Grundfos Unilift APG Betriebsanleitung

UNILIFT APG

Service instructions

Unilift APG Service video

(all available languages)

https://youtu.be/MZXm6PFQmpE

GRUNDFOS INSTRUCTIONS

UNILIFT APG

English (GB)

Service instructions ........................................................................4

Table of contents

English (GB) Service instructions

Original service instructions

Table of contents

1. General information ........................4

2. Hazard statements .........................4

3. Notes..................................4

4. Returning the product for service ...............5

5. Safety .................................5

6. Identification .............................5

6.1 Nameplate, UNILIFT APG .....................5

6.2 Type key, UNILIFT APG ......................6

6.3 Storing and handling the product .................6

6.4 Torques and lubricants .......................7

7. Servicing the product .......................8

7.1 General information .........................8

7.2 Replacing the grinder system ..................10

7.3 Adjusting the impeller clearance ................10

7.4 Replacing the cable and float switch ..............11

7.5 Changing the oil ..........................11

8. Fault finding ............................12

8.1 The motor does not start .....................12

8.2 The motor protection or thermal relay trips after a short

time of operation ..........................12

8.3 The pump runs constantly or gives too little water ......12

8.4 The pump runs but gives no water ...............12

9. Drawings ..............................13

1. General information

Read this document before you start service work on the

product. Service work must comply with local regulations

and accepted codes of good practice.

Observe the safety instructions in the installation and op-

erating instructions for the product.

2. Hazard statements

The symbols and hazard statements below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

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.

The hazard statements are structured in the following way:

SIGNAL WORD

Description of the hazard

Consequence of ignoring the warning

• Action to avoid the hazard.

3. Notes

The symbols and notes below may appear in Grundfos installation

and operating instructions, safety instructions and service

instructions.

Observe these instructions for explosion-proof products.

A blue or grey circle with a white graphical symbol indi-

cates 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 mal-

function or damage to the equipment.

Tips and advice that make the work easier.

English (GB)

4. Returning the product for service

If you request Grundfos to service the product, contact Grundfos

with details about the pumped liquid before returning the product.

Otherwise Grundfos can refuse to accept the pump for service.

Costs of returning the product are to be 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 product

has been used for liquids which are injurious to health or toxic.

5. Safety

WARNING

Installation fault

Death or serious personal injury

‐Pump installation in pits must be carried out by spe-

cially trained persons.

‐Work in or near wastewater pits must be carried out

according to local regulations.

CAUTION

Electric shock

Minor or moderate personal injury

‐It must be possible to lock the mains switch in position

‐Type and requirements as specified in EN 60204-1,

5.3.2.

We recommend that you make all maintenance and serv-

ice work when the pump is placed outside the pit.

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

outside the pump pit.

Pits for submersible wastewater pumps contain 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 hygiene regulations in force.

Before attempting to lift the pump, make sure that the lift-

ing bracket is tightened. Tighten if necessary.

6. Identification

6.1 Nameplate, UNILIFT APG

DK - 8850 Bjerringbro Denmark

21 0197

10 11

TM081769

Nameplate, UNILIFT APG

Pos. Description

1 Product type

2 Product number

3 Supply voltage

4 Voltage tolerance

5 Power consumption

6 Max. current

7 Max. flow rate

8 Max. head

9 Factory code and production code (year and week)

10 Insulation class

11 Serial number

12 Max. installation depth [m]

13 Net weight [kg]

14 Enclosure class

15 Cosinus phi

16 Speed of rotation

17 Frequency

18 Marks of approval

19 Max. liquid temperature

English (GB)

6.2 Type key, UNILIFT APG

Example: UNILIFT APG.40.10.A1. 1x220-240V SCH

Code Explanation Designation

UNILIFT APG Product name

40 Nominal diameter of the

outlet

10 Power output, P2 / 100

[W]

[ ] Manual operation with-

out float switch Level control

AAutomatic operation

with float switch

1 Single-phase Motor type

3 Three-phase

1 x 230 V

Nominal voltage

1 x 220 - 240 V

3 x 220 V

3 x 380 V

3 x 400 V

[ ] No plug

Plug type

SCH Europe - F type wall

plug

ARG Argentina - IRAM ap-

proved I type wall plug

AUS Australia, New Zealand

- I type wall plug

6.3 Storing and handling the product

The pump can be transported in a vertical or horizontal position.

