Grindex Bravo 900 8153.190, Bravo 900 8153.020 Installation, Operation And Maintenance Manual

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Revision 8.0

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Installation, Operation, and Maintenance Manual

8153.020/.190 Bravo 900

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Table of Contents

1 Introduction and Safety..................................................................................................... 3

1.1 Introduction.................................................................................... 3

1.2 Safety terminology and symbols.........................................................3

1.3 User safety......................................................................................4

1.4 Ex-approved products....................................................................... 4

1.5 Special hazards................................................................................5

1.6 Protecting the environment................................................................6

1.7 Spare parts..................................................................................... 7

1.8 Warranty.........................................................................................7

2 Transportation and Storage.............................................................................................. 8

2.1 Inspect the delivery..........................................................................8

2.1.1 Inspect the package....................................................................8

2.1.2 Inspect the unit.......................................................................... 8

2.2 Transportation guidelines...................................................................8

2.2.1 Lifting....................................................................................... 8

2.3 Temperature ranges for transportation, handling and storage................. 9

2.4 Storage guidelines............................................................................9

Table of Contents

3 Product Description......................................................................................................... 11

3.1 Products included........................................................................... 11

3.2 Pump design.................................................................................. 11

3.3 Parts.............................................................................................12

3.4 Monitoring equipment..................................................................... 13

3.5 The data plate................................................................................14

3.6 Approvals...................................................................................... 15

4 Installation........................................................................................................................ 17

4.1 Install the pump.............................................................................17

4.2 Make the electrical connections........................................................ 18

4.2.1 Prepare the SUBCAB® cables.......................................................20

4.2.2 Connect the motor cable to the pump.......................................... 21

4.2.3 Connect the motor cable to the starter and monitoring equipment... 22

4.2.4 Cable charts............................................................................. 22

4.2.5 Sensor connection.....................................................................28

4.3 Check the impeller rotation.............................................................. 29

5 Operation.......................................................................................................................... 31

5.1 Precautions....................................................................................31

5.2 Start the pump...............................................................................31

6 Maintenance..................................................................................................................... 33

6.1 Torque values.................................................................................34

6.2 Change the coolant.........................................................................34

6.2.1 Empty the coolant..................................................................... 35

6.2.2 Fill with coolant.........................................................................37

6.3 Replace the impeller....................................................................... 38

6.3.1 Remove the impeller..................................................................39

6.3.2 Install the impeller.................................................................... 41

6.4 Replace the agitator........................................................................43

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Table of Contents

6.4.1 Remove the agitator unit............................................................43

6.4.2 Install the agitator unit.............................................................. 44

6.5 Service the pump........................................................................... 44

6.5.1 Inspection................................................................................45

6.5.2 Major overhaul......................................................................... 46

6.5.3 Service in case of alarm............................................................. 46

7 Troubleshooting...............................................................................................................47

7.1 The pump does not start..................................................................47

7.2 The pump does not stop when a level sensor is used........................... 48

7.3 The pump starts-stops-starts in rapid sequence.................................. 49

7.4 The pump runs but the motor protection trips.....................................49

7.5 The pump delivers too little or no water.............................................50

8 Technical Reference........................................................................................................ 51

8.1 Application limits............................................................................ 51

8.2 Motor data.....................................................................................51

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1 Introduction and Safety

1.1 Introduction

Purpose of the manual

The purpose of this manual is to provide necessary information for working with the unit. Read this manual carefully before starting work.

Read and keep the manual

Save this manual for future reference, and keep it readily available at the location of the unit.

Intended use

WARNING:

Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment and the surroundings. 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.

1 Introduction and Safety

Other manuals

See also the safety requirements and information in the original manufacturer's manuals for any other equipment furnished separately for use in this system.

1.2 Safety terminology and symbols

About safety messages

It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards:

• Personal accidents and health problems

• Damage to the product and its surroundings

• Product malfunction

Hazard levels

Hazard level Indication

DANGER:

WARNING:

A hazardous situation which, if not avoided, will result in death or serious injury

A hazardous situation which, if not avoided, could result in death or serious injury

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 3

CAUTION:

A hazardous situation which, if not avoided, could result in minor or moderate injury

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1 Introduction and Safety

Hazard level Indication

NOTICE:

Special symbols

Some hazard categories have specific symbols, as shown in the following table.

Electrical hazard Magnetic fields hazard

1.3 User safety

All regulations, codes, and health and safety directives must be observed.

The site

• Observe lockout/tagout procedures before starting work on the product, such as transportation, installation, maintenance, or service.

• Pay attention to the risks presented by gas and vapors in the work area.

• Always be aware of the area surrounding the equipment, and any hazards posed by the site or nearby equipment.

Electrical Hazard:

Notices are used when there is a risk of equipment damage or decreased performance, but not personal injury.

CAUTION:

Qualified personnel

This product must be installed, operated, and maintained by qualified personnel only.

Protective equipment and safety devices

• Use personal protective equipment as needed. Examples of personal protective equipment include, but are not limited to, hard hats, safety goggles, protective gloves and shoes, and breathing equipment.

• Make sure that all safety features on the product are functioning and in use at all times when the unit is being operated.

1.4 Ex-approved products

Follow these special handling instructions if you have an Ex-approved unit.

Personnel requirements

These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:

• All work on the product must be carried out by certified electricians and Grindex-authorized mechanics. Special rules apply to installations in explosive atmospheres.

• All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas.

• 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 products in potentially explosive atmospheres:

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1 Introduction and Safety

• Only use the product in accordance with the approved motor data.

• You must fully submerge the Ex-approved product during normal operation. Dry running during service and inspection is only permitted outside the classified area.

• Before you start work on the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized.

• Do not open the product while it is energized or in an explosive gas atmosphere.

• Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product, and that they are in use.

• Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0.

• The yield stress of fasteners must be in accordance with the approval drawing and the product specification.

• Do not modify the equipment without approval from an authorized Grindex representative.

• Only use parts that are provided by an authorized Grindex representative.

• The thermal detectors fitted to the stator windings must be connected into the motor control circuit in such a manner as to disconnect the supply to the motor in order to prevent the Temperature Class T3.

• The width of flameproof joints is more than the values specified in the tables of the IEC 60079–1 standard.

• The gap of flameproof joints is less than the values specified in Table 1 of the IEC 60079–1 standard.

• The equipment must be submerged during normal operation.

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–

14).

Minimum permitted liquid level

See the dimensional drawings of the product for the minimum permitted liquid level according to the approval for explosion proof products. If the information is missing on the dimensional drawing, the product must be fully submerged. Level-sensing equipment must be installed if the product can be operated at less than the minimum submersion depth.

