SE1 50, 80, 100 SEV 65, 80, 100

Transcription

1 GRUNDFOS INSTRUCTIONS SE1 50, 80, 100 SEV 65, 80, 100 Installation and operating instructions

2 English (GB) English (GB) Installation and operating instructions Original installation and operating instructions CONTENTS Page 1. Symbols used in this document 2 2. General description Product drawing Control and monitoring Applications Pump selection Operating conditions 4 3. Delivery and handling Transportation Storage 4 4. Identification Nameplate Type key 6 5. Approvals Approval standards Explanation to Ex approval 7 6. Safety Potentially explosive environments 8 7. Installation Submerged installation on auto coupling Free-standing submerged installation on ring stand Dry installation Tightening torques for suction and discharge flanges Electrical connection Wiring diagrams, 7-core cable Wiring diagrams, 10-core cable Pump controllers Thermal switch, PT 1000 and thermistor (PTC) WIO sensor Moisture switch IO IO Frequency converter operation Start-up SE SEV Direction of rotation Maintenance and service Inspection Dismantling the pump Assembling the pump Oil quantities Service kits Contaminated pumps Fault finding chart Sensor check measurements Check measurement using a standard instrument Technical data Disposal Symbols used in this document Caution Note If these safety instructions are not observed, it may result in personal injury. If these instructions are not observed, it may lead to electric shock with consequent risk of serious personal injury or death. These instructions must be observed for explosionproof pumps. We recommend that you also follow these instructions for standard pumps. If these safety instructions are not observed, it may result in malfunction or damage to the equipment. Notes or instructions that make the job easier and ensure safe operation. 2. General description This booklet includes instructions for installation, operation and maintenance of Grundfos SE1 and SEV submersible sewage and wastewater pumps with motors of 1.1 to 11 kw. Grundfos SE1 and SEV sewage and wastewater pumps are designed for pumping domestic, municipal and industrial sewage and wastewater. Two types of pumps are available: SE1 pumps with S-tube impeller SEV pumps with SuperVortex impeller. The pumps can be installed on an auto-coupling system or stand freely on the bottom of a pit. They can even be dry-installed in either vertical or horizontal position. Grundfos SE1 and SEV pumps are designed with an S-tube and SuperVortex impeller, respectively, to ensure reliable and optimum operation. The booklet also includes specific instructions for the explosionproof pumps. Prior to installation, read these installation and operating instructions. Installation and operation must comply with local regulations and accepted codes of good practice. The use of this product requires experience with and knowledge of the product. Persons with reduced physical, sensory or mental capabilities must not use this product, unless they are under supervision or have been instructed in the use of the product by a person responsible for their safety. Children must not use or play with this product. 2

3 2.1 Product drawing Fig SE pump Pos. Description 1 Lifting bracket 2 Nameplate 3 Sleeve 4 Oil screw 5 Discharge flange 6 Discharge 7 Cable plug 8 Top cover 9 Clamp 10 Pump housing 2.2 Control and monitoring The pumps can be controlled via the Grundfos controllers LC, LCD 107, LC, LCD 108, LC, LCD 110 and DC, DCD. Pumps with a sensor are supplied together with an IO 111 or IO 113 which can receive signals from the following transmitters: water-in-oil-sensor (WIO sensor) in the pump moisture sensor in the motor temperature sensor in the stator windings winding resistance sensor in the motor. For further information, see installation and operating instructions for the specific sensor TM Applications SE1 and SEV pumps are designed for pumping these liquids: large quantities of drainage and surface water domestic wastewater with discharge from toilets wastewater with a high content of fibres (SuperVortex impeller) industrial wastewater wastewater with gaseous sludge municipal and commercial sewage and wastewater. SE1 and SEV pumps are ideal for installation in locations such as: public buildings blocks of flats industry garages multi-storey car parks vehicle washing tunnels restaurants. Stainless steel versions Stainless steel versions are further more suitable for the following applications: industrial process water containing chemicals aggressive or corrosive drain water and effluent abrasive particles in wastewater wastewater contaminated with seawater. The compact design makes the pumps suitable for both temporary and permanent installation. 2.4 Pump selection The table below shows which pump version to select for a number of liquids: Impeller type: 1 = S-tube impeller, V = SuperVortex impeller. Pump passage [mm] Pumped liquid Drainage water 1 V 1 / V 1 / V Domestic wastewater without discharge from toilets 1 V 1 / V 1 / V Domestic wastewater with discharge from toilets 1 / V 1 / V Wastewater with a high content of fibres V 1 / V 1 / V Industrial wastewater 1 / V 1 / V Wastewater with gaseous sludge 1 / V 1 / V Municipal wastewater 1 / V 1 / V English (GB) 3