Make sure that it cannot roll or fall over.

6.3.1 Storing the product

During long periods of storage, protect the pump against moisture

and heat.

If the pump has been in use, change the motor liquid before

storage.

After a long period of storage, inspect the pump before putting it

into operation. Make sure that the impeller can rotate freely. Pay

special attention to the shaft seals, O-rings, motor oil and the cable

entry.

6.3.2 Transporting the product

Rate all lifting equipment for the purpose. Check the lifting

equipment for damage before making any attempts to lift the pump.

Do not exceed the lifting equipment rating under any

circumstances. For pump weights, see the pump nameplate

Nameplate.

WARNING

Instable pump

Death or serious personal injury

‐Always lift the pump by its lifting bracket or by means

of a forklift if the pump is fixed on a pallet. Never lift

the pump by means of the motor cable or the hose/

pipe.

The polyurethane-embedded plug prevents water from entering the

motor via the motor cable.

6.3.3 Lifting the product

Do not pull or lift the product by the power cable or by the

outlet pipe or hose.

• Lift the pump using the pump handle.

• If the pump is installed in a well or tank, lower and lift it by

means of a wire or chain fastened to the pump handle. The

handle is provided with two lateral holes which may be used to

lift the pump.

··

TM081445

Lifting the product

English (GB)

6.3.4 Contaminated products

CAUTION

Biological hazard

Minor or moderate personal injury

‐If a pump has been used for a liquid which is injurious

to health or toxic, the pump will be classified as conta-

minated.

See section Returning the product for service.

6.4 Torques and lubricants

Pos. Designa-

tion Quantity Dimen-

sion

Torque

[Nm]

Lubri-

cant

All O-rings All

Rocol

Sapphire

Aqua-Sil

12c Setscrew 3 M6 × 16 -

Castrol

Optimol

Paste

26 Screw 3 M8 × 25 7 ± 1

34 Screw 2 PH

4.2 × 13 2 ± 0.5

44a Screw 1 M8 × 25 7 ± 1

184b Screw 4 TORX

M6 × 20 12 ± 2

188a Screw 1 M8 × 25 10 ± 2

193 Screw 4 TORX

M6 × 75 5 ± 1

Rocol Sapphire Aqua-Sil, product number RM2924 (1 kg).

Castrol Optimol Paste White T, product number V6001176 (0.4 l).

Related information

7.2 Replacing the grinder system

7.3 Adjusting the impeller clearance

7.4 Replacing the cable and float switch

English (GB)

7. Servicing the product

7.1 General information

DANGER

Electric shock

Death or serious personal injury

‐Switch off the power supply before you start any work

on the product.

‐Make sure that the power supply cannot be switched

on accidentally.

CAUTION

Biological hazard

Minor or moderate personal injury

‐Use gloves and other suitable personal protection

equipment in accordance with local regulations.

CAUTION

Sharp element

Minor or moderate personal injury

‐Wear protective gloves when working with the grinder

system.

CAUTION

Biological hazard

Minor or moderate personal injury

‐Flush the product thoroughly with clean water before

starting the service.

‐Wear personal protective equipment.

Position numbers of parts (numbers in brackets) refer to

the drawings in the section Drawings.

All service work must be carried out by specially trained staff.

Before carrying out service, make sure that the pump has been

thoroughly flushed with clean water. Rinse the pump parts in water

after dismantling.

Related information

9. Drawings

7.1.1 Maintaining the product

• Check the pump and replace the oil once a year. If the pump is

used for pumping liquids containing abrasive particles or it is

operating continuously, the pump must be checked at shorter

intervals.

• If the drained oil contains water or other impurities, we

recommend that you replace the shaft seal. Contact Grundfos

Service.

7.1.2 Maintenance schedule

Inspect pumps running normal operation every 3000 operating

hours or at least once a year. If the dry-solids content of the

pumped liquid is very high or sandy, check the pump at shorter

intervals.

Check the following:

•Power consumption

See the nameplate.

•Oil level and oil condition

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

check the oil level after one week of operation.

Use MARCOL 152 ESSO oil or equivalent type. Oil auto-ignition

temperature must be above 180 °C.

