Grundfos DWK O.6.50.15 User manual

DWK
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
To ensure reliable and optimum operation, Grundfos
dewatering pumps, type DWK, are designed with two
types of impeller:
• 0.75 - 15 kW models have semi-open impeller
• 22 and 90 kW models have enclosed impeller.
DWK pumps are used for removal of surface and
underground water in small and medium systems.
DWK pumps can be controlled via the pump
controllers GU01 and GU02. For further information,
see data sheet for GU01/GU02 module at
www.grundfos.com.
1. Symbols used in this document 2
2. General description 2
3. Operating conditions 3
4. Applications 4
5. Safety 4
6. Transportation and storage 4
6.1 Transportation 4
6.2 Storage 5
7. Nameplate 5
8. Approvals 6
9. Type key 6
10. Installation 7
10.1 Free-standing submerged installation 7
11. Electrical connection 8
11.1 Pump controllers 10
11.2 GU01 and GU02 10
11.3 Frequency converter operation 10
12. Startup 11
12.1 Direction of rotation 11
13. Operation 12
14. Maintenance, inspection and overhaul 12
14.1 Maintenance 12
14.2 Inspection 13
14.3 Overhaul 13
15. Fault finding 14
16. Service 15
16.1 Service documentation 15
16.2 Contaminated pumps 15
17. Disposal 15
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
If these instructions are not observed, it
may lead to electric shock with consequent
risk of serious personal injury or death.
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.

English (GB)
3
3. Operating conditions
The DWK pump range is suitable for two operating
modes:
• continuous, submerged operation, S1, with
minimum liquid level above the pump
• intermittent operation, S3, with the pump partly
submerged. See fig. 1.
Fig. 1 Liquid level
pH value
DWK pumps in permanent installations can cope
with pH values ranging from 4 to 10.
Liquid temperature
0 to 40 °C.
Density of pumped liquid
Maximum 1000 kg/m3.
In the case of higher values, contact Grundfos.
Installation depth
Maximum 25 metres below liquid level.
Operating pattern
DWK.O: Maximum 30 starts per hour.
DWK.E: Maximum 18 starts per hour.
Fig. 2 DWK pump
TM04 4142 0909
S1
S3
TM04 4143 0909
Pos. Description
1 Lifting bracket
2 Nameplate
3Motor
4 Oil plug
5 Outlet flange/hose connection
6 Cable entry
7 Top cover
8 Inlet strainer
9 Pump housing

English (GB)
4
4. Applications
DWK pumps are designed for pumping these liquids:
• underground water
• drainage water
• water containing abrasives such as sand and
gravel.
The pumps are ideal for pumping the above liquids
from installations in or near these places:
• construction sites
• tunnels
• quarries
• fish ponds
• basements
• drain water collecting tanks.
5. Safety
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.
6. Transportation and storage
6.1 Transportation
The pump can be transported in a vertical or
horizontal position. Make sure that it cannot roll or
fall over.
Always lift the pump by its lifting bracket, never by
the motor cable or the hose/pipe.
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.
Pump type Weight [kg]
DWK O 6.50.075. 39
DWK O.6.50.15 41
DWK O.6.80.15 41
DWK O.6.50.22 45
DWK O.6.80.22 45
DWK O.10.80.37 80.5
DWK.O.10.100.37 80.5
DWK.O.13.80.55 110
DWK.O.13.100.55 110
DWK.O.13.100.75 156
DWK.O.13.150.75 156
DWK.O.13.100.110 189.5
DWK.O.13.150.110 189.5
DWK.O.13.100.150 194.5
DWK.O.13.150.150 194.5
DWK.E.10.100.220 420
DWK.E.10.150.220 427
DWK.E.10.150.300 452
DWK.E.10.200.300 462
DWK.E.10.150.370 839
DWK.E.10.200.370 841
DWK.E.10.150.450 858
DWK.E.10.200.450 860
DWK.E.10.150.550 920
DWK.E.10.200.550 923
DWK.E.10.200.750 973
DWK.E.10.200.900 1028

English (GB)
5
6.2 Storage
6.2.1 Warehouse storage
• The warehouse must be free from excessive
humidity, corrosive gases, vapours or vibrations
which might damage the pumps.
• Store the pumps in a vertical position on a pallet
or stand to keep the pump off the floor and
facilitate easy removal.
• Coil up the cable, and seal the open end tightly
with waterproof plastic and tape or a cable cap.
Do this to prevent moisture from penetrating into
the motor which will cause severe damage to the
windings.
• Give all unpainted surfaces a light coat of oil or
grease to prevent corrosion.
• If new pumps are stored for more than two
months, turn the impeller by hand every two
months to prevent the mechanical seal faces
from seizing up. Failure to do this may result in
seal damage when the pump is started up again.
6.2.2 Storage in the tank
• If an installed pump is not in operation for a long
time, check the insulation resistance and run the
pump for 30 minutes every month. If the pump
cannot be run due to lack of water in the tank,
inspect the pump and turn the impeller by hand
each month and prior to putting the pump back
into service. If the insulation resistance drops
below 10 megohms, contact Grundfos.
• When the pump is not in service, disconnect the
power supply from the control panel.
• If the pump is disconnected from the control
panel when not in service, protect the cable end
as described in section 6.2.1 Warehouse
storage.
7. Nameplate
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.
Fig. 3 Nameplate
TM04 4093 0709
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
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 [m3/h]
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)
6
8. Approvals
The standard version of DWK pumps has been
tested by TÜV, in relation to EC Council Directive 98/
37/EC Machinery, registration no. AM 5014341 3
0001 and report no. 13009106 001.
9. Type key
The pump can be identified by the type designation
stated on the pump nameplate. See section
7. Nameplate.
* Exception: Code 075 = 0.75 kW
Code Example DWK .O .6 .50 .075 .S .5 .0D .R
DWK Dewatering pump
O
E
Semi-open impeller
Enclosed impeller
6
Strainer hole size:
Maximum solids size [mm]
50
Pump outlet:
Nominal diameter of pump outlet port [mm]
075
Code for output power, P2:
P2*: Code number from type designation / 10 [kW]
-
S
Equipment:
Standard
Sensor
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
[ ]
R
Material in pump
Standard
Cast iron pump with high-chrome stainless steel impeller and stainless steel inlet strainer

