Installation and Operating Instructions

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1 ABS submersible mixer RW ABS submersible recirculation pumps RCP RCP SB-KA RW GB Installation and Operating Instructions

2 2 Installation and Operating Instructions Installation and Operating Instructions RW 300 RW 400 RW 650 RW 900 RW 400 LW RW 550 DM RW 650 LW RCP 250 RCP 400 RCP 500 RCP 800 SB 1236 KA SB 1237 KA

3 Installation and Operating Instructions 3 1 General Safety Transport and storage Product description RW 300/400/ RW 900/SB-KA RCP 400/ RCP Installation... 23

4 4 Installation and Operating Instructions Brackets RW/SB-KA Commisioning Maintenance

5 Installation and Operating Instructions 5

6 6 Installation and Operating Instructions 1 General 1.1 Introduction These Installation and Operating Instructions Safety Hints - m c g 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. 1.2 Correct usage of the products - - of the installation and operating instructions and the safety hints 1.3 Application restrictions of RW/RCP/SB-KA Limitations: ATTENTION 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.

7 g g For the operation of units as explosion-proof execution the following applies: Installation and Operating Instructions 7 ATTENTION RW/RCP with Ex d IIB T4 approval are not equipped with a DI in the oil chamber. ATTENTION RW 400/650 and RCP 400/500 with FM approval (NEC 500) can be equipped (as an option) with a special DI in the oil chamber. Due to the design this is not possible in RW 900 and RCP 800. For the operation of ex-rw/rcp applies: - For the operation of EX-RW/RCP with frequency inverter applies: 1.4 Application areas Application areas RW Application areas RCP -

8 8 Installation and Operating Instructions Application areas SB-KA - Hydraulics Motor AAA BB C D U VVV / W-XY.Z Ex EC; CR Material used Ex-version Gearbox ratio (only RW 900, RCP 800 and SB-KA) Motor size Number of poles in motor Motor power (P 2 [kw] x 10) Motor designation (e.g. A) Identity number Propeller type* Discharge size DN [cm] for RCP PropellerØ [cm] for RW/SB-KA Series 1.6 Technical data merged unit.

9 Installation and Operating Instructions Technical data RW 50 Hz Propeller Motor (50 Hz/400 V) Installation Mixer type Propeller diameter Speed Motor type Rated power input P 1 Rated power output P 2 Starting: Direct Starting: Star/Delta Rated current at 400 V Starting current at 400 V Cable type** Temperature monitoring Seal monitoring Ex d IIB T4 Total weight Total weight RW A 15/ RW A 15/ RW A 15/ RW A 28/ RW A 28/ RW A 28/ RW A 30/ RW A 30/ RW A 30/ RW A 30/ RW A 40/ RW A 40/ RW A 40/ RW A 50/ RW A 50/ RW A 50/ RW A 50/ RW A 50/ RW A 75/ RW A 75/ RW A 100/ RW A 110/ RW A 110/ RW A 110/ RW A 150/ RW A 150/ RW A 220/ RW A 220/ P 1 2 Other voltages available on request.

10 10 Installation and Operating Instructions Technical data RW 60 Hz Propeller Motor (60 Hz/460 V) Installation Mixer type Propeller diameter Speed Motor type Rated power input P 1 Rated power output P 2 Starting: Direct Starting: Star/Delta Rated current at 460 V Starting current at 460 V Cable type** Temperature monitoring Seal monitoring FM (NEC 500) Total weight Total weight RW A 17/ RW A 17/ RW A 32/ RW A 32/ RW A 35/ RW A 35/ RW A 35/ RW A 46/ RW A 46/ RW A 60/ RW A 60/ RW A 90/ RW A 90/ RW A 90/ RW A 120/ RW A 120/ RW A 130/ RW A 130/ RW A 130/ RW A 170/ RW A 170/ RW A 250/ RW A 250/ P 1 2

