Grundfos SCALA 2 Original operating manual

SCALA

Service instructions

GRUNDFOS INSTRUCTIONS

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English (GB)

English (GB) Service instructions

Original service instructions

CONTENTS

Page

1. Symbols used in this document

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION is structured in the following way:

2. Identification

2.1 Nameplate

Fig. 1 Example of nameplate

1. Symbols used in this document 2

2. Identification 2

2.1 Nameplate 2

2.2 Type key 3

3. Service tools 4

3.1 Standard tools 4

4. Lubricants 4

5. Dismantling and assembly 5

5.1 General information 5

5.2 Removing the control box cover 5

5.3 Removing the pressure tank 5

5.4 Removing the chamber stack 7

5.5 Removing the shaft seal 7

6. Fitting the shaft seal 7

6.1 Fitting the chamber stack 8

6.2 Fitting the pressure tank 8

6.3 Fitting the control box cover 9

7. Fault finding the product 10

7.1 Grundfos Eye operating indications 10

7.2 Fault resetting 10

7.3 Fault finding chart 11

8. Exploded view 13

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.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

TM06 4340 2015

Pos. Description

1 Type designation

2 Product number

3 Serial number

4 Production code, year and week

5 Maximum head

6 Minimum head

7 Rated head

8 Rated flow rate

9 Maximum ambient temperature

10 IP class

11 Maximum operation pressure

12 Maximum liquid temperature

13 Minimum and maximum rated power

14 Model

15 Voltage and frequency

16 Approvals

17 Minimum and maximum rated current

DK-8850 Bjerringbro, Denmark

SCALA2 3-45 AKCHDE

Model A

200-240V 50/60Hz

Made in Serbia

P/N 99999999

S/N 

P/C 1519

Hmax

Hmin

Hnom

Qnom

45 m

16 m

27 m

3m /h

45 C/

55 C

Tamb.max

IPX4D

I(A)

Min.

Max.

P1(W)

0.01

2.8 550

Tliq.max/Psyst.max:

1MPa

NRP XXX-XXX-XXXXXX

PCS XXXXX.XX.XX 04-6292.2.41-2003

LSPr-022-IDN

English (GB)

2.2 Type key

SCALA2 3 -45 A K C H D E

Type range

SCALA1 Economy

SCALA2 Comfort

Rated flow rate

[m3/h]

Maximum head

[m]

Material code

A: Standard

Supply voltage

K: 1 x 200-240 V, 50/60 Hz

M: 1 x 208-230 V, 60 Hz

V: 1 x 115 V, 60 Hz

W: 1 x 100-115 V, 50/60 Hz

Motor

C: High-efficiency motor with frequency converter

Power supply cable and plug

A: Cable with plug, IEC type I, AS/NZS3112, 2 m

B: Cable with plug, IEC type B, NEMA 5-15P, 6 ft

C: Cable with plug, IEC, type E&F, CEE7/7, 2 m

D: Cable without plug, 2 m

G: Cable with plug, IEC type G, BS1363, 2 m

H: Cable with plug, IEC type I, IRAM 2073, 2 m

J: Cable with plug, NEMA 6-15P, 6 ft

Controller

D: Integrated frequency converter

Thread

A: R 1" EN 1.4308

C: NPT 1" EN 1.4308

E: R 1" composite material

F: NPT 1" composite material

English (GB)

3. Service tools

3.1 Standard tools

Standard tools

4. Lubricants

If nothing else is specified, all O-rings are to be lubricated with

Rocol Sapphire Aqua-Sil.

ABCD

Pos. Range Designation Description Part number

AAll Torx screwdriver - -

BAll Torque screwdriver 1-6 Nm SV0438

CAll Bits kit 5 mm hexagon SV2010

DAll Needle-nose pliers - -

EAll Ring/open-end spanner M89 - 13 mm SV0055

FFlat-blade screwdriver - -

Product Product number

Rocol Sapphire Aqua-Sil, 1 kg RM2924

Castrol Optimol Paste White T, 0.5 kg V6001176

English (GB)

5. Dismantling and assembly

5.1 General information

5.1.1 Before dismantling

• Disconnect the power supply to the motor.

• Remove the power cable in accordance with local regulations.

• Open a tap to release the pressure in the pipe system.

• Gradually loosen the non-return valve (65a) to release the

pressure in the pump.

• Remove the drain plug (7) to drain the pump.

5.1.2 Before assembly

• Always replace gaskets and O-rings when you overhaul the

pump.

• Clean and check all parts.

• Replace defective parts.

5.2 Removing the control box cover

1. Remove the six pan-head torx screws in the cover (164a).

2. Carefully lift off the control box cover and disconnect the HMI

plug.

Fig. 2 Removing the control box cover

Fig. 3 Disconnecting the HMI plug

5.3 Removing the pressure tank

1. Slowly unscrew the non-return valve (65a) to release any

pressure in the pump.

2. Remove the drain plug (7).

3. Remove the union nut (100) by turning it counterclockwise by

hand.

4. Pull out the nipples (100a).

5. Pull out the non- return valve (65) from the inlet.

6. Remove the O-rings from the nipples, valves and plugs.

7. Carefully remove the pump cover (403) using a flat-blade

screwdriver.

Fig. 4 Removing the cover

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

Always use an antistatic service kit when handling

electronic components. This will prevent static

electricity from damaging components.

