Grundfos DWK Series Bedienungsanleitung

DWK

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Installation and operating instructions

DWK

http://net.grundfos.com/qr/i/97515233

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions

describe Grundfos DWK pumps, 0.75 - 90 kW.

Sections 1-5 give the information necessary to be

able to unpack, install and start up the product in a

safe way.

Sections 6-11 give important information about the

product, as well as information on service, fault

finding and disposal of the product.

CONTENTS

Page

1. General information

1.1 Target group

These installation and operating instructions are

intended for professional installers.

1.2 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. General information 2

1.1 Target group 2

1.2 Hazard statements 2

1.3 Notes 3

2. Receiving the product 3

2.1 Inspecting the product 3

3. Installing the product 3

3.1 Mechanical installation 4

3.2 Electrical connection 6

3.3 Thermal protection 6

3.4 Frequency converter operation 8

4. Starting up the product 8

4.1 Operating modes 8

4.2 Checking the direction of rotation 9

4.3 Preparing for startup 10

4.4 Startup 10

5. Handling and storing the product 10

5.1 Handling 10

5.2 Storing the product 10

6. Product introduction 11

6.1 Product description 11

6.2 Applications and intended use 11

6.3 Improper operating methods 11

6.4 Approvals 11

6.5 Identification 12

7. Protection and control functions 13

7.1 Pump controllers 13

7.2 Level controllers 13

7.3 GU01 and GU02 13

7.4 Switches and sensors 13

8. Servicing the product 14

8.1 Safety instructions and requirements 14

8.2 Service documentation 14

8.3 Contaminated products 14

8.4 Maintenance 14

9. Fault finding the product 16

10. Technical data 17

10.1 Operating conditions 17

10.2 Dimensions and weights 17

11. Disposing of the product 17

Read this document before installing the

product. Installation and operation must

comply with local regulations and accepted

codes of good practice.

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.

English (GB)

1.3 Notes

The symbols and notes below may appear in

Grundfos installation and operating instructions,

safety instructions and service instructions.

2. Receiving the product

The product is supplied from the factory in a proper

packing in which it must remain until it is to be

installed. Make sure that the product cannot roll or

fall over.

If the product is not going to be installed immediately,

the free end of the power cable or the sensor cables

must be protected from moisture which could

otherwise penetrate the motor windings. This must

be done as soon as the product is received.

Protection can be carried out by fitting a cable cap or

by wrapping the free end of the cable in plastic and

taping over the plastic with strong waterproof tape.

2.1 Inspecting the product

After receiving and before installing the product,

check the following points:

• Check that the pump corresponds to the order.

• Check that accessories and other equipment are

not damaged during transport.

3. Installing the product

Before beginning the installation, check that the

pump is suitable for the supply voltage and

frequency available at the installation site.

For safety reasons, all work in pits must be

supervised by a person outside the pump pit.

Pits for submersible sewage and wastewater

products contain sewage and wastewater with toxic

and/or disease-causing substances. Therefore, all

persons involved must wear appropriate personal

protective equipment and clothing and all work on

and near the product must be carried out under strict

observance of the hygiene regulation in force.

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.

DANGER

Electric shock

Death or serious personal injury

- Before beginning the installation, switch

off the power supply and lock the main

switch in position 0.

- Before working on the pump, switch off

any external voltage connection to the

pump.

CAUTION

Sharp element

Minor or moderate personal injury

- Wear protective clothing (gloves) when

working on the pump.

Observe all safety regulations at the

installation site, for instance the use of

blowers for fresh-air supply to the pit.

Product installation in pits must be carried

out by specially trained persons.

Work in or near pits must be carried out

according to local regulations.

English (GB)

3.1 Mechanical installation

Before installation, check the oil level in the oil

chamber. See section 8.4.5 Oil check and oil

change.

The DWK pumps are suitable for free-standing

installation with a hose or flange connection on top of

the motor.

3.1.1 Lifting the product

It is very important to use the approved lifting

equipment.

The weight of the specific product is stated on the

nameplate.

Always lift the product from the lifting eyes on top of

the motor.

DANGER

Electric shock

Death or serious personal injury

- Before installation and the first startup

of the product, check the power cable

for visible defects and measure the

cable resistance to avoid short circuits.

The pumps are designed for operation in

vertical position only.

WARNING

Crushing hazard

Death or serious personal injury

- All lifting equipment must be rated for

the purpose and checked for damage

before any attempts are made to lift the

product. The lifting equipment rating

must under no circumstances be

exceeded.

