Grundfos BMP 5.1 RS Operating instructions

Service instructions
BMP 5.1-10.2 RS
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96611958 1105 GB 10
Table of contents
1. Type identification........................................................................................................................... 2
1.1 Nameplate ..........................................................................................................................................................2
1.2 Type key..............................................................................................................................................................2
2. Torques and lubricants................................................................................................................... 3
3. Service tools .................................................................................................................................... 4
3.1 Special tools ........................................................................................................................................................4
3.2 Standard tools......................................................................................................................................................4
3.3 Torque tools.........................................................................................................................................................4
4. Dismantling and assembly ............................................................................................................. 5
4.1 General................................................................................................................................................................5
4.2 Dismantling..........................................................................................................................................................5
4.3 Assembly.............................................................................................................................................................6
4.4 Checking the wear parts......................................................................................................................................7
4.5 Fault finding.........................................................................................................................................................8
5. Checking of motor and cable ......................................................................................................... 9
5.1 Exploded view....................................................................................................................................................10

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1. Type identification
This section shows the type key, the nameplate and the codes that can appear in the variant code.
Note: As codes can be combined, a code position may contain more than one code (letter).
1.1 Nameplate
1.2 Type key
TM029357 2404
Fig. 1 Nameplate
Pos. Description Pos. Description
1 Type designation 6 Pressure
2 Model 7 Liquid temperature
3Rated flow rate [m3/h] 8 Weight
4 Head 9 Country of origin
5 Speed
Example BMP 10,2 R- A- P- G- BBVP
Pump range
BMP = With standard motor
BMPE= With external frequency
converter
Maximum flow rate [m3/h]
Blank =All components in contact with
the pumped liquid are made of
stainless steel EN/DIN 1.4301 and PEEK
N = Designed for demineralised water.
All components in contact with
the pumped liquid are made of
stainless steel EN/DIN 1.4301 and PEEK
R = All components in contact with
the pumped liquid are made of
stainless steel 1.4410 and PEEK
Code for pump version
A = First generation
Code for pipe connection
O = External thread
G = Victaulic/PJE
Code for materials
I = Stainless steel (1.4301)
G = Stainless steel (1.4401)
Code for shaft seal
B = Bellows (rubber)
B = Carbon
V=Al
2O3
P=NBR
Type: BMP 10.2 R - A - P - G - BBVP
Model: A96126108 - 0424
Q: 10.2
H: 816.0
n min /max: 700 1800
P min /max: 10 80
T min /max:
Weight: 272
Made in DK
96126190
m 2677
m/h 2.32
3US GPM
Feet
min-1
PSI
LB
/
/
3/ 50 C 37/122 F
bar
˚
Kg
˚
1
2
3
4
5
6
7
89

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2. Torques and lubricants
This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used.
Gardolube L 6034, part no. SV9995 (1 l).
Rocol 22, part no. RM2924 (1 kg).
Pos. Description Number Torque [Nm] Lubricant
26 Screw 16 30 ± 3
Gardolube L 603434 1 8 ± 1
29 Air vent screw 1 4 ± 1
12
O-ring
Soapy water
13
24 2 Rocol 22
38 1

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3. Service tools
The following drawings and tables show special, standard and torque tools for pump service.
3.1 Special tools
3.2 Standard tools
3.3 Torque tools
ABCD
EFGH
IJKL
Pos. Description For pos. Suppl. information Part no.
A Torpedo 17 Included in the shaft seal tool kit
BMP 0.6-2.2 R
BMP 5.1-10.2 R 96560410 96560411
B Press ring 4
C Puller for shaft seal 4
Pos. Description For pos. Suppl. information Part no.
D Hexagon key 26, 29
E Ring/open-end spanner 34
F Screwdriver Straight slot
G Puller SV0335
H Circlip pliers 20 SV0302
Pos. Description For pos. Suppl. information Part no.
I Torque wrench
1-6 [Nm] SV0438
4-20 [Nm] SV0292
20-100 [Nm] SV0269
J Ratchet insert tool I SV0295
K Hexagon socket driver
L Hexagon socket

