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Sulzer ABS RCP 400, Инструкция по установке и эксплуатации, Страница: 3 / 42

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3

4 

Product description ............................................................................................................................15

4.1 

General description ...............................................................................................................................15

4.2 

Structural design  ..................................................................................................................................16

4.2.1 

RW 400 and 650 ...................................................................................................................................16

4.2.2 

RCP 400 and 500 ..................................................................................................................................17

4.3 

Operation with frequency inverters .......................................................................................................18

5 Installation ...........................................................................................................................................19

5.1 

Installation RW / RCP ............................................................................................................................19

5.2 

Tightening torque ..................................................................................................................................19

5.2.1 Nord-Lock

® 

washer

 

 ...............................................................................................................................19

5.3 

Installation examples RW ......................................................................................................................20

5.3.1 

Installation example with existing accessories  ..................................................................................... 20

5.3.2 

Installation example with alternative fixing possibilities

 ......................................................................... 21

5.3.3 

Installation example with fixed installation as flow booster 

 .................................................................. 22

5.3.4 

Fixed installation with vibration damper   ..............................................................................................23

5.4 

Brackets RW .........................................................................................................................................23

5.4.1 

Fitting of the open bracket with vertical swivelling (option) ................................................................... 24

5.4.2 

Fitting of the closed bracket with vertical swivelling (option) ................................................................. 24

5.4.3 

Bracket alignment on guide rail .............................................................................................................26

5.5 

Guide tube lengths RW (square tube)  ..................................................................................................26

5.6 

Installation RCP ....................................................................................................................................27

5.6.1 

Installation example with Sulzer lifting unit ............................................................................................27

5.6.2 

Guide tube installation ...........................................................................................................................28

5.6.3 

Securing and positioning of the motor connection cables of the RCP .................................................. 29

5.6.4 

Lowering of the RCP along the guide tube ...........................................................................................30

5.7 

Electrical connection .............................................................................................................................31

5.7.1 

Standard connection diagrams. mains voltage 380 - 420 V at 50 Hz / 460 V at 60 Hz ........................ 32

5.7.2 

Lead designations .................................................................................................................................33

5.7.3 

Soft starter (option) ...............................................................................................................................33

5.7.4 

Checking direction of rotation ................................................................................................................34

5.7.5 

Changing direction of rotation  ..............................................................................................................35

5.7.6 

Connection of the seal monitoring unit to the control panel .................................................................. 35

6 Commissioning ...................................................................................................................................36

6.1 

Types of operation .................................................................................................................................37

7 Maintenance ........................................................................................................................................37

7.1 

General maintenance hints ...................................................................................................................37

7.2 

Maintenance RW/RCP ..........................................................................................................................38

7.2.1 Faults ....................................................................................................................................................38
7.3 

Inspection and maintenance intervals ...................................................................................................39

Содержание ABS RCP 400

Страница 1: ...www sulzer com 1549 01 310190014014 EN 07 2019 Installation and Operating Instructions en Submersible Mixer Type ABS RW 400 and 650 NG Submersible Recirculation Pump Type ABS RCP 400 and 500 NG ...

Страница 2: ... Technical data RCP 60 Hz 9 1 7 Dimensions and weights 10 1 7 1 Dimensions RW 10 1 7 2 Dimensions RCP 11 1 7 3 Flange dimension check 12 1 8 Nameplate 13 2 Safety 14 3 Transport and storage 14 3 1 Transport 14 3 2 Transport securing devices 14 3 2 1 Motor connection cable moisture protection 14 3 3 Storage of the units 15 Installation and Operating Instructions Original Instructions Submersible mi...

Страница 3: ...acket with vertical swivelling option 24 5 4 3 Bracket alignment on guide rail 26 5 5 Guide tube lengths RW square tube 26 5 6 Installation RCP 27 5 6 1 Installation example with Sulzer lifting unit 27 5 6 2 Guide tube installation 28 5 6 3 Securing and positioning of the motor connection cables of the RCP 29 5 6 4 Lowering of the RCP along the guide tube 30 5 7 Electrical connection 31 5 7 1 Stan...

Страница 4: ...afety requirements and conscious of the need to avoid potential dangers The contents of the Installation and Operating Instructions and the Safety Instructions for Sulzer Products Type ABS 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 ...

Страница 5: ...must be connected to a suitable release device which is certified in accordance with EC directive 2014 34 EU and FM 3650 Machines designated as Ex machines may never without exception be operated using a mains frequency that is greater than the maximum of 50 Hz or 60 Hz as indicated on the nameplate In the event that the pump is to be operated in explosive atmospheres using a variable speed drive ...

