Grundfos SE 12-42 hp Betriebsanleitung

GRUNDFOS INSTRUCTIONS

SE/SL 12-42 hp

Service instructions

Installation and operating instructions in

English and other languages for 50/60 Hz

http://net.grundfos.com/qr/i/98142268

Service animation video, YouTube

English (US)

English (US) Service instructions

Original service instructions

In this document there are references to the installation and

operating instructions for SE, SL 12-42 Hp (9-30 kW) (98142268).

The installation and operating instructions are accessible via the

QR code and link on the front of this document.

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 text accompanying the three hazard symbols DANGER,

WARNING and CAUTION is 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

1.3 Safety 3

2. Maintaining the product 3

2.1 Checking the motor liquid 4

2.2 Inspecting the shaft 4

2.3 Changing the motor liquid 4

2.4 Inspecting and adjusting the impeller clearance 6

3. Preparing the dismantling of the product 6

3.1 Transporting the product 6

3.2 Handling and storing the product 6

4. Dismantling and assembling the product 8

4.1 Explosion-proof products 8

4.2 General information 8

4.3 Dismantling the pump 8

4.4 Assembling the pump 11

5. Electrical connection 14

5.1 Motor protection 14

6. Starting up the product 17

6.1 General startup procedure 17

6.2 Direction of rotation 17

7. Additional information 18

7.1 Refractive index 18

7.2 Motor liquid quantities 18

7.3 Special tools 18

7.4 Tightening torques and lubricants 19

7.5 Fault finding the product 19

7.6 Wiring diagrams 20

7.7 Sensor connections 21

7.8 Exploded drawings 25

7.9 Motor drawings 33

7.10 Pump drawings 35

7.11 Components and material specification 37

7.12 Sensor positions 39

7.13 Alignment grooves 40

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.

English (US)

1.3 Safety

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

person outside the pump pit.

Pits for submerged sewage and wastewater pumps may contain

sewage or 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 hygienic regulations in force.

2. Maintaining the product

Check pumps running normal operation every 3000 operating

hours or at least once a year.

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

shorter intervals.

Check the following points:

•Power consumption

See pump nameplate.

•Motor liquid level and liquid condition

When the pump is new or after replacement of the shaft seal,

check the motor liquid level and water content after one week

of operation.

The motor liquid must be changed after 3000 operating hours

or once a year.

Use SML3 motor liquid, product number 795898 [5.25 qt (5 l)].

See section 2.3 Changing the motor liquid.

•Pump parts

Check the impeller, pump housing, etc. for possible wear.

Replace defective parts.

See section 4. Dismantling and assembling the product for

dismantling and assembly of the pump.

•Ball bearings

Check the shaft for noisy or heavy operation by turning the

shaft by hand. Replace defective ball bearings.

See section 4. Dismantling and assembling the product.

In case of defective ball bearings or poor motor function, a

complete overhaul of the pump is usually required.

This work must be carried out by Grundfos or an authorized

service centre.

•O-rings and similar parts

During service or replacement, make sure that the grooves for

O-rings and seal faces have been cleaned before the new

parts are fitted.

•Measuring the insulation resistance

Megging must take place at a voltage of minimum 500 V. The

insulation resistance measured must be minimum 50 kΩ.

Installation of products in pits must be carried out by

specially trained persons.

Work in or near pits must be carried out according to

local regulations.

DANGER

Electric shock

Death or serious personal injury

- It must be possible to lock the main switch in

position 0. Type and requirements as specified in

EN 60204-1, 5.3.2.

Persons must not enter the installation area when the

atmosphere is explosive.

We recommend that you carry out all maintenance

and service work when the product is placed outside

the pit.

DANGER

Crushing hazard

Death or serious personal injury

- Always lift the product by its lifting bracket or by

means of a forklift truck if the product is fixed on a

pallet. Do not lift the product by the power cable.

Defective bearings may reduce the Ex safety.

On Ex pumps, the ball bearings may only be

replaced by a FM-approved service centre.

Never reuse used rubber parts.

Explosion-proof products must be checked by a FM-

approved service centre once a year.

