Grundfos DPK Operating instructions

DPK
DPK 0.75 - 22 kW, 50/60 Hz, 1/3~
Service instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Service instructions
Original service instructions
CONTENTS
Page
1. Symbols used in this document
1.1 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The hazard statements are structured in the following way:
1.2 Notes
The symbols and notes below may appear in Grundfos
installation and operating instructions, safety instructions and
service instructions.
1. Symbols used in this document 2
1.1 Hazard statements 2
1.2 Notes 2
2. Identification 3
2.1 Nameplate 3
2.2 Type key 4
3. Tightening torques 5
4. Service tools 6
4.1 Standard tools 6
4.2 Torque tools 6
5. Dismantling 7
5.1 General information 7
5.2 Oil change 7
5.3 Removing impeller and pump housing 8
5.4 Removing shaft seals 9
5.5 Removing bearings 9
5.6 Removing cable 10
5.7 Removing stator 10
6. Assembly 11
6.1 Fitting stator 11
6.2 Fitting cable 11
6.3 Fitting bearings 13
6.4 Fitting shaft seals 13
6.5 Fitting impeller and pump housing 14
7. Fault finding 15
8. Components and material specification 16
8.1 DPK.10.50.075, DPK.10.50.15 and DPK.10.80.22 17
8.2 DPK.15.80.30 18
8.3 DPK.15.80.37, DPK.15.80.55, DPK.15.100.75,
DPK.20.100.110 and DPK.20.100.150 19
8.4 DPK.20.150.190 and DPK.20.150.220 20
8.5 DPK.V.65.80.15.2 and DPK.V.65.80.22.2 21
8.6 DPK.V.80.80.37.2 22
8.7 DPK.V.80.80.55.2 and DPK.V.80.80.75.2 23
8.8 DPK.V.65.80.15.4 and DPK.V.65.80.22.4 24
8.9 DPK.V.80.80.37.4, DPK.V.80.80.55.4 and
DPK.V.80.80.75.4 25
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious personal injury.
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious personal injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate personal injury.
SIGNAL WORD
Description of hazard
Consequence of ignoring the warning.
- Action to avoid the hazard.
Observe these instructions for explosion-proof
products.
A blue or grey circle with a white graphical symbol
indicates that an action must be taken.
A red or grey circle with a diagonal bar, possibly with
a black graphical symbol, indicates that an action
must not be taken or must be stopped.
If these instructions are not observed, it may result in
malfunction or damage to the equipment.
Tips and advice that make the work easier.

English (GB)
3
2. Identification
The nameplate is fitted to the top cover of the pump. Fix the extra
nameplate supplied with the pump at the installation site or keep
it in the cover of this booklet.
2.1 Nameplate
Fig. 1 Nameplate
TM04 4093 1016
Pos. Description
1 Notified body
2 Type designation
3 Product number and serial number
4 Maximum head [m]
5 Enclosure class
6 Maximum installation depth [m]
7 Number of phases
8 Frequency [Hz]
9 Speed [min-1]
10 Weight [kg]
11 Rated voltage [V] Star
12 Rated voltage [V] Delta
13 Insulation class
14 Rated current [A] Star
15 Rated current [A] Delta
16 Motor input power P1 [kW]
17 Motor output power P2 [kW]
18 Power factor
19 Maximum liquid temperature [°C]
20 Maximum flow [l/s]
21 Production code (year/week)
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15
16
17
18
19
20
21
DK-8850 Bjerringbro Denmark
Type
Model
Hmax Qmax Tmax. :
P.c.
m l/s c
P,3,QVXOFODVV&RVĭ
96883812 Made in China
Motor ~ Hz P1/P2 kW
n min
-1
Weight kg A
A
V
V

English (GB)
4
2.2 Type key
* Exception: Code 075 = 0.75 kW.
** Only for 0.75 to 3.7 kW, except for 3.0 kW.
Code Example DPK .V .65 .80 .22 .S .4 .5 0D Z
DPK Drainage pump
[ ]
V
Impeller design
Semi open impeller
Vortex impeller
65 Free passage Maximum solids size [mm]
80 Pump outlet Nominal diameter of pump outlet port [mm]
22 Code for output power, P2 P2* = Code number from type designation / 10 [kW]
-
S
Equipment
Standard
With extra sensor**
2
4
Motor pole no.
2-pole motor
4-pole motor
5
6
Frequency
50 Hz
60 Hz
0D
1D
0E
1E
Voltage and starting method
380-415 V, DOL
380-415 V, Y/D
220-240 V, DOL
220-240 V, Y/D
ZCustom-built variant

