Grundfos seg autoadapt Operating instructions

SEG AUTOAdapt
0.9 - 4.0 kW, DIN, 50 Hz
Service instructions
GRUNDFOS INSTRUCTIONS

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:
1. Symbols used in this document 2
2. Returning the product for service 3
2.1 Servicing pumps with explosion-proof motors 3
3. Safety 3
4. Identification 4
4.1 Nameplate 4
4.2 Type key 4
5. Approvals 5
5.1 Approval standards 5
5.2 Explanation to the Ex approval 5
5.3 IEC countries (Australia and other countries) 5
6. Installation types 6
6.1 Installation on auto-coupling 6
6.2 Free-standing submerged installation 6
7. Storing and handling the product 7
7.1 Storing the product 7
7.2 Transporting the product 7
7.3 Lifting the product 7
7.4 Contaminated products 7
8. Torques and lubricants 8
9. Service tools 9
9.1 Standard tools 9
9.2 Special tools 9
9.3 Tightness test tools 9
10. Servicing the product 10
10.1 General information 10
10.2 Yearly maintenance 10
10.3 Checking and changing the motor oil 10
10.4 Checking the shaft seal 11
10.5 Adjusting the impeller clearance 11
10.6 Replacing the cable 11
11. Dismantling and assembling the product 12
11.1 Dismantling the product 12
11.2 Assembling the product 13
11.3 Electronic unit 15
11.4 Replacing the run capacitor, single-phase pumps 16
11.5 Replacing the sensors 16
11.6 Replacing the cable plug 17
12. Testing the product 17
12.1 Tightness tests 17
12.2 Testing the operation of the motor 17
12.3 Testing the sensors 18
13. Drawings 19
13.1 Sectional drawing, 0.9 to 1.5 kW 19
13.2 Exploded view, 0.9 to 1.5 kW 20
13.3 Sectional drawing, 2.6 to 4.0 kW 21
13.4 Exploded view, 2.6 to 4.0 kW 22
13.5 Material specification 23
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.

English (GB)
3
2. 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.
2.1 Servicing pumps with explosion-proof motors
Service work on Ex pumps must be carried out by Grundfos or a
workshop authorised by Grundfos. Violation of this requirement
will invalidate the Ex classification of the pump.
Overhauled and repaired explosion-proof pumps are provided
with a repair plate giving this information:
• repair symbol R
• name of registered trade mark of the repairing workshop
• workshop reference number relating to the repair
• date of overhaul or repair.
In case of subsequent repairs, the existing repair plate should be
replaced by a new, updated repair plated and earlier markings
must be covered.
The repairing workshop must keep records of performed
overhauls and repairs together with records of all previous
overhauls, repairs and possible modifications. Copies of the
repairing workshop’s detailed records should be filed by the
owner or operator together with the original type certificate of the
explosion-proof motor in question.
3. Safety
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.
WARNING
Installation fault
Death or serious personal injury
- Pump installation in pits must be carried out by
specially 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 0.
- Type and requirements as specified in EN 60204-
1, 5.3.2.
We recommend that you make all maintenance and
service work when the pump is placed outside the
pit.
Before attempting to lift the pump, make sure that the
lifting bracket is tightened. Tighten if necessary.

English (GB)
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4. Identification
4.1 Nameplate
Fig. 1 Nameplate, SEG AUTOADAPT, 50 Hz
* For Russia only.
** For Australia only.
4.2 Type key
The type key covers the entire Grundfos SEG AUTOADAPT range
of wastewater pumps. This is why the type key has a number of
empty fields for the grinder pumps. Each SEG grinder pump is
identified by means of the type key below.
Please note that not all combination options are available.
Example: SEG.40.12.E.Ex.2.1.502
* Even if the pumps belong to different design generations, they
are similar in terms of power rating.
TM05 8872 3615
Pos. Description
1 Type designation
2 Product number
3Approval
4 ATEX certificate number
5 IEC Ex description
6 IEC Ex certificate number
7 Production code [year and week]
8 Enclosure class according to IEC 60529
9 Maximum head [m]
10 Rated input power [kW]
11 Rated voltage
12 Speed [rpm]
13 Net weight [kg]
14 EAC mark*
15 Run capacitor [µF]
16 RCM logo**
17 CE mark
18 Installation and operation instructions, publication
number
19 Ex description
20 Maximum installation depth [m]
21 Maximum flow rate [l/s]
22 Rated output power [kW]
23 Maximum current [A]
24 Cos φ, 1/1 load
25 Maximum liquid temperature [°C]
26 Frequency [Hz]
27 Insulation class
28 Production country
98807792
Code Explanation Designation
SE Grundfos sewage pumps Pump type
GGrinder system in the pump
inlet Impeller type
40 Nominal diameter of outlet
port [mm] Pump outlet
12 Code number from type
designation / 10 [kW] Output power
[ ] Standard, without equipment
Sensor version
EElectronic version with
AUTOADAPT functions
[ ] Standard pump Pump version
Ex Explosion-proof pump
2 2-pole Number of poles
1 Single-phase motor Number of phases
[ ] Three-phase motor
5 50 Hz Frequency [Hz]
02 230 V, direct-on-line starting
Supply voltage and
starting method
0B 400-415 V, direct-on-line
starting
0C 230-240 V, direct-on-line
starting
[ ] First generation
Generation*A Second generation
B Third generation
[ ] Standard material (EN-GJL-
200) Pump material
Z Custom-built pump Customisation

