Grundfos KPL Series Service Instructions Manual
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Grundfos KPL Series Service Instructions Manual

Grundfos KPL Series Service Instructions Manual

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GRUNDFOS INSTRUCTIONS
KPL, KWM
Service instructions

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  • Page 1 GRUNDFOS INSTRUCTIONS KPL, KWM Service instructions...

  • Page 2: Table Of Contents

    English (GB) Service instructions Original service instructions. Assembling KPL 900-1800, KWM 800-1600 15.1 Mounting the bearings and the lower bearing bracket 36 CONTENTS 15.2 Mounting the upper bearing bracket 15.3 Mounting the shaft into the stator Page 15.4 Mounting the discharge casing Symbols used in this document 15.5 Mounting the shaft seal...

  • Page 3: Safety

    2. Safety Warning Pump installation in pits must be carried out by specially trained persons. Warning It must be possible to lock the mains switch in position 0. Type and requirements as specified in EN 60204-1, 5.3.2. Warning Observe local regulations setting limits for manual lifting or handling.

  • Page 4: Storing The Pump

    3.2 Storing the pump 4. Identification Do not remove the protection from the free end of 4.1 Nameplate the power cable or sensor cable until the The nameplate is fixed to the side of the stator housing near the electrical connection is to be made. cable entry to the motor.

  • Page 5: Type Key

    5. Type key All KPL and KWM pumps are identified by the type designation stated in the order confirmation and in other documentation supplied with the pump. Code Example .1800 .600 Pump type Submersible axial-flow pump Submersible mixed-flow pump Column pipe diameter DN 500 DN 600 DN 700...

  • Page 6: Service Tools

    6. Service tools Service of a KPL, KWM pump requires, besides standard and special tools, sufficient lifting equipment and, if possible, some pallets to put for instance the suction casing, discharge casing, propeller or motor on, when they have been removed from the pump. 6.1 Standard tools Standard tools Pos.

  • Page 7: Special Tools

    Pos. Range Designation Description Part number 8 mm SV0273 10 mm SV0083 12 mm SV0274 16 mm SV0185 Ring/open-end spanner 20 mm 24 mm SV0122 27 mm SV0084 30 mm SV0073 Puller for bearing SV0335 Sliding gauge 0-150 mm SV0307 Side cutter Feeler gauge 6.2 Special tools...

  • Page 8: Tightening Torques And Lubricants

    7. Tightening torques and lubricants 8. Electrical connection The following instructions will not contain information regarding All electrical work must be carried out by an authorised torques for bolts and nuts. When assembling the pump, identify electrician. the size and class of the bolts and nuts used in the pump and Warning then use the torque table below to determine the right torque.

  • Page 9: Sensor Fault Finding

    8.1 Sensor fault finding PVS3 fault finding table When the pump is connected to an IO 113 with or without an SM Measure between 113 module, it is possible to identify faults by means of its display. these points:* See instruction and operating instructions for IO 113. If you require a more detailed fault finding, such as size of mA in Multimeter connection SM 113...

  • Page 10: Terminal Connections

    WIO fault finding table** Measure between these points:* Multimeter connection SM 113 Wire name terminal Measured value: 0 mA Fault Measured value: 3.5 mA Low oil level Measured value: 22 mA Water content high 10mm Measured value: 4-20 mA 0-20 % water in oil PVS3 fault finding table** Measure between these points:*...

  • Page 11: Symbols Used In The Wiring Diagrams

    8.2.2 Low-voltage connection Fig. 14 Terminal board, low voltage 8.2.3 High-voltage connection Fig. 15 Terminal board, high voltage 8.3 Symbols used in the wiring diagrams Symbol Description Thermal switch Moisture switch Pt100 sensor Earth conductor Water-in-oil sensor...

  • Page 12: Wiring Diagrams

    8.4 Wiring diagrams Power cables Control cable Control cable Fig. 16 Direct-online-starting (DOL), one power cable Fig. 18 Direct-online-starting (DOL), three power cables Control cable Control cable Fig. 17 Direct-online-starting (DOL), two power cables Fig. 19 Star-delta starting (Y/D), one power cable...
  • Page 13 Sensor cables Thermal switch Moisture switch Pt100 sensor PT-100 COM2 Earth B/S-H TP/B conductor B/S-L Water-in-oil COM1 PT-100 sensor COM2 B/S-H Transient B/S-L protector TP/B COM1 Fig. 20 Standard sensor connection, SM 113 outside the pump. See also fig. 115. PT-100 COM2 B/S-H...

  • Page 14: Pump Protection

    9. Pump protection KPL, KWM pumps are equipped with the following protective switches and sensors. In the FPV (Factory Product Variant) Moisture version, the sensors can be chosen individually. switch Standard Sensor Type [Qty] [Qty] Thermal switch, stator Bi-metal Temperature sensor, stator Pt-100 Thermal switch Vibration...

