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Workshop Magnum
Workshop Magnum
00
MAGNUM PROLINE
Congratulations on a sound choise!
GRINDEX
Service Manager
Foreword ______________________________________________ 2
Product description 50 Hz ______________________________________________ 3
Product description 60 Hz ___________________________________ 4
Operation ________________________________________ 5
Electrical Connections ________________________________________ 6
Dismantling ___________________________________________ 7-14
Cover, power cable, draining of oil __________________________________________ 8
Lifting, handling of the pump ____________________________________________ 9
Lower diffuser, impeller ___________________________________________ 10
Shaft seal lower, diffuser lower ________________________________________________ 11
Rotor, oil housing, outer casing _________________________________________ 12
Stator housing, bearing holder, main cover, shaft seal upper _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 13
Ball bearings, rotor unit, removing stator _______________________________________ 14
1
Workshop Manual Foreword
Please carefully read this Workshop Manual to gain the benefit of the information it contains, so
that:
you will acquire knowledge of Grindex drainage pumps.
you will be able to make certain that the pumps retain their high reliability by following the
specified service and inspection instructions.
you will be able to remedy various problems quickly and methodically.
2
Workshop Manual Product Description
Technical Data 50 Hz
10
H (m) 100
80
Strainer hole: H
Ø 12 mm 60
40
N
20
Weight: 540 kg L
750 mm 0
0 50 100 150 200 250 300 350
Q (l/s)
H (m) 120
H
100
80
Strainer hole:
Ø 12 mm 60
N
40
L
20
Weight: 540 kg
0
750 mm 0 50 100 150 200 250 300 350
Q (l/s)
Check the direction of rotation. See the figure. When 1. Water + coarse gravel 4 m/s (13.1ft/s)
started, the pump will jerk in the opposite direction to the 2. Water + gravel 3 m/s (11.5 ft/s)
direction in which the impeller rotates. 3. Water + sand
Sand particles < 0.1 mm 1.5 m/s
Beware! (0.004 in) (4.9 ft/s)
The start reaction on large pumps can be powerful. Sand particles < 0.6 mm 2.5 m/s
(0.024 in) (8.2 ft/s)
Start reaction The pump can be provided with level regulation in order
to prevent unnecessary wear on the hydraulic compo-
nents.
Cleaning
If the pump has been running in very dirty water, let it
run for a while in clean water, or flush it through the dis-
charge connection. If clay, cement or other similar dirt is
left in the pump it may clog the impeller and sealing pre-
venting the pump from working.
5
Workshop Manual Electrical Connections
All electrical work shall be carried out under the supervi- Connect the motor cable to the terminal board as illus-
sion of an authorized electrician. trated in the figure. Mount the closing links in accord-
ance with the figure.
Local codes and regulations shall be complied with.
If star-delta start is used, both motor cables are con-
Check that the main (line) voltage and frequency agree
nected as shown below. Closing links are not used with
with the specifications on the pump data plate.
star-delta start.
The motor can be connected for different voltages as
Connect the control leads from the motor control circuit
shown on the data plate.
to T1 and T2. See figure.
Under no circumstances may the starter equipment be
Make sure that the pump is correctly earthed (grounded).
installed in the pump pit.
Install the cover.
To avoid leakage into the pump, check:
- that the cable entry seal sleeve and washers con- Tighten the nuts so that the cable entry unit bottoms out.
form to the outside diameter of the cable. See the
Connect the motor cable and the control cable to the
parts list.
start equipment. Check the direction of rotation, see “Be-
- that the outer jacket on the cable is not damaged. fore starting".
When refitting a cable which has been used before,
If the direction of rotation is wrong, transpose two of the
always cut off a short piece of the cable so that the
phase leads.
cable entry seal sleeve does not close around the
cable at the same point again. Remember that the starting surge with the direct-on line
start can be up to six times higher that the rated current.
NOTE!
Make sure that the fuses or circuit breakers are of the
For safety reasons, the earth lead should be approx.
proper amperage.