4 English (GB) 2.5 Operating conditions The Grundfos SE1 and SEV pumps are suitable for the following operating situations: Dry installation without separate motor cooling arrangements. Submerged installation S1 operation (continuous operation) ph value SE pumps in permanent installations can cope with the following ph values: Pump type Material variant Installation SE1/SEV Standard 1) Dry and submerged SEV Q 2) Dry and submerged ph value 6.5 to 14 6) 6 to 14 6) SEV S 3) Submerged 5.5 to 14 6) Dry 1 to 14 SEV R 4) Dry and submerged 1 to 14 SEV D 5) Dry and submerged 0 to 14 1) Cast iron impeller, pump housing and motor top. 2) Stainless steel impeller. Cast iron pump housing and motor top. 3) Stainless steel impeller and pump housing. Cast iron motor top. Material variant S is available on request. 4) Entire pump in stainless steel. 5) Stainless steel pump according to EN / Material variant D is available on request. 6) For fluctuating ph values, the range is ph 4 to 14. Liquid temperature 0 C to +40 C. For short periods (maximum 1 hour) a temperature of up to 60 C is permissible (non-ex versions only). Density and viscosity of pumped liquid When pumping liquids with a density and/or a kinematic viscosity higher than that of water, use motors with correspondingly higher outputs. Flow velocity It is advisable to keep a minimum flow velocity to avoid sedimentations in the piping system. Recommended flow velocities: - in vertical pipes: 1.0 m/s - in horizontal pipes: 0.7 m/s Maximum solids size From 50 to 100 mm, depending on pump size. Operating mode Maximum 20 starts per hour. S1, continuous operation. The pump can operate continuously without having to be stopped for cooling. 3. Delivery and handling The pump may be transported and stored in a vertical or horizontal position. Make sure that it cannot roll or fall over. 3.1 Transportation All lifting equipment must be rated for the purpose and checked for damage before any attempts to lift the pump. The lifting equipment rating must under no circumstances be exceeded. The pump weight is stated on the pump nameplate. The polyurethane-embedded plug prevents moisture from penetrating into the motor via the motor cable. Always lift the pump by its lifting bracket or by means of a fork-lift truck if the pump is fixed on a pallet. Never lift the pump by means of the motor cable or the hose/pipe. 3.2 Storage During long periods of storage, the pump must be protected against moisture, heat and cold. Storage temperature: -30 C to +60 C. Explosion-proof pumps must never pump liquids of a temperature higher than +40 C. Ambient temperature For explosion-proof pumps, the ambient temperature on the installation site must be in the range from -20 C to +40 C. For explosion-proof pumps with WIO sensor, the ambient temperature at the installation site must be in the range from 0 C to +40 C. If the pumps are stored for more than one year or it takes a long time before it is put into operation after the installation, the impeller must be turned at least once a month. If the pump has been in use, the oil should be changed before storage. See section Oil change. After a long period of storage, the pump should be inspected before it is put into operation. Make sure that the impeller can rotate freely. Pay special attention to the condition of the shaft seal, O-rings, oil and the cable entry. 4

5 4. Identification 4.1 Nameplate The nameplate states the operating data and approvals applying to the pump. 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. English (GB) CE0344 II2GD KEMA 04ATEX 2201X Ex cd llb T4, T3 Ex ctd A21 T135 C, T200 C Type: SE EX.4.51D P.c Model: XXXXXXXX EN Hmax: 14.4 m Qmax: 25.0 m/ h Tmax: 40 C 20 m Insul.class: F Cosφ : 0.88 Motor: 3 ~ 50Hz V A n: min V 8.2 A P1/P2 4.9/4.0 kw IP68 : 130 kg 0197 Made in Tatabanya Hungary DK-8850 Bjerringbro, Denmark DOP TM Fig. 2 Nameplate Pos. Description 1 Notified body Explosion protection mark, X for special 2 requirements applicable to explosion-proof equipment according to IEC Type designation 4 Product number and serial number 5 Maximum head [m] 6 Enclosure class to IEC Maximum installation depth [m] 8 Number of phases 9 Frequency [Hz] 10 Speed [min -1 ] 11 Motor input power P1 [kw] 12 Motor output power P2 [kw] 13 Country of production 14 Explosion protection classification and certificate number 15 EN approval 16 Maximum flow [m 3 /h] 17 Production code (year/week) 18 Maximum liquid temperature [ C] 19 Insulation class 20 Power factor 21 Rated current 1 22 Rated voltage 1 23 Rated current 2 24 Rated voltage 2 25 without cable 5

6 English (GB) 4.2 Type key The pump can be identified by the type designation stated on the pump nameplate. See section 4.1 Nameplate. Code Example SE A.Ex.4.5 1D B SE Blank Pump type Grundfos sewage/wastewater pumps Material version Standard 1 V Impeller type S-tube impeller SuperVortex (free-flow) impeller Pump passage Maximum solids size [mm] Pump discharge Nominal diameter of pump discharge port [mm] Output power, P2 P2 = Code number from type designation/10 [kw] Blank A Blank Ex Sensor Standard (without sensor) Sensor version Pump version Non-explosion-proof pump (standard) Explosion-proof pump 2 4 Number of poles 2-pole, 3000 min -1, 50 Hz 4-pole, 1500 min -1, 50 Hz Blank Number of phases Three-phase motor 5 0B 0D 1D 0E 1E Frequency 50 Hz Voltage and starting method V, DOL V, DOL V, Y/D V, DOL V, Y/D Blank A B Blank Q R S D Generation First generation Second generation Third generation etc. The generation code distinguishes between structurally different pumps with the same power rating Pump materials Cast iron impeller, pump housing and motor top according to EN-GJL-200/250. Stainless steel impeller according to EN , cast iron pump housing and motor top according to EN-GJL-250. Entire pump in stainless steel according to EN Stainless steel pump housing, impeller and intermediate flange (according to EN ) and cast iron motor top according to EN-GJL-250 (available on request). Stainless steel pump according to EN / (available on request). 6

