Grundfos S Series User manual

S pumps, ranges 72-74-78
S2, S3, S4, ST
55-520 kW
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions describe Grundfos S
wastewater pumps, ranges 72, 74 and 78.
Sections 1-5 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 6-11 give important information about the product, as
well as information on service, fault finding and disposal of the
product.
CONTENTS
Page
1. General information
1.1 Target groups
These installation and operating instructions are intended for
professional installers.
1.2 Hazard statements
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
The text accompanying the three hazard symbols DANGER,
WARNING and CAUTION is structured in the following way:
1.3 Notes
The symbols and hazard statements below may appear in
Grundfos installation and operating instructions, safety
instructions and service instructions.
1. General information 2
1.1 Target groups 2
1.2 Hazard statements 2
1.3 Notes 2
2. Receiving the product 3
3. Installing the product 3
3.1 Mechanical installation 4
3.2 Electrical connection 9
3.3 Frequency converter operation 11
4. Starting up the product 11
4.1 Preparations for starting up 12
4.2 Checking the direction of rotation 13
4.3 Start up 13
5. Handling and storing the product 14
5.1 Handling the product 14
5.2 Storing the product 14
6. Product introduction 14
6.1 Product description 14
6.2 Applications 14
6.3 Pumped liquids 15
6.4 Potentially explosive environments 15
6.5 Identification 16
6.6 Installation types 19
7. Protection and control functions 20
7.1 Motor protection devices 20
7.2 Pump controller 20
7.3 IO 113 20
7.4 SM 113, optional 21
7.5 Switches and sensors 21
7.6 WIO sensor 22
8. Servicing and maintaining the product 22
8.1 Safety instructions and requirements 22
8.2 Maintenance schedule 23
8.3 Oil check and oil change 23
8.4 Inspection and adjustment of impeller clearance 24
8.5 Pump cleaning and visual inspection 26
8.6 Power cables 26
8.7 Spare parts 26
8.8 Contaminated pumps and service 26
9. Fault finding the product 27
10. Technical data 29
10.1 Operating conditions 29
10.2 Electrical data 30
10.3 Dimensions and weights 30
11. Disposing of the product 31
Read this document before installing the product.
Installation and operation must comply with local
regulations and accepted codes of good practice.
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)
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2. Receiving the product
The pump is supplied from factory on a steel transportation stand
in horizontal position. Pump and stand are protected by a special
cover.
Fig. 1 Covered pump on transportation stand
3. Installing the product
S pumps are designed for various installation types. See section
6.6 Installation types.
For safety reasons, all work in pits must be supervised by a
person outside the pit.
Pits for submersible sewage and wastewater pumps contain
sewage and wastewater with toxic and/or disease-causing
substances. Therefore, 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.
The rated capacity of the lifting equipment is stated on the
equipment nameplate. The weight of the pump is stated on the
pump nameplate.
TM03 3069 4809
We recommend that you keep the transportation
stand in storage for later use.
We recommend that you keep the cable end
protectors in storage for later use.
Pump installation in pits must be carried out by
specially trained persons.
Work in or near pits must be carried out according to
local regulations.
DANGER
Electric shock
Death or serious personal injury
- It must be possible to lock the main switch in
position 0. Type and requirements as specified in
EN 60204-1.
Persons must not enter the installation area when the
atmosphere is explosive.
DANGER
Overhead load
Death or serious personal injury
- Never work under a pump when it is hanging from
a crane.
WARNING
Crushing hazard
Death or serious personal injury
- Make sure the rated capacity of the lifting
equipment, incl. the lifting chain, is adequate for
the lifting work.
CAUTION
Hot surface
Minor or moderate personal injury
- Do not touch the pump or cables during operation
because the surface temperature may exceed
70 °C.

