Grundfos NK Series User manual

NK, NKG
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 information
NK, NKG are non-self-priming, single stage, centrifugal volute
pumps with axial suction port and radial discharge port.
NK pumps comply with EN 733.
NKG pumps comply with ISO 2858.
3. Receiving the product
3.1 Delivery
The pumps are tested 100 % before leaving the factory. The test
includes a function test where the pump performance is
measured to ensure that the pump meets the requirements of
relevant standards. Test certificates are available from Grundfos.
After the installation, the alignment of pump and motor must be
checked again. See section 7.3 Alignment.
3.2 Transporting the product
Always transport the pump in the specified position. During
transport, the pump must be fastened securely to prevent
damage to the shaft and shaft seal caused by excessive
vibrations and knocks. The pump must not be lifted by the shaft.
1. Symbols used in this document 2
2. General information 2
3. Receiving the product 2
3.1 Delivery 2
3.2 Transporting the product 2
3.3 Handling 3
3.4 Storing the product 3
4. Identification 3
4.1 Nameplate 3
4.2 Type key 4
5. Applications 6
5.1 Pumped liquids 6
6. Operating conditions 7
6.1 Ambient temperature and altitude 7
6.2 Liquid temperature 7
6.3 Maximum operating pressure 7
6.4 Minimum inlet pressure 7
6.5 Maximum inlet pressure 7
6.6 Minimum flow rate 7
6.7 Maximum flow rate 7
6.8 Shaft seals 8
7. Mechanical installation 9
7.1 Pump location 9
7.2 Foundation and grouting of horizontally mounted NK,
NKG pumps with base frame 9
7.3 Alignment 12
7.4 Pipework 15
7.5 Vibration damping 15
7.6 Expansion joints 16
7.7 Stuffing box piping 16
7.8 Bearing bracket 17
7.9 Bearing monitoring 18
7.10 Pressure gauge and mano-vacuum gauge 18
7.11 Ammeter 18
8. Flange forces and torques 19
9. Electrical connection 20
9.1 Motor protection 20
9.2 Frequency converter operation 20
10. Commissioning and startup 20
10.1 General information 20
10.2 Commissioning 20
10.3 Priming 21
10.4 Checking the direction of rotation 21
10.5 Startup 21
10.6 Shaft seal run-in period 22
10.7 Motor start/stop 22
10.8 Reference readings of monitoring equipment 22
11. Maintenance 22
11.1 Pump 22
11.2 Lubrication of bearings in bearing bracket 23
11.3 Monitoring equipment 25
11.4 Motor 25
12. Periods of inactivity and frost protection 25
13. Service 26
13.1 Service kits 26
14. Technical data 26
14.1 Electrical data 26
14.2 Sound pressure level 26
14.3 Belt drive 26
14.4 Operation with combustion engine 26
15. Fault finding 27
16. Disposal 28
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.
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.
Warning
Pay attention to the pump weight, and take
precautions to prevent personal injury if the
pump should topple or fall by accident.

English (GB)
3
3.3 Handling
Lift the pumps by means of nylon straps and shackles.
Fig. 1 Correct lifting of pump
Fig. 2 Incorrect lifting of pump
3.4 Storing the product
The contractor must inspect the equipment on delivery and make
sure that it is stored in such a way that corrosion and damage are
avoided.
If more than six months will pass before the equipment is put into
operation, please consider applying a suitable corrosion inhibitor
to the internal pump parts.
Make sure that the corrosion inhibitor used does not affect the
rubber parts with which it comes into contact.
Make sure that the corrosion inhibitor can be easily removed.
To prevent water, dust, etc. from entering the pump, all openings
must be kept covered until the pipes are fitted. The cost of having
to dismantle the pump during startup to remove foreign objects
can be very high.
4. Identification
4.1 Nameplate
Fig. 3 Example of NKG nameplate
Legend
Warning
Motors from 4 kW and up are supplied with lifting
eyes which must not be used for lifting the entire
pump unit.
