Grundfos S Series Bedienungsanleitung

S pumps, ranges 72-74-78

S2, S3, S4, ST

55-520 kW

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos S

wastewater pumps, ranges 72, 74 and 78.

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 groups

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 text accompanying the three hazard symbols DANGER,

WARNING and CAUTION is structured in the following way:

1.3 Notes

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

1. General information 2

1.1 Target groups 2

1.2 Hazard statements 2

1.3 Notes 2

2. Receiving the product 3

3. Installing the product 3

3.1 Mechanical installation 4

3.2 Electrical connection 9

3.3 Frequency converter operation 11

4. Starting up the product 11

4.1 Preparations for starting up 12

4.2 Checking the direction of rotation 13

4.3 Start up 13

5. Handling and storing the product 14

5.1 Handling the product 14

5.2 Storing the product 14

6. Product introduction 14

6.1 Product description 14

6.2 Applications 14

6.3 Pumped liquids 15

6.4 Potentially explosive environments 15

6.5 Identification 16

6.6 Installation types 19

7. Protection and control functions 20

7.1 Motor protection devices 20

7.2 Pump controller 20

7.3 IO 113 20

7.4 SM 113, optional 21

7.5 Switches and sensors 21

7.6 WIO sensor 22

8. Servicing and maintaining the product 22

8.1 Safety instructions and requirements 22

8.2 Maintenance schedule 23

8.3 Oil check and oil change 23

8.4 Inspection and adjustment of impeller clearance 24

8.5 Pump cleaning and visual inspection 26

8.6 Power cables 26

8.7 Spare parts 26

8.8 Contaminated pumps and service 26

9. Fault finding the product 27

10. Technical data 29

10.1 Operating conditions 29

10.2 Electrical data 30

10.3 Dimensions and weights 30

11. Disposing of the product 31

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.

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. Receiving the product

The pump is supplied from factory on a steel transportation stand

in horizontal position. Pump and stand are protected by a special

cover.

Fig. 1 Covered pump on transportation stand

3. Installing the product

S pumps are designed for various installation types. See section

6.6 Installation types.

For safety reasons, all work in pits must be supervised by a

person outside the pit.

Pits for submersible sewage and wastewater pumps 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 pump must be carried out under strict

observance of the hygiene regulations in force.

The rated capacity of the lifting equipment is stated on the

equipment nameplate. The weight of the pump is stated on the

pump nameplate.

TM03 3069 4809

We recommend that you keep the transportation

stand in storage for later use.

We recommend that you keep the cable end

protectors in storage for later use.

Pump installation in pits must be carried out by

specially trained persons.

Work in or near pits must be carried out according to

local regulations.

DANGER

Electric shock

Death or serious personal injury

- It must be possible to lock the main switch in

position 0. Type and requirements as specified in

EN 60204-1.

Persons must not enter the installation area when the

atmosphere is explosive.

DANGER

Overhead load

Death or serious personal injury

- Never work under a pump when it is hanging from

a crane.

WARNING

Crushing hazard

Death or serious personal injury

- Make sure the rated capacity of the lifting

equipment, incl. the lifting chain, is adequate for

the lifting work.

CAUTION

Hot surface

Minor or moderate personal injury

- Do not touch the pump or cables during operation

because the surface temperature may exceed

70 °C.

English (GB)

3.1 Mechanical installation

Fix the extra nameplate supplied with the pump at the installation

site.

Observe all safety regulations at the installation site, for instance

the use of blowers for fresh-air supply to the pit.

Prior to installation, check the oil level in the oil chamber. See

section 8.3 Oil check and oil change.

3.1.1 Lifting the pump

S pumps weigh up to 8100 kg without accessories.

It is therefore very important to use the right lifting equipment.

The pump weight is stated on the pump nameplate.

See sections 6.5.2 Nameplate and 10.3 Dimensions and weights.

Lifting the pump by the power cables may result in electric short

circuit and risk of electric shock when the pump is connected to

the mains. The cables and cable entries may be damaged,

leading to loss of watertightness and consequent severe damage

to the motor.

If the pump is tilted more than 10 ° in any direction from its normal

position (EN 809, 5.2.1.4), the pump may lose its stability.

