S pumps, ranges 72-74-78
S2, S3, S4, ST
55-520 kW
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
This booklet includes instructions for installation, operation and
maintenance of Grundfos submersible sewage and wastewater
S-range pumps with motors of 55 to 520 kW.
Fig. 1 S pump, range 72
1. Symbols used in this document
2
2. General description
2
2.1 Applications
3
2.2 Potentially explosive environments
3
2.3 Operating conditions
4
2.4 Sound pressure level
4
3. Identification
5
3.1 Type key
5
3.2 Nameplates
6
3.3 Approval plates, range 72
6
3.4 Ex certification and classification
6
4. Safety
7
5. Transportation and storage
7
5.1 Lifting the pump
7
5.2 Raising pump to upright position
9
5.3 Storage
10
6. Installation
10
6.1 Installation types
10
6.2 Start and stop levels
12
6.3 Submerged installation on auto-coupling
12
6.4 Column pipe installation
12
6.5 Dry installation
13
7. Motor protection
14
7.1 IO 113
14
7.2 SM 113
14
7.3 Switches and sensors
14
8. Electrical connection
16
8.1 Cross-sections for power cables
16
8.2 Wiring diagram for sensors
17
8.3 Frequency converter operation
17
9. Startup
18
9.1 Checking the direction of rotation
18
10. Maintenance and service
19
10.1 Oil check and oil change
19
10.2 Inspection and adjustment of impeller clearance
20
10.3 Contaminated pumps
22
11. Fault finding chart
23
12. Disposal
23
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.
Warning
These instructions must be observed for
explosion-proof pumps. We recommend that you
also follow these instructions for standard
pumps.
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.
Warning
The sound pressure level is so high that hearing
protection must be used.
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.
TM03 1507 1110
Pos. Description
1 Inlet
2Outlet
3 Power supply cables
4 Control cable
5 Lifting bracket
6 Terminal box
7 Submersible motor
8Pump
17 Air vent valve
English (GB)
3
2.1 Applications
S pumps, range 72, 74 and 78, are designed for the pumping of
sewage and wastewater in a wide range of municipal and
industrial applications.
Depending on the installation type, the pumps can be used for
submerged or dry, horizontal or vertical, installation.
Maximum solids size: 90-145 mm, depending on impeller type.
2.2 Potentially explosive environments
In potentially explosive environments, use only Ex-approved
apparatus. All range-72 pumps are available as Ex versions.
Range 72 Ex pumps can be used in hazardous areas classified
as Zone 1 or Zone 2.
Warning
Special conditions for safe use of S pumps,
range 72 Ex, 74 and 78:
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 EN/ISO 3506-1.
3. The flame path gaps of the motor are specified by
the manufacturer and are narrower than
standard. Please see the manufacturer's
installation, operation and maintenance
document for guidance.
4. During operation, the cooling jacket, when fitted,
must be filled with pumped liquid.
5. 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.
6. Dry-running is not allowed.
7. Make sure the permanently attached cables are
suitably mechanically protected and terminated in
a suitable terminal board.
8. The sewage pumps have an ambient temperature
range of 0-40 °C and a maximum process
temperature 40 °C.
9. The control unit must protect the WIO against the
short circuit current of the supply to which it is
connected. The maximum current from the
control unit must be limited to 350 mA.
10.The maximum submersion depth is 20 m.
Warning
Special conditions for safe use of WIO sensor
1. The control unit must protect the sensor against
the short-circuit current of the current supply to
which it is connected.
2. The sensor must be installed in such a way that
danger of mechanical impact is avoided.
3. The WIO sensor must not be used in oil with a
flash point below 250 °C.
4. The WIO sensor is approved according to
EN/IEC 60079-18:2004. In Ex and IEC Ex
applications, the maximum current supplied to the
sensor must be limited to 350 mA according to
EN/IEC 60079-18:2004.
Installation
type
Description Accessories
S
Sewage pump without
cooling jacket for
submerged installation on
auto coupling.
Auto coupling
C
Sewage pump with
cooling jacket for
submerged installation on
auto coupling.
Auto coupling
D
Sewage pump with
cooling jacket for dry
vertical installation.
