PPS 2500 Installation instructions

Submersible Motor Pump
PPS Series 2500/2545/2600
Installation/Operating
Manual
T. 01279 757400
E. [email protected]
W. www.ppsgroupuk.com

PPS Series 2500/2545/26002
Contents
Contents
Glossary 4
1 General 5
1.1 Principles 5
1.2 Installation of partly completed machinery 5
1.3 Target group 5
1.4 Other applicable documents 5
1.5 Symbols 6
2 Safety 7
2.1 Key to safety symbols/markings 7
2.2 General 7
2.3 Intended use 7
2.4 Personnel qualication and training 8
2.5 Consequences and risks caused by non-compliance with these operating
instructions 9
2.6 Safety awareness 9
2.7 Safety information for the user/operator 9
2.8 Safety information for maintenance, inspection and installation work 9
2.9 Unauthorised modes of operation 10
3 Transport/Temporary Storage/Disposal 11
3.1 Checking the condition upon delivery 11
3.2 Transport 11
3.3 Storage/preservation 11
3.4 Return to supplier 12
3.5 Disposal 12
4 Description of the Pump (Set) 14
4.1 General description 14
4.2 Name plate 14
4.3 Design details 14
4.4 Types of installation 15
4.5 Conguration and function 16
4.6 Scope of supply 16
4.7 Dimensions and weights 17
5 Installation at Site 18
5.1 Safety regulations 18
5.2 Checks to be carried out prior to installation 18
5.3 Installing the pump set 19
5.4 Electrical system 25

PPS Series 2500/2545/2600 3
Contents
6 Commissioning/Start-up/Shutdown 29
6.1 Commissioning/start-up 29
6.2 Operating limits 30
6.3 Shutdown/storage/preservation 31
6.4 Returning to service 32
7 Servicing/Maintenance 33
7.1 Safety regulations 33
7.2 Servicing/inspection 34
7.3 Drainage/cleaning 37
7.4 Dismantling the pump set 37
7.5 Reassembling the pump set 39
7.6 Bolt tightening torques 41
7.7 Spare parts stock 41
8 Trouble-shooting 43
9 Related Documents 44
9.1 General assembly drawings with lists of components 44
9.2 Exploded views 46
9.3 Wiring diagram 48
10 EC Declaration of Conformity 50
11 CerticateofDecontamination 51
Index 52

PPS Series 2500/2545/26004
Glossary
Glossary
Certicateofdecontamination
A certicate of decontamination is enclosed by the customer when returning the product
to the manufacturer to certify that the product has been properly drained to eliminate
any environmental and health hazards arising from components in contact with the uid
handled.
Hydraulic system
The part of the pump in which the kinetic energy is converted into pressure energy.

PPS Series 2500/2545/2600 5
1 General
1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated on
the front cover (for details, please refer to the tables below).
Table 1: Variants covered by this manual
Sizes Impeller type Material variant G
2500 F G
2545 S G
2600 F G
The manual describes the proper and safe use of this equipment in all phases of
operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number uniquely
identify the pump (set) and serve as identication for all further business processes.
In the event of damage, immediately contact your nearest PPS service centre to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by PPS, refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This manual is aimed at the target group of trained and qualied specialist technical
personnel. (Section 2.4 Page 8)
1.4 Other applicable documents
Table 2: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement
drawing/ outline drawing
Description of mating and installation dimensions for the
pump (set), weights
Hydraulic characteristic
curve
Characteristic curves showing head, ow rate, eciency
and power input
General assembly
drawing*
Sectional drawing of the pump
Spare parts lists* Description of spare parts
Supplementary operating
manuals*
e.g. for installation parts for stationary wet installation
For accessories and/or integrated machinery components observe the relevant
manufacturer’s product literature.
* If agreed to be included in the scope of supply

PPS Series 2500/2545/26006
1 General
1.5 Symbols
Table 3: Symbols used in this manual
Symbol Description
Conditions which need to be fullled before proceeding with the
step-by-step instructions
Safety instructions
Result of an action
Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle the
product

