JCC - JSC iii - PD Water Systems

JCC - JSC
SHALLOW WELL PUMPS
INSTALLATION AND OPERATING INSTRUCTIONS
1. GENERAL INFORMATION
Before using the product carefully read the information contained
in this instruction manual, the manual should be kept for future
reference.
This manual is part of the essential safety requirement and must
be retained until the product is finally decommissioned.
The customer, in case of loss, can request a copy of the manual
by contacting the manufacturer or their agent, specifying the
type of product data shown on the label of the machine (see 2.3
Marking)
Any changes, alterations or modifications made to the product or
part of it, not authorized by the manufacturer, will revoke the “CE
declaration” and warranty.
This appliance should not be operated by children younger
than 8 years, people with reduced physical, sensory or mental
capacities, or inexperienced people who are not familiar with the
product, unless they are given close supervision or instructions
on how to use it safely and are made aware by a responsible
person of the dangers its use might entail.
Children must not play with the appliance.
It is the user’s responsibility to clean and maintain the appliance.
Children should never clean or maintain it unless they are given
supervision.
Do not use in ponds, tanks or swimming pools or where people
may enter or come into contact with the water.
Read carefully the installation section which sets forth:
- The maximum permissible structural working pressure
(chapter 3.1).
- The type and section of the power cable (chapter 6.5).
- The type of electrical protection to be installed (chapter 6.5).
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Operations that must be performed by a qualified electrician. Specialized technician authorized to affect all
electrical operations including maintenance. They are
able to operate with in the presence of high voltages.
1.1. Symbols
OFF
Operations that must be done performed by a
qualified technician. Specialized technician able
to install the device, under normal conditions,
working during “maintenance”, and allowed to
do electrical and mechanical interventions for
maintenance. They must be capable of executing simple
electrical and mechanical operations related to the
maintenance of the device.
To improve the understanding of the manual, below are
indicated the symbols used with the related meaning.
OFF
ON
Indicates that it is mandatory to use individual
protection devices.
OFF
OFF
OFF
ON
OFF - Operations that must be done with the device
switched off and disconnected from the power supply.
ON
ON
ON
ON - Operations that must be done with the device
switched on.
Information and warnings that must be observed,
otherwise there is a risk that compromise personnel
safety.
The failure to observe electrical information and
warnings, could damage the machine or compromise
personnel safety.
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Information and warnings that must be observed,
otherwise there is a risk that compromise personnel
safety.
Notes and warnings for the correct management of the
machine and its parts.
Operations that could be performed by the final
user. After carefully reading of the instructions, is
responsible for maintenance under normal conditions.
They are authorized to affect standard maintenance
operations.
1.2. Authorized operators
The product is intended for use by expert operators divided into
end users and specialized technicians. (see the symbols above).
It’s forbidden, for the end user, carry out operations which must
be done only by specialized technicians. The manufacturer
declines any liability for damage related to the non-compliance
of this warning.
1.3. Warranty
For the product warranty refer to the general terms and
conditions of sale.
i
The warranty covers only the replacement and the
repair of the defective parts of the goods (recognized
by the manufacturer).
The Warranty will not be considered in the following cases:
- Whenever the use of the device does not conform to the
instructions and information described in this manual.
- In case of changes or variations made without authorization of
the manufacturer.
- In case of technical interventions executed by a nonauthorized
personnel.
- In case of failing to carry out adequate maintenance.
1.4. Technical assistance
Any further information about the documentation, technical
assistance and spare parts, shall be requested to the:
manufacturer (paragraph 1.2).
OFF
2. TECHNICAL DESCRIPTION
ON
Close-coupled self-priming shallow well jet pumps with built-in
ejector.
JCC: version with pump casing in cast iron.
JSC: version with pump casing in stainless steel (AISI 304).
3. TECHNICAL FEATURES
3.1. Technical data
Dimensions and weight (see technical catalogue).
Nominal speed 3450 rpm
Protection TEFC
The electric data marked on the label are referred to the nominal
power of the motor.
Sound pressure: < 70 dB (A).
Max. starts per hour: 40 at regular intervals.
