A22.SOW_REFERENCE_4_PUMP_O&M_MANUAL.pdf

SULZER

OPERATION AND

MAINTENANCE MANUAL

Section 22 11 23.00 10 Submersible Pump, Axial & Mixed Flow-Type

PROJECT: Rice Lake Habitat Rehab and Enhancement

LOCATION: Illinois Waterway, Lagrange Pool, Fulton County IL

CONTRACTOR: SAF, Inc.

ABS REP: Flow Technics, Inc. Frankfort, IL

PREPARED BY: Mike Stroh DATE: 3/7/2013

REVIEWED BY: Mark Jaminet DATE: 3/7/2013

APPROVED BY: DATE:

ABS USA 140 Pond View Drive, Meriden, CT 06450 203-238-2700 www.absgroup.com

CONT ACT LIST

1. Flow-Technics, Inc.

181 Ontario Street Frankfort, IL. 60423 815-277-2600 815-534-5311 (Fax)

2. ABS Main Office (Corporate head office & warehouse for N America) Sulzer Pumps

ABS USA

140 Pond View Drive Meriden, CT 06450 Phone (203) 514-4276 Fax (203) 238-0738

ABS USA 140 Pond View Drive, Meriden, CT 06450 203-238-2700 www.absqroup.com l.

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C\I C\i co (9

Weknowhowwalerworks

ABS submersible sewage pumps AFP MS, M9 ABS submersible mixed flow column pumps AFL Ml and MS, M9

ABS submersible propeller pumps VUP Ml and MB, M9 alie

Installation and Operating Instructions www.absgroup.com 0521-B

2 Installation and Operating Instructions

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

Installation and Operating Instructions for ABS submersible sewage pumps, ABS submersible mixed flow column pumps and ABS submersible propeller pumps

Motors M8+M9 with AFP-Hydraulics

AFP 4003 (50/60 Hz)

AFP 4004 (60 Hz)

AFP 5002 (50/60 Hz)

Motors M3 with AFL-Hydraulics

AFL0601

Motors M8+M9 with AFL-Hydraulics

AFL 1202

AFL 1203

AFL 1207

Motors M3 with VUP-Hydraulics

VUP0401

VUP0402

VUP0403

Motors M8+M9 with VUP-Hydraulics

VUP0801

VUP0802

VUP 1001

VUP 1002

AFP 6001 (50/60 Hz)

AFP 6003 (50/60 Hz)

AFP 6004 (50/60 Hz)

VUP 1201

VUP 1202

ABS reseives the right to alter specifications due to technical developments I

AFP 8001 (50/60 Hz) abS Installation and Operating Instructions 3

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, MS, M9

Table of contents

1 General .•••.•••..•..•.•.•..••.•.......•...•..........••.••••.•.•..••••.•..•.........••...•.••••.•...•••.••.•......................••..••.•.•..••••..•••••• &

1.1 Introduction

1.2 Correct usage of the products

1.3 Application restrictions of the submersible pumps

1.4 Application areas for the submersible pumps

1.4.1 Application areas for the series AFP

1.4.2 Application areas for the series AFL

1.4.3 Application areas for the series VUP

1.5 Identification coding

1.6 Technical data

1. 7 Dimensions and weights

1.8 Nameplate

2 Safety •...•..•.........•••......................................•.•.••....•.....................••......•......•...•.........................•.•.....•... 10

3 Transport and storage ••........••.•..•.••.•••••.•..•..............•...•.....••.......................•.•.•.•.•...••......•...............•.•• 10

3.1 Transport .....................................................................•

3.1.1 Standing transport

3.1.2

3.2

3.2.1

Transport in a horizontal manner

Transport securing devices

Motor connection cable moisture protection

3.2.2 Transport securing device for AFP submersible pump shafts

3.2.3 Transport security of pump and impeller for motors with an impeller installed

3.2.4 Constructional assembly of the volute for motors with an impeller installed

3.2.5 Transport securing device for submersible pump shafts AFLNUP .......................................•

3.3 Storage of the units

4 Product description ...............................•.....................•..•...............................•...............................•..• 16

4.1 Structural design

4.2 Motor monitoring system

4.2.1 Temperature monitoring of the stator

4.2.2 DI-Electrode

4.2.3 Temperature monitoring of the bearings (Option M3) ...................................................... :

4.2.4 Temperature indication

4.3 Operation with frequency inverters

5 Installation

5.1 Installation of the AFP submersible pumps

5.1.1 Installation options for the AFP submersible pumps

5.2

5.2.1

5.2.2

Installation examples

Wet installation of the AFP submersible pump

Installation of the AFP submersible pump in a dry sump 0521·8

5.3

5.4

Installation and Operating Instructions

AFP MB, M9 I AFl M3, MB, M9 I VUP M3, MB, M9

Fitting the pedestal ..............................................................................................•

Installation of the AFL and VUP submersible pumps

5.4.1 Types of installation of the AFL and VUP submersible pumps

5.4.2 Installations examples with AFL and VUP submersible pumps

5.4.3 Installation of the AFL and VUP submersible pumps

5.4.4 Lowering of the AFL and VUP submersible pump into the coupling ring

5.5 Electrical connection ........................................................................................•

5.5.1 Standard connection diagrams, mains voltage 380 - 420 Vat 50 Hz/460 Vat 60 Hz, M3 motors

5.5.2 Standard connection diagrams, mains voltage 400 V at 50 Hz/460 Vat 60 Hz, M8/M9 motors

5.5.3 Lead designations

5.5.4 Checking direction of rotation

5.5.5 Changing direction of rotation

5.5.6 Connection of the control circuit leads

5.5.7 Connection of the seal monitoring unit to the control panel

6 Commissioning •.•••..••.•.•••••••••••••..••...••••.••....•.•••••••.•.•••......•.•..••••••••.•....••....•.••••..•.•.••.•..•••••••••••.•.•...•••.•• 33

6.1 · Starting frequency of the motors

7 Maintenance •.•.........••.••••••••••••••.•••••••••••••••..••••..•...••.••••.•••••.•••.....•..•••••••••••••....•••••.•.•.•••••••....•••••.•••••....• 34

7.1 General maintenance hints

7 .2 Maintenance hints if the submersible pump is out of use for a considerable period

