Grundfos Unilift kp 150 User manual

GRUNDFOS INSTRUCTIONS

Unilift KP 150, KP 250, KP 350

Installation and operating instructions

English (US)

English (US) Installation and operating instructions

Original installation and operating

instructions

These installation and operating instructions

describe Grundfos Unilift KP 150, KP 250 and

KP 350.

Sections 1-5 give the information necessary to

be able to unpack, install and start up the

product in a safe way.

Sections 6-10 give important information about

the product, as well as information on service,

fault finding and disposal of the product.

CONTENTS

Page

1. Limited warranty 3

2. General information 3

2.1 Hazard statements 3

2.2 Notes 4

2.3 Overview drawing 4

3. Receiving the product 4

3.1 Inspecting the product 4

3.2 Scope of delivery 4

4. Installing the product 5

4.1 Pipe connection 5

4.2 Minimum space 6

4.3 Location 6

4.4 Adjustment of cable length for a float

switch 7

4.5 Check valve 7

4.6 Electrical connection 7

5. Starting up the product 8

5.1 Starting 8

6. Product introduction 9

6.1 Product description 9

6.2 Applications 9

6.3 Identification 10

6.4 Functions 11

6.5 Pump construction 11

7. Servicing the product 12

7.1 Cleaning the pump 12

7.2 Contaminated pumps 14

7.3 Replacement of parts 14

8. Fault finding the product 15

9. Technical data 17

9.1 Electrical data 17

9.2 Operating conditions 17

9.3 Storage temperature 17

9.4 Sound pressure level 17

10. Disposing of the product 17

Read this document before installing

the product. Installation and operation

must comply with local regulations

and accepted codes of good practice.

Successful operation depends on

careful attention to the procedures

described in this manual. Keep this

manual for future use.

English (US)

1. Limited warranty

Products manufactured by Grundfos Pumps

Corporation (Grundfos) are warranted to the

original user only to be free of defects in

material and workmanship for a period of 24

months from date of installation, but not more

than 30 months from date of manufacture.

Grundfos' liability under this warranty shall be

limited to repairing or replacing at Grundfos'

option, without charge, F.O.B. Grundfos' factory

or authorized service station, any product of

Grundfos manufacture. Grundfos will not be

liable for any costs of removal, installation,

transportation, or any other charges that may

arise in connection with a warranty claim.

Products which are sold, but not manufactured

by Grundfos, are subject to the warranty

provided by the manufacturer of said products

and not by Grundfos' warranty.

Grundfos will not be liable for damage or wear to

products caused by abnormal operating

conditions, accident, abuse, misuse,

unauthorized alteration or repair, or if the

product was not installed in accordance with

Grundfos' printed installation and operating

instructions and accepted codes of good

practice. The warranty does not cover normal

wear and tear.

To obtain service under this warranty, the

defective product must be returned to the

distributor or dealer of Grundfos' products from

which it was purchased together with proof of

purchase and installation date, failure date and

supporting installation data. Unless otherwise

provided, the distributor or dealer will contact

Grundfos or an authorized service station for

instructions. Any defective product to be

returned to Grundfos or a service station must

be sent freight prepaid; documentation

supporting the warranty claim and/or a Return

Material Authorization must be included if so

instructed.

Grundfos will not be liable for any incidental or

consequential damages, losses, or expenses

arising from installation, use, or any other

causes. There are no express or implied

warranties, including merchantability or fitness

for a particular purpose, which extend beyond

those warranties described or referred to above.

Some jurisdictions do not allow the exclusion or

limitation of incidental or consequential

damages and some jurisdictions do not allow

limitations on how long implied warranties may

last. Therefore the above limitations or

exclusions may not apply to you. This warranty

gives you specific legal rights and you may also

have other rights which vary from jurisdiction to

jurisdiction.

Products which are repaired or replaced by

Grundfos or authorized service center under the

provisions of these limited warranty terms will

continue to be covered by Grundfos warranty

only through the remainder of the original

warranty period set forth by the original

purchase date.

2. General information

2.1 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:

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.

English (US)

2.2 Notes

The symbols and notes below may appear in

Grundfos installation and operating instructions,

safety instructions and service instructions.