Maximum permissible pressure in the pump casing:
- 267 ft (116 PSI)
- 334 ft (145 PSI) for JCCQ15, JCCH 15, JCCH 20.
3.2. OPERATING CONDITIONS
Installation in well ventilated location protected from
the weather, with a maximum ambient temperature of
104 °F.
4. SAFETY
4.1. General provisions
Before using the product it is necessary to know all the
safety indications.
2.1. Intended use
For water and other clean liquids which are nonaggressive for the
pump materials; for slightly dirty surface water.
Liquid temperature from 32 °F to + 95 °F.
2.2. Improper use
The device is designed and built only for the purpose described
in paragraph 2.1.
Improper use of the device is forbidden, as is use
under conditions other than those indicated in these
instructions.
Improper use of the product reduces the safety and the efficiency
of the device, the manufacturer shall not be responsible for
failure or accident due to improper use.
2.3. Marking
Carefully read all operating instructions and the indications
defined for the different steps: from transportation to disposal.
The specialized technicians must carefully comply with all a
pplicable standards and laws, including local regulations of the
country where the pump is sold.
The device has been built in conformity with the current safety
laws. The improper use could damage people, animals and
objects.
The manufacturer declines any liability in the event of damage
due to improper use or use under conditions other than those
indicated on the name-plate and in these instructions.
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Use only original spare parts provided by the manufacturer or
from an authorized distributor.
Don’t remove or change the labels placed on the
device.
The following picture is a copy of the name-plate that is on the
external case of the pump.
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1 Pump type
2 Delivery
3 Head
4 Rated power
5 Tension nominale
6 Nom. motor current
7 Ambient temperature
8 Frequence
9 Operation Duty
10 Liquid temperature
11 Service factor
12 Insulation class
13 Weight
14 Power factor
15 Rotation speed rpm
16 Protection
17 Serial number
18 Certifications
OFF
Follow the routine maintenance schedules and the
promptly replace damaged parts, this will allows the
device to work in the best conditions.
Do not start the device in case of defects or damaged parts.
OFF
Example plate pump
18
1
2
3
4
5
6
XXXXXXX
XXXXXXX
Q min/max X/X US gpm
H max/min X/X ft
TEFC
X kW (XHp) S.F.
n XXXX/min
V3~60HzP
FX
X/X AT amb XX F CONT l.cl. X X lb
Tmax liq.XX F SF XX
7 819
01
1
Maintenance operations, requiring full or partial
disassembly of the device, must be done only after
disconnection from the supply.
17
4.2. Safety devices
ON
16
15
14
13
12
The device has an external case that prevents any contact with
OFF
internal parts.
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4.3. Residual risks
ON
The appliance, designed for use, when used in-line with the
design and safety rules, doesn’t have residual risks.
4.4. Information and Safety signals
For this product there will not be any signals on the product.
ON
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4.5. Individual protection devices
6.4.1. Pipes
During installation, starting and maintenance it is suggested
to the authorized operators to consider the use of individual
protection devices suitable for described activities.
During ordinary and extraordinary maintenance interventions,
safety gloves are required.
Ensure the insides of pipes are clean and unobstructed before
connection.
Signal
Individual protection device
HAND PROTECTION
(gloves for protection against chemical, thermal and
mechanical risks).
5.OFF
TRANSPORTATION AND HANDLING
The product is packed to maintain the content intact.
During
ON transportation avoid to stack excessive weights.
Ensure that during the transportation the box cannot move.
It is not necessary to use any special vehicle to transport the
packaged device.
The transport vehicles must comply, for the weight and
dimensions, with the chosen product (see technical catalogue
dimensions and weights).
5.1. Handling
Handle with care, the packages must not receive impacts.
Avoid to impact onto the package materials that could damage
the pump.
If the weight exceeds 55 lbs the package must be handled by
two person at the same time.
6. INSTALLATION
6.1. Dimensions
For the dimensions of the device (see technical catalogue).
6.2. Ambient requirements and installation site dimensions.
The customer has to prepare the installation site in order to
guarantee the right installation and in order to fulfill the device
requirements (electrical supply, etc...).