7 5. Approvals The standard versions of SE1, SEV pumps have been tested by VDE, and the explosion-proof versions approved by KEMA according to the ATEX directive. 5.1 Approval standards The standard variants are approved by LGA (notified body under the Construction Products Directive) according to EN or EN as specified on the pump nameplate. English (GB) 5.2 Explanation to Ex approval The SE1 and SEV pumps have the following explosion protection classifications: CE 0344 II2 GD Ex c d IIB T4, T3 Ex c td A21 IP68 T135 C,T200 C X CE 0344 II 2 GD Ex c d mb IIB T4, T3 Ex c td A21 IP68 T135 C,T200 C X Directive/standard Code Description ATEX Harmonized European standard EN CE 0344 = II CE marking of conformity according to the ATEX directive 94/9/EC, Annex X is the number of the notified body which has certified the quality system for ATEX. = Marking of explosion protection. = Equipment group according to the ATEX directive, Annex II, point 2.2, defining the requirements applicable to the equipment in this group Equipment category according to the ATEX directive, Annex II, point 2.2, defining the requirements 2 = applicable to the equipment in this category G = Explosive atmospheres caused by gases, vapours or mists D = Explosive atmospheres caused by dust EN :2006 Ex = The equipment conforms to harmonized European standard c Constructional safety according to EN :2003 and EN :2001 d = Flame-proof enclosure according to EN :2007 mb = Encapsulation according to EN :2004 II = Suitable for use in explosive atmospheres (not mines) B = Classification of gases, see EN :2006, Annex A. Gas group B includes gas group A. T4/T3 = Maximum surface temperature is 135 C/200 C according to EN :2006* td = Protection by enclosure EN :2006 A21 = The zone in which the pump can be used according to EN :2004 IP68 = Enclosure class according to IEC X The letter X in the certificate number indicates that the equipment is subject to special conditions for safe use. The conditions are mentioned in the certificate and the installation and operating instructions. * For motors supplied via a frequency converter, the type of protection is Ex c d IIB T3 and T 200 C Australia Explosion proof variants for Australia are approved as Ex na II T3 according to IEC (corresponding to AS ). Standard Code Description IEC 79-15:1987 Ex = Area classification according to AS na = Non-sparking according to AS :1991, section 3 (IEC 79-15:1987) II = Suitable for use in explosive atmospheres (not mines) T3 = Maximum surface temperature is 200 C The letter X in the certificate number indicates that the equipment is subject to special conditions for X safe use. The conditions are mentioned in the certificate and the installation and operating instructions. 7

8 English (GB) 6. Safety 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. Persons must not enter the installation area when the atmosphere is explosive. It must be possible to lock the mains switch in position 0. Type and requirements as specified in EN , For safety reasons, all work in pits must be supervised by a person outside the pump pit. Note It is advisable to make all maintenance and service jobs when the pump is placed outside the pit. Pits for submersible sewage and wastewater pumps may contain sewage or 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. 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 personnel or damage to the pump. Special conditions for safe use of SE1 and SEV explosion-proof pumps: 1. Make sure the moisture switch and thermal switches are connected in the same circuit but have separate alarm outputs (motor stop) in case of high humidity or high temperature in the motor. 2. Bolts used for replacement must be class A2-70 or better according to EN/ISO Contact the manufacturer for information on the dimensions of the flameproof joints. 4. The level of pumped liquid must be controlled by level switches connected to the motor control circuit. The minimum level depends on the installation type and is specified in these installation and operating instructions. 5. Make sure the permanently attached cable is suitably mechanically protected and terminated in a suitable terminal board placed outside the potentially explosive area. 6. The sewage pumps have an ambient temperature range of -20 C to +40 C and a maximum process temperature +40 C. The minimum ambient temperature for a pump with a water-inoil sensor is 0 C. 7. The thermal protector in the stator windings has a nominal switch temperature of 150 C and must guarantee the disconnection of the power supply; the power supply must be reset manually. 8. The control unit must protect the WIO sensor against the short circuit current of the supply to which it is connected. The maximum current from the control unit must be limited to 350 ma. 6.1 Potentially explosive environments Use explosion-proof pumps for applications in potentially explosive environments. See section 5.2. SE1 and SEV pumps must under no circumstances pump combustible liquids. The classification of the installation site must be approved by the local fire-fighting authorities in each individual case. 7. Installation Caution Prior to installation make sure the pit bottom is even. 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. Any external voltage connected to the pump must be switched off before working on the pump. The pump must not run dry. An additional level switch must be installed to ensure that the pump is stopped in case the stop level switch is not operating. Before beginning installation procedures, carry out these checks: 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? Fix the extra nameplate supplied with the pump at the installation site or keep it in the cover of this booklet. All safety regulations must be observed at the installation site, e.g. the use of blowers for fresh-air supply to the pit. Prior to installation, check the oil level in the oil chamber. See section 10. Maintenance and service. 8

