Grundfos AP80 Series User manual

AP80-100
50 Hz DIN, all languages
Installation and operating instructions
QR99912898
Installation and operating instructions
(all available languages)
http://net.grundfos.com/qr/i/99912898
GRUNDFOS INSTRUCTIONS

AP80-100
English (GB)
Installation and operating instructions ..................................5
Български (BG)
Упътване за монтаж и експлоатация.................................21
Čeština (CZ)
Montážní a provozní návod ........................................38
Deutsch (DE)
Montage- und Betriebsanleitung .....................................54
Dansk (DK)
Monterings- og driftsinstruktion ......................................71
Eesti (EE)
Paigaldus- ja kasutusjuhend........................................87
Español (ES)
Instrucciones de instalación y funcionamiento...........................103
Suomi (FI)
Asennus- ja käyttöohjeet .........................................120
Français (FR)
Notice d'installation et de fonctionnement..............................136
Ελληνικά (GR)
Οδηγίες εγκατάστασης και λειτουργίας................................153
Magyar (HU)
Telepítési és üzemeltetési utasítás ..................................170
Italiano (IT)
Istruzioni di installazione e funzionamento .............................187
Lietuviškai (LT)
Įrengimo ir naudojimo instrukcija ....................................204
Latviešu (LV)
Uzstādīšanas un ekspluatācijas instrukcija .............................220
Nederlands (NL)
Installatie- en bedieningsinstructies ..................................236
Polski (PL)
Instrukcja montażu i eksploatacji....................................253
Português (PT)
Instruções de instalação e funcionamento .............................270
3
Table of contents

Română (RO)
Instrucţiuni de instalare şi utilizare...................................287
Srpski (RS)
Uputstvo za instalaciju i rad .......................................303
Svenska (SE)
Monterings- och driftsinstruktion ....................................319
Slovensko (SI)
Navodila za montažo in obratovanje .................................335
Slovenčina (SK)
Návod na montáž a prevádzku .....................................351
Türkçe (TR)
Montaj ve kullanım kılavuzu .......................................367
Українська (UA)
Інструкції з монтажу та експлуатації ................................383
中文 (CN)
安装和使用说明书 ..............................................401
(AR) 
    .............................................414
Appendix A..................................................427
4AP80-100
Table of contents

English (GB) Installation and operating instructions
Original installation and operating instructions
Table of contents
1. General information ............. 5
1.1 Hazard statements .............. 5
1.2 Notes ..................... 5
1.3 Target group.................. 6
2. Product introduction ............ 6
2.1 Product description .............. 6
3. Receiving the product............ 7
3.1 Transporting the product ........... 7
3.2 Handling and lifting the product ....... 7
4. Mechanical installation ........... 8
4.1 Installation requirements ........... 8
4.2 Installation on auto-coupling ......... 8
4.3 Installation on ring stand ........... 9
5. Electrical connection ............10
5.1 Frequency converter operation ........11
5.2 Sensors ....................12
5.3 CU 100 control unit ..............12
5.4 Level controllers................12
6. Startup ....................12
6.1 Operating modes ...............13
6.2 Start and stop levels .............14
6.3 Direction of rotation ..............14
6.4 Resetting the pump ..............15
7. Storing the product .............15
8. Maintenance and service ..........15
8.1 Maintenance schedule ............15
8.2 Test insulation resistance ...........16
8.3 Replacing the impeller ............16
8.4 Ball bearing maintenance...........16
8.5 Oil check and change.............16
8.6 Service kits ..................17
8.7 Contaminated pumps .............17
9. Fault finding .................17
9.1 The pump does not start ...........17
9.2 The pump runs, but delivers no liquid ....18
9.3 The pump starts, but the motor-protective
circuit breaker trips after a short time ....18
9.4 The pump runs at below standard
performance and power consumption ....18
9.5 Mechanical shaft seal leaks, sealing
chamber monitor reports fault and
switches the pump off.............18
10. Technical data ................19
10.1 Operating conditions .............19
10.2 Weights ....................19
10.3 Electrical data .................19
11. Disposing of the product ..........19
1. General information
Read this document before you install the
product. Installation and operation must
comply with local regulations and accepted
codes of good practice.
1.1 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.
1.2 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 indicates that an action must be
taken.
5
English (GB)

