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Grindex 8151 Bravo 700 Service And Repair Instructions
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Grindex 8151 Bravo 700 Service And Repair Instructions

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Service and Repair Instructions
8151 Bravo 700, 8152 Bravo 800

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Summary of Contents for Grindex 8151 Bravo 700

  • Page 1 Service and Repair Instructions 8151 Bravo 700, 8152 Bravo 800...
  • Page 3 4.6.1 Inspection................31 4.6.2 Overhaul..................32 4.6.3 Service in case of alarm............. 32 4.7 Change the coolant................. 33 4.7.1 Empty the coolant..............33 4.7.2 Fill with coolant.................35 4.8 Disassemble the pump..............36 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 4 5.5 The pump runs but the motor protection trips........71 5.6 The pump delivers too little or no water..........72 6 Technical Reference......................74 6.1 Application limits................74 6.2 Motor data..................74 6.3 Tools.....................75 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 5 This includes any modification to the equipment or use of parts not provided by Grindex. If there is a question regarding the intended use of the equipment, please contact a Grindex representative before proceeding.
  • Page 6 • Any maintenance for Ex-approved products must conform to international and national standards (for example, IEC/EN 60079-17). Grindex disclaims all responsibility for work done by untrained and unauthorized personnel. Product and product handling requirements These are the product and product handling requirements for Ex-approved...
  • Page 7 Guidelines for compliance Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of a Grindex representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/EN 60079–...
  • Page 8 Emissions and waste disposal Observe the local regulations and codes regarding: • Reporting of emissions to the appropriate authorities • Sorting, recycling and disposal of solid or liquid waste • Clean-up of spills 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 9 1 Introduction and Safety Exceptional sites CAUTION: Radiation Hazard Do NOT send the product to Grindex if it has been exposed to nuclear radiation, unless Grindex has been informed and appropriate actions have been agreed upon. 1.7 End of life product disposal Handle and dispose of all waste in compliance with local laws and regulations.
  • Page 10 • Modifications to the unit or installation should only be carried out after consulting with Grindex. • Original spare parts and accessories authorized by Grindex are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation.
  • Page 11 The impeller is a shrouded three-channel H-impeller. Mechanical seals One inner and one outer seal in a combination of materials: • Tungsten carbide • Silicon carbide RSiC • Aluminium oxide Al • Corrosion-resistant cemented carbide WCCR 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 12 Thermistor Thermistors are optional sensors for measuring the temperature. They are connected in series in the stator and activate the alarm at overtemperature. Thermistors are not applicable to Ex-approved pumps. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 13 16.Direction of the impeller rotation 17.Maximum head 18.Serial number The first two characters describe the production year. 19.Rated voltage 20.Pump model This is the data plate for non explosion-proof version .020: WS011380B 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 14 I M2 Ex db h I Mb • IECEx scheme • IEC 60079-0:2011, IEC 60079-1:2014; IEC 80079-36:2016; IEC 80079-37:2016 • Ex db h IIB T3 Gb • Ex db h l Mb 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 15 15.Country of origin FM approval plate This illustration describes the FM approval plate and the information that is contained in its fields. 1. Temperature class 2. Maximum ambient temperature WS003973A 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 16 Prevent cables from becoming sharply bent or damaged. NOTICE: Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the cable ends dry at all times. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 17 (VFD- supplier). ® • For SUBCAB cables, the twisted pair copper foil must be trimmed. • All unused conductors must be insulated. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 18 Peel the insulation jacket or plastic jacket. b) Peel the aluminum and textile layers. The aluminum foil is a conductive screen. Do not peel more than necessary, and remove the peeled foil. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 19 3.2.4 Connect the motor cable to the pump NOTICE: Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the end of the motor cable dry at all times. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 20 If the product is rated explosion- proof or intrinsically-safe, then see the specific explosion-proof information in the safety chapter before taking any further actions. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 21 T1 T2 Figure 4: Phase sequence Connection locations The figures in this section illustrate how to interpret the connection strip symbols. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 22 8. CLS 9. Thermistor 10.Level sensor 11.Capacitor 12.Crimp connection 13.Crimp isolation 14.Current transformer FLS 10 Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Grey Blue Yellow 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 23 GN/YE GN/YE is stranded around core from cores GC=Ground check Screen (WH) Screen (WH) Screen (WH) 51 680 01 Terminal clamps 6 stator leads U1 W2 V1 U2 W1 V2 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 24 U1 W2 W1 V2 One cable Two cables U1W2 V1 U2 W1V2 Two cables One cable L2:1 L3:1 L1:1 L2:2 L3:2 L1:2 Figure 5: One cable (left) and two cables (right) 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 25 Screened SUBCAB & FGB Screened Cable without sep. ground conductor Screen as ground conductor GN/YE shrink hose FGB Screened Mini CAS Mini CAS+AUX Figure 7: Screened SUBCAB and FGB screened 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 26 WH/YE WH/YE Mini Mini T1/*OG/1 T1/*OG/1 T2/*BU/2 T2/*BU/2 WH/YE WH/YE **T3 **T3 **T4 **T4 *SUBCAB AWG *SUBCAB AWG *Screened SUBCAB *Screened SUBCAB ∞ Ohm Overtemperature 1200 Ohm 430 Ohm Leakage 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 27 The correct direction of impeller rotation is clockwise when you look at the pump from above. 4. If the impeller rotates in the wrong direction, then transpose two phase leads (3-phase) and do this procedure again. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 28 During the maintenance and before reassembly, always remember to perform these tasks: • Clean all parts thoroughly, particularly O-ring grooves. • Change all O-rings, gaskets, and seal washers. • Lubricate all springs, screws, O-rings with grease. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 29 If a disassembled product has to await ordered spare parts, then all parts have to be carefully lubricated and covered. Store all parts separately to ensure that no damage occurs. 4.4 The fault-tracing process 4.4.1 Trace faults in the drive 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 30 3. Use the following flowchart to determine the action needed. Insulation test New stator, and → Yes → → → –R : 1 or more value is 0 MΩ ↓ 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 31 If there is a question regarding the tightening torques, then contact a sales or authorized service representative. Screws and nuts Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs) (0.74) (1.5) (2.2) (5.9) (11) (20) (48) (93.7) (162) (320) 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 32 Grindex operation. service representative and, based on the result and findings from these measures, to determine the intervals for periodical inspection and overhaul for the specific installation. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 33 2. Conduct a phase-to-phase resistance check. Junction box Check that it is clean and dry. Level regulators Check the condition and functionality. Lifting device Check that the local safety regulations are followed. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 34 1. Drain the fluid. 2. Change the mechanical seal unit. 3. Replace with new coolant. The thermistor/Thermal 1. Check the coolant level. contact 2. Check the start and stop levels. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 35 1. Empty the coolant in the inspection chamber: a) Remove the inspection plug. Figure 11: With a cooling jacket Figure 12: Without a cooling jacket b) Pump out any coolant from the inspection chamber, as shown here. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 36 After venting any built-up pressure in the cooling jacket, re-install the coolant plugs. c) Remove the pump housing screws. d) Remove the drive unit from the pump housing. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 37 DOWCAL 200 monopropylene glycol. If DOWCAL 200 from Dow Chemical Company is not available, then contact your local Grindex representative. The monopropylene glycol must fulfill the Grindex material standard M0800.82.0002. NOTICE: Deionized or distilled water must be used in the water-glycol mixture.
