Grindex 8109.282 Salvador Installation, Operation And Maintenance Manual
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Summary of Contents for Grindex 8109.282 Salvador
- Page 1 Revision 2.0 Installation, Operation, and Maintenance Manual 8109.282/.583 Salvador...
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Page 3: Table Of Contents
Table of Contents Table of Contents Introduction and Safety......................3 Introduction................... 3 Safety terminology and symbols............... 3 Product warranty..................4 Safety....................5 User safety.................... 5 Environmental safety................7 Transportation and Storage....................8 Inspect the delivery................8 Inspect the package................8 Inspect the unit................... 8 Transportation guidelines................. - Page 4 Table of Contents The pump does not start................ 38 The pump does not stop when a level sensor is used......... 39 The pump starts-stops-starts in rapid sequence........40 The pump runs but the motor protection trips........... 40 The pump delivers too little or no water........... 41 Technical Reference......................
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Page 5: Introduction And Safety
Introduction and Safety Introduction and Safety Introduction Purpose of this manual The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance CAUTION: Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty. -
Page 6: Product Warranty
• The product is used only under the conditions described in this manual. • The monitoring equipment incorporated in the product is correctly connected and in use. • All service and repair work is done by personnel authorized by Grindex. • Genuine Grindex parts are used. Limitations The warranty does not cover faults caused by the following: •... -
Page 7: Safety
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 an Grindex representative before proceeding. - Page 8 Introduction and Safety Electrical connections Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections. Hazardous liquids The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product: •...
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Page 9: Environmental Safety
1. Follow local laws and regulations regarding recycling if the unit or parts are accepted by an authorized recycling company. 2. If the first guideline is not applicable, then return the unit or parts to the nearest Grindex representative. 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual... -
Page 10: Transportation And Storage
Transportation and Storage Transportation and Storage Inspect the delivery Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor. -
Page 11: Temperature Ranges For Transportation, Handling And Storage
Transportation and Storage Temperature ranges for transportation, handling and storage Handling at freezing temperature At temperatures below freezing, the product and all installation equipment, including the lifting gear, must be handled with extreme care. Make sure that the product is warmed up to a temperature above the freezing point before starting up. -
Page 12: Product Description
Always follow the limits given in Application limits (page 43). If there is a question regarding the intended use of the equipment, please contact a Grindex representative before proceeding. WARNING: In explosive or flammable environments, only use Ex- or MSHA-approved products. -
Page 13: The Data Plate
Product Description • The level regulator can be set at different operating levels by adjusting the length of cable. • A clamping bracket situated at the lifting handle holds the level regulator cable in place. • If continuous pumping is required, the level regulator can be placed in a special rubber bracket on the discharge connection to eliminate the level regulator function. - Page 14 Product Description 11. Degree of protection 12. Maximum capacity 13. Rated current 14. Direction of the start reaction 15. Direction of the impeller rotation 16. Maximum head 17. Serial number 18. Rated voltage 19. Pump model Warning plate Pumps without built-in motor protection have an additional data plate. This pump must be used with separate overload protection in accordance with technical data.
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Page 15: Installation
Installation Installation Install the pump DANGER: Disconnect and lock out electrical power before installing or servicing the unit. WARNING: • Do not install the starter equipment in an explosive zone unless it is explosion-proof rated. • Do not install CSA-approved products in locations that are classified as hazardous in the national electric code, ANSI/NFPA 70-2005. -
Page 16: Install
Installation Figure 2: Settling pump-sump Discharge line requirements The discharge line can be run vertically or horizontally, but must be without sharp bends. Proper horizontal and vertical installation Improper installation with a sharp bend Fasteners WARNING: • Only use fasteners of the proper size and material. •... -
Page 17: Make The Electrical Connections
Installation Heavier pumps must be lifted and lowered down by crane. Suspend the pump by the lifting handle or the eyebolts with chains or wires. 4. Place the pump on the base and make sure it cannot fall over or sink. The base should consist of a plank, a bed of coarse gravel, or a cut-down and perforated oil drum. - Page 18 If the outer sheath of the cable is damaged, then replace the cable. Contact a Grindex service shop. • The voltage drop in long cables must be taken into account. The drive unit’s rated voltage is the voltage measured at the cable connection point in the pump.
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Page 19: Product-Specific Precautions
Installation Product-specific precautions Electrical Hazard: This information is valid only for standard version products: For a pump with a level regulator and a cable with earth (ground) check: Make sure that the earth (ground) check connection is done at the GC-connection point with a cable lug and one screw. - Page 20 Installation Starter equipment and main Coil leads (L1, L2, L3) Earth (ground) Transformer Functional ground Capacitor Control leads (T1, T2, T3, T4) Softstarter Phase shifter Level regulator Diode Contactor, start relay or thermal relay Motor cable Thermal detector in stator Screen Thermal detector in main bearing Pump...