English (GB)
7
10. Installation
Check these points before beginning installation
procedures:
• 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 during transportation.
Prior to installation, check the oil level in the oil
chamber. See section 14. Maintenance, inspection
and overhaul.
The DWK pumps can be installed with a hose or
pipe.
10.1 Free-standing submerged installation
Pumps for free-standing submerged installation can
stand freely on the bottom of the tank or the like.
Fit a flexible union or coupling to the outlet port in
order to facilitate service on the pump and easy
separation of pump and outlet line.
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 outlet 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, we recommend that you support the
pump on bricks or a similar support.
Installation procedure
1. Lower the pump into the liquid by means of a
chain secured to the lifting bracket of the pump.
We recommend that you place the pump on a
plane, solid foundation. Make sure that the pump
stands securely.
2. 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.
3. 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
cable is not sharply bent or pinched.
4. Connect the motor cable.
Fig. 4 Free-standing pump on strainer
Warning
Observe all safety regulations at the
installation site.
Use blowers for fresh-air supply to the
tank.
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 persons or damage to the pump.
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.
Switch off any external voltage connected
to the pump before working on the pump.
Caution
The pumps are designed for operation in
vertical position only.
TM04 4144 0909

English (GB)
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11. Electrical connection
The electrical connection must be carried out in
accordance with local regulations.
The supply voltage and frequency are marked on the
pump nameplate. The voltage tolerance must be
within - 5 %/+ 5 % of the rated voltage. Make sure
that the motor is suitable for the power supply
available at the installation site.
All pumps are supplied with 10 m cable and a free
cable end.
Pumps with sensors must be connected to a GU01
or GU02 pump controller. See fig. 5for DOL-
connected pumps or fig. 6for star-delta-connected
pumps. For further information see the installation
and operating instructions for the selected control
box or pump controller at www.grundfos.com.
Warning
Before installation and the first startup of
the pump, check the condition of the cable
visually and measure the cable resistance
to avoid short circuits.
Warning
The pump must be connected to a mains
switch with a minimum contact gap of 3
mm in all poles.
The classification of the installation site
must be approved by the local fire-fighting
authorities in each individual case.
Grundfos control boxes and pump
controllers must not be installed in
potentially explosive environments.
Make sure that all protective equipment
has been connected correctly.

English (GB)
9
Fig. 5 Wiring diagram, DOL starting
Fig. 6 Wiring diagram, star-delta starting
TM04 4096 0709TM04 4097 3316
L1 L2 L3
MCCB
V
AMCCB
MC Md My
THR
GU 01 / GU 02
E
U1 V1 W1 W2 U2 V2
1.M
3 ~
T/P T/P S/S S/S
S/S
F/L
MC
T
TMyMdMC
AUX
THR THR
MC
OL RL GL AUX
6
5
GU01/GU02
6
8
AUX
F/L
E1
E2
E3
GU01/ GU02
10
9
3
21
T/P
S/S
T/P
S/S
11
OP.TR

English (GB)
10
11.1 Pump controllers
The pumps must be connected to a control box with
a motor protection relay with IEC trip class 10 or 15.
The pumps can be controlled by the following LC and
LCD pump controllers:
• LC 107, LCD 107 with air bells
• LC 108, LCD 108 with float switches
• LC 110, LCD 110 with water level electrodes.
LC controllers are for single-pump installations. LCD
controllers are for two-pump installations.
In the following description, “level switch” can be air
bells, float switches or water level electrodes,
depending on the pump controller selected.
The LC controller is fitted with two or three level
switches: One for start and one for stop of pump.
The third level switch, which is optional, is for high-
level alarm.
The LCD controller is fitted with three or four level
switches: One for common stop and two for start of
the pumps. The fourth level switch, which is optional,
is for high-level alarm.
For further information, see the installation and
operating instructions for the pump controller
selected.
Fig. 7 Pump controllers
11.2 GU01 and GU02
GU01 is a monitoring device for monitoring the stator
temperature and water penetration into the motor. It
receives a digital signal.
GU02 is a monitoring device for monitoring stator
and bearing temperature as well as water
penetration into the motor. It receives an analog
signal.
Both monitoring devices must be connected to the
control panel via a relay.
GU01 and GU02 are manufactured for Grundfos. For
further information, please contact your local
Grundfos company.
11.3 Frequency converter operation
11.3.1 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 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.
11.3.2 Possible 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.
TM04 4098 0709
S1
S3
E1 E2 E3
Min.
Max.
Max.
Min.