Sulzer ABS XFP-PE4 Bedienungsanleitung

www.sulzer.com

EN 6556-H

Submersible Sewage Pump Type ABS XFP-PE4 to PE6

Submersible Mixed Flow Column Pump Type ABS AFLX-PE3 to PE6

Submersible Propeller Pump Type ABS VUPX-PE3 to PE6

6006556 (02.12.2021)

Installation and Operating Instructions

Sulzer reserves the right to alter specications due to technical developments !

EN 6556-H

Installation and Operating Instructions (translation of original instruction)

For submersible sewage pumps

XFP CB - Hydraulics

XFP 105J XFP 150M XFP 205J XFP 250J XFP 305J XFP 356M XFP 405M

XFP 106J XFP 151M XFP 206J XFP 255J XFP 305M

XFP 155J XFP 306M

XFP CH; SK - Hydraulics

XFP 100J XFP 150J XFP 200J XFP 250M XFP 300J XFP 351M XFP 400M XFP 500U XFP 600V

XFP 200M XFP 300M XFP 400R XFP 501U XFP 600X

XFP 301M

AFLX-Hydraulics

AFLX 0601 AFLX 0701 AFLX 0801 AFLX 1202

AFLX 0803 AFLX 1203

AFLX 1207

VUPX-Hydraulics

VUPX 0402 VUPX 0501 VUPX 0601 VUPX 0801 VUPX 1001 VUPX 1201

VUPX 0403 VUPX 0502 VUPX 0602 VUPX 0802 VUPX 1002 VUPX 1202

VUPX 0503

EN 6556-H

Table of contents

1 General................................................................................................................................................... 5

1.1 Correct usage of the products ................................................................................................................ 5

1.2 Application areas for the series XFP....................................................................................................... 6

1.3 Application areas for the series AFLX ..................................................................................................... 6

1.4 Application areas for the series VUPX .................................................................................................... 7

1.5 Technical data ......................................................................................................................................... 7

1.6 Nameplate............................................................................................................................................... 8

2 Safety ..................................................................................................................................................... 8

3 Lifting, transport and storage .............................................................................................................. 9

3.1 Lifting ...................................................................................................................................................... 9

3.2 Transport securing devices ................................................................................................................... 10

3.3 Storage of the units ............................................................................................................................... 10

4 Monitoring system .............................................................................................................................. 10

4.1 Monitoring options................................................................................................................................. 10

4.2 Leakage sensor (DI).............................................................................................................................. 11

4.3 Temperature monitoring of the stator .................................................................................................... 11

4.4 Temperature monitoring of the bearings (Option) ................................................................................. 11

4.5 Temperature sensor indication .............................................................................................................. 11

4.5.1 Temperature sensor bimetall................................................................................................................. 11

4.5.2 Temperature sensor PTC ...................................................................................................................... 12

4.5.3 Temperature sensor PT 100.................................................................................................................. 12

4.6 Operation with frequency inverters ....................................................................................................... 12

5 Installation ........................................................................................................................................... 13

5.1 Installation of the XFP submersible sewage pumps ............................................................................. 14

5.1.1 Installation options for the XFP submersible sewage pumps................................................................ 14

5.1.2 Pedestalttingofo-ringandguidepiece .............................................................................................. 16

5.1.3 Tightening torque .................................................................................................................................. 16

5.1.4 Fitting position of the Nord-Lock® securing washers............................................................................. 16

5.2 Installation of the AFLX and VUPX submersible pumps ....................................................................... 17

5.2.1 Installations examples with AFLX and VUPX submersible pumps........................................................ 17

5.3 Electrical connection ............................................................................................................................. 19

5.3.1 Lead designations ................................................................................................................................ 20

5.4 Checking direction of rotation................................................................................................................ 21

5.5 Connection of the control circuit leads .................................................................................................. 21

5.6 Connection of the seal monitoring unit to the control panel .................................................................. 22