7.2.1

7.2.2

Before installation

After installation

7.3 Removal of the submersible pump ......................................................•

7 .3.1 Removal of the AFP submersible pump from a wet sump

7 .3.2 Removal of the AFP submersible pump when dry installed

7.3.3 Removal oftheAFL and VUP submersible pump ................ ~

8 Assembling the gearbox AFLNUP ••••.••••..•.•••.•••••••••••••.•...•.•••...•.•••••.•••••••.•..•..•.•.•.•••••••.....••••.••••.•..•... 36

8.1 Assembling the motor and the gearbox/hydraulic unit (M8)

8.2 Remove transport securing device (M8)

8.3 Remove transport securing device of the gearbox (M8)

8.4 Assembly instructions for gearbox/motor housing (M8)

8.5 Assembling the motor and the gearbox/hydraulic unit (M9)

8.6 Remove transport securing device {M9) ..................................................•

8. 7 Remove transport securing device of the ge;arbox (M9)

8.8 Assembly instructions for gearbox/motor housing (M9) ............................•

0521-B

Installation and Operating Instructions 5

AFP MS, M9 f AFL M3, MS, M9 f VUP M3, MS, M9

6 Installation and Operating Instructions

AFP M8, M9 I AFL M3, M8, M9 f VUP M3, M8, M9

1 General

1.1 Introduction

These Installation and Operating Instructions and the separate booklet Safety Hints contain basic instructions and safety hints which must be observed during transport, installation and commissioning. For this reason it is essential that they are read by the installing technician as well as by relevant skilled operators or users. They should also be always available where the unit is installed.

Safety Instructions which might cause danger to life in case of non-observance have been specifically highlighted with the general danger symbol.

The presence of a dangerous voltage is identified with this safety symbol.

This symbol indicates the danger of an explosion occurring.

ATTENTION Appears at safety hints, the non-observance of which could damage the unit or affect its functioning.

NOTE Used for important pieces of information.

Illustrations code; e.g. {3/2). The first digit refers to the figure no. and the second digit to the position in that figure.

1.2 Correct usage of the products

The ABS products have been designed and built in accordance with the latest technology and taking into account the relevant safety regulations. However improper usage could cause a danger to life or limb of the user of a third party or cause damage or function impairment to the unit itself and other items of value.

The ABS units should only be used if they are in perfect technical condition taking into account all safety requirements and conscious of the need to avoid potentially dangers. The contents of the installation and operating instructions and the safety hints must be applied! Any other usage (abnormal usage) or usage beyond that specified will be considered as non-compliance.

The manufacturer/supplier will not accept any responsibility for damage due to this. The risk is borne by the user. In case of doubt the entire scope of the planned application must be approved by ABS.

In the case of any faults arising, the ABS units should immediately be taken out of use and secured. The fault should be immediately rectified or, if necessary, contact your ABS service centre.

1.3 Application restrictions of the submersible pumps

The submersible pumps can be supplied both as standard versions and in explosion-proof execution with {ATEX II 2Gk EEx dll B T4} for 50 Hz or FM (NEC 500, Class I, Division 1, Group C&D, T3C) approval for 60 Hz

Limitations:

ATTENTION

Fluid temperature maximum 40 °C (104 °F)

Immersion depth maximum 20 m (65 ft)

If cable length is less than 20 m/65 ft the max. immersion depth reduces accordingly. In special cases an immersion depth greater than 20 m/65 ft is possible. In order to do this you need the written approval from the manufacturer ABS.

I

Installation and Operating Instructions 7

AFP MS, M9 I AFl M3, MS, M9 I VUP M3, MS, M9

Pumping of flammable or explosive liquids with these pumps is not allowed!

Only explosion-proof executions may be used in hazardous areas!

For the operation of units as explosion-proof execution the following applies:

In hazardous areas care must be taken that during switching on and operation of the pumps the pump section is filled with water (dry installation) or alternatively is submerged or under water (wet installation with cooling jacket. Other types of operation e.g. snore operation or dry running are not allowed!

ATTENTION The ex versions are not fitted with a seal monitor (DJ) in the monitoring chamber or in the oil chamber. There is an option of an external seal monitor for the ex versions

For the operation of explosion-proof submersible pumps in wet-well installation without cooling jacket applies:

It must be ensured that the motor of the ex-submersible pump is always fully submerged during start-up and operation!

For the operation of explosion-proof submersible pumps applies:

The temperature monitoring of the explosion-proof submersible pumps has to be carried out by bimetallic temperature limiters or thermistors according to DIN 44 081-150 connected to a suitable release device which is certified in accordance with EC directive 94/9/EC.

For the operation of explosion-proof submersible pumps with frequency inverter applies:

Motors must have direct thermal protection devices fitted. These consist of temperature sensors (PTC DIN 44081-150} embedded in the windings. These must be connected to a suitable release device which is certified in accordance with EC directive 94/9/EC.

Machines designated as Ex machines may never, without exception, be operated using a mains frequency that is greater than the maximum of 50 or 60 Hz as indicated on the nameplate.

1.4 Application areas for the submersible pumps

1.4.1 Application areas for the series AFP

The ABS submersible sewage pumps of the AFP series have been designed for the economical and reliable pumping of commercial, industrial and municipal sewage and can be installed dry or wet.

They are suitable for pumping of the following liquids:

• Clear and wastewater, for sewage containing solids and fibrous material

• Faecal matter

•Sludge

• Fresh and process water pumping

• Raw water for drinking water supply

• Surface and rain water

•Sewage

In combination with the ABS automatic coupling system, the below ground level wet installation is a particularly economical and environmentally friendly solution. The pumps are also suitable for horizontal or vertical dry installation.

1.4.2 Application areas for the series AFL

The ABS mixed flow column pump of the AFL series have been developed for environmental protection, water supply, municipal sewage treatment and dewatering of polders.

8 Installation and Operating Instructions

AFP MS, M9 I AFl M3, MS, M9 I VUP M3, MS, M9

They are suitable for the following liquids:

• Raw water with solid or fibrous material.

•Sewage

• Surface water, rain water, drainage water

•Sludge

The AFL pumps are installed in a concrete sump or in a steel pressure pipe using a suitable coupling ring

1.4.3 Application areas for the series VUP

ABS submersible propeller pumps of the VUP series are designed for those applications where large water volumes must be pumped at low heads (up to 10 m/33 ft).

