Robot Pumps RS Series Manual

782-020-GB HS 09-W46 Edition 4
OPERAOPERA
OPERAOPERA
OPERATIONTION
TIONTION
TION
&&
&&
&
MAINTENMAINTEN
MAINTENMAINTEN
MAINTENANCE MANUANCE MANU
ANCE MANUANCE MANU
ANCE MANUALAL
ALAL
AL
RS-SERIESRS-SERIES
RS-SERIESRS-SERIES
RS-SERIES
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual
Pump
RS
782-020-GB HS 09-W46 Edition 4 3/26
Contents............................................................................................................................... page
1. FOREWORD................................................................................................................. 4
2. GUARANTEE ............................................................................................................... 4
3. SAFETYAND ENVIRONMENT .................................................................................... 5
3.1 Symbols ............................................................................................................................................... 5
3.2 General safety instructions................................................................................................................... 5
3.3 Environment......................................................................................................................................... 5
4. TECHNICALDATA ....................................................................................................... 6
4.1 General ................................................................................................................................................ 6
4.2 Main parts ............................................................................................................................................ 6
5. FIRST PUMP START.................................................................................................... 7
5.1 Delivery check...................................................................................................................................... 7
5.2 Oillevel ................................................................................................................................................. 7
5.3 Power supply........................................................................................................................................ 7
5.4 Thermoswitches ................................................................................................................................... 7
5.5 Cable entry........................................................................................................................................... 7
5.6 Motor protection ................................................................................................................................... 7
5.7 Motor check.......................................................................................................................................... 8
5.8 Installation parts ................................................................................................................................... 8
5.9 Direction of rotation.............................................................................................................................. 8
5.10 Current-check....................................................................................................................................... 8
5.11 Medium temperature / max. motorload ................................................................................................ 9
5.12 Start frequency...................................................................................................................................... 9
5.13 Min. and max. submersible depth ........................................................................................................ 9
6. INSTALLATION OPTIONS ........................................................................................... 10
6.1 Installation -H ....................................................................................................................................... 10
6.2 Installation -V ....................................................................................................................................... 11
6.3 Installation -F ....................................................................................................................................... 12
6.4 Installation -T ....................................................................................................................................... 12
7. MAINTENANCE............................................................................................................ 13
7.1 General ................................................................................................................................................ 13
7.2 Maintenanceschedule .......................................................................................................................... 13
7.3 Lubricants............................................................................................................................................. 13
7.4 Cable entry........................................................................................................................................... 14
7.5 Oil level................................................................................................................................................ 14
7.6 Oil change............................................................................................................................................ 15
7.7 Motor housing ...................................................................................................................................... 15
7.8 Adjustment suction cover-impeller-cutter............................................................................................. 15
8. TRANSPORT AND STORAGE..................................................................................... 16
9. OPTIONS...................................................................................................................... 17
9.1 Waterdetector ...................................................................................................................................... 17
9.2 Thermoswitches ................................................................................................................................... 17
9.3 Thermistors .......................................................................................................................................... 17
9.4 Cable protection ................................................................................................................................... 18
9.5 Special oil ............................................................................................................................................. 18
9.6 Special tool ........................................................................................................................................... 18
10. TROUBLE SHOOTING ................................................................................................ 19
APPENDIX 1; Dataplate ....................................................................................................... 20
APPENDIX 2; Direct-on-line start motor ............................................................................ 21
APPENDIX 3; Star-delta start motor ................................................................................... 23
APPENDIX 4; Single phase start ........................................................................................ 25
APPENDIX 5; Notes ............................................................................................................. 26
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual
Pump
RS
782-020-GB HS 09-W46 Edition 4 5/26
3. SAFETYAND ENVIRONMENT
3.1 Symbols
* In this manual
General warning
Danger !
Electrical hazard !
Attention !
* On the pump
Danger of physical injury
Rotating parts !
Electrical hazard !
