Sulzer ABS AFC 0831 User manual

www.sulzer.com
Dry-Installed Sewage Pump Type ABS AFC 50/50-2046
15975180EN (07/2019)
Installation and operating instructions
en

Sulzer reserves the right to alter specications due to technical developments
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Dry-Installed Sewage Pump Type ABS AFC
0831 0841 1032 1041 1541 2046 80/80
0832 0844 1033 1045 1543 50/50 80/80 RV
0835 1031 1035 1049 1546 50/50 RV

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Contents
1 General................................................................................................................................................... 4
1.1 Application areas..................................................................................................................................... 4
1.1.1 Explosion-proof approvals....................................................................................................................... 4
1.1.2 Particular comments on the use of explosion-proof pumps in explosive zones...................................... 4
1.2 Technical data ......................................................................................................................................... 4
1.2.1 Nameplate............................................................................................................................................... 4
2 Safety ..................................................................................................................................................... 5
3 Transport................................................................................................................................................ 5
4 Electrical connection ............................................................................................................................ 5
4.1 Seal monitoring ....................................................................................................................................... 5
4.2 Temperature monitoring (PTC thermistor)............................................................................................... 6
4.3 Bearing temperature monitor (optional) .................................................................................................. 6
5 Mounting and installation..................................................................................................................... 6
5.1 Installation example ................................................................................................................................ 6
5.2 Discharge line ......................................................................................................................................... 6
5.3 Checking direction of rotation.................................................................................................................. 7
5.4 Changing direction of rotation ................................................................................................................. 7
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Commissioning.............................................................................................................................................8
5.1 Types of operation and frequency of starting .......................................................................................... 8
6 Maintenance .......................................................................................................................................... 8
6.1 General maintenance hints ..................................................................................................................... 8
6.2 Coolantllingandcoolantchanging ....................................................................................................... 9
6.3 Venting of the volute................................................................................................................................ 9
6.4 Draining of the volute .............................................................................................................................. 9

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1 General
1.1 Application areas
ATTENTION The maximum allowable temperature of the medium pumped is 80 °C.
When switching on and operating the pump, the hydraulic section of dry-installation pumps must always be
lledwithwater.
The pumps of the AFC series have been designed for the economical and reliable pumping of commercial,
industrial and municipal sewage.
They are suitable for pumping of the following liquids:
• clearandwastewater,forsewagecontainingsolidsandbrousmaterial
• faecal matter
The regulations of DIN 1986 as well as local regulations should be observed when installing the pumps.
1.1.1 Explosion-proof approval
The motors can be supplied both as standard versions and in explosion-proof execution ATEX (II 2G Ex db IIB
T4 Gb).
1.1.2 Particular comments on the use of explosion-proof pumps in explosive zones.
1. Explosion-proof pumps may only be operated with the thermal sensing system connected.
2. Ifballtypeoatswitchesareused,thesemustbeconnectedtoanintrinsicallysafeelectricalcircuit
“Protection type EX (i)” in accordance with VDE 0165.
3. Dismantling and repair of explosion-proof motors may only be carried out by approved personnel in
specially approved workshops.
4. In the event that the pump is to be operated in explosive atmospheres, using a variable speed drive,
please contact your local Sulzer representative for technical advice regarding the various Approvals and
Standards concerning thermal overload protection.
5. Machines designated as Ex machines may never, without exception, be operated using a mains frequency
that is greater than the maximum of 50 Hz, as indicated on the nameplate.
1.2 Technical data
Maximumnoiselevel≤70dB.Thismaybeexceededincertaincircumstances.
1.2.1 Nameplate
We recommend that you record the data from the standard 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 number and serial number in all communications.
xx/xxxx
Legend
Typ Pump type
Nr Item number
SN Serial number
xx/xxxx Production date (week/year)
Qmax Maximumow m3/h
Hmax Maximum head m
Ø Imp. Impeller diameter mm
Hmin Minimum head m
DN Discharge diameter mm