TM03 3948 1206TM03 3769 1006
TM05 6007 1215
Pos. Description
1 Type designation
2 Model
3 Rated flow
4 Pressure rating or maximum temperature
5 Country of origin
6 Rated speed
7 Pump head
8 Minimum efficiency index
9Hydraulic pump efficiency at optimum efficiency
point
bar/°C MAX
m /h
3H
Q
p/t
mnmin-1
Model
96145329
Type
Made in Hungary
6
7
1
2
3
4
5
%
DK-8850 Bjerringbro, Denmark
89
0(, p
Ș
NKG 200-150-200/210-170 H2 F 3 N KE O 2926
B 98051910 P2 0512 0001
225.5 2.8 960
25/120 0.70 77.1

English (GB)
4
4.2 Type key
Model B
Example 1, pump design according to EN 733 NK 32 -125 .1 /142 A1 F 1 A E S BAQE
Example 2, pump design according to ISO 2858 NKG 200 -150 -200 /210-170 H2 F 3 N KE O2926
Type range
Nominal diameter of suction port (DN)
Nominal diameter of discharge port (DN)
Nominal impeller diameter [mm]
Reduced performance: .1
Actual impeller diameter [mm]
Code for pump version; the codes may be combined
A1 Basic version, grease-lubricated standard bearing design, standard coupling
A2 Basic version, grease-lubricated standard bearing design, spacer coupling
BOversizemotor
EWithATEX approval, certificate or test report, the second character of the pump version code is an E
G1 Grease-lubricated heavy-duty bearing design, standard coupling
G2 Grease-lubricated heavy-duty bearing design, spacer coupling
H1 Oil-lubricated heavy-duty bearing design, standard coupling
H2 Oil-lubricated heavy-duty bearing design, spacer coupling
I1 Pump without motor, grease-lubricated standard bearing design, standard coupling
I2 Pump without motor, grease-lubricated standard bearing design, spacer coupling
J1 Pump without motor, grease-lubricated heavy-duty bearing design, standard coupling
J2 Pump without motor, grease-lubricated heavy-duty bearing design, spacer coupling
K1 Pump without motor, oil-lubricated heavy-duty bearing design, standard coupling
K2 Pump without motor, oil-lubricated heavy-duty bearing design, spacer coupling
Y1 Bare shaft pump, grease-lubricated standard bearing design
W1 Bare shaft pump, grease-lubricated heavy-duty bearing design
Z1 Bare shaft pump, oil-lubricated heavy-duty bearing design
X Special version; used in case of further customisation than already listed
Pipe connection
E Table E flange
F DIN flange
G ANSI flange
J JIS flange
Flange pressure rating (PN - rated pressure)
1 10 bar
2 16 bar
3 25 bar
4 40 bar
5 Other pressure rating
Materials
Pump housing Impeller Wear ring Shaft
A EN-GJL-250 EN-GJL-200 Bronze/brass 1.4021/1.4034
B EN-GJL-250 Bronze CuSn10 Bronze/brass 1.4021/1.4034
C EN-GJL-250 EN-GJL-200 Bronze/brass 1.4401
D EN-GJL-250 Bronze CuSn10 Bronze/brass 1.4401
E EN-GJL-250 EN-GJL-200 EN-GJL-250 1.4021/1.4034
F EN-GJL-250 Bronze CuSn10 EN-GJL-250 1.4021/1.4034
G EN-GJL-250 EN-GJL-200 EN-GJL-250 1.4401
H EN-GJL-250 Bronze CuSn10 EN-GJL-250 1.4401
I 1.4408 1.4408 1.4517 1.4462
J 1.4408 1.4408 Carbon-graphite-filled
PTFE (Graflon®)1.4462
K 1.4408 1.4408 1.4517 1.4401
L 1.4517 1.4517 1.4517 1.4462
M 1.4408 1.4517 1.4517 1.4401
N 1.4408 1.4408 Carbon-graphite-filled
PTFE (Graflon®)1.4401

English (GB)
5
Example 1 shows an NK 32-125.1 pump with these
characteristics:
Example 2 shows an NKG 200-150-200 pump with these
characteristics:
P 1.4408 1.4517 Carbon-graphite-filled
PTFE (Graflon®)1.4401
R 1.4517 1.4517 Carbon-graphite-filled
PTFE (Graflon®)1.4462
S EN-GJL-250 1.4408 Bronze/brass 1.4401
T EN-GJL-250 1.4517 Bronze/brass 1.4462
U 1.4408 1.4517 1.4517 1.4462
W 1.4408 1.4517 Carbon-graphite-filled
PTFE (Graflon®)1.4462
X Special version
Rubber parts in pump
The first letter indicates material of O-rings for pump cover and seal cover. O-ring for seal cover is only for double seal
arrangements
The second letter indicates material of O-ring for seal housing. O-ring for seal housing is only for double seal arrangements
EEPDM
F FXM (Fluoraz®)
K FFKM (Kalrez®)
M FEPS (PTFE-sheathed silicone O-ring)
VFKM(Viton
®)
XHNBR
Shaft seal arrangement
B Stuffing box
C Cartridge seal, single
D Cartridge seal, double
O Back-to-back, double seal
P Tandem, double seal
S Single seal
Shaft seal(s) in pump
Letter or digit code for mechanical shaft seal and shaft seal rubber parts
4 letters: Single mechanical shaft seal, such as BQQE, or single cartridge seal, such as HBQV
4 digits: Double seal solution; example 2716, where 27 is DQQV, primary seal, and 16 is BQQV, secondary seal;
double cartridge seal; example 5150, where 51 is HQQU, primary seal, and 50 is HBQV, secondary seal
The relation between letters and digits of the shaft seals is described on page 6.
Example 1, pump design according to EN 733 NK 32 -125 .1 /142 A1 F 1 A E S BAQE
Example 2, pump design according to ISO 2858 NKG 200 -150 -200 /210-170 H2 F 3 N KE O2926
• reduced performance
• 142 mm impeller
• grease-lubricated standard bearing design
• standard coupling
• DIN flange to EN 1092-2 pipework connection
• 10 bar flange pressure rating
• cast iron pump housing, EN-GJL-250
• cast iron impeller, EN-GJL-200
• bronze/brass wear ring
• stainless steel shaft, EN 1.4021/1.4034
• EPDM O-ring for pump cover
• single shaft seal arrangement
• BAQE shaft seal
• 210-170 mm conical impeller
• grease-lubricated heavy-duty bearing design
• spacer coupling
• DIN flange to EN 1092-2 pipework connection
• 25 bar flange pressure rating
• stainless steel pump housing, EN 1.4408
• stainless steel impeller, EN 1.4408
• carbon-graphite-filled PTFE (Graflon®) wear ring
• stainless steel shaft, EN 1.4401
• FFKM O-rings for pump cover and seal cover
• EPDM O-ring for seal housing
• back-to-back double shaft seal arrangement
• primary shaft seal: DQQK
• secondary shaft seal: DQQE

English (GB)
6
4.2.1 Codes for shaft seals
The digits are only used for double shaft seal solutions.
4.2.2 Letter codes for shaft seals
For a thorough description of shaft seal types and materials, see
the data booklet "NB, NBG, NK, NKG, NBE, NBGE, NKE, NKGE -
Custom-built pumps according to EN 733 and ISO 2858".
4.2.3 Letter codes for stuffing boxes
For a thorough description of stuffing boxes and materials, see
the data booklet "NB, NBG, NK, NKG, NBE, NBGE, NKE, NKGE -
Custom-built pumps according to EN 733 and ISO 2858".
5. Applications
5.1 Pumped liquids
Clean, thin, non-explosive liquids without solid particles or fibres.
The pumped liquid must not attack the pump materials
chemically.
