Betriebsanleitung Operating Instructions Instructions de

Betriebsanleitung
Operating Instructions
Instructions de service
ENGLISH
SW 22
Seite
3
3.4 Motor .................................................................................................................................................................................... 5
2.2
Konservieren
2.1
4
3.1
N
M
TH
TV
Motor
Laufradformen
3.2.3
3.4
5
3.4.2
AM1
DOL
AM2
DOL
AM3A
B
Y
1
2
Y
1
2
DOL
Y
1
2
AM3B
DOL
Y
1
2
AM3C
DOL
Y
1
2
AM3C
DOL
Δ
3
4
AM3C
S/D
Y/Δ
5
6
AM3D
S/D
Y/Δ
5
6
AM3E
S/D
Y/Δ
7
8
AM3F
S/D
Y/Δ
7
8
Motor
Ölkammer
Motor-/Steuerkabel
Motorkabel
Motorkabel
Motor
Motor
Ölkammer
Ölkammer
Motor-/Steuerkabel
Motor-/Steuerkabel
Motor
Ölkammer
Ölkammer
Motor-/Steuerkabel
Motor-/Steuerkabel
6
3.4.3
Motorkabel
Motor
3.4.3.1
3.4.3.2
Motorkabel
Motor
Ölkammer
Motor-/Steuerkabel
Motorkabel
Motor
Ölkammer
Motor-/Steuerkabel
7
11
12
3.6.2
14
1-
2+
A1
A2
3.6.3
L0 (N)
8
4.6.3
4.3
5.1
5.1.1
9
4.2
5.1.2.1
5.2
Pumpentyp
µF
VAC
SW 65-160 und 80-160
2-polig bis 0,8 kW (P2)
25
450
30
450
SW 65-160 und 80-160
4-polig bis 0,9 kW (P2)
40
450
40
450
5.1.2.2
Funktionskontrolle
5.4
5.4.1
6.1
6.2.1.1
0,01
AM1 2-polig 1,8 kW bis 3,4 kW
1,1
AM1 4-polig
1,1
AM2 2-polig
0,5
AM2 4-polig 0,9 kW bis 1,3 kW
0,5
AM2 4-polig 1,9 kW bis 2,4 kW
0,6
AM3A
0,6
AM3B
0,6
AM3C
1,9
AM3D
3,7
AM3E
10
12
6.2.1.2
Motortyp
EX
0,4
6.2.6
11
6.2.7
Lauf- Pumpenrad typ
Motor
Hydraulik
B
C
D
F
SW 65-160.F
-
1
2
-
-
F
SW 80-160.F
-
1
3
-
-
F
SW 80-170.F
-
4
5
-
-
F
SW 80-230.F
AM3B
6
7
-
-
F
SW 80-230.F
AM3C
8
9
10
11
F
SW 80-230.F
AM3D
12
13
14
15
F
SW 100-230.F
AM3C
8
9
10
11
F
SW 100-230.F
AM3D
12
13
14
15
F
SW 100-280.F
AM3C
16
17
18
19
F
SW 100-280.F
AM3D
20
21
22
23
K
SW 65-160.K
-
24
25
-
-
K
SW 80-160.K
-
24
26
-
-
K
SW 80-210.K
Hydr. A+B
27
28
-
-
K
SW 80-210.K
Hydr. C+D
29
30
-
-
K
SW 80-250.K
AM3A
31
32
K
SW 80-250.K
AM3B
33
34
-
-
K
SW 80-250.K
AM3C
35
36
37
38
K
SW 80-250.K
AM3D
39
40
41
42
K
SW 100-250.K
AM3A
31
32
-
-
K
SW 100-250.K
AM3B
33
34
-
-
K
SW 100-250.K
AM3C
35
36
37
38
K
SW 100-250.K
AM3D
39
40
41
42
K
SW 100-310.K
AM3C
43
44
45
46
K
SW 100-310.K
AM3D
47
48
49
50
K
SW 150-370.K
AM3D
51
52
53
54
K
SW 150-370.K
AM3E
55
55
56
56
Z
SW 150-350.Z
AM3E
55
55
56
56
Z
SW 200-400.Z
AM3F
57
57
58
58
Z
SW 250-380.Z
AM3E
59
59
60
60
Z
SW 250-380.Z
AM3F
57
57
58
58
12
Pumpe verstopft
13
8. Anhang
8.1
VDMA-Nr.
VDMA-Nr.