The place where the device will be installed must fulfill the
requirements in the paragraph
3.2. Operating conditions
ATTENTION: The pipes connected to the pump should be
secured to rest clamps so that they do not transmit stress, strain or
vibrations to the pump (par. 13 fig. 3).
Tighten the pipes or union coupling to the extent sufficient to
ensure a tight seal.
Excessive torque may cause damage to the pump.
When the pipe or union coupling is mounted, keep the pump
casing connection blocked with a second wrench, making sure
the connection is not deformed by excessive tightening.
The pipe diameters must not be smaller than the pump
connections.
6.4.2. Suction pipe
For capacities over 17,6 US gpm use a suction pipe 1” 1/4 (DN
32).
The suction pipe must be perfectly airtight and be led upwards in
order to avoid air pockets.
With a pump located above the water level (suction lift operation,
par. 13. fig. 2) fit a foot valve with strainer which must always
remain immersed or a check valve on the suction connection.
If operating with flexible hoses use a reinforced spiral suction
hose, in order to avoid the hose narrowing due to suction vacuum.
With the liquid level on the suction side above the pump (inflow
under positive suction head, par. 13. fig.1 fit an inlet gate valve.
For suction from a storage tank fit an anti-backflow valve. Follow
local specifications if increasing network pressure.
Install a strainer on the suction side of the pump to prevent
foreign particles from entering the pump.
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6.4.3. Delivery pipe
Fit a gate valve in the delivery pipe to adjust delivery and head.
Install a pressure gauge.
With a geodetic head at outlet over 49 ft fit a check valve
between the pump and the gate valve in order to protect the
pump from water hammering.
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6.5. Electrical connection
OFF
ON
It’s Absolutely forbidden to install the machine in an environment
with potentially explosive atmosphere.
6.3. Unpacking
i
Inspect the device in order to check any damages
which may have occurred during transportation.
Package material, once removed, must be discarded/
recycled according to local laws of the destination
country.
6.4. Installation
See installation examples, par. 13 fig. 1 and 2.
The pumps must be installed with the rotor axis in the horizontal
position and with the feet under the pump.
Place the pump as close as possible to the suction source.
Provide space around the pump for motor ventilation, to allow
for checking of shaft rota-tion, for filling and draining the pump.
Electrical connection must be carried out only by
a qualified electrician in accordance with local
regulations.
Always follow the National Electrical Code (NEC), or the
Canadian Electrical Code, as well as all local, state and provincial
codes. Code questions should be directed to your local electrical
inspector. Failure to follow electrical codes and OSHA safety
OFFresult in personal injury or equipment damage.
standards may
Failure to follow manufacturer’s installation instructions may
result in electrical shock, fire hazard, personal injury or death,
damaged equipment,
provide unsatisfactory performance, and
ON
may void manufacturer’s warranty.
i
Install, ground and wire according to local and National
Electrical Code Requirements.
Electrical supply MUST match pump’s nameplate specifications.
Incorrect voltage can cause fire, damage to the motor and voids
the warranty.
i
Pumps not protected MUST be provided with contactors and
thermal overloads for single phase motors. See motor nameplate.
OFF
Use only copper wire to motor and ground. The ground wire
MUST be at least as large as the wire to the motor.
Wires should be color coded for ease of maintenance.
Compare the frequency and mains voltage with the name-plate
data and connect the supply conductors to the terminals in
accordance with the appropriate diagram inside the terminal box
cover.
ATTENTION: never allow washers or other metal parts to fall into
the internal cable opening between the terminal box and stator.
If this occurs, dismantle the motor to recover the object which
has fallen inside.
If the terminal box is provided with an inlet gland, use a flexible
power supply cord of the H07 RN-F type with section of cable not
less than 11 TAB IEC 60335-1.
If the terminal box is provided with an inlet bushing, connect the
power supply cord through a conduit.
For use in swimming pools (not when persons are in the pool),
garden ponds and similar places, a residual current device with
IΔN not exceeding 30 mA must be installed in the supply circuit.
Install a device for disconnection from the mains (switch) with a
contact separation of at least 0,12 inch in all poles.