CAUTION

Crushing hazard

Minor or moderate personal injury

- The area below the lifted pump must be

clear of people and marked off.

- Lift the pump in a way that the pump will

not start swing.

- Place the pump on a solid foundation

which is suitable to hold the weight.

- Make sure that the pump cannot roll or

fall over.

CAUTION

Crushing hazard

Minor or moderate personal injury

- Always check the lifting bracket and

chain for corrosion or wear before

lifting.

- Always lift the product by its lifting

bracket or by means of a fork-lift truck.

- Never lift the product by the power

cable or the hose or the pipe.

CAUTION

Crushing hazard

Minor or moderate personal injury

- Make sure the lifting bracket is

tightened before attempting to lift the

product. Tighten if necessary.

Do not lift the DWK pumps from the

brackets on the motor.

TM07 0309 4817

Do not use for lifting

English (GB)

3.1.2 Raising the product to upright position

Carelessness during lifting or transport may cause

injury to persons or damage the product.

Fig. 1 Raising the product to upright position,

step 1

Fig. 2 Raising the product to upright position,

step 2

Fig. 3 Raising the product to upright position,

step 3

3.1.3 Free-standing submerged installation

Pumps for free-standing submerged installation can

stand freely on the bottom of the pit or the like. See

fig. 4.

Fig. 4 Free-standing pump on strainer

Fit a flexible union or coupling to the outlet in order

to facilitate service on the pump and easy separation

of pump and outlet 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 outlet.

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, support the pump on bricks or a

similar support.

Proceed as follows:

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

chain secured to the lifting bracket of the pump.

Place the pump on a plane, solid foundation to

make sure that the pump stands securely.

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

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

chain cannot come into contact with the pump

housing.

3. 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.

4. Fasten the relief fitting to a suitable hook.

5. Connect the power cable.

TM07 0306 4817TM07 0307 4817TM07 0307 4817

TM04 4144 0909

Make sure that the cable is not sharply

bent or pinched.

English (GB)

3.2 Electrical connection

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. 5 for DOL-

connected pumps or fig. 6 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.

3.3 Thermal protection

One thermal switch is built into the motor winding

and will break the circuit in case of over temperature.

In case of intermittent operation, with water level up

to half of the motor, the thermal switch inside the

motor winding might be activated and cause the

pump to stop.

The following thermal protections can be found in

DWK pumps, depending on the specific pump type:

• thermal switch (Bi-metallic) type PTO or Klixon

• circuit breaker - Klixon (connected to the star

point of the stator)

• thermal sensor PT100 (PCA Platinium chip).

The thermal switch must be connected according to

the wiring diagram fig. 5 or fig. 6. Make sure that the

alarm output will cause a motor stop in case of high

temperature in the motor.

The thermal switch must be connected to the control

wire of the power cable inside the pump and to the

safety circuit of the separate pump controller.

3.3.1 Checking after electrical connection

Use a multimeter to check the two signal wires of the

power cable. The circuit must be closed and the

resistance must be less than 1 Ohm.

DANGER

Electric shock

Death or serious personal injury

- A motor protector, set to rated current

+10 %, must be installed by the

customer.

- Make sure that all protective equipment

has been connected correctly.

DANGER

Electric shock

Death or serious personal injury

- It is not permitted to extend the pump

cable. Contact Grundfos to get the right

cable length.

DANGER

Electric shock

Death or serious personal injury

- The motor-protective circuit breaker of

the pump controller must include a

circuit which automatically disconnects

the power supply in case the protective

circuit for the pump is opened.

Carry out the electrical connection in

accordance with local regulations.

Do not install Grundfos control boxes and

pump controllers in potentially explosive

environments.

Connect the pump to a control box with a

motor protective relay with IEC trip class

10 or 15.

The pump must be connected to a main

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.

English (GB)

3.3.2 Wiring diagrams

Fig. 5 Direct-on-line starting

Fig. 6 Star-delta starting

TM04 4096 0709TM04 4097 3316

L1 L2 L3

MCCB

AMCCB

MC Md My

THR

GU 01 / GU 02

U1 V1 W1 W2 U2 V2

1.M

3 ~

T/P T/P S/S S/S

S/S

F/L

TMyMdMC

AUX

THR THR

OL RL GL AUX

GU01/GU02

AUX

F/L

GU01/

GU02

21 T/P

S/S

T/P

S/S

OP.TR

English (GB)

3.4 Frequency converter operation

Before installing a frequency converter, calculate the

lowest allowable frequency in the installation in order

to avoid zero flow.

3.4.1 Requirements

• The thermal protection of the motor must be

connected.