EC-conformity symbol
3.2 General safety instructions
* Onlytrained andauthorized personnel mayinstall and
maintain the pump after carefully reading this
manual.
* Only use the pump for its intended purpose and
under the regulated circumstances.
* Don’t go near rotating parts.
* Clean the pump before maintenance and inspection.
* Observe the local regulations when working with
agressive,corrossive, toxic, flammableandexplosive
chemicals.
* Never remove safety signs, keep them clean.
* Always connect to a grounded circuit.
* Before maintenance and inspection always
disconnect the pump from the mains.
* Use a proper hoist for lifting and handling the pump.
* Do not leave a large loop of cable in the sump,
as the pump may eventually damage it.
* Never drop the loose cable end in water.
The water may enter the cable and finally enter the
motorhousing, eventually causing motor failure.
3.3 Environment
Parts which are replaced during repair, maintenance or
renewal, could contain materials which could be harmful
to the environment.
Please take care in the disposal of these parts.
Do this in accordance with the local environmental
regulations.
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual Pump RS
6/26 Edition 4 HS 09-W46 782-020-GB
4. TECHNICALDATA
4.1 General
The RS-pump is a cast iron grinder pump designed to
pumpsmall quantityof water.
Large solids are cut into very small particles.
Thepump canbeused forsewageand othernon-
agressivewaste water applications.
The cutting device, installed in the suction opening,
effectively cuts larger solids into very small particles that
can easily pass through the pump.
1 Pumpcasing
2 Impeller
3 Cutting device
4 Suction cover
5 Delivery
6 Motorcasing
7 Rotor
8 Stator
9 Shaft
10 Bearings
11 Mechanical seal
(2x)
12 Oil reservoir
13 Oil plug
14 Cable entry
15 Cable
16 Inspection plug
4.2 Main parts
Construction:
- High efficiency motor, standard class F
insulation (up to 155oC).
- Two independent mechanical seals, running in oil,
form an effective barrier between pump and motor.
- Heavyduty bearings, greasedforlife.
- Hardened stainless steel grinder device, cutting
solids in small particles.
- Vanes at the backside prevent solids entering the
seal area and reduce the pressure on the seal.
Fig. 4.1
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual
Pump
RS
782-020-GB HS 09-W46 Edition 4 7/26
5. FIRST PUMSTART
After unpacking the pump, carry out the following check
points:
5.1 Delivery-check
Check for possible transport damage and especially
check that the cable has not been nicked or
damaged.
Check for complete delivery.
When the delivery is incomplete or damaged, please,
contact your dealer immediately.
5.2 Oil level
Check the oil level. (see 7.5)
5.3 Power supply
Before making the electrical connections, check if
the line voltage and frequency are the same as on the
pump dataplate.
If thermostats are supplied make sure that they are
correctly connected.
For examples of electrical diagrams and pump
cable coding, see appendix 2, 3 and 4.
5.4 Thermoswitches
Check if the pump is equipped with thermoswitches
(optional).
Contact rating: max. 250V-1.6A
The contacts are normally closed.
5.5 Cable entry
Especially when the pump has been in store for a
long time, the cable gland should be checked and
if necessary tightened (see 7.4).
5.6 Motor protection
The pump should always be connected to the line by
means of a suitable motor protection circuitbreaker.
If the pump is started direct on line (DOL), the protection
breaker should be set to the current, as given on the
dataplate.
For star delta start (YD), it is good practice to install the
overcurrent relay directly after the main contactor. In this
case, the pump is also adequately protected in star-
connection. The maximum setting of the overcurrent
relay is 0.6x the current as given on the dataplate.
It is good practice to set the protection breaker at a 10%
lower current, because all breakers require at least
110% of the adjusted current before tripping.
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual Pump RS
8/26 Edition 4 HS 09-W46 782-020-GB
5.7 Motor check
If in doubt about the condition of the motor or cable,
Megger test motorwindings against grounding wire.