They are suitable for the following liquids

• Fresh and process water pumping

• Raw water for drinking water supply

• Surface and rain water

Die VUP pumps are installed in a concrete sump or in a steel pressure pipe using a suitable coupling ring.

1.5 Identification coding

Hydraulics Motor

MA .6§ ~.c. .YU. vw I W-XY.Z .

T L Number of poles in motor

L Motor power [P2 x 1 O in kW]

.___ _____ Motor designation (e.g. ME)

~-------Hydraulic-number

~---------Discharge size ON [cm]

.__ _____________ Series

Figure 1 Identification coding

X: Part of the manufacturing code for the motor size X gives the motor size

Y: Part of the manufacturing code for the motor size Y indicates the stator length. Selection here is between a motor frame size and number of poles 1 to n.

Z: Information on the motor (50 Hz) or FM (60 Hz) for explosion proof versions.

1.6 Technical data

The electrical data is dependent on the operating point for which the unit was designed. Please take the technical data from the name plate or from the ABS EL data files.

The maximum noise level of the units of this series is ~ 70 dB(A). In some types of installation and at certain operating points on the performance curve it is possible that the noise level of 70 dB(A) or the measured noise level will be exceeded.

Installation and Operating Instructions 9

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

1. 7 Dimensions and weights

The dimensions of the unit can be found on the relevant dimensional sheet. The hydraulic curves and impeller type can be found on the ABSEL hydraulics curve sheet. Please take the technical data and the weight of the units from the nameplate.

1.8 Nameplate

We recommend that you record the data from the original nameplate Figure 2 so that you can refer to the data at anytime.

$: amr 101 I Type:@ I Year:©

I Part-No.:@ IPO·No.:@ I Pump-No.:([)

UN:@ v® Hz ON:@ I® P1N:@ P2N :@ Jrv Mot. Q:@

IN: @ An:@ IP68 H:@

Serv.·F.:@ Nema Code:@) I lns.-CI.:@ lmp.-0/Ang.:@

Oper. Temp.:@ Amb. Temp. max.: @ max.SZ:@ I® db(A'

I® I® I Weight: @ Made in:@

1£:33+-uDuor® & D? not open while ene~.gized $ N1cht unter Spannung offnen $ Figure 2 Nameplate 42240223

Legend

Address 16 Speed [1/min/rpm] 2 Logo approval 17 Nominal delivery head [m/mm/in/ft] 3 Model designation 18 Service factor (only applied to 60 Hz orders), e.g. 1.15) 4 Year of manufacture 19 Nema Code Letter (only at 60 Hz, e.g. H) 5 Item no. 20 Insulation class (e.g. F) 6 Customer order no. 21 Impeller 0 / Propeller angle [mm/°] 7 Pump no. 22 Temperature class (only with FM, e.g. T3C) 8 Nominal voltage (and phase switching) 23 Max. ambient temperature [°C, °F] 9 Frequency 24 Max. immersion depth [m, ft]

10 Nominal discharge diameter 25 Sound level 11 Free reserve field 26 Ex-symbol (only with Ex-pumps) 12 Power (uptake) [kW] 27 Ex/FM designation 13 Power {delivery) [kW/hp] 28 Weight (without attached parts) [kg, lbs] 14 Nominal flow rate [l/s, m3/h, gpm] 29 Country of manufacture 15 Nominal current 30 Direction of rotation of motor shaft

NOTE In all communication please state type of the unit, item and serial number!

NOTE Additional country specific nameplates possible.

10 Installation and Operating Instructions

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

2 Safety

The general and specific health and safety hints are described in detail in the separate booklet Safety Hints. If anything is not clear or you have any questions as tp safety make certain to contact the manufacturer ABS.

3 Transport and storage

3.1 Transport

The unit must never be raised by the power cable.

Depending on model and mode of installation, the units are prepared at the factory for vertical or horizontal transportation.

Depending on the version, the units are fitted with eyes (M3), eyebolts or attachment swivels (horizontal installation), to which a chain can be fastened by means of shackles to transportation, installation or removal.

3.1.1

Take note of the entire weight of the unit (see nameplate Figure 2) The hoist and chain must be adequately dimensioned for the weight of the unit and must comply with the current valid safety regulations.

The unit should be protected from rolling over!

The unit is prepared for'transportation by placing it on an adequately strong, completely horizontal sur face taking care that it cannot topple over.

Do not stay or work in the swivel area of a suspended load!

The lifting hook height must take into consideration the entire height of the unit as well as the length of the lifting chain!

Standing transport

Figure 3 Standing transport AFP Figure 4 Standing transport AFL and VUP

0521-B

Installation and Operating Instructions 11

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

The safety hints in the section above must be observed!

3.1.2 Transport in a horizontal manner

Figure 5 Transport in a horizontal manner AFP Figure 6 Transport in a horizontal manner AFLNUP

ATTENTION a max. S 45°. The angle a between the centre line of the unit and the lifting tools should not exceed 45°.

The safety hints in the previous sections must be observed!

Submersible pumps are only transported in a horizontal position if they have been built for horizontal installation.

The submersible pump can be placed on the mounting frame fitted on the pump and transported .

ATTENTION Avoid point loading. If necessary, place the pump on a secure robust pallet and tie down using steel bands or other fixing methods.

Only lift up the submersible pump if it is suspended horizontally on the crane hooks.

If necessary, adjust the chain accordingly.

3.2 Transport securing devices

3.2.1 Motor connection cable moisture protection

The motor connection cables are protected against the ingress of moisture along the cable by having the ends sealed at the works with protective covers.

ATTENTION These protective covers should only be removed immediately prior to connecting the pumps electrically.

Particular attention is necessary during storage or installation of pumps in locations, which could fill with water prior to laying and connection of the power cable of the AFP-motor. Please note that the cable ends, even where fitted with protective sleeves, cannot be immersed in water.

ATTENTION These protective covers only provide protection against water spray or similar and are not a water tight seal. The ends of the cables should not be immersed in water, otherwise moisture could enter the connection chamber of the motor.

0521·9

12 Installation and Operating Instructions abs AFP M8, M9 f AFL M3, M8, M9 I VUP M3, M8, M9

NOTE

ATTENTION

If there is a possibility of water ingress then the cables should be secured so that the ends are above the maximum possible flood level.

