Grundfos DPK Betriebsanleitung

DPK

DPK 0.75 - 22 kW, 50/60 Hz, 1/3~

Service instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Service instructions

Original service instructions

CONTENTS

Page

1. Symbols used in this document

1.1 Hazard statements

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

The hazard statements are structured in the following way:

1.2 Notes

The symbols and notes below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

1. Symbols used in this document 2

1.1 Hazard statements 2

1.2 Notes 2

2. Identification 3

2.1 Nameplate 3

2.2 Type key 4

3. Tightening torques 5

4. Service tools 6

4.1 Standard tools 6

4.2 Torque tools 6

5. Dismantling 7

5.1 General information 7

5.2 Oil change 7

5.3 Removing impeller and pump housing 8

5.4 Removing shaft seals 9

5.5 Removing bearings 9

5.6 Removing cable 10

5.7 Removing stator 10

6. Assembly 11

6.1 Fitting stator 11

6.2 Fitting cable 11

6.3 Fitting bearings 13

6.4 Fitting shaft seals 13

6.5 Fitting impeller and pump housing 14

7. Fault finding 15

8. Components and material specification 16

8.1 DPK.10.50.075, DPK.10.50.15 and DPK.10.80.22 17

8.2 DPK.15.80.30 18

8.3 DPK.15.80.37, DPK.15.80.55, DPK.15.100.75,

DPK.20.100.110 and DPK.20.100.150 19

8.4 DPK.20.150.190 and DPK.20.150.220 20

8.5 DPK.V.65.80.15.2 and DPK.V.65.80.22.2 21

8.6 DPK.V.80.80.37.2 22

8.7 DPK.V.80.80.55.2 and DPK.V.80.80.75.2 23

8.8 DPK.V.65.80.15.4 and DPK.V.65.80.22.4 24

8.9 DPK.V.80.80.37.4, DPK.V.80.80.55.4 and

DPK.V.80.80.75.4 25

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.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

Observe these instructions for explosion-proof

products.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Tips and advice that make the work easier.

English (GB)

2. Identification

The nameplate is fitted to the top cover of the pump. Fix the extra

nameplate supplied with the pump at the installation site or keep

it in the cover of this booklet.

2.1 Nameplate

Fig. 1 Nameplate

TM04 4093 1016

Pos. Description

1 Notified body

2 Type designation

3 Product number and serial number

4 Maximum head [m]

5 Enclosure class

6 Maximum installation depth [m]

7 Number of phases

8 Frequency [Hz]

9 Speed [min-1]

10 Weight [kg]

11 Rated voltage [V] Star

12 Rated voltage [V] Delta

13 Insulation class

14 Rated current [A] Star

15 Rated current [A] Delta

16 Motor input power P1 [kW]

17 Motor output power P2 [kW]

18 Power factor

19 Maximum liquid temperature [°C]

20 Maximum flow [l/s]

21 Production code (year/week)

10 11 12 13 14 15

DK-8850 Bjerringbro Denmark

Type

Model

Hmax Qmax Tmax. :

P.c.

m l/s c

P,3,QVXOFODVV&RVĭ

96883812

Made in China

Motor ~ Hz P1/P2 kW

n min

-1

Weight kg A

English (GB)

2.2 Type key

* Exception: Code 075 = 0.75 kW.

** Only for 0.75 to 3.7 kW, except for 3.0 kW.

Code Example DPK .V .65 .80 .22 .S .4 .5 0D Z

DPK Drainage pump

[ ]

Impeller design

Semi open impeller

Vortex impeller

65 Free passage

Maximum solids size [mm]

80 Pump outlet

Nominal diameter of pump outlet port [mm]

22 Code for output power, P2

P2* = Code number from type designation / 10 [kW]

Equipment

Standard

With extra sensor**

Motor pole no.

2-pole motor

4-pole motor

Frequency

50 Hz

60 Hz

Voltage and starting method

380-415 V, DOL

380-415 V, Y/D

220-240 V, DOL

220-240 V, Y/D

ZCustom-built variant

English (GB)

3. Tightening torques

Position numbers (refer to figures in sections 5. Dismantling and 6. Assembly).

