APEC J Series User manual

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J-series
JDS/JDSK/JKD/JKS/JA
Installation and operation manual

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Instruction Manual
Submersible Sewage Pumps
JDS/JDSK/JKD/JKS/JA
Introduction
Check the following points upon receipt of your pump:
> Is the pump exactly what you ordered? Check nameplate. It is especially important that you check
whether the pump is to be used with 50 or 60 Hz.
> Has any damage occurred during shipment? Are any bolts or nuts loose?
> Have all necessary accessories been supplied? (For a list of standard accessories see Construc-
tion.)
We recommend that you keep a spare pump on hand in case of emergencies.
Keep this instruction manual in a place for future reference.
Specifications
Check the nameplate for your pump’s head, discharge volume, speed (R.P.M), motor voltage and
current.
Other specifications are noted in the chart below.
Item Specifications
Liquid handled
Type Sewage, waste water, miscellaneous drain water
Temperature Non-Automation 0.3~7.5 HP 0~40℃(32~104°F)
Automation 0.3~2 HP 0~40℃(32~104°F)
Materials
Casing Cast iron
Impeller Cast iron
Shaft
Motor type Dry type submersible motor
Shaft seal lubrication oil Turbine No.32 ISO VG-32
Maximum water depth 10m (33ft)
SUS410
INDEX
Introduction………..…..PAGE. 3
Specifications……...….PAGE. 3
Installation………..…....PAGE. 4
Electrical wiring………..PAGE. 4
Operation………..….….PAGE. 5
Maintenance……………..…....PAGE. 5
Construction…………………...PAGE. 6
Disassembly and Assembly….PAGE. 17
Nameplate format…………..…PAGE. 17
Troubleshooting…………….…PAGE. 18

4
Installation
1. Check the following before beginning installation.
Insulation resistance measurement:
With the motor and cable (excluding the power supply cable) immersed in water, use a Megger to measure the insulation
resistance between ground and each phase of the motor, and again between each phase of the motor. The Megger should
indicate an insulation resistance of not less than 20mega ohms. While making the measurement, keep the power supply ca-
ble off the ground.
We recommend that an auxiliary pump be kept on hand in case of emergency.
2. Installation
Fig-1
H2
H1
off
on
Fig-2
Operating Water Level
Stop Water Level
H1: Lowest water level (Motor flange)
H2: Operating water level
This must be above the top of the motor
1.! WARNING : Under no circumstances should cable be
pulled while the pump is being transported or installed.
Attach a chain or rope to the grip and install the pump.
2.This pump must not be installed on its side or operated a
dry condition. Ensure that it is installed upright on a se-
cure base.
3.Install the pump at a location in the tank where there is
the least turbulence.
4. If there is a flow of liquid inside the tank, support the pip-
ing where appropriate.
5.Install piping so that air will not be entrapped. If piping
must be installed in such a way that air pockets are un-
avoidable, install an air release valve wherever such air
pockets are most likely to develop.
6.Do not permit end of discharge piping to be submerged,
as backflow will result when the pump is shut down.
7..! WARNING : Non-automatic pumps do not have an
automatic operating system. Do not operate the pump for
a long time with the water level near the lowest water
level(H1) as shown in Fig.1, as the automatic cut-off
switch incorporated inside the motor will be activated.
8.To avoid dry operation, install an automatic operating sys-
tem so that this will not happen, as shown in Fig.2 and
maintain a safe operating water level.
Electrical wiring
1.Wiring
A. Wire as indicated for the appropriate start system as
shown in Fig-3.
B. Loose connections will stop the pump. Make sure all
electrical connections secure.
2. Cable
C. ! WARNING : Never let the end of the cable con-
tact water.
D. If the cable is extended, do not immerse the splice
in water.
E. Fasten the cable to the discharge piping with tape or
vinyl strips.
F. Install the cable so that it will not overheat. Over-
heating caused by coiling the cable and exposing it
to direct sunlight.
3. Grounding
As shown in Fig-4 ground the green wire (label E).
Under no circumstances should the green wire be
connected to the power supply.
4. ! WARNING : Use short circuit breakers to prevent
danger of electrical shock.
Fig-3
Fig-4