Take care not to damage the cable or its insulation when doing this!

3.2.2 Transport securing device for AFP submersible pump shafts

NOTE Does not apply to all models.

In order to avoid damage to the pump shaft or the bearings during horizontal transport, the shaft is clamped in an axial direction when leaving the works.

ATTENTION The transport securing device on the pump shaft should only be removed immediately before installation or connecting up the pump.

LOCTITE243

Figure 7 Removal of the transport securing devices AFP (without holes on the suction side)

• Before commissioning remove securing device (7/1-6). Fit impeller washer with securing pin (7/7) and impeller screw (7/9) complete with lock washers (7/8).

ATTENTION Hold the impeller washer (7n) in position when unscrewing the threaded rod (712).

The impeller screws of the M4 motors are in addition secured with LOCTITE Type 243 (LOCTITE will be supplied if required).

• Insert the impeller washer (7/7) so that the securing pin of the washer fits into the drilled hole of the shaft.

Fasten the socket head screw (7/9) together with the lock washers (7/8).

ATTENTION Ensure that the fitting position and tightening torque of the Nord-Lock® securing washers is correct as in Figure 8 and table for tightening torque!

0521-B

I •

Installation and Operating Instructions 13

AFP MS, M9 ( AFL M3, MS, M9 ( VUP M3, MS, M9

Outer side of the 2 securing washers

Inner side of the 2 securing washers

Figure 8 Correct fitting position of the Nord-Lock® securing washers

Tightening torque for ABS stainless steel screws A4-70:

Thread I M6 I MS I M10 I M12 I M16 I M20

Tightening torque I 6.9Nm I 17Nm I 33Nm I 56Nm I 136Nm I 267Nm

I

2 3 4 5 1

Figure 9 Removal of the transport securing devices AFP (with holes on suction side)

• Before commissioning, remove the transport securing devices (9/1-5).

I M24

I 460Nm

ATTENTION After fitting of the impeller washer, check that the impeller can be turned by hand.

1-4

3.2.3

Installation and Operating Instructions

AFP M8, M9 I AFl M3, M8, M9 I VUP M3, M8, M9

Transport security of pump and impeller for motors with an impeller installed

The safety hints in the previous sections must be observed!

• Before commissioning, remove the transport securing devices (10/1-5).

ATTENTION

The transport securing device on the pump shaft should only be removed immediately prior to installation or connecting to the pump •

• ,--5 9----y

"1.--4 ll-t----1 k~~-2 ----~3

. Figure 10 Removal of the transport devices in motors with an impeller installed and a volute to be fitted at the construction stage

3.2.4 Constructional assembly of the volute for motors with an impeller installed

& The safety hints in the previous sections must be observed!

• Lightly grease the 0-Ring (10/6) and draw it carefully over the impeller and insert into the centring seating of

· the oil chamber flange.

• Using a suitable hoist, carefully set up the motor (10/7) over the volute (10/8) so that the cast on lugs in the oil chamber point in the direction of the discharge flange (See arrow illustrated in Figure 10).

ATTENTION When lowering the motor with impeller into the volute care should be taken that the impeller slides in a straight manner into the wear ring.

• Lower the motor so that the flanged holes in the oil chamber line up with the pre-assembled studs (10/10) on the volute (10/8). Place the motor on the pump housing.

•Tighten the hex. nuts (10/9) using the recommended tightening torque.

ATTENTION After fitting of the impeller washer, check that the impeller can be turned by hand.

0521-B • abS Installation and Operating Instructions 15

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

3.2.5 Transport securing device for submersible pump shafts AFUVUP

NOTE Does not apply to all models!

In order to avoid damage to the pump shaft or bearings during horizontal transport, the shaft is clamped in an axial direction when leaving the works.

The safety hints in the previous sections must be observed!

ATTENTION The transport securing device on the motor shaft should only be removed immediately prior to installation or connecting up to the pump.

Figure 11 Removal of the transport devices on VUP and AFL pumps

• Remove the transport securing device {11/1) .

3.3 Storage of the units

ATTENTION

NOTE

The ABS products must be protected from weather influences such as UV from direct sunlight, high humidity, aggressive dust emissions, mechanical damage, frost etc. The ABS original packaging with the relevant transport securing devices (where used) ensures optimum protection of the unit. If the units are exposed to temperatures under O °C/32 °F check that there is no water in the hydraulics, cooling system, or other spaces. In the case of heavy frosts, the units and cable should not be moved if possible. When storing under extreme conditions, e.g. in tropical or desert conditions suitable additional protective steps should be taken. We would be glad to advise you further.

ABS units do not generally require any particular maintenance during storage. After long storage periods (after approx. one year), the transportation Jocking device on the motor shaft (not with all versions) should be disassembled. By rotating the shaft several times by hand, new lubricating oil or, depending on the version, a small amount of coolant (which also serves to cool or lubricate the mechanical seals) is applied to the sealing surfaces, thus ensuring perfect operation of the mechanical seals. The bearings supporting the motor shaft are maintenance-free.

4.1

Installation and Operating Instructions

AFP MS, M9 I AFl M3, MS, M9 I VUP M3, M8, M9

Product description

Structural design

2 3

----12

/Y,A. _ _J_ __ _!,j,/22

25 27 28

Figure 12 AFP MB

Figure 14 AFL MB I M9

I

27 28

Figure 13 AFP M9 ahi

Figure 15 VUP MB I M9 0521-B

Installation and Operating Instructions 17

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

Legend

1 Lifting hoop {Standard) 2 Eyebolts (Option) 3 Cable inlet 4 Connection chamber 5 Cable gland 6 Seal monitoring (DI) connection chamber (option) 7 Temperature monitoring upper bearing {option) 8 Filling - and venting screw 9 Cooling jacket

10 Cooling liquid 11 Stator 12 Rotor shaft 13 Temperature monitoring lower bearing {Option) 14 Mechanical seal (medium side) 15 Seal monitoring (DI) oil chamber

18 Release screw 19 Plug screw motor chamber 20 Contrablock {CB) - impeller 21 Contrablock (CB) - bottom plate 22 Release screw (horizontal dry- installation) 23 Adjusting screw for bottom plate 24 Connection for pressure monitoring/venting 25 Discharge outlet 26 Volute 27 Impeller (closed multi channel version) 28 Wear ring in the volute 29 Wear ring on the impeller (option) 30 Bellmouth 31 Wear ring {not for all versions) 32 Guide ring 33 Propeller VUP, impeller AFL 16 Seal monitoring (DI) motor chamber

