Grundfos S Series, S1 Series, S2 Series, S3 Series, ST Series Installation And Operating Instructions Manual
...
S pumps, ranges 50-70
S1, S2, S3, ST, SV
7.5 - 155 kW
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
Caution
Note
Note
English (GB)
Original installation and operating instructions.
CONTENTS
1. Symbols used in this document
2. General description
2.1 Applications
2.2 Operating conditions
2.3 Sound pressure level
2.4 Type key
2.5 Nameplate
3. Safety
3.1 Lifting points for submerged and dry vertical
installation (S/C/D)
4. Transportation and storage
5. Installation
5.1 Installation type
5.2 Submerged installation on auto coupling
5.3 Dry installation
5.4 Submerged installation, portable
5.5 Vertical installation in column pipe
5.6 Pump controller
5.7 Galvanic separation
5.8 IO 113
5.9 Thermal switches
5.10 Moisture switches
5.11 Thermistors
5.12 Pt100 temperature sensor
6. Water-in-oil (WIO) sensor
6.1 WIO as accessory
6.2 Fitting the WIO sensor
6.3 Electrical data, WIO sensor
6.4 Sensor signals
7. Electrical connection
7.1 Frequency converter operation
7.2 Cable data
8. Startup
8.1 Checking the direction of rotation
9. Maintenance and service
9.1 Oil check and oil change
9.2 Inspection and adjustment of impeller clearance
9.3 Explosion-proof S pumps, range 50-70
9.4 Contaminated pumps
10. Fault finding
11. Di spo sal
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
1. Symbols used in this document
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.
Warning
The surface of the product may be so hot that
it may cause burns or personal injury.
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Warnin g
These instructions must be observed for
explosion-proof pumps. We recommend that you
also follow these instructions for standard
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2. General description
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This booklet includes instructions for installation, operation and
8
maintenance of Grundfos submersible sewage and wastewater
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S pumps, range 50-70, fitted with motors of 7.5 to 160 kW.
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The booklet also includes specific instructions for the explosion-
9
proof pumps.
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9
pumps.
Warnin g
The sound pressure level is so high that hearing
protection must be used.
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.
Special conditions for safe use of S pumps,
range 50-70 Ex:
1. Make sure the moisture switches and thermal
switches are connected in two separate circuits
and 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 A4-80
or A2-80 according to EN/ISO 3506-1.
3. The flame path gaps of the motor are specified by
the manufacturer and are narrower than
standard.
Note: In case of repairs always use original
service parts from the manufacturer as this
ensures correct dimensions of flame path gaps.
4. During operation the cooling jacket, when fitted,
must be filled with pumped liquid. The level of
pumped liquid must be controlled by level
switches connected to the motor control circuit.
5. The minimum level depends on the installation
type and is specified in these installation and
operating instructions.
6. Make sure the permanently attached cable is
suitably mechanically protected and terminated in
a suitable terminal board.
2.1 Applications
S pumps, range 50-70 are designed for the pumping of sewage
and wastewater in a wide range of municipal, private and
industrial applications.
Depending on the installation type, the pumps can be used for
submerged or dry, horizontal or vertical installation.
Maximum solids size: 80-145 mm depending on range.
2.1.1 Potentially explosive environments
Use the explosion-proof S pumps, range 50-70, in potentially
explosive environments. See section 2.5.1 Ex certification and
classification.
The explosion classification of the pump is Ex bc
d IIB T3. The installation must be approved by the
local authorities in each individual case.
2
2.2 Operating conditions
Installation type S and C
S1 operation and Ex
pumps, installation
type S
Installation type C
2.2.1 pH value
All pumps can be used for pumping liquids with a pH value
between 4 and 10.
2.2.2 Liquid temperature
0 °C to +40 °C.
2.2.3 Ambient temperature
-20 °C to +40 °C.
2.2.4 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.
2.2.5 Flow velocity
It is advisable to keep a minimum flow velocity to avoid
sedimentations in the piping system.
Recommended velocities
In vertical pipes: 0.7 m/s
In horizontal pipes: 1.0 m/s
2.2.6 Level of pumped liquid
For a submerged pump, installation type C, the lowest stop level
must always be above the pump housing.