THREAD-EZE, part number SV9997 (0.5 litre).

Gardolube L 6034, part number SV9995 (1 litre).

Rocol 22, part number RM2924 (1 kg).

Pos. Pump type Designation Dimension Torque

[Nm] Lubricant

All All O-rings Rocol

35 DPK Screw 25

60a All Screw 20

88 DPK.V Screw M10 50

M12 75

105b All Socket-head screw 15

178

DPK.10.XX

DPK.15.XX (3.0 kW only) Screw 20

DPK.15-20.XX 25

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 20

DPK.V. others Screw 25

181a

DPK.10.XX

DPK.15.XX (3.0 kW only) Screw 12

DPK.15 -20.XX 25

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 12

DPK.V others Screw 25

182 All Socket-head screw 30

183

DPK.10.XX

DPK.15.XX (3.0 kW only) Screw 30

DPK.15 -20.XX 45

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 30

DPK.V others Screw 45

183b DPK.20.150.XX Screw 45

184

DPK.10.XX Screw 30

DPK.15 -20.XX 45

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 30

DPK.V Screw 45

188

DPK.10.XX

Nut

DPK.15.XX (3.0 kW only) 60

DPK.15 -20.XX 70

DPK.V 55

188a

DPK.10.50.XX

Screw

DPK.15.XX 45

DPK.20.100.XX 30

DPK.20.150.XX 25

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 25

DPK.V Screw 45

190b DPK.20.150.XX Screw 45

193 All 15

English (GB)

4. Service tools

4.1 Standard tools

4.2 Torque tools

ABCD

EFGH

IJK

Pos. Description Further information Part number

AMultigrip pliers SV0150

BRing/open-end spanner

10 mm SV0083

13 mm SV0055

17 mm SV0056

19 mm SV0063

24 mm SV0122

CRatchet handle 96777072

DHexagon socket

17 mm SV0417

19 mm SV0419

24 mm SV0424

30 mm

36 mm

EScrewdriver

FRubber mallet

GAdjustable wrench SV0349

HPuller for bearing SV0335

ICirclip pliers SV2014

Pos. Description Further information Part number

JTorque wrench 9 x 12 mm - 4-20 Nm SV2092

9 x 12 mm - 20-100 Nm SV0269

KRatchet insert tool 9 x 12 mm - 1/2" SV0295

English (GB)

5. Dismantling

5.1 General information

If the pump needs to be dismantled, either because it is choked

or damaged, follow the instructions in the following sections.

Parts are signalled by a position number and refer to drawings

and parts lists. Tools are signalled by a letter and refer to section

4. Service tools.

Before dismantling the pump

• Disconnect the power supply to the motor.

• Remove the power cable in accordance with local regulations.

• Be aware of the centre of gravity of the pump in order to

prevent it from overturning.

This is especially important in the case of high pumps.

Before assembly

• Clean and check all parts.

• Replace defective parts by new parts.

• Order the necessary service kits.

• Always replace gaskets and O-rings when the pump is

overhauled.

During assembly

• Lubricate and tighten screws and nuts to correct torque. See

section 3. Tightening torques.

5.2 Oil change

After 3000 operating hours or once a year, change the oil in the

oil chamber as described below.

If the shaft seal has been changed, the oil must be changed as

well.

Fig. 2 Position of oil screw on DPK

1. Place the pump on a plane surface with the oil screw pointing

downwards.

2. Place a container under the pump. The container must be

able to hold the oil of the specific pump. The quantity of oil for

the specific pump appears from the table below.

3. Remove the oil screw (pos. 193 - M12 x 20) and let the oil

drain into the container.

If 20 % of the liquid in the container is water, the shaft seal is

defective and must be replaced. You can see this at once as

water and oil will separate almost immediately.

4. Turn the pump so that the oil filling hole is pointing upwards.

WARNING

Pressurised system

Death or serious personal injury

- When loosening the screws of the oil chamber,

note that pressure may have built up in the

chamber. Do not remove the screws until the

pressure has been fully relieved.

