Grundfos SEG Series Bedienungsanleitung

SEG

50 Hz

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions

describe Grundfos SEG pumps.

Sections 1-5 give the information necessary to be

able to unpack, install and start up the product in a

safe way.

Sections 6-11 give important information about the

product, as well as information on service, fault

finding and disposal of the product.

CONTENTS

Page

1. General information 3

1.1 Hazard statements 3

1.2 Notes 3

1.3 Target groups 3

2. Receiving the product 3

2.1 Transporting the product 3

3. Installing the product 4

3.1 Mechanical installation 4

3.2 Electrical connection 8

4. Starting up the product 10

4.1 Operating modes 11

4.2 Start and stop levels 11

4.3 Direction of rotation 12

4.4 Startup 12

4.5 Resetting the pump 13

5. Handling and storing the product 13

5.1 Handling the product 13

5.2 Storing the product 13

6. Product introduction 13

6.1 Product description 13

6.2 Applications 14

6.3 Pumped liquids 14

6.4 Potentially explosive environments 14

6.5 Approvals 15

6.6 Identification 16

7. Protection and control functions 17

7.1 LC and LCD level controllers 17

7.2 Thermal switches 17

7.3 CU 100 control unit 18

7.4 Frequency converter operation 18

8. Servicing and maintaining the product 19

8.1 Safety instructions and requirements 19

8.2 Contaminated pumps 20

8.3 Maintenance schedule 20

8.4 Oil check and oil change 21

8.5 Adjusting the impeller clearance 21

8.6 Replacing the grinder system 22

8.7 Cleaning the pump housing 22

8.8 Checking or replacing the shaft seal 23

8.9 Service kits 24

9. Fault finding the product 25

10. Technical data 26

10.1 Operating conditions 26

10.2 Electrical data 26

10.3 Dimensions and weights 26

11. Disposing of the product 27

Read this document before installing the

product. Installation and operation must

comply with local regulations and accepted

codes of good practice.

This appliance can be used by children

aged from 8 years and above and persons

with reduced physical, sensory or mental

capabilities or lack of experience and

knowledge if they have been given

supervision or instruction concerning use

of the appliance in a safe way and

understand the hazards involved.

Children shall not play with the appliance.

Cleaning and user maintenance shall not

be made by children without supervision.

English (GB)

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 hazard statements are 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.

The Ex symbol refers to ATEX-approved and IECEx-

approved products.

1.3 Target groups

These installation and operating instructions are

intended for professional installers.

2. Receiving the product

The pump may be transported and stored in a

vertical or horizontal position. Make sure that the

pump cannot roll or fall over.

2.1 Transporting the product

All lifting equipment must be rated for the purpose

and checked for damage before any attempts to lift

the pump. The lifting equipment rating must under no

circumstances be exceeded. The pump weight is

stated on the nameplate.

The polyurethane-embedded plug prevents water

from penetrating into the motor via the power cable.

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.

WARNING

Crushing hazard

Death or serious personal injury

- Do not stack pump packages or pallets

on top of each other when lifting or

moving them.

- Always lift the pump by its lifting bracket

or by means of a forklift truck if the

pump is fixed on a pallet. Never lift the

pump by means of the power cable or

the hose or pipe.

CAUTION

Sharp element

Minor or moderate personal injury

- Make sure not to cut your hands on the

sharp edges when opening the pump

package.

We recommend that you keep the cable

end protectors in storage for later use.

English (GB)

3. Installing the product

For safety reasons, all work in pits must be

supervised by a person outside the pit.

Carelessness during lifting or transportation may

cause personal injury or damage to the pump.

3.1 Mechanical installation

Fit the extra nameplate supplied with the pump at the

installation site or keep it in the cover of this booklet.

Observe all safety regulations at the installation site,

for instance the use of blowers for fresh-air supply to

the pit.

Check the oil level in the oil chamber before

installing the pump. See section 8.4 Oil check and oil

change.

The pumps are suitable for different installation types

which are described in sections 3.1.2 Installation on

auto coupling and 3.1.3 Free-standing submerged

installation.

SEG.50 (high-flow) pumps have a cast DN 50 outlet

flange. All other pumps have a cast DN 40 outlet

flange.

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.

Persons must not enter the installation

area when the atmosphere is explosive.

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.

DANGER

Electric shock

Death or serious personal injury

- Make sure there are at least 3 m free

cable above the maximum liquid level.

We recommend that you make all

maintenance and service work when the

pump is placed outside the pit.

DANGER

Crushing hazard

Death or serious personal injury

- Make sure that the lifting bracket is

tightened before attempting to lift the

pump. Tighten if necessary.