Digits Letters Description
10 BAQE Single mechanical shaft seal
11 BAQV Single mechanical shaft seal
12 BBQE Single mechanical shaft seal
13 BBQV Single mechanical shaft seal
14 BQBE Single mechanical shaft seal
15 BQQE Single mechanical shaft seal
16 BQQV Single mechanical shaft seal
17 GQQE Single mechanical shaft seal
18 GQQV Single mechanical shaft seal
19 AQAE Single mechanical shaft seal
20 AQAV Single mechanical shaft seal
21 AQQE Single mechanical shaft seal
22 AQQV Single mechanical shaft seal
23 AQQX Single mechanical shaft seal
24 AQQK Single mechanical shaft seal
25 DAQF Single mechanical shaft seal
26 DQQE Single mechanical shaft seal
27 DQQV Single mechanical shaft seal
28 DQQX Single mechanical shaft seal
29 DQQK Single mechanical shaft seal
50 HBQV Cartridge seal
51 HQQU Cartridge seal
52 HAQK Cartridge seal
SNEA Stuffing box
SNEB Stuffing box
SNEC Stuffing box
SNED Stuffing box
SNOA Stuffing box
SNOB Stuffing box
SNOC Stuffing box
SNOD Stuffing box
SNFA Stuffing box
SNFB Stuffing box
SNFC Stuffing box
SNFD Stuffing box
Example: 10 is BAQE B A Q E
Shaft seal type
A O-ring seal with fixed driver
B Rubber bellows seal
D O-ring seal, balanced
GBellows seal, type B, with reduced
seal faces
H Cartridge seal, balanced
Material, rotating seal face
ACarbon, metal-impregnated with antimony
which is not approved for potable water
B Carbon, resin-impregnated
Q Silicon carbide
Material, stationary seat
ACarbon, metal-impregnated with antimony which
is not approved for potable water
B Carbon, resin-impregnated
Q Silicon carbide
Material, secondary seal and other rubber and
composite parts, except the wear ring
EEPDM
VFKM(Viton
®)
F FXM (Fluoraz®)
K FFKM (Kalrez®)
X HNBR
U Dynamic O-rings in FFKM and static O-rings in PTFE
Example: S N E A
Stuffing box type
S Packing type stuffing box
Cooling method
N Uncooled stuffing box
Barrier liquid
E With internal barrier liquid
F With external barrier liquid
O Without barrier liquid
Material
APTFE-impregnated fibre packing rings (Buraflon®) and
EPDM O-rings in the pump housing
BGraphite-PTFE compound packing rings
(Thermoflon®) and EPDM O-ring in the pump housing
CPTFE-impregnated fibre packing rings (Buraflon®) and
FKM O-ring in the pump housing
DGraphite-PTFE compound packing rings
(Thermoflon®) and FKM O-ring in the pump housing
Example: 10 is BAQE B A Q E

English (GB)
7
6. Operating conditions
6.1 Ambient temperature and altitude
The ambient temperature and the installation altitude are
important factors for the motor life as they affect the life of the
bearings and the insulation system.
If the ambient temperature exceeds the recommended maximum
ambient temperature or the installation altitude exceeds the
recommended maximum altitude above sea level, see fig. 4, the
motor must not be fully loaded due to the low density and
consequently low cooling effect of the air. In such cases, it may
be necessary to use a motor with a higher output.
Fig. 4 The maximum motor output depends on the ambient
temperature and altitude
Legend
Example: A pump with a 1.1 kW IE2 MG motor: If this pump is
installed 4750 m above sea level, the motor must not be loaded
more than 88 % of the rated output. At an ambient temperature of
75 °C, the motor must not be loaded more than 78 % of the rated
output. If the pump is installed 4750 m above sea level at an
ambient temperature of 75 °C, the motor must not be loaded
more than 88 % x 78 % equal to 68.6 % of the rated output.
6.2 Liquid temperature
-40 - +140 °C.
The maximum liquid temperature is stated on the pump
nameplate. It depends on the shaft seal chosen.
For EN-GJL-250 cast iron pump housings, local regulations may
not allow liquid temperatures above +120 °C.
6.3 Maximum operating pressure
Fig. 5 Pressures in the pump
The inlet pressure + the pump pressure must be lower than the
maximum operating pressure stated on the pump nameplate.
Operation against a closed discharge valve gives the highest
operating pressure.
6.4 Minimum inlet pressure
Pay attention to the minimum inlet pressure to avoid cavitation.
The risk of cavitation is higher in the following situations:
• The liquid temperature is high.
• The flow rate is considerably higher than the pump's rated flow
rate.