Monitoring equipment

For additional safety, use condition-monitoring devices. Examples of conditionmonitoring devices include, but are not limited to, the following:

• Level indicators

• Temperature detectors in addition to the stator thermal detectors

Any thermal detectors or thermal protection devices delivered with the pump must be installed and in use at all times.

1.5 Special hazards

Working in temporary installations

Certain industries, such as mining or construction, have a dynamic nature and require temporary installation of equipment. Due to the rugged nature of these applications, normal use of electrical equipment causes wear and tear that can

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1 Introduction and Safety

result in insulation breaks, short-circuits, and exposed wires. To maximize safety when using the unit in rugged applications, the following conditions must be met:

• If electrical cables must be located such that they are at risk of being run over by heavy equipment, then provide mechanical protection to prevent physical damage to the cables.

• Visually inspect electrical equipment before use. Remove from service any equipment with exposed wires or visible damage.

• Use ground-fault circuit interrupters on all receptacles, or have an assured equipment grounding conductor program.

Biological hazards

The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product:

• Make sure that all personnel who may come into contact with biological hazards are vaccinated against diseases to which they may be exposed.

• Observe strict personal cleanliness.

WARNING: Biological Hazard

Infection risk. Rinse the unit thoroughly with clean water before working on it.

Wash the skin and eyes

Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:

Condition Action

Chemicals or hazardous fluids in eyes

Chemicals or hazardous fluids on skin

1. Hold your eyelids apart forcibly with your fingers.

2. Rinse the eyes with eyewash or running water for

3. Seek medical attention.

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least 1

3. Seek medical attention, if necessary.

1.6 Protecting the environment

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

Exceptional sites

at least 15 minutes.

minute.

CAUTION: Radiation Hazard

Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.

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1.7 Spare parts

CAUTION:

Only use the manufacturer’s original spare parts to replace any worn or faulty components. The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as void the warranty.

1.8 Warranty

For information about warranty, see the sales contract.

1 Introduction and Safety

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2 Transportation and Storage

2.1 Inspect the delivery

2.1.1 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.

2.1.2 Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.

2. Inspect the product to determine if any parts have been damaged or are missing.

3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.

4. Contact the local sales representative if there is any issue.

2.2 Transportation guidelines

Precautions

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

Position and fastening

The unit can be transported either horizontally or vertically. Make sure that the unit is securely fastened during transportation, and cannot roll or fall over.

2.2.1 Lifting

Always inspect the lifting equipment and tackle before starting any work.

WARNING: Crush Hazard

1) Always lift the unit by its designated lifting points. 2) Use suitable lifting

equipment and ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4) Stay clear of cables and suspended loads.

NOTICE:

Never lift the unit by its cables or hose.

Lifting equipment

Lifting equipment is always required when handling the unit. It must fulfill the following requirements:

• The minimum height (contact Grindex for information) between the lifting hook and the floor must be sufficient to lift the unit.

• The lifting equipment must be able to hoist the unit straight up and down, preferably without the need for resetting the lifting hook.

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2 Transportation and Storage

• The lifting equipment must be securely anchored and in good condition.

• The lifting equipment must support weight of the entire assembly and must only be used by authorized personnel.

• Two sets of lifting equipment must be used to lift the unit for repair work.

• The lifting equipment must be dimensioned to lift the unit with any remaining pumped media in it.

• The lifting equipment must not be oversized.

CAUTION: Crush Hazard

Over-dimensioned lifting equipment can lead to injury. A sitespecific risk analysis must be done.

2.3 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. Avoid rotating the impeller/propeller by hand at temperatures below the freezing point. The recommended method to warm the unit up is to submerge it in the liquid which will be pumped or mixed.

NOTICE:

Never use a naked flame to thaw the unit.

Unit in as-delivered condition

If the unit is still in the condition in which it left the factory - all packing materials are undisturbed - then the acceptable temperature range during transportation, handling and storage is: –50°C (–58ºF) to +60°C (+140ºF).

If the unit has been exposed to freezing temperatures, then allow it to reach the ambient temperature of the sump before operating.

Lifting the unit out of liquid

The unit is normally protected from freezing while operating or immersed in liquid, but the impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding temperature below freezing.

Units equipped with an internal cooling system are filled with a mixture of water and 30% glycol. This mixture remains a flowing liquid at temperatures down to – 13°C (9°F). Below –13°C (9°F), the viscosity increases such that the glycol mixture will lose its flow properties. However, the glycol-water mixture will not solidify completely and thus cannot harm the product.

Follow these guidelines to avoid freezing damage:

1. Empty all pumped liquid, if applicable.

2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for the presence of unacceptable amounts of water. Change if needed.

2.4 Storage guidelines

Storage location

The product must be stored in a covered and dry location free from heat, dirt, and vibrations.

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2 Transportation and Storage

NOTICE:

Protect the product against humidity, heat sources, and mechanical damage.

NOTICE:

Do not place heavy weights on the packed product.

Long-term storage

If the unit is stored more than six months, then the following apply:

• Before operating the unit after storage, it must be inspected with special attention to the seals and the cable entry.

• The impeller/propeller must be rotated every other month to prevent the seals from sticking together.

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3 Product Description

3.1 Products included

Pump model Standard EX Slurry

Bravo 900, 8153.020 X X

Bravo 900, 8153.190 X X

3.2 Pump design

The pump is submersible, and driven by an electric motor.

Intended use

The product is intended for moving waste water, sludge, raw and clean water. Always follow the application limits given in Technical Reference (page 51). If there is a question regarding the intended use of the equipment, please contact an Grindex representative before proceeding.

DANGER: Explosion/Fire Hazard

Special rules apply to installations in explosive or flammable atmospheres. Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explosion-proof or intrinsically-safe. If the product is EN/ATEX-, MSHAor FM-approved, then see the specific EX information in the Safety chapter before taking any further actions.

3 Product Description

Spare parts

Pressure class

NOTICE:

Do NOT use the unit in highly corrosive liquids.

• 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. For more information contact your Grindex representative.

N Medium head

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7 6

WS006111A

WS000353A

WS006110A

3 Product Description

3.3 Parts

Figure 1: Without cooling jacket

Position Part Description

Figure 2: With cooling jacket

1 Motor For information about the motor, see Technical

Reference (page 51).

2 Monitoring

equipment

For more information about the monitoring equipment, see Monitoring equipment (page 13).

3 Flow diffuser Provides heat transfer from the coolant to the

pumped media (liquid).