Base plate for vertical
installation
H
Sewage pump with
cooling jacket for dry
horizontal installation.
Base plate for
horizontal installation
ST
Sewage pump without
cooling jacket for
installation in vertical
column pipe.
Seat ring
Note
Ranges 74 and 78 are not available with Ex
approval.
English (GB)
4
2.3 Operating conditions
pH value
All pumps can be used for pumping liquids with a pH value
between 4 and 10.
Liquid temperature
The allowed temperature is 0-40 °C.
Ambient temperature
The allowed temperature is 0-40 °C.
Density and viscosity of pumped liquid
Density: 1000 kg/m
3
.
Kinematic viscosity: 1 mm
2
/s (1 cSt).
2.3.1 Installation depth
The maximum submersion depth is 20 m.
2.3.2 Level of pumped liquid
To avoid air being sucked into the pump and 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. See fig. 2. See also section 9.1 Checking the direction
of rotation.
• Installation type C:
The pump housing must always be covered by the pumped
liquid.
Fig. 2 Stop levels
• Installation types D and H:
See section 6.5 Dry installation.
• Installation type ST:
The liquid level must be at least 900-1100 mm above the pump
inlet. See fig. 21.
2.3.3 Pressure version
See section 4. Safety.
2.3.4 Operating mode
The pumps are designed for continuous operation with the
maximum number of starts per hour stated in the table below:
2.3.5 Enclosure class
IEC IP68.
2.4 Sound pressure level
Note
In special situations the temperature of the
pumped liquid may be higher, if the motor is not
fully loaded.
If necessary, contact the nearest Grundfos
company or service workshop.
Warning
Explosion-proof pumps must never pump liquids
with a temperature higher than 40 °C.
Note
In special situations the ambient temperature
may be higher, if the motor is not fully loaded.
If necessary, contact the nearest Grundfos
company or service workshop.
Warning
For explosion-proof pumps, the ambient
temperature on the installation site must be in
the range between 0 and 40 °C.
Note
When pumping liquids with a density and/or a
kinematic viscosity higher than the values stated
above, use motors with correspondingly higher
outputs.
Warning
An Ex motor must always be fully submerged
during operation.
Warning
Install an additional level switch to ensure that
the pump is stopped in case the stop level switch
is not operating.
Warning
Installation type S and C pumps must always be
fully submerged in the pumped liquid to be Ex
protected.
Note
For installation type C pumps, the air vent valve
must always be open, also during operation.
See fig. 1.
Installation types C and S
TM03 1626 0208
Warning
During operation, the cooling jacket must be
filled with pumped liquid to ensure sufficient
cooling. Before the first startup and after long
standstill periods, the air must be evacuated from
the cooling jacket through an air-vent valve.
S pump, range Starts per hour
72 15
74 and 78 10
Warning
Depending of the installation type the sound
pressure level of the pump can be higher than
70 dB (A). Use hearing protection when working
nearby such an installation in operation.
Ex pumps,
installation type S
Installation type C
English (GB)
5
3. Identification
3.1 Type key
All S pumps, ranges 72, 74 and 78, described in this booklet are identified by the type designation 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 2 .90 .250 .2250 .4 .72 S .C .496 .G .N .D .5 13 .Z
S
ST
Pump type:
Grundfos sewage and wastewater pump
Multi-channel impeller pump installed in a column pipe
2
3
4
Impeller type:
Two-channel
Three-channel
Four-channel
Pump passage:
Maximum solids size [mm]
250
[ ]
Pump discharge, S-type:
Nominal diameter of pump discharge port [mm]
Pump discharge, ST-type:
Nominal diameter of column pipe [mm]
Output power, P2:
P2 = Code number from type designation / 10 [kW]
4
6
8
10
12
14
Number of poles:
4-pole motor
6-pole motor
8-pole motor
10-pole motor
12-pole motor
14-pole motor
72
74
78
Pump range:
Range 72
Range 74
Range 78
S
H
M
L
E
F
Pressure version:
Super high
High
Medium
Low
Extra low
Super low
S
C
D
H
Installation type:
Submerged installation without cooling jacket
Submerged installation with cooling jacket
Dry installation with cooling jacket
Dry horizontal installation with cooling jacket
Impeller diameter (mean):
[mm]
G
Q
Material code for impeller, pump housing and stator housing:
Cast iron impeller, pump housing and stator housing
Stainless steel impeller, DIN W.-Nr. 1.4408
N
Ex
Pump version:
Non-explosion-proof pump
Pump with explosion-proof motor
B
D
Sensor version:
S pump with built-in SM 113 module. PTC sensors are connected directly to IO 113 or other PTC relay.