With a three-phase motor install an overload protection device
with curve D appropriate for the rated current of the pump.
Single-phase, are supplied with a capacitor connected to the
terminals with an incorporated thermal protector.
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ATTENTION: When the pump is fed by a frequency
converter, the minimum frequency should not fall
below 25Hz and in any case the total head of the pump
should never be lower than 10 ft.
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7. STARTUP AND OPERATION
7.1. Preliminary checks before start-up of the pump
Do not start-up the device in case of damaged parts.
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7.2. First starting
OFF
ATTENTION: never run the pump dry. Start the pump after filling
ON
it completely
with liquid.
When the pump is located above the water level (suction lift
operation par. 13 fig. 2) or with a positive suction head which
is too low (lessOFF
than 33 ft) to open the non-return valve, fill the
pump through the priming hole (par. 13 fig. 4).
When the liquid level on the suction side is above the pump (inflow under positive suction head part. 13
ON
OFF the suction gate valve slowly
fig. 1), fill the pump by opening
and completely, keeping the delivery gate valve open to release
the air.
Before starting, check thatON
the shaft turns by hand. For this
purpose use the screwdriver notch on the shaft end on the
ventilation
OFF side.
When starting, with a three-phase motor, check that the direction
of rotation is as shown by the arrows on the lantern bracket.
Otherwise, disconnect electrical power and reverse the
ON
connections
of two phases.
Check that the pump works within its field of perfor-mance and
that the absorbed current
shown on the name-plate is not exceeded. Otherwise adjust the
delivery gate valve or the setting of any pressure switches.
If a priming loss occurs (interruption of delivery flow)
or if a pressure oscillation is indicated by the pressure gauge,
make sure all the suction pipe couplings are perfectly sealed and
tighten the two sealed plugs on the pump casing.
Never run the pump for more than five minutes with a
closed gate valve.
Prolonged operation without a change of water in the pump
causes dangerous increases of temperature and pressure.
When the water is overheated due to prolonged operation with a
closed port, stop the pump before opening the gate valve.
To avoid any risk of danger to users and the creation of harmful
thermal stress in the pump and system due to large temperature
differentials, wait until the water has cooled inside the pump
before starting again.
If the water is overheated on account of prolonged operation with
a non-primed or insufficiently filled pump (suction lift operation),
wait until cool before opening the draining and filling plugs.
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Care must be taken when the pumped fluid has a high
temperature. Do not touch the fluid when its temperature is higher than 140 °F. Do not touch the pump
when the surface temperature is higher than 176 °F.
7.3. Self-priming
(Capability to clear the air in the suction pipe when starting with
the pump located above the water level).
Conditions for self-priming:
• suction pipe with connections perfectly airtight and properly
immersed
OFF in the water to be lifted;
• discharge pipe with a straight vertical free line above discharge
port ≥16,5 ft (≥33 ft for JCCQ15, JCCH 15, JCCH 20), before a
non-return valve (par. 13 fig. 6).
ON casing completely filled with clean cold water berfore
• pump
starting.
The pump is not self-priming with liquids containing oil, alcohol
or foaming substances.
The
check valve prevents reverse siphoning through the pump
OFF
when the pump is stopped and retains water in the pump for
the next start.
Without a foot valve or a check valve on the suction connection
theON
filling operation must be repeated before each start-up.
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ATTENTION: avoid a prolonged operation with
unprimed pump, without water delivery from the completely opened outlet. If the pump does not prime in 5
minutes: stop the motor, remove the priming plug and
add more water.
If necessary, repeat the priming operation after the pump has
been first emptied and then completely filled with clean cold
water.
7.4. Gate valve regulation
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With the gate valve completely open or with an outlet pressure
lower than the minimum pressure shown on the name-plate, the
pump may be noisy. To reduce noise regulate the delivery gate
valve.
OFF
7.5. Switch off of the pump
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ON
The appliance must be switch off every time there are
faults. (see troubleshooting).
The product is designed for a continuous duty, the switch off
is performed by disconnecting the power supply by means the
OFF
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expected disconnecting devices.
(see paragraph “6.5 Electrical connection”).