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Operation
1. Before starting the pump
a. After completing installation, measure the insulation resistance again as described in Installation.
b. Check water level.
If the pump is operated continuously for an extended period of time in a dry condition or at the lowest water level,
the motor protector will be activated. Constant repetition of this action will shorten pump service life. Do not start
the pump again in such a situation until after the motor has completely cooled.
2. Test operation….
Non-automatic pump
Automatic pump
a. Turn the operating switch on and off a couple of times to check for normal pump start.
Floating switch must be raised for the pump to start.
b. Next, check direction of rotation. If discharge volume is low or unusual sounds are heard when the pump is operat-
ing, rotation has been reversed. When this happens, reverse two of the wires.
Maintenance
Check pressure, output, voltage, current and other specifications. Unusual readings may indicate. Refer
to Troubleshooting and correct as soon as possible.
1. Daily inspections
Check current and ammeter fluctuation daily. If ammeter fluctuation is great, even though within the limits of pump rat-
ing, foreign matter may be clogging the pump. If the quantity of liquid discharged falls suddenly, foreign matter may be
blocking the suction inlet.
2. Regular inspections
1. Monthly inspections
Measure the insulation resistance. The value should be more than 1M ohm. If resistance starts to fall rapidly even with an
initial indication of over 1M ohm, this nay be an indication of trouble and repair work is required.
2. Annual inspections
To prolong the service life of the mechanical seal by replacing the oil in the mechanical seal chamber once a year. Water
mixed the oil or cloudy textures are indications of a defective mechanical seal requiring replacement. When replacing the
oil, lay the pump on its side with filler plug on top. Inject suitable amount turbine oil No.32 (ISO VG-32)
.
3. Inspections at 3-5year intervals
Conduct an overhaul of the pump. These intervals will preclude the possibility of future trouble.
3. Parts that will need to be replaced
Replace the appropriate part when the following conditions are apparent.
Replaceable part Mechanical seal Oil filler plug O-ring Lubricating oil O-ring
Replacement guide Whenever oil in mechanical seal
chamber is clouded
Whenever oil is replaced
or inspected Whenever clouded or dirty Whenever pump is overhauled
Frequency Annually A half yearly A half yearly Annually
Note: above replacement schedule is based on normal operating conditions.
Motor output 0.3HP 0.5HP 1HP 2HP 3HP 5HP 7.5HP
Mechanical seal 12Ø19.05(3/4”)Ø25Ø
Oil seal 12Øx 24Øx7 t18Øx 35Øx7 t25Øx 47Øx8 t
Oil filler plug O-ring (Inner diameter) x (outer diameter) x (thickness) =7.52Øx14.5Øx3.53t
Lubricating oil
(turbine oil #32) 120 cc 220cc 500 cc 600 cc

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JDS-Material Construction
JDS-0.3~1 HP JDS-2~7.5 HP