S pump without built-in SM 113 module
5
6
Frequency:
50 Hz
60 Hz
11
13
18
1G
1B
1D
11
1G
1H
Voltage and connection:
50 Hz
3 x 400 / 690 V Y/D
3 x 415 / 719 V Y/D
3 x 380-400 / 660-690 V Y/D
3 x 380 / 660 V Y/D
3 x 400-415 / 690-719 V Y/D
3 x 380-415 / 660-719 V Y/D
60 Hz:
3 x 575 / (996) V Y/D
3 x 380 / 660 V Y/D
3 x 460 / (797) V Y/D
Z Custom-built products
English (GB)
6
3.2 Nameplates
Fig. 3 Pump nameplate
3.3 Approval plates, range 72
Fig. 4 Approval plates of explosion-proof S-pumps, range 72
The approval plate gives the following details:
3.4 Ex certification and classification
The range 72 Ex-pumps have an EC-type Examination Certificate
issued by Baseefa Ltd.
The certified pumps (Ex-pumps) are supplied with an approval
plate fixed in a visible place close to the nameplate.
Figure 4 shows the approval plates for range 72 pumps equipped
optionally with the motors classified to T3 or T4 temperature
class.
TM06 1781 2514 - TM06 0370 5313
Pos. Description
1 Type designation
2 Product number
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 [kW]
10 Power factor
11 Production code [YYWW]
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 P2
21 Insulation class
22 Weight
23 Place of production
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
TM06 0916 1214 - TM06 0917 1214
CE CE mark
Baseefa 1180 ATEX-notified body identification number
EU ex symbol
II Equipment group (II = non-mining)
2 Equipment category (high protection)
G Type of explosive atmosphere (G = Gas)
Ex
Explosion-proof motor according to European
standard
b Control of ignition sources
c Constructional safety
d Flameproof
IIB Gas group (Ethylene)
T3
Maximum surface temperature of the motor is
200 °C
T4
Maximum surface temperature of the motor is
135 °C
Baseefa Certificate number
Type 72X2254 (example)
No. Serial number
PC Production code (year/week)
72
Direct drive, 50 or 60 Hz CE 1180 II 2 G Ex bcd IIB T4
Frequency converter
drive
CE 1180 II 2 G Ex bcd IIB T3
English (GB)
7
4. Safety
For safety reasons, all work in pits must be supervised by a
person outside the pump pit.
Pits for submersible sewage and wastewater pumps contain
sewage and wastewater with toxic and/or disease-causing
substances. Therefore, all persons involved must wear
appropriate personal protective equipment and clothing, and all
work on and near the pump must be carried out under strict
observance of the hygiene regulations in force.
5. Transportation and storage
The pump is supplied from factory on a steel transportation stand
in horizontal position. Pump and stand is protected by a special
cover.
Fig. 5 Covered pump in transportation stand
The pump is equipped with a label indicating the centre of gravity
of the pump including installation/transportation accessories.
See fig. 5. The position of the label varies depending on pump
type and accessories.
Fig. 6 Symbol of centre of gravity
Fig. 7 Transportation stand with cable holders
5.1 Lifting the pump
S pumps, range 78 weigh up to 8100 kg without accessories.
It is therefore very important to use the right lifting equipment.
The pump weight is stated on the pump nameplate.
See section 3.2 Nameplates.
Warning
Pump installation in pits must be carried out by
specially trained persons.
Work in or near pits must be carried out
according to local regulations.
Warning
It must be possible to lock the main power switch
in position 0. Type and requirements as specified
in EN 60204-1, 5.3.2.
Warning
Persons must not enter the installation area
when the atmosphere is explosive.
Warning
Never work under a pump when it is hanging
from crane!
