Grundfos DPK.10.50.075 Bedienungsanleitung

DPK

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Symbols used in this document

2. General description

To ensure reliable and optimum operation, Grundfos

drainage pumps, type DPK, are designed with two

types of impeller:

• 0.75 - 15 kW models have semi-open impeller

• 19 and 22 kW models have closed impeller.

DPK pumps are used for removal of surface and

underground water in small and medium systems.

DPK pumps can be controlled via the pump

controllers GU01 and GU02. For further information,

see data sheet for GU01 / GU02 module at

www.grundfos.com.

1. Symbols used in this document 2

2. General description 2

3. Operating conditions 3

4. Applications 4

5. Safety 4

6. Transportation and storage 4

6.1 Transportation 4

6.2 Storage 4

6.2.1 Warehouse storage 4

6.2.2 Storage in the tank 4

7. Nameplate 5

8. Approvals 6

9. Type key 6

10. Installation 7

10.1 Installation types 7

10.2 Submerged installation on auto coupling 7

10.3 Free-standing submerged installation 8

11. Electrical connection 9

11.1 Pump controllers 10

11.2 GU01 and GU02 10

11.3 Frequency converter operation 10

11.3.1 Recommendations 10

11.3.2 Possible consequences 10

12. Startup 11

12.1 Direction of rotation 11

13. Operation 12

14. Maintenance, inspection and overhaul 12

14.1 Maintenance 12

14.1.1 Current and voltage 12

14.1.2 Vibration 12

14.1.3 Discharge pressure and flow rate 12

14.1.4 Insulation resistance 12

14.2 Inspection 13

14.2.1 How to remove the pump 13

14.2.2 Inspection of seal sensor 13

14.2.3 Inspection of impeller and wear plate 13

14.3 Overhaul 13

15. Fault correction 14

16. Service 15

16.1 Service documentation 15

16.2 Contaminated pumps 15

17. Disposal 15

Warning

Prior to installation, read these

installation and operating instructions.

Installation and operation must comply

with local regulations and accepted

codes of good practice.

Warning

If these safety instructions are not

observed, it may result in personal

injury.

Caution

If these safety instructions are not

observed, it may result in malfunction

or damage to the equipment.

Note

Notes or instructions that make the job

easier and ensure safe operation.

English (GB)

3. Operating conditions

The DPK pump range is suitable for two operating

modes:

• continuous, submerged operation, S1, with

min. liquid level above the pump

• intermittent operation, S3, with the pump partly

submerged. See fig. 1.

Fig. 1 Liquid level

pH value

DPK pumps in permanent installations can cope with

pH values ranging from 4 to 10.

Liquid temperature

0 °C to +40 °C.

Density of pumped liquid

Maximum 1,000 kg/m3.

In the case of higher densities, contact Grundfos.

Installation depth

Maximum 25 metres below liquid level.

Operating pattern

Maximum 30 starts per hour.

Fig. 2 DPK pump

TM04 4124 0809

TM04 4092 0709

Pos. Description

1 Lifting bracket

2 Nameplate

3Motor

4 Flush valve connection

5 Discharge flange

6 Cable entry

7 Top cover

8 Ring stand

9 Pump housing

English (GB)

4. Applications

DPK pumps are designed for pumping these liquids:

• drainage water

• surface water

• groundwater.

The pumps are ideal for pumping the above liquids

from installations in or near these places:

• commercial buildings

• residential buildings

• courtyards

• farms

• industries

• underground car parks.

The pumps are suitable for both permanent and

temporary installation.

5. Safety

All persons involved must wear appropriate personal

protective equipment and clothing, and all work on

and near the pump must be carried out under strict

observance of the hygiene regulations in force.

6. Transportation and storage

6.1 Transportation

The pump can be transported in a vertical or

horizontal position. Make sure that it cannot roll or

fall over.

Always lift the pump by its lifting bracket, never by

the motor cable or the hose/pipe.

6.2 Storage

6.2.1 Warehouse storage

• The warehouse must be dry and free from

corrosive gases, vapours or vibrations which

might damage the pump.

• Store the pump in a vertical position on a pallet or

a stand to keep the pump off the floor and

facilitate easy removal.

• Coil up the cable, and seal the open end tightly

with waterproof plastic and tape or a cable cap.

Do this to prevent moisture from penetrating into

the motor which will cause severe damage to the

windings.

• Give all unpainted surfaces a light coat of oil or

grease to prevent corrosion.

• If new pumps are stored for more than two

months, turn the impeller by hand every two

months to prevent the mechanical seal faces

from seizing up. Failure to do this may result in

seal damage when the pump is started up again.

