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PompDirect ROBOT PUMPS RW Series, Operation & Maintenance Manual

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PompDirect ROBOT PUMPS RW Series Operation & Maintenance Manual Download Page 1

 782-001-GB

HSC

   08-W36

Edition 4

OPERA

OPERA

OPERA

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OPERATION

TION

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MAINTEN

MAINTEN

MAINTEN

MAINTEN

MAINTENANCE MANU

ANCE MANU

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RW

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W-SERIES

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www.robotpompen-onderdelen.nl

T +31(0)294-457712

[email protected]

Summary of Contents for ROBOT PUMPS RW Series

Page 1: ...A OPERATION TION TION TION TION MAINTEN MAINTEN MAINTEN MAINTEN MAINTENANCE MANU ANCE MANU ANCE MANU ANCE MANU ANCE MANUAL AL AL AL AL R R R R RW W W W W SERIES SERIES SERIES SERIES SERIES www robotpompen onderdelen nl T 31 0 294 457712 info pompdirect nl ...

Page 2: ...LLATION OPTIONS 12 6 1 Installation H 12 6 2 Installation V 13 6 3 Checkpoint installation V 14 6 4 Installation F 15 6 5 Installation T 15 6 6 Installation A 16 6 7 Flange forces and moments for stationary immersible pumps 16 7 MAINTENANCE 17 7 1 General 17 7 2 Maintenance schedule 17 7 3 Lubricants 17 7 4 Cable entry 18 7 5 Oil level 19 7 6 Oil change 20 7 7 Motor housing 21 8 TRANSPORT AND STOR...

Page 3: ...ice and maintenance may only be done by authorised personnel after reading this manual The RW pump in basic version may not be used in a potentially explosive atmosphere When ordering spareparts always quote 1 Pump type 2 Code 3 Serial number This information is found on the dataplate See appendix 1 Sectional drawings and parts lists are available on request All products manufactured by ITT W WW A...

Page 4: ...th agressive corrossive toxic flammable and explosive chemicals Never remove safety signs keep them clean Always connect to a grounded circuit Before maintenance and inspection always disconnect the pump from the mains Use a proper hoist for lifting and handling the pump Do not leave a large loop of cable in the sump as the pump may eventually damage it Never drop the loose cable end in water The ...

Page 5: ...pcasing 2 Impeller 3 Suction 4 Delivery 5 Motorcasing 6 Rotor 7 Stator 8 Shaft 9 Bearings 10 Mechanical seal 2x 11 Oil reservoir 12 Oil plug 13 Cable entry 14 Cable 15 Inspection plug 4 2 Main parts Construction High efficiency motor standard class F insulation up to 155 o C Two independent mechanical seals running in oil form an effective barrier between pump and motor Heavy duty bearings greased...

Page 6: ...3 Suction 4 Delivery 5 Motorcasing 6 Rotor 7 Stator 8 Shaft 9 Bearings 10 Mechanical seal 2x 11 Oil reservoir 12 Oil plug 13 Cable entry 14 Cable 15 Inspection plug 5 7 15 8 10 2 1 4 3 13 12 11 9 6 9 14 OIL Fig 4 2 RW40 RW60 Fig 4 3 www robotpompen onderdelen nl T 31 0 294 457712 info pompdirect nl ...

Page 7: ...on 4 Delivery 5 Motorcasing 6 Rotor 7 Stator 8 Shaft 9 Bearings 10 Mechanical seal 2x 11 Oil reservoir 12 Oil plug 13 Cable entry 14 Cable 15 Inspection plug 16 Cable entry box 15 15 1 4 3 2 5 OIL 7 6 9 9 10 10 8 14 13 11 12 16 Fig 4 4 RW80 www robotpompen onderdelen nl T 31 0 294 457712 info pompdirect nl ...

Page 8: ...ional for RW20 and RW40 standard for RW60 series Contact rating max 250V 1 6A The contacts are normally closed 5 5 Cable entry Especially when the pump has been in store for a long time the cable gland should be checked and if necessary tightened see 7 4 5 6 Motor protection The pump should always be connected to the line by means of a suitable motor protection circuitbreaker If the pump is starte...

Page 9: ...ut the pump in horizontal position and start the pump Looking on the impeller through the suction opening the correct direction of rotation is counter clockwise See arrow on pumpcasing Fig 5 2 or Starting the pump will give a recoil on the pump frame Looking at the motor in vertical position see Fig 5 3 the recoil is counter clockwise Take care The recoil can be very powerful Don t go near rotatin...