English (GB)
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5. Approvals
5.1 Approval standards
All versions have been approved by LGA (Notified body under the
Construction Products Directive) according to EN 12050-1.
5.2 Explanation to the Ex approval
The explosion-proof version has been approved by DEKRA
according to the ATEX directive. The explosion protection
classification of the SEG AUTOADAPT pump is Europe CE 0344
II 2 G Ex b c d ib IIB T4 Gb.
5.3 IEC countries (Australia and other countries)
For IEC countries, such as Australia and others, the explosion-
proof versions of SEG AUTOADAPT pumps have been approved
by DEKRA, certificate no IECEx DEK 11.0026X, according to IEC
60079-0:2007, IEC 60079-1:2007 and IEC 60079-11:2006.
The explosion-protection classification of the pumps is Ex d ib IIB
T4 Gb.
Directive/
standard Code Description
ATEX
CE 0344 = CE mark of conformity according to the ATEX directive 2014/34/EU.
0344 is the number of the notified body which has certified the quality system for ATEX.
= Explosion protection mark.
II = Equipment group according to the ATEX directive, defining the requirements applicable to the
equipment in this group.
2=
Equipment category according to the ATEX directive, defining the requirements applicable to the
equipment in this category.
G = Explosive atmospheres caused by gases, vapours or mists.
Harmonised
European
standard
Ex = The equipment conforms to the harmonised European standard.
b = Control of ignition sources according to EN 13463-6.
c = Constructional safety according to EN 13463-5 and EN 13463-1.
d = Flame-proof enclosure according to EN 60079-1:2007.
ib = Intrinsic safety enclosure according to EN 60079-11:2007.
IIB = Classification of gases according to EN 60079-0:2009.
Gas group B includes gas group A.
T4 = Maximum surface temperature is 135 °C according to EN 60079-0.
Gb = Equipment protection level (IEC).
Directive/
standard Code Description
IEC 60079-0,
IEC 60079-1 and
IEC 60079-11
Ex = The equipment conforms to the harmonised European standard.
d = Flame-proof enclosure according to IEC 60079-1:2007.
ib = Intrinsic safety according to EN 60079-11:2007.
IIB = Classification of gases according to IEC 60079-0:2009.
Gas group B includes gas group A.
T4 = Maximum surface temperature is 135 °C according to IEC 60079-0:2006.
Gb = Equipment protection level.

English (GB)
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6. Installation types
6.1 Installation on auto-coupling
Pumps for permanent installation can be mounted on a stationary
auto-coupling guide rail system or a hookup auto-coupling
system.
Auto-coupling guide rail system
Fig. 2 Guide rail installation
Hookup auto-coupling
Fig. 3 Hookup auto-coupling installation
6.2 Free-standing submerged installation
Pumps for free-standing submerged installation can stand freely
on the bottom of the pit or similar location.
Fig. 4 Free-standing submerged installation
TM06 6125 0816TM06 6126 0816
TM06 6127 0816

English (GB)
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7. 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.
7.1 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. See section 10.3 Checking and changing the motor oil.
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 cable
entry.
7.2 Transporting the product
Make sure that all lifting equipment is rated for the purpose.
Check the lifting equipment for damage before making any
attempts to lift the pump. Do not exceed the rating data under any
circumstances. For pump weights, see the pump nameplate,
section 4.1 Nameplate.
The polyurethane-embedded plug prevents water from entering
the motor via the motor cable.
7.3 Lifting the product
The SEG AUTOADAPT pumps weigh between 38 kg and 65 kg
without accessories. It is therefore essential to use the correct
lifting equipment.
When lifting the pump, use the correct lifting point to keep the
pump balanced. Place the lifting chain hook in point A for auto-
coupling installations and in point B for other installations. See
fig. 5.
Fig. 5 Lifting points
7.4 Contaminated products
See section 2. Returning the product for service.
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.
Rate all lifting equipment for the purpose and check it
for damage before making any attempts to lift the
pump. Do not exceed the lifting equipment rating
under any circumstances.
TM06 0066 4813
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 contaminated.