English (US)

2.1 Checking the motor liquid

You can check the ingress level of the media in the motor liquid.

By use of a refractometer, the refractive index will show the

ingress in percent.

If the refractive index is higher than -7 °F (-22 °C), change the

motor liquid.

We recommend that you do not exceed this level of refractive

index to ensure that the shaft seal and bearings are in the best

possible condition for reliable operation.

2.2 Inspecting the shaft

Only the SL pumps

You can check the leakage of the shaft seal by checking the

upper seal housing chamber (58) for water.

1. Place the pump in a horizontal position on a plane surface

with the drain plug (193a) pointing downwards.

2. Place a container under the drain plug (193a).

3. Remove the plug (193a).

4. If you drain less than 0.052 qt (5 cl), then the shaft seal is OK,

and the shaft seal does not need to be replaced.

5. If you drain more than 0.052 qt (5 cl), replace the shaft seal.

See section 4.3 Dismantling the pump.

Fig. 1 Oil plugs

2.3 Changing the motor liquid

When the pump is new or after replacement of the shaft seal,

check the motor liquid level and water content after one week of

operation.

Change the motor liquid after 3000 operating hours or once a

year. See description below.

If you replace the shaft seal, change the motor liquid.

2.3.1 SL pumps

Draining of motor liquid

1. Place a container under the pump which can contain 6.34 qt

(6 l) of motor liquid.

2. Place the pump in a horizontal position on a plane surface

with plug B pointing downwards. See fig. 2.

3. Remove plug B.

4. Allow all motor liquid to drain from the seal housing into the

container. Remove plug A to get a better flow of the motor

liquid.

Fig. 2 SL pump, horizontal view

5. Replace the O-ring with a new ring on the plug.

6. Fit plug B and tighten it to the correct torque. See section

7.4 Tightening torques and lubricants.

Media ingress in % Refractive index

[°F (°C)]

0 -22.0 (-30)

5 -16.6 (-27)

10 -13.0 (-25)

15 -9.4 (-23)

20 -7.6 (-22)

TM06 6219 0916

193a 193

WARNING

Pressurised system

Death or serious personal injury

- When loosening the screws of the motor liquid

chamber, note that pressure may have built up in

the chamber. Do not remove the screws until the

pressure has been fully relieved.

TM05 2768 0612

If the motor liquid in the container contains more than

20 % water, the shaft seal may be defective and must

be replaced.

If the quantity of motor liquid deviates considerably

from the quantity stated in the table below, the shaft

seal is defective.

Dispose of used motor liquid (propylene glycol) in

accordance with local regulations.

English (US)

Filling with motor liquid, vertical installation

1. Place the pump in vertical position.

2. Fill the shaft seal housing with motor liquid through hole A

until the motor liquid reaches the level indicated by plug B.

See fig. 3.

3. Replace the O-ring with a new ring.

4. Insert plugs A and B and tighten them to the correct torque.

See section 7.4 Tightening torques and lubricants.

Fig. 3 SL pump, vertical view

Filling with motor liquid, horizontal installation

1. Place the pump in horizontal position with plug B mounted and

facing downwards. Fill the shaft seal housing with motor liquid

through hole A until the motor liquid reaches the level

indicated in fig. 2. See also section 7.2 Motor liquid quantities.

2. Replace the O-ring with a new O-ring.

3. Insert plug A and tighten it to the correct torque. See section

7.4 Tightening torques and lubricants.

2.3.2 SE pumps

Draining of motor liquid

1. Place a container under the pump which can contain 15.85 qt

(15 l) of motor liquid.

2. Place the pump in horizontal position on a plane surface with

plug D pointing downwards. See fig. 4.

3. Remove plug D, and then remove plug C to get a better flow

of the motor liquid.

4. Allow all motor liquid to drain from the seal housing into the

container.

5. Replace the O-ring with a new ring on the plug.

6. Insert plug D and tighten it to the correct torque. See section

7.4 Tightening torques and lubricants.

Fig. 4 SE pump, horizontal view

Filling with motor liquid, vertical installation

1. Remove plug A and B on both sides. This makes it possible to

get the trapped air out while filling. See fig. 5.