4 Impeller The impeller is a shrouded three-channel H-impeller.

5 Mechanical seals One inner and one outer seal in a combination of

materials:

• Tungsten carbide

• Silicon carbide RSiC

• Aluminium oxide Al2O

• Corrosion-resistant cemented carbide WCCR

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3 Product Description

Position Part Description

6 Seal housing Includes a coolant that lubricates and cools the

seals; the housing acts as a buffer between the pumped liquid and the electric motor.

External cooling

7 Inspection

chamber

8 Main bearing The bearing consists of a two row angular contact

9 Shaft The shaft is stainless steel, with an integrated rotor.

10 Cooling The pump is cooled by the ambient liquid.

11 Support bearing The bearing consists of a two-row ball bearing.

12 Agitator The agitator stirs the slurry in order to prevent

13 Cooling with

cooling jacket

The following items are required in order to use external cooling:

• Cooling jacket

• Inlet/outlet pipes with M16 threads (replacing the coolant plugs)

• External cooling system (hose, water source, etc.)

Contact your local Grindex representative for more information.

The inspection chamber is equipped with a FLS10 leakage sensor in order to prevent damages on the motor.

ball bearing.

deposition of material on the sump bottom. Use of the agitator is optional.

The motor is cooled by a closed loop system. An integrated coolant pump circulates the coolant whenever the pump is operated. The cooling jacket can also be used with a external cooling system. For more information, see External cooling (page 13).

3.4 Monitoring equipment

The following applies to the monitoring equipment of the pump:

• The stator incorporates three thermal contacts connected in series that activate the alarm and stops the pump at overtemperature

• The thermal contacts open at 140°C (285°F).

• Ex-approved pumps must have thermal contacts connected to the control panel.

• The sensors and optional sensors must be connected to the monitoring equipment.

• The monitoring equipment must be of a design that makes automatic restart impossible.

• The pump is supplied with an inspection sensor FLS 10 for sensing the presence of any liquid in the inspection chamber.

• Information in the junction box shows if the pump is equipped with optional sensors.

Optional sensors

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.

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3 4

8910111213

WS001008C

3 Product Description

3.5 The data plate

Introduction

The data plate is a metal label located on the main body of the pump. The data plate lists key product specifications.

The data plate

This list of callouts is applicable for all versions of data plates:

1. Pump type number

2. Frequency

3. Phases, type of current

4. Rated shaft power

5. Thermal class

6. Locked rotor code-letter

7. Country of origin

8. Maximum power consumption

9. Product weight

10.Maximum submersion depth

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 The first two characters describe the production year.

18.Rated voltage

19.Pump model

This is the data plate for non explosion-proof version .020:

NOTICE:

Thermistors must never be exposed to voltages higher than 2.5 V. If the voltage exceeds this value, for example when the control circuit is tested, then the thermistors will be destroyed.

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These are the data plates for explosion-proof version .190:

1 2

4 5

8910111213

WS001006C

WS001007C

1 2

4 5

8910111213

3 Product Description

3.6 Approvals

Product approvals for hazardous locations

Pump Approval

8153.190 European Norm (EN)

EN approval plate

This illustration describes the EN approval plate and the information that is contained in its fields.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 15

• ATEX Directive

• EN 60079-0:2012/A11:2013, EN 60079-1:2007, EN 13463-1:2009, EN 13463-5:2011

•

I M2 c Ex d I Mb

•

II 2 G c Ex d IIB T3 Gb

FM (FM Approvals)

• Explosion proof for use in Class I, Div. 1, Group C and D

• Dust ignition proof for use in Class II, Div. 1, Group E, F and G

• Suitable for use in Class III, Div. 1, Hazardous Locations

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1 2 3

6 7

9 10

WS003972A

WS003973A

3 Product Description

FM approval plate

1. Approval

2. Approval authority and Approval number

3. Approval for Class I

4. Approved for drive unit

5. Stall time

6. Starting current or Rated current

7. Duty class

8. Duty factor

9. Input power

10.Rated speed

11.Controller

12.Additional information

13.Maximum ambient temperature

14.Serial number

15.ATEX marking

This illustration describes the FM approval plate and the information that is contained in its fields.

1. Temperature class

2. Maximum ambient temperature

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4 Installation

4.1 Install the pump

Before starting work, make sure that the safety instructions in the chapter

Introduction and Safety (page 3) have been read and understood.

DANGER: Electrical Hazard

Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. This applies to the control circuit as well.

DANGER: Inhalation Hazard

Before entering the work area, make sure that the atmosphere contains sufficient oxygen and no toxic gases.

Hazardous atmospheres

DANGER: Explosion/Fire Hazard

4 Installation

WARNING: Explosion/Fire Hazard

Do not install CSA-approved products in locations that are classified as hazardous in the National Electric Code(TM), ANSI/NFPA 70-2005.

General requirements

These requirements apply:

• Use the pump dimensional drawing in order to ensure proper installation.

Before installing the pump, do the following:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that equipment is in place so that the unit cannot roll or fall over during the installation process.

• Check the explosion risk before you weld or use electric hand tools.

• Check that the cable and cable entry have not been damaged during transport.

• Always remove all debris and waste material from the sump, inlet piping, and discharge connection, before you install the pump.

• Always check the impeller rotation before lowering the pump into the pumped liquid.

NOTICE:

Do not run the pump dry.

NOTICE:

Never force piping to make a connection with a pump.

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Equipment

locked out by

Name .......................

DANGER

4 Installation

Authority regulation

Vent the tank of a sewage station in accordance with local plumbing codes.

Fasteners

• Only use fasteners of the correct size and material.

• Replace all corroded or damaged fasteners.

• Make sure that all the fasteners are correctly tightened and that there are no missing fasteners.

4.2 Make the electrical connections

General precautions

DANGER: Electrical Hazard

Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. This applies to the control circuit as well.

WARNING: Electrical Hazard

Risk of electrical shock or burn. A certified electrician must supervise all electrical work. Comply with all local codes and regulations.

WARNING: Electrical Hazard

There is a risk of electrical shock or explosion if the electrical connections are not correctly carried out, or if there is fault or damage on the product. Visually inspect equipment for damaged cables, cracked casings or other signs of damage. Make sure that electrical connections have been correctly made.

WARNING: Crush Hazard

Risk of automatic restart.

CAUTION: Electrical Hazard

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.

Requirements

These general requirements apply for electrical installation:

• The supply authority must be notified before installing the pump if it will be connected to the public mains. When the pump is connected to the public power supply, it may cause flickering of incandescent lamps when started.

