BJM Pumps PGV Seies Instruction manual

Version 4/10/2013
INSTALLATION, OPERATION & MAINTENANCE MANUAL
PGV SERIES
VERTICAL DISCHARGE
Horizontal Electric Submersible Pumps
CAST IRON
Three Phase
460V
PGV 55
PGV 75
PGV 110
Three Phase
460V
PGV 220
Read this manual carefully before installing, operating or servicing these pump models.
UObserve all safety information.UFailure to comply with instructions may result in personal
injury and/or property damage. Please retain these instructions.

TABLE OF CONTENTS
INTRODUCTION .......................................................................................................................................................4
SAFETY .......................................................................................................................................................................5
INSPECTION ..............................................................................................................................................................6
TRANSPORTATION .................................................................................................................................................6
RECEIVING ................................................................................................................................................................6
PRE-INSTALLATION INSPECTION .................................................................................................................6
INSTALLATION: .......................................................................................................................................................7
WIRING:......................................................................................................................................................................8
INTENDED METHODS OF CONNECTION ..........................................................................................................9
THREE PHASE WIRING INSTRUCTION.........................................................................................................9
PUMP OPERATION ................................................................................................................................................11
MAINTENANCE AND INSPECTION ...................................................................................................................12
DISPOSAL OF PUMP ..............................................................................................................................................13
TROUBLE SHOOTING ...........................................................................................................................................13
ASSEMBLING: .........................................................................................................................................................18
SECTIONAL VIEW OF PGV55, 75 & 110.............................................................................................................19
SECTIONAL VIEW OF PGV220............................................................................................................................20
PGV SERIES PARTS LIST .....................................................................................................................................21
WARRANTY AND LIMITATION OF LIABILITY .............................................................................................23
START-UP REPORT FORM ..................................................................................................................................24
NOTES: ......................................................................................................................................................................27

4
INTRODUCTION
This Installation, Operation and Maintenance manual provides important information on
safety and the proper inspection, disassembly, assembly and testing of the BJM
Pumps® PGV Series horizontal submersible pump. This manual also contains
information to optimize performance and longevity of your BJM Pumps submersible
pump.
The submersible PGV Series pumps are designed to pump municipal; and
industrial wastewater. The PGV Series pumps are not explosion-proof. They are
not designed to pump volatile or flammable liquids.
Note: Consult chemical resistance chart for compatibility between pump
materials and liquid before operating pump.
If you have any questions regarding the inspection, disassembly, assembly or testing
please contact your BJM Pumps distributor, or BJM Pumps, LLC.
BJM Pumps, LLC
123 Spencer Plain Rd.
Old Saybrook, CT 06475, USA
Fax: [phone]
Phone: [phone]
Phone: [phone]
Information, including pump data sheets and performance curves, is also available on
our web site: HUwww.bjmpumps.comU
For assistance with your electric power source, please contact a certified electrician.
Please pay attention to the following alert notifications. They are used to notify
operators and maintenance personnel to pay special attention to procedures, to avoid
causing damage to the equipment, and to avoid situations that could be dangerous to
personnel.
NOTE: Instructions to aid in installation, operation, and maintenance or which
clarify a procedure.
Immediate hazards that WILL result in severe personal injury or
death. These instructions describe the procedure required and the injury which will
result from failure to follow the procedure.
Hazards or unsafe practices that COULD result in severe personal
injury or death. These instructions describe the procedure required, and the injury which
could result from failure to follow the procedure.
Hazards or unsafe practices which COULD result in personal injury
or product or property damage. These instructions describe the procedure required and
the possible damage which could result from failure to follow the procedure.