101
812
Motorgehäusedeckel
135
814
151
819
162
Saugdeckel
822.01
163
822.02
230.xx
Laufrad
824.xx
320.01
Kugellager
826.xx
320.02
Kugellager
834.xx
360
835.xx
Motoren-Klemmbrett
411.xx
836.xx
412.xx
O-Ring
839.05
433
839.06
433.01
839.09
433.02
839.10
Spaltring
900.xx
903.xx
502
550.xx
552
561
Halbrundkerbnagel
914.xx
576
Griff
920.xx
Hutmutter
690.01
690.02
904
922
Sechskantmutter
930.xx
702
932.xx
704
940
732.01
950
732.02
970
811
14
990.xx
Motoröl
Index
Page
1. Safety instructions ................................................................................................................16
2. Handling and intermediate storage .....................................................................................16
2.1 Handling ............................................................................................................................................................................. 16
2.2 Unpacking .......................................................................................................................................................................... 16
2.3 Intermediate storage .......................................................................................................................................................... 16
2.4 Preservation ....................................................................................................................................................................... 16
3. Description.............................................................................................................................16
3.1 Designation ........................................................................................................................................................................ 17
3.2 Construction ....................................................................................................................................................................... 17
3.3 Mounting arrangements ..................................................................................................................................................... 17
3.4 Motor .................................................................................................................................................................................. 17
3.5 Dimensions, weights, centers of gravity, capacity.............................................................................................................. 20
3.6 Installation requirements .................................................................................................................................................... 20
4. Mounting/installation ............................................................................................................20
4.1 Preliminary checks ............................................................................................................................................................. 20
4.2 Stationary wet-pit installation (N) ....................................................................................................................................... 21
4.3 Mobile wet-pit installation (M)............................................................................................................................................. 21
4.4 Dry-pit installation (TV, TH)................................................................................................................................................ 21
4.6 Piping ................................................................................................................................................................................. 21
5. Commissioning/decommissioning ......................................................................................21
5.1 Preparing the pump for operation ...................................................................................................................................... 21
5.2 Level control....................................................................................................................................................................... 22
5.3 Commissioning................................................................................................................................................................... 22
5.4 Decommissioning............................................................................................................................................................... 22
6. Maintenance/servicing ..........................................................................................................23
6.1 General notes..................................................................................................................................................................... 23
6.2 Maintenance and inspections............................................................................................................................................. 23
6.3 Disassembly and assembly instructions ............................................................................................................................ 24
7. Problems: causes and remedies..........................................................................................25
8. Appendix ................................................................................................................................26
8.1 Parts list ............................................................................................................................................................................. 26
8.2 Sectional drawings ............................................................................................................................................................. 27
15
ENGLISH
4.5 Grouting of the pump and other final checks (N, TV, TH) .................................................................................................. 21
These instructions must be read in conjunction with the
separate User’s Safety Instructions, the Motor Operating
Instructions as well as the Operating Instructions supplied
for other components.
Examples of correct handling of the unit:
1. Safety instructions
• These operating instructions contain basic instructions, which
have to be adhered to during installation, operation and maintenance. These operating instructions must be read by the
mechanic and the operator before installation and operation
of the pump and have to be kept available at the operating
place of the machine/unit at all times. Persons who are not familiar with the operating instructions shall not use this product.
• The working area has to be closed off expediently and must
adhere to local workplace regulations.
• Make sure that the emergency exit from the workplace is not
barricaded.
• To prevent suffocation and poisoning caused by venomous
gases, make sure that enough oxygen exists at the workplace.
• If you have to work with welding tools or electric tools, make
sure that there is no explosion hazard.
• Always use personal safety equipment such as safety boots,
rubber gloves, safety glasses and helmet.
• Immediately after repair or maintenance work, all safety and
protection equipment must be reinstalled and placed in function again.
• The operator is responsible to third parties for the work area
of the pump.
• Rules for accident prevention as well as engineering rules
must be observed.
• Never put a hand or finger into suction inlet or discharge of the
pump while the impeller is rotating.
• Persons are not permitted to stay in the pumping medium during operation of the pump.
• For operation of the pumps in explosive environments only
models with explosion-proof motors (Ex model) must be
used.
• In accordance with product liability law, we point out that we
shall not be liable for damages caused by the pump due to
non-observance of the instructions and guidelines set forth in
the operating instructions. Same terms are valid for accessories.
Proper handling
Improper handling
2.2
Unpacking
Check that the delivery is complete and undamaged. If any defects are found, have them confirmed on the original bill of lading by the carrier and report these defects to us immediately.
The cable end is fitted with a moisture-proof seal. Do
not remove this seal until the cable is to be connected to the power supply.
2.3
Intermediate storage
• Store the pump in an upright position.
• Seal all suction and pressure ports with a sealing cap, a dummy flange or a dummy plug.
• Storage location: must be free of dust, dry and protected
against heat and frost.
• Long-time storage of more than 3 months: preservation
required!
• Long-time storage of more than 2 years: renew the lubricants before setting the pump into operation.
2. Handling and intermediate storage
2.4
2.1
If requested, we will preserve your pumps before delivery or at
site. Please contact our service department.
16
Handling
• Heed the weight and the center of gravity.
• Attach the lifting gear to the lifting eyes or lifting ear
of the motor. Do not lift the unit by the electric cable.
Preservation
3. Description
The channel impeller pumps of the SW series are single-stage
submersible sewage pumps with a pressure-water-tight motor
and a closed-coupled design. They can be supplied for different
types of installation and with various impeller types. For dry well
installation of the pump in a separate sump all models are available with a motor jacket cooling.
The pumps are not suitable for pumping liquids containing
heavy abrasive solids, like sand or stones. Before pumping of
chemically aggressive liquids, the resistance of the materials
must be checked.
For details on the supplied execution, please refer to the documentation related to the contract.
3.1
Designation
Example:
• Function of a mechanical seal: Two slide faces rub against
each other and are lubricated by a liquid film at the same time.
Mechanical seals are wearing parts for which no guarantee
can be given.
3.3
Nominal width
discharge branch [mm]
Mounting arrangements
N
M
TH
TV
Impeller
nominal diameter [mm]
Impeller form
Hydraulic basic number
Installation
Motor type
Rated output P2 [kW]
No. of poles
Kind of current
Explosion-proof
Motor cooling shroud
Example
The individual mounting arrangements are described in section
3.3.
3.2
Construction
Also refer to the sectional drawings (section 8.2).
3.2.1
Pump casing
3.4
Motor
Pressure-water-tight squirrel cage motor. Temperature class F,
protection class IP 68. Explosion-proof motors are also available. (For details, please refer to the documentation related to
the contract.)
3.2.2
Impeller types
Vortex impeller (.F)
For high gas content liquids, as well as stringy or
matting materials, sludge and abrasive suspensions.
Single-channel impeller (.K)
For media that contain coarser solid particles or
stringy or matting materials. Large impeller free passage for smooth transport.
Two-channel impeller (.Z)
For contaminated media that contain solid particles
but no strand-forming admixtures with long fibers or
gas and air bubbles.
3.2.3
Shaft and bearings
Greased maintenance-free roller bearings.