Страница 6: ...Ex EC CR Hydraulics Motor designation e g A Propeller Ø cm for RW Discharge size DN cm for RCP Propeller type Identity number Series 0551 0003 Propeller type 1 Mixing propeller only without flow ring 2 2 blade thrust propeller 3 3 blade thrust propeller 4 2 blade thrust propeller with flow ring 5 3 blade thrust propeller with flow ring 7 3 blade special propeller for biofilm carrier process 1 6 Te...

Страница 7: ...40 1 96 107 RW 4031 400 680 A 40 8 5 6 4 0 10 9 40 2 96 107 RW 4032 400 680 A 40 8 5 6 4 0 10 9 40 2 96 107 RW 4033 400 680 A 40 8 5 6 4 0 10 9 40 2 96 107 RW 6521 580 470 A 50 12 7 1 5 0 18 2 52 2 155 173 RW 6522 580 470 A 50 12 7 1 5 0 18 2 52 2 155 173 RW 6523 650 470 A 50 12 7 1 5 0 18 2 52 2 155 173 RW 6524 650 470 A 50 12 7 1 5 0 18 2 52 2 155 173 RW 6525 650 470 A 50 12 7 1 5 0 18 2 52 2 15...

Страница 8: ...858 A 35 8 4 6 3 5 8 7 38 1 96 107 RW 4024 400 841 A 46 8 6 0 4 6 10 3 38 2 96 107 RW 4031 400 841 A 46 8 6 0 4 6 10 3 38 2 96 107 RW 6521 580 571 A 60 12 8 0 6 0 17 5 50 2 155 173 RW 6522 580 571 A 60 12 8 0 6 0 17 5 50 2 155 173 RW 6531 650 567 A 90 12 11 5 9 0 23 9 52 2 182 200 RW 6532 650 567 A 90 12 11 5 9 0 23 9 52 2 182 200 RW 6533 650 567 A 90 12 11 5 9 0 23 9 52 2 182 200 RW 6534 650 569 ...

Страница 9: ...31 9 91 3 255 RCP 5036 492 470 1 27 655 A 100 12 13 3 10 0 31 9 91 3 255 P1 Power input P2 Power output Standard Option Cable type 10 m cable with free cable ends as standard 1 1 x 10G 1 5 2 1 x 10G 2 5 3 2 x 4G 4 2 x 0 75 1 6 4 Technical data RCP 60 Hz Propeller Motor 60 Hz 460 V RCP hydraulics type Propeller diameter Propeller speed H max Q max Motor type Rated input power P 1 Rated motor power ...

Страница 10: ...00 50 Hz A120 60 Hz D1 ø 400 ø 650 ø 650 ø 650 D2 ø 560 ø 810 ø 810 ø 810 d1 ø 222 5 ø 262 5 ø 262 5 ø 262 5 H 60 262 H 100 306 306 306 306 h1 700 1100 1100 1100 L1 60 665 L1 100 700 830 970 970 L2 60 685 L2 100 720 850 990 990 l1 795 925 1065 1065 l2 60 300 l2 100 300 400 630 530 X1 60 360 X1 100 280 320 420 400 X2 60 300 X2 100 310 330 430 410 20 60 44 100 min 50 60 x 60 l2 min h 1 min 190 min l...

Страница 11: ...800 min 400 DN 400 188 5 2 EN 10255 M X PN6 Type 11 DIN EN 1092 1 0553 0001 Figure 2 RCP 400 min 600 DN500 85 187 447 865 A50 12 1005 A75 12 A90 12 A100 12 A120 12 min 1000 X X PN6 Type 11 DIN EN 1092 1 2 EN 10255 M 0554 0001 Figure 3 RCP 500 ...

Страница 12: ...n Y DN mm 400 22 0 5 500 24 0 5 NPS inch 16 1 44 0 016 20 1 69 0 022 0555 0001 Figure 4 Flange dimensions ATTENTION Before installing the recirculation pump check the Y dimension of the flange Make sure that the dimensions specified in the table are adhered to otherwise the flange will need to be reworked ...

Страница 13: ...nation Production date Week Year Nr Item number Sn Serial number Order number Un Nominal voltage V In Nominal current A S1 Continuous operating mode 3 Number of phases Hz Frequency Hz P1 Power consumption kW Insul Cl H Insulation class n Rotation speed rpm P2 Power output kW Figure 5 Nameplate 50 Hz Weight kg Ø Prop Propeller diameter mm Max amb Temp Maximum ambient temperature 40 C Maximum immers...

Страница 14: ...uspended load The lifting hook height must take into consideration the entire height of the unit as well as the length of the lifting chain 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 manufacture with protective covers ATTENTION These protective...

Страница 15: ...plied to the sealing surfaces thus ensuring perfect operation of the mechanical seals The bearings supporting the motor shaft are maintenance free 4 Product description 4 1 General description Hydraulically optimized propeller with high wear resistance The motor shaft is supported in lubricated for life maintenance free ball bearings The shaft is sealed on the medium side by means of a high qualit...