5
SAFETY
Pump installations are seldom identical. Each installation and application can vary due
to many different factors. It is the owner/service mechanics responsibility to repair,
service, and test to ensure that the pump integrity is not compromised according to this
manual.
Risk of electric shock – this pump has not been investigated for use
in swimming pool areas.
Do not pump flammable, inflammable or volatile liquids. UDeath
or serious injury will result.
Before attempting to open or service the pump:
1) Familiarize yourself with this manual.
2) Unplug or disconnect the pump power cable to ensure that the pump will remain
inoperative.
3) Allow the pump to cool if overheated.
Do not operate the pump with a worn or damaged electric power
cable. Death or serious injury could occur.
Never attempt to alter the length or repair any power cable with a
splice. The pump motor and pump motor and cable must be completely waterproof.
Damage to the pump or personal injury may result from alterations.
After the pump has been installed, make sure that the pump and all
piping are secure before operation.
Do not lift the pump by the power cable piping or discharge hose.
Attach proper lifting equipment to the lifting handle (or lifting rings) fitted to the pump. Do
not suspend the pump by the power cable.
Obtain the services of a qualified electrician to troubleshoot, test
and/or service the electrical components of this pump.
Pumps and related equipment must be installed and operated
according to all national, local and industry standards.
Make sure to ground the terminal (green) exclusive for grounding in accordance with
local electrical codes and internal regulations.

6
Transportation, installation, wiring, operation, maintenance, and inspection should be
performed only by authorized and qualified personnel.
INSPECTION
Review all safety information before servicing pump.
•Do not exceed rated specifications for use; a submersible pump should
not be used on land. Failure to observe this caution may cause electric
shock, injury to a person or damage to the product.
•Do not use pump if damaged in anyway.
•Any modifications of the product made by the user shall void guarantee.
•Do not remove the nameplate.
TRANSPORTATION
During transport, care must be taken to avoid dropping or overturning the pump.
Failure to observe this caution may cause injury or damage to the product.
When lifting the pump, be sure to lift it using its lifting rings or handle.
•Do not lift a pump with machine connected, using only the lifting rings of
the pump. Failure to observe this caution may cause injury or damage to
the product.
•Do not lift by cables. Failure to observe this caution may cause injury or
damage to the product.
RECEIVING
Open packing after confirming that pump is right side up. Failure to observe this caution
may cause injury.
Verify that the received pump is the one you ordered. Installing the wrong product can
cause unwanted results, and damage to the product.
The following are recommended installation practices/procedures for the pump. If there
are questions in regards to your specific application, contact your local BJM Pumps
distributor or BJM Pumps, LLC.
PRE-INSTALLATION INSPECTION
1) Check the pump for damage that may have occurred during shipment.
2) Inspect the pump for any cracks, dents, damaged threads, etc.
3) Check power cord (and seal minder cord, if installed) for any cuts or damage.
4) Check for, and tighten any hardware that appears loose.

7
5) Carefully read all tags, decals and markings on the pump.
6) Important: Always verify that the pump nameplate, amps, voltage, phase, and
HP ratings match your control panel and power supply.
Warranty does not cover damage caused by connecting pumps and controls to an
incorrect power source (voltage/phase supply). Record the model numbers and serial
numbers from the pumps and control panel on the front of this instruction manual for
future reference. Give it to the owner or affix it to the control panel when finished with
the installation.
If anything appears to be abnormal, contact your BJM Pumps distributor or BJM
Pumps, LLC. If damaged, the pump may need to be repaired before use. Do not install
or use the pump until appropriate action has been taken.
INSTALLATION:
1. Inspect each part/component to verify that it is free of damage and imperfections.
2. Do not lift or move the pump by the power cable. Use the lifting handle or eye
bolt attachment to support movement of the pump.
3. Never place the pump on loose or soft ground. The pump may sink, preventing
water from reaching the impeller. Place on a solid surface or suspended the
pump with a lifting rope/chain. The pump can pass solids that are compatible with
the suction/agitator opening size (see technical data sheet).
4. Running the pump dry for extended periods of time may damage the seals and
over-heat the motor. Do not run the pump below the recommended operating
level (see technical data sheet).
5. Pumping liquid should not exceed a maximum temperature of 104°F.
Remove foreign matter such as concrete clods or stones after installing the pump in the
tank. Failure to observe this caution may cause damage to the impeller or casing, or
block the intake port.

