104-00 5230-104-00 5231-104-00 5230-104-00 5231-104-00
1
8
Float
5239-107-00 5239-107-00 5239-107-00 5239-107-00 5239-107-00 5239-107-00 5239-107-00 5239-107-00 5239-107-00
1
9
Screen
5230-040-00 5230-040-00 5230-040-00 5230-040-00 5230-040-00 5230-040-00
1
10 Shaft Assembly
5239-140-90 5239-140-90 523A-140-90 5239-140-90 523A-140-90 5239-140-90 523A-140-90 5239-140-90 523A-140-90
1
11 Standoff Bracket Kit
5230-102-90 5230-102-90 5230-102-90 5230-102-90 5230-102-90 5230-102-90 5230-102-90 5230-102-90 5230-102-90
1
12 Volute/Tube Kit Cast Iron (-95)
4021-150-95
1
Volute/Tube Kit S.S. (-98)
—
Volute/Tube Kit Bronze (-97)
—
—
—
13 Impeller Cast Iron
4021-010-95
—
4021-010-95
Impeller S.S.
—
14 Base Kit (Includes Screws)
Base Kit S.S. (Includes Screws)
—
4020-061-90
—
—
—
—
4022-150-95 5230-151-95 5231-151-95 5230-151-95 5231-151-95 5230-151-95 5231-151-95
4021-150-98 4022-150-98 5230-150-98 5231-150-98 5230-150-98 5231-150-98 5230-150-98 5231-150-98
5239-152-97 523A-152-97 5239-152-97 523A-152-97 5239-152-97 523A-152-97
—
—
—
—
—
—
1
4021-010-98 4021-010-98 5230-012-98 5230-012-98 5233-011-98 5233-011-98 5236-010-98 5236-010-98
—
4020-061-90
—
—
—
—
—
—
1
4021-060-98 4021-060-98 5230-060-98 5230-060-98 5230-060-98 5230-060-98 5230-060-98 5230-060-98
15 Bearing
2196-004-00 2196-004-00 2196-004-00 2196-004-00 2196-004-00 2196-004-00 2196-004-00 2196-004-00 2196-004-00
Please use correct 6-digit number:
-95 =Cast Iron
-97 =Bronze
-98 =Stainless Steel
1
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