No: ?? ??? ?? Revision 2 2001.

09

Workshop manual

Midi Matador www.grindex.com

Semi Senator NEW LINE

Workshop Manual Index

Foreword _______________________________________________ 3
Product description ____________________________________ 4
Technical data __________________________________________ 6
Dismantling ____________________________________________ 8
To drain the oil ___________________________________________ 8
Lower diffuser ____________________________________________ 8
Pump casing _____________________________________________ 9
Impeller ________________________________________________ 10
Lower shaft seal unit _____________________________________ 11
Upper diffuser ___________________________________________ 11
Upper shaft seal unit __________________________________ 11–12
Bearing holder and rotor unit _______________________________ 13
Upper ball bearing _______________________________________ 13
Rotor unit and lower ball bearing ____________________________ 14
Power cable, starter equipment and motor protection ____________ 15
Main cover, air valve and terminal board ______________________ 16
Stator _________________________________________________ 17
Assembly _____________________________________________ 18
Stator _________________________________________________ 18
Ball bearings and rotor unit into the bearing holder ___________ 19–20
Motor unit and upper shaft seal _____________________________ 20
Upper diffuser ___________________________________________ 21
Terminal plate ___________________________________________ 21
Main cover and air valve ___________________________________ 22
Lower shaft seal _________________________________________ 22
Impeller ________________________________________________ 23
Starter equipment, motor protection, power cable and oil fill ____ 24–25
Lower diffuser ___________________________________________ 26
Outer casing, strainer bottom and discharge connection __________ 27
Trouble shooting _____________________________________ 28
Checks _______________________________________________ 30
Motor unit, power cable, oil and discharge head ________________ 30
Stator _________________________________________________ 31
Contactor and SMART motor protection ______________________ 32
Tools _________________________________________________ 33

GRINDEX 2
 Workshop Manual Foreword

Please carefully read this Workshop Manual to gain the benefit of the information it contains, so
that:
l you will acquire knowledge of Grindex drainage and sludge pumps.
l you will be able to make certain that the pumps retain their high reliability by following the
specified service and inspection instructions.
l you will be able to remedy various problems quickly and methodically.

The Workshop Manual

l contains a product description and technical data.
l describes dismantling and assembly in their entirety. If any pump model differs from the
standard design, this is described immediately adjacent to the general description.
l describes troubleshooting, inspection measures and suitable special tools.
l shows various operations by means of photos/exploded views.

Information on the data plate

Before use see operators manual

Model Serial No.

Box 538 S-136 25 Haninge SWEDEN
MADE IN SWEDEN
Pump type No. Maximum power
SEMI SER. No 123456 consumption
Rated voltage
TYPE 8821
Rated current Maxumum head
U 460 V D P max 16 kW
Number of phases I 22 A H max 27 m Maximum capacity
and frequency
Ø 3 ~ c/s 60 Hz Q max 2400 l/min Maximum
Direction of ROTATION submersion depth
impeller rotation START REACTION 20 m 95
Start reaction
Before use see operators manual

Model Serial No.

Box 538 S-136 25 Haninge SWEDEN
MADE IN SWEDEN

Pump type No. Maximum power

MATADOR N SER. No 123456
consumption
Rated voltage 4551
TYPE
Rated current Maxumum head
U 380–400 V P max 23 kW
Number of phases I 6.2–5.7 A H max 43 m Maximum capacity
and frequency 3 ~ c/s 50 Hz Q max 6100 l/min
Ø
Maximum
Direction of ROTATION submersion depth
impeller rotation START REACTION 20 m 95
Start reaction

Before using, see operators manual.

Design and specification subject to changes without prior notice.

GRINDEX 3
 Workshop Manual Product description

Grindex submersible electric drainage and sludge pumps are designed for continuous opera-
tion. The pumps can be run dry. The drainage pumps are intended for pumping liquids that may
contain small particles. The sludge pumps are designed for pumping sludge which may contain
coarse solid particles.

FIELDS OF APPLICATION
Liquid temperature: 40°C max.
pH of liquid: 5-8
Submersion depth: 20 m max.
Liquid density, 1.1 kg/dm3 max.
drainage pumps: Particles up to a size corresponding to the holes in the strainer (12 mm)
are permissible in the pumped liquid.
Liquid density, 2.0 kg/dm3 max.
sludge pumps: Particles up to a size corresponding to the pump casing inlet
(about 60 mm) are permissible in the pumped sludge.
CAUTION

WARNING
The pumps must not be used in an explosive or flammable environment or for pumping
combustible liquids.

