Service instructions

AP12, AP35, AP50

50/60 Hz 1/3~

Table of contents
1. 1.1 1.2 2. 2.1 2.2 3. 3.1 3.2 3.3 4. 4.1 4.2 Type identification ........................................................................................................................... 2 Type key ............................................................................................................................................ 2 Nameplate ......................................................................................................................................... 2 Torques and winding resistances.................................................................................................. 3 Torques.............................................................................................................................................. 3 Winding resistances........................................................................................................................... 3 Service tools .................................................................................................................................... 4 Special tools ...................................................................................................................................... 4 Standard tools.................................................................................................................................... 4 Torque tools....................................................................................................................................... 4 Dismantling and assembly ............................................................................................................. 5 Dismantling ........................................................................................................................................ 5 Assembly ........................................................................................................................................... 6

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

1.1 Type key

Example 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-phase 3 = three-phase Vortex impeller AP 35 40 08 A 1 V

1.2 Nameplate

1 2 3/4 5 6 7 8 9

10 11

Type: APxx.xx.xx.xx No. 95xxxxxx V: ~ xxxxx Hz: xx cos : x.xx P1/P2: x.xx/x.xx KW I: x.x Amp : 10 m Qmax: xx/m/h Hmax: xx m n: xxxx min kg: xx.x Class F Temp: 55 IP 68 P. date: xx/xx/xx

12 13 14 15 16 17 18
TM00 5502 0995

Pos. 1 2 3 4 5 6 7 8 9

Description Type designation Rated voltage Rated power input Rated power output Maximum installation depth Speed Maximum liquid temperature Enclosure class to IEC Production week/year/day

Pos. 10 11 12 13 14 15 16 17 18

Description Product number Frequency Power factor Rated current Head at rated flow rate Insulation class Maximum flow rate Weight Enclosure class to CEE

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2. Torques and winding resistances

2.1 Torques
This section shows the screws and nuts that must be tightened to a certain torque. Pos. Lock nut 67 Nut 188a 195 196 Nut 30 mm 10 Hexagon socket head screw M10 M6 x 12 - 5 mm 25 10 Description Suppl. information M8 Torque [Nm] 12

197

Union nut

As from week 3, 1998

25

2.2 Winding resistances

This section deals with the measuring points for measurement of winding resistance. See parts list pos. 150. Remove the level switch and fit the connecting plug, part number SV0128, see section 3. Service tools or short-circuit the plug pins A1 and B1. Main winding = A - B. The auxiliary winding cannot be measured. Auxiliary winding = A - B / A - C / B - C.

Single-phase

Three-phase

Single-phase

Single-phase

Three-phase

C A A1 B1 B A B A B

Level switch

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TM00 5622 0399

TM00 6318 3395

Up to and including week 2, 1998

Max. 13 mm

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

3.1 Special tools

Pos. A B C Description Spanner for union nut Connecting plug Punch for shaft seal For pos. 197 Suppl. information Part no. SV0455 SV0128 SV0129

3.2 Standard tools

Pos. Description For pos. 67 67 D Ring/open-end spanner A 197 195 - 196 E F Tee key Screwdriver for cross-head screws 188a 193 Suppl. information M8 - 13 mm M10 - 17 mm 22 mm 30 mm 30 mm M6 - 5 mm Part no. SV0055 SV0056 SV0186 SV0073 SV0073 SV0124 SV0279

3.3 Torque tools

Pos. G Description Torque wrench For pos. Suppl. information 4 - 20 Nm 20 - 100 Nm H I J K Ratchet insert tool Ring insert tool Hexagon socket driver Open-end insert tool 67 188a G-I A-G M8 - 13 mm M10 - 17 mm M6 - 5 mm 9 x 12 x " x " 22 mm 9 x 12 9 x 12 9 x 12 9 x 12 " x " Part no. SV0292 SV0269 SV0294 SV0270 SV0296 SV0295 SV0622

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TM00 5618 0302

4. Dismantling and assembly

If 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.

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 slackened 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.

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TM00 2928 0794

4.2 Assembly
Before 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.
a

150

Fig. 2

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.

Fig. 3

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.

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TM00 2929 5098

TM00 6282 3295

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.

49

66 66b 67

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.

67a

TM00 6283 3295 TM00 5749 3295

Fig. 5

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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.

Fig. 6

Press home the cable in the motor and tighten the union nut by means of the special key, pos. A, see section 2. Torques and winding resistances. The pump is now assembled. Check the head and flow and compare the results with test specification no. 96010964.

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TM00 5619 1395