The phase resistance against grounding wire should be
at least 1 MOhm.
Turn the impeller clockwise by hand, using a proper
socket wrench (see fig.5.1)
This should be possible without much force.
With this procedure sticking mechanical seal
surfaces will be loosened smoothly.
5.8 Installation parts
Check if all components for your installation
are delivered. See also chapter 6.
5.9 Direction of rotation
A correct direction of rotation is essential for proper
operation. This can be checked as follows:
- Put the pump in horizontal position and start the
pump.
Looking on the impeller through the suction
opening, the correct direction of rotation is
counter-clockwise
(See arrow on pumpcasing, Fig. 5.2).
or:
- Starting the pump will give a recoil on the
pump frame.
Looking at the motor (in vertical position see
Fig. 5.3), the recoil is counter-clockwise.
Take care !
The recoil can be very powerful !
Don’tgo nearrotating parts!
5.10 Current-check
Notethe maximumcurrent fromthedataplate.
Apply an ammeter to one of the phase wires during
normaloperation. Checkthatthe current
is not higher than the value on the dataplate.
(see appendix 1). If so check for:
- voltage (too low ?)
- specific gravity or viscosity of the fluid
(too high ?)
- blocked impeller ?
- direction of rotation correct ?
If the problem cannot be solved contact your dealer.
Fig. 5.1
Fig. 5.2
Fig. 5.3
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual
Pump
RS
782-020-GB HS 09-W46 Edition 4 9/26
5.11 Medium temp. / max.motorload
When the medium temperature is higher than 40oC, the
maximum motorload must be reduced.
The relationship between medium temperature and
maximum absorbed motor current is shown below.
Checkthe readingofthe dataplateagainst thereadingof
anAmmeter.
Ifthe motorcurrent exceedsthe max. motorcurrentfrom
the table below the pump is not suitable or the
motorcurrent must be reduced.
The motorcurrent can be reduced by installing a
smaller impeller. Contact your dealer.
Temperature Max.motorcurrent
oCoF %
40 104 100
50 122 95
60 144 90
70 158 80
80 176 70
5.12 Start frequency
When the pump is controlled by level regulators, the on
and off levels should be adjusted in such a way, that the
pump does not make more than 20 starts per hour.
5.13 Min. and max. submersion depth
Themotorhousing shouldbeat least2/3submerged for
continuous operation at full load (see Hmin.1 Fig. 5.4). It
is good practice, whenever possible to keep the
motorhousing completely under water.
For interrupted level controlled operation, less cooling is
required.
We recommend not to run the pump with the water level
below the top of the volute in order to avoid air being
drawn in (see Hmin.2 Fig. 5.4).
Air in the discharge pipes might impair performance.
The maximum submersion depth is 20m / 60ft.
Fig. 5.4
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual Pump RS
10/26 Edition 4 HS 09-W46 782-020-GB
6. INSTALLATION OPTIONS
For the submersible pump the following installations are
possible:
-H Stationary wet installation with a header
coupling type HK.
-V Stationary wet installation with a guide bar
quick release coupling type V.
-F Freestanding wet installation.
-T Transportable wet installation.
6.1 INSTALLATION - H
Stationary wet installation with a ROBOT quick-release
header coupling type HK.
A flexible hose connects pump and coupling.
Except for the pump the following components are
necessary:
1. Hose connection, which is fastened to the
pump;
2. Flexible hose, between pump and coupling;
3. Header coupling, consisting of coupling
bend, rubber joint and a fixed coupling part;
4. Suspension bracket and chain, for lifting the
pump;
5. Level regulators for start-, stop- and alarm-
signals;
6. Suspension for level regulators and power
supply cable;
7. Piping, non return valve, bends etc.
Checkpoints before operating:
- Ensure a good free passage beneath
the suction opening of the pump
(at least the same as the suction diameter).
- Adjust the start- and stoplevels in such a
way that the motor does not make more
than 20 starts per hour.
