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Summary of Contents for Sulzer PE1
- Page 1 Original instructions Installation, operation and maintenance instructions Submersible Sewage Pump Type ABS XFP PE1 - PE3 www.sulzer.com SULZER CONFIDENTIAL...
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Page 2: Table Of Contents
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS Table of contents Page 2 Table of contents 1. Important notice....................................4 2. Symbols and notices................................... 4 3. General........................................5 3.1. Hydraulics....................................5 3.2. Intended use and application..............................5 3.3. - Page 3 14.1.1. Inspection intervals.............................. 40 14.2. Lubricant changing (PE1 & PE2)............................40 14.2.1. Drain and fill the seal chamber (PE1 & PE2)....................... 41 14.3. Lubricant changing (PE3 - version without cooling jacket)....................42 14.3.1. Drain and fill the inspection and seal chambers (PE3 - version without cooling jacket)........43 14.4.
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Page 4: Important Notice
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 1. Important notice Page 4 1. Important notice NOTE The original version of this document is in English. All other languages are a translation of the original. In case of a discrepancy, the English version will prevail. -
Page 5: General
Municipal combined sewage and storm water systems. • Seawater applications with cathodic protection and IM5 coating (consult Sulzer for advice). XFP-CP (Chopper) pumps have been designed for the pumping of heavily contaminated commercial, Industrial, municipal and agricultural wastewater, sewage and sludge, in wet well installations. -
Page 6: Identification Code
ATTENTION Leakage of lubricants could result in pollution of the medium being pumped. ATTENTION Always consult with your local Sulzer representative for advice on approved use and application before installing the pump. 3.3. Identification code Table 2. e.g. XFP 80C CB1.3 PE22/4-C-50... -
Page 7: Performance Range
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 4. Performance range Page 7 4. Performance range Figure 1. Contrablock impeller 50 Hz / 60 Hz 50 Hz 107G 101G 105J 105G 100G 155G 155J... -
Page 8: Safety
5. 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. -
Page 9: Special Conditions For Safe Use
Protection Type EX (i), in accordance with IEC 60079-11 and FM 3610. In the event that the unit is to be operated in explosive atmospheres using a variable speed drive (VFD), please contact your local Sulzer representative for technical advice regarding the various approvals and standards concerning thermal overload protection. -
Page 10: Nameplate Drawings
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 7. Technical data Page 10 7.1.1. Nameplate drawings Figure 3. Standard nameplate PE1-3, CE, 50 Hz PE1-3, US/CA, 60 Hz Table 3. Legend Description Data Pump type Item No. -
Page 11: General Design Features
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 8. General design features Page 11 Legend Description Data Motor efficiency standard NEMA NEMA code Class Figure 4. Ex nameplate PE1 and PE2, 50 Hz PE3, 50 Hz 8. -
Page 12: Design Features Pe1 & Pe2
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 8. General design features Page 12 8.1. Design features PE1 & PE2 Pressure release screw 10-pole terminal block Leakage sensor (DI) Seal chamber Seal chamber drain plug /pressure test point... -
Page 13: Design Features Pe3 (Version With Cooling Jacket)
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 8. General design features Page 13 Motor chamber Lower bearing - double row Bearing housing Mechanical seals Seal holding plate Motor chamber drain plug /pressure test point... -
Page 14: Weights
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9. Weights Page 14 Stainless steel lifting hoop Lid assembly Cable gland Upper bearing - cylindrical roller bearing Coolant fill plug Cooling jacket Motor housing Lower bearing housing... -
Page 15: Xfp - 50 Hz
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9. Weights Page 15 9.1. XFP - 50 Hz Table 4. XFP (50 Hz) Pedestal Horizontal Transport- Cable** Pump*** bracket and supports* able pump (kg) without cable... - Page 16 Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9. Weights Page 16 XFP (50 Hz) Pedestal Horizontal Transport- Cable** Pump*** bracket and supports* able pump (kg) without cable fasteners (kg) (kg) stand (kg) (kg)
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Page 17: Xfp - 60 Hz
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9. Weights Page 17 XFP (50 Hz) Pedestal Horizontal Transport- Cable** Pump*** bracket and supports* able pump (kg) without cable fasteners (kg) (kg) stand (kg) (kg) - Page 18 Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9. Weights Page 18 XFP (60 Hz) Pedestal Horizontal Transport- Cable** Pump*** without cable bracket and supports* able pump kg (lbs) kg (lbs) fasteners kg (lbs)
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Page 19: Chain (En 818)
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 9. Weights Page 19 XFP (60 Hz) Pedestal Horizontal Transport- Cable** Pump*** without cable bracket and supports* able pump kg (lbs) kg (lbs) fasteners kg (lbs) -
Page 20: Lifting, Transport And Storage
The hoist must be adequately dimensioned for the total weight of the Sulzer units (including lifting chains or steel ropes,and all accessories which may be attached). The end user assumes sole responsibility that lifting equipment is certified, in good condition, and inspected regularly by a competent person at intervals in accordance with local regulations. -
Page 21: Transport
10. Lifting, transport and storage Page 21 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. Related concepts... - Page 22 Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 10. Lifting, transport and storage Page 22 Figure 5. XFP 80C - 151E (PE1 & PE2) Vortex Contrablock Figure 6. XFP 100G - 305J (PE3) Table 5.