Страница 16: ...0556 0001 Figure 7 RW 400 650 Legend 1 Bracket 8 Mechanical seal 2 Cable inlet 9 Propeller boss 3 Connection chamber 10 Propeller 4 Sealing of the motor chamber 11 Shaft unit with rotor and bearings 5 Stator 12 SD ring 6 Bracket with shackle 7 Stainless steel covering option ...

Страница 17: ...Figure 8 RCP 400 500 Legend 1 Bracket 8 Mechanical seal 2 Cable inlet 9 Propeller boss 3 Connection chamber 10 Propeller 4 Sealing of the motor chamber 11 Shaft unit with rotor and bearings 5 Stator 12 SD ring 6 Lifting hook 13 DI electrode seal monitor 7 Inlet cone ...

Страница 18: ...g 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 it is not falling below 25 Hz The maximum frequency must be set so the rated power of the motor is not exceeded Modern frequency inverters use higher wave frequencies and a steeper rise on the flank...

Страница 19: ...The electrical connection is carried out in accordance with section 5 7 Electrical connection NOTE We recommend that Sulzer installation accessories be used for the installation of the RW RCP 5 2 Tightening torque Tightening torque for Sulzer stainless steel screws A4 70 Thread M6 M8 M10 M12 M16 M20 M24 Tightening torque 6 9 Nm 17 Nm 33 Nm 56 Nm 136 Nm 267 Nm 460 Nm 5 2 1 Nord Lock washer 1176 00 ...

Страница 20: ...is type of installation See Figure 17 1 2 7 6 5 4 3 8 0558 0001 Figure 11 Installation example with exising accessories Legend 1 Hoist with winch and rope 5 Safety stop clamp 2 Upper bracket with locking plate 6 Swivelling square guide tube 3 Closed bracket 7 Cable clamp with cable hook 4 Bottom plate 8 Stop for vibration damper option ...

Страница 21: ... of installation See Figure 17 1 8 3 4 7 2 5 6 0559 0001 Figure 12 Installation example with alternative fixing possibilities Legend 1 Transportable lifting unit 5 Swivelling wall mounted bracket 2 Swivel handle 6 Open bracket 3 Socket fixed installed 7 Cable clamp with cable hook 4 Swivelling square guide tube 8 Rope block ...

Страница 22: ... this type of installation See Figure 17 1 3 2 5 4 6 7 8 9 0560 0001 Figure 13 Installation example with fixed installation as flow booster Legend 1 Rope block 2 Tube retainer 3 Cable clamp with cable hook 4 Sulzer lifting unit 5 kN 5 Square guide tube 6 Open bracket 7 Vibration damper 8 Tube connector 9 Bottom plate ...

Страница 23: ...mper for the relevant mixer can be ordered see table below Vibration damper listing Mixer Part no RW 400 6 162 0019 RW 650 6 162 0020 A50 12 A 60 12 6 162 0027 A75 12 A 90 12 A100 12 A 120 12 0561 0001 Figure 14 Fixed installation with vibration damper 5 4 Brackets RW Brackets which can be swivelled vertically only optional are available for both open and closed models of the brackets for all mixe...

Страница 24: ...8 2x 5 2x 9 2x 10 2x 9 2x 11 2x 3 2x 10 2x 1 10 2x 9 2x 8 2x 4 2x 10 2x 5 2x 2 2x 1 8 2x 9 2x 5 2x 4 2x 12 2x 13 2x 10 2x 7 2x 0564 0001 Figure 16 Open bracket with vertical swivelling Legend 1 Bracket 6 Strap 10 Hex nut 2 Cladding 7 Flat head screw 11 Socket head screw 3 Threaded inserts 8 Tube 12 Hinge bolt 4 Hex bolts 9 Washer 13 Linchpin 5 Roller ...

Страница 25: ...x 9 2x 11 2x 8 2x 3 2x 5 2x 4 2x 5 2x 2 2x 4 2x 5 2x 3 7 2 1 5 4 3 8 2x 11 2x 10 2x 9 2x 1 6 2x 0565 0001 Figure 17 Closed bracket with vertical swivelling Legend 1 Bracket 7 Bolt long 2 Cladding 8 Washer 3 Roller 9 Hex nut 4 Bolt short 10 Threaded insert 5 Linchpin 11 Socket head screw 6 Strap ...

Страница 26: ... shows the maximum lengths of the guide tubes based on the maximum allowable bending 1 300 th of the length These values have been determined in clean water of density 1000 kg m3 for the maximum thrust of the most powerful mixer Maximum guide tube length L for an installation with square guide tube Mixer with push in type lifting unit with separate lifting unit guide tube with additional wall fixi...

Страница 27: ...27 5 6 Installation RCP 5 6 1 Installation example with Sulzer lifting unit 0570 0001 Figure 19 Installation example with Sulzer lifting unit 5 kN ...

