Grindex 8109.282 Salvador, 8109.583 Salvador, Matador N, 8106.181, Matador H Installation, Operation And Maintenance Manual
...Page 1
Revision 2.0
www.grindex.com
Installation, Operation, and Maintenance
Manual
8109.282/.583 Salvador
Page 2
Page 3
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......................................................................... 8
Lifting.................................................................................................8
Temperature ranges for transportation, handling and storage........................9
Storage guidelines.................................................................................. 9
Table of Contents
Product Description.............................................................................................................10
Pump design........................................................................................ 10
Monitoring equipment............................................................................10
Level regulators................................................................................. 10
The data plate...................................................................................... 11
Installation............................................................................................................................ 13
Install the pump................................................................................... 13
Install...............................................................................................14
Make the electrical connections...............................................................15
Product-specific precautions.................................................................17
Connect the motor cable to the pump................................................... 17
Cable charts...................................................................................... 17
Cable charts, MSHA version................................................................. 21
Check the impeller rotation: Pumps without built-in motor protection...........21
Check the phase sequence: Pumps with built-in motor protection................ 22
Operation.............................................................................................................................. 25
Start the pump..................................................................................... 25
Clean the pump.................................................................................... 26
Maintenance......................................................................................................................... 27
Torque values....................................................................................... 28
Service................................................................................................ 29
Inspection......................................................................................... 29
Major overhaul...................................................................................31
Change the oil...................................................................................... 31
Replace the impeller..............................................................................32
Remove the impeller ..........................................................................32
Install the impeller ............................................................................ 34
Troubleshooting...................................................................................................................37
The pump does not start, for pumps with SMART™.....................................38
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 1
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............................................................................................................ 43
Application limits...................................................................................43
Specific motor data, standard version...................................................... 43
Specific motor data, MSHA version.......................................................... 45
Dimensions and weights........................................................................ 46
Performance curves...............................................................................47
2 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 5
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.
NOTICE:
Save this manual for future reference, and keep it readily available at the
location of the unit.
Introduction and Safety
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
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
WARNING:
CAUTION:
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
A hazardous situation which, if not
avoided, could result in minor or
moderate injury
NOTICE:
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 3
• A potential situation which, if not
avoided, could result in undesirable
conditions
• A practice not related to personal
injury
Page 6
Introduction and Safety
Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols
replace the ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the
ordinary hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Product warranty
Coverage
Grindex undertakes to remedy the following faults in products sold by Grindex
under the following conditions:
• The faults are due to defects in design, materials or workmanship.
• The faults are reported to an Grindex representative within the warranty
period.
• 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
Warranty claim
Spare parts
The warranty does not cover faults caused by the following:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation carried out without
consulting Grindex
• Incorrectly executed repair work
• Normal wear and tear
Grindex assumes no liability for the following:
• Bodily injuries
• Material damages
• Economic losses
Grindex products are high-quality products with expected reliable operation and
long life. However, should the need arise for a warranty claim, please contact
your Grindex representative.
Grindex guarantees that spare parts will be available for 10 years after the
manufacture of this product has been discontinued.
4 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 7
Safety
Introduction and Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its
contents if it is over-pressurized. Take all necessary measures to avoid overpressurization.
• 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. 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.
• This manual clearly identifies accepted methods for disassembling units.
These methods must be adhered to. Trapped liquid can rapidly expand and
result in a violent explosion and injury. Never apply heat to impellers,
propellers, or their retaining devices to aid in their removal.
• Do not change the service application without the approval of an authorized
Grindex representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so
could result in physical injury, damage, or delays.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc
• Always bear in mind the risk of drowning, electrical accidents, and burn
Safety equipment
Use safety equipment according to the company regulations. Use this safety
equipment within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
flash hazards.
injuries.
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific
information about safety devices in other chapters of this manual.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 5
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:
• Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
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
MSHA requirements
According to the United States of America's Code of Federal Regulations, the
following requirements must be fulfilled to maintain Mine Safety and Health
Administration (MSHA) permissibility of this equipment:
Subject area Requirements
General safety • Frequent inspections must be made.
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
at least 15 minutes.
3. Seek medical attention.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1
minute.
3. Seek medical attention, if necessary.
• All electrical parts, portable cable, and wiring must be
kept in a safe condition.
• There must not be any openings into the casings of the
electrical parts.
• The machine frame must be effectively earthed
(grounded).
• Power wires must not be used for earthing (grounding).
• The operating voltage must match the voltage rating of
the motor.
6 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 9
Introduction and Safety
Subject area Requirements
Service and repair • Inspections, service, and repairs are only allowed when
the portable cable is disconnected from the power
supply.
• Work must be performed by trained personnel
(preferably the manufacturer or agent) to ensure that
the pump is restored to its original state of safety in
regards to all flame-arresting paths.
• Replacement parts must be exactly equal to those
provided by the manufacturer.
• When cable entries are disturbed on pump or control,
they must be reassembled in the approved manner.