DESIGN

Hydraulic part
l The impellers of all drainage and sludge pumps are made of chromium-alloyed white iron
with a hardness of 55 ± 5 HRC.
l The impellers of the drainage pumps are of open centrifugal type, whereas those of the
sludge pumps are of vortex type.
l The lower diffusers of the drainage pumps are coated with polyurethane or nitrile rubber.
The upper diffusers and diffuser rings are coated with nitrile rubber.
l The pump housings of the sludge pumps are lined with polyurethane.

Shaft seals
Lower shaft seal: Duratite - Duratite (based on silicon carbide)
Upper shaft seal: Nitrided steel - graphite

GRINDEX 4
 Workshop Manual Product description

Bearings
Grease-packed ball bearings with C3 clearance of the following types:

Bearing Type
Upper bearing Single-row grooved ball bearing
Lower bearing Double-row, angular-contact bearing

Starter equipment
The pumps are supplied with built-in direct on-line (DOL) or star/delta starter equipment.
The pumps can also be supplied with external starter equipment. All pumps are equipped
with overcurrent protection and SMART systems.

SMART - Electronic motor monitoring system

l Rotasense: Allows the pump to start only if the phase sequence of the power
supply is correct.
l Phase monitor: Allows the pump to run only if all three phases are connected.
l Temperature monitor: A temperature switch is incorporated into each winding. The switches
open at a temperature of 130°C and open the circuit to the contactor coil.
l Restart-protection: Prevents the pump from restarting automatically after the motor
protection has tripped.

Motor
Two-pole squirrel-cage induction motor for 50 Hz or 60 Hz. The stator is insulated to IEC 85
Class F (155°C).
The difference between the supply voltage to each of the phases must not exceed 2% (as
specified in IEC 34-1). Maximum number of evenly distributed starts: 12 times/hour.
The voltage supply to the motor must not vary by more than 5%.

Power cable
To class H07RN-F of the following sizes:
4 x 4 mm2 4 x 16 mm2
4 x 6 mm2 4 x 25 mm2
4 x 10 mm2

GRINDEX 5
 Workshop Manual Technical data

Drainage pumps 50 Hz
MIDI MATADOR
N H N H
Rated power kW 11 10 19 20
Speed rpm 2900 2900 2900 2900
Max power demand kW 13 12 23 24
Rated current A at 220 V 37 36 64 70
“ A at 230 V 36 35 62 67
“ A at 346 V 24 23 41 44
“ A at 380 V 22 21 37 40
“ A at 400 V 21 20 35 38
“ A at 415 V 20 19 34 37
“ A at 440 V 19 18 32 35
“ A at 500 V 16 16 28 31
“ A at 550 V 15 14 26 28
Discharge connection inch 6 4 6 4
Strainer hole Ø mm 12 12 12 12
Weight kg 120 120 160 160
Height mm 810 810 930 930
Width, max. mm 530 490 530 490
Strainer bottom Ø mm 380 380 380 380
Max. discharge head, H m 34 63 43 58
Max capacity, Q l/min 4400 1400 6100 3100

Sludge pumps 50 Hz
SEMI SENATOR
Rated power kW 11 21
Speed rpm 2850 2900
Max power demand kW 14 26
Rated current A at 220 V 41 75
“ A at 230 V 39 72
“ A at 346 V 26 48
“ A at 380 V 24 43
“ A at 400 V 22 41
“ A at 415 V 22 40
“ A at 440 V 20 37
“ A at 500 V 18 33
“ A at 550 V 16 30
Discharge connection inch 4 (3) 4 (3)
Strainer hole Ø mm 80 80
Weight kg 130 165
Height mm 1010 1130
Width, max. mm 500 500
Max. discharge head, H m 25 33
Max capacity, Q l/min 2400 2700
GRINDEX 6
 Workshop Manual Technical data