Lifting points

Fig. 2 Lifting points on pump, range 72

Fig. 3 Lifting points on pumps, range 74 and 78

The design of the lifting bracket may be different from the one in

the drawing. It does not affect the handling of the product,

however.

DANGER

Electric shock

Death or serious personal injury

- Before beginning the installation, switch off the

power supply and lock the main switch in position

- Before working on the pump, switch off any

external voltage connected to the pump.

DANGER

Crushing

Death or serious personal injury

- During installation, always support the pump by

means of lifting chains or place it in horizontal

position to secure stability.

CAUTION

Crushing of hands

Minor or moderate personal injury

- Do not put your hands or any tool into the pump

inlet or outlet port after the pump has been

connected to the power supply, unless the main

switch has been locked in the 0-position.

- Make sure that the power supply cannot be

accidentally switched on.

We recommend that you always use Grundfos

accessories to ensure correct functioning.

If the installation has to be tested at a pressure

higher than 1.3 times maximum pump head, isolate

the pump from the installation before the test to avoid

damage to the pump.

We recommend that you always use CE marked

lifting equipment.

DANGER

Crushing hazard

Death or serious personal injury

- Always check the lifting bracket and chain for

corrosion or wear before lifting.

- Always lift the pump by the marked lifting points or

by means of a fork-lift truck.

DANGER

Crushing hazard

Death or serious personal injury

- Make sure the centre of gravity is between the

fork-lift arms when lifting the pump.

The approximate centre of gravity is marked with a

label attached to the transportation stand.

DANGER

Electric shock

Death or serious personal injury

- Never lift the pump by the power cables.

TM03 4459 0208TM04 6068 4809

Always lift installation type ST pumps by the lifting

bracket to make sure the pump is in balance.

English (GB)

3.1.2 Raising pump to upright position

Carelessness during lifting or transportation may cause injury to

persons or damage to the pump.

Fig. 4 Raising the pump to upright position, step 1

Fig. 5 Raising the pump to upright position, step 2

Fig. 6 Raising the pump to upright position, step 3

3.1.3 Lowering the pump onto auto coupling

The pump can easily be pulled out of and lowered into the pit by

means of the guide rails. The stop level is lower for installation

type C than for installation type S. See fig. 16.

Fig. 7 Upper guide rail bracket

Fig. 8 Intermediate guide rail bracket; guide rails longer than

6 m require intermediate guide rail brackets

DANGER

Crushing hazard

Death or serious personal injury

- Make sure that the lifting bracket is tightened

before attempting to lift the pump. Tighten if

necessary.

DANGER

Crushing hazard

Death or serious personal injury

- Do not stand under or next to the pump when

raising it to upright position in order to avoid being

crushed in case the pump overturns.

- Make sure the pump is raised gently into upright

position to avoid the lifting chain slipping off the

crane when the pump is not in balance.

TM03 3034 0208TM03 3035 0208

TM03 3036 0208TM03 3066 0206TM03 3068 0206

English (GB)

Correct plinth height for installation on auto coupling is important

in order to obtain the best efficiency for the pump.

Fig. 9 Auto-coupling base unit installation on a plinth

The minimum required plinth heights (A) for installation on auto

coupling appear from the following table.

Fig. 10 Lowering the pump onto an auto coupling

TM03 2018 0208

Pump type Minimum plinth height (A) [mm]

Range 72

S2.90.250.xxxx.x.x 375

S2.100.250.xxxx.x.x 375

S2.100.300.xxxx.x.x 400

S3.110.300.xxxx.x.x 400

S3.120.500.xxxx.x.x 425

S3.135.500.xxxx.x.x 425

S3.140.600.xxxx.x.x 425

Range 74

S2.90.xx.xxx.xxxx.x.x 400

S2.100.xxx.xxx.xxxx.x.x 400

S3.110.xxx.xxx.xxxx.x.x 400

S3.120.xxx.xxx.xxxx.x.x 425

S3.135.xxx.xxx.xxxx.x.x 425

Range 78

Pressure class E, L, M, H 425

Pressure class F 0

TM03 3067 0208

Required tilt

angle when the

pump is lowered

onto the auto

coupling: 5 ° ± 5 °

English (GB)

3.1.4 Submerged installation on auto coupling

Pumps for permanent installation can be installed on a stationary

auto coupling and operated completely or partially submerged in

the pumped liquid.

