Grundfos seg autoadapt Original operating manual

GRUNDFOS INSTRUCTIONS
SEG AUTOADAPT
Service instructions

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Content
1. Symbols used in this document....................................................................................... 4
2. Identification...................................................................................................................... 4
2.1 Nameplate ........................................................................................................................................4
2.2 Type key...........................................................................................................................................5
3. Service tools...................................................................................................................... 5
3.1 Special tools .....................................................................................................................................5
3.2 Standard tools ..................................................................................................................................6
3.3 Torque tools .....................................................................................................................................6
4. Tightening torques, lubricants and oil............................................................................. 6
4.1 Tightening torques ............................................................................................................................6
4.2 Lubricants.........................................................................................................................................6
4.3 Oil.....................................................................................................................................................6
5. Dismantling and assembly ............................................................................................... 6
5.1 Position numbers ..............................................................................................................................6
5.2 Before dismantling ............................................................................................................................7
5.3 Before assembly ...............................................................................................................................7
5.4 During assembly ...............................................................................................................................7
5.5 After assembly..................................................................................................................................7
6. Cleaning the pump housing ............................................................................................. 7
7. Grinder system.................................................................................................................. 7
7.1 Dismantling.......................................................................................................................................7
7.2 Assembly ..........................................................................................................................................8
8. Impeller.............................................................................................................................. 8
8.1 Dismantling.......................................................................................................................................8
8.2 Assembly ..........................................................................................................................................9
9. Oil....................................................................................................................................... 9
9.1 Oil change ........................................................................................................................................9
9.2 Draining of oil ...................................................................................................................................9
9.3 Oil filling............................................................................................................................................9
10. Shaft seal......................................................................................................................... 10
10.1 Dismantling, 0.9 - 1.5 kW................................................................................................................10
10.2 Assembly, 0.9 - 1.5 kW ...................................................................................................................10
10.3 Dismantling, 2.6 - 4 kW...................................................................................................................11
10.4 Assembly, 2.6 - 4 kW......................................................................................................................11
11. Bearings .......................................................................................................................... 12
11.1 Dismantling.....................................................................................................................................12
11.2 Assembly ........................................................................................................................................12
12. Electronic unit................................................................................................................. 13
12.1 Dismantling.....................................................................................................................................13
12.2 Assembly ........................................................................................................................................14
13. Run capacitor (single-phase pumps)............................................................................. 14
13.1 Dismantling.....................................................................................................................................14
13.2 Assembly ........................................................................................................................................14
14. Dry-running sensor......................................................................................................... 14
14.1 Dismantling.....................................................................................................................................14
14.2 Assembly ........................................................................................................................................14
15. Level sensor.................................................................................................................... 15
15.1 Dismantling.....................................................................................................................................15
15.2 Assembly ........................................................................................................................................15
16. Cable plug........................................................................................................................ 15
16.1 Dismantling.....................................................................................................................................15
16.2 Assembly ........................................................................................................................................15

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17. Supply scable.................................................................................................................. 16
17.1 Dismantling.....................................................................................................................................16
17.2 Assembly ........................................................................................................................................16
18. Replacing the electronic unit.......................................................................................... 17
19. Exploded views ...............................................................................................................18
20. Fault finding .................................................................................................................... 19