Drainage pumps 60 Hz
MIDI MATADOR
N H N H
Rated power kW 12 13 22 24
Speed rpm 3500 3500 3500 3500
Max power demand kW 15 16 27 29
Rated current A at 220 V 43 46 75 82
“ A at 230 V 41 44 72 78
“ A at 380 V 25 27 44 47
“ A at 440 V 21 23 38 41
“ A at 460 V 20 22 36 39
“ A at 575 V 16 16 29 31
Discharge connection inch 6 4 6 4
Strainer hole Ø mm 12 12 12 12
Weight kg 120 120 160 160
Height mm 810 810 930 930
Width, max. mm 530 490 530 490
Strainer bottom Ø mm 380 380 400 400
Max. discharge head, H m 35 74 47 65
Max capacity, Q l/min 4600 1250 6200 3200

Sludge pumps 60 Hz
SEMI SENATOR
Rated power kW 12 22
Speed rpm 3450 3500
Max power demand kW 16 28
Rated current A at 220 V 46 79
“ A at 230 V 44 75
“ A at 380 V 27 46
“ A at 440 V 23 39
“ A at 460 V 22 38
“ A at 575 V 18 30
Discharge connection inch 4 (3) 4 (3)
Strainer hole Ø mm 80 80
Weight kg 130 165
Height mm 1010 1130
Width, max. mm 500 500
Max. discharge head, H m 27 39
Max capacity, Q l/min 2400 2700

GRINDEX 7
 Workshop Manual Dismantling

To drain the oil from drainage pumps

Remove the nuts retaining the strainer bottom.
Remove the strainer bottom. Remove the
strainer (Matador). Remove the outer casing and
remove the O-ring that seals between the top
part and the outer casing. Remove the diffuser
and the diffuser ring. Place the pump on its side.
Remove the protective washer outside the oil
screw, and remove the oil screw and the O-
ring. Turn the pump so that the oil hole is at the
bottom and drain the oil.

To drain the oil from sludge pumps

Place the pump on its side. Remove the inspec-
tion screw. Remove the oil screw and the O-
ring. Insert an inspection tube (132810) which
fits into the rubber in the upper diffuser. Turn
the pump so that the oil hole is at the bottom
and drain the oil.

WARNING
If water has leaked into the oil casing, the inside of the casing may be pressurized. So al-
ways remove the oil screw slowly and carefully. Place a piece of cloth over the oil screw to
prevent oil splashing around.
GRINDEX 8
 Workshop Manual Dismantling

To dismantle the pump casing (sludge pumps)

Remove the bolts (55) and remove the spring
washers (54). Remove the stand (79). Remove
the bolts (75) and the spring washers (76). Re-
move the clamp (77) and the discharge connec-
tion (74). Remove the nuts (53) and the spring
washers (52). Remove the lower pump housing
(78) and bolts (49). Remove the nuts (51), the
spring washers (50) and the upper pump hous-
ing (73). Remove the gaskets (48) from the studs
(47). Remove the seal (70). Remove the screws
(71) and the holders (72). Withdraw the wear
ring (69) from the upper pump housing. Remove
the nuts (46) and the spring washers (45). Re-
move the spacer ring (64).

GRINDEX 9
 Workshop Manual Dismantling

To remove the impeller

Midi Semi
Fold back the lock washer (A) A Remove the screw (B). This A
and remove the screw (B). screw is self-locking and
should therefore not be re- B
B
used. Remove the washer (A).

Matador A
Senator
Fold back the lock washer (A) Remove the screw (A). A
and remove the nut (B). B

NOTE! NOTE!
Certain Matador pumps are of the same Certain Senator pumps are of the same de-
design as the Midi. sign as the Semi.

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 your eyes. Use the GRINDEX tool (114386)
intended for this purpose or a wooden shaft to restrain the impeller.
Remove the impeller, shaft key and adjusting washers.

GRINDEX 10
 Workshop Manual Dismantling

To dismantle the lower shaft seal unit

Carefully use two screwdrivers to remove the
unit (B, C, D, E). The upper diffuser must be
removed to allow the O-ring (A) to be removed.

To dismantle the upper diffuser

Remove the protective washers (133) (applies
to Matador and Senator) and remove the screws
(132). Remove the upper diffuser (131), the
thrust plate (130), spring (129) and spring sup-
port (128). Remove the O-ring (122). The O-ring
for the lower seal unit can now be removed.

To dismantle the upper shaft seal unit

Use circlip pliers to remove the circlip (127). Use
the tool (114627) to remove the seal ring (126)
from the shaft.
Use the same tool to lift up the seal ring (125).
Remove the O-ring (124) from the seal ring.