DANGER:
Failure to restore the permissible equipment
to its original state of safety will void the
MSHA approval. The creation of a safety
hazard will subject the owner / operator of a
mine to citations and penalties under the
law.
Fastenings All bolts, nuts, screws, and threaded covers must be
properly tightened and secured.
Cables A flame-resistant portable cable must be used. It has to
Operation Polyurethane-equipped products must not be operated dry
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Dispose appropriately of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always recycle according to the guidelines listed below:
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.
bear an MSHA-assigned identification number and be
adequately protected by an automatic circuit-interrupting
device. Special care must be taken in handling the cable to
avoid mechanical damage and wear.
in hazardous areas.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 7
Page 10
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.
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.
Transportation guidelines
Precautions
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
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.
Lifting
WARNING:
Crush Hazard.
• Always lift the unit by its designated lifting points.
• Use suitable lifting equipment and ensure that the product is properly
harnessed.
• Wear personal protective equipment.
• Stay clear of cables and suspended loads.
Lifting equipment and tackle should always be inspected before starting work.
8 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 11
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. 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 water. Change if needed.
Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt,
and vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• 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.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 9
Page 12
Product Description
Product Description
Products included
Pump model Approvals
Salvador 8109.282 Standard
Salvador 8109.583
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 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.
NOTICE:
Do NOT use the pump in highly corrosive liquids.
For information about pH, see Application limits (page 43).
Particle size
The pump can handle liquid containing particles with the diameter of 50 mm
(1.97 in).
Pressure class
N Medium head
Impeller type
Sludge
Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates thermal contacts connected in series that activate the
alarm at overtemperature.
• The thermal contacts open at 125°C (257°F) and close at 95°C (203°F)
Level regulators
About level regulators
Starting and stopping the pump at different water levels can be manual or
automatic. If automatic start and stop is required, a level regulator can be
ordered (as an option). The option is only available for standard pumps.
Features
Below are some of the features of the level regulators:
10 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 13
Illustration
1
2
WS006210B
1
2
3
4
5
6
7
8910111213
14
15
16
18
17
19
WS001008A
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.
1. On
2. Off
Figure 1: The functionality of the level regulator
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
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 11
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
Page 14
WS006204A
WS006212A
Product Description
Warning plate
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
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.
The MSHA approval plate
12 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 15
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.
• Vent the tank of a sewage station in accordance with local plumbing codes.
• Make sure that the unit cannot roll or fall over and injure people or damage
property.
Installation
WARNING:
Electrical shock hazard. Check that the cable and cable entry have not been
damaged during transport before installing the pump.
NOTICE:
• Never force piping to make a connection with a pump.
These requirements apply:
• Use the pump dimensional drawing in order to ensure proper installation.
• Provide a suitable barrier around the work area, for example, a guard rail.
• Check the explosion risk before you weld or use electric hand tools.
• Remove all debris from the inlet piping system before you install the pump.
• Always check the impeller rotation before lowering the pump into the
pumped liquid.
Sedimentation prevention
In order to avoid sedimentation when the pumped liquid contains solid particles,
the velocity of the liquid in the discharge line must exceed a certain value.
Choose applicable minimum velocity from the table, and choose proper
dimension of the discharge line accordingly.
Mixture Minimum velocity, meter per
second (feet per second)
Water + coarse gravel 4 (13)
Water + gravel 3.5 (11)
Water + sand, particle size <0.6 mm
(0.024 in)
Water + sand, particle size <0.1 mm
(0.004 in)
For more permanent installations with a heavily contaminated pumped liquid, a
settling pump-sump is recommended.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 13
2.5 (8.2)
1.5 (4.9)
Page 16
WS001380B
WS001379A
WS001346A
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
Install
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no
missing fasteners.
The pump is transportable and intended to operate either completely or partially
submerged in the pumped liquid. The pump is equipped with a connection for
hose or pipe.
These requirements and instructions only apply when the installation is made
according to the dimensional drawing.
1. Run the cable so that it has no sharp bends, is not pinched, and cannot be
sucked into the pump inlet.
2. Connect the discharge line.
The discharge line can be run vertically or horizontally, but must be without
sharp bends.
3. Lower the pump into the sump.
The cable must not be used for this purpose. You should attach a rope or
similar to the handle or the eyebolts for lowering and lifting the pump.
14 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 17
Heavier pumps must be lifted and lowered down by crane. Suspend the
WS006209A
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.
Alternatively, the pump can be suspended with a lifting chain just above the
sump bottom. Make sure that the pump cannot rotate at startup or during
operation.
5. Connect the motor cable and the starter and monitoring equipment according
to the separate instructions.
Salvador MSHA: Make sure that the impeller rotation is correct. For more
information, see Check the impeller rotation: Pumps without built-in motor
protection (page 21).
Salvador: Make sure that the phase sequence is correct. For more
information, see Check the phase sequence: Pumps with built-in motor
protection (page 22).
Make the electrical connections
General precautions
Installation
Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local
codes and regulations.
• 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.
• Leakage into the electrical parts can cause damaged equipment or a blown
fuse. Keep the end of the motor cable above the liquid level.
