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Summary of Contents for Sulzer AS 0530
- Page 1 Submersible Wastewater Pump Type ABS AS 0530 - 0841 Installation and Operating Instructions www.sulzer.com...
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Page 2: Table Of Contents
9.2 Discharge line ............................11 Installation types ........................... 12 9.3.1 Submerged in concrete sump ....................... 12 9.3.2 Dry-installed ............................13 9.3.3 Transportable ............................15 9.3.4 Venting of the volute ..........................15 Sulzer reserves the right to alter specifications due to technical developments ! 6006077-02... - Page 3 Electrical connection .......................... 15 10.1 Seal monitoring ............................. 16 10.2 Temperature monitoring ........................17 10.2.1 Temperature sensor bimetal ........................17 10.3 Wiring diagrams ............................ 17 Commissioning ........................... 19 11.1 Types of operation and frequency of starting ..................19 11.2 Checking direction of rotation ........................ 19 11.3 Changing direction of rotation .......................
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Page 4: General
Leakage of lubricants could result in pollution of the medium being pumped. AS pumps must not be used in certain applications e.g. pumping of flammable, combustible, chemical, corrosive, or explosive liquids. ATTENTION! Always consult with your local Sulzer representative for advice on approved use and application before installing the pump. 1.2 Identification code e.g. AS 0840 S 12/2 Ex... -
Page 5: Performance Range
Contrablock impeller 50 Hz Vortex impeller 50 Hz 0641 0530 0840 0630 0631 & 0841 0830 0831 Contrablock impeller 60 Hz Vortex impeller 60 Hz 0641 0530 0840 0630 & 0830 0631 0831 0841 Safety The general and specific health and safety guidelines are described in detail in the “Safety Instructions for Sulzer Products Type ABS” booklet. If anything is not clear or you have any questions as to safety make certain to contact the manufacturer Sulzer. This unit can be used by children aged 8 years and above, and persons with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, when they have been given supervision or instruction concerning the safe use of the device and understand the hazards involved. Children must not play with the appliance. Cleaning and user maintenance should not be performed by children without supervision. 6006077-02... -
Page 6: Personal Protective Equipment
Under no circumstances place a hand inside the suction or discharge openings unless the pump is completely isolated from the power supply. Personal protective equipment Submersible electrical pumps can present mechanical, electrical, and biological hazards to personnel during installation, operation, and service. It is obligatory that appropriate personal protective equipment (PPE) is used. The minimum requirement is the wearing of safety glasses, footwear, and gloves. However, an on-site risk assessment should always be carried out to determine if additional equipment is required e.g. safety harness, breathing equipment etc. Use of motors in Ex zones Approvals Electrical safety of the AS series is CSA and CSA(U) approved. Explosion-proof approvals Explosion-proof motors of the AS series have certification in accordance with Factory Mutual (FM) Class 1 Div. 1 Groups C and D (60 Hz, US), and ATEX 2014/34/EU [II 2G Ex h db IIB T4 Gb] (50 Hz). NOTE! Ex protection method type c “Constructional Safety” and k “Liquid immersion“ in accordance with EN ISO 80079-36, EN ISO 80079-37 are used. General information In hazardous areas care must be taken that during switching on and operation of the pumps, the... -
Page 7: Technical Data
Technical data Detailed technical information is available in the technical data sheet “Submersible Wastewater Pump Type ABS AS 0530 - 0841” which can be downloaded from www.sulzer.com > Products > Pumps > Submersible Pumps. Maximum noise level ≤ 70 dB. In some types of installations it is possible that during pump operation the noise level of 70 dB(A) or the measured noise level may be exceeded. Nameplate We recommend that you record the data from the standard nameplate on the pump in the corresponding form below, and maintain it as a source of reference for the ordering of spare parts, repeat orders and general queries. Always state the pump type, item number and serial number in all communications. 0598 II 2G Ex db h IIB T4 Gb Baseefa 03ATEX xxxx Amb. Max 40°C Max. Liquid Temp Ex version Standard version Legend Pump type Rated input power Item no. -
Page 8: General Design Features
