SL1 and SLV pumps
1.1 - 11 kW, 50 Hz
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
Caution
Note
English (GB)
Original installation and operating instructions
CONTENTS
1. Symbols used in this document
2. General description
2.1 Product drawing
2.2 Control and monitoring
2.3 Applications
2.4 Operating conditions
3. Delivery and handling
3.1 Transportation
3.2 Storage
4. Identification
4.1 Nameplate
4.2 Type key
5. Approvals
5.1 Approval standards
5.2 Explanation to Ex approval
6. Safety
6.1 Potentially explosive environments
7. Installation
7.1 Submerged installation on auto-coupling
7.2 Free-standing submerged installation on ring stand
7.3 Torques for suction and discharge flanges
8. Electrical connection
8.1 Wiring diagrams
8.2 Pump controllers
8.3 Thermal switch, Pt1000 and PTC thermistor
8.4 WIO sensor (water-in-oil sensor)
8.5 Moisture switch
8.6 IO 113
8.7 Frequency converter operation
9. Startup
9.1 General startup procedure
9.2 Operating modes
9.3 Direction of rotation
10. Maintenance and service
10.1 Inspection
10.2 Dismantling the pump
10.3 Assembling the pump
10.4 Oil quantities
10.5 Service kits
10.6 Contaminated pumps
11. Fault finding
12. Technical data
13. Disposal
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1. Symbols used in this document
Warning
If these safety instructions are not observed, it may
2
2
3
3
3
3
4
4
4
4
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5
6
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2. General description
8
This booklet includes instructions for installation, operation and
8
maintenance of Grundfos SL1 and SLV submersible sewage and
9
wastewater pumps with motors of 1.1 to 11 kW. Grundfos SL1
9
and SLV sewage and wastewater pumps are designed for
pumping domestic, municipal and industrial sewage and
wastewater.
Two types of pumps are available:
• SL1 sewage pumps with S-tube impeller
• SLV sewage pumps with SuperVortex, free-flow impeller.
The pumps can be installed on an auto-coupling system or stand
freely on the bottom of a tank.
Grundfos SL1 and SLV pumps are designed with an S-tube and
SuperVortex impeller, respectively, to ensure reliable and
optimum operation.
The booklet also includes specific instructions for the explosionproof pumps.
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.
Warning
These instructions must be observed for explosion-
proof pumps. We recommend that you also follow
these instructions for standard pumps.
If these safety instructions are not observed, it may
result in malfunction or damage to the equipment.
Notes or instructions that make the job easier and
ensure safe operation.
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.
2
2.1 Product drawing
1
5
2
6
4
3
7
S1 operation
S3 operation
Fig. 1 SL1 pump
Fig. 2 Stop levels
pH value
TM04 2648 0616
SL1 and SLV pumps in permanent installations can be used for
pumping liquids with the following pH values:
English (GB)
TM04 2649 2808
Pos. Description
1 Lifting bracket
2Nameplate
3 Oil screws
4 Discharge flange
5 Cable plug
6Clamp
7 Pump housing
2.2 Control and monitoring
The pumps can be controlled via the Grundfos controllers LC,
LCD and dedicated controls DC and DCD. See section 8.2 Pump
controllers.
Pumps with sensor are supplied together with an IO 113.
See section 8.6 IO 113.
2.3 Applications
SL1 and SLV pumps are designed for pumping these liquids:
• large quantities of drainage and surface water
• domestic wastewater with discharge from toilets
• wastewater with a high content of fibres (SuperVortex impeller)
• municipal and commercial sewage and wastewater.
2.4 Operating conditions
The Grundfos SL1 and SLV pumps are suitable for the following
operating situations:
• S1 operation (continuous operation), the pump must always
be covered by the pumped liquid to the top of the motor.
See fig. 2.
• S3 operation (intermittent operation), the pump must always
be covered by the pumped liquid up to the top of the cable
entry. See fig. 2.
For further information about S1 and S3 operation, see section
9.2 Operating modes.
Pump
type
SL1/SLV Standard
SLV Q
1)
For fluctuating pH values, the range is pH 4 to 14.
Liquid temperature
0 °C - +40 °C.
For short periods (maximum 3 minutes) a temperature of up to
+60 °C is permissible (non-Ex versions only).
Ambient temperature
For non-explosion proof pumps, the ambient temperature may
exceed +40 °C for a short period (max. 3 minutes).
Density and viscosity of pumped liquid
When pumping liquids with a density and/or a kinematic viscosity
higher than that of water, use motors with correspondingly higher
outputs.
Flow velocity
We recommend you to keep a minimum flow velocity to avoid
sedimentations in the piping system. Recommended flow
velocities:
• in vertical pipes: 1.0 m/s
• in horizontal pipes: 0.7 m/s
Free spherical passage
From 50 to 100 mm, depending on pump size.
