ABS Piranha S10/4W-50 User manual

www.cardo.com
ABS Piranha submersible grinder pump S10 - PE125
01/2011
GB
Installation, Operating and Maintenance Instructions

2 Installation, Operating and Maintenance Instructions (Original Instructions)
ABS Piranha submersible grinder pump S10 - PE125
ABS reserves the right to alter specifications due to technical developments!
ABS Piranha submersible grinder pump
S10/4W-50 S10/4W-50 Ex PE30/2C-50 Ex S10/4-60 S10/4-60 Ex PE25/2W-C-60 Ex PE80/2-E-60 Ex
S12/2-50 S12/2-50 Ex PE 55/2E-50 Ex S10/4W-60 S10/4W-60 Ex PE28/2-C-60 Ex PE100/2-E-60 Ex
S12/2W-50 S12/2W-50 Ex PE70/2E-50 Ex S20/2-60 S20/2-60 Ex PE35/2-C-60 Ex PE110/2-E-60 Ex
S13/4-50 S13/4-50 Ex PE90/2E-50 Ex S20/2W-60 S20/2W-60 Ex PE35/2W-C-60 Ex PE125/2-E-60 Ex
S17/2-50 S17/2-50 Ex PE110/2E-50 Ex S26/2W-60 S26/2W-60 Ex PE45/2-C-60 Ex
S17/2W-50 S17/2W-50 Ex S30/2-60 S30/2-60 Ex PE45/2W-C-60 Ex
S21/2-50 S21/2-50 Ex
S26/2-50 S26/2-50 Ex
Contents
1 Application areas �������������������������������������������������������������������������������������������������������������������������������������������������������3
1.1 Explosion-proof approval..............................................................................................................................................3
2 Safety���������������������������������������������������������������������������������������������������������������������������������������������������������������������������3
2.1 Use of explosion-proof pumps in explosive zones. ......................................................................................................3
2.2 Special conditions for safe use of S-type, explosion-proof motors.............................................................................. 3
3 Technical data�������������������������������������������������������������������������������������������������������������������������������������������������������������4
3.1 Nameplate ....................................................................................................................................................................4
4 General design features �������������������������������������������������������������������������������������������������������������������������������������������5
4.1 Design features Piranha-S ...........................................................................................................................................5
4.2 Design features Piranha-PE.........................................................................................................................................6
5 Transport and Storage�����������������������������������������������������������������������������������������������������������������������������������������������7
5.1 Transport ......................................................................................................................................................................7
5.2 Storage .........................................................................................................................................................................7
5.2.1 Moisture protection of motor connection cable ............................................................................................................7
6 Mounting and installation �����������������������������������������������������������������������������������������������������������������������������������������8
6.1 Installation example in concrete sump .........................................................................................................................8
6.2 Discharge Line..............................................................................................................................................................8
7 Electrical Connection ������������������������������������������������������������������������������������������������������������������������������������������������9
7.1 Temperature monitoring ...............................................................................................................................................9
7.2 Seal monitoring.............................................................................................................................................................9
7.3 Wiring diagrams.......................................................................................................................................................... 10
7.4 Checking direction of rotation..................................................................................................................................... 11
7.5 Changing direction of rotation ................................................................................................................................... 11
8 Commissioning �������������������������������������������������������������������������������������������������������������������������������������������������������� 12
9 Maintenance�������������������������������������������������������������������������������������������������������������������������������������������������������������� 12
9.1 General maintenance hints......................................................................................................................................... 12
9.2 Shredding system ....................................................................................................................................................... 13
9.3 Oil filling and oil changing........................................................................................................................................... 13
9.4 Oil-fill quantities .......................................................................................................................................................... 13
9.5 Bearings and Mechanical Seals .................................................................................................................................14
9.6 Maintenance of Lifting Stations in accordance with EN 12056.................................................................................. 14
9.7 Cleaning...................................................................................................................................................................... 14
9.8 Venting of the volute ................................................................................................................................................... 14
10 Troubleshooting Guide��������������������������������������������������������������������������������������������������������������������������������������������15
EC Declaration of Conformity ���������������������������������������������������������������������������������������������������������������������������������������������� 16