3.2.4
• Maximum coolant temperature 35°C, short term up to 60°C.
• Motors for operation mode S1 are designed with a maximum
number of 15 switches per hour.
• As a general rule: Starting method up to 3 kW DOL, for more
then 3 kW star-delta. For accurate details please refer to the
nameplate or to the documentation related to the contract.
• For operation, the motor must be fully submersed.
• If the motor is operated in a surfaced or not fully submersed state: operation in this state requires forced circulation cooling or a special motor dimensioning.
• Noise level during operation, 1.60 m from the ground
≤ 70 d(B)A.
• When operating the pumps with a frequency converter the
converter must be equipped with an outlet filter to protect the
pump motor from damaging voltage spikes. Such voltage
spikes may destroy parts of the pump motor.
3.4.1
Electrical connecting plan
Depending on the type and the size, the motor can be fitted with
different connection cables. For details on the motor type,
please refer to the documentation related to the contract.
Shaft seal
Shaft sealing by to mechanical seals acting irrespective of direction of rotation. Motors AM1 / 2 poles up to 1.2 kW with mechanical seal and radial sealing ring. For details on the supplied
shaft seal, please refer to the documentation related to the contract.
17
ENGLISH
The pump casing has a radial discharge branch and a axial suction branch.
3.4.2
Connecting plans
• Connecting plan - No. 3
• Execution A: Standard
• Execution B: Explosion proof
Motor
type
Starting
Connection
AM1
DOL
AM2
DOL
AM3A
Execution
A
B
Y
1
2
Y
1
2
DOL
Y
1
2
AM3B
DOL
Y
1
2
AM3C
DOL
Y
1
2
AM3C
DOL
Δ
3
4
AM3C
S/D
Y/Δ
5
6
AM3D
S/D
Y/Δ
5
6
AM3E
S/D
Y/Δ
7
8
AM3F
S/D
Y/Δ
7
8
Main supply
Motor protection
Motor protection
Motor cable
Motor
Oil chamber
Motor-/Control cable
Table 1: Allocation of connecting plans
T1, T3 : Temperature sensor (controller)
S1, S2 : Leak monitoring oil chamber
• Connecting plan - No. 1
• Connecting plan - No. 4
Main supply
Motor protection
Main supply
Motor protection
Motor protection
Motor protection
Motor cable
Motor cable
Motor
Motor
Oil chamber
Oil chamber
Motor-/Control cable
T1, T3 : Temperature sensor (controller)
S1, S2 : Leak monitoring oil chamber (acc. execution)
Motor-/Control cable
T1, T2 : Temperature sensor (limiter)
S1, S2 : Leak monitoring oil chamber
• Connecting plan - No. 2
• Connecting plan - No. 5
Main supply
Motor cable
Motor protection
Motor protection
Motor
Motor cable
Motor
Oil chamber
Oil chamber
Motor-/Control cable
Motor-/Control cable
T1, T2 : Temperature sensor (limiter)
S1, S2 : Leak monitoring oil chamber (acc. execution)
18
T1, T3 : Temperature sensor (controller)
S1, S2 : Leak monitoring oil chamber
• Connecting plan - No. 6
3.4.3
Monitoring devices
To avoid damage, the pump unit is fitted with various monitoring
devices. For the connection of the monitoring devices, refer to
section 3.4.2.
Motor cable
Motor
3.4.3.1
Protective motor switch
Depending on the current consumption of the motor during operation, the protective motor switch must be set to 90 - 100% of
the nominal motor current (refer to the nameplate).
Oil chamber
Connection
space
3.4.3.2
Temperature feeler
All motors are fitted with a temperature sensor. This sensor prevents the motor coils from overheating.
Standard execution:
Motor-/Control cable
T1, T2 : Temperature sensor (limiter)
S1, S2 : Leak monitoring oil chamber
S3, S4 : Leak monitoring connection space (acc. execution)
• Connecting plan - No. 7
Motor cable
Motor
Standard models have the sensors connected to the motor
power supply cable, the wire ends marked T1 and T3. They
must be connected to the safety circuit of the control box in order to provide an automatic re-start of the motor, when the motor cooled down. The switch-off temperature of the sensors for
standard models is from 130°C to 150°C.
Standard models of 1Ph-motors have the sensors internally
connected, so that no external connection to the control box is
necessary. When the motor cools, it is switched on again automatically.
Oil chamber
Connection
space
Motor-/Control cable
T1, T3 : Temperature sensor (controller)
S1, S2 : Leak monitoring oil chamber
S3, S4 : Leak monitoring connection space (acc. execution)
• Connecting plan - No. 8
Motor cable
Motor
Explosion proof models (1 Ph and 3 Ph) have a set of temperature sensors with a higher switch-off temperature of approx.
140°C, connected to the motor cable, the wires are marked T1
and T2. They must be connected to the safety circuit of the control box in order to provide a manual re-start, when the motor
cools. Fitted are looking ex sensors instead of standard sensors, i. e. in case of series connection to the relay the sensors
can be positioned back for the duration of the cooling by simply
detaching the pump from power supply.
Explosion proof execution, AM3C, AM3D:
Explosion proof models have a set of temperature sensors
built-in, instead of standard sensor with a higher switch-off temperature of approx. 140°C, connected to the motor cable, the
wire ends marked T1 and T2. They must be connected to a special relay in the starter box in order to provide manual pump restart.
Explosion proof execution, AM3E, AM3F:
Oil chamber
Connection
space
Motor-/Control cable
T1, T3 : Temperature sensor (controller)
T1, T2 :Temperature sensor (limiter)
S1, S2 : Leak monitoring oil chamber
S3, S4 : Leak monitoring connection space (acc. execution)
Explosion proof models have a set of temperature sensors
built-in additionally to the standard sensor as described above,
with a higher switch-off temperature of approx. 140°C, connected to the motor cable, the wire ends marked T1 and T2. Ex-sensors must be connected to a special relay in the starter box in
order to provide manual pump re-start. The manual re-start
must be assured by a special combination of relays in the control panel.
