Grundfos SE 12-42 hp Operating instructions

GRUNDFOS INSTRUCTIONS
SE/SL 12-42 hp
Service instructions
Installation and operating instructions in
English and other languages for 50/60 Hz
http://net.grundfos.com/qr/i/98142268
Service animation video, YouTube

English (US)
2
English (US) Service instructions
Original service instructions
In this document there are references to the installation and
operating instructions for SE, SL 12-42 Hp (9-30 kW) (98142268).
The installation and operating instructions are accessible via the
QR code and link on the front of this document.
CONTENTS
Page
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 text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is 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.
1. General information 2
1.1 Hazard statements 2
1.2 Notes 2
1.3 Safety 3
2. Maintaining the product 3
2.1 Checking the motor liquid 4
2.2 Inspecting the shaft 4
2.3 Changing the motor liquid 4
2.4 Inspecting and adjusting the impeller clearance 6
3. Preparing the dismantling of the product 6
3.1 Transporting the product 6
3.2 Handling and storing the product 6
4. Dismantling and assembling the product 8
4.1 Explosion-proof products 8
4.2 General information 8
4.3 Dismantling the pump 8
4.4 Assembling the pump 11
5. Electrical connection 14
5.1 Motor protection 14
6. Starting up the product 17
6.1 General startup procedure 17
6.2 Direction of rotation 17
7. Additional information 18
7.1 Refractive index 18
7.2 Motor liquid quantities 18
7.3 Special tools 18
7.4 Tightening torques and lubricants 19
7.5 Fault finding the product 19
7.6 Wiring diagrams 20
7.7 Sensor connections 21
7.8 Exploded drawings 25
7.9 Motor drawings 33
7.10 Pump drawings 35
7.11 Components and material specification 37
7.12 Sensor positions 39
7.13 Alignment grooves 40
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.
FM

3
English (US)
1.3 Safety
For safety reasons, all work in pits must be supervised by a
person outside the pump pit.
Pits for submerged sewage and wastewater pumps may contain
sewage or 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 hygienic regulations in force.
2. Maintaining the product
Check pumps running normal operation every 3000 operating
hours or at least once a year.
If the pumped liquid is very muddy or sandy, check the pump at
shorter intervals.
Check the following points:
•Power consumption
See pump nameplate.
•Motor liquid level and liquid condition
When the pump is new or after replacement of the shaft seal,
check the motor liquid level and water content after one week
of operation.
The motor liquid must be changed after 3000 operating hours
or once a year.
Use SML3 motor liquid, product number 795898 [5.25 qt (5 l)].
See section 2.3 Changing the motor liquid.
•Pump parts
Check the impeller, pump housing, etc. for possible wear.
Replace defective parts.
See section 4. Dismantling and assembling the product for
dismantling and assembly of the pump.
•Ball bearings
Check the shaft for noisy or heavy operation by turning the
shaft by hand. Replace defective ball bearings.
See section 4. Dismantling and assembling the product.
In case of defective ball bearings or poor motor function, a
complete overhaul of the pump is usually required.
This work must be carried out by Grundfos or an authorized
service centre.
•O-rings and similar parts
During service or replacement, make sure that the grooves for
O-rings and seal faces have been cleaned before the new
parts are fitted.
•Measuring the insulation resistance
Megging must take place at a voltage of minimum 500 V. The
insulation resistance measured must be minimum 50 kΩ.
Installation of products in pits must be carried out by
specially trained persons.
Work in or near pits must be carried out according to
local regulations.
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.
Persons must not enter the installation area when the
atmosphere is explosive.
We recommend that you carry out all maintenance
and service work when the product is placed outside
the pit.
DANGER
Crushing hazard
Death or serious personal injury
- Always lift the product by its lifting bracket or by
means of a forklift truck if the product is fixed on a
pallet. Do not lift the product by the power cable.
FM
Defective bearings may reduce the Ex safety.
On Ex pumps, the ball bearings may only be
replaced by a FM-approved service centre.
Never reuse used rubber parts.
Explosion-proof products must be checked by a FM-
approved service centre once a year.
FM
FM
FM