GRINDEX 11
Workshop Manual Dismantling

NOTE!
If the seal ring (126) is jammed in position, both this seal ring and the seal ring (125) can be
removed together by means of two screwdrivers. Fit the screwdrivers in the free groove of the
stationary ring (125) and prise it carefully out of the bearing holder. Then use the tool (114627)
for removing both seal rings.

GRINDEX 12
 Workshop Manual Dismantling

To remove the bearing holder with rotor unit

Place the pump horizontally on the workbench.
Withdraw the rotor unit with bearing holder from
the stator housing.
If the rotor unit is difficult to remove, the tool
(114645) should be used.

To remove the upper ball bearing

Use a puller to remove the upper ball bearing.

GRINDEX 13
 Workshop Manual Dismantling

To remove the rotor unit

Place the bearing holder with the shaft end point-
ing upwards in a press, and press out the rotor
unit.

To remove the lower ball bearing

Use circlip pliers to remove the circlip (117), and
remove the cover plate (118). Use a gas burner
to preheat the bearing holder (121) and remove
the bearing. Remove the spacer washer (120).

GRINDEX 14
 Workshop Manual Dismantling

To remove the power cable

Remove the cover from the junction box cham-
ber. Disconnect the power cable from the con-
tactor. Disconnect the earth cable from the
mounting plate.
Remove the bolts (6) which retain the cable en-
try flange (7). Withdraw the power cable and
remove the washers (8) and the rubber seal (9)
from the cable. Remove the nuts (4) holding the
clamps (3) together. Remove the cable entry
flange from the cable.

To remove the starter equipment and motor protection

Remove the bolts holding the mounting plate
and main cover together. Disconnect the earth
cable between the mounting plate and the main
cover. Lift out the starter equipment. Release
the screws on the terminal board. Disconnect
the cables from the terminal board.

GRINDEX 15
 Workshop Manual Dismantling

To remove the main cover and air valve

Remove the screws (A) retaining the main cover
on the stator housing. Lift off the main cover.
Remove the O-ring from the stator housing.
Remove the screws (B). Remove the valve cover
(C).
Remove the spring (D) from the valve (E).

To remove the terminal board

Remove the screws (113). Lift out the terminal
board (102). Remove the nuts (104) from the
underside of the terminal board. Disconnect the
stator leads. Remove the O-ring (105). Remove
the cover (106) and the O-ring (107).

GRINDEX 16
 Workshop Manual Dismantling

To remove the stator

Fold the leads down so that they do not pass
through the openings in the stator housing. Place
the stator housing on a suitable support. Heat
the outside of the stator housing quickly and
uniformly, e.g. using two gas burners, until the
stator slides out of the stator housing under its
own weight.

GRINDEX 17
 Workshop Manual Assembly

NOTE
Before starting the assembly work
l Carefully clean all machined surfaces.
l Check that the O-ring grooves and shaft end are clean and undamaged.
l Fit new parts to replace all damaged or worn parts. Use only genuine parts.
l Always change all O-rings, rubber seals and the cable entry seal.
l Oil thoroughly the O-rings and the sliding surfaces of seals.
l Grease all bolts and nuts before fitting them.

To fit the stator

Fit insulating tubes to the stator leads. Place the
stator on a suitable stand. Heat the stator hous-
ing to about 150°C. Lower the stator housing
onto the stator so that the stator leads can eas-
ily be drawn through the three openings in the
top of the stator housing. Allow the stator hous-
ing to cool, and then draw the uniformly distrib-
uted stator leads through the openings in the
stator housing. Fit cable lugs to the leads.

WARNING
Make sure that the stator leads do not come
into contact with the hot stator housing.

GRINDEX 18
 Workshop Manual Assembly

To fit the ball bearings and rotor unit into the bearing holder
Lower ball bearing
Place the bearing holder (121) on the tool
(114363). Place the spacer washer (120) with
the recess facing downwards. Pack the ball bear-
ing (119) 2/3 full of grease.

Use a drift to press in the ball bearing:

Midi, Semi: 114489
Matador, Senator: 114364
Place the cover plate (118) on the ball bearing
and fit the circlip (117).

Upper ball bearing

Place the rotor unit in a press. Place the drift
(see below) on the upper ball bearing and press
down the upper ball bearing. Pack the upper ball
bearing 2/3 full of grease.