PPS Series 2500/2545/2600 7
2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 4: Denition of safety symbols/markings
Symbol Description
!
DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions that
must be observed to ensure safe pump operation and prevent personal injury and
damage to property. The safety information in all sections of this manual must be
complied with. This manual must be read and completely understood by the specialist
personnel/operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times. Information attached directly to the pump must always be complied with
and be kept in a perfectly legible condition at all times. This applies to, for example:
• Arrow indicating the direction of rotation
• Markings for connections
• Name plate
The operator is responsible for ensuring compliance with all local regulations not taken
into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits described in the other
applicable documents.
• Only operate pump sets which are in perfect technical condition.
• Do not operate partially assembled pump sets.
• Only use the pump set to handle the uids described in the data sheet or product
• literature of the pump model.
• Never operate the pump set without the uid to be handled.
!
DANGER

PPS Series 2500/2545/26008
2 Safety
• Observe the limits for continuous operation specied in the data sheet or product
literature (Qmin* and Qmax**) (to prevent damage such as shaft fracture, bearing failure,
mechanical seal damage, etc).
• When untreated waste water is handled the duty points in continuous operation lie
within 0.7 to 1.2 x Qopt*** to minimise the risk of clogging/hardening.
• Avoid duty points for continuous operation at very low speeds and small ow rates
(<0.7 x Qopt***).
• Observe the maximum ow rates indicated in the data sheet or product literature
(to prevent overheating, mechanical seal damage, cavitation damage, bearing
damage, etc).
• Do not throttle the ow rate on the suction side of the pump set (to prevent
cavitation damage).
• Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
• The pump set must only be used in the following applications:
Impeller with cutter
PPS 2545 (three-phase)
Impeller with cutter
PPS 2545 (single-phase)
Impeller type F Suitable for intermittent
operation handling the
followinguids: rainwater,
surface water (car parks,
wash water), drainage,
drainage of pump sumps.
Waste water containing
solid particles and long
bres as well as uids
containing air or gas.
Prevention of foreseeable misuse
• Observe the minimum ow velocities required to fully open the swing check valves
to prevent the reduction of pressure and risk of clogging.
• (Contact the manufacturer for the required minimum ow velocities/loss
coecients.)
• Never exceed the permissible operating limits specied in the data sheet and in the
product literature regarding pressure, temperature, etc.
• Observe all safety information and instructions in this manual.
2.4 Personnelqualicationandtraining
All personnel involved must be fully qualied to transport, install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in transport,
installation, operation, maintenance and inspection must be clearly dened by the
operator.
* Minimum permissible ow rate
** Maximum permissible ow rate
*** Best eciency point

PPS Series 2500/2545/2600 9
2 Safety
Decits in knowledge must be rectied by means of training and instruction provided
by suciently trained specialist personnel. If required, the operator can commission the
manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist personnel.
2.5 Consequences and risks caused by non-compliance with these
operating instructions
• Non-compliance with these operating instructions will lead to forfeiture of warranty
cover and of any and all rights to claims for damages.
• Non-compliance can, for example, have the following consequences:
- Hazards to persons due to electrical, thermal, mechanical and chemical
eects and explosions
- Failure of important product functions
- Failure of prescribed maintenance and servicing practices
- Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use, the
following safety regulations shall be complied with:
• Accident prevention, health and safety regulations
• Explosion protection regulations
• Safety regulations for handling hazardous substances
• Applicable standards and laws
2.7 Safety information for the user/operator
• Provide the personnel with protective equipment and make sure it is used.
• Contain leakages (e.g. at the shaft seal) of hazardous uids handled (e.g. explosive,
toxic, hot) so as to avoid any danger to persons and the environment. Adhere to
all relevant laws.
• Eliminate all electrical hazards. (In this respect refer to the applicable national safety
regulations and/or regulations issued by the local energy supply companies.)
• If shutting down the pump does not increase potential risk, t an emergency
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation
work
• Modications or alterations of the pump are only permitted with the manufacturer’s
prior consent.
• Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
• The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualied specialist personnel who are thoroughly familiar
with the manual.
• Only carry out work on the pump (set) during standstill of the pump.
• The pump casing must have cooled down to ambient temperature.
• Pump pressure must have been released and the pump must have been drained.
• When taking the pump set out of service always adhere to the procedure described
in the manual. (Section 6.3 Page 31)
• Decontaminate pumps which handle uids posing a health hazard.
• As soon as the work is completed, re-install and/or re-activate any safety
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (Section 6.1 Page 29)

PPS Series 2500/2545/260010
2 Safety
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump (set)
is only valid if the equipment is used in accordance with its intended use.