• The mains voltage and frequency must agree with the specifications on the data plate. If the pump can be connected to different voltages, then the connected voltage is specified by a yellow sticker close to the cable entry.

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Cables

4 Installation

• The fuses and circuit breakers must have the proper rating, and the pump overload protection (motor protection breaker) must be connected and set to the rated current according to the data plate and if applicable the cable chart. The starting current in direct-on-line start can be up to six times higher than the rated current.

• The fuse rating and the cables must be in accordance with the local rules and regulations.

• If intermittent operation is prescribed, then the pump must be provided with monitoring equipment supporting such operation.

• If stated on the data plate, then the motor is convertible between different voltages.

• The thermal contacts/thermistors must be in use.

• For FM-approved pumps, a leakage sensor must be connected and in use in order to meet approval requirements.

These are the requirements to follow when you install cables:

• The cables must be in good condition, not have any sharp bends, and not be pinched.

• The cables must not be damaged and must not have indentations or be embossed (with markings, etc.) at the cable entry.

• The minimum bending radius must not be below the accepted value.

• If using a cable which has been used before, a short piece must be peeled off when refitting it so that the cable entry seal sleeve does not close around the cable at the same point again. 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.

• The screened cable must be used according to the European CE and EMC requirements if a Variable Frequency Drive (VFD) is used. For more information, contact your Grindex representative (VFD-supplier).

• For SUBCAB® cables, the twisted pair copper foil must be trimmed.

• All unused conductors must be insulated.

Grounding (earthing)

Grounding (earthing) must be done in compliance with all local codes and regulations.

DANGER: Electrical Hazard

All electrical equipment must be grounded (earthed). Test the ground (earth) lead to verify that it is connected correctly and that the path to ground is continuous.

WARNING: Electrical Hazard

If the power cable is jerked loose, then the ground (earth) conductor must be the last conductor to come loose from its terminal. Make sure that the ground (earth) conductor is longer than the phase conductors at both ends of the cable.

WARNING: Electrical Hazard

Risk of electrical shock or burn. You must connect an additional ground- (earth-) fault protection device to the grounded (earthed) connectors if persons are likely to come into contact with liquids that are also in contact with the pump or pumped liquid.

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SUBCAB 1000V

WS004299E

WS004298C

Screened SUBCAB

WS004313C

4 Installation

4.2.1 Prepare the SUBCAB® cables

This section applies to SUBCAB® cables with twisted-pair control cores.

The prepared SUBCAB® cable The prepared screened SUBCAB® cable

1. T1+T2 twisted pairs in control element

2. Drain wire in control element (bare copper wire)

3. Screened copper pt-foil

4. Insulation sheath (jacket) or PT-foil for control element

5. Power cores

6. Ground (earth) core

1. Peel off the outer sheath at the end of the cable.

2. Prepare the control element: a) Peel the sheath (if applicable) and the copper foil.

The copper foil is a screen and is conductive. Do not peel more than necessary, and remove the peeled foil.

Figure 3: Copper foil on control element.

b) Put a white shrink hose over the drain wire and the cable terminal. c) Fit a cable lug on the drain wire. d) Twist T1+T2 and T3+T4. e) Put a shrink hose over the control element.

Make sure that the conductive copper foil and drain wire is covered.

3. Prepare the ground (earth) core for SUBCAB™ cable: a) Peel the yellow-green insulation from the ground (earth) core.

b) Check that the ground (earth) core is at least 10% longer than the phase

cores in the cabinet.

c) If applicable, put a cable lug on the ground core.

4. Prepare the ground (earth) core for screened SUBCAB™ cable: a) Untwist the screens around the power cores.

b) Put a yellow-green shrink hose over the ground (earth) core.

20 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

1. T1+T2 and T3+T4 twisted pairs in control element

2. Drain wire in control element (bare copper wire)

3. Screened copper pt-foil

4. Insulation sheath (jacket) for control element

5. Power cores

6. Aluminum foil

7. Ground (earth) core with green/yellow shrink hose

8. Uncovered screen/braided wire

Page 23

Leave a short piece uncovered.

WS006002B

c) If applicable, put a cable lug on the screened ground core. d) Twist all power core screens together to create a ground (earth) core and

fit a cable terminal to the end.

e) Check that the ground (earth) core is at least 10% longer than the phase

cores in the cabinet.

5. Connect to ground (earth):

– Screw: Fit cable terminals to the ground (earth) core and the power cores. – Terminal block: Leave the core ends as they are.

6. Prepare the main leads: a) Remove the aluminum foil around each power core.

b) Peel the insulation from each power core.

4.2.2 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.

4 Installation

1. Entrance cover

2. O-ring

For more information about the cable entry, see the Parts list.

1. Remove the entrance cover and the O-ring from the stator housing. This provides access to the terminal board.

2. Check the data plate to see which connections are required for the power supply.

3. Arrange the connections on the terminal board in accordance with the required power supply.

Links (jumper strips) are not used with the Y/D start.

4. Connect the mains leads (L1, L2, L3, and ground (earth) ) according to applicable cable chart.

The ground (earth) lead must be150 mm (6.0 in.) longer than the phase leads in the junction box of the unit.

5. Make sure that the pump is correctly connected to ground (earth).

6. Connect the control leads to the applicable terminal board.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 21

Page 24

4 Installation

7. Make sure that any thermal contacts incorporated in the pump are properly connected to the terminal board.

8. Install the entrance cover and the O-ring on the stator housing.

9. Fasten the screws on the entrance flange so that the cable insertion assembly bottoms out.

4.2.3 Connect the motor cable to the starter and monitoring equipment

If there are two power cables, then the cable that is connected to T1 and T2 is labeled. If a separate control cable is used, then the control leads in the power cable are never connected.

DANGER: Explosion/Fire Hazard

NOTICE:

• Thermal contacts are incorporated in the pump.

• Thermal contacts must never be exposed to voltages higher than 250 V, breaking current maximum 4 A. It is recommended that they are connected to 24 V over separate fuses to protect other automatic equipment.

1. Connect the T1 and T2 control conductors to the monitoring equipment. Do not connect the T1 and T2 leads to thermal contacts if the temperature of

the pumped liquid is above 40°C (104°F).

NOTICE:

Ex-approved products must always have the thermal contacts connected irrespective of the ambient temperature.

2. Connect the mains leads (L1, L2, L3, and earth [ground]) to the starter equipment.

For information about the phase sequence and the color codes of the leads, see Cable charts (page 22).