17 Mechanical seal (motor side) 34 Adjusting screw for gap between impeller and wall {AFL)

4.2 Motor monitoring system

Motor equipment:

Motors M3/ME8/ME9

Monitoring Standard Ex FM

Stator Bimetallic • • • Thermistors (PTC) 0 0 0

PT100 0 - -

Seal monitor Oil chamber • o onlyAFP •{-only M3)

Motor chamber •(-only M3) • •{-only M3)

Connection chamber •{-only M3) • •(-only M3)

Bearing temperature Bimetallic • (o only M3) • {o only M3) • (o only M3) Upper /lower Thermistors {PTC) 0 0 0

PT100 0 0 0

• = Standard o = Option - = not possible

4.2.1 Temperature monitoring of the stator

Thermal limiters protect the stator from overheating in the case of asymmetric phase loading or voltage, continuous dry running or excessive temperatures in the medium itself.

The stator is equipped with three bimetallic thermal limiters which are connected in series.

Additionally it is possible to fit temperature dependent resistors (PT 100 (not for Ex)) with linear characteristics.

4.2.2 DI-Electrode

The DI-electrodes carry out the seal monitoring function and signal the ingress of moisture into the motor by means of a special electronic device.

See also section 5.5.7.

18 Installation and Operating Instructions abs AFP M8, M9 I AFl M3, M8, M9 I VUP M3, M8, M9

ATTENTION Thermistors or PT 100 devices must never be directly connected into the control or power system. They must always be connected to a suitable evaluation device.

Switch off temperature of the thermal sensors fitted to standard motors of Insulation Class F = 140° C/284° F. The temperature limiting switches may only be operated as specified by the manufacturer (See table below).

Operating voltage ••. AC/ ••• DC ••• 500 V -/ ••• 101 V=

Rated voltage AC

Rated current AC cos cp = 1,0

Rated current AC cos cp = 0,6 max. switching current at IN

250V

2.5A

1.6A

5.0A

ATTENTION The maximum switching ability of the thermal sensors is 5 A, the rated voltage 250 V.

Explosion-proof motors which are connected to static frequency inverters must be fitted with thermistors. Activation must be by means of a thermistor protective relay device with PTB-Approva/ number.

4.2.3 Temperature monitoring of the bearings (Option M3)

If bearing temperature monitoring is supplied, the standard versions of the pump possess a bimetallic thermal limiter which opens at a pre-set temperature and is fitted into the bearing block. This allows switching off of the motor to take place in plenty of time, e.g. where excessive bearing temperature due to wear occurs.

Switching temperature of motors of insulation class F :

• Upper bearing = 140 °C/284 °F

• lower bearing = 120 °C/248 °F

As an alternative temperature dependent resistors (thermistors,/PTC) with non-linear characteristics or PT 100 elements with linear characteristics can be fitted.

Installation and Operating Instructions 19

AFP M8, M9 ( AFl M3, M8, M9 ( VUP M3, M8, M9

4.2.4 Temperature indication

A continuous indication of the temperature in the stator and the bearings is not possible using bimetallic thermal limiters or thermistors. For this application it is necessary to fit thermal sensors of the type PT 100 with linear characteristics into the stator and bearing blocks. This type of resistor has a linear characteristic, i.e. the resistance rise is proportional to the temperature rise.

r r r

I I I -~ Resistance

Temperature I I I I I I

.... Application

I Function

Switching

I I

Option

Temperature switch using the bimetallic principle, which opens at a rated temperature ·

Taking care not to exceed the allowable switching current, these can be fitted directly into the control circuit

Figure 16 Curve showing principle of operation of bimetallic temperature limiter

I I I

- f- Resistance

I I

I I I -t- Resistance v

/v

I/

' I I I

Temperature - I I I I I I I I

:!! Application

I Function

Switching

Option

Temperature dependent resistance (no switch) curve with stepwise behaviour

Cannot be installed direct into the control circuit. Evaluation of the signal must be carried out by suitable electronic equipment

Figure 17 Curve showing principle of operation of thermistor v v

~v v v

Temperature - I I I I I I I I

Application

Function

Switching

Option (not for Ex)

Function temperature dependent resistance (no switch). The linear curve allows continuous measurement and indication of the temperature

Cannot be installed direct into the control circuit. Evaluation of the signal must be carried out by suitable electronic equipment

Figure 18 Curve showing principle of operation of PT 100

20 Installation and Operating Instructions

AFP MB, M9 I AFL M3, MB, M9 I VUP M3, MB, M9

4.3 Operation with frequency inverters

The stator design and the insulation grade of the motors from ABS means that they suitable for usage with fre quency inverters. It is however essential that the following conditions are met when the motors are used with frequency inverters:

• The guidelines for EMC (electromagnetic compatibility) are complied with.

• Explosion-proof motors must be equipped with thermistors {PTC temperature sensors).

• Machines designated as Ex machines may never, without exception, be operated using a mains frequency that is greater than the maximum of 50 or 60 Hz as indicated on the type plate.

• Machines that are not designated as Ex machines may only be operated using the mains frequency indicated on the type plate. Greater frequencies can be used but only after consulting with and receiving permission from the ABS manufacturing plant.

• For operation of ex-motors on frequency inverters special requirements in relation to the tripping times of the thermo control elements, must be observed.

• The lowest frequency must be set so that the minimum fluid velocity of 1 m/s is present in the volute.

• The maximum frequency must be set so the rated power of the motor is not exceeded.

Modern frequency inverters are using higher wave frequencies and a steeper rise on the flanks of the voltage wave. This means that motors losses and motor noise is reduced. Unfortunately these inverter output signals cause higher voltage spikes in the stator. Experience has shown that, depending on rated voltage and the length of the cable between the inverter and the motor, these voltage spikes can adversely affect the life of the motor. In order to avoid this, inverters of this type must equipped with sinus filters when used in the critical zone (see Figure 19). The sinus filter chosen must be suitable for the inverter with regard to rated voltage, inverter wave frequency, rated current of the inverter and maximum inverter output frequency.

