Grundfos SRG Series Bedienungsanleitung

SRG

50 Hz

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 SRG 50 Hz recirculation pumps.

Sections 1-5 give the information necessary to be

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

safe way.

Sections 6-10 give important information about the

product, as well as information on service, fault

finding, and disposal of the product.

CONTENTS

Page

1. General information

This booklet includes instructions for installing,

starting-up and servicing Grundfos 50 Hz

recirculation pumps, type SRG, designed for transfer

of liquids of low to medium viscosity ( ≤500 mPas)

from one tank to another.

1.1 Symbols used in this document

1. General information 2

1.1 Symbols used in this document 2

2. Safety instructions 3

3. Receiving the product 4

3.1 Transporting the product 4

3.2 Inspecting the product 4

3.3 Storing the product 4

4. Installing the product 4

4.1 Positioning 4

4.2 Torques 5

4.3 Mechanical installation 5

4.4 Electrical connection 7

4.5 Electrical protection 10

4.6 Protection against electro-chemical

corrosion 11

5. Starting-up the product 12

6. Product introduction 12

6.1 Applications 12

6.2 Identification 13

7. Servicing the product 14

7.1 Contaminated pump 14

7.2 Service chart 15

7.3 Oil 16

7.4 Changing the oil 16

8. Fault finding the product 17

9. Technical data 19

9.1 General technical data 19

9.2 Motor 19

9.3 Gearbox 19

9.4 Shaft seals 19

9.5 Impeller 19

9.6 Sound pressure level 19

10. Disposing of the product 19

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

The use of this product requires

experience with and knowledge of the

product.

Persons with reduced physical, sensory or

mental capabilities must not use this

product, unless they are under supervision

or have been instructed in the use of the

product by a person responsible for their

safety.

Children must not use or play with this

product.

Warning

If these safety instructions are not

observed, it may result in personal injury.

Warning

If these instructions are not observed, it

may lead to electric shock with consequent

risk of serious personal injury or death.

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)

2. Safety instructions

Receiving the product

Installing the product

Starting-up the product

Servicing the product

Fault finding the product

Warning

Before starting work on the product, make

sure that the fuses have been removed or

the mains switch has been switched off.

Make sure that the power supply cannot

be accidentally switched on.

Warning

These safety instructions as well as the

instructions in each individual section must

be followed when transporting, storing,

handling and operating the pump.

The pump must be installed, connected,

started up and serviced by qualified

persons.

Beware of rotating parts.

Make sure that persons cannot

accidentally fall into the tank, e.g. by

installing a cover or railing.

Warning

Make sure that the pump cannot roll or fall

over.

Warning

Before attempting to lift or otherwise

handle the individual components of the

pump, observe any local regulations that

set limits for the weight of the components

to be lifted manually by individuals, i.e.

handled without the use of lifting

equipment.

Warning

Make sure the power supply to the control

cabinet has been switched off.

Warning

Before making any electrical connections,

make sure that the fuses have been

removed or the mains switch has been

switched to off. Make sure that the power

supply cannot be accidentally switched on.

Warning

When adjusting the relay, beware of

electric voltage.

Warning

When loosening the oil level screw, note

that pressure may have built up in the

chamber.

Do not remove the screw until the pressure

has been fully relieved.

Warning

Make sure that no persons can fall into the

tank.

Warning

Before starting work on the pump, make

sure that the fuses have been removed or

the mains switch has been switched to off.

Make sure that the power supply cannot

be accidentally switched on.

All rotating parts must have stopped

moving.

Warning

If a pump has been used for a liquid which

is injurious to health or toxic, it will be

classified as contaminated.

Warning

When loosening the oil level screw, note

that pressure may have built up in the

chamber.

Do not remove the screw until the pressure

has been fully relieved.

Warning

Before starting any work on the pump,

make sure that the fuses have been

removed or the mains switch has been

switched to off. Make sure that the power

supply cannot be accidentally switched on.

All rotating parts must have stopped

moving.

English (GB)

3. Receiving the product

3.1 Transporting the product

The individual components of the pump must be

packed carefully to prevent any damage to the

surface protection during transportation.

All lifting equipment must be rated for the purpose

and checked for damage before any attempts to lift

the components are made. The lifting equipment

rating must under no circumstances be exceeded.

3.2 Inspecting the product

On delivery, the pump and any accessories supplied

with it must be checked for transport damage. This

also applies when the equipment is delivered to the

installation site.

If the pump or any accessories have been damaged

during transportation, contact your local Grundfos

company before continuing to install the equipment.

Do not dismantle a damaged new component for

further inspection, unless instructed by your local

Grundfos company.