3. Check the functionality of the monitoring equipment: a) Check that the signals and the tripping function work properly.

b) Check that the relays, lamps, fuses, and connections are intact. Replace any defective equipment.

4.2.4 Cable charts

Description

This topic contains general connection information. It also provides cable charts that show connection alternatives for use with different cables and power supply.

22 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 25

WS000509E

L3L1

L3L2

Figure 4: Phase sequence

L1 L2 L3

T3 T4T1 T2

*YE

GN/YE

WS004133D

Connection locations

The figures in this section illustrate how to interpret the connection strip symbols.

4 Installation

1. Stator leads

2. Terminal board

3. Power cable leads

4. Stator (internal connection illustrated)

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 23

Page 26

L1 L2 L3

T3 T4T1 T2

CLS

FLS

FLS 10

WS004134A

4 Installation

Color code standard

Code Description

1. Starter equipment and mains leads (L1, L2, L3)

2. ground (earth)

3. Functional ground

4. Control leads (T1, T2, T3, T4)

5. Thermal contact

6. FLS

7. FLS 10

8. CLS

9. Thermistor

10.Level sensor

11.Capacitor

BN Brown

BK Black

WH White

OG Orange

GN Green

GNYE Green-Yellow

RD Red

GY Grey

BU Blue

YE Yellow

24 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 27

Colors and markings of leads

Motor Connection

Colors and marking of the main leads

773 29 01/1

51 680 01

Mains

SUBCAB 7GX

SUBCAB 4GX

Screenflex 7GX

Screenflex 4GX

SUBCAB AWG

SUBCAB Screened

BK 1

BK 2

BK 3

BK 4

BK 5

BK 6

GN/YE

**Screen/PE from cores

Screen (WH)

COLOR STANDARD

STATOR LEADS

BN = Brown

U1,U5 = RD

BK = Black

U2 = GN

WH = White

V1,V5 = BN

OG = Orange

V2 = BU

GN = Green

W1,W5 = YE

GN/YE = Green-Yellow

W2 = BK

RD = Red

T1,T2 = WH or YE GY = Grey BU = Blue YE = Yellow

*SUBCAB AWG * * Ground conductor is stranded around core GC=Ground check

Terminal clamps 6 stator leads

WS004546A

4 Installation

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 25

Page 28

6 LEADS

One cable

Two cables

GN/YE

*YE

One cable

Two cables

GN/YE

*YE

Y/D

One cable

Two cables

L1:1

L3:1

L2:1

L1:2

L3:2

L2:2

GN/YE

*YE

Only applicable to 70mm2 terminal clamp

GN/YE

*YE

WS004547A

4 Installation

6-leads connection

Figure 5: One cable (left) and two cables (right)

26 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 29

9-leads connection

9 LEADS

One cable

Two cables

Y-

GN/YE

*YE

Y-SER

Two cables

GN/YE

*YE

WS004549A

One cable

Screened SUBCAB & FGB Screened

Cable without sep. ground conductor Screen as ground conductor

GN/YE shrink hose

L2 L3

Mini CAS

Mini CAS+AUX

FGB Screened

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)

WS004548A

4 Installation

Figure 6: One cable (left) and two cables (right)

4.2.4.1 Screened cable connection

Cable without separate ground conductor. Screen as ground conductor.

Figure 7: Screened SUBCAB and FGB screened

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 27

Page 30

Screenflex and SUBCAB with functional ground

* For screened SUBCAB T3 & T4 shall also be twisted separately

T1 and T2 twisted*

White insulation hose

Screen

GN/YE

T1 and T2

White insulation hose

twisted*

Screen

GN/YE

WS004612A

Sensor terminal clamps

SENSORS

Color and marking of control leads

T15

T16

Control

SUBCAB 4GX/7G and

Screenflex

SUBCAB AWG

SUBCAB Screened

WH T1

WH T2

WH T3

WH T4

Thermal detectors FLS Disconnected

FLS + Thermal detectors

FLS

Max 12 V

WH/YE

Control leads

T1/*OG/1

Mini

CAS

WH/YE

T2/*BU/2

-5

T15

**T3

*SUBCAB AWG

**T4

*Screened SUBCAB

FLS

Max 12 V

WH/YE

Control leads

T1/*OG/1

Mini

CAS

T2/*BU/2

-5

WH/YE

T15

**T3

*SUBCAB AWG

**T4

*Screened SUBCAB

WS004550A

4 Installation

Figure 8: Screenflex and SUBCAB with functional ground

*For screened SUBCAB T3 and T4 shall also be twisted separately.

4.2.5 Sensor connection

4.2.5.1 Connection to the pump

∞ Ohm Overtemperature 1200 Ohm OK

28 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

430 Ohm Leakage

Page 31

4.2.5.2 Connection to the monitoring equipment

24 V AC/DC

102

7 +T1

T15

FLS10

5 -

12 VDC

10S

WS002623B

WS006253A

MiniCAS II

4.3 Check the impeller rotation

4 Installation

C Pump contactor CC Control circuit L1 Caution light (leakage) L2 Caution light (stator over-

temperature) P Pump main supply R Reset switch

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

1. Start the motor.

2. Stop the motor after a few seconds.

3. Check that the impeller rotates according to this illustration.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 29

Page 32

4 Installation

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.

30 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 33

5 Operation

5.1 Precautions

Before taking the unit into operation, check the following:

• All recommended safety devices are installed.

• The cable and cable entry have not been damaged.

• All debris and waste material has been removed.

NOTICE:

Never operate the pump with the discharge line blocked, or the discharge valve closed.

WARNING: Crush Hazard

Risk of automatic restart.

Distance to wet areas

5 Operation

WARNING: Electrical Hazard

CAUTION: Electrical Hazard

Risk of electrical shock or burn. The equipment manufacturer has not evaluated this unit for use in swimming pools. If used in connection with swimming pools then special safety regulations apply.

Noise level

NOTICE:

The sound power level of the product is lower than 70 dB(A). However, in some installations the resulting sound pressure level may exceed 70 dB(A) at certain operating points on the performance curve. Make sure that you understand the noise level requirements in the environment where the product is installed. Failure to do so may result in hearing loss or violation of local laws.

5.2 Start the pump

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

NOTICE:

Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 31

Page 34

5 Operation

1. Check the coolant level in the seal housing.

2. Remove the fuses or open the circuit breaker, and check that the impeller can rotate freely.

WARNING: Crush Hazard

Never put your hand into the pump housing.