PTC resistor protection:
For operation in conjunction with a frequency converter, the explosion-proof submersible motors must be protected by a thermal motor circuit breaker comprised of PTC resistors according
to DIN 44081 / 44082 and an approved triggering device (heed
the documentation related to the contract and the separate connecting plan!).
19
ENGLISH
Explosion proof execution,
AM1, AM2, AM3A and AM3B:
3.4.3.3 Leak monitoring
Except for the AM1 motor, all motors are fitted with a moisture
feeler. This sensor is installed in the oil chamber resp. in the
connection space. In combination with the DG 110 control unit
supplied as an accessory, it ensures secure and reliable monitoring of the mechanical seal for leaks. Depending on the type
of the control unit, either the motor is automatically switched off
or appropriate signals are issued if any water enters the oil
chamber or the connecting space.
Leak monitoring oil chamber:
The electrical resistance of the oil in the chamber is measured
by two sensors S1/S2. The sensors must be connected to a
tripping unit in the control panel (electrode relays). In case of
water entering the chamber through the shaft seals, the resistance will change. For explosion-proof models an intrinsicallysafe relay has to be chosen.
The DG 110 is used for monitoring the conductivity of the
pumps’ oil filling. This conductivity is an indicator for the amount
of water that has penetrated inside. It is measured by an electrode that reaches into the oil chamber resp. into the connection
space. The DG 110 is fitted with a sensitive measuring and
switching amplifier with a relay output. The measuring voltage
applied for the measurements is 2.5V. The theoretically possible measuring current is 0.1mA. The threshold value of the relay is 100kOhm. The relay picks up when the measured value
drops below this threshold. This state is indicated by a red lightemitting diode on the control unit. The input circuit is fitted with
a filter against noise pulses. An isolating transformer isolates
the measuring circuit from the mains voltage.
3.5
On request.
Weight: refer to the documentation related to the contract.
3.6
Leak monitoring connection space:
Two sensors S3/S4 are used for monitoring leaks into the connection chamber. The sensors must also be connected in the
control panel to a tripping unit with galvanically separated safety circuit (electrode relays). For explosion-proof models an intrinsically-safe relay has to be choosen.
Control unit DG 110
L01 (L)
A1/A2 polarity = as required
A1
11
12
2+
14
A2
Sensor in the pump
Space requirements for operation and maintenance
• Ensure that sufficient space, at least from 2 sides, is left for
subsequent maintenance requirements. This space should
have, for reason of good accessibility, min. 0.8 m width.
• The set should be easily accessible from all sides.
3.6.2
Subsoil, foundation
• The subsoil or concrete foundation must be sufficiently strong
to ensure that the pump can be safely installed as required for
proper functioning.
3.6.3
L0 (N)
Installation requirements
• Protect the unit against atmospheric influences.
• Ensure sufficient ventilation, heating and cooling and heed
any sound proofing regulations that might be applicable.
• Check that the unit and its components can be safely transported to or removed from the installation location without accidents. Make sure that the existing doors or openings are
large enough.
• Make sure that the required lifting gear and the tools required
for attaching the gear are available.
3.6.1
1-
Dimensions, weights, centers of gravity, capacity
Supply connections
Check that all supplies like power, water and drainage necessary for installation and later operation are available in the form
required.
4. Mounting/installation
Sensor in the pump
Sketch of the DG 110 control unit
Auxiliary voltage A1 - A2 220-240 V +/- 10%, 50/60 Hz
Special voltage
24 V u. 110/115 V 50/60 Hz
24 V = galvanically separated,
unpoled
Current consumption
1.5 VA
Measuring voltage 1 - 2 2.5 V
Measuring current max. 0.1 mA
Switching threshold
100 kOhm +/- 5%
Operating mode
static current principle
Output
1 change-over contact
20
For proper functioning, the pump must be installed in a
careful and proper manner. Installation faults can cause injuries and damage and can also result in premature wear
of the pump.
Check the oil level before installing the pump (refer to section 6.2.1).
4.1
Preliminary checks
• The building must have been prepared according to the dimensions given on the foundation and layout plans.
• Pay attention to the maximum depth of immersion of the
pump (see pump label).
• If the pump is installed in a sump, the sump opening must be
covered with a tread-safe cover after installation.
• The operator has to prevent damage through the flooding of
rooms caused by defects of the pump through the use of appropriate measures (e.g. installation of alarm units, backup
pump or alike).
Stationary wet-pit installation (N)
• Install the foot bend, the guide rail and the ceiling bracket (refer to the dimension sheet).
• Then attach the pump so that it hangs in the guide rail and
lower it using the chain. The pump automatically engages in
the foot bend installed on the floor.
4.3
Dry-pit installation (TV, TH)
• Install the pump (refer to the dimension sheet).
• Connect the suction line and the discharge line to the pump.
Make sure that the lines are not subjected to stress.
• If necessary, mount a venting pipe on the pump casing.
4.5
Piping
The following not binding specifications are recommendations
for the correct dimensioning and laying of pipework (the planner
is responsible for the correct dimensioning of the pipework!).
4.6.1
•
•
•
•
•
•
•
•
Lay the pipe in a continuously ascending manner.
Maximum flow rate: 3 m/s (heed the head loss).
There must be no bottlenecks in the discharge pipe.
Lay the pipework system in such a manner that no inerts will
deposit in any other pump.
Dimension the flange and the pipe according to the maximum
possible pressure.
Prevent air pockets. If necessary, vent high points.
Prevent changing flow rates by using a uniform pipe diameter.
