Grundfos DWK Series Betriebsanleitung

DWK and DPK

DWK 0.75 - 90 kW, 50/60 Hz, 1/3~

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

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

1. Symbols used in this document 2

2. Identification 2

2.1 Nameplate 2

2.2 Type key, DWK 3

2.3 Type key, DPK 3

3. Tightening torques 4

4. Service tools 5

4.1 Standard tools 5

4.2 Torque tools 5

5. Dismantling 6

5.1 General information 6

5.2 Oil change 6

5.3 Removing impeller and pump housing 7

5.4 Removing shaft seals 8

5.5 Removing bearings 8

5.6 Removing cable 9

5.7 Removing stator 9

6. Assembly 10

6.1 Fitting stator 10

6.2 Fitting cable 10

6.3 Fitting bearings 12

6.4 Fitting shaft seals 12

6.5 Fitting impeller and pump housing 13

7. Fault finding 14

8. Components and material specification 15

8.1 DWK.O.6.50.075, DWK.O.6.50.15 and DWK.O.6.50.22 16

8.2 DWK.O.6.80.15, DWK.O.6.80.22, DWK.O.10.80.37

and DWK.O.10.100.37 17

8.3 DWK.O.13.80.55, DWK.O.13.100.55,

DWK.O.13.100.75, DWK.O.13.100.110,

DWK.O.13.100.150 and DWK.O.13.150.150 18

8.4 DWK.E.10.100.220, DWK.E.10.150.220,

DWK.E.10.150.300, DWK.E.10.200.300 19

8.5 DWK.E.10.150.370, DWK.E.10.150.450,

DWK.E.10.200.370, DWK.E.10.200.450,

DWK.E.10.150.550, DWK.E.10.200.550 20

8.6 DWK.E.10.200.750, DWK.E.10.200.900 21

8.7 DPK.10.50.075, DPK.10.50.15 and DPK.10.80.22 22

8.8 DPK.15.80.37, DPK.15.80.55, DPK.15.100.75,

DPK.20.100.110 and DPK.20.100.150 23

8.9 DPK.20.150.190 and DPK.20.150.220 24

8.10 DPK.V.65.80.15.2 and DPK.V.65.80.22.2 25

8.11 DPK.V.80.80.37.2 26

8.12 DPK.V.80.80.55.2 and DPK.V.80.80.75.2 27

8.13 DPK.V.65.80.15.4 and DPK.V.65.80.22.4 28

8.14 DPK.V.80.80.37.4, DPK.V.80.80.55.4 and

DPK.V.80.80.75.4 29

Warning

If these safety instructions are not observed, it may

result in personal injury.

Warning

The surface of the product may be so hot that it may

cause burns or 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.

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

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, DWK

* Exception: Code 075 = 0.75 kW

2.3 Type key, DPK

* Exception: Code 075 = 0.75 kW.

Example DWK .O .6 .50 075 - .5 0D R

DWK Dewatering pump

Impeller

Semi-open impeller

Enclosed impeller

6Strainer hole size

Maximum solids size [mm]

50 Pump discharge

Nominal diameter of pump discharge port [mm]

075 Code for output power, P2

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

Equipment

Standard

With extra sensor (only for 0.75 to 3.7 kW)

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

[ ]

Material

Standard

Cast iron pump with high-chrome stainless steel impeller and stainless steel suction strainer

ZCustom built variant

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

DPK Drainage pump

[ ]

Impeller design

Semi open impeller

Vortex impeller

65 Free passage

Maximum solids size [mm]

80 Pump discharge

Nominal diameter of pump discharge port [mm]

22 Code for output power, P2

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

Equipment

Standard

Sensor(s)

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

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 ± 2

DWK 30 ± 2

60a All Screw 20 ± 2

84b DWK Screw 30 ± 2

88 DPK.V Screw M10 50 ± 5

M12 75 ± 5

105b All Socket head screw 15 ± 2

178

DPK.10.XX Screw 20 ± 2

DPK.15-20.XX 25 ± 2

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 20 ± 2

DPK.V. others Screw 25 ± 2

DWK.O.XX.XX.15-37 30 ± 2

181a

DPK.10.XX Screw 12 ± 2

DPK.15 -20.XX 25 ± 2

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 12 ± 2

DPK.V others Screw 25 ± 2

DWK 25 ± 2

182 All Socket head screw 30 ± 2

183

DPK.10.XX Screw 30 ± 2

DPK.15 -20.XX 45 ± 5

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 30 ± 2

DPK.V others Screw 45 ± 2

DWK 45 ± 5

183b DPK.20.150.XX Screw 45 ± 5

DWK.E 30 ± 2

184

DPK.10.XX Screw 30 ± 2

DPK.15 -20.XX 45 ± 5

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 30 ± 2

DPK.V Screw 45 ± 2

DWK 45 ± 5

184b DWK.E Screw 15 ± 2

186 DWK.E Screw 30 ± 2

188

DPK.10.XX

Nut

55 ± 5

DPK.15 -20.XX 70 ± 5

DPK.V 55 ± 5

DWK 70 ± 5

188a

DPK.10.50.XX

Screw

25 ± 2

DPK.15.XX 45 ± 5

DPK.20.100.XX 30 ± 2

DPK.20.150.XX 25 ± 2

DPK.V.65.80.15.2

DPK.V.65.80.22.2 Screw 25 ± 2

DPK.V Screw 45 ± 2

DWK 30 ± 2

190b

DPK.20.150.XX

Screw

45 ± 5

DWK.O.13.XX.55-150 30 ± 2

DWK.E 45 ± 5

193 All 15 ± 2

English (GB)

4. Service tools

4.1 Standard tools

4.2 Torque tools

ABCD

EFGH

IJK

Pos. Description For pos. 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 For pos. 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, please follow the instructions in the following

sections.

