Grundfos HS Installation And Operating Instructions Manual

HS

Horizontal split case pump

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

http://net.grundfos.com/qr/i/99296580

English (GB) Installation and operating instructions

English (GB)

Original installation and operating instructions

These installation and operating instructions
describe HS.

Sections 1-5 give the information necessary to be
able to unpack, install and start up the product in a
safe way.

Sections 6-12 give important information about the
product, as well as information on service, fault
finding and disposal of the product.

CONTENTS

1. General information

1.1 Symbols used in this document

2. Receiving the product

2.1 Inspecting the product

3. Installing the product

3.1 Mechanical installation

3.2 Electrical connection

3.3 Pipes

3.4 Inlet pipe guidelines

4. Starting up the product

4.1 Prestart checks

4.2 Priming

4.3 Startup

4.4 Final alignment

4.5 Greasing the grid coupling

5. Storing and handling the product

5.1 Handling the product

5.2 Temporary storage

6. Product introduction

6.1 Applications

6.2 Pumped liquids

6.3 Identification

7. Operating the product

7.1 Operating checks

7.2 Frequency of starts and stops

7.3 Operating at reduced flow and/or head

8. Servicing the product

8.1 Maintaining the product

9. Taking the product out of operation

9.1 Short-time shutdown

9.2 Long-term shutdown

10. Fault finding the product

11. Technical data

11.1 Operating conditions

11.2 Flange forces and torques

12. Disposing of the product

Page

1. General information

Grundfos HS horizontal split case pumps are
supplied either as a complete pump with motor, base
frame and approved coupling guard or as a bare
shaft pump.

These instructions apply to both types.

2

The HS pump can be driven by an electric motor or

2

another type of driver. In the following we assume

3

that the pump is driven by an electric motor.

3

1.1 Symbols used in this document

3

3

1.1.1 Warnings against hazards involving risk of

6
7
9

11

11
11
12
13
14

15

15
15

16

16
16
16

The text accompanying the three hazard symbols

19

DANGER, WARNING and CAUTION is structured in

19

the following way:
19
19

19

19

21

21
21

22

25

25
27

27

Prior to installation, read this document
and the online version of the installation
and operating instructions. Installation and
operation must comply with local
regulations and accepted codes of good
practice.

death or personal injury

DANGER

Indicates a hazardous situation which, if
not avoided, will result in death or serious
personal injury.

WARNING

Indicates a hazardous situation which, if
not avoided, could result in death or
serious personal injury.

CAUTION

Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

2

1.1.2 Other important notes

A blue or grey circle with a white graphical
symbol indicates that an action must be
taken.

A red or grey circle with a diagonal bar,
possibly with a black graphical symbol,
indicates that an action must not be taken
or must be stopped.

If these instructions are not observed, it
may result in malfunction or damage to the
equipment.

Tips and advice that make the work easier.

2. Receiving the product

2.1 Inspecting the product

The pump is delivered from factory in a crate or
wooden box specially designed for transport by a
forklift truck or a similar vehicle.

Upon receipt, check the pump visually to determine
whether any damage has happened to it during
transport or handling.

Check especially for these points:

1. broken or cracked equipment, including base
frame, motor or pump feet and flanges

2. broken motor fan cover, bent eyebolts or
damaged terminal box

3. missing parts.

Parts or accessories are sometimes wrapped
individually or fastened to the equipment.

If any damage or losses have occurred, promptly
notify Grundfos' representative and the carrier's
agent at once.

Bolts for HS bare shaft pumps have US
threads for which inch tools are required.

Bolts for coupling guard and for mounting
of pump and motor on the base frame
have metric threads.

3. Installing the product

3.1 Mechanical installation

WARNING

Crushing hazard

Death or serious personal injury

- Make sure that all installations are
performed by persons experienced in
the placement, alignment and
connection of pumping equipment.

3.1.1 Location

Install the pump with accessibility for inspection and
maintenance. Allow ample space and headroom for
the use of an overhead crane or hoist sufficiently
strong to lift the unit.

Fig. 1 HS pump with accessibility for

Install the pump as close as possible to the supply of
pumped liquid, so that the inlet pipe is as short and
direct as possible.

3.1.2 Foundation

We recommend that you install the pump on a
concrete foundation which is heavy enough to
provide permanent and rigid support for the entire
pump. The foundation must be capable of absorbing
any vibration, normal strain or shock. We
recommend that the weight of the concrete
foundation is 3 times the weight of the complete
pump unit. For specific requirements, consult the
contractor, engineer, or established industry
standards.

In installations where silent operation is particularly
important, we recommend a foundation that is up to
5 times as heavy as the complete pump unit.

inspection and headroom for the use of
an overhead crane

English (GB)

TM04 0382 1016

3

3.1.3 Vibration dampers

5-10 mm

Bolt length

above base

frame

Thickness of

base frame

19 to 32 mm

allowance

for grout

Base frame

Top of
foundation
left rough

Pipe sleeveLugWasher

Wedges and
shims left in
place

English (GB)

Vibration dampers may be required to prevent pump
vibrations from being transmitted to the building or
the pipes. In order to select the right type of vibration
damper, you need this information:

• Forces transmitted through the damper.

• Motor speed. Take the motor speed into account
in the case of speed control.

• Desired dampening in %. The recommended
value is 70 %.

The choice of vibration dampers differs from
installation to installation. In certain cases a wrong
damper may increase the vibration level. Vibration
dampers must therefore be sized by the supplier of
the vibration dampers.

3.1.4 Expansion joints

Expansion joints provide these advantages:

• absorption of thermal expansion and contraction
of pipes caused by variations in liquid
temperature

• reduction of mechanical influences in connection
with pressure surges in the pipes

• isolation of structure-borne noise in the pipes
(only rubber bellows expansion joints).

Do not fit expansion joints to make up for
inaccuracies in the pipes, such as centre
displacement or misalignment of flanges.

Fit the expansion joints at a minimum distance of 2
pipe diameters (DN) away from the pump flange on
the inlet side. This prevents turbulence in the joints,
thus ensuring optimum inlet conditions and minimum
pressure drop on the outlet side.

At flow velocities greater than 2.4 m/s, we
recommend that you fit larger expansion joints
matching the pipes.

3.1.5 Foundation and preliminary alignment

procedure

The foundation and preliminary alignment procedure
has four steps:

1. pouring of foundation

2. shimming of base frame

3. preliminary alignment

4. grouting.

Pouring of foundation

We recommend the following procedure to ensure a
good foundation:

1. Pour the foundation without interruptions to
within 19-32 mm of the final level. Use vibrators
to ensure that the concrete is evenly distributed.
The top surface must be well scored and grooved
before the concrete sets. This provides a bonding
surface for the grout.

2. Embed anchor bolts in the concrete as shown in
fig. 2. Allow enough bolt length to reach through
grout, shims, lower base frame, nuts and
washers.

Fig. 2 Typical anchor bolt design

Let the foundation cure for several days before the
base frame is shimmed and grouted.

Shimming of base frame

TM04 0383 0608TM04 0381 0608

4

Fig. 3 Shimming of base frame and levelling of

pump

1. Lift/jack up the base frame to the final level 19-32

Vertical Horizontal

Vertical Horizontal

mm above the concrete foundation, and support
the base frame by means of blocks and shims,
both at the anchor bolts and midway between
bolts. See fig. 3.

2. Level the base frame by adding or removing
shims under the base frame. See fig. 3.

3. Tighten the anchor bolt nuts against the base
frame. Make sure the pipes can be aligned to the
pump flanges without putting strain on the pipes
or flanges.

Preliminary alignment

DANGER

Electric shock

Death or serious personal injury

- Before starting work on the pump, make
sure that the power supply has been
switched off and that it cannot be
accidentally switched on.

The pump and motor are pre-aligned on the base
frame from the factory. Some deformation of the
base frame may occur during transport and it is
therefore essential to check alignment at the
installation site prior to final grouting.

Inaccurate alignment results in vibration and
excessive wear on the bearings, shaft and wear
rings.

2. Checking soft foot on pump and motor
A pump or a motor having a soft foot can be

compared to sitting down at a table and finding that
the table rocks when someone leans on it.
Technically, it is a condition where the feet of a motor
or a pump are not at the same level as the base
plate.

To check for soft foot, set the pump or motor on its
base plate and bolt it down. Set up a dial gauge on
one foot, loosen the hold-down bolt, and watch the
dial gauge. If the dial gauge indicator moves while
loosening the bolt, the pump or motor has soft foot.
The movement measured by the dial gauge indicates
how many shims you need to level the pump or
motor. Repeat this procedure at all four corners.

If the pump was installed a long time ago, the
stresses induced in the pump casing by soft foot can
cause permanent deformation of the casing.

3. Checking parallel alignment
Place a straight edge across both coupling rims at

the top, the bottom and both sides. See fig. 4. After
each adjustment, recheck all features of alignment.
Parallel alignment is correct when the measurements
show that all points of the coupling faces are within ±

0.2 mm of each other.

English (GB)

Carry out alignment of the motor only, as
pipe strain will occur if the pump is shifted.

Carry out alignment of the motor by placing shims of
different thickness under the motor. If possible,
replace several thin shims with one thick shim.