Legend (FM and CSA) Model (FM) Motor type F.L.Amps Full load amps Model (CSA) Pump type Frequency Pump Pump type Number of phases ######### Item no. Speed Serial no. Imp. dia Impeller diameter ▽ Max Item no. Max submersible depth xx/xxxx Production date (week/year) Flow Max Rated discharge Volts Rated voltage Hmax Max. head Rated output power General design features... -
Page 9: Weights
0.74 / 1.63 load of any lifting equipment. 3.0 / 9.84 1.28 / 2.82 Please consult with your local 4.0 / 13.12 1.67 / 3.68 Sulzer representative prior to installation. 6.0 / 19.68 2.45 / 5.40 7.0 / 22.96 2.84 / 6.26 * For chain supplied by Sulzer only. 6006077-02... -
Page 10: Lifting, Transport And Storage
Worn or damaged lifting equipment must not be used and must be properly disposed of. Lifting equipment must also comply with the local safety rules and regulations. NOTE! The guidelines for the safe use of chains, ropes and shackles supplied by Sulzer are outlined in the Lifting Equipment manual provided with the items and must be fully adhered to. -
Page 11: Set-Up And Installation
Set-up and installation AS pumps are designed for wet well vertical installation on a fixed pedestal or as transportable on a movable stand (skirtbase). The pumps are also suitable for horizontal (except 0631, 0641) or vertical (only 0831, 0841) dry installation. The regulations of DIN 1986 as well as local regulations should be observed when installing the pump. The following guidelines must be observed when setting the lowest switch off point for AS pumps: • Care must be taken during switching on and operation that the hydraulic section is filled with water (dry installation) or alternatively is submerged or under water (wet installation). Other types of operation e.g. snore operation or dry running are not allowed! • The minimum submergence allowed for specific pumps can be found on the dimension installation sheets available by download from www.sulzer.com > Products > Pumps > Submersible Pumps. The regulations covering the use of pumps in sewage applications, together with all regulations involving the use of explosion-proof motors, should be observed. The cable ducting to the control panel should be sealed off in a gas-tight manner by the use of a foaming material after the cable and control circuits have been pulled through. In particular the safety regulations covering work in enclosed areas in sewage plants should be observed together with general good technical practice. Equipotential bonding In pump stations/tanks, equipotential bonding must be carried out according to EN 60079-14:2014 [Ex] or IEC 60364-5-54 [non-Ex] (Regulations for the installation of pipelines, protective measures in high voltage systems). Connection point: Discharge line The discharge line must be installed in compliance with the relevant regulations. DIN 1986/100 and EN 12056 applies in particular to the following: - The discharge line should be fitted with a backwash loop (180° bend) located above the backwash level and should then flow by gravity into the collection line or sewer. - The discharge line should not be connected to a down pipe. - No other inflows or discharge lines should be connected to this discharge line. ATTENTION The discharge line should be installed so that it is not affected by frost. -
Page 12: Installation Types
Chain Inflow line Ball type float switch Submersible pump Concrete sump. 10 Pedestal 11 Guide tube. 12 Discharge line 13 Non-return valve 14 Gate valve 15 Power cable to motor The pump is installed using the Sulzer pedestal kit as specified below for the particular AS model (assembly leaflet is supplied with kit). Size Part number 0530 2” without bend 62320560 0630, 0631, 0641 DN 65: 90º cast bend 62320673 DN 80 without bend 62320557 0830, 0831, 0840, 0841 DN 80: 90º cast bend... -
Page 13: Dry-Installed
Lowering the pump on the guide rail: • Fit the pedestal coupling bracket (a) and seal (b) to the discharge flange of the pump. • Fit a chain to the shackle on the lifting handle and using a hoist lift the pump into position where the pedestal bracket can slide into place on the guide rail. • Lower the pump slowly down along the guide rail at a slight angle. • The pump couples automatically on the pedestal, and seals to a leak-tight connection by the compression from the combination of its own weight and the fitted seal. 9.3.2 Dry-installed Horizontal 6006077-02... - Page 14 The pump is installed using the Sulzer horizontal support kit as specified below for the particular AS model (assembly leaflet is supplied with kit). Part number 0630, 0830, 0840 62665103 0831, 0841 61825001 Vertical Control panel Non-return valve Collection sump Discharge line Power cable from motor to Inflow line control panel Gate valve Ball-type float switch Pump Gate valve Particular attention should be paid to: • the provision of venting to the sump •...