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1. Symbols used in this document
2. Identification
This section shows the nameplate, type key and the codes that can appear in the variant code.
2.1 Nameplate
The nameplate states the operating data and approvals applying to the pump. It is fixed to the side of the stator
housing opposite to the electronic unit.
The additional nameplate supplied with the pump can be fixed close to the pit.
Fig. 1 Nameplate
* Only explosion-proof pumps.
Warning
If these safety instructions are not observed, it may result in personal injury!
Warning
These instructions must be observed for explosion-proof pumps. It is advisable also to follow
these instructions for standard pumps.
Caution
If these safety instructions are not observed, it may result in malfunction or damage to the
equipment!
Note
Notes or instructions that make the job easier and ensure safe operation.
Note
As codes can be combined, a code position may contain more than one code (one letter).
TM04 4459 1309
Pos. Description Pos. Description
1 Type designation 13 Weight without cable
2 Product number 14 Run capacitor
3 CE mark 15 EN approval
4 ATEX certificate * 16 Ex mark *
5 IEC Ex mark * 17 Maximum installation depth
6 IEC Ex certificate * 18 Maximum flow rate
7 Production code (year and week) 19 Output power
8 Enclosure class to IEC 20 Rated current
9 Maximum head 21 Power factor
10 Rated input power 22 Maximum liquid temperature
11 Number of phases 23 Frequency
12 Rated speed 24 Insulation class
Àß56
Made in Tatabánya, Hungary
Type:
96770195
Model:
P.c. Auto Adapt
IP68
Hmax: m Qmax:
P1: kW
l/s
m
kW
A
P2:
Weight: Tmax: °C
Insul.class:
kg
n: Cos φmin -1
opr.:: μF Hz
~
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

5 /20
2.2 Type key
3. Service tools
3.1 Special tools
Code Example SE G .40 .11 E .Ex .2 .1 5 02
SE Type range Grundfos sewage pumps
GImpeller type Grinder system in the pump inlet
40 Pump outlet Nominal diameter of pump discharge port [mm]
11 Output power, P2 P2 = code number from type designation/10 kW
Blank
E
Equipment in pump
Standard
Electronic version with AUTOADAPT functions
Blank
Ex
Pump version
Non-explosion-proof pump (standard)
Explosion-proof pump
2Number of poles 2 poles, n = 3000 min-1, 50 Hz
1
Blank
Number of phases
Single-phase motor
Three-phase motor
5 Mains frequency 50 Hz
02
0B
Supply voltage and starting method
230 V, direct-on line starting
400-415 V, direct-on-line starting
Blank
A
B
Generation
First generation
Second generation
Third generation, etc.
The pumps belonging to the individual generations differ in design, but are similar in terms of power rating.
Blank Materials in pump Standard materials in pump
ABCD
EFGH
IJKL
Pos. Designation For pos. Description Product
number
APuller 49 M24 x 1.5 SV2097
BSpanner for cable nut 181 95043464

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3.2 Standard tools
* Pos. C is included in the shaft seal kit for 0.9 to 1.5 kW pumps.
3.3 Torque tools
4. Tightening torques, lubricants and oil
4.1 Tightening torques
4.2 Lubricants
4.3 Oil
5. Dismantling and assembly
5.1 Position numbers
Position numbers of pump parts (digits) refer to exploded views, sectional drawings and parts lists; position
numbers of tools (letters) refer to section 3. Service tools.
Pos. Designation For pos. Description Product
number
CTool for shaft seal 172 *
DBit holder D 1/4" SV2011
EBits kit 188a M8 - 6 mm SV2010
FScrewdrivers Straight slot -
GPunch 44, 49 ∅10 -
HRing/open-end spanner 68 24 mm SV0122
IHexagon head driver 188a M8 - 6 mm SV0297
JBearing heater 153, 154 Induction heater -
Pos. Designation For pos. Description Product
number
KTorque wrench J 4-20 Nm SV0292
LRatchet insert tool H 9 x 12 - > 1/2" SV0295
Pos. Designation Dimensions Material Torque [Nm]
161f Screw for capacitor plate M5 x 10 Galvanised steel 3
188a Screw for end cover M10 x 30 A2-70 35
188a Screw for grinder ring M8 x 25 A2-80 16
188a Screw for grinder head M8 x 25 A2-80 20
188a Screw for lifting bracket M8 x 25 A2-80 16
188a Screw for seal ring retainer M8 x 25 A2-80 16
188a Screw for oil chamber M8 x 25 A2-80 16
193 Filling screw M12 x 20 A2-70 16
199 Union nut for cable plug M48 x 1.5 EN 1.4408 30
285b Set screw for dry-running sensor M6 x 18 ISO 898 5
287c Set screw for level sensor M6 x 18 ISO 898 5
Screw for earth lead M5 x 10 Galvanised steel 3
161 Capacitor M8 Galvanised steel 5
Designation Quantity [kg] Type Product number
O-ring grease 1 Rocol Sapphire Aqua-Sil RM2924
Designation Quantity [l] Type Product number
Oil 1 Shell Ondina 917 96001442
Warning
Service and dismantling of electrical parts and replacement of bearings must only be carried
out by Grundfos or an authorised service workshop.