Installation, Operating and Maintenance Instructions (Original Instructions) 3
ABS Piranha submersible grinder pump S10 - PE125
Symbols and notices used in this booklet:
Presence of dangerous voltage.
Non-compliance may result in personal injury.
Danger of an explosion occurring.
ATTENTION! Non-observance may result in damage to the unit or negatively affect its performance.
NOTE: Important information for particular attention.
1 Application areas
Piranha submersible grinder pumps have been designed for the pumping of sewage containing faecal matter
from buildings and sites where the location is below the sewer level.
In addition Piranha pumps are ideal for effective and economical pressurised dewatering using pipes of small
cross-sectional area, in private, municipal, and industrial applications.
The regulations of DIN EN 12056-4 as well as other local codes should be observed.
ATTENTION The maximum allowable temperature of the medium pumped is 40 °C
1�1 Explosion-proof approval
The motors of the Piranha series have explosion-proof certification in accordance with Ex d ll BT4 and ATEX
94/9C.
2 Safety
The general and specific Health and Safety requirements are described in detail in the Safety Instructions for
ABS Products booklet. If anything is not clear or you have any questions as to safety make certain to contact
the manufacturer ABS.
2�1 Use of explosion-proof pumps in explosive zones�
Explosion-proof submersible pumps may only be operated with the thermal sensing system connected.
If ball type float switches are used, these must be connected to an intrinsically safe electrical circuit
“Protection type EX (i)” in accordance with VDE 0165.
Dismantling and repair of submersible explosion-proof motors may only be carried out by approved
personnel in specially approved work shops.
2�2 Special conditions for safe use of S-type, explosion-proof motors�
The integral supply cable shall be suitably protected from mechanical damage and terminated within an
appropriate termination facility.
Pump motors rated for use with 50/60 Hz sinusoidal supplies shall have the thermal protection devices
connected in such a way that the machine is isolated from the supply in the event of the stator reaching
130 °C.
Pump motors rated for use with variable frequency or non-sinusoidal supplies shall have the thermal
protection devices connected in such a way that the machine is isolated from the supply in the event of the
stator reaching 100 °C for T4 classified machines, or 160 °C for T3 classified machines.
These motor units are not intended for user service or repair, any operation that may affect the explosion
protection characteristics should be referred to the manufacturer. The maximum permitted flamepath gaps
are tighter than those specified in EN 50018.
1.
2.
3.
1.
2.
3.
4.

4 Installation, Operating and Maintenance Instructions (Original Instructions)
ABS Piranha submersible grinder pump S10 - PE125
3 Technical data
Maximum noise level ≤ 70dB. This may be exceeded in certain circumstances.
Detailed technical information is available in the technical data sheet ABS Piranha submersible grinder pump 08
- 125 which can be downloaded from www.absgroup.com > Downloads.
3�1 Nameplate
We recommend that you record the data from the nameplate on the pump in the corresponding form below, and
maintain it as a source of reference for the ordering of spare parts, repeat orders and general queries.
Always state the pump type, item no. and serial no. in all communications.
Piranha-PE pumps are rated for use in hazardous locations (Ex) as standard, and are fitted with a standard
nameplate containing technical data and a secondary nameplate to certify that the pump is Ex rated (examples
below).
If a Piranha-PE pump is serviced or repaired in a workshop that is not Ex approved then it must no longer be
used in hazardous locations and the Ex nameplate must be removed.
Standard nameplate
Cardo Production Wexford Ltd.
Wexford, Ireland
www.cardo.com
TypNr Sn xx/xxxx UN IN Ph Hz P1: P2: 1/minCos φ NEMA IP68Qmax Hmax ØImpDN Hmin Weight EN 12050-1
Piranha-S
Piranha-PE
Ex nameplate
Piranha-PE
Piranha-S
Legend
Typ Pump type
Nr Item No.
Sn Serial No.
xx/xxxx Production date (Week/Year)
UNRated voltage V
INRated current A
Ph Number of phases
Hz Frequency Hz
P1 Rated input power kW
P2 Rated output power kW
Legend
Typ Pump type
Nr Item No.
Sn Serial No.
xx/xxxx Production date (Week/Year)
UNRated voltage V
INRated current A
Ph Number of phases
Hz Frequency Hz
P1 Rated input power kW
P2 Rated output power kW
1/min Speed r/min
Cos φ Power factor pf
NEMA NEMA code
Qmax Max. Flow m3/h
Hmax Max. Head m
Ø Imp. Impeller diameter mm
DN Discharge diameter mm
1/min Speed r/min
Cos φ Power factor pf
NEMA NEMA code
Qmax Max. Flow m3/h
Hmax Max. Head m
Ø Imp. Impeller diameter mm
DN Discharge diameter mm
Cardo Production Wexford Ltd.
Wexford, Ireland
www.cardo.com
Cardo Production Wexford Ltd.
Wexford, Ireland
www.cardo.com
2G k Ex d B T4
0102
Do not open while energized
Nicht unter Spannung öffnen
2G k Ex d B T4
0102
Do not open while energized
Nicht unter Spannung öffnen