The packaging material must be disposed of

according to local regulations.

3.3 Storing the product

The pump must be stored in a dry location in which

the temperature is not subject to major fluctuations.

If the pump has been stored for more than one year,

the gearbox oil must be changed. The oil must be

changed even if the pump has never been in use.

This is necessary because of natural aging of

mineral oil lubricants.

4. Installing the product

During installation, the pump must only be lifted

when using the suspension point.

The lifting equipment supplied with the pump as well

as the wire used for lifting and lowering the pump

into the tank must not be used as universal lifting

equipment.

4.1 Positioning

Correct positioning of the pump is essential to

ensure trouble-free operation and long life. The

following guidelines must be observed:

• If more pumps are installed in the same tank,

they must not generate opposite flows.

• The distance from the centre of the pump to the

tank bottom (Hmin) must be equal to the impeller

diameter. See fig. 1.

• The distance from the top of the pump rack to the

liquid surface (HABOVE) must fulfil one of the

following two requirements:

– For pumps with vortex shield, the distance

must at least be equal to the impeller diameter.

– For pumps without vortex shield, the distance

must at least be equal to 1.5 times the impeller

diameter. See fig. 1.

Fig. 1 Distance to liquid surface and tank

bottom

Warning

Make sure that the pump cannot roll or fall

over.

Warning

Before attempting to lift or otherwise

handle the individual components of the

pump, observe any local regulations that

set limits for the weight of the components

to be lifted manually by individuals, i.e.

handled without the use of lifting

equipment.

Caution

Never hang the pump by the supply cable.

Never let the pump run while hanging in

the lifting equipment.

TM02 9478 0215

Hmin HAbove

English (GB)

Fig. 2 Open installation

* Guide claws are only available for SRG.xx.80.

4.2 Torques

All nuts and screws used for the installation must be

made of stainless steel.

Use grease (Alu-paste) together with a spring

washer or lock nut; otherwise, use Loctite or a

similar product for lubrication and locking.

All stainless-steel nuts and screws must be tightened

to the following torques:

4.3 Mechanical installation

See section 4.2 Torques and fig. 2.

1. Weld the connection flange to the cast-in pipe

end in the tank.

2. Weld the profile section to the connection flange

and pipe end. Place it in position 12 o'clock.

Fig. 3 Profile section on connection flange

3. SRG.xx.80.xx: Weld the guide claws to the

connection flange. See fig. 4.

Fig. 4 Position of guide claws

TM04 3962 0215

Pos. Designation

1Bottom fixation bracket and guide

claws on connection flange*

2 Column profile

5 Top fixation bracket

12 Crane foot

13 Crane with winch and lifting wire

15 Lifting wire incl. wire clamp

17 Cable clamp

18 Cable sock, incl. shackle ∅10

19 Intermediate fixation bracket

23 Connection flange

Screws F-Class 70

[Nm]

Screws F-Class 80

[Nm]

M6 8.8 11.8

M8 21.4 28.7

M10 44 58

M12 74 100

M16 183 245

M20 370 494

TM03 0572 0205TM03 3028 0106

English (GB)

4. Drill the holes for the mounting screws for the top

fixation bracket in the concrete.

5. Mount the screws and fit the top fixation bracket.

6. Depending on the length of the column profile,

weld the turnable part of an intermediate fixation

bracket to the column profile.

Fig. 5 Top fixation

7. Position and align the column profile with the

profile section on the connection flange. Shorten

the column profile (pos. 2) to the correct length to

match the position of epoxy insulator (pos. C) at

the top fixation bracket. A gap of 5 to 10 mm

between collar of epoxy and column profile is

optimal. See fig. 5.

8. Remove the epoxy insulator and the turnable

metal part by removing the centre screw (pos. A)

and the two fixation screws (pos. B).

9. Adapt the outside of the square epoxy insulator

to the inside of the column profile. The epoxy

insulator must fit tightly inside the column profile.

10. Place the column profile on the profile section on

the connection flange and mount the top end with

the epoxy insulator and the turnable metal part

on the already installed top fixation bracket.

Tighten the three screws (pos. A) and (pos. B) in

the desired position. It is possible to adjust the

angle in steps of 7.5 °.

11. Fit an intermediate fixation bracket to the

turnable part welded on to the profile tube in step

6. Drill holes in the tank wall, fit screws in the

bracket and tightening the screws.

12. Drill the holes for the mounting screws for the

crane foot in the concrete.

13. Mount the crane foot and fit and tighten the

screws.

14. Mount the lifting wire on the pump rack using the

shackle. See fig. 6.