2. Fill the shaft seal housing with motor liquid through hole A

until the motor liquid reaches the level indicated in fig. 5.

3. Replace the O-rings with new rings, insert the plugs and

tighten to the correct torque. See section 7.4 Tightening

torques and lubricants.

Filling with motor liquid, horizontal installation

1. Remove plug C.

2. Fill the shaft seal housing with motor liquid through hole C

until the motor liquid reaches the level indicated in fig. 4.

See also section 7.2 Motor liquid quantities.

3. Replace the O-ring with a new ring.

4. Insert plug C and tighten to the correct torque. See section

7.4 Tightening torques and lubricants.

Fig. 5 SE pump, vertical, top view

TM05 2768 1216TM05 2775 0512

A-A

Liquid level

TM05 2779 0512

English (US)

2.4 Inspecting and adjusting the impeller clearance

You can inspect the impeller clearance of installation types S and

C directly through the pump inlet.

You can inspect and adjust the installation types D and H with the

pump installed on the base stand and connected to the pipes.

2.4.1 Adjusting the impeller clearance

1. Loosen the set screws by two full turns each.

2. Close the impeller clearance by lightly tightening the fastening

screws diagonally until the impeller touches the pump

housing.

3. Loosen the fastening screws to make the correct gap under

the heads of the fastening screws. See fig. 6.

4. Tighten the set screws tightly. For more information about

torques, see section 7.4 Tightening torques and lubricants.

5. Tighten the fastening screws diagonally.

Fig. 6 Impeller clearance adjustment

3. Preparing the dismantling of the product

3.1 Transporting the product

You can transport the pump in vertical or horizontal position.

Make sure that the pump cannot roll or fall over.

See the installation and operating instructions for SE, SL 12-42

Hp (9-30 kW). Use the QR code and link on the front page of this

document.

3.2 Handling and storing the product

3.2.1 Contaminated products

3.2.2 Lifting the product

The product weighs between 639 and 1521 lb (290 and 690 kg)

without accessories. It is therefore very important to use the

correct lifting equipment. The product weight is stated on the

pump nameplate.

DANGER

Electric shock

Death or serious personal injury

- Before inspection, make sure that the motor is

switched off and that the main switch is locked in

position 0.

Check the impeller clearance every time service is

carried out to prevent hot surfaces in the hydraulic

parts.

Pressure range Impeller clearance X

[in (mm)]

E = Extra low pressure 0.028 ± 0.004 (0.7 ± 0.1)

L = Low pressure 0.028 ± 0.004 (0.7 ± 0.1)

M = Medium pressure 0.023 ± 0.004 (0.6 ± 0.1)

H = High pressure 0.023 ± 0.004 (0.6 ± 0.1)

S = Super high pressure 0.019 ± 0.004 (0.5 ± 0.1)

Do not use too much force when tightening the

fastening screws as this may damage the bearings.

Use the clearance stated in the impeller clearance

table above.

TM05 1916 3911

Fastening screw Fastening screw

Set screw

X inch (mm)

CAUTION

Biological hazard

Minor or moderate personal injury

- Flush the product thoroughly with clean water and

rinse the product parts in water after dismantling.

Make sure that all lifting equipment is rated for the

purpose.

Check the lifting equipment for damage before

attempting to lift the product.

DANGER

Crushing hazard

Death or serious personal injury

- Make sure that the shackles are tightened before

attempting to lift the product. Tighten if necessary.

DANGER

Crushing hazard

Death or serious personal injury

- Always lift the product by its lifting bracket or by

means of a forklift truck if the product is fixed on a

pallet.

Do not lift the product by the power cable.

It may result in electric short circuit and risk of chock

when the product is connected to the mains. The

cable and cable entry may be damaged, leading to

loss of watertightness and consequent severe

damage to the motor.

English (US)

Installation types S, C and D

When lifting the pump, use the right lifting points to keep the

pump balanced. SE, SL pumps installation types S, C and D are

equipped with two lifting point which ensure that the pump can be

lifted in a safe manner. See fig. 7and the table below to find the

correct lifting point.