Drifts for upper ball bearings:

Midi, Semi: 114383
Matador, Senator: 114371

The following bearing greases or equivalent are

recommended:
ESSO Unirex 3, BP Energrease LS3, Shell
Alvania Grease R3.

GRINDEX 19
 Workshop Manual Assembly

To fit the rotor unit and bearing holder

Heat the ball bearing inner race with the heater
body placed on a hot-plate.
Fit the bearing holder to the rotor unit.

Heater body:
Midi/Semi: 114653
Matador/Senator: 114650

To fit the motor unit

Place the stator housing upside down. Fit the
rotor unit into the stator housing.

To fit the upper shaft seal unit

Fit the O-ring (124) into the groove in the seal
ring (125). Press the seal ring into place in the
bearing holder, using the tool (114626). Oil the
surface of the seal ring. Oil the inside of the seal
ring (126) and press it about 30 mm up onto the
shaft. Use circlip pliers to fit the circlip (127) to
the shaft. Use the tool (114626) to press the
circlip and seal ring down until the circlip snaps
into its groove.

NOTE
Check that the surfaces of both seal rings are perfectly clean and that the shaft is not scratched.

GRINDEX 20
 Workshop Manual Assembly

To fit the upper diffuser

Place the spring support (128), spring (129) and
thrust plate (130) on the bearing holder. Fit the
O-ring (122). Fit the O-ring for the lower seal
unit into the O-ring groove in the upper diffuser
(131). Fit the upper diffuser.

NOTE
Check that the pin in the upper diffuser (131) enters its groove in the thrust plate (130). Screw
in the screws (132) and press in the protective washers (133) (Matador and Senator).

To fit the terminal board

Fit the O-ring (107) and protective cover (106)
into the stator housing. Fit the O-ring (105) to
the stator housing. Fit the stator leads in accord-
ance with the colour coding to the underside of
the terminal board. Fit the O-rings (114) to the
screws (113). Secure the terminal board to the
stator housing.

GRINDEX 21
 Workshop Manual Assembly

To fit the air valve and main cover

Insert the valve guide pin from the inside, through
the hole in the main cover. Fit the spring (D) to
the guide pin. Secure the valve cover (C) to the
main cover. Fit the O-ring to the stator housing.
Secure the main cover to the stator housing.

To fit the lower shaft seal

Lubricate the outside of the stationary seal ring
(B) before pressing it in, and then turn it until a
clear snap indicates that it is secured in the thrust
plate. Grease the rubber ring (D) and place it in
the seal ring holder (E). Place the seal ring (C)
in the seal ring holder (E). Fit the O-ring (A) in
conjunction with fitting the upper diffuser.
Oil the surface of the seal ring holder. Fit the
seal ring onto the shaft. Check that the lower
shaft seal unit is resilient.

NOTE
The seal ring is lapped on one side. The
side which is not intended for use as a seal-
ing surface is marked and should face to-
wards the rubber ring.

NOTE
Check that the surfaces of both seal rings
are perfectly clean. Never use anything that
may damage the sealing surfaces on as-
sembly. During the assembly work, hold the
seal ring with a clean, soft piece of cloth.

GRINDEX 22
 Workshop Manual Assembly

To fit the impeller

Drainage pumps
Fit a suitable number of adjusting washers (A)
to the shaft so that a clearance of 0.1 mm will
be obtained (use tool 114648) between the
impeller and the upper diffuser when the impeller
has been tightened. Carefully press the impeller
into place so that the key (B) slides into the
keyway in the impeller. Fit the lock washer (C)
and tighten the bolt (D) hard. Use the tool
(114386) to restrain the impeller. Lock the screw
by folding up the lock washer. Check that the
impeller can be turned by hand.

Sludge pumps
Fit a suitable number of adjusting washers to
the shaft. Carefully press the impeller onto the
shaft so that the key (65) slides into the impeller
keyway. Fit the washer (67) (Semi) and tighten
the screw (68) hard. Use the tool (114386) to
restrain the impeller.

N.B.!
Certain Senator pumps are of the same design as the Semi.

NOTE
The screw for the Semi is self-locking, which means that it cannot be re-used.
Check that the impeller is free to turn by hand.

GRINDEX 23
 Workshop Manual Assembly

To fit the starter equipment and motor protection

Fit the electrical components onto the mounting

plate. Connect the cabling in accordance with
the wiring diagram. Connect the cables between
the contactor and terminal board. Fit the unit onto
the main cover. Connect the earth cable between
the main cover and the mounting plate.