Fig. 6 Mounting of lifting wire on the pump rack

15. Mount the top end of the safety wire to the hole

(pos. 31, fig. 5) of the top fixation bracket by

means of a shackle. The other end of the safety

wire ends in a shackle through which the lifting

wire must run.

Fig. 7 Safety wire

16. Fix the power supply cable to the lifting wire by

means of a cable clamp approx. 0.8 m above the

pump. This will prevent the cable from falling

down and becoming entangled in the impeller

during operation. Connect the cable clamp to the

lifting wire above the wire clamp by means of a

snap hook. See fig. 8. Attach the power supply

cable to the lifting wire by means of cable clamps

placed at 1 m intervals.

TM04 2719 2908

TM04 4006 0215TM04 3932 4914

English (GB)

Fig. 8 Attaching the power supply cable to the

lifting wire

17. Position the crane in the foot and mount the

lifting wire in the drum of the winch.

18. Lift the complete pump (pump rack with motor)

using the crane and slide it over the column

profile.

19. Slowly lower the pump into the tank and down to

position on the connection flange.

20. Mount the cable sock (pos. 18) to the top fixation

bracket using the shackle, and pull the motor

cable through it to the desired position. See fig.

9. The power supply cable should be slightly

tightened.

Fig. 9 Top fixation bracket with lifting and

safety wires and cable sock

21. Remove the lifting wire from the winch and fit it to

the wire clamping (pos. 20) on the top fixation

bracket.

Use the lifting wire as a relief for the power supply

cable. For this reason, the lifting wire must always be

tightened.

22. Connect the power supply cable to the terminals

in the control cabinet.

4.4 Electrical connection

The electrical connections must be carried out by a

qualified electrician in accordance with local

regulations.

All national and local regulations relating to safety

and accident prevention must be observed.

The supply voltage and frequency are marked on the

pump nameplate. Make sure that the pump is

suitable for the power supply available at the

installation site.

The pump is supplied complete with a power supply

cable of 10 m (standard length, suitable for up to 7 m

deep tanks). Standard cable lengths are 10 and 15

m, longer cables are available on request. See

section 6.2 Identification.

The motor is marked either with a Y (star) or Δ

(delta). Make this connection in an external control

panel using conductors 1 to 6 of the power supply

cable.

Figure 10 shows a schematic drawing of these star

and delta connections. See also section 4.4.2 Wiring

diagrams.

If the pump is connected in delta during operation,

the pump can be started in a star-delta connection.

Fig. 10 Schematic drawing of delta and star

connection

TM02 4938 1802

Caution

Always leave at least three turns of wire on

the drum. Otherwise the wire may break

loose from the drum fixation.

Note

Follow the separate installation and

operating instructions for cranes.

TM04 3929 2813

Caution

Remove the lifting wire from the crane

before starting the pump.

Power

supply

cable

Wire clamp

Lifting wire (15)

Snap hook

Cable

clamp (17)

Warning

Make sure the power supply to the control

cabinet has been switched off.

Warning

Before making any electrical connections,

make sure that the fuses have been

removed or the mains switch has been

switched to off. Make sure that the power

supply cannot be accidentally switched on.

TM02 4953 2002

L1 L2 L3

Star

Delta

English (GB)

4.4.1 Starting method

Continuous operation

We recommend star-delta starting, soft starter or

frequency converter throughout the entire power

range.

Intermittent operation

Start via softstarter or frequency converter is

mandatory throughout the entire power range.

4.4.2 Wiring diagrams

Fig. 11 Three thermal switches (PTO)

Fig. 12 Three PTC sensors

4.4.3 Direction of rotation

When the electrical connections have been carried

out, check that the impeller is rotating in the correct

direction. When viewed from the motor, the impeller

must rotate clockwise. An arrow on the motor

housing shows the correct direction of rotation.

If the impeller rotates in the wrong direction,

interchange two phases of the mains supply (L1, L2,

L3).

TM02 4940 1802

Terminals Description

1, 2, 3, 4, 5, 6 Ends of the three stator windings

(U1, U2, V1, V2, W1, W2)

11, 12 Thermal switches (F6)

21, 22 Leak sensor in gearbox (B)

LSV2U2W2W1V1U1 PEPTO

TM02 4932 1802

Terminals Description

1, 2, 3, 4, 5, 6 Ends of the three stator windings

(U1, U2, V1, V2, W1, W2)

31, 32 PTC sensors (according to DIN 44

081) (1, 2, 3)

21, 22 Leak sensor in gearbox (B)

LSV2U2V1U1 W2W1 PTC PE

English (GB)

4.4.4 Frequency converter operation

All SRG pumps are designed for frequency converter

operation for energy saving and for soft start. For

frequency converter operation, please observe the

following information:

• Requirements must be fulfilled.