3. Conduct insulation test phase to ground. To pass, the value must exceed 5 megaohms.

4. Check that the monitoring equipment works.

5. Start the pump.

32 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 35

6 Maintenance

Equipment

locked out by

Name .......................

DANGER

Precautions

Before starting work, make sure that the safety instructions in the chapter

Introduction and Safety (page 3) have been read and understood.

WARNING: Biological Hazard

Infection risk. Rinse the unit thoroughly with clean water before working on it.

6 Maintenance

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

CAUTION: Crush Hazard

Make sure that the unit cannot roll or fall over and injure people or damage property.

Make sure that you follow these requirements:

• Check the explosion risk before you weld or use electrical hand tools.

• Allow all system and pump components to cool before you handle them.

• Make sure that the product and its components have been thoroughly cleaned.

• Make sure that the work area is well-ventilated before you open any vent or drain valves, remove any plugs, or disassemble the unit.

• Do not open any vent or drain valves or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

Ground continuity verification

A ground (earth) continuity test must always be performed after service.

Maintenance guidelines

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.

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.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 33

Page 36

WS001479A

WS001480A

6 Maintenance

6.1 Torque values

All screws and nuts must be lubricated to achieve correct tightening torque. Screws that are screwed into stainless steel must have the threads coated with suitable lubricants to prevent seizing.

If there is a question regarding the tightening torques, please contact the local sales and service representative.

Screws and nuts

Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)

Propert

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

y class

50 1.0

(0.74)

70, 80 2.7 (2) 5.4 (4) 9.0

2.0 (1.5)

3.0 (2.2)

8.0

15 (11) 27 (20) 65 (48) 127

(5.9)

22 (16) 44 (32) 76 (56) 187

(6.6)

100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) 115

(84.8)

Table 2: Steel, torque Nm (ft-lbs)

Propert

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

y class

8.8 2.9 (2.1)

10.9 4.0 (2.9)

12.9 4.9 (3.6)

5.7 (4.2)

9.8 (7.2)

24 (18) 47 (35) 81(60) 194

8.1 (6) 14 (10) 33 (24) 65 (48) 114 (84)

9.7

(7.2)

17 (13) 40 (30) 79 (58) 136

(100)

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.

(138)

248 (183)

(143)

277 (204)

333 (245)

(93.7)

364 (268)

481 (355)

385 (285)

541 (399)

649 (480)

220 (162)

629 (464)

434 (320)

1240 (915)

— —

665 (490)

935 (689)

1120 (825.1)

1310 (966.2)

1840 (1357)

2210 (1630)

6.2 Change the coolant

34 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Figure 9: With a cooling jacket

Figure 10: Without a cooling jacket

Page 37

1. Inspection plug

WS002122B

WS001505A

WS009196B

WS001471B

2. Coolant plugs

6.2.1 Empty the coolant

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Hold a rag over the plug to prevent liquid from spraying out.

1. Empty the coolant in the inspection chamber: a) Remove the inspection plug.

6 Maintenance

Figure 11: With a cooling jacket

Figure 12: Without a cooling jacket

b) Pump out any coolant from the inspection chamber, as shown here.

Figure 13: With a cooling jacket

Figure 14: Without a cooling jacket

c) Fit a new O-ring and re-install the inspection plug. Tighten the plug.

Tightening torque: 44 Nm (33 ft-lbs)

2. To empty the coolant with the pump upright, do the following: This method is applicable only for pumps without cooling jackets. a) Remove the coolant plugs.

b) Use a pump to remove the coolant.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 35

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Hold a rag over the plug to prevent liquid from spraying out.

Page 38

WS001463A

6 Maintenance

3. If it is necessary to separate the drive unit from the hydraulic unit, then do the following:

a) Carefully open the coolant plugs to relieve any built-up pressure inside the

cooling jacket.

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Hold a rag over the plug to prevent liquid from spraying out.

b) 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.

NOTICE:

Do not allow the weight of the pump to rest on any portion of the impeller.

The impeller must not be allowed to make contact with the concrete floor

or other hard or rough surfaces.

4. To empty the coolant with the pump in a horizontal position, do the following: a) Place the pump horizontally, so that one of the coolant plugs is at the

lowest point of the pump, to ensure that the coolant will drain completely.

It is important to empty all of the coolant. b) Place a container under the pump. c) Remove the coolant plugs and empty the coolant.

36 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 39

WS001411A

WS001412A

6 Maintenance

Figure 15: With a cooling jacket

6.2.2 Fill with coolant

Use a coolant that is a mixture of 70% deionized or distilled water, and 30% 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.

If the pumped liquid includes potable water or substances to be ingested, then contact your local Grindex sales representative.

1. Fill with coolant until it overflows through the opposite hole, as shown here.

Pump Quantity, L (qt.)

8153 47 (49.6) 11 (11.6)

Figure 16: Without a cooling jacket

With cooling jacket Without cooling jacket

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 37

Page 40

WS001469A

WS006142A

6 Maintenance

Figure 17: With cooling jacket

2. Fit new O-rings and re-install the coolant plugs. Tighten the plugs. Tightening torque: 44 Nm (33 ft-lb)

6.3 Replace the impeller

Figure 18: Without cooling jacket

Required tools:

• 17 mm hexagon bit adapter with an extension of at least 125 mm (4.92 in.)

• Impeller puller If applicable, contact your local Grindex representative for correct type and

size.

• Chain

• Rod (wooden or copper) for locking the impeller in place, if applicable.

• Two crowbars, if applicable

38 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 41

WARNING:

WS002430A

WS002428A

• If you fail with the impeller installation, you must redo the installation procedure from the beginning.

• When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller. The impeller must not be allowed to make contact with the concrete floor or other hard and rough surfaces.

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

6.3.1 Remove the impeller

1. Lock the impeller: a) Place the pump in a horizontal position.

Do not remove the round sling. b) Thread a chain through the impeller and pump housing outlet. c) Lock the chain so the impeller cannot rotate.

6 Maintenance

2. Remove the impeller from the shaft: a) Remove the wear protection/plug.

b) Remove the impeller screw. c) Turn the adjustment screw counterclockwise until the impeller breaks free

from the shaft.

d) Hand-tighten the impeller screw to prevent it from falling off.

3. Remove the drive unit from the pump housing: a) 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.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 39

Page 42

WS002416A

WS002418A

WS002431A

WS002411A

6 Maintenance

4. Secure the wearing cover: a) Place the drive unit horizontally.

WARNING:

When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller. The impeller must not be allowed to make contact with the concrete floor or other hard and rough surfaces.

b) Prevent the wearing cover from falling off when removing the impeller by

attaching a round sling.