English (US)
4
2.1 Checking the motor liquid
You can check the ingress level of the media in the motor liquid.
By use of a refractometer, the refractive index will show the
ingress in percent.
If the refractive index is higher than -7 °F (-22 °C), change the
motor liquid.
We recommend that you do not exceed this level of refractive
index to ensure that the shaft seal and bearings are in the best
possible condition for reliable operation.
2.2 Inspecting the shaft
Only the SL pumps
You can check the leakage of the shaft seal by checking the
upper seal housing chamber (58) for water.
1. Place the pump in a horizontal position on a plane surface
with the drain plug (193a) pointing downwards.
2. Place a container under the drain plug (193a).
3. Remove the plug (193a).
4. If you drain less than 0.052 qt (5 cl), then the shaft seal is OK,
and the shaft seal does not need to be replaced.
5. If you drain more than 0.052 qt (5 cl), replace the shaft seal.
See section 4.3 Dismantling the pump.
Fig. 1 Oil plugs
2.3 Changing the motor liquid
When the pump is new or after replacement of the shaft seal,
check the motor liquid level and water content after one week of
operation.
Change the motor liquid after 3000 operating hours or once a
year. See description below.
If you replace the shaft seal, change the motor liquid.
2.3.1 SL pumps
Draining of motor liquid
1. Place a container under the pump which can contain 6.34 qt
(6 l) of motor liquid.
2. Place the pump in a horizontal position on a plane surface
with plug B pointing downwards. See fig. 2.
3. Remove plug B.
4. Allow all motor liquid to drain from the seal housing into the
container. Remove plug A to get a better flow of the motor
liquid.
Fig. 2 SL pump, horizontal view
5. Replace the O-ring with a new ring on the plug.
6. Fit plug B and tighten it to the correct torque. See section
7.4 Tightening torques and lubricants.
Media ingress in % Refractive index
[°F (°C)]
0 -22.0 (-30)
5 -16.6 (-27)
10 -13.0 (-25)
15 -9.4 (-23)
20 -7.6 (-22)
TM06 6219 0916
193a 193
WARNING
Pressurised system
Death or serious personal injury
- When loosening the screws of the motor liquid
chamber, note that pressure may have built up in
the chamber. Do not remove the screws until the
pressure has been fully relieved.
TM05 2768 0612
If the motor liquid in the container contains more than
20 % water, the shaft seal may be defective and must
be replaced.
If the quantity of motor liquid deviates considerably
from the quantity stated in the table below, the shaft
seal is defective.
Dispose of used motor liquid (propylene glycol) in
accordance with local regulations.

5
English (US)
Filling with motor liquid, vertical installation
1. Place the pump in vertical position.
2. Fill the shaft seal housing with motor liquid through hole A
until the motor liquid reaches the level indicated by plug B.
See fig. 3.
3. Replace the O-ring with a new ring.
4. Insert plugs A and B and tighten them to the correct torque.
See section 7.4 Tightening torques and lubricants.
Fig. 3 SL pump, vertical view
Filling with motor liquid, horizontal installation
1. Place the pump in horizontal position with plug B mounted and
facing downwards. Fill the shaft seal housing with motor liquid
through hole A until the motor liquid reaches the level
indicated in fig. 2. See also section 7.2 Motor liquid quantities.
2. Replace the O-ring with a new O-ring.
3. Insert plug A and tighten it to the correct torque. See section
7.4 Tightening torques and lubricants.
2.3.2 SE pumps
Draining of motor liquid
1. Place a container under the pump which can contain 15.85 qt
(15 l) of motor liquid.
2. Place the pump in horizontal position on a plane surface with
plug D pointing downwards. See fig. 4.
3. Remove plug D, and then remove plug C to get a better flow
of the motor liquid.
4. Allow all motor liquid to drain from the seal housing into the
container.
5. Replace the O-ring with a new ring on the plug.
6. Insert plug D and tighten it to the correct torque. See section
7.4 Tightening torques and lubricants.
Fig. 4 SE pump, horizontal view
Filling with motor liquid, vertical installation
1. Remove plug A and B on both sides. This makes it possible to
get the trapped air out while filling. See fig. 5.
2. Fill the shaft seal housing with motor liquid through hole A
until the motor liquid reaches the level indicated in fig. 5.
3. Replace the O-rings with new rings, insert the plugs and
tighten to the correct torque. See section 7.4 Tightening
torques and lubricants.
Filling with motor liquid, horizontal installation
1. Remove plug C.
2. Fill the shaft seal housing with motor liquid through hole C
until the motor liquid reaches the level indicated in fig. 4.
See also section 7.2 Motor liquid quantities.
3. Replace the O-ring with a new ring.
4. Insert plug C and tighten to the correct torque. See section
7.4 Tightening torques and lubricants.
Fig. 5 SE pump, vertical, top view
TM05 2768 1216TM05 2775 0512
D
C
C
C
A-A
Liquid level
TM05 2779 0512