Make sure the pit bottom is even before

installing the product.

DANGER

Electric shock

Death or serious personal injury

- Switch off the power supply and lock the

main switch in position 0.

- Switch off any external voltage

connected to the product before working

on it.

CAUTION

Hot surface

Minor or moderate personal injury

- Make sure that the pump has cooled

down before touching it.

DANGER

Electric shock

Death or serious personal injury

- Before installing the pump and starting it

up for the first time, check the power

cable for visible defects to avoid short

circuits.

CAUTION

Biological hazard

Minor or moderate personal injury

- Flush the pump thoroughly with clean

water and rinse the pump parts in water

after dismantling.

Pits for submersible sewage and

wastewater pumps may contain sewage

or wastewater with toxic and/or disease-

causing substances.

- Wear appropriate personal protective

equipment and clothing.

- Observe the local hygiene regulations in

force.

English (GB)

3.1.1 Lifting the product

Carelessness during lifting or transportation may

cause personal injury or damage to the pump.

Carelessness during lifting or transportation may

cause injury persons or damage to the pump.

When lifting the pump, use the right lifting point to

keep the pump balanced. Place the lifting chain hook

in point A for auto-coupling installations and in point

B for other installations. See fig. 1.

Fig. 1 Lifting points

The pumps are designed for intermittent

operation. When completely submerged in

the pumped liquid, the pumps can also

operate continuously (S1).

Always use Grundfos accessories to avoid

malfunctions due to incorrect installation.

Only use the lifting bracket for lifting the

pump. Do not use it to hold the pump when

in operation.

CAUTION

Crushing of hands

Minor or moderate personal injury

- Do not put your hands or any tool into

the pump inlet or outlet port after the

pump has been connected to the power

supply, unless the pump has been

switched off by removing the fuses or

switching off the main switch.

- Make sure that the power supply cannot

be accidentally switched on.

CAUTION

Sharp element

Minor or moderate personal injury

- Do not touch the sharp edges of the

impeller, grinder head, and grinder ring

without wearing gloves.

CAUTION

Biological hazard

Minor or moderate personal injury

- Make sure to seal the pump outlet

properly when fitting the outlet pipe,

otherwise water might spray out of the

sealing.

WARNING

Crushing of hands

Death or serious personal injury

- When lifting the pump, make sure your

hand is not caught between the lifting

bracket and the hook.

WARNING

Crushing hazard

Death or serious personal injury

- Make sure that the hook is fixed

properly to the lifting bracket.

- Always lift the pump by its lifting bracket

or by means of a forklift truck if the

pump is fixed on a pallet.

- Never lift the pump by means of the

power cable, hose or pipe.

- Make sure that the lifting bracket is

tightened before attempting to lift the

pump. Tighten if necessary.

TM06 0066 4813

English (GB)

3.1.2 Installation on auto coupling

Pumps for permanent installation can be mounted on

a stationary auto-coupling guide rail system or a

hookup auto-coupling system.

Both auto-coupling systems facilitate maintenance

and service as the pump can easily be lifted out of

the pit.

We recommend that you use loose flanges to ease

the installation and to avoid pipe tension at flanges

and bolts.

Auto-coupling guide rail system

See fig. 1in Appendix.

Proceed as follows:

1. Drill mounting holes for the guide rail bracket on

the inside of the pit, and fasten the guide rail

bracket provisionally with two anchor bolts.

2. Place the auto-coupling base unit on the bottom

of the pit. Use a plumb line to establish the

correct positioning. Fasten the auto coupling with

heavy-duty anchor bolts. If the bottom of the pit is

uneven, the auto-coupling base unit must be

supported so that it is level when being fastened.

3. Assemble the outlet line in accordance with the

generally accepted procedures and without

exposing the line to distortion or tension.

4. Insert the guide rails in the auto-coupling base

unit and adjust the length of the rails accurately

to the guide rail bracket at the top of the pit.

5. Unscrew the provisionally fastened guide rail

bracket, fit it on top of the guide rails, and finally

fasten it firmly to the pit wall.

6. Clean out debris from the pit before lowering the

pump into the pit.

7. Fit the guide claw to the pump outlet. Grease the

gasket of the guide claw before lowering the

pump into the pit.

8. Slide the guide claw between the guide rails and

lower the pump into the pit by means of a chain

secured to the lifting bracket of the pump. When

the pump reaches the auto-coupling base unit,

the pump will automatically connect tightly.