Warning
Before attempting to lift the pump, make sure the
rated capacity of the lifting equipment (lifting
chain etc.) is adequate for the lifting work.
The rated capacity of the lifting equipment is
stated on the equipment nameplate. The weight
of the pump is stated on the pump nameplate.
Warning
For some installation types, the surface
temperature may be up to 90 °C.
Warning
The surface temperature of the cables may
exceed 70 °C.
TM03 3069 4809
Note
We recommend that you keep the transportation
stand in storage for later use.
TM04 6728 0810TM03 3365 4809
Note
The weight is stated with 10 m cables.
Note
The weights of installation type S and C pumps
include the weight of the guide claw.
The weight of installation type H pumps includes
the weight of the horizontal base stand.
English (GB)
8
Pump type
Net weight [kg]
SCDH
Range 72
S2.90.250.2250.4.72S 1770 1950 1955 2250
S2.100.250.2250.4.72H 1760 1945 1955 2240
S2.100.250.1750.4.72H 1760 1945 1955 2240
S2.100.300.2250.4.72M 1840 2020 2010 2300
S2.100.300.1750.4.72M 1840 2020 2010 2300
S3.110.300.1800.6.72H 1965 2160 2150 2440
S3.110.300.1600.8.72H 1965 2165 2155 2445
S3.120.500.1800.6.72M 2335 2520 2360 2700
S3.120.500.1600.8.72M 2330 2530 2370 2700
S3.120.500.1250.8.72M 2330 2530 2370 2700
S3.135.500.1800.6.72L 2340 2525 2360 2700
S3.135.500.1600.8.72L 2335 2535 2375 2705
S3.135.500.1250.8.72L 2335 2535 2375 2705
S3.135.600.1600.8.72E 2710 2910 2690 3020
S3.135.600.1300.10.72E 2730 2930 2710 3040
S3.135.600.1100.10.72E 2720 2920 2700 3030
S3.135.600.900.10.72E 2710 2910 2690 3020
Range 74 CDH
S2.90.300.2500.4.74S 2800 2800 3000
S2.90.300.3150.4.74S 3500 3500 3700
S2.100.300.2500.4.74H 2800 2800 3000
S2.100.300.3150.4.74H 3500 3500 3700
S3.110.300.2000.6.74H 3000 3000 3200
S3.110.300.2500.6.74H 3100 3100 3400
S3.110.300.3150.6.74H 3900 3900 4100
S3.120.300.2000.6.74M 3300 3200 3400
S3.120.300.2500.6.74M 3500 3300 3500
S3.120.300.3150.6.74M 4300 4100 4300
S3.135.500.2000.6.74L 3300 3300 3500
S3.135.500.2500.6.74L 3500 3400 3700
S3.135.500.3150.6.74L 4200 4200 4400
S3.135.600.2000.8.74E 3900 3700 4000
S3.135.600.2500.8.74E 4600 4400 4700
Range 78 CDH
S3.115.500.3150.8.78H 5600 5500 6000
S3.115.500.3500.8.78H 6000 5800 6300
S3.115.500.4000.8.78H 6100 5900 6400
S3.115.500.4500.8.78H 6200 6000 6500
S3.115.500.5000.8.78H 6200 6100 6600
S3.115.500.5200.8.78H 6400 6200 6700
S3.130.500.2500.10.78M 5200 5100 5600
S3.130.500.3150.8.78M 5500 5400 5900
S3.130.500.3150.10.78M 5800 5600 6100
S3.130.500.3500.8.78M 5900 5800 6300
S3.130.500.3500.10.78M 6100 5900 6400
S3.130.500.4000.8.78M 6000 5900 6400
S3.130.500.4000.10.78M 6100 6000 6500
S3.130.500.4500.8.78M 6100 6000 6500
S3.130.500.5000.8.78M 6200 6100 6600
S3.130.500.5200.8.78M 6300 6200 6700
S3.145.500.1600.10.78L 5000 4900 5300
S3.145.500.2000.10.78L 5100 5000 5500
S3.145.500.2500.10.78L 5400 5300 5800
S3.145.500.3150.8.78L 5700 5600 6100
S3.145.500.3150.10.78L 5900 5800 6300
S3.145.500.3500.8.78L 6000 5900 6400
S3.145.500.3500.10.78L 6200 6100 6600
S3.145.500.4000.8.78L 6100 6000 6500
S3.145.500.5000.8.78L 6300 6200 6700
S3.145.500.5200.8.78L 6400 6300 6800