English (GB)
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8. Torques and lubricants
* Pumps manufactured from week 19, 2014, production code
(P.c.) 1419.
Soapy water.
Rocol Sapphire Aqua-Sil, product number 96102356 (1 kg).
Motor oil: Shell Ondina X420, product number 96586753 (1 l).
Painting: RAL 9005 black, product number 95039317 (50 ml).
Pos. Description Quantity 0.9 to 1.5 kW
Dimensions 2.6 to 4.0 kW Dimensions Torque [Nm] Lubricant
9a Key 1 5 x 5 x 12 - - Rocol Sapphire
26a O-ring 1 D32.0 x 4 D32.0 x 4 - Rocol Sapphire
37 O-ring 1 D164.5 x 3 D204.0 x 3 - Rocol Sapphire
37a O-rings 2 D114.0 x 3 - - Rocol Sapphire
66 Locking ring 2 - - - Rocol Sapphire
68 Adjusting nut 1 - - 1/4 turn Rocol Sapphire
90b O-ring 1 D180.0 x 4 D180.0 x 4 - Rocol Sapphire
92 Clamp 1 - - 12 ± 2 -
102 O-ring 1 D16.0 x 1.5 D17.3 x 2.4 - Rocol Sapphire
105 Shaft seal 1 - - - Soapy water
107
O-ring 2 D47.0 x 3 - -
Rocol Sapphire
O-ring 2 - D50.0 x 3
D90.0 x 4 -
159 O-ring 1 D32.0 x 2
D37.0 x 2* D52.0 x 3 - -
172 Rotor/shaft 1 - - - Rocol Sapphire
181 Outer plug part 1 - - 30 ± 2 Rocol Sapphire
188a
Screw (shaft head) 1 M8 x 25 M8 x 25 20 ± 2 Rocol Sapphire
Screw (impeller foot) 1 M8 x 25 M8 x 25 18 ± 2 -
Screw (shaft seal carrier) 2 M8 x 25 M8 x 25 16 ± 2 -
Screw (oil chamber) 2 M8 x 25 M8 x 25 16 ± 2 -
Screw (lifting handle) 1 M8 x 25 - 16 ± 2 Rocol Sapphire
Screw (lifting handle) 2 - M8 x 25 16 ± 2 Rocol Sapphire
Screw (lid) 4 - M10 x 30 35 ± 2 Rocol Sapphire
193 Oil screw 2 M12 x 20 M12 x 20 18 ± 2 -
198 O-ring 1 D34.2 x 3 D34.2 x 3 - Rocol Sapphire
285a O-ring 4 D29.74 x 2.95 D29.74 x 2.95 - Rocol Sapphire
285b Set screw 2 M6 x 18 M6 x 18 5.5 ± 0.5 -
287b O-ring 2 D20.2 x 3 D20.2 x 3 - -
287c Set screw 1 M6 x 18 M6 x 18 5.5 ± 0.5 -

English (GB)
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9. Service tools
9.1 Standard tools
Standard tools
9.2 Special tools
Special tools
9.3 Tightness test tools
ABCD
EFGH
IJKL
Pos. Designation Description Part No
ABit holder 1/4" SV2011
BBits kit - SV2010
CScrewdriver Straight slot -
DPunch ∅10 -
ERing/open-end spanner 24 mm SV0122
FRatchet handle 1/2" 96777072
GHexagon socket driver M8 - 6 mm
M12 - 10 mm
SV0297
SV0299
HLocking-ring pliers - SV2014
IPlastic hammer - SV0349
JFunnel --
KPuller for shaft seal - -
LBearing heater Inductor heater -
MN
Pos. Designation Description Part No
MPuller for impeller - SV2097
NHook spanner for cable
plug 45-50 mm 95043464
Designation Description Part No
Grundfos PC Tool PC Tool link USB 97655366
Test plug M48 x 1.5 - 6G -
Test plug M12 x 20 -

English (GB)
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10. Servicing the product
10.1 General information
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.
Position numbers of parts (digits) refer to section 13. Drawings.
Position numbers of tools (letters) refer to section 9. Service
tools.
10.2 Yearly maintenance
Check 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 these points:
•Power consumption
See section 4.1 Nameplate.
•Oil level and oil condition
See section 10.3 Checking and changing the motor oil.
•Electronic unit
See section 11.3 Electronic unit.
•Sensors
See section 11.5 Replacing the sensors.
•Cable entry
Make sure that the cables are not sharply bent and/or pinched.
See section 10.6 Replacing the cable.
•Shaft seal
See section 10.4 Checking the shaft seal.
•Pump parts
Check the impeller and pump housing for possible wear.
Replace defective parts.
See section 11. Dismantling and assembling the product.
•Ball bearings
Check the shaft for noisy or heavy operation by turning the
shaft by hand. Replace defective ball bearings. In case of
defective ball bearings or poor motor function, a complete
overhaul of the product is usually required. A complete
overhaul must be carried out by Grundfos or an authorised
service workshop. See sections 11.1.6 Removing the bearings
and 11.2.1 Fitting the bearings.
•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.
•Grinder system
In case of frequent choke-ups, check the grinder system for
wear. If worn, the edges of the grinding parts are round and
worn. Compare with a new grinder system.
•Insulation resistance
Megging must take place at a voltage of minimum 1000 V. The
insulation resistance measured must be minimum 2 MΩ.
10.3 Checking and changing the motor oil
When the pump is new or after replacement of the shaft seal,
check the motor liquid level and water content after one week.
Change the oil in the oil chamber at least once a year or after
3000 operating hours. The number of operating hours can be
read by means of a CIU XX2 and a Grundfos GO remote control.
Change the oil if the shaft seal has been replaced.
Quantity of oil
The table shows the quantity of motor oil in the cooling chamber.
Use Shell Ondina X420 motor oil (product No 96586753).
Draining the motor oil
1. Place the pump with the oil level screw pointing downwards.
See fig. 6.
Fig. 6 Oil screws
DANGER
Crushing of hands
Death or serious personal injury
- Before starting service work, remove the fuses or
switch off the power supply. Make sure that the
power supply cannot be accidentally switched on.
- All rotating parts must have stopped moving.
Except for the replacement or dismantling of the
pump housing, shaft seal or impeller, all other service
work must be carried out by Grundfos or an
authorised service workshop.
The paint on the motor is part of the protection of the
product. If the paint is damaged, apply new paint to
keep the sealing effect of the paint intact.
Defective bearings may reduce the Ex safety.
Bearings of explosion-proof products must only be
replaced by an authorised Ex workshop.
Do not reuse used rubber parts.
CAUTION
Pressurised system
Minor or moderate personal injury
- When slackening the screws of the oil chamber,
note that pressure may have built up in the
chamber. Do not remove the screws until the
pressure has been fully relieved.
Pump type
[kW] Oil in oil chamber [l]
0.9 to 1.5 kW 0.17
2.6 to 4.0 kW 0.42
TM06 5758 0116
Pos. Description
1 Oil filling screw
2 Oil level screw
1
2