2.3 Overview drawing

Fig. 1 Unilift KP pump

3. Receiving the product

3.1 Inspecting the product

Check that the product received is in

accordance with the order.

Check that the voltage and frequency of the

product match the voltage and frequency of the

installation site.

3.2 Scope of delivery

The box contains the following items:

• pump

• power cable

• float switch (if included with the model)

• installation and operating instructions.

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.

TM03 4327 2006

Pos. Description

1 Outlet port 1.25" NPT

2 Handle

3Clamp

4 Inlet strainer

5 Pump housing

6 Float switch (optional)

With float switch

CAUTION

Crushing of feet

Minor or moderate personal injury

- Wear safety shoes when handling

the product.

- Use the pump handle to move the

pump. Do not lift it by the power

cable.

English (US)

4. Installing the product

4.1 Pipe connection

Threaded steel or rigid plastic pipes can be

screwed directly into the 1.25" NPT outlet port.

For permanent installation, we recommend that

you fit a union, a check valve and a gate valve in

the outlet pipe.

Other recommendations:

• For portable or temporary installations, a

plastic outlet pipe can be used in conjunction

with a suitable screwed connection or hose

coupling.

• To remove the pump, secure a cable to the

pump handle. Do not remove it by the pipes.

• Threads must be sealed using Teflon®tape.

DANGER

Electric shock

Death or serious personal injury

- The installation, electrical

connection, and maintenance of

the product must be carried out by

an authorized electrician in

accordance with the National

Electrical Code and any state, local

governing codes and regulations.

DANGER

Electric shock

Death or serious personal injury

- Switch off the power supply before

starting any work on the product.

- Make sure that the power supply

cannot be accidentally switched

on.

DANGER

Electric shock

Death or serious personal injury

- Pump installation in a sump pit,

basin or tank must be carried out

by qualified, specially trained

persons in accordance with the

National Electrical Code and any

state, local governing codes and

regulations.

DANGER

Electric shock

Death or serious personal injury

- Route the power cable in a way

that supports it and protects it from

being cut, pinched or damaged.

- If the power cable is cut, pinched,

or damaged, replace it before

using the product.

DANGER

Electric shock

Death or serious personal injury

- Do not remove the power cable

and strain relief.

- Do not connect electrical conduit to

the pump.

WARNING

Moving parts

Minor or moderate personal injury

- Make sure that persons cannot

come into contact with moving

parts.

If the pump is used without a float

switch, use an approved level

controller with a motor protection unit

and set the current rating to match the

nominal current marked on the

product's nameplate.

Do not lift the pump by the power

cable or by the outlet pipe or hose.

If the pump is installed in a well or

tank, lower and lift it by means of a

wire or chain fastened to the pump

handle.

Do not install the pump hanging from

the outlet pipe or hose.

Do not lift the pump by its power

cable. Lower and lift it by means of a

wire or chain fastened to the pump

handle.

English (US)

4.2 Minimum space

When the pump is installed in a permanent

installation with a float switch, and the cable

length is set to the minimum length of at least

2.5 in. (63.5 mm), the minimum dimensions of

the sump pit, basin or tank must be as shown in

fig. 2.

In addition, the sump pit, basin or tank must be

sized according to the relation between the

water flow to the sump pit, basin or tank and the

pump capacity.

Fig. 2 Minimum installation dimensions

4.3 Location

Pumps with or without a float switch can be used

in vertical position with the outlet port uppermost

or in horizontal or tilted position with the outlet

port as the highest point of the pump. See fig. 3.

During operation, the inlet strainer must be

completely covered by the pumped liquid.

Fig. 3 Pump positions

When the pipe or hose has been connected,

place the pump in its operating position.

Position the pump so that the inlet strainer will

not be blocked by sludge, mud or similar

materials.

We recommend that you place the pump on a

solid base. See fig. 4.

Fig. 4 Pump placed on a plate

TM03 4330 2006

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ø 350 mm

400 mm

With float switch

14 in. (356 mm)

16 in. (407 mm)

TM00 1548 0493

TM00 1549 0493

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English (US)

4.4 Adjustment of cable length for a

float switch

The difference in level between start and stop

can be adjusted by changing the free cable

length between the float switch and the pump

handle.