660+-~~~~--+"'-~~~~~-'-+-~~~~~--+~----;

600--~~~----~~ critical area

10 50 100 150 L[m]

L = total length (from frequency inverter to motor)

Figure 19 Critical/non critical area

Installation and Operating Instructions 21

AFP M8, M9 ( AFL M3, M8, M9 ( VUP M3, M8, M9

5 Installation

A The safety hints in the previous sections must be observed!

5.1 Installation of the AFP submersible pumps

5.1.1 Installation options for the AFP submersible pumps

There are three main installation options for the submersible pumps:

1. Wet installation vertical with ABS automatic coupling system

2. Dry installation with ground support ring (with cooling jacket)

3. Dry installation horizontal (with cooling jacket)

NOTE The dimensional sheets and foundation plans for each type of installation are supplied either with the planning documents or your order confirmation.

5.2 Installation examples

4 2 3 5 6 1 7 10 9 8

14~~~~--+-.t-~f-+--l---+'!~~--1-

1a~~~--jt:-t----:±=b..._L

17 ~~~~-f-.J.\---+--

Figure 20 Wet installation vertical with ABS automatic coupling system

Legend

Venting 10 Guide tube 2 Valve chamber 11 Discharge line 3 Shut-off valve 12 Inflow chamber with impact wall 4 Outflow line 13 Inflow line 5 Non-return valve 14 ABS submersible sewage pump 6 Fitting for valve removal 15 Automatic level control 7 Cable duct 16 Concrete benching 8 Bracket for float switches 17 Pedestal 9 Collection sump 18 Bracket

22 Installation and Operating Instructions ahi AFP MS, M9 I AFl M3, MS, M9 I VUP M3, MS, M9

NOTE

The pedestal and guide tube for the submersible pump must be fitted on site before installation of the pump. On request, we can send you detailed installation and foundation drawings. The specified concrete quality, min. 825 must be used.

11 9 7

8 1

---+'ot-----20

19 ----H--------;

Legend

1 Venting 3 Valve chamber 4 Outflowline 5 Non-return valve 6 Fitting for removal valves 7 Cable duct 8 Holder for float switches 9 Pump sump

11 Discharge line

6 3 16 21

Figure 21 Installation in a dry sump with ground support ring

12 Inflow chamber with impact wall 13 lnflowline 14 ABS submersible pump 15 Automatic level control 16 Concrete benching (after installation of suction pipe) 18 Flexible pipe connector 19 Ground support ring 20 Collection sump 21 Suction line

NOTE Any support frame needed for the submersible pump should be erected on site before the pump itself is installed. The specified concrete quality, min. 825 must be used.

I

0521-B

/ t . ,.

. Installation and Operating Instructions 23

AFP MS, M9 f AFL M3, MS, M9 f VUP M3, MS, M9

9 4111 7 8 1

---+---20

.. --13

24 15

25 6 3 16 21

Figure 22 Horizontal dry installation

Legend

Venting 3 Shut-off valve 4 Outflow line 5 Non-return valve 6 Fitting for removal valves 7 Cable duct 8 Holder for float switches 9 Pump sump

11 Discharge line 12 Inflow chamber with impact wall

13 lnflowline 14 ABS submersible pump 15 Automatic level control 16 Concrete benching (after installation of suction pipe) 20 Collection sump 21 Suction line 23 Compensation piece 24 Diffuser 25 Head support/volute support

NOTE. Any support frame needed for the submersible pump should be erected on site before the pump itself is installed. The specified concrete quality, min. 825 must be used.

24 Installation and Operating Instructions abs AFP MS, M9 I AFl M3, MS, M9 I VUP M3, MS, M9

5.2.1 Wet installation of the AFP submersible pump

The safety hints in the previous sections must be observed!

ATTENTION Submersible pumps should be installed in accordance with Figure 23.

• Fit a hoist to the submersible pump.

• The ABS submersible pump is suspended on the guide tube by means of the pedestal bracket on the pressure connection and carefully lowered vertically, or at a slight inclination (max. 3°). It couples automatically at the pedestal and seals the pressure connection at the pedestal leak-tight by means of its own weight and a seal.

• Make electrical connection as described in section 5.5.

o· -3•

Figure 23 LoweringoftheAFP

ATTENTION a max. ::; 45°. The angle a between the centre line of the unit and the lifting tools should not exceed 45°.

5.2.2 Installation of the AFP submersible pump in a dry sump

The safety hints in the previous sections must be observed!

• Fit a hoist to the submersible pump.

• With the aid of the hoist place the submersible pump carefully into the prepared mounting frame and fasten.

• Fit the suction and discharge ports to the volute.

• If required, fit the vent line to the volute.

• Open the gate valves on the suction and discharge side.

Installation and Operating Instructions 25

AFP MS, M9 I AFL M3, MS, M9 I VUP M3, MS, M9

5.3 Fitting the pedestal

A Care, ensure that adhesive does not come into contact with skin or eyes! Wear goggle and gloves!

The groove of the guide piece and 0-ring must be clean and free of grease. The instant adhesive LOCTITE type 406 (supplied with the unit) is spread evenly on the base ofthe groove in the bracket (24/1) and the 0-ring inserted immediately.

NOTE The hardening time of the adhesive is only about 10 seconds!

The guide piece (24/3) must be screwed on as shown in the drawing! Fasten the guide piece (24/3) with the two M12 screws (24/2). Tighten the screws with a torque of 56 Nm.

1------/,~~f'

Legend

Bracket (is fitted to the pump) 2 Screws (2 off) 3 Guide piece

LOCTITE406

Figure 24 HD- Pedestal DN 100 - 500

4 0-ring 5 Pedestal

5.4

Installation and Operating Instructions

AFP MS, M9 ( AFL M3, MS. M9 ( VUP M3, MS, M9

Installation of the AFL and VUP submersible pumps

The safety hints in the previous sections must be observed!

5.4.1 Types of installation of the AFL and VUP submersible pumps

There are two main types of installation possible with the AFLNUP submersible pumps.

1. Installation in a steel discharge pipe in accordance with Figure 25

2. Installation in a concrete sump in accordance with Figure 26

The inflow to the sump for AFL pumps must be fitted with a screen. The maximum bar spacing depends on the type of hydraulics fitted to the pump and can be obtained from the table below.