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.
1.3 Target group
These installation and operating instructions are
intended for professional installers.
2. Product introduction
2.1 Product description
The AP80-100 pumps are a range of vortex and
single-channel (1-channel) impeller pumps designed
for pumping sewage, effluents, sludge and surface
water.
1
2
3
4
6
5
AP80 pump
Position Description
1 Lifing bracket
2 Stator housing
3 Nameplate
4 Pump housing
5 Outlet
6 Cable plug
2.1.1 Pumped liquids
The pumps must not be used for
pumping combustible, flammable, or
corrosive liquids.
The pumps are designed for transferring the following
liquids:
• sewage
• drainage and surface water
• sludge with minimal dry-solids content
• effluent.
2.1.2 Intended use
These pumps are designed for pumping sewage and
wastewater in a wide range of private and industrial
applications.
6
English (GB)

2.1.3 Identification
Nameplate
Fix the extra nameplate supplied with the pump at the
installation site or keep it in the cover of this booklet.
1 53 6
4
7
2
8
9
12 19
18 15
13
10
16
20
11
14
17
P1/P2 kW cos Ф
V A A
V Y
Made in
Germany DE
DK-8850 Bjerringbro,Denmark
Type
Model No.
Hmax
Motor ~ Hz
n min-1
Qmax
Temp.
Date
ºC
m³/h
kg IP68
Insul. class
99945810
Pos. Description
1 Type designation
2 Maximum head [m]
3 Product number
4 Maximum liquid temperature [°C]
5 Production code, year and week
6Maximum flow rate [m3/h]
7 Maximum installation depth [m]
8 Speed [rpm]
9 Net weight [kg]
10 Enclosure class
11 Phase
12 Frequency [Hz]
13 Insulation class
14 Motor input power P1 [kW]
15 Motor input power P2 [kW]
16 Cos φ, 1/1 load
17 Rated voltage [V], delta connection
18 Rated current [A], delta connection
19 Rated voltage [V], star connection
20 Rated current [A], star connection
Type key
Fix the extra nameplate supplied with the pump at the
installation site or keep it in the cover of this booklet
Example: AP80.80.13.3.V
Code Description Explanation
AP Wastewater/
sewage pump Pump type
80
Maximum
solids size 80 =
80 mm
Pump passage
80
Nominal outlet
diameter 80 =
80 mm
Pump outlet
13 Output power
P2 07 = 0.7 kW Power [kW]
1Single-phase
motor Number of
phases
3Three-phase
motor
1Single-channel
impeller Impeller type
V Vortex impeller
ZCustom-built
products Customisation
3. Receiving the product
3.1 Transporting the product
The pump can be transported and stored in vertical
or horizontal position. Make sure it cannot roll or fall
over. Make sure that the received product
corresponds to the order. In case of damage or
missing parts, inform the transport company or the
manufacturer immediately.
3.2 Handling and lifting the product
All lifting equipment must be rated for the purpose
and checked for damage before lifting the pump. The
lifting equipment rating must not be exceeded. The
pump weight is stated on the nameplate.
7
English (GB)

WARNING
Crushing hazard
Death or serious personal injury
‐Do not stack pump packages or pallets
on the top of each other when lifting or
moving them.
‐Always lift the pump by its lifting
bracket or by a forklift truck, if the
pump is fixed on a pallet. Never lift the
pump by the power cable, hose or
pipe.
CAUTION
Sharp element
Minor or moderate personal injury
‐Wear protective gloves when opening
the pump package.
Keep the cable end protectors in storage
for later use.
WARNING
Crushing hazard
Death or serious personal injury
‐Make sure your hand cannot get
caught between the lifting bracket and
the hook.
WARNING
Crushing hazard
Death or serious personal injury
‐Make sure the hook is fixed to the
lifting bracket properly.
‐Always lift the pump by its lifting
bracket or by a forklift truck, if the
pump is fixed on a pallet.
‐Make sure that the lifting bracket is
tightened before lifting the pump.
4. Mechanical installation
The compact design makes the pumps suitable for
both temporary and permanent installation. The
pumps can be installed on an auto-coupling system
or on a ring stand to the bottom of the pit.
4.1 Installation requirements
Pump installation in pits must be carried
out by specially trained persons.
DANGER
Electric shock
Death or serious personal injury
‐It must be possible to lock the main
switch in position 0. Type and
requirements are specified in EN
60204-1.
DANGER
Electric shock
Death or serious personal injury
‐Make sure there is at least 3 m free
cable above the maximum liquid level.
Maintenance and service work must be
carried out when the pump is outside the
pit. For safety reasons, all work inside pits
must be supervised by a person outside
the pit.
WARNING
Crushing hazard
Death or serious personal injury
‐Make sure the lifting bracket is
tightened before lifting the pump.
4.2 Installation on auto-coupling
Pumps for permanent, vertical installation in a pit can
be installed on a stationary auto-coupling unit.
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. Use loose flanges to
ease the installation and to avoid pipe
tension at the flanges.
Do not use elastic elements or bellows to
connect the pipes.
In some installations, a plinth is required
beneath the auto coupling to ensure the
correct installation of the pump.
The free end of the cable must not be
submerged as water may penetrate into
the motor.
The guide rails must not have any axial play as this
can cause noise during operation.
Proceed as follows:
1. Drill mounting holes for the guide-rail bracket on
the inside of the pit and fasten the guide-rail
bracket with two screws.
8
English (GB)

