Service instructions. Table of contents BMP S BMP NS

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Service instructions BMP 2.5-8.0 S BMP 3.4-8.0 NS Table of contents 1. Type identification... 2 1.1 Nameplate... 2 1.2 TType key... 2 2. Torques and lubricants... 3 3. Service tools... 4 3.

1 Service instructions BMP S BMP NS Table of contents 1. Type identification Nameplate TType key Torques and lubricants Service tools Special tools Standard tools Torque tools Dismantling and assembly General Dismantling Assembly Checking the wear parts Fault finding Checking of motor and cable Exploded view GB 10 1 / 10

2 1. Type identification This section shows the type key, the nameplate and the codes that can appear in the variant code. Note: As codes can be combined, a code position may contain more than one code (letter). 1.1 Nameplate Type: BMP 10.2 R - A - P - G - BBVP Model: A Q: 10.2 m/h 2.32 US GPM H: m 2677 Feet n min /max: 700 / 1800 min -1 P min /max: 10 / 80 bar PSI T min /max: 3/ 50 C 37/122 F Weight: 272 Kg LB Made in DK TM Fig. 1 Nameplate Pos. Description Pos. Description 1 Type designation 6 Pressure 2 Model 7 Liquid temperature 3 Rated flow rate [m 3 /h] 8 Weight 4 Head 9 Country of origin 5 Speed 1.2 TType key Example BMP 10,2 R- A- P- G- BBVP Pump range BMP = With standard motor BMPE= With external frequency converter Maximum flow rate [m 3 /h] Blank =All components in contact with the pumped liquid are made of stainless steel EN/DIN and PEEK N = Designed for demineralised water. All components in contact with the pumped liquid are made of stainless steel EN/DIN and PEEK R = All components in contact with the pumped liquid are made of stainless steel and PEEK Code for pump version A = First generation Code for pipe connection O = External thread G = Victaulic/PJE Code for materials I = Stainless steel (1.4301) G = Stainless steel (1.4401) Code for shaft seal B = Bellows (rubber) B = Carbon V= Al 2 O 3 P= NBR 2 / 10

3 2. Torques and lubricants This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used. Pos. Model Description Number Torque [Nm] Lubricant BMP ± 3 BMP Screw BMP ± 1 Gardolube L BMP ± 1 29 Air vent screw 2 10 ± per piston Soapy water 13 O-ring 24 2 Rocol Soapy water Gardolube L 6034, part no. SV9995 (1 l). Rocol 22, part no. RM2924 (1 kg). 3 / 10

3. Service tools The following drawings and tables show special, standard and torque tools for pump service. A B C D E F G H I J K L 3.1 Special tools Pos. Description For pos. Suppl.

4 3. Service tools The following drawings and tables show special, standard and torque tools for pump service. A B C D E F G H I J K L 3.1 Special tools Pos. Description For pos. Suppl. information Part no. A Torpedo (Included in the shaft seal tool kit) 17 Shaft seal tool kit: B Press ring (Included in the shaft seal tool kit) 4 BMP , BMP N C Puller for shaft seal (Included in the shaft seal tool kit) 4 BMP , BMP N Standard tools Pos. Description Model For pos. Suppl. information Part no. D Hexagon key 26, 29, 34 - E Ring/open-end spanner BMP F Screwdriver Straight slot - G Puller SV0335 H Circlip pliers 20 SV Torque tools Pos. Description For pos. Suppl. information Part no. I Torque wrench 4-20 [Nm] SV [Nm] SV0269 J Ratchet insert tool I SV0295 K Hexagon socket driver - L Hexagon socket - 4 / 10

