DanPumps S-WP Series User manual

End-of-life, the pump must be recycled in accordance with local regulations. Version: 1.0 2015. English.

1. Content.
2. Pump labels.
3. Applications.
4. Technical specification.
5. Handling the pump.
6. Pump installation.
7. Electrical installation.
8. Operation.
9. Service & maintenance.
10. Pump data – 50Hz.
11. Pump data – 60Hz.
12. Pump cutaway.
13. CE Declaration.
14. Warranty.
2. Pump label.
Technical information is subject to change without notice.
3. Applications.
This installation and service manual are valid to the pump type S-WP series.
The series are manufactured in size S-WP1, S-WP2, S-WP3, S-WP4 and S-WP5, and in 3 applications:
1. Wet-Pit.
2. Dry-Pit.
3. Portable.
The S-WP pumps are single stage, and non-self-priming pumps.
They are designed for pumping water, wastewater with pollutants, as well as low-viscosity types of sludge.
The pumps can also be used as drainage pumps where sand and gravel occur.
The impeller design allows each individual impeller to be trimmed to your exact performance requirements.
ATEX and FM edition can be offered. Fee will be added. (FM exceptions for some models)
WARNING
If the location has a hazardous media, then make sure the pump has been delivered with the right approval.
If there are local restrictions concerning fire risks, they must be obeyed at all time.
The pumps meet EU’s machine directive, see declaration of conformity at the back of this manual.
DanPumps A/S guarantees that the pumps’ airborne noise level does not exceed the noise level between 70
to 74 dB (at normal operation).
WARNING
If people can get physical contact with the pump or the fluid that is being pumped at e.g. open excavations,
building sites or the like, a fault circuit-breaker (HFI or HPFI) must be mounted in the electrical installation. If
the pump is used in oceans, lakes etc. there must be a minimum safety distance of 20 meters between the
pump and any persons in the water. The national country and local standards have at all time to be
observed.
If there are local restrictions concerning fire risks, they must be obeyed.

4. Technical specification.
The S-WP pumps have a built-in motor in3-phased version for either 50 Hz (230/400 Vor 400/690 V)or
60 Hz (220 V, 460 Vor 575/1000 V).
Please see motor label for accurate information for this pump.
Ambient temperature and media up to max.+75ºC.
The motor is CE marked according to the Low Voltage Directive 2006/95/EC.

Motor protection.
Degree of protection is standard IP68,and insulation class isH. Made according standard EN 60204-1.
The electro motor has a thermal protection switch build-in. The thermal switches open at 150°C and close
again at 90°C. Automatic restart.
The terminals for the thermal protection switch are F0 &F1.
Absent the use of this warranty is voided.
Moisture protection.
The pump is mounted with a moisture sensor as standard. It detects moisture in the stator compartment as
well as the oil compartment simultaneously.
The terminals for the moisture protection are D1 (D1 to ground)
This conductor shall be connected to an extern moisture relay installed in the main control box.
The relay will cut off or signal (depending on connection) that the pump has moisture or water infiltration.
The normal alarm level is 100 kΩfor submersed wet-pit and for dry-pit installation.
The voltage of 24V DC. Moisture relays (10519004/05/06) are available as accessories at DanPumps A/S)
Absent the use of this warranty is voided.
Motor cable.
All standard pumps are delivered with 10 meters cable of the type H07RN-F preassembled.
There can be up to two cable preassembled according the pump configuration, one for main power and one
control cable. Other pumps have only one cable for both power and control.
For installation of a longer cable please contact your local DanPumps A/S dealer, who can advise you about
volt drop and dimensions. Also note that cable type and number of cables can vary depending on voltage,
start method and country restrictions. The conductors in the main cable are marked L1,L2, L3 + PE for
ground. Please see drawings 1,2 and 3 on page 3.
Cooling jacket.
The pumps can optionally be equipped with an internal cooling jacket for cooling the motor. The cooling
jacket is a closed cooling circuit system, which means the system will not be clogged or lose its function due
to polluted water.
Amount of cooling fluid, please see table. (30% Propylene glycol DOWCAL ® 30 + 70% water)
The cooling system for the seal, is also a close circuit system, which means that the system will not be
clogged or lose its function due to polluted water. (Mobil DTE20/24)
Model.
S-WP1
S-WP2
S-WP3
S-WP4
S-WP5
Amount of liquid in liters.
Without cooling jacket.
0,5
1,3
3,5
5,5
14
With cooling jacket.
2,9
5,7
11
44
134
Seal cooling oil.
0,32
0,45
0,15
0,4
0,4
Pump material.
Pump housing: Gray cast iron GJL-250 (GG25)
Pump impeller: Ductile cast iron GJS-400-15 (GGG-40). Stainless steel & duplex is an option.
Pump shaft: Stainless cast steel W. Nr. 1.4401 / AISI 329
O-rings: Nitrile / NBR.
Seal type: (After specification)
Scope of delivery.
The pump is delivered without DCB, UGB and guide pipes.
DCB and UGB must be ordered separately. The pump is delivered without moisture relay.
Relay (10519004/05/06) is available as accessories at DanPumps A/S.

