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Installation, Operation, and Maintenance Manual
JCU
Table of Contents
Table of Contents
Safety regulations for Ex-approved products in potentially explosive atmospheres ................ 6
JCU Installation, Operation, and Maintenance Manual 1
2
Introduction
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Requesting other information
Special versions can be supplied with supplementary instruction leaflets. See the sales contract for any modifications or special version characteristics. For instructions, situations, or events that are not considered in this manual or in the sales documents, please contact the nearest ITT representative.
Always specify the exact product type and identification code when requesting technical information or spare parts.
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
JCU Installation, Operation, and Maintenance Manual
Safety
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is overpressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by ITT. If there is a question regarding the intended use of the equipment, please contact an ITT representative before proceeding.
• Do not change the service application without the approval of an authorized ITT representative.
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• Never use heat to disassemble the pump due to the risk of an explosion from trapped liquid.
• Always lockout power to the driver before performing pump maintenance.
• Never operate any pumping system with a blocked suction and discharge. Operation, even for a brief period under these conditions, can cause confined pumped fluid to overheat. If pump becomes plugged, shut down and unplug prior to restarting pump.
• The pump can handle hazardous and toxic fluids. Identify the contents of the pump and observe proper decontamination procedures in order to eliminate the possible exposure to any hazardous or toxic fluids. Wear the proper personal protective equipment. Potential hazards include, but are not limited to, high temperature, flammable, acidic, caustic, explosive, and other risks. You must handle and dispose of pumped fluid in compliance with the applicable environmental regulations.
• If the pump/motor is damaged or leaking oil, do not operate as it may cause an electric shock, fire, explosion, liberation of toxic fumes, physical harm, or environmental damage.
Correct/repair the problem prior to putting back in service.
• Never apply heat to remove an impeller. The use of heat may cause an explosion due to trapped liquid, resulting in severe physical injury and property damage.
• Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Hazard levels
Hazard level
DANGER:
Indication
A hazardous situation which, if not avoided, will result in death or serious injury
JCU Installation, Operation, and Maintenance Manual 3
4
Safety
Hazard level
WARNING:
Indication
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
CAUTION:
NOTICE:
• A potential situation which, if not avoided, could result in undesirable conditions
• A practice not related to personal injury
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Do NOT send the product to the manufacturer if it has been contaminated by any nuclear radiation. Inform ITT so that accurate actions can take place.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
JCU Installation, Operation, and Maintenance Manual
Safety
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other sections of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage property.
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
JCU Installation, Operation, and Maintenance Manual 5
6
Safety
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
• A small amount of liquid will be present in certain areas like the seal chamber.
Wash the skin and eyes
1. Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:
Condition
Chemicals or hazardous fluids in eyes
Chemicals or hazardous fluids on skin
Action
1.
Hold your eyelids apart forcibly with your fingers.
2.
Rinse the eyes with eyewash or running water for at least
15 minutes.
3.
Seek medical attention.
1.
Remove contaminated clothing.
2.
Wash the skin with soap and water for at least 1 minute.
3.
Seek medical attention, if necessary.
Safety regulations for Ex-approved products in potentially explosive atmospheres
Guidelines for compliance
WARNING:
This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly stated in this manual.
If there are any questions regarding these requirements, the intended use, or if the equipment requires modification, contact an ITT representative before you proceed.
Personnel requirements
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical characteristics of the gas and/or vapor present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national standards (for example IEC/EN 60079-17).
JCU Installation, Operation, and Maintenance Manual
Safety
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data stated on the nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running during service and inspection is only permitted outside the classified area.
• Before you start working with the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product.
• Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the product specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that have been provided by an authorized ITT representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices:
• Pressure gauges
• Flow meters
• Level indicators
• Motor load readings
• Temperature detectors
• Bearing monitors
• Leak detectors
• PumpSmart control system
JCU Installation, Operation, and Maintenance Manual 7
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Transportation and Storage
Transportation and Storage
Receive the unit
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
4. Pump should be placed in upright position only.
Unpack the unit
1. Remove packing materials from the unit.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the unit to determine if any parts have been damaged or are missing.