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NO Name Mtrl NO Name Mtrl
1 Cable H07RN-F/SJTOW/STOW 19-4 Screw SUS 304
5 Motor Housing +Stator SUS 304 19-6 Screw SUS 304
6 Shaft with Rotor SUS 410 19-7 Screw of flange SUS 304
8 Double Mech. Seal 19-8 Screw SUS 304
13 Protector (3 Phase) KLIXON 19-9 Screw of protector Steel
14 Capacitor (1 Phase) 20-5 Washer of impeller NBR
15-1 Upper Bearing TPI 21-1 Spring Washer of cover NBR
15-2 Lower Bearing TPI 21-6 Spring Washer NBR
17-1
17-2 O-ring NBR 21-9 Spring Washer of impeller NBR
17-3 O-ring of volute (2HP only) NBR 22 Oil Filler Plug
18 Gasket of motor NBR 22-1 O-ring of Oil Filler Plug NBR
18-1 Gasket of elbow NBR 24 Wire and Screw SUS 304
18-2 Gasket of flange NBR 27 Flange FC 200
19 Screw of handle SUS 304 28 Elbow FC 200
19-1 Screw of motor cover SUS 304 31 Nut of impeller SUS 304
19-2 Long Screw of motor Steel 32 Shaft end sleeve SUS 304
19-3 Screw of cable gland SUS 304 35 Key SUS 304
NO Name Mtrl Photo NO Name Mtrl Photo
2 Handle
(0.3~1HP) Nylon 6
7 Oil Chamber
(5~7.5HP) FC 200
2 Handle
(2~3HP&5~7.5HP) SS41
9 Seal Housing
(0.3~0.5HP) Nylon
3 Motor Cover
(0.3~0.5HP) Nylon 66
9 Seal Housing
(1HP) FC 200
3 Motor Cover (1HP&2~3HP
&5~7.5HP) FC 200
9 Seal Housing
(2~3HP) FC 200
4 Bracket
(0.3~0.5HP&1HP) FC 200
9 Seal Housing
(5~7.5HP) FC 200
4 Bracket
(2~3HP) FC 200 10 Oil Seal NBR
4 Bracket
(5~7.5HP) FC 200 11 Impeller FC 200
7 Oil Chamber
(0.3~0.5HP&1HP) FC 200 12 Pump Casing
(0.3~1HP) FC 200
7 Oil Chamber
(2~3HP) FC 200
12 Pump casing (2~3HP
&5~7.5HP) FC 200

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JDSK-Material Construction
JDSK-0.5~1HP JDSK-2~7.5 HP

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NO Name Mtrl NO Name Mtrl
1 Cable H07RN-F/SJTOW/STOW 19-4 Screw SUS 304
5 Motor Housing +Stator SUS 304 19-6 Screw SUS 304
6 Shaft with Rotor SUS 410 19-7 Screw of flange SUS 304
8 Double Mech. Seal 19-8 Screw SUS 304
10 Oil Seal NBR 19-9 Screw of protector Steel
13 Protector (3 Phase) KLIXON 20-5 Washer of impeller NBR
14 Capacitor (1 Phase) 21-1 Spring Washer of cover NBR
15-1 Upper Bearing TPI 21-6 Spring Washer NBR
15-2 Lower Bearing TPI 21-9 Spring Washer of impeller NBR
17-1
17-2 O-ring NBR 22 Oil Filler Plug
18 Gasket of motor NBR 22-1 O-ring of Oil Filler Plug NBR
18-1 Gasket of elbow NBR 24 Wire and Screw SUS 304
18-2 Gasket of flange NBR 27 Flange FC 200
19 Screw of handle SUS 304 28 Elbow FC 200
19-1 Screw of motor cover SUS 304 31 Nut of impeller SUS 304
19-2 Long Screw of motor Steel 32 Shaft end sleeve SUS 304
19-3 Screw of cable gland SUS 304 35 Key SUS 304
NO Name Mtrl Photo NO Name Mtrl Photo
2 Handle
(0.5~1HP) Nylon 6
7 Oil Chamber
(5~7.5HP) FC 200
2 Handle
(2~3HP&5~7.5HP) SS41
9 Seal Housing
(0.5HP) Nylon
3 Motor Cover
(0.5HP) Nylon 66
9 Seal Housing
(1HP) FC 200
3 Motor Cover (1HP&2~3HP
&5~7.5HP) FC 200
9 Seal Housing
(2~3HP) FC 200
4 Bracket
(0.5HP&1HP) FC 200
9 Seal Housing
(5~7.5HP) FC 200
4 Bracket
(2~3HP) FC 200 11 Impeller
FCD 450+
Tungsten
edge
4 Bracket
(5~7.5HP) FC 200 12 Pump Casing (0.5~1HP) FC 200
7 Oil Chamber
(0.5&1HP) FC 200 12 Pump casing
(2~3HP
&5~7.5HP) FC 200
7 Oil Chamber
(2~3HP) FC 200
16 Bottom Base FCD 450