2. Place the auto-coupling base unit on the bottom
of the pit. If the bottom is uneven, the auto-
coupling base unit must be supported. Use a
plumb line to establish the correct positioning.
Fasten the auto coupling with expansion bolts.
3. Connect the outlet pipe in accordance with the
generally accepted procedures. Avoid exposing
the pipe to distortion or tension.
4. Place the guide rails on the auto-coupling base
unit and adjust the length of the rails to the
guide-rail bracket at the top of the pit.
5. Unscrew the guide-rail bracket. Insert the
expansion dowels into the holes. Fasten the
guide-rail bracket on the inside of the pit. Tighten
the bolts in the expansion dowels.
6. Clean out debris from the pit before lowering the
pump.
7. Fit the guide shoe to the pump outlet. Grease the
gasket of the guide shoe before lowering the
pump into the pit.
8. Slide the guide shoe along the guide rails
and lower the pump into the pit using the chain
secured to the lifting bracket. When the pump
reaches the auto-coupling base unit, pull the
lifting chain towards the guide rail several times
to shake off any substances. When the chain is
unstrained, the pump automatically connects to
the auto-coupling unit.
9. Hang up the end of the chain on a suitable hook
at the top of the pit. Make sure that the chain is
straight but not strained.
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. Ensure that the
coiled cable cannot fall into the pit. Make sure
that the cables are not sharply bent or pinched.
11. Connect the power cable and the control cable, if
any.
Lowering the pump to the auto-coupling base
Connecting the pump to the auto-coupling base
4.3 Installation on ring stand
The free end of the cable must not be
submerged as water may penetrate into
the motor.
9
English (GB)

If several pumps are installed in the same
pit, the pumps must be installed at the
same level to allow optimum pump
alternation.
Pumps for submerged ring stand installation can
stand freely on the bottom of the pit or similar
location.
If a hose is used, make sure it does not buckle and
that the inside diameter of the hose matches the
outlet.
If a rigid pipe is used, fit the parts in the following
order:
1. union or coupling
2. non-return valve
3. isolating valve.
If the pump is installed in muddy conditions or on
uneven ground, place it on a solid support.
1. Fit a 90° elbow to the pump outlet and connect
the outlet pipe or hose.
2. Lower the pump into the liquid by a chain
secured to the lifting bracket. Place the pump on
a plain, solid foundation.
3. Hang up the end of the chain on a suitable hook
at the top of the pit, so 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 cables are not sharply bent or
pinched.
5. Connect the power cable and the control cable, if
any.
Installation on ring stand
5. Electrical connection
AP80 pumps cannot be operated with
frequency converter.
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.
‐It must be possible to lock the main
switch in position 0. Type and
requirements as specified in EN
60204-1.
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.
10
English (GB)