Install non-return valves and shut-off valves.
4.6.2
5. Commissioning/decommissioning
5.1
5.1.1
Preparing the pump for operation
Checks
Before switching on the pump, ensure that the following actions
have been carried out:
• Check the oil level (refer to section 6.2.1).
• Check that the fastening screws of the pump, the foot bend,
etc. are firmly tightened.
5.1.2
Electrical connections
The electrical connections may only be established
by a qualified electrician. The connections must be
established according to the VDE and EVU regulations and according to the relevant regulations for
motors with an explosion-proof design.
Grouting of the pump and other final checks (N, TV,
TH)
• After the pump or the foot bend has been aligned and fastened: grout in/underpour and, if necessary, also underpack
the fastening device with flash-set, non-shrinking cement.
• Let the cement set for at least 48 hours.
• Retighten the foundation bolts.
4.6
• Heed the relevant regulations.
• Heed the permissible nominal pressure of the individual components.
Mobile wet-pit installation (M)
• Attach a rigid or a flexible pipe to the discharge branch of the
pump.
• Lower the pump using the chain and place it in a vertical position onto a firm subsoil, with the motor facing upwards.
• Tighten the chain vertically and secure it to prevent the pump
from tipping over.
4.4
Pressure tests
• Before operation, an expert check must secure that the required electrical protection measures exist. The connection to
ground, earthing, isolating transformer, fault current breaker
or fault voltags circuit must correspond to the guidelines set
forth by the responsible power plant.
• Connect the motor according to the electrical connecting
plans (refer to section 3.4.2).
• Make sure that the electrical pin-and-socket connections are
installed flood- and moisture-safe. Before starting operation
check the cable and the plug against damages.
• The end of the pump power supply cable must not be submerged in order to prevent water from penetrating through the
cable into the motor.
• Ensure that motor starter/control box are not installed in explosive environments.
• Do not operate the motor without a protective motor switch
and a temperature and a leak monitoring device (if such a device exists).
• Make sure that the available mains voltage and frequency
match the data given on the nameplate.
• The connection and control cables of the motor and the level
controller must be routed in such a manner that they cannot
get caught by the suction force of the pump.
Suction line (mounting arrangement TV, TH)
• Maximum flow rate: 2 m/s (at maximum capacity).
• Do not install bends on different levels following one after the
other.
• Lay the pipe in a continuously descending manner (at least
1 %) towards the pump).
• Provide a separate suction pipe for each pump.
• Make sure that no air pockets can develop in the pipe.
21
ENGLISH
4.2
4.6.3
5.1.2.1
Connection of 1 Ph-Motors
5.2
Pumps with 230V/1Ph-motors must be connected to a seperate
control box with motor starter and operating capacitor. Original/
Matching control units can be supplied as accessory. If any other then an original control unit is used, make sure that the thermal relay in the motor starter is set according to the nominal
current consumption of the pump motor.
For capacitor sizes, see table below:
Pump type
Operating capacitor
µF
VAC
SW 65-160 and 80-160
2 poles up to 0.8 kW (P2)
25
450
SW 65-160 and 80-160
2 poles over 1 kW (P2)
30
450
SW 65-160 and 80-160
4 poles up to 0.9 kW (P2)
40
450
SW 80-170 and 80-210
up to 1.1 kW (P2)
40
450
Table 2: Data for capacitor
5.1.2.2
Connection of 3 Ph-Motors
Pumps with 3Ph-motors are supplied with or must be connected to a separate control box. Original/Matching control units
can be supplied as accessory. If any other than an original control unit is used, make sure that the thermal relay in the motor
starter is set according to the nominal current consumption of
the pump motor.
5.1.3
5.1.3.1
Check of the direction of rotation
1 Ph-pumps
1 Ph-pumps do not require any check, as they always run with
the correct direction of rotation.
5.1.3.2
3 Ph-pumps
• When connecting to a right handed rotating field all pumps
run with the correct direction of rotation (U, V, W -> L1, L2,
L3). The direction of rotation of the mains can be controlled by
a rotating field measuring instrument.
• If no rotating field measuring instrument is available, the
pump can be briefly switched off and immediately switched on
again in both horizontal/vertical position. Observe direction of
rotation of the impeller throught the suction branch/delivery
branch. The direction of rotation is correct, when the impeller
is rotating anti-clockwise in the suction branch and clockwise in the discharge branch.
Before checking the direction of rotation, make sure
that no foreign particles are in the pump casing. Never reach into the pump or hold any objects into the
pump. Keep a sufficient safety distance to the pump.
• If the direction of rotation is not correct, have the direction of
rotation of the motor corrected by an electrician.
Do not run pump counter to its given operation direction.
Level control
For stations with automatic pump operation, a level controller
must be installed. When the pump is switched off, the motor still
must be fully submersed. The water level may only be lowered
down to the pump casing if the pump is designed for S3 (intermittent) operation or if it is fitted accordingly (e.g. with a forced
circulation cooling system).
5.3
5.3.1
Commissioning
Initial commissioning/recommissioning
• Mounting arrangement N: Only start up the pump when it is
fully submersed. The gate valve must be throttled. Slowly
open the gate valve until the discharge line is completely
filled.
• Mounting arrangement M: Only start up the pump when it is
fully submersed.
• Mounting arrangement TV, TH: Fill and vent the suction
pipe and the pump. Only start up the pump when it is filled
with liquid. The gate valve must be throttled. Slowly open the
gate valve until the discharge line is completely filled.
5.3.2
Function check
• Check that the values displayed at the pressure gauge, at the
vacuum gauge, at the ammeter and, if installed, at the flow
meter match the values given in the documentation related to
the contract.
• Check the operating data at all operating states possible in
the system (parallel operation of pumps, other delivery purposes, etc.).
• Write down the determined values as standard values for
subsequent monitoring.