English (GB)
5
3. Tightening torques
Position numbers (refer to figures in sections 5. Dismantling and 6. Assembly).
THREAD-EZE, part number SV9997 (0.5 litre).
Gardolube L 6034, part number SV9995 (1 litre).
Rocol 22, part number RM2924 (1 kg).
Pos. Pump type Designation Dimension Torque
[Nm] Lubricant
All All O-rings Rocol
35 DPK Screw 25
60a All Screw 20
88 DPK.V Screw M10 50
M12 75
105b All Socket-head screw 15
178
DPK.10.XX
DPK.15.XX (3.0 kW only) Screw 20
DPK.15-20.XX 25
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 20
DPK.V. others Screw 25
181a
DPK.10.XX
DPK.15.XX (3.0 kW only) Screw 12
DPK.15 -20.XX 25
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 12
DPK.V others Screw 25
182 All Socket-head screw 30
183
DPK.10.XX
DPK.15.XX (3.0 kW only) Screw 30
DPK.15 -20.XX 45
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 30
DPK.V others Screw 45
183b DPK.20.150.XX Screw 45
184
DPK.10.XX Screw 30
DPK.15 -20.XX 45
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 30
DPK.V Screw 45
188
DPK.10.XX
Nut
55
DPK.15.XX (3.0 kW only) 60
DPK.15 -20.XX 70
DPK.V 55
188a
DPK.10.50.XX
Screw
25
DPK.15.XX 45
DPK.20.100.XX 30
DPK.20.150.XX 25
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 25
DPK.V Screw 45
190b DPK.20.150.XX Screw 45
193 All 15

English (GB)
6
4. Service tools
4.1 Standard tools
4.2 Torque tools
ABCD
EFGH
IJK
Pos. Description Further information Part number
AMultigrip pliers SV0150
BRing/open-end spanner
10 mm SV0083
13 mm SV0055
17 mm SV0056
19 mm SV0063
24 mm SV0122
CRatchet handle 96777072
DHexagon socket
17 mm SV0417
19 mm SV0419
24 mm SV0424
30 mm
36 mm
EScrewdriver
FRubber mallet
GAdjustable wrench SV0349
HPuller for bearing SV0335
ICirclip pliers SV2014
Pos. Description Further information Part number
JTorque wrench 9 x 12 mm - 4-20 Nm SV2092
9 x 12 mm - 20-100 Nm SV0269
KRatchet insert tool 9 x 12 mm - 1/2" SV0295

English (GB)
7
5. Dismantling
5.1 General information
If the pump needs to be dismantled, either because it is choked
or damaged, follow the instructions in the following sections.
Parts are signalled by a position number and refer to drawings
and parts lists. Tools are signalled by a letter and refer to section
4. Service tools.
Before dismantling the pump
• Disconnect the power supply to the motor.
• Remove the power cable in accordance with local regulations.
• Be aware of the centre of gravity of the pump in order to
prevent it from overturning.
This is especially important in the case of high pumps.
Before assembly
• Clean and check all parts.
• Replace defective parts by new parts.
• Order the necessary service kits.
• Always replace gaskets and O-rings when the pump is
overhauled.
During assembly
• Lubricate and tighten screws and nuts to correct torque. See
section 3. Tightening torques.
5.2 Oil change
After 3000 operating hours or once a year, change the oil in the
oil chamber as described below.
If the shaft seal has been changed, the oil must be changed as
well.
Fig. 2 Position of oil screw on DPK
1. Place the pump on a plane surface with the oil screw pointing
downwards.
2. Place a container under the pump. The container must be
able to hold the oil of the specific pump. The quantity of oil for
the specific pump appears from the table below.
3. Remove the oil screw (pos. 193 - M12 x 20) and let the oil
drain into the container.
If 20 % of the liquid in the container is water, the shaft seal is
defective and must be replaced. You can see this at once as
water and oil will separate almost immediately.
4. Turn the pump so that the oil filling hole is pointing upwards.
WARNING
Pressurised system
Death or serious personal injury
- When loosening the screws of the oil chamber,
note that pressure may have built up in the
chamber. Do not remove the screws until the
pressure has been fully relieved.
TM07 1898 5118
CAUTION
Biological hazard
Minor or moderate personal injury
- Dispose of used oil in accordance with local
regulations.
If the same shaft seal is still used, the motor will be
damaged within a short time.
Oil screw
pos. 193