• Recommendations ought to be fulfilled.

• Consequences must be considered.

4.4.5 Requirements

• Peak voltage and dU/dt must be in accordance

with the table below. The values stated are

maximum values supplied to the motor terminals.

The cable influence has not been taken into

account. See the frequency converter data sheet

regarding the actual values and the cable

influence on the peak voltage and dU/dt.

3x400V 50 Hz:

• In case the above values are too high, a dU/dt

filter could prevent the voltage peaks.

• The thermal protection of the motor must be

connected.

• Do not exceed the frequency indicated on the

nameplate. Otherwise, there is a risk of motor

overload.

• Local regulations or standards must be fulfilled.

4.4.6 Recommendations

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

of the rated speed.

• Do not set any slip compensation, as it may lead

to an over speed and therefore to motor

overload.

• Set the frequency converter U/f ratio to a linear

relation, and use the data from the motor

nameplate for settings about rated current,

power, voltage and frequency.

• Use input and output filters on the frequency

converter. See data sheet for the frequency

converter used.

• 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 a screened power cable if there is a risk that

electrical noise can disturb other electrical

equipment. See data sheet for the frequency

converter used.

• Ramp-up and ramp-down time must be at least 5-

10 seconds.

4.4.7 Consequences

When operating the product 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 for advice as to how to

reduce the acoustic noise.

Product type

Maximum

repetitive

peak voltage

[V]

Maximum

dU/dt [V/μs]

SRG.xx.30

SRG.35.50 1500 15000

SRG.xx.xx 1000 3000

English (GB)

4.5 Electrical protection

4.5.1 Motor protection

The pumps are provided with the following type of

motor protection:

Standard SRG pumps incorporate three bimetallic

PTO thermal switches (PTO = Protection Thermique

á Ouverture). See fig. 11.

Function of thermal switches

The motor is protected against overheating by three

thermal switches connected in series, one switch in

each winding.

When the maximum winding temperature is reached,

the switch will open the circuit and stop the motor.

When the windings have cooled to normal

temperature, the switch will close the circuit and the

motor can be restarted. Manual restarting is

necessary.

See wiring diagram in fig. 11.

Thermal switches (F6)

• Two conductors (terminals 11 and 12).

• Maximum operating voltage of switch: 250 V.

• Maximum switching current: 2.5 A at cos φ= 1.

• Cutting-out temperature: 150 °C.

Function of PTC sensors (optional)

The motor is protected against overheating by three

thermal sensors connected in series, one in each

winding. When overheated, the motor will stop.

Automatic restarting is not permitted in such cases.

This requires a thermistor trigger unit with a

reconnection suppressor in the control circuit of the

motor contactor.

See wiring diagram in fig. 12.

1, 2, 3: PTC sensors:

• Two conductors (terminals 31 and 32).

• Maximum voltage at the terminals: Umax. = 2.5 V

(AC/DC).

• Resistance between terminals 31 and 32:

– at room temperature R = 150 to 750 Ω.

– at cutting-out temperature (130 °C) R ≥4000

Ω.

4.5.2 Gearbox protection

The gearbox is monitored for the ingress of water by

a leak sensor incorporated in the gearbox.

If the monitoring function is required, the leak sensor

must be connected to a Grundfos relay, type ALR-20/

The ALR-20/A relay must be ordered separately.

Product number: 96489569.

For a longer distance, use an additional, screened

cable. An external alarm indicator, if any, must be

connected to the potential-free outputs, terminals 1

and 3 or 4, respectively. Maximum load: 250 V, 5 A.

When the ALR-20/A-Ex relay is connected, a current

of up to 10 mA will flow through the leak sensor

(terminals 5 and 7 in fig. 13 connected to wires 21

and 22). If water penetrates into the oil chamber, the

relay will trigger an alarm signal and/or switch off the

motor.

See wiring diagram in fig. 11 or 12.

Leak sensor

• Two conductors (terminals 21 and 22).

• Maximum operating voltage: Approx. 12 V.

• Maximum current: 1 to 10 mA.

To adjust the sensitivity of the ALR-20/A relay,

proceed as follows:

1. Turn adjusting screw (pos. a) on the relay until

indicator light (pos. b) illuminates.

2. Turn the adjusting screw in the opposite direction

until the indicator light goes out.

3. Continue to turn the adjusting screw 60 ° (same

direction as instep 2).

Note

For transmission tests at terminals 31 and

32, the test voltage must not exceed 2.5 V

(AC/DC).

Use an ohmmeter for the test.

Note

The cable between the relay and the pump

must not be longer than 50 m.

Warning

When adjusting the relay, beware of

electric voltage.

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