The preliminary alignment procedure has four steps:

1. Checking coupling clearance
Make sure that the gap between the coupling halves

is equal to the values in the table and that the
keyways are 180 ° displaced.

For a coupling with

an outside diameter

of ∅ [mm]

∅90-213 3.2 0/-1

∅251-270 4.8 0/-1

∅306-757 6.4 0/-1

Coupling clearance

[mm]

Nominal Tolerance

Fig. 4 Checking parallel alignment

4. Checking angular alignment
Insert a pair of inside callipers or a taper gauge at

four points at 90 ° intervals around the coupling. See
fig. 5. The angular alignment is correct when the
measurements show that all points of the coupling
faces are within ± 0.2 mm of each other.

Fig. 5 Checking angular alignment

Recheck the coupling clearance and tighten the set
screws on the couplings.

TM03 0209 4504TM03 0213 4504

5

Grouting

5-10 mm

Base frame

Grout

Levelling
wedges or
shims left
in place

Top of
foundation
(rough)

19 to 32

mm grout

Formwork

English (GB)

Grouting compensates for uneven foundation,
distributes the weight of the unit, dampens vibrations
and prevents shifting. Use an approved,
non-shrinking grout. If you have questions or doubts
about the grouting, consult an expert on grouting.

Proceed as follows:

1. Build a strong formwork around the foundation to
contain the grout.

2. Soak the top of the concrete foundation
thoroughly, then remove surface water.

3. Fill the formwork with grout up to the top edge of
the base frame. See fig. 6. Allow the grout to dry
thoroughly before attaching the pipe to the pump.
24 hours is sufficient time with approved grouting
procedure.

4. When the grout has thoroughly hardened, check
the anchor bolt nuts and tighten them if
necessary.

5. Approximately two weeks after the grout has
been poured, or when the grout has thoroughly
dried, apply an oil-based paint to the exposed
edges of the grout to prevent air and moisture
from getting in contact with the grout.

3.2 Electrical connection

The electrical connections must be carried out by an
authorised electrician in accordance with local
regulations.

DANGER

Electric shock

Death or serious personal injury

- Before you remove the terminal box
cover and before you remove or
dismantle the pump, make sure that the
power supply has been switched off and
that it cannot be accidentally switched
on.

The operating voltage and frequency are marked on
the motor nameplate.

Make sure that the motor is suitable for the power
supply of the installation site.

Carry out the electrical connections as shown on the
motor nameplate or in the wiring diagram on the
back of the terminal box cover.

For further information, contact the motor supplier.

DANGER

Electric shock

Death or serious personal injury

- Whenever you use powered equipment
in explosive surroundings, observe the
rules and regulations generally or
specifically imposed by the relevant
responsible authorities or trade
organisations.

Fig. 6 Sectional view of foundation with anchor

6

bolt, grouting and base frame

TM04 0384 0608

3.2.1 Frequency converter operation

You can connect all three-phase motors to a
frequency converter.

However, frequency converter operation often
exposes the motor insulation system to a heavier
load and causes the motor to be more noisy than
usual due to eddy currents caused by voltage peaks.

If in doubt whether the supplied motor can
handle frequency converter operation,
contact the motor supplier.

In addition, large motors driven via a frequency
converter will be loaded by bearing currents.

When the pump is operated via a frequency
converter, check the following operating conditions:

Operating
conditions

2-, 4- and 6-pole
motors of 45 kW
and up

Noise-critical
applications

Particularly
noise-critical
applications

Cable length Fit a cable that meets the

Supply voltage
up to 500 V

Supply voltage
between 500 V
and 690 V

Supply voltage
of 690 V and
upwards

Action

Check that one of the motor
bearings is electrically isolated.
Contact Grundfos.

Fit a dU/dt filter between the
motor and the frequency
converter. It reduces the voltage
peaks and thus the noise.

Fit a sinusoidal filter.

specifications laid down by the
frequency converter supplier.
The length of the cable between
the motor and frequency
converter affects the motor
load.

Make sure that the motor is
suitable for frequency converter
operation.

• Fit a dU/dt filter. It reduces
the voltage peaks and thus
the noise.

• Or make sure that the motor
has reinforced insulation.

• Fit a dU/dt filter.

• Make sure that the motor
has reinforced insulation.

3.3 Pipes

Protective covers are fitted to the inlet and
outlet ports to prevent foreign bodies from
entering the pump during transportation
and installation. Remove these covers
from the pump before connecting any
pipes.

Inlet and outlet pipe

In order to minimise friction losses and hydraulic
noise in the pipes, choose a pipe that is one or two
sizes larger than the pump inlet and outlet ports.
Typically, flow velocities must not exceed 2 m/s (6
ft/sec) for the inlet pipe (port) and 3 m/s (9 ft/sec) for
the outlet pipe (port).

Make sure that the NPSH available (NPSHA) is
higher than the NPSH required (NPSHR). NPSH =
Net Positive Suction Head.

3.3.1 General precautions

When installing the pipes, observe these
precautions:

1. Always run the pipes directly to the pump.

2. Do not move the pump to the pipes. This could
make the final alignment impossible and cause
stress to the pump flanges and pipes.

Make sure that both the inlet and outlet
pipes are independently supported near
the pump so that no strain is transmitted to
the pump when you tighten the flange
bolts. Use pipe hangers or other supports
with necessary spacing to provide support.

3. When you use expansion joints in the pipe
system, fit the joints at a minimum distance of 2
pipe diameters away from the pump on the inlet
side. This prevents turbulence in the joints, thus
ensuring optimum inlet conditions.

4. Install the pipes as straight as possible and avoid
unnecessary bends. Where necessary, use 45 °
or long-sweep 90 ° fittings to reduce friction loss.

5. Make sure that all pipe joints are tight.

6. Where you use flanged joints, ensure that the
inside diameters match properly.

7. Remove burrs and sharp edges when making up
joints.

8. Make sure that the pipes do not cause stress or
strain in the pump.

9. Provide for expansion of pipe material by means
of expansion joints on both sides of the pump.

10. Always allow sufficient space and accessibility for
maintenance and inspection.

English (GB)

7

3.3.2 Inlet pipes

English (GB)

Place the pump below system level whenever
possible. This will facilitate priming, assure a steady
liquid flow and provide a positive suction head.

The sizing and installation of the inlet pipe
is extremely important.

You can avoid many NPSH problems if you install the
inlet pipe properly. See section 3.3.1 General

precautions.

In section 12. Disposing of the product, common
inlet pipe installations are illustrated for two
situations:

• flooded systems
Closed systems and open systems where the
liquid level is above the pump inlet.

• suction lift systems
Closed systems and open systems where the
liquid level is below the pump inlet.

3.3.3 Valves in the inlet pipe

If the pump is operating under permanent suction lift
conditions, install a non-return valve in the inlet pipe
to avoid having to prime the pump each time it is
started. The non-return valve must be of the flap type
or a foot-valve with a minimum of pressure loss.

3.3.4 Outlet pipe

The outlet pipe is usually preceded by a non-return
valve and an isolating or throttle valve. The
non-return valve protects the pump against
excessive counterpressure and reverse rotation of
the pump and prevents backflow through the pump in
case of operational stop or failure of the motor.

In order to minimise friction losses and hydraulic
noise in the pipes, flow velocities must not exceed 3
m/s (9 ft/sec) in the outlet pipe (port).

On long horizontal runs, keep the pipe as level as
possible.

Avoid high spots, such as loops as they will collect
air and throttle the system or lead to uneven
pumping.

3.3.5 Auxiliary pipes

Drains

Install the drain pipes from the pump casing and
stuffing boxes to a convenient disposal point.

Flushing pipes

• Pumps fitted with stuffing boxes
When the inlet pressure is below the ambient

pressure, supply the stuffing boxes with liquid to
provide lubrication and prevent the ingress of air.
This is normally achieved via a flushing pipe from the
outlet side to the stuffing box. You can fit a control
valve or orifice plate in the flushing pipe to control
the pressure to the stuffing box.

If the pumped liquid is dirty and cannot be used for
flushing the packing rings, we recommend a
separate clean, compatible liquid supply to the
stuffing box at 1 bar (15 psi) above the inlet
pressure.

• Pumps fitted with mechanical seals
Seals requiring re-circulation will normally be

provided with a flushing pipe from the pump casing.

3.3.6 Measuring instruments

To ensure continuous monitoring of operation, we
recommend that you install pressure gauges on the
pump inlet and outlet flanges. The pressure gauge
on the inlet side must be capable of measuring
vacuum. The pressure tappings must only be opened
for test purposes. The measuring range of the outlet
side pressure gauge must be minimum 20 % above
the maximum pump outlet pressure.

When measuring with pressure gauges on the pump
flanges, note that a pressure gauge does not register
dynamic pressure (velocity pressure). The diameters
of the inlet and outlet flanges are different, and this
results in different flow velocities in the two flanges.
Consequently, the pressure gauge on the outlet
flange will not show the pressure stated in the
technical documentation, but a value which may be
lower.