3. Contact your ITT representative if anything is out of order.
4. Pump should be placed in upright position only.
Pump handling
WARNING:
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• These pumps might use carbon or ceramic silicon carbide components. Do not drop the pump or subject it to shock loads as this can damage the internal ceramic components.
NOTICE:
Use a forklift truck or an overhead crane with sufficient capacity to move the pallet with the pump unit on top. Failure to do so can result in equipment damage.
Lifting methods
WARNING:
• All lifting must be done in compliance with all applicable regulations/standards.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.
Use the supplied lifting lugs and suitable slings in order to lift the entire pump to a vertical position and lower the unit into the sump. Then use the lifting lugs on the motor and a suitable sling, or optional slide rail system to hoist the motor into position. Use a tag line attached to the casing end in order to prevent the pump from swinging.
JCU Installation, Operation, and Maintenance Manual
Examples
Transportation and Storage
Figure 1: Example of proper lifting method using lifting lugs
Pump storage requirements
Requirements
Submersible units require proper preparation for storage and regular maintenance during storage. The unit is considered in storage when it has been delivered to the job site and is awaiting installation.
For specific requirements for storing motors, gearheads, and engines, contact the equipment manufacturer.
JCU Installation, Operation, and Maintenance Manual 9
Transportation and Storage
Storage preparation
Condition
Indoor storage area (preferred)
Outdoor storage area (when indoor storage is not available)
Placement of pumps and component parts
Stacking of units or component parts
Rotation of the pump and bowl assembly shaft
Controlled storage facilities
Uncontrolled storage facilities that have uneven temperatures, higher humidity, and/or dusty conditions)
Proper preparation
• Pave the area.
• Clean the area.
• Drain the area and keep it free from flooding.
• Observe all indoor storage requirements.
• Use weather-proof coverings such as flame-resistant sheeting or tarpaulins.
• Place coverings in a manner that maximizes drainage and air circulation.
• Tie coverings down in order to protect the pump from wind damage.
• Place the unit on skids, pallets, or shoring higher than 6 in.
(15 cm) from the ground for good air circulation.
• Sort the parts in order to permit easy access for inspection and/or maintenance without excessive handling.
• Pump should be stored in upright position only.
• Make sure that racks, containers, or crates bear the full weight of units or parts in order to prevent distortion.
• Keep identification markings readily visible.
• Immediately replace any cover you remove for internal access.
• Store pump/motor in upright position.
• Rotate the shaft and bowl assembly shaft counterclockwise once a month, at a minimum.
• Make sure that the shaft rotates freely.
• Maintain an even temperature of 10°F (6°C) or higher above the dew point.
• Keep the relative humidity to less than 50%.
• Make sure that there is little or no dust.
• Inspect the unit periodically to make sure that all preservatives are intact.
• Seal all pipe threads and flanged pipe covers with tape.
When pump is not in regular operation
If a pump has been installed, but is not in regular operation for an extended period of time, such as during a seasonal shutdown, then operate it for at least 15 minutes every two weeks, if possible.
Preservation and Storage
ITT Goulds Pump Division's normal domestic shipping and storage preparation is suitable for protecting the pump during shipment in covered trucks. Although this is a submersible pump, storage in a clean, dry area will help preserve the paint and prevent corrosion. Hand rotation of the shaft every thirty days is recommended to keep the seals free and the bearings lubricated.
For additional storage requirements, reference ABB/Baldor/Reliance Submersible motor
Instruction Manual.
10 JCU Installation, Operation, and Maintenance Manual
Installation
Installation
Inspect the Pump
Install the sump
1. The sump floor should be level and firm where the pump will be placed.
2. Make sure the sump and sump inlet line are free from large pieces of debris which could eventually obstruct the pump inlet.
Install the motor
The motor is furnished with thermal protection and a moisture probe.
1. Wire the motor according to the motor manufacturer's wiring diagram in the motor IOM.
2. Recheck the protective circuits after the wiring is completed to avoid a possible motor failure because of an oversight.