NOTE
The overcurrent protection should be set to AUTO. The tripping current should be 10% higher
than the rated current of the pump. Note that the scales for direct on-line and star/delta are
different.

GRINDEX 24
 Workshop Manual Assembly

To fit the power cable

Thread the cable entry flange (7) onto the ca-
ble. Thread the washers (8) and rubber seal (9)
onto the cable. Tighten the clamps (3). Fit the
cable entry flange onto the main cover. Connect
the earth cable to the mounting plate and con-
nect the phase conductors to the contactor in
accordance with the wiring diagram.

NOTE
When connecting a cable that has previously been used in the pump, always cut off a piece of
the cable so that the rubber seal of the cable entry will be in a new place on the cable.

Filling the pump with oil

Place the pump on the workbench with the oil

hole at the top. Fill the pump with the oil quanti-
ties given in the table below. The oil housing
must never be completely full. Fit the O-ring to
the oil screw and fit the oil screw in place. Fit
the protective washer.
Midi, Semi: 1,25 litres
Matador, Senator: 1,15 litres
Recommended oils: BP Enerpar M006, Mobile
White Rex 309 or equivalent

GRINDEX 25
 Workshop Manual Assembly

To fit the diffuser ring and lower diffuser (drainage pumps)

Midi
Fit the studs (A) to the stator housing. Fit the
spacer sleeves (B) to the diffuser ring (C).
Thread the diffuser ring onto the studs. Fit the
nuts (D) and (E) and lock them to one another.
Fit the studs (F). Thread on the protective
sleeves (G) and upper nuts (H). Fit the lower
diffuser (I) and the lower nuts (J).
Adjust the nuts in diagonally opposite pairs until
the impeller is only just clear of the lower dif-
fuser. When the clearance between the impeller
and the lower diffuser is 0.10 mm (use feeler
gauge 114648), lock the nuts. Check that the
impeller rotates freely.

Matador
Fit the studs (A) to the stator housing. Fit the
spacer sleeves (B) to the diffuser ring (C).
Thread the diffuser ring onto the studs. Fit the
spacer sleeves (D). Tighten the nuts (E) and lock
them. Fit the lower diffuser (F) and bolts (G),
but do not tighten the bolts.
Adjust the diffuser by turning it until the impeller
is only just clear of the lower diffuser. When the
clearance between the impeller and the lower
diffuser is 0.10 mm (use feeler gauge 114648),
tighten the nuts. Check that the impeller rotates
freely.

NOTE
The bolts retaining the lower diffuser on the Matador pump must not be tightened too hard,
since the plate in the diffuser ring may otherwise be deformed.

GRINDEX 26
 Workshop Manual Assembly

To fit the outer casing, strainer bottom and discharge connection

(drainage pumps)
Grease the outside of the diffuser. Fit the O-ring
which seals between the main cover and the
outer casing. Fit the outer casing, strainer (Mata-
dor) and strainer bottom.
Fit the discharge connection.

NOTE
If the pump has a polyurethane-coated diffuser, the clearance between the diffuser and the
impeller should be 0.30 mm.

To fit the pump housing, outer casing, stand and discharge connection
(sludge pumps).
Fit the studs (43) to the stator housing. Fit the
O-ring which seals between the main cover and
the outer casing. Fit the outer casing. Fit the
spacer ring (64). Fit the spring washers (45) and
the nuts (46). Fit the wear ring (69) in the upper
pump housing (73). Fit the holder (72) and bolts
(71). Place the seal (70) on the spacer ring. Fit
the gaskets (48) to the studs (47). Fit the upper
pump housing to the spacer ring. Fit the spring
washers (50) and nuts (51). Use the bolts (49),
spring washers (52) and nuts (53) to bolt down
the pump housing (78). Fit the stand (79) and
the discharge connection (74).

GRINDEX 27
 Workshop Manual Trouble Shooting

NOTE
The pump must not be connected to the power supply during trouble shooting, except for the
checks that cannot be carried out with the pump de-energized.
Electrical work must be carried out by authorized personnel.

THE PUMP FAILS TO START

Fault Action
1. Wrong phase sequence. Grindex pumps are equipped with Rotasense which will not
allow the pump to start if phase sequence of the power sup-
ply is wrong. Transpose two phases.