English (GB)
11
2. Place a container with a capacity of 0.5 litre under the pump.
3. Slacken and remove both oil screws (193) and gaskets (194)
to allow all the oil to drain from the chamber.
4. Check the oil for impurities. This gives a good indication of the
condition of the shaft seal. See section 10.4 Checking the
shaft seal.
5. Clean the pump for spilled oil.
Filling the oil chamber with oil, method 1
1. Place the pump in such a position that it is lying on the stator
housing and the outlet flange with the oil screws pointing
upwards. See fig. 6.
2. Fill oil into the oil chamber through the oil filling hole until it
starts running out of the oil level hole. The oil level is now
correct.
3. Fit the gaskets (194) and both oil screws (193). Tighten the
screws. See section 8. Torques and lubricants.
4. Clean the pump for spilled oil.
Filling the oil chamber with oil, method 2
1. Place the pump in the upright position on a plate.
2. Measure the correct amount of oil in the container and pour
the oil into the oil chamber (M). See fig. 7.
Fig. 7 Oil filling
3. Fit and tighten the screws (193) and the seal washers (194).
See section 8. Torques and lubricants.
4. Clean the pump for spilled oil.
10.4 Checking the shaft seal
Check the oil to make sure that the shaft seal is intact.
If the oil is greyish white like milk or contains a large quantity of
water, the primary part of the seal is worn. Replace the shaft seal.
If the seal is not replaced, the motor will be damaged within a
short time. If the oil is clean, it can be reused.
If the shaft seal needs to be replaced, see sections
11.1.5 Removing the shaft seal and 11.2.2 Fitting the shaft seal.
10.5 Adjusting the impeller clearance
To adjust the impeller, first dismantle the grinder system.
1. See section 11.1.2 Removing the grinder system.
2. Tighten the adjusting nut (68) until the impeller (49) cannot
rotate any more.
3. Slacken the adjusting nut (68) by 1/4 turn.
10.6 Replacing the cable
Dismantling the cable
1. Remove the locking ring (199) with hook spanner (B).
2. Insert two screwdrivers (E) into the groove and prise the cable
out of the cable entry. See fig. 8.
Fig. 8 Removing the supply cable
3. Carefully pull the cable out of the stator housing and
disconnect the plug.
4. Check the cable for damage.
5. Remove the O-ring (26a) from the cable with a pair of pincers
or similar tool.
6. Remove the O-ring (198) from the cable and clean the groove.
Assembling the cable
1. Clean the cable entry, locking ring (199) and cable.
2. Lubricate the groove for the O-ring (198).
3. Fit the O-ring (198) on the plug and lubricate it.
4. Fit the O-ring (26a).
5. Fit the outer plug part (181). The projection must engage with
the hole.
6. Fit the locking ring (199). See section 8. Torques and
lubricants. Hold the plug with a hook spanner (B) to prevent it
from turning.
Used motor oil must be disposed of in accordance
with local regulations.
TM04 6970 1810
CAUTION
Crushing of hands
Minor or moderate personal injury
- Before inspection, make sure that the motor is
switched off and that the mains switch is locked in
position 0.
DANGER
Electric shock
- Death or serious personal injury
- The cable must only be replaced by Grundfos or
an authorized service workshop.
TM04 6983 1810
If the cable is to be reused, be careful not to damage
the flash path gap and plastic pin on the cable when
the cable is removed.
If a new cable is not fitted, then cover the cable entry
to protect the cable entry against dirt.
DANGER
Electric shock
Death or serious personal injury
- Make sure that the plastic pin on the cable is
intact. In case the pin is damaged, replace the
cable.

