Grundfos SCALA 2 Original operating manual

SCALA
Service instructions
GRUNDFOS INSTRUCTIONS
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English (GB)
2
English (GB) Service instructions
Original service instructions
CONTENTS
Page
1. Symbols used in this document
The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is structured in the following way:
2. Identification
2.1 Nameplate
Fig. 1 Example of nameplate
1. Symbols used in this document 2
2. Identification 2
2.1 Nameplate 2
2.2 Type key 3
3. Service tools 4
3.1 Standard tools 4
4. Lubricants 4
5. Dismantling and assembly 5
5.1 General information 5
5.2 Removing the control box cover 5
5.3 Removing the pressure tank 5
5.4 Removing the chamber stack 7
5.5 Removing the shaft seal 7
6. Fitting the shaft seal 7
6.1 Fitting the chamber stack 8
6.2 Fitting the pressure tank 8
6.3 Fitting the control box cover 9
7. Fault finding the product 10
7.1 Grundfos Eye operating indications 10
7.2 Fault resetting 10
7.3 Fault finding chart 11
8. Exploded view 13
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.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
TM06 4340 2015
Pos. Description
1 Type designation
2 Product number
3 Serial number
4 Production code, year and week
5 Maximum head
6 Minimum head
7 Rated head
8 Rated flow rate
9 Maximum ambient temperature
10 IP class
11 Maximum operation pressure
12 Maximum liquid temperature
13 Minimum and maximum rated power
14 Model
15 Voltage and frequency
16 Approvals
17 Minimum and maximum rated current
DK-8850 Bjerringbro, Denmark
SCALA2 3-45 AKCHDE
Model A
200-240V 50/60Hz
Made in Serbia
P/N 99999999
S/N 
P/C 1519
Hmax
Hmin
Hnom
Qnom
45 m
16 m
27 m
3m /h
3
45 C/
55 C
Tamb.max
IPX4D
I(A)
Min.
Max.
P1(W)
0.01
2.8 550
2
Tliq.max/Psyst.max:
1MPa
NRP XXX-XXX-XXXXXX
PCS XXXXX.XX.XX 04-6292.2.41-2003
LSPr-022-IDN
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
12

English (GB)
3
2.2 Type key
SCALA2 3 -45 A K C H D E
Type range
SCALA1 Economy
SCALA2 Comfort
Rated flow rate
[m3/h]
Maximum head
[m]
Material code
A: Standard
Supply voltage
K: 1 x 200-240 V, 50/60 Hz
M: 1 x 208-230 V, 60 Hz
V: 1 x 115 V, 60 Hz
W: 1 x 100-115 V, 50/60 Hz
Motor
C: High-efficiency motor with frequency converter
Power supply cable and plug
A: Cable with plug, IEC type I, AS/NZS3112, 2 m
B: Cable with plug, IEC type B, NEMA 5-15P, 6 ft
C: Cable with plug, IEC, type E&F, CEE7/7, 2 m
D: Cable without plug, 2 m
G: Cable with plug, IEC type G, BS1363, 2 m
H: Cable with plug, IEC type I, IRAM 2073, 2 m
J: Cable with plug, NEMA 6-15P, 6 ft
Controller
D: Integrated frequency converter
Thread
A: R 1" EN 1.4308
C: NPT 1" EN 1.4308
E: R 1" composite material
F: NPT 1" composite material

English (GB)
4
3. Service tools
3.1 Standard tools
Standard tools
4. Lubricants
If nothing else is specified, all O-rings are to be lubricated with
Rocol Sapphire Aqua-Sil.
ABCD
EF
Pos. Range Designation Description Part number
AAll Torx screwdriver - -
BAll Torque screwdriver 1-6 Nm SV0438
CAll Bits kit 5 mm hexagon SV2010
DAll Needle-nose pliers - -
EAll Ring/open-end spanner M89 - 13 mm SV0055
FFlat-blade screwdriver - -
Product Product number
Rocol Sapphire Aqua-Sil, 1 kg RM2924
Castrol Optimol Paste White T, 0.5 kg V6001176

English (GB)
5
5. Dismantling and assembly
5.1 General information
5.1.1 Before dismantling
• Disconnect the power supply to the motor.
• Remove the power cable in accordance with local regulations.
• Open a tap to release the pressure in the pipe system.
• Gradually loosen the non-return valve (65a) to release the
pressure in the pump.
• Remove the drain plug (7) to drain the pump.
5.1.2 Before assembly
• Always replace gaskets and O-rings when you overhaul the
pump.
• Clean and check all parts.
• Replace defective parts.
5.2 Removing the control box cover
1. Remove the six pan-head torx screws in the cover (164a).
2. Carefully lift off the control box cover and disconnect the HMI
plug.
Fig. 2 Removing the control box cover
Fig. 3 Disconnecting the HMI plug
5.3 Removing the pressure tank
1. Slowly unscrew the non-return valve (65a) to release any
pressure in the pump.
2. Remove the drain plug (7).
3. Remove the union nut (100) by turning it counterclockwise by
hand.
4. Pull out the nipples (100a).
5. Pull out the non- return valve (65) from the inlet.
6. Remove the O-rings from the nipples, valves and plugs.
7. Carefully remove the pump cover (403) using a flat-blade
screwdriver.
Fig. 4 Removing the cover
DANGER
Electric shock
Death or serious personal injury
- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.
Always use an antistatic service kit when handling
electronic components. This will prevent static
electricity from damaging components.
TM06 5151 3915TM06 5282 4315
To avoid damage to the connection part, insert the
flat-blade screwdriver in the top slots and pop the
cover loose by moving the screwdriver handle
towards the pump body. See fig. 4.
TM06 7639 3816 - TM0 67640 3816 - TM06 7641 3816