8
WIRING:
Risk of electric shock. PGV Series pump models do not come
with electric plug connectors. To reduce the risk of electric shock, be certain that it is
connected only to a properly grounded, grounding-type receptacle.
•Perform wiring conforming to National Electrical Code or to local electrical
codes. Failure to observe this caution may cause fire or damage to the
product.
•Make sure that the pump is rotating in the correct direction. Forward
rotation creates more pressure and discharge power than reverse rotation.
•For built-in automatic level control pump never take the float bracket to lift
the pump or pull the lead. Failure to observe this caution may cause injury
or damage to the product.
Do not alter the length or repair any power cable with a splice. The
pump motor and cable must be completely waterproof. Damage to the pump or
personal injury may result from alterations.
1. Voltage and frequency check- check whether the supply voltage and frequency
meet those indicated on the pump name plate.
2. Power connection- connect three wires U (red), V (white) and W (black) of the
power cable of the pump to a power supply unit at site.
a. Terminal E9 (green) is for ground use. Connect a grounding wire to this
terminal pursuant to the relevant law.
b. Also, provide electric leakage breaker.
3. Allowable cable length- keep voltage drop of the power cable with in 5% of the
specified voltage. Table 1 shows the allowable cable length subject to 5%
voltage down. (In case of 200V class)
a. The allowable cable length for the specified voltage 400V is four times the
values shown in Table-1.
Nominal sectional area of cabtyre cable
(mm) 3.5 5.5 8 14 22 30 38
Allowable current of cabtyre cable (Amps) 28 36 44 62 83 98
Pump model and motor output
PGV55 50 75 105 185 290 410
PGV75 55 80 140 215 305
PGV110 95 155 210 240
PGV220 110 130
Table 1 Allowable cable length (m)

9
INTENDED METHODS OF CONNECTION
BJM Pumps has been evaluated for use with water or water based solutions. Please
contact the manufacturer for additional information.
THREE PHASE WIRING INSTRUCTION
FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP
FROM ITS POWER SOURCE BEFORE HANDLING.
“Risk of electrical shock” Do not remove power supply cord and
strain relief or connect conduit directly to the pump.
Installation and checking of electrical circuits and hardware should
be performed by a qualified licensed electrician.
To automatically operate a non-automatic three phase pump, a control panel is
required. Follow the instructions provided with the panel to wire the system for automatic
three phase pumps see automatic three phase wiring diagram.
Before installing a pump, check the pump rotation to insure that wiring has been
connected properly to power source, and that the green lead of power cord (See wiring
diagram), is connected to a valid ground, momentarily energize the pump, observing the
directions of kick back due to starting torque. Rotation is correct if kick back is in the
opposite direction of rotation arrow on the pump casing. If rotation is not correct,
switching of any two power leads other than ground will provide the proper rotation.

10
BJM Pumps three phase pumps have integral motor overload protection. BJM
recommends that all three phase pumps using a motor starting device also incorporate
motor overload protection. Pumps must be installed in accordance with the National
Electrical Code and all applicable local codes and ordinances. Pumps are not to be
installed in locations classified as hazardous in accordance with National Electrical
Code, ANSI/NFPA 70.
Connect pump to a junction box, outlet box, control box, enclosure with a wiring
compartment that meets NEC and local codes in volume, and applicable fittings for
supply connection. The provision for supply connection shall reduce the risk of water
entry during temporary, limited submersion and shall comply with the applicable
requirements of the Standard for Enclosures for Electrical Equipment, UL 50, or the
standard for Metallic Outlet Boxes, UL 514A, and the standard for Motor-Operated
Water Pumps. UL 778.
4. Pump revolution direction- the correct revolution direction of the impeller is
counterclockwise viewing from the strainer side as shown in Fig. 1.
Figure 1
Safety glasses must be worn when visually checking impeller
rotation.
Switch ON the pump in inching mode and look into the impeller from the strainer side to
check its normal rotational direction, just before complete stop of the impeller.
Checking before piping connection can be made by looking into the impeller from the
discharge pipe side.
If the rotational direction of the impeller is reverse upon checking, interchange optional
two wires of the power cable.