English (GB)
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11. Dismantling and assembling the product
General information
Position numbers of parts (digits) refer to section 13. Drawings.
Position numbers of tools (letters) refer to section 9. Service
tools.
Before dismantling the product
• Switch off the power supply.
• Close the isolating valves, if fitted, to avoid draining the piping
system.
• Disconnect the power supply cable in accordance with local
regulations.
• Note the centre of gravity of the pump to prevent it from
overturning.
11.1 Dismantling the product
11.1.1 Draining the motor oil
See section 10.3 Checking and changing the motor oil.
11.1.2 Removing the grinder system
1. See section 11.1.1 Draining the motor oil.
2. Place the pump horizontally on the table.
3. Loosen and remove the screw (188a) in one of the pump feet.
4. Loosen the grinder ring (44) by knocking it clockwise with a
punch (F). See fig. 9.
Fig. 9 Dismantling the grinder ring
5. Gently remove the grinder ring (44) from the pump housing
using a screwdriver (E).
6. Insert the punch (F) into the hole to hold the impeller to
prevent it from moving during dismantling.
7. Remove the screw (188a) from the shaft end. Remove the
locking ring (66). See fig. 10.
Fig. 10 Dismantling the screw and grinder head
8. Remove the grinder head (45).
11.1.3 Removing the pump housing
1. See section 11.1.2 Removing the grinder system.
2. Place the pump vertically.
3. Support the pump from the lifting bracket (190) with a hoist.
4. Loosen the clamp (92) holding the pump housing (50) and
stator housing (55) together.
5. Lift the pump housing (50) off the stator housing (55) including
the O-ring (37) and the impeller (49). Place the pump
horizontally.
6. Clean the pump housing (50).
11.1.4 Removing the impeller
1. See section 11.1.3 Removing the pump housing.
2. Insert the punch (F) in the impeller (49) to prevent it from
moving during dismantling.
3. Remove the adjusting nut (68).
4. Fit the puller (A) on the shaft. See fig. 11.
Fig. 11 Fitting the puller on the impeller
5. Fit the M8 screw in the puller and pull out the impeller (49).
6. Remove the key (9a).
7. Clean the shaft and key.
DANGER
Sharp element
Death or serious personal injury
- Be careful of the sharp edges on the impeller,
grinder head and grinder ring.
TM06 5756 0116
Make sure that the grinder ring does not get stuck
against the grinder head.
TM06 5747 0116
Clean the pump housing. Grind the surfaces slightly
with emery cloth, if necessary.
CAUTION
Sharp element
Minor or moderate personal injury
- Be careful of the sharp edges on the impeller and
the grinder head.
TM04 6969 1810
Clean the impeller. Grind the surfaces slightly with
emery cloth, if necessary.

English (GB)
13
11.1.5 Removing the shaft seal
0.9 to 1.5 kW
1. See section 11.1.4 Removing the impeller.
2. Remove the two screws (188a) in the middle securing the
shaft seal carrier (58), and fit them into the tapped extractor
holes in the shaft seal carrier.
3. Remove the shaft seal assembly by means of the two screws
(188a).
4. Pull out the shaft seal assembly (105).
5. Check the condition of the shaft where the secondary seal of
the shaft seal touches the shaft. The bush (103) fitted to the
shaft must be intact.
2.6 to 4.0 kW
1. See section 11.1.4 Removing the impeller.
2. Remove the retaining ring (112a).
3. Remove the two screws (188a) in the middle securing the
shaft seal carrier (58), and fit them into the tapped extractor
holes in the shaft seal carrier.
4. Remove the shaft seal carrier (58) by means of the two
screws (188a).
5. Remove the retaining ring (112a).
6. Pull out the shaft seal assembly (105).
7. Check the condition of the shaft where the secondary seal of
the shaft seal touches the shaft. The bush (103) fitted to the
shaft must be intact.
11.1.6 Removing the bearings
1. See section 11.1.5 Removing the shaft seal.
2. Remove the four screws (188a) from the oil chamber (155).
3. Remove the oil chamber (155) from the stator housing (55)
using screwdrivers (E). If the fitting is tight, remove the oil
chamber assembly by gently tapping the screwdrivers with a
plastic hammer (K).
4. Place the oil chamber assembly in a vice and check that the
rotor is not damaged.
5. Remove the O-rings (37a) from the oil chamber (155).
6. Pull out the bush (103) including the O-ring (102) from the
rotor/shaft (172).
7. Pull the oil chamber (155) out of the rotor/shaft (172) using a
puller.
8. Pull the lower bearing (153) out of the oil chamber (155).
9. Pull the upper bearing (154) off the rotor/shaft (172) using a
puller.
10. Remove the corrugated spring (158).
11.2 Assembling the product
Before assembling the product
• Clean and check all parts.
• Replace defective parts.
• Order the necessary service kits.
• Always replace gaskets and O-rings when the pump is
serviced.
During assembly
Lubricate and tighten screws and nuts according to section
8. Torques and lubricants.
11.2.1 Fitting the bearings
Lower bearings
1. Clean the bearing in the oil chamber (155).
2. Heat the oil chamber (155) up to 100 °C.
3. Press the cold lower bearing (153) into the heated oil chamber
(155). See fig. 12. Press and let the oil chamber cool. Use a
heat-resistance punch.
4. Allow the assembly to cool.
Fig. 12 Fitting the lower bearing in the heated oil chamber
5. Fix the rotor/shaft (172) in a vice with the shaft pointing
upwards.
The shaft seal is a complete unit for all SEG
AUTOADAPT pumps.
Bearings of explosion-proof products must only be
replaced by Grundfos or a service workshop
authorised by Grundfos.
If you remove the rotor/shaft from the oil chamber, it
will break the lower bearing. Replace the broken
bearing.
Bearings of explosion-proof products must only be
replaced by Grundfos or a service workshop
authorised by Grundfos.
TM04 6984 1810
To avoid damaging the rotor, do not overtighten the
vice. Use protection between vice and rotor.

