Grundfos seg autoadapt User manual

SEG AUTOADAPT
0.9 - 4.0 kW
50 Hz
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
Installation and operating instructions
SEG AUTOADAPT
http://net.grundfos.com/qr/i/97525813

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions
describe Grundfos SEG AUTOADAPT pumps.
Sections 1-5 give the information necessary to be
able to unpack, install and start up the product in a
safe way.
Sections 6-11 give important information about the
product, as well as information on service, fault
finding and disposal of the product.
CONTENTS
Page
1. General information 3
1.1 Hazard statements 3
1.2 Notes 3
1.3 Target groups 3
2. Receiving the product 3
2.1 Transporting the product 3
3. Installing the product 4
3.1 Mechanical installation 4
3.2 Electrical connection 8
4. Starting up the product 10
4.1 Operating modes 11
4.2 Preparations for starting up 11
4.3 Start and stop levels 12
4.4 Direction of rotation 13
4.5 Startup 13
4.6 Resetting the pump 13
5. Handling and storing the product 13
5.1 Handling the product 13
5.2 Storing the product 13
6. Product introduction 14
6.1 Product description 14
6.2 Applications 14
6.3 Pumped liquids 14
6.4 Potentially explosive environments 14
6.5 Approvals 15
6.6 Identification 16
7. Protection and control functions 17
7.1 Built-in protection 17
7.2 Thermal switches 17
8. Servicing and maintaining the product 17
8.1 Safety instruction and requirements 17
8.2 Contaminated pumps 18
8.3 Maintenance schedule 19
8.4 Oil check and oil change 19
8.5 Cleaning the sensors 20
8.6 Adjusting the impeller clearance 21
8.7 Replacing the grinder system 21
8.8 Cleaning the pump housing 22
8.9 Checking or replacing the shaft seal 22
8.10 Service kits 23
9. Fault finding 25
9.1 Megging 25
10. Technical data 26
10.1 Operating conditions 26
10.2 Electrical data 26
10.3 Dimensions and weights 26
11. Disposing of the product 26
Read this document before installing the
product. Installation and operation must
comply with local regulations and accepted
codes of good practice.
This appliance can be used by children
aged from 8 years and above and persons
with reduced physical, sensory or mental
capabilities or lack of experience and
knowledge if they have been given
supervision or instruction concerning use
of the appliance in a safe way and
understand the hazards involved.
Children shall not play with the appliance.
Cleaning and user maintenance shall not
be made by children without supervision.

English (GB)
3
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 hazard statements are 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.
1.3 Target groups
These installation and operating instructions are
intended for professional installers.
2. Receiving the product
The pump may be transported and stored in a
vertical or horizontal position. Make sure that the
pump cannot roll or fall over.
Check that the protective cap for the level sensor
has not been damaged during transportation. See
pos. 7 in fig. 10. If the protective cap is defective,
contact your nearest Grundfos company.
2.1 Transporting the product
All lifting equipment must be rated for the purpose
and checked for damage before any attempts to lift
the pump. The lifting equipment rating must under no
circumstances be exceeded. The pump weight is
stated on the pump nameplate.
The polyurethane-embedded plug prevents water
from penetrating into the motor via the power cable.
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.
WARNING
Crushing hazard
Death or serious personal injury
- Do not stack pump packages or pallets
on top of each other when lifting or
moving them.
- Always lift the pump by its lifting bracket
or by means of a forklift truck if the
pump is fixed on a pallet. Never lift the
pump by means of the power cable,
hose or pipe.
CAUTION
Sharp element
Minor or moderate personal injury
- Make sure not to cut your hands on the
sharp edges when opening the pump
package.
We recommend that you keep the cable
end protectors in storage for later use.

English (GB)
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3. Installing the product
For safety reasons, all work in pits must be
supervised by a person outside the pit.
Carelessness during lifting or transportation may
cause injury to persons or damage to the pump.
3.1 Mechanical installation
Fit the extra nameplate supplied with the pump at the
installation site or keep it in the cover of this booklet.
Observe all safety regulations at the installation site,
for instance the use of blowers for fresh-air supply to
the pit.
Check the oil level in the oil chamber before
installing the pump. See section 8.4 Oil check and oil
change.
Pump installation in pits must be carried
out by specially trained persons.
Work in or near pits must be carried out
according to local regulations.
Persons must not enter the installation
area when the atmosphere is explosive.
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.
DANGER
Electric shock
Death or serious personal injury
- Make sure there are at least 3 m free
cable above the maximum liquid level.
We recommend that you make all
maintenance and service work when the
pump is placed outside the pit.
DANGER
Crushing hazard
Death or serious personal injury
- Make sure that the lifting bracket is
tightened before attempting to lift the
pump. Tighten if necessary.
Make sure the pit bottom is even before
installing the product.
DANGER
Electric shock
Death or serious personal injury
- Before beginning the installation, switch
off the power supply and lock the main
switch in position 0.
- Switch off any external voltage
connected to the product before working
on it.
CAUTION
Hot surface
Death or serious personal injury
- Make sure that the pump has cooled
down before touching it.
DANGER
Electric shock
Death or serious personal injury
- Before installing the pump and starting it
up for the first time, check the power
cable for visible defects to avoid short
circuits.
CAUTION
Biological hazard
Minor or moderate personal injury
- Flush the pump thoroughly with clean
water and rinse the pump parts in water
after dismantling.
Pits for submersible sewage and
wastewater pumps may contain sewage
or wastewater with toxic and/or disease-
causing substances.
- Wear appropriate personal protective
equipment and clothing.
- Observe the local hygiene regulations in
force.