5.6.1 Internal leakage sensor (DI).................................................................................................................. 22

5.6.2 External leakage sensor (DI)................................................................................................................. 23

5.7 Connecting the EMC cable in the control cabinet ................................................................................. 24

6 Commissioning ................................................................................................................................... 25

EN 6556-H

7 Maintenance ........................................................................................................................................ 25

7.1 Oilllingwithoutcoolingjacket ............................................................................................................. 26

7.1.1 Symbols ................................................................................................................................................ 26

7.1.2 OilllingXFPPE4/PE5 ....................................................................................................................... 27

7.1.3 OilllingVUPX/AFLX .......................................................................................................................... 28

7.1.4 Oilllinginspectionchamber ................................................................................................................ 30

7.1.5 LubricantllingquantitysealchamberPE3,PE4,PE5......................................................................... 30

7.1.6 LubricantllingquantitysealchamberVUPX/AFLXPE6.................................................................... 30

7.2 Coolant/oilllingwithcoolingjacket.................................................................................................... 31

7.2.1 Symbols ................................................................................................................................................ 31

7.2.2 Coolingliquid/oilllingandemptyingXFPPE4/PE5......................................................................... 31

7.2.3 Coolingliquid/oilllingandemptyingXFPPE6 ................................................................................. 32

7.2.4 Reference values for antifreeze behaviour ........................................................................................... 33

7.2.5 CoolantllingquantitiesXFPPE4 ........................................................................................................ 33

7.2.6 CoolantllingquantitiesXFPPE5 ........................................................................................................ 34

7.2.7 CoolantllingquantitiesXFPPE6 ........................................................................................................ 34

7.3 Starting frequency of the motors ........................................................................................................... 35

7.4 Removal of the submersible sewage pump ......................................................................................... 35

7.4.1 Removal of the XFP submersible sewage pump from a wet sump....................................................... 35

7.4.2 RemovaloftheXFPsubmersiblesewagepumpwhendry-installed .................................................... 35

7.4.3 Removal of the AFLX and VUPX submersible pump ........................................................................... 35

EN 6556-H

1 General

These Installation and Operating Instructions and the separate booklet Safety Instructions for Sulzer

Products Type ABS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specically

highlighted with the general danger symbol.

Thepresenceofadangerousvoltageisidentied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 aect

its functioning.

NOTE Used for important pieces of information.

1.1 Correct usage of the products

Inthecaseofanyfaultsarising,theSulzerunitsshouldimmediatelybetakenoutofuseandsecured.Thefault

shouldbeimmediatelyrectiedor,ifnecessary,contactyourSulzerServiceCentre.

ThesubmersiblepumpswithPEmotorcanbesuppliedbothasstandardversionsandinexplosion-proof

executionwithExII2GExhdbIIBT4Gbfor50HzaccordingtothestandardsENISO12100:2010,EN

809:1998+A1:2009+AC:2010,EN60079-0:2012+A11:2018,EN60079-1:2014,EN60034-1:2010,ENISO

80079-36,ENISO80079-37,orFMexecution(NEC500,ClassI,Division1,GroupC&D,T3C)for60Hzin

isolation class H (140).

Temperaturelimiterinthewinding=140°C/284°F(bimetallicorthermistor[PTC]asanoption).

Special version Class H

Aspecialversionwithtemperaturelimiterinthewinding=160°C/320°F(bimetallic,temperaturesensor[PTC]

asanoptionorPT100)isalsoavailable.Thisversionisonlyavailablewithoutexplosion-prooforNEC500

approval with isolation class H (160) components.

ForbothversionsanEMV-executionisavailableasanoption.

ATTENTION Repair work on explosion-proof motors may only be carried out in authorized

workshops by qualied personnel using original parts supplied by the manufacturer.

Otherwise the Ex-approvals are no longer valid. All Ex-relevant components and

dimensions can be found in the modular workshop manual and the spare parts list.