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4. Dismantling and assembly
4.1 General
If it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instructions in the
following sections.
Position numbers of parts (digits) refer to drawings and parts lists; position numbers of tools (letters) refer to section.
Before dismantling the pump:
• Disconnect the electricity supply to the motor.
• Close the isolating valves, if fitted, to avoid draining the system.
• Remove the electric cable in accordance with local regulations.
• Note the centre of gravity of the pump to prevent it from overturning. This is especially important in the case of long
pumps.
Before assembly:
• Clean and check all parts.
• Replace defective parts by new parts.
• Order the necessary service kits.
• Replace gaskets and O-rings when the pump is overhauled.
During assembly:
• Lubricate and tighten screws and nuts to correct torque as stated in section.
4.2 Dismantling
Note: The pump must only be dismantled in absolutely clean environment.
4.2.1 Removing the coupling
1. Remove the screws and the washers of the coupling.
2. Pull the pump off the motor.
3. Remove the coupling insert.
4. Remove the screws of the coupling guard and remove the guard.
5. Slacken the set screw.
6. Remove the coupling half with a puller.
4.2.2 Removing the shaft seal
1. Remove the key (pos. 30), and remove the bush (pos. 37) and the O-ring (pos. 38).
2. Remove the rotating shaft seal part (pos. 4) with the puller (C).
3. Remove the stationary shaft seal part (pos. 4) from the bush using a screwdriver.
4.2.3 Removing the cylinder barrel and valve plate
1. Remove the screws (pos. 26).
2. Remove the top flange (pos. 35) and swash plate (pos. 6).
3. Remove the O-ring (pos. 24) from the swash plate.
4. Lift the cylinder barrel (pos. 17) with retaining plate (pos. 10), pistons (pos. 11) and valve plate (pos. 14) out of
the pump housing.
4.2.4 Dismantling and checking the barrel unit
1. Lift the pistons (pos. 11) with retaining plate (pos. 10) out of the barrel (pos. 17).
2. Remove the pistons from the retaining plate.
3. Separate the valve plate (pos. 14) and the barrel (pos. 17).
4. Remove the circlip (pos. 20) from the shaft, and remove the spring (pos. 18) and spring guide (pos. 19).
5. Remove the port plate (pos. 21) and the pin (pos. 8) from the pump housing.

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4.3 Assembly
4.3.1 Checking
Check all wear parts before assembling pump, see 4.4 Checking the wear parts.
4.3.2 Fitting the cylinder barrel and valve plate
1. Fit the spring (pos. 18), spring guide (pos. 19) and circlip (pos. 20) on the cylinder barrel (pos. 17).
2. Fit the backup rings (pos. 13) and O-rings (pos.12) on the valve plate (pos.14); one pair per piston. Moisten
them with soapy water, see fig. 2.
3. Fit the valve plate (pos.14) on the cylinder barrel (pos.17). Press the part together using your fingers, see fig.
3.
4. Insert the pistons into the retaining plate from the chamfered side.
5. Fit the piston unit into the cylinder barrel.
6. Fit the pin (pos. 8) into the bottom flange and fit the port plate (pos. 21).
7. Insert the cylinder barrel into the pump housing.
8. Fit the O-ring (pos. 24) to the swash plate (pos. 6) and lubricate it.
9. Fit the pin (pos. 7) into the pump housing and fit the top flange.
10.Fit the screws (pos. 26).
4.3.3 Fitting the shaft seal
1. Fit the thread bush (A) on the shaft and moisten it with soapy water.
2. Fit the rotating shaft seal part (pos. 4) with the seal face upwards using the punch (B).
3. Place the bush (pos. 37) on the table with the turned down end upwards.
4. Fit the stationary shaft seal part (pos. 4) with the rubber gasket downwards using the punch (B).
5. Fit the O-ring (pos. 38) on the bush (pos. 37) and lubricate it with Rocol 22.
6. Fit the bush on the pump.
4.3.4 Fitting the coupling
1. Fit the coupling half.
2. Tighten the set screw.
3. Fit the coupling insert on the coupling half.
4. Fit the coupling guard and screws.
5. Mount the pump on the motor.
6. Tighten the pump to the motor with the screws and washers.
Fig. 2 Backup rings and O-rings Fig. 3 Fitting the valve plate