3. The motor must be completely submerged for continuous operation. It can be operated for a maximum of 15 minutes without being submerged, The sump controls should be set to allow a maximum possible run of 15 minutes after the motor is no longer completely submerged if the sump is large enough to not have completed the pump-down in that time.
Motor is rated for a maximum 10 starts per hour.
NOTICE: The motor is rated for full horsepower with liquid temperatures of 104°F (40°C) or lower, unless noted otherwise on nameplate or ITT documentation.
Install the pump
1. Make sure the lifting device is securely fastened to the motor lugs or hooks so the unit will not be dropped when it is lowered into the sump.
2. Check the 1/8" vent hole in the adapter plate, between the motor and the casing, to make certain it is not plugged and then carefully lower the unit into position in the sump.
3. Check the pump for being approximately level.
4. Support the discharge pipe to prevent excessive loads from being transmitted to the pump flange and casing.
Slide rail system (optional)
Install the base component assembly
1. Apply gasket adhesive to item #360W and place on side shown in Section Y-Y to base upright.
NOTICE: Quantity two 1/2" holes may need to be punched or cut in gasket to allow clearance for items #372K.
2. Position item #787G, sump flange adapter, as shown in section Y-Y and secure to base upright using items #372K.
3. Apply gasket adhesive to item #360W and place in section Y-Y and secure to base upright.
4. Insert short-threaded end of stubs, items #787U, through base uprights and into the top two holes of the sump flange adapter, item #787G.
JCU Installation, Operation, and Maintenance Manual 11
Installation
5. Position top two holes of the discharge elbow, item #315, over the two studs, items #787U, and thread nuts, items #787V, onto studs finger tight. Insert items #370S, hex head cap screws, through remaining elbow and base upright holes, and thread into sump flange adapter finger tight.
6. Level discharge flange then tighten nuts and hex head cap screws, items #370S and
#787V.
7. Secure item #787H, adjusting bracket, to sump flange adapter using items 370T, hex head cap screws.
8. Thread quantity one nut, item #357, onto the entire length of item #787J, adjusting bolts, and insert into the hole centered in item #787H, adjusting bracket.
NOTICE: The adusting bolt's head should face towards the sump flange adapter.
Install the guide bracket / pivot bracket assembly
Apply Loctite 242 on all hardware unless otherwise specified.
1. Apply gasket adhesive to item #360W and place on side shown in Section "Y"-"Y" to base upright. Note, quantity two 1/2" holes may need to be punched or cut in gasket to allow clearance for items
2. Position item #787G, sump flange adapter, as shown in section "Y"-"Y" and secure to base upright using items #372K.
3. Apply gasket adhesive to item #360W and place on opposite side shown in Section "Y"-"Y" to base upright..
4. Insertshort-threaded end of studs, items #787U, through base upright and into the top two holes of the sump flange adapter, item#787G.
5. Position top two holes of the discharge elbow, item #315, over the two studs, items #787U, and thread nuts, items #787V, onto studs finger tight. Insert items #370S, hex head cap screws, through remaining elbow and base upright holes, and thread into sump flange adapter finger tight.
6. Level discharge flange then tighten nuts and hex head cap screws, items #370S and
#787V.
7. Secure item #787H, adjusting bracket, to sump flange adapter using items 370T, hex head cap screws.
8. Thread quantity one nut, item #357, onto the entire length of item #787J, adjusting bolt, and insert into the hole centered in item #787H, adjusting bracket. Note, the adjusting bolt's head should face towards the sump flange adapter.
Install the lifting bracket assembly
Apply Loctite 271 to all lifting bracket hardware.
1. Position left and right lifting brackets as shown on the top and elevation views of the drawing. Insert item #370R, hex head cap screw, through the right lifting bracket, the motor's lifting lug, and out left lifting bracket. Thread item #357C onto item #370R finger tight.
2. Place washers, items #788B, over items # 788A, hex head cap screws, and insert them into the holes located in the motor adapter, item #240, finger tight. Note, drill and tap holes in motor adapter at the location shown on page 4 of the slide rail installation instructions.