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JKD-Material Construction
JKD-0.3~1 HP JKD-2~7.5 HP

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NO Name Mtrl NO Name Mtrl
1 Cable H07RN-F/SJTOW/STOW 19-4 Screw SUS 304
5 Motor Housing +Stator SUS 304 19-6 Screw SUS 304
6 Shaft with Rotor SUS 410 19-7 Screw of flange SUS 304
8 Double Mech. Seal 19-8 Screw SUS 304
13 Protector (3 Phase) KLIXON 19-9 Screw of protector Steel
14 Capacitor (1 Phase) 20-5 Washer of impeller NBR
15-1 Upper Bearing TPI 21-1 Spring Washer of cover NBR
15-2 Lower Bearing TPI 21-6 Spring Washer NBR
17-1
17-2 O-ring NBR 21-9 Spring Washer of impeller NBR
17-3 O-ring of volute (2HP only) NBR 22 Oil Filler Plug
18 Gasket of motor NBR 22-1 O-ring of Oil Filler Plug NBR
18-1 Gasket of elbow NBR 24 Wire and Screw SUS 304
18-2 Gasket of flange NBR 27 Flange FC 200
19 Screw of handle SUS 304 28 Elbow FC 200
19-1 Screw of motor cover SUS 304 31 Nut of impeller SUS 304
19-2 Long Screw of motor Steel 32 Shaft end sleeve SUS 304
19-3 Screw of cable gland SUS 304 35 Key SUS 304
NO Name Mtrl Photo NO Name Mtrl Photo
2 Handle
(0.3~1HP) Nylon 6
7 Oil Chamber
(5~7.5HP) FC 200
2 Handle
(2~3HP&5~7.5HP) SS41
9 Seal Housing
(0.3~0.5HP) Nylon
3 Motor Cover
(0.3~0.5HP) Nylon 66
9 Seal Housing
(1HP) FC 200
3 Motor Cover (1HP&2~3HP
&5~7.5HP) FC 200
9 Seal Housing
(2~3HP) FC 200
4 Bracket
(0.3~0.5HP&1HP) FC 200
9 Seal Housing
(5~7.5HP) FC 200
4 Bracket
(2~3HP) FC 200 10 Oil Seal NBR
4 Bracket
(5~7.5HP) FC 200 11 Impeller with Agitator
Impeller :
FC 200
Agitator :
SUS 316
7 Oil Chamber
(0.3~0.5HP&1HP) FC 200 12 Pump Casing (0.3~1HP) FC 200
7 Oil Chamber
(2~3HP) FC 200
12 Pump casing (2~3HP
&5~7.5HP) FC 200

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JKS-Material Construction
JKS-0.3~1 HP JKS-2~7.5 HP

