Grundfos KPG Installation And Operating Instructions Manual Download Page 1

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KPL, KPG and KWM

11-700 kW, 50 Hz
11-800 kW, 60 Hz, DIN

Installation and operating instructions

GRUNDFOS

INSTRUCTIONS

Installation and operating instructions

KPL, KPG and KWM

http://net.grundfos.com/qr/i/96770326

Summary of Contents for KPG

Page 1: ...L KPG and KWM 11 700 kW 50 Hz 11 800 kW 60 Hz DIN Installation and operating instructions GRUNDFOS INSTRUCTIONS Installation and operating instructions KPL KPG and KWM http net grundfos com qr i 96770326 ...

Page 2: ...ency converter operation 15 4 Starting up the product 16 4 1 Preparations for starting up 16 4 2 Startup 18 5 Handling and storing the product 18 5 1 Handling the product 18 5 2 Storing the product 18 6 Product introduction 19 6 1 Applications 19 6 2 General description 19 7 Identification 20 7 1 Type key 20 7 2 Nameplate 21 8 Protection and control functions 22 8 1 Sensors 22 8 2 Pump control 26 ...

Page 3: ...work easier If the pump is not going to be installed immediately the free end of the power cables or the sensor cables must be protected from moisture which could otherwise enter the motor windings This must be done as soon as the pump is received Protection can be carried out by fitting a cable cap or by wrapping the free end of the cables in plastic and taping over the plastic with strong waterp...

Page 4: ...n for corrosion or wear before lifting Always lift the pump by its lifting bracket or lifting eyes or by means of a fork lift truck see fig 1 to 10 Do not use the holes in the inlet and outlet casing to lift the pump see fig 2 and 3 DANGER Crushing hazard Death or serious personal injury Always use certified lifting equipment Note that the cable suspension system is not certified lifting equipment...

Page 5: ...rotation brackets 3 2 1 Lifting with single or double wire Lifting with single wire Fig 4 KPL and KWM lifting with single wire Fig 5 KPG lifting with single wire for transport Fig 6 KPG lifting with single wire connected to both lifting eyes for installation Do not lift the pump by the anti rotation brackets TM05 9209 3313 TM07 4685 2219 TM05 9207 3313 TM07 4686 2219 TM07 4799 2219 During installa...

Page 6: ...ation is prevented when the impeller is running 3 3 1 Requirement for free space below the pump Measure the column pipe diameter D and find the minimum value for free space below the pump Min C in the following table See fig 11 and fig 12 TM05 9208 3313 TM05 9208 3313 TM07 4687 2219 TM07 4688 2219 DANGER Electric shock Death or serious personal injury Before beginning the installation switch off t...

Page 7: ...ed before the pouring of the concrete as part of the construction work If this was not done then mark out and install the anchor bolts during the installation of the column pipe TM05 5305 3512 TM05 5306 3812 TM05 5596 3812 TM05 5597 3812 D C D C Under floor installation Above floor installation D C D C Under floor installation Above floor installation ...

Page 8: ...English GB 8 3 3 3 Guide for pit construction Fig 13 Schematic view of pit design TM03 9470 4007 Screen Max 10 TM03 9471 4212 D D D D D 2 D 2 D 2 4D 2D ...

Page 9: ...D D D L D B W C C Max 20 C C B T 4D T A D mm A mm B mm C mm W mm L mm T 500 2000 1000 250 2000 2000 Depending on construction contact Grundfos 600 2400 1200 300 2400 2400 650 2600 1300 325 2600 2600 700 2800 1400 350 2800 2800 800 3200 1600 400 3200 3200 900 3600 1800 450 3600 3600 1000 4000 2000 500 4000 4000 1200 4800 2400 600 4800 4800 1400 5600 2800 700 5600 5600 1500 6000 3000 750 6000 6000 1...