• Make sure that all unused conductors are insulated.
• 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.
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosionproof rated.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor,
there is a risk of sudden restart.
Requirements
These general requirements apply for electrical installation:
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 15
Page 18
Installation
Cables
• 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.
• 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.
• The thermal contacts/thermistors must be in use.
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 sheathing must not be damaged and must not have indentations or be
embossed (with markings, etc.) at the cable entry.
• The cable entry seal sleeve and washers must conform to the outside
diameter of the cable.
• 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.
• For SUBCAB cables, the twisted pair copper foil must be trimmed.
Earthing (Grounding)
Electrical Hazard:
• You must earth (ground) all electrical equipment. This applies to the pump
equipment, the driver, and any monitoring equipment. Test the earth
(ground) lead to verify that it is connected correctly.
• If the motor cable is jerked loose by mistake, the earth (ground) conductor
should be the last conductor to come loose from its terminal. Make sure that
the earth (ground) conductor is longer than the phase conductors. This
applies to both ends of the motor cable.
• Risk of electrical shock or burn. You must connect an additional earth(ground-) fault protection device to the earthed (grounded) connectors if
persons are likely to come into physical contact with the pump or pumped
liquids.
Earth (ground) conductor length
The earth (ground) conductor must be 270mm (10.6 in) longer than the phase
conductors in the junction box of the unit.
16 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 19
Product-specific precautions
WS001021B
L1 L2 L3
T3 T4T1 T2
15
13
14
42 31
7
10
5
9
8
6
11
12
17
16
24
22
23
19
20
21
18
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. Connect the ground cable from the level
switch to the other screw at the GC-connection point.
Connect the motor cable to the pump
CAUTION:
Leakage into the electrical parts can cause damaged equipment or a blown fuse.
Keep the end of the motor cable above the liquid level.
1. Check the data plate to see which connections are required for the power
supply.
2. Connect the motor cable conductors, including earth (ground), to the
terminal or starter unit.
3. Make sure that the pump is correctly connected to earth (ground).
4. Firmly tighten the cable entry into its bottom-most position.
The seal sleeve and the washers must conform to the outside diameter of the
cables.
Installation
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosionproof rated.
Cable charts
Connection locations
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 17
Page 20
Installation
1 Starter equipment and main
2 Earth (ground) 14 Transformer
3 Functional ground 15 Capacitor
4 Control leads (T1, T2, T3, T4) 16 Softstarter
5 Phase shifter 17 Level regulator
6 Diode 18 Contactor, start relay or thermal
7 Motor cable 19 Thermal detector in stator
8 Screen 20 Thermal detector in main bearing
9 Pump 21 Jumper
10 Crimp connection 22 Terminal board, terminal plate
11 Crimp isolation 23 Leakage sensor
12 Motor protector 24 Stator leads (U1, U2, U5, U6, V1,
Color code standard
Code Description
13 Coil
leads (L1, L2, L3)
relay
V2, V5, V6, W1, W2, W5, W6,
Z1, Z5, Z6)
BN Brown
BK Black
WH White
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow
Terminal plate markings, 1–phase
Marking Description
A Auxiliary winding
C Common
M Main winding
18 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 21
Stator leads and thermal contacts connection to the terminal plate
WS004777C
773 45 03
51 671 00
8101.160
8101.172
8102.172
8109.282
1 - P H A S E (1~)
V / C
T1
T2
Terminal
plate
STATOR LEADS AND THERMAL CONTACTS 1-PHASE
4 leads
T1
T2
Z1 U2
serial
8 leads
T1
T2
Z1 U6
Z2 Z5
U2 U5
//
8 leads
T1
T2
U2 U6 Z1 Z5
U / M
U1 U1 U1 U5