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 nameplate.
Make sure that the pump is connected in
accordance with the instructions of this
booklet.
The supply voltage and frequency are marked on the
nameplate. Make sure the power supply at the
installation site is suitable for the pump motor.
All pumps are supplied with 10 m cable and a free
cable end.
DANGER
Electric shock
Death or serious personal injury
‐Before the first startup, check the cable
for visible defects to avoid short
circuits.
The pumps must be connected to one of the
following:
• a control unit with motor-protective circuit
breaker, such as Grundfos CU 100
• Grundfos LC 231 or 241 pump controller.
AP80 pumps cannot be operated with
frequency converter.
5.1 Frequency converter operation
In principle, all three-phase motors can be connected
to a frequency converter.
However, frequency converter operation often
exposes the motor insulation system to a heavier load
and causes the motor to be more noisy.
For frequency converter operation, observe the
following:
• The thermal protection of the motor must be
connected.
• Peak voltage and dU/dt must be in accordance
with the table below. The values stated are
maximum values supplied to the motor terminals.
The cable influence is not taken into account.
See the frequency converter data sheet
regarding the actual values and the cable
influence on the peak voltage and dU/dt.
• Set the frequency converter U/f ratio according to
the motor data.
• Use a screened power cable if there is a risk that
electrical noise may disturb other electrical
equipment.
When operating the pump by a frequency converter,
consider the following:
• The locked-rotor torque can be lower depending
on the type of the frequency converter.
• The noise level may increase. See the
installation and operating instructions for the
frequency converter of choice.
Maximum repetitive
peak voltage
[V]
Maximum dU/dt UN 400
V
[V/μ sec.]
850 2000
Frequency converter use may reduce the
life span of the bearings and the shaft
seal, depending on operating mode and
other circumstances.
For more information about the frequency converter
operation, see the data sheet and the installation and
operating instructions for the frequency converter of
choice.
11
English (GB)

5.2 Sensors
The thermal switch in circuit 1 (T1-T3) and circuit 2
(T1-T2) breaks the circuit at an approximate 140 °C
winding temperature. This thermal switch must
always be connected.
AP80-100
Thermal protection Enclosed in motor winding, requires outside control
through the signal wires of the power cable.
Oil chamber seal probe Requires outside control through the signal wires of
the power cable.
5.3 CU 100 control unit
CU 100 incorporates a motor-protective circuit
breaker and is available with level switch and cable.
5.4 Level controllers
The liquid level can be controlled by the Grundfos LC
level controllers.
Suitable level controllers:
• LC 231: compact solution with certified motor
protection for single- and dual-pump versions.
• LC 241: cabinet solution offering modularity and
customisation for single- and dual-pump
versions.
In the following description, "level switches" can be air
bells, float switches or electrodes depending on the
selected pump controller.
Depending on the security levels and the number of
pumps, level switches can be used in the following
setups:
• Dry run (optional)
• Stop
• Start pump 1 (single-pump version)
• Start pump 2 (dual-pump version)
• High level (optional)
Analogue level transmitters can be used, and all
levels can be customised. Level switches can be
used with level transmitters, for dry-run protection and
high level alarm.
The pump must not run dry. Install an
additional level switch to ensure that the
pump is stopped in case the stop level
switch is not operating.
5.4.1 Installing level switches
When installing the level switches, observe the
following points:
• To prevent air intake and vibrations, install the
stop level switch, so the pump is stopped before
the liquid level is lowered to the middle of the
motor housing.
• Install the start level switch, so the pump is
started at the required level. The pump must
always start before the liquid level reaches the
bottom inlet pipe.
• Always install the high-level alarm switch about
10 cm above the start level switch. However, the
alarm must always be given before the liquid
level reaches the inlet pipe.
For further settings and information, see the
installation and operating instructions for the selected
level controllers.
6. Startup
Before starting the product:
• Make sure that the fuses have been
removed.
• Make sure that all protective
equipment has been connected
correctly.
• Check the oil level.
• Test the insulation resistance.
CAUTION
Crushing of hands
Minor or moderate personal injury
‐Do not put your hands or any tool into
the pump inlet or outlet 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 switched on unintentionally.
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.
12
English (GB)

WARNING
Crushing of hands
Death or serious personal injury
‐When lifting the pump, make sure your
hand cannot get 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 a forklift truck, if the
pump is fixed on a pallet.
‐Never lift the pump by the power cable,
hose or pipe.
‐Make sure that the lifting bracket is
tightened before lifting the pump.
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 after
dismantling.
‐Wear appropriate personal protective
equipment and clothing.
CAUTION
Hot surface
Minor or moderate personal injury
‐Do not touch the surface of the pump
while it is running.
6.1 Operating modes
Never use these pumps for siphoning
operation. The pumps must always be
completely submerged in the pumped
liquid.
The pumps are designed for continuous (S1)
operation. In this operating mode, the pump can
operate continuously without being stopped for
cooling. Being completely submerged, the pump is
sufficiently cooled by the surrounding liquid. During
S1 operation, the maximum number of starts per
hour is 15.
The pumps must be completely
submerged for continuous operation.
P
1
t
2
S1 operation
Position Description
1 Operation
2 Stop
The minimum liquid level is at the top of the pump
housing.
For AP40 and AP50 pumps,
intermittent (S3) operation between 40°C and 60°C
liquid temperature is permitted up to 30%. S3
operation is a series of 10-minute duty cycles. Each
cycle has a 3-minute period of constant load followed
by a 7-minute period of rest. Thermal equilibrium is
not reached during the cycle.
13
English (GB)