Operating mode
Maximum 20 starts per hour.
Material
variant
Warning
Explosion-proof pumps must never pump liquids of a
temperature higher than +40 °C.
Warning
For explosion-proof pumps, the ambient temperature
on the installation site must be in the range from -20
°C to +40 °C.
For explosion-proof pumps with WIO sensor, the
ambient temperature at the installation site must be
in the range from 0 °C to +40 °C.
Material pH value
Cast-iron impeller and pump
housing
Stainless-steel impeller and
cast-iron pump housing
6.5 - 14
1)
6-14
1)
3
3. Delivery and handling
Type: SLV.80.80.110.EX.2.51D
Model: 9687208500000001
P.c. 0845 IP68
44.9 90
40
12.5 11.0
2950 0.89
50
0197
180
22.4-20.8
380-415
3 ~
20 m
Hmax:
Motor:
P1:
Qmax:
Tmax.:
n:
kg
min
kW
V
A
mmh/
3
C
kW
P2:
-1
V
A
Hz Insul.class:
Weight: EN 12050-1
Made in Tatabanya. Hungary
98808079
96771279
3
5
6
9
10
12
8
7
11
17
15
19
13
14
16
22
24
21
23
4
1
2
18
20
25
H
CE0344
II2G
KEMA 08ATEX 0125X
Ex cd llB T4, T3 Gb
&RVij
DK-8850 Bjerringbro, Denmark
English (GB)
The pump may be transported and stored in a vertical or
horizontal position. Make sure that it cannot roll or fall over.
3.1 Transportation
All lifting equipment must be rated for the purpose and checked
for damage before any attempts to lift the pump. The lifting
equipment rating must under no circumstances be exceeded.
The pump weight is stated on the pump nameplate.
3.2 Storage
During long periods of storage, the pump must be protected
against moisture and heat.
Storage temperature: -30 °C - +60 °C
If the pump has been in use, the oil should be changed before
storage.
After a long period of storage, the pump should be inspected
before it is put into operation. Make sure that the impeller can
rotate freely. Pay special attention to the condition of the shaft
seal, O-rings, oil and the cable entry.
4
Warning
Always lift the pump by its lifting bracket or by means
of a fork-lift truck if the pump is fixed on a pallet.
Never lift the pump by means of the motor cable or
the hose/pipe.
Warning
If the pump is stored for more than one year or it
takes a long time before it is put into operation after
the installation, the impeller must be turned at least
once a month.
4. Identification
4.1 Nameplate
The nameplate states the operating data and approvals applying
to the pump. The nameplate is fitted to the side of the motor
housing close to the cable entry.
Fix the extra nameplate supplied with the pump to the cable end
in the control cabinet.
TM04 3279 4108
Fig. 3 Nameplate
Pos. Description
1 Ex mark Approvals
2 Type designationExplosion protection certificate No.
3 Model numberEx description
4 Production code (year/week)Pump type designation
5 Maximum headModel number
Maximum installation depth
6
week)
7 Number of phasesEnclosure class
8 Rated voltage, DMaximum installation depth
9 Rated voltage, YMaximum head
10 Rated input powerMaximum flow rate
11 Power factorNumber of phases
12 Maximum liquid temperature
13 Country of production Rated power input P1
14 CE markRated power output P2
15 Rated speed
16 Maximum liquid temperatureCos φ, 1/1-load
17 Maximum flow rateRated voltage, D
18 Rated current, D
19 Enclosure class to IECRated voltage, Y
20 Rated speedRated current, Y
21 Frequency
22 Rated current, D
Insulation class
23 Rated current, YApproval
24 Shaft powerWeight
25 Insulation classCountry of production
Production code (year/
4.2 Type key
The pump can be identified by means of the type designation stated on the pump nameplate. See section 4.1 Nameplate.
Code Example SL V .80 .80 .40 .A .Ex .4 .5 .OD .Q
Pump type:
SL
Grundfos wastewater pump
Impeller type:
S-tube impeller
1
SuperVortex (free-flow) impeller
V
Free spherical passage:
50 mm
50
65 mm
65
80 mm
80
100
100
150
Blank
100 mm
Pump discharge:
DN 65
65
DN 80
80
DN 100
DN 150
Motor power, P2 (motor output power P2/10 [kW]):
4 kW
40
Sensor version:
Standard
Sensor version
A
English (GB)
Blank
Ex
2
4
50
0B
0D
1D
0E
1E
Blank
A
B
Blank
Q
Blank
Z
Pump version:
Non-explosion-proof pump (standard)
Explosion-proof pump
Number of poles:
2-pole
4-pole
Frequency:
50 Hz
Voltage and starting method:
3 x 400-415 V, direct-on-line starting
3 x 380-415 V, direct-on-line starting
3 x 380-415 V, star-delta starting
3 x 220-240 V, direct-on-line starting
3 x 220-240 V, star-delta starting
Generation:
1st generation
2nd generation
3rd generation
Pump materials:
Cast-iron impeller, pump housing and motor housing
Stainless-steel impeller, cast-iron pump housing and motor housing
Customisation:
Pump in standard range
Custom-built pump
5
5. Approvals
English (GB)
The SL1 and SLV pumps have been tested by KEMA.