2. One or several phases are not Change the fuses or cable.

live: Check the power supply.
- fuses blown
- loss of power supply
- cable failure

3. Underrated power supply. Check that the power supply is sufficient for the power de-
mand of the pump. Check that the rating of the protection is
sufficient.

4. The impeller is clogged. Clean.

5. The stator is burned. See under the headings To check the stator insulation and
To check the resistance of the stator windings.

6. The contactor coil is burned. See under the heading To check the contactor.

THE PUMP STARTS BUT STOPS AFTER RUNNING

Fault Action
1. A fuse has blown. Grindex pumps are equipped with a phase monitor which
allows the pump to run only if all three phases are connected.
Correct the fault and change the fuse. Note that the pump
will restart automatically when all three phases are live.

2. The temperature monitors or Grindex pumps are equipped with a temperature switch in
overcurrent protection has each winding. These are connected in series with a switch
tripped the power supply to in the overcurrent protection and with the contactor coil. If
the contactor coil. the temperature in the motor winding is in excess of 130°C
or if the current is in excess of 110% of the rated current, the
circuit to the contactor coil will be opened. The pump can be
restarted by interrupting the power supply and then switch-
ing it on again.

GRINDEX 28
 Workshop Manual Trouble Shooting

THE PUMP STARTS BUT STOPS AFTER RUNNING (cont.)

The pump has ”burried” itself Change the location of the pump.

Temperature of the pumped Consult your GRINDEX representative.

medium is too high (>40°C)

The density or viscosity of the Fit an impeller of a smaller diameter (sludge pumps only).
pumped medium is too high

The impeller is stiff to turn Clean around the impeller. Check that the adjustment is not
too close.

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).

3. 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.

THE PUMP RUNS BUT DELIVERS INSUFFICIENT WATER OR NONE AT ALL

Fault Action
1. Impeller and lower diffuser Adjust to compensate for the wear. (See under the heading
haevily 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).
GRINDEX 29
 Workshop Manual Checks

Tightness check
The following check is recommended to ensure
that the motor unit is tight. Make a cover which
fits the stator housing. Fit an air adapter to the
cover. Seal the cover with a gasket. Pressurize
the motor unit to 1 - 1.5 PSI at gauge (make
sure that the air is dry). Lower the motor unit
into a suitable container with water. Check for
leakage.

To check the power cable

Check that the cable sheath is not damaged.
Damage may cause water to seep into the ca-
ble and then to the junction box chamber of the
pump. Using an ohmmeter, check that none of
the cable conductors has failed.
Use a 1 kV megger to check the insulation be-
tween the phase conductors and protective earth
and between the phase conductors.

To check the oil

If the oil is turbid or whitish and viscous, or if a
certain amount of water separation is noticeable,
this indicates that water has leaked into the oil
casing. If so, fit a new lower shaft seal.

NOTE
A certain amount of leakage may occur when the shaft seal is new. This does not indicate that
the shaft seal is defective. Change the oil and check the new oil after one week. If the oil is still
discoloured, fit a new lower shaft seal.
Follow carefully the oil volume recommendations under the heading Filling the pump with oil.

To check the discharge head

Fit a pressure gauge tube (114422) to the pump.
Use a rubber hose. Place the pump in water
and start it. Read the pressure gauge (114335).
The maximum discharge head of the pump is
specified under the heading Technical data.
If the discharge head is too low, adjust the lower
diffuser, and fit new parts to replace those that
are worn. For adjustment, see under the head-
ing To fit the lower diffuser

GRINDEX 30
 Workshop Manual Checks

To check the stator insulation

Check that the insulation resistance between
each winding and between the windings and
earth is at least 1 Mohm. Use a 1 kV megger.

To check the stator winding resistances

Use an ohmmeter to check the resistance of
each winding. The difference between the
resistances of the windings in a 3-phase stator
must not exceed 5%.
The terminal cables are marked as follows
1 and 4 (red and green)
2 and 5 (brown and blue)
3 and 6 (yellow and black)
The resistance values tabulated below are ap-
proximate and apply at 20°C.