- Page 21 Installation Stator leads and thermal contacts connection to the terminal plate Terminal plate 8101.160 8101.172 8102.172 8109.282 51 671 00 STATOR LEADS AND THERMAL CONTACTS 1-PHASE STATOR LEADS 1-ph U1,Z5 serial Terminal 4 leads 8 leads 8 leads plate Terminal plate U2, Z6 W / A Z2 Z6...
- Page 22 Installation Motor cable and starter unit connection to the terminal plate SYMBOLS AND DENOMINATIONS Terminal plate BN=Brown =Terminal plate BK=Black =Screen WH=White 8101.160 =Ground OG=Orange =Functional ground 8101.172 GN=Green GNYE=Green-Yellow =Crimp isolation for 8102.172 RD=Red cable, if not in use 8109.282 GY=Grey =Socket - Plug...
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Page 23: Cable Charts, Msha Version
Installation Cable charts, MSHA version Motor 60 Hz, 1-phase, 115V parallel and 230V serial WS004860A Motor 60 Hz, 1-phase, 115V or 220-240V WS004861A Check the impeller rotation: Pumps without built-in motor protection ™ Follow this procedure if your product does not have the rotation control SMART WARNING: The starting jerk can be powerful. -
Page 24: Check The Phase Sequence: Pumps With Built-In Motor Protection
Installation Figure 3: Start reaction 4. If the impeller rotates in the wrong direction, then do the following: • If the motor has a 1-phase connection, then contact the local sales and service representative. • If the motor has a 3-phase connection, then transpose two phase conductors and repeat this procedure from step 1. - Page 25 Installation Figure 4: Start reaction 1. Connect the pump to power as follows: Condition Action The pump has a CEE plug with Connect the plug. internal phase shifter. The pump has a phase shifter with an Turn the knob on the phase shifter in on/off switch.
- Page 26 Installation Condition Action The pump has a CEE plug with 1. Pull out the plug. internal phase shifter. 2. Shift two phases. 3. Wait until the motor has stopped. 4. Connect the plug. The pump has a phase shifter with an 1.
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Page 27: Operation
Operation Operation Precautions WARNING: • Never operate the pump without safety devices installed. • Never operate the pump with the discharge line blocked, or the discharge valve closed. • Make sure you have a clear path of retreat. • Never work alone. CAUTION: If the pump is equipped with automatic level control and/or internal contactor, there is a risk of sudden restart. -
Page 28: Clean The Pump
Operation WARNING: • Make sure that the unit cannot roll or fall over and injure people or damage property. • In some installations, the pump and the surrounding liquid may be hot. Bear in mind the risk of burn injuries. •... -
Page 29: Maintenance
Maintenance Maintenance Precautions DANGER: Disconnect and lock out electrical power before installing or servicing the unit. WARNING: • Always follow safety guidelines when working on the product. See Introduction and Safety (page 3). • Make sure that the unit cannot roll or fall over and injure people or damage property. -
Page 30: Torque Values
Maintenance Figure 5: Example of O-ring adjacent surfaces During the reassembly, always make sure that existing index markings are in line. The reassembled drive unit must always be insulation-tested and the reassembled pump must always be test-run before normal operation. Torque values All screws and nuts must be lubricated to achieve correct tightening torque. -
Page 31: Service
Maintenance Propert y class 12.9 17 (13) 40 (30) 79 (58) 136 1120 2210 (3.6) (7.2) (100) (245) (480) (825.1) (1630) Hexagon screws with countersunk heads For hexagon socket head screws with countersunk head, maximum torque for all property classes must be 80% of the values for property class 8.8 above. Service Regular inspection and service of the pump ensures more reliable operation. - Page 32 Maintenance Service item Action Check the oil: 1. Take an oil sample. 2. If the oil contains particles, then replace the mechanical seal. Contact an authorized service shop. Make sure that the volume is filled to the correct level. See Fill with oil (page 32).
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Page 33: Major Overhaul
Maintenance Major overhaul For a major overhaul, take this action in addition to the tasks listed under Inspection. Service item Action Support and main Replace the bearings with new bearings. bearing Mechanical seal Replace with new seal units. Change the oil A paraffin oil with viscosity close to ISO VG32 is recommended. -
Page 34: Replace The Impeller
Maintenance Fill with oil 1. Replace the oil screw O-ring. 2. Turn the pump so that the oil hole faces upwards and fill with new oil. Fill until the oil level reaches the inlet hole. Quantity: 0.44 L (0.46 qt) 3. - Page 35 Maintenance 2. Loosen the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Remove the impeller screw and washer. 3. Remove the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft.