Pump curves – 50 Hz.
Pump curves – 60 Hz.

5. Handling the pump.
The pump must be packaged properly during transport to avoid damage to the pump or its
surroundings. It can be transported and/or stored in vertical or horizontal position.
Always place the pump on a stable surface, so it cannot tip over during service, transport,
testing and installation.
For storage for long periods of time the pump must be serviced and checked again before
use. Before electrical connection the impeller shall be turned by hand to ensure the correct
friction of the mechanical seal.
Accidents in relation to installation can be minimized by taking care. Be especially careful with the pump’s
weight and the risk of electrical accidents.
When lifting with hoisting equipment, these must always be of the correct dimensions, with consideration to
the lifted weight.
- Never walk under hanging loads.
- Never lift or tow the pump in the cable.
- Never get entangled in pump cables and lifting chains.
6. Pump installation.
The immersion depth for pumps covered by this manual is max. 20 meters.
The temperature of the pumped media must not continuously exceed +45°C.
Cavitation may occur, if the pump intake becomes obstructed or if the NPSH value is too low,
causing damage to the internal elements of the pump.
Always provide the right suction conditions for the pump.
Accidents in relation to installation can be minimized by taking special care. Be especially
careful with the pump’s weight and the risk of electrical accidents.
When lifting with hoisting equipment, these must always be of the correct dimensions, with
consideration to the lifted weight. Never get entangled in pump cables and lifting chains.
Wet-Pit installation with submerged pump on DCB.
Cables for the pump must be installed in such a way that they avoid
any sharp bends or getting squeezed. Never let the cables hang in a
way that they might get sucked into the pump.
Mount the DCB (Discharge Connection Bracket) firmly onto the
bottom of the well with expanding bolts.
When mounting the upper guide brackets (UGB), the guide tubes
must be vertical and parallel.
Connect the discharge pipe to the DCB flange. We recommend
mounting a non-return check valve on the discharge pipe.
The hoisting device must be installed directly above the pump’s
center of gravity.
The pump will then automatically connect at bottom position on the
DCB, loosen again when lifted. (Cooling jacket is an option)
Always check the discharge pipe dimension is correct according to the required m³/h capacity.
Contact your local DanPumps A/S dealer, who can advise you.

Dry-Pit installation with submerged pump on legs.
Cables for the pump must be installed in such a way that they avoid any sharp
bends or getting squeezed. Never let the cables hang in a way that they might get
sucked into the pump.
The pump is delivered with support legs.
The pump must be mounted on a solid surface, and the foundation/base must have
sufficiently strength to support the pump.
The legs are adjustable; the height is regulated by loosening the two bolts on each
leg and tighten them again at the desired height. The pump volute is predrilled for
standard DN flange
Then mount the inlet and discharge pipes. (Suction elbows can be supplied)
We recommend mounting a ball valve on the suction side, and a ball valve + a non-
return check valve on the discharge side.
Check that the pipe dimensions are correct according to the required m³/h capacity.
Contact your local DanPumps A/S dealer, who can advise you.
Portable installation.
When mounting this installation type, it is very important that the cables are
installed in such a way that they do not bend, get damaged by vehicles etc.
It is also important that there is no pulling /towing in the cables or discharge
hose.
The pump must be mounted on a solid surface and in a vertical position, so it
does not tip over or “dig” into the sand, sludge etc.
Please note the pump’s inlet is exposed all physical contact must be avoided.
Keep a minimum safety distance of 5 meters from a pump in operation.
The pump is capable to give a very powerful suction under water. Never
underestimate this.
If necessary, then mount a plate with holes like a strainer, which can be
screwed onto the pump’s frame to avoid large objects being sucked into the
pump.
Discharge info for all 3 installations.
To reduce load and power dissipation, we recommend use of pipes with the same (DN) or larger diameter
than the pump discharge. Connection elements that may cause air pockets should not be used under any
circumstances.
The diameter of the pipes used, ought to be such, which ensures the water speed remains below
2 m/s (7 feet per second).
7. Electrical installation.
Work is only permitted to be carried out by qualified specialists and must to be carried
out in accordance with local regulations. Let a qualified electrician do this job.
Before work commences, ensure that all power is switched off and cannot be switched
on again. Check that supply voltage and frequency are the same as rated data on the
pump.
Motors can be used with a power supply deviation of ± 5% voltage and ± 2% frequency, according to
IEC60034-1
Connections must be made in such a way as to ensure that a permanently safe electrical connection is
maintained, both for the main supply and the earth connection. A ground fault circuit breaker is a must.
The electric board must be equipped with a motor guard that fits the motor size.
This relay must be set as follow for direct or star-delta start:

Direct start
The motor guard is set to the current (measured in ampere) that is stated on the identification plate. When
the thermal surveillance is connected, the motor guard’s setting is increased by 10%.
Star-delta start
The motor guard is set to the current (measured in ampere) that is stated on the identification plate multiplied
by 0.58. When the thermal overload switches are connected add 8% to the calculated value.
The grid must be secured with ordinary safety cutouts.
Thermal protection:
All pumps are equipped, with thermal overload switches built into the stator. These are marked F0 & F1. The
thermal protection conductors must be connected in series with the motor guard in the extern control board.
If this protection is not connected the guarantee will be void in case of damage.
See also technical specification.
Moisture sensor:
The conductor marked “D1” is connected to a moisture sensor, which is placed between the oil housing and
the motor housing. This sensor must be connected to a relay in the extern control board.
If moisture is registered in oil or stator housing, will the moisture relay cut off.
Your local DanPumps A/S dealer can supply you with the correct relay as an accessory.
8. Operation.
Before start, the pump must be fully assembled and ready for operation, and this manual read through.
Before the pump is started, the rotation direction must be checked.
At start the motors starting torque will cause the pump to jerk. The start reaction will be counter-clockwise,
seen from the top of the motor.
The starting torque can be very powerful even with small pumps. Never hold on to the
pump and do not start the pump when hanging in free air.
Place the pump solid so it cannot rotate or tip over before starting.
Never start the pump without impeller, the pump must be fully assembled and ready for operation.
At wrong start reaction two phases must be switched at the extern control box.
Never start up a pump with incompletely connected cables or non-operational overload switches and
leakage sensor.
Let a qualified electrician do this job.
9. Service & maintenance.
Before any inspection, service or repair of the pump, it must be physically disconnected from the electrical
power supply. Remove connectors or dismount the wires on the electric board.
(Any emergency stop can be released or be defective and start the pump by mistake)
All pumps require regular control and preventive maintenance to operate economically and reliably.
The pump should be checked every 6 months and during possible extreme operating conditions more often.
For complete overhaul of the pump contact an authorized DanPumps A/S workshop, or your local
DanPumps A/S dealer.
Clean the pump carefully before dismantling it. Follow local and national safety instructions.
Service Instructions for the S-WP pumps.
Type W - Wet Pit Installation
Install on a guide rail system, with a quick-release discharge connection bracket (DCB). The DCB is bolted to
the floor of the tank / well. The volute is equipped with an adapter to guide the pump via two 2” guide rails, to
secure connection on the DCB.