ATTENTION After repair work in unauthorized workshops by unqualied personnel the

Ex-approvals are no longer valid. After such repair the unit must not be operated in

hazardous areas. The Ex-nameplate (see gure 2, 3) has to be removed.

NOTE All regulations and guidelines, which may vary from country to country, must be

followed without exception.

Limitations: The ambient temperature range is 0 °C to + 40 °C (32 °F to 104 °F)

Immersion depth maximum 20 m (65 ft)

NOTE Leakage of lubricants could result in pollution of the medium being pumped.

EN 6556-H

Operation of units as explosion-proof execution:

In hazardous areas care must be taken that during switching on and operation of the pumps the pump section

islledwithwater(dryinstallation)oralternativelyissubmerged(wetinstallation).Othertypesofoperatione.g.

snore operation or dry running are not allowed!

Thetemperaturemonitoringoftheexplosion-proofsubmersiblepumpshastobecarriedoutbybimetallic

temperature limiters or thermistors according to DIN 44 082 connected to a suitable release device which is

certiedinaccordancewithECdirective2014/34/EU.

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.

Operation of explosion-proof submersible pumps in wet-well installation without cooling jacket

ItmustbeensuredthatthemotoroftheExsubmersiblepumpisalwaysfullysubmergedduringstart-upand

operation!

Operation of explosion-proof submersible pumps with frequency inverter in hazardous areas (ATEX

Zone 1 and 2):

Motorsmusthavedirectthermalprotectiondevicestted.Theseconsistoftemperaturesensors(PTCDIN

44082)embeddedinthewindings.Thesemustbeconnectedtoasuitablereleasedevicewhichiscertiedin

accordancewithECdirective2014/34/EU.

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.

Operation with frequency inverters

See section 4.6

1.2 Application areas for the series XFP

The submersible sewage pumps type ABS XFP 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brousmaterial

• Faecal matter

• Sludge

• Fresh and process water pumping

• Raw water for drinking water supply

• Surface and rain water

• Sewage

1.3 Application areas for the series AFLX

ThemixedowcolumnpumptypeABSAFLX serieshavebeendevelopedforenvironmentalprotection,water

supply,municipalsewagetreatmentanddewateringofpolders.

They are suitable for the following liquids:

• Stormwaterprotection,irrigationandaquaculture

• Industrial raw water and process water

• Combined sewage and surface water

• Recirculation sludge or return activated sludge (RAS)

• Hazardous locations:

CerticationforATEX(ExII2GExhdbIIBT4Gb),FMandCSAavailableasanoption

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

A screen must be attached to the inlet (see section 5.2).

EN 6556-H

1.4 Application areas for the series VUPX

The submersible propeller pumps type ABS VUPX 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

• Stormwaterprotection,irrigationandaquaculture

• Industrial raw water and process water

• Combined sewage and surface water

• Recirculation sludge or return activated sludge (RAS)

• Hazardous locations:

CerticationforATEX(ExII2GExhdbIIBT4Gb),FMandCSAavailableasanoption

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

A screen must be attached to the inlet (see section 5.2).

1.5 Technical data

Please take the technical data and the weight from the nameplate. Please take the dimensions of the units from

the respective dimension drawing.

Themaximumnoiseleveloftheunitsofthisseriesis≤70dB(A).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.

HINT The respective dimension drawings can be found in downloads „dimension drawing“

at the following link: www.sulzer.com.

The weights in the dimension sheets refer to a cable length of 10 m. In the case of cable lengths exceeding

10 m the additional weight must be determined and added using the following table.