100 mm (4”) longer than the phase leads. If the motor
cable is jerked loose by mistake, the earth lead should Fuse amperage and cable shall be selected in accord-
be the last lead to come loose from its terminal. This ance with local rules and regulations. Note that with long
applies to both ends of the cable. cables, the voltage drop in the cable must be taken into
consideration, since the motor’s rated voltage is the volt-
Check on the data plate which connection, Y or is
age that is measured at the terminal board in the pump.
valid for the voltage supply. Then depending on voltage
arrange the connection on the terminal board in accord- The overload protection (motor protection breaker) shall
ance with the figures. always be set to the motor’s rated current as given on
the data plate.
L1L2L3 L1L2L3
DIRECT ON LINE STAR/DELTA
6
Workshop Manual Dismantling
7
Workshop Manual Dismantling
Check that the insulation resistance between the Disconnect the control and motor cable from the
phase windings and between each phase and terminal board.
earth (ground) ≥ 1 Mohm. Use a 1000V megger.
WARNING
The inside of the oil casing may be
pressurized. So always remove the oil
screw slowly and carefully. Place a piece
of cloth over the oil screw to prevent oil
from splashing around.
Remove the oil screws and lean over the pump Undo the 6 strainer bolts when the pump is
to easier drain the oil into a bucket. standing vertical on the work floor.
8
Workshop Manual Dismantling
Attach the support unit 114723 to the main cover. Lift the pump in the 2 lifting eyes to detach the
strainer.
Use one lifting eye to lower the pump. Place the pump to a horizontal position on the
work floor.
Use the flat bar on the diffuser ring as the next Place the pump vertical on the support unit.
lifting point.
9
Workshop Manual Dismantling
Remove the lower diffuser. Remove the diffuser ring, use bending iron or
a screwdriver to loosen it.
Lift off the diffuser ring. Knock down the tab on the lock washer.
WARNING
Don’t use screwdrivers or the like for restraining
the impeller. Small shards of metal could otherwise
break away from the impeller and injure eyes. Use
a wooden shaft or similar to restrain the impeller.
Screw out the impeller nut. Lift off the impeller by using a standard puller, use
protecting gloves to handle the impeller.
10
Workshop Manual Dismantling
Remove the key, the shims, the plastic washer Remove the circlip.
and the rubber seal.
Remove the rotating seal by using two screwdrivers. Remove the holder ring.
Remove the static seal ring and the o-ring. Remove the upper diffuser by first pulling out the
screw protecting plugs.
11
Workshop Manual Dismantling
Remove the nuts and bolts from the bearing Lift up the rotor half way and detach the cables.
holder. Use tool 114620 to lift the rotor unit.
Use three M10 bolts to pull out the oil housing Remove the oil housing by attaching two M16
from the stator housing. lifting eyes.
Remove the outer casing. Remove the nuts and the O-ring.
12
Workshop Manual Dismantling
Remove the circlip from the bearing holder. Remove the lock spring from the shaft and pull out the
rotating seal ring by using two screwdrivers.
WARNING
Heat dismantling
To avoid burn injury use heat
protective gloves
Remove the static seal ring. Remove the bearing holder. Heating should be done
rapidly and evenly all around. At a temperature of about
150 °C (300°F) lift off the bearing holder.
13
Workshop Manual Dismantling
Removing the lower ball bearing. Removing the upper bearing holder and ball bearing.
Removing the stator Lift the stator casing about 20mm above the floor.
Apply the lifting tool 114722 in the rotor position just Heating should be done quickly and evenly all around.
above the centre of gravity of the stator. Tighten the At a temperature of about 150°C(300°F), the stator
casing screw for the tool to 35-40Nm. will slide off the stator, continue to lift off the stator.
14
Workshop Manual Assembling
15
Workshop Manual Assembling
Apply the lifting tool 114722 in the stator. Place the Tighten the screw for the tool to 35-40Nm.
tool near the end of the stator plates and perpendicular
to the centreline of the stator for easier fitting in the
stator housing.
Inside of stator housing. Heating of the stator housing should be done quickly
and evenly all around. At a temperature of 150°C (300°F)
lower the stator into the housing.
Leaders with
thermal cables
Machined
groove in the
stator plates
Boss on the
stator housing
When fitting the stator make sure the following. Fit the insulating tubes.