PPS Series 2500/2545/2600 11
3 Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and notify
PPS or the supplying dealer (as applicable) and the insurer about the damage in
writing immediately.
3.2 Transport
!
DANGER
Improper transport
Danger to life from falling parts!
Damage to the pump set!
Use the attachment point provided (pump handle) for attaching
lifting accessories.
Never suspend the pump set by its power cable.
Use the lifting chain/rope included in the scope of supply
exclusively for lowering/lifting the pump set into/out of the
pump sump.
Securely attach the lifting chain/rope to the pump and crane.
Use tested, marked and approved lifting accessories only.
Observe any regional transport regulations.
Observe the product literature supplied by the lifting accessory
manufacturer.
The load-carrying capacity of the lifting accessory must be
higher than the weight indicated on the name plate of the
pump set to be lifted. Take into account any additional system
components to be lifted.
Always use the pump handle for transporting the pump (also
for manual transport).
Always place the pump vertically on a solid surface with the
motor on top.
Transport the pump set as illustrated.
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storage:
2539:101
Fig. 1: Transporting the
pump set

PPS Series 2500/2545/260012
3 Transport/Temporary Storage/Disposal
CAUTION
Improper storage
Damage to the power cable!
Support the power cables at the cable entry to prevent
permanent deformation.
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
For outdoor storage cover the packed or unpacked pump (set)
and accessories with waterproof material.
• Store the pump set under dry and vibration-free conditions at a temperature above
0 °C, in a vertical position and in its original packaging.
1. Spray-coat the inside wall of the pump casing, and in particular the impeller
clearance areas, with a preservative.
2. Spray the preservative through the suction and discharge nozzles. It is advisable to
then close the pump nozzles (e.g. with plastic caps or similar).
3. Check the power cable for damage. Attach it to the pump handle to prevent it from
trailing on the oor. Protect the cable end against moisture.
NOTE
Observe the manufacturer’s instructions for application/removal of
the preservative.
3.4 Return to supplier
1. Drain the pump as per operating instructions. (Section 7.3 Page 37)
2. Always ush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous uids.
3. If the uids handled by the pump set leave residues which might lead to corrosion
damage when coming into contact with atmospheric humidity, or which might ignite
when coming into contact with oxygen, the pump set must also be neutralised, and
anhydrous inert gas must be blown through the pump for drying purposes.
4. Always complete and enclose a certicate of decontamination when returning the
pump (set). Always indicate any safety and decontamination measures taken.
(Section 11 Page 51)
3.5 Disposal
!WARNING
Fluids, consumables and supplies which are hot or pose a health
hazard
Hazard to persons and the environment!
Collect and properly dispose of ushing uid and any residues
of the uid handled.
Wear safety clothing and a protective mask, if required.
Observe all legal regulations on the disposal of uids posing a
health hazard.

PPS Series 2500/2545/2600 13
3 Transport/Temporary Storage/Disposal
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another controlled
manner.

PPS Series 2500/2545/260014
4 Description of the Pump (Set)
4 Description of the Pump (Set)
4.1 General description
Submersible motor pump for handling domestic waste water, raw water and waste water
containing faeces in intermittent operation. Non-explosionproof, non-self-priming.
PPS pumps are not approved for use in countries stipulating explosion-proof units for
handling waste water containing faeces.
4.2 Name plate
1 Type series, size 2 Rated voltage/frequency
3 Maximum head 4 Thermal class of winding insulation
5 Enclosure 6 Maximum uid and ambient
temperature
7 Maximum immersion depth 8 Max. ow rate
9 Rated power
4.3 Design details
Design
• Fully oodable submersible motor pump
• Close-coupled design
• Vertical installation
• Single-stage
Fig. 2: Name plate (example) 01279 757 400
www.ppsgroupuk.com
230V~ 50Hz 1.9A 430W
Hmax=6.7m Qmax=2.75 l/s
Classo F IP68 T50°C
Made in France 30-001
2m
V3P DMS 116
1
2
3
4
9
7
6
5 8