English (GB)
14
6. Fit the oil chamber (155) with bearing (153) on the rotor/shaft
(172). Fit the punch (F) on the inner ring and tighten gently.
See fig. 13.
Fig. 13 Fitting the oil chamber on the rotor/shaft
7. Turn the assembly horizontally in the vice.
8. Press the bearing home on the journal.
Upper bearings
1. Fit the corrugated spring (158) on the stator housing (55).
2. Fit the upper bearing (154) on the rotor/shaft (172) by
pressing on the inner ring.
3. Make sure that the O-ring (159) is fitted in the groove of the
stator housing (55).
4. Fit the corrugated spring (158) on the upper bearing (154).
5. Lubricate the groove for the O-rings (37a).
6. Fit and lubricate the O-rings (37a).
7. Make sure that the spring pins (6a) are fitted on the stator
housing (55).
8. Fit the rotor assembly to the stator housing (55). The pin on
the stator housing (55) must engage with the hole in the oil
chamber (155).
9. Fit the screws (188a) to attach the oil chamber (155) to the
stator housing (55). See section 8. Torques and lubricants.
11.2.2 Fitting the shaft seal
0.9 to 1.5 kW
1. Check and clean the oil chamber (155).
2. Lubricate the groove for the O-rings (107).
3. Fit and lubricate the two O-rings (107) on the shaft seal.
4. Make sure that the O-ring (102) is fitted inside the bush (103).
5. Cover the shaft end and lubricate the shaft.
6. Fit the bush (103) in the seal ring (104) of the shaft seal (105).
7. Fit a new shaft seal (105) using the mounting bush included in
the shaft seal kit. See fig. 14.
Fig. 14 Shaft seal assembly, 0.9 - 1.5 kW
8. Remove the screw (188a) from the shaft end.
9. Fit two screws (188a) in the shaft seal carrier (58). See
section 8. Torques and lubricants.
10. Fit the key (9a) on the shaft (172) and lubricate the surface of
the key.
2.6 to 4 kW
1. Lubricate the shaft surface on the point where the seal is
fitted.
2. Fit the locking washer (153a).
3. Fit the shaft seal (105a) to the shaft. Make sure that the pin of
the shaft seal engages with the shaft groove. See fig. 15.
Fig. 15 Fitting the shaft seal, 2.6 - 4 kW
4. Lubricate the groove for the O-ring (107) on the shaft seal
carrier (58).
5. Fit and lubricate the O-ring (107).
6. Fit the shaft seal carrier (58) with screws (188a). See section
8. Torques and lubricants.
7. Fit the retaining ring (112a).
8. Fit the key (9a).
TM04 6974 1810 - TM04 6975 1810
Pos. Description
1Punch
Make sure that the shaft seal parts are concentric.
Wrong orientation breaks the seal parts when they
are pressed home.
1
TM05 7246 0813
Pos. Description
1Lubricate with soapy water only.
Do not use oil.
2No soap or oil between the SiC ring and the rubber
seal.
TM04 7130 1810
Make sure that the shaft seal parts are concentric.
Wrong orientation breaks the seal parts when they
are pressed home.
2
1

English (GB)
15
11.2.3 Fitting the impeller
1. Fit the impeller (49).
2. Fit and tighten the adjusting nut (68). See section 8. Torques
and lubricants.
11.2.4 Fitting the pump housing
1. Fit the grinder head (45). Make sure that the projections on
the back of the grinder head engage with the holes in the
impeller (49).
2. Fit the locking ring (66) on the screw (188a). Make sure that
the locking ring is fitted correctly.
3. Turn the motor to the vertical position and lift it up with a hoist.
4. Fit the motor on the pump housing (50).
5. Close the clamp (92). See section 8. Torques and lubricants.
6. Turn the pump to the horizontal position with a hoist. Remove
the screw (188a), locking ring (66) and grinder head (45).
7. See section 12.1 Tightness tests.
11.2.5 Adjusting the impeller clearance
See section 10.5 Adjusting the impeller clearance,
11.2.6 Fitting the grinder system
1. Fit the grinder head (45). Make sure that the projections on
the back of the grinder head engage with the holes in the
impeller (49).
2. Fit the locking ring (66) on the screw (188a). Make sure that
the washer is fitted correctly.
3. Fit the screw (188a) including locking ring (66) to the shaft
end and tighten to 20 Nm ± 2. Insert the punch (F) to prevent
the impeller from moving.
4. Fit the grinder ring (44). Make sure that the grinder head does
not drag on the grinder ring.
5. Fit the screw (188a) on the feet of the pump housing. See
section 8. Torques and lubricants.
6. Fill oil into the oil chamber. See 10.3 Checking and changing
the motor oil.
11.3 Electronic unit
11.3.1 Opening the electronic unit
1. Clean the pump around the electronic unit to protect the
electronic parts from dirt when opening the electronic unit.
2. Place the pump on the side with the level sensor pointing
upwards. See fig. 16.
Fig. 16 Correct opening of the electronic unit
3. Remove the four screws (188a) and place the electronic unit
next to the pump on a block or similar support. See fig. 17.
Fig. 17 Electronic unit on a block
4. Raise the pump to the vertical position. See fig. 18.
Fig. 18 Pump in the vertical position
5. Remove the O-ring (90b) from the electronic unit.
6. Clean the contact surfaces of the stator housing and the
electronic unit. Clean the O-ring groove.
CAUTION
Sharp element
Minor or moderate personal injury
- Be careful of the sharp edges of the impeller.
The pump housing must engage with the guide pin.
The pump outlet must point in the opposite direction
to the electronic unit.
Pay special attention to assembling the grinder head.
Moving the grinder head may also move the
adjusting nut resulting in wrong impeller clearance.
Make sure that the grinder head rotates freely and
noiselessly.
Be careful not to disconnect the wires.
TM04 6976 1810TM04 6977 1810TM04 6978 1810