Cable type Weight

kg/m Cable type Weight

kg/m

Weight

lb/1000ft

EMC-FC / S1BC4N8-F / S1BC4N8-F

3x6/6KON 0,4

S1BN8-F / H07RN8-F / 07BN8-F

2 x 4 G 4 + 2 x 0,75 0,6

G-GC

AWG 8-3 0,9 597

3x10/10KON 0,7 4 G 4 0,5 AWG 6-3 1,2 764

3x16/16KON 1 4 G 6 0,5 AWG 4-3 1,6 1070

4 G 10 0,8 AWG 2-3 2,3 1533

3x6/6KON +3x1,5ST 0,6 4 G 16 1,3 AWG 1-3 2,8 1865

4 G 25 1,8 AWG 1/0-3 3,5 2315

3x25 +3G16/3 1,5 4 G 35 2,3 AWG 2/0-3 4,1 2750

3x35 +3G16/3 1,9 4 G 50 3,0 AWG 3/0-3 53330

3x50 +3G25/3 2,6 4 G 70 4,2 AWG 4/0-3 6,1 4095

3x70 +3G35/3 3,6 4 G 95 5,5

DLO

AWG 1/0 0,7 480

3x95 +3G50/3 4,7 4 G 120 6,7 AWG 2/0 0,8 558

3x120 + 3G70/3 6 7 G 1,5 0,5 AWG 3/0 1,1 742

3x150 + 3G70/3 7,1 10 G 2,5 0,8 AWG 4/0 1,3 872

3x185 +3G95/3 8,8

3x240 +3G120/3 11 4 G 1,5 0,2 262 MCM 1,6 1068

3x300 +3G150/3 13,5 8 G 1,5 0,4 313 MCM 1,9 1258

10 G 1,5 0,5 373 MCM 2,2 1462

1x185 2,2 12 G 1,5 0,5 444 MCM 2,6 1726

1x240 2,7 535 MCM 3,1 2047

1x300 3,4 1x150 1,8 646 MCM 3,6 2416

1x185 2,2

SOOW

AWG 16/4 0,3 144

1x300 3,4 AWG 16/8 0,4 222

1x400 4,1 AWG 16/10 0,5 278

AWG 16/12 0,5 305

EN 6556-H

1.6 Nameplate

We recommend that you record the data from the original nameplate Figure 1 so that you can refer to the data

at any time.

Motor E. Cl

IP68

Weight

Hmax.

Hmin.

Nema Code

max. °C

max.

PN SN

Type

3 4

7 8 9 10

11 12 13 14

15 16 17

18 19 20 21

23 24

2526

Sulzer Pump Sweden AB

Vadstena factory

Box 170

SE-592 24 Vadstena

Sweden

2500-0001

Figure 1: Standard nameplate

Legend

1 Address  15 Max.ambienttemperature[exibleunit]

2 Typedesignation  16 Nemacodeletter(onlyat60Hz,e.g.,H)

3 Art.no.  17 Min.pumpingheight[exibleunit]

4 Serialnumber  18 Nominalwidth[exibleunit]

5 Ordernumber  19 Pumpingquantity[exibleunit]

6 Yearofmanufacture[month/year]  20 Pumpingheight[exibleunit]

7 Nominalvoltage  21 Max.pumpingheight[exibleheight]

8 Max.immersiondepth[exibleunit]  22 Weight(withoutattachedparts)[exibleunit]

9 Nominalcurrent  23 Motore󰀩ciencyclass

10 Frequency 24 Motor shaft direction of rotation

11 Power(consumption)[exibleunit]  25 Continuousoperatingmode

12 Power(output)[exibleunit]  26 Soundlevel

13 Rotationspeed[exibleunit]  27 Phaseconnection

14 Impeller/propellerø[exibleunit]  28 Protectionmethod

SN:

Figure 2: Nameplate ATEX Figure 3: Nameplate CSA / FM

2 Safety

ThegeneralandspecichealthandsafetyhintsaredescribedindetailintheseparatebookletSafety

Instructions for Sulzer Products Type ABS. If anything is not clear or you have any questions as to safety

make certain to contact the manufacturer Sulzer.

EN 6556-H

3 Lifting, transport and storage

3.1 Lifting

ATTENTION! Observe the total weight of the Sulzer units and their attached components! (see

nameplate for weight of base unit).