11 Installation and Operating Instructions Technical data RW- special executions Mixer type Propeller diameter Speed Motor type Rated power input P 1 Rated power output P 2 Starting: Direct Starting: Star/Delta Rated current Starting current Cable type** Temperature monitoring Seal monitoring Ex d IIB T4 Frequency Total weight RW 4033 LW A 40/ RW 6532 LW A 75/ RW 6533 LW A 100/ RW 5531 DM A 100/ RW 5531 DM A 120/ RW 5531 DM A 120/ P Technical data RCP 50 Hz Propeller Motor (50 Hz/400 V) RCP hydraulics type Propeller diameter Propeller speed H max Q max Motor type Rated input power P 1 Rated motor power P 2 Starting: Direct Starting: Star/Delta Rated current at 400 V Starting current at 400 V Cable type** Temperature monitoring Seal monitoring Ex d IIB T4 Total weight RCP A 15/ RCP A 28/ RCP A 28/ RCP A 40/ RCP A 40/ RCP A 40/ RCP A 40/ RCP A 40/ RCP A 40/ RCP A 50/ RCP A 75/ RCP A 75/ RCP A 75/ RCP A 100/ RCP A 100/ RCP A 150/ RCP A 220/ RCP A 220/ RCP A 220/ P 1 2

12 12 Installation and Operating Instructions 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 P 2 Starting: Direct Starting: Star/Delta Rated current at 460 V Starting current at 460 V Cable type** Temperature monitoring Seal monitoring FM (NEC 500) Total weight RCP A 17/ RCP A 32/ RCP A 32/ RCP A 46/ RCP A 46/ RCP A 46/ RCP A 46/ RCP A 90/ RCP A 120/ RCP A 120/ RCP A 120/ RCP A 130/ RCP A 250/ RCP A 250/ RCP A 250/ P Technical data SB-KA Propeller Motor Weight Flow booster type Propellerdurchdiameter Speed Motor type Rated input power P 1 Rated motor power P 2 Starting: Direct Starting: Star/ Delta Rated current at 400 V / 460 V Starting current 400 V / 460 V Cable type** Temperature monitoring Seal monitoring EEx dii BT4 Total weight SB 1236 KA A 30/ SB 1237 KA A 40/ SB 1236 KA A 35/ SB 1237 KA A 46/ P 1 2 NOTE Other voltages available on request.

13 Installation and Operating Instructions Dimensions and weights NOTE The weights of the units can be obtained from the nameplate of the unit or from the Dimensions RW Dimension RW 300 A15/28 A17/32 RW 400 A30/40 A35/46 RW 650 A50 A60 RW 650 A75 A90 RW 650 A100 A120 RW 900 A110/150 A130/170 RW 900 A220 A250 D 1 ø 300 ø 400 ø 650 ø 650 ø 650 ø 900 ø 900 D 2 ø 462 ø 560 ø 810 ø 810 ø 810 ø 1150 ø ø 158 ø ø ø ø ø ø h L L L L l l l

14 14 Installation and Operating Instructions Dimensions RCP 210,5 125, DN 250 Ø 52 Ø 267 X , min. 400 DN 400 min. 800 X 683

15 Installation and Operating Instructions DN500 min. 600 min X 865 (A50/12) 1005 (A75/12, A90/12, A100/12, A120/12) min. 700 DN 800 min X 1174 (A130/4, A150/4) 1274 (A220/4, A250/4)

16 16 Installation and Operating Instructions Dimensions SB-KA D C A C = 15 A B D SB 1236 KA SB 1237 KA D B C = 22 A B D SB 1236 KA SB 1237 KA C = 30 A B D SB 1236 KA SB 1237 KA Nameplate Figure File no Use with approved motor control that matches motor input in full load amperes. To reduce the risk of injury or electrical shock, disconnect the power be- fore raising or lowering and servicing this device Utiliser un Demarreur approuve covenant au courant a pleine charge du moteur This plate was supplied originally with certified pump FM APPROVED EXPLOSIONPROOF G k Ex d B T4 Do not open while energized Nicht unter Spannung öffnen Legend

17 Installation and Operating Instructions 17 NOTE In all communication please state type of the unit, item and serial number. 2 Safety Safety Hints 3 Transport and storage 3.1 Transport c m. - - m m m m 3.2 Transport securing devices Motor connection cable moisture protection ATTENTION These protective covers should only be removed immediately prior to connecting the pumps electrically. - ATTENTION NOTE 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. If there is a possibility of water ingress then the cables should be secured so that the

18 18 Installation and Operating Instructions ATTENTION Take care not to damage the cable or its insulation when doing this! 3.3 Storage of the units 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 tempera- tem, 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 4 Product description 4.1 General description ABS units do not generally require any particular maintenance during storage. After long storage periods (after approx. one year), the transportation locking 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. Motor Motor monitoring - Seal monitoring Operation with frequency inverters suitably selected Observe the EMC-Directive and the installation and operating instructions of the inverter manufacturer!