English (US)
6
2.4 Inspecting and adjusting the impeller clearance
You can inspect the impeller clearance of installation types S and
C directly through the pump inlet.
You can inspect and adjust the installation types D and H with the
pump installed on the base stand and connected to the pipes.
2.4.1 Adjusting the impeller clearance
1. Loosen the set screws by two full turns each.
2. Close the impeller clearance by lightly tightening the fastening
screws diagonally until the impeller touches the pump
housing.
3. Loosen the fastening screws to make the correct gap under
the heads of the fastening screws. See fig. 6.
4. Tighten the set screws tightly. For more information about
torques, see section 7.4 Tightening torques and lubricants.
5. Tighten the fastening screws diagonally.
Fig. 6 Impeller clearance adjustment
3. Preparing the dismantling of the product
3.1 Transporting the product
You can transport the pump in vertical or horizontal position.
Make sure that the pump cannot roll or fall over.
See the installation and operating instructions for SE, SL 12-42
Hp (9-30 kW). Use the QR code and link on the front page of this
document.
3.2 Handling and storing the product
3.2.1 Contaminated products
3.2.2 Lifting the product
The product weighs between 639 and 1521 lb (290 and 690 kg)
without accessories. It is therefore very important to use the
correct lifting equipment. The product weight is stated on the
pump nameplate.
DANGER
Electric shock
Death or serious personal injury
- Before inspection, make sure that the motor is
switched off and that the main switch is locked in
position 0.
Check the impeller clearance every time service is
carried out to prevent hot surfaces in the hydraulic
parts.
Pressure range Impeller clearance X
[in (mm)]
E = Extra low pressure 0.028 ± 0.004 (0.7 ± 0.1)
L = Low pressure 0.028 ± 0.004 (0.7 ± 0.1)
M = Medium pressure 0.023 ± 0.004 (0.6 ± 0.1)
H = High pressure 0.023 ± 0.004 (0.6 ± 0.1)
S = Super high pressure 0.019 ± 0.004 (0.5 ± 0.1)
Do not use too much force when tightening the
fastening screws as this may damage the bearings.
Use the clearance stated in the impeller clearance
table above.
TM05 1916 3911
FM
Fastening screw Fastening screw
Set screw
X inch (mm)
CAUTION
Biological hazard
Minor or moderate personal injury
- Flush the product thoroughly with clean water and
rinse the product parts in water after dismantling.
Make sure that all lifting equipment is rated for the
purpose.
Check the lifting equipment for damage before
attempting to lift the product.
DANGER
Crushing hazard
Death or serious personal injury
- Make sure that the shackles are tightened before
attempting to lift the product. Tighten if necessary.
DANGER
Crushing hazard
Death or serious personal injury
- Always lift the product by its lifting bracket or by
means of a forklift truck if the product is fixed on a
pallet.
Do not lift the product by the power cable.
It may result in electric short circuit and risk of chock
when the product is connected to the mains. The
cable and cable entry may be damaged, leading to
loss of watertightness and consequent severe
damage to the motor.