W / A
Z2 Z6 Z2 Z6
U1,Z5
U6
U2, Z6
U5
Z1 4 leads
Z1 8 leads
Z2
T1,T2
STATOR LEADS 1-ph
RD
GN
BN
YE
YE
BU
BK
WH/YE
Terminal plate
markings 1-phase:
A=Auxiliary winding
C=Common
M=Main winding
STATOR LEADS 3-ph
RD
GN
BN
BU
YE
BK
WH/YE
U1,U5
U2,U6
V1,V5
V2,V6
W1,W5
W2,W6
T1,T2
U2V1
V1
U2
V2
W2
U5
V5
W5
6 leads
D
T1
T2
U2
V2
W2
T1
T2
9 leads
Y serial
9 leads
Y //
V1
T1
T2
V1
T1
T2
V5
U2
V2
W2
V
3 leads
Y
T1
T2
12 leads
Y //
12 leads
D //
12leads
D serial
V1
T1
T2
V5
U2
V2
W2
U6
V6
W6
T1
T2
V1 V5 U2 U6
U2
V2
W2
U5
V5
W5
V1 U6
T1
T2
W2U1
U1
U1
U1 U5UU1 U5 U1 U5 W2 W6U1 W6
V2W1
W1
W1
W1 W5WW1 W5 W1 W5 V2 V6W1 V6
V / C
T1
T2
Terminal
plate
U / M
W / A
6 leads
Y
3 - P H A S E (3~)
STATOR LEADS AND THERMAL CONTACTS 3-PHASE
U/M
V/C
W/A
T1
T2
Terminal plate
Installation
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 19
Page 22
WS004778C
SYMBOLS AND DENOMINATIONS
BN=Brown
BK=Black
WH=White
OG=Orange
GN=Green
GNYE=Green-Yellow
RD=Red
GY=Grey
BU=Blue
YE=Yellow
*SUBCAB AWG/CSA
**GC= Ground check
U/M
V/C
W/A
T1
T2
773 45 03
51 671 00
Terminal plate
8101.160
8101.172
8102.172
8109.282
=Terminal plate
=Screen
=Ground
=Functional ground
=Crimp isolation for
cable, if not in use
=Socket - Plug
=Inside pump
Pump
1 - P H A S E (1~)
22
21
20
GC**
BU/WH*
BN/BK*
GNYE/*
Motor cable
(3/4*
conductors)
YE*
19
18
START RELAY, 1-PHASE
start run
17
16
15
V / C
T1
T2
Terminal
plate
U / M
W / A
BU
BU
Pump
Capacitors
Relay
Thermal
contact
BN
GY
BK
WH
Float switch
BU/WH*
BN/BK*
GNYE/GN*
GC**
(Optional)
BU
3 - P H A S E (3~)
PHASE SHIFTER ON MOTOR CABLE
L3 GY/WH*
L2
L3 GY/WH*
L2 BK/BK*
L1 BN/RD*
W
V
U
L3
L1
L2 BK/BK*
L1 BN/RD*
GNYE
GNYE
Motor cable from grid
(4/4* conductors)
Motor cable to pump
(4/4* conductors)
1 - 0 - 1
min 20m
Pump
Phase shifter
BK
GY
BN
1 - 2
3 - 4
5 - 6
A1
A2
GC**
L1 BN/RD*
L3 GY/WH*
L2 BK/BK*
GNYE/*
YE*
BU*
OG*
V / C
T1
T2
Terminal
plate
U / M
W / A
Motor cable
(4/4*/7*
conductors)
F
G
H
A2
15
16
14
13
SMART
CONTACTOR UNIT, 3-PHASE
BU
BU
Pump
Thermal
contact
Contactor
BK
GY
BN
WH
BK
GY
BN
Float switch
BU/WH*
BN/BK*
GNYE/GN*
GC**
Optional
BU
FLOAT SWITCH OPTIONAL
EU: MAX 400V
US/CDN: MAX 250V
3 - P H A S E (3~)
SCREENED MOTOR CABLE
GNYE
shrink hose
Screen as ground conductor
Subcab
(S3+3/3+S4)
FGB
(3+S)
T1 WH
T2 WH
T3 WH
T4 WH
-
-
-
-
L3
L2L1BK
GY
BN
Motor cable
1
3
5
Pump
Contactor
(GC)
1 - 2
3 - 4
5 - 6
A1
A2
GC**
L1 BN/RD*
L3 GY/WH*
L2 BK/BK*
GNYE/*
YE*
BU*
OG*
V / C
T1
T2
Terminal
plate
U / M
W / A
Motor cable
(4/4*/7*
conductors)
F
G
H
A2
15
16
14
13
CONTACTOR UNIT, 3-PHASE, FLOAT SWITCH. EU OVER 400V, US/CDN OVER 250V
Pump
Contactor
BK
GY
BN
BK
GY
BN
BU
WH
GY
YE
BK
RD
BN
SUPERVISION RELAY
Float switch
BU/WH*
BN/BK*
BN=500-600V
RD=380-460V
SMART
WH
GNYE/GN*
GC**
BU
BU
Thermal
contact
Installation
Motor cable and starter unit connection to the terminal plate
20 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 23
Cable charts, MSHA version
WS004860A
WS004861A
Motor 60 Hz, 1-phase, 115V parallel and 230V serial
Motor 60 Hz, 1-phase, 115V or 220-240V
Installation
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.
Check the direction of rotation each time the cable has been re-connected and
after phase or total supply failure.
1. Start the motor.
2. Stop the motor.
3. Check that the impeller rotates in the correct direction.
The correct direction of impeller rotation is clockwise when you look at the
pump from above. When started, the pump will react in the opposite
direction to the impeller rotation.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 21
Page 24
L2
L1 L2 L3
L3L1
WS001397A
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.
For 3-phase pumps with external starters or without built-in motor
protection, the phases must be shifted on the output terminal of the starter.
Check the phase sequence: Pumps with built-in motor protection
Follow this procedure if your product is equipped with the rotation control
SMART™.
WARNING:
The starting jerk can be powerful.
The correct direction of impeller rotation is clockwise when you look at the pump
from above. When started, the pump will react in the opposite direction to the
impeller rotation.