19 Installation and Operating Instructions Structural design RW/SB-KA RW 300/400/ RW 900/SB-KA

20 20 Installation and Operating Instructions Legend 1 Bracket 5 Stator 10 Propeller 13 Gear 4.3 Rinsing system for mechanical seal (Option) Z Z

21 Y Installation and Operating Instructions Structural design RCP RCP 400/ RCP

22 22 Installation and Operating Instructions Legend 6 Stator 9 Propeller 13 Gear 4.5 Operation with frequency inverters

23 Installation and Operating Instructions 23 U N [V] critical area non critical area 5 Installation m L[m] L = total length (from frequency inverter to motor) 5.1 Installation RW/SB-KA c c NOTE. We recommend that ABS installation accessories be used for the installation of the 5.2 Propeller assembly (only for RW 900 and SB-KA) position of the securing washers) and that the prescribed tightening torque is used!

24 24 Installation and Operating Instructions Legend 6 Propeller 5.3 Tightening torque Outer side of the 2 securing washers Inner side of the 2 securing washers Tightening torque for ABS stainless steel screws A4-70: Thread M6 M8 M10 M12 M16 M20 M24

25 Installation and Operating Instructions Installation examples RW/SB-KA Installation example with existing accessories Legend

26 26 Installation and Operating Instructions Legend

27 Installation and Operating Instructions Legend 8 9

28 28 Installation and Operating Instructions Installationsbeispiel SB-KA Fixed installation with vibration damper Vibration damper listing Mixer Part no. RW RW RW 650 RW 900/SB-KA RW 400/650 RW 900/SB-KA

29 Installation and Operating Instructions Brackets RW/SB-KA open closed Fitting of the open bracket with vertical swivelling (option) (2x) 9 (2x) 5 (2x) 4 (2x) 10 (2x) 2 (2x) 13 (2x) 10 (2x) 1 7 (2x) VKT (2x) 2 8 (2x) 9 (2x) 5 (2x) 4 (2x) 10 (2x) 10 (2x) 9 (2x) 10 (2x) 9 (2x) 6 (2x) 2 8 (2x) 5 (2x) 9 (2x) 4 (2x) 3 (2x) 11 (2x) 3 (2x) 1 VKT (2x) 10 (2x) 9 (2x) 10 (2x) 4 (2x) 9 (2x) 8 (2x) 5 (2x)

30 30 Installation and Operating Instructions Legend Fitting of the closed bracket with vertical swivelling (option) 2 (2x) (2x) 5 (2x) 9 (2x) 1 VKT (2x) 5 (2x) 3 (2x) 4 (2x) 9 (2x) 8 (2x) 6 (2x) (2x) 10 (2x) 11 (2x) 3 (2x) 1 VKT (2x) 9 (2x) Legend 6 Strap

31 Installation and Operating Instructions Guide tube lengths (square tube) RW/SB-KA - 3 Mixer/ Flow booster Maximum guide tube length (L) for an installation with square guide tube with push in type with separate guide tube with additional lifting unit lifting unit L L L RW 300 RW 400 RW 650

32 32 Installation and Operating Instructions 5.7 Installation RCP Installation example with ABS lifting unit

33 Installation and Operating Instructions Guide tube installation m

34 34 Installation and Operating Instructions Securing and positioning of the motor connection cables of the RCP m NOTE The cable holders described here are not supplied as part of the standard execution of the RCP c c.

35 Installation and Operating Instructions Lowering of the RCP along the guide tube m ATTENTION The power cable should be connected to the wire rope or chain in such a manner that it cannot become entangled in the propeller and that it is not subjected to any tension

36 36 Installation and Operating Instructions 5.8 Electrical connection m 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 c - on the nameplate. If you want to use other starting methods please consult the manufacturer. In the case a control panel is not supplied as standard the following applies: The unit must only be operated with a motor protection switch with overload relay and thermal sensors connected.