Type of hydraulics Clean water Runoff water, river water, used water, rain water, pre-screened liquid, recirculation

Bar spacing in mm Bar width in mm

AFL0600 S40 S20

AFL0800 S60 S30

AFL 1200 s 100 S50

If larger bar spacings are required, please contact ABS

The inflow to the sump for VUP pumps must be fitted with a screen. The maximum bar spacing depends on the type of hydraulics fitted to the pump and can be obtained from the table below.

Type of hydraulics Clean water Runoff water, river water, pre-screened liquid, VUP0400

VUP 0600

VUP 0800

VUP 1000

VUP 1200

ATTENTION

used water, rain water recirculation

Bar spacing in mm Bar spacing in mm Bar spacing in mm

S30 S25 S6

S50

S60 sso S80 ff larger bar spacings are required, please contact ABS

When setting the switching off level the minimum cover as given in the installation documents must be adhered to.

0521·8 ce c•

Installation and Operating Instructions 27

AFP MS, M9 I AFL M3, MS, M9 I VUP M3, MS, M9

5.4.2 Installations examples with AFL and VUP submersible pumps

7 1 8

.a·

6-~

Figure 25 VUPIAFL in a steel discharge pipe

Legend

Tank cover 2 Discharge pipe (riser pipe) 3 Concrete sump 4 AFLNUP submersible pump

7 8 1

" ' 4 ,''4

3----+-

Figure 26 VUPIAFL in a concrete sump

5 Coupling ring 6 Minimum water level (see installation drawings) 7 Connection cable 8 Cable support (for fixing the power cable)

5.4.3

Installation and Operating Instructions

AFP MB, M9 I AFl M3, MB, M9 I VUP M3, MB, M9

Installation of the AFL and VUP submersible pumps

The safety hints in the previous sections must be observed!

ATTENTION The power cables should be handled carefully during installation and removal of the pumps in order to avoid damage to the insulation.

The coupling ring required for installation of the AFLNUP submersible pump must already be installed as shown in Figure 25 and 26. Before installation of the pump a suitable support (hook) for the chain, as well as an opening and suspension (cable sock) for the cable must be provided in the sump or riser pipe.

NOTE In the case of AFLNUP submersible pumps with gearbox the submersible motor and hydraulics mounted to the gearbox are supplied separately.

Before or during the installation the motor connection cables should be fitted on site with suitable strain relief (e.g. cable socks). Particular care should be taken that the cable insulation is not crushed or damaged by the weight of the hanging cable especially in the area of the cable inlet.

ATTENTION When raising the submersible pump out of the concrete sump or the steel discharge pipe with the hoist ensure that the connection cables are lifted out simultaneously as the pump itself is being raised.

5.4.4 Lowering of the AFL and VUP submersible pump into the coupling ring

ATTENTION Before lowering the pump a direction of rotation check should be carried out, see section 5.5.4.

• Draw the cable hose over the end of the connection cable.

ATTENTION The steel riser pipe, or concrete sump must be cleaned thoroughly (builder's rubble, etc.). Before fitting the pump into a sump or into a steel discharge pipe, care should be taken that any paint remnants are completely removed from the conical surfaces on the pumps or on the coupling ring. These conical surfaces must then be greased.

To optimise the in ff ow and to reduce the noise level it is important that one pair of fins of the suction pipe are in line with the main ff ow direction of the inflow chamber.

This must be observed when fitting the pump into a sump or into a steel discharge pipe.

• Carefully lower the submersible pump with the aid of a hoist into the coupling ring in the sump. Take care that the cable is lowered simultaneously and cannot snag.

• Attach the lifting chain to the hook provided so that it cannot strike either the pump cable or the sump wall.

• Tension the pump cable and fasten to the hook provided with the aid of the cable sock. Where a steel pressure pipe is used the connection cable should be brought through the connection cable inlet and sealed off in a watertight manner.

The connection cable should only be tightened sufficiently so that no tension acts at the cable inlet in the head of the pump. The connection cable should not strike the chain or the sump wall.

• If necessary, the steel riser pipe is sealed off in a watertight manner.

Installation and Operating Instructions 29

AFP M8, M9 I AFL M3, MB, M9 I VUP M3, MS, M9

5.5 Electrical connection

The safety hints in the previous sections must be observed!

Before commissioning an expert should check that one of the necessary electrical protective devices is avail able. Earthing, neutral, earth leakage circuit breakers, etc. must comply with the regulations of the local electric ity supply authority and a qualified person should check that these are in perfect order.

ATTENTION The power supply system on site must comply with VDE or other local regulations with regard to cross-sectional area and maximum voltage drop. The voltage stated on

· the nameplate of the pump must correspond to that of the mains.

The incoming power supply as well as the connection of the pump itself to the terminals on the control panel must comply with the circuit diagram of the control panel as well as the motor connection diagrams and must be carried out by a qualified person.

The power supply cable must be protected by an adequately dimensioned slow-blow fuse corresponding to the rated power of the pump.

ATTTENTION The unit should only be operated with the overload relay and thermal sensors/limiters connected.

5.5.1 Standard connection diagrams, mains voltage 380 - 420 V at 50 Hzl460 V at 60 Hz, M3 motors r.----, I PE I

I o

I U1 lv1

I I W1

I I I )W2

I U2

I I V2

I FO

I F1 I

I I

- I~ DI I [ ___ J

Figure 27a (One power cable with integrated control leads)

Cable 1 r-01

-<=J2i I

I PE

I :

I I U1

V1

W1

I W2

I U2 I

I V2 c;t;o L_fU

Cable2

Figure 27b (Two power cables, each with integrated control leads)

0521·8

30 Installation and Operating Instructions abs AFP MB. M9 I AFl M3, MB, M9 I VUP M3, MB, M9

5.5.2 Standard connection diagrams, mains voltage 400 Vat 50 Hz/460 Vat 60 Hz, M8/M9 motors

Cable 1 j"P"El I ' I I U1 i I I I V1 I r-\-7.~ .... -o;-:-;;--f---+-~W1 i L __ _J c---, i ~E i I