Position numbers of parts (digits) refer to drawings and parts lists;

position numbers of tools (letters) 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 DWK-O

1. Place pump on a plane surface with 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 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

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.

TM04 4144 0909

Note

Dispose of used oil in accordance with local

regulations.

Caution

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

table below.

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

193).

7. Lubricate and mount a new O-ring (pos. 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 oil chamber. See section 5.2 Oil change.

2. Remove suction strainer/ring stand (pos. 84a).

3. Remove suction cover (pos. 189).

4. Remove impeller (pos. 49).

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

6. Remove pump housing (pos. 50).

Pump type No. of poles Shaft power

[kW] Oil capacity [l]

DWK.O 2 pole

0.75

0.521.5

2.2

3.7 1.04

5.5

2.15

7.5

DWK.E 2 pole

22 3.00

6.10

DPK 2 pole

0.75

0.401.5

2.2

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

TM04 5530 3309

DWK-O DPK

English (GB)

5.4 Removing shaft seals

Fig. 4 Removing the shaft seal and bearings

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

2. Remove impeller and pump housing. See section

5.3 Removing impeller and pump housing.

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

(pos. 105) from pump housing (pos. 50).

4. Remove lip seals (pos. 46) from pump housing/cover for oil

chamber if fitted.

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

shaft.

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

7. Remove cover for bearings (pos. 59).

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

bearing bracket (pos. 60).

5.5 Removing bearings

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

2. Remove impeller and pump housing. See section

5.3 Removing impeller and pump housing.

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

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

bracket.

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

from shaft using a puller for bearings (H).

6. Remove upper bearing (pos. 154) from 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 top cover (pos. 151).

3. Disconnect power and signal conductors from top cover.

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

5. Remove cable (pos. 181).

5.7 Removing stator

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

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

2. Remove impeller and pump housing. See section

5.3 Removing impeller and pump housing.

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

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

bracket.

5. Remove top cover (pos. 151).

6. Disconnect power and signal conductors from top cover.

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

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

later refitting stator in the same position.

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

fig. 6.

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

TM04 5532 3309

168a 168a

168

TM04 5533 3309

Warning

The surface of the stator housing is so hot that it will

cause burns or personal injury if touched.

Caution

Make sure that the stator will not be damaged when

dropping out of the stator housing.

English (GB)

6. Assembly

6.1 Fitting stator

Fig. 7 Heating up the stator housing prior to fitting the stator

1. Place stator housing in upright position.

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

3. Slowly heat up stator housing evenly to approx. 200 °C.

4. Make sure stator is placed in correct position according to

section 5.7 Removing stator, point 8.

5. Lower stator into the preheated stator housing.

6. Make sure stator reaches the bottom recess in stator housing.

7. Let stator housing cool down by natural cooling.

6.2 Fitting cable

1. Fit cable in top cover (pos. 151).

2. Fit and lubricate O-ring (pos. 37) on top cover (pos. 151). See

section 3. Tightening torques.

3. Connect power and signal conductors to top cover. See figs 8

to 10.

4. Check connection again. See fig. 8.

5. Fit top cover (pos. 151) on stator housing, tighten screws

(pos. 183) according to torques in section 3. Tightening

torques.

6. Fit cable entry (pos. 168), tighten screws (pos. 181a)

according to torques in section 3. Tightening torques.

Fig. 8 Marking of conductors

TM04 5534 3309

Warning

The surface of the stator housing is so hot that it will

cause burns or personal injury if touched.

TM04 5535 3309

UVWG

UV XZ YW G

U X V Y W Z

1 4 2 5 3 6

U V U W V W

0MΩ0MΩ0MΩ0MΩ0MΩ0MΩ

U, Z (1, 6) L

V, X (2, 4) L

W, Y

(3, 5) L

1.U:Red

When checking pumps wired star-delta to DOL, see list

below.

2.V:White

3.W:Black

G:Green

1.U:Red

2.V:White

3.W:Black

6.Z:Red

4.X:White

5.Y:Black

G:Green

UVWG

UV XZ YW G

U X V Y W Z

1 4 2 5 3 6

U V U W V W

0MΩ0MΩ0MΩ0MΩ0MΩ0MΩ

U, Z (1, 6) L

V, X (2, 4) L

W, Y

(3, 5) L

1. U: Red

When checking pumps wired star-delta to DOL, see list

below.

2. V: White

3. W: Black

G: Green

1. U: Red

2. V: White

3. W: Black

6. Z: Red

4. X: White

5. Y: Black

G: Green

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