Before installing the auto-coupling base unit, ensure the quality

and strength of the concrete foundation. See the pull-out

strengths required for anchor bolts at the end of this section. To

ensure adequate pull-out strength, we recommend that you weld

the threaded bushings to the steel reinforcement in the concrete.

1. Drill mounting holes for the guide rail bracket on the inside of

the pit and fasten the guide rail bracket provisionally with two

anchor screws.

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

Use a plumb line to establish the correct positioning. Fasten

the auto coupling with anchor bolts. If the bottom of the pit is

uneven, support the auto-coupling base unit so that it is level

when being fastened.

3. Connect the outlet pipe in accordance with the generally

accepted procedures and without exposing the pipe to

distortion or tension. Do not allow loads from the weight of the

pipes to be carried by the auto coupling.

4. Fit the guide rails. An intermediate guide rail bracket is

required if guide rails are more than 6 m long. Place the guide

rails on the auto coupling, then place the guide rail bracket on

the guide rails and fasten the guide rail bracket to the pit wall.

Tighten the anchor bolts.

5. Clean out debris from the pit before lowering the pump into

the pit.

6. Before lowering the pump into the wet pit, check the cables

visually for cuts or ruptures which may have been caused by

rough handling during transportation or installation.

7. Slide the guide claw of the pump between the guide rails and

lower the pump into the pit by means of a certified chain

secured to the lifting bracket of the pump. 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 pit and in such a way that the chain cannot come into

contact with the pump.

9. Adjust the length of the power cables, but remember to have

enough cable length to be able to make service on the pump.

Make sure that the cables are not sharply bent or pinched. Fix

the cables at the top of the pit in such a way that no extra

cable slides into the pit.

10. Connect the power cables and the control cable.

Pull-out strengths for anchor bolts

For auto-coupling installations, types S and C, the

guide claw is mounted on the outlet flange from

factory.

Avoid pipe tension at flanges and bolts.

The free end of the cables must not be submerged,

as water may penetrate through the cables into the

motor.

Auto-coupling

base unit Bolts Pull-out strength

[kN]

DN 250 4 x M24 30

DN 300 4 x M24 40

DN 500 6 x M30 40

DN 600 6 x M30 40

DN 800 6 x M30 20

The pull-out strengths stated are without safety

factor. The required safety factor may depend on the

materials and the methods used for anchoring.

English (GB)

3.1.5 Dry installation

Install pumps in dry installation permanently in a pump room.

The pump motor is enclosed and watertight and will not be

damaged if the installation site is flooded with water.

1. Mark and drill mounting holes in the concrete foundation.

2. Fit the base plate or base stand on the concrete with anchor

bolts. Check the pull-out strengths required for bolts in the

end of this section.

3. Check that the base plate or base stand is horizontal or

vertical.

4. Fasten the pump to the base plate or base stand.

In order to facilitate service on the pump, we recommend that you

fit isolating valves on either side of the pump.

5. Fit the inlet and outlet pipes and isolating valves, if used, and

ensure that the pump is not stressed by the pipes.

6. Adjust the length of the power cables by coiling them up on a

relief fitting to ensure that the cables are not damaged during

operation, but remember to have enough cable length to be

able to service the pump. Fasten the relief fitting to a suitable

hook. Make sure that the cables are not sharply bent or

pinched.

7. Connect the power cables and the control cable according to

the wiring diagrams.

The inlet and outlet pipes are bolted to the pump by means of

flange connections.

Foundation

To ensure minimum vibration levels, all parts of the system must

be sufficiently stiff and firmly anchored:

• The foundation and concrete must be of adequate strength to

support the weight of the pump including accessories, the

weight of the liquid passing through the pump and the forces

generated by the pump.

• As a rule of thumb, the mass of the concrete foundation must

be minimum three to five times the mass of the supported

equipment and must have sufficient rigidity to withstand the

axial, transverse and torsional loads generated by these

machines.

• The foundation must be 15 cm wider than the base plate or

base stand for pumps up to 350 kW and 25 cm wider for larger

pumps.

• The concrete used in the foundation must have a minimum

tensile strength of 250 N/cm2 .

