Grundfos DWK Series Operating instructions

DWK and DPK
DWK 0.75 - 90 kW, 50/60 Hz, 1/3~
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
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
1. Symbols used in this document 2
2. Identification 2
2.1 Nameplate 2
2.2 Type key, DWK 3
2.3 Type key, DPK 3
3. Tightening torques 4
4. Service tools 5
4.1 Standard tools 5
4.2 Torque tools 5
5. Dismantling 6
5.1 General information 6
5.2 Oil change 6
5.3 Removing impeller and pump housing 7
5.4 Removing shaft seals 8
5.5 Removing bearings 8
5.6 Removing cable 9
5.7 Removing stator 9
6. Assembly 10
6.1 Fitting stator 10
6.2 Fitting cable 10
6.3 Fitting bearings 12
6.4 Fitting shaft seals 12
6.5 Fitting impeller and pump housing 13
7. Fault finding 14
8. Components and material specification 15
8.1 DWK.O.6.50.075, DWK.O.6.50.15 and DWK.O.6.50.22 16
8.2 DWK.O.6.80.15, DWK.O.6.80.22, DWK.O.10.80.37
and DWK.O.10.100.37 17
8.3 DWK.O.13.80.55, DWK.O.13.100.55,
DWK.O.13.100.75, DWK.O.13.100.110,
DWK.O.13.100.150 and DWK.O.13.150.150 18
8.4 DWK.E.10.100.220, DWK.E.10.150.220,
DWK.E.10.150.300, DWK.E.10.200.300 19
8.5 DWK.E.10.150.370, DWK.E.10.150.450,
DWK.E.10.200.370, DWK.E.10.200.450,
DWK.E.10.150.550, DWK.E.10.200.550 20
8.6 DWK.E.10.200.750, DWK.E.10.200.900 21
8.7 DPK.10.50.075, DPK.10.50.15 and DPK.10.80.22 22
8.8 DPK.15.80.37, DPK.15.80.55, DPK.15.100.75,
DPK.20.100.110 and DPK.20.100.150 23
8.9 DPK.20.150.190 and DPK.20.150.220 24
8.10 DPK.V.65.80.15.2 and DPK.V.65.80.22.2 25
8.11 DPK.V.80.80.37.2 26
8.12 DPK.V.80.80.55.2 and DPK.V.80.80.75.2 27
8.13 DPK.V.65.80.15.4 and DPK.V.65.80.22.4 28
8.14 DPK.V.80.80.37.4, DPK.V.80.80.55.4 and
DPK.V.80.80.75.4 29
Warning
If these safety instructions are not observed, it may
result in personal injury.
Warning
The surface of the product may be so hot that it may
cause burns or personal injury.
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.
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
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)
3
2.2 Type key, DWK
* Exception: Code 075 = 0.75 kW
2.3 Type key, DPK
* Exception: Code 075 = 0.75 kW.
Example DWK .O .6 .50 075 - .5 0D R
DWK Dewatering pump
O
E
Impeller
Semi-open impeller
Enclosed impeller
6Strainer hole size Maximum solids size [mm]
50 Pump discharge Nominal diameter of pump discharge port [mm]
075 Code for output power, P2 P2* = Code number from type designation / 10 [kW]
-
S
Equipment
Standard
With extra sensor (only for 0.75 to 3.7 kW)
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
Standard
Cast iron pump with high-chrome stainless steel impeller and stainless steel suction strainer
ZCustom built variant
Code Example DPK .V .65 .80 .22 .S .4 .5 0D
DPK Drainage pump
[ ]
V
Impeller design
Semi open impeller
Vortex impeller
65 Free passage Maximum solids size [mm]
80 Pump discharge Nominal diameter of pump discharge port [mm]
22 Code for output power, P2 P2* = Code number from type designation / 10 [kW]
-
S
Equipment
Standard
Sensor(s)
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

English (GB)
4
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 ± 2
DWK 30 ± 2
60a All Screw 20 ± 2
84b DWK Screw 30 ± 2
88 DPK.V Screw M10 50 ± 5
M12 75 ± 5
105b All Socket head screw 15 ± 2
178
DPK.10.XX Screw 20 ± 2
DPK.15-20.XX 25 ± 2
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 20 ± 2
DPK.V. others Screw 25 ± 2
DWK.O.XX.XX.15-37 30 ± 2
181a
DPK.10.XX Screw 12 ± 2
DPK.15 -20.XX 25 ± 2
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 12 ± 2
DPK.V others Screw 25 ± 2
DWK 25 ± 2
182 All Socket head screw 30 ± 2
183
DPK.10.XX Screw 30 ± 2
DPK.15 -20.XX 45 ± 5
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 30 ± 2
DPK.V others Screw 45 ± 2
DWK 45 ± 5
183b DPK.20.150.XX Screw 45 ± 5
DWK.E 30 ± 2
184
DPK.10.XX Screw 30 ± 2
DPK.15 -20.XX 45 ± 5
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 30 ± 2
DPK.V Screw 45 ± 2
DWK 45 ± 5
184b DWK.E Screw 15 ± 2
186 DWK.E Screw 30 ± 2
188
DPK.10.XX
Nut
55 ± 5
DPK.15 -20.XX 70 ± 5
DPK.V 55 ± 5
DWK 70 ± 5
188a
DPK.10.50.XX
Screw
25 ± 2
DPK.15.XX 45 ± 5
DPK.20.100.XX 30 ± 2
DPK.20.150.XX 25 ± 2
DPK.V.65.80.15.2
DPK.V.65.80.22.2 Screw 25 ± 2
DPK.V Screw 45 ± 2
DWK 30 ± 2
190b
DPK.20.150.XX
Screw
45 ± 5
DWK.O.13.XX.55-150 30 ± 2
DWK.E 45 ± 5
193 All 15 ± 2