The explosion-proof versions hold two examination certificates:
• ATEX (EU): KEMA08ATEX0125X
• IECEX: IECEX KEM08.0039X
Both certificates have been issued by KEMA according to the
ATEX directive.
5.1 Approval standards
The standard variants are approved by LGA (notified body under
the Construction Products Directive) according to EN 12050-1 or
EN 12050-2 as specified on the pump nameplate.
5.2 Explanation to Ex approval
The SL1 and SLV pumps have the following explosion protection
classifications:
Direct-drive pump, without sensor: CE 0344 II 2 G Ex c d IIB T4 Gb
Direct-drive pump, with sensor: CE 0344 II 2 G Ex c d mb IIB T4 Gb
Pump driven by frequency converter, without sensor: CE 0344 II 2 G Ex c d IIB T3 Gb
Pump driven by frequency converter, with sensor: CE 0344 II 2 G Ex c d mb IIB T3 Gb
5.2.1 Europe
Directive/standard Code Description
CE 0344 =
ATEX
Harmonized
European standard
EN 60079-0
5.2.2 Australia
Explosion proof variants for Australia are approved as Ex d IIB T3/T4 Gb or Ex d mb T3/T4 Gb
Ex d mb T3/T4 Gb (with WIO sensor)..
II =
2=
G = Explosive atmosphere caused by gases or vapours.
Ex = The equipment conforms to harmonized European standard.
c Constructional safety according to EN 13463-5:2011 and EN 13463-1:2009.
d = Flameproof enclosure according to EN 60079-1:2007.
mb = Encapsulation according to EN 60079-18:2009.
II
IIB = Classification of gases, see EN 60079-0:2012, Annex A. Gas group B includes gas group A.
T4/T3 = Maximum surface temperature is 135 °C / 200 °C according to EN 60079-0:2012.
Gb = Equipment protection level.
X
CE marking of conformity according to the ATEX directive 94/9/EC
0344 is the number of the notified body which has certified the quality system for ATEX
= Marking of explosion protection.
Equipment group according to the ATEX directive, Annex II, point 2.2
applicable to the equipment in this group.
Equipment category according to the ATEX directive, Annex II, point 2.2
applicable to the equipment in this category.
= Suitable for use in explosive atmospheres (not mines).
The letter X in the certificate number indicates that the equipment is subject to special conditions for
=
safe use. The conditions are mentioned in the certificate and the installation and operating
instructions.
2014/34/EU, Annex X.
.
, defining the requirements
, defining the requirements
Ex d IIB T3/T4 Gb (without WIO sensor) or
Standard Code Description
Ex = Area classification according to AS 2430.1.
d = Flameproof enclosure according to IEC 60079-1:2007.
mb = Encapsulation according to IEC 60079-18:2009.
II
= Suitable for use in explosive atmospheres (not mines).
IEC 60079-0 and
IEC 60079-1
IIB = Classification of gases, see IEC 60079-0:2011, Annex A. Gas group B includes gas group A.
T4/T3 = Maximum surface temperature is 135 °C / 200 °C according to IEC 60079-0:2011.
Gb = Equipment protection level.
The letter X in the certificate number indicates that the equipment is subject to special conditions for
=
X
safe use. The conditions are mentioned in the certificate and the installation and operating
instructions.
6
6. Safety
Note
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.
Warning
Persons must not enter the installation area when the
atmosphere is explosive.
Warning
It must be possible to lock the mains switch in
position 0. Type and requirements as specified in EN
60204-1, 5.3.2.
For safety reasons, all work in tanks must be supervised by a
person outside the pump tank.
We recommend you to make all maintenance and
service jobs when the pump is placed outside the
tank.
Tanks for submersible sewage and wastewater pumps may
contain sewage or 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.
Warning
Make sure that the lifting bracket is tightened before
attempting to lift the pump. Tighten if necessary.
Carelessness during lifting or transportation may
cause injury to personnel or damage to the pump.
6.1 Potentially explosive environments
Use explosion-proof pumps for applications in potentially
explosive environments. See section 5.2 Explanation to Ex
approval.
Warning
SL1 and SLV pumps must under no circumstances
be used to pump explosive, flammable or
combustible liquids.
Warning
The classification of the installation site must be
approved by the local fire-fighting authorities in each
individual case.