11
PUMP OPERATION
Never get near or touch the suction port and discharge ports
during operation. Failure to observe this warning may cause injury by being
caught in a rotating part such as impeller. Do not put fingers in strainer or pump
intake.
•Never operate the pump under minimum water levels during continuous
operation
•When changes in current and pressure occur during operation, check for
abnormalities such as overload due to entrance of foreign matter.
•Immediately stop operation upon detection of any malfunction. Failure to
observe this caution may cause electric shock, injury or fire.
•Make sure to turn OFF the power source at power failure. Failure to
observe this caution may cause injury.
•Make sure to maintain the specified liquid temperature. For high-
temperature liquid specification, refer to the catalogue. Failure to observe
this caution may cause injury.
•For pumps with cutting mechanism, never rotate in reverse. Failure to
observe this caution may cause burn-out of motor and injury.
This pump is designed to handle dirty water that contains some
solids. It is not designed to pump volatile or flammable liquids. Do not attempt to pump
any liquids which may damage the pump or endanger personnel as a result of pump
failure.
Do not operate this pump where explosive vapors or
flammable material exist. Death or Serious injury will result.
1. Change of running condition depending on water level. If the suction water level
comes down near “LEVEL 1”, air will be suctioned with generated vortex and
consequently the pump is put in water-roaring run condition, which continues until
the water level reaches next “LEVEL 2”. (Refer to Fig. 2)

12
Figure 2
If the water level is below “LEVEL 2”, the suctioned air rate will increase; causing
pumping failure of the pump and finally the pump is put in no-load running condition.
In case of this pump, however, unlike vertical submersible pumps the motor frame of
this pump is submerged in the range from “LEVEL 1” to “LEVEL 2” so that the motor is
effectively cooled. When the water level is below “LEVEL 2”, the motor frame exposes
to the atmosphere and consequently the cooling effect comes down, but it is safety with
low temperature because of its non-load run condition.
2. Voltage check - during pump running; sometimes measure the power voltage to
check that it is within the range of 95% - 105% of the specified voltage.
3. Attention to pumping up of high density water where sand, slurry and other solids
are much contained in the pumping of water, the shaft power increases with
increasing mixture density of solids and the motor is eventually overloaded. (Special
technical instructions on this matter are available. It will be furnished upon request).
In such case, read the ammeter to monitor the electric current of the motor and adjust
the pump location.
MAINTENANCE AND INSPECTION
To service or repair your pump, please contact your local BJM Pumps distributor.
Service should only be performed by a qualified electrician.
Insulation resistance of 1MΩ or greater, or unstable values with sudden drops indicates
potential malfunction and should be investigated.
Never touch terminals when measuring insulation resistance. Failure to observe this
caution may cause electric shock.
•Pump should be disconnected from the electric power supply before proceeding
to do any service or maintenance.

13
•Pump should be inspected at regular intervals.
•More frequent inspections are required if the pump is used in a harsh
environment.
•Preventative maintenance should be performed to reduce the chance of
premature failure.
•Worn impellers and lip seals should be replaced.
•Cut or cracked power cords must be replaced. (Never operate a pump with a
cut, cracked or damaged power cord.)
•Seal oil should be checked once per year.
•Maintenance should always be done when taking a pump out of service before
storage.
DISPOSAL OF PUMP
When disposing a pump, treat it as a general industrial waste, abiding by federal, state
and local regulations.
TROUBLE SHOOTING
Disconnect the power source to the pump BEFORE attempting
any type of trouble shooting, service or repair.
Warning: Pump will restart automatically when motor over-heat protection switch
cools.
Repair and assembly should be performed by qualified personnel only. Failure to
observe this caution may cause electric shock, injury or fire.
1) Pump fails to run (no running noise)
No electric current in power
distribution line
Power switch in OFF. Or 2 phase or more in open
condition due to fault of the switch
No electric current in pump
cable
Operation switch in OFF. Or 2 phase or more in
open condition due to fault of the switch. Possible
causes: Contact failure of switch, fuse
disconnection, reset-missing of over current relay
Inspect and repair.

