Grundfos BMP 5.1 RS Betriebsanleitung

Service instructions

BMP 5.1-10.2 RS

1 / 10

96611958 1105 GB 10

Table of contents

1. Type identification........................................................................................................................... 2

1.1 Nameplate ..........................................................................................................................................................2

1.2 Type key..............................................................................................................................................................2

2. Torques and lubricants................................................................................................................... 3

3. Service tools .................................................................................................................................... 4

3.1 Special tools ........................................................................................................................................................4

3.2 Standard tools......................................................................................................................................................4

3.3 Torque tools.........................................................................................................................................................4

4. Dismantling and assembly ............................................................................................................. 5

4.1 General................................................................................................................................................................5

4.2 Dismantling..........................................................................................................................................................5

4.3 Assembly.............................................................................................................................................................6

4.4 Checking the wear parts......................................................................................................................................7

4.5 Fault finding.........................................................................................................................................................8

5. Checking of motor and cable ......................................................................................................... 9

5.1 Exploded view....................................................................................................................................................10

2 / 10

1. Type identification

This section shows the type key, the nameplate and the codes that can appear in the variant code.

Note: As codes can be combined, a code position may contain more than one code (letter).

1.1 Nameplate

1.2 Type key

TM029357 2404

Fig. 1 Nameplate

Pos. Description Pos. Description

1 Type designation 6 Pressure

2 Model 7 Liquid temperature

3Rated flow rate [m3/h] 8 Weight

4 Head 9 Country of origin

5 Speed

Example BMP 10,2 R- A- P- G- BBVP

Pump range

BMP = With standard motor

BMPE= With external frequency

converter

Maximum flow rate [m3/h]

Blank =All components in contact with

the pumped liquid are made of

stainless steel EN/DIN 1.4301 and PEEK

N = Designed for demineralised water.

All components in contact with

the pumped liquid are made of

stainless steel EN/DIN 1.4301 and PEEK

R = All components in contact with

the pumped liquid are made of

stainless steel 1.4410 and PEEK

Code for pump version

A = First generation

Code for pipe connection

O = External thread

G = Victaulic/PJE

Code for materials

I = Stainless steel (1.4301)

G = Stainless steel (1.4401)

Code for shaft seal

B = Bellows (rubber)

B = Carbon

V=Al

2O3

P=NBR

Type: BMP 10.2 R - A - P - G - BBVP

Model: A96126108 - 0424

Q: 10.2

H: 816.0

n min /max: 700 1800

P min /max: 10 80

T min /max:

Weight: 272

Made in DK

96126190

m 2677

m/h 2.32

3US GPM

Feet

min-1

PSI

3/ 50 C 37/122 F

bar

3 / 10

2. Torques and lubricants

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

Gardolube L 6034, part no. SV9995 (1 l).

Rocol 22, part no. RM2924 (1 kg).

Pos. Description Number Torque [Nm] Lubricant

26 Screw 16 30 ± 3

Gardolube L 603434 1 8 ± 1

29 Air vent screw 1 4 ± 1

O-ring

Soapy water

24 2 Rocol 22

38 1

4 / 10

3. Service tools

The following drawings and tables show special, standard and torque tools for pump service.

3.1 Special tools

3.2 Standard tools

3.3 Torque tools

ABCD

EFGH

IJKL

Pos. Description For pos. Suppl. information Part no.

A Torpedo 17 Included in the shaft seal tool kit

BMP 0.6-2.2 R

BMP 5.1-10.2 R 96560410

96560411

B Press ring 4

C Puller for shaft seal 4

Pos. Description For pos. Suppl. information Part no.

D Hexagon key 26, 29

E Ring/open-end spanner 34

F Screwdriver Straight slot

G Puller SV0335

H Circlip pliers 20 SV0302

Pos. Description For pos. Suppl. information Part no.

I Torque wrench

1-6 [Nm] SV0438

4-20 [Nm] SV0292

20-100 [Nm] SV0269

J Ratchet insert tool I SV0295

K Hexagon socket driver

L Hexagon socket

5 / 10

4. Dismantling and assembly

4.1 General

If it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instructions in the

following sections.

Position numbers of parts (digits) refer to drawings and parts lists; position numbers of tools (letters) refer to section.

Before dismantling the pump:

• Disconnect the electricity supply to the motor.

• Close the isolating valves, if fitted, to avoid draining the system.

• Remove the electric cable in accordance with local regulations.