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2 Safety
Thegeneralandspecichealthandsafetyguidelinesaredescribedindetailinthe”SafetyInstructionsfor
Sulzer Products Type ABS” booklet. If anything is not clear or you have any questions as to safety make certain
to contact the manufacturer Sulzer.
3 Transport
During transport the pump should not be dropped or thrown.
The unit must never be raised by the power cable.
PumpsoftheAFCseriesmustbettedwithliftingslingsfortransportorforsuspension.Liftingeyesshouldnot
be used.
See nameplate for weight of base unit.
Take note of the entire weight of the unit. The hoist and chain must be adequately dimensioned for
the total weight of the unit (including lifting chains or steel ropes, and all accessories which may be
attached) and must comply with the current valid safety regulations.
All relevant safety regulators as well as general good technical practice must be complied with.
4 Electrical connection
Befor e 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qualied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.
ATTENTION Explosion-proof pumps may only be used in explosive zones with the thermal
sensors tted (leads: FO, F1).
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qualiedperson.
All relevant safety regulators as well as general good technical practice must be complied with.
Please consult your electrician.
4.1 Seal monitoring
The pumps are supplied as standard with a DI probe for seal monitoring. The lighting up of the inspection
controlindicatorinthecontrolpanelbytheDIelectrodettedinthepumpmeansthatthereiswaterinthedry
chamber.
ATTENTION If the DI seal monitor is activated the unit must be immediately taken out of service.
Please contact your Sulzer Service Centre.

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4.2 Temperature monitoring (PTC thermistor)
Thermal sensors protect the motor from overheating.
Thermal protection is in accordance with DIN 44082. PTC relays for use in control panels must also be in
accordance with this standard.
4.3 Bearing temperature monitor (optional)
PTC thermistor bearing monitor versions of AFC pumps include thermal protection in accordance with DIN
44082. PTC relays for use in control panels must also be in accordance with this standard.
NOTE! Running the pump with the thermal and/or moisture sensors disconnected will invalidate
related warranty claims.
5 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o󰀨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.
5.1 Installation example
1
2
6
5
4
3
1Inowline
2 Gate valve
3Pump
4Non-return valve
5 Gate valve
6Discharge line
5.2 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ttedwithabackwashloop(180°bend)locatedabovethebackwashleveland
shouldthenowbygravityintothecollectionlineorsewer.
- The discharge line should not be connected to a down pipe.
- Nootherinowsordischargelinesshouldbeconnectedtothisdischargeline.
ATTENTION The discharge line should be installed so that it is not aected by frost.

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5.3 Checking direction of rotation
Whenthreephaseunitsarebeingcommissionedforthersttimeandalsowhenusedonanewsite,the
directionofrotationmustbecarefullycheckedbyaqualiedperson.
When checking the direction of rotation, the pump should be secured in such a manner that no
dangertopersonneliscausedbytherotatingimpeller,orbytheresultingairow.Donotplaceyour
hand into the hydraulic system!
The direction of rotationshouldonlybealteredbyaqualiedperson.
When carrying out the direction of rotation check as well as when starting the unit pay attention to the
START REACTION. This can be very powerful.
ATTENTION
The direction of rotation is
correct if the impeller rotates in a
clockwise manner when viewing
down from the motor end of the
placed unit.
1019-00
ATTENTION
The start reaction is
anti-clockwise.
Rotor rotation
NOTE If a number of pumps are connected to a single control panel then each unit must be
individually checked.
ATTENTION The mains supply to the control panel should have a clockwise rotation. If the leads
are connected in accordance with the circuit diagram and lead designations, the
direction of rotation will be correct.
5.4 Changing direction of rotation
The direction of rotationshouldonlybealteredbyaqualiedperson.
If the direction of rotation is incorrect then this is altered by changing over two phases of the power supply cable
in the control panel. The direction of rotation should then be rechecked.