Special conditions for safe use of SL1 and SLV
explosion-proof pumps:
1. Make sure the moisture switch and thermal
switches are connected in the same circuit but
have separate alarm outputs (motor stop) in case
of high humidity or high temperature in the motor.
2. Bolts used for replacement must be class A2-70
or better according to EN/ISO 3506-1.
3. Contact the manufacturer for information on the
dimensions of the flameproof joints.
4. The level of pumped liquid must be controlled by
two level switches connected to the motor control
circuit. The minimum level depends on the
installation type and is specified in these
installation and operating instructions.
5. Make sure the permanently attached cable is
suitably mechanically protected and terminated in
a suitable terminal board placed outside the
potentially explosive area.
6. The sewage pumps have an ambient temperature
range of -20 °C to +40 °C and a maximum
process temperature of +40 °C. The minimum
ambient temperature for a pump with a water-inoil sensor is 0 °C.
7. The thermal protection in the stator windings has
a nominal switch temperature of 150 °C and must
guarantee the disconnection of the power supply;
the power supply must be reset manually.
8. The control unit must protect the WIO sensor
against short circuit current of the supply to which
it is connected. The maximum current from the
control unit must be limited to 350 mA.
9. In case of frequency converter usage, the
Maximum surface temperature of the pump can
be 200 °C.
English (GB)
7
7. Installation
Caution
Note
Caution
Caution
Caution
Note
English (GB)
Warning
During installation, always support the pump by
means of lifting chains or place it in horizontal
position to secure stability.
Prior to installation, make sure the tank bottom is
even.
Warning
Before beginning the installation, switch off the
power supply and lock the mains switch in position 0
with a padlock to ensure that the power supply
cannot be accidentally switched on.
Any external voltage connected to the pump must be
switched off before working on the pump.
Before beginning installation procedures, carry out these checks:
• 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?
Further details concerning accessories can be found
in the data booklet on SL1, SLV pumps on
www.grundfos.com.
Fix the extra nameplate supplied with the pump to the cable end
in the control cabinet.
All safety regulations must be observed at the installation site,
e.g. the use of blowers for fresh-air supply to the tank.
Prior to installation, check the oil level in the oil chamber.
See section 10. Maintenance and service.
Warning
Do not put your hands or any tool into the pump
suction or discharge port after the pump has been
connected to the power supply, unless the pump has
been switched off by removing the fuses or switching
off the mains switch. Make sure that the power
supply cannot be accidentally switched on.
We recommend to always use Grundfos accessories
to avoid malfunctions due to incorrect installation.
Warning
Only use the lifting bracket for lifting the pump. Do
not use it to hold the pump when in operation.
Installation types
The SL1 and SLV pumps are designed for two installation types:
• submerged installation on auto-coupling
• free-standing submerged installation on ring stand.
7.1 Submerged installation on auto-coupling
TM04 2650 2808
Fig. 4 Submerged installation on auto coupling
Pumps for permanent installation can be installed 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.
Warning
Before beginning installation procedures, make sure
that the atmosphere in the tank is not potentially
explosive.
Make sure that the pipework is installed without the
use of undue force. No loads from the pipework
weight must be carried by the pump. We recommend
the use of loose flanges to ease the installation and
to avoid pipe tension at flanges and bolts.
Do not use elastic elements or bellows in the
pipework; these elements should never be used as a
means to align the pipework.
Proceed as follows:
1. Drill mounting holes for the guide rail bracket on the inside of
the tank and fasten the guide rail bracket provisionally with
two screws.
2. Place the auto-coupling base unit on the bottom of the tank.
Use a plumb line to establish the correct positioning.
Fasten the auto-coupling with expansion bolts. If the bottom of
the tank is uneven, the auto-coupling base unit must be
supported so that it is level when being fastened.
3. Assemble the discharge pipe in accordance with the generally
accepted procedures and without exposing the pipe to
distortion or tension.
4. Place the guide rails on the auto-coupling base unit and adjust
the length of the rails accurately to the guide rail bracket at
the top of the tank.
5. Unscrew the provisionally fastened guide rail bracket.
Insert the upper guide rail bracket into the guide rails.
Fasten the guide rail bracket on the inside of the tank.
The guide rails must not have any axial play as this
would cause noise during pump operation.
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.
8
8. Slide the guide claw of the pump between the guide rails and
Note
Note
Caution
lower the pump into the tank by means of a chain secured to
the lifting bracket of the pump. When the pump reaches the
auto-coupling base unit, the pump will automatically connect
tightly.
9. 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.
10. 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 cables are not sharply bent or
pinched.
11. Connect the motor cable.
The free end of the cable must not be submerged, as
water may penetrate into the cable .