9. Hang up the end of the chain on a suitable hook

at the top of the pit and in such a way that the

chain cannot come into contact with the pump

housing.

10. Adjust the length of the power cable by coiling it

up on a relief fitting to ensure that the cable is not

damaged during operation. Fasten the relief

fitting to a suitable hook at the top of the pit.

Make sure that the cable is not sharply bent or

pinched.

11. Connect the power cable and the control cable, if

any.

Before beginning installation procedures,

make sure that the atmosphere in the pit is

not potentially explosive.

Make sure that the pipes are installed

without the use of undue force. No loads

from the weight of the pipes must be

carried by the pump.

Do not use elastic elements or bellows in

the pipes. Never use these elements as a

means to align the pipes.

The guide rails must not have any axial

play as this would cause noise during

pump operation.

When the pump has reached the auto-

coupling base unit, shake the pump by

means of the chain to make sure that it is

placed in the correct position.

The free end of the cable must not be

submerged as water may penetrate

through the cable into the motor.

English (GB)

Hookup auto-coupling system

See fig. 2in Appendix.

Proceed as follows:

1. Fit a crossbar in the pit.

2. Fit the stationary part of the auto coupling on top

of the crossbar.

3. Fit the adapted piece of pipe for the movable part

of the hookup auto coupling to the pump outlet.

4. Fasten a shackle and a chain to the movable part

of the hookup auto coupling.

5. Clean out debris from the pit before lowering the

pump.

6. Lower the pump into the pit by means of the

chain secured to the lifting bracket of the pump.

When the movable part of the auto coupling

reaches the stationary part, the two will normally,

automatically connect tightly.

7. Hang up the end of the chain on a suitable hook

at the top of the pit and in such a way that the

chain cannot come into contact with the pump

housing.

8. Adjust the length of the power cable by coiling it

up on a relief fitting to ensure that the cable is not

damaged during operation. Fasten the relief

fitting to a suitable hook at the top of the pit.

Make sure that the cable is not sharply bent or

pinched.

9. Connect the power cable and the control cable, if

any.

3.1.3 Free-standing submerged installation

Pumps for free-standing submerged installation can

stand freely on the bottom of the pit or similar

location. See fig. 3in Appendix.

The pump must be mounted on separate feet

(accessory).

In order to facilitate service on the pump, fit a flexible

union or coupling to the outlet line for easy

separation.

If a hose is used, make sure that the hose does not

buckle and that the inside diameter of the hose

matches that of the outlet port.

If a rigid pipe is used, fit the union or coupling, non-

return valve and isolating valve in the order

mentioned, when viewed from the pump.

If the pump is installed in muddy conditions or on

uneven ground, we recommend that you support the

pump on bricks or a similar support.

Proceed as follows:

1. Fit a 90 ° elbow to the pump outlet port and

connect the outlet pipe or hose.

2. Lower the pump into the liquid by means of a

chain secured to the lifting bracket of the pump.

We recommend that you place the pump on a

plane, solid foundation. Make sure that the pump

is hanging from the chain and not the power

cable.

3. Hang up the end of the chain on a suitable hook

at the top of the pit and in such a way that the

chain cannot come into contact with the pump

housing.

4. Adjust the length of the power cable by coiling it

up on a relief fitting to ensure that the cable is not

damaged during operation. Fasten the relief

fitting to a suitable hook at the top of the pit.

Make sure that the cable is not sharply bent or

pinched.

5. Connect the power cable and the control cable, if

any.

When the pump has reached the auto-

coupling base unit, shake the pump by

means of the chain to make sure that it is

placed in the correct position.

The free end of the cable must not be

submerged as water may penetrate

through the cable into the motor.

The free end of the cable must not be

submerged as water may penetrate

through the cable into the motor.

If several pumps are installed in the same

pit, the pumps must be installed at the

same level in order to allow optimum pump

alternation.

English (GB)

3.2 Electrical connection

Carry out the electrical connection according to local

regulations.

DANGER

Electric shock

Death or serious personal injury

- Connect the pump to an external main

switch which ensures all-pole

disconnection with a contact separation

according to EN 60204-1, 5.3.2.

- It must be possible to lock the main

switch in position 0. Type and

requirements as specified in EN 60204-

1, 5.3.2.

Connect the pumps to a control unit with a

motor protection relay with IEC trip class

10 or 15.

Pumps to be installed in potentially

explosive locations must be connected to

a control box with a motor protection relay

with IEC trip class 10.

The permanent installation must be fitted

with an earth-leakage circuit breaker.

Make sure there are at least 3 m free cable

above the maximum liquid level.