  • Page 38 44 Remove the main bearing from the bearing holder on page 46 Remove the support bearing on page 48 4.8.1 Remove the entrance cover 1. Remove the entrance cover screws. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 39 Remove the coolant filling plugs. b) Screw two M16 screws into the coolant filler holes of the cooling jacket. The screws needs to be about 50 mm (2 in.) long. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 40 Remove the screws and washers or the four wire bows that hold the inner cooling jacket in place. If the cooling jacket is mounted with wire bows, use a screwdriver to bend them loose. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 41 62. 4.8.3 Remove the mechanical seal 1. Fit the lifting equipment: a) Bolt the assembly/dismantling stand in position. Secure it using the screws for the entrance cover. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 42 Screw a lifting eyebolt into the shaft end. WS001506A 2. Place the drive unit upside down on the stand. 3. Remove the seal housing cover: a) Remove the screws that hold the seal housing cover in place. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 43 WS001951A b) Fit two lifting eye bolts to the seal housing cover and remove it. 4. Remove the circlip. Figure 21: With cooling jacket 5. Remove the mechanical seal unit. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 44 Only pumps that are equipped with cooling jacket have a flow diffuser. WS002127A 2. Remove the screws for the adapter. WS002108A 3. Fit two lifting eyebolts to the adapter and remove it. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 45 4.8.5 Disconnect the FLS10 1. Screw the lifting eyebolt into the shaft end. 2. Carefully lift out the shaft unit. 3. Disconnect the sockets. WS001481A 4. Lower the shaft unit back into position. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 46 To remove the bearings, you need the disassembly tool (Bearing puller). For more information about the tool, see Technical Reference on page 74. 4.8.7.1 Remove the bearing holder 1. Bolt the ring onto the bearing holder. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 47 4 Maintenance WS001935A 2. Assemble the disassembling tool. 3. Connect the hydraulic hose to the hydraulic unit. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 48 4.8.7.2 Remove the main bearing from the bearing holder 1. Dismantle the hydraulic unit and let the rest of the tool still be assembled. WS002049A 2. Add the sleeve from the disassembling tool. 3. Assemble the disassembling tool. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 49 4 Maintenance 4. Connect the hydraulic hose to the hydraulic unit and press out the bearing. 5. Dismantle the tool and remove the bearing. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 50 To install the bearings, you need the assembly tool. For more information, see Tools on page 75. 4.9.1.1 Install the support bearing 1. Put the support washer in the bearing seat in the stator housing. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 51 Put the rotor-and-shaft unit into the stator housing. WS001541A 4.9.1.2 Install the main bearing in the bearing holder 1. Place the support washer in the bearing holder. 2. Assemble the assembly tool. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 52 5. Connect the hydraulic hose to the hydraulic cylinder. 6. Mount the bearing into the bearing holder. WS002019A 4.9.1.3 Install the bearing holder 1. Oil the rotor shaft. 2. Place the bearing holder on the shaft. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 53 4 Maintenance WS002135A 3. Assemble the assembly tool according to the drawing. 4. Connect the hydraulic hose to the hydraulic cylinder. WS002020A 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 54 1. Fit the outer washer. WS002112A 2. Fit the inner washer. 3. Fit the inner circlip. WS002125A 4. Place and turn the outer circlip with the phased edge facing upwards. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 55 1. Screw the lifting eyebolt into the shaft end. 2. Carefully lift the rotor-and-shaft unit with the bearing holder. 3. Grease the surface of the bearing holder. 4. Connect the sockets for the FLS10. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 56 6. Check that the sockets are between the coil end and the stator housing. 4.9.4 Install the adapter 1. Grease the spring and fit it in position. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 57 5. Fit the screws. Tighten the screws diametrically. 6. Place the flow diffuser in position and press it down until it bottoms out (only for pumps that are equipped with cooling jacket). 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 58 2. Fit a new and lubricated mechanical seal unit. Check that the drive pin in the shaft engages in the drive groove in the seal unit. WS002128A 3. Push down the mechanical seal unit. 4. Fit the circlip. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 59 5. Use a suitable sleeve to press down the circlip and make sure that the circlip is in position. WS002131A 6. Fit new greased O-rings to the seal housing cover 7. Fit the seal housing cover. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 60 1. Apply a negative differential pressure of about 0.5–0.7 bar (0.5–0.3 bar absolute pressure) in the empty seal housing. 