• An increased free cable length will result in

fewer starts and stops and a large difference

in level.

• A reduced free cable length will result in

more frequent starts and stops and a small

difference in level.

The free cable length must be:

• at least 2.5 in. (63.5 mm)

• no more than 6 in. (152 mm)

Fig. 5 Start and stop levels

The start and stop levels vary according to the

cable length.

Manual operation can be achieved in one of two

ways:

• Unplug both the pump and float switch from

the wall socket. Insert the pump plug into the

wall socket.

• Keep the float switch in a high position by

attaching it to the outlet pipe or hose.

4.5 Check valve

Whenever the pump is installed in a permanent

installation with a float switch, a check valve

must be fitted in the outlet pipe or hose.

4.6 Electrical connection

The electrical connection must be carried out in

accordance with local regulations and follow the

National Electrical Code (USA) and the

Canadian Electrical Code. The pump must be

grounded. The operating voltage and frequency

are marked on the nameplate. Make sure that

the motor is suitable for the power supply on

which it will be used.

TM03 4331 2006

Unilift KP start and stop levels

Pump

type

Cable length min.

2.5 in. (63.5 mm)

Cable length max.

6 in. (152 mm)

Start Stop Start Stop

150

250

11.5 in.

(292 mm)

5.5 in.

(140 mm)

12.5 in.

(318 mm)

3.5 in.

(89 mm)

350

12 in.

(305 mm)

6 in.

(152 mm)

13 in.

(330 mm)

4 in.

(102 mm)

••••••••••••••

••••••••••••

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••••••••••

•••••••••••

••••••••••

•••••••••

••••••••

Minimum and maximum cable length

Start

Stop

DANGER

Electric shock

Death or serious personal injury

- Pump installation in a sump pit,

basin or tank must be carried out

by qualified, specially trained

persons in accordance with the

National Electrical Code and any

state, local governing codes and

regulations.

WARNING

Electric shock

Death or serious personal injury

- Connect the product only to a

properly grounded receptacle.

- We recommend that you connect

the pump to an electrical circuit

with a Ground Fault Circuit

Interrupter (GFCI).

WARNING

Electric shock

Death or serious personal injury

- The protective ground of the pump

power plug must be connected to

the protective ground receptacle of

the power outlet.

- The plug must have the same

ground connection system as that

of the power outlet. If not, use a

suitable adapter.

English (US)

Power supply

• 1 x 115 V, 60 Hz

To connect the pump for manual operation,

insert the pump plug into a wall socket. If a float

switch is included for automatic operation, it will

be of the "piggy-back" design. Insert the float-

switch plug into the wall socket, and insert the

pump plug into the back of the float-switch plug.

Fig. 6 Pump and float-switch plugs

Fig. 7 Wiring diagram

Motor protection

The Unilift KP pumps have built-in thermal

overload protection and require no additional

motor protection. If the motor is overloaded, it

stops automatically. When cooled to normal

temperature, the motor starts automatically.

5. Starting up the product

5.1 Starting

Before starting the pump, check that the

following requirements are fulfilled:

• The pump is submerged in liquid. During

normal operation, the inlet strainer of the

pump must be below the surface of the

liquid.

• The pump is placed on a base so that the

inlet strainer is not blocked by sludge, mud

or similar materials.

• The pipe or hose connection is tight.

• The outlet pipe is open, that is the hose is

not bent, etc.

• The pump is connected to the power supply

in accordance with the instructions.

• For pumps with a float switch, check that the

float switch will allow the pump to pump

down to the chosen level according to fig. 5.

If you want to pump below this level, hold the

float switch in vertical position.

Startup procedure:

Switch on the pump and check:

• that the pump is operating properly

• that water is being pumped.

TM03 4461 2106

TM06 9144 1717

115 V outlet

Float-switch plug

("Piggy-back") Pump plug

Power cable leads

Motor connections

Brown Black

Yellow/green

Green

Blue White

DANGER

Moving parts

Death or serious personal injury

- Do not touch the inside of the

pump while the pump is running.

