ITT GOULDS PUMPS JCU User manual

Installation, Operation, and
Maintenance Manual
JCU

Table of Contents
1 Introduction and Safety ....................................................................................................................................2
1.1 Safety ........................................................................................................................................................2
1.1.1 Safety terminology and symbols ..................................................................................................... 3
1.1.2 Environmental safety.......................................................................................................................3
1.1.3 User safety ......................................................................................................................................4
1.1.4 Safety regulations for Ex-approved products in potentially explosive atmospheres ....................... 6
1.1.5 Product approval standards ............................................................................................................ 7
1.1.6 Product warranty .............................................................................................................................8
2 Transportation and Storage..............................................................................................................................9
2.1 Receive the unit......................................................................................................................................... 9
2.2 Unpack the unit ......................................................................................................................................... 9
2.3 Pump handling .......................................................................................................................................... 9
2.3.1 Lifting methods................................................................................................................................9
2.4 Pump storage requirements .................................................................................................................... 10
2.5 Preservation and Storage ....................................................................................................................... 11
3 Installation........................................................................................................................................................12
3.1 Inspect the Pump .................................................................................................................................... 12
3.2 Install the sump .......................................................................................................................................12
3.3 Install the motor.......................................................................................................................................12
3.4 Install the pump ....................................................................................................................................... 12
3.5 Slide rail system (optional) ......................................................................................................................12
3.5.1 Install the base component assembly ...........................................................................................12
3.5.2 Install the guide bracket / pivot bracket assembly......................................................................... 13
3.5.3 Install the lifting bracket assembly ................................................................................................13
3.5.4 Install the slide rail.........................................................................................................................14
4 Commissioning, Startup, Operation, and Shutdown ...................................................................................17
4.1 Start the pump.........................................................................................................................................17
5 Maintenance..................................................................................................................................................... 18
5.1 Maintenance............................................................................................................................................18
5.1.1 Maintenance - O-ring, pump flange to slide rail base flange......................................................... 18
5.2 Disassembly ............................................................................................................................................ 18
5.2.1 Disassembly precautions .............................................................................................................. 18
5.2.2 Disassemble the pump..................................................................................................................19
5.3 Pre-assembly .......................................................................................................................................... 19
5.3.1 Pre-assembly inspections ............................................................................................................. 19
5.3.2 Replacement guidelines................................................................................................................ 19
5.4 Reassembly............................................................................................................................................. 20
5.4.1 Reassemble the pump .................................................................................................................. 20
6 Troubleshooting ..............................................................................................................................................23
6.1 Troubleshooting.......................................................................................................................................23
Table of Contents
JCU Installation, Operation, and Maintenance Manual 1

1 Introduction and Safety
1.1 Safety
WARNING:
•The operator must be aware of the pumpage and take appropriate safety precautions to
prevent physical injury.
• Risk of serious injury or death. If any pressure-containing device is over-pressurized, it
can explode, rupture, or discharge its contents. It is critical to take all necessary meas-
ures to avoid over-pressurization.
• Risk of death, serious personal injury, and property damage. Installing, operating, or
maintaining the unit using any method not prescribed in this manual is prohibited. Prohib-
ited methods include any modification to the equipment or use of parts not provided by
ITT. If there is any uncertainty regarding the appropriate use of the equipment, please
contact an ITT representative before proceeding.
• Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining
devices can cause trapped liquid to rapidly expand and result in a violent explosion. This
manual clearly identifies accepted methods for disassembling units. These methods must
be adhered to. Never apply heat to aid in their removal unless explicitly stated in this
manual.
• Risk of serious personal injury or property damage. Dry running may cause rotating parts
within the pump to seize to non-moving parts. Do not run dry.
• Running a pump without safety devices exposes operators to risk of serious personal in-
jury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are
properly installed. See specific information about safety devices in other sections of this
manual.
• Risk of death, serious personal injury, and property damage. Heat and pressure buildup
can cause explosion, rupture, and discharge of pumpage. Never operate the pump with
suction and/or discharge valves closed.
• Risk of severe physical injury or death from explosion of trapped liquid. Never use heat to
remove parts unless explicitly stated in this manual.
• 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 over-
heat. If pump becomes plugged, shut down and unplug prior to restarting pump.
• Precautions must be taken to prevent physical injury. The pump may handle hazardous
and/or toxic fluids. Proper personal protective equipment should be worn. Pumpage must
be handled and disposed of in conformance with applicable environmental regulations.
• If the pump or motor is damaged or leaking, electric shock, fire, explosion, liberation of
toxic fumes, physical harm, or environmental damage may result. Do not operate the unit
until the problem has been corrected or repaired.
CAUTION:
Risk of injury and/or property damage. Operating a pump in an inappropriate application can
cause over pressurization, overheating, and/or unstable operation. Do not change the service
application without the approval of an authorized ITT representative.
1 Introduction and Safety
2 JCU Installation, Operation, and Maintenance Manual