English (GB)
5
4. Service tools
4.1 Standard tools
4.2 Torque tools
ABCD
EFGH
IJK
Pos. Description For pos. 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 For pos. 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)
6
5. Dismantling
5.1 General information
If the pump needs to be dismantled, either because it is choked
or damaged, please follow the instructions in the following
sections.
Position numbers of parts (digits) refer to drawings and parts lists;
position numbers of tools (letters) 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 DWK-O
1. Place pump on a plane surface with 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 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
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.
TM04 4144 0909
Note
Dispose of used oil in accordance with local
regulations.
Caution
If the same shaft seal is still used, the motor will be
damaged within a short time.
Oil screw
pos. 193

English (GB)
7
5. Add the appropriate quantity of oil to the specific pump. See
table below.
6. Clean the O-ring seats on the pump and on the oil screw (pos.
193).
7. Lubricate and mount a new O-ring (pos. 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 oil chamber. See section 5.2 Oil change.
2. Remove suction strainer/ring stand (pos. 84a).
3. Remove suction cover (pos. 189).
4. Remove impeller (pos. 49).
5. Remove key (pos. 9a) from shaft.
6. Remove pump housing (pos. 50).
Pump type No. of poles Shaft power
[kW] Oil capacity [l]
DWK.O 2 pole
0.75
0.521.5
2.2
3.7 1.04
5.5
2.15
7.5
11
15
DWK.E 2 pole
22 3.00
30
37
6.10
45
55
75
90
DPK 2 pole
0.75
0.401.5
2.2
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
TM04 5530 3309
DWK-O DPK

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

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

English (GB)
10
6. Assembly
6.1 Fitting stator
Fig. 7 Heating up the stator housing prior to fitting the stator
1. Place stator housing in upright position.
2. Protect the free conductors from the heat of the stator.
3. Slowly heat up stator housing evenly to approx. 200 °C.
4. Make sure stator is placed in correct position according to
section 5.7 Removing stator, point 8.
5. Lower stator into the preheated stator housing.
6. Make sure stator reaches the bottom recess in stator housing.
7. Let stator housing cool down by natural cooling.
6.2 Fitting cable
1. Fit cable in top cover (pos. 151).
2. Fit and lubricate O-ring (pos. 37) on top cover (pos. 151). See
section 3. Tightening torques.
3. Connect power and signal conductors to top cover. See figs 8
to 10.
4. Check connection again. See fig. 8.
5. Fit top cover (pos. 151) on stator housing, tighten screws
(pos. 183) according to torques in section 3. Tightening
torques.
6. Fit cable entry (pos. 168), tighten screws (pos. 181a)
according to torques in section 3. Tightening torques.
Fig. 8 Marking of conductors
TM04 5534 3309
Warning
The surface of the stator housing is so hot that it will
cause burns or personal injury if touched.
TM04 5535 3309
UVWG
UV XZ YW G
U X V Y W Z
1 4 2 5 3 6
U V U W V W
0MΩ0MΩ0MΩ0MΩ0MΩ0MΩ
U, Z (1, 6) L
V, X (2, 4) L
W, Y
1
2
3
(3, 5) L
1.U:Red
When checking pumps wired star-delta to DOL, see list
below.
2.V:White
3.W:Black
G:Green
1.U:Red
2.V:White
3.W:Black
6.Z:Red
4.X:White
5.Y:Black
G:Green
UVWG
UV XZ YW G
U X V Y W Z
1 4 2 5 3 6
U V U W V W
0MΩ0MΩ0MΩ0MΩ0MΩ0MΩ
U, Z (1, 6) L
V, X (2, 4) L
W, Y
1
2
3
(3, 5) L
1. U: Red
When checking pumps wired star-delta to DOL, see list
below.
2. V: White
3. W: Black
G: Green
1. U: Red
2. V: White
3. W: Black
6. Z: Red
4. X: White
5. Y: Black
G: Green