7.2 Free-standing submerged installation on ring
stand
7.3 Torques for suction and discharge flanges
Grade 4.6 (5) galvanized steel screws and nuts
Pitch
Nominal
diameter
DN 65 145 4 x M16 70 60
DN 80 160 8 x M16 70 60
DN 100 180 8 x M16 70 60
Discharge
DN 150 240 8 x M20 140 120
and suction
Grade A2.50 (AISI 304) steel screws and nuts
Nominal
diameter
DN 65 145 4 x M16 - 60
DN 80 160 8 x M16 - 60
DN 100 180 8 x M16 - 60
Discharge
DN 150 240 8 x M20 - 120
and suction
circle
diameter
[mm]
Pitch
circle
diameter
[mm]
Screws
Screws
Specified torques
rounded off by ± 5
[Nm]
Slightly
oiled
Specified torques
rounded off by ± 5
[Nm]
Slightly
oiled
Well
lubricated
Well
lubricated
English (GB)
Fig. 5 Free-standing submerged installation on a ring stand
Pumps for free-standing submerged installation can stand freely
on the bottom of the tank. The pump must be installed on a ring
stand. See fig. 5.
The ring stand is available as an accessory.
In order to facilitate service on the pump, fit a flexible union or
coupling to the elbow on the discharge port for easy separation.
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, 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. 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 to place the
pump on a plane, solid foundation. Make sure that the pump is
hanging from the chain and not the cable. Make sure that the
pump is standing 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 at the top
of the tank. Make sure that the cable is not sharply bent or
pinched.
5. Connect the motor cable.
The free end of the cable must not be submerged, as
water may penetrate into the cable.
The gasket must be a full face, reinforced paper
gasket like Klingersil C4300. If softer gasket material
is used, torques must be reconsidered.
TM04 2651 2808
9
8. Electrical connection
Caution
Caution
Caution
English (GB)
Warning
The pump must not run dry.
An additional level switch must be installed to ensure
that the pump is stopped in case the stop level switch
is not operating.
Warning
Connect the pump to an external mains switch which
ensures all-pole disconnection with a contact
separation according to EN 60204-1, 5.3.2.
It must be possible to lock the mains switch in
position 0. Type and requirements as specified in EN
60204-1, 5.3.2.
The electrical connection must be carried out in
accordance with local regulations.
Warning
The pumps must be connected to a control box with
a motor protection relay with IEC trip class 10 or 15.
Warning
Power supply for motor protection circuit must be low
voltage, Class 2.
See motor protection wiring diagram in section
8.1 Wiring diagrams.
Warning
Pumps for hazardous locations must be connected to
a control box with a motor protection relay with IEC
trip class 10.
Warning
Do not install Grundfos control boxes, pump
controllers, Ex barriers and the free end of the power
cable in potentially explosive environments.
The classification of the installation site must be
approved by the local fire-fighting authorities in each
individual case.
On explosion-proof pumps, make sure that an
external earth conductor is connected to the external
earth terminal on the pump using a secure cable
clamp. Clean the surface of the external earth
connection and mount the cable clamp.
The cross section of the earth conductor must be at
least 4 mm
green.
Make sure that the earth connection is protected
from corrosion.
Make sure that all protective equipment has been
connected correctly.
Float switches used in potentially explosive
environments must be approved for this application.
They must be connected to the Grundfos LC, LCD
108 pump controller via the intrinsically safe LC-Ex4
barrier to ensure a safe circuit.
2
, e.g. type H07 V2-K (PVT 90 °) yellow/
All pumps are supplied with 10 m cable and a free cable end,
except for pumps for Australia which have 15 m cable.
Pumps without sensor must be connected to one of these three
controller types:
• a control box with motor-protective circuit breaker, such as a
Grundfos CU 100
• a Grundfos LC, LCD 107, LC, LCD 108 or LC, LCD 110 pump
controller
• a Grundfos DC, DCD pump controller.
Pumps with sensor must be connected to a Grundfos IO 113
and one of these three controller types:
• a control box with motor-protective circuit breaker, such as a
Grundfos CU 100
• a Grundfos LC, LCD 107, LC, LCD 108 or LC, LCD 110 pump
controller
• a Grundfos DC and DCD pump controller.
Warning
Before installation and the first startup of the pump,
check the condition of the cable visually to avoid
short circuits.
Pumps with WIO sensor
For safe installation and operation of pumps equipped with a
WIO sensor, we recommend to install an RC filter between the
power contactor and the pump.
If an RC filter is installed to avoid any kind of
transients in the installation, the RC filter must be
installed between the power contactor and the pump.
Please note that the following aspects may cause problems in
case of transients in the power supply system:
• Motor power:
– The bigger the motor, the higher the transients.
• Length of motor cable:
– Where power and signal conductors are running in parallel
close to each other, the risk of transients causing
interference between power and signal conductors will
increase with the length of the cable.