The leaders witch includes the thermal cables should
be to the left of the machined groove in the stator
plates. The groove and the boss on the outside of
the stator housing should line up.
16
Workshop Manual Assembling
Attach the support unit to the main cover and place it on Protection ring.
the work floor, fit the O-ring for the stator housing.
Stator housing
boss
Fit the protection ring and the stator housing, pull Place the stator housing boss to line up in the centre
the stator leaders through the junction box. of the junction box, fit the washers and the nuts.
Protection ring from above. Fit the conductor set in the groove between the
stator and housing and the stator.
17
Workshop Manual Assembling
Fit the O-ring in the stator housing. Fit the O-ring in the oil housing. Use 2 eyebolts to lift it up.
Use a soft hammer to get the oil housing to enter on Use 3 nuts and tight them evenly to get the oil housing
the outer casing. in its position.
18
Workshop Manual Assembling
Screw on the 3 socket head screws to connect the Heating of the upper ball bearing.
oil housing and the stator housing. When finished
undo and remove the nuts fitted on the previous page.
WARNING
FOR HEAT ASSEMBLING
To avoid burn injury use heat
protective gloves.
Fit the upper ball bearing. Pack the bearing with grease.
WARNING
FOR HEAT ASSEMBLING
To avoid burn injury use heat
protective gloves.
Heat the upper bearing holder to 100-120°C (250°F). Fit the bearing holder and the O-ring.
19
Workshop Manual Assembling
IMPORTANT
Fit the circlip before
the lower bearing.
WARNING
FOR HEAT ASSEMBLING
To avoid burn injury use
heat protective gloves.
WARNING
FOR HEAT ASSEMBLING
To avoid burn injury use
heat protective gloves.
Pack the bearing with grease. Heating of the lower bearing holder should be done
quickly end evenly all around. At a temperature of
150°C (300°F) fit the holder onto the bearing.
20
Workshop Manual Assembling
Slide the bearing holder onto the shaft. Fit the circlip holding the bearing.
Fit the regulator, use a Ø 4 x 30mm pin to lock the Fit the O-ring before lowering the rotor unit into the stator.
regulator in its position. Use tool 114620 to lift the rotor unit.
Connect the conductor set and the regulator cables. Pull the conductor set cable from the junction box.
21
Workshop Manual Assembling
Turn the rotor until the cable will have a gentle bend. Fit the washers and the nuts holding the oil housing
and the rotor unit together.
22
Workshop Manual Assembling
IMPORTANT
Mechanical seals are precision parts. Before
starting to fit the seals wash hands and keep
the sealing surfaces absolutely clean.
IMPORTANT
Use soap solution to lubricate the
O-ring on the stationary seal, oil
must not be used.
Fit the O-ring on the stationary seal ring and place it on Use assembly tool 114690 to press the stationary
top of its seat. seal down into its seat.
Oil the sealing surface on the rotating seal ring. Make sure that the slot in the rotating seal ring and the
hole in the shaft are aligned when sliding the rotating
seal ring onto the shaft.
Fit the rotating seal ring on the shaft and slide it by If necessary use tool 114690 to push the rotating seal
hand to its position. ring to its position.
23
Workshop Manual Assembling
Stop ring for the rotating seal ring. Press down the seal so that the ball on the stop spring
slips into the groove.
24
Workshop Manual Assembling
Fitting of the upper diffuser by tightening the 6 screws Fit the O-ring for the stationary seal ring. For easer
M12x30. assembly of the static seal ring hang the O-ring on
the 20° chamfer.
IMPORTANT
Mechanical seals are precision parts. Before
starting to fit the seals wash hands and keep the
sealing surfaces absolutely clean.
Put the stationary seal ring in place on the O-ring. Turn the holder to match the four mounting holes in
the upper diffuser.
Use tool 114690 to push the seal ring down to its Fit the 4 screws and washers holding the holder ring
final position, make shore that the O-ring slides down do not over tight.
evenly all around.
25
Workshop Manual Assembling
Pin on the
shaft
Oil the seal surface of the static seal ring. Fitting of the rotating seal ring, note the pin on the shaft and
the groove in the rotating seal ring, make shore that the pin
and the slot line up.