22 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 25
L2
L1 L2 L3
L3L1
WS001397A
Figure 4: Start reaction
WS006205A
WS006207A
1. Connect the pump to power as follows:
Installation
Condition Action
The pump has a CEE plug with
Connect the plug.
internal phase shifter.
The pump has a phase shifter with an
on/off switch.
The pump has neither a CEE plug
with internal phase shifter, nor a
Turn the knob on the phase shifter in
either direction.
1. Connect the pump to power.
2. Switch on the power.
phase shifter with an on/off switch.
The pump should start. If it does not, then continue to the next step.
2. If the pump does not start and the fuses are correct, then shift two phases:
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 23
Page 26
WS006206A
WS006208A
Installation
Condition Action
The pump has a CEE plug with
internal phase shifter.
The pump has a phase shifter with an
on/off switch.
1. Pull out the plug.
2. Shift two phases.
3. Wait until the motor has stopped.
4. Connect the plug.
1. Turn the knob on the phase
shifter to neutral position.
2. Wait until the motor has stopped.
3. Turn the knob to the opposite
position from before.
The pump has neither a CEE plug
with internal phase shifter, nor a
Transpose two phase leads on the
output terminal of the starter.
phase shifter with an on/off switch.
NOTICE:
Do not reverse the phase sequence while the pump is running. Temporarily
incorrect rotation can occur, resulting in damage to motor electronics and
rotating parts.
The pump should start. If it does not, then contact a certified electrician to
check the mains and the junctions.
24 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 27
Operation
WS006209A
Precautions
WARNING:
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge line blocked, or the discharge
• 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.
Operation
valve closed.
Distance to wet areas
Electrical Hazard:
• Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to
the unit when being in contact with the pumped or mixed liquid.
• Risk of electrical shock. This unit has not been investigated for use in
swimming pools. If used in connection with swimming pools special safety
regulations apply.
Noise level
NOTICE:
The noise level of the product is lower than 70 dB. However, the noise level of
70 dB may be exceeded in some installations and at certain operating points on
the performance curve. Make sure that you understand the noise level
requirements in the environment where the pump is installed. Failure to do so
may result in hearing loss or violation of local laws.
Start the pump
DANGER:
If you need to work on the pump, make sure that it is isolated from the power
supply and cannot be energized.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 25
Page 28
WS006209A
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.
• Make sure nobody is close to the unit when it is started. The unit will jerk in
the opposite direction of the impeller rotation.
• Never put your hand into the pump housing.
NOTICE:
Make sure that the rotation of the impeller is correct. For more information, see
Check the impeller rotation.
1. Inspect the pump. Check that there is no physical damage to the pump or
cables.
2. Check the oil level in the oil housing.
3. Remove the fuses or open the circuit breaker, and check that the impeller can
be rotated freely.
4. Check that the monitoring equipment (if any) works.
5. Check that the impeller rotation is correct.
6. Start the pump.
Clean the pump
The pump must be cleaned if it has been running in very dirty water. If clay,
cement or other similar dirt is left in the pump it may clog the impeller and seal,
preventing the pump from working.
Let the pump run for a while in clean water, or flush it through the discharge
connection.
26 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 29
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.
• Rinse the unit thoroughly with clean water before working on the unit.
• Rinse the components in water after dismantling.
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.
• 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.
Maintenance
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.
For an optimal corrosion protection, all O-rings and adjacent surfaces must be
coated with Exxon Mobil Unirex N3 or equivalent.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 27
Page 30
WS006894A
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.
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
y class
50 1.0
70, 80 2.7 (2) 5.4 (4) 9.0
100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) 115
Table 2: Steel, torque Nm (ft-lbs)
Propert
y class
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
(0.74)
2.0
(1.5)
3.0
(2.2)
8.0
(5.9)
15 (11) 27 (20) 65 (48) 127
22 (16) 44 (32) 76 (56) 187
(6.6)
(84.8)
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
(138)
248
(183)
(93.7)
364
(268)
481
(355)
220
(162)
629
(464)
434
(320)
1240
(915)
— —
8.8 2.9
(2.1)
10.9 4.0
5.7
(4.2)
9.8
(7.2)
8.1 (6) 14 (10) 33 (24) 65 (48) 114
(2.9)
28 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
24 (18) 47 (35) 81(60) 194
(143)
277
(84)
(204)
385
(285)
541
(399)
665
(490)
935
(689)
1310
(966.2)
1840
(1357)
Page 31
Maintenance
Propert
y class
12.9 4.9
Hexagon screws with countersunk heads
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
(3.6)
9.7
(7.2)
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.
17 (13) 40 (30) 79 (58) 136
Service
Regular inspection and service of the pump ensures more reliable operation.
Type of
service
Inspection To prevent operational interruptions and
Major
overhaul
Purpose Inspection
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.
To secure a long operating lifetime for the
product. It includes replacement of key
components and the measures taken during
an inspection.
(100)
333
(245)
649
(480)
1120
(825.1)
interval
Twice a year or
every 2,000 hours
Every year, under
normal operating
conditions
2210
(1630)
Inspection
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).