Pump Voltage Frequency Resistance

V Hz W
Midi/Semi 200/346 50 0.76
220/380 50 0.28
346/600 50 0.28
380/660 50 0.83
400-440 50 1.1
500-550 50 1.67
220/380 60 0.28
230/460 60 0.28
380/660 60 0.47
575 60 1.35
Matador/Senator 200/346 50 0.09
220/380 50 0.11
346/600 50 0.33
380/660 50 0.33
400-440 50 0.35
500-550 50 0.64
220/380 60 0.07
230/460 60 0.11
380/660 60 0.44
575 60 0.57

GRINDEX 31
 Workshop Manual Checks

To check the contactor

Check the mechanical parts of the contactor. Check that the contacts of the contactor are not
burned. Check the resistance across the contactor contacts. The difference in resistance between
the various pairs of contacts should not exceed 5%.
Check that there is no open circuit in the contactor coil.

To check the 3-phase SMART motor protection

To check the operation of the motor protection

1. Connect a voltmeter between the incoming phase (L 3) and the pin (A 2) on the motor protec-
tion.
2. Connect a switch between pins 13 and 14 of the motor protection.
3. Check that the voltage and frequency are suitable for the relevant motor protection.
Connect the cables L 1 (R), L 2 (S) and L 3 (T) from the motor protection to the 3-phase power
supply.
4. Now that the power supply is connected to cables L 1, L 2 and L 3, the built-in relay should be
energized and the voltmeter should give a reading. If not, transpose two phases.
5. Open the switch connected between 13 and 14 on the motor protection.
The built-in relay will then be de-energized and there will be no reading on the voltmeter.
Close the switch. There should be no reading on the voltmeter.
Open the incoming 3-phase supply and then close it again. A reading should now be obtained
on the voltmeter.

GRINDEX 32
 Workshop Manual Tools

6 9
13
1
4

2
10 14
7

11

3 5 8
12 15

Grindex special tools

Item No. Part No. Description Used for:

1 114 627 Puller tool Upper seal
2 130 960 Eyebolt Shaft/rotor unit
3 114 386 Restraining tool Impeller
4 114 651 Adapter Shaft end
5 114 645 Tapping hammer Dismantling of rotor
6 114 363 Drift/support Lower ball bearing
7 114 489 Drift for pressing in Lower ball bearing
8 114 364 Drift for pressing in Lower ball bearing
9 114 650 Heater body Heating of ball bearings
10 114 652 Heater body Heating of ball bearings
11 114 371 Drift for pressing in Upper ball bearing
12 114 383 Drift for pressing in Upper ball bearing
13 114 626 Sleeve Upper seal
14 114 648 Feeler gauge Adjustment of impeller/diffuser
15 114 422 Pressure gauge tube Checking of discharge head

GRINDEX 33
 Workshop Manual Tools

5
1
2 3 6
4

13

7 8 9 10 11 12

Other service tools

Item No. Part No. Description/tool size Used for:

1 Purchased Spanner/14, 16, 17, 18, 19, 24 mm Nuts
2 Purchased Bent socket spanner/8, 11, 16 mm Nuts
3 Purchased Ratchet handle with expansion and Allen screws for main
allen key/10 mm cover/stator housing
4 Purchased Allen key with handle/6, 8, 10 mm Allen screws
5 Purchased Bounce free hammer Dismantling of outer
casing/diffuser
6 Purchased Hammer Lock washer
7 Purchased Wide screw driver Oil screw
8 Purchased Screw driver Screws/upper seal
9 Purchased Awl with hook, bent, angeld bent Removal of O-rings
10 Purchased Slip-joint pliers Impeller lock washer
11 Purchased Circlip pliers, external/internal Circlips
12 Purchased Two-arm puller Ball bearings
13 Purchased Gas burner set, large/small burners Heating of stator and
bearing housing

GRINDEX 34
 Workshop Manual Tools

1
2 3

4 5 6

Electrical metering tools

Item No. Part No. Description/tool size Used for:

1 Purchased Insulation meter, 1kV Meggar, Insulation resistance
0-200 Mohm measurement
2 Purchased Tong ammeter, 600 V AC 0-200 A Current measurement
3 Purchased Digital universal meter, Measurement of
1000 V AC, 10 A, 600 V max voltage, current, con-
ductivity, resistance,
frequency and tempe-
rature
4 Purchased Voltage tester, 0-600 V AC Measurement of
voltage and phase
polarity
5 Purchased Electrically insulated bent-tip pliers Electrical connection
terminals
6 Purchased Cross, Allen/3, 4, 5, 6/ socket screw Electrical terminals,
driver starter unit and
terminal plate

GRINDEX 35
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