5. Remove the impeller: a) Remove the impeller screw.

b) Remove the impeller and the conical sleeve.

c) Remove the wearing cover.

40 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 43

6.3.2 Install the impeller

WS006895A

WS001759A

NOTICE:

If you fail with the impeller installation, you must redo the installation procedure from the beginning.

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. The proper lubrication is grease for bearings, for example Exxon Mobil

Unirex N3, Mobil Mobilith SHC 220 or equivalent.

NOTICE:

Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves.

6 Maintenance

2. Mount the impeller: a) Lubricate the threads of the impeller screw and the washer.

Always use a new impeller screw.

b) Adjust the adjustment screw so that it is flush with the sleeve.

c) Assemble the wearing cover to the drive unit and secure it with a round

sling. d) Fit the sleeve and the impeller to the shaft. e) 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.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 41

Page 44

WS002421A

WS002416A

WS002430A

WS002429A

6 Maintenance

3. Mount the pump housing: a) Lubricate the pump housing screws.

b) Place the drive unit in the pump housing. c) Tighten the screws in a diagonal sequence.

For tightening torque, see Torque values (page 34).

4. Lock the impeller: a) Place the pump in a horizontal position.

b) Thread a chain through the impeller and pump housing outlet. c) Lock the chain so the impeller cannot rotate.

5. Adjust the impeller: a) Remove the impeller screw.

b) Using a hexagon-bit adapter, turn the adjustment screw clockwise until the

impeller makes contact with the pump housing.

c) Tighten it a further 1/8 turn (45°).

6. Fasten the impeller:

42 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 45

a) Fit the lubricated washer and impeller screw.

WS006181B

Equipment

locked out by

Name .......................

DANGER

b) Tighten the impeller screw.

For tightening torque, see Torque values (page 34). c) Tighten it a further 1/8 turn (45°). d) Fit the wear protection/plug. e) 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.).

6.4 Replace the agitator

6 Maintenance

1. Impeller screw

2. Tension pin

3. Barrel nut

4. Propeller shaft

5. Agitator propeller

6. Washer

7. Retaining ring

8. Propeller screw

9. Wear protection/plug

Rotating propeller

6.4.1 Remove the agitator unit

Remove the necessary pump parts to make the agitator area accessible.

1. Lock the impeller: If applicable use a rod (wooden or plastic) or a chain to lock the impeller in

place.

2. Remove the wear protection/plug.

3. Remove the propeller screw.

4. Remove the retaining ring and the washers.

5. Remove the propeller from the propeller shaft: a) Put the propeller screw in its hole.

b) Place the washer on the top of the propeller screw, and insert the retaining

ring into the groove in the propeller.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 43

c) Undo the propeller screw.

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

Page 46

6 Maintenance

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.

6.4.2 Install the agitator unit

Remove the necessary pump parts to make the agitator area accessible.

1. Lock the impeller: If applicable use a rod (wooden or plastic) or a chain to lock the impeller in

place.

2. Install the propeller shaft: a) Fit the barrel nut and the impeller screw and tighten.

Always use a new impeller screw. Make sure that the tension pin fits into the groove in the impeller.

For tightening torque, see Torque values (page 34). b) Tighten it a further 1/8 turn (45°). c) Apply grease to the contact surfaces between the propeller shaft and the

barrel nut. d) Fit the propeller shaft into the barrel nut and tighten, using the key handle

on the propeller shaft.

Tightening torque: 187 Nm (138 ft-lbs) e) Check that the impeller can rotate freely.

3. Fit the strainer, if any.

4. Apply a small amount of grease into the taped hole in the agitator propeller.

5. Fit the propeller, the retaining ring, washer, the propeller screw into the propeller shaft and tighten.

Tightening torque: For tightening torque, see Torque values (page 34).

6. Fit the wear/protective plug into the propeller.

7. Check that the impeller can rotate freely.

6.5 Service the pump

Type of service

Initial inspection

Periodical inspection

44 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Purpose Inspection interval

To make a check up of the pump condition by an authorized Grindex service representative and, based on the result and findings from these measures, to determine the intervals for periodical inspection and major overhaul for the specific installation.

To prevent operational interruptions and machine breakdown. Measures to secure performance and pump efficiency are defined and decided for each individual application. It can include such things as impeller trimming, wear part control and replacement, control of zinc-anodes and control of the stator.

Within the first year of operation.

Up to 4,000 hours or 1 year, whichever comes first.

Applies to normal applications and operating conditions at media (liquid) temperatures <40°C.

Page 47

6 Maintenance

Type of service

Major overhaul

NOTICE:

Shorter intervals may be required when the operating conditions are extreme, for example with very abrasive or corrosive applications or when the liquid temperatures exceed 40°C (104°F).

6.5.1 Inspection

Purpose Inspection interval

To secure a long operating lifetime for the product. It includes replacement of key components and the measures taken during an inspection.

Service item Action

Cable 1. If the outer jacket is damaged, replace the

cable.

2. Check that the cables do not have any sharp bends and are not pinched.

Up to 8,000 hours or 3 years, whichever comes first.

These intervals apply to normal applications and operating conditions at media (liquid) temperatures <40°C.

Connection to power Check that the connections are properly secured.

Electrical cabinets Check that they are clean and dry.

Impeller 1. Check the impeller clearance.

2. Adjust the impeller, if necessary.

Inspection chamber 1. Drain all liquid, if any.

2. Check the resistance of the leakage sensor. Normal value approximately1200 ohms, alarm

approximately 430 ohms.

Insulation Use a megger maximum 1000 V.

1. Check that the resistance between the ground (earth) and phase lead is more than 5 megohms.

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.

Lifting handle 1. Check the screws.

2. Check the condition of the lifting handle and the chain.

3. If necessary, replace.

O-rings 1. Replace the oil plug O-rings.

Overload protection and other protections

Personnel safety devices Check the guard rails, covers, and other

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 45

2. Grease the new O-rings.

Check the correct settings.

protections.

Page 48

6 Maintenance

Service item Action

Rotation direction Check the impeller rotation.

Seal housing 1. Fill with new coolant, if necessary.

Terminal board Check that the connections are properly secured.

Thermal contacts Normally closed circuit; interval 0–1 ohm.

Thermistor Check the resistance is between 20–250 ohms and

Voltage and amperage Check the running values.

6.5.2 Major overhaul

The basic repair kit includes O-rings, seals, and bearings.

For a major overhaul, do the following in addition to the tasks listed under Inspection.