Fig. 7 Lifting points, installation types S, C and D

Installation type H

Installation type H can be lifted by a hole in the flange and the

front lifting point. See fig. 8.

Fig. 8 Lifting points, installation type H

3.2.3 Raising the pump to upright position

1. Fasten the lifting equipment as shown in the figure below.

Fig. 9 Lifting the pump

2. Lift at the top end of the pump as shown in the figure below.

Fig. 10 Lifting the pump

Fig. 11 Pump correctly raised to upright position

3.2.4 Storing the product

See the installation and operating instructions for SE, SL 12-42

Hp (9-30 kW). Use the QR code and link on the front page of this

document.

Always handle the pump by means of the correct

lifting points.

TM05 2684 0312

Outlet flange size lifting point

NPS 3" (DN 80)

MiddleNPS 4" (DN 100)

NPS 6" (DN 150)

NPS 8" (DN 200)

FrontNPS 10" (DN 250)

NPS 12" (DN 300)

TM05 3449 1312

Middle

Front

TM05 4169 2112TM05 4170 2112TM05 4171 2112

English (US)

4. Dismantling and assembling the product

Before staring any work on the product used in liquids, which

could constitute a hazard to health, thorough cleaning or venting

of the product, pit, etc. must be carried out according to local

regulations.

4.1 Explosion-proof products

Only FM-approved service centres are allowed to intervene in the

flameproof enclosure of the product. Service not affecting the

explosion protection of the product and not violating the

explosion-proof regulations may be carried out by service

persons who are not FM-authorized.

Consequently, these persons are allowed to replace the following

parts of explosion-proof products:

• pump housing

•impeller

• seal ring and wear ring

• shaft seal

• motor liquid

All other service work must be carried out by a FM-approved

service centre. Violation of this requirement will invalidate the

explosion-proof classification of the product.

4.2 General information

Before dismantling the pump

• Switch off the power supply.

• Close the isolating valves, if fitted, to avoid draining the pipe

system.

• Disconnect the power 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 assembling the pump

• Clean and check all parts.

• Use the drawing and follow the alignment grooves in order to

place the components correctly. See fig. 43.

• Replace defective parts by new parts.

• Order the necessary service kits.

• Always replace gaskets and O-rings.

During assembling the pump

• Lubricate and tighten screws and nuts according to section

7.4 Tightening torques and lubricants.

• Use the drawing and follow the alignment grooves in order to

place the components correctly. See section 7.13 Alignment

grooves43.

4.3 Dismantling the pump

DANGER

Electric shock

Death or serious personal injury

- Before starting work on the product, make sure

that the fuses have been removed or the main

switch has been switched off.

Make sure that the power supply cannot be

accidentally switched on.

WARNING

Crushing of hands

Death or serious personal injury

- Make sure that all rotating parts have stopped

moving.

WARNING

Crushing hazard

Death or serious personal injury

- At all times during service, make sure to secure

the product against rolling over, for instance by

placing a wooden wedge on either side of the

motor.

Except for replacement or dismantling of pump

housing, shaft seal, impeller, seal ring and wear ring,

all other service work must be carried out by

Grundfos or a FM-approved service centre.

Service must be carried out by specially trained

persons.

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

Position numbers of parts (numbers in brackets) refer

to section 7.8 Exploded drawings.

Position numbers of tools (letters in brackets) refer to

section 7.3 Special tools.

Position numbers of parts (numbers in brackets) refer

to section 7.8 Exploded drawings.

Position numbers of tools (letters in brackets) refer to

section 7.3 Special tools.

Except for replacement or dismantling of pump

housing, shaft seal, impeller, seal ring and wear ring,

all other service work must be carried out by

Grundfos or a FM-approved service centre.

English (US)

4.3.1 Removing the cable

1. Remove the screw (181a) in the cable entry (168).

2. Slightly lift the cable entry (168).

3. Using a screwdriver, disconnect both the signal wires and the

power wires from the terminal block (176a). See fig. 12.

