Grundfos 72 Betriebsanleitung

S pumps, range 72 - 74 - 78

DIN 50/60 Hz

Service instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Service instructions

Original service instructions.

CONTENTS

Page

1. Symbols used in this document

1. Symbols used in this document 2

2. Servicing S pumps with explosion-proof motors 3

3. Safety 3

4. Identification 3

4.1 Nameplate 3

4.2 Type key 4

5. Handling the pump 6

5.1 Lifting the pump 6

5.2 Lifting points 6

5.3 Raising pump to upright position 6

6. Torques, lubricants and special liquids 7

6.1 Common torques 7

6.2 Special torques and lubricants 7

6.3 Quantities of grease in bearings 7

6.4 Special liquids 7

7. Service tools 8

7.1 Standard tools 8

7.2 Special tools 9

7.3 Tightness test tools 9

7.4 Lifting tools 9

8. Service 10

8.1 General information 10

8.2 Pump cleaning and visual inspection 10

8.3 Annual maintenance 10

8.4 Oil check and oil change 11

8.5 Inspection and adjustment of impeller clearance 12

9. Dismantling and assembly instructions 13

9.1 Checking and replacing the cable 13

9.2 Replacing the terminal board 14

9.3 Replacing the protection sensors 17

9.4 Dismantling range 72 19

9.5 Assembling range 72 21

9.6 Dismantling range 74 23

9.7 Assembling range 74 25

9.8 Dismantling range 78 29

9.9 Assembling range 78 30

10. Tightness tests 32

10.1 Tightness test of stator (submerged) 32

10.2 Tightness test of terminal box (cable side, submerged) 32

11. Drawings 33

11.1 Range 72 33

11.2 Range 74 42

11.3 Range 78 48

11.4 Position numbers and material specification 56

11.5 Sensor positions 58

11.6 Electrical connections 60

Warning

If these safety instructions are not observed,

it may result in personal injury.

Warning

These instructions must be observed for

explosion-proof pumps. It is advisable also to

follow these instructions for standard pumps.

Warning

If these instructions are not observed, it may lead

to electric shock with consequent risk of serious

personal injury or death.

Warning

The surface of the product may be so hot that

it may cause burns or personal injury.

Warning

The sound pressure level is so high that hearing

protection must be used.

Caution

If these safety instructions are not observed,

it may result in malfunction or damage to the

equipment.

Note

Notes or instructions that make the job easier

and ensure safe operation.

English (GB)

2. Servicing S pumps with explosion-proof

motors

S pumps, range 72 to 78 have the following explosion protection

classification:

Service work on Ex pumps must be carried out by Grundfos or a

workshop authorised by Grundfos. Violation of this requirement

will invalidate the Ex classification of the pump.

Overhauled and repaired explosion-proof pumps are provided

with a repair plate giving the following information:

• the repair symbol R

• name of registered trade mark of the repairing workshop

• workshop reference number relating to the repair

• date of overhaul or repair.

In case of subsequent repairs, the existing repair plate should be

replaced by a new, updated repair plate and earlier markings

must be recorded.

The repairing workshop must keep records of performed

overhauls and repairs together with records of all previous

overhauls, repairs and possible modifications. Copies of the

repairing workshop’s detailed records should be filed by the

owner or operator together with the original type certificate of the

explosion-proof motor in question.

3. Safety

For safety reasons, all work in pits must be supervised by a

person outside the pump pit.

Pits for submersible sewage and wastewater pumps contain

sewage and wastewater with toxic and/or disease-causing

substances. Therefore, all persons involved must wear

appropriate personal protective equipment and clothing, and all

work on and near the pump must be carried out under strict

observance of the hygienic regulations in force.

If Grundfos is requested to service the pump, Grundfos must be

contacted with details about the pumped liquid, etc., before the

pump is returned for service. Otherwise Grundfos can refuse to

accept the pump.

Possible costs of returning the pump are paid by the customer.

However, any application for service (no matter to whom it may

be made) must include details about the pumped liquid if the

pump has been used for liquids which are injurious to health or

toxic.

4. Identification

4.1 Nameplate

Fig. 1 Pump nameplate

All pumps can be identified by means of the nameplate on the

motor top cover, see fig. 1.

Direct drive, 50 or 60 Hz CE 1180 II2 G Ex bc d IIB T4

Frequency converter

drive CE 1180 II2 G Ex bc d IIB T3

74, 78

Direct drive, 50 or 60 Hz Only on request

Frequency converter

drive Only on request

Warning

Pump installation in pits must be carried out by

specially trained persons.

Work in or near pits must be carried out

according to local regulations.

Warning

Before attempting to lift the pump, make sure the

rated capacity of the lifting equipment (lifting

chain etc.) is adequate for the lifting work.