PPS Series 2500/2545/2600 15
4 Description of the Pump (Set)
Installation types
• Stationary installation
• Transportable models
Shaft seal
Drive end
• Shaft seal ring
Pump end
• 1 bi-directional mechanical seal with liquid reservoir
Impeller type
• Free-ow impeller
• Cutter
Drive
• Single-phase AC motor
-50 Hz: 230 V (240 V max.)
-60 Hz: 220 V (255 V max.)
- With integrated temperature switch
• Three-phase asynchronous motor
-50 Hz: 380 V (415 V max.)
-60 Hz: 380 V (460 V max.)
- DOL starting
• Enclosure: IP 68 (permanently submerged) to EN 60529 / IEC 529
• Thermal class of winding insulation: F
Bearings
• Grease-lubricated bearings sealed for life
4.4 Types of installation
Two design variants are available, depending on the installation type:
• Stationary wet installation (installation type S)
• Transportable wet installation (installation type P)
The pump set is designed for continuously submerged operation. The motor is cooled
by the pumped uid on the motor surface. Short-term operation with the motor outside
the uid handled is possible if the uid level is above the level R specied by PPS (see
outline drawings).

PPS Series 2500/2545/260016
4 Description of the Pump (Set)
4.5 Congurationandfunction
1 Shaft 2 Bearing bracket
3 Discharge nozzle 4 Suction cover
5 Suction nozzle 6 Impeller
7 Shaft seal 8 Rolling element bearing, pump end
9 Rolling element bearing, motor end
The pump is designed with an axial uid inlet and a radial outlet. The hydraulic system
sits on the extended motor shaft. The shaft runs in common bearings.
The uid enters the pump axially via the suction nozzle (5) and is accelerated outward
in a cylindrical ow by the rotating impeller (6). In the ow passage of the pump casing
the kinetic energy of the uid is converted into pressure energy. The uid is pumped to
the discharge nozzle (3), where it leaves the pump. At the rear side of the impeller, the
shaft (1) enters the casing via the discharge cover. The shaft passage through the cover
is sealed towards the atmosphere with a shaft seal (7). The shaft runs in rolling element
bearings (8 and 9), which are supported by a bearing bracket (2) connected to the pump
casing and/or discharge cover.
The pump end shaft seal is a bi-rotational mechanical seal; the motor end seal is a shaft
seal ring. A lubricant reservoir between the shaft seal ring and the mechanical seal
provides cooling and lubrication.
4.6 Scope of supply
Depending on the model, the following items are included in the scope of supply:
Stationary wet installation (installation type S)
• Pump set complete with power cables
• Claw with sealing and mounting elements
• Lifting rope or chain
• Mounting bracket with mounting elements
9
8
7
6
5 4
3
2
1
Design
Function
Sealing
Fig. 3: Sectional drawing

PPS Series 2500/2545/2600 17
4 Description of the Pump (Set)
• Duckfoot bend with mounting elements
• Guiding equipment
(guide rails are not included in PPS’s scope of supply)
Transportable wet installation (installation type P)
• Pump set complete with power cables
• Installation kit for transportable version, comprising: three feet, connection elbow,
connection piece and clamp
• Lifting rope or chain
NOTE
A separate name plate is included in PPS’s scope of supply.
This name plate must be attached in a clearly visible position outside
the place of installation, e.g. at the control panel, pipeline or
mounting bracket.
4.7 Dimensions and weights
For dimensions and weights please refer to the general arrangement drawing/outline
drawing or data sheet of the pump set.