Page 10: ...ogether at distances of 0 5 m between the clamps adapted to the weight of the cables See fig 15 cable clamps distance 2 Fasten the wire rope to the eye at the top of the column pipe 3 Adjust the turnbuckle between the wire rope and the eye of the beam Make sure there is no slack in the cable suspension and that the cables are fixed to the cable suspension and are unable to swing during operation 4...

Page 11: ...o the specific pump model Fig 15 Securing the cables to the lifting wire A cable suspension system is mandatory to avoid cable damage during operation TM05 5940 4212 D Turnbuckle Sensor cable Power cable Intermediate lifting ring on request Wire rope Lifting wire detail D Wire rope View A A Cable clamps distance Max 50 cm ...

Page 12: ...ng on the pump switch off any external voltage connected to the pump Observe all safety regulations at the installation site for instance the use of blowers for fresh air supply to the pit TM07 4713 2319 0 M 2 3 3 5 KUM A 1 G P I 0 5 1 5 2 5 0 M 2 3 3 5 KUM A 1 G P I 0 5 1 5 2 5 B1 D C A1 A1 0 M 2 3 3 5 KUM A 1 G P I 0 5 1 5 2 5 B2 A2 D Model Outlet diameter 1 gate and 1 pump 1 gate and 2 pumps A1...

Page 13: ...table for the power supply available at the installation site Connect the pump to an external main switch ensuring all pole disconnection with a contact separation according to EN 60240 1 5 3 2 Connect P1 P2 and P3 in series with the thermal protectors and moisture sensors See section 3 5 2 Wiring diagrams 3 5 1 Wire colours Fig 16 Wire colours direct online starting two power cables The use of 8 ...

Page 14: ...ine starting three power cables Fig 20 Star delta starting one power cable TM05 6180 4512 TM05 6181 4512 V1 W1 U1 M 3 PE Control cable L1 L2 L3 PE V1 W1 U1 PE M 3 V2 W2 U2 PE Control cable L1 L2 L3 PE TM05 6182 4512 TM05 6183 4512 V1 W1 U1 PE M 3 V2 W2 U2 PE V3 W3 U3 PE Control cable L1 L2 L3 PE V1 W1 U1 PE M 3 V2 W2 U2 Control cable L1 L2 L3 PE ...

Page 15: ...o not exceed the frequency indicated on the nameplate If you do there is a risk of motor overload Keep the power cable as short as possible The peak voltage will increase with the length of the power cable See the data sheet for the frequency converter used Use input and output filters on the frequency converter See the data sheet for the frequency converter used Use a screened power cable if ther...

Page 16: ... is essential that the ground earth conductor is at least 2 inches 50 mm longer than the other conductors after connection This is to ensure that if a cable is accidentally pulled out the ground earth conductor connection will be the last to be disconnected Check the direction of the rotation See section 4 1 1 Checking the direction of rotation 4 1 1 Checking the direction of rotation Check the di...

Page 17: ...lumn pipe is free of water before and during checking the direction of rotation Make sure the pump is installed correctly See section 3 3 5 Installing the KPL and KWM pump Proceed as follows 1 Check the electrical connections with a phase detector to make sure the connections are correct 2 Start and run the pump for a few seconds 3 Observe the jerk of the pump If the pump jerks counterclockwise th...

Page 18: ...sphere allow the pump to stand submerged in the liquid for a short period before starting it up This eliminates the possibility of a frozen propeller or impeller Never use an open flame to thaw out the pump If the pump is submerged in liquid operate it for 30 seconds every month 5 2 2 Storing in dry conditions During storage pay special attention to the condition of the shaft seals and the cable e...

Page 19: ...of water in fish farms water level control in coastal and low lying areas filling and emptying water from dry docks and harbour 6 2 General description KPL pumps are submersible axial flow propeller pumps Fig 26 KPL pump KWM pumps are submersible mixed flow pumps Fig 27 KWM pump KPG pumps are gate pumps for submersible installation Fig 28 KPG pump TM05 5309 3812 1 2 3 4 5 6 7 8 TM05 5620 3912 TM07...