Page 10: ...176 70 5 12 Start frequency When the pump is controlled by level regulators the on and off levels should be adjusted in such a way that the pump does not do more than 20 starts an hour 5 13 Min and max submersion depth The motorhousing should be at least 2 3 submerged for continuous operation at full load see Hmin 1 Fig 5 4 It is good practice whenever possible to keep the motorhousing completely ...

Page 11: ... coupling consisting of coupling bend rubber joint and a fixed coupling part 4 Suspension bracket and chain for lifting the pump 5 Level regulators for start stop and alarm signals 6 Suspension for level regulators and power supply cable 7 Piping non return valve bends etc Checkpoints before operating Ensure a good free passage beneath the suction elbow of the pump at least the same as the suction...

Page 12: ...ical maximum tolerance 3o The installation angle should be RW20 RW40 RW60 10 15o RW80 5o see Fig 6 4 If necessary this angle can be changed by alteration of the position of the lifting hook on the suspension bracket on top of the motor pos 1 Adjust the start and stoplevels in such a way that the motor does not make more than 20 starts per hour Check that the motor is adequately cooled The motorhou...

Page 13: ...nd a special gasket must be fitted see fig 6 5 When air is present this will escape through the hole When the fluid arrives the special gasket will close the hole Take part 1 fig 6 6 Drill a 8mm hole in the cast boss on top of the coupling adapter Deburr the hole Place a special gasket 3 Fig 6 7 Mount the coupling adapter 1 to the pump 2 Part numbers for special gaskets Coupling type part number V...

Page 14: ...lute in order to avoid air being drawn in see Hmin 2 Fig 6 8 Air in the discharge pipes might impair performance 6 5 INSTALLATION T Transportable wet installation Except for the pump the following components are necessary 1 Hose connection which is fastened to the pump 2 Flexible hose 3 Pump support Checkpoints before operating Do not let the pump bury itself in the mud Do not leave a large loop o...

Page 15: ... way that the motor does not make more than 20 starts per hour If maintenance and or inspection is necessary as described in chapter 7 we recommend to disconnect the motorunit from the pumpcasing This can easily be done by removing the nuts of the sealhousing pumpcasing connection 6 7 Flange forces and moments for stationary immersible pumps Because of the pipeline system specific forces on the di...

Page 16: ...ing hours Check the oil and oil level see chapter 7 5 If there is more than a few cm3 water in it contact your dealer Refresh the oil every year or when it is no longer transparent see chapter 7 6 RW80 refresh the grease of the main bearing every 10 000 running hours 7 3 Lubricants The bearings are greased for life and need no refill except RW80 Main bearing RW80 SHELL ALBIDA EP 2 The oil reservoi...

Page 17: ...clamp 2 Turn the hexagon head of the entry 1 clockwise using the right tool so far that it is possible to replace the cable clamp again Screw in the 2 hexagon socket screws 1 It is possible that your pump is fitted with 2 cable entries 7 4 3 RW 60 RW 80 Unscrew the 4 hexagon socket screws 1 from the outer cable entries Remove the cable clamps 2 Turn the hexagon heads of the entry clockwise using t...

Page 18: ...on so that 2 hexagonal socket screws are on top and one at the bottom see fig 7 5 Unscrew the level plug 1 and the vent plug 2 The oil level should be at the lower side of the openings see drawing By turning the pump a bit this should be visible If not so fill up to the right level Always use the right kind of oil 7 5 3 RW 60 RW 80 Put the pump in a vertical position Unscrew the M20 oil pug 1 whic...

Page 19: ...osition A Replace the plugs 7 6 2 RW 40 Put the pump in a horizontal position so that the drain plug 3 is at the bottom Fig 7 8 position A Remove the vent plugs 1 and 2 Put a receiving bin underneath the drain plug Remove the plug and drain the oil Replace the drain plug Refill the oilhousing The oil level should be at the lower side of the openings Fig 7 8 position A Replace the plugs 7 6 3 RW 60...

Page 20: ...e pump in horizontal position with the inspection opening downwards If water is present this will come out this way A small amount of water due to condensation is permissable More water is an indication of leakage of the construction Oil is an indication of seal failure between motorhousing and oil chamber If so contact your dealer 7 7 3 RW 60 Place the pump in a vertical position and remove the 4...