English (GB)
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The pumps are suitable for different installation types
which are described in sections 3.1.2 Installation on
auto coupling and 3.1.3 Free-standing submerged
installation.
High-flow pumps have a cast DN 50 outlet flange. All
other pumps have a cast DN 40 outlet flange.
3.1.1 Lifting the product
Carelessness during lifting or transportation may
cause injury to persons or damage to the pump.
When lifting the pump, use the right 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. 1.
Fig. 1 Lifting points
The pumps are designed for intermittent
operation. When completely submerged,
the pumps can also operate continuously.
Always use Grundfos accessories to avoid
malfunctions due to incorrect installation.
Only use the lifting bracket for lifting the
pump. Do not use it to hold the pump when
in operation.
CAUTION
Crushing of hands
Minor or moderate personal injury
- Do not put your hands or any tool into
the pump inlet or outlet port after the
pump has been connected to the power
supply, unless the pump has been
switched off by removing the fuses or
switching off the main switch.
- Make sure that the power supply cannot
be accidentally switched on.
Make sure that the liquid entering the pit
through the inlet does not cause water to
be splashed on the sensors of the pump.
CAUTION
Sharp element
Minor or moderate personal injury
- Do not touch the sharp edges of the
impeller, grinder head, and grinder ring
without wearing gloves.
CAUTION
Biological hazard
Minor or moderate personal injury
- Make sure to seal the pump outlet
properly when fitting the outlet pipe,
otherwise water might spray out of the
sealing.
WARNING
Crushing of hands
Death or serious personal injury
- When lifting the pump, make sure your
hand is not caught between the lifting
bracket and the hook.
WARNING
Crushing hazard
Death or serious personal injury
- Make sure that the hook is fixed
properly to the lifting bracket.
- Always lift the pump by its lifting bracket
or by means of a forklift truck if the
pump is fixed on a pallet.
- Never lift the pump by means of the
power cable, hose or pipe.
- Make sure that the lifting bracket is
tightened before attempting to lift the
pump. Tighten if necessary.
TM06 0066 4813

English (GB)
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3.1.2 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.
Both auto-coupling systems facilitate maintenance
and service as the pump can easily be lifted out of
the pit.
We recommend that you use loose flanges to ease
the installation and to avoid pipe tension at flanges
and bolts.
Auto-coupling guide rail system
See fig. 1 in Appendix.
Proceed as follows:
1. Drill mounting holes for the guide rail bracket on
the inside of the pit, and fasten the guide rail
bracket provisionally with two anchor bolts.
2. Place the auto-coupling base unit on the bottom
of the pit. Use a plumb line to establish the
correct positioning. Fasten the auto coupling with
anchor bolts. If the bottom of the pit is uneven,
the auto-coupling base unit must be supported so
that it is level when being fastened.
3. Assemble the outlet line in accordance with the
generally accepted procedures and without
exposing the line to distortion or tension.
4. Insert the guide rails in the auto-coupling base
unit and adjust the length of the rails accurately
to the guide rail bracket at the top of the pit.
5. Unscrew the provisionally fastened guide rail
bracket, fit it on top of the guide rails, and finally
fasten it firmly to the pit wall.
6. Clean out debris from the pit before lowering the
pump into the pit.
7. Fit the guide claw to the pump outlet. Grease the
gasket of the guide claw before lowering the
pump into the pit.
8. Slide the guide claw between the guide rails and
lower the pump into the pit by means of a chain
secured to the lifting bracket of the pump. When
the pump reaches the auto-coupling base unit,
the pump will automatically connect tightly.
9. Hang up the end of the chain on a suitable hook
at the top of the pit and in such a way that the
chain cannot come into contact with the pump
housing.
10. Adjust the length of the power cable by coiling it
up on a relief fitting to ensure that the cable is not
damaged during operation. Fasten the relief
fitting to a suitable hook at the top of the pit.
Make sure that the cable is not sharply bent or
pinched.
11. Connect the power cable and the control cable, if
any.
Before beginning installation procedures,
make sure that the atmosphere in the pit is
not potentially explosive.
Make sure that the pipes are installed
without the use of undue force. No loads
from the weight of the pipes must be
carried by the pump.
Do not use elastic elements or bellows in
the pipes. Never use these elements as a
means to align the pipes.
The guide rails must not have any axial
play as this would cause noise during
pump operation.
When the pump has reached the auto-
coupling base unit, shake the pump by
means of the chain to make sure that it is
placed in the correct position.
The free end of the cable must not be
submerged as water may penetrate
through the cable into the motor.