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Page 36: Install The Impeller
Maintenance c) Pull off the impeller. Install the impeller 1. Prepare the shaft: a) Polish off any flaws with a fine emery cloth. The end of the shaft must be clean and free from burrs. b) Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical sleeve with a thin layer of grease. - Page 37 Maintenance 3. Grease the threads of the screw and the washer. The proper lubrication of the screw and washer is lubricating grease for assembly of bolts etc., for example, Kluber ALTEMP Q NB 50 or equivalent. 4. Check that the impeller screw is clean and easy to screw into the shaft end. This is to prevent the shaft from rotating with the impeller screw.
- Page 38 Maintenance 8. Mount the O-ring, the pump housing, and stand. 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual...
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Page 39: Troubleshooting
Troubleshooting Troubleshooting Introduction DANGER: Personal injury hazard. Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician. Failure to follow these instructions will result in serious personal injury, death, and/or property damage. Follow these guidelines when troubleshooting the pump: •... -
Page 40: The Pump Does Not Start, For Pumps With Smart
• If no glove or phase shifter is used, then shift two phase conductors in the cabinet. If the problem persists, contact the local Grindex service shop. Always state the product number and the serial number of your pump when you contact Grindex, Product Description (page 10). -
Page 41: The Pump Does Not Stop When A Level Sensor Is Used
• The sump in order to prevent the impeller from clogging again. If the problem persists, contact the local Grindex service shop. Always state the product number and the serial number of your pump when you contact Grindex, Product Description (page 10). -
Page 42: The Pump Starts-Stops-Starts In Rapid Sequence
The stop level is set too Raise the stop level. low. If the problem persists, contact the local Grindex service shop. Always state the product number and the serial number of your pump when you contact Grindex, Product Description (page 10). -
Page 43: The Pump Delivers Too Little Or No Water
The pump will restart automatically after a corrected phase fault or power cut. If the problem persists, contact the local Grindex service shop. Always state the product number and the serial number of your pump when you contact Grindex, Product Description (page 10). - Page 44 • Depending on the installation type, add a means for priming the pump, such as a foot valve. If the problem persists, contact the local Grindex service shop. Always state the product number and the serial number of your pump when you contact Grindex, Product Description (page 10).
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Page 45: Technical Reference
For specific weight, current, voltage, power rating, and speed of the pump, see the data plate on the pump. For starting current, see Motor data (page 43). For other applications, contact the nearest Grindex representative for information. Motor data Feature Description... - Page 46 Technical Reference 1-phase, 50 Hz Motor type: • 2,830 rpm • Rated output 1.5 kW (2.0 hp) • Maximum power consumption 1.9 kW (2.5 hp) Voltage, V Rated current, A Starting current, Power factor, cos φ 0.99 0.98 0.96 3-phase, 50 Hz Motor type: •...
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Page 47: Specific Motor Data, Msha Version
Technical Reference Voltage, V Rated current, A Starting current, Power factor, cos φ 200 Y 11.0 0.88 208 Y 10.0 0.84 220 D 0.85 220 D parallel 220 Y parallel 0.88 230 D 10.0 0.79 230 D parallel 0.87 230 Y parallel 0.83 240 D 0.78... -
Page 48: Dimensions And Weights
Technical Reference • 3,300 rpm • Rated output 2.6 kW (3.5 hp) • Maximum power consumption 3.1 kW Voltage, V Rated current, A Starting current, Power factor, cos φ 460 Y 480 Y 0.86 575 Y 600 Y 0.88 Dimensions and weights All measurements in the illustration are in millimeters, if not otherwise specified. -
Page 49: Performance Curves
Technical Reference Figure 10: MSHA version Performance curves Test standard Pumps are tested in accordance with ISO 9906:2012, HI 11.6:2012. 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual... - Page 50 Technical Reference Standard pump version [hp] / [kW] [hp] / [kW] H [ft] / [m] H [ft] / [m] Q [l/s] / [usgpm] Q [l/s] / [usgpm] Figure 11: 50 Hz, 1- and 3-phase Figure 12: 60 Hz, 1- and 3-phase MSHA pump version [hp] / [kW] H [ft] / [m]...
- Page 52 Visit our Web site for the latest version of this document and more information Gesällvägen 33 174 87 Sundbyberg The original instruction is in English. All non-English www.grindex.com instructions are translations of the original instruction. Sweden Tel: +46-8-606 66 00 © 2012 Grindex Fax: +46-8-745 53 28 www.grindex.com 883983_2.0_en-US_2013-04_IOM_8109.282/.583...
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