Slide the rotating seal ring on the shaft and use tool Fit the circlip.
114690 to push it to its position.
Fit the rubber seal on the rotating seal ring and fit Fit the plastic washer, adjusting washers and the impeller
the 6 washers. key.
26
Workshop Manual Assembling
Lubricate the shaft end. Fit the impeller, make sure that there is at least 0,3mm
clearance between the impeller and the upper diffuser.
Add or remove adjusting washers to accomplish this.
WARNING
Don’t use screwdrivers or the like for restraining
the impeller. Small shards of metal could
otherwise break away from the impeller and injure
eyes. Use a wooden shaft or similar to restrain
the impeller.
Fit the washer and the impeller nut. Bend up the tag on the washer to lock the impeller nut.
27
Workshop Manual Assembling
Fitting the diffuser ring, make sure that the inner and Fit the holder.
the outer holes line up with the center of the water
channel.
Fit the washers and tighten the nuts. Fit the O-ring in the lower diffuser.
Fit 6 nuts and washers and then the lower diffuser. Fit the next set of washers and nuts and adjust the
clearance between the impeller and the diffuser to
0.2- 0.3mm. Turn the impeller when adjusting.
28
Workshop Manual Assembling
Lift the pump by using the holder. Rotate the pump and place it horizontal on the work floor.
Lift the pump vertical by using the two eyes bolts. Lower the pump onto the strainer.
Tighten the screws holding the strainer. Fill the oil casing, volume 4,5l.
29
Workshop Manual Assembling
Connect the stator leaders and the control cables to Check that the insulation resistance between the
the terminal board. phase windings and between each phase and earth
(ground) ≥ 1 Mohm. Use a 1000V megger.
Start reaction
30
Workshop Manual Trouble Shooting
The pump has ”burried” itself Change the location of the pump.
down
Temperature of the pumped Consult your GRINDEX representative.
medium is too high (>40°C)
The density or viscosity of the Magnum pumps are designed for liquides up to 1100kg/m³
pumped medium is too high
The impeller is stiff to turn Clean around the impeller. Check that the adjustment is not
too tight.
Voltage drop due to the cables The voltage drop must not exceed 5% of the rated voltage.
being too long or undersized The maximum cable lengths are specified in the Technical
File.
The supply currents are ir- Check the power supply. Check the stator (see under the
regular or too high headings To check the stator winding resistances and To
check the power cable).
The insulation resistance be- Clean the stator and, if it is found to be damp, dry it in a hot-
tween the phases and earth in air oven. Then check the insulation resistance and the wind-
the stator is too low ing resistances (see under the heading To check the stator
insulation). If the stator fault cannot be remedied, fit a new
stator.
Fault Action
1. Impeller and lower diffuser Adjust to compensate for the wear. See under the heading
heavily worn diffuser heavily To fit the diffuser ring and lower diffuser.) If
necessary , fit a new impeller and diffuser.
2. Pressure loss is too high be- Reduce the number of bends and valves. Increase the hose/
cause of hoses/pipes being pipe sizes.
too long, too many valves, etc.
3. The hose is nipped or kinked Arrange the hose so that the number of bends is as small as
possible.
4. The discharge head is too low Change over to a pump with a higher discharge head or
connect several pumps in series.
5. Wrong direction of rotation The motor protection of the pump ensures that the impeller
will not rotate in the wrong direction. If the pump has been
wrongly connected, it may run in the wrong direction (see
under the heading To fit the starter equipment).
31
Workshop Manual Checks
2-Pol
Voltage Frequency Resistance
V Hz W
400 50 0.150
500-550 50 0.259
460 60 0.150
575 60 0.259
4-Pol
Voltage Frequency Resistance
V Hz W
400 50 0.163
500-550 50 0.276
460 60 0.163
575 60 0.276
32
Workshop Manual Tools
33
Workshop Manual Tools
34
Grindex AB Box 538 SE-136 25 Haninge Sweden
Tel:+46 8 606 66 00 Fax:+46 8 745 53 28
e-mail: grindex@grindex.com www.grindex.com