PPS Series 2500/2545/260018
5 Installation at Site
5 Installation at Site
5.1 Safety regulations
!
DANGER
Persons in the tank during pump operation
Electric shock!
Never start up the pump set when there are persons in the tank.
!
WARNING
Impermissible solid objects (tools, screws/bolts or similar) in the
pump sump/inlet tank during pump start-up
Personal injury and damage to property!
Check the pump sump/inlet tank for impermissible solid objects
before ooding, and remove, if necessary.
5.2 Checks to be carried out prior to installation
5.2.1 Preparing the place of installation
Place of installation for stationary models
!
WARNING
Installation on mounting surfaces which are unsecured and
cannot support the load
Personal injury and damage to property!
Ensure the concrete’s compressive strength is sucient (in
accordance with C35/45 in exposure class XC1 to EN 206-1).
The mounting surface must have set and must be completely
horizontal and even.
Observe the weights indicated.
Any resonances at the usual excitation frequencies (1 x and 2 x rotational frequency,
rotational noise) must be prevented both in the foundation and in the connected piping,
as such frequencies may cause extreme vibrations.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
Place of installation for transportable models
!WARNING
Incorrect positioning
Personal injury and damage to property!
Set the pump set down in a vertical position with the motor
on top.
Use appropriate means to secure the pump set against
overturning and tipping over.
Refer to the weights given in the data sheet/on the name plate.
Resonances

PPS Series 2500/2545/2600 19
5 Installation at Site
Any resonances at the usual excitation frequencies (1 x and 2 x rotational frequency,
rotational noise) must be prevented both in the foundation and in the connected piping,
as such frequencies may cause extreme vibrations.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.2.2 Checking the direction of rotation
!
WARNING
Hands or objects inside the pump casing
Risk of injuries, damage to the pump!
Never insert your hands or any other objects into the pump.
Check that the inside of the pump is free from any foreign
objects.
Take suitable precautions (e.g. wear safety goggles, etc).
The pump set is connected to the power supply.
Pump sets with three-phase motor: Check the direction of rotation via the reactive
force generated by the motor torque.
1. Hold the pump by the handle.
2. Start up the pump for a short period (5 seconds max.).
A reactive force in anti-clockwise direction must be felt.
3. If the impeller is running in the wrong direction of rotation, check the electrical
connection of the pump in the control system.
4. Disconnect the pump set from the power supply again and make sure it cannot be
switched on unintentionally.
5.3 Installing the pump set
Always observe the general arrangement drawing/outline drawing when installing the
pump set.
5.3.1 Stationary wet installation
5.3.1.1 Fastening the duckfoot bend
Depending on the pump size, the duckfoot bend is either fastened with chemical
anchors and/or foundation rails.
Fastening the duckfoot bend with chemical anchors
1. Position duckfoot bend 72-1 on the oor of the tank/sump.
2. Insert chemical anchors 90-3.38.
3. Bolt duckfoot bend 72-1 to the oor with chemical anchors 90-3.38.
Resonances
Fig. 4: Fastening the
duckfoot bend

PPS Series 2500/2545/260020
5 Installation at Site
Table 5: Chemical anchor dimensions
Size do
[mm]
t=hreq
[mm]
tx
[mm]
WAF
[mm]
M
[mm]
Hex.
head
WAF
[mm]
Torqueassy
[Nm]
10x130 12 90 20 17 10 7 20
Table 6: Curing times of mortar cartridge
Floor temperature Curing time [min]
-5 °C to 0 °C 240
0 °C to +10 °C 45
+10 °C to +20 °C 20
> +20 °C 10
5.3.1.2 Connecting the piping
!
DANGER
Impermissibleloadsactingontheangeoftheduckfootbend
Danger to life from leakage of hot, toxic, corrosive or ammable
uids!
Do not use the pump as an anchorage point for the piping.
Anchor the pipelines in close proximity to the pump and
connect them without transmitting any stresses or strains.
Observe the permissible ange loads.
Take appropriate measures to compensate thermal expansion
of the piping.
NOTE
When the pump set is used for draining low-level building areas,
install a swing check valve in the discharge line to avoid backow
from the sewer system.
CAUTION
Critical speed
Increased vibrations!
Damage to mechanical seals and bearings!
Install a swing check valve in longer riser pipes to prevent the
pump from excessive running in reverse.
When tting a swing check valve, make sure that the unit can
still be vented properly.
Table 7: Permissible ange loads
Nominalangediameter Forces [N] Moments [Nm]
FyFzFx∑F MyMzMx∑M
50-65 1350 1650 1500 2600 1000 1150 1400 2050
t = hreq tx
WAF
M
Hex. head WAF
do
l
F
x
F
z
F
y
M
y
M
z
M
x
Fig. 5: Dimensions
Fig. 6: Permissible ange
loads