Regular inspection and service of the pump ensures more reliable operation.
Service item Action
Visible parts
on the pump
and
installation
Pipes, valves,
and other
peripheral
equipment
Impeller 1. Check for worn or damaged parts.
1. Check that all screws, bolts, and nuts are properly
tightened.
2. Check the condition of the pump casing, strainer, cover,
lifting handles, eye bolts, ropes, chains, and wires.
3. Check for worn or damaged parts.
4. Adjust and/or replace if necessary.
1. Check for worn or damaged parts.
2. Adjust and/or replace if necessary.
2. Adjust and/or replace if necessary.
Wear on the impeller or surrounding parts necessitates fine
adjustments of the impeller or replacement of worn parts.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 29
Page 32
Maintenance
Service item Action
Oil 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).
A smaller amount of water is not harmful for the mechanical
seal.
Cable entry 1. Check that the following requirements are met:
• The cable entry must be firmly tightened into its
bottom-most position.
• MSHA pump version: The cable entry must be
tightened so that the clearance between the gland
screw and the MSHA cover is >3.175 mm (1/8 in).
Use a feeler gauge to check the clearance.
• MSHA pump version:The gland screw is secured from
rotating with a screw and washer.
• The seal sleeve and the washers must conform to the
outside diameter of the cables.
2. Cut off a piece of the cable so that the seal sleeve closes
around a new position on the cable.
3. Replace the seal sleeve, if necessary.
Inspection
volume
1
1. Check that the inspection screw is properly tightened.
2. Remove the inspection screw.
3. Drain all liquid, if any.
4. If there is oil in the inspection volume, then empty the
oil and check again after one week. If there is oil in the
inspection volume again, then replace the mechanical
seal. Contact an authorized service shop.
5. If there is water in the inspection volume, then check
that the inspection screw O-ring is not damaged.
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.
Cooling system If the flow through the system has been partly restricted,
then rinse and clean.
Level sensors
or other
sensor
1. Check the functionality.
2. Repair or replace any damaged equipment.
3. Clean and adjust the equipment.
equipment
Starter
equipment
Insulation
resistance in
the stator
1. Check the condition and functionality.
2. Contact an electrician, if necessary.
1. Check the insulation between:
• Phase–phase on the stator
• Phase–earth (ground)
The insulation should be > 1 megohm. Use a 1000-VDC
megger to test the insulation.
2. If the resulting value is < 1 megohm, then contact an
authorized service shop.
1
Regardless of individual applications, the inspection volume should not be inspected less frequently than
the intervals for normal applications and operating conditions at media (liquid) temperatures <40°C
(104°F).
30 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 33
Major overhaul
1 2
WS006203A
WS004762A
Maintenance
For a major overhaul, take this action in addition to the tasks listed under
Inspection.
Service item Action
Change the oil
A paraffin oil with viscosity close to ISO VG32 is recommended. The pump is
delivered from the factory with this type of oil. In applications where poisonous
properties are of less concern, a mineral oil with viscosity up to ISO VG32 can be
used.
1. Inspection screw
2. Oil screw
Figure 6: Symbols
Empty the oil
1. Lay the pump on its side.
2. Remove the oil screw.
Support and main
Replace the bearings with new bearings.
bearing
Mechanical seal Replace with new seal units.
Lock the pump with supports to prevent it from rolling over.
WARNING:
The oil housing may be pressurized. Hold a rag over the oil plug
to prevent oil from spraying out.
3. Turn the pump so that the oil hole faces downwards and let the oil run out.
Some oil will be left in the oil housing.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 31
Page 34
WS004782A
WS004763A
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. Put the oil screw back and tighten it.
Replace the impeller
Remove the impeller
WARNING:
A worn impeller and/or pump housing can have very sharp edges. Wear
protective gloves.
1. Remove the stand and the pump housing.
32 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 35
WS004783A
2. Loosen the impeller:
WS004784A
a) Lock the impeller to prevent rotation.
Use pliers, a screwdriver, or similar.
b) Remove the impeller screw and washer.
Maintenance
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.
Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.)
extension.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 33
Page 36
WS004785A
WS004786A
WS006895A
Maintenance
c) Pull off the impeller.
Install the impeller
1. Prepare the shaft:
a) Polish off any flaws with a fine emery cloth.
b) Coat the inner conic, the outer cylindrical surfaces, and the thread of the
The end of the shaft must be clean and free from burrs.
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.
2. Assemble the adjustment screw with the conical sleeve.
Make sure that there is a 1.5 mm (0.06 in.) gap.
34 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 37
WS004769A
WS004787A
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.
5. Assemble the conical sleeve in the impeller.
Make sure that the conical sleeve bottoms in the impeller.
6. Assemble the impeller with the conical sleeve onto the shaft.
Make sure that the conical sleeve bottoms in the impeller.
7. Fasten the impeller:
a) Place the washer on the impeller screw.
b) Lock the impeller to prevent rotation.
Use pliers, a screwdriver, or similar.
c) Tighten the impeller screw.