• Switchboard layout:
– Power and signal conductors must be physically separated
as much as possible. Close installation can cause
interference in case of transients.
• Supply network "stiffness":
– If a transformer station is located close to the installation,
the supply network may be "stiff" and transient levels will be
higher.
If combinations of the above aspects are present, it may be
necessary to install RC filters for pumps with WIO sensors to
protect against transients.
Transients can be completely eliminated if soft starters are used.
But be aware that soft starters and variable speed drives have
other EMC-related issues that must be taken into consideration.
For more information, see section 8.7 Frequency converter
operation
Warning
If the supply cable is damaged, it must be replaced
by the manufacturer, its service agent or similarly
qualified persons.
Set the motor-protective circuit breaker to the rated
current of the pump. The rated current is stated on
the pump nameplate.
If the pump has an Ex mark on the nameplate, make
sure that the pump is connected in accordance with
the instructions given in this booklet.
The mains supply voltage and frequency are marked on the pump
nameplate. The voltage tolerance must be within - 10 %/+ 10 % of
the rated voltage. Make sure that the motor is suitable for the
power supply available at the installation site.
10
8.1 Wiring diagrams
Standard version
Thermal switch and
moisture switch*
Sensor version
Thermal switch, Pt1000 resistor,
moisture switch and water-in-oil sensor
Sensor version
Thermal switch, PTC thermistor*,
moisture switch and water-in-oil sensor
Yellow/green
* Pumps from 4 kW and up sold in Australia/New Zealand are fitted with a PTC thermistor.
Yellow/green
Standard version
Thermal switch and
moisture switch*
Sensor version
Thermal switch, Pt1000 resistor,
moisture switch and water-in-oil sensor
Sensor version
Thermal switch, PTC thermistor*,
moisture switch and water-in-oil sensor
* Pumps from 4 kW and up sold in Australia/New Zealand are fitted with a PTC thermistor.
The pumps are supplied via either a 7-core cable or a 10-core cable. See fig. 6 for wiring diagrams for 7-core cable connection or figures.
7, 8 and 9 for wiring diagrams for 10-core cable connection. For further information, see the installation and operating instructions for the
selected control box or pump controller.
English (GB)
Fig. 6 Wiring diagram, 7-core cable, DOL
TM04 6884 0314
Fig. 7 Wiring diagram, 10-core cable, star/delta (Y/D)
TM04 6885 0314
11
English (GB)
Yellow/green
Standard version
Thermal switch and
moisture switch*
Sensor version
Thermal switch, Pt1000 resistor,
moisture switch and water-in-oil sensor
Sensor version
Thermal switch, PTC thermistor*,
moisture switch and water-in-oil sensor
* Pumps from 4 kW and up sold in Australia/New Zealand are fitted with a PTC thermistor.
Yellow/green
Standard version
Thermal switch and
moisture switch*
Sensor version
Thermal switch, Pt1000 resistor,
moisture switch and water-in-oil sensor
Sensor version
Thermal switch, PTC thermistor*,
moisture switch and water-in-oil sensor
* Pumps from 4 kW and up sold in Australia/New Zealand are fitted with a PTC thermistor.
Fig. 8 Wiring diagram, 10-core cable, star-connected (Y)
TM04 6886 0314
Fig. 9 Wiring diagram, 10-core cable, delta-connected (D)
To find out whether the pump is fitted with a thermal switch or a
PTC thermistor, measure the motor winding resistance. See table
below.
Without cable
Thermal switch < 50 mΩ < 320 mΩ < 390 mΩ
PTC thermistor > 100 mΩ > 370 mΩ > 440 mΩ
12
With 10 m
cable
With 15 m
cable
TM04 6887 0314
8.2 Pump controllers
Caution
SL1 and SLV pumps can be connected to the following Grundfos
pump controllers for level control:
LC controllers are for one-pump-installations and LCD controllers
are for two-pump installations.
• LC 107 and LCD 107 with air bells
• LC 108 and LCD 108 with float switches
• LC 110 and LCD 110 with electrodes
• Grundfos DC and DCD.
For further information on controllers, please see the installation
and operation instructions for the selected controller or go to
www.grundfos.com.
8.3 Thermal switch, Pt1000 and PTC thermistor
All SL1 and SLV pumps have thermal protection incorporated in
the stator windings.
Pumps without sensor
Pumps without sensor have a thermal switch or a PTC thermistor.
Via the pump controller safety circuit, the thermal switch will stop
the pump by breaking the circuit in case of overtemperature
(approx. 150 °C). The thermal switch will reclose the circuit after
cooling. For pumps equipped with a PTC thermistor, connect the
thermistor to either the PTC relay or the I/O module to break the
circuit at 150 °C.