• 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 pipe

system.

• Do not exceed the frequency indicated on the

nameplate. In this case there is a risk of motor

overload.

• Keep the power cable as short as possible.

The peak voltage will increase with the length of

the power 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.

3.4.2 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.

4. Starting up the product

You can start up the product using either direct-on-

line (DOL) starting or star-delta (Y/D) starting. The

selection of the starting method depends on several

considerations regarding usage and mains supply

conditions.

4.1 Operating modes

DANGER

Electric shock

Death or serious personal injury

- Before installation and the first startup

of the product, check the power cable

for visible defects and measure the

cable resistance to avoid short circuits.

DANGER

Electric shock

Death or serious personal injury

- Make sure that the power supply cannot

be accidentally switched on.

CAUTION

Sharp element

Minor or moderate personal injury

- Wear protective clothing (gloves) when

working on the pump or touching the

impeller.

Before starting the product:

- Make sure that the fuses have been

removed.

- Make sure that all protective equipment

has been connected correctly.

WARNING

Electric shock

Death or serious personal injury

- The pump must be stopped by signal

from the level sensors depending on the

S1 or S3 operation modes.

- The pump must be stopped when the

liquid level falls below the top cover

(S1) when operated continuously in S1

mode.

- The pump must be stopped when the

liquid level falls below the mid stator

housing (S3) when operated

intermittently in S3 mode.

English (GB)

The pumps are designed for intermittent operation

(S3). When completely submerged, the pumps can

also operate continuously (S1).

Fig. 7 Operating levels of DWK

S3, intermittent operation

S3 operation is a series of identical duty cycles (TC)

each with a constant load for a period, followed by a

rest period. Thermal equilibrium is not reached

during the cycle. See fig. 8.

Fig. 8 S3 operation

S1, continuous operation

In this operating mode, the pump can operate

continuously without being stopped for cooling.

Being completely submerged, the pump is

sufficiently cooled by the surrounding liquid. See fig.

Fig. 9 S1 operation

4.2 Checking the direction of rotation

Check the direction of rotation in the following way

every time the pump is connected to a new

installation.

Proceed as follows:

1. Remove the pump from the system. Let the pump

hang from a lifting device, for example the hoist

used for lowering the pump into the pit.

2. Start and run the pump for a few seconds.

3. Observe the jerk of the pump. If the pump jerks

counterclockwise, the direction of rotation is

correct. See fig. 10.

4. Reinstall the pump in the system

In case the direction of rotation is wrong, interchange

any two phases in the power cable.

Fig. 10 Jerk direction

TM04 4142 0909TM04 9231 3710TM02 7775 4003

Stop TC

Operation

Stop

Only start and run an unsubmerged pump

for a few seconds to check the direction of

rotation.

TM04 4146 0909

English (GB)

4.3 Preparing for startup

Before starting the product, follow the steps below:

• Check that the fuses have been removed.

• Check that the impeller can rotate freely by

turning the impeller by hand.

– Wear protective clothing (gloves) when

touching the impeller.

• Check the condition of the oil.

See section 8.4.5 Oil check and oil change.

• Check the direction of the rotation.

See section 4.2 Checking the direction of

rotation.

• Make sure that the monitoring units, if used, are

operating.

• Check the setting of the level and float switches,

or electrodes.

4.4 Startup

Proceed as follows:

1. Switch on the power supply.

2. Open the isolating valves, if fitted.

3. Check that the motor is 2/3 covered with liquid.

If the liquid level is below that, add liquid to the

pit until the minimum level is reached.

4. Vent the pump by tilting it by means of the lifting

chain and let trapped air escape.

5. Run the pump briefly, and check if the liquid level

is falling. A correctly vented pump will quickly

lower the liquid level.

6. Start the pump.

5. Handling and storing the product

5.1 Handling

When handling the product, observe the following

points:

• Check the lifting equipment and lifting

instructions.

See section 3.1.1 Lifting the product.

• Move the pump only with a fork-lift or a lifting

crane.

5.2 Storing the product

5.2.1 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.

5.2.2 Storage in the pit (dry or wet)

• 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 pit, inspect the pump and turn the impeller by

hand each month and before 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

cabinet when not in service, protect the cable

end as described in section 5.2.1 Warehouse

storage.

The pump must not run dry.

In case of abnormal noise or vibrations

from the pump or other pump or power

supply failure, stop the pump immediately.

Do not attempt to restart the pump until the

cause of the fault has been found and

corrected.

CAUTION

Sharp element

Minor or moderate personal injury

- Wear protective clothing (gloves) when

working on the pump.

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