Tightening torque: 22 Nm (16.2 ft-lbs)
d) Tighten a further 1/8 turn, 45°.
The screw will be loaded to its yield point and the load capacity of the
joint will be higher.
e) Check that the impeller can rotate easily.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 35
Page 38
WS004788A
WS004789A
Maintenance
8. Mount the O-ring, the pump housing, and stand.
36 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 39
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:
• Disconnect and lock out the power supply except when conducting checks
that require voltage.
• Make sure that no one is near the pump when the power supply is
reconnected.
• When troubleshooting electrical equipment, use the following:
• Universal instrument multimeter
• Test lamp (continuity tester)
• Wiring diagram
Troubleshooting
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 37
Page 40
WS002614A
WS002616A
WS002615A
Troubleshooting
The pump does not start, for pumps with SMART
Cause Remedy
The phase sequence may
be incorrect.
1. Pull out the plug.
2. Do one of the following:
• Shift two phases by turning two contact pins
with a screwdriver.
NOTICE:
Do not take the plug apart.
Figure 7: CEE plug
• Turn the knob to the opposite position 1, with
8 seconds delay.
NOTICE:
Do not reverse the phase sequence while the
motor is running. Doing so may cause
incorrect rotation resulting in damages to the
motor electronics and the rotating parts.
Respect the 8 seconds delay.
™
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 10).
The pump does not start
WARNING:
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.
Figure 8: Phase shifter On/Off switch
• If no glove or phase shifter is used, then shift
two phase conductors in the cabinet.
38 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 41
Cause Remedy
Troubleshooting
An alarm signal has been
triggered on the control
panel.
The pump does not start
automatically, but can be
started manually.
The installation is not
receiving voltage.
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.
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 is stuck. Clean:
• The impeller
• 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,
see Product Description (page 10).
The pump does not stop when a level sensor is used
WARNING:
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.
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.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 39
Page 42
Troubleshooting
Cause Remedy
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 10).
• 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.
The pump starts-stops-starts in rapid sequence
Cause Remedy
The pump starts due to
back-flow which fills the
sump to the start level
again.
The self-holding function
of the contactor
malfunctions.
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.
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 10).
The pump runs but the motor protection trips
WARNING:
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.
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.
40 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 43
Cause Remedy
WS002610A
WS002611A
WS002612A
Troubleshooting
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.
The density of the
pumped fluid is too high.
The ambient temperature
exceeds the maximum
ambient temperature.
The cooling system is
clogged.
There is a malfunction in
the overload protection.
• Check the fuses. Replace fuses that have tripped.
• If the fuses are intact, 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 megohms.
2. If the insulation is less:
Contact the local Grindex service shop.
Make sure that the maximum density is 1100 kg/m
(9.2 lb/US gal)
• Change to a more suitable pump.
• Contact the local Grindex service shop.
The pump must not be used for such an application.
Rinse and clean if the flow through the system has
been partly restricted.
Replace the overload protection.
3
The SMART™ motor
protection may need to
be reset.
Try one of the following:
• Reset the SMART™ motor protection by pulling
and reinserting the power plug.
• Or, disconnect and reconnect the power.
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 10).
The pump delivers too little or no water
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected
startup. Failure to do so could result in death or serious injury.
WARNING:
The pump will restart
automatically after a corrected
phase fault or power cut.
NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may
result in equipment damage.
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 41
Page 44
Troubleshooting
Cause Remedy
The impeller rotates in
the wrong direction.
• If it is a 3-phase pump without SMART™,
transpose two phase leads.
• If it is a 3-phase pump with SMART™, correct the
internal wiring.
• If it is a 1-phase pump:
Contact the local Grindex service shop.
One or more of the valves
are set in the wrong
positions.
• 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.
The impeller is difficult to
rotate by hand.
• Clean the impeller.
• Clean out the sump.
• Check that the impeller is properly trimmed.
The pipes are obstructed. Clean out the pipes to ensure a free flow.
The pipes and joints leak. Find the leaks and seal them.
There are signs of wear
Replace the worn parts.
on the impeller, pump,
and casing.
The liquid level is too low. • Check that the level sensor is set correctly.
• 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 10).
42 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 45
Technical Reference
Application limits
Data Description
Technical Reference
Motor data
Media (liquid)
temperature
pH of the pumped
media (liquid)
Media (liquid)
density
Depth of
immersion
Other For specific weight, current, voltage, power rating, and
Feature Description
Motor type Squirrel-cage induction motor
Frequency Standard version: 50 or 60 Hz
Supply 1-phase or 3-phase
Maximum temperature 40°C (104°F)
5–8
Maximum density: 1100 kg/m3 (9.2 lb. per US gal.)
20 m (65 ft.)
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.