1
Minimum liquid level
Position Description
1 Minimum liquid level
P
t
1
23
S3 operation
Position Description
1 Operation
2 Stop
3 Duty cycle
6.2 Start and stop levels
Start and stop levels can be adjusted by changing the
free cable length of the float switch.
Long free cable = large difference in level.
Short free cable = small difference in level.
• To prevent air intake and vibrations, install the
stop level switch, so the pump is stopped before
the liquid level reaches the upper edge of the
clamp.
• Install the start level switch, so the pump is
started at the required level. The pump must
always be started before the liquid level reaches
the bottom of the inlet pipe.
1
2
3
Start and stop levels
Position Description
1 Alarm
2 Start
3 Stop
6.3 Direction of rotation
All single-phase pumps are factory-wired for the
correct direction of rotation. Before starting up three-
phase pumps, check the direction of rotation. An
arrow on the stator housing indicates the correct
direction of rotation.
The impeller rotates clockwise. When
started, the pump jerks counterclockwise.
Procedure 1:
14
English (GB)

1. Start the pump and measure the quantity of liquid
or the outlet pressure.
2. Stop the pump and interchange two phases in
the power cable.
3. Restart the pump and measure the quantity of
liquid or the outlet pressure.
4. Stop the pump.
5. Compare the results of steps 1 and 3. The
connection which gives the larger quantity of
liquid or the higher pressure is the correct
direction of rotation.
Procedure 2:
1. Let the pump hang from a lifting device such as
the chain used for lowering the pump into the pit.
2. Start and stop the pump while observing the
movement (jerk) of the pump.
3. If connected correctly, the pump jerks
counterclockwise.
4. If the direction of rotation is wrong, interchange
two phases in the power cable.
Jerk direction
6.4 Resetting the pump
To reset the pump, switch off the power supply for a
minute, then switch it on again.
7. Storing the product
For periods of storage the pump must be protected
against moisture and heat.
After a period of storage, inspect the pump before
putting it into operation. Make sure that the impeller
can rotate freely. Pay attention to the condition of the
shaft seals, O-rings and the cable entries.
Leave the cable-end protectors on the
power and control cables until starting the
electrical connection. Whether insulated or
not, the free cable end must never be
exposed to moisture or water. Non-
compliance with this may cause damage
to the motor.
If the pump is being stored for more than
one month, turn the impeller at least every
month to prevent the seal faces of the
lower mechanical shaft seal from seizing
up.
If you do not do this, the shaft seal may be
damaged when the pump is started.
If the impeller cannot be turned, contact
Grundfos or an authorised service
workshop.
WARNING
Crushing hazard
Death or serious personal injury
‐Do not turn the impeller by hand.
Always use an appropriate tool.
8. Maintenance and service
8.1 Maintenance schedule
Before initial startup or after a longer period of
storage:
• Check the insulation resistance.
• Check the fill level in the sealing chamber.
• Check possible damage on the axial face seal.
Monthly:
• Monitor the power input and voltage.
• Check the used switchgears for
resistance and sealed space control.
Every six months:
• Inspect the power supply cable.
• Inspect the cable holder and wiring.
• Inspect the accessories, such as the suspension
device and hoisting gears.
After 3000 operating hours:
• Perform visual check of the pump and inspect
the wear ring.
• Check the oil level and condition. Change the oil.
Change the shaft seal in case of water ingress or
oil leakage.
• Check the hydraulic components and wear
ring for wear. Replace if necessary.
After 8 000 operating hours or two years:
• Check the insulation resistance
• Empty the leakage chamber. Not available for
all models. For more information, contact
Grundfos.
• Inspect all safety and control devices.
• Check the coating and touch-up as required.
After 15 000 operating hours or five years:
• General overhaul.
15
English (GB)