- Check that the motor is adequately cooled.
The motorhousing should be at least 2/3 submerged
for continuous operation at full load (see Hmin.1
Fig. 6.1).
It is good practice, whenever possible to keep the
motorhousing completely under water.
For interrupted level controlled operation, less cooling is
required. We recommend not to run the pump with the
water level below the top of the volute in order to avoid
air being drawn in (see Hmin.2 Fig. 6.1).
Air in the discharge pipes might impair performance.
Fig. 6.1
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual
Pump
RS
782-020-GB HS 09-W46 Edition 4 11/26
6.2 INSTALLATION -V
Stationary wet installation with a ROBOT quick-release
guide bar coupling type -V. The pump is automatically
coupledto thedischarge.
Except for the pump the following components are
necessary:
1. Bottom elbow, rubber joint and coupling
adapter;
2. One guide bar
3. Top bracket,mountedwithin thewell cover
clearance;
4. Level regulators for start-, stop- and alarm-
signals;
5. Suspension for level regulators and power
supply cables;
6. Piping, non return valve, discharge bends etc.
Checkpoints before operating:
- The guide bar must stand vertical
(maximum tolerance 3o).
- The installation angle must be about 0-5o
(see Fig. 6.3). If necessary, this angle can be
changed by alterating of the position of the
lifting hook at the top of the motorhousing
(Pos. 1)
- Adjust the start- and stoplevels in such a
way that the motor does not make more
than 20 starts per hour.
- Check that the motor is adequately cooled.
The motorhousing should be at least 2/3 submerged
for continuous operation at full load (see Hmin.1
Fig. 6.3).
It is good practice, whenever possible to keep the
motorhousing completely under water.
For interrupted level controlled operation, less cooling is
required. We recommend not to run the pump with the
water level below the top of the volute in order to avoid
air being drawn in (see Hmin.2 Fig. 6.2).
Air in the discharge pipes might impair performance.
Fig. 6.2
Fig. 6.3
www.robotpompen-onderdelen.nl
T [phone]
[email protected]

Operation &
Maintenance Manual Pump RS
12/26 Edition 4 HS 09-W46 782-020-GB
6.3 INSTALLATION - F
Freestanding:semi-permanent fixedwet installation.
Except for the pump the following components are
necessary:
1. Hose or threaded connection, which is fastened to the
pump;
2. Flexible hose or pipe;
3. Levelregulators.
Checkpoints before operating:
- Adjust the start- and stoplevels in such a
way that the motor does not make more
than 20 starts per hour.
- Check that the motor is adequately cooled.
The motorhousing should be at least 2/3 submerged
for continuous operation at full load (see Hmin.1
Fig. 6.4).
It is good practice, whenever possible to keep the
motorhousing completely under water.
For interrupted level controlled operation, less cooling
is required. We recommend not to run the pump with
the water level below the top of the volute in order to
avoid air being drawn in (see Hmin.2 Fig. 6.4).
Air in the discharge pipes might impair performance.
6.4 INSTALLATION - T
Transportablewetinstallation.
Except for the pump the following components are
necessary:
1. Hose connection, which is fastened to the pump;
2. Flexiblehose;
Checkpoints before operating:
- Do not let the pump bury itself in the mud.
- Do not leave a large loop of the cable in
the sump, as the pump may eventually
damage it.
- Check that the motor is adequately cooled.
The motorhousing should be at least 2/3 submerged
for continuous operation at full load (see Hmin.1
Fig. 6.5).
It is good practice, whenever possible to keep the
motorhousing completely under water.
For interrupted level controlled operation, less cooling
is required. We recommend not to run the pump with
the water level below the top of the volute in order to
avoid air being drawn in (see Hmin.2 Fig. 6.5).
Air in the discharge pipes might impair performance.
Fig. 6.4
Fig. 6.5
www.robotpompen-onderdelen.nl
T [phone]
[email protected]