Pump does not need to be disassembled for drill and tap operation.
3. Insert item #371G, hex head cap screw, through both lifting brackets and thread heavy hex nut, item #357A, finger tight. Do not apply Loctite 271to items #371G and #357A at this time. Text of third step.
4. Tighten items #788A and #357C.
5. Remove items #371G and #357A and position lift cable loop between lifting brackets. Apply
Loctite 271 and reinsert item #371G, hex head cap screw, through cable and lifting brackets and thread heavy hex nut, item #357A, and item #415A, jam nut, onto item
#371G. Check cable clamps..
12 JCU Installation, Operation, and Maintenance Manual
Installation
Install the slide rail
Refer to drawing B1-445153SLR and B2-445153SLR
1. With anchor bolts in position, lower the base, item #787A, onto a flat, clean foundation and tighten anchor bolt nuts.
2. Insert the slide rails, items #787C over the cylinders on the base and insert intermediate bracket, item #787P, cylinders into the tops of the slide rails. Allow .25" gap between the top of the slide rails and the intermediate bracket for thermal expansion. Secure the intermediate bracket to the sump wall. Repeat as necessary with the remainder of the rails and brackets.
3. Install the discharge pipe.
4. Lift the pump using the lift cable and lower it to have the guide bracket fit between the rail pipes. The pump should be reasonably level to keep the guide bracket from exerting too much force on the rail pipes when the pump is lowered or raised
5. Carefully lower the pump into position. Turn the adjusting bolts, items #787J, to provide the proper o-ring compression. The pump may need to be raised and lowered back into position a few times until the proper adjustment is found. The pump should properly lock into place with no visible gap between the o-ring and sump flange adapter. Tighten items
#357, hex nuts, against items #787H, adjusting brackets, to prevent movement of adjusting bolts.
JCU Installation, Operation, and Maintenance Manual 13
Installation
14
Figure 2: Slide rail system (optional)
JCU Installation, Operation, and Maintenance Manual
Installation
Figure 3: Slide rail system (optional)
JCU Installation, Operation, and Maintenance Manual 15
Commissioning, Startup, Operation, and Shutdown
Commissioning, Startup, Operation, and
Shutdown
Start the pump
The most important concern is the prevention of motor overloading.
1. Refer to the motor nameplate for full load ampere rating of the motor.
2. Install an ammeter on the motor leads and check the motor draw immediately after the unit is started.
NOTICE: A lower than expected current draw with a 3-phase motor may be an indication of incorrect rotation. If the amps are lower than expected, check rotation.
a) Observe the discharge for flow rate. If it is lower than expected change two of the three motor leads to reverse the direction of rotation.
NOTICE: Single-phase motors are internally wired for correct rotation.
b) Check the motor overload at some other condition from that encountered at start-up
The ammeter on the motor leads should be checked for overload at all sump level heights with the liquid that will be normally pumped. The horsepower will tend to increase as the level in the sump rises, due to increased flow.
16 JCU Installation, Operation, and Maintenance Manual
Maintenance
Maintenance
Maintenance - O-ring, pump flange to slide rail base flange
Whenever the pump is removed from the sump using the slide rail system, the pump flange to slide rail base flange O-ring should be inspected for wear. If it does not appear to be in good condition, a replacement O-ring should be installed after the groove has been cleaned and dried so the adhesive will bond to the metal and rubber.
NOTICE: Cleaning the guide bracket around the hinge pin 9868 will help ensure proper operation when the pump is lowered back into place.
JCU Installation, Operation, and Maintenance Manual 17
Disassembly
Disassembly
Disassembly precautions
WARNING:
• This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal unless explicitly stated in this manual.
• Always disconnect and lock out power to the driver before you perform any installation or maintenance tasks. Failure to disconnect and lock out driver power will result in serious physical injury.
• Electrical connections must be made by certified electricians in compliance with all international, national, state, and local rules.
• Refer to driver/coupling/gear manufacturers installation and operation manuals (IOM) for specific instructions and recommendations.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times.
• A small amount of liquid will be present in certain areas like the seal chamber.
