Grundfos DPK.10.50.15, DPK.20.100.110, DPK.15.80.37, DPK.15.100.75, DPK.10.80.22 Installation And Operating Instructions Manual
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DPK
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB)
2
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 eq uipmen t.
Note
Notes or instructions that make the job
easier and ensure safe operation.
English (GB)
3
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/m
3
.
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
S1
S3
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
1
6
7
9
8
2
3
5
4
English (GB)
4
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)
5
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 [m
3
/h]
21 Production code (year/week)
1
2
3
4
5
6
7
8
9
10
11
12 13 14 15
16
17
18
19
20
21
English (GB)
6
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
10
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]
S
Equipment:
Standard
Sensor(s)
5
6
Frequency:
50 Hz
60 Hz
0D
1D
0E
1E
Voltage and starting method:
380-415 V, DOL
380-415 V, Y/D
220-240 V, DOL
220-240 V, Y/D
English (GB)
7
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)
8
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, nonreturn 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
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