7
English (US)
Installation types S, C and D
When lifting the pump, use the right lifting points to keep the
pump balanced. SE, SL pumps installation types S, C and D are
equipped with two lifting point which ensure that the pump can be
lifted in a safe manner. See fig. 7and the table below to find the
correct lifting point.
Fig. 7 Lifting points, installation types S, C and D
Installation type H
Installation type H can be lifted by a hole in the flange and the
front lifting point. See fig. 8.
Fig. 8 Lifting points, installation type H
3.2.3 Raising the pump to upright position
1. Fasten the lifting equipment as shown in the figure below.
Fig. 9 Lifting the pump
2. Lift at the top end of the pump as shown in the figure below.
Fig. 10 Lifting the pump
Fig. 11 Pump correctly raised to upright position
3.2.4 Storing the product
See the installation and operating instructions for SE, SL 12-42
Hp (9-30 kW). Use the QR code and link on the front page of this
document.
Always handle the pump by means of the correct
lifting points.
TM05 2684 0312
Outlet flange size lifting point
NPS 3" (DN 80)
MiddleNPS 4" (DN 100)
NPS 6" (DN 150)
NPS 8" (DN 200)
FrontNPS 10" (DN 250)
NPS 12" (DN 300)
TM05 3449 1312
Middle
Front
TM05 4169 2112TM05 4170 2112TM05 4171 2112

English (US)
8
4. Dismantling and assembling the product
Before staring any work on the product used in liquids, which
could constitute a hazard to health, thorough cleaning or venting
of the product, pit, etc. must be carried out according to local
regulations.
4.1 Explosion-proof products
Only FM-approved service centres are allowed to intervene in the
flameproof enclosure of the product. Service not affecting the
explosion protection of the product and not violating the
explosion-proof regulations may be carried out by service
persons who are not FM-authorized.
Consequently, these persons are allowed to replace the following
parts of explosion-proof products:
• pump housing
•impeller
• seal ring and wear ring
• shaft seal
• motor liquid
All other service work must be carried out by a FM-approved
service centre. Violation of this requirement will invalidate the
explosion-proof classification of the product.
4.2 General information
Before dismantling the pump
• Switch off the power supply.
• Close the isolating valves, if fitted, to avoid draining the pipe
system.
• Disconnect the power 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 assembling the pump
• Clean and check all parts.
• Use the drawing and follow the alignment grooves in order to
place the components correctly. See fig. 43.
• Replace defective parts by new parts.
• Order the necessary service kits.
• Always replace gaskets and O-rings.
During assembling the pump
• Lubricate and tighten screws and nuts according to section
7.4 Tightening torques and lubricants.
• Use the drawing and follow the alignment grooves in order to
place the components correctly. See section 7.13 Alignment
grooves43.
4.3 Dismantling the pump
DANGER
Electric shock
Death or serious personal injury
- Before starting work on the product, make sure
that the fuses have been removed or the main
switch has been switched off.
Make sure that the power supply cannot be
accidentally switched on.
WARNING
Crushing of hands
Death or serious personal injury
- Make sure that all rotating parts have stopped
moving.
WARNING
Crushing hazard
Death or serious personal injury
- At all times during service, make sure to secure
the product against rolling over, for instance by
placing a wooden wedge on either side of the
motor.
Except for replacement or dismantling of pump
housing, shaft seal, impeller, seal ring and wear ring,
all other service work must be carried out by
Grundfos or a FM-approved service centre.
Service must be carried out by specially trained
persons.
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
FM
FM
Position numbers of parts (numbers in brackets) refer
to section 7.8 Exploded drawings.
Position numbers of tools (letters in brackets) refer to
section 7.3 Special tools.
Position numbers of parts (numbers in brackets) refer
to section 7.8 Exploded drawings.
Position numbers of tools (letters in brackets) refer to
section 7.3 Special tools.
Except for replacement or dismantling of pump
housing, shaft seal, impeller, seal ring and wear ring,
all other service work must be carried out by
Grundfos or a FM-approved service centre.
FM