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NO Name Mtrl Photo NO Name Mtrl Photo
3 Motor Cover
(0.3~0.5HP) Nylon 66
9 Seal Housing
(2~3HP) FC 200
3 Motor Cover (1HP&2~3HP
&5~7.5HP) FC 200
9 Seal Housing
(5~7.5HP) FC 200
4 Bracket
(0.3~0.5HP&1HP) FC 200
11 Impeller FC 200
4 Bracket
(2~3HP) FC 200 12 Pump Casing
(0.3~1HP) FC 200
4 Bracket
(5~7.5HP) FC 200 12 Pump casing
(2~3HP
&5~7.5HP) FC 200
7 Oil Chamber
(0.3~0.5HP&1HP) FC 200 16 Strainer SUS 304
7 Oil Chamber
(2~3HP) FC 200
25 Bottom Plate
(1HP) FC 200
7 Oil Chamber
(5~7.5HP) FC 200 25 Bottom Plate
(2~3HP)
FC 200
9 Seal Housing
(0.3~0.5HP) Nylon 25 Bottom Plate
(5~7.5HP) FC 200
9 Seal Housing
(1HP) FC 200
NO Name Mtrl NO Name Mtrl
1 Cable H07RN-F/SJTOW/STOW 19-3 Screw of cable gland SUS 304
2 Handle (0.5~1HP) Nylon 6 19-4 Screw SUS 304
2 Handle (2~7.5HP) SS41 19-6 Screw SUS 304
5 Motor Housing +Stator SUS 304 19-7 Screw of flange SUS 304
6 Shaft with Rotor SUS 410 19-8 Screw SUS 304
8 Double Mech. Seal 19-9 Screw of protector Steel
10 Oil Seal NBR 20-5 Washer of impeller NBR
13 Protector (3 Phase) KLIXON 21-1 Spring Washer of cover NBR
14 Capacitor (1 Phase) 21-6 Spring Washer NBR
15-1
15-2 Bearing TPI 21-9 Spring Washer of impeller
17-1 O-ring NBR 22 Oil Filler Plug
17-2 O-ring NBR 22-1 O-ring of Oil Filler Plug NBR
18 Gasket of motor NBR 24 Wire and Screw SUS 304
18-1 Gasket of elbow NBR 27 Flange FC 200
18-2 Gasket of flange NBR 28 Elbow FC 200
19 Screw of handle SUS 304 31 Nut of impeller SUS 304
19-1 Screw of motor cover SUS 304 32 Shaft end sleeve SUS 304
19-2 Long Screw of motor Steel 35 Key SUS 304
NBR

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JA-Material Construction
JA-0.5~1 HP

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JA-2~7.5 HP

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NO Name Mtrl NO Name Mtrl
1 Cable H07RN-F/
SJTOW/STOW 19-4 Screw SUS 304
5 Motor Housing +Stator SUS 304 19-6 Screw SUS 304
6 Shaft with Rotor SUS 410 19-8 Screw SUS 304
8 Double Mech. Seal 19-9 Screw of protector Steel
13 Protector (3 Phase) KLIXON 20-5 Washer of impeller NBR
14 Capacitor (1 Phase) 21-1 Spring Washer of cover NBR
17-1 O-ring NBR 21-6 Spring Washer NBR
17-2 O-ring NBR 21-9 Spring Washer of impeller NBR
17-3 O-ring of volute (2HP only) NBR 22 Oil Filler Plug
18 Gasket of motor NBR 22-1 O-ring of Oil Filler Plug NBR
19 Screw of handle SUS 304 24 Wire and Screw SUS 304
19-1 Screw of motor cover SUS 304 31 Nut of impeller SUS 304
19-2 Long Screw of motor Steel 32 Shaft end sleeve SUS 304
19-3 Screw of cable gland SUS 304 35 Key SUS 304
NO Name Mtrl Photo NO Name Mtrl Photo
2 Handle
(0.5~1HP) Nylon 6
9 Seal Housing
(0.5HP) Nylon
2 Handle
(2~3HP&5~7.5HP) SS41
9 Seal Housing
(1HP) FC 200
3 Motor Cover
(0.5HP) Nylon 66
9 Seal Housing
(2~3HP) FC 200
3 Motor Cover (1HP&2~3HP
&5~7.5HP) FC 200
9 Seal Housing
(5~7.5HP) FC 200
4 Bracket
(0.5HP&1HP) FC 200
10 Oil Seal NBR
4 Bracket
(2~3HP) FC 200 11 Impeller FC 200
4 Bracket
(5~7.5HP) FC 200 12 Pump Casing
(0.5~1&2~3&
5~7.5HP) FC 200
7 Oil Chamber
(0.5&1HP) FC 200 15-1
15-2
Upper Bearing
Lower Bearing TPI
7 Oil Chamber
(2~3HP) FC 200
26 Jet Aerator FC 200
7 Oil Chamber
(5~7.5HP) FC 200 26-1 Nozzle (2~7.5HP) Steel