9 Caution Do not put your hands or any tool into the pump suction or discharge port after the pump has been connected to the power supply, unless the pump has been switched off by removing the fuses or switching off the mains switch. It must be ensured that the power supply cannot be accidentally switched on. We recommend to always use Grundfos accessories to avoid malfunctions due to incorrect installation. Only use the lifting bracket for lifting the pump. Do not use it to hold the pump when in operation. The SE1, SEV pumps are suitable for different installation types which are described in sections 7.1, 7.2 and 7.3. All pump housings have a cast iron PN 10 discharge flange, size DN 65, DN 80, DN 100 or DN 150 according to EN The pumps are designed for continuous operation, Note both for submerged and dry installation. See section 13. Technical data. Installation types The SE1, SEV pumps are designed for two installation types: Submerged installation - on auto coupling - free-standing on ring stand. Dry installation - vertical on base stand - horizontal with brackets secured to a concrete floor or foundation. When mounted on base stand or brackets, the pump must be installed outside the pit. A suction line must be connected to the pump. A dimensional sketch for each individual installation type can be found at the end of this booklet. 7.1 Submerged installation on auto coupling Pumps for permanent installation can be installed on a stationary auto-coupling guide rail system. The auto-coupling system facilitates maintenance and service as the pump can easily be lifted out of the pit. Proceed as follows: 1. Drill mounting holes for the guide rail bracket on the inside of the pit and fasten the guide rail bracket provisionally with two 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 expansion bolts. If the bottom of the pit is uneven, the auto-coupling base unit must be supported so that it is level when being fastened. 3. Assemble the discharge pipe in accordance with the generally accepted procedures and without exposing the pipe to distortion or tension. 4. Place the guide rails on the auto-coupling base unit and adjust the length of the rails accurately to the guide rail bracket at the top of the pit. 5. Unscrew the provisionally fastened guide rail bracket. Insert the upper guide rail bracket into the guide rails. Fasten the guide rail bracket on the inside of the pit. Note 6. Clean out debris from the pit before lowering the pump into the pit. 7. Fit the guide claw to the discharge port of the pump. 8. Slide the guide claw of the pump between the guide rails and lower the pump into the pit by means of a chain secured to the lifting bracket of the pump. When the pump reaches the autocoupling base unit, the pump will automatically connect tightly. 9. 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 housing. 10. 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 at the top of the pit. Make sure that the cables are not sharply bent or pinched. 11. Connect the motor cable. Note The guide rails must not have any axial play as this would cause noise during pump operation. The free end of the cable must not be submerged, as water may penetrate through the cable into the motor. English (GB) Before beginning installation procedures, make sure that the atmosphere in the pit is not potentially explosive. Caution Caution Make sure that the pipework is installed without the use of undue force. No loads from the pipework weight must be carried by the pump. We recommend the use of loose flanges to ease the installation and to avoid pipe tension at flanges and bolts. Do not use elastic elements or bellows in the pipework; these elements should never be used as a means to align the pipework. TM Fig. 3 Submerged pump on auto coupling 9

10 English (GB) 7.2 Free-standing submerged installation on ring stand Pumps for free-standing submerged installation can stand freely on the bottom of the pit. The pump must be installed on a ring stand. See fig. 4. The ring stand is available as an accessory. In order to facilitate service on the pump, fit a flexible union or coupling to the elbow on the discharge port for easy separation. 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 discharge 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, support the pump on bricks or a similar support. Proceed as follows: 1. Fit a 90 elbow to the pump discharge port and connect the discharge pipe/hose. 2. Lower the pump into the liquid by means of a chain secured to the lifting bracket of the pump. We recommend to place the pump on a plane, solid foundation. Make sure that the pump is hanging from the chain and not the cable. Make sure that the pump is standing securely. 3. 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 housing. 4. 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 at the top of the pit. Make sure that the cable is not sharply bent or pinched. 5. Connect the motor cable. Note The free end of the cable must not be submerged, as water may penetrate through the cable into the motor. 7.3 Dry installation In dry installations, the pump must be installed permanently outside the pit. The motor is totally enclosed and watertight. Consequently, it will not be damaged in case the installation site is flooded. Precautions As the pump is installed outside the pit, make sure that the liquid level in the pit is high enough to ensure sufficient NPSH. Size the suction line according to the length and the desired pump performance. A possible difference in level between the pit and the pump inlet must also be taken into account. Support the pipework so that no strain or other mechanical influences are transmitted to the pump. We recommend to install expansion joints and pipe hangers. See fig. 5. Fig. 5 Horizontal dry installation with brackets Pos. Description 1 Expansion joint 2 Non-return valve 3 Isolating valve 4 Pipe hanger If a reducer is fitted between the suction line and the pump, it must be of the eccentric type. The reducer must be fitted so that the straight edge is upwards to avoid air locks in the suction line. Air in the suction line may cause cavitation. See fig. 5. Install the pump on a separate foundation, e.g. concrete foundation. The weight of the foundation should be approx. 1.5 times the weight of the pump. To prevent vibrations from being transmitted to the building and pipework, we recommend to place the pump on vibration absorbing material. TM TM Fig. 4 Free-standing submerged pump on ring stand 10