  • Page 15: Service

    – An O-ring is damaged. service must be performed more frequently. – Make sure that the cable clamps are tight. Grundfos’ sales companies may offer service contracts in – Make sure that the cable entry is accordance with a preventive maintenance schedule.

  • Page 16: Propeller/Impeller Clearance

    10.3.1 Oil level and oil condition 10.5 Oil check and oil change Check the oil level after one month of operation if the pump is The oil chamber is filled with oil acting as lubricant and coolant for new or the shaft seals have been replaced. The oil must be the mechanical shaft seal.
  • Page 17 10.5.3 KPL 700-1800, KWM 700-1600 These pumps have an oil service kit which can be ordered in Grundfos. Use order no. 98887554. With this kit it is easy to check the oil level. Take an oil sample and change the oil, if necessary, without having to remove any part of the pump.

  • Page 18: Power-Lock

    ® 11. Power-lock Warning ® Before removing Power-lock , place the pump in Caution horizontal position, and secure the impeller by means of a strap and a crane Warning MxxDR200 MxxDR400 ® Before removing Power-lock , make sure that there is no thrust on the propeller/impeller. ®...

  • Page 19: Dismantling Kpl 500-800, Kwm

    12. Dismantling KPL 500-800, KWM 600-700 Fig. 36 Assembly order, column pipe diameter 500 to 800 If service includes oil change or removal of the Caution shaft seal, the oil must be removed at the beginning of the service job. Position numbers of parts refer to section Drawings, 21.

  • Page 20: Removing The Power Cable/Sensor Cable

    12.2 Removing the power cable/sensor cable 12.3 Removing the cable entries Removing the cable clamps KPL 500-800, KWM 600-700 1. Loosen and remove the screws (pos.180a). See section Power cable, see fig. 22. Exploded views. 1. Remove the power cable entry from the terminal box cover 2.

  • Page 21: Removing The Suction Casing

    12.5 Removing the suction casing KPL 500-800, KWM 600-700 1. Turn the pump upside down, placing the upper bearing cover on wooden beams. 2. Mount shackles and/or lifting straps on the suction casing. 3. Loosen and remove the screws (pos. 26). 4.

  • Page 22: Removing The Propeller/Impeller

    12.7 Removing the propeller/impeller KPL 500-650, KWM 600-700 Warning ® Before dismantling Power-lock , make sure that there is no thrust on the propeller/impeller. 1. Loosen and remove the screw (pos. 67a). 2. Remove the cap (pos. 66). ® 3. Loosen and remove Power-lock (pos.

  • Page 23: Removing The Discharge Casing

    Fig. 53 Shaft seal, KPL, KWM 600-1800 12.9 Removing the discharge casing If the turbulence optimiser and/or the discharge casing protector are worn down or defective, Grundfos recommend a change of these. See fig. for a more detailed view. Removing the turbulence optimiser 1.

  • Page 24: Removing The Lower Bearings

    12.11 Removing the lower bearings 12.12 Removing the upper bearing and bearing bracket KPL 500-800, KWM 600-700 Place the rotor with bearing bracket in vertical position on a KPL 500-800, KWM 600-700 suitable, stable workbench. 1. Lift the rotor from the stator housing. Both inner and outer ring of the upper bearing will follow the shaft.

  • Page 25: Assembling Kpl 500-800, Kwm

    13. Assembling KPL 500-800, KWM 600-700 Make sure the WIO sensor is placed correctly in Note relation to the direction of rotation. See fig. 60. Before assembling • Clean and check all parts. • Replace defective parts with new parts. •...

  • Page 26: Mounting The Shaft Seal

    13.4 Mounting the shaft seal KPL 500 1. Make sure the shaft seal locks (pos. 105e) are engaged. See fig. 63. 2. Lubricate and fit the O-rings (pos. 105b and 105c). 3. Push the shaft seal (pos. 105) on to the shaft. Make sure the shaft seal is engaged with the seal Note bracket.

  • Page 27: Mounting The Propeller/Impeller

    13.5 Mounting the propeller/impeller KWM 600-700 1. Mount the water chamber (pos. 77) and fit the screw (pos. KPL 500-650 26a) and tighten it according to section 7. Tightening torques 1. Fit the propeller (pos. 49). lubricants. ® 2. Fit Power-lock 2.

  • Page 28: Mounting The Suction Casing And The Wear Ring

    13.6 Mounting the suction casing and the wear ring 13.7 Mounting the sensors 1. Place the suction casing (pos. 12a) on two wooden beams. 1. Mount the sensors according to fig. or 73. 2. Lower and fit the wear ring (pos. 46) into its place. See figs 2.

  • Page 29: Mounting The Motor Top Cover

    13.8 Mounting the motor top cover KPL 500-600 1. Lubricate and fit the O-ring (pos. 157) on the upper bearing bracket (pos. 61c). See fig. 75. 2. Lubricate and fit the O-rings (pos. 157d) on the cable entry (pos. 168). 3.

  • Page 30: Mounting The Cable Entry

    13.9 Mounting the cable entry 1. Push the cable through the cable entry. 2. Mount the washer, rubber seal (pos. 198, 250b) and washer on the power cable and the sensor cable. The inner diameter of the washer needs to fit with Caution the outer diameter of the cable in order to avoid deformation of the rubber seal (pos.

  • Page 31: Dismantling Kpl 900-1800, Kwm 800-1600

    14. Dismantling KPL 900-1800, KWM 800-1600 Fig. 78 Assembly order column 900 to 1800 If service includes oil change or removing the Caution shaft seal, you must remove the oil at the beginning of the service job. Position numbers of parts refer to section Drawings, 21.

  • Page 32: Removing The Power Cable/Sensor Cable

    14.2 Removing the power cable/sensor cable 14.3 Removing the cable entry KPL 900-1800, KWM 800-1600 KPL 900-1800, KWM 800-1600 1. Loosen and remove the screws (pos.180a). See fig. 79. Power cable 2. Remove the cable clamps. 1. Remove the power cable entry from the motor top cover (pos. 164a).

  • Page 33: Removing The Suction Casing

    198e 198f Fig. 86 Suction casing, KWM, high head 14.6 Removing the wear ring KPL 900-1800, KWM 800-1600 1. Place the suction casing on two wooden beams with the wear ring facing downwards. Make sure the beams are placed in such way that there is access to all set screws (pos.

  • Page 34: Removing The Shaft Seal

    KWM 800-1600 1. Turn the pump upside down so that the upper bearing bracket is facing down, and place it on two wooden beams. 2. Loosen the screw (pos. 26a) and remove the water chamber (pos. 77). 3. Pull off intermediate ring (pos. 110). 4.

  • Page 35: Removing The Rotor With Bearings

    KPL 900-1800, KWM 800-1600 14.11 Removing the lower bearings 1. Mount two shackles with lifting straps in the anti-rotation KPL 900-1800, KWM 800-1600 brackets/lifting brackets and connect them to a crane hook. 1. Place the rotor with bearing cover in vertical position on a 2.

  • Page 36: Removing The Upper Bearing And The Bearing Bracket

    14.12 Removing the upper bearing and the bearing 15. Assembling KPL 900-1800, KWM 800-1600 bracket Before assembling KPL900-1800, KWM 800-1600 • Clean and check all parts. • Replace defective parts with new parts. The upper bearing is a "separable bearing" type, •...

  • Page 37: Mounting The Upper Bearing Bracket

    15.2 Mounting the upper bearing bracket 15.4 Mounting the discharge casing 1. Place the stator housing (pos. 55) on two wooden beams. 1. Lubricate and fit the O-ring (pos. 72a) on the lower bearing bracket (pos. 155). 2. Press the seal sleeve (pos. 154b) into place in the upper bearing bracket (pos.

  • Page 38: Mounting The Shaft Seal

    15.5 Mounting the shaft seal 15.6 Mounting the propeller/impeller 1. Make sure the shaft seal locks (pos. 105e) are engaged. See Place the pump in a horizontal position. See fig. 78, drawing 8. fig. 103. KPL 900-1800 2. Lubricate and fit the O-rings (pos. 105b, 105c and 106a). 1.

  • Page 39: Mounting The Suction Casing And The Wear Ring

    KWM 800-1600 15.7 Mounting the suction casing and the wear ring 1. Mount the water chamber (pos. 77) and fit the screws (pos. 1. Place the suction casing (pos. 12a) on two wooden beams. 26a) and tighten them according to section 7.

  • Page 40: Mounting The Sensors

    15.8 Mounting the sensors 1. Mount the sensors according to fig. 111. 2. Mount the terminal board (pos. 176a), fit the screws (pos. 176b) and tighten them according to section 7. Tightening torques and lubricants. 198e 198f Fig. 112 Turbulence optimiser and discharge casing protector 250a 181a 250b...

  • Page 41: Starting-Up The Pump

    16. Starting-up the pump 16.2 Direction of rotation The pump may be started for a very short period Warning Note without being submerged to check the direction Before starting work on the pump, make sure that of rotation. the fuses have been removed or the mains switch has been switched off.

  • Page 42: Fault Finding

    17. Fault finding Warning Before attempting to diagnose any fault, make sure that the fuses have been removed or the mains switch has been switched off. Make sure that the power supply cannot be accidentally switched on. All rotating parts must have stopped moving. Warning Observe all regulations applying to pumps installed in potentially explosive environments.