MSHA version: 60 Hz
Starting method Direct on-line
Maximum starts
per hour
Code compliance IEC 60034-1
Rated output
variation
Voltage variation
without
overheating
Voltage imbalance
tolerance
Maximum
frequency
variation (for
pumps with
SMART™)
Stator insulation
class
30 evenly spaced starts per hour
±10%
±10%, provided that it does not run continuously at full load
2%
±3 Hz
F (155°C [310°F])
Specific motor data, standard version
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 43
Page 46
Technical Reference
1-phase, 50 Hz
3-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,APower factor, cos
φ
220 8.7 31 0.99
230 8.4 32 0.98
240 8.3 34 0.96
Motor type:
• 2,800 rpm
• Rated output 2.2 kW (3.0 hp)
• Maximum power consumption 2.7 kW (3.6 hp)
Voltage, V Rated current, A Starting current,APower factor, cos
φ
1-phase, 60 Hz
220 D 8.1 44 0.88
230 D 8.1 47 0.85
240 D 8.1 48 0.81
380 Y 4.7 24 0.89
400 Y 4.5 25 0.88
415 Y 4.3 23 0.89
440 Y 4.2 25 0.85
500 Y 3.6 20 0.87
525 Y 3.7 22 0.82
550 Y 3.7 22 0.77
Motor type:
• 3,405 rpm
• Rated output 1.8 kW (2.4 hp)
• Maximum power consumption 2.2 kW (3.0 hp)
Voltage, V Rated current, A Starting current,APower factor, cos
φ
220 10.0 35 0.98
230 9.9 37 0.97
240 9.8 39 0.95
3-phase, 60 Hz
Motor type:
• 3,410 rpm
• Rated output 2.6 kW (3.5 hp)
• Maximum power consumption 3.1 kW (4.2 hp)
44 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 47
Technical Reference
Voltage, V Rated current, A Starting current,APower factor, cos
φ
200 Y 11.0 61 0.88
208 Y 10.0 71 0.84
220 D 9.6 65 0.85
220 D parallel 9.4 59 0.9
220 Y parallel 9.4 59 0.88
230 D 10.0 67 0.79
230 D parallel 9.2 62 0.87
230 Y parallel 9.5 65 0.83
240 D 9.8 67 0.78
240 Y parallel 10.0 67 0.76
380 Y 5.6 37 0.86
380 Y parallel 5.4 34 0.9
400 Y 5.5 37 0.83
400 Y parallel 5.4 36 0.85
440 D serial 4.7 29 0.9
440 Y 4.6 26 0.91
440 Y serial 4.7 29 0.88
460 D serial 4.6 31 0.87
460 Y 4.4 28 0.9
460 Y serial 4.7 32 0.83
480 Y 4.4 29 0.86
480 Y serial 4.9 34 0.78
575 Y 3.5 22 0.9
600 Y 3.5 23 0.88
Specific motor data, MSHA version
1-phase, 60 Hz
Motor type:
• 3,300 rpm
• 1.8 kW (2.4 hp)
• Maximum power consumption 2.2 kW
Voltage, V Rated current, A Starting current,APower factor, cos
φ
220 10 35 0.98
230 9.9 37 0.97
240 9.8 39 0.95
3-phase, 60 Hz
Motor type:
8109.282/.583 Salvador Installation, Operation, and Maintenance Manual 45
Page 48
WS004708A
33
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,APower factor, cos
460 Y 4.4 28 0.9
480 Y 4.4 29 0.86
575 Y 3.5 22 0.9
600 Y 3.5 23 0.88
Dimensions and weights
All measurements in the illustration are in millimeters, if not otherwise specified.
φ
Figure 9: Standard version
46 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Page 49
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 47
Page 50
0 2 4 6 8 10 12 14
0 50 100 150 200 250
0
2
4
6
8
10
12
14
16
0
10
20
30
40
50
1.0
1.5
2.0
2.5
1
2
3
4
Q [l/s] / [usgpm]
1~
1~
3~
3~
P1 [hp] / [kW]
H [ft] / [m]
WS006388A
0 2 4 6 8 10 12 14
0 50 100 150 200 250
0
2
4
6
8
10
12
14
16
0
10
20
30
40
50
1.0
1.5
2.0
2.5
3.0
1
2
3
4
Q [l/s] / [usgpm]
1~
1~
3~
3~
P1 [hp] / [kW]
H [ft] / [m]
WS006389A
P1 [hp] / [kW ]
H [ft] / [m]
0
0
00
10
20
30
40
50
1
2
3
4
2
4
6
8
10
12
14
16
1.0
1.5
2.0
2.5
3.0
2 4 6 8 10 12 14
50 100 150 200 250
Q [l/s] / [usgpm]
WS006387A
Technical Reference
Standard pump version
Figure 11: 50 Hz, 1- and 3-phase
MSHA pump version
48 8109.282/.583 Salvador Installation, Operation, and Maintenance Manual
Figure 13: 60 Hz, 3-phase
Figure 12: 60 Hz, 1- and 3-phase
Page 51
Page 52
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Grindex
Gesällvägen 33
174 87 Sundbyberg
Sweden
Tel: +46-8-606 66 00
Fax: +46-8-745 53 28
www.grindex.com
883983_2.0_en-US_2013-04_IOM_8109.282/.583
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The original instruction is in English. All non-English
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