Страница 28: ...ange 20 9 and fasten using hex nuts 20 7 together with spring washers 20 8 and the special nuts 20 10 ATTENTION The flattened edge of the special nuts 20 10 must point towards the flange centre Position the tube retainer 20 1 vertically over the bracket 20 6 Mount with the aid of the wall plugs 20 4 but do not tighten yet Place the guide tube 20 5 alongside the conical section of the bracket 20 6 ...

Страница 29: ...tion cable close to the RCP itself and tighten using hex screw 21 1 Connect the snap hook 21 4 to the cable holder 21 2 and attach to the wire rope or chain Care must be taken that the connection cables are positioned that they cannot be caught up in the propeller blades and that they are not subjected to tension Assemble all other cable holders in a similar manner The spacing can be increased as ...

Страница 30: ...pump created by the lifting hook when suspended by the hoist has to be checked prior to lowering For this purpose begin lifting the pump from a horizontal surface and check that the rear end of the fixing support rises 2 to 4 cm from the floor before the front end begins to lift clear see Figure 22 2 4 cm 0573 0001 Figure 22 checking installation angle of pump ATTENTION The power cable should be c...

Страница 31: ...nameplate of the pump must correspond to that of the mains The incoming power supply as well as the connection of the unit 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 co...

Страница 32: ...tion diagrams mains voltage 380 420 V at 50 Hz 460 V at 60 Hz M3 PE F1 DI W2 V2 W1 V1 U2 U1 F0 W1 U1 V1 0575 0001 50 Hz 60 Hz A 30 8 A 35 8 Figure 24 One power cable with integrated control leads internal connection in the motor only for motor 3 kW M3 PE F1 DI W2 V2 W1 V1 U2 U1 F0 V2 U2 W2 W1 U1 V1 0576 0001 50 Hz 60 Hz A 40 8 A 46 8 A 50 12 A 60 12 A 75 12 A 90 12 A 120 12 Figure 25 One power cab...

Страница 33: ... a manner that a manual reset is required ATTENTION The temperature limiting switches may only be operated as specified by the manufacturer see following table Operating voltage AC 100 V to 500 V Rated voltage AC 250 V Rated current AC cos φ 1 0 2 5 A Rated current AC cos φ 0 6 1 6 A Max switching current at IN 5 0 A 5 7 3 Soft starter option For units 15 kW we recommend the use of a soft starter ...

Страница 34: ...o the longest possible starting time within the adjustment range possible 0581 0001 Figure 28 Testing and adjustment of soft starter 5 7 4 Checking direction of rotation When the 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 The direction of rotation propeller rotation is correct if the pro...

Страница 35: ...ncorrect 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 5 7 6 Connection of the seal monitoring unit to the control panel The standard versions of the units are fi...

Страница 36: ...ommissioning the unit should be checked and a functional test carried out Particular attention should be paid to the following Have the electrical connections been carried out in accordance with regulations Have the thermal sensors limiters been connected Is the seal monitoring device where fitted correctly installed Is the motor overload switch correctly set Have the power and control circuit cab...

Страница 37: ...g maintenance in paragraph 3 2 of the separate booklet Safety In structions for Sulzer Products Type ABS are to be observed 7 1 General maintenance hints Before commencing any maintenance work the unit should be completely disconnected from the mains by a qualified person and care should be taken that it cannot be inadvertently switched back on Servicing must only be carried out by qualified perso...

Страница 38: ...or this purpose special care must be taken that all parts of the unit are in a good condition and that operational security is guaranteed The inspection period is determined by the type of usage of the units but should however not exceed one year The maintenance and inspection work must be carried through corresponding to the subsequent inspection plan The executed work must be documented in the a...

Страница 39: ...contact your local Sulzer Service Centre ACTIVITY Inspection of the propeller and the SD ring Solids Deflection Ring DESCRIPTION The propeller should be inspected carefully The propeller might show spots of rupture and wear due to strongly abrasive or aggressive mixing material In both cases the flow formation is reduced considerably and the propeller must be replaced The solids deflection ring mu...

Страница 40: ...rews are checked for their perfect positioning once a year MEASURE Tighten screws with correct tightening torques see 5 1 1 Manufacturer Sulzer Pump Solutions Ireland Ltd Clonard Road Wexford Ireland 2 Year of production 3 Serial no 4 Type 5 Check before first operation on by Recurring checks at least once a year Date Remarks Operating hours Signature Repaired on by ...

Страница 41: ...41 Recurring checks at least once a year Date Remarks Operating hours Signature Repaired on by ...

Страница 42: ...42 Sulzer Pump Solutions Ireland Ltd Clonard Road Wexford Ireland Tel 353 53 91 63 200 www sulzer com ...

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