If the pump is used in highly abrasive or
corrosive matter, the maintenance
intervals should be reduced.
Tightening torques
A2/A4,
Hardness
class 70
A2/A4,
Hardness
class 80
DIN912 / DIN933
M6 7 Nm 11.8 Nm
M8 17 Nm 28.7 Nm
M10 33 Nm 58 Nm
M12 57 Nm 100 Nm
M16 140 Nm 245 Nm
M20 273 Nm 494 Nm
8.2 Test insulation resistance
To check the insulation resistance, proceed as
follows:
1. Disconnect the power supply cable.
2. Measure the resistance with an insulation tester.
Measuring DC voltage is 1000 V.
During commissioning, the insulation resistance of 20
MΩ must be met or exceeded. For additional
measurements, the value must be larger than 2 MΩ.
Low insulation resistance indicates that moisture may
have penetrated to the cable and/or the motor
insulation. Do not connect the pump, contact
Grundfos.
8.3 Replacing the impeller
The stationary wear ring determines the gap between
the impeller and the inlet. If this gap is too big, the
pump performance decreases and may lead to
impeller jams. The wear ring can be replaced, which
reduces the wear on the inlet and the
impeller, and consequently the expense for spare
parts.
1. Loosen and remove the screws on the seal
housing.
2. Remove the pump housing from the seal
housing.
3. Place the pump housing on a secure base.
4. Hold the impeller steady with a suitable tool, and
remove the impeller fastener.
5. Remove the impeller from the shaft.
6. Clean the shaft.
7. Attach a new impeller to the shaft. Make sure the
sliding surfaces remain undamaged.
8. Hold the impeller steady with a suitable tool, then
insert a new impeller fastener and tighten it.
9. Assemble the pump housing with the seal
housing.
10. After the assembly is finished, check that the
impeller can be turned by hand.
8.4 Ball bearing maintenance
Check the shaft for noisy or heavy operation by
turning 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 Grundfos or an
authorised service workshop.
8.5 Oil check and change
Only use original parts.
Use Shell Ondina X420 oil or equivalent
type.
Dispose of used oil must comply with local
regulations
CAUTION
Pressurised system
Minor or moderate personal injury
‐The oil chamber may be under
pressure. Loosen the screws carefully
and do not remove them until the
pressure has been completely relieved.
After 3000 operating hours or at least once
a year, change the oil in the oil chamber as
described below. If the shaft seal has been
replaced, the oil must be changed.
When the pump is new or the shaft seal is replaced,
check the oil level and water content after one week
of operation. If there is more than 20 % extra liquid
(water) in the oil chamber, the shaft seal is defective.
The table below states the quantity of oil in the oil
chamber:
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English (GB)

Pump type Quantity of oil in the
oil chamber [l]
AP80 0.6
AP100 1.9
8.5.1 Draining of oil
1. Place the pump on a level surface with one oil
screw pointing downwards.
2. Place a 2.5 litre capacity transparent container
under the oil screw.
3. Remove the lower oil screw.
4. Remove the upper oil screw. Inspect the oil. If the
colour is greyish white, the oil may contain
water.If the oil contains water, the shaft seal is
defective and must be replaced. If the oil quantity
is less than the specified, the shaft seal is
defective and must be replaced. If the shaft seal
is not replaced, it can cause motor damage.
5. Clean the surfaces for gaskets and oil screws.
8.5.2 Filling with oil
1
Oil filling position
Proceed as follows:
1. Place the pump horizontally, on a level surface.
2. Fill new oil into the chamber through the oil filling
position (1). The correct oil volume is prescribed
in the Table above. Use Shell Ondina X420 or
equivalent.
3. Remove the old seal (gasket) for the oil plug,
and replace it with a new seal, which can be
found in Kit Oil Plug Seals.
4. Fit both oil screws
8.6 Service kits
For details on available service kits, see the Grundfos
Product Center (GPC) at product-
selection.grundfos.com.
8.7 Contaminated pumps
The product is classified as contaminated, if it is used
for contagious or toxic liquid.
CAUTION
Biological hazard
Minor or moderate personal injury
‐Flush the pump thoroughly with clean
water and rinse the pump parts after
dismantling.
Before returning the product for service, contact
Grundfos with details about the pumped liquid.
Otherwise, Grundfos can deny to service the product.
Any application for service must include details about
the pumped liquid.
Clean the product in the best possible way before you
return it.
9. Fault finding
9.1 The pump does not start
Cause
Electricity supply interrupted – short circuit or
earth connection in the cable or motor windings.
Remedy
• Have the motor and wires checked by a
specialist and replaced, if necessary.
Cause
Fuses, motor protection switch and/or monitoring
devices are triggered.
Remedy
• Have a specialist inspect the connection and
correct them as necessary.
• Have the motor protection switch adjusted
according to the technical specifications and
reset monitoring equipment.
• Check that the impeller/propeller runs
smoothly.
• Clean it or free it as necessary.
Cause
The oil chamber seal probe (optional) has
interrupted the power circuit
Remedy
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English (GB)