The duplicate nameplate provided must always be located and visible close to where the pump is installed (e.g.

attheterminalboxes/controlpanelwherethepumpcablesareconnected).

NOTE! Lifting equipment must be used if the total unit weight and attached accessories

exceeds local manual lifting safety regulations.

The total weight of the unit and accessories must be observed when specifying the safe working load of any

liftingequipment!Theliftingequipment,e.g.craneandchains,musthaveadequateliftingcapacity.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

certied,ingoodcondition,andinspectedregularlybyacompetentpersonatintervalsinaccordancewithlocal

regulations. 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.

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.

Theunitsareequippedwithasafetyshackle(seriesforverticalsetup)orswivelringbolt(horizontalsetup),

whichallowxingchainsfortransportingorforinstallingorremoving.Werecommendusingchainsfromthe

Sulzer list of accessories.

Take note of the entire weight of the unit (see nameplate Figure 1) The hoist and chain must be

adequately dimensioned for the weight of the unit and must comply with the current valid safety

regulations.

ATTENTION In the case of pumps set up vertically, sealing plugs are mounted for protecting the

thread holes instead of swivel ring bolts. These seals may only be replaced by a

swivel ring bolt for maintenance work but must be screwed on again before startup!

0838-0005

0838-0004

Figure 4: Transport in a horizontal manner XFP Figure 5: Transport in a horizontal manner AFLX/VUPX

ATTENTION α max. ≤ 45°. The angle α between the centre line of the unit and the lifting tools

should not exceed 45°.

EN 6556-H

3.2 Transport securing devices

The motor connection cables are protected against the ingress of moisture along the cable by having the ends

sealed with protective covers at manufacture.

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

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.

NOTE If there is a possibility of water ingress then the cables should be secured so that the

ends are above the maximum possible ood level. Take care not to damage the cable

or its insulation when doing this!

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 motor shaft transport lock must be removed before startup!

3.3 Storage of the units

ATTENTION The Sulzer products must be protected from weather inuences such as UV from

direct sunlight, high humidity, aggressive dust emissions, mechanical damage,

frost etc. The Sulzer original packaging with the relevant transport securing devices

(where used) ensures optimum protection of the unit. If the units are exposed to

temperatures under 0 °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

NOTE The Sulzer units normally require no maintenance during storage. During longer

storage times, (after approx. one year) the transport locks on the motor shaft (not all

versions) must be dismantled. Coolant is applied to the sealing surfaces by manually

turning the shaft several times (also for the purpose of cooling or lubricating so that

trouble-free function of the sliding ring seal is ensured). No maintenance is required

when storing the motor shaft.

4 Monitoring system

4.1 Monitoring options

Motor equipment:

Motors PE3

50 Hz

PE4/PE5

50 Hz

PE6

50 Hz

PE3

60 Hz

PE4/PE5

60 Hz

PE6

60 Hz

Non-

Ex Ex Non-

FM FM Non-

FM FM

Stator

temperature

Bimetallic ●●* ●●* ●●* ●●* ●●* ●●*

Thermistors (PTC) ○○* ○○* ○○* ○○* ○○* ○○*

PT 100 - - ○ ○ ○ ○ - - ○ ○ ○ ○

Leakage

sensor

Inspection chamber - - ●○●○ - ●●●●●

Motor chamber ●●○●●●● - ○○●●

Connection chamber - - ○ ○ ● ● - - ○ ○ ● ●

Upper and

lower bearing

temperature

Bimetallic - - ○ ○ ● ● - - ○ ○ ● ●

Thermistors (PTC) - - ○ ○ ○ ○ - - ○ ○ ○ ○

PT 100 - - ○ ○ ○ ○ - - ○ ○ ○ ○

●=Standard○○=Option*ExwithVFD,monitoringviaPTC

Dieses Handbuch passt für folgende Modelle

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