8

3.4 Inlet pipe guidelines

Eccentric reducer

Turbulent flow

Airlock

Concentric reducer

Eccentric reducer

Pipe sloping down
towards pump

Eccentric reducer

Pipe sloping
up towards
pump

Eccentric reducer

Airlock

Pipe sloping
down towards
pump

3.4.1 Common guidelines

Avoid airlocks or turbulence in the inlet pipe

Never use reducers in a horizontal inlet pipe as shown in fig. 8. Instead, use an eccentric reducer as illustrated
in fig. 7.

Correct Wrong

English (GB)

TM04 0093 4907

Fig. 7 Correctly mounted reducer Fig. 8 Reducers resulting in airlocks and

turbulence

3.4.2 Flooded systems

Closed systems and open systems where the liquid level is above the pump inlet.

Correct

TM04 0148 4907

Fig. 9 Correctly mounted inlet pipe

3.4.3 Suction lift systems

Closed systems and open systems where the liquid level is below the pump inlet.
Install the inlet pipe sloping upwards towards the inlet port. Any high point in the pipe will be filled with air and

thus prevent proper operation of the pump. When reducing the pipe to the inlet port diameter, use an eccentric
reducer with the eccentric side down to avoid airlocks.

Correct Wrong

TM04 0098 4907

Fig. 10 Correctly mounted inlet pipe Fig. 11 Inlet pipe resulting in airlocks

TM04 0092 4907

TM04 0097 4907

9

3.4.4 Inlet pipe if the feed line comes in different horizontal planes

Eccentric reducer

Eccentric reducer

Airlock

DN

10 x DN

 10 X DN plus
expansion joint

Uneven flow

Water pressure

increases here

causing a

greater flow to

one side of the

impeller than to

the other

English (GB)

Avoid high spots, such as loops, as they will collect
air and throttle the system or lead to uneven
pumping.

Correct Wrong

TM04 0095 4907

Fig. 12 Correctly mounted inlet pipe Fig. 13 Inlet pipe resulting in airlocks

3.4.5 Inlet pipe with a horizontal elbow in the feed line

Make sure that the liquid flow is evenly distributed to
both sides of the double-suction impeller.

There is always an uneven, turbulent flow through an
elbow. See below. If you install an elbow in the inlet
pipe near the pump in a position other than vertical,
more liquid will enter one side of the impeller than
the other. This will result in heavy, unbalanced thrust
loads overheating the bearings, causing rapid wear
and reducing the hydraulic performance.

Correct Wrong

TM04 0150 4907

Fig. 14 Recommended inlet pipe installation

with a length of straight pipe between
horizontal elbow and pump

Fig. 15 Unbalanced loading of a double-suction

impeller due to uneven flow through a
horizontal elbow close to the pump

3.4.6 Installations with vertical inlet pipe in confined space

TM04 0094 4907

TM04 0149 4907

Fig. 16 Inlet diffuser (1) in the inlet pipe

10

TM04 0096 4907

4. Starting up the product

The startup procedure for the pumps has four steps:

1. Prestart checks. See section 4.1 Prestart checks.

2. Priming. See section 4.2 Priming.

3. Starting. See section 4.3 Startup.

4. Final alignment. See section 4.4 Final alignment.

Only start the pump when you have gone
through all the prestart checks.

4.1 Prestart checks

Prestart checks have four steps:

1. Bearings

2. Stuffing boxes

3. Pressure gauge

4. Direction of rotation.

4.1.1 Bearings

Make sure that all bearings are properly lubricated.
See section 8.1.3 Lubrication.

4.1.2 Stuffing boxes

Make sure that the stuffing box packing rings have
been properly tightened.

4.2 Priming

If not primed properly, the pump will not
deliver liquid.

Closed systems or open systems where the
liquid level is above the pump inlet (flooded
systems)

Fill the inlet pipe and pump with liquid and vent them
before the pump is started. Proceed as follows:

1. Close the outlet isolating or throttle valve.

2. Loosen the vent screw (17) and the plug for shaft
seal flushing (20d).

English (GB)

This does not apply to pumps with
mechanical shaft seals.

4.1.3 Pressure gauges

Make sure that the pressure gauge connections are
closed.

4.1.4 Direction of rotation

Check the direction of rotation in the following way:

1. Disconnect the two coupling halves between
pump and motor.

2. Make sure that the motor shaft can turn freely.

3. Start the motor briefly to check the direction of
rotation. The correct direction of rotation is
indicated by the arrows on the pump casing.

The direction of rotation of the pump is not
always the same as the flow direction.

4. If the direction of rotation is wrong, correct it by
interchanging two phases on the motor.

DANGER

Electric shock

Death or serious personal injury

- Before interchanging two phases, make
sure that the power supply has been
switched off and that it cannot be
accidentally switched on.

5. Check the direction of rotation again.

6. Reassemble the coupling and the guards.

Fig. 17 Position of the vent valve and plug for

shaft seal flushing

WARNING

Hot or cold surface

Death or serious personal injury

- Pay attention to the direction of the vent
hole, and ensure that the escaping
water does not cause injury to persons
or damage to the motor or other
components.

- In hot-water installations, pay special
attention to the risk of injury caused by
scalding hot water and hot surfaces.

- In cold-liquid installations, pay special
attention to the risk of injury caused by
cold liquids and cold surfaces.

3. Slowly open the isolating valve in the inlet pipe
until a steady flow of liquid runs out of the vent
hole.

4. Rotate the shaft by hand, if possible, while
priming and venting to free entrapped air from
the impeller channels.

5. Tighten the vent screw and completely open the
isolating or throttle valve(s).

TM04 2592 2708

11

Open systems where the liquid level is below the

English (GB)

pump inlet (suction lift systems)

Fill the inlet pipe and pump with liquid and vent them
before the pump is started. Proceed as follows:

Suction lift system with foot valve

1. Close the outlet isolating or throttle valve and
open the isolating valve in the inlet pipe.

2. Remove the vent screw and connect a priming
device to a drain hole.

3. Fill the inlet pipe and casing with liquid at a
pressure of 1 to 2 bar from an external source
until the inlet pipe and pump are completely filled
with liquid.

4. Rotate the shaft by hand while priming and
venting to free entrapped air from the impeller
channels.

5. Refit the vent screw and tighten it securely.

6. You can fill the inlet pipe with liquid and vent it
before you connect the pipe to the pump. You
can also install a priming device before the pump.

Suction lift system without foot valve

1. Connect an external vacuum pump to the vent
hole on the top of the pump casing.

2. Close the outlet isolating or throttle valve and
open the isolating valve in the inlet pipe.

3. Open the valves between the pump and vacuum
pump.

4. Start the external vacuum pump.

5. Pump until the inlet pipe and the pump are
completely filled with liquid.

6. Rotate the shaft by hand while priming and
venting to free entrapped air from the impeller
channels.

7. When the liquid runs out of the vacuum pump,
stop the external vacuum pump and close the
valves between the pump and vacuum pump.

Never let the pump run dry. The pump is
not self-priming.

Dry-running will cause serious damage to
the stuffing boxes, shaft seals, wear rings
and shaft sleeves.

4.2.1 Opening of valves

1. Open the valves for the flushing liquid to the
stuffing boxes.

2. Completely open the isolating valve on the inlet
side of the pump and leave the outlet isolating or
throttle valve partly open.

4.3 Startup

Make sure that the pump is filled with
liquid. The pump must not run dry.
Dry-running will cause serious damage to
the stuffing boxes, shaft seals, wear rings
and shaft sleeves.

1. Start the pump.

2. Vent the pump during startup by loosening the
vent screw until a steady flow of liquid runs out of
the vent hole.

WARNING

Hot or cold surface

Death or serious personal injury

- Pay attention to the direction of the vent
hole, and ensure that the escaping
water does not cause injury to persons
or damage to the motor or other
components.

- In hot-water installations, pay special
attention to the risk of injury caused by
scalding hot water and hot surfaces.

- In cold-liquid installations, pay special
attention to the risk of injury caused by
cold liquids and cold surfaces.

3. When the pipe system has been filled with liquid,
slowly open the outlet isolating or throttle valve
until it is completely open.

4. Adjust the stuffing box gland (stuffing boxes
only). With the pump running, tighten the stuffing
box gland to allow a leakage of 40-60 drops per
minute. This is required for shaft sleeve
lubrication. Tighten the stuffing box gland evenly
to provide uniform compression on the packing
rings. After initial startup, additional packing rings
and adjustment may be required until the packing
rings are properly seated.

Do not allow a stuffing box to run dry, and
do not overtighten the stuffing box gland to
eliminate leaking as the shaft sleeve will
become damaged.

12

4.4 Final alignment

0°

90°

180°

270°

Dial gauge (2) for
parallel alignment

Index
line

Dial gauge (1) for angular
alignment

(12)

(3)

(6)

(9)

Make the final alignment by shimming the
motor only.

1. Let the pump run until it has reached its operating
temperature under normal operating conditions
(approximately 1 hour).

2. Stop the pump.

3. Remove the coupling guard.

4. Check the alignment on the coupling by means of
dial gauges. See below.

Checking coupling alignment by means of dial
gauges

Alternatively, use laser equipment for the final
alignment.