11 Proceed as follows: 1. Fit the base stand or brackets to the pump. See dimensional sketches at the end of this booklet. 2. Mark and drill fixing holes in the concrete floor/foundation. 3. Fasten the pump with expansion bolts. 4. Check that the pump stands vertically/horizontally. Use a spirit level 5. Connect the motor cable. Note We recommend to fit an isolating valve on the suction side of the pump and a non-return valve as well as an isolating valve on the discharge side. 6. Install the suction and discharge lines as well as the valves, if any. Make sure that the pump is not stressed by the pipework. 7.4 Tightening torques for suction and discharge flanges Grade 4.6 (5) galvanised steel screws and nuts Discharge and suction DN DC Screw Specified tightening torques rounded off by +/- 5 [Nm] Slightly oiled Well lubricated DN x M DN x M DN x M DN x M English (GB) Grade A2.50 (AISI 304) steel screws and nuts DN DC Screw Specified tightening torques rounded off by +/- 5 [Nm] Slightly oiled Well lubricated TM Discharge and suction DN x M16-60 DN x M16-60 DN x M16-60 DN x M Fig. 6 Vertical dry installation on base stand Caution TM The gasket must be a full face, reinforced paper gasket like Klingersil C4300. If softer gasket material is used, torques must be reconsidered. Fig. 7 Horizontal dry installation with brackets 11

12 English (GB) 8. Electrical connection The supply voltage and frequency are marked on the pump nameplate. The voltage tolerance must be within - 10 %/+ 6 % of the rated voltage. Make sure that the motor is suitable for the power supply available at the installation site. Caution Caution Connect the pump to an external mains switch which ensures all-pole disconnection with a contact separation according to EN , It must be possible to lock the mains switch in position 0. Type and requirements as specified in EN , The electrical connection must be carried out in accordance with local regulations. The pumps must be connected to a control box with a motor protection relay with IEC trip class 10 or 15. Pumps for hazardous locations must be connected to a control box with a motor protection relay with IEC trip class 10. Do not install Grundfos control boxes, pump controllers, Ex barriers and the free end of the power cable in potentially explosive environments. The classification of the installation site must be approved by the local fire-fighting authorities in each individual case. On explosion-proof pumps, make sure that an external earth conductor is connected to the external earth terminal on the pump using a secure cable clamp. Clean the surface of the external earth connection and mount the cable clamp. The cross section of the earth conductor must be at least 4 mm 2, e.g. type H07 V2-K (PVT 90 ) yellow/ green. Make sure that the earth connection is protected from corrosion. Make sure that all protective equipment has been connected correctly. Float switches used in potentially explosive environments must be approved for this application. They must be connected to the Grundfos LC, LCD 108 or DC, DCD pump controller via the intrinsically safe LC-Ex4 barrier to ensure a safe circuit. If the supply cable is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons. Set the motor-protective circuit breaker to the rated current of the pump. The rated current is stated on the pump nameplate. If the pump has an Ex mark on the nameplate, make sure that the pump is connected in accordance with the instructions given in this booklet. All pumps are supplied with 10 m cable and a free cable end, except for pumps for Australia which have 15 m cable. Pumps without sensor must be connected to one of these two controller types: a control box with motor-protective circuit breaker, such as a Grundfos CU 100 control box a Grundfos LC, LCD 107, LC, LCD 108, LC, LCD 110 or DC, DCD pump controller. Pumps with sensor must be connected to a Grundfos IO 111 and one of these two controller types: a control box with motor-protective circuit breaker, such as a Grundfos CU 100 control box a Grundfos LC, LCD 107, LC, LCD 108 LC, LCD 110 or DC, DCD pump controller. Pumps with WIO sensor For safe installation and operation of pumps equipped with a WIO sensor, we recommend to install an RC filter between the power contactor and the pump. Caution Before installation and the first start-up of the pump, check the condition of the cable visually to avoid short circuits. If an RC filter is installed to avoid any kind of transients in the installation, the RC filter must be installed between the power contactor and the pump. Please note that the following aspects may cause problems in case of transients in the power supply system: Motor power: The bigger the motor, the higher the transients. Length of motor cable: Where power and signal conductors are running in parallel close to each other, the risk of transients causing interference between power and signal conductors will increase with the length of the cable. Switchboard layout: Power and signal conductors must be physically separated as much as possible. Close installation can cause interference in case of transients. Supply network "stiffness": If a transformer station is located close to the installation, the supply network may be "stiff" and transient levels will be higher. If combinations of the above aspects are present, it may be necessary to install RC filters for pumps with WIO sensors to protect against transients. Transients can be completely eliminated if soft starters are used. But be aware that soft starters and variable-speed drives have other EMC-related issues that must be taken into consideration. For more information, see section 8.9 Frequency converter operation. Wiring diagrams See fig. 8 for wiring diagrams for 7-core cables or figs. 9 to 11 for wiring diagrams for 10-core cables. For further information see the installation and operating instructions for the selected control box or pump controller. 12

