Service instructions

AP12, AP35, AP50

50/60 Hz

1/3~

1 / 805.04.2002 GB

Table of contents

1. Type identification ........................................................................................................................... 2

1.1 Type key ............................................................................................................................................ 2

1.2 Nameplate ......................................................................................................................................... 2

2. Torques and winding resistances.................................................................................................. 3

2.1 Torques.............................................................................................................................................. 3

2.2 Winding resistances........................................................................................................................... 3

3. Service tools .................................................................................................................................... 4

3.1 Special tools ...................................................................................................................................... 4

3.2 Standard tools.................................................................................................................................... 4

3.3 Torque tools....................................................................................................................................... 4

4. Dismantling and assembly ............................................................................................................. 5

4.1 Dismantling ........................................................................................................................................ 5

4.2 Assembly ........................................................................................................................................... 6

05.04.2002 GB 2 / 8

1. Type identificationThis section shows the type key and the nameplate as well as the codes used.

1.1 Type key

1.2 Nameplate

Example AP 35 40 08 A 1 V

Type range

Maximum particle size (mm)

Nominal diameter of discharge port (mm)

Motor output P2/100 (W)

A = automatic operation (with level switch)= manual operation (without level switch)

Motor:1 = single-phase3 = three-phase

Vortex impeller

TM

00 5

502

0995

Pos. Description Pos. Description

1 Type designation 10 Product number

2 Rated voltage 11 Frequency

3 Rated power input 12 Power factor

4 Rated power output 13 Rated current

5 Maximum installation depth 14 Head at rated flow rate

6 Speed 15 Insulation class

7 Maximum liquid temperature 16 Maximum flow rate

8 Enclosure class to IEC 17 Weight

9 Production week/year/day 18 Enclosure class to CEE

18

17

16

15

14

13

12

11

10

8

9

7

6

5

3/4

2

1

Type: APxx.xx.xx.xx No. 95xxxxxxV: ~ xxxxx Hz: xx cos : x.xxP1/P2: x.xx/x.xx KW I: x.x Amp

: 10 m Qmax: xx/m³/h Hmax: xx mn: xxxx min¯¹ kg: xx.x Class FTemp: 55˚ IP 68P. date: xx/xx/xx

05.04.2002 GB 3 / 8

2. Torques and winding resistances

2.1 TorquesThis section shows the screws and nuts that must be tightened to a certain torque.

2.2 Winding resistancesThis section deals with the measuring points for measurement of winding resistance.See parts list pos. 150.

Pos. Description Suppl. information Torque [Nm]

67Lock nut M8 12

Nut M10 25

188a Hexagon socket head screw M6 x 12 - 5 mm 10

195Nut 30 mm 10

196

197 Union nut

Up to and including week 2, 1998

TM

00 6

318

3395

As from week 3, 1998

25

Single-phase

Remove the level switch and fit the con-necting plug, part number SV0128, see section 3. Service toolsor short-circuit the plug pins A1 and B1.

Main winding = A - B.The auxiliary winding cannot be meas-ured.

Three-phase Auxiliary winding = A - B / A - C / B - C.

TM

00

562

2 0

399

Max

. 13

mm

BA

A1

B1

BA

C

BA

Level switch

Single-phase Single-phase Three-phase

05.04.2002 GB 4 / 8

3. Service toolsThe following drawings and tables show special, standard and torque tools for service.

3.1 Special tools

3.2 Standard tools

3.3 Torque toolsT

M00

561

8 03

02

Pos. Description For pos. Suppl. information Part no.

A Spanner for union nut 197 SV0455

B Connecting plug SV0128

C Punch for shaft seal SV0129

Pos. Description For pos. Suppl. information Part no.

D Ring/open-end spanner

67 M8 - 13 mm SV0055

67 M10 - 17 mm SV0056

A 22 mm SV0186

197 30 mm SV0073

195 - 196 30 mm SV0073

E Tee key 188a M6 - 5 mm SV0124

F Screwdriver for cross-head screws 193 SV0279

Pos. Description For pos. Suppl. information Part no.

G Torque wrench4 - 20 Nm 9 x 12 SV0292

20 - 100 Nm 9 x 12 SV0269

H Ratchet insert tool 67M8 - 13 mm 9 x 12 SV0294

M10 - 17 mm 9 x 12 SV0270

I Ring insert tool 188a M6 - 5 mm ½" x ½" SV0296

J Hexagon socket driver G - I 9 x 12 x ½" x ½" SV0295

K Open-end insert tool A - G 22 mm SV0622

4. Dismantling and assemblyIf it is choked, damaged, or other faults are observed, the pump must be overhauled. Before dismantling the pump, make sure that the electricity supply to the motor has been switched off. It must be ensured that the electricity supply cannot be accidentally switched on.

The overhaul must be carried out in accordance with local rules and regulations covering health, safety and environment.

Replacement of the motor cable and possible level switch connected to the pump must be carried out by an authorised GRUNDFOS workshop.

Position numbers, see the parts list and section 3. Service tools.

Before overhauling the pump, clean and flush it thoroughly with clean water.

4.1 Dismantling

Pump

Empty the pump and place it on a solid foundation.

Insert a screwdriver between the suction strainer, pos. 84, and the pump sleeve, pos. 55, and turn it. Do so at various spots around the suction strainer until the strainer is free, see fig. 1.