Type D - Dry Pit Installation.
Installed in a dry well. The pump has a factory mounted adjustable stand. The height of the stand makes it
possible to install a standard suction elbow. The pump volute is predrilled for standard DN flange.
Type P - Portable Pit or fixed installation.
A pump model, which is suitable for temporary or permanent installations. The pump is equipped with a
steel foot stand and is built with a threaded (BSP) or just plain hose connection.
The Volute.
The volutes are equipped with adjustable wear rings as standard.
The volute has between 2 or 6 pcs. fast lock latches for easy release
between motor unit and volute.
Lift the pump from the sump and clean thoroughly.
Loosen the latches and lift the motor unit out from the volute.
Changing the oil.
Remove the inlet and outlet plugs. Tilt the pump against the outlet and
discharge used oil according to the
local regulations. See technical specification for oil amount.
If there is any problem filling in oil, tilt the pump slightly so that air can escape.
Inspect the motor housing by removing the screw marked “motor”. Tilt the pump slightly. If water, oil or other
debris is present in the motor housing, a full dismantling is required.
Note! Do not forget to tighten plugs after filling.
Changing the cooling liquid.
Remove the cooling liquid plug on the cooling flange (water out). Remove the plug on top of the cooling
jacket (water inlet) for fast emptying. Re-plug the water outlet. Slowly fill the new cooling liquid into the water
inlet on top of the cooling jacket. See technical specification for cooling liquid amount.
Note! Do not forget to tighten plugs after filling.
Removal of the impeller.
The impeller is fixed to the shaft with a washer and a screw. Secure
the impeller and remove the impeller bolt with a wrench.
Removal of the seal cartridge.
Disassemble volute and impeller as above and empty the motor of
cooling liquid and oil. Lay the rotating element on its side. Remove
the four screws that hold the seal cartridge. The cartridge can be
removed from the oil chamber by inserting the set screws into the
“jacking holes” in the cartridge, which will force the cartridge from the
lower bearing housing.
Disassembling the enclosure cover.
Remove the screws fixing the cover. Gently lift the cover to gain access to the terminal board area.
Be careful not to damage the cable and motor connections. If any wires are disconnecting, then make sure
you are capable to reinstall them correctly again.
Removal of the terminal housing.
Disconnect all wires from the terminal board. The terminals are spring operated and can be opened by a
screwdriver. Open the cable glands for wiring to the stator. Remove the screws and lift the terminal housing
carefully. Do not damage the wires to the stator.
Removal of the cooling jacket.
Drain out cooling water. Disassemble by lifting off the jacket. Inspect where the O-rings are located and
clean if necessary.

Check the stator unit.
If the motor protection trips repeatedly, the stator must be inspected. Open the terminal housing cover.
Disconnect the stator wires (spring terminals). Check the insulation resistance with min. 500V insulation
tester. Test between U1, V1 and W1 and to GND.
Test between U1, V1 and W1. The insulation resistance must exceed 1 mega ohm. If the insulation
resistance is below 1 mega ohm, clean the stator and dry it in an oven for 2-3 hours at 100°C.
Check the circuit of the three built-in thermal overload switches using a buzzer or other measuring device.
Before reconnecting:
Check that the motor cable has no broken wires. Check the motor cable insulation with a 500V insulation
tester, between the wires.
Removal of the stator housing.
Mark the stator housing position on the bearing house to be able to reinstall correctly. Remove the six
screws fixing the stator casing. Lift the stator casing approx. 5 cm from the shaft and rotor - use a hoist.
Disconnect the wire from the moisture sensor. Continue lifting off the stator housing.
Disassembling the rotor and bearings.
When the stator housing has been removed, the shaft with rotor and bearing has to be lifted out. (Lower
bearing will stay in the lower bearing house).
Do not reuse worn bearings or bearings which have been in contact with water.
Assembling.
Clean all O-ring grooves and all other contact surfaces carefully. Use a wire brush when necessary. Change
all O-rings. Lubricate all O-rings with oil or grease to prevent the O-rings from getting stuck or damaged
when remounted. Also lubricate the threads on all the screws to facilitate disassembling when servicing next
time.
Mounting the bearings.
Check that the shaft is straight, and that the keyway is not damaged.
Polish possible scratches and burrs off. Push the upper bearing into its
position. If pressure is needed, then put pressure only on the inner ring of
the bearing, using a piece of pipe and a soft hammer. Put the shaft
through the shaft hole in the bearing house. Mount the lower bearing from
the bottom side of the bearing house. You may need a piece of pipe and a
soft hammer to install the bearings. The lower bearing is a double bearing.
Make sure that the bearings are placed face to face. Please see picture. Remember to lubricate the
bearings, if the bearings aren’t standard closed with caps (2RS).
Mounting the seal cartridge.
Put down the motor unit. Lubricate the shaft and all four O-rings on the seal unit (3 external on the seal
housing, and 1 internal in the seal cap). Carefully push the seal unit onto the shaft, and place into position by
aligning the screw holes. Do not use hard striking tools. Tighten the seal unit by fastening the four screws. All
4 screws must follow each other, to make sure that the seal unit does not tilt.
NOTE. Never run the motor without having the impeller mounted, if the seal is mounted.
This will cause damage to the O-rings in the seal, and it also a danger to your safety.
Changing the Cable
Note that a damaged cable always must be replaced. Connecting the pump with a defective cable can be life
endangering. Never try to lengthen the cable, only use cables in complete length, as water would be able to
get into the motor and damage it.
Check the following to avoid water getting into the pump when changing the cable:
A) Cable packing of rubber as well as cable washers must fit the cable dimension perfectly.
B) The cable’s outer diameter must not be deformed. Always cut off a piece so it will seal in a new
place in case of a reused cable.
C) A lubricant can be used to easy the cable connecting.
NOTE. The grounding conductor must be longer in the pump, then the line conductors.
The ground wire will therefore be the last to be torn of in a case of an accident.