Installation, Operating and Maintenance Instructions (Original Instructions) 5
ABS Piranha submersible grinder pump S10 - PE125
4 General design features
Submersible grinder pump fitted with a shredding system hydraulic.
The shredding system is located before the impeller and consists of a shredding rotor in combination with a
stationary cutting ring fixed to a spiral bottom plate.
4�1 Design features Piranha-S
Shredding system
1
5
6
7
9
3
8
10
11
12
13
14
15
16
17
19
18
4
2
1
5
6
7
9
3
8
10
11
12
13
14
15
16
17
19
18
4
2
1 Cast iron lifting handle and
steel shackle
2 Upper bearing - single row
3 Motor with thermal sensors
4 Motor housing
5 Motor chamber pressure
test point
6 Stainless steel shaft
7 Lower bearing - double row
8 Oil-lubricated lip seal
9 Bearing housing
10 Volute
1 Cast iron lifting handle and
steel shackle
2 Upper bearing - single row
3 Motor with thermal sensors
4 Motor housing
5 Motor chamber pressure
test point
6 Stainless steel shaft
7 Lower bearing - double row
8 Oil-lubricated lip seal
9 Bearing housing
10 Volute
11 Bottom plate adjustment
screw
12 Moisture sensor (DI)
13 Oil chamber
14 Oil chamber drain plug/
pressure test point
15 Mechanical seal
16 Impeller
17 Shredding rotor
18 Cutting ring (fixed to bottom
plate)
19 Bottom plate
11 Bottom plate adjustment
screw
12 Moisture sensor (DI)
13 Oil chamber
14 Oil chamber drain plug/
pressure test point
15 Mechanical seal
16 Impeller
17 Shredding rotor
18 Cutting ring (fixed to bottom
plate)
19 Bottom plate
17
18
17
18

6 Installation, Operating and Maintenance Instructions (Original Instructions)
ABS Piranha submersible grinder pump S10 - PE125
4�2 Design features Piranha-PE
Submersible grinder pump fitted with a shredding system hydraulic and a Premium Efficiency motor.
18
7
8
9
10
12
13
14
15
14
16
11
1
3
4
5
6
19
20
2
17
21
18
7
8
9
10
12
13
14
15
14
16
11
1
3
4
5
6
19
20
2
17
21
1 Pressure release screw
2 Motor housing
3 10-pole terminal block
4 Moisture sensor (Di)
5 Oil chamber
6 Oil chamber drain plug/
pressure test point
7 Stainless steel lifting hoop
1 Pressure release screw
2 Motor housing
3 10-pole terminal block
4 Moisture sensor (Di)
5 Oil chamber
6 Oil chamber drain plug/
pressure test point
7 Stainless steel lifting hoop
8 Upper bearing - single row
9 Motor with thermal sensors
10 Stainless steel shaft
11 Motor chamber
12 Lower bearing - double row
13 Bearing housing
14 Mechanical seals
15 Seal holding plate
8 Upper bearing - single row
9 Motor with thermal sensors
10 Stainless steel shaft
11 Motor chamber
12 Lower bearing - double row
13 Bearing housing
14 Mechanical seals
15 Seal holding plate
16 Motor chamber drain plug/
pressure test point
17 Volute
18 Impeller
19 Shredding rotor
20 Cutting ring (fixed to bottom
plate)
21 Bottom plate
16 Motor chamber drain plug/
pressure test point
17 Volute
18 Impeller
19 Shredding rotor
20 Cutting ring (fixed to bottom
plate)
21 Bottom plate