- The inlet strainer must always be

fitted to the pump during operation.

English (US)

6. Product introduction

6.1 Product description

The Grundfos Unilift KP 150, KP 250 and KP

350 pumps are single-stage, submersible pumps

designed for pumping grey water, that is, the

wastewater from showers, sinks, washing

machines, etc.

The pump is capable of pumping water which

contains a limited quantity of spherical solids up

to 0.39 in. (10 mm) in diameter without being

blocked or damaged.

The product is designed for automatic operation

with a float switch or for manual operation.

The product can be installed in a permanent

installation or used as a portable pump.

6.2 Applications

Incorrect use of the product, for example

resulting in blockage or wear of the pump, will

void the pump's warranty. Note that the pump is

not suitable for these liquids:

• sewage

• liquids containing long fibers

• flammable liquids (oil, gasoline, etc.)

• aggressive liquids

• liquids containing solids exceeding the

pump's recommended maximum particle

size of 0.39 in. (10 mm).

Pumping of particles exceeding maximum

particle size for the pump may block or damage

the pump.

The pump contains approximately 70 ml of non-

poisonous motor liquid that may pollute the

pumped liquid if the pump should leak.

The pump is suitable for the following

applications.

Check the regional or local EX-approval requirements for surface water at gas stations and in parking

areas.

Note: Unilift KP does not have any explosion-proof approval. See the Grundfos SL range.

This pump has been evaluated for

use with water, grey wastewater and

heated wastewater.

DANGER

Electric shock

Death or serious personal injury

- Do not use the pumps in or at

swimming pools, garden ponds,

etc. when there are persons in the

water.

If the pump has been used for very

dirty or chlorinated water, flush the

pump thoroughly with clean water

after use.

Wear gloves and other suitable

personal protective equipment in

accordance with local regulations.

Observe local regulations on any

exposure to wastewater.

The product is not designed for

pumping stones and similar materials

Applications KP 150 KP 250 KP 350

Drainage of basements or buildings prone to flooding. ●●●

Pumping of wastewater from washing machines, sinks, baths,

showers, etc., up to the sewer level. ●●●

Dewatering of sites or pumping of water for fountains. ●●●

Pumping in draining wells. ●●●

Emptying of swimming pools, ponds, tanks, or fountains. ●●●

English (US)

6.3 Identification

6.3.1 Nameplate

Fig. 8 Nameplate information, located on the top of the pump

TM06 9736 3117

Company code

Year

Week

Weekly production number

Serial no.

Pos. Nameplate text Description

1Type See6.3.2 Type key

2 Voltage Voltage (-/+ 5 %) [V]

3 Frequency [Hz]

2Power output [Hp]

5 Ins. cl. Insulation class

6 XXX A Maximum current [A]

7 Serial no. Serial number showing company code, year, week and

weekly production number

8 Tmax Maximum liquid temperature [°F]

9Qmax Maximum flow rate

[gal/min]

10 Hmax Maximum head [ft]

11 Maximum

installation depth [ft]

English (US)

6.3.2 Type key 6.4 Functions

Pump with float switch

The float switch enables automatic start and

stop of the pump according to the water level.

Pump without float switch

A pump without a float switch requires manual.

external start and stop.

6.5 Pump construction

Fig. 9 Pump components

Code Example Unilift KP 150 A 1

Type range

Rated motor output, P2[W]

150

250

350

Level control

SIntegrated, electronic sensor,

automatic operation

A Float switch, automatic operation

M No level switch, manual operation

Motor

1 Single-phase

3 Three-phase

TM03 4328 2006

Power

cable

Impeller

Nut

Gasket

Pump

housing

Strainer

English (US)

7. Servicing the product

Under normal operating conditions, the pump is

maintenance-free.

If the pump has been used for liquids other than

clean water, it must be flushed through with

clean water immediately after use. See section

7.1 Cleaning the pump.

7.1 Cleaning the pump

If the pump does not deliver a sufficient quantity

of water because of sediment, dismantle and

clean the pump.

To dismantle the pump, follow this procedure:

1. Disconnect the power supply.

2. Allow the pump to drain.

3. Carefully loosen the inlet strainer by

inserting a screwdriver in the recess

between the pump housing and the strainer.