5.3.3
5.4
5.4.1
Operation with closed gate valve
Do not operate the pump when the gate valves on
the suction and the discharge sides are closed or, if
a non-return valve is installed on the suction side,
when the gate valve on the discharge side is closed.
In this mode, the medium to be delivered heats up
very quickly in the pump, causing a high pressure in
the pump due to the generation of steam. If the casing’s bursting pressure is exceeded, the casing parts
can burst apart as in an explosion, causing severe
injuries and damage.
Decommissioning
Switching off the pump
• Close the shut-off device in the discharge line.
• A non-return valve above which a corresponding pressure is
built by the liquid column makes the actuation of a discharge
side valve unnecessary.
• Switch off the pump.
5.4.2
Draining the pump
• With danger of frost: drain the pump and the pipes and protect
them from freezing up while they are decommissioned.
• After contaminated media have been delivered: drain the
pump and, if necessary, flush it. This measure is also required
to protect the pump against corrosion while it is standing still.
22
6.1
6.2.1.2
General notes
• Always disconnect the electrical connections before carrying out any work on the machine. Secure
the pump unit so that it cannot be switched on inadvertently.
• Before maintenance or repair make sure that all rotating parts stand still!
• Before carrying out maintenance and service, the pump must
be thoroughly flushed with clean water. Rinse the pump parts
in clean water after dismanteling.
• In case of a defect of the pump, a repair shall be carried out
only by the manufacturer or through an authorized workshop.
Conversions or alternations of the machine/unit are permitted
only after arrangement with the manufacturer. Only original
spare parts shall be used.
• In accordance with the product liability law we point out that
we shall not be liable for damages caused by our product due
to unauthorized repair by persons other than the manufacturer or an authorized workshop or due to the use of spare parts
other than original parts. The same product liability limitations
are valid for accessories.
6.2
• Have the oil changed after 3.000 operating hours, however
latest after one year of operation.
• When the pump is new or after replacement of the shaft seals,
check the oil level after one week of operation.
• The oil becomes greyish white like milk if it contains water.
This may be the result of defective shaft seal.
Hot oil or liquid to be delivered that has penetrated
into the intermediate casing can cause an excess
pressure in the intermediate casing. Therefore, use
a cover (e.g. a piece of cloth) when opening the oil
drain outlet/oil filler cap to protect against liquid that
spurts out.
•
•
•
•
•
•
•
•
Maintenance and inspections
Oil change
Turn the pump to horizontal position.
Place an oil pan below the drain outlet.
Open the oil drain outlet.
Completely drain the old oil and dispose it in the stipulated
manner.
Rinse the oil chamber using some fresh oil while turning the
rotor on the impeller.
Fill in oil until the oil chamber is completely filled.
Check oil level in upright position of the pump. Oil chamber
must be filled up to the bottom line of the inspection hole.
Insert the adjusting screw.
Pumps running under normal operation conditions should be inspected at least once a year. If the pumped liquid is very muddy
or sandy or if the pump is operating continu-ously, the pump
should be inspected every 1.000 operating hours.
6.2.2
6.2.1
Check all components for possible wear. Replace defective
parts.
6.2.1.1
Lubricants: filling quantity and lubrication intervals
• Oil quality: The oil chamber is filled with medical white oil by
factor standard: Brand name Ondina 917, Co. Shell. Equivalent oils may be used alternatively.
• Filling quantity: Fill the oil chamber with appropiate oil up to
the bottom line of the inspection hole. Keep pump in upwright
position. Following table is indicating values for the oriantation:
Oil quantity in liter with
execution
Motor type
AM1 2 poles 0.8 kW up to 1.2 kW
Nominal current (A): Check with ampmeter.
6.2.3
6.2.4
Quality and filling quantity
Standard
EX
0.01
0.4
Nominal current
Pump casing and impeller
Checking the bearing clearance
Apply radial and axial pressure to the impeller. If the impeller
can be moved in radial or axial direction, the ball bearings must
be replaced.
6.2.5
Cable entry
Make sure that the cable entry is watertight and that the cables
are not bent sharply and/or pinched.
6.2.6
Leak monitoring
AM1 2 poles 1.8 kW up to 3.4 kW
1.1
AM1 4 poles
1.1
AM2 2 poles
0.5
AM2 4 poles 0,9 kW up to 1.3 kW
0.5
AM2 4 poles 1.9 kW up to 2.4 kW
0.6
AM3A
0.6
AM3B
0.6
• Change the oil if the indicator signals that water has penetrated into the intermediate casing (refer to section 6.2.1).
• If, after a short time, the indicator again signals that water has
penetrated, drain the oil into a glass vessel and check whether the oil contains water. If it does, replace the mechanical
seal. Mechanical seals are wearing parts for which no guarantee can be given.
• When the mechanical seal has been replaced, check it for
leaks after one or two weeks.
AM3C
1.9
6.2.7
AM3D
3.7
AM3E
10
12
For a regular and workmanlike accomplishment of all neccesary service and control works we recomend to conclude a
maintenance contract. Kindly contact our service department.
16
Maintenance contract
Table 3: Oriantation values for filling quantity
• Recommended commercially available oils:
Shell, Ondina 917
Shell, Tellus C22
23
ENGLISH
6. Maintenance/servicing
6.3
Disassembly and assembly instructions
Only qualified personnel may disassemble and assemble
the pump as shown in the sectional drawing (refer to section 8.2). The order of the steps to be carried out for the disassembly is indicated in the sectional drawing.