NOTICE:
• Avoid injury. Worn pump components can have sharp edges. Wear appropriate gloves while handling these parts.
• Make sure that all replacement parts are available before you disassemble the pump for overhaul.
Disassemble the pump
1. Disconnect all electrical service. Mark leads for reassembly.
2. Remove cap screws 370E that fasten suction cover to casing. Remove cover and suction cover liner.
3. Remove impeller cap screw 370C. Pull impeller out of casing. If impeller cannot be easily removed, proceed to next step.
If the impeller could not be easily removed, carefully pry the mount away from the motor.
Use two locations on opposite sides simultaneously to prevent possible damage to motor.
4. Remove cap screw 370K which fastens motor-to-motor mount 340. Carefully pull mount with casing attached away from motor.
5. Remove cap screws 370J (or flat head screws 372J) and separate motor mount from casing.
NOTICE:
The motor shall be disassembled only by an authorized repair center. Failure to comply will result in voiding warranty.
For motor instructions see ABB/Baldor/Reliance Electrical Manual B-3629.
18 JCU Installation, Operation, and Maintenance Manual
Pre-assembly
Pre-assembly
Pre-assembly inspections
Guidelines
Before you assemble the pump parts, make sure you follow these guidelines:
• Inspect the pump parts according to the information in these pre-assembly topics before you reassemble your pump. Replace any part that does not meet the required criteria.
• Make sure that the parts are clean. Clean the pump parts in solvent in order to remove oil, grease, and dirt.
NOTICE:
Protect machined surfaces while you clean the parts. Failure to do so may result in equipment damage.
Replacement guidelines
Casing check and replacement
WARNING:
Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Inspect and assure gasket sealing surfaces are not damaged and repair or replace as necessary.
Inspect the casing for cracks and excessive wear or pitting. Thoroughly clean gasket surfaces and alignment fits in order to remove rust and debris.
Repair or replace the casing if you notice any of these conditions:
• Localized wear or grooving that is greater than 1/8 in. (3.2 mm) deep
• Pitting that is greater than 1/8 in. (3.2 mm) deep
• Irregularities in the casing-gasket seat surface
Impeller replacement
Inspect impeller vane edges for excessive cracks, pitting or corrosion damage. Replace impeller if excessively worn or defective.
Gaskets, O-rings, and seats replacement
WARNING:
Avoid death or serious injury. Leaking fluid can cause fire and/or burns. Replace any damaged or worn gaskets/o-rings.
• Replace all gaskets and O-rings at each overhaul and disassembly.
• Inspect the seats. They must be smooth and free of physical defects.
• Replace parts if the seats are defective.
Motor support
Inspect the motor support for any cracks or excessive corrosion damage. Replace if necessary.
Motor shaft check
Check the shaft for straightness or excessive wear, including thread wear or galling. If damage is evident, contact Baldor authorized motor repair center for motor repairs.
JCU Installation, Operation, and Maintenance Manual 19
Reassembly
Reassembly
Reassemble the pump
1. Check the vent hole in the adapter 340 to be sure it is clear.
2. Clean and remove any burrs from all mating metal surfaces, including shaft and impeller bore.
3. Install new O-ring (496).
4. Fasten casing and motor mount together.
5. Install mount on motor flange, align and fasten.
6. Push impeller on the shaft until seated. Push suction cover liner into casing and measure clearance between impeller and liner. Feeler gauges can be used with larger pumps by reaching in the suction opening.
An alternate method, recommended for smaller pumps, is to bend a short length (1") of soft solder over each vane and tap the liner into position. Measure the thickness of the compressed solder strip.
7. Use impeller shims (330) for total thickness of the measured thickness, minus the amount shown in the impeller shim thickness table below.
8. Remove liner and impeller and install shim in impeller bore.
9. Install key and reinstall impeller on motor shaft. Secure with washer (199) and cap screw
(370C). Tighten impeller hardware according to information in Impeller hardware torque
values table.
10. Push suction cover liner into casing bore. Check that the lip contacts the casing rather than the face against the impeller.