13 8.1 Wiring diagrams, 7-core cable Figure 8 shows the wiring diagrams for SE1, SEV pumps with 7-core cable in three versions, one without sensors and two with WIO sensor and moisture switch. Yellow/green (Not used) English (GB) Fig. 8 Standard version Thermal switches Wiring diagram, 7-core cable, DOL Sensor version Thermal switch, Pt1000, moisture switch and water-in-oil sensor * Pumps from 4 kw and up sold in Australia/New Zealand are fitted with a PTC thermistor. Sensor version Thermal switch, PTC thermistor*, moisture switch and water-in-oil sensor TM Wiring diagrams, 10-core cable Figures 9, 10 and 11 show the wiring diagrams for SE1, SEV pumps with 10-core cable in three versions, one without sensors and two with WIO sensor and moisture switch. Yellow/green (Not used) Fig. 9 Standard version Thermal switches Wiring diagram, 10-core cable, star/delta (Y/D) Sensor version Thermal switch, Pt1000, moisture switch and water-in-oil sensor * Pumps from 4 kw and up sold in Australia/New Zealand are fitted with a PTC thermistor. Sensor version Thermal switch, PTC thermistor*, moisture switch and water-in-oil sensor TM

14 English (GB) Yellow/green (Not used) Standard version Thermal switches Fig. 10 Wiring diagram, 10-core cable, star-connected (Y) Sensor version Thermal switch, Pt1000, moisture switch and water-in-oil sensor * Pumps from 4 kw and up sold in Australia/New Zealand are fitted with a PTC thermistor. Sensor version Thermal switch, PTC thermistor*, moisture switch and water-in-oil sensor TM Yellow/green (Not used) Standard version Thermal switches Sensor version Thermal switch, Pt1000, moisture switch and water-in-oil sensor * Pumps from 4 kw and up sold in Australia/New Zealand are fitted with a PTC thermistor. Fig. 11 Wiring diagram, 10-core cable, delta-connected (D) Sensor version Thermal switch, PTC thermistor*, moisture switch and water-in-oil sensor TM To find out whether the pump is fitted with a thermal switch or a PTC thermistor, measure the motor winding resistance. See table below. Without cable With 10 m cable With 15 m cable Thermal switch < 50 mω < 320 mω < 390 mω PTC thermistor > 100 mω > 370 mω > 440 mω 14

15 8.3 Pump controllers The following LC, LCD, DC and DCD pump controllers are available for level control: LC controllers are for one-pump-installations and LCD controllers are for two-pump installations. LC 107 and LCD 107 with air bells LC 108 and LCD 108 with float switches LC 110 and LCD 110 with electrodes DC for one-pump installations DCD for two-pump installations. In the following description, "level switches" can be air bells, float switches or electrodes, depending on the pump controller selected. LC LCD The LC controller is fitted with two or three level switches: One for start and the other 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. When installing the level switches, observe the following points: To prevent air intake and vibrations install the stop level switch in such a way that the pump is stopped before the liquid level falls below the upper edge of the clamp of the pump. In pits with one pump, install the start level switch in such a way that the pump is started at the required level; however, the pump must always be started before the liquid level reaches the bottom inlet pipe to the pit. In pits with two pumps, the start level switch for pump 2 must start the pump before the liquid level reaches the bottom inlet pipe to the pit, and the start level switch for pump 1 must start this pump correspondingly earlier. If installed, always install the high-level alarm switch about 10 cm above the start level switch; however, the alarm must always be given before the liquid level reaches the bottom inlet pipe to the pit. For further information, see the installation and operating instructions for the pump controller selected. Float switches used in potentially explosive environments must be approved for this application. They must be connected to the Grundfos LC, LCD 108 pump controller via the intrinsically safe LC-Ex4 barrier to ensure a safe circuit. DC DCD The Dedicated Controls system consists of a CU 362 control unit connected to one or two IO 351 modules. An optional IO 111 sensor module can be connected to each pump. The CU 362 is the 'brains' of the system and must be incorporated in all installations. The units in the system can be combined in different ways according to the user s needs. Dedicated Controls controls the pumps by means of power contactors and IO 351 modules. Power contactors, cables and other high-voltage components should be positioned as far away as possible from the control system and the signal cables. Dedicated Controls is operated via a user-friendly control panel on the CU 362 or via a PC. Wireless remote control is available throughout the world, using a PC or mobile phone. Dedicated Controls can be integrated into a user's existing SCADA system. Fig. 12 Start and stop levels Max. Min. Make sure that the effective volume of the pit does not become so low that the number of starts per hour exceeds the maximum permissible number. See section 13. Technical data. TM English (GB) 15