Warnin g
Dry-running is not allowed.
The level of pumped liquid must be controlled by
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.
To ensure adequate cooling of the motor during operation, the
following minimum requirements must be met:
• Installation type S
For S1 operation (continuous operation), the pump must
always be covered by the pumped liquid to the top of the
motor.
For S3 operation (intermittent operation), the pump must
always be covered by the pumped liquid to the middle of the
motor.
Warnin g
Installation type S pumps must always be fully
submerged in the pumped liquid to be Ex
protected.
• Installation type C
The pump housing must always be covered by the pumped
liquid.
English (GB)
Installation
type
S
C
D
ST
H
Description Accessories
Sewage pump without
cooling jacket for
submerged installation on
auto coupling.
Sewage pump with cooling
jacket for submerged
installation on auto
coupling.
Sewage pump with cooling
jacket for dry vertical
installation.
Sewage pump with or
without cooling jacket for
vertical installation in
column pipe.
Sewage pump with cooling
jacket for dry horizontal
installation.
Auto coupling
Auto coupling
Range 50, 54, 58
and 62: Base stand
for vertical
installation.
Range 66 and 70:
Base plate for
vertical installation.
Seat ring for vertical
installation in
column pipe.
Base stand for
horizontal
installation.
Fig. 1 Liquid level
• Installation type D and H
No special requirements.
• Pump type ST
The liquid level must be at least 350 mm above the pump inlet.
See fig. 9.
2.2.7 Operating mode
The pumps are designed for continuous operation or for
intermittent operation with the maximum number of starts per
hour stated in the table below:
S pump, range Starts per hour
50
54
58
62
66
70
2.2.8 Enclosure class
IEC IP68.
20
15
2.3 Sound pressure level
Warning
Depending on the installation type the sound
pressure level of the pump can be higher than
70 dB(A).
When working nearby such an installation in
operation, hearing protection must be used.
TM02 4000 0309
3
2.4 Type key
English (GB)
All S pumps, range 50-70, described in this booklet are identified by the type code stated in the confirmation of order and other
documentation supplied with the pump.
Please note that the pump type described in this booklet is not necessarily available in all variants.
Code Example S 1 .100 .100 .55 4 .50 M .S .205 .G .N .D .5 11 .Z
Pump type
S
Grundfos sewage and wastewater pump
ST
Multi-channel impeller pump installed in column pipe
Impeller type
1
Single-channel
2
Two-channel
3
Three-channel
V
SuperVortex
Pump passage
Maximum solids size [mm]
Pump discharge
Nominal diameter of pump discharge port [mm]
Output power P2
Code number from type designation / 10 [kW]
Number of poles
2
2-pole motor
4
4-pole motor
6
6-pole motor
8
8-pole motor
10
10-pole motor
12
12-pole motor
Pump range
50
Range 50
54
Range 54
58
Range 58
62
Range 62
66
Range 66
70
Range 70
Pressure version
S
Super high
H
High
M
Middle
L
Low
E
Extra low
F
Super low
Installation type
S
Submersible installation without cooling jacket
C
Submersible installation with cooling jacket
D
Dry, vertical installation
H
Dry, horizontal installation
Actual impeller diameter [mm]
Material code for impeller, pump- and motor housing
G
Cast iron impeller, pump housing and motor housing
Q
Stainless steel impeller, DIN W.-Nr. 1.4408
S
Stainless steel impeller and pump housing, DIN W.-Nr. 1.4408
R
Stainless steel impeller, pump housing and motor housing, DIN W.-Nr. 1.4408
Pump version
N
Non-ex pump
Ex
Pump with explosion-proof motor
Sensor version
B
S pump with built-in SM 113 module. PTC sensors are connected directly to IO 113 or other PTC relay.
C
Not in use
D
S pump without built-in SM 113 module
Frequency:
5
50 Hz
6
60 Hz
Voltage code and connection:
50 Hz:
11
3 x 400 / 690 V Y/D
13
3 x 415 / (719) V Y/D
60 Hz:
11
3 x 460 / (797) V Y/D
15
3 x 380 / 660 V Y/D
Z Custom-built products
4
2.5 Nameplate
1
2
3
4
5
6
7
8
9
10
11
12
23
13
14
15
16
17
18
19
20
21
22
12
22
23
All pumps can be identified by means of the nameplate on the
motor top cover. See fig. 2. If the nameplate is missing or
damaged, the pump can be identified by the serial number
stamped under the nameplate.