Page 21: ...es see Fig 8 1 After 6 months of storage a general inspection is advised before installing the pump Follow the instructions of chapter 5 Fig 8 1 7 7 4 RW 80 Place the pump in a vertical position and remove the 4 hexagon socket screws 1 Fig 7 14 from the cover of the cable entry box 2 and remove the cover Remove the 4 hexagon socket screws 3 from the flange Carefully pull the flange a few cm s from...

Page 22: ...e OMRON relay 61 F GP or an equivalent This relay switches at 5000 ohm No water present high resistance between terminals 1and 7 5000 Ohm terminals 2 and 4 closed terminals 3 and 4 open Water present low resistance between terminals 1 and 7 300 500 Ohm terminals 2 and 4 open terminals 3 and 4 closed 9 2 Thermoswitches Thermoswitches are standard for the RW60and RW80 pumps and optional for the RW20...

Page 23: ...lushing 9 6 1 Internal cooling system Mostly an internal cooling system is supplied The pumped medium is circulated from the backside of the impeller through the cooling jacket and back into the pump flushing the seal The whole system is self venting For horizontally installed pumps the cable entries are underneath the motor otherwise the cooling system will not vent itself On top of the cooling j...

Page 24: ...ing Check motor Check power supply Check pump Check dicharge and coupling Check pump Check power supply Check discharge Check pump Check power supply Check motor CHECKPOINTS No power Main isolator switch Fuses Earth leakage relay Motor protection relay Motor temperature Water detector Too low waterlevel Obstructed level switches Switches interchanged Controlpanel Continuity and isolation Phase res...

Page 25: ...d Rijn The Netherlands 1 17 2 16 19 18 15 12 10 9 8 6 20 3 7 5 4 13 14 11 Nr Description 1 Pump type 2 Serial number 3 Impeller diameter 4 Rated electrical power 5 Rated voltage current and connection 6 Certificate number 7 Rated shaft power 8 Rated voltage current and connection 9 Power factor 10 Number of phases 11 Degree of protection 12 Type of duty cycle 13 Temperature class 14 Frequency 15 S...

Page 26: ...xtra 10 mm2 earth cable is fitted to the motorhousing to fulfill the demands of the Low Voltage Directive Always connect this cable also to the earth connection PUMP CABLE BR brown BL blue or gray B black G Y green yellow CONTROL PANEL U V W line T thermostats Wa water detector earth connection Star high voltage Delta low voltage www robotpompen onderdelen nl T 31 0 294 457712 info pompdirect nl ...

Page 27: ... control circuit e6 Fuses secondary control circuit F1 Motor protection circuit breaker with manual reset C Maincontactor D1 Auxiliary relay for motor protection D2 Auxiliary relay for power failure Tr Transformer S Manual off auto selector switch Start Level switch pump start Stop Level switch pump stop Re Reset push button M Pump motor T Thermostats if fitted www robotpompen onderdelen nl T 31 0...

Page 28: ...w CONTROL PANEL U V W line T thermostats Wa water detector earth connection In some situations where a longer pump cable is used an extra 10 mm2 earth cable is fitted to the motorhousing to fulfill the demands of the Low Voltage Directive Always connect this cable also to the earth connection Star high voltage Delta low voltage www robotpompen onderdelen nl T 31 0 294 457712 info pompdirect nl ...

Page 29: ...1 Motor protection circuit breaker with manual reset C1 Maincontactor C2 Relay delta connection C3 Relay star connection D1 Auxiliary relay for motor protection D2 Auxiliary relay for power failure D3 Timer relay star delta start Tr Transformer S Manual off auto selector switch Start Level switch pump start Stop Level switch pump stop Re Reset push button M Pump motor T Thermostats if fitted www r...

Page 30: ... 3 red white thick 4 5 red PUMP CABLE BR brown BL blue or gray B black G Y green yellow CONTROL PANEL P O line C capacitor T thermostats Wa water detector if fitted earth EXAMPLE OF A SINGLE PHASE CONNECTION DIAGRAM In some situations where a longer pump cable is used an extra 10 mm2 earth cable is fitted to the motorhousing to fulfill the demands of the Low Voltage Directive Always connect this c...

Page 31: ...Operation Maintenance Manual Pump RW 32 32 Edition 4 HSC 08 W36 782 001 GB APPENDIX 5 Notes Name Date Remarks www robotpompen onderdelen nl T 31 0 294 457712 info pompdirect nl ...

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