Page 20: ...800 DN 800 900 DN 900 1000 DN 1000 1200 DN 1200 1400 DN 1400 1500 DN 1500 1600 DN 1600 1800 DN 1800 Output power P2 22 22 kW Power kW 4 4 pole Number of poles 6 6 pole 8 8 pole 10 10 pole 12 12 pole 14 14 pole 16 16 pole 18 18 pole T Three phase motor Number of phases 50 50 Hz Frequency 60 60 Hz 9 9 degrees Hydraulic properties KPL KPG propeller pitch angle 11 11 degrees 13 13 degrees 15 15 degree...

Page 21: ...m head 6 Duty point flow rate Best efficiency point flow rate Maximum flow rate 7 Maximum installation depth 8 Enclosure class according to IEC 60529 9 Number of poles 10 Frequency 11 Rated speed 12 Voltage and current DOL connection 13 Voltage and current star delta connection 14 Input power 15 Shaft power 16 Power factor 17 Insulation class 18 Production code year and week 19 Pump weight DK 8850...

Page 22: ...onnect all 3 stator thermal sensors if bearing sensors are also connected Fig 30 KPL switches and sensors Fig 31 KWM switches and sensors Sensor Type Number of sensors Standard FPV Stator thermal protection Bi metal 3 3 Stator thermal protection Pt100 1 3 Terminal box moisture sensor Switch 1 1 Motor housing moisture sensor Switch 1 1 Bearing thermal protection lower Pt100 1 1 Bearing thermal prot...

Page 23: ...B 23 Fig 32 KPG switches and sensors Legend for figures 30 31 and 32 TM07 4690 2619 2 or 4 2 2 3 3 Pos Description 1 Vibration sensor 2 Thermal sensor 3 Moisture switch 4 Thermal switch 5 Water in oil sensor WIO ...

Page 24: ...IO 113 The resistance of the sensor varies with the temperature The table below show approximate values 8 1 3 Moisture switches The pumps have two moisture switches one in the terminal box one in the lower part of the stator housing Moisture switches are motor protection devices protecting the motor from damage due to moisture The moisture switches are non reversing and must be replaced after they...

Page 25: ... chamber and converts the value into an analog current signal The two sensor wires are for power supply and for carrying the signal to the measuring device or controller The sensor measures the water content from 0 to 20 It also sends a signal if the water content is outside the normal range warning or if the oil level is low alarm The sensor is fitted in a stainless steel tube for mechanical prot...

Page 26: ...ontrols system for high level and dry running alarm 8 2 2 IO 113 IO 113 forms the interface between a Grundfos stormwater or wastewater pump with analog and digital sensors and the pump controller The most important sensor data are indicated on the front panel See also the installation and operating instructions for IO 113 on www grundfos com One pump can be connected to an IO 113 Together with th...

Page 27: ...lt indication GENIbus connection Pt100 Pt1000 sensor input PTC thermal switch input 9 Servicing and maintaining the product 9 1 Safety instructions and requirements 9 2 Maintenance Normally the pump must be subjected to a major overhaul in a service workshop every third year This requires special tools and must be done by an authorised service workshop Inspect pumps running normal operation twice ...

Page 28: ...the propeller or impeller clearance When the clearance between the propeller or impeller blade and the wear ring exceeds 2 mm replace the wear ring If you have any questions please contact Grundfos or the nearest authorised service workshop KPL and KWM replacing the wear ring 1 Remove the screws and lift the pump off the inlet casing 2 Replace the wear ring 3 Assemble the pump in reverse order 9 2...

Page 29: ... and earth The resistance is above 10 MΩ OK The resistance is 1 to 10 MΩ warning The resistance is below 1 MΩ alarm Use an insulation resistance tester set to 1000 VDC Check the phase to phase and phase to earth resistance The test result must be over 100 MΩ 9 3 Spare parts Always replace damaged motor parts with new and approved parts Motor parts must not be reconditioned by machining re tapping ...