37 Installation and Operating Instructions Standard connection diagrams. mains voltage V at 50 Hz/460 V at 60 Hz U2 V2 U1 V1 PE U1 V Hz 60 Hz A 15/6 A 17/6 A 28/6 A 32/6 A 30/8 A 35/8 W2 M3 ~ W1 W1 F0 F1 DI U2 V2 W2 M3 ~ U1 V1 W1 PE U1 V1 W1 W2 U Hz 60 Hz A 40/8 A 46/8 A 50/12 A 60/12 A 75/12 A 90/12 A 110/4 A 120/12 A 130/4 A 170/4 V2 F0 F1 DI U2 V2 W2 M3 ~ U1 V1 W1 Cable 1 Di Di PE U1 V1 W Hz 60 Hz A 100/12 A 250/4 A 150/4 A 220/4 PE W2 U2 V2 F0 F1 Cable 2

38 38 Installation and Operating Instructions Lead designations Direct starting in star L1 L2 L W1 1 U1 4 U2 6 5 W2 V2 3 2 W1 V Direct starting in delta L1 L2 L W2 1 U W1 3 5 V2 U2 4 V12 c turer (See following table)....ac/...dc V ~/ V= AC 250 V AC cos = A AC cos = A I N 5.0 A Soft starter (Option) ATTENTION The units must be connected DOL when used with soft starters Legend PE U2 U1 U1 V2 V1 V1 W2 M3 ~ W1 W1 2 3 F0 F1 DI RW/RCP/SB-KA

39 Installation and Operating Instructions Testing and adjustment of soft starter: Test: Setting: Set to the lowest possible starting torqu Set to the longest possible starting time Checking direction of rotation m

40 40 Installation and Operating Instructions c m Start reaction NOTE If a number of units are connected to a single control panel then each unit must be individually checked. ATTENTION The mains supply in the control panel must have a clockwise sense of rotation. If the units are connected in accordance with the wiring diagram and the lead designations the direction of rotation will be correct Changing direction of rotation m c NOTE The direction of rotation measuring device monitors the direction of rotation of the mains supply or that of an emergency generator.

41 Installation and Operating Instructions Connection of the seal monitoring unit to the control panel ATTENTION If the DI-seal monitoring is activated the unit must be immediately taken out of service. Please contact your ABS service centre. MAINS MAINS 3 (DI) PE M2+ 3 (DI) PE M2+ M1- M Electrode X1 X2 Bulb 24V 2-5 W Electrode / MAINS 3 (DI) PE M2+ M1- Pump 2 Pump Electrode ATTENTION Maximum relay contact loading: 2 Ampere.

42 42 Installation and Operating Instructions 6 Commisioning m 6.1 Types of operation min. H min. 0,5 B ATTENTION ATTENTION The illustration is only an example. For the correct installation please contact ABS. Operation within the directly aerated area is not allowed! not vibrate heavily when in operation.

43 Installation and Operating Instructions 43 7 Maintenance m 7.1 General maintenance hints c NOTE g The maintenance hints given here are not designed for do-it-yourself repairs as special technical knowledge is required. - - ATTENTION The lifting tools like chains and shackles should be visually checked in regular inter- if required! NOTE ATTENTION The ABS warranty conditions are only valid provided that any repair work has been carried out in ABS approved workshops and where original ABS spare parts have been used. Regular checks are highly recommended and other checks are prescribed regula-

44 44 Installation and Operating Instructions 7.2 Maintenance RW/RCP and SB-KA m Faults - Possible causes: 7.3 Inspection and maintenance intervals for RW/RCP and SB-KA m PERIOD OF TIME: Regulation: once a month - -

45 Installation and Operating Instructions 45 PERIOD OF TIME: PERIOD OF TIME: PERIOD OF TIME: PERIOD OF TIME: Recommendation: once a month Regulation: every 3 months - Recommendation: every 6 months Recommendation: once a year

46 46 Installation and Operating Instructions Recurringchecks(at leastonceayear) Date Remarks Operating hours Signature Repaired on/by

47 Installation and Operating Instructions 47 Recurringchecks(at leastonceayear) Date Remarks Operating hours Signature Repaired on/by

Flow booster type ABS SB 900 to 2500

Flow booster type ABS SB 900 to 2500 6005583 EN 08.2018 en EN 0580-I Installation and operating instructions Translation from original instruction www.sulzer.com Installation and operating instructions