S4.135.600.1300.12.78E 5700 5700 6300
S4.135.600.1600.12.78E 5900 5900 6500
S4.135.600.2000.10.78E 5800 5800 6400
S4.135.600.2500.10.78E 6000 6000 6600
S4.135.600.3150.8.78E 6300 6300 6900
S4.135.600.3150.10.78E 6600 6600 7100
S4.135.600.3500.8.78E 6700 6700 7300
S4.135.600.4000.8.78E 6800 6800 7300
S4.135.600.4500.8.78E 6900 6900 7500
S4.135.600.5000.8.78E 7000 7000 7500
S4.135.600.5200.8.78E 7100 7100 7700
S4.155.800.2500.10.78F 6600 6500 7200
S4.155.800.3150.10.78F 7100 7000 7700
S4.155.800.3500.10.78F 7400 7300 8000
S4.155.800.4000.10.78F 7500 7400 8100
S4.155.800.1600.12.78F 6500 6400 7100
S4.155.800.2000.12.78F 7100 7000 7700
S4.155.800.2500.12.78F 7300 7200 8000
S4.155.800.1100.14.78F 6300 6200 6900
S4.155.800.1300.14.78F 6500 6400 7100
S4.155.800.1600.14.78F 7000 6900 7600
ST pumps Weight [kg]
Range 74
ST3.135.1200.2000.8.74E 2800
ST3.135.1200.2500.8.74E 3400
Range 78
ST4.135.1400.3150.8.78E 4700
ST4.135.1400.3500.8.78E 5000
ST4.135.1400.4000.8.78E 5100
ST4.135.1400.4500.8.78E 5200
ST4.135.1400.5000.8.78E 5300
ST4.135.1400.5200.8.78E 5400
ST4.135.1400.5200.8.78E 5400
ST4.135.1400.2000.10.78E 4200
ST4.135.1400.2500.10.78E 4400
ST4.135.1400.3150.10.78E 4900
ST4.135.1400.1300.12.78E 4100
ST4.135.1400.1600.12.78E 4300
ST4.155.1600.2500.10.78F 4700
ST4.155.1600.3150.10.78F 5200
ST4.155.1600.3500.10.78F 5500
ST4.155.1600.4000.10.78F 5500
ST4.155.1600.1600.12.78F 4600
ST4.155.1600.2000.12.78F 5200
ST4.155.1600.2500.12.78F 5400
ST4.155.1600.1100.14.78F 4400
ST4.155.1600.1300.14.78F 4600
ST4.155.1600.1600.14.78F 5100
Pump type
Net weight [kg]
SCDH
English (GB)
9
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.
Fig. 8 Lifting points on pump, range 72
Fig. 9 Lifting points on pump, range 74 and 78
5.2 Raising pump to upright position
Fig. 10 Raising the pump to upright position, step 1
Fig. 11 Raising the pump to upright position, step 2
Fig. 12 Raising the pump to upright position, step 3
Note
The weights are net weights including the
accessories mounted from factory.
Warning
Always lift the pump by the marked lifting points
or by means of a fork-lift truck.
To make the use of a fork-lift truck when moving
a pump safer, the approximate centre of gravity is
marked with a label attached to the
transportation stand. Make sure the centre of
gravity is between the fork-lift arms when lifting
the pump.
Never lift the pump by the power supply cables.
It may result in electric short-circuit and risk of
electric shock when the pump is connected to the
mains. The cables and cable entry may be
damaged, leading to loss of watertightness and
consequent severe damage to the motor.
TM03 4459 0208TM04 6068 4809
Warning
If during transportation, assembly or dismantling
the pump is tilted more than 10 ° in any direction
from its normal position (EN 809, 5.2.1.4), the
pump may lose its stability. Secure the pump by
means of chains or place it in horizontal position.
Warning
Make sure that the lifting brackets 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.
TM03 3034 0208TM03 3035 0208TM03 3036 0208
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