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Page 15: Transportable
9.3.3 Transportable For transportable installation the AS is fitted to a skirtbase. Place the pump on a firm surface which will prevent it from overturning or burrowing down. The skirtbase can also be bolted down to the floor surface, or the pump suspended slightly by the lifting handle. Connect the discharge pipe and cable. Arrange the cable run so that the cables will not be kinked or nipped. Submersible pumps used outdoors must be fitted with a power cable of at least 10 meter length. Other regulations may apply in different countries. Hoses, pipes and valves must be sized to suit the pump performance. 9.3.4 Venting of the volute After lowering the pump into a sump full of water, an air lock may occur in the volute and cause pumping problems. To clear the air lock, shake the pump, or raise the pump in the medium and then lower it again. If necessary, repeat this venting procedure. We strongly recommend that dry-installed AS pumps are vented back into the sump by means of the drilled and tapped hole provided in the volute. Electrical connection Before commissioning, an expert should check that one of the necessary electrical protective devices is available. Earthing, neutral, earth leakage circuit breakers, etc. must comply with the regulations of the local electricity supply authority and a qualified person should check that these are in perfect order. ATTENTION! The power supply system on site must comply with local regulations with regard to cross-sectional area and maximum voltage drop. -
Page 16: Seal Monitoring
• Motor contactor that complies with the requirements of IEC Standard 60947-4-1 and rated for the motor that it controls. This pump has not been investigated for use in swimming pools. 10.1 Seal monitoring AS pumps can be fitted with an optional leakage sensor (DI) to detect and alert to the ingress of water into the motor chamber (non-Ex and Ex), and seal chamber (non-Ex only). Fitted as standard on 60 Hz Ex (FM). In order to integrate this seal monitoring function into the control panel of the pump it is necessary to fit a Sulzer DI module and connect this in accordance with the circuit diagram below. Power supply Connect terminal 3 to ground or housing of the pump. CA 461 Output Input leakage Sulzer leakage control type CA 461 Electronic amplifier: 110 - 230 V AC 50/60 Hz (CSA). Part No.: 16907010. 18-36 VDC, SELV. Part No.: 16907011. 6006077-02... -
Page 17: Temperature Monitoring
It is very important to note that with the connection example above it is not possible to identify which sensor/alarm is being activated. As an alternative Sulzer highly recommends to use a separate CA 461 module for each sensor/input, to allow not only identification but also to prompt to the appropriate response to the alarm category/severity. - Page 18 Three phase wiring with temperature limiter Single phase wiring with temperature limiter Three phase wiring with temperature limiter and DI Single phase wiring with temperature limiter and DI Three phase Single phase AS 50 Hz: AS 50 Hz: S12/2 D, S13/4 D, S17/2 D, S22/4 D, S26/2 D, S30/2 D, S10/4 W, S12/2 W AS 60 Hz: AS 60 Hz:...