OFF
8. MAINTENANCE
Before any operations it’s necessary to disconnect the
power supply.
If required ask to an electrician or to an expert technician.
Every maintenance operations, cleaning or reparation executed
with the electrical system under voltage, it could cause serious
injuries to people.
In case of extraordinary maintenance, or maintenance
operations that require part-removing, the operator must be a
qualified technician able to read schemes and drawings.
It is suggest to register all maintenance operation executed.
OFF
During maintenance keep particular attention in order
to avoid the introduction of small external parts, that
ON could compromise the device safety.
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It is forbidden to execute any operations with the direct
use of hands. Use water-resistant, anti-cut gloves to
disassemble and clean the filter or in other particular
cases.
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During maintenance operations external personnel
is not allowed.
Maintenance operations that are not described in this manual
must be made only by special personnel authorized by the
manufacturer.
For further technical information regarding the use or the
maintenance of the device, contact the manufacturer.
OFF
8.1.
Routine maintenance
OFF
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ON
ON
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OFF
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9. DISPOSAL
Before every
OFFmaintenance operations disconnect the
power supply and make sure that the device could not
accidentally operate.
For good ON
measure, as in the case of temporary
operation with dirty liquids, run the pump briefly with
clean water to remove deposits.
ON
When the pump remains inactive it must be emptied completely
if there is a risk of freezing (par. 13 fig. 5).
OFFrestarting
Before
OFF the unit, check that the shaft is not jammed and
fill the pump casing completely with liquid.
i
The final disposal of the device must be done by specialized
ON
company.
Make sure the specialized company follows the classification of
the material parts for the separation.
Observe the local regulations and dispose the device accordingly
with the international rules for environment protection.
10. SPARE PARTS
10.1. Spare-parts request
When ordering spare parts, please quote their designation,
position number in the cross section drawing and rated data from
the pump name plate (type, date and serial number).
The spare parts request shall be sent to the manufacturer by
phone, fax, e-mail.
11. DESIGNATION OF PARTS
N°
Designation
14.00 Pump casing
14.04 Plug
14.12 Plug
14.20 O-ring
14.24 Screw
14.46 Plug with washer
22.00 Ejector
22.12 O-ring
22.16 O-ring
26.00 Diffuser
26.02 Diffuser plate
26.06 O-ring
28.00 Impeller
28.04 Impeller nut
28.12 Circlip
28.20 Impeller key
32.00 Lantern bracket
34.00 Casing cover
36.00 Mechanical seal
36.52 Shoulder ring
46.00 Deflector
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N°
Designation
70.00 Lantern bracket
73.00 Ball bearing
76.00 Motor casing with winding
76.04 Cable gland
76.16 Support
76.20 Pin
76.54 Terminal box, set
78.00 Shaft with rotor packet
81.00 Ball bearing
82.00 Motor end shield
82.04 Compensating spring
82.08 Screw
88.00 Motor fan
90.00 Fan cover
90.04 Screw
92.00 Tie-bolt
94.00 Capacitor
94.02 Capacitor gland
98.00 Terminal box cover
98.04 Screw
98.08 Gasket
Changes reserved
8.2.
Dismantling
ON
ON the system
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Close the suction and delivery gate valves and drain the pump
casing before dismantling the pump.
8.3. Dismantling the pump
OFF
Close the suction and delivery gate valves and drain the pump
ON before dismantling the pump (par. 13 fig. 5).
casing
For
dismantling and re-assembly see construction
OFF
in the cross section drawing.
OFF
ON
ON
12. TROUBLESHOOTING
OFF
WARNING:
ON
Turn off the power supply before performing any operations.
Do not allow the pump or motor to run when dry even for a
short period.OFF
Strictly follow the user instructions and if necessary contact an
authorized service centre.
ON
PROBLEM
1.MOTOR DOES
NOT START
POSSIBLE CAUSE
REMEDY
1a
Unsuitable power supply
Check that the mains frequency and voltage correspond to the electrical
characteristics shown on the indicator plate
1b
Incorrect electrical connections
Connect the power supply cable to the terminal board correctly. Check
that the thermal overload protection is set correctly (see data on the
engine indicator plate) and make sure that the fuseboard upline of the
engine has been properly connected
1c
Engine overload protective device cuts in.