Fig. 18 The end view of the coupling is seen

The coupling alignment procedure has four steps:

Parallel alignment - vertically

1. Mount the dial gauge (2) in position 0 ° (12

2. Make the index lines on the two coupling halves.

3. Set the dial gauge pointer to zero, turn the motor

4. Read the dial gauge (2). If the dial gauge shows

from the motor

o'clock). See fig. 18.

See fig. 18.

and pump shaft simultaneously until the dial
gauge is in position 180 ° (6 o'clock) and check
that the index lines are still in line.

a deflection exceeding ± 0.2 mm, add or remove
the shims under the motor until the reading of the
dial gauge is within the allowable tolerance of ±

0.2 mm.

Parallel alignment - horizontally

1. Turn the motor and pump shaft to 270 ° (9
o'clock).

2. Set the dial gauge pointer to zero, turn the motor
and pump shaft to 90 ° (3 o'clock) and check that
the index lines are still in line.

3. Read the dial gauge. If the dial gauge shows a
deflection exceeding ± 0.2 mm, move the motor
sideways until the reading of the dial gauge is
within the allowable tolerance of ± 0.2 mm.

4. Remove the dial gauge (2).

Angular alignment - horizontally

1. Mount the dial gauge (1) in position 90 ° (3
o'clock). See fig. 18.

2. Make the index lines on the two coupling halves.

TM03 0210 4504TM03 2939 4905

See fig. 18.

3. Set the dial gauge pointer to zero, turn the motor
and pump shaft simultaneously until the dial
gauge is in position 270 ° (9 o'clock) and check
that the index lines are still in line.

4. Read the dial gauge (1). If the dial gauge shows
a deflection exceeding ± 0.2 mm, move the motor
sideways until the deflection is halved.

5. Set the dial gauge pointer to zero, turn the motor
and pump shaft simultaneously until the dial
gauge is in position 90 ° (3 o'clock) and read the
dial gauge (1) again.

6. Now the reading must be within the allowable
tolerance of ± 0.2 mm. If not, repeat the
procedure.

English (GB)

TM03 2941 4905TM03 2942 4905

13

Angular alignment - vertically

English (GB)

1. Turn the motor and pump shaft until the dial
gauge (1) is in position 0 ° (12 o'clock).

2. Set the dial gauge pointer to zero, turn the motor
and pump shaft simultaneously until the dial
gauge is in position 180 ° (6 o'clock) and check
that the index lines are still in line.

3. Read the dial gauge (1). If the dial gauge shows
a deflection exceeding ± 0.2 mm, add or remove
the shims under the motor until the deflection is
halved.

4. Set the dial gauge pointer to zero, turn the motor
and pump shaft simultaneously until the dial
gauge is in position 0 ° (12 o'clock) and read the
dial gauge (1) again.

5. Now the reading must be within the allowable
tolerance of ± 0.2 mm. If not, repeat the
procedure.

6. Remove the dial gauge (1).

The coupling tolerances may differ from
coupling make to coupling make. For the
standard coupling, the allowable tolerance
is ± 0.2 mm. For other coupling types, see
the coupling data supplied with the pump.

Finish the alignment procedure by refitting and
tightening the coupling.

4.5 Greasing the grid coupling

Pack the spaces between and around the grid with
as much lubricant as possible and wipe off the
excess lubricant so that it is flush with the top of the
grid. See section 8.1.3 Lubrication.

Position the seals on the hubs so they line up with
the grooves in the coupling cover. Position the
gaskets on the flanges of the lower coupling cover
half and assemble the covers so that the matching
marks are on the same side.

TM03 2940 4905

Push the gaskets in until they stop against the seals
and secure the coupling cover halves with the
fasteners provided and tighten them properly. Make
sure that the gaskets stay in position during this
tightening procedure.

Once the coupling is completely assembled, remove
both of the lubricating plugs in the covers, insert a
lubricating nipple in one of the lubricating holes,
pump in lubricant until it is forced out of the opposite
lubricating hole and refit the two lubrication plugs.
The installation is now complete.

WARNING

Crushing hazard

Death or serious personal injury

- To protect persons from rotating
machine parts, always install all guards
after the installation is complete and
before starting the pump.

14

5. Storing and handling the product

5.1 Handling the product

WARNING

Crushing hazard

Death or serious personal injury

- Handling must be performed by
qualified persons.

- When unloading the pump, lift equally at
four or more points on the base frame.
Do not lift by the motor or by the pump.
Do not lift by the flanges or by the
eyebolts on the motor.

Lift the pump by means of nylon straps and shackles.

Fig. 19 How to lift and handle the HS pumps

5.2 Temporary storage

If you do not store or operate the pump soon after
arrival, store it in a clean, dry place with slow,
moderate changes in ambient temperature. Protect
the pump from moisture, dust, dirt and foreign
bodies. Prior to and during storage we recommend
these precautions:

1. Make sure that the bearings are filled with the
recommended grease to prevent moisture from
entering around the shaft. See section

8.1.3 Lubrication.

2. Make sure that the inlet and outlet ports and all
other openings are covered with cardboard,
wood or masking tape to prevent foreign objects
from entering the pump.

3. Cover the unit with a tarpaulin or other suitable
covering if it is to be stored where there is no
protective covering.

4. Rotate the shaft two turns every two weeks to
prevent corrosion of the bearing surfaces and the
stuffing box or shaft seal faces due to moisture.

TM06 8170 4816TM04 0380 0608

English (GB)

Fig. 20 How to lift and handle the HS bare shaft

pumps

15

6. Product introduction

1 2 3 4 5

6

7

891011

MADE IN XXXXXXXX

HS1-0-$/ )'6%A4(1 11/4

98824568P115130001

1/100

bar/ Cmax

Type

Model

Q

H

p/t

n

ȘS

min

-1

%

1755

73.9

m /h

3

m

DK - 8850 Bjerringbro, Denmark

R

Refer HS I/O for lubrication instruction

80

27

English (GB)

6.1 Applications

Grundfos HS horizontal split case pumps are
typically used in these applications:

• circulation in heating and air conditioning
systems, water condensing and boiler feed
systems

• liquid transfer and pressure boosting in various
industrial systems

• water distribution and water treatment in public
water systems.

6.2 Pumped liquids

Clean, thin, non-aggressive liquids, not containing
solid particles or fibres. Do not pump liquids that will
attack the pump materials chemically.

CAUTION

Hot liquid

Minor or moderate personal injury

- Do not exceed the maximum
operating temperature stated on the
nameplate.

When pumping liquids with a density and/or viscosity
higher than that of water, the head and flow will be
reduced. Alternatively, use motors with
correspondingly higher outputs.

The stuffing box packing rings or mechanical shaft
seal O-rings chosen must be suitable for the liquid to
be pumped.

Special stuffing box packing rings or shaft seal
O-rings may be required if you use the pump for
pumping treated water:

• at temperatures above 80 °C (176 °F).

• containing additives to prevent system corrosion,
calcareous deposits, etc. (this may be the case in
heating and ventilating systems).

When pumping liquids other than water, select an
appropriate stuffing box or shaft seal. For further
information, contact Grundfos.

6.3 Identification

The type designation and rating information of
Grundfos horizontal split case pumps are stated on
the nameplate. See fig. 21. The type designation
includes model number, size and type.

Permanent records for this pump are kept under its
year-week code and serial number (pos. 4 and pos.

5) and this number must therefore be stated in all
correspondence and spare parts orders.

For more information about weight, see the label on
the packaging.

6.3.1 Nameplate

Fig. 21 Nameplate of CE-marked HS pump

Pos. Description

1 Type designation

2 Product number

3 Place of production

4 Production year and week

5 Serial number

6 Maximum pressure and temperature

7 Rated flow rate (duty-point flow)

8 Head at rated flow rate (duty-point head)

9 Speed

10 Country of production

Reference to lubrication instruction. See

11

section 8.1.3 Lubrication.

TM04 2243 1617

16

6.3.2 Type key

The type key is an explanation of the product type designation. See fig. 21, pos. 1.