Service item Action

2. Check that the freezing point is lower than

-13°C (9°F).

the measured voltage is maximum 2 V DC.

Support and main bearing

Mechanical seal Replace with new seal units.

6.5.3 Service in case of alarm

For information about indication values for sensors, see Sensor connection (page

28).

Alarm source Action

FLS10 1. Drain the fluid in the inspection chamber.

The thermistor/Thermal contact

Replace the bearings with new bearings.

2. Check the coolant level. Fill with new coolant if necessary.

3. Check the freezing point (lower than -13°C or 9°F).

Check the inspection chamber again after one week of operation. If leakage has occurred, then do the following:

1. Drain the fluid.

2. Change the mechanical seal unit.

3. Replace with new coolant.

1. Check the coolant level.

2. Check the start and stop levels.

The overload protection Check that the impeller can rotate freely.

46 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

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7 Troubleshooting

Introduction

DANGER: Electrical Hazard

Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician.

Follow these guidelines when troubleshooting:

• Disconnect and lock out the power supply except when conducting checks that require voltage.

• Make sure that no one is near the unit when the power supply is reconnected.

• When troubleshooting electrical equipment, use the following:

– Universal instrument multimeter – Test lamp (continuity tester) – Wiring diagram

7.1 The pump does not start

7 Troubleshooting

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause Remedy

An alarm signal has been triggered on the control panel.

The pump does not start automatically, but can be started manually.

Check that:

• The impeller rotates freely.

• The sensor indicators do not indicate an alarm.

• The overload protection is not tripped. If the problem still persists: Contact the local Grindex service shop.

Check that:

• The start level regulator is functioning. Clean or

replace if necessary.

• 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.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 47

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7 Troubleshooting

Cause Remedy

The installation is not receiving voltage.

The impeller is stuck. Clean:

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, see Product Description (page 11).

Check that:

• The main power switch is on.

• There is control voltage to the start equipment.

• The fuses are intact.

• There is voltage in all phases of the supply line.

• All fuses have power and that they are securely

fastened to the fuse holders.

• The overload protection is not tripped.

• The motor cable is not damaged.

• The impeller

• The sump in order to prevent the impeller from

clogging again.

7.2 The pump does not stop when a level sensor is used

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

Cause Remedy

The pump is unable to empty the sump to the stop level.

There is a malfunction in the level-sensing equipment.

The stop level is set too 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, see Product Description (page 11).

Check that:

• There are no leaks from the piping and/or

discharge connection.

• The impeller is not clogged.

• The non-return valve(s) are functioning properly.

• The pump has adequate capacity. For

information: Contact the local Grindex service shop.

• Clean the level regulators.

• Check the functioning of the level regulators.

• Check the contactor and the control circuit.

• Replace all defective items.

Raise the stop level.

48 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 51

7.3 The pump starts-stops-starts in rapid sequence

Cause Remedy

7 Troubleshooting

The pump starts due to back-flow which fills the sump to the start level again.

The self-holding function of the contactor malfunctions.

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, see Product Description (page 11).

Check that:

• The distance between the start and stop levels is

sufficient.

• The non-return valve(s) work(s) properly.

• The length of the discharge pipe between the

pump and the first non-return valve is sufficiently short.

Check:

• The contactor connections.

• The voltage in the control circuit in relation to the

rated voltages on the coil.

• The functioning of the stop-level regulator.

• Whether the voltage drop in the line at the

starting surge causes the contactor's self-holding malfunction.

7.4 The pump runs but the motor protection trips

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause Remedy

The motor protection is set too low.

The impeller is difficult to rotate by hand.

The drive unit is not receiving full voltage on all three phases.

The phase currents vary, or they are too high.

The insulation between the phases and ground in the stator is defective.

Set the motor protection according to the data plate and if applicable the cable chart.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

• Check the fuses. Replace fuses that have tripped.

• If the fuses are intact, then notify a certified

electrician.

Contact the local Grindex service shop.

1. Use an insulation tester. With a 1000 V DC

megger, check that the insulation between the phases and between any phase and ground is > 5 megaohms.

2. If the insulation is less, then do the following:

Contact the local Grindex service shop.

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 49

Page 52

7 Troubleshooting

Cause Remedy

The density of the pumped fluid is too high.

There is a malfunction in the overload protection.

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, see Product Description (page 11).

Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)

• Change to a more suitable pump

• Contact the local Grindex service shop.

Replace the overload protection.

7.5 The pump delivers too little or no water

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause Remedy

The impeller rotates in the wrong direction.

One or more of the valves are set in the wrong positions.

The impeller is difficult to rotate by hand.

The pipes are obstructed. To ensure a free flow, clean out the pipes.

The pipes and joints leak. Find the leaks and seal them.

There are signs of wear on the impeller, pump, and casing.

The liquid level is too low. • Check that the level sensor is set correctly.

• If it is a 3-phase pump, then transpose two phase

leads.

• If it is a 1-phase pump, then do the following:

Contact the local Grindex service shop.

• Reset the valves that are set in the wrong

position.

• Replace the valves, if necessary.

• Check that all valves are correctly installed

according to media flow.

• Check that all valves open correctly.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

Replace the worn parts.

• 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, see Product Description (page 11).

50 8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual

Page 53

8 Technical Reference

8.1 Application limits

Data Description

Liquid temperature 40°C (104°F) maximum

pH of the pumped media (liquid) 5.5–14

Liquid density Contact the nearest Grindex

Depth of immersion Maximum 20 m (65 ft)

Other For the specific weight, current,

8.2 Motor data

8 Technical Reference

representative

voltage, power ratings, and speed of the pump, see the data plate of the pump.

Feature Description

Motor type Squirrel-cage induction motor

Frequency 50 Hz or 60 Hz

Supply 3-phase

Starting method Direct on-line

Maximum starts per hour

Code compliance IEC 60034-1

Voltage variation without overheating

Voltage imbalance tolerance

Stator insulation class

Motor encapsulation

Motor encapsulation is in accordance with IP68.

Star-delta

30 evenly spaced starts per hour

±10%, if it does not run continuously at full load

H (180°C [360°F])

8153.020/.190 Bravo 900 Installation, Operation, and Maintenance Manual 51

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Grindex Gesällvägen 33 174 07 Sundbyberg Sweden Tel: +46-8-606 66 00 Fax: +46-8-745 53 28 www.grindex.com

Visit our Web site for the latest version of this document and more information

The original instruction is in English. All non-English instructions are translations of the original instruction.

2011 Grindex

899402_8.0_en-US_2016-09_IOM.8153