14
2) Pump fails to run, or runs but fails to reach full speed.
Voltage drop in power line
Check whether or not the power voltage is normal
Single-phase run
Power switch, operation switch or pump cable
with either one wire opened or disconnected.
Inspect and repair or replace.
Stuck impeller
Repair
Motor trouble
Causes: Insulation fault, interlayer and interphase
short-circuit, single-phase disconnection
Inspect and repair.
3) Pump runs at full speed, but produces abnormal noise mechanically.
Broken impeller
Replace
Worn or damage bearing
Replace
Low level running
Not harmful, but less pumping rate and low
efficiency, caused by low suction level. Raise
suction level or stop the pump
4) Small pumping rate (capacity)
Reverse rotation of pump
Interchange two wires of the cable
for correct rotational direction
Impeller clogged with foreign matter
Remove foreign matter
Clogged pipe
Repair
Small size pipe
Replace
Water leakage from pipeline and channel
Inspect and repair
5) Motor overheated
Overload
Large mixture percentage of solids
to pumping water or use of liquids
with high viscosity or high specific
gravity.
Motor exposed to atmosphere
Consider of the pump location and
adjust or relocate.
Motor abnormal
Inspect insulation fault, interlayer
short-circuit and interphase short-
circuit.
In this event, the over current relay
of the operation switch might work.
If failed to work, check whether the
relay is properly set. In many cases,
motor abnormal is primarily caused
by its insulation down by leaked
water in section 7.

15
6) Water leakage into oil chamber
Worn or abnormal shaft seal
Considerably worn or vital
abnormality.
Replace the shaft seal.
7) Water leakage into motor chamber
Worn or abnormal shaft seal
Refer to (6)
Loosened cable packing gland
Re tighten
Tear cable
Repair or replace a torn portion.
Where water has leaked into the
motor chamber, stator and rotor
must be inspected to check for their
abnormality and, in many cases, re-
dried. Checking by electric
technician is preferred.
Inspection immediate after operation-start- This inspection is performed to judge the
sealing performance of the shaft seal. Carry out this inspection about one week after
startup of the operation.
1. Oil chamber check- The sealing performance can be judged by contamination
degree of the sealing oil depending on the quantity of water leakage into the oil
chamber.
•The upper oil box located at the center part of the pump is provided with
two oil plugs spaced at 180° from each other (one is located upside from
the shaft center and other located downside from the shaft center) as
illustrated in Fig. 3.
•As illustrated in Fig. 3, locate a proper chute and a proper oil pan just
under the downside plug to discharge the oil from the oil chamber.
•After that, unscrew off the plug to discharge and take the oil into the oil
pan.
•When oil flow from the chamber is not smooth, unscrew off the upside
plug to intake the air into the chamber.
•Use a transparent oil pan.
•Take (sample) a small quantity of oil into the pan. (Small quantity is
sufficient for oil analysis).
•The sampled oil looks like cloudy emulsion when the mixture ration with
leaked water is small and is separated from the water when it is 5% and
over.
•Inspect the sampled oil based on the above criterion and determine further
periodic oil inspection interval according to the obtained result.
2. Recommended oil brand-When the oil must be replaced with fresh one upon
above inspection or further periodic inspection, use the oil recommended below.
ISO 32 NSF Food Grade Mineral Oil

