GRUNDFOS DP04 (01) PDF Document

The hazard statements for the GRUNDFOS DP04 pump are structured to indicate the level of risk:

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.

Each statement includes a description of the hazard, the consequence of ignoring the warning, and the action to avoid the hazard.

The symbols used in the GRUNDFOS DP04 pump instructions have specific meanings:

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.

An exclamation mark indicates that if these instructions are not observed, it may result in malfunction or damage to the equipment.

A lightbulb symbol provides tips and advice that make the work easier.

The main components of the GRUNDFOS DP04 pump are identified as follows:

The GRUNDFOS DP04 pump is designed for pumping the following liquids:

• drainage and surface water

• groundwater

• industrial process water without solids or fibers.

The nameplate on your GRUNDFOS DP04 pump provides detailed specifications. You can identify them using the following key:

The type key for a GRUNDFOS DP04 pump, such as DP04.A20.20.2.60M, can be decoded as follows:

1) Maximum frequency in case of frequency converter operation.

When handling and lifting your GRUNDFOS DP04 pump, follow these precautions:

Handling:

• Do not stack pump packages or pallets on top of each other.

• Always lift the pump by its lifting bracket or by a forklift if it’s on a pallet.

• Never lift the pump by the power cable, hose, or pipe.

• Wear protective gloves when opening the pump package to protect from sharp elements.

Lifting:

• Ensure your hand cannot be caught between the lifting bracket and the hook.

• Make sure the hook is properly fixed to the lifting bracket.

• Ensure the lifting bracket is tightened before lifting.

• Use the correct lifting point to keep the pump balanced. Use point A for auto-coupling installations and point B for other installations.

Before and during installation of the GRUNDFOS DP04 pump, observe the following critical safety precautions:

Electrical Safety:

• Switch off the power supply and lock the main switch in position 0 before working on the product.

• It must be possible to lock the main switch in position 0.

• Check the power cable for visible defects before installation to avoid short circuits.

• Ensure there is at least 10 ft (3m) of free cable above the maximum liquid level.

Personal Safety:

• Do not install the pump more than 6560 ft (3000 m) above sea level.

• Make sure the pump has cooled down before touching it to avoid burns from hot surfaces.

• Flush the pump thoroughly with clean water after dismantling. Pits may contain toxic or contagious substances.

• Wear appropriate personal protective equipment and clothing.

• Do not touch the sharp edges of the impeller without wearing protective gloves.

• Make sure the lifting bracket is tightened before lifting the pump to prevent crushing hazards.

Follow these steps to install your GRUNDFOS DP04 pump on an auto-coupling guide-rail system:

1. Drill mounting holes for the guide-rail bracket on the inside of the pit and fasten it with two anchor bolts.

2. Place the auto-coupling base unit on the bottom of the pit. Use a plumb line for correct positioning and fasten it with anchor bolts. If the pit bottom is uneven, support the base unit so it is level.

3. Assemble the outlet line without exposing it to distortion or tension.

4. Insert the guide rails into the base unit and adjust their length to the guide-rail bracket at the top of the pit.

5. Fit the guide-rail bracket on top of the guide rails and fasten it firmly to the pit wall. Ensure the guide rails have no axial play.

6. Clean any debris from the pit before lowering the pump.

7. Fit the guide claw to the pump outlet. Grease the gasket of the guide claw.

8. Lower the pump into the pit by a chain secured to the lifting bracket, sliding the guide claw between the guide rails. When the pump reaches the base unit, it connects automatically. Shake the pump by the chain to ensure it is seated correctly.

9. Hang the end of the chain on a suitable hook at the top of the pit so it does not contact the pump housing.

10. Adjust the power cable length by coiling it on a relief fitting. Fasten the fitting to a hook at the top of the pit. Ensure cables are not sharply bent or pinched.

11. Connect the power and control cables. The free end of the cable must not be submerged.

For a free-standing submerged installation of your GRUNDFOS DP04 pump, follow these steps:

1. Fit a 90° elbow to the pump outlet and connect the outlet pipe or hose. Ensure the hose does not buckle and its inside diameter matches the pump outlet port.

2. Lower the pump into the liquid using a chain secured to the lifting bracket. Place the pump on a plain, solid foundation. If the ground is muddy or uneven, place it on bricks or similar support. Ensure the pump is lifted by the chain, not the power cable.

3. Hang the end of the chain on a suitable hook at the top of the pit so it cannot contact the pump housing.

4. Adjust the length of the power cable by coiling it up on a relief fitting and fastening it to a suitable hook at the top of the pit. Ensure the cables are not sharply bent or pinched.

5. Connect the power and control cables. The free end of the cable must not be submerged as water may penetrate into the motor.

To ensure safe operation, the GRUNDFOS DP04 pump must be connected according to these requirements:

• Connect the pump to an external main switch that ensures all-pole disconnection.

• The main switch must be lockable in position 0.

• Connect the pump to a control unit with a motor protection relay (IEC trip class 10 or 15).

• The permanent installation must be fitted with an earth-leakage circuit breaker.

• Ensure there is at least 10 ft (3 m) of free cable above the maximum liquid level.

• If the power cable is damaged, it must be replaced by the manufacturer, a service agent, or a similarly qualified person.

• Set the motor-protective circuit breaker to the rated current stated on the pump nameplate.

• Before the first startup, check the cable for visible defects to avoid short circuits.

The wiring connections for single-phase GRUNDFOS DP04 pumps are as follows:

When operating a three-phase GRUNDFOS DP04 pump with a frequency converter, observe the following guidelines:

• The thermal protection of the motor must be connected.

• Peak voltage and dU/dt must be in accordance with the table below.

• The switching frequency is 2 kHz. Variable switching frequency is accepted.

• Set the frequency converter U/f ratio according to the motor data.

• Do not reduce the motor speed to less than 50%.

• Keep the flow rate above 3.3 ft/s (1 m/s).

• Let the pump run at rated speed at least once a day to prevent sedimentation.

• Do not exceed the frequency indicated on the nameplate.

• Keep the power cable as short as possible.

• Use input and output filters on the frequency converter.

• Use a screened power cable if there is a risk of electrical noise.

• Set the frequency converter for constant-torque operation.

Before starting the GRUNDFOS DP04 pump, you must adhere to the following safety precautions:

• Do not put your hands or any tool into the pump inlet or outlet port after the pump is connected to the power supply unless it is switched off.

• Make sure the power supply cannot be switched on unintentionally.

• Ensure that all protective equipment is connected correctly and fuses are removed before starting.

• Before the first startup, check the power cable for visible defects.

• If the power cable is damaged, it must be replaced by a qualified person.

• Ensure the product is earthed properly.

• Switch off the power supply and lock the main switch in position 0.

• Do not touch the surface of the pump while it is running as it may be hot.

• Do not open the clamp while the pump is running.

The GRUNDFOS DP04 pump is designed for two primary operating modes:

S1, continuous operation: In this mode, the pump can operate continuously without stopping for cooling. This is possible when the pump is completely submerged, as it is sufficiently cooled by the surrounding liquid.

S3, intermittent operation: This mode consists of a series of 10-minute duty cycles. Each cycle has a period of constant load followed by a period of rest. This mode is used when the pump is only partly submerged in the liquid. The minimum liquid level is at the top of the cable entry.

Before starting up a three-phase GRUNDFOS DP04 pump, you must check the direction of rotation. The correct rotation is clockwise, which results in a counterclockwise jerk when started. Use one of the following procedures:

Procedure 1 (Measuring output):

1. Start the pump and measure the liquid quantity or the outlet pressure.

2. Stop the pump and interchange any two of the phases in the power cable.

3. Restart the pump and measure the liquid quantity or the outlet pressure again.

4. Stop the pump. The connection that yields the larger liquid quantity or higher pressure is the correct one.

Procedure 2 (Observing jerk):

1. Let the GRUNDFOS DP04 pump hang from a lifting device.

2. Start and stop the pump while observing its movement (jerk).

3. If connected correctly, the pump jerks counterclockwise.

4. If the direction of rotation is wrong, interchange two of the phases in the power cable.

To start up your GRUNDFOS DP04 pump, follow these steps:

1. Remove the fuses and check that the impeller can rotate freely by turning it by hand.

2. Check the condition of the oil in the oil chamber.

3. Check that any monitoring units are operating satisfactorily and appropriately.

4. Check the setting of air bells, float switches, or electrodes.

5. Open the isolating valves, if fitted.

6. Lower the pump into the liquid and insert the fuses.

7. Check if the system is filled with liquid and vented. The pump is self-venting.

8. Switch on the power supply to the pump. The pump will start and pump down to the dry-running level. This confirms the pump is functioning correctly.

Note: If you observe abnormal noise or vibrations, stop the pump immediately and do not restart it until the fault is identified and eliminated.

To reset the GRUNDFOS DP04 pump, switch off the power supply for one minute, and then switch it on again.

For a GRUNDFOS DP04 pump in normal operation, inspect it every 3000 operating hours or at least once a year. If the liquid has a high dry solids content or is sandy, check the pump at shorter intervals. During inspection, check the following points:

• Power consumption: See the nameplate for specifications.

• Oil level and condition: When the pump is new or after a shaft seal replacement, check the oil level after one week. Use Shell Ondina X420 oil or equivalent. Oil autoignition temperature must be above 356 °F (180 °C).

• Cable entry: Make sure the cable entry is watertight and the cables are not sharply bent or pinched.

• Pump parts: Check wear parts and replace any defective ones.

• Ball bearings: Check the shaft for noisy or heavy operation by turning it by hand. Replace defective ball bearings if necessary. This work must be done by Grundfos or an authorized service workshop.

• Cable handling: Do not lay the pump on its power cable.

Change the oil in the oil chamber of your GRUNDFOS DP04 pump every 3000 operating hours, at least once a year, or if the shaft seal is replaced. If the drained oil contains water, check and replace the shaft seal.

Draining of oil:

1. Loosen and remove both oil screws to allow all the oil to drain from the chamber. The chamber may be under pressure, so loosen screws carefully.

2. Check the drained oil for water and impurities.

Oil quantity: The required quantity of oil is 5.74 fl oz (0.17 ltr).

Oil filling, pump in a horizontal position:

1. Place the pump horizontally on the stator housing with the outlet flange and oil screws pointing upwards.

2. Fill oil into the chamber through the upper hole until it starts running out of the lower hole.

3. Fit both oil screws using the gaskets from the O-ring service kit.

Oil filling, pump in a vertical position:

1. Place the pump on a plain, horizontal surface.

2. Fill oil into the oil chamber through hole Nr. 1 until it starts running out from the other hole on the side (Nr. 2).

3. Fit both oil screws using the gaskets from the O-ring service kit.

To clean the pump housing of your GRUNDFOS DP04 pump, follow these dismantling and assembly steps:

Dismantling:

1. Place the pump in a vertical position.

2. Loosen and remove the clamp that fastens the pump housing to the motor.

3. Lift the motor out of the pump housing. The impeller is fastened to the shaft end and will be removed with the motor.

4. Clean the pump housing and the impeller.

Assembly:

1. Place the motor with the impeller back into the pump housing.

2. Fit and tighten the clamp.

If the oil in your GRUNDFOS DP04 pump contains more than 20% water, the shaft seal is defective and must be replaced. Follow these steps:

1. Loosen and remove the clamp fastening the pump housing to the motor.

2. Lift the motor out of the pump housing. The impeller will be removed with the motor.

3. Remove the screw from the shaft end.

4. Remove the impeller from the shaft.

5. Drain the oil from the oil chamber.

6. Remove the screws securing the shaft seal.

7. Lift the shaft seal out of the oil chamber using the two dismounting holes in the shaft seal carrier and two screwdrivers.

8. Check the condition of the bush where the secondary seal touches. The bush must be intact. If it is worn, the pump must be checked by an authorized service workshop.

9. Check and clean the oil chamber.

10. Lubricate the faces in contact with the shaft seal with oil.

11. Insert the new shaft seal using the plastic bush included in the kit.

12. Tighten the screws securing the shaft seal to 16 Nm.

13. Fit the impeller, ensuring the key is fitted correctly.

14. Fit and tighten the screw securing the impeller to 22 Nm.

15. Place the motor with the impeller in the pump housing.

16. Fit and tighten the clamp.

17. Fill the oil chamber with oil.

For long periods of storage, protect the GRUNDFOS DP04 pump against moisture and heat. After a long period (1-3 months), rotate the shaft at least once a month to prevent internal parts from seizing. Before putting the pump into operation after long storage, inspect it to make sure the impeller can rotate freely and check the condition of the shaft seal and cable entry.

If the motor of your GRUNDFOS DP04 pump does not start and the breaker trips immediately, check the following possible causes and remedies:

If the motor-protective circuit breaker on your GRUNDFOS DP04 pump trips after a short period of operation, consider these causes and solutions:

If the thermal switch on your GRUNDFOS DP04 pump trips while it is running, check the following potential issues:

If your GRUNDFOS DP04 pump is showing below-standard performance and power consumption, here are the likely causes and how to fix them:

If your GRUNDFOS DP04 pump is running but not delivering any liquid, check for these issues:

The technical specifications and operating conditions for the GRUNDFOS DP04 pump are as follows:

• Operating pressure: Maximum 87.0 psi (6 bar)

• Number of starts per hour: Maximum 30

• pH value: For permanent installations, the pump can handle liquids with a pH value between 4 and 10.

• Installation depth: Maximum 65.6 ft (20 m) below liquid level.

• Liquid temperature: 32-104 °F (0 – 40 °C). A temperature up to 140°F (60 °C) is allowed for short periods (max 15 minutes).

The electrical specifications for the GRUNDFOS DP04 pump are:

• Power supply:

– 1 x 208 V – 230 V – 10% / +6%, 60 Hz

– 3 x 200 V – 230 V – 10% / +6%, 60 Hz

– 3 x 460 V – 10% / +6%, 60 Hz

– 3 x 575 V – 10% / +6%, 60 Hz

• Enclosure class: IP68, according to IEC 60529

• Insulation class: F (311 °F/155 °C)

Winding Resistances (at 68 °F, ± 10% tolerance):

Single-phase motor:

Three-phase motor:

Note: These values do not include the cable resistance, which is approximately 0.28 Ω for 2 x 33 ft (10 m).

The GRUNDFOS DP04 pump or its parts 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.

The crossed-out wheelie bin symbol on the product means that it must be disposed of separately from household waste. When a 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.