16 English (GB) 8.4 Thermal switch, PT 1000 and thermistor (PTC) All SE1 and SEV pumps have thermal protection incorporated in the stator windings. Pumps without sensor Pumps without sensor have a thermal switch or a PTC thermistor. Via the pump controller safety circuit, the thermal switch will stop the pump by breaking the circuit in case of overtemperature (approx. 150 C). The thermal switch will reclose the circuit after cooling. For pumps equipped with a PTC thermistor, connect the thermistor to either the PTC relay or the I/O module to break the circuit at 150 C. The maximum operating current of the thermal switch is 0.5 A at 500 VAC and cos φ 0.6. The switch must be able to break a coil in the supply circuit. Pumps with sensor Pumps with sensor have either a thermal switch and a Pt1000 sensor or a PTC thermistor in the windings, depending on the installation site. Via the pump controller safety circuit, the thermal switch or the thermistor will stop the pump by breaking the circuit in case of overtemperature (approx. 150 C). The thermal switch or the thermistor will reclose the circuit after cooling. The maximum operating current of both the Pt1000 and the thermistor is 1 ma at 24 VDC. Non-explosion-proof pumps When closing the circuit after cooling, the thermal protection can restart the pump automatically via the controller. Pumps from 4 kw and up sold in Australia/New Zealand are fitted with a PTC thermistor. Explosion-proof pumps The thermal protection of explosion-proof pumps must not restart the pump automatically. This ensures protection against overtemperature in potentially explosive environments. In pumps with sensor this is done by removing the short-circuit between terminals R1 and R2 in the IO 111. See Electrical data in the IO 111 installation and operating instructions. The separate motor-protective circuit breaker/control box must not be installed in potentially explosive environments. 8.5 WIO sensor The WIO sensor measures the water content in the oil and converts the value into an analog current signal. The two sensor conductors are for power supply as well as for carrying the signal to the IO 111 module. The sensor measures the water content from 0 to 20 %. It also sends a signal if the water content is outside the normal range (), or if there is air in the oil chamber (alarm). The sensor is fitted in a stainless steel tube for mechanical protection. Fig. 13 WIO sensor Fitting the WIO sensor Fit the sensor next to one of the shaft seal openings. See fig. 13. The sensor must be tilted into the motor s direction of rotation to ensure that oil is led into the sensor. Make sure that the sensor is submerged in the oil Technical data Input voltage: VDC Output current: ma Power input: 0.6 W Ambient temperature: 0 to 70 C See also the installation and operating instructions for IO 111 at Moisture switch The moisture switch is positioned in the bottom of the motor. If there is moisture in the motor, the switch will break the circuit and send a signal to the IO 111. The moisture switch is non-reversing and must be replaced after use. The moisture switch is connected in series with the thermal switch and connected to the monitoring cable, and it must be connected to the safety circuit of the separate pump controller. See section 8. Electrical connection. TM Caution The motor-protective circuit breaker of the pump controller must include a circuit which automatically disconnects the power supply in case the protective circuit for the pump is opened. 16

17 8.7 IO 111 The IO 111 forms interface between a Grundfos sewage or wastewater pump with analogue and digital sensors and the pump controller. The most important sensor data are indicated on the front panel. One pump can be connected to an IO 111. Together with the sensors, the IO 111 forms a galvanic separation between the motor voltage in the pump and the controller connected. IO 111 can distinguish between two categories of fault: Alarm: The pump stops. The fault is serious, such as too high motor temperature. : The pump does not stop. The fault is not serious, such as too much water in the oil Pos. Symbol Description 6 Stator temperature 7 Stator insulation resistance 8 Water in oil chamber 12 Pump running 13 Moisture in motor English (GB) Fig. 14 IO 111 module Pos. Description 1 Terminal for alarm relay 2 Terminal for analog and digital inputs and outputs 3 Terminal for supply voltage (24 VAC/24 VDC) Potentiometer for setting the limit of stator 4 insulation resistance 5 Terminal for RS T1 T2 Reset G1 A1 G2 A2 K1 K2 R1 R2 D1 D2 D3 D4 D5 D6 D7 D8 ON DIP P1 P2 P3 P4 P5 10 Red indicator light. Alarm in case of too high motor temperature. Indicator lights for stator insulation resistance. Green = OK. 7 Yellow =. Red = Alarm. 8 Indicator lights for measurement of water in oil 9 Terminal for measurement of stator insulation resistance 10 Terminal for connection of pump sensors 11 DIP switch for configuration 12 Green indicator light. On when the pump is running. 13 Red indicator light. Alarm in case of moisture in the motor. 14 Button for reset of alarm 15 Yellow indicator light. in case of pump fault. 16 Terminal for digital outputs PE A Y B I1 I2 I TM Pump fault Technical data Supply voltage: 24 VAC - 10 %/+ 10 %, 50 and 60 Hz 24 VDC - 10 %/+ 10 % Input current: Min. 0.5 A; max. 8 A Power input: Max. 5 W Ambient temperature: -25 C to +65 C Enclosure class: IP20 For further information, see installation and operating instructions for IO IO 113 IO 113 provides an interface between a Grundfos wastewater pump equipped with sensors and the pump controller(s). The most important sensor status information is indicated on the front panel. One pump can be connected to one IO 113 module. Together with the sensors, the IO 113 provides a galvanic isolation between the motor voltage in the pump and the connected controller(s). IO 113 can do the following as standard: Protect the pump against overheating. Monitor the status of these items: motor winding temperature leakage (WIO/WIA) moisture in pump. Measure the stator insulation resistance. Stop the pump in case of alarm. Remotely monitor the pump via RS-485 communication (Modbus or GENIbus). Control the pump via a frequency converter. The IO 113 must not be used for purposes other than those specified above. 17