W2 i ~-----------;~ I

I U2 I I

I V2 I L __ _J

Cable2

Cable 3

1--------------------------~

I 1---JI• PE[Rj I ~ I

11 t 10 0 040--::Ztn ~ 030~ I

I '3 110 winding 11:041~ ~031~ I I ti O upper bearing 0 042--:::::ttl lll 034~ I I ~; 12 ;g043~ ~ 035~ I I ~044 ::::i03s~I I 130 lowerbearing 045~ l037~ I I E I I --20§ DI connection chamber .S I I --21 DI motor chamber I I --22 DI oil chamber I l_~.'.:_bleco..'.:_~rki~~~~:_ _______________ J Figure 28a Special versions: two power cables and one control cable - for optlonal motor monitoring features

Cable 8 or cable 8 and 9 r--------------------------~

I l---11• P@ 1: I r--+:-c:!'"•-~:--\---+o~jiJJ Cable 1 r-+-+-= ...... .._~+--1-o~jiJJ Cable 2 115 110 winding 041~ ~031?I 1 t 10

0 040--:S:m ~03o PT1oo I

1 -5 11:0 ~034 I ,.-'\--;-;~ .... ~-f--._1-c-~j Cable 3

~-,,,__ __ L....,~iJ Cable4

~-------:....,_~2} Cable 5

~---------':~_ui} cables

~-----------+o:_vi} cable 7

I·! 120 upper bearing :§o~~# ~ 0 35? I

I 0 -~04445-=m ~ 036--=m I I 13 lowerbearing 0 ~ gio 37~ I I E I

2 I I ---20§ Dlconnectionchamber I I --- 21 DI motor chamber I I ---22 DI oil chamber I

LI (X) cable core marking control cable I

Figure 28b Six single power cables + one earth cable + one or two control cable{s)

- standard and optional motor monitoring features

ATTENTION The cable leads are routed out of the motor. No switching takes place in the motor!

Any switching required (use of bridges) must be carried out in the control panel.

I

NOTE Information on the type of starting can be obtained from the nameplate of the pump.

5.5.3 Lead designations

Direct starting in star

I 1 I U1 L1 L2 L3 Join

North America 1 2 3 4&5&6 4 U2

ABS/Germany U1 V1 W1 U2&V2&W2 3c~2 Direct starting in delta ;!;

L1 L2 L3

North America 1; 6 2;4 3;5 -

ABS/GElrmany ~ u:

U1;W2 V1; U2 W1;V2 - 5 V2 V1 2

0521-B

Installation and Operating Instructions 31

AFP M8, M9 I AFL M3, M8, M9 I VUP M3, M8, M9

5.5.4 Checking direction of rotation

The safety hints in the previous sections must be observed!

When three phase units are being commissioned for the first time and also when used on a new site, the direction of rotation must be carefully checked by a qualified person.

When checking the direction of rotation, the submersible pump should be secured in such a manner that no danger to personnel is caused by the rotating impeller, or by the resulting air flow. Do not place your hand into the hydraulic system!

The direction of rotation should only be altered by a qualified person.

When carrying out the direction of rotation check as well as when starting the unit pay attention to the START REACTION. This can be very powerful.

ATTENTION

The direction of rotation is correct if the imeller/propeller rotates in a clockwise manner when viewing down from the top of the placed unit

ATTENTION

The start reaction is anti clockwise

NOTE

Figure 29 Rotor rotation

If a number of pumps are connected to a single control panel then each unit must be Individually checked.

ATTENTION The mains supply to the control panel should have a clockwise rotation. If the leads are connected in accordance with the circuit diagram and lead designations, the direction of rotation will be correct.

5.5.5 Changing direction of rotation

The safety hints in the previous sections must be observed!

The direction of rotation should only be altered by a qualified person.

If the direction of rotation is incorrect then this is altered by changing over two phases of the power supply cable in the control panel. The direction of rotation should then be rechecked.

NOTE The direction of rotation measuring device monitors the direction of rotation of the mains supply or that of an emergency generator.

32 Installation and Operating Instructions abs AFP M8, M9 I AFL M3, M8, M9 ( VUP M3, M8, M9

5.5.6 Connection of the control circuit leads

The safety hints in the previous sections must be observed!

0 Motoriiberwachung I Motor monitoring 0

3bsl::: I dVl (X) Adem Kennzeichnung Steuerkabel

1------(1• P~ Cable core marking control cable

~ :~DD Wicklung/ ~040~ ~1030~ ~ Winding ~D41-w11 ~ ~031~ (/) (/)B l) E:gB 1l

: 120 Lageroben/ ~ 42~ EE 34~ •• Upper bearing ~ 43--g_r-' ., · 35~

~ 130 Lagerunten/ 1044--=rr, 11036--=rr, ~ Lower bearing ~ D 45-:!fr.P""' !!!. ~ 0 37 ~

1l I- 1l

---20§ DI AnschluBraum I Connection chamber

---21 DI Motorraum I Motor chamber t;x-DI Clraum / ---22 DI 61- / Oberwachungsraum Oil chamber

DI Oil-/ Separation chamber ~2211 B a f----@@--2212 . 0

~ Control circuit leads for ~ submersible pumps

10 =Common lead 11 =Stator upper 12 = Bearing upper 13 = Bearing lower 20 = DI-connection chamber 21 = DI-Motor chamber 22 = DI-Oil chamber

_l_ = PE (green/yellow)

Figure 30 Designation of control circuit leads

NOTE The available connections can be obtained from the relevant connection diagram.

5.5.7 Connection of the seal monitoring unit to the control panel

The submersible pumps are supplied as standard with DI-probes for seal monitoring. In order to integrate this seal monitoring function into the control panel of the pump it is necessary to fit an ABS DI-module and connect this in accordance with the circuit diagrams below.

ATTENTION If the DI-seal monitoring ls activated the unit must be immediately taken out of service. Please contact your ABS service centre.

r--l-- -l--, r--l-- -l--, MAINS MAINS I I I I I I I I I I I I I I I I I I I I I e. I I I I + ' I I e. + ' I I w N

::E I I w N ~ I I

<') c.. :2 I I <') c.. :2 :2 I L _ _ --4 -- _ _ _J L __ --4-- __ _J

I $: I ---~----~-----; I I 1-8 10 14 I

I ~ I I ml I X1 I I ---- ------- ~I I > I I I '<!' I I ~I I N I

~~~ ~-~~-- 1~-~~-:J I Cl. I I ::; I

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