Slacken and remove the six screws, pos. 188a, securing the lower pump housing, pos. 6, and remove the pump housing by pulling it downwards.

Remove the O-ring, pos. 37a.

Loosen the protective cap, pos. 67a (only AP35; left out between week 30 and 40, 1998), from the impeller by means of a screwdriver.

Slacken and remove the nut, pos. 67, together with (the lock washer, pos. 66b, only AP35; left out between week 30 and 40, 1998, and) the washer, pos. 66.

Remove the impeller, pos. 49. If the impeller sticks, loosen it from the shaft by means of a pair of tongs or two screwdrivers.

There may be an overpressure in the oil chamber, and oil will run out when the screws, pos. 193, are slack-ened and removed together with the O-rings, pos. 194.

Collect the oil and check it visually. Afterwards it must be disposed of in accordance with local rules and regulations covering safety and environment.

If the collected oil contains water or other impurities, the shaft seal, pos. 105, should be replaced.

Remove the shaft seal as follows:

Pull the rotating seal ring downwards and off the shaft.

Remove the stationary seal ring from the motor sleeve by wedging a screwdriver between the seal ring and the motor sleeve.

Motor

Remove level switch, pos. 182, and/or cable, pos. 181, by slackening the union nut (right-hand thread) by means of the special key, pos. A, and pulling the cable out of the socket.

Slacken and remove the nuts, pos. 195 and 196.

Push the motor, pos. 150, the riser pipe, pos. 31, and the pump housing, pos. 6d, out of the pump sleeve, pos. 55.

Knock the pump housing, pos. 6d, free of the motor, pos. 150, with light blows of a rubber or plastic mallet.

Remove the O-rings, pos. 198 and 199.

TM

00 2

928

0794

Fig. 1

05.04.2002 GB 5 / 8

4.2 AssemblyBefore assembly, clean and check all parts and replace possible defective parts.

Fit the shaft seal as follows:

Clean the shaft and the recess in the motor sleeve.

Press the stationary seal ring, pos. a, into the L-seal, pos. b, see fig. 2. Moisten the seal with water and carefully press it home in the recess of the motor, pos. 150, using the punch, pos. C.

Clean the stationary and the rotating seal faces as well as the shaft thoroughly of dirt and oil, using clean paper or a lint-free cloth.

Moisten the shaft seal with water and press the rotating seal ring home, using the punch, pos. C. The lower rubber edge must be flush with the shoulder of the shaft.

Check that the seal faces are in contact with each other, and that the bellows can move freely, see fig. 3.

Stand the motor upside-down.

Fill the chamber with oil of the right quality and in sufficient quantity, see the parts list.

Fit the screws, pos. 193. Do not forget the O-rings, pos. 194.

Lubricate the seal faces by pulling them apart for a short period while the motor is vertical to allow a little oil to run out of the oil chamber, see fig. 3.

TM

00 6

282

3295

Fig. 2

TM

00 2

929

5098

Fig. 3

150

b

a

05.04.2002 GB 6 / 8

Assembly of pump and motor

Fit the O-rings, pos. 198 and 199, to the tubes for the electrical connection.

In the top of the motor and inside the top of the pump sleeve there are a stamped depression and bulge, respectively. These stampings must engage when the motor is secured to the pump sleeve by means of the nuts, pos. 195 and 196.

Fit the riser pipe, pos. 31, into the hole in the pump sleeve. The end in which part of the longitudinal joint has been removed must face the motor.

Fit the upper pump housing, pos. 6d, so that it engages with the motor and the riser pipe.

Fix the upper pump housing, pos. 6d, by means of two screws, pos. 188a, screwed diagonally into the pump sleeve, pos. 55.

Knock the pump housing into the recess of the motor with light blows of a plastic hammer.

Remove the two screws, pos. 188a.

Check whether the impeller touches the pump housing when it is pressed against and engages with the parallel faces on the shaft. If so, repeat the assembly of the pump housing.

Fit the impeller, pos. 49, and turn it until it engages with the two parallel faces on the shaft.

Fit the washer, pos. 66, (and the lock washer, pos. 66b, only AP35; left out between week 30 and 40, 1998), see fig. 4.

Fit and tighten the nut, pos. 67, see section 2. Torques and winding resistances.

Check that the impeller can turn easily.

Fit the protective cap, pos. 67a (only AP35; left out between week 30 and 40, 1998), see fig. 5.

TM

00 6

283

3295

Fig. 4

TM

00 5

749

3295

Fig. 5

67

66b

6649

67a

05.04.2002 GB 7 / 8

05.04.2002 GB 8 / 8

Fit the lower pump housing, pos. 6, and tighten the screws, pos. 188a, diagonally, see section 2. Torques and winding resistances. Do not forget the O-ring, pos. 37a.

Fit the suction strainer, pos. 84, with light blows of a rubber or plastic mallet around the edge.

Before fitting the cables, make sure that the plugs and sockets are clean and dry.

Note: The cable and the level switch can be fitted in either socket.

Fit the electric cable, pos. 181, and the level switch so that the marking on the the cable and that on the tube are flush, see fig. 6.

Press home the cable in the motor and tighten the union nut by means of the special key, pos. A, see section2. Torques and winding resistances.

The pump is now assembled. Check the head and flow and compare the results with test specification no. 96010964.

TM

00 5

619

1395

Fig. 6