Only specially trained personnel may disassemble explosion-proof motors
6.3.1
•
•
•
•
Assignment of the sectional drawings:
Execution A: Standard
Execution B: Explosion proof
Execution C: Standard, with cooling jacket
Execution D: Explosion proof, with cooling jacket
Imp- Pump
eller type
Motor
Hydraulic
Execution
A
B
C
D
F
SW 65-160.F
-
1
2
-
-
F
SW 80-160.F
-
1
3
-
-
F
SW 80-170.F
-
4
5
-
-
F
SW 80-230.F
AM3B
6
7
-
-
F
SW 80-230.F
AM3C
8
9
10
11
F
SW 80-230.F
AM3D
12
13
14
15
F
SW 100-230.F
AM3C
8
9
10
11
F
SW 100-230.F
AM3D
12
13
14
15
F
SW 100-280.F
AM3C
16
17
18
19
F
SW 100-280.F
AM3D
20
21
22
23
K
SW 65-160.K
-
24
25
-
-
K
SW 80-160.K
-
24
26
-
-
K
SW 80-210.K
Hydr. A+B
27
28
-
-
K
SW 80-210.K
Hydr. C+D
29
30
-
-
K
SW 80-250.K
AM3A
31
32
K
SW 80-250.K
AM3B
33
34
-
-
K
SW 80-250.K
AM3C
35
36
37
38
K
SW 80-250.K
AM3D
39
40
41
42
K
SW 100-250.K
AM3A
31
32
-
-
K
SW 100-250.K
AM3B
33
34
-
-
K
SW 100-250.K
AM3C
35
36
37
38
K
SW 100-250.K
AM3D
39
40
41
42
K
SW 100-310.K
AM3C
43
44
45
46
K
SW 100-310.K
AM3D
47
48
49
50
K
SW 150-370.K
AM3D
51
52
53
54
K
SW 150-370.K
AM3E
55
55
56
56
Z
SW 150-350.Z
AM3E
55
55
56
56
Z
SW 200-400.Z
AM3F
57
57
58
58
Z
SW 250-380.Z
AM3E
59
59
60
60
Z
SW 250-380.Z
AM3F
57
57
58
58
Table 4: Assignment of the sectional drawings
24
7. Problems: causes and remedies
1) Output low or no output at all
2) Excessive output
3) Motor overload
4) Temperature monitoring device switches off
5) Leak monitoring device indicates that water has penetrated into the intermediate casing
1) 2) 3) 4) 5) Cause of the malfunction
Remedy
The water level is lowered excessively (suction head is too high, inlet level is too low)
• Check the supply and the dimensioning of the system
• Check the level controller
The pump has not been fully vented
• Vent the pump
The temperature of the medium is too high
• Lower the temperature (please contact the manufacturer)
The gas content of the medium is too high
• Check the gas content of the medium (please contact the
manufacturer)
The counterpressure is too high
• Open the shut-off devices further
• Check the dimensioning of the system
(pressure losses too high?)
• Adjust the head of the pump
(only after the manufacturer has been consulted)
The counterpressure is too low
• Check the dimensioning of the system
• Throttle the discharge side shut-off valve further
Wrong direction of rotation
• Correct the direction of rotation
The pump is clogged
• Remove the deposits
The interior parts are worn
• Replace the worn parts
The speed is too low
• Check the electrical installation
The speed is too high
• Check the electrical installation
The pump runs on two phases
• Check the electrical installation
There are deposits on the motor
• Clean the motor on the outside
The switching frequency is too high
• Check the level controller
Water has penetrated into the intermediate
casing
• Change the oil. If leaks occur again: check and, if necessary,
replace the mechanical seal
Table 5: Problems
25
ENGLISH
The inlet/suction line has not been fully
• Vent the inlet/suction line
vented (mounting arrangements TH, TV only) • Check the inlet/suction line and the fittings for leaks
8. Appendix
8.1
Parts list
VDMA No.
Designation
VDMA No.
101
Pump casing
812
Motor casing cover
135
Wear plate
814
Stator with winding
151
Cooling jacket
819
Motor shaft with rotor
162
Suction cover
822.01
Lower bearing cover
163
Pressure cover
822.02
Upper bearing cover
230.xx
Impeller
824.xx
Connection cable
320.01
Lower ball bearing
826.xx
Cable leading-in socket
320.02
Upper ball bearing
834.xx
Cable inlet
360
Bearing cover
835.xx
Motor terminal board
411.xx
Sealing ring
836.xx
Terminal strip
412.xx
O-Ring
839.05
Protective conductor clamp
433
Mechanical seal
839.06
Connection
433.01
Mechanical seal
839.09
Cable socket, insulated
433.02
Mechanical seal
839.10
Cable socket, insulated
502
Wear ring
900.xx
Ring nut/ Special screws
550.xx
Supporting ring
903.xx
Locking screw
552
Clamping disc
904
Threaded pin
561
Grooved drive stud
914.xx
Threaded pin
576
Handle
920.xx
Dome nut
690.01
Leak monitoring
922
Hexagonal nut
690.02
Leak monitoring
930.xx
Tooth washer
702
Threaded tube (discharge)
932.xx
Circlip
704
Threaded tube (suction)
940
Key
732.01
Holder for leak monitoring
950
Ball bearing disc
732.02
Holder for leak monitoring
970
Pump label
811
26
Designation
Motor casing
990.xx
Motor oil
8.2
Schnittbild | Sectional drawing | Vue en coupe 01
8.2.2
Schnittbild | Sectional drawing | Vue en coupe 02
8.2.1
Schnittbilder | Sectional drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 03
8.2.4
Schnittbild | Sectional drawing | Vue en coupe 04
ENGLISH
8.2.3
SW 80-170.F
27
8.2
8.2.5
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 05
8.2.7
Schnittbild | Sectional drawing | Vue en coupe 07
28
8.2.6