2. After applying the correct pressure, close the evacuation line using a valve. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 61 1. If the pump does not stand, then raise the pump. 2. Remove the stand. 3. Fit a new and greased O-ring to the inner cooling jacket. 4. Fit the inner cooling jacket. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 62 Figure 23: Mounted with screws – Press the wire bows in position as shown in the illustration. WS001944A Figure 24: Mounted with wire bows 6. Fit a new and greased O-ring to the adapter. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 63 4.9.8 Install the entrance cover 1. Fit a new and greased O-ring between the stator housing and outer cooling jacket. WS001511A 2. Fit a new and greased O-ring to the entrance cover. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 64 3. Connect the motor cable leads according to the wiring diagram on the inside of the entrance cover. 4. Install the entrance cover. Tighten the screws diagonally. 4.10 Replace the hydraulic parts 4.10.1 Replace the impeller Required tools: 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 65 Remove the chain from the impeller and pump housing. b) Raise the pump. c) Remove the pump housing screws. d) Remove the drive unit from the pump housing. e) Remove the O-rings. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 66 Prevent the wearing cover from falling off when removing the impeller by attaching a round sling. WS002418A 5. Remove the impeller: a) Remove the impeller screw. b) Remove the impeller and the conical sleeve. WS002431A c) Remove the wearing cover. WS002411A 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 67 Fit the washer and impeller screw onto the shaft. f) Hand-tighten the impeller screw to prevent it from falling off. g) Remove the sling and fit new O-rings to the wearing cover. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 68 Remove the chain from the impeller and pump housing. 7. Check that the impeller can rotate freely. The clearance between the impeller and the pump housing should be 0.4 – 1.3 mm (0.015–0.05 in.). 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 69 This causes the head of the propeller screw to press the propeller outward. 6. Remove the strainer, if any. 7. Remove the propeller shaft. 8. Remove the impeller screw, the barrel nut, and the parallel key. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 70 Tightening torque: For tightening torque, see Torque values on page 29. 6. Fit the wear/protective plug into the propeller. 7. Check that the impeller can rotate freely. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 71 • All connections are intact. • The relay and contactor coils are intact. • The control switch (Man/Auto) makes contact in both positions. Check the control circuit and functions. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 72 • Check the contactor and the control circuit. • Replace all defective items. The stop level is set too Raise the stop level. low. If the problem persists, then contact a sales or authorized service representative. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 73 The drive unit is not • Check the fuses. Replace fuses that have tripped. receiving full voltage on • If the fuses are intact, then notify a certified all three phases. electrician. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 74 • Replace the valves, if necessary. • Check that all valves are correctly installed according to media flow. • Check that all valves open correctly. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 75 If the problem persists, then contact a sales or authorized service representative. Always state the product number and the serial number of the pump, see Product Description on page 8. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 76 ±10%, if it does not run continuously at full load without overheating Voltage imbalance tolerance Stator insulation H (180°C [356°F]) class Motor encapsulation Motor encapsulation is in accordance with IP68. 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 77 Figure 25: Disassembly (left) and assembly (right) of the bearing from the rotor shaft Position Part number Denomination 13 22 56 Hexagon nut 41 09 23 Tension pin 518 21 03 Stud 518 21 00 518 21 13 Sleeve 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 78 518 21 08 Hexagon head screw 518 21 04 Bearing holder 511 31 00 Cross piece 41 09 24 Plain washer 41 03 82 Hydraulic nut 518 21 05 Stud 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 79 13 22 56 Hexagon nut 41 09 23 Tension pin 518 21 05 Stud 41 03 82 Hydraulic unit 518 21 04 Washer 518 21 15 Plate 518 21 14 Cross piece 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 80 Hexagon socket head screw 518 21 02 Stud 518 21 08 Hexagon head screw 518 21 01 Washer 511 31 00 Cross piece 41 09 24 Plain washer 518 21 00 8151 Bravo 700, 8152 Bravo 800 Service and Repair Instructions...
  • Page 84 Services AB 361 80 Emmaboda The original instruction is in English. All non-English www.grindex.com instructions are translations of the original instruction. Sweden Tel: +46-471-24 70 00 © 2014 Grindex Fax: +46-471-24 74 01 http://tpi.xyleminc.com 885177_5.0_en-US_2020-08_SR_8151 Bravo 700, 8152 Bravo 800...

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8152 bravo 800