English (GB)
6
Fig. 5 Removing the nipples and the cover
8. Remove the retaining clip (175) for the sensor and remove the
sensor (174a).
9. Remove the sensor (174a).
Fig. 6 Sensor and retaining clip
10. Remove the screws (26) that hold the connection part. Note
that one of the screws holds the earth connection bracket
(173c) and washer.
11. Remove the connection part and the pressure tank.
12. Remove the seal ring (44a).
Fig. 7 Removing the connection part
13. Remove the self-priming valve (10) and O-ring (37).
Fig. 8 Self-priming valve and O-ring for connections part
TM06 5150 3915TM06 5152 3915
TM06 5149 3915TM06 5153 3915

English (GB)
7
14. Unscrew the pressure tank (42) counterclockwise and remove
the gasket for the tank (42a).
Fig. 9 Removing the pressure tank
5.4 Removing the chamber stack
1. Remove the plug (169) on nameplate to access the shaft end.
2. Remove the locking nut (67) and the washer (66). Hold the
shaft with a screwdriver in the shaft end.
Fig. 10 Loosening the locking nut for the chamber stack
3. Remove the chamber stack.
Fig. 11 Chamber stack and shaft seal
5.5 Removing the shaft seal
1. Remove the rotating shaft seal face (104).
2. Remove the stationary seat (103) using a needle-noise pliers.
Fig. 12 Removing the stationary shaft seal
6. Fitting the shaft seal
1. Fit the stationary seat (103) with the O-ring (102) against the
pump housing.
Fig. 13 Shaft seal complete
2. Fit the rotating shaft seal face (104).
Fig. 14 Fitting the shaft seal and the chamber stack
TM06 5154 3915TM06 5155 3915TM06 5170 3915
TM06 5169 3915
TM06 5341 4415
Do not touch the ceramic faces of the shaft seal.
TM06 5170 3915
112
108
104
103
102
107
111a
111

English (GB)
8
6.1 Fitting the chamber stack
1. Fit the impellers (49), the seal (45) and the chambers (4). Fit
the seal ring (44a) last.
2. Fit the washer (66) and the locking nut (67) and tighten it to 5
Nm. Hold the shaft end using a screwdriver.
Fig. 15 Tightening the nut of the chamber stack
6.2 Fitting the pressure tank
1. Fit the flat gasket (42a) and screw the pressure tank (42) on to
the connection part (2) by hand.
Fig. 16 Fitting the pressure tank
2. Fit the self-priming valve (10) and the O-ring (37).
Fig. 17 Fitting the self-priming valve and the O-ring
3. Check that the self-priming valve is fitted correctly.
Fig. 18 Correct position of the self-priming valve
4. Fit the connection part to the pump housing. Note that one
screw holds the earth connection bracket and the washer.
5. Cross-tighten the screws according to table below.
Fig. 19 Fitting the connection part
TM06 5158 3915TM06 5154 3915TM06 5153 3915
TM06 5149 3915
Sequence Torque
[Nm]
1
3 ± 0.5
2
3
4
5
6

English (GB)
9
6. Fit the sensor (174a) and fasten it by means of the retaining
clip (175).
Fig. 20 Sensor and retaining clip
7. Press the pump cover back onto the pump housing.
8. Fit new O-rings to the valves, nipples and plugs.
9. Fit the inlet valve in the connection part.
10. Press the nipples into the connection part, fit the union nuts
and tighten them by hand.
11. Fit the drain plug (7) and the non-return valve (65a).
Fig. 21 Fitting the nipples and the cover
6.3 Fitting the control box cover
1. Connect the HMI plug and place the control box cover on the
pump.
Fig. 22 Connecting the HMI plug
2. Cross-tighten the six pan-head torx screws according to the
table below.
Fig. 23 Tightening sequence
Check that the rubber sensor pocket is are seated
correctly.
TM06 5152 3915
Always tighten plastic nuts and plugs by hand so as
not to break the material.
TM06 5150 3915
TM06 5150 3915TM06 4959 0516
Sequence Torque
[Nm]
1
2 ± 0.25
2
3
4
5
6
3 - 6 3 - 6
2 - 5 2 - 5
1 - 4 1 - 4

English (GB)
10
7. Fault finding the product
7.1 Grundfos Eye operating indications
7.2 Fault resetting
You can reset a fault indication in one of the following ways:
• When you have eliminated the fault cause, reset the pump
manually by pressing the button. The pump then reverts to
normal duty.
• If the fault disappears by itself, the pump attempts to reset
automatically and the fault indication disappears if automatic
reset is successful and provided that you have enabled "Auto
reset" in the service menu.
Grundfos Eye Indication Description
No lights are on. The power is off.
The pump is not running.
Two opposite green indicator lights running in the
direction of rotation of the pump.
The power is on.
The pump is running.
Two opposite green indicator lights at a 45 °
angle is the icon used throughout this document
for pump running.
The power is on.
The pump is running.
Two opposite green indicator lights permanently
on.
The power is on.
The pump is not running.
Two opposite red indicator lights flashing
simultaneously.
Alarm.
The pump has stopped.
Two opposite red indicator lights is the icon used
throughout this document for pump stopped.
Alarm.
The pump has stopped.