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Page 23: Storage
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 23 CAUTION For angular lifting, shoulder-type machinery eyebolts (EN ISO 3266) rated to take loads ≤ 90° must be used and the workload must be adjusted accordingly. -
Page 24: Equipotential Bonding
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 24 • 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). -
Page 25: Installation Types
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 25 11.3. Installation types 11.3.1. Submerged in a concrete sump Sump cover Venting line Sump cover Sleeve for cable ducting to the control panel as well as for aeration and venting... - Page 26 Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 26 Table 6. Fasten the pedestal to the sump base using Sulzer anchor bolt kits: Pedestal DN 80 & DN 100 DN 150...
- Page 27 Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 27 Procedure Fit the pedestal coupling bracket (a) and seal (b) to the discharge flange of the pump. Fit a chain and shackle to the lifting hoop 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.
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Page 28: Dry-Installed
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 28 11.3.2. Dry-installed Figure 7. Horizontal The pump is installed using the Sulzer horizontal support kit as specified for the particular model (assembly leaflet 15975757 is supplied with kit). SULZER CONFIDENTIAL Copyright ©... - Page 29 Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 29 Figure 8. Vertical Control panel Discharge line Gate valve Non-return valve Power cable from motor to control panel Pump Collection sump...
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Page 30: Transportable
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 11. Setup and installation Page 30 ATTENTION XFP 100G - 305J pumps must not be dry-installed without a cooling jacket. The oil-cooled version of 80C - 151E must be used. -
Page 31: Venting Of The Volute
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 12. Electrical connection Page 31 11.3.4. Venting of the volute After lowering the pump into the sump medium, an air lock may occur in the volute causing pumping problems. To clear the air lock, you can shake the pump and/or raise and lower the pump in the medium, until the resulting air bubbles no longer appear at surface level. -
Page 32: Seal Monitoring
(PE1 & PE2), motor (PE3, 50 Hz), or motor and inspection chambers (PE3, 60Hz). In order to integrate this seal monitoring function into the control panel of the unit it is necessary to fit a Sulzer DI module and connect this in accordance with the circuit diagram below. - Page 33 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.