The rated capacity of the lifting equipment is

stated on the equipment nameplate. The weight

of the pump is stated on the pump nameplate.

Note

If a pump has been used for a liquid which is

injurious to health or toxic, the pump will be

classified as contaminated.

TM05 8220 2113

Pos. Description

1 Type designation

2 Product number

3 Serial number

4 Maximum head (m)

5 Number of phases

6 Voltage, delta connection

7 Voltage, star connection

8 Rated power input (kW)

9 Power factor (Cos φ)

10 Production code (YYWW)

11 Model

12 Maximum liquid temperature

13 Maximum flow rate (l/s)

14 Enclosure class according to IEC 60529

15 Frequency (Hz)

16 Rated speed

17 Current, delta connection

18 Current, star connection

19 Rated power output P2

20 Insulation class

21 Weight

English (GB)

4.2 Type key

All S pumps, range 72, 74 and 78, described in this product guide are identified by the type designation stated in the confirmation of order

and other documentation supplied with the pump.

Please note that the pump type described in this type key is not necessarily available in all variants.

Code Example S 2 .90 .250 .2250 .4 .72 S .C .496 .G .N .D .5 13 .Z

Pump type:

Grundfos sewage and wastewater pump

Multi-channel impeller pump installed in a column pipe

Impeller type:

Two-channel

Three-channel

Four-channel

Pump passage:

Maximum solids size [mm]

250

[ ]

Pump discharge, S type:

Nominal diameter of pump discharge port [mm]

Pump discharge, ST-type:

Nominal diameter of column pipe [mm]

Output power, P2:

P2 = Code number from type designation/10 [kW]

Number of poles:

4-pole motor

6-pole motor

8-pole motor

10-pole motor

12-pole motor

14-pole motor

Pump range:

Pressure version:

Super-high

High

Medium

Low

Extra-low

Super low

Installation type:

Submerged installation without cooling jacket

Submerged installation with cooling jacket

Dry installation with cooling jacket

Dry horizontal installation with cooling jacket

Impeller diameter (average):

[mm]

Material code for impeller, pump housing and stator housing:

Cast iron impeller, pump housing and stator housing

Cast iron pump with stainless steel impeller

Pump version:

Non-explosion-proof pump

Pump with explosion-proof motor

Sensor version:

S pump with built-in SM 113 module. PTC sensors are connected directly to IO 113 or other PTC relay.

S pump without built-in SM 113 module

Frequency:

50 Hz

60 Hz

Voltage and connection:

50 Hz 60 Hz

3 x 400 / 690 V Y/D 3 x 575 / (996) V Y/D

3 x 415 / 719 V Y/D

3 x 380-400 / 660-690 V Y/D

3 x 380 / 660 V Y/D 3 x 380 / 660 V Y/D

3 x 460 / (797) V Y/D

3 x 400-415 / 690-719 V Y/D

3 x 380-415 / 660-719 V Y/D

Z Custom-built products

English (GB)

Type key used for frame size 74 and 78 until 2010. May still be used for spare pumps manufactured later.

Code Example S 2 X 250 4 H 2 5 11 Z

SPump type:

Grundfos (or Sarlin) wastewater pump/sewage pump

Impeller type:

Two-channel

Three-channel

Four-channel

Axial Propeller

Multi-channel, small pump passage

[ ]

Pump version:

Standard pump

In conformity with the ATEX directive

100 Power:

Motor power in kW

Number of poles:

2-pole motor

4-pole motor

6-pole motor

8-pole motor

10-pole motor

12-pole motor

14-pole motor

[ ]

Pump generation:

First generation

Second generation

Third generation

[ ]

Pressure version:

No classification

Super high

High

Medium

Low

Super extra low

Installation type:

Submerged installation without cooling jacket

Submerged installation with cooling jacket

Dry installation with cooling jacket

Submerged installation, portable. Pump without cooling jacket.

Submerged installation, portable. Pump with cooling jacket.

Dry horizontal installation with base stand and bracket. Pump with cooling jacket

Submerged column installation

[ ]

A,B,C

Interchangeability:

No letter indicates full interchangeability of parts and use of the same spare parts catalogue.

The letters (A, B, C...) indicate interchangeability of parts between otherwise identical pumps.

[ ]

Number of phases:

Single-phase

Three-phase

Frequency:

50 Hz

60 Hz

Voltage and starting method:

50 Hz 60 Hz

660-690 V Y

288-500 V Y/D

400-690 V Y/D 460-(796) V Y/D

220-380 V Y/D

415-(719) V Y/D

500-(865) V Y/D

380-660 V Y/D

USpecial equipment:

Flanges sized according to ANSI specifications

Non-standard parts:

Special diameter in impeller

Special length of cable

Combination of C and D or other special part

Material code for impeller, pump and stator housing:

Stainless steel impeller, pump housing and stator housing, AISI 316 (DIN W.-Nr. 1.4408)

Stainless steel impeller and pump housing, AISI 316 (DIN W.-Nr. 1.4408)

Stainless steel impeller, AISI 316 (DIN W.-Nr. 1.4408)

English (GB)

5. Handling the pump

S pumps, range 78 weigh up to 7800 kg without accessories. It is

therefore very important to use the right lifting equipment.