Do not install Grundfos control boxes,

pump controllers, Ex barriers and the free

end of the power cable in potentially

explosive environments.

The classification of the installation site

must be approved according to local rules

in each individual case.

On explosion-proof pumps, make sure that

an external earth conductor is connected

to the external earth terminal of the pump

using a conductor with a secure cable

clamp. Clean the surface of the external

earth connection and fit the cable clamp.

The cross-section of the earth conductor

must be at least 4 mm2, e.g. type H07 V2-

K (PVT 90 °) yellow and green.

Make sure that the earth connection is

protected against corrosion.

Make sure that all protective equipment

has been connected correctly.

Float switches used in potentially

explosive environments must be approved

for this application. They must be

connected to the Grundfos LC, LCD 108

pump controller via the intrinsically safe

LC-Ex4 barrier to ensure a safe circuit.

DANGER

Electric shock

Death or serious personal injury

- If the power cable is damaged, it must

be replaced by the manufacturer, his

service agent or a similarly qualified

person.

Set the motor-protective circuit breaker to

the rated current of the pump. The rated

current is stated on the pump nameplate.

Make sure that the pump is connected in

accordance with the instructions given in

this booklet.

English (GB)

The supply voltage and frequency are marked on the

pump nameplate. For voltage tolerance, see section

10. Technical data. Make sure that the motor is

suitable for the power supply available at the

installation site.

All pumps are supplied with 10 m cable and a free

cable end.

The pump must be connected to one of these two

controller types:

• a control unit with motor-protective circuit

breaker, such as a Grundfos CU 100

• a Grundfos LC, LCD 107, LC, LCD 108 or LC,

LCD 110 pump controller.

See fig. 2or 3and the installation and operating

instructions for the selected control unit or pump

controller.

In potentially explosive environments you have two

options:

• Use float switches made for an Ex environment

and a safety barrier in combination with either

DC, DCD or LC, LCD 108.

• Use air bells in combination with LC, LCD 107.

For more information about the function of the

thermal switches, see section 7.2 Thermal switches.

3.2.1 Wiring diagrams

Fig. 2 Wiring diagram for single-phase pumps

Fig. 3 Wiring diagram for three-phase pumps

DANGER

Electric shock

Death or serious personal injury

- Before the first startup of the pump,

check the power cable for visible

defects to avoid short circuits.

A possible replacement of the power cable

must be carried out by Grundfos or a

service workshop authorised by Grundfos.

TM06 5691 5315TM06 5692 5315

English (GB)

4. Starting up the product

CAUTION

Crushing of hands

Minor or moderate personal injury

- Do not put your hands or any tool into

the pump inlet or outlet port after the

pump has been connected to the power

supply, unless the pump has been

switched off by removing the fuses or

switching off the main switch.

- Make sure that the power supply cannot

be accidentally switched on.

Before starting the product:

- Make sure that the fuses have been

removed.

- Make sure that all protective equipment

has been connected correctly.

CAUTION

Biological hazard

Minor or moderate personal injury

- Make sure to seal the pump outlet

properly when fitting the outlet pipe

otherwise water might spray out of the

sealing.

WARNING

Crushing of hands

Death or serious personal injury

- When lifting the pump, make sure your

hand is not caught between the lifting

bracket and the hook.

DANGER

Crushing hazard

Death or serious personal injury

- Make sure that the hook is fixed

properly to the lifting bracket.

- Always lift the pump by its lifting bracket

or by means of a forklift truck if the

pump is fixed on a pallet.

- Never lift the pump by means of the

power cable, hose or pipe.

- Make sure that the lifting bracket is

tightened before attempting to lift the

pump. Tighten if necessary.

DANGER

Electric shock

Death or serious personal injury

- Before starting up the product for the

first time, check the power cable for

visible defects to avoid short circuits.

- If the power cable is damaged, it must

be replaced by the manufacturer, his

service agent or a similarly qualified

person.

- Make sure that the product is earthed

properly.

- Switch off the power supply and lock the

main switch in position 0.

- Switch off any external voltage

connected to the product before working

on it.

CAUTION

Biological hazard

Minor or moderate personal injury

- Flush the pump thoroughly with clean

water and rinse the pump parts in water

after dismantling.

Pits for submersible sewage and

wastewater pumps may contain sewage

or wastewater with toxic and/or disease-

causing substances.

- Wear appropriate personal protective

equipment and clothing.

- Observe the local hygiene regulations in

force.

CAUTION

Hot surface

Minor or moderate personal injury

- Do not touch the surface of the pump

while the pump is running.

Do not open the clamp while the pump is

running.

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