Page 30: ...gnal is indicated on the control panel Check the following and if necessary take corrective action Is the supply voltage correct on all phases Is the main power switch on and are the fuses intact Has the overload protection been reset Is the power cable damaged 2 The pump starts but the motor protection stops it after a few seconds a The motor protection is set too low Check the motor data in the ...

Page 31: ...pump starts stops and starts in rapid sequence a The pump starts due to backflow which fills the pit to the start level again Check the following and if necessary take corrective action Is the distance between the start and stop level too small Are the valves if any OK Does the non return valve function correctly b The control voltage is lower than the rated control voltage Check the following and...

Page 32: ...5 to 55 C Maximum 70 C for short periods not exceeding 24 hours EN 60204 1 4 5 11 2 Dimensions and weights For pump dimensions and weights see data booklet on www grundfos com 11 2 1 Bending radius of cables The bending radius of the cables is 15 times the outer cable diameter When pumping liquids with a density or kinematic viscosity higher than that of water the values stated above use a motor w...

Page 33: ...for C S and M W L in the table below are minimum values Depending on the specific pump type and operating range the specific level for S and M W L must be selected using the NPSH curve for the specific pump and the max and min operating range for the application The M W L is a guide only The specific M W L must be calculated based on minimum and maximum operating range for the specific pump TM07 4...

Page 34: ...rements TM07 3741 2219 7 5HP G F E M W L H Model Outlet diameter D E F G H KPG 500 DN 500 1450 900 500 1250 3700 KPG 600 DN 600 1700 1050 600 1500 4200 KPG 700 DN 700 1700 1250 700 1500 4500 KPG 800 DN 800 1950 1400 800 1750 4500 KPG 900 DN 900 2200 1600 850 2000 5200 KPG 1000 DN 1000 2200 1750 900 2000 5200 KPG 1200 DN 1200 2450 2000 1100 2250 5700 KPG 1400 DN 1400 2450 2250 1300 2250 5700 ...

Page 35: ...product marked with this symbol reaches its end of life take it to a collection point designated by the local waste disposal authorities The separate collection and recycling of such products will help protect the environment and human health See also end of life information on www grundfos com products product sustainability product recycling TM07 4053 2219 D mm C mm I mm S mm M W L mm 600M 300 2...

Page 36: ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PVS TP R COM1 B S L B S H MS COM2 TP B COM WIO PE TP B MS COM2 BS L COM1 TP R B S H Resistor PE A C B D E G F TP R B S L B S H COM1 COM2 MS TP B TP R B S L B S H COM1 COM2 MS TP B A B C D E G F Ɍ Ɍ G1 A1 G2 A2 K1 K2 R1 R2 PE D1 D2 D3 D4 D5 D6 D7 D8 A Y B P1 P2 P3 P4 P5 DIP ON Reset 1 2 3 4 5 6 7 8 9 10 IO 113 1112 1 2 ON ...

Page 37: ... TP B MS COM2 COM1 B S L TP R B S H PVS COM WIO WIO PVS3 COM WIO PVS T B PVS TP R COM1 B S L B S H MS COM2 TP B COM WIO TP R B S L B S H COM1 PE COM2 MS TP B H I J A C B D E G F COM WIO PVS TP R B S L B S H COM1 COM2 MS TP B A B C D E I F H G J Ɍ Ɍ G1 A1 G2 A2 K1 K2 R1 R2 PE D1 D2 D3 D4 D5 D6 D7 D8 A Y B P1 P2 P3 P4 P5 DIP ON Reset 1 2 3 4 5 6 7 8 9 10 IO 113 1112 1 2 ON ...

Page 38: ... P5 P4 MS COM2 TP B PE PE TP B MS COM2 SIGNAL SUPPLY 1 SM113 2 3 4 5 6 7 8 9 10 11 12 13 14 3 3Kȍ COM1 A C B D E SIGNAL SIGNAL SUPPLY MS TP B COM2 SUPPLY MS TP B COM2 B S L B S H TP R A B C D E Ɍ Ɍ G1 A1 G2 A2 K1 K2 R1 R2 PE D1 D2 D3 D4 D5 D6 D7 D8 A Y B P1 P2 P3 P4 P5 DIP ON Reset 1 2 3 4 5 6 7 8 9 10 IO 113 1112 1 2 ON ...