English (GB)
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3.1 Mechanical installation
Fix the extra nameplate supplied with the pump at the installation
site.
Observe all safety regulations at the installation site, for instance
the use of blowers for fresh-air supply to the pit.
Prior to installation, check the oil level in the oil chamber. See
section 8.3 Oil check and oil change.
3.1.1 Lifting the pump
S pumps weigh up to 8100 kg without accessories.
It is therefore very important to use the right lifting equipment.
The pump weight is stated on the pump nameplate.
See sections 6.5.2 Nameplate and 10.3 Dimensions and weights.
Lifting the pump by the power cables may result in electric short
circuit and risk of electric shock when the pump is connected to
the mains. The cables and cable entries may be damaged,
leading to loss of watertightness and consequent severe damage
to the motor.
If the pump is tilted more than 10 ° in any direction from its normal
position (EN 809, 5.2.1.4), the pump may lose its stability.
Lifting points
Fig. 2 Lifting points on pump, range 72
Fig. 3 Lifting points on pumps, range 74 and 78
The design of the lifting bracket may be different from the one in
the drawing. It does not affect the handling of the product,
however.
DANGER
Electric shock
Death or serious personal injury
- Before beginning the installation, switch off the
power supply and lock the main switch in position
0.
- Before working on the pump, switch off any
external voltage connected to the pump.
DANGER
Crushing
Death or serious personal injury
- During installation, always support the pump by
means of lifting chains or place it in horizontal
position to secure stability.
CAUTION
Crushing of hands
Minor or moderate personal injury
- Do not put your hands or any tool into the pump
inlet or outlet port after the pump has been
connected to the power supply, unless the main
switch has been locked in the 0-position.
- Make sure that the power supply cannot be
accidentally switched on.
We recommend that you always use Grundfos
accessories to ensure correct functioning.
If the installation has to be tested at a pressure
higher than 1.3 times maximum pump head, isolate
the pump from the installation before the test to avoid
damage to the pump.
We recommend that you always use CE marked
lifting equipment.
DANGER
Crushing hazard
Death or serious personal injury
- Always check the lifting bracket and chain for
corrosion or wear before lifting.
- Always lift the pump by the marked lifting points or
by means of a fork-lift truck.
DANGER
Crushing hazard
Death or serious personal injury
- Make sure the centre of gravity is between the
fork-lift arms when lifting the pump.
The approximate centre of gravity is marked with a
label attached to the transportation stand.
DANGER
Electric shock
Death or serious personal injury
- Never lift the pump by the power cables.
TM03 4459 0208TM04 6068 4809
Always lift installation type ST pumps by the lifting
bracket to make sure the pump is in balance.

English (GB)
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3.1.2 Raising pump to upright position
Carelessness during lifting or transportation may cause injury to
persons or damage to the pump.
Fig. 4 Raising the pump to upright position, step 1
Fig. 5 Raising the pump to upright position, step 2
Fig. 6 Raising the pump to upright position, step 3
3.1.3 Lowering the pump onto auto coupling
The pump can easily be pulled out of and lowered into the pit by
means of the guide rails. The stop level is lower for installation
type C than for installation type S. See fig. 16.
Fig. 7 Upper guide rail bracket
Fig. 8 Intermediate guide rail bracket; guide rails longer than
6 m require intermediate guide rail brackets
DANGER
Crushing hazard
Death or serious personal injury
- Make sure that the lifting bracket is tightened
before attempting to lift the pump. Tighten if
necessary.
DANGER
Crushing hazard
Death or serious personal injury
- Do not stand under or next to the pump when
raising it to upright position in order to avoid being
crushed in case the pump overturns.
- Make sure the pump is raised gently into upright
position to avoid the lifting chain slipping off the
crane when the pump is not in balance.
TM03 3034 0208TM03 3035 0208
TM03 3036 0208TM03 3066 0206TM03 3068 0206

English (GB)
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Correct plinth height for installation on auto coupling is important
in order to obtain the best efficiency for the pump.
Fig. 9 Auto-coupling base unit installation on a plinth
The minimum required plinth heights (A) for installation on auto
coupling appear from the following table.
Fig. 10 Lowering the pump onto an auto coupling
TM03 2018 0208
Pump type Minimum plinth height (A) [mm]
Range 72
S2.90.250.xxxx.x.x 375
S2.100.250.xxxx.x.x 375
S2.100.300.xxxx.x.x 400
S3.110.300.xxxx.x.x 400
S3.120.500.xxxx.x.x 425
S3.135.500.xxxx.x.x 425
S3.140.600.xxxx.x.x 425
Range 74
S2.90.xx.xxx.xxxx.x.x 400
S2.100.xxx.xxx.xxxx.x.x 400
S3.110.xxx.xxx.xxxx.x.x 400
S3.120.xxx.xxx.xxxx.x.x 425
S3.135.xxx.xxx.xxxx.x.x 425
Range 78
Pressure class E, L, M, H 425
Pressure class F 0
TM03 3067 0208
Required tilt
angle when the
pump is lowered
onto the auto
coupling: 5 ° ± 5 °