The maximum operating current of the thermal switch is 0.5 A at
500 VAC and cos φ 0.6. The switch must be able to break a coil in
the supply circuit.
Pumps with WIO sensor
Pumps with WIO sensor have either a thermal switch and a
Pt1000 sensor or a PTC thermistor in the windings, depending on
the installation site.
Via the pump controller safety circuit, the thermal switch or the
thermistor will stop the pump by breaking the circuit in case of
overtemperature (approx. 150 °C). The thermal switch or the
thermistor will reclose the circuit after cooling.
The maximum operating current of both the Pt1000 and the
thermistor is 1 mA at 24 VDC.
Non-explosion-proof pumps
When closing the circuit after cooling, the thermal protection can
restart the pump automatically via the controller. Pumps from
4 kW and up sold in Australia/New Zealand are fitted with a PTC
thermistor.
Explosion-proof pumps
Warning
The thermal protection of explosion-proof pumps
must not restart the pump automatically.
This ensures protection against overtemperature in
potentially explosive environments. In pumps with
sensor this is done by removing the short circuit
between terminals R1 and R2 in the IO 113. See
Electrical data in the IO 113 installation and
operating instructions.
Warning
The separate motor-protective circuit breaker/
controller must not be installed in potentially
explosive environments.
8.4 WIO sensor (water-in-oil sensor)
The WIO sensor measures the water content in the oil and
converts the value into an analogue current signal. The two
sensor conductors are for power supply and for carrying the
signal to the IO 113. The sensor measures the water content from
0 to 20 %. It also sends a signal if the water content is outside the
normal range (warning), or if there is air in the oil chamber
(alarm). The sensor is fitted in a stainless-steel tube for
mechanical protection.
Fig. 10 WIO sensor
8.4.1 Fitting the WIO sensor
Fit the sensor next to one of the shaft seal openings. See fig. 10.
The sensor must be tilted into the motor's direction of rotation to
ensure that oil is led into the sensor. Make sure that the sensor is
submerged in the oil.
8.4.2 Technical data
Input voltage: 12-24 VDC
Output current: 3.4 - 22 mA
Power input: 0.6 W
Ambient temperature: 0-70 °C
See also the installation and operating instructions for IO 113 on
www.grundfos.com.
8.5 Moisture switch
All pumps are fitted with a moisture switch as standard with the
moisture switch being connected via the supply cable, see
section 8. Electrical connection, and connected to a separate
circuit breaker.
The moisture switch is positioned in the bottom of the motor.
If there is moisture in the motor, the switch will break the circuit
and send a signal to the IO 113.
The moisture switch is non-reversing and must be replaced after
use.
The moisture switch is connected to the monitoring cable, and it
must be connected to the safety circuit of the separate pump
controller. See section 8. Electrical connection.
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.
English (GB)
TM04 5238 2909 - TM03 1164 1105
13
English (GB)
PET1 T2
G1 A1 G2 A2 K1 K2 R1 R2
D1 D2D3 D4 D5 D6D7 D8
P1 P2 P3 P4 P5
AYB
I1 I2 I3
ON DIP
12345678910
11 12
12 3
4
5
6
7
8
9
1011
12
13
14
16
15
17
8.6 IO 113
IO 113 provides an interface between a Grundfos wastewater
pump equipped with sensors and the pump controller(s).
The most important sensor status information is indicated on the
front panel.
One pump can be connected to one IO 113 module.
Together with the sensors, the IO 113 provides a galvanic
isolation between the motor voltage in the pump and the
connected controller(s).
IO 113 can do the following as standard:
• Protect the pump against overheating.
• Monitor the status of these items:
– motor winding temperature
– leakage (WIO)
– moisture in pump.
• Measure the stator insulation resistance.
• Stop the pump in case of alarm.
• Remotely monitor the pump via RS-485 communication
(Modbus or GENIbus).
• Control the pump via a frequency converter.
Warning
IO 113 must not be used for purposes other than
those specified above.
Fig. 11 IO 113 module
Pos. Description
1 Terminals for alarm relay
2 Terminals for analog and digital inputs and outputs
3 Terminals for supply voltage
Potentiometer for setting the warning limit of stator
4
insulation resistance
5 Terminals for RS-485 for GENIbus or Modbus
6 Indicator light for moisture measurement
7 Indicator light for stator insulation resistance
8 Indicator light for leakage (WIO)
9 Indicator light for vibration in pump
Terminals for measurement of stator insulation
10
resistance
11 Terminals for connection of pump sensors
12 DIP switch for configuration
13 Indicator light for motor temperature
14 Button for resetting alarms
15 Indicator light for motor running
16 Indicator light for service
17 Terminals for digital outputs
8.7 Frequency converter operation
All SL1/SLV pump types are designed for frequency converter
operation to keep the energy consumption at a minimum.