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5.2 Before dismantling
• Disconnect the power supply to the pump.
• Disconnect the power cable in accordance with local regulations.
5.3 Before assembly
• Clean and check all parts.
• Replace defective parts by new parts.
• Order the necessary service kits.
• Always replace gaskets and O-rings when the pump is serviced.
5.4 During assembly
• Lubricate and tighten bolts and nuts according to section 4. Tightening torques, lubricants and oil.
5.5 After assembly
• Test the pump according to test specification No 96076172.
6. Cleaning the pump housing
1. Place the pump upside down in a vice (soft jaws). Tighten on lifting bracket (pos. 190).
2. Loosen clamp (pos. 92) holding pump housing (pos. 50) and stator housing (pos. 55) together.
3. Lift pump housing (pos. 50) off stator housing (pos. 55).
4. Remove clamp (pos. 92).
5. Clean the pump housing and the impeller. Grind the surfaces slightly with emery cloth, if necessary.
6. Fit clamp (pos. 92) loosely on stator housing (pos. 55).
7. Lubricate O-ring (pos. 37). See section 4.2 Lubricants.
8. Carefully lower pump housing (pos. 50) down over grinder head (pos. 45) and impeller (pos. 49). Turn the
pump housing so that it engages with the guide pin. The pump discharge must point in the opposite direction
as the electronic unit.
9. Tighten clamp (pos. 92).
10.Check that the grinder head rotates freely and noiselessly.
7. Grinder system
7.1 Dismantling
Warning
Beware of the sharp edges on the impeller, grinder head and grinder ring.
Warning
Beware of the sharp edges on the impeller, grinder head and grinder ring.
1. Remove bolt (pos. 188a) in one of the pump feet.
2. Loosen grinder ring (pos. 44) by knocking/turning 15
to 20 ° clockwise.
3. Carefully prise grinder ring (pos. 44) out of the pump
housing with a screwdriver.
Make sure that the grinder ring does not get stuck
against the grinder head!
4. Insert punch (pos. G) into the hole in the pump
housing to hold the impeller.
5. Remove bolt (pos. 188a) in the shaft end and lock
ring (pos. 66).
6. Remove grinder head (pos. 45).
TM04 4480 1509

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7.2 Assembly
8. Impeller
Fig. 2 Removing the impeller
8.1 Dismantling
1. Remove the grinder system. See section 7.1 Dismantling.
2. Remove adjusting nut (pos. 68).
3. Fit a puller (pos. A) on the impeller.
4. Loosen the clamp and remove the pump housing.
5. Pull impeller (pos. 49) off the shaft using a puller (pos. A).
6. Remove key (pos. 9a) from the shaft.
7. Clean shaft and key.
1. Fit grinder head (pos. 45). The dogs on the back of
the grinder head must engage with the impeller
holes (pos. 49).
2. Tighten bolt (pos. 188a) in the shaft end. Do not
forget the lock washer.
3. Fit grinder ring (pos. 44).
4. Turn grinder ring (pos. 44) 15 to 20 ° anti-clockwise
until it is tightened.
5. Check that the grinder ring does not touch the
grinder head.
6. Fit and tighten bolt (pos. 188a) in one of the pump
feet. See section 4.1 Tightening torques.
7. Check that the grinder head rotates freely and
noiselessly.
TM04 4481 1509
Warning
Beware of the sharp edges on the impeller.
TM04 6969 1810