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Page 34: Temperature Monitoring
12. Electrical connection Page 34 ATTENTION If the leakage sensor (DI) is activated the unit must be immediately taken out of service. Please contact your Sulzer service center. 12.2. Temperature monitoring Thermal sensors in the stator windings protect the motor from overheating. -
Page 35: Temperature Sensor Ptc
12.3. Operation with variable frequency drive (VFD) The stator design and the insulation grade of the motors from Sulzer means that they are suitable for usage with VFD, according to IEC 60034-25:2022 / NEMA 61800-2:2005. It is however essential that the following conditions are met: •... -
Page 36: Wiring Diagrams
• Machines that are not designated as Ex machines may only be operated using the mains frequency indicated on the nameplate. Greater frequencies can be used but only after consulting with and receiving permission from the Sulzer manufacturing plant. •... -
Page 37: Commissioning
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 13. Commissioning Page 37 50 Hz 60 Hz 13/6 20/6 15/4 22/4 D01,D14, D68, D80 D66, D62, D77, D85 22/4 28/4 29/4 35/4 30/2 D64, D67,... -
Page 38: Types Of Operation And Frequency Of Starting
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 13. Commissioning Page 38 • Do the non-return valves (where fitted) function easily? • Has the volute been vented? • Have the power and control circuit cables been correctly fitted? •... -
Page 39: Changing Direction Of Rotation
CAUTION Repair work must only be carried out by qualified personnel approved by Sulzer. WARNING Hot surface Under continuous running conditions the pump motor housing can become very hot. -
Page 40: General Maintenance Instructions
Contact your local Sulzer Service Center for more information. A maintenance contract with our Service Department will guarantee the best technical service. The Sulzer service organisation would be pleased to advise you on any applications you may have and to assist you in solving any problems you may encounter. -
Page 41: Drain And Fill The Seal Chamber (Pe1 & Pe2)
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 14. Maintenance and service Page 41 14.2.1. Drain and fill the seal chamber (PE1 & PE2) About this task Drain plug screw Drain Fill Procedure Loosen the drain plug screw (1) enough to release any pressure that may have built-up, and re-tighten... -
Page 42: Lubricant Changing (Pe3 - Version Without Cooling Jacket)
14.3. Lubricant changing (PE3 - version without cooling jacket) An oil change is only necessary: • at specified service intervals (for details contact your local Sulzer Service Center). • if the DI leakage sensor detects an ingress of water into the motor, seal, or inspection chambers. -
Page 43: Drain And Fill The Inspection And Seal Chambers (Pe3 - Version Without Cooling Jacket)
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 14. Maintenance and service Page 43 14.3.1. Drain and fill the inspection and seal chambers (PE3 - version without cooling jacket) About this task Seal ring - Inspection chamber... -
Page 44: Coolant Changing (Pe3 - Version With Cooling Jacket)
-15 °C / 5 °F. A glycol change is only necessary: • at specified service intervals (for details contact your local Sulzer Service Center). • if the DI leakage sensor detects an ingress of water into the motor chamber or seal chamber. -
Page 45: Oil And Glycol Quantities (Liters)
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 14. Maintenance and service Page 45 Note: because there is insufficient space to place a waste container underneath the drain plug by the completion of step 5, the waste must be drained into a sump. -
Page 46: Bottom Plate Adjustment (Cb & Cp)
PE220/6 PE250/6 Volume ratio: 86% oil or water/propylene glycol: 14% air Specification: Lubricant PE1 & PE2: white mineral oil VG8 - VG10. Lubricant PE3: hydraulic oil VG32 HLP-D. Coolant PE3: 70% water/30% glycol 14.6. Bottom plate adjustment (CB & CP) At manufacture, the 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). -
Page 47: Adjust The Bottom Plate (Cb & Cp)
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 14. Maintenance and service Page 47 14.6.1. Adjust the bottom plate (CB & CP) About this task Factory pre-set position Adjustment position Note: when adjusting PE3 and CP pumps, steps 1, 2 and 3 do not apply. -
Page 48: Bearings And Mechanical Seals
The power cable must be replaced by the manufacturer, its service agent or a similar qualified person, in strict adherence to relevant safety regulations. PE1 & PE2: To facilitate quick and easy changing or repair of the power cable, the connection between the cable and motor is by means of an integrated 10-pole terminal block. -
Page 49: Cleaning
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 14. Maintenance and service Page 49 CAUTION Adequate personal protective equipment must be worn at all times. CAUTION Lifting safety regulations must be adhered to when lifting the pump. -
Page 50: Troubleshooting Guide
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 15. Troubleshooting guide Page 50 15. Troubleshooting guide Table 11. Fault Cause Pump does not run Leakage sensor shutdown Check for loose or damaged oil plug, or locate and replace faulty mechanical seal / damaged o-rings. -
Page 51: Company Details
Submersible Sewage Pump Type ABS XFP PE1 - PE3 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS 16. Company details Page 51 CAUTION Before commencing any inspection or repair work the pump should be completely disconnected from the mains by a qualified person and care should be taken that it cannot be inadvertently switched back on.
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