Example HS 125 -100 -305X /273.1 , (W) 1 F1 D S BAQE 1

Type range

HS horizontal version

Nominal diameter of the inlet port (DN)

Nominal diameter of the outlet port (DN)

Maximum impeller diameter [mm]

If suffix is used, "X" = different impeller design

Actual impeller diameter [mm]

Potable-water code (optional)

ACS or WRAS certified pump

Pump variant

Basic version, grease-lubrication, pump with motor, common base frame, standard

1:

coupling
2: Grease-lubrication, bare shaft pump with common base frame, standard coupling
3: Grease-lubrication, bare shaft pump
4: Grease-lubrication, pump with motor, separate base frames, spacer coupling
5: Grease-lubrication, bare shaft pump with separate base frame, spacer coupling
6: Oil-lubrication, pump with motor, common base frame, standard coupling
7: Oil-lubrication, bare shaft pump with common base frame, standard coupling
8: Oil-lubrication, bare shaft pump
9: Oil-lubrication, pump with motor, separate base frames, spacer coupling
A: Oil-lubrication, bare shaft pump with separate base frame, spacer coupling
X: Special variant

Code for pipe connection

F1: 10 bar, DIN PN 10 G1: 10 bar, ANSI 125LB/150LB
F2: 16 bar, DIN PN 16 G2: 16 bar, ANSI 250LB/300LB
F3: 25 bar, DIN PN 25 G3: 25 bar, ANSI 250LB/300LB
XX: Special flanges

Code for shaft and sleeve materials (sleeve is only used for 25 bar pump)

D: SS420 and no sleeve A: SS420 and SS304
E: SS304 and no sleeve C: SS420 and SS316
J: SS316 and no sleeve B: SS420 and bronze
L: Duplex stainless steel and no sleeve K: Duplex stainless steel and duplex stainless steel
X: Special

English (GB)

17

English (GB)

Example HS 125 -100 -305X /273.1 , (W) 1 F1 D S BAQE 1

Code for pump casing and impeller materials

S: Cast iron and SS304 Q: Ductile iron and SS304
C: Cast iron and SS316 G: Ductile iron and SS316
B: Cast iron and bronze A: Ductile iron and bronze
D: Cast iron and duplex stainless steel H: Ductile iron and duplex stainless steel
U: SS304 and SS304 J: SS316 and SS316
K: Duplex stainless steel and duplex stainless steel
X: Special

Code for shaft seal or stuffing box

BAQE: Rubber bellows seal, unbalanced, carbon*/SiC, EPDM
BAQV: Rubber bellows seal, unbalanced, carbon*/SiC, FKM
AAQE: O-ring seal, unbalanced, carbon*/SiC, EPDM
AAQV: O-ring seal, unbalanced, carbon*/SiC, FKM
DAQE: O-ring seal, balanced, carbon*/SiC, EPDM
DAQV: O-ring seal, balanced, carbon*/SiC, FKM
SAQE: Rubber bellows seal, balanced, carbon*/SiC, EPDM
SAQV: Rubber bellows seal, balanced, carbon*/SiC, FKM
BBQE: Rubber bellows seal, unbalanced, carbon/SiC, EPDM
BBQV: Rubber bellows seal, unbalanced, carbon/SiC, FKM
ABQE: O-ring seal, unbalanced, carbon/SiC, EPDM
ABQV: O-ring seal, unbalanced, carbon/SiC, FKM
DBQE: O-ring seal, balanced, carbon/SiC, EPDM
DBQV: O-ring seal, balanced, carbon/SiC, FKM
SBQE: Rubber bellows seal, balanced, carbon/SiC, EPDM
SBQV: Rubber bellows seal, balanced, carbon/SiC, FKM
BQQE: Rubber bellows seal, unbalanced, SiC/SiC, EPDM
BQQV: Rubber bellows seal, unbalanced, SiC/SiC, FKM
AQQE: O-ring seal, unbalanced, SiC/SiC, EPDM
AQQV: O-ring seal, unbalanced, SiC/SiC, FKM
DQQE: O-ring seal, balanced, SiC/SiC, EPDM
DQQV: O-ring seal, balanced, SiC/SiC, FKM
SQQE: Rubber bellows seal, balanced, SiC/SiC, EPDM
SQQV: Rubber bellows seal, balanced, SiC/SiC, FKM
BBVP: Rubber bellows seal, carbon/aluminium oxide, nitrile rubber
SNEK: Stuffing box with synthetic polymer packing rings, uncooled, with internal barrier fluid

Direction of rotation

(Pump direction of rotation as seen from the motor end)

1: Clockwise
2: Counterclockwise

* Antimony, not approved for potable water.

The example shown is an HS 125-100-305/273.1,
standard type with standard coupling, DIN PN 10
flange, cast iron pump casing with SS304 impeller,
BAQE mechanical shaft seal and clockwise direction
of rotation.

18

7. Operating the product

7.1 Operating checks

1. Check the pump and pipes for leaks.

2. Check and record the pressure gauge readings

for future reference.

3. Check the differential pressure. If the differential

pressure is lower than anticipated, the motor may
be overloaded. See description of measuring
instruments in section 3.3.6 Measuring

instruments.

4. Measure the motor current consumption and

compare the result with the rated current stated
on the motor nameplate. In case of overload,
throttle the outlet isolating or throttle valve until
the motor is no longer overloaded.

5. Check the bearings for lubrication and

temperature. Normal temperature is 70 °C (158
°F). The maximum temperature depends on the
type of lubrication. See the lubricating plate on

the pump.
Stop the pump immediately if you notice any defects.
Do not start the pump unless the defects have been

remedied. See section 10. Fault finding the product.
Report immediately to the supplier that you cannot
remedy the defects.

The operating checks apply both during
the startup procedure and when checking
the pump during normal operation.

7.2 Frequency of starts and stops

The recommended maximum number of starts per
hour below apply to complete pumps with a motor
supplied by Grundfos. The values are
recommendations only.

0 to 50 kW

15 starts per hour. The motor must be stopped for at
least 3 minutes before restart.

51 to 100 kW

10 starts per hour. The motor must be stopped for at
least 5 minutes before restart.

101 to 315 kW

5 starts per hour. The motor must be stopped for at
least 10 minutes before restart.

Greater than 315 kW

2 starts per hour.

7.3 Operating at reduced flow and/or head

Do not operate the pump at a flow rate below 10 % of
the maximum flow rate stated on the nameplate or
with the outlet isolating or throttle valve closed.
Operating the pump under such conditions may
involve the risk of the pump being overheated. To
prevent possible damage, use protective devices
such as liquid temperature relay, bearing
temperature relay, inlet pressure monitoring, etc.

If a pump is operated at reduced head, the flow will
increase and the motor will consume more current
than normal. This will result in overheating of the
motor. In such situations, throttle the valve on the
outlet side, instead. If an automatic throttle valve is
installed, this can be done automatically.

8. Servicing the product

DANGER

Toxic material

Death or serious personal injury

- If a pump has been used for a liquid
injurious to health or toxic, the pump will
be classified as contaminated.

If you want Grundfos to service the pump, contact
Grundfos with details about the pumped liquid, etc.
before you return the pump for service. Otherwise
Grundfos can refuse to accept the pump for service.

8.1 Maintaining the product

DANGER

Electric shock

Death or serious personal injury

- Before starting work on the pump, make
sure that the power supply has been
switched off and that it cannot be
accidentally switched on.

8.1.1 General information

Routine maintenance is essential to maintain the
pump in a good condition.

A high degree of cleanliness must be maintained
during all maintenance procedures.

English (GB)

19

8.1.2 Frequency of inspections

English (GB)

Carry out inspections in accordance with the
maintenance table below.

Depending on operating and environmental
conditions together with a comparison of previous
inspections, the frequency of inspections may be
altered to maintain satisfactory operation of the
pump.

Every
week

Every
month

Every 6
months

Every
year

• Visually check for leaks.

• Check for vibrations.

• Hand test the bearing housing for
any sign of temperature rise.

• Check correct leaking from the
stuffing boxes (approximately 40-60
drops per minute).

• Check the pump bearing
temperature.

• Check the shaft for scores.

• Check the alignment of the pump
and motor.

• Check the fixing bolts and tighten, if
necessary.

• Check the coupling for wear.

• Check whether the grease in the
pump bearings has hardened.

• Check the rotating assembly for
wear.

• Check the wear ring clearances.

CAUTION

Sharp element

Minor or moderate personal
injury

- Wear protective gloves to
protect yourself against
sharp edges on the
impeller and wear rings.

Between the regular maintenance inspections, be
aware of signs of motor or pump trouble.

Common symptoms are listed in section 10. Fault

finding the product.

Remedy any fault immediately and avoid costly
repairs and shutdowns.

8.1.3 Lubrication

Pump bearings

Pump bearings are lubricated prior to delivery.
We recommend relubricating intervals of 2000

operating hours. Depending on duty conditions this
may, however, vary.

To refill the bearings with fresh grease, follow this
procedure:

1. Remove the bearing cap.

2. Add enough grease to fill up 1/3 of the ball
bearing.

3. Note the quantity required.

4. Refit the bearing cap.

Repeat this procedure the first three times. Based on
the first three relubrications, determine the correct
quantity of grease required.

For future relubrications, apply the established
quantity of grease through the lubricating nipples.
You do not have to remove the bearing caps.

For every 10,000 operating hours or every two years:

1. Remove the bearing caps from pump.

2. Remove old grease.

3. Thoroughly clean the bearing caps.

4. Refill the bearings with fresh grease.

5. Refill the bearing caps completely with fresh
grease.

6. Refit the bearing caps in accordance with the
assembly instructions.

7. Start the pump briefly several times to distribute
the grease in the bearings and to prevent
overheating of the grease.

Grease specifications: See Ball bearing grease
below.

Do not overgrease.
Too much grease can cause overheating

and premature bearing failure.

Motor bearings

Lubricate the motor bearings in accordance with the
indications on the motor nameplate.

Grease specifications: See Ball bearing grease
below.

Ball bearing grease

20

Manufacturer Lubricant

Shell Dolium R

Exxon Polyrex

Chevron

Philips Polytac

Texaco Polystar RB

SRI grease NLGI 2

Black pearl NLGI 2

Grid coupling

Drain plug, inlet portDrain plug, pump casing

and outlet port

A grid coupling must be regreased at intervals.
Normally, the interval is one year, but it can be
shorter if the environment is aggressive or the
operating conditions are harsh. Use the same grease
for the coupling as for the ball bearings. See Ball

bearing grease.