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6 Commissioning
Before commissioning, the pump should be checked and a functional test carried out. Particular attention
should be paid to the following:
- Have the electrical connections been carried out in accordance with regulations?
- Have the thermal sensors been connected?
- Is the seal monitoring device correctly installed?
- Is the motor overload switch correctly set?
- Is the direction of rotation of the pump correct - even if run via an emergency generator?
- Are the level control switches functioning correctly?
- Aretherequiredgatevalves(wheretted)open?
- Dothenon-returnvalves(wheretted)functioneasily?
6.1 Types of operation and frequency of starting
All pumps of the AFC series have been designed for continuous operation S1.
ATTENTION Explosion-proof pumps may only be used in explosive zones with the thermal
sensors tted (leads: FO, F1).
7 Maintenance
Before commencing any maintenance work the pump should be completely disconnected from the
mainsbyaqualiedpersonandcareshouldbetakenthatitcannotbeinadvertentlyswitchedback
on.
When carrying out any repair or maintenance work, the safety regulations covering work in enclosed
areas of sewage installations as well as good general technical pratices should be followed.
To avoid danger if the power cable is damaged, it must be replaced by the manufacturer or its service
agentorasimilarlyqualiedperson.
Repair work on explosion-proof pumps may only be carried out by approved personnel in approved
workshops.
When carrying out repairs only original spare parts, supplied by the manufacturer, should be used.
NOTE The maintenance hints given here are not designed for “do-it-yourself” repairs as
special technical knowledge is required.
A maintenance contract with our service department will guarantee you the best technical service
under all circumstances.
7.1 General maintenance hints
Sulzerpumpsarereliablequalityproductseachbeingsubjectedtocarefulnalinspection.Lubricated-for-life
ball bearings together with monitoring devices ensure optimum pump reliability provided that the pump has
been connected and operated in accordance with the operating instructions.
Should nevertheless, a malfunction occur, do not improvise, but ask your Sulzer Customer Service Department
for assistance.
Thisappliesparticularlyifthepumpiscontinuallyswitchedo󰀨bythecurrentoverloadinthecontrolpanel,by
the thermal sensors of the thermo-control system or by the seal monitoring system (DI).
Regular inspection and care is recommended to ensure a long service life.

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The Sulzer Service Organisation would be pleased to advise you on any applications you may have
and to assist you in solving your pumping problems.
NOTE The Sulzer warranty conditions are only valid provided that any repair work has been
carried out in Sulzer pproved workshop and where original Sulzer spare parts have
been used.
7.2 Coolantllingandcoolantchanging
Thechamberbetweenthemotorandthehydraulicsectionhasbeenlledatmanufacturewithcoolant.
A coolant change is only necessary if a fault occurs.
Coolantspecication: 70% water and 30% propylene glycol.
AFC COOLANT QUANTITY (litres)
Pump type Motors Coolant
AFC 0831 3/4, 3/6 0.63
AFC 0832 4/2, 7.5/2 0.63
AFC 0835 7.5/2, 11/2 2.00
AFC 0841 3/4, 3/6 0.63
AFC 0844 7.5/2, 11/2 0.87
AFC 1031 3/4, 3/6 0.63
AFC 1032 7.5/4, 9.2/4, 3/6 1.15
AFC 1033 15/4, 18.5/4, 9.2/6 2.65
AFC 1035 22/2 2.00
AFC 1041 3/4, 3/6 0.63
AFC 1045 15/4, 18.5/4, 22/4, 9.2/6 2.65
AFC 1049 7.5/4, 9.2/4, 3/6 1.15
AFC 1541 7.5/4, 9.2/4, 3/6 1.15
AFC 1543 15/4, 18.5/4, 22/4, 9.2/6 2.65
AFC 1546 7.5/4, 9.2/4, 3/6 1.15
AFC 2046 9.2/6, 11/6, 15/6 2.65
AFC 50/50 7.5/4, 3/6 2.00
AFC 50/50 RV 15/2, 22/2 2.00
AFC 80/80 7.5/4, 9.2/4, 15/4, 3/6, 9.2/6 2.00
AFC 80/80 RV 22/2 2.00
A coolant change is only necessary when carrying out repair work or if the inspection lamp lights up.
The70%waterand30%propyleneglycolcoolantisfrostresistingdownto-15°C/5°F.
Incaseofextremeambienttemperaturesbelow-15°C/5°F(e.g.duringtransport,storageorifthepumpisout
of duty) the cooling liquid must be drained. Otherwise the pump may be damaged. Please contact your Sulzer
consultant!
7.3 Venting of the volute
We strongly recommend that AFC pumps are vented back into the sump by means of the drilled and tapped
hole provided in the volute.
7.4 Draining of the volute
To drain the volute on the AFC series remove the plug from the tapped hole on the under side of the volute.

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Sulzer Pump Solutions Ireland Ltd. Clonard Road, Wexford, Ireland
Tel. [phone].. www.sulzer.com