6.2.2 Storage in the tank

• If an installed pump is not in operation for a long

time, check the insulation resistance and run the

pump for 30 minutes every month. If the pump

cannot be run due to lack of water in the tank,

inspect the pump and turn the impeller by hand

each month and prior to putting the pump back

into service. If the insulation resistance drops

below 10 megohms, contact Grundfos.

• When the pump is not in service, disconnect the

power supply from the control panel.

• If the pump is disconnected from the control

panel when not in service, protect the cable end

as described in section 6.2.1 Warehouse

storage.

Warning

Pump installation in tanks must be

carried out by specially trained

persons.

Work in or near tanks must be carried

out according to local regulations.

Pump type Weight

[kg]

DPK.10.50.075 31

DPK.10.50.15 35

DPK.10.80.22 40

DPK.15.80.37 60

DPK.15.100.55 113

DPK.15.100.75 118

DPK.20.100.110 166

DPK.20.100.150 177

DPK.20.150.190 312

DPK.20.150.220 312

English (GB)

7. Nameplate

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.

Fig. 3 Nameplate

TM04 4093 0709

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

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 [m3/h]

21 Production code (year/week)

10 11 12 13 14 15

English (GB)

8. Approvals

The standard version DPK pumps have been tested

by TÜV according to EC Council Machinery Directive

98/37/EC, registration no. AM 5014341 3 0001 and

report no. 13009106 001.

9. Type key

The pump can be identified by the type designation stated on the pump nameplate. See section 7. Nameplate.

* Exception: Code 075 = 0.75 kW.

Code Example DPK .10 .80 22 .S .5 0D

DPK Drainage pump

Free passage:

Maximum solids size [mm]

Pump discharge:

Nominal diameter of pump discharge port [mm]

Code for output power, P2:

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

Equipment:

Standard

Sensor(s)

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

English (GB)

10. Installation

Check these points before beginning installation

procedures:

• Does the pump correspond to order.

• Is the pump suitable for the supply voltage and

frequency available at the installation site.

• Are accessories and other equipment

undamaged during transportation.

Prior to installation, check the oil level in the oil

chamber. See section 14. Maintenance, inspection

and overhaul.

The DPK pumps are suitable for different installation

types which are described in sections

10.2 Submerged installation on auto coupling and

10.3 Free-standing submerged installation.

All pump housings can be connected to JIS flange,

hose coupling and auto coupling.

10.1 Installation types

DPK pumps are suitable for two types of installation:

• submerged installation on auto-coupling

• free-standing submerged installation.

10.2 Submerged installation on auto coupling

Pumps for permanent installation can be mounted on

a stationary auto-coupling guide rail system.

The auto-coupling system facilitates maintenance

and service as the pump can easily be lifted out of

the tank. See fig. 4.

Fig. 4 Submerged pump on auto-coupling

Intallation procedure:

1. Fit the guide rail bracket on the inside of the tank

and fasten it provisionally with anchor bolts.

2. Place the auto-coupling base unit on the bottom

of the tank. Use a plumb line to establish the

correct positioning. Fasten with heavy-duty

expansion bolts. Support the auto-coupling base

unit so that it is level when being fastened.

3. Connect the discharge line without exposing it to

distortion or tension.

4. Insert the guide rails in the auto-coupling base

unit and adjust the length of the rails accurately

to the guide rail bracket.

5. Unscrew the provisionally fastened guide rail

bracket and fit it on top of the guide rails.

Fasten the bracket firmly to the tank wall.

Warning

Observe all safety regulations at the

installation site.

Use blowers for fresh-air supply to the

tank.

Caution

The pumps are designed for operation

in vertical position only.

TM04 4094 0709

English (GB)

6. Clean out debris from the tank before lowering

the pump into the tank.

7. Fit the guide claw to the discharge port of the

pump. Then slide the guide claw down the guide

rails and lower the pump into the tank by means

of a chain fastened to the lifting bracket.

When the pump reaches the auto-coupling base

unit, the pump will automatically connect tightly.

8. Hang up the end of the chain on a suitable hook

at the top of the tank and in such a way that the

chain cannot come into contact with the pump

housing.

9. Adjust the length of the motor cable by coiling it

up on a relief fitting to ensure that the cable is not

damaged during operation. Fasten the relief

fitting to a suitable hook at the top of the tank.

Make sure that the cable is not sharply bent or

pinched.

10. Connect the motor cable

10.3 Free-standing submerged installation

Pumps for free-standing submerged installation can

stand freely on the bottom of the tank or the like.

The pump must be installed on a ring stand.

See fig. 5.

Fig. 5 Free-standing pump on ring stand

Fit a flexible union or coupling to the discharge port

in order to facilitate service on the pump and easy

separation of pump and discharge line.

If a hose is used, make sure that the hose does not

buckle and that the inside diameter of the hose

matches that of the pump discharge port.