Page 39: ... COM2 TP B PE 1 SM113 2 3 4 5 6 7 8 9 10 11 12 13 14 COM1 SIGNAL SIGNAL SUPPLY MS TP B COM2 SUPPLY MS TP B COM2 B S L B S H TP R PE TP B MS COM2 SIGNAL SUPPLY WIO PVS3 Transient Barrier WIO COM PVS A B C D E A C B D E Ɍ Ɍ G1 A1 G2 A2 K1 K2 R1 R2 PE D1 D2 D3 D4 D5 D6 D7 D8 A Y B P1 P2 P3 P4 P5 DIP ON Reset 1 2 3 4 5 6 7 8 9 10 IO 113 1112 1 2 ON ...

Page 40: ...teur d humidité Nedvességérzéke lő Drėgmės relė Sensor Pt100 Pt100 anturi Capteur Pt100 Pt100 érzékelő Pt100 jutiklis Conductor de tierra Maajohdin Conducteur de terre Testvezető Įžeminimo laidas Sensor de agua en aceite Öljyn vesipitoisuuden anturi Capteur d eau dans l huile Víz az olajban WIO érzékelő Vandens alyvoje jutiklis M T WIO Apzīmējums LV Oznaczenie PL Designação PT Denumire RO Oznaka R...

Page 41: ...ač vlhkosti Nem sensörü 湿度开关 Fuktbryter Pt100 sensor Snímač Pt100 Pt100 sensörü Pt100传感器 Pt100 sensor Jordledare Uzemňovací vodič Topraklama iletkeni 地线 Jordleder Sensor för vatten i olja Senzor vody v oleji Yağda su sensörü 油中含水传感器 Sensor for vann i oljen ﻣﻳﺔ ﺍﻟﺗﺳ AR ﺭﺍﺭﻱ ﺣ ﺎﺡ ﻣﻔﺗ M ﺔ ﺍﻟﺭﻁﻭﺑ ﺎﺡ ﻣﻔﺗ T ﺎﺱ ﺣﺳ Pt100 ﺄﺭﻳﺽ ﺗ ﻝ ﻣﻭﺻ WIO ﻲ ﻓ ﺎء ﻣ ﺎﺱ ﺣﺳ ﺕ ﺍﻟﺯﻳ ...

Page 42: ...ro Tlf 45 87 50 50 50 Telefax 45 87 50 51 51 E mail info_GDK grundfos com www grundfos com DK Estonia GRUNDFOS Pumps Eesti OÜ Peterburi tee 92G 11415 Tallinn Tel 372 606 1690 Fax 372 606 1691 Finland OY GRUNDFOS Pumput AB Trukkikuja 1 FI 01360 Vantaa Phone 358 0 207 889 500 France Pompes GRUNDFOS Distribution S A Parc d Activités de Chesnes 57 rue de Malacombe F 38290 St Quentin Fallavier Lyon Tél...

Page 43: ...020 1426 sk grundfos com Slovenia GRUNDFOS LJUBLJANA d o o Leskoškova 9e 1122 Ljubljana Phone 386 0 1 568 06 10 Telefax 386 0 1 568 06 19 E mail tehnika si grundfos com South Africa Grundfos PTY Ltd 16 Lascelles Drive Meadowbrook Estate 1609 Germiston Johannesburg Tel 27 10 248 6000 Fax 27 10 248 6002 E mail lgradidge grundfos com Spain Bombas GRUNDFOS España S A Camino de la Fuentecilla s n E 281...

Page 44: ...6977 Trademarks displayed in this material including but not limited to Grundfos the Grundfos logo and be think innovate are registered trademarks owned by The Grundfos Group All rights reserved 2019 Grundfos Holding A S all rights reserved ...

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