English (GB)
16
11.3.2 Replacing the electronic unit
1. See section 11.3.1 Opening the electronic unit
2. Remove the wires of the dry-running sensor, Pt1000 sensor
and capacitor (single-phase pumps) as well as the earth lead.
3. Cut the motor leads between the electronic unit and the stator
housing in the middle.
4. Remove the level sensor (see section 11.5.2 Replacing the
level sensor) and the cable plug (see section 11.6 Replacing
the cable plug) from the old electronic unit and fit them in the
new one.
5. Remove approximately 60 mm of the insulating sheath of the
cable from the new electronic unit so that approximately 75
mm of the three leads are stripped.
6. Cut away 5, 30 and 55 mm of the three leads from the
electronic unit and from the stator housing so that the joints
are displaced from each other. See fig. 19. For instance, if 5
mm of the red lead from the electronic unit are cut away, 55
mm of the red lead from the stator housing must be cut away.
Fig. 19 Leads with connectors
7. Strip the three leads from the electronic unit and from the
stator housing using a cable stripper.
8. Pull a new 16 mm insulation sheath over the original
insulating sheath of the motor leads. See fig. 20.
Fig. 20 Insulating sheath on the three leads
9. Pinch connectors on the three leads with a crimping tool.
10. Grab the leads on each side of the connector and pull a little
to check the joints.
11. Carefully pull the new insulating sheath over the joints and fix
it with a cable clip.
12. Connect the wires from the dry-running sensor, Pt1000 sensor
and capacitor (single-phase pumps) as well as the earth lead.
13. Fit the electronic unit. See section 11.3.2 Replacing the
electronic unit.11.3.3 Closing the electronic unit.
11.3.3 Closing the electronic unit
1. Lubricate the O-ring (90b) and the contact surfaces of the
stator housing and the electronic unit.
2. Fit the O-ring in the stator housing.
3. Place the wires in the hollow space and fit the electronic unit
on the stator housing.
4. Fit the four screws (188a). See section 8. Torques and
lubricants.
11.4 Replacing the run capacitor, single-phase pumps
11.4.1 Dismantling the run capacitor
1. Open the electronic unit. See section 11.3.1 Opening the
electronic unit.
2. Disconnect the capacitor wire from the electronic unit.
3. Remove the Pt1000 plug from the PC board.
4. Remove the earth lead from bracket (161c).
5. Remove the capacitor bracket with capacitor from the stator
housing.
11.4.2 Assembling the run capacitor
1. Fix the capacitor wire on the PC board.
2. Fit the earth lead on the new bracket.
3. Fit the new Pt1000 sensor.
4. Fit the electronic unit. See section 11.3.3 Closing the
electronic unit.
11.5 Replacing the sensors
11.5.1 Replacing the dry-running sensor
Observe the bar code on the sensor wire, for example 96892923-
01-039-01192. In case the bar code contains the figure 01,
replace the sensor with a new one, version 02.
Dismantling the dry-running sensor
1. Open the electronic unit. See section 11.3.1 Opening the
electronic unit.
2. Remove the sensor wire from the PC board.
3. Remove the set screw (285b).
4. Press the sensor out of the stator housing with a screwdriver
(E). Do not reuse the sensor.
5. Clean the sensor hole.
Assembling the dry-running sensor
1. Lubricate and fit the O-rings (285a).
2. Lubricate the sensor hole.
3. Press the sensor home in the stator housing.
4. Connect the sensor wire to the PC board.
5. Fit a new set screw. See section 8. Torques and lubricants.
6. Fit the electronic unit. See section 11.3.3 Closing the
electronic unit.
TM04 6979 1810
Do not use side-cutting pliers due to the risk of
pulling the leads out of the stator housing.
TM04 6980 1810
The leads must be connected in such a way that the
colours from the electronic unit and the stator
housing match.
Make sure that the wires are not pinched between
the stator housing and electronic unit.