9 /20
8.2 Assembly
1. Lubricate key and shaft. See section 4.2 Lubricants.
2. Fit key and impeller. The impeller blades must point away from the stator housing.
3. Fit clamp (pos. 92) loosely on stator housing (pos. 55).
4. Fit adjusting nut (pos. 68) in the impeller.
5. Lubricate O-ring (pos. 37). See section 4.2 Lubricants.
6. Lower pump housing (pos. 50) down over impeller (pos. 49). Turn the pump housing so that it engages with
the guide pin. The pump discharge must point in the opposite direction as the electronic unit.
7. Tighten clamp (pos. 92).
8. Tighten adjusting screw (pos. 68) until impeller (pos. 49) touches the pump housing.
9. Slacken the adjusting nut (pos. 68) by 1/4 turn. The impeller should now be able to rotate freely.
10.Fit the grinder system. See section 7.2 Assembly.
9. Oil
9.1 Oil change
The oil in the oil chamber should be changed at least once a year or after 3000 operating hours. (The number of
operating hours can read by means of a CIU XX2 and an R100 remote control.)
9.2 Draining of oil
1. Remove both oil screws (pos. 193) to allow the oil to drain from the chamber into a container.
2. Lay the pump on the side and turn it to empty the oil chamber.
3. Check the oil for impurities.
4. Clean the pump of spilled oil.
9.3 Oil filling
1. Pour new oil into the oil chamber. See fig. 3. See table below.
Fig. 3 Oil filling
2. Fit and tighten the two oil screws (pos. 193). See section 4.1 Tightening torques.
3. Clean the pump of spilled oil.
Note
If the oil contains more than 20 % of water, the shaft seal may be defective.
If the shaft seal is replaced, the oil must be changed. Check the oil after one week of operation.
Warning
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.
Note
Oil, gaskets and metal parts must be disposed of in accordance with local regulations.
TM04 6970 1810
Pump
[kW] Oil [l] Type
0.9 - 1.5 0.17 Shell Ondina 917
2.6 - 4.0 0.42

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10. Shaft seal
10.1 Dismantling, 0.9 - 1.5 kW
1. Drain the oil. See section 9.2 Draining of oil.
2. Remove the two bolts (pos. 188a) in seal ring retainer (pos. 58) and fit them into the extractor holes.
3. Remove the retainer by means of the two bolts. Cross-tighten the bolts to ensure an even pull.
4. Remove the rotating shaft seal part with two angle screwdrivers. Insert the screwdriver tips behind the shaft
seal.
Fig. 4 Removing the shaft seal, 0.9 - 1.5 kW
5. Check the shaft where the secondary seal touches the shaft. If there signs of wear, replace the shaft.
6. Carefully loosen bush (pos. 103) from the bearing using two screwdrivers with straight slot and pull it off the
shaft using two angle screwdrivers.
10.2 Assembly, 0.9 - 1.5 kW
1. Check and clean the oil chamber.
2. Fit tool (pos. C) on the shaft.
3. Check O-ring (pos. 102) in bush (pos. 103).
4. Lubricate the shaft end and journal. See section 4.2 Lubricants.
5. Fit bush (pos. 103) and press it home with a piece of pipe.
6. Lubricate O-ring (pos. 107) of the shaft seal. See section 4.2 Lubricants.
7. Fit shaft seal (pos. 105a) with tool (pos. C) from the shaft seal kit.
Fig. 5 Fitting the shaft seal
8. Tighten the two bolts (pos. 188a) in seal ring retainer (pos. 58). See section 4.1 Tightening torques.
9. Fit key and impeller (see section 8.2), grinder head (see section 7.2) and fill the oil chamber with oil (see
section 9.3).
10.Check that the grinder head rotates freely and noiselessly.
TM04 6971 1810TM04 6972 1810