The pump weight is stated on the pump nameplate. See section

4.1 Nameplate.

5.1 Lifting the pump

All lifting equipment must be rated for the purpose and checked

for damage before any attempt to lift the pump. The lifting

equipment rating must under no circumstances be exceeded.

See section 7.4 Lifting tools.

5.2 Lifting points

Fig. 2 Lifting points, range 72

Fig. 3 Lifting points, range 74 and 78

5.3 Raising pump to upright position

Fig. 4 Raising the pump to upright position, step 1

Fig. 5 Raising the pump to upright position, step 2

Fig. 6 Raising the pump to upright position, step 3

Warning

Never lift the pump by the power supply cables.

It may result in electric short-circuit and risk of

electric shock when the pump is connected to the

mains. The cables and cable entry may be

damaged, leading to loss of watertightness and

consequent severe damage to the motor.

TM03 4459 0208TM04 6068 4809

Warning

Make sure that the lifting brackets are tightened

before attempting to lift the pump. Tighten if

necessary. Carelessness during lifting or

transportation may cause injury to personnel or

damage to the pump.

TM03 3034 0208TM03 3035 0208TM03 3036 0208

English (GB)

6. Torques, lubricants and special liquids

This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used.

6.1 Common torques

6.2 Special torques and lubricants

Oils:

Silicone spray Valvoline: 96249498.

Esso Unirex S2: 96248520/SKF LGHP 2 (-).

Motor oil with viscosity grade SAE 10 W 30 or SAE 10 W 40.

6.3 Quantities of grease in bearings

6.4 Special liquids

Würth Ergo 4307 or similar (thread-locking compound)

Henkel Loclite 290 or similar (thread-locking compound)

ACC Silicone Silcoset 151 (glue, FM approved).

Dimension M8 M10 M12 M16 M20 M24 M27 M30

Torque [Nm] 20 40 70 170 330 570 820 1120

Range Pos. Description Quantity Dimension Torque

[Nm] Lubricant

74, 78 61a O-ring (primary shaft seal) 2 - - Oil

74, 78 62 O-ring 1 - - Oil

72, 74 67 Screw (impeller) 1 M24 600 Oil

78 67 Screw (impeller) 1 M24 160 Oil

67a Screw (fastening plate of impeller) 3 - 170 Oil

All 72a O-ring 1 - - Oil

All 105 O-ring (inside of stationary part) 1 - - Oil

Primary shaft seal (sliding surfaces) 1 - - Silicone spray

72 105 Screw of primary shaft seal 5 - 8 -

74, 8 105 Screw of primary shaft seal 5 - 15 -

All 105b O-ring (inside stationary part) 1 - - Oil

Secondary shaft seal (sliding surfaces) 1 - - Silicone spray

72, 74 105b Screw of secondary shaft seal 5 - 8 -

78 105b Screw of secondary shaft seal 5 - 15 -

74, 78 153 Angular contact ball bearings 2 - - Unirex S2 / LGHP 2

All 157 O-ring 1 - - Oil

All 157a O-ring 1 - - Oil

All 162 Roller bearings 1 - - Unirex S2 / LGHP 2

All 154 Ball bearing 1 - - Unirex S2 / LGHP 2

All 193 Oil plug 3 R 3/4 55 ± 5 -

74, 78 756 O-ring 1 - - Oil

Range Bearing Amount of grease

Lower bearings

2.2 litres

74 2.3 litres

78 4.2 litres

Range Bearing Amount of grease

Upper bearing

0.28 litres

74 1.0 litres

78 1.7 litres

Range Pos. Component Liquid

All

523 Cable gland for WIO Ergo 4307

520d Moisture switch Loclite 290

177 Terminal board Silcoset 151

English (GB)

7. Service tools

The following sections shows tools for pump service.