2.5.1 Ex certification and classification
Direct drive, 50 or 60 Hz: CE 1180 II2 G Ex bc d IIB T4.
Frequency converter drive: CE 1180 II2 G Ex bc d IIB T3.
Explosion-proof pumps have been approved by Baseefa (2001)
Ltd. in conformity with the essential health and safety
requirements relating to the design and construction of equipment
intended for use in potentially explosive atmospheres given in
Annex II to the Council Directive 94/9/EC (ATEX).
The certified pumps (Ex pumps) are supplied with an approval
plate fixed in the visible place close to the nameplate.
Fig. 3 shows the approval plates for the pumps equipped
optionally with the motors classified to T3 or T4 temperature
class.
English (GB)
TM06 1781 2514 - TM06 0370 5313
Fig. 2 Pump nameplate
Pos. Description
1 Type designation
2 SAP code
3 Serial number
4 Maximum head (m)
5 Maximum installation depth (m)
6 Number of phases
7 Voltage, delta connection
8 Voltage, star connection
9 Rated power input
10 Cos φ, 1/1 load
11 Production code (YY/WW)
12 Production number
13 Maximum liquid temperature (°C)
14 Maximum flow rate (l/s)
15 Enclosure class
16 Frequency (Hz)
17 Rated speed
18 Current, delta connection
19 Current, star connection
20 Rated power output
21 Insulation class
22 Net weight (kg)
23 Production site
Fig. 3 Approval plates of explosion-proof pumps, T3 and T4
classification
The approval plate gives the following details:
EU ex-symbol
II Equipment group (II = non-mining)
2 Equipment category (high protection)
G Type of explosive atmosphere
CE CE mark
1180 Number of quality assurance notified body
Ex Motor explosion-proof according to European
standard
b Control of ignition sources
c Constructional safety
d Motor withstands explosion pressure
IIB Gas group (ethylene)
T3 Maximum surface temperature of the motor is 200 °C
T4 Maximum surface temperature of the motor is 135 °C
Gb Equipment protection level, zone 1
Baseefa Certificate number
IECEx Certificate number
TM06 1779 2814 - TM06 1780 2814 - TM05 8222 2113 - TM05 8224 2113
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3. Safety
Range 50 and 54
Range 58, 62, 66 and 70
Front
Middle
Nose
Front
Middle
Caution
English (GB)
Warnin g
Pump installation in tanks must be carried out by
specially trained persons.
Warnin g
Persons must not enter the installation area when
the atmosphere is explosive.
Warnin g
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.
Tanks 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.
Warnin g
For some installation types, the surface
temperature may be up to 90 °C.
Warnin g
Make sure that the lifting eye bolts are 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.
Warning
Make sure the rated lifting capacity of the lifting
equipment (lifting chain etc.) is adequate before
attempting to lift the pump.
The rated lifting capacity of the lifting equipment
is marked in the identification label. The weight
of the pump is marked in the pump nameplate.
3.1 Lifting points for submerged and dry vertical installation (S/C/D)
When lifting the pump, it is important to use the right lifting point
to keep the pump balanced. S pumps model S/C/D are equipped
with a bracket with lifting points ensuring that the pump can be
lifted in a safe manner. See fig. 4 and table below to find the
correct lifting point.
Discharge
flange size
DN80 MiddleMiddle---DN100 MiddleMiddle---DN125 Middle Middle Middle Middle - DN200 Front Front Front Middle Middle Middle
DN250 - Front - - Middle Middle
DN300 - - Front Middle Middle Middle
DN500 - - - - Nose Front
DN600 - - - - Nose Front
50 54 58 62 66 70
Pump range
4. Transportation and storage
The pump is supplied from the factory in proper packing in which
it should remain until it is to be installed.
Make sure that the pump cannot roll or fall over.
All lifting equipment must be rated for the purpose and checked
for damage before any attempt to lift the pump. The lifting
equipment rating must under no circumstances be exceeded.
The pump weight is stated on the pump nameplate.
