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