• Always use epoxy grout to fasten the pump base plate to the

foundation.

Pull-out strengths for anchor bolts

Installation type H and D.

For vertical, dry installations, type D, install the pump

on a permanent concrete foundation.

For horizontal, dry installations, type H, the pump is

mounted on a base plate from factory.

We recommend that you use a reducer between the

inlet pipe and the pump in dry installations. In

horizontal installations the reducer must be of the

eccentric type and must be installed so that the

straight edge is pointing upwards. In this way, the

accumulation of air in the inlet pipe is avoided and

the risk of disturbance of operation is eliminated.

Make sure that the pipes are installed without the use

of undue force. Do not allow loads from the weight of

the pipes to be carried by the pump. We recommend

that you use loose flanges to ease the installation

and to avoid pipe tension at flanges and bolts.

Do not use elastic elements or bellows in the pipes;

never use these elements as a means to align the

pipes.

Dry installation Bolts Pull-out strength

[kN]

DN 400

6 x M24 25

DN 500

DN 600

DN 800

The pull-out strengths stated are without safety

factor. The required safety factor may depend on the

materials and the methods used for anchoring.

English (GB)

3.1.6 Column pipe installation

Install pumps for column pipe installation permanently in a

column pipe. Grundfos does not normally supply the column pipe.

Dimensioning of the column pipes is suggested in the pump

specific dimensional drawings.

1. Fit the seat ring to the bottom of the column pipe.

2. Clean out debris from the pit.

3. Before lowering the pump into the column pipe, check the

cables visually for cuts or ruptures which may have been

caused by rough handling during transportation or installation.

4. Lower the pump into the column pipe by means of a certified

chain secured to the lifting bracket of the pump. The pump will

rest on the conical surface of the seat ring. Normally the

friction between the conical surfaces will prevent the pump

from rotating. As an extra precaution there are three guide

pins on the seat ring which will limit the possible rotation to

maximum 60 °.

5. Hang up the end of the chain above or at the top of the

column pipe in such a way that the chain cannot come into

contact with the pump.

6. Adjust the length of the cables, but remember to have enough

cable length to be able to service the pump. Make sure that

the cables are not sharply bent or pinched. Fix the cables in

such a way that there is no extra slack inside the column pipe.

In the case of long column pipes, it may be necessary to

arrange cable support for the cables inside the column pipe. If

necessary, please contact Grundfos.

7. Connect the power cables and the control cable.

Fig. 11 Column pipe installation, pump type ST

3.2 Electrical connection

Connect the pump to an external main switch ensuring all-pole

disconnection with a contact separation according to EN 60204-1.

It must be possible to lock the main switch in position 0. Type and

requirements as specified in EN 60204-1.

The supply voltage and frequency are marked on the pump

nameplate. Make sure that the motor is suitable for the power

supply available at the installation site.

The pump must be connected to a motor-protective circuit

breaker.

The motor is effectively earthed via the earth conductor of the

power cables and the pipes. The motor top cover for Ex pumps is

equipped with connections for external earthing or an

equipotential bonding conductor.

TM04 6908 1110

72 and 74: 900 mm

78: 1100 mm

All: 400 mm

DANGER

Electric shock

Death or serious personal injury

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

Carry out the electrical connection in accordance

with local regulations.

Connect the pump to a control box with a motor

protection relay with an IEC trip class 10 or 15.

Connect pumps installed in hazardous locations to a

control box with a motor protection relay with an IEC

trip class 10.

DANGER

Short-circuit

Death or serious personal injury

- For Ex models in dry-installation, version D and H,

connect an external earthing.

English (GB)

3.2.1 Wiring diagrams

Standard power cables

Fig. 12 Wiring diagram for standard power cables

Sensors

Fig. 13 Wiring diagram for sensors

TM05 5943 4212

U1W1

U2W2

TM05 5947 4212

Oil indicator 4...20 mA

Pt100 in upper bearing

Pt100 in stator

Pt100 in lower bearing

Thermal switches

Thermistors

Moisture switches

Terminal board

connection

The wiring diagrams in custom-built products may be

different from the standard. In this case we

recommend that you contact the nearest Grundfos

company or authorised workshop.

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