Installation, Operating and Maintenance Instructions (Original Instructions) 7
ABS Piranha submersible grinder pump S10 - PE125
5 Transport and Storage
5�1 Transport
During transport, care should be taken that the pump is not dropped or thrown.
The unit is fitted with a lifting device to which a chain and shackle may be attached for transport purposes.
The unit should never be raised or lowered by the power cable.
Take note of the weight of the entire unit. The hoist and chain must be adequately dimensioned for
that weight and must comply with the current valid safety regulations.
All relevant safety regulations as well as general good technical practice must be complied with.
5�2 Storage
During long periods of storage the pump should be protected from moisture and extremes of cold or heat.
To prevent the mechanical seals from sticking it is recommended that occasionally the impeller is rotated by
hand.
If the pump is being taken out of service the oil should be changed before storage.
After storage the pump should be inspected for damage, the oil level should be checked, and the impeller
checked to ensure it rotates freely.
5�2�1 Moisture protection of motor connection cable
The motor connection cables are protected against the ingress of moisture along the cable by having the ends
sealed at the factory with protective covers.
ATTENTION! The ends of the cables should never be immersed in water as the protective covers
only provide protection against water spray or similar (IP44) and are not a water tight
seal. The covers should only be removed immediately prior to connecting the pumps
electrically.
During storage or installation, prior to the laying and connection of the power cable, particular attention should
be given to the prevention of water damage in locations which could flood.
ATTENTION! If there is a possibility of water ingress then the cable should be secured so that the
end is above the maximum possible flood level. Take care not to damage the cable or
its insulation when doing this.
1.
2.
3.
4.

8 Installation, Operating and Maintenance Instructions (Original Instructions)
ABS Piranha submersible grinder pump S10 - PE125
6 Mounting and installation
The regulations covering the use of pumps in sewage applications together with all regulations
involving the use of explosion-proof motors should be observed.The cable ducting to the control panel
should be sealed off in a gas-tight manner by the use of a foaming material after the cable and control
circuits have been pulled through. In particular the safety regulations covering work in enclosed areas
in sewage plants should be observed together with general good technical practice.
For the Piranha transportable version, arrange the cable run so that the cables will not be kinked or nipped.
Connect the discharge pipe and cable (see section ”Electrical Connection”). Place the pump on a firm surface
which will prevent it from overturning or burrowing down. The pump can also be bolted down to the base or
suspended slightly by the lifting handle. Hoses, pipes and valves must be sized to suit the pump performance.
6�1 Installation example in concrete sump
1 Sump cover
1005-00
2 Venting line
3 Sump cover
4 Protective duct to the
control panel for cable
5 Chain
6 Inflow line
7 Ball type float switch
8 Submersible pump
9 Concrete sump
10 Pedestal
11 Guide tube
12 Discharge line
13 Non-return valve
14 Gate valve
15 Power cable to motor
ATTENTION For those applications subject to Regulation DIN 1986, a backwash loop should be
provided in the discharge line.
6�2 Discharge Line
The discharge line must be installed in compliance with the relevant regulations.
DIN 1986/100 and EN 12056 applies in particular to the following:
The discharge line should be fitted with a backwash loop (180° bend) located above the backwash level and
should then flow by gravity into the collection line or sewer.
The discharge line should not be connected to a down pipe.
No other inflows or discharge lines should be connected to this discharge line.
ATTENTION! The discharge line should be installed so that it is not affected by frost.
The vent line is connected by means of a push-on sleeve to the vertical outlet at the top of the collection tank.
It should be of constant cross-section (min. DN 70) and should have a continuous rise to above roof level.
-
-
-

