Grundfos JP PS Series Operating instructions

GRUNDFOS INSTRUCTIONS
JP-PS
Jet pumps with pressure switch, 115/230 V, 60 Hz
Service instructions

English (US)
2
English (US) Service instructions
CONTENTS
Page
1. General information
1.1 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The hazard statements are structured in the following way:
1.2 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
1. General information 2
1.1 Hazard statements 2
1.2 Notes 2
2. Safety information for working on the product 3
3. Maintenance 3
4. Dismantling the product 3
4.1 Before dismantling the product 3
4.2 Dismantling the pressure switch 3
4.3 Dismantling the pump housing 4
4.4 Replacing the plugs 4
4.5 Dismantling the hydraulic parts 4
4.6 Dismantling the motor housing 5
5. Disconnecting the power cable from the pressure
switch 6
5.1 Removing the motor fan 6
5.2 Removing the impeller 6
5.3 Removing the shaft seal 7
6. Assembling the product 8
6.1 Before assembling the product 8
6.2 Fitting the shaft seal 8
6.3 Fitting the impeller 9
6.4 Fitting the motor fan 9
6.5 Fitting the motor housing 9
6.6 Fitting the hydraulic parts 10
6.7 Fitting the pump housing 10
6.8 Connecting the power cable via the pressure switch 11
7. Additional information 13
7.1 Lubricant 13
7.2 Torques 13
7.3 Nameplate 13
7.4 Type key 14
7.5 Fault finding the product 14
7.6 Exploded view 15
Read this document before starting service work on
the product. Installation and service work must
comply with local regulations and accepted codes of
good practice.
Observe the safety instructions in the installation and
operating instructions for the product.
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
Observe these instructions for explosion-proof
products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.

3
English (US)
2. Safety information for working on the product
3. Maintenance
The product is maintenance-free during normal operation. For
cleaning, use a dry and dust-free cloth.
4. Dismantling the product
4.1 Before dismantling the product
• Disconnect the power supply to the motor.
• Remove the power cable in accordance with local regulations.
• Gradually open a tap to release the pressure in the pump.
• Remove the drain plug (26) to drain the pump.
• Remove the pump from the plumbing.
Fig. 1 Plugs (25, 26), pressure switch (407), and pressure
switch connections (408)
4.2 Dismantling the pressure switch
1. Loosen the nut on the top cover of the pressure switch (407).
2. Lift up the pressure switch cover and set it aside.
3. Inside the pressure switch, use a large flat screw driver to turn
the locking ring counterclockwise to loosen it.
4. Use small pliers or a wrench to loosen the pressure
switch (407) and pressure switch connections (408).
5. Remove the pressure switch (407) and pressure switch
connections (408) from the pump.
WARNING
Electric shock
Death or serious personal injury
- Switch off the power supply before you start any
work on the product. Make sure that the power
supply cannot be switched on accidentally.
WARNING
Electric shock
Death or serious personal injury
- The product is supplied with a grounding
conductor and grounding-type attachment plug. To
reduce the risk of electric shock, be certain that the
product is connected only to a properly grounded,
grounding-type receptacle (protective earth).
WARNING
Electric shock
Death or serious personal injury
- Power cables without a plug must be connected to
a supply disconnecting device incorporated in the
fixed wiring according to the local wiring rules.
WARNING
Chemical hazard
Death or serious personal injury
- Make sure that the product has only been used for
water. If the product has been used for pumping
aggressive liquids, flush the system with clean
water before you start work on the product.
WARNING
Pressurized system
Death or serious personal injury
- Before dismantling the pump, drain the system or
close the isolating valves on both sides of the
pump. Slowly loosen the drain plug and
unpressurize the system.
CAUTION
Impurities in the water
Minor or moderate personal injury
- Before the pump is used for supplying drinking
water, flush the pump thoroughly with clean water.
CAUTION
Crushing of feet
Minor or moderate personal injury
- Wear safety shoes when handling the product.
CAUTION
Hot surface
Minor or moderate personal injury
- Use protective gloves if the liquid or ambient
temperature is higher than 104 °F (40 °C).
CAUTION
Hot or cold liquid
Minor or moderate personal injury
- Make sure that escaping hot or cold liquid does not
cause injury to persons or damage to the
equipment.
Only qualified persons are allowed to service the
pump.
Do not turn on the power supply until the pump has
been filled with liquid.
Position numbers of parts (numbers in brackets) refer
to section 7.6 Exploded view.
TM07 4518 1419
26 32
1
31
408
25 407