Proceed like this:

1. Remove the coupling guards.

2. Remove the two lubricating plugs.

3. Pump grease into one of the lubricating holes to
push the old grease out of the opposite hole.

4. Keep pumping until the fresh grease comes out.

5. Refit and fasten the two plugs.

6. Mount the coupling guards again.

9. Taking the product out of operation

The following shutdown procedures apply to most
normal shutdowns. If the pump is to be inoperative
for a long time, follow the storage procedures in
section 9.2 Long-term shutdown.

1. Always close the outlet or throttle valve before
stopping the pump. Close the valve slowly to
prevent hydraulic shock, but make sure that the
pump does not run against a closed valve for
more than a few seconds.

2. Switch off the power supply to the motor.

9.1 Short-time shutdown

1. For overnight or temporary shutdown periods
under non-freezing conditions, the pump may
remain filled with liquid. Make sure the pump is
fully primed before restarting.

2. For short or frequent shutdown periods at
temperatures below 0 °C, keep the liquid moving
within the pump casing and insulate or heat the
pump exterior to prevent freezing.

9.2 Long-term shutdown

For long shutdown periods or to isolate the pump for
maintenance, close the inlet and outlet valves. If no
inlet valve is fitted and the pump has positive inlet
height, drain all liquid from the inlet pipe to terminate
the liquid flow into the pump inlet port. If applicable,
turn off any external source of cooling or lubricating
liquid to the stuffing boxes or shaft seals. Remove
the plugs in the pump drain and vent tappings, as
required, and drain all liquid from the pump casing.
Remove the stuffing box glands and packing rings, if
applicable.

CAUTION

Hot or cold surface

Minor or moderate personal injury

- Make sure that the escaping water does
not cause injury to persons or damage
to the motor or other components.

- In hot-water installations, pay special
attention to the risk of injury caused by
scalding hot water.

- In cold-liquid installations, pay special
attention to the risk of injury caused by
cold liquid and cold surfaces.

Fig. 22 Example of drain plugs

1. If freezing conditions will prevail during long
shutdown periods after draining the pump, blow
out all liquid in passages and airlocks using
compressed air. You can prevent freezing of
pumped liquid by filling the pump with antifreeze
solution.

WARNING

Harm to health

Death or serious personal injury

- Do not use antifreeze solution if you use
the pump for public or potable-water
supply.

2. Rotate the shaft by hand monthly to coat the
bearings with lubricant and delay oxidation and
corrosion.

3. Where applicable, follow the motor
manufacturer's storage recommendations.

Do not tighten the vent screw or refit the
drain plug until the pump is to be used
again.

English (GB)

TM04 0378 0608

21

10. Fault finding the product

English (GB)

DANGER

Electric shock

Death or serious personal injury

- Before you remove the terminal box
cover and before you remove or
dismantle the pump, make sure that the
power supply has been switched off and
that it cannot be accidentally switched
on.

Faults Causes

A: The pump delivers no liquid.

B: The pump does not deliver enough liquid.

C: The pump does not create enough pressure.

D: The pump loses liquid after running for a short time.

E: The pump consumes too much power.

F: The motor is overloaded.

G: Vibrations.

H: Cavitation noise.

I: The pump bearings are overheated.

J: The pump operates for a short time and then stops. K: Reference numbers to remedies.

ABCDEFGHI J K

●●

● Loss of priming liquid. 2

●● ● ●The suction lift or static lift is too high. 3

●●

●●● The speed is too low. 5

●● Wrong direction of rotation. 6

●● The impeller is completely clogged. 7

● The inlet pipe is partially blocked. 8

●●● ● ●Air leak in the inlet pipe or flange. 9

●● ●

●●● ●

●● ● The impeller or wear rings are worn. 12

●● Defective packing rings. 13

●

●● ●

●

The pump is not primed, lack of priming
liquid, incomplete priming.

The outlet pressure is too high
(measured at the outlet port).

Air leak in the stuffing box. The flushing
pipe may be blocked.

Cavitation; insufficient NPSH (depending
on installation).

The non-return valve is too small or
partially obstructed. The cross section of
the non-return valve port must be at
least as large as the cross section of the
inlet pipe.

The inlet pipe is not immersed deeply
enough.

The impeller diameter is too small. This
is the most probable cause, if none of
the above causes apply.

1

4

10

11

14

15

16

22

Faults Causes

A: The pump delivers no liquid.

B: The pump does not deliver enough liquid.

C: The pump does not create enough pressure.

D: The pump loses liquid after running for a short time.

E: The pump consumes too much power.

F: The motor is overloaded.

G: Vibrations.

H: Cavitation noise.

I: The pump bearings are overheated.

J: The pump operates for a short time and then stops. K: Reference numbers to remedies.

ABCDEFGHI J K

● Obstruction in the casing. 17

●●● ● Air or gases in the liquid. 18

The actual duty point of the pump lies to

●●

●●

●●● ● The shaft is bent due to damage. 21

●●● ●

●●●Misalignment. 23

●● Electrical defects. 24

●● ● The speed is too high. 25

● The foundation is not rigid enough. 26

●

the right of the specified duty point on
the pump curve. The result is lower
head, higher flow and higher power
consumption.

The viscosity or specific gravity of the
pumped liquid is higher than that of
water.

Mechanical failure of the bearing and/or
impeller.

The lubricating oil or grease is dirty or
contaminated.

19

20

22

27

English (GB)

No. Cause Remedy

The pump is not primed, lack of

1

priming liquid, incomplete priming.

2 Loss of priming liquid.

The suction lift or static lift is too

3

high.

4 The outlet pressure is too high. Make sure that valves in the outlet pipe are fully open.

5 The speed is too low.

6 Wrong direction of rotation.

The impeller is completely

7

clogged.

8 The inlet pipe is partially blocked. Remove any obstructions in the inlet pipe.

Fill the pump and inlet pipe completely with pumped liquid.

Mend possible leaks in the inlet pipe, joints and fittings. Vent the
pump casing to remove accumulated air.

Reduce the difference in height between the water reservoir or
water supply and the pump.

1. Make sure that the motor receives full voltage.

2. Make sure that the frequency is correct.

3. Make sure that all phases are connected.

Compare the direction of rotation with the directional arrow on
the pump casing. If required, change the direction of rotation by
interchanging two phases in the motor.

Dismantle the pump and clean the impeller.

23

English (GB)

No. Cause Remedy

9 Air leak in the inlet pipe or flange. Replace or repair the defective pipe section or flange.

10 Air leak in the stuffing box.

Cavitation; insufficient NPSH

11

(depending on installation).

The impeller or wear rings are

12

worn.

13 Defective packing rings. Replace the packing rings.

The non-return valve is too small

14

or partially obstructed.

The inlet pipe is not immersed

15

deeply enough.

16 The impeller diameter is too small.

17 Obstruction in pump casing. Dismantle the pump and remove the obstruction.

18 Air or gases in the liquid.

The actual duty point of the pump
lies to the right of the specified
duty point on the pump curve. The

19

result is lower head, higher flow
and higher power consumption.

The viscosity or specific gravity of

20

the pumped liquid is higher than
that of water.

21 The shaft is bent due to damage.

Mechanical failure of bearing

22

and/or impeller.

23 Misalignment. Realign the pump and motor.

24 Electrical defects.

25 The speed is too high.

26 The foundation is not rigid enough.

The lubricating oil or grease is dirty

27

or contaminated.

Clean the flushing pipe. Replace the stuffing box packing rings, if
necessary.

1. Increase the net positive suction head by placing the pump in
a lower position.

2. Pressurise the inlet vessel.

Replace the impeller and/or wear rings. If necessary, also
replace the bearings and the shaft.

Replace or clean the non-return valve.

Extend the inlet pipe so that the risk of sucking air is eliminated.

Check with Grundfos if you can use a larger impeller. If not,
reduce the outlet pipe friction losses. But be careful not to
seriously overload the motor.

Remove the gas or air from the pumped liquid.
See 11) above.

Install an orifice plate immediately after the outlet flange. The
orifice plate will raise the system characteristic or increase the
counterpressure thus increasing the head and lowering the flow.
The size of the orifice plate must be adapted so that the pressure
corresponds to the required duty point.

Use a larger motor. Consult Grundfos for recommended size.
Test the liquid for viscosity and specific gravity.

Check the deflection of the shaft. The total indicator runout must
not exceed 0.05 mm.
Possibly replace the shaft.

Check the bearings and the impeller for damage.
Replace the bearings or the impeller, if necessary.

Check that the voltage and frequency of the power supply are
correct.
Remedy the possible defects in the motor.
Check that the motor is properly cooled.

Check that the frequency of the power supply corresponds to the
frequency stated on the motor nameplate.

Retighten the anchor bolt nuts. Make sure that the foundation is
made according to the installation and operating instructions.

Clean the bearings and bearing housings according to the
instructions and relubricate the bearings.

24

11. Technical data

11.1 Operating conditions

11.1.1 Ambient temperature and altitude

The ambient temperature and the installation altitude
are important factors for the motor life, as they affect
the life of the bearings and the insulation system.