11. Install the O-ring (412F) around the liner lip and install suction cover with cap screws
(370E) and washers (528K). Check for free rotation by turning impeller clockwise by hand with wrench on impeller screw.
12. When connecting electrical service, make sure polarity is correct to give counterclockwise rotation when looking into the suction opening.
Table 1: Typical Parts List
Item
100
100B *
101 *
182
199
330 *
340
370C
370E
370J
370K
412F *
496 *
528K
9700
Qty / Pump
1
1
1
1
1
1 set
1
1 varies varies varies
1
1 varies
1
Part Name
Casing
Liner, Suction Cover
Impeller
Suction Cover
Washer. Impeller
Shim, Impeller
Motor Mount
Hex Cap Screw, Impeller
Hex Cap Screw
Hex Cap Screw
Hex Cap Screw
O-ring
O-ring
Washer
Motor
* Recommended spare parts, including outer mechanical seal for motor.
20 JCU Installation, Operation, and Maintenance Manual
Reassembly
Table 2: Impeller Shim Thickness
Impeller Diameter (inches)
up to 11
11 to 14 over 14
Measure Clearance Minus Shim Thickness
(inches)
.010 to .015
.015 to .020
.020 to .025
NOTICE:
• For 360TY with 320TY mounting flange motors only, delete impeller washer (199) and impeller screw (370C) and replace with impeller nut (304) of 316SS for all pump constructions.
• Flat head screws (372J) furnished instead of hex cap screw (370J) on 3" JCU with
210TYZB motor.
• Threaded hardware coated with Loctite 242, or equal.
Table 3: Impeller hardware torque values
Motor Frame
180TY
Impeller Mounting Hardware
1/2"-13 UNC bolt w/washer
Required Torque, Lubricated
(ft/lbs)
27
JCU Installation, Operation, and Maintenance Manual 21
Reassembly
Motor Frame
210TYZ
250TY
320TY
360TY
Impeller Mounting Hardware Required Torque, Lubricated
(ft/lbs)
5/8"-11 UNC bolt w/washer
5/8"-11 UNC bolt w/washer
54
54
3/4"-10 UNC bolt w/washer
1-1/2"-12 UNF nut
66
623
NOTICE:
1. Loctite 242 shall be applied to threads prior to each assembly. Refer to Loctite for thread-lock application instructions.
2. Impeller mounting hardware is designed for one time use only. New hardware shall be installed during each assembly.
3. Torques in this table are based on a 416 stainless steel motor shaft material and bolt/ nut materials of SAE F593 Groups 1 & 2. For other material combinations, refer to factory for torque value.
22 JCU Installation, Operation, and Maintenance Manual
Troubleshooting
Troubleshooting
Troubleshooting
Symptom
Insufficient or no discharge
Cause Remedy
Speed too low (usually due to low voltage) Verify proper voltage
System head too high Verify discharge pressure
Insufficient NPSH or submergence
Wear of pump parts
Verify liquid level is above minimum required
Review pump parts for wear
Wrong direction of rotation Verify rotation, or swap two of the three electrical leads
Pump not completely primed (plugged vent Check vent hole hole)
Suction opening or discharge pipe clogged Clean suction area, and check discharge piping for clogs
Viscosity of slurry too high Check for solids settling that increases viscosity
Excessive current draw Pump operating at a high horsepower area Increase discharge pressure by partially closing disof the pump curve (capacity is greater than charge valve the design capacity)
Impeller rubbing or mechanical defect in Check impeller clearance as previously described in the motor these instructions
Specific gravity or viscosity too high
Low voltage
Check for solids settling that increases viscosity
Verify proper voltage
JCU Installation, Operation, and Maintenance Manual 23
Visit our website for the latest version of this document and more information:
http://www.gouldspumps.com
Goulds Pumps Inc.
240 Fall Street
Seneca Falls, NY 13148
USA
Tel. 1-800-446-8537
Fax 1-315-568-2418
© 2015 ITT Corporation
The original instruction is in English. All non-English instructions are translations of the original instruction.
Form IOM.JCU.EN-US.2015-11
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