English (US)
4
4.3 Dismantling the pump housing
Fig. 2 Dismantling the pump housing
1. Place the pump vertically with the inlet facing upwards.
2. Unscrew the clamp ring (92) by loosening screw (93) and nut
(94).
3. Remove the clamp ring (92) from the recess. Use two flat
screw drivers to lift the clamp ring from the recess.
Fig. 3 Removing the clamp ring
4. Remove the pump housing (1) including the hydraulic parts
(20 and 21).
5. Remove the O-ring (28).
4.4 Replacing the plugs
Fig. 4 Replacing the plugs
To replace the fill plug (25) and drain plug (26):
1. Remove the two plugs (25, 26) by turning each plug
counterclockwise with a big flat screwdriver.
2. Lubricate the O-ring seats on the pump housing (1). See
section 7.1 Lubricant.
3. Place the new plugs (25, 26) and O-rings (31, 32). Fasten the
plugs (25, 26) by turning the plug clockwise with a large flat
screwdriver.
4.5 Dismantling the hydraulic parts
Fig. 5 Hydraulic parts and pump housing
1. Place the pump housing (1) vertically with the inlet facing
upwards.
2. Use a suitable tool which fits inside the inlet and gently press
down on the venturi tube (21) to loosen the hydraulic parts
(20, 21, 21a and 13).
TM07 4514 1419TM07 4534 1419
28
92
1
94
93
TM07 4513 1419TM07 4530 1419
26 32
1
31
408
25
1
21
20
13
21a

5
English (US)
Fig. 6 Removal of hydraulic parts
Fig. 7 Incorrect way to remove the diffuser
4.6 Dismantling the motor housing
Fig. 8 Dismantling the motor housing
1. Remove the terminal box cover (51) and upper motor shell
housing (44) by loosening the screws (53).
2. Disconnect the power connections as required and follow the
instructions in section 5. Disconnecting the power cable from
the pressure switch.
3. Remove the motor housing grid (43).
4. Remove the base plate (56) by loosening the screw and nut
(56a).
5. Remove the lower motor housing (42).
TM07 4538 1419
Do not try to remove the diffuser (20) by using
screwdrivers or similar tools, as it might break.
TM07 3813 0519
1
21
20
20
TM07 3465 1319
56a
56
407
51
44
181
43
14
53
42
408
161

English (US)
6
5. Disconnecting the power cable from the
pressure switch
1. Locate the power-supply terminal and cable clamp inside the
pressure switch.
Fig. 9 Disconnecting the power cable
2. Loosen the three wires from the pressure switch.
3. Loosen the screw that holds the cable clamp.
4. Pull out the cable through the cable gland located on the side
of the pressure switch.
5.1 Removing the motor fan
Fig. 10 Removing the motor fan
1. Remove the motor fan (14) from the shaft with two large flat
screw drivers. Make sure to use sufficiently large screw
drivers. Place the screw drivers between motor flange and fan
at any two points.
5.2 Removing the impeller
1. Place the motor vertically with the impeller (19) facing
upwards.
2. Clamp the motor shaft end in a vice with soft copper or
aluminium jaw faces to protect the shaft end.
Fig. 11 Placing the motor shaft in a vice
3. Turn the impeller (19) counterclockwise by hand and
remove it.
Fig. 12 Removing the impeller
If you are replacing the motor housing (42, 44),
disconnect the power cable from the pressure switch
(407).
If you are replacing the impeller, remove the lower
motor housing (42) and the upper motor housing (44)
and disconnect the power cable from the pressure
switch (407).
TM07 4373 1319TM07 4329 1319
14
TM07 3817 0519TM07 3818 0519
19
19

7
English (US)
5.3 Removing the shaft seal
Fig. 13 Shaft seal and seal disc
Fig. 14 How to hold the shaft seal correctly
1. Remove the rotating part of the shaft seal (16) by inserting two
flat screw drivers in the shaft seal spring. Lever the screw
drivers against any two points at the edge of the seal disc.
Fig. 15 Removing the rotating part of the shaft seal
2. Remove the seal disc (15) including the stationary part of the
shaft seal (16a).
3. Remove the stationary shaft seal ring (16a) from the seal disc
(15) by pushing gently with a finger from below. Hold the seal
ring on the lower side and on the rubbery outer diameter. Do
not touch the seal face.
Fig. 16 Removing the stationary part of the shaft seal
Do not touch the seal faces.
TM07 4366 1319TM07 3820 0519
16
16a
15
16
16a
TM07 3821 0519TM07 3822 0519