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Page 19: Commissioning
Commissioning The safety hints in the previous sections must be observed! In explosive zones care must be taken that during switching on and operation of the pumps, the pump section is filled with water (dry running) or alternatively is submerged or under water (wet installation). Ensure in this case that the minimum submergence given in the data sheet is observed. Other types of operation e.g. snore operation or dry running are not allowed. Before commissioning, the unit should be checked and a functional test carried out. Particular attention should be paid to the following: - Have the electrical connections been carried out in accordance with regulations? - Have the thermal sensors been connected? - Is the seal monitoring device (where fitted) correctly installed? - Is the motor overload switch correctly set? - Have the power and control circuit cables been correctly fitted? - Was the sump cleaned out? - Have the inflow and outflows of the pump station been cleaned and checked? - Is the direction of rotation correct - even if run via an emergency generator? - Are the level controls functioning correctly? - Are the required gate valves (where fitted) open? - Do the non-return valves (where fitted) function easily? - Have the hydraulics been vented in the case of dry installed pumps? - Has the volute been vented (see Sec. 9.3.4) ? 11.1 Types of operation and frequency of starting... -
Page 20: Changing Direction Of Rotation
NOTE The direction of rotation measuring device monitors the direction of rotation of the mains supply or that of an emergency generator. Maintenance and service Before commencing any maintenance work the unit should be completely disconnected from the mains by a qualified person and care should be taken that it cannot be inadvertently switched back Repair work must only be carried out by qualified personnel approved by Sulzer. When carrying out any on-site service or maintenance work i.e. cleaning, venting, fluid inspection or changing, and adjustment of the bottom plate gap, the safety regulations covering work in enclosed areas of sewage installations as well as good general technical practices should be followed. Under continuous running conditions the pump motor housing can become very hot. To prevent burn injury allow to cool down before handling. Coolant temperature can reach up to 60 °C under normal operating conditions. -
Page 21: Oil Filling And Changing
Draining: Remove screw (1) and sealing washer (2). Place pump in a horizontal position with the plug hole underneath. Filling: Rotate the pump into a horizontal position with the plug hole to the top. Slowly fill oil into the fill hole. Select the required volume from the oil filling quantities table. Refit screw (1) and sealing washer (2). Oil: white ISO VG15 FP175C 12.3 Oil quantities (liters) Pump Type Motor 50 Hz 60 Hz AS 0530 S12/2 S16/2 0.48 AS 0530 S17/2 S18/2 0.48 AS 0530 S26/2 S30/2 0.48 AS 0630 S10/4 S10/4 0.56... -
Page 22: Bottom Plate Adjustment (Contrablock)
12.4 Bottom plate adjustment (Contrablock) At manufacture, the Contrablock bottom plate is fitted to the volute with the correct clearance gap set between the impeller and the bottom plate (for optimum performance max 0.2 mm). 12.4.1 Re-setting the clearance gap following wear AS 0641 and 0840: 1. Loosen the three securing screws (a) and washers (b). 2. Rotate the bottom plate anti-clockwise to lower it until there is contact with the impeller. 3. Rotate the bottom plate clockwise until there is 0.3 mm to 0.5 mm clearance between it and the impeller. 4. Tighten the securing screws to 17 Nm. 5. Check that the impeller rotates freely. AS 0831 and 0841: 1. Loosen the four securing screws (b). 2. Rotate the four adjusting screws (a) anti-clockwise until there is contact between the bottom plate and the impeller. 3. Rotate the adjusting screws clockwise until there is 0.3 mm to 0.5 mm clearance between the bottom plate and the impeller. 4. -
Page 23: Bearings And Mechanical Seals
12.5 Bearings and mechanical seals AS pumps are fitted with lubricated-for-life ball bearings. Shaft sealing between the motor and hydraulic section is by means of a mechanical seal (Sic/Sic). Seal at the motor side is by an oil lubricated lip seal. ATTENTION! Once removed, bearings and seals must not be re-used, and must be replaced in an approved workshop with genuine Sulzer spare parts. 12.6 Changing the power cable The power cable must be replaced by the manufacturer, its service agent or a similar qualified person, in strict adherence to relevant safety regulations. 12.7 Clearing pump blockage 12.7.1... -
Page 24: Troubleshooting Guide
Troubleshooting Guide Fault Cause Pump does not Leakage sensor shutdown. Check for loose or damaged oil plug, or locate and replace faulty mechanical seal / damaged o-rings. Change oil. Air lock in volute Shake or raise and lower the pump repeatedly until resulting air bubbles no longer appear at surface level. Level control override. Check for float switch that is faulty or tangled and held in OFF position in sump. Impeller jammed. Inspect and remove jammed object. Check gap between impeller and bottom plate and adjust if necessary. Gate valve closed, non-return valve Open gate valve, clean blockage from non-return blocked. - Page 25 SERVICE LOG Date Hours of Comments Sign Operation 6006077-02...
- Page 26 SERVICE LOG Date Hours of Comments Sign Operation 6006077-02...
- Page 27 SERVICE LOG Date Hours of Comments Sign Operation 6006077-02...
- Page 28 Sulzer Pump Solutions Ireland Ltd. Clonard Road, Wexford, Ireland Tel. +353 53 91 63 200. www.sulzer.com...
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