• The pump is operating in an open system with suction lift.
• The liquid is sucked through long pipes.
• The inlet conditions are poor.
• The operating pressure is low.
6.5 Maximum inlet pressure
The inlet pressure + the pump pressure must be lower than the
maximum operating pressure stated on the pump nameplate.
Operation against a closed discharge valve gives the highest
operating pressure.
6.6 Minimum flow rate
The pump must not run against a closed discharge valve as this
will cause an increase in temperature/formation of steam in the
pump. This may cause shaft damage, impeller erosion, short life
of bearings and damage to stuffing boxes or mechanical shaft
seals due to stress or vibration. The continuous flow rate must be
at least 10 % of the rated flow rate. The rated flow rate is stated
on the pump nameplate.
6.7 Maximum flow rate
The maximum flow rate must not be exceeded as otherwise there
is a risk of for instance cavitation and overload.
The minimum and maximum flow rates can be read either from
the performance curve pages in the relevant data booklets or
from a curve for a specific pump when selecting it in Grundfos
Product Center.
Fig. 6 Example from Grundfos Product Center showing
minimum and maximum flow rate
TM04 4914 2209
Pos. Description
1 0.25 - 0.55 kW MG motors
20.75 - 22 kW MG motors, IE2/IE3
0.75 - 450 kW MMG-H motors, IE2
3 0.75 - 462 kW Siemens motors, IE2
TM04 0062 4907
20 25 30 35 40 45 50 55 60 65 70 75 80
50
60
70
80
90
100
[%]
P2
1
2
3
t[°C]
1000 2250 3500 4750 m
Inlet pressure
Pump pressure
Maximum operating pressure, i.e. pressure
above atmospheric pressure
TM05 2444 5111
Minimum flow rate
Maximum flow rate

English (GB)
8
6.8 Shaft seals
Mechanical shaft seals
Stuffing box
The operating range of the seals is described for two main
applications: pumping of water or pumping of coolants.
Seals with a temperature range of 0 °C and up are mainly used for
pumping water, while seals for temperatures below 0 °C are mainly
intended for coolants.
Note: We do not recommend operation at maximum temperature
and maximum pressure at the same time as the seal life will be
reduced and periodical noise will occur.
Shaft seal diameter [mm] 28, 38 48 55 60
d5 [mm] 24, 32 42 48 60
Shaft seal type Seal
faces Rubber Code Temperature
range Max. pressure [bar]
Bellows seal, type B, unbalanced
AQ1EPDM BAQE 0-120 °C 16 16 16 16
AQ1FKM BAQV 0-90 °C 16 16 16 16
BQ1EPDM BBQE 0-120 °C 16 16 16 16
BQ1FKM BBQV 0-90 °C 16 16 16 16
Q1B EPDM BQBE 0-100 °C 16 - - -
Q7Q7EPDM BQQE -25 - +110 °C 16 16 16 16
Q7Q7FKM BQQV -10 - +90 °C 16 16 16 16
Bellow seal, type B, unbalanced
with reduced seal faces
Q1Q1EPDM GQQE -25 - +60 °C 16 16 16 16
Q1Q1FKM GQQV -10 - +60 °C 16 16 16 16
O-ring seal, type A, unbalanced
Q1A EPDM AQAE 0-120 °C 16 16 16 16
Q1A FKM AQAV 0-90 °C 16 16 16 16
Q1Q1EPDM AQQE -25 - +90 °C 16 16 16 16
Q1Q1FKM AQQV -10 - +90 °C 16 16 16 16
Q1Q1HNBR AQQX -15 - +90 °C 16 16 16 16
Q1Q1FFKM AQQK 0-90 °C 16 16 16 16
O-ring seal, type D, balanced
AQ1FXM DAQF 0-140 °C 25 25 25 25
Q6Q6EPDM DQQE -20 - +120 °C 25 25 25 25
Q6Q6FKM DQQV -10 - +90 °C 25 25 25 25
Q6Q6HNBR DQQX -15 - +120 °C 25 25 25 25
Q6Q6FFKM DQQK 0-120 °C 25 25 25 25
Code Temperature range Max. pressure [bar]
Stuffing box without cooling, with internal barrier liquid
Stuffing box without cooling, without barrier liquid
Stuffing box without cooling, with external barrier liquid
SNE
SNO
SNF
-30 - +120 °C 16

English (GB)
9
7. Mechanical installation
7.1 Pump location
The pump must be sited in a well-ventilated, but frost-free
location.