English (GB)
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Hookup auto-coupling system
See fig. 2 in Appendix.
Proceed as follows:
1. Fit a crossbar in the pit.
2. Fit the stationary part of the auto coupling on top
of the crossbar.
3. Fit the adapted piece of pipe for the movable part
of the hookup auto coupling to the pump outlet.
4. Fasten a shackle and a chain to the movable part
of the hookup auto coupling.
5. Clean out debris from the pit before lowering the
pump.
6. Lower the pump into the pit by means of the
chain secured to the lifting bracket of the pump.
When the movable part of the auto coupling
reaches the stationary part, the two will
automatically connect tightly.
7. Hang up the end of the chain on a suitable hook
at the top of the pit and in such a way that the
chain cannot come into contact with the pump
housing.
8. Adjust the length of the power cable by coiling it
up on a relief fitting to ensure that the cable is not
damaged during operation. Fasten the relief
fitting to a suitable hook at the top of the pit.
Make sure that the cable is not sharply bent or
pinched.
9. Connect the power cable and the control cable, if
any.
3.1.3 Free-standing submerged installation
Pumps for free-standing submerged installation can
stand freely on the bottom of the pit or similar
location. See fig. 3 in Appendix.
The pump must be mounted on separate feet
(accessory).
In order to facilitate service on the pump, fit a flexible
union or coupling to the outlet line for easy
separation.
If a hose is used, make sure that the hose does not
buckle and that the inside diameter of the hose
matches that of the outlet port.
If a rigid pipe is used, fit the union or coupling, non-
return valve and isolating valve in the order
mentioned, when viewed from the pump.
If the pump is installed in muddy conditions or on
uneven ground, we recommend that you support the
pump on bricks or a similar support.
Proceed as follows:
1. Fit a 90 ° elbow to the pump outlet port and
connect the outlet pipe or hose.
2. Lower the pump into the liquid by means of a
chain secured to the lifting bracket of the pump.
We recommend that you place the pump on a
plane, solid foundation. Make sure that the pump
is hanging from the chain and not the power
cable.
3. Hang up the end of the chain on a suitable hook
at the top of the pit and in such a way that the
chain cannot come into contact with the pump
housing.
4. Adjust the length of the power cable by coiling it
up on a relief fitting to ensure that the cable is not
damaged during operation. Fasten the relief
fitting to a suitable hook. Make sure that the
cable is not sharply bent or pinched.
5. Connect the power cable and the control cable, if
any.
When the pump has reached the auto-
coupling base unit, shake the pump by
means of the chain to make sure that it is
placed in the correct position.
The free end of the cable must not be
submerged as water may penetrate
through the cable into the motor.
The free end of the cable must not be
submerged as water may penetrate
through the cable into the motor.
If several pumps are installed in the same
pit, the pumps must be installed at the
same level in order to allow optimum pump
alternation.

English (GB)
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3.2 Electrical connection
Carry out the electrical connection according to local
regulations.
The pump incorporates a motor-protective circuit
breaker and all control logic.
The supply voltage and frequency are marked on the
pump nameplate. For voltage tolerance, see section
10. Technical data. Make sure that the motor is
suitable for the power supply available at the
installation site.
All pumps are supplied with 10 m power cable and a
free cable end.
Do not run the pump via a frequency
converter.
DANGER
Electric shock
Death or serious personal injury
- Connect the pump to an external main
switch which ensures all-pole
disconnection with a contact separation
according to EN 60204-1, 5.3.2.
- It must be possible to lock the main
switch in position 0. Type and
requirements as specified in EN 60204-
1, 5.3.2.
Make sure there are at least 3 m free cable
above the maximum liquid level.
The classification of the installation site
must be approved according to local rules
in each individual case.
The CIU unit, if used, must not be installed
in potentially explosive environments.
On explosion-proof pumps, make sure that
an external earth conductor is connected
to the external earth terminal of the pump
using a conductor with a secure cable
clamp. Clean the surface of the external
earth connection, and fit the cable clamp.
The cross section of the earth conductor
must be at least 4 mm2, e.g. type H07 V2-
K (PVT 90 °) yellow and green.
Make sure that the earth connection is
protected from corrosion.
DANGER
Electric shock
Death or serious personal injury
- If the power cable is damaged, it must
be replaced by the manufacturer, his
service agent or a similarly qualified
person.
Set the motor-protective circuit breaker to
the maximum current of the pump. The
maximum current is stated on the pump
nameplate.
Make sure that the pump is connected in
accordance with the instructions given in
this booklet.
DANGER
Electric shock
Death or serious personal injury
- Before installing the pump and starting it
up for the first time, check the power
cable for visible defects to avoid short
circuits.
A possible replacement of the power cable
must be carried out by Grundfos or a
service workshop authorised by Grundfos.