• See fault: Mechanical shaft seal leaks, sealing
chamber monitor reports fault and switches
the pump off.
9.2 The pump runs, but delivers no liquid
Cause
Outlet valve is closed or blocked.
Remedy
• Check the outlet valve and open and/ or clean
it, if necessary.
Cause
Non-return valve is blocked.
Remedy
• Clean the non-return valve.
Cause
There is air in the pump.
Remedy
• Vent the pump.
9.3 The pump starts, but the motor-
protective circuit breaker trips after a
short time
Cause
Low setting of the thermal relay in the motor-
protective circuit breaker.
Remedy
• Set the relay in accordance with the
specifications on the nameplate.
Cause
Increased power consumption due to large
voltage drop.
Remedy
• Measure the voltage between two motor
phases. Tolerance: - 10 %/+ 6 %. Re-establish
correct voltage supply.
Cause
The impeller is blocked by impurities. Increased
power consumption in all three phases.
Remedy
• Clean the impeller.
Cause
The impeller clearance is incorrect.
Remedy
• Dismantle and inspect hydraulic components
for wear, replace warn components if
necessary. The impeller clearance is not
adjustable.
9.4 The pump runs at below standard
performance and power consumption
Cause
The impeller is blocked by impurities.
Remedy
• Clean the impeller.
Cause
The direction of rotation is wrong.
Remedy
• Check the direction of rotation. If it is not
correct, interchange two phases in the power
cable.
9.5 Mechanical shaft seal leaks, sealing
chamber monitor reports fault and
switches the pump off
Cause
Increased leakage when running in new
mechanical shaft seals.
Remedy
• Change the oil.
Cause
Defective oil chamber seal probe.
Remedy
• Replace the oil chamber seal probe.
Cause
Mechanical shaft seal is defective.
Remedy
• Replace the mechanical shaft seal
• After a shaft seal has been removed from the
shaft, always replace with a new shaft seal.
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English (GB)

10. Technical data
Maximum
solids size
[mm]
Impeller
type
Shaft seal Ball bearing types
Motor side Medium
side Upper Lower
AP80 (1.3 kW)
80
1-channel
SIC / SIC SIC / SIC Double row
angular Deep groove
AP80 (2.6 kW) Vortex
AP80 (2.0 kW)
AP100 (2.9 kW) 100 1-channel
10.1 Operating conditions
Operating
mode S1
Liquid
temperature
0-40 °C. For short periods, a
temperature of up to 60 °C is
allowed.
Maximum
density of the
medium
1040 kg/m³
pH 6 – 11
Maximum
installation
depth
20 m
Operating
pressure 6 bar
Regular cable
length 10 m
Maximum
starts per hour 15
The sound pressure level of the pumps is
lower than the limiting values stated in the
EC Council directive 2006/42/EC relating
to machinery.
10.2 Weights
Type (kW) Weight (kg)
AP80.80.13.3.1.28 (1.3)
74
AP80.80.13.3.1.30 (1.3)
AP80.80.100.13.3.1.28 (1.3)
AP80.80.100.13.3.1.30 (1.3)
AP80.80.26.3.V (2.6) 66
AP80.80.20.3.V (2.0)
AP100.100.29.3.1 (2.9) 104
10.3 Electrical data
Power supply 3 x 400 V 50 Hz
1 x 230 V 50 Hz
Enclosure class IP68
Insulation class H (180°C)
11. Disposing of the product
This product or parts of it must be disposed of in an
environmentally sound way.
1. Use the public or private waste collection service.
2. If this is not possible, contact the nearest
Grundfos company or service workshop.
19
English (GB)

The crossed-out wheelie bin symbol
on a product means that it must be
disposed of separately from
household waste. When a product
marked with this symbol reaches its
end of life, take it to a collection point
designated by the local waste
disposal authorities. The separate
collection and recycling of such
products will help protect the
environment and human health.
See also end-of-life information at
www.grundfos.com/product-recycling.
20
English (GB)