For inspection and repair, allow suitable clearances for pump or
motor removal.
• Pumps fitted with motors up to and including 4 kW require a
0.3 m clearance behind the motor.
• Pumps fitted with motors of 5.5 kW and up require a 0.3 m
clearance behind the motor and at least a 1 m clearance
above the motor to allow the use of lifting equipment.
Fig. 7 Clearance behind the motor
7.2 Foundation and grouting of horizontally mounted
NK, NKG pumps with base frame
We recommend that you install the pump on a plane and rigid
concrete foundation which is heavy enough to provide permanent
support for the entire pump. The foundation must be capable of
absorbing any vibration, normal strain or shock. As a rule of
thumb, the weight of the concrete foundation must be 1.5 times
the weight of the pump.
The foundation must be 100 mm larger than the base frame on all
four sides. See fig. 8.
Fig. 8 Foundation, X equal to minimum 100 mm
The minimum height of the foundation, hf, can then be calculated:
The density, δ, of concrete is usually taken as 2,200 kg/m3.
Place the pump on the foundation, and fasten it. The base frame
must be supported under its entire area. See fig. 9.
Fig. 9 Correct foundation
Fig. 10 Incorrect foundation
Fig. 11 Base frame with pouring holes
It is important to prepare a good foundation prior to the
installation of the pump.
NK, NKG pumps with base frame are always prepared for
grouting.
For NK, NKG pumps with 2-pole motors equal to or bigger than
55 kW, grouting of the base frame is mandatory in order to
prevent vibration energy from the rotating motor and liquid flow to
evolve.
Warning
When pumping hot or cold liquids, make sure that
persons cannot accidentally come into contact
with hot or cold surfaces.
TM05 3727 1612TM03 3771 1206
0.3 m
0.25 - 4 kW
5.5 kW and up
1 m
0.3 m
hf=mpump ×1.5
Lf×Bf×δconcrete
TM03 3950 1206TM03 4324 1206TM03 4587 2206
P2 lower than or
equal to 45 kW P2 equal to or higher than 55 kW
2-pole Grouting optional Grouting mandatory
4-pole Grouting optional
6-pole Grouting optional

English (GB)
10
7.2.1 Procedure
1. Preparing the foundation
2. Levelling of the base frame
3. Preliminary alignment
4. Grouting
5. Final alignment according to section 7.3 Alignment.
1: Preparing the foundation
We recommend the following procedure to ensure a good foundation.
2: Levelling of the base frame
Step Action Illustration
1
Use an approved, non-shrinking concrete. Contact your
concrete supplier for advice if any doubts.
Pour the foundation without interruptions to within 19 to
32 mm of the final level. Use vibrators to ensure that the
concrete is evenly distributed. The top surface must be
well scored and grooved before the concrete sets. This
provides a bonding surface for the grout.
2
Embed foundation bolts in the concrete. Allow enough
bolt length to reach through grout, shims, lower base
frame, nuts and washers.
TM03 0190 4707
3Let the foundation cure for several days before the base
frame is levelled and grouted.
5-10 mm
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Bolt length
above base
frame
Thickness of
base frame
19-32 mm
allowance for
grout
Base frame
Top of foundation
left rough
Pipe sleeve
Lug
Washer
Wedges and
shims left in
place
Step Action Illustration
1
Lift/jack up the base frame to the final level 19-32 mm
above the concrete foundation, and support the base
frame by means of blocks and shims both at the
foundation bolts and midway between bolts.
TM04 0489 0708
2Level the base frame by adding or removing shims under
the base frame.
TM04 0489 0708
3
Tighten the foundation bolt nuts against the base frame.
Make sure the piping can be aligned to the pump flanges
without putting strain on pipes or flanges.