9
English (US)
4.3.1 Removing the cable
1. Remove the screw (181a) in the cable entry (168).
2. Slightly lift the cable entry (168).
3. Using a screwdriver, disconnect both the signal wires and the
power wires from the terminal block (176a). See fig. 12.
4. Remove the O-ring (157d).
Fig. 12 Illustration of cable wires
5. Place the service tool for cable entry (D) in a vice.
6. Mount the cable entry (168) in the service tool for cable entry
(D).
7. Disconnect the signal wires from the molex plug using the
molex tool (A). Remember to mark the position of the wires
carefully. See fig. 12.
8. Unscrew the lower cable entry (168a).
9. Push the cable (181) together with the rubber seal (198) out of
the plug.
10. Remove the rubber seal (198), washers (198a and 198b) and
disc spring (198c) from the cable. See fig. 13.
11. Pull and remove the cable (181) from the cable entry.
Fig. 13 Sectional drawing, cable entry
4.3.2 Draining of motor liquid
See section 2.3 Changing the motor liquid.
4.3.3 Removing the motor top cover
1. Remove the cable. See section 4.3.1 Removing the cable.
2. Drain the motor liquid. See section 2.3 Changing the motor
liquid.
3. Remove the moisture absorbing bag from the cables.
4. Remove the six screws (178) including washers.
5. Remove the motor top cover (164a).
6. Remove the O-ring (157).
7. Remove the pressure test plug (25).
4.3.4 Removing the upper bearing bracket
1. Remove screws (183).
2. Use 3 x M10 x 80 screws to lift up the bracket in a balanced
way, using the 0.433 in (11 mm) holes. See fig. 14.
3. Remove the upper bearing bracket (61).
Fig. 14 Upper bearing bracket
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
Remember to mark the position of the wires carefully.
Do not loosen the lower cable entry (168a) as this
will impair the water tightness.
TM05 4343 2212
FM
Signal wires
Power wires
TM05 7898 0817
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
TM05 5624 3912
168
198a
198
198b
198c
168a
168c
168b
FM
FM
7/16 in
(M10)
0.433 in
(11 mm)

English (US)
10
4.3.5 Removing SM 113 and the moisture switch
1. Remove the screw and washer of the moisture switch (520).
2. Disconnect the moisture switch wires.
3. Disconnect all wires from SM 113. Remember to mark all
wires carefully.
4. Loosen and remove the screws and washers for the bracket of
SM 113, and remove the SM 113 and the bracket.
4.3.6 Removing the cooling jacket ring (only SE pump)
1. Remove the cooling jacket ring (754) by means of crowbars or
by using the lifting points (if available). See fig. 15.
2. Remove O-rings (157c and 157b).
3. Remove outer cooling jacket (150c).
4. Remove O-rings (37a).
Fig. 15 Lifting points in cooling jacket ring
4.3.7 Removing inner cooling jacket (only SE pump)
1. See section 4.3.6 Removing the cooling jacket ring (only SE
pump)
2. Remove screws (150d).
3. Remove inner cooling jacket (150b).
4.3.8 Removing the impeller and pump housing
1. Remove the outer screws (26).
2. Lift the pump including the impeller (49) out of the pump
housing (50).
3. Remove the O-ring (37b).
4. Place the motor with impeller in horizontal position on a stable
surface.
5. Bend down the tabs on the lock washer (66) and loosen the
impeller screw (67).
6. Remove the impeller screw (67) and the washer (66).
7. Pull off the impeller (49) using a puller. Support the impeller
with a hoist.
4.3.9 Removing the wear ring
1. Remove the screws (49b).
2. Push out the wear ring (49c) from the pump housing (50).
4.3.10 Removing the lower seal housing
1. Mount the shaft seal protection tool (C).
Fig. 16 Shaft seal protection tool
2. Remove screws (184b).
3. Gently remove the lower seal housing. You may use crowbars
and a soft hammer.
4.3.11 Removing the intermediate seal housing (only SE)
1. Remove the three screws (185).
2. Dismantle the intermediate seal housing (58).You may have to
use a soft hammer very gently.
3. Remove the O-rings (37b and 107).
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
TM05 5625 3912
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
FM
FM
Lifting points
FM
Protect the cone of the impeller shaft against
scratches by taping in the cone or protecting it by
other means.
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
TM06 5453 4615
Maintenance and service work on explosion-proof
products must be carried out by Grundfos or a
service workshop authorized by Grundfos.
FM
FM