Warning
Always lift the pump by its lifting bracket or by
means of a fork-lift truck, never by means of the
motor cable or the hose/pipe.
Do not remove the insulation from the free end of
the supply cable until the electrical connection is
to be made. Whether insulated or not, the free
cable end must never be exposed to moisture or
water. Non-compliance with this may cause
damage to the motor.
For long periods of storage, the pump must be protected against
moisture and heat.
Storage temperature: -30 °C to +60 °C.
Warning
If the pump is stored for more than one year or it
will be a long time before it is put into operation
after the installation, the impeller must be turned
at least once a month.
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
seals and the cable entry.
Fig. 4 Lifting points
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TM04 7173 1710
5. Installation
Caution
Caution
Warnin g
During installation, always support the pump by
means of lifting chains or place it in horizontal
position to secure stability.
Warnin g
Before beginning the installation, switch off the
power supply and lock the mains switch in
position 0.
Any external voltage connected to the pump must
be switched off before working on the pump.
The extra nameplate supplied with the pump should be fixed at
the installation site.
All safety regulations must be observed at the installation site, for
instance the use of blowers for fresh-air supply to the tank.
Warnin g
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.
Prior to installation, check the oil level in the oil chamber.
See section 9.1 Oil check and oil change.
5.1 Installation type
S pumps, range 50-70 are designed for various installation types.
Figures 5 to 9 show the possible installation types.
Permanent installation in tank
The pump can easily be pulled out and lowered into the tank by
means of the guide rails. The liquid level can be set lower for type
C than for type S. See fig. 1.
Installation type D
English (GB)
TM02 4001 4601 - TM02 4023 4701
Fig. 6 Dry, vertical installation with base stand (left) and base
plate on two concrete pedestals (right)
Permanent installation in a pump room
The pump is bolted to the suction and discharge pipes by means
of flange connections. Pumps with DN 500 or DN 600 flange are
to be installed on a concrete foundation (see the above figure to
the right).
Installation type S and C
Installation type S and C
Fig. 5 Submerged installation on auto coupling
Avoid pipe tension at flanges and bolts.
The free end of the cable must not be submerged
as water may penetrate through the cable into the
motor.
TM02 4002 4601
Fig. 7 Submerged, temporary installation
Temporary installation in a tank
The liquid level can be set lower for type C than for type S.
See fig. 1.
Installation type H
TM02 4000 0309
TM02 4003 4601
Fig. 8 Dry horizontal installation with base stand and bracket
7
Permanent installation in a pump room
Note
Note
Note
Note
Caution
Reducer of the eccentric type
0.2 m
English (GB)
The pump is bolted to the suction and discharge pipes by means
of flange connections.
Pump type ST
Fig. 9 Vertical column pipe installation
Vertical column pipe installation in steel pipe or concrete shaft.
5.2 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.
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.
In some installations, a plinth is required beneath
the auto coupling to ensure correct installation of
the pump. This should be considered during the
design of the installation.
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 expansion dowels into the guide rails. Fasten the
guide rail bracket on the inside of the tank. Tighten the bolts in
the expansion dowels.
6. Clean out debris from the tank before lowering the pump into
the tank.
7. Fit the guide claw to the pump.
8. Slide the guide claw of the pump between the guide rails and
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 and the control cable, if any.
The free end of the cable must not be submerged,
as water may penetrate through the cable into the
motor.
5.3 Dry installation
Pumps in dry installation are installed 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.
TM02 2494 4401
1. Mark and drill mounting holes in the concrete floor/concrete
foundation.
2. Fit the bracket or base stand to the pump.
3. Fasten the pump with expansion bolts.
4. Check that the pump is vertical/horizontal.
In order to facilitate service on the pump, we recommend to use
isolating valves on either side of the pump.
5. Fit the suction and discharge pipes and isolating valves, if
used, and ensure that the pump is not stressed by the
pipework.
6. 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 cables are not sharply bent or pinched.
7. Connect the motor cable and the control cable, if any.
We recommend to use a reducer between the
suction pipe and the pump 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 suction pipe is
avoided and the risk of disturbance of operation
is eliminated. See fig. 10.
Fig. 10 Eccentric reducer
TM02 2396 4201
8
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