TM07 1898 5118

CAUTION

Biological hazard

Minor or moderate personal injury

- Dispose of used oil in accordance with local

regulations.

If the same shaft seal is still used, the motor will be

damaged within a short time.

Oil screw

pos. 193

English (GB)

5. Add the appropriate quantity of oil to the specific pump. See

the table below.

6. Clean the O-ring seats on the pump and on the oil screw

(193).

7. Lubricate and mount a new O-ring (194) on the oil screw.

Lubricate and tighten the oil screw to correct torque. See

section 3. Tightening torques.

5.3 Removing impeller and pump housing

Fig. 3 Removing the impeller and pump housing

1. Drain oil from the oil chamber. See section 5.2 Oil change.

2. Remove the inlet strainer/ring stand (84a).

3. Remove the inlet cover (189).

4. Remove the impeller (49).

5. Remove the key (9a) from the shaft.

6. Remove the pump housing (50).

Pump type No. of poles Shaft power

[kW] Oil capacity

[l]

DPK 2-pole

0.75

0.401.5

2.2

3.0

3.7 0.92

5.5

1.92

7.5

19 2.20

DPK.V

2-pole

1.5 0.44

2.2

3.7 0.88

5.5 1.84

7.5

4-pole

1.5 0.80

2.2

3.7

1.825.5

7.5

TM07 3972 0619

English (GB)

5.4 Removing shaft seals

Fig. 4 Removing the shaft seal and bearings

1. Drain oil from the oil chamber. See section 5.2 Oil change.

2. Remove the impeller and pump housing. See section

5.3 Removing impeller and pump housing.

3. Remove the stationary shaft seal part (105d) of the shaft seal

(105) from the pump housing (50).

4. Remove the lip seals (46) from the pump housing or cover for

the oil chamber if fitted.

5. Remove rotating parts of the shaft seal (105e and 105g) from

the shaft.

6. Remove the lower bearing bracket (60) and the rotor (172).

7. Remove the cover for bearings (59).

8. Remove the stationary shaft seal part (105f) from the lower

bearing bracket (60).

5.5 Removing bearings

1. Drain oil from the oil chamber. See section 5.2 Oil change.

2. Remove the impeller and pump housing. See section

5.3 Removing impeller and pump housing.

3. Remove the lower bearing bracket (60) and the rotor (172).

4. Remove the cover for bearings (59) from the lower bearing

bracket.

5. Remove the lower bearing (153 and 153a), if mounted, from

the shaft using a puller for bearings (H).

6. Remove the upper bearing (154) from the shaft using a puller

for bearings (H).

TM04 5531 3309

105c

105

105f

105d

105c

105g

105e

English (GB)

5.6 Removing cable

Fig. 5 Cable entries

1. Disconnect the power supply to the motor.

2. Remove the top cover (151).

3. Disconnect power and signal conductors from the top cover.

4. Remove the cover for the cable entry (168).

5. Remove the cable (181).

5.7 Removing stator

Fig. 6 Heating up the stator housing in order to remove the

stator

1. Drain oil from the oil chamber. See section 5.2 Oil change.

2. Remove the impeller and pump housing. See section

5.3 Removing impeller and pump housing.

3. Remove the lower bearing bracket (60) and the rotor (172).

4. Remove the cover for bearings (59) from the lower bearing

bracket.

5. Remove the top cover (151).

6. Disconnect power and signal conductors from the top cover.

7. Protect the free conductors from the heat of the stator.

8. Mark the position of stator conductors on the stator housing

for later refitting the stator in the same position.

9. Block up the stator housing in upside-down position as shown

in fig. 6.

10. Slowly heat up the stator housing evenly until the stator drops

out.

TM04 5532 3309

168a 168a

168

TM04 5533 3309

WARNING

Hot surface

Death or serious personal injury

- Make sure not to touch the surface of the stator

housing to avoid burns or personal injury.

Make sure that the stator will not be damaged when

dropping out of the stator housing.

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