5 4. Dismantling and assembly 4.1 General If it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instructions in the following sections. Position numbers of parts (digits) refer to drawings and parts lists; position numbers of tools (letters) refer to section. Before dismantling the pump: Disconnect the electricity supply to the motor. Close the isolating valves, if fitted, to avoid draining the system. Remove the electric cable in accordance with local regulations. Note the centre of gravity of the pump to prevent it from overturning. This is especially important in the case of long pumps. Before assembly: Clean and check all parts. Replace defective parts by new parts. Order the necessary service kits. Replace gaskets and O-rings when the pump is overhauled. During assembly: Lubricate and tighten screws and nuts to correct torque as stated in section. 4.2 Dismantling Note: The pump must only be dismantled in absolutely clean environment Removing the coupling 1. Remove the screws and the washers of the coupling. 2. Pull the pump off the motor. 3. Remove the coupling insert. 4. Remove the screws of the coupling guard and remove the guard. 5. Slacken the set screw of the pump coupling. 6. Remove the coupling half with a puller Removing the shaft seal 1. Remove the key (pos. 30), the screws (pos. 26 and 34) and the sealing (pos. 33). 2. Remove the flange (pos. 28). 3. Remove the stationary shaft seal part (pos. 4), O-ring (pos. 35) and the pins (pos. 7) from the flange. The rotating part consists of washer, spring and gasket. Remove the shaft seal gasket and the spring, and remove the washer by means of the puller (C). 4. Remove the swash plate (pos. 6) Removing the pistons and valve plate 1. Remove the cylinder barrel (pos. 17) with pistons and valve plate from the pump housing (pos. 5). 2. Remove the port plate (pos. 21) and the pin (pos. 7) from the pump housing. 3. Place the cylinder barrel (pos. 17) with valve plate (pos. 14) on the table and twist them apart with a screwdriver. 4. Lift the retainer plate (pos. 10) with the pistons (pos. 11) out of the cylinder barrel. 5. Remove the circlip (pos. 20) from the shaft, and remove the spring (pos. 18) and spring guide (pos. 19). 5 / 10

4.3 Assembly 4.3.1 Checking Check all wear parts before assembling the pump, see 4.4 Checking the wear parts. 4.3.2 Fitting the pistons and valve plate 1. Fit the spring (pos. 18), spring guide (pos.

Moisten them with soapy water, see fig. 4. Fig. 2 Backup rings and O-rings Fig. 3 Fitting the valve plate 3. Fit the valve plate (pos.14) on the cylinder barrel (pos.17).

6 4.3 Assembly Checking Check all wear parts before assembling the pump, see 4.4 Checking the wear parts Fitting the pistons and valve plate 1. Fit the spring (pos. 18), spring guide (pos. 19) and circlip (pos. 20) on the cylinder barrel (pos. 17). 2. Fit the backup rings (pos. 13) and O-rings (pos. 12) on the valve plate (pos. 14); one pair per piston. Moisten them with soapy water, see fig. 4. Fig. 2 Backup rings and O-rings Fig. 3 Fitting the valve plate 3. Fit the valve plate (pos.14) on the cylinder barrel (pos.17). Press the parts together using your hands, see fig Insert the pistons in the retainer plate from the side of the plate which is not chamfered. 5. Insert the piston unit into the cylinder barrel. 6. Fit the pin (pos. 8) into the bottom flange and fit the port plate (pos. 21). 7. Insert the cylinder barrel into the pump housing. 8. Place the swash plate (pos. 6) in the pump housing. 9. Fit the pins (pos. 7) in the swash plate and pump housing Fitting the shaft seal 1. Fit the thread bush A on the shaft and moisten it with soapy water. 2. Fit the rotating shaft seal part (pos. 4) with the seal face upwards using the punch (B). Avoid touching the seal face with your fingers. 3. Place the flange (pos. 28) on the table with the turned down end upwards. 4. Fit the stationary shaft seal part (pos. 4) with the rubber gasket downwards using the punch (B). 5. Fit the O-ring (pos. 35) on the flange and lubricate it with Rocol Fit the flange on the pump. Note the position of the three pins. 7. Fit the sealing (pos. 33), the screws (pos. 26 and 34) and the key (pos. 33) Fitting the coupling 1. Fit the coupling half. 2. Tighten the set screw. 3. Fit the coupling insert on the coupling half. 4. Fit the coupling guard and screws. 5. Mount the pump on the motor. 6. Tighten the pump to the motor with the screws and washers. 6 / 10

4.4 Checking the wear parts If there are any steel wear particles, caused by plastic, which is

Port plate and thrust plate: There must be no wear on whether port plate or thrust plate.

against the light. Pistons: Play in ball- and -socket joint must not exceed 0.1 mm.

If pistons are with wear layer (black colour), partial wear of this is acceptable. > 4.1 mm. >4.