Mounting the impeller.
Turn the shaft so that the keyway is upward. Put the key in its groove and push the impeller onto the shaft.
Lock the impeller from rotating with a pipe or similar and fasten the impeller washer and screw.
Mounting the stator.
Erect the oil housing and clean all contact surfaces between the oil housing and the stator unit with a wire
brush. Lubricate and mount a new O-ring on the oil housing. The stator is now ready to be mounted on the
oil housing. Lift the stator unit with a lifting device and lower it carefully over the rotor. Make sure that the
rotor does not damage the windings or the stator stick. Remember to connect the wire from the moisture
sensor. Fasten the stator with its four screws. Make sure that the external markings are in line.
Mounting the cooling jacket.
Put the gasket on top of the stator house. Fit the 2 external cooling tubes. Make sure that the O-rings are
hanged. Lower the cooling mantle over the stator casing and make sure that the external markings are in line
and that the cooling pipes are in their right positions. Fasten the cooling jacket with four screws.
Mounting the motor unit in the volute.
Turn the latch bolts so that the driving unit is free down to the upper edge of the volute. Turn the latch bolts
in and fasten the screws alternately. Make sure that the external markings are in line. Tighten completely by
hand using a wrench.
Adjusting the wear ring.
Lay the pump down on its side and check the clearance between impeller and wear ring. The clearance
should be max. 0.4 mm. The wear ring is placed on the bottom side of the volute and is fastened by three
screws placed horizontally. Loosen these screws and adjust with the three vertically placed screws. When
necessary, strike carefully with a hammer or plastic club. When the distance is adjusted the horizontally
placed screws can be tightened.
If using vortex impeller, then there is no need to adjust the wear ring!
Tightening torque screws
Size (Nm)
M6: 7
M8:17
M10: 33
M12: 57
M14: 91
M16:140
M20: 275
Tightening factor.
Cable gland: A specific estimation of the tightening factor cannot be given for the cable gland. Tighten it until
the rubber offers good resistance, and thereafter one more full rotation for each screw.

10. Pump data – 50Hz & 60Hz.

12. Pump cutaway.

13. CE Declaration.

14. Warranty
Comprehensive and global 1-year warranty included in pump sales price
All DanPumps products come with a 1-year warranty that fully complies with legal requirements.
The warranty covers product and material defects which are not the results of normal wear and
tear for a period of 12 months from the date of delivery. The warranty period may not, however,
exceed 30 months from the date of production.
Warranty claims will be rejected in the following situations:
•If the defect in the product arises from:
- any drawing, design or specification supplied by the customer/purchaser
- Modifications undertaken by the customer/purchaser or athird party without the consent of
DanPumps
•If a defect is caused by:
- normal wear and tear
- inadequate maintenance or faulty repair by unauthorized technician
- failure to observe the operating instructions
- over-loading
- use of any unsuitable material
- the effects of chemical or electrolytic action
- building or assembly work not undertaken by authorized technician
- other reasons beyond DanPumps' control
As a general rule, DanPumps will not accept to pay transportation/replacement/installation costs
for faulty products.
Warranty claims may be submitted by contacting the local DanPumps sales company or the point
of sale.
Benefit:
•Knowledge that DanPumps backs its products with clearly defined warranty terms
•Warranty claims with well-defined contacts and short response time
Nordager 25
DK-6000 Kolding
Denmark Tel. [phone]
www.sonflow.dk