If a rigid pipe is used, fit the union or coupling, non-

return valve and isolating valve in the order

mentioned when viewed from the pump.

If the pump is installed in muddy conditions or on

uneven ground, we recommend that you support the

pump on bricks or a similar support.

Installation procedure:

1. Fit a 90 ° elbow to the pump discharge port and

connect the discharge pipe/hose.

2. Lower the pump into the liquid by means of a

chain secured to the lifting bracket of the pump.

We recommend that you place the pump on a

plane, solid foundation. Make sure that the pump

stands securely.

3. Hang up the end of the chain on a suitable hook

at the top of the tank and in such a way that the

chain cannot come into contact with the pump

housing.

4. Adjust the length of the motor cable by coiling it

up on a relief fitting to ensure that the cable is not

damaged during operation. Fasten the relief

fitting to a suitable hook. Make sure that the

cable is not sharply bent or pinched.

5. Connect the motor cable.

Note

The guide rails must not have any axial

play as this will cause noise during

pump operation.

TM04 4095 0709

English (GB)

11. Electrical connection

The electrical connection must be carried out in

accordance with local regulations.

The supply voltage and frequency are marked on the

pump nameplate. The voltage tolerance must be

within - 5 %/+ 5 % of the rated voltage. Make sure

that the motor is suitable for the power supply

available at the installation site.

All pumps are supplied with 10 m cable and a free

cable end.

Pumps with sensors must be connected to a GU01

or GU02 pump controller. See fig. 6 for DOL-

connected pumps or fig. 7 for star-delta-connected

pumps. For further information, see the installation

and operating instructions for the selected control

box or pump controller at www.grundfos.com.

Fig. 6 Wiring diagram, DOL starting

Fig. 7 Wiring diagram, star-delta starting

Warning

The pump must be connected to a

mains switch with a minimum contact

gap of 3 mm in all poles.

The classification of the installation

site must be approved by the local fire-

fighting authorities in each individual

case.

Grundfos control boxes, pump

controllers must not be installed in

potentially explosive environments.

Make sure that all protective equipment

has been connected correctly.

TM04 4096 0709TM04 4097 0709

English (GB)

11.1 Pump controllers

The pumps must be connected to a control box with

a motor protection relay with IEC trip class 10 or 15.

The pumps can be controlled by the following LC and

LCD pump controllers:

• LC 107, LCD 107 with air bells

• LC 108, LCD 108 with float switches

• LC 110, LCD 110 with water level electrodes.

LC controllers are for single-pump installations.

LCD controllers are for two-pump installations.

In the following description, "level switch" can be air

bells, float switches or water level electrodes,

depending on the pump controller selected.

The LC controller is fitted with two or three level

switches: One for start and one for stop of pump.

The third level switch, which is optional, is for high-

level alarm.

The LCD controller is fitted with three or four level

switches: One for common stop and two for start of

the pumps. The fourth level switch, which is optional,

is for high-level alarm.

For further information, see the installation and

operating instructions for the pump controller

selected.

Fig. 8 Pump controllers

11.2 GU01 and GU02

GU01 is a monitoring device for monitoring the stator

temperature and water penetration into the motor.

It receives a digital signal.

GU02 is a monitoring device for monitoring stator

and bearing temperature as well as water

penetration into the motor. It receives an analog

signal.

Both monitoring devices must be connected to the

control panel via a relay.

GU01 and GU02 are manufactured for Grundfos.

For further information, please contact your local

Grundfos company.

11.3 Frequency converter operation

11.3.1 Recommendations

Before installing a frequency converter, calculate the

lowest allowable frequency in the installation in order

to avoid zero flow.

• Do not reduce the motor speed to less than 30 %

of rated speed.

• Keep the flow velocity above 1 m/sec.

• Let the pump run at rated speed at least once a

day in order to prevent sedimentation in the

piping system.

• Do not exceed the frequency indicated on the

nameplate. In this case there is risk of motor

overload.

• Keep the motor cable as short as possible.

The peak voltage will increase with the length of

the motor cable. See data sheet for the frequency

converter used.

• Use input and output filters on the frequency

converter. See data sheet for the frequency

converter used.

11.3.2 Possible consequences

When operating the pump via a frequency converter,

please be aware of these possible consequences:

• The locked-rotor torque will be lower. How much

lower will depend on the frequency converter

type. See the installation and operating

instructions for the frequency converter used for

information on the locked-rotor torque available.

• The working condition of bearings and shaft seal

may be affected. The possible effect will depend

on the application. The actual effect cannot be

predicted.

• The acoustic noise level may increase. See the

installation and operating instructions for the

frequency converter used for advice as to how to

reduce the acoustic noise.

TM04 4098 0709

E1 E2 E3

Min.

Max.

Min.

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