Sulzer ABS RW 300 User manual

www.sulzer.com
Submersible Mixer Type ABS RW 300
Submersible Recirculation Pump Type ABS RCP 250
1 5975086 03.2021
Installation and Operating Instructions
en

Sulzer reserves the right to alter specications due to technical developments !
2
Table of contents
1 General................................................................................................................................................... 4
1.1 Introduction ............................................................................................................................................. 4
1.2 Correct usage of the products................................................................................................................. 4
1.3 Application restrictions of RW / RCP....................................................................................................... 4
1.4 Application areas .................................................................................................................................... 5
1.4.1 Application areas RW.............................................................................................................................. 5
1.4.2 Application areas RCP ............................................................................................................................ 5
1.5 Nameplate............................................................................................................................................... 6
1.6 Tightening torque .................................................................................................................................... 6
1.6.1 Fitting position of the Nord-Lock®securing washers............................................................................... 6
2.0 Technical data ....................................................................................................................................... 7
2.1 Technical data RW 300 ........................................................................................................................... 7
2.2 Technical data RCP 250.......................................................................................................................... 7
3.0 Dimensions (mm) .................................................................................................................................. 8
3.1 Dimensions RW 300 ............................................................................................................................... 8
3.2 Dimension RCP 250................................................................................................................................ 9
3.3 Flange dimension check RCP 250 (mm) .............................................................................................. 10
4 Safety ................................................................................................................................................... 11
5 Lifting, transport and storage ............................................................................................................ 11
5.1 Lifting..................................................................................................................................................... 11
5.2 Transport securing devices ................................................................................................................... 11
5.3 Storage of the units ............................................................................................................................... 12
6 Product description ............................................................................................................................ 12
6.1 General description ............................................................................................................................... 12
6.2 Structural design RCP 250.................................................................................................................... 13
6.3 Structural design RW 300 ..................................................................................................................... 14
7 Installation ........................................................................................................................................... 15
7.1 Installation RCP 250 ............................................................................................................................. 15
7.1.1 Installation example with Sulzer lifting unit............................................................................................ 15
7.1.2 Guide tube installation RCP .................................................................................................................. 16
7.1.3 Lowering of the RCP along the guide tube ........................................................................................... 17
Installation and Operating Instructions
For Submersible Recirculation Pump RCP 250 and Submersible Mixer RW 300

7.1.4 Securing and positioning of the motor connection cables of the RCP ....................................................18
7.2 Installation RW 300 ............................................................................................................................... 19
7.2.1 Brackets RW 300 ....................................................................................................................................20
7.2.2 Fitting of the open bracket with vertical swivelling (option) .....................................................................20
7.2.3 Fitting of the closed bracket with vertical swivelling (option)...................................................................21
7.2.4 Bracket alignment on guide rail...............................................................................................................21
7.2.5 Vertical adjustment..................................................................................................................................22
8 Electrical connection ............................................................................................................................22
8.1 Standard connection diagram, mains voltage 380 - 420 V at 50 Hz / 460 V at 60 Hz .......................... 23
8.2 Lead designations ................................................................................................................................. 23
8.3 Operation with frequency inverters ....................................................................................................... 24
8.4 Connection of the seal monitoring unit to the control panel .................................................................. 25
9 Commissioning .....................................................................................................................................26
9.1 Types of operation................................................................................................................................. 26
9.2 Checking direction of rotation................................................................................................................ 27
9.3 Changing direction of rotation .............................................................................................................. 27
10 Maintenance ..........................................................................................................................................28
10.1 General maintenance hints ................................................................................................................... 28
10.2 Faults .................................................................................................................................................... 28
10.3 Inspection and maintenance intervals................................................................................................... 29

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1 General
1.1 Introduction
These Installation and Operating Instructions and the separate booklet ”Safety Instructions for Sulzer
Products Type ABS” contain basic instructions and safety hints which must be observed during transport, in-
stallation and commissioning. For this reason it is essential that they are read by the installing technician as well
as by relevant skilled operators or users. They should also be always available where the unit is installed.
m SafetyInstructionswhichmightcausedangertolifeincaseofnon-observancehavebeenspecically
highlighted with the general danger symbol.
c Thepresenceofadangerousvoltageisidentiedwiththissafetysymbol.
gThis symbol indicates the danger of an explosion occurring.
ATTENTION Appears at safety hints, the non-observance of which could damage the unit or aect
its functioning.
NOTE Used for important pieces of information.
Illustrationscode;e.g.(3/2).Therstdigitreferstothegureno.andtheseconddigittothepositioninthat
gure.
1.2 Correct usage of the products
The Sulzer products have been designed and built in accordance with the latest technology and taking into ac-
count the relevant safety regulations. However improper usage could cause a danger to life or limb of the user
of a third party or cause damage or function impairment to the unit itself and other items of value.
The Sulzer units should only be used if they are in perfect technical condition taking into account all safety
requirements and conscious of the need to avoid potentially dangers. The contents of the installation and
operating instructions and the safety hints must be applied! Any other usage (abnormal usage) or usage
beyondthatspeciedwillbeconsideredasnon-compliance.
The manufacturer/supplier will not accept any responsibility for damage due to this. The risk is borne by
the user. In case of doubt the entire scