Installation and operating instructions

Transcription

1 Dry-installed Sewage Pump Type ABS AFC 50/ EN (04/2016) Installation and operating instrutions

2 2 Installation and Operating Instrutions (Original Instrutions) Dry-installed Sewage Pump Type ABS AFC / /50 80/80 RV /50 RV Sulzer reserves the right to alter speifiations due to tehnial developments

3 Installation and Operating Instrutions (Original Instrutions) 3 Contents 1 General Appliation areas Explosion-proof approvals Partiular omments on the use of explosion-proof pumps in explosive zones Tehnial data Nameplate Safety Transport Eletrial onnetion Seal monitoring Temperature monitoring (PTC thermistor) Bearing temperature monitor (optional) Mounting and installation Installation example Disharge line Cheking diretion of rotation Changing diretion of rotation Commissioning Types of operation and frequeny of starting Maintenane General maintenane hints Coolant filling and oolant hanging Venting of the volute Draining of the volute... 9

4 4 Installation and Operating Instrutions (Original Instrutions) 1 General 1.1 Appliation areas The maximum allowable temperature of the medium pumped is 80 C. When swithing on and operating the pump, the hydrauli setion of dry-installation pumps must always be filled with water. The pumps of the AFC series have been designed for the eonomial and reliable pumping of ommerial, industrial and muniipal sewage. They are suitable for pumping of the following liquids: lear and wastewater, for sewage ontaining solids and fibrous material faeal matter The regulations of DIN 1986 as well as loal regulations should be observed when installing the pumps Explosion-proof approval The motors an be supplied both as standard versions and in explosion-proof exeution ATEX (II 2G Ex db IIB T4 Gb) Partiular omments on the use of explosion-proof pumps in explosive zones. 1. Explosion-proof pumps may only be operated with the thermal sensing system onneted. 2. If ball type float swithes are used, these must be onneted to an intrinsially safe eletrial iruit Protetion type EX (i) in aordane with VDE Dismantling and repair of explosion-proof motors may only be arried out by approved personnel in speially approved workshops. 4. In the event that the pump is to be operated in explosive atmospheres, using a variable speed drive, please ontat your loal Sulzer representative for tehnial advie regarding the various Approvals and Standards onerning thermal overload protetion. 5. Mahines designated as Ex mahines may never, without exeption, be operated using a mains frequeny that is greater than the maximum of 50 Hz, as indiated on the nameplate. 1.2 Tehnial data Maximum noise level 70 db. This may be exeeded in ertain irumstanes Nameplate We reommend that you reord the data from the standard nameplate on the pump in the orresponding form below, and maintain it as a soure of referene for the ordering of spare parts, repeat orders and general queries. Always state the pump type, item number and serial number in all ommuniations. xx/xxxx Legend Typ Pump type Nr Item number SN Serial number xx/xxxx Prodution date (week/year) Qmax Maximum flow m 3 /h Hmax Maximum head m Ø Imp. Impeller diameter mm Hmin Minimum head m DN Disharge diameter mm

5 Installation and Operating Instrutions (Original Instrutions) 5 2 Safety The general and speifi health and safety guidelines are desribed in detail in the Safety Instrutions for Sulzer Produts Type ABS booklet. If anything is not lear or you have any questions as to safety make ertain to ontat the manufaturer Sulzer. 3 Transport During transport the pump should not be dropped or thrown. The unit must never be raised by the power able. Pumps of the AFC series must be fitted with lifting slings for transport or for suspension. Lifting eyes should not be used. m See nameplate for weight of base unit. m Take note of the entire weight of the unit. The hoist and hain must be adequately dimensioned for the total weight of the unit (inluding lifting hains or steel ropes, and all aessories whih may be attahed) and must omply with the urrent valid safety regulations. All relevant safety regulators as well as general good tehnial pratie must be omplied with. 4 Eletrial onnetion Before ommissioning, an expert should hek that one of the neessary eletrial protetive devies is available. Earthing, neutral, earth leakage iruit breakers, et. must omply with the regulations of the loal eletriity supply authority and a qualified person should hek that these are in perfet order. The power supply system on site must omply with VDE or other loal regulations with regard to ross-setional area and maximum voltage drop. The voltage stated on the nameplate of the pump must orrespond to that of the mains. Explosion-proof pumps may only be used in explosive zones with the thermal sensors fitted (leads: FO, F1). The power supply able must be proteted by an adequately dimensioned slow-blow fuse orresponding to the rated power of the pump. The inoming power supply as well as the onnetion of the pump itself to the terminals on the ontrol panel must omply with the iruit diagram of the ontrol panel as well as the motor onnetion diagrams and must be arried out by a qualified person. All relevant safety regulators as well as general good tehnial pratie must be omplied with. Please onsult your eletriian. 4.1 Seal monitoring The pumps are supplied as standard with a DI probe for seal monitoring. The lighting up of the inspetion ontrol indiator in the ontrol panel by the DI eletrode fitted in the pump means that there is water in the dry hamber. If the DI seal monitor is ativated the unit must be immediately taken out of servie. Please ontat your Sulzer Servie Centre.

6 6 Installation and Operating Instrutions (Original Instrutions) 4.2 Temperature monitoring (PTC thermistor) Thermal sensors protet the motor from overheating. Thermal protetion is in aordane with DIN PTC relays for use in ontrol panels must also be in aordane with this standard. 4.3 Bearing temperature monitor (optional) PTC thermistor bearing monitor versions of AFC pumps inlude thermal protetion in aordane with DIN PTC relays for use in ontrol panels must also be in aordane with this standard. NOTE! Running the pump with the thermal and/or moisture sensors disonneted will invalidate related warranty laims. 5 Mounting and installation The regulations overing the use of pumps in sewage appliations, together with all regulations involving the use of explosion-proof motors, should be observed.the able duting to the ontrol panel should be sealed off in a gas-tight manner by the use of a foaming material after the able and ontrol iruits have been pulled through. In partiular the safety regulations overing work in enlosed areas in sewage plants should be observed together with general good tehnial pratie. 5.1 Installation example Inflow line 2 Gate valve 3 Pump 4 Non-return valve 5 Gate valve 6 Disharge line Disharge line The disharge line must be installed in ompliane with the relevant regulations. DIN 1986/100 and EN applies in partiular to the following: The disharge line should be fitted with a bakwash loop (180 bend) loated above the bakwash level and should then flow by gravity into the olletion line or sewer. The disharge line should not be onneted to a down pipe. No other inflows or disharge lines should be onneted to this disharge line. The disharge line should be installed so that it is not affeted by frost.

7 Installation and Operating Instrutions (Original Instrutions) Cheking diretion of rotation When three phase units are being ommissioned for the first time and also when used on a new site, the diretion of rotation must be arefully heked by a qualified person. m When The m When heking the diretion of rotation, the pump should be seured in suh a manner that no danger to personnel is aused by the rotating impeller, or by the resulting air flow. Do not plae your hand into the hydrauli system! diretion of rotation should only be altered by a qualified person. arrying out the diretion of rotation hek as well as when starting the unit pay attention to the START REACTION. This an be very powerful. The diretion of rotation is orret if the impeller rotates in a lokwise manner when viewing down from the motor end of the plaed unit The start reation is anti-lokwise. Rotor rotation NOTE If a number of pumps are onneted to a single ontrol panel then eah unit must be individually heked. The mains supply to the ontrol panel should have a lokwise rotation. If the leads are onneted in aordane with the iruit diagram and lead designations, the diretion of rotation will be orret. 5.4 Changing diretion of rotation The diretion of rotation should only be altered by a qualified person. If the diretion of rotation is inorret then this is altered by hanging over two phases of the power supply able in the ontrol panel. The diretion of rotation should then be reheked.

8 8 Installation and Operating Instrutions (Original Instrutions) 6 Commissioning Before ommissioning, the pump should be heked and a funtional test arried out. Partiular attention should be paid to the following: Have the eletrial onnetions been arried out in aordane with regulations? Have the thermal sensors been onneted? Is the seal monitoring devie orretly installed? Is the motor overload swith orretly set? Is the diretion of rotation of the pump orret - even if run via an emergeny generator? Are the level ontrol swithes funtioning orretly? Are the required gate valves (where fitted) open? Do the non-return valves (where fitted) funtion easily? 6.1 Types of operation and frequeny of starting All pumps of the AFC series have been designed for ontinuous operation S1. Explosion-proof pumps may only be used in explosive zones with the thermal sensors fitted (leads: FO, F1). 7 Maintenane Before ommening any maintenane work the pump should be ompletely disonneted from the mains by a qualified person and are should be taken that it annot be inadvertently swithed bak on. m When arrying out any repair or maintenane work, the safety regulations overing work in enlosed areas of sewage installations as well as good general tehnial praties should be followed. To avoid danger if the power able is damaged, it must be replaed by the manufaturer or its servie agent or a similarly qualified person. m Repair work on explosion-proof pumps may only be arried out by approved personnel in approved workshops. When arrying out repairs only original spare parts, supplied by the manufaturer, should be used. NOTE The maintenane hints given here are not designed for do-it-yourself repairs as speial tehnial knowledge is required. A maintenane ontrat with our servie department will guarantee you the best tehnial servie under all irumstanes. 7.1 General maintenane hints Sulzer pumps are reliable quality produts eah being subjeted to areful final inspetion. Lubriated-for-life ball bearings together with monitoring devies ensure optimum pump reliability provided that the pump has been onneted and operated in aordane with the operating instrutions. Should nevertheless, a malfuntion our, do not improvise, but ask your Sulzer Customer Servie Department for assistane. This applies partiularly if the pump is ontinually swithed off by the urrent overload in the ontrol panel, by the thermal sensors of the thermo-ontrol system or by the seal monitoring system (DI). Regular inspetion and are is reommended to ensure a long servie life.

9 Installation and Operating Instrutions (Original Instrutions) 9 The Sulzer Servie Organisation would be pleased to advise you on any appliations you may have and to assist you in solving your pumping problems. NOTE The Sulzer warranty onditions are only valid provided that any repair work has been arried out in Sulzer pproved workshop and where original Sulzer spare parts have been used. 7.2 Coolant filling and oolant hanging The hamber between the motor and the hydrauli setion has been filled at manufature with oolant. A oolant hange is only neessary if a fault ours. Coolant speifiation: 70% water and 30% propylene glyol. AFC COOLANT QUANTITY (litres) Pump type Motors Coolant AFC /4, 3/ AFC /2, 7.5/ AFC /2, 11/ AFC /4, 3/ AFC /2, 11/ AFC /4, 3/ AFC /4, 9.2/4, 3/ AFC /4, 18.5/4, 9.2/ AFC / AFC /4, 3/ AFC /4, 18.5/4, 22/4, 9.2/ AFC /4, 9.2/4, 3/ AFC /4, 9.2/4, 3/ AFC /4, 18.5/4, 22/4, 9.2/ AFC /4, 9.2/4, 3/ AFC /6, 11/6, 15/ AFC 50/50 7.5/4, 3/ AFC 50/50 RV 15/2, 22/ AFC 80/80 7.5/4, 9.2/4, 15/4, 3/6, 9.2/ AFC 80/80 RV 22/ A oolant hange is only neessary when arrying out repair work or if the inspetion lamp lights up. The 70% water and 30% propylene glyol oolant is frost resisting down to -15 C / 5 F. In ase of extreme ambient temperatures below -15 C / 5 F (e.g. during transport, storage or if the pump is out of duty) the ooling liquid must be drained. Otherwise the pump may be damaged. Please ontat your Sulzer onsultant! 7.3 Venting of the volute We strongly reommend that AFC pumps are vented bak into the sump by means of the drilled and tapped hole provided in the volute. 7.4 Draining of the volute To drain the volute on the AFC series remove the plug from the tapped hole on the under side of the volute.

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11 Installation and Operating Instrutions (Original Instrutions) 11

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