Schnittbild | Sectional drawing | Vue en coupe 06
8.2.8
Schnittbild | Sectional drawing | Vue en coupe 08
SW 80-230.F ... AM3C
SW 100-230.F ... AM3C
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 09
8.2.10
Schnittbild | Sectional drawing | Vue en coupe 10
8.2.9
SW 80-230.F ... AM3C ... EX
SW 100-230.F ... AM3C ... EX
Schnittbild | Sectional drawing | Vue en coupe 11
8.2.12
Schnittbild | Sectional drawing | Vue en coupe 12
ENGLISH
8.2.11
SW 80-230.F ... AM3C ... MK
SW 100-230.F ... AM3C ... MK
SW 80-230.F ... AM3C ... EX ... MK
SW 100-230.F ... AM3C ... EX ... MK
29
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
8.2.13 Schnittbild | Sectional drawing | Vue en coupe 13
8.2.15 Schnittbild | Sectional drawing | Vue en coupe 15
30
8.2.14 Schnittbild | Sectional drawing | Vue en coupe 14
8.2.16 Schnittbild | Sectional drawing | Vue en coupe 16
SW 100-280.F ... AM3C
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 17
8.2.18
Schnittbild | Sectional drawing | Vue en coupe 18
8.2.17
SW 100-280.F ... AM3C ... EX
Schnittbild | Sectional drawing | Vue en coupe 19
8.2.20
Schnittbild | Sectional drawing | Vue en coupe 20
ENGLISH
8.2.19
SW 100-280.F ... AM3C ... MK
SW 100-280.F ... AM3C ... EX ... MK
31
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
8.2.21 Schnittbild | Sectional drawing | Vue en coupe 21
8.2.23 Schnittbild | Sectional drawing | Vue en coupe 23
32
8.2.22 Schnittbild | Sectional drawing | Vue en coupe 22
8.2.24 Schnittbild | Sectional drawing | Vue en coupe 24
SW 65-160.K
SW 80-160.K
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 25
8.2.26
Schnittbild | Sectional drawing | Vue en coupe 26
8.2.25
Schnittbild | Sectional drawing | Vue en coupe 27
8.2.28
Schnittbild | Sectional drawing | Vue en coupe 28
ENGLISH
8.2.27
SW 80-210.K ... (A,B)
SW 80-210.K ... (A,B) ... EX
33
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
8.2.29 Schnittbild | Sectional drawing | Vue en coupe 29
8.2.31 Schnittbild | Sectional drawing | Vue en coupe 31
SW 80-250.K ... AM3A
SW 100-250.K ... AM3A
34
8.2.30 Schnittbild | Sectional drawing | Vue en coupe 30
8.2.32 Schnittbild | Sectional drawing | Vue en coupe 32
SW 80-250.K ... AM3A ... EX
SW 100-250.K ... AM3A ... EX
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 33
8.2.34
Schnittbild | Sectional drawing | Vue en coupe 34
8.2.33
Schnittbild | Sectional drawing | Vue en coupe 35
8.2.36
Schnittbild | Sectional drawing | Vue en coupe 36
ENGLISH
8.2.35
SW 80-250.K ... AM3C
SW 100-250.K ... AM3C
SW 80-250.K ... AM3C ... EX
SW 100-250.K ... AM3C ... EX
35
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
8.2.37 Schnittbild | Sectional drawing | Vue en coupe 37
SW 80-250.K ... AM3C ... MK
SW 100-250.K ... AM3C ... MK
8.2.39 Schnittbild | Sectional drawing | Vue en coupe 39
36
8.2.38 Schnittbild | Sectional drawing | Vue en coupe 38
SW 80-250.K ... AM3C ... EX ... MK
SW 100-250.K ... AM3C ... EX ... MK
8.2.40 Schnittbild | Sectional drawing | Vue en coupe 40
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 41
8.2.42
Schnittbild | Sectional drawing | Vue en coupe 42
8.2.41
8.2.44
Schnittbild | Sectional drawing | Vue en coupe 44
ENGLISH
Schnittbild | Sectional drawing | Vue en coupe 43
8.2.43
SW 100-310.K ... AM3C
SW 100-310.K ... AM3C ... EX
37
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
8.2.45 Schnittbild | Sectional drawing | Vue en coupe 45
8.2.46 Schnittbild | Sectional drawing | Vue en coupe 46
SW 100-310.K ... AM3C ... MK
8.2.47 Schnittbild | Sectional drawing | Vue en coupe 47
38
SW 100-310.K ... AM3C ... EX ... MK
8.2.48 Schnittbild | Sectional drawing | Vue en coupe 48
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 49
8.2.50
Schnittbild | Sectional drawing | Vue en coupe 50
8.2.49
Schnittbild | Sectional drawing | Vue en coupe 51
8.2.52
Schnittbild | Sectional drawing | Vue en coupe 52
ENGLISH
8.2.51
39
Baureihe | Series | Série SW 22
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
8.2.53 Schnittbild | Sectional drawing | Vue en coupe 53
8.2.55 Schnittbild | Sectional drawing | Vue en coupe 55
40
8.2.54 Schnittbild | Sectional drawing | Vue en coupe 54
8.2.56 Schnittbild | Sectional drawing | Vue en coupe 56
8.2
Schnittbilder | Sectional | drawings | Vues en coupe
Schnittbild | Sectional drawing | Vue en coupe 57
8.2.58
Schnittbild | Sectional drawing | Vue en coupe 58
8.2.57
Schnittbild | Sectional drawing | Vue en coupe 59
8.2.60
Schnittbild | Sectional drawing | Vue en coupe 60
ENGLISH
8.2.59
41
Technische Änderungen vorbehalten
We reserve the right to make technical changes
Tous droits réservés pour actualisation technique
ANDRITZ Ritz GmbH | Güglingstraße 50 | 73529 Schwäbisch Gmünd | Germany
Phone +49 (0) 7171 609-0 | Fax +49 (0) 7171 609-287 | [email protected] | www.ritz.de
4009113/08.11