English (GB)
17
11.5.2 Replacing the level sensor
Dismantling the level sensor
1. Open the electronic unit. See section 11.3.1 Opening the
electronic unit.
2. Remove the sensor wire from the PC board.
3. Remove the set screw (287c).
4. Press the sensor out of the electronic unit.
5. Clean the sensor hole.
Assembling the level sensor
1. Lubricate and fit the O-ring (287b).
2. Lubricate the sensor hole.
3. Press the sensor home in the electronic unit.
4. Connect the sensor wire to the PC board.
5. Fit a new set screw. See section 8. Torques and lubricants.
6. Fit the electronic unit. See section 11.3.3 Closing the
electronic unit.
11.6 Replacing the cable plug
11.6.1 Dismantling the cable plug
1. Open the electronic unit. See section 11.3.1 Opening the
electronic unit.
2. Remove the earth lead screw and the washer.
3. Remove the two plugs from the electronic unit.
4. Press in the three barbs and press the cable plug out of the
electronic unit.
5. Clean the cable entry.
11.6.2 Assembling the cable plug
1. Press the cable plug into the cable entry.
2. Check that the three barbs have engaged with the electronic
unit.
3. Connect the two plugs to the PC board.
4. Fix the earth lead with the screw. Do not forget to fit the
washer.
5. Fit the O-ring (26a)
6. Fit the electronic unit. See section 11.3.3 Closing the
electronic unit.
12. Testing the product
12.1 Tightness tests
12.1.1 Testing the motor
Carry out a tightness test if the motor has been dismantled.
Proceed as follows:
1. Secure the pump in vertical position.
2. Remove the cable, if assembled. See section
11.6.1 Dismantling the cable plug.
3. Fit the test plug. See section 9.3 Tightness test tools.
4. Pressurise the chamber with 0.6 bar.
5. Observe the pressure approximately 1 minute to detect
possible leaks.
6. If the pressure drops, dismantle the pump, and find and
correct the cause of the leak.
7. Remove the pressure.
8. Remove the test plug.
9. Fit the cable plug. See section 11.6.2 Assembling the cable
plug.
12.1.2 Testing the oil chamber
Carry out a tightness test if the motor has been opened, and
before refilling the oil. Use nitrogen gas to test the tightness.
Proceed as follows:
1. Secure the pump in vertical position.
2. Remove one oil plug (193), including the washer (194).
3. Fit the test plug instead of the oil plug (193).
4. Pressurise the chamber with 0.6 bar.
5. Observe the pressure approximately 1 minute to detect
possible leaks.
6. If the pressure drops, dismantle the pump, and find and
correct the cause of the leak.
7. Remove the pressure from the oil chamber.
8. Remove the test plug.
9. Fill with oil. See section 10.3 Checking and changing the
motor oil.
12.2 Testing the operation of the motor
Proceed as follow:
1. Connect the pump to Grundfos PC Tool.
2. Connect the pump to the power supply.
3. Check the line current and phase values with the operation
report.
Line current (L1, L2 and L3): 0.1 ~ 0.2 A
Average of line voltages: ~400 V
Phase voltage (L1, L2 and L3): ~230 V.
4. If the stator is in normal condition, the values are close to
each other (between 0.1 and 0.2). If the values differ too much
from each other, then test the stator by means of the motor
tester.
Be careful not to damage the three barbs.
Maintenance and service work on explosion-proof
pump must be carried out by Grundfos or a service
workshop authorised by Grundfos.

English (GB)
18
12.3 Testing the sensors
In case the pump software version is old, we recommend that you
update it to the latest one.
12.3.1 Dry-running sensor (dry test)
1. Place the pump in horizontal position.
2. Connect Grundfos PC Tool to the pump.
3. Connect the pump to the power supply, but do not start it yet.
4. Clean the dry-running sensor.
5. Cover the sensor with wet cloth and start the pump.
6. Let the pump run for a maximum of 5 seconds.
7. Remove the wet cloth and dry the sensor.
8. Turn off the power supply.
9. Disconnect the power supply cable and PC Tool.
12.3.2 Dry-running and/or level sensor (submersion test)
1. Connect the pump to Grundfos PC tool.
2. Connect the pump to the power supply.
3. Secure the pump in vertical position.
4. Lower the pump carefully into the test basin.
5. Start the pump and find the start level.
In case the pump does not start automatically within 5
seconds, reverse the phase connections.
6. Observe the pump data through PC Tool in case of sensor
warnings.
7. Pump water into the test basin until the pump start level is
reached.
8. The pump starts to pump down to the stop level.
9. Let the pump start a few times to make sure that it operates
correctly.
10. Remove the pump from the test basin.
11. Remove the power supply cable and PC Tool.
Make sure that the pump base is clear from objects.
Make sure that the flow is lower than the pump
capacity when the liquid is pumped into the test
basin.

English (GB)
19
13. Drawings
13.1 Sectional drawing, 0.9 to 1.5 kW
TM06 6109 0716
6a
Single-phase pump only

English (GB)
20
13.2 Exploded view, 0.9 to 1.5 kW
TM06 5750 0316