Check the power supply and make sure that the pump shaft is turning
freely. Check that the thermal overload protection has been set
correctly (see engine indicator plate)
1d
Blown or defective fuses
Replace the fuses, check the electric power supply and points a) and c)
1e
Shaft blocked
Remove the cause of blockage as indicated in the “Blocked pump”
instruction booklet
1f
If the above causes have already been
checked, the engine may be malfunctioning
Repair or replace the engine by applying to an authorized service centre
2a
2. PUMP BLOCKED
2b
2c
3. THE PUMP
FUNCTIONS BUT
NO WATER
COMES OUT
4. INSUFFICIENT
FLOW
5. NOISE AND
VIBRATIONS
FROM THE PUMP
6. LEAKAGE FROM
THE MECHANICAL
SEAL
3a
Rotation may be started directly from the pump shaft or from the
Prolonged periods of inactivity with formation
joint (remember to turn off the electricity supply first ) or contact an
of rust inside the pump
authorized service centre
If possible, dismantle the pump casing and remove any solid foreign
Presence of solid bodies in the pump rotor
bodies inside the rotor, if necessary contact an authorized service
centre
If the bearings are damaged replace them or if necessary contact an
Bearings siezed
authorized service centre
Possible infiltration of air from suction tube
connections, drain plugs or filling of pump
Check which part is not tight and seal the connection adequately
or from the gaskets of the suction pipe
Foot valve blocked or suction pipe not
fully immersed in liquid
Clean or replace the bottom valve and use a suction pipe suitable for
the application
3c
Suction filter blocked
Clean the filter, if necessary, replace it . See point 2a) also.
4a
Pipes and accessories with diameter too
small causing excessive loss of head
Use pipes and accessories suitable for the specific application
4b
Presence of deposits or solid bodies in the
internal passages of the rotor
Clean the rotor and install a suction filter to prevent other foreign
bodies from entering
4c
4d
Rotor deteriorated
Worn rotor and pump case
Replace the rotor, if necessary, contact an authorised service centre
Replace the rotor and the pump casing
4e
Excessive viscosity of the liquid pumped
(if other than water)
The pump is unsuitable
4f
Incorrect direction of rotation
Invert the electrical connections on the terminal board or control panel
4g
Suction head excessive in relation to the
suction capacity of pump
Try to close the feeder gate partially and/or reduce the difference in
level of the pump and the liquid being aspirated
4h
Suction pipe too long
Bring the pump closer to the suction tank so as to use a shorter pipe.
If necessary use a pipe of a wider diameter
5a
5b
5c
Rotating part unbalanced
Worn bearings
Pump and pipes not firmly attached
Check that no solid bodies are obstructing the rotor
Replace the bearings
Anchor the delivery and suction piping as needed
5d
Flow too strong for the diameter of the
delivery pipe
Use bigger diameters or reduce the pump flow
5e
Functioning in cavitation
Reduce the flow by adjusting the feeder gate and/or using pipes with
a bigger internal diameter. See point 4g) too
5f
5g
Unbalanced power supply
Incorrect alignment of pump-motor unit
6a
The mechanical seal has functioned when
dry or has stuck
6b
Mechanical seal scored by presence of
abrasive parts in the liquid pumped
6c
Mechanical seal unsuitable for the type
of application
Choose a seal with characteristics suitable for the specific application
6d
Slight initial drip during filling or on first
start-up
Wait for the seal to adjust to the rotation of the shaft. If the problem persists, see points 6a), 6b) or 6c) or contact an authorized service centre.
3b
Check that the mains voltage is right
If necessary, the unit must be re-aligned
Make sure that the pump casing (and the suction pipe if the pump is
not self-priming) are full of liquid and that all the air has been expelled.
See point 5 e) too.
Install a suction filter and use a seal suited to the characteristics of the
liquid being pumped.
In cases 6a), 6b) and 6c), replace the seal, if necessary contact an
authorized service centre
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