• Note the centre of gravity of the pump to prevent it from overturning. This is especially important in the case of long

pumps.

Before assembly:

• Clean and check all parts.

• Replace defective parts by new parts.

• Order the necessary service kits.

• Replace gaskets and O-rings when the pump is overhauled.

During assembly:

• Lubricate and tighten screws and nuts to correct torque as stated in section.

4.2 Dismantling

Note: The pump must only be dismantled in absolutely clean environment.

4.2.1 Removing the coupling

1. Remove the screws and the washers of the coupling.

2. Pull the pump off the motor.

3. Remove the coupling insert.

4. Remove the screws of the coupling guard and remove the guard.

5. Slacken the set screw.

6. Remove the coupling half with a puller.

4.2.2 Removing the shaft seal

1. Remove the key (pos. 30), and remove the bush (pos. 37) and the O-ring (pos. 38).

2. Remove the rotating shaft seal part (pos. 4) with the puller (C).

3. Remove the stationary shaft seal part (pos. 4) from the bush using a screwdriver.

4.2.3 Removing the cylinder barrel and valve plate

1. Remove the screws (pos. 26).

2. Remove the top flange (pos. 35) and swash plate (pos. 6).

3. Remove the O-ring (pos. 24) from the swash plate.

4. Lift the cylinder barrel (pos. 17) with retaining plate (pos. 10), pistons (pos. 11) and valve plate (pos. 14) out of

the pump housing.

4.2.4 Dismantling and checking the barrel unit

1. Lift the pistons (pos. 11) with retaining plate (pos. 10) out of the barrel (pos. 17).

2. Remove the pistons from the retaining plate.

3. Separate the valve plate (pos. 14) and the barrel (pos. 17).

4. Remove the circlip (pos. 20) from the shaft, and remove the spring (pos. 18) and spring guide (pos. 19).

5. Remove the port plate (pos. 21) and the pin (pos. 8) from the pump housing.

6 / 10

4.3 Assembly

4.3.1 Checking

Check all wear parts before assembling pump, see 4.4 Checking the wear parts.

4.3.2 Fitting the cylinder barrel and valve plate

1. Fit the spring (pos. 18), spring guide (pos. 19) and circlip (pos. 20) on the cylinder barrel (pos. 17).

2. Fit the backup rings (pos. 13) and O-rings (pos.12) on the valve plate (pos.14); one pair per piston. Moisten

them with soapy water, see fig. 2.

3. Fit the valve plate (pos.14) on the cylinder barrel (pos.17). Press the part together using your fingers, see fig.

4. Insert the pistons into the retaining plate from the chamfered side.

5. Fit the piston unit into the cylinder barrel.

6. Fit the pin (pos. 8) into the bottom flange and fit the port plate (pos. 21).

7. Insert the cylinder barrel into the pump housing.

8. Fit the O-ring (pos. 24) to the swash plate (pos. 6) and lubricate it.

9. Fit the pin (pos. 7) into the pump housing and fit the top flange.

10.Fit the screws (pos. 26).

4.3.3 Fitting the shaft seal

1. Fit the thread bush (A) on the shaft and moisten it with soapy water.

2. Fit the rotating shaft seal part (pos. 4) with the seal face upwards using the punch (B).

3. Place the bush (pos. 37) on the table with the turned down end upwards.

4. Fit the stationary shaft seal part (pos. 4) with the rubber gasket downwards using the punch (B).

5. Fit the O-ring (pos. 38) on the bush (pos. 37) and lubricate it with Rocol 22.

6. Fit the bush on the pump.

4.3.4 Fitting the coupling

1. Fit the coupling half.

2. Tighten the set screw.

3. Fit the coupling insert on the coupling half.

4. Fit the coupling guard and screws.

5. Mount the pump on the motor.

6. Tighten the pump to the motor with the screws and washers.

Fig. 2 Backup rings and O-rings Fig. 3 Fitting the valve plate

7 / 10

4.4 Checking the wear parts

If there are any steel wear particles, caused by plastic, which is worn of, then scrap the pump!

Port plate and thrust plate:

There must be no wear on whether port plate or thrust plate. This can be

checked by laying a (hair) ruler upon the surface controlling the tightening

land against the light.

Pistons:

Play in ball- and -socket joint must not exceed 0.1 mm.

Thickness of slippers collar must not be below 4,4 mm.

The surface of the slippers must be plane and smooth (can be checked by

hair ruler). If pistons are with wear layer (black colour), partial wear of this is

acceptable.