18 English (GB) User interface Fig. 15 IO 113 module Pos. Description 1 Terminals for alarm relay 2 Terminals for analog and digital inputs and outputs 3 Terminals for supply voltage Potentiometer for setting the warning limit of stator 4 insulation resistance 5 Terminals for RS-485 for GENIbus or Modbus 6 Indicator light for moisture measurement 7 Indicator light for stator insulation resistance 8 Indicator light for leakage (WIO/WIA) 9 Indicator light for vibration in pump 10 Terminals for measurement of stator insulation resistance 11 Terminals for connection of pump sensors 12 DIP switch for configuration 13 Indicator light for motor temperature 14 Button for resetting alarms 15 Indicator light for motor running 16 Indicator light for service 17 Terminals for digital outputs General installation data T1 T G1 A1 G2 A2 K1 K2 R1 R2 D1 D2 D3 D4 D5 D6 D7 D8 ON DIP P1 P2 P3 P4 P5 Supply voltage: 24 VAC ± 10 % 50 or 60 Hz 24 VDC ± 10 % Supply current: Min. 2.4 A; max. 8 A Power consumption: Max. 5 W Ambient temperature: -25 C to +65 C Enclosure class: IP20 11 For further information, see installation and operating instructions for IO 113. PE A Y B I1 I2 I TM Frequency converter operation All SE1/SEV pump types are designed for frequency converter operation to keep the energy consumption at a minimum. For frequency converter operation, please observe the following information: Requirements must be fulfilled. Recommendations ought to be fulfilled. Consequences should be considered Requirements The thermal protection of the motor must be connected. Peak voltage and du/dt must be in accordance with the table below. The values stated are maximum values supplied to the motor terminals. The cable influence has not been taken into account. See the frequency converter data sheet regarding the actual values and the cable influence on the peak voltage and du/dt. Maximum repetitive peak voltage [V] Maximum du/dt U N 400 V [V/μ sec.] If the pump is an Ex-approved pump, check if the Ex certificate of the specific pump allows the use of a frequency converter. Set the frequency converter U/f ratio according to the motor data. Local regulations/standards must be fulfilled Recommendations Before installing a frequency converter, calculate the lowest allowable frequency in the installation in order to avoid zero flow. 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. Use screened motor cable if there is a risk that electrical noise can disturb other electrical equipment. See data sheet for the frequency converter used 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. 18

19 9. Start-up 9.1 SE1 Before starting work on the pump, make sure that the fuses have been removed or the mains switch has been switched off. It must be ensured that the power supply cannot be accidentally switched on. Make sure that all protective equipment has been connected correctly. The pump must not run dry. 1. Remove the fuses and check that the impeller can rotate freely. Turn the impeller by hand. 2. Check the condition of the oil in the oil chamber. See also section Oil change. 3. Check that the system, bolts, gaskets, pipework and valves etc. are in correct condition. 4. Mount the pump in the system. 5. Switch on the power supply. 6. Check whether the monitoring units, if used, are operating satisfactorily. 7. For pumps with sensor, switch on the IO 111 and check that there are no alarms or s. See section 8.7 IO Check the setting of air bells, float switches or electrodes. 9. Check the direction of rotation. See section 9.3 Direction of rotation. 10. Open the isolating valves, if fitted. 11. Check that the liquid level is above the upper edge of the clamp on the pump. If the level is below the clamp, add liquid to the pit until the minimum level is obtained. 12. Remove trapped air from the pump housing by tilting the pump with the lifting chain. 13. Start the pump and let the pump run briefly, and check if the liquid level is falling. A correctly vented pump will quickly lower the liquid level. Note The pump must not be started if the atmosphere in the pit is potentially explosive. It may lead to personal injuries or death to open the clamp while the pump is operating. The impeller can have sharp edges - wear protective gloves. Trapped air can be removed from the pump housing by tilting the pump by means of the lifting chain when the pump is in operation. 9.2 SEV 1. Remove the pump from the system. 2. Check that the impeller can rotate freely. Turn the impeller by hand. The impeller can have sharp edges - wear protective gloves. 3. Check the condition of the oil in the oil chamber. See also section Oil change. 4. Check whether the monitoring units, if used, are operating satisfactorily. 5. Check the setting of the air bells, float switches or electrodes. 6. Check the direction of rotation. See section 9.3 Direction of rotation. 7. Submerged pumps: Start the pump above water level and lower the pump into the pit to avoid air being trapped in the pump housing. 8. Dry-installed pumps with positive inlet pressure (if the pump is installed in a pump room next to the pit): Open the isolating valve on the suction side. Loosen the vent screw until water comes out of the vent hole; then tighten the vent screw again. Open the isolating valve on the discharge side and start the pump. 9. Dry-installed pumps with inlet pipe and foot valve: Open the isolating valve on the discharge side to let the water above the valve run backwards to prime the inlet pipe. Loosen the vent screw until water comes out of the vent hole; then tighten the vent screw again. Start the pump. 10. Dry-installed pumps with inlet pipe and foot valve, without or with short discharge pipe (we recommend the use of a vacuum system): Keep the isolating valve on the discharge side closed. Start the vacuum system until liquid has been sucked in and the pump has been vented. Open the isolating valve on the discharge side and start the pump. Air vent screw English (GB) Caution In case of abnormal noise or vibrations from the pump, other pump failure or power supply failure or water supply failure, stop the pump immediately. Do not attempt to restart the pump until the cause of the fault has been found and the fault corrected. After one week of operation or after replacement of the shaft seal, check the condition of the oil in the chamber. For pumps without sensor, this is done by taking a sample of the oil. See section 10. Maintenance and service for procedure. Fig. 16 Position of the air vent screw TM