  • Page 43: Power-Lock

    ® 18. Power-lock M06.DR200-30x55 M06.DR200-35x60 M06.DR200-40x65 M08.DR200-50x80 M08.DR200-60x90 M08.DR400-50x80 M08.DR400-60x90 M10.DR400-70x110 M10.DR400-75x115 M10.DR400-80x120 M10.DR400-90x130 M12.DR400-100x145 M12.DR400-110x155 M12.DR400-120x165 M14.DR400-130x180 M14.DR400-140x190 M14.DR400-150x200 M14.DR400-160x210...

  • Page 44: Wiring Diagrams

    19. Wiring diagrams 220 Vac L1 L2 L3 SM113 U V W Pump T1 T2 G1 A1 G2 A2 K1 K2 R1 R2 A Y B D1 D2 D3 D4 D5 D6 D7 D8 IO113 1 2 3 4 5 6 7 8 9 10 11 12 P1 P2 P3 P4 P5 I1 I2 I3 3 x y...
  • Page 45 220 Vac L1 L2 L3 SM113 U V W Pump+WIO: T1 T2 G1 A1 G2 A2 K1 K2 R1 R2 A Y B D1 D2 D3 D4 D5 D6 D7 D8 IO113 11 12 1 2 3 4 5 6 7 8 9 10 11 12 P1 P2 P3 P4 P5 I1 I2 I3 1 2 3 4 5 6 7 8 9 10 11 1213 14...
  • Page 46 220 Vac L1 L2 L3 U V W Pump T1 T2 G1 A1 G2 A2 K1 K2 R1 R2 A Y B D1 D2 D3 D4 D5 D6 D7 D8 IO113 IO113 1 2 3 4 5 6 7 8 9 10 11 12 P1 P2 P3 P4 P5 I1 I2 I3 3 4 5...
  • Page 47 220 Vac L1 L2 L3 U V W Pump+WIO: T1 T2 G1 A1 G2 A2 K1 K2 R1 R2 IO113 A Y B D1 D2 D3 D4 D5 D6 D7 D8 IO113 11 12 1 2 3 4 5 6 7 8 9 10 11 12 P1 P2 P3 P4 P5 I1 I2 I3 3 4 5...

  • Page 48: Drawings

    20. Drawings KPL 500...
  • Page 49 KPL 600...
  • Page 50 KPL 650...
  • Page 51 KPL 700-800...
  • Page 52 KPL 900...
  • Page 53 KPL 1000-1800...
  • Page 54 KWM 600-700 M...
  • Page 55 KWM 600-700 H...
  • Page 56 KWM 800-1600 M...
  • Page 57 KWM 800-1600 H...

  • Page 58: List Of Materials

    21. List of materials Pos. Component Material ASTM Suction casing Cast iron GG25 A48-CL35 Screw Stainless steel X5CrNi-189-1.4301 A276-304 Screw Stainless steel X5CrNi-189-1.4301 A276-304 Washer Wear ring (KPL) Stainless steel X5CrNi-189-1.4301 A276-304 Wear ring (KWM) Ductile cast iron GGG-40 A536-65-45-12 Set screw O-ring NBR rubber...
  • Page 59 Pos. Component Material ASTM 154c O-ring NBR rubber 154d Sleeve (top bearing) Bearing bracket, lower Cast iron GG25 A48-CL35 O-ring NBR rubber 157a O-ring NBR rubber 157d O-ring NBR rubber 157e O-ring NBR rubber Terminal box cover Cast iron GG25 A48-CL35 164a Motor top cover...
  • Page 60 Pos. Component Material ASTM 250b Washer/rubber seal/washer Stainless steel/NBR rubber Sensor cable Lock nut Steel Lock washer Steel Bearing temperature sensor O-ring NBR rubber Moisture switch, upper 520c Screw Stainless steel X5CrNi-189-1.4301 A276-304 Moisture switch, lower 521a Washer Stainless steel X5CrNi-189-1.4301 A276-304 521b...

  • Page 61: Exploded Views

    22. Exploded views Fig. 119 Exploded view, KPL 500...
  • Page 62 Fig. 120 Exploded view, KPL 1800...
  • Page 63 Fig. 121 Exploded view, KWM 700...
  • Page 64 Fig. 122 Exploded view, KWM 1200...

  • Page 65: Resistance Table For The Pt100 Sensor

    23. Resistance table for the Pt100 sensor °C 80.31 79.91 79.51 79.11 78.72 78.32 77.92 77.52 77.13 76.73 84.27 83.88 83.48 83.08 82.69 82.29 81.89 81.50 81.10 80.70 88.22 87.83 87.43 87.04 86.64 86.25 85.85 85.46 85.06 84.67 92.16 91.77 91.37 90.98 90.59...
  • Page 66 98383809 0515 ECM: 1159109 www.grundfos.com...

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