If the ambient temperature or the pump installation
altitude exceeds the values below, the motor must
not be fully loaded due to the risk of overheating.
Overheating may result from excessive ambient
temperature or the low density and consequently low
cooling effect of the air. In such cases, it may be
necessary to use a motor with a higher output.

Bearing service intervals are shorter at
temperatures above 40 °C.

Legend

English (GB)

Maximum ambient
temperature at full

Pos.

load
[°C]

Maximum

altitude above

sea level

[m]

1 40 1000

2 60 3500

3 55 2750

Motor Number of poles

MG

2 11-22 2 - -

41.5 - 152--

IE2 and IE3 motors

2 30-90

Siemens

4 18.5 - 200

6 11-160

2 11-90 1 - -

MMG-G

4 1.5 - 630 1 - -

6 11-132 1 - -

2 11-90 2 - -

MMG-H

4 1.5 - 315 2 - -

6 11-132 2 - -

1)

At ambient temperatures above 40 °C, the motor
temperature class is changed from B to F.

P2

[kW]

Pos.

1)

1)

1)

Other motor sizes

P2

[kW]

Pos.

3--

3 250-630 1

3 200-315 1

25

English (GB)

20 25 30 35 40 45 50 55 60 65 70 75 80

50

60

70

80

90

100

[%]

P2

1

2

3

t[°C]

1000 2250 3500 4750 m

Inlet pressure

Pump pressure

Pressure p stated on the pump
(pressure above atmospheric

pressure)

11.1.3 Pressure in the pump

Fig. 23 Motor output in relation to

temperature/altitude

Example

Figure 23 shows that you must reduce the load of an
MG motor to 88 % when installed 4750 m above sea
level.

At an ambient temperature of 75 °C, you must
reduce the load of the motor to 78 % of the rated
output.

If you install the pump 4750 m above sea level at an
ambient temperature of 75 °C, do not load the motor
more than 88 % x 78 % = 68.6 % of the rated output.

11.1.2 Liquid temperature

The maximum liquid temperature marked on the
pump nameplate depends on the mechanical shaft
seal used:

Temperature range for NBR: 0 up to 100 °C.

Temperature range for FKM: 15-100 °C.

TM04 4914 2209

Fig. 24 Pressure in the HS pump

Maximum outlet pressure

The maximum outlet pressure is the
pressure (p) stated on the pump
nameplate.

Minimum inlet pressure

The minimum inlet pressure must correspond to the
NPSH curve for the pump + a safety margin of
minimum 0.5 metres head.

NPSH appears from the data booklet and Grundfos
Product Center.

Maximum inlet pressure

The inlet pressure + pump pressure must be lower
than the maximum pressure (p) of the pump. This is
stated on the nameplate. See fig. 21, position 7.

Minimum flow rate

The pump must not run against a closed outlet valve
as this will cause an increase in the temperature or
formation of steam in the pump. This may cause
shaft damage, impeller erosion, short life of
bearings, damage to stuffing boxes or mechanical
shaft seals due to stress or vibration.

The continuous flow rate must be at least 25 % of the
flow rate in the best efficiency point.

Maximum flow rate

The maximum flow rate must not exceed the value
stated on the nameplate. If the maximum flow rate is
exceeded, cavitation and overload may occur.

Sound pressure level

See page 29 and 30.

TM04 0062 4907

26

11.2 Flange forces and torques

Fig. 25 Flange forces and torques

Horizontal pump, side branch, y-axis

English (GB)

TM06 6281 1016

Diameter

DN

25 340 280 300 520 180 210 270 390
32 420 340 360 660 225 255 330 480
40 500 400 440 780 270 315 390 570
50 660 540 600 1040 300 345 420 615
65 840 680 740 1320 330 360 450 660

80 1000 820 900 1580 345 390 480 705
100 1340 1080 1200 2100 375 435 525 780
125 1580 1280 1420 2480 450 570 630 915
150 2000 1620 1800 3140 525 615 750 1095
200 2680 2160 2400 4180 690 795 975 1440
250 3340 2700 2980 5220 945 1095 1335 1965
300 4000 3220 3580 6260 1290 1485 1815 2670
350 4660 3760 4180 7300 1650 1905 2325 3420
400 5320 4300 4780 8340 2070 2385 2910 4290
450 5980 4840 5380 9380 2550 2940 3585 5280
500 6640 5380 5980 10420 3075 3540 4335 6390
550 7300 5920 6580 11460 3660 4215 5130 7590
600 7960 6460 7180 12500 4320 4980 6060 8970

* ΣF and ΣM are the vector sums of the forces and

torques.

If not all loads reach the maximum permissible value,
one of the values is allowed to exceed the normal
limit. Contact Grundfos for further information.

Fy Fz Fx ΣF* My Mz Mx ΣM*

Force [N] Torque [Nm]

12. Disposing of the product

Dispose of this product or parts of it in an
environmentally sound way:

1. Use the public or private waste collection service.

2. If this is not possible, contact the nearest
Grundfos company or service workshop.

Subject to alterations.

27

Appendix 1

Appendix

Airborne noise emitted by HS pumps

MG motors:

[dB(A)]

L

pA

Motor

[kW]

1.5

2.2

3.0

4.0

5.5

7.5

11 60 54

15 60 54

18.5 60

22 64

Siemens motors:

Motor

[kW]

11

15

18.5

22

30 71 62 59

37 71 66 60

45 71 66 58

55 71 67 58

75 73 70 61

90 73 70 61

110767061

132

160

200

250

315

355

400 75

500 75

560 78

630 78

50 Hz

2-pole 4-pole

47

48

52

48

51

52

[dB(A)]

L

pA

50 Hz

2-pole 4-pole 6-pole

60 59

60 59

70 61

70 64

70 68

73 68

73 71

75

66

56

28

MMG-G motors:

L

[dB(A)]

pA

Motor

[kW]

2-pole 4-pole 6-pole 2-pole 4-pole 6-pole

1.5

2.2 63 63

3.0 63 63

3.7 63 63

4.0 63 63

5.5 64 65

7.5 68 68

11 70 68 62 78 68 59

15 72 75 65 81 75 62

18.5 727569 817566

22 72 75 70 81 75 67

30 73 78 74 86 78 71

37 73 78 75 86 78 72

45 73 80 75 87 80 72

55 78 83 81 88 82 79

75 80 83 81 90 83 79

90 80 85 84 91 85 81

110 848584 918581

132

160

200

220

250

315

335

355

375

400

450

500

525 90 90

560 90 90

600 90 90

50 Hz 60 Hz

59 59

88 84 85 81

88 86 85 82

90 86 90 82

86 82

90 87 90 82

90 87 90 85

90 87 90 85

90 87 90 90

90 90 90 90

90 90 90 95

90 90 90 95

90 90

Appendix

29

MMG-H motors:

Appendix

L

[dB(A)]

pA

Motor

[kW]

2-pole 4-pole 6-pole

1.5

2.2 60

3 60

4 61

5.5 62

7.5 62

11 66 60 56

15 66 60 56

18.5 66 65 59

22 70 65 59

30 73 68 59

37 73 68 59

45 78 68 60

55 78 69 60

75 79 70 68

90 79 70 69

110

132

160

200 76

250 79

315 80

50 Hz

58

74 70

74 70

74

30

Subject to alterations.

31

Grundfos companies

Argentina

Bombas GRUNDFOS de Argentina S.A.
Ruta Panamericana km. 37.500 Centro
Industrial Garin
1619 Garín Pcia. de B.A.
Phone: [phone]
Telefax: [phone]

Australia

GRUNDFOS Pumps Pty. Ltd.
P.O. Box 2040
Regency Park
South Australia 5942
Phone: [phone]
Telefax: [phone]

Austria

GRUNDFOS Pumpen Vertrieb
Ges.m.b.H.
Grundfosstraße 2
A-5082 Grödig/Salzburg
Tel.: [phone]
Telefax: [phone]

Belgium

N.V. GRUNDFOS Bellux S.A.
Boomsesteenweg 81-83
B-2630 Aartselaar
Tél.: [phone]
Télécopie: [phone]

Belarus

Представительство ГРУНДФОС в
Минске
220125, Минск
ул. Шафарнянская, 11, оф. 56, БЦ
«Порт»
Тел.: [phone]
Факс: [phone]

E-mail: [e-mail]

Bosnia and Herzegovina

GRUNDFOS Sarajevo
Zmaja od Bosne 7-7A,
BH-71000 Sarajevo
Phone: [phone]
Telefax: [phone]
www.ba.grundfos.com
e-mail: [e-mail]

Brazil

BOMBAS GRUNDFOS DO BRASIL
Av. Humberto de Alencar Castelo
Branco, 630
CEP 09850 - 300
São Bernardo do Campo - SP
Phone: [phone]
Telefax: [phone]

Bulgaria

Grundfos Bulgaria EOOD
Slatina District
Iztochna Tangenta street no. 100
BG - 1592 Sofia
Tel. [phone]
Fax. [phone]
email: [e-mail]

Canada

GRUNDFOS Canada Inc.
2941 Brighton Road
Oakville, Ontario
L6H 6C9
Phone: [phone]
Telefax: [phone]

China

GRUNDFOS Pumps (Shanghai) Co. Ltd.
10F The Hub, No. 33 Suhong Road
Minhang District
Shanghai 201106
PRC
Phone: [phone]
Telefax: [phone]

COLOMBIA

GRUNDFOS Colombia S.A.S.
Km 1.5 vía Siberia-Cota Conj. Potrero
Chico,
Parque Empresarial Arcos de Cota Bod.
1A.
Cota, Cundinamarca
Phone: [phone]
Telefax: [phone]

Croatia

GRUNDFOS CROATIA d.o.o.
Buzinski prilaz 38, Buzin
HR-10010 Zagreb
Phone: [phone]
Telefax: [phone]
www.hr.grundfos.com

GRUNDFOS Sales Czechia and
Slovakia s.r.o.