1.1.1 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 Indication
DANGER:
A hazardous situation which, if not avoided, will result in death or seri-
ous injury
WARNING:
A hazardous situation which, if not avoided, could result in death or
serious injury
CAUTION:
A hazardous situation which, if not avoided, could result in minor or
moderate injury
NOTICE:
• A potential situation which, if not avoided, could result in unde-
sirable 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
1.1.2 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:
1.1 Safety
JCU Installation, Operation, and Maintenance Manual 3

• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regula-
tions.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
If the product has been contaminated in any way, such as from toxic chemicals or nuclear radi-
ation, do NOT send the product to ITT until it has been properly decontaminated and advise
ITT of these conditions before returning.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
1.1.2.1 Recycling guidelines
Always follow local laws and regulations regarding recycling.
1.1.3 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
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, nation-
al, state, and local regulations. For more information about requirements, see sections dealing specifical-
ly with electrical connections.
1.1.3.1 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.
1.1 Safety
4 JCU Installation, Operation, and Maintenance Manual

• Make sure that all safety guards are in place and secure.
• Recognize the site emergency exits, eye wash stations, emergency showers and toilets.
• 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.
1.1.3.2 Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
CAUTION:
Failure to observe the instructions contained in this manual could result in personal injury
and/or property damage, and may void the warranty. Read this manual carefully before instal-
ling and using the product.
• Never work alone.
•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.
1.1.3.3 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.
1.1.3.4 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 Action
Chemicals or hazardous fluids
in eyes
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.
1.1 Safety
JCU Installation, Operation, and Maintenance Manual 5

Condition Action
Chemicals or hazardous fluids
on skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.1.4 Safety regulations for Ex-approved products in potentially explosive
atmospheres
Guidelines for compliance
WARNING:
Risk of serious personal injury. Applying heat to impellers, propellers, or their retaining devices
can cause trapped liquid to rapidly expand and result in a violent explosion. This manual clear-
ly identifies accepted methods for disassembling units. These methods must be adhered to.
Never apply heat 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 mechan-
ics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical character-
istics of the gas and/or vapor present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national stand-
ards.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially explo-
sive 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 iso-
lated 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.
1.1 Safety
6 JCU Installation, Operation, and Maintenance Manual

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
1.1.5 Product approval standards
Regular standards
WARNING:
Use of equipment unsuitable for the environment can pose risks of ignition and/or explosion.
Ensure the pump driver and all other auxiliary components meet the required area classifica-
tion at the site. If they are not compatible, do not operate the equipment and contact an ITT
representative before proceeding.
All standard products are approved according to CSA standards in Canada and UL standards in USA.
The drive unit degree of protection follows IP68 See the nameplate for maximum submersion, according
to standard IEC 60529.
All electrical ratings and performance of the motors comply with IEC 600341.
Explosion-proofing standards
CSA certification
Intrinsically safe for:
• Class I, Div. 1, Groups A, B, C, D
• Class II, Div. 1, Groups E, F, G
• Class III
• Certified to Canadian and US requirements
SERIAL NO. & YEAR OF
MANUFACTURE HERE.
1.1 Safety
JCU Installation, Operation, and Maintenance Manual 7

1.1.6 Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
•The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved prod-
ucts.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should
the need arise for a warranty claim, then contact your ITT representative.
1.1 Safety
8 JCU Installation, Operation, and Maintenance Manual