English (GB)
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3.1.4 Submerged installation on auto coupling
Pumps for permanent installation can be installed on a stationary
auto coupling and operated completely or partially submerged in
the pumped liquid.
Before installing the auto-coupling base unit, ensure the quality
and strength of the concrete foundation. See the pull-out
strengths required for anchor bolts at the end of this section. To
ensure adequate pull-out strength, we recommend that you weld
the threaded bushings to the steel reinforcement in the concrete.
1. Drill mounting holes for the guide rail bracket on the inside of
the pit and fasten the guide rail bracket provisionally with two
anchor screws.
2. Place the auto-coupling base unit on the bottom of the pit.
Use a plumb line to establish the correct positioning. Fasten
the auto coupling with anchor bolts. If the bottom of the pit is
uneven, support the auto-coupling base unit so that it is level
when being fastened.
3. Connect the outlet pipe in accordance with the generally
accepted procedures and without exposing the pipe to
distortion or tension. Do not allow loads from the weight of the
pipes to be carried by the auto coupling.
4. Fit the guide rails. An intermediate guide rail bracket is
required if guide rails are more than 6 m long. Place the guide
rails on the auto coupling, then place the guide rail bracket on
the guide rails and fasten the guide rail bracket to the pit wall.
Tighten the anchor bolts.
5. Clean out debris from the pit before lowering the pump into
the pit.
6. Before lowering the pump into the wet pit, check the cables
visually for cuts or ruptures which may have been caused by
rough handling during transportation or installation.
7. Slide the guide claw of the pump between the guide rails and
lower the pump into the pit by means of a certified chain
secured to the lifting bracket of the pump. When the pump
reaches the auto-coupling base unit, the pump will
automatically connect tightly.
8. Hang up the end of the chain on a suitable hook at the top of
the pit and in such a way that the chain cannot come into
contact with the pump.
9. Adjust the length of the power cables, but remember to have
enough cable length to be able to make service on the pump.
Make sure that the cables are not sharply bent or pinched. Fix
the cables at the top of the pit in such a way that no extra
cable slides into the pit.
10. Connect the power cables and the control cable.
Pull-out strengths for anchor bolts
For auto-coupling installations, types S and C, the
guide claw is mounted on the outlet flange from
factory.
Avoid pipe tension at flanges and bolts.
The free end of the cables must not be submerged,
as water may penetrate through the cables into the
motor.
Auto-coupling
base unit Bolts Pull-out strength
[kN]
DN 250 4 x M24 30
DN 300 4 x M24 40
DN 500 6 x M30 40
DN 600 6 x M30 40
DN 800 6 x M30 20
The pull-out strengths stated are without safety
factor. The required safety factor may depend on the
materials and the methods used for anchoring.

English (GB)
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3.1.5 Dry installation
Install pumps in dry installation permanently in a pump room.
The pump motor is enclosed and watertight and will not be
damaged if the installation site is flooded with water.
1. Mark and drill mounting holes in the concrete foundation.
2. Fit the base plate or base stand on the concrete with anchor
bolts. Check the pull-out strengths required for bolts in the
end of this section.
3. Check that the base plate or base stand is horizontal or
vertical.
4. Fasten the pump to the base plate or base stand.
In order to facilitate service on the pump, we recommend that you
fit isolating valves on either side of the pump.
5. Fit the inlet and outlet pipes and isolating valves, if used, and
ensure that the pump is not stressed by the pipes.
6. Adjust the length of the power cables by coiling them up on a
relief fitting to ensure that the cables are not damaged during
operation, but remember to have enough cable length to be
able to service the pump. Fasten the relief fitting to a suitable
hook. Make sure that the cables are not sharply bent or
pinched.
7. Connect the power cables and the control cable according to
the wiring diagrams.
The inlet and outlet pipes are bolted to the pump by means of
flange connections.
Foundation
To ensure minimum vibration levels, all parts of the system must
be sufficiently stiff and firmly anchored:
• The foundation and concrete must be of adequate strength to
support the weight of the pump including accessories, the
weight of the liquid passing through the pump and the forces
generated by the pump.
• As a rule of thumb, the mass of the concrete foundation must
be minimum three to five times the mass of the supported
equipment and must have sufficient rigidity to withstand the
axial, transverse and torsional loads generated by these
machines.
• The foundation must be 15 cm wider than the base plate or
base stand for pumps up to 350 kW and 25 cm wider for larger
pumps.
• The concrete used in the foundation must have a minimum
tensile strength of 250 N/cm2 .
• Always use epoxy grout to fasten the pump base plate to the
foundation.
Pull-out strengths for anchor bolts
Installation type H and D.
For vertical, dry installations, type D, install the pump
on a permanent concrete foundation.
For horizontal, dry installations, type H, the pump is
mounted on a base plate from factory.
We recommend that you use a reducer between the
inlet pipe and the pump in dry installations. In
horizontal installations the reducer must be of the
eccentric type and must be installed so that the
straight edge is pointing upwards. In this way, the
accumulation of air in the inlet pipe is avoided and
the risk of disturbance of operation is eliminated.
Make sure that the pipes are installed without the use
of undue force. Do not allow loads from the weight of
the pipes to be carried by the pump. We recommend
that you use loose flanges to ease the installation
and to avoid pipe tension at flanges and bolts.
Do not use elastic elements or bellows in the pipes;
never use these elements as a means to align the
pipes.
Dry installation Bolts Pull-out strength
[kN]
DN 400
6 x M24 25
DN 500
DN 600
DN 800
The pull-out strengths stated are without safety
factor. The required safety factor may depend on the
materials and the methods used for anchoring.