Use the screwdriver to push apart the outer

casing and the strainer. Repeat the

procedure, working around the pump, until

the strainer is free and can be removed. See

fig. 10.

Fig. 10 Loosening the strainer

4. Remove the inlet strainer, clean, and refit it.

DANGER

Electric shock

Death or serious personal injury

- Switch off the power supply before

starting any work on the product.

Make sure that the power supply

cannot be accidentally switched

on.

CAUTION

Biological hazard

Minor or moderate personal injury

- Before carrying out maintenance

and service, flush the pump

thoroughly with clean water.

- After dismantling the pump, rinse

the pump parts in clean water.

CAUTION

Sharp element

Minor or moderate personal injury

- Wear protective gloves.

- Never touch the inside of the pump

while the pump is running.

CAUTION

Biological hazard

Minor or moderate personal injury

- If a pump has been used for a

liquid which is injurious to health or

toxic, the pump will be classified as

contaminated.

Service must be carried out by

specially trained persons.

Furthermore, all rules and regulations

covering safety, health and

environment must be observed.

TM03 4329 2006

English (US)

If the pump still does not deliver a sufficient

quantity of water, dismantle the pump as follows:

1. Disconnect the power supply.

2. Turn the pump housing 90 °

counterclockwise using a screwdriver. See

the arrow on the pump housing. Pull off the

housing. See fig. 11.

Fig. 11 Removing the inlet strainer from the

pump housing

3. Clean and flush the pump with water to

remove possible impurities between the

motor and the outer pump housing. Clean

the impeller. See fig. 12.

Fig. 12 Cleaning the impeller

4. Check that the impeller can rotate freely. If

not, remove the impeller:

– Loosen and remove the nut on the motor

shaft (13 mm). Use a screwdriver to

prevent the impeller from rotating. See fig.

13.

– Clean the impeller and the area around the

shaft.

Fig. 13 Removing the impeller

5. Check the impeller, the pump housing and

the sealing part. Replace possible defective

parts.

6. Assemble the pump in reverse order of

dismantling.

TM03 1168 1205

TM03 1169 1205

Pump housing

TM03 1170 1205

Check before and when fitting the

pump housing that the sealing part is

positioned correctly, see fig. 14.

Moisten the sealing part with water to

facilitate the fitting.

English (US)

7.2 Contaminated pumps

Any application for service must include details

about the pumped liquid.

The product will be classified as contaminated if

it has been used for a liquid which is injurious to

health or toxic.

If you request Grundfos to service the product,

contact Grundfos with details about the pumped

liquid before returning the product for service.

Otherwise Grundfos can refuse to accept the

product for service.

Any application for service must include details

about the pumped liquid.

Clean the product in the best possible way

before you return it.

Costs of returning the product are to be paid by

the customer.

7.3 Replacement of parts

The impeller assembly and power cable can be

replaced. The part numbers and the

components included in the service kits are

found in Grundfos Product Center at

www.grundfos.us. Alternatively, contact your

local Grundfos dealer or service center.

Fig. 14 Pump components

CAUTION

Biological hazard

Minor or moderate personal injury

- Flush the pump thoroughly with

clean water and rinse the pump

parts in water after dismantling.

TM03 4328 2006

Power

cable

Impeller

Nut

Gasket

Pump

housing

Strainer

English (US)

8. Fault finding the product

DANGER

Electric shock

Death or serious personal injury

- Switch off the power supply before

starting any work on the product.

Make sure that the power supply

cannot be accidentally switched

on.

Fault Cause Remedy

1. The motor does

not start.

a) No power supply. Connect the power supply.

b) The motor is switched off by the

float switch. Adjust or replace the float switch.

c) The fuses are blown. Replace the fuses.

d) The motor protection or thermal

relay has tripped.

Wait until the motor protection

trips in again or reset the relay.

e) The impeller is blocked by

impurities.

Clean the impeller.

See section 7.1 Cleaning the

pump.

f) There is a short circuit in the cable

or motor. Replace the defective part.

2. The motor

protection or

thermal relay

trips after a short

time of operation.

a) The temperature of the pumped

liquid is too high.