16
3. Required oil volume: As Table-2
Pump Model
PGV55, 75
PGV110
PGV220
Required oil volume (L)
1.3
1.6
5.8
Table 2 – Required Oil Volume in submersible pumps
4. Motor chamber check-When much water leakage is detected upon oil chamber
check, inspect further the motor chamber.
•Should any leakage into the motor chamber be detected, the shaft seal
must be checked for abnormal wear and other fault. In this case, the pump
shall be overhauled. Follow Section 8 for the detailed overhauling
procedure.
•If its measured insulation resistance is 20MΩ and over after adequately
dried, the stator is available for further continued use.
Periodic Inspection:
Periodically inspect the mechanical seal (most important check item), impeller,
bottom plate, dust seal, strainer, etc. to check that they are abnormal-free.
In addition, inspect the insulation resistance.
1) Oil chamber and shaft seal (mechanical seal) in case of continuous running; inspect
them at least once every 6 months.
2) Insulation resistance- check once per year. The pump motor may be further used
provided that the measured value is 1MΩ and over.
3) Impeller- in addition to periodic inspection, carefully inspect it when the suction
(pumping) capacity decreases, too. Refer to section 6.
4) Other Inspection- check the bolts and nuts for loose, damaged and deformation.
5) Overhauling- overhaul the pump at least once a year, though depending on the
service conditions, to inspect each component/part and replace any abnormally-
abrased part or faulty part with new one and clean adequately other parts available
for further use in thinner or washing oil. In addition, refill fresh oil in the oil chamber.
•Each seal packing may be possibly damaged by over-hauling work. It
is therefore recommendable to stock and provide the spare parts
recommended in Section-7.
6) Inspection of Pumping Capacity- various causes for the decreased pumping capacity
are as described in section 12 “troubleshooting”. The causes by the impeller, bottom
plate, etc. are described hereunder.
1. Impeller- check whether or not the water passage is
narrowed and the pump function is disturbed by solids
adhered to the central boss of the impeller and between
vanes.
2. Passage in bottom plate and casing- check whether or not
the passage is narrowed by solids adhered to the bottom
plate and the casing.
7) Recommended Spare Parts- it is recommendable to stock the following parts which
may require replacement within 1 to 2 years from startup of the initial running.

17
Part description
Quantity per pump
Impeller
1 piece
Shaft Seal
1 set
Bottom Plate
1 piece
Packing
Full set
8) Overhauling procedure (refer to section 11 “Sectional Drawing”).
•Perform the overhauling work with the pump kept in horizontal position.
•Unscrew off the bolts (B1 in Sectional DWG) to separate the pump
from the pump base (170). Then, lift up the pump using the lifting eye-
bolt (58).
•Provided two wooden blocks of about 100mm square onto clean floor
and put the pump thereon horizontally.
•By this, the pump is ready for overhaul. Overhaul the pump in the
procedure given below.
Step
Part Name
( ) : part No. in sectional DWG
Overhauling Procedure
( ): Part No. in sectional DWG.
Note
1
Strainer (16)
Unscrew off stud nut (SN1)
2
Bottom Plate (15)
Unscrew off stud-nut (SN2)
3
Impeller nut (B2)
Unscrew off the nut
4 Impeller (14) Draw off the shaft from shaft (8).
Be careful not
to damage the
vanes
5
Casing (13)
Unscrew off stud nut (SN3)
6
Drain-out of oil
Remove oil plug (28)
Follow 5.1 (1)
7
Lower oil box (12L)
Unscrew off stud nut (SN4)
8 Shaft seal (10)
After removal of the lower oil
box (12L) in step 7, mechanical
seal parts appear. Pull them out
one by one from the shaft using
a hooked-shaped puller.
9 Upper oil box (12U) and rotor (7) Unscrew off stud nut (SN5)
In this case,
be careful not
to damage
stator coil,
shaft and
bearing.

18
ASSEMBLING:
Assemble the pump in the reverse sequence of the overhauling with good care
for the following points.
1) Shaft seal (Mechanical Seal)
•The contact surface of each seal ring shall keep right vertical to the
shaft axis.
•The contact surfaces shall be free from dust and foreign matter.
2) Cautions in assembling
•Handle each part/component with good care not to damage it.
•Securely restore o-rings and seal packing’s in their original
positions.
•Replace worn or damaged o-ring and seal packing with new ones.
•Tighten securely bolts and screws with specific tightening torque.
•After assembled, turn the impeller by hand to check its smooth
rotation.
After-operation Maintenance
•When the pump is put in long term rest, operate it under clean water for a
while for internal cleaning. Leaving the pump as is without cleaning would
cause early corrosion of the pump components and finally pump trouble.
•When the pump handled liquid containing solids such as cement slurry,
limestone slurry, etc., adequately clean each component, especially
impeller and shaft seal for complete removal of such adhered solids.
Otherwise, adhesion of solids will interfere with the normal running.

19
SECTIONAL VIEW OF PGV55, 75 & 110

20
SECTIONAL VIEW OF PGV220