Installation, Operating and Maintenance Instructions (Original Instructions) 9
ABS Piranha submersible grinder pump S10 - PE125
7 Electrical Connection
Before commissioning an expert should check that one of the necessary electrical protective devices
is available. Earthing, neutral, earth leakage circuit breakers, etc. must comply with the regulations
of the local electricity supply authority and a qualified person should check that these are in perfect
order.
ATTENTION! The power supply system on site must comply with VDE or other local regulations
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
The power supply cable must be protected by an adequately dimensioned slow-blow fuse corresponding to the
rated power of the pump.
The incoming power supply as well as the connection of the pump 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.
All relevant safety regulations as well as general good technical practice must be complied with.
ATTENTION! For use in the open air, the following VDE regulations apply:
Submersible pumps used outdoors must be fitted with a power cable of at least 10 m length. Other regulations
may apply in different countries.
For pumps intended to be used in outdoor fountains, garden ponds and similar places, the pump is to be
supplied through a residual current device (RCD) having a rated residual operating current not exceeding
30 mA.
NOTE: Please consult your electrician.
7�1 Temperature monitoring
Thermal sensors in the stator windings protect the motor from overheating.
Piranha motors are fitted with bimetallic thermal sensors in the stator as standard in Piranha-PE and
Ex Piranha-S, and as an option in non-Ex Piranha-S.
ATTENTION: Explosion-proof pumps may only be used in explosive zones with the thermal sensors connected.
7�2 Seal monitoring
Piranha-PE and Piranha-S pumps are supplied with a moisture sensor (DI), to detect and alert to the ingress of
water into the motor and oil chambers.
DI is optional with Piranha-S, and in the Ex-version monitors only the motor chamber.
NOTE! Running the Piranha-PE pump with the thermal and/or moisture sensors disconnected will
invalidate related warranty claims.

10 Installation, Operating and Maintenance Instructions (Original Instructions)
ABS Piranha submersible grinder pump S10 - PE125
7�3 Wiring diagrams
Single phase:
Three phase:
U1 V1 W1 V2 W2 U2 F1 FO DI PE
1 2 3 4 5 678 9
U V W F1 FO DI PE
1 2 3 4 5 6
60 Hz: PE
T1 T2 T3 1 2 3
50 Hz:
U V W F1 FO PE
1 2 3 4 5
50 Hz:
U V W PE
50 Hz:
blk gry br
6.
5. 7. 4.
Single phase Three phase
1� 2� 3� 4� 5� 6� 7�
Piranha 50 Hz
S10/4,
S12/2,
S17/2
S10/4-Ex,
S12/2-Ex,
S17/2-Ex
S10/4,
S10/4-Ex,
S12/2,
S12/2-Ex,
S17/2,
S17/2-Ex
S13/4,
S12/2,
S17/2,
S21/2,
S26/2
S13/4-Ex,
S12/2-Ex,
S17/2-Ex,
S21/2-Ex,
S26/2-Ex
S13/4,
S13/4-Ex,
S12/2,
S12/2-Ex,
S17/2,
S17/2-Ex,
S21/2,
S21/2-Ex,
S26/2,
S26/2 (DO5)*
S26/2-Ex,
PE30/2C-Ex
PE55/2E-Ex,
PE70/2E-Ex,
PE90/2E-Ex,
PE110/2E-Ex
Piranha 60 Hz - -
S10/4,
S10/4-Ex,
S20/2,
S20/2-Ex,
S26/2,
S26/2-Ex,
PE25/2C-Ex,
PE35/2C-Ex,
PE45/2C-Ex
- -
S10/4,
S10/4-Ex,
S20/2,
S20/2-Ex,
S30/2,
S30/2-Ex,
PE28/2C-Ex,
PE35/2C-Ex,
PE45/2C-EX,
PE80/2E-EX
PE100/2E-EX,
PE110/2E-EX,
PE125/2E-EX
-
* 400/695V
ATTENTION: It is important to use the correct capacitors with single phase pumps, use of incorrect capacitors will lead to motor burn-out.
NOTE:
R = Run
S = Start
C = Neutral (Common)
F1, F0 = Thermal sensor
DI = Seal monitor
PE = Earth
blk = Black
gry = Grey
br = Brown
NOTE:
R = Run
S = Start
C = Neutral (Common)
F1, F0 = Thermal sensor
DI = Seal monitor
PE = Earth
blk = Black
gry = Grey
br = Brown
1
1
2 3 4 5 6
60 Hz: PE R S C 1 2 3
DIF1 FOR
50 Hz:
S C PE
1
1
2 3 4 5
F1 FOR50 Hz: S C PE
R C S PE
1
blk gry br
50 Hz:
2. 3.1.
1
1
2 3 4 5 6
60 Hz: PE R S C 1 2 3
DIF1 FOR
50 Hz:
S C PE
1
1
2 3 4 5
F1 FOR50 Hz: S C PE
R C S PE
1
blk gry br
50 Hz:
2. 3.1.