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Disassembly and Assembly
Nameplate format
1. Disassembly-
When disassembling pump, have a piece of cardboard or wooden board ready to
place the different parts on as you work. Do not pile parts on top of each other. They
should be laid out neatly in rows. The “O” ring and gasket cannot be used again
once they are removed. Have replacement parts ready. Disassemble in the following
order, referring to the sectional view.
Be sure to cut off power source before disassembly.
(1) Remove pump casing bolts, raise the motor section and remove pump casing.
(2) Remove shaft head bolt and impeller.
(3) Remove oil filler plug and drain lubricating oil.
(4) Remove intermediate casing bolts and oil chamber.
(Remember that any lubricating oil remaining in the mechanical seal chamber
will flow out.)
(5) Carefully remove mechanical seal, beware of not to scratch sliding surface of
motor shaft.
2. Assembly-
Re-assemble in reverse order of disassembly.
Be careful of the following points.
(a) During re-assembly, rotate the impeller by hand and check for smooth rotation.
If rotation is not smooth, perform steps-(3) through -(5) again.
(b) Upon completion of re-assembly step -(1) rotate the impeller by hand from the
suction inlet and check that it rotates smoothly without touching the suction
cover before operating the pump.
Please order “O” rings, packing, shaft seals and other parts from your dealer.

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Troubleshooting
Trouble Cause Remedy
Does not start.
Starts, but imme-
diately stops.
(1) Power failure (1)~(3) Contact electric power company and
devise counter-measures
(2) Large discrepancy between power source and
voltage
(3) Significant drop in voltage
(4) Motor phase malfunction (4) Inspect electric circuit
(5) Electric circuit connection faulty (5) Correct wiring
(6) Faulty connection of control circuit (6) Inspect connections and magnetic coil
(7) Fuses is blown (7) Check circuit then replace fuse
(8) Faulty magnetic switch (8) Replace with correct one
(9) Water is not at level indicated by Float (9) Raise water level
(10) Float is not in appropriate level (10) Adjust the position of float
(11) Float is not effective (11) Repair or replace
(12) Short circuit breaker is functioning (12) Repair location of short circuit
(13) Foreign matter clogging pump (13) Remove foreign matter
(14) Motor burned out (14) Repair or replace
(15) Motor bearing broken (15) Repair or replace
Operates, but
stops after a
while.
(1) Prolonged dry operation has activated motor pro-
tector and caused pump to stop (1) Raise water level to C.W.L
(2) High liquid temperature has activated motor pro-
tector and caused pump to stop (2) Lower liquid temperature
(3) Reverse rotation ! WARNING : (3) Correct rotation
Does not pump.
Inadequate vol-
ume.
(1) Reverse rotation (1) Correct rotation (see Operation)
(2) Significant drop in voltage (2) Contact electric power company
(3) Operating a 60Hz pump with 50Hz (3) Check nameplate
(4) Discharge head is high (4) Recalculate and adjust
(5) Large piping loss (5) Recalculate and adjust
(6) Low operating water level causes air suction (6) Raise water level or lower pump
(7) Leaking from discharge piping (7) Inspect, repair
(8) Clogging of discharge piping (8) Remove foreign matter
(9) Foreign matter in suction inlet (9) Remove foreign matter
(10) Foreign matter clogging pump (10) Remove foreign matter
(11) Worn impeller (11) Replace impeller
Over current (1) Unbalanced current and voltage (1) Contact electric power company
(2) Significant voltage drop (2) Contact electric power company and de-
vise counter-measure
(3) Motor phase malfunction (3) Inspect connections and magnetic switch
(4) Operating 50Hz pump on 60Hz (4) Check nameplate
(5) Reverse rotation ! WARNING : (5) Correct rotation
(6) Low head. Excessive volume of water (6) Replace pump with high head pump
(7) Foreign matter clogging pump (7) Remove foreign matter
(8) Motor bearing is worn out or damaged (8) Replace bearing
Pump vibrates;
excessive oper-
ating noise.
(1) Reverse rotation (1) Correct rotation
(2) Pump clogged with foreign matter
(2) Disassemble and remove foreign matter
(3) Piping resonates (3) Improve piping
(4) Strainer is closed too far (4) Open strainer

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Vol.PMJDS-19111