Contact your Grundfos

representative.

b) The impeller is blocked or partly

blocked by impurities.

Clean the impeller.

See section 7.1 Cleaning the

pump.

c) Phase failure. Consult an electrician.

d) The voltage is too low. Consult an electrician.

e) The overload setting of the motor-

protective circuit breaker is set too

low.

Adjust the setting.

3. The pump runs

constantly or

gives insufficient

water.

a) The pump is partly blocked by

impurities.

Clean the pump. See section

7.1 Cleaning the pump.

b) The outlet pipe or valve is partly

blocked by impurities. Clean the outlet pipe or valve.

c) The impeller is not properly fixed to

the shaft. Tighten the impeller.

d) The float switch is set incorrectly. Adjust the float switch setting.

e) The pump is too small for the

application. Replace the pump.

f) The impeller is worn. Replace the impeller.

English (US)

4. The pump runs

but gives no

water.

a) The pump is blocked by impurities. Clean the pump. See section

7.1 Cleaning the pump.

b) The outlet pipe or check valve is

blocked by impurities.

Clean the outlet pipe or the check

valve.

c) The impeller is not properly fixed to

the shaft. Tighten the impeller.

d) Air is trapped in the pump. Vent the pump and the outlet

pipe.

e) The liquid level is too low. The inlet

strainer is not completely

submerged in the pumped liquid.

Submerge the pump’s inlet

strainer in the liquid or adjust the

float switch.

f) Pumps with float switch: The float

switch does not move freely.

Adjust the float switch cable. See

section 4.4 Adjustment of cable

length for a float switch.

Fault Cause Remedy

English (US)

9. Technical data

The pump can run continuously. Make sure the

inlet strainer is covered by the pumped liquid.

See the nameplate on the pump for the electrical

and hydraulic performance data.

9.1 Electrical data

Enclosure class

IP68.

Insulation class

9.2 Operating conditions

Liquid temperature

Minimum 32 °F (0 °C).

The maximum liquid temperature depends on

the rated voltage of the pump according to the

table:

* At intervals of at least 30 minutes, the pump

can run for 2 minutes with a liquid

temperature of 158 °F (70 °C).

Minimum water level

The water level must be above the inlet strainer.

Maximum installation depth

30 ft (9.1 m) below the liquid level.

pH value

Between 4 and 9.

Maximum particle size

0.39 in. (10 mm).

Density

146.88 ounce/gallon (8.24 gram/liter)

Viscosity

Close to the viscosity of water or 1 cSt (1 mm2/s)

at 68 °F (20 °C).

9.3 Storage temperature

Minimum -4 °F (-20 °C).

9.4 Sound pressure level

The sound pressure level of the pump is lower

than the limiting values stated in the EC Council

Directive 98/37/EC relating to machinery.

A-weighted sound pressure level

< 65 dB(A) in accordance with ISO 3743.

For further technical data, see section

6.3 Identification and 6.3.2 Type key.

10. Disposing of the product

This product or parts of it must be disposed of in

an environmentally sound way:

1. Use the public or private waste collection

service.

2. If this is not possible, contact the nearest

Grundfos company or service workshop.

Voltage Maximum liquid

temperature

1 x 115 V, 60 Hz

KP 150, KP 250

122 °F (50 °C)*

KP 350

113 °F (45 °C)*

Grundfos companies

GRUNDFOS Kansas City

17100 West 118th Terrace

Olathe, Kansas 66061

Phone: (913) 227-3400

Fax: (913) 227-3500

www.grundfos.us

GRUNDFOS Canada

2941 Brighton Road

Oakville, Ontario L6H 6C9 Canada

Phone: +1-905 829 9533

Telefax: +1-905 829 9512

www.grundfos.ca

GRUNDFOS México

Boulevard TLC No. 15

Parque Industrial Stiva Aeropuerto

C.P. 66600 Apodaca, N.L. México

Phone: 011-52-81-8144 4000

Fax: 011-52-81-8144 4010

www.grundfos.mx

96637677 0118

ECM: 1207317

www.grundfos.com

The name Grundfos, the Grundfos logo, and be think innovate are registered trademarks

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