English (GB)
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3.2.1 Wiring diagrams
Single-phase pumps
The pump has a patented start function which
eliminates the need for a start capacitor. The run
capacitor is incorporated in the pump.
Fig. 2 Wiring diagram for single-phase pumps
Three-phase pumps
The pump motor is designed so that the phase
sequence in the terminal box is clockwise. This can
be determined with a phase sequence detector. The
pump does not start unless the phase sequence is
correct.
If the dry-running sensors are covered by liquid, and
the pump does not start, the cause may be wrong
phase sequence. Interchange L1 and L2.
Fig. 3 Wiring diagram for three-phase pumps
3.2.2 Grundfos CIU
CIU stands for "Communication Interface Unit" and
the CIU is used as a communication interface
between an SEG AUTOADAPT pump and a main data
communication network.
The CIU is optional. See separate installation and
operating instructions supplied with the unit.
3.2.3 Alarm relay or communication connection
The pump incorporates an alarm relay output. NC
and NO are available and can be used as required,
for example for acoustic or visual alarms. Maximum
load of relay is 230 VAC 2 A.
Alternatively, the wires 4 and 6 can be used for
external communication via a CIU.
See example of wiring diagram in the documentation
supplied with CIU.
3.2.4 Supply requirement
The maximum permissible system impedance Zmax
must be 0.24 Ohm at 50 Hz at the interface point of
the user’s supply or the current capacity, which is
100 A per phase, supplied from a distribution
network.
If not, a minor voltage drop may occur, which may
result in a brief flashing of an electric light.
Consult the supply authority, if necessary, to ensure
that the current capacity at the interface point is
sufficient for the equipment.
TM04 4297 1209TM04 4298 1209
If a CIU is connected, do not use a relay.
CIU incorporates a relay which takes over
the alarm function.

English (GB)
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4. Starting up the product
CAUTION
Crushing of hands
Minor or moderate personal injury
- Do not put your hands or any tool into
the pump inlet or outlet port after the
pump has been connected to the power
supply, unless the pump has been
switched off by removing the fuses or
switching off the main switch.
- Make sure that the power supply cannot
be accidentally switched on.
Before starting the product:
- Make sure that the fuses have been
removed.
- Make sure that all protective equipment
has been connected correctly.
CAUTION
Biological hazard
Minor or moderate personal injury
- Make sure to seal the pump outlet
properly when fitting the outlet pipe,
otherwise water might spray out of the
sealing.
WARNING
Crushing of hands
Death or serious personal injury
- When lifting the pump, make sure your
hand is not caught between the lifting
bracket and the hook.
DANGER
Crushing hazard
Death or serious personal injury
- Make sure that the hook is fixed
properly to the lifting bracket.
- Always lift the pump by its lifting bracket
or by means of a forklift truck if the
pump is fixed on a pallet.
- Never lift the pump by means of the
power cable, hose or pipe.
- Make sure that the lifting bracket is
tightened before attempting to lift the
pump. Tighten if necessary.
DANGER
Electric shock
Death or serious personal injury
- Before starting up the product for the
first time, check the power cable for
visible defects to avoid short circuits.
- If the power cable is damaged, it must
be replaced by the manufacturer, his
service agent or a similarly qualified
person.
- Make sure that the product is earthed
properly.
- Switch off the power supply and lock the
main switch in position 0.
- Switch off any external voltage
connected to the product before working
on it.
CAUTION
Biological hazard
Minor or moderate personal injury
- Flush the pump thoroughly with clean
water and rinse the pump parts in water
after dismantling.
Pits for submersible sewage and
wastewater pumps may contain sewage
or wastewater with toxic and/or disease-
causing substances.
- Wear appropriate personal protective
equipment and clothing.
- Observe the local hygiene regulations in
force.
CAUTION
Hot surface
Minor or moderate personal injury
- Do not touch the surface of the pump
while the pump is running.
Do not open the clamp while the pump is
running.