Čajkovského 21
779 00 Olomouc
Phone: [phone]

Denmark

GRUNDFOS DK A/S
Martin Bachs Vej 3
DK-8850 Bjerringbro
Tlf.: [phone]
Telefax: [phone]
E-mail: [e-mail]
www.grundfos.com/DK

Estonia

GRUNDFOS Pumps Eesti OÜ
Peterburi tee 92G
11415 Tallinn
Tel: + 372 606 1690
Fax: + 372 606 1691

Finland

OY GRUNDFOS Pumput AB
Trukkikuja 1
FI-01360 Vantaa
Phone: [phone]

France

Pompes GRUNDFOS Distribution S.A.
Parc d’Activités de Chesnes
57, rue de Malacombe
F-38290 St. Quentin Fallavier (Lyon)
Tél.: [phone]
Télécopie: [phone]

Germany

GRUNDFOS GMBH
Schlüterstr. 33
40699 Erkrath
Tel.: [phone]
Telefax: [phone]
e-mail: [e-mail]
Service in Deutschland:
e-mail: [e-mail]

Greece

GRUNDFOS Hellas A.E.B.E.
20th km. Athinon-Markopoulou Av.
P.O. Box 71
GR-19002 Peania
Phone: [phone]
Telefax: +0030-210-66 46 273

Hong Kong

GRUNDFOS Pumps (Hong Kong) Ltd.
Unit 1, Ground floor
Siu Wai Industrial Centre
29-33 Wing Hong Street &
68 King Lam Street, Cheung Sha Wan
Kowloon
Phone: [phone]
Telefax: [phone]

Hungary

GRUNDFOS Hungária Kft.
Park u. 8
H-2045 Törökbálint,
Phone: [phone]
Telefax: [phone]

India

GRUNDFOS Pumps India Private
Limited
118 Old Mahabalipuram Road
Thoraipakkam
Chennai 600 096
Phone: [phone]

Indonesia

PT. GRUNDFOS POMPA
Graha Intirub Lt. 2 & 3
Jln. Cililitan Besar No.454. Makasar,
Jakarta Timur
ID-Jakarta 13650
Phone: [phone]
Telefax: [phone] / 460 6901

Ireland

GRUNDFOS (Ireland) Ltd.
Unit A, Merrywell Business Park
Ballymount Road Lower
Dublin 12
Phone: [phone]
Telefax: [phone]

Italy

GRUNDFOS Pompe Italia S.r.l.
Via Gran Sasso 4
I-20060 Truccazzano (Milano)
Tel.: [phone]
Telefax: [phone] / 95838461

Japan

GRUNDFOS Pumps K.K.
1-2-3, Shin-Miyakoda, Kita-ku,
Hamamatsu
431-2103 Japan
Phone: [phone]
Telefax: [phone]

Korea

GRUNDFOS Pumps Korea Ltd.
6th Floor, Aju Building 679-5
Yeoksam-dong, Kangnam-ku, 135-916
Seoul, Korea
Phone: [phone]
Telefax: [phone]

Latvia

SIA GRUNDFOS Pumps Latvia
Deglava biznesa centrs
Augusta Deglava ielā 60, LV-1035, Rīga,
Tālr.: + 371 714 9640, 7 149 641
Fakss: + 371 914 9646

Lithuania

GRUNDFOS Pumps UAB
Smolensko g. 6
LT-03201 Vilnius
Tel: + 370 52 395 430
Fax: + 370 52 395 431

Malaysia

GRUNDFOS Pumps Sdn. Bhd.
7 Jalan Peguam U1/25
Glenmarie Industrial Park
40150 Shah Alam
Selangor
Phone: [phone]
Telefax: [phone]

Mexico

Bombas GRUNDFOS de México S.A. de
C.V.
Boulevard TLC No. 15
Parque Industrial Stiva Aeropuerto
Apodaca, N.L. 66600
Phone: [phone]
Telefax: [phone]

Netherlands

GRUNDFOS Netherlands
Veluwezoom 35
1326 AE Almere
Postbus 22015
1302 CA ALMERE
Tel.: [phone]
Telefax: [phone]
E-mail: [e-mail]

New Zealand

GRUNDFOS Pumps NZ Ltd.
17 Beatrice Tinsley Crescent
North Harbour Industrial Estate
Albany, Auckland
Phone: [phone]
Telefax: [phone]

Norway

GRUNDFOS Pumper A/S
Strømsveien 344
Postboks 235, Leirdal
N-1011 Oslo
Tlf.: [phone]
Telefax: [phone]

Poland

GRUNDFOS Pompy Sp. z o.o.
ul. Klonowa 23
Baranowo k. Poznania
PL-62-081 Przeźmierowo
Tel: [phone]
Fax: [phone]

Portugal

Bombas GRUNDFOS Portugal, S.A.
Rua Calvet de Magalhães, 241
Apartado 1079
P-2770-153 Paço de Arcos
Tel.: [phone]
Telefax: [phone]

Romania

GRUNDFOS Pompe România SRL
Bd. Biruintei, nr 103
Pantelimon county Ilfov
Phone: [phone]
Telefax: [phone]
E-mail: [e-mail]

Russia

ООО Грундф ос Россия
ул. Школьная, 39-41
Москва, RU-109544, Russia
Тел. [phone] (495)

737-30-00
Факс [phone]
E-mail [e-mail]

Serbia

Grundfos Srbija d.o.o.
Omladinskih brigada 90b
11070 Novi Beograd
Phone: [phone]
Telefax: [phone]
www.rs.grundfos.com

Singapore

GRUNDFOS (Singapore) Pte. Ltd.
25 Jalan Tukang
Singapore 619264
Phone: [phone]
Telefax: [phone]

Slovakia

GRUNDFOS s.r.o.
Prievozská 4D
821 09 BRATISLAVA
Phona: [phone]
sk.grundfos.com

Slovenia

GRUNDFOS LJUBLJANA, d.o.o.
Leskoškova 9e, 1122 Ljubljana
Phone: [phone]
Telefax: [phone]
E-mail: [e-mail]

South Africa

GRUNDFOS (PTY) LTD
Corner Mountjoy and George Allen
Roads
Wilbart Ext. 2
Bedfordview 2008
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

Spain

Bombas GRUNDFOS España S.A.
Camino de la Fuentecilla, s/n
E-28110 Algete (Madrid)
Tel.: [phone]
Telefax: [phone]

Sweden

GRUNDFOS AB
Box 333 (Lunnagårdsgatan 6)
431 24 Mölndal
Tel.: [phone]
Telefax: [phone]

Switzerland

GRUNDFOS Pumpen AG
Bruggacherstrasse 10
CH-8117 Fällanden/ZH
Tel.: [phone]
Telefax: [phone]

Tai wan

GRUNDFOS Pumps (Taiwan) Ltd.
7 Floor, 219 Min-Chuan Road
Taichung, Taiwan, R.O.C.
Phone: [phone]
Telefax: [phone]

Thailand

GRUNDFOS (Thailand) Ltd.
92 Chaloem Phrakiat Rama 9 Road,
Dokmai, Pravej, Bangkok 10250
Phone: [phone]
Telefax: [phone]

Turkey

GRUNDFOS POMPA San. ve Tic. Ltd.
Sti.
Gebze Organize Sanayi Bölgesi
Ihsan dede Caddesi,

2. yol 200. Sokak No. 204
41490 Gebze/ Kocaeli
Phone: +90 - 262-679 7979
Telefax: +90 - 262-679 7905
E-mail: [e-mail]

Ukraine

Бізнес Центр Європа
Столичне шосе, 103
м. Київ, 03131, Україна
Телефон: [phone]
Факс.: [phone]

E-mail: [e-mail]

United Arab Emirates

GRUNDFOS Gulf Distribution
P.O. Box 16768
Jebel Ali Free Zone
Dubai
Phone: [phone]
Telefax: [phone]

United Kingdom

GRUNDFOS Pumps Ltd.
Grovebury Road
Leighton Buzzard/Beds. LU7 4TL
Phone: [phone]
Telefax: [phone]

U.S.A.

GRUNDFOS Pumps Corporation
17100 West 118th Terrace
Olathe, Kansas 66061
Phone: [phone]
Telefax: [phone]

Uzbekistan

Grundfos Tashkent, Uzbekistan The Rep­resentative Office of Grundfos Kazakhstan
in Uzbekistan
38a, Oybek street, Tashkent
Телефон: [phone] / 71 150
3291
Факс: [phone]

Addresses Revised 09.08.2017

Grundfos companies

99296580 0617

ECM: 1211021

www.grundfos.com

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