English (US)
8
6. Assembling the product
6.1 Before assembling the product
• Clean and check all parts.
• Replace defective parts.
6.2 Fitting the shaft seal
Fig. 17 Shaft seal and seal disc
Fig. 18 How to correctly hold the shaft seal
1. Clamp the motor shaft end in a vice with soft copper or
aluminium jaw faces to protect the shaft end. See fig. 11.
2. Lubricate the seal disc opening. See section 7.1 Lubricant.
Fig. 19 Lubricating the seal disc
3. Fit the stationary part of the shaft seal (16a) inside the seal
disc (15).
Fig. 20 Fitting the stationary part of the shaft seal
4. Lubricate the shaft. See section 7.1 Lubricant.
5. Place the seal disc (15) with the stationary part of the shaft
seal (16a) on the shaft and make sure the seal disc (15)
centers on the motor flange.
Fig. 21 Lubricating the shaft and placing the rotating part of
the shaft seal.
6. Place the rotating part of the shaft seal (16) on the shaft and
press it down with two fingers.
Position numbers of parts (numbers in brackets) refer
to section 7.6 Exploded view.
Do not touch the seal faces.
TM07 4366 1319TM07 3820 0519
16
16a
15
16
16a
TM07 3823 0519TM07 3824 0519TM07 3825 0519

9
English (US)
Fig. 22 Fitting the rotating part of the shaft seal
6.3 Fitting the impeller
1. Fit the impeller (19) on the shaft.
2. Spin the impeller (19) clockwise and tighten by hand until you
feel the resistance of the mechanical stop.
Fig. 23 Fitting the impeller
6.4 Fitting the motor fan
1. Place the pump in a vertical position with the shaft end facing
upwards. The surface must be smooth or soft to protect the
impeller (15) facing downwards.
2. Fit the motor fan (14) on the shaft by hand.
Fig. 24 Fitting the motor fan
6.5 Fitting the motor housing
Fig. 25 Fitting the motor housing
1. Place the pump in a vertical position with the motor fan (14)
facing upwards.
Fig. 26 Fitting the nut and the lower motor housing
2. Place the nut (56a) in the groove on the motor flange.
3. Fit the lower motor housing (42). Align the guides on the
inside of the lower motor housing (42) with the metal cooling
ribs on the stator housing. Click the motor housing in place.
4. Mount the foot (56) and tighten the screw (56a).
Torque: 12 ± 1 Nm.
5. Fit the motor housing grid (43) in the groove in the motor shell
(42).
TM07 3826 0519TM07 3827 0519TM07 4369 1319
19
14
TM07 3465 1319TM07 3829 0519
56a
56
407
51
44
181
43
14
53
42
408
161

English (US)
10
6. Fit the upper motor housing (44).
7. Fasten the screws (53) that hold the motor housing together.
Torque: 1.5 ± 0.1 Nm.
8. Fit the terminal box lid (51) and fasten the screws (53) that
hold it in place.
9. Follow the instructions below on how to connect the power
cable in section 6.6 Fitting the hydraulic parts.
6.6 Fitting the hydraulic parts
Fig. 27 Exploded view of hydraulic parts and pump housing
1. Lubricate the O-ring seat on the diffuser (20).See section
7.1 Lubricant.
2. Fit the two O-rings (13, 21a) on the venturi tube (21).
3. Assemble the venturi tube (21) and diffuser (20) by hand.
4. Lubricate the O-ring seat inside the inlet on the pump housing
(1). See section 7.1 Lubricant.
5. Fit by hand the venturi tube (21) and diffuser (20) inside the
pump housing (1).
Fig. 28 Fitting the hydraulic parts in the pump housing
6.7 Fitting the pump housing
Fig. 29 Exploded view of the pump housing
1. Place the pump in a vertical position with the motor housing
grid (43) facing downwards.
2. Fit the O-ring (28) on the seal disc (15). No lubrication is
needed. Run a screw driver along the ring to remove any
twisting.
Fig. 30 Fitting the O-ring on the seal disc
3. Fit the pump housing (1) so that the cut-out on the edge of the
pump housing is aligned with the marker on the edge of the
motor flange.
Fig. 31 Aligning the pump housing on the motor flange
4. Fit the clamp ring (92) on the recess. Use two flat screw
drivers to widen the clamp.
Verification of assembly:
Turn the shaft by rotating the impeller (19) clockwise
and check that the motor fan (14) does not touch the
motor housing (42 and 44).
TM07 4531 1419TM07 4532 1419
1
21
21a
20
13
1
21
20
TM07 4533 1419TM07 3835 0919TM07 3833 0519
28
92
1
94
93
15
28
1
!