7 4.4 Checking the wear parts If there are any steel wear particles, caused by plastic, which is worn of, then scrap the pump! Port plate and thrust plate: There must be no wear on whether port plate or thrust plate. This can be checked by laying a (hair) ruler upon the surface controlling the tightening land against the light. Pistons: Play in ball- and -socket joint must not exceed 0.1 mm. Thickness of slippers collar must not be below: BMP NS and BMP S > 4.1 mm. BMP NS and BMP S > 4.4 mm. The surface of the slippers must be plane and smooth (can be checked by hair ruler). If pistons are with wear layer (black colour), partial wear of this is acceptable. > 4.1 mm. >4.4 mm. Cylinder barrel: The outer bearing surface must be without any bigger wear grooves (not critical). There must be no seizures and bigger scratches in the bushings, - and ensure that the pistons move freely in them! Housing with swash plate and bearing: The surface on the swash plate must be smooth without any bigger scratches. More than 0.1 mm wear in depth will reject the pump. The bearing must be without any bigger wear grooves (not critical). 7 / 10

8 4.5 Fault finding Before starting work on the pump, make sure that the electricity supply has been switched off and that it cannot be accidentally switched on. Fault Possible cause Remedy The pump stops during operation. The pump runs, but gives no water or develops any pressure. The pump runs at reduced capacity. No water supply. Low-pressure switch has cut out. The level switch has cut out. The fuses are blown. The motor starter overload unit has tripped out. The magnetic coil in the motor starter/contactor is defective (not cutting in). The control circuit has cut out or is defective. The motor/supply cable is defective. No or insufficient water supply at the pump suction port. The piping system or pump is choked up. The prefilter is clogged. The pump is worn. Wrong direction of rotation. The pump is partly blocked by impurities. The pump is defective. The prefilter is clogged. The motor speed is too low. Check that the low-pressure switch functions normally and is adjusted correctly. Check that the minimum inlet pressure is correct. If not, check the feed pump. Check the water level in the water tank. Check and replace the main fuses and/or fuses for control circuit, if necessary. Reset the starter overload. Replace the coil. Check the coil voltage. Check the control circuit and the contacts in the monitoring devices (low-pressure switch, level switch, etc.). Check motor and cable Check that the inlet pressure is at least 0 bar. Check the piping system and pump. Clean the prefilter. Replace wear parts. Contact Grundfos Service. Interchange two phases in the motor main connection. Dismantle, clean and check the pump. Replace defective parts. Contact Grundfos Service. Replace defective parts. Contact Grundfos Service. Clean the prefilter. Check the electricity supply. Contact the electricity supply authorities, if necessary. If a frequency converter is used, adjust the speed. 8 / 10

9 5. Checking of motor and cable 1. Supply voltage 2. Current consumption TM Measure the voltage between the phases by means of a voltmeter. Connect the voltmeter to the terminals at the mains connection. The voltage should, when the motor is loaded, be within ±5% of the rated voltage. The motor may burn if there are larger variations in voltage. If the voltage is constantly too high or too low, the motor must be replaced by one corresponding to the supply voltage. Large variations in voltage indicate poor electricity supply, and the pump should be stopped until the defect has been found. Resetting of the motor starter may be necessary. TM Measure the current of each phase while the pump is operating at a constant discharge pressure (if possible at the capacity where the motor is most heavily loaded). The motor full-load current appears on the motor nameplate. Points 3 and 4: Measurement not needed if supply voltage and current consumption are normal. 3. Winding resistance The difference between the current of the phase with the highest amp consumption and the one with the lowest amp consumption must not exceed 10% of the lowest amp consumption. If so, or if the current exceeds the full-load current, check the following possible faults: Too high operating pressure which may overload the motor. Too high speed which may overload the motor. Damaged pump which may overload the motor. The motor windings are short-circuited or partly disjointed. Too high or too low supply voltage. Poor connection in leads. Weak cables. 4. Insulation resistance TM Disconnect the phase leads in the terminal box. Measure the winding resistance as shown on the drawing. The highest value must not exceed the lowest value by more than 5%. If the deviation is higher, and the supply cable is OK, the motor should be overhauled. TM Disconnect the phase leads in the terminal box. Measure the insulation resistance from each phase to earth (frame). (Make sure that the earth connection is made carefully.) The insulation resistance for a new, cleaned or repaired motor must be approx. 10 MΩ measured to earth. For a given motor the critical insulation resistance (R crit ) can be calculated as follows: R crit = U N [kv] x 0.5 [MΩ/ kv]. If the measured insulation resistance is lower than R crit, the motor must be overhauled. 9 / 10

10 5.1 Exploded view TM / 10

Service instructions. MS6 3.7 kw - 30 kw. 50/60 Hz 3~

Service instructions. MS6 3.7 kw - 30 kw. 50/60 Hz 3~ Service instructions MS6 3.7 kw - 30 kw 50/60 Hz 3~ 1. Symbols used in this document... 2 2. Identification... 2 2.1 Nameplate... 2 2.2 Frequency converter operation... 2 2.3 Product number key... 3 2.4