English (GB)
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3.1.6 Column pipe installation
Install pumps for column pipe installation permanently in a
column pipe. Grundfos does not normally supply the column pipe.
Dimensioning of the column pipes is suggested in the pump
specific dimensional drawings.
1. Fit the seat ring to the bottom of the column pipe.
2. Clean out debris from the pit.
3. Before lowering the pump into the column pipe, check the
cables visually for cuts or ruptures which may have been
caused by rough handling during transportation or installation.
4. Lower the pump into the column pipe by means of a certified
chain secured to the lifting bracket of the pump. The pump will
rest on the conical surface of the seat ring. Normally the
friction between the conical surfaces will prevent the pump
from rotating. As an extra precaution there are three guide
pins on the seat ring which will limit the possible rotation to
maximum 60 °.
5. Hang up the end of the chain above or at the top of the
column pipe in such a way that the chain cannot come into
contact with the pump.
6. Adjust the length of the cables, but remember to have enough
cable length to be able to service the pump. Make sure that
the cables are not sharply bent or pinched. Fix the cables in
such a way that there is no extra slack inside the column pipe.
In the case of long column pipes, it may be necessary to
arrange cable support for the cables inside the column pipe. If
necessary, please contact Grundfos.
7. Connect the power cables and the control cable.
Fig. 11 Column pipe installation, pump type ST
3.2 Electrical connection
Connect the pump to an external main switch ensuring all-pole
disconnection with a contact separation according to EN 60204-1.
It must be possible to lock the main switch in position 0. Type and
requirements as specified in EN 60204-1.
The supply voltage and frequency are marked on the pump
nameplate. Make sure that the motor is suitable for the power
supply available at the installation site.
The pump must be connected to a motor-protective circuit
breaker.
The motor is effectively earthed via the earth conductor of the
power cables and the pipes. The motor top cover for Ex pumps is
equipped with connections for external earthing or an
equipotential bonding conductor.
TM04 6908 1110
72 and 74: 900 mm
78: 1100 mm
All: 400 mm
DANGER
Electric shock
Death or serious personal injury
- Before starting any work on the product, make
sure that the power supply has been switched off
and that it cannot be accidentally switched on.
Carry out the electrical connection in accordance
with local regulations.
Connect the pump to a control box with a motor
protection relay with an IEC trip class 10 or 15.
Connect pumps installed in hazardous locations to a
control box with a motor protection relay with an IEC
trip class 10.
DANGER
Short-circuit
Death or serious personal injury
- For Ex models in dry-installation, version D and H,
connect an external earthing.

English (GB)
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3.2.1 Wiring diagrams
Standard power cables
Fig. 12 Wiring diagram for standard power cables
Sensors
Fig. 13 Wiring diagram for sensors
TM05 5943 4212
V1
U1W1
V2
U2W2
V1
U1
W1
V2
U2
W2
V1
U1
W1
V2
U2
W2
1
2
3
4
5
6
V1
U1
W1
V2
U2
W2
TM05 5947 4212
Oil indicator 4...20 mA
Pt100 in upper bearing
Pt100 in stator
Pt100 in lower bearing
Thermal switches
Thermistors
Moisture switches
Terminal board
connection
The wiring diagrams in custom-built products may be
different from the standard. In this case we
recommend that you contact the nearest Grundfos
company or authorised workshop.