To avoid the risk of sedimentation in the pipes, we recommend
that you operate the speed-controlled pump at a flow rate above
1 m/s.
For frequency converter operation, please observe the following
information:
• Requirements must be fulfilled. See section
8.7.1 Requirements.
• Recommendations ought to be fulfilled. See section
8.7.2 Recommendations.
• Consequences should be considered. See section
8.7.3 Consequences.
8.7.1 Requirements
• The thermal protection of the motor must be connected.
• Minimum switching frequency: 2.5 kHz.
• 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.
Maximum repetitive peak
voltage
[V]
850 2000
• If the pump is an Ex-approved pump, check if the Ex certificate
of the specific pump allows the use of a frequency converter.
• Set the frequency converter U/f ratio according to the motor
data.
• Local regulations/standards must be fulfilled.
8.7.2 Recommendations
Before installing a frequency converter, calculate the lowest
allowable frequency in the installation in order to avoid zero flow.
• 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
TM05 1881 3811
prevent sedimentation in the piping system.
• Do not exceed the frequency indicated on the nameplate.
In this case there is risk of motor overload.
• Keep the motor cable as short as possible. The peak voltage
will increase with the length of the motor 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.
• Use screened motor cable if there is a risk that electrical noise
can disturb other electrical equipment. See data sheet for the
frequency converter used.
8.7.3 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.
Maximum dU/dt
U
400 V
N
[V/μ sec.]
14
9. Startup
Note
Caution
Operation
Stop
6 min.4 min.
10 min.
P
t
P
t
Operation
Stop
Start
Stop S1 operation
Alarm
Min. 10 cm
Stop S3 operation
Warning
Before starting work on the pump, 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.
Make sure that all protective equipment has been
connected correctly.
The pump must not run dry.
Warning
The pump must not be started if the atmosphere in
the tank is potentially explosive.
S3, intermittent operation:
Operating mode S3 means that within 10 minutes the pump must
be in operation for 4 minutes and stopped for 6 minutes.
See fig. 12.
In this operating mode, the pump is partly submerged in the
pumped liquid, i.e. the liquid level reaches at minimum the top of
the cable entry on the motor housing. See fig. 2.
English (GB)
Warning
It may lead to personal injuries or death to open the
clamp while the pump is operating.
9.1 General startup procedure
This procedure applies to new installations as well as after
service inspections if startup takes place some time after the
pump was placed in the tank.
1. Remove the fuses and check that the impeller can rotate
freely. Turn the impeller by hand.
Warning
The impeller can have sharp edges - wear protective
gloves.
2. Check the condition of the oil in the oil chamber. See also
section 10.1 Inspection.
3. Check that the system, bolts, gaskets, pipework and valves
etc. are in correct condition.
4. Mount the pump in the system.
5. Switch on the power supply.
6. Check whether the monitoring units, if used, are operating
satisfactorily.
7. For pumps with WIO sensor, switch on the IO 113 and check
that there are no alarms or warnings. See section 8.6 IO 113.
8. Check the setting of air bells, float switches or electrodes.
9. Check the direction of rotation. See section 9.3 Direction of
rotation.
10. Open the isolating valves, if fitted.
11. Check that the liquid level is above the motor for S1 operation
and above the cable entry for S3 operation. See fig. 14. If the
minimum level is not reached do not start the pump.
12. Start the pump and let the pump run briefly, and check if the
liquid level is falling.
13. Observe if the discharge pressure and input current are
normal. If not there might be air trapped inside the pump.
TM04 4527 1509TM04 4528 1509TM04 2654 2808
Fig. 12 S3, intermittent operation
S1, continuous operation:
In this operating mode, the pump can operate continuously
without being stopped for cooling. See fig. 13. Being completely
submerged, the pump is sufficiently cooled by the surrounding
liquid. See fig. 2.
Fig. 13 S1, continuous operation
Trapped air can be removed from the pump housing
by tilting the pump by means of the lifting chain when
the pump is in operation.
In case of abnormal noise or vibrations from the
pump, other pump failure or power supply failure or
water supply failure, stop the pump immediately. Do
not attempt to restart the pump until the cause of the
fault has been found and the fault corrected.
After one week of operation or after replacement of the shaft seal,
check the condition of the oil in the chamber. For pumps without
sensor, this is done by taking a sample of the oil. See section
10. Maintenance and service for procedure.
Every time the pump has been removed from the tank, go through
the above procedure when starting up again.
9.2 Operating modes
The pumps are designed for intermittent operation (S3).
When completely submerged, the pumps can also operate
continuously (S1).
Fig. 14 Start and stop levels
Make sure that the effective volume of the tank does not become
so low that the number of starts per hour exceeds the maximum
permissible number.
15
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