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4.4 Checking the wear parts
If there are any steel wear particles, caused by plastic, which is worn of, then scrap the pump!
Port plate and thrust plate:
There must be no wear on whether port plate or thrust plate. This can be
checked by laying a (hair) ruler upon the surface controlling the tightening
land against the light.
Pistons:
Play in ball- and -socket joint must not exceed 0.1 mm.
Thickness of slippers collar must not be below 4,4 mm.
The surface of the slippers must be plane and smooth (can be checked by
hair ruler). If pistons are with wear layer (black colour), partial wear of this is
acceptable.
Cylinder barrel:
The outer bearing surface must be without any bigger wear grooves
(not critical).
There must be no seizures and bigger scratches in the bushings, - and
ensure that the pistons move freely in them!
Housing with swash plate and bearing:
The surface on the swash plate must be smooth without any bigger
scratches. More than 0.1 mm wear in depth will reject the pump.
The bearing must be without any bigger wear grooves (not critical).
>4.4mm

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4.5 Fault finding
Before starting work on the pump, make sure that the electricity supply has been switched off and that it cannot be
accidentally switched on.
Fault Possible cause Remedy
The pump stops
during operation.
No water supply.
Low-pressure switch has cut out.
The level switch has cut out.
Check that the low-pressure switch functions normally and is
adjusted correctly.
Check that the minimum inlet pressure is correct. If not, check the
feed pump.
Check the water level in the water tank.
The fuses are blown. Check and replace the main fuses and/or fuses for control circuit,
if necessary.
The motor starter overload unit has tripped out. Reset the starter overload.
The magnetic coil in the motor starter/contactor is
defective (not cutting in). Replace the coil. Check the coil voltage.
The control circuit has cut out or is defective. Check the control circuit and the contacts in the monitoring
devices (low-pressure switch, level switch, etc.).
The motor/supply cable is defective. Check motor and cable
Thepump runs,but
gives no water or
develops any
pressure.
No or insufficient water supply at the pump suction
port. Check that the inlet pressure is at least 0 bar.
The piping system or pump is choked up. Check the piping system and pump.
The prefilter is clogged. Clean the prefilter.
The pump is worn. Replace wear parts. Contact Grundfos Service.
Wrong direction of rotation. Interchange two phases in the motor main connection.
The pump runs at
reduced capacity.
The pump is partly blocked by impurities. Dismantle, clean and check the pump.
Replace defective parts. Contact Grundfos Service.
The pump is defective. Replace defective parts. Contact Grundfos Service.
The prefilter is clogged. Clean the prefilter.
The motor speed is too low. Check the electricity supply. Contact the electricity supply authorities, if necessary.
If a frequency converter is used, adjust the speed.

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5. Checking of motor and cable
1. Supply voltage
TM00 1371 3597
Measure the voltage between the phases by means of a
voltmeter.
Connect the voltmeter to the terminals at the mains
connection.
The voltage should, when the motor is loaded, be within ±5% of
the rated voltage. The motor may burn if there arelarger variations
in voltage.
If the voltage is constantly too high or too low, the motor must be
replaced by one corresponding to the supply voltage.
Large variations in voltage indicate poor electricity supply, and the
pump should be stopped until the defect has been found.
Resetting of the motor starter may be necessary.
2. Current consumption
TM00 1372 3597
Measure the current of each phase while the pump is
operating at a constant discharge pressure (if possible
at the capacity where the motor is most heavily loaded).
The motor full-load current appears on the motor
nameplate.
The difference between the current of the phase with the highest
amp consumption and the one with the lowest amp consumption
must not exceed 10% of the lowest amp consumption.
If so, or if the current exceeds the full-load current, check the
following possible faults:
• Too high operating pressure which may overload the motor.
• Too high speed which may overload the motor.
• Damaged pump which may overload the motor.
• The motor windings are short-circuited or partly disjointed.
• Too high or too low supply voltage.
• Poor connection in leads. Weak cables.
Points 3 and 4: Measurement not needed if supply voltage and current consumption are normal.
3. Winding resistance
TM00 1373 3597
Disconnect the phase leads in the terminal box.
Measure the winding resistance as shown on the
drawing.
The highest value must not exceed the lowest value by more than
5%.
If the deviation is higher, and the supply cable is OK, the motor
should be overhauled.
4. Insulation resistance
TM00 1374 3597
Disconnect the phase leads in the terminal box.
Measure the insulation resistance from each phase to
earth (frame).
(Make sure that the earth connection is made carefully.)
The insulation resistance for a new, cleaned or repaired motor
must be approx. 10 MΩ measured to earth.
For a given motor the critical insulation resistance (Rcrit) can be
calculated as follows:
Rcrit = UN[kV] x 0.5 [MΩ/ kV].
If the measured insulation resistance is lower than Rcrit, the motor
must be overhauled.

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5.1 Exploded view
TM029438 4605