TM06 5151 3915TM06 5282 4315

To avoid damage to the connection part, insert the

flat-blade screwdriver in the top slots and pop the

cover loose by moving the screwdriver handle

towards the pump body. See fig. 4.

TM06 7639 3816 - TM0 67640 3816 - TM06 7641 3816

English (GB)

Fig. 5 Removing the nipples and the cover

8. Remove the retaining clip (175) for the sensor and remove the

sensor (174a).

9. Remove the sensor (174a).

Fig. 6 Sensor and retaining clip

10. Remove the screws (26) that hold the connection part. Note

that one of the screws holds the earth connection bracket

(173c) and washer.

11. Remove the connection part and the pressure tank.

12. Remove the seal ring (44a).

Fig. 7 Removing the connection part

13. Remove the self-priming valve (10) and O-ring (37).

Fig. 8 Self-priming valve and O-ring for connections part

TM06 5150 3915TM06 5152 3915

TM06 5149 3915TM06 5153 3915

English (GB)

14. Unscrew the pressure tank (42) counterclockwise and remove

the gasket for the tank (42a).

Fig. 9 Removing the pressure tank

5.4 Removing the chamber stack

1. Remove the plug (169) on nameplate to access the shaft end.

2. Remove the locking nut (67) and the washer (66). Hold the

shaft with a screwdriver in the shaft end.

Fig. 10 Loosening the locking nut for the chamber stack

3. Remove the chamber stack.

Fig. 11 Chamber stack and shaft seal

5.5 Removing the shaft seal

1. Remove the rotating shaft seal face (104).

2. Remove the stationary seat (103) using a needle-noise pliers.

Fig. 12 Removing the stationary shaft seal

6. Fitting the shaft seal

1. Fit the stationary seat (103) with the O-ring (102) against the

pump housing.

Fig. 13 Shaft seal complete

2. Fit the rotating shaft seal face (104).

Fig. 14 Fitting the shaft seal and the chamber stack

TM06 5154 3915TM06 5155 3915TM06 5170 3915

TM06 5169 3915

TM06 5341 4415

Do not touch the ceramic faces of the shaft seal.

TM06 5170 3915

112

108

104

103

102

107

111a

111

English (GB)

6.1 Fitting the chamber stack

1. Fit the impellers (49), the seal (45) and the chambers (4). Fit

the seal ring (44a) last.

2. Fit the washer (66) and the locking nut (67) and tighten it to 5

Nm. Hold the shaft end using a screwdriver.

Fig. 15 Tightening the nut of the chamber stack

6.2 Fitting the pressure tank

1. Fit the flat gasket (42a) and screw the pressure tank (42) on to

the connection part (2) by hand.

Fig. 16 Fitting the pressure tank

2. Fit the self-priming valve (10) and the O-ring (37).

Fig. 17 Fitting the self-priming valve and the O-ring

3. Check that the self-priming valve is fitted correctly.

Fig. 18 Correct position of the self-priming valve

4. Fit the connection part to the pump housing. Note that one

screw holds the earth connection bracket and the washer.

5. Cross-tighten the screws according to table below.

Fig. 19 Fitting the connection part

TM06 5158 3915TM06 5154 3915TM06 5153 3915

TM06 5149 3915

Sequence Torque

[Nm]

3 ± 0.5

English (GB)

6. Fit the sensor (174a) and fasten it by means of the retaining

clip (175).

Fig. 20 Sensor and retaining clip

7. Press the pump cover back onto the pump housing.

8. Fit new O-rings to the valves, nipples and plugs.

9. Fit the inlet valve in the connection part.

10. Press the nipples into the connection part, fit the union nuts

and tighten them by hand.

11. Fit the drain plug (7) and the non-return valve (65a).

Fig. 21 Fitting the nipples and the cover

6.3 Fitting the control box cover

1. Connect the HMI plug and place the control box cover on the

pump.

Fig. 22 Connecting the HMI plug

2. Cross-tighten the six pan-head torx screws according to the

table below.

Fig. 23 Tightening sequence

Check that the rubber sensor pocket is are seated

correctly.

TM06 5152 3915

Always tighten plastic nuts and plugs by hand so as

not to break the material.

TM06 5150 3915

TM06 5150 3915TM06 4959 0516

Sequence Torque

[Nm]

2 ± 0.25

3 - 6 3 - 6

2 - 5 2 - 5

1 - 4 1 - 4

English (GB)

7. Fault finding the product

7.1 Grundfos Eye operating indications

7.2 Fault resetting

You can reset a fault indication in one of the following ways:

• When you have eliminated the fault cause, reset the pump

manually by pressing the button. The pump then reverts to

normal duty.

• If the fault disappears by itself, the pump attempts to reset

automatically and the fault indication disappears if automatic

reset is successful and provided that you have enabled "Auto

reset" in the service menu.

Grundfos Eye Indication Description

No lights are on. The power is off.

The pump is not running.

Two opposite green indicator lights running in the

direction of rotation of the pump.

The power is on.

The pump is running.

Two opposite green indicator lights at a 45 °

angle is the icon used throughout this document

for pump running.

The power is on.

The pump is running.

Two opposite green indicator lights permanently

on.

The power is on.

The pump is not running.

Two opposite red indicator lights flashing

simultaneously.

Alarm.

The pump has stopped.

Two opposite red indicator lights is the icon used

throughout this document for pump stopped.

Alarm.

The pump has stopped.

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