7.1 Standard tools

Standard tools

ABCD

EFGH

IJKL

Pos. Range Designation Description Part number

A All Pinch bar - SV5201

B All Screwdriver Straight slot -

C All Lock-ring pliers - SV2014

D All Plastic hammer - SV0349

72 Hook spanner (Walter) 120-130 mm -

74 Hook spanner (SKF) HN22 -

78 Impact spanner (TMFN) 30-40 -

F All Warm-air heater - -

G All Multimeter - -

H All Ratchet handle 1/2" - 96777072

I All Hexagon head driver

4 mm SV0414

M6 - 5 mm SV0296

M8 - 6 mm SV0297

M10 - 8 mm SV0298

M12 - 10 mm SV0299

M16 - 12 mm - 1/2" SV0394

J All Ring/open-end spanner

8 mm SV0273

10 mm SV0083

12 mm SV0274

16 mm SV0185

20 mm -

24 mm SV0122

27 mm SV0084

30 mm SV0073

K All Puller for bearing - SV0335

L All Sliding gauge 0-150 mm SV0307

M All Cable pliers - -

N All Feeler gauge - -

English (GB)

7.2 Special tools

Special tools

7.3 Tightness test tools

Tightness test tools

7.4 Lifting tools

Lifting tools

OPQR

STUV

Pos. Range Designation Description Part number

O All Torque wrench - -

P 74 Seal assembly tool (PUR127) Roplan 85 mm 96242908

Q 74 Seal assembly tool (PUR128) Roplan 95 mm 96242909

R 78 Seal assembly tool (PUR129) Roplan 110 mm 96242910

S 78 Seal assembly tool (PUR130) Roplan 110 mm 96242911

T 74 Seal assembly tool (PUR131) Roplan 100 mm 96242912

U 78 Seal assembly tool (PUR132) Roplan 120 mm 96242913

V 72 Seal assembly tool (PUR133) Roplan 65 mm 96255372

WXY

BAR

Pos. Designation Description Part number

W Pressure gauge --

X Test plug (KOE045) Connector M3\8-24 UNF F-ISO

228-G 3\8M 96061209

Y Test plug (KOE171) Connector R3/4 96061213

AA BB CC DD

Pos. Designation Description Part number

AA Eyebolt with rotating swivel Range 74 and 78 -

BB Shackle All -

CC Eye bolt All -

DD Lifting clamp Range 78 98253177

English (GB)

8. Service

8.1 General information

Service must be carried out by specially trained persons.

Before carrying out maintenance and service, it must be ensured

that the pump has been thoroughly flushed with clean water.

Rinse the pump parts with water after dismantling.

Before assembly:

• Clean and check all parts.

• Replace defective parts with new parts.

• Order the necessary service kits.

• Gaskets and O-rings should always be replaced when the

pump is overhauled.

During assembly:

• Lubricate and tighten screws and nuts to correct torque as

stated in section.

8.2 Pump cleaning and visual inspection

A simple maintenance measure is to clean the pumps at regular

intervals. The pumps may be cleaned on site at the pumping

station when lifted up from the wet pit. Hose down the pump

externally using a high-pressure jet cleaner (maximum pressure

100 bar). Caked dirt on the motor must be removed to ensure

good heat conductivity. A mild detergent approved for disposal

into the sewage system may be used. The pumps may be

scrubbed, using a soft brush, if necessary.

Visual inspection of the pump should include search for cracks or

other external damage. Inspect the lifting bracket and lifting chain

for wear and corrosion. Inspect the pump cable for cracks or

lacerations in the sheath, kinks or other damage. Inspect visible

parts of the cable entry for cracks and for being firmly connected

to the motor top cover. Check all visible screws and tighten, if

necessary.

The air vent valve at the top of the cooling jacket may be removed

and cleaned, if necessary. Clean the vent hole before refitting the

valve after cleaning.

8.3 Annual maintenance

Pumps in normal operation should be inspected once a year.

If the pumped liquid is very muddy or sandy, check the pump at

shorter intervals.

The following points should be checked:

•Power consumption

See section 4.1 Nameplate.

•Oil level and oil condition

See section 8.4 Oil check and oil change.

•Cable entry

Make sure that the cables are not sharply bent or pinched.

Replace the cables if necessary.

See section 9.1 Checking and replacing the cable.

•Sensors

Make sure that sensor are working. Replace the sensors if

necessary.

See section 9.3 Replacing the protection sensors

•Impeller clearance

Check the impeller clearance.

See section 8.5 Inspection and adjustment of impeller

clearance.

•Pump parts

Check the pump housing, etc. for possible wear.

Replace defective parts.

•Ball bearings

Check the shaft for noisy or heavy operation (turn the shaft by

hand). Replace defective ball bearings.

A general overhaul of the pump is usually required in case of

defective ball bearings or poor motor function. This work must

be carried out by an authorized service workshop.

•O-rings and similar parts

During service / replacement, it must be ensured that the

grooves for O-rings and seal faces have been cleaned before

the new parts are fitted.

Warning

Before starting work on the pump, make sure that

the mains switch has been locked in position 0.

All rotating parts must have stopped moving.

Warning

Except for replacement/dismantling of bearings,

all other service work must be carried out by

Grundfos or an authorised service workshop.

Warning

On Ex pumps, the ball bearings must only be

replaced by an authorised Ex workshop.

Note

Used rubber parts must not be reused.

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