4. Remove the O-ring (157d).

Fig. 12 Illustration of cable wires

5. Place the service tool for cable entry (D) in a vice.

6. Mount the cable entry (168) in the service tool for cable entry

(D).

7. Disconnect the signal wires from the molex plug using the

molex tool (A). Remember to mark the position of the wires

carefully. See fig. 12.

8. Unscrew the lower cable entry (168a).

9. Push the cable (181) together with the rubber seal (198) out of

the plug.

10. Remove the rubber seal (198), washers (198a and 198b) and

disc spring (198c) from the cable. See fig. 13.

11. Pull and remove the cable (181) from the cable entry.

Fig. 13 Sectional drawing, cable entry

4.3.2 Draining of motor liquid

See section 2.3 Changing the motor liquid.

4.3.3 Removing the motor top cover

1. Remove the cable. See section 4.3.1 Removing the cable.

2. Drain the motor liquid. See section 2.3 Changing the motor

liquid.

3. Remove the moisture absorbing bag from the cables.

4. Remove the six screws (178) including washers.

5. Remove the motor top cover (164a).

6. Remove the O-ring (157).

7. Remove the pressure test plug (25).

4.3.4 Removing the upper bearing bracket

1. Remove screws (183).

2. Use 3 x M10 x 80 screws to lift up the bracket in a balanced

way, using the 0.433 in (11 mm) holes. See fig. 14.

3. Remove the upper bearing bracket (61).

Fig. 14 Upper bearing bracket

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

Remember to mark the position of the wires carefully.

Do not loosen the lower cable entry (168a) as this

will impair the water tightness.

TM05 4343 2212

Signal wires

Power wires

TM05 7898 0817

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

TM05 5624 3912

168

198a

198

198b

198c

168a

168c

168b

7/16 in

(M10)

0.433 in

(11 mm)

English (US)

4.3.5 Removing SM 113 and the moisture switch

1. Remove the screw and washer of the moisture switch (520).

2. Disconnect the moisture switch wires.

3. Disconnect all wires from SM 113. Remember to mark all

wires carefully.

4. Loosen and remove the screws and washers for the bracket of

SM 113, and remove the SM 113 and the bracket.

4.3.6 Removing the cooling jacket ring (only SE pump)

1. Remove the cooling jacket ring (754) by means of crowbars or

by using the lifting points (if available). See fig. 15.

2. Remove O-rings (157c and 157b).

3. Remove outer cooling jacket (150c).

4. Remove O-rings (37a).

Fig. 15 Lifting points in cooling jacket ring

4.3.7 Removing inner cooling jacket (only SE pump)

1. See section 4.3.6 Removing the cooling jacket ring (only SE

pump)

2. Remove screws (150d).

3. Remove inner cooling jacket (150b).

4.3.8 Removing the impeller and pump housing

1. Remove the outer screws (26).

2. Lift the pump including the impeller (49) out of the pump

housing (50).

3. Remove the O-ring (37b).

4. Place the motor with impeller in horizontal position on a stable

surface.

5. Bend down the tabs on the lock washer (66) and loosen the

impeller screw (67).

6. Remove the impeller screw (67) and the washer (66).

7. Pull off the impeller (49) using a puller. Support the impeller

with a hoist.

4.3.9 Removing the wear ring

1. Remove the screws (49b).

2. Push out the wear ring (49c) from the pump housing (50).

4.3.10 Removing the lower seal housing

1. Mount the shaft seal protection tool (C).

Fig. 16 Shaft seal protection tool

2. Remove screws (184b).

3. Gently remove the lower seal housing. You may use crowbars

and a soft hammer.

4.3.11 Removing the intermediate seal housing (only SE)

1. Remove the three screws (185).

2. Dismantle the intermediate seal housing (58).You may have to

use a soft hammer very gently.

3. Remove the O-rings (37b and 107).

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

TM05 5625 3912

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

Lifting points

Protect the cone of the impeller shaft against

scratches by taping in the cone or protecting it by

other means.

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

TM06 5453 4615

Maintenance and service work on explosion-proof

products must be carried out by Grundfos or a

service workshop authorized by Grundfos.

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