English (GB)
8
5. Add the appropriate quantity of oil to the specific pump. See
the table below.
6. Clean the O-ring seats on the pump and on the oil screw
(193).
7. Lubricate and mount a new O-ring (194) on the oil screw.
Lubricate and tighten the oil screw to correct torque. See
section 3. Tightening torques.
5.3 Removing impeller and pump housing
Fig. 3 Removing the impeller and pump housing
1. Drain oil from the oil chamber. See section 5.2 Oil change.
2. Remove the inlet strainer/ring stand (84a).
3. Remove the inlet cover (189).
4. Remove the impeller (49).
5. Remove the key (9a) from the shaft.
6. Remove the pump housing (50).
Pump type No. of poles Shaft power
[kW] Oil capacity [l]
DPK 2-pole
0.75
0.401.5
2.2
3.0
3.7 0.92
5.5
1.92
7.5
11
15
19 2.20
22
DPK.V
2-pole
1.5 0.44
2.2
3.7 0.88
5.5 1.84
7.5
4-pole
1.5 0.80
2.2
3.7
1.825.5
7.5
TM07 3972 0619

English (GB)
9
5.4 Removing shaft seals
Fig. 4 Removing the shaft seal and bearings
1. Drain oil from the oil chamber. See section 5.2 Oil change.
2. Remove the impeller and pump housing. See section
5.3 Removing impeller and pump housing.
3. Remove the stationary shaft seal part (105d) of the shaft seal
(105) from the pump housing (50).
4. Remove the lip seals (46) from the pump housing or cover for
the oil chamber if fitted.
5. Remove rotating parts of the shaft seal (105e and 105g) from
the shaft.
6. Remove the lower bearing bracket (60) and the rotor (172).
7. Remove the cover for bearings (59).
8. Remove the stationary shaft seal part (105f) from the lower
bearing bracket (60).
5.5 Removing bearings
1. Drain oil from the oil chamber. See section 5.2 Oil change.
2. Remove the impeller and pump housing. See section
5.3 Removing impeller and pump housing.
3. Remove the lower bearing bracket (60) and the rotor (172).
4. Remove the cover for bearings (59) from the lower bearing
bracket.
5. Remove the lower bearing (153 and 153a), if mounted, from
the shaft using a puller for bearings (H).
6. Remove the upper bearing (154) from the shaft using a puller
for bearings (H).
TM04 5531 3309
105c
105
105f
105d
105c
105g
105e

English (GB)
10
5.6 Removing cable
Fig. 5 Cable entries
1. Disconnect the power supply to the motor.
2. Remove the top cover (151).
3. Disconnect power and signal conductors from the top cover.
4. Remove the cover for the cable entry (168).
5. Remove the cable (181).
5.7 Removing stator
Fig. 6 Heating up the stator housing in order to remove the
stator
1. Drain oil from the oil chamber. See section 5.2 Oil change.
2. Remove the impeller and pump housing. See section
5.3 Removing impeller and pump housing.
3. Remove the lower bearing bracket (60) and the rotor (172).
4. Remove the cover for bearings (59) from the lower bearing
bracket.
5. Remove the top cover (151).
6. Disconnect power and signal conductors from the top cover.
7. Protect the free conductors from the heat of the stator.
8. Mark the position of stator conductors on the stator housing
for later refitting the stator in the same position.
9. Block up the stator housing in upside-down position as shown
in fig. 6.
10. Slowly heat up the stator housing evenly until the stator drops
out.
TM04 5532 3309
168a 168a
168
TM04 5533 3309
WARNING
Hot surface
Death or serious personal injury
- Make sure not to touch the surface of the stator
housing to avoid burns or personal injury.
Make sure that the stator will not be damaged when
dropping out of the stator housing.