•Cable entry

Make sure that the cable entry is watertight and that

the cables are not sharply bent and/or pinched.

•Pump parts

Check the wearing parts, for example, impeller and pump

housing. Replace defective parts.

•Grinder system and parts

In case of frequent choke-ups, check the grinder system for

visible wearing. If necessary, replace the grinder system.

7.1.3 Oil

In the case of long operating time or continuous operation, the oil

must be replaced as follows:

Liquid temperature The oil must be replaced after

20 °C 4500 operating hours

40 °C 3000 operating hours

The pump contains 140 ml of non-poisonous oil. Use MARCOL 152

ESSO oil or equivalent type.

Used oil must be disposed of in accordance with local regulations.

English (GB)

7.1.4 Service kits

The following service kits are available for all pumps.

Service kit Contents Pos. O-ring material Product number

Impeller 49, 9a, 66, 188a 92693611

Grinder parts 45, 44, 44a, 66,

188a 92693612

Set of screws 5 × M8, 3 × M6 26, 12c 92693631

O-ring kit NBR 194, 157, 37 92693638

Motor kit

Complete motor, single-phase, 220-240 V, 50 Hz

150, 190, 34, 86,

193, 194, 157, 37,

184b

NBR

92693542

Complete motor, single-phase, 220-240 V, 50 Hz, without

hole for float switch 92701743

Complete motor, single-phase, 230 V, 50 Hz 92693544

Complete motor, single-phase, 230 V, 50 Hz, without hole

for float switch 92701745

Complete motor, three-phase, 220 V 50 Hz 92701748

Complete motor, three-phase, 220 V 50 Hz, without hole for

float switch 92701747

Complete motor, three-phase, 380V 50 Hz 92701760

Complete motor, three-phase, 380 V 50 Hz, without hole for

float switch 92701746

Complete motor, three-phase, 400 V 50 Hz 92701761

Complete motor, three-phase, 400 V 50 Hz, without hole for

float switch 92693545

Capacitor (230 V) 161, 194, 157 92695572

Cables

Cable, single-phase without a plug

181, 34, 86, 194,

157 NBR

92693615

Cable, single-phase with AU plug 92697765

Cable, single-phase with ARG plug 92697766

Cable, single-phase with SCHUKO plug 92697767

Cable, three-phase 92693617

Float switch 92695571

English (GB)

7.2 Replacing the grinder system

CAUTION

Sharp element

Minor or moderate personal injury

‐Wear protective gloves when touching the sharp

edges of the impeller, grinder head and grinder ring.

For position numbers in brackets, see the exploded drawing in the

appendix.

Proceed as follows:

Dismantling

1. Loosen the screw (44a) that holds the grinder ring in place.

2. Loosen the grinder ring (44) and open the bayonet socket by

knocking or turning the grinder ring 15 to 20° clockwise. See the

figure below.

TM081555

Removing the grinder ring

3. Gently prise the grinder ring (44) out of the pump housing with a

screwdriver.

Make sure that the grinder ring does not get stuck

against the grinder head.

4. Use a plier to hold the grinder head.

5. Loosen and remove the screw (188a) and the locking ring (66)

in the shaft end.

TM081602

Loosen the grinder head

6. Remove the grinder head (45).

Assembly

1. When fitting the grinder head (45), the projections on the back of

the grinder head must engage with the holes in the impeller

(49).

2. Tighten the screw (188a) for the grinder head with a torque of

10 Nm. Do not forget the lock washer.

3. Fit the grinder ring (44).

4. Turn the grinder ring (44) 15 to 20° counterclockwise until it is

tightened.

5. Tighten the screw (44a) with a torque of 7 Nm.

6. Check that the grinder rotates freely.

Related information

6.4 Torques and lubricants

9. Drawings

7.3 Adjusting the impeller clearance

For position numbers in brackets, see exploded drawing in the

appendix.

Proceed as follows:

1. Loosen the set screws fully (12c).

2. Gently tighten the screws (26).

3. Gently tighten the set screws (12c).

4. Loosen the screws (26) with at least three turns.

5. Tighten the set screw (12c) by 180°.

6. Tighten the screws (26) with a torque of 7 Nm.

Related information

6.4 Torques and lubricants

9. Drawings

English (GB)

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