Cylinder barrel:

The outer bearing surface must be without any bigger wear grooves

(not critical).

There must be no seizures and bigger scratches in the bushings, - and

ensure that the pistons move freely in them!

Housing with swash plate and bearing:

The surface on the swash plate must be smooth without any bigger

scratches. More than 0.1 mm wear in depth will reject the pump.

The bearing must be without any bigger wear grooves (not critical).

>4.4mm

8 / 10

4.5 Fault finding

Before starting work on the pump, make sure that the electricity supply has been switched off and that it cannot be

accidentally switched on.

Fault Possible cause Remedy

The pump stops

during operation.

No water supply.

Low-pressure switch has cut out.

The level switch has cut out.

Check that the low-pressure switch functions normally and is

adjusted correctly.

Check that the minimum inlet pressure is correct. If not, check the

feed pump.

Check the water level in the water tank.

The fuses are blown. Check and replace the main fuses and/or fuses for control circuit,

if necessary.

The motor starter overload unit has tripped out. Reset the starter overload.

The magnetic coil in the motor starter/contactor is

defective (not cutting in). Replace the coil. Check the coil voltage.

The control circuit has cut out or is defective. Check the control circuit and the contacts in the monitoring

devices (low-pressure switch, level switch, etc.).

The motor/supply cable is defective. Check motor and cable

Thepump runs,but

gives no water or

develops any

pressure.

No or insufficient water supply at the pump suction

port. Check that the inlet pressure is at least 0 bar.

The piping system or pump is choked up. Check the piping system and pump.

The prefilter is clogged. Clean the prefilter.

The pump is worn. Replace wear parts. Contact Grundfos Service.

Wrong direction of rotation. Interchange two phases in the motor main connection.

The pump runs at

reduced capacity.

The pump is partly blocked by impurities. Dismantle, clean and check the pump.

Replace defective parts. Contact Grundfos Service.

The pump is defective. Replace defective parts. Contact Grundfos Service.

The prefilter is clogged. Clean the prefilter.

The motor speed is too low. Check the electricity supply.

Contact the electricity supply authorities, if necessary.

If a frequency converter is used, adjust the speed.

9 / 10

5. Checking of motor and cable

1. Supply voltage

TM00 1371 3597

Measure the voltage between the phases by means of a

voltmeter.

Connect the voltmeter to the terminals at the mains

connection.

The voltage should, when the motor is loaded, be within ±5% of

the rated voltage. The motor may burn if there arelarger variations

in voltage.

If the voltage is constantly too high or too low, the motor must be

replaced by one corresponding to the supply voltage.

Large variations in voltage indicate poor electricity supply, and the

pump should be stopped until the defect has been found.

Resetting of the motor starter may be necessary.

2. Current consumption

TM00 1372 3597

Measure the current of each phase while the pump is

operating at a constant discharge pressure (if possible

at the capacity where the motor is most heavily loaded).

The motor full-load current appears on the motor

nameplate.

The difference between the current of the phase with the highest

amp consumption and the one with the lowest amp consumption

must not exceed 10% of the lowest amp consumption.

If so, or if the current exceeds the full-load current, check the

following possible faults:

• Too high operating pressure which may overload the motor.

• Too high speed which may overload the motor.

• Damaged pump which may overload the motor.

• The motor windings are short-circuited or partly disjointed.

• Too high or too low supply voltage.

• Poor connection in leads. Weak cables.

Points 3 and 4: Measurement not needed if supply voltage and current consumption are normal.

3. Winding resistance

TM00 1373 3597

Disconnect the phase leads in the terminal box.

Measure the winding resistance as shown on the

drawing.

The highest value must not exceed the lowest value by more than

5%.

If the deviation is higher, and the supply cable is OK, the motor

should be overhauled.

4. Insulation resistance

TM00 1374 3597

Disconnect the phase leads in the terminal box.

Measure the insulation resistance from each phase to

earth (frame).

(Make sure that the earth connection is made carefully.)

The insulation resistance for a new, cleaned or repaired motor

must be approx. 10 MΩ measured to earth.

For a given motor the critical insulation resistance (Rcrit) can be

calculated as follows:

Rcrit = UN[kV] x 0.5 [MΩ/ kV].

If the measured insulation resistance is lower than Rcrit, the motor

must be overhauled.

10 / 10

5.1 Exploded view

TM029438 4605

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