BJM Pumps KZN(R)-F User Manual
CAST IRON
Three Phase
208V, 230V, 460V, & 575V
KZN37-F
KZN55CH-F
KZN37R-F
KZN55R-F
KZN55-F
KZN55CHR-F
Three Phase
230V, 460V & 575V
KZN75-F
KZN110H-F
KZN75R-F
KZN110R-F
KZN110-F
KZN110HR-F
Three Phase
460V & 575V
KZN150-F
KZN220-F
KZN150L-F
KZN220L-F
KZN150LR-F
KZN220LR-F
KZN150R-F
KZN220R-F
INSTALLATION, OPERATION & MAINTENANCE MANUAL
FARHENHEIT
™
KZN(R)-F SERIES
HEAVY DUTY AGITATOR
TOP DISCHARGE
Electric Submersible Pumps
Read this manual carefully before installing, operating or servicing these pump models.
UObserve all safety information.U Failure to comply with instructions may result in personal
injury and/or property damage. Please retain these instructions.
Version 2/24/2014
TABLE OF CONTENTS
INTRODUCTION ............................................................................................................................................................ 4
SAFETY ......................................................................................................................................................................... 5
INSPECTION ................................................................................................................................................................. 6
PRE-INSTALLATION INSPECTION ......................................................................................................................... 6
OIL FILL QUANTITY/TYPE ....................................................................................................................................... 6
PUMP INSTALLATION ............................................................................................................................................. 7
POSITIONING THE PUMP ....................................................................................................................................... 7
PUMP ROTATION .................................................................................................................................................... 8
PUMP OPERATION ....................................................................................................................................................... 9
TYPICAL MANUAL DEWATERING INSTALLATION ..................................................................................................... 9
STOPPING ................................................................................................................................................................ 9
TYPICAL AUTOMATIC DEWATERING INSTALLATION ............................................................................................ 10
STOPPING .............................................................................................................................................................. 10
INTENDED METHODS OF CONNECTION ................................................................................................................. 11
THREE PHASE WIRING INSTRUCTION ............................................................................................................... 11
TROUBLE SHOOTING ................................................................................................................................................ 12
PUMP WILL NOT RUN ........................................................................................................................................... 12
PUMP RUNS BUT DOES NOT DELIVER RATED CAPACITY ............................................................................... 12
SERVICING YOUR SUBMERSIBLE PUMP............................................................................................................ 13
MAINTAINING YOUR PUMP .................................................................................................................................. 13
CHANGING SEAL OIL ............................................................................................................................................ 13
CHANGING SEALS* ............................................................................................................................................... 14
EXPLODED VIEW OF KZN37-F, 55-F, 55R-F, 55CH-F, 55CHR-F, 75-F, 75R-F ........................................................ 15
EXPLODED VIEW OF KZN110-F, 110R-F, 110H-F, 110HR-F, 150-F, 150R-F, 150L-F, 150LR-F ............................. 16
EXPLODED VIEW OF KZN220-F, 220R-F, 220L-F, 220LR-F ..................................................................................... 17
KZN-F SERIES PARTS LIST ....................................................................................................................................... 18
KZNRF PARTS LIST .................................................................................................................................................... 20
THREE PHASE WIRING DIAGRAMS ......................................................................................................................... 22
208V ........................................................................................................................................................................ 22
MODELS KZN37-F, 37R-F, 55-F, 55CH-F, 55R-F, 55CHR-F ............................................................................ 22
230V ........................................................................................................................................................................ 23
MODELS KZN37-F, 37R-F, 55-F, 55CH-F, 55R-F, 55CHR-F, 75-F, 75R-F, 110-F, 110H-F, 110R-F, 110HR-F23
460V ........................................................................................................................................................................ 24
MODELS KZN37-F, 37R-F, 55-F, 55R-F, 55CHR-F, 75-F, 75R-F, 110-F, 110H-F, 110HR-F, 150-F, 150L-F,
150L-F, 150LR-F, 150R-F, 220-F, 220L-F, 220LRF, 220R-F ............................................................................. 24
575V ........................................................................................................................................................................ 25
MODELS KZN37-F, 37R-F, 55-F, 55R-F, 55CHR-F, 75-F, 75R-F, 110-F, 110H-F, 110HR-F, 150-F, 150L-F,
150L-F, 150LR-F, 150R-F, 220-F, 220L-F, 220LR-F, 220R-F ............................................................................ 25
SEAL MINDER® - THERMAL MOTOR SENSOR SWITCH .......................................................................................... 26
WARRANTY AND LIMITATION OF LIABILITY ............................................................................................................ 28
START-UP REPORT FORM ........................................................................................................................................ 29
NOTES: ........................................................................................................................................................................ 32
INTRODUCTION
This Installation, Operation and Maintenance manual provides important information on
safety and the proper inspection, disassembly, reassembly and testing of the BJM
Pumps® KZN-F Series submersible pump. This manual also contains information to
optimize performance and longevity of your BJM Pumps submersible pump. The F
Series FARHRENHEIT™ pumps are engineered to pump water based liquids up to 200°
Fahrenheit (93°C).
The submersible KZN-F Series pumps are designed to pump water and water
based slurries. The KZN-F 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. Consult BJM Engineering if there is a
question on chemical compatibility.
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: 860-399-7784
Phone: 877-256-7867
Phone: 860-399-5937
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.
4
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 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.
5
Qty. oil in seal chamber
Models
U.S. fl. oz.
C.C.
Type of oil
KZN37-F, 37R-F, 55-F, 55CH-F, 55RF, 55CHR-F, 75-F, 75R-F
49
1450
ISO 32 Food Grade Mineral Oil
KZN110-F, 110H-F, 110R-F, 110HRF, 150-F, 150L-F, 150LR-F, 150R-F
125
3700
ISO 32 Food Grade Mineral Oil
KZN220-F, 220L-F, 220LR-F, 220R-F
213
6300
ISO 32 Food Grade Mineral Oil
INSPECTION
Review all safety information before servicing pump.
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 sensor cable for any cuts or damage.
4) Check for, and tighten any hardware that appears loose.
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.
Lubrication:
No additional lubrication is necessary. The shaft seal and bearings are fully lubricated
from the factory. Seal oil should be checked once per year. See table below.
Note: The stator on this model is oil filled. This needs to be changed annually
when the seal oil is changed. With the power cable entry removed, fill the motor
chamber with oil to a level that insures the oil is covering the motor windings by
OIL FILL QUANTITY/TYPE
6
½”, and that will be above the upper bearing. Do not overfill, an air gap of 10-15%
must be maintained for heat expansion.
PUMP INSTALLATION
KZN-F Series pumps have been evaluated for use with water or water based solutions.
Please contact the manufacturer for additional information.
Risk of electric shock. KZN-F 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 or control panels.
Lifting:
Attach a rope or lifting chain (not included) to the handle (or lifting rings) on the top of
the pump.
Do not lift the pump by the power cable or discharge hose/piping.
Proper lifting equipment (rope/chain) must be used.
POSITIONING THE PUMP
BJM Pumps, KZN-F Series pumps are designed to operate fully or partially submerged.
Do not run the pump dry. Refer to data sheet for minimum submersion depth for your
particular model. Data sheets can be obtained online at HUwww.bjmpumps.comUH or by
calling BJM Pumps, LLC at 860-399-5937. As a general rule, KZN Series top discharge
pumps can pump down to a level above the suction screen. Pumping lower than the
screen will permit air to enter the pump and cavitate, lose prime or become air bound.
Do not run pumps dry.
Pump liquid should not exceed a maximum temperature of 200°F (93°C).
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 suspend the pump
with a lifting rope/chain. The KZN-F Series pumps are provided with a suction
strainer to prevent large solids from clogging the impeller. Any spherical solids
which pass through the strainer should pass through the pump.
For maximum pumping capacity, use the proper size non-collapsible hose or rigid
piping. A check valve may be installed after the discharge to prevent back flow
when the pump is shut off.
7
PUMP ROTATION
Two ways to check the correct pump rotation:
1. By looking at the impeller; the rotation of the impeller should be counter
clockwise as shown in the picture below.
2. By looking from the top of the pump. Since the impeller cannot be seen, the best
way to check the rotation is to check the kick back motion of the pump when the
pump just starts. The kick back motion of the pump should be counter clockwise
as shown in the picture below.
8
PUMP OPERATION
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.
TYPICAL MANUAL DEWATERING INSTALLATION
NOTE: Maximum recommended starts should not exceed 10 times per hour.
All KZN-F models are provided with a 50’ (10m) power cord. UNEVERU splice the power
cable due to safety and warranty considerations. Always keep the lead end dry.
Note: 208V, 230V, 460V & 575V three phase units do not have a plug and have to
be provided separately.
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.
For manual operation: 208, 230, 460 & 575 volt: Attach the proper plug or connect
directly to the power source or control box. KZN-F model pumps are supplied with two
grounding wires; one green for grounding to the panel; the other is orange and is to be
used for grounding check systems or can be also connected to the grounding point on
the control. Check the direction of the rotation. Tilt the pump and start it. It should twist
in the opposite direction of the arrow (on pump). It is recommended that a Ground Fault
Interrupter (GFI) type receptacle (or equivalent) be used.
STOPPING
To stop the pump (manual and automatic mode), unplug it from the power source, turn
off the breaker, or turn the power source off (generator).
Typical 3 phase manual control 1
9
TYPICAL AUTOMATIC DEWATERING INSTALLATION
NOTE: Maximum recommended starts should not exceed 10 times per hour.
Three phase pumps need a separate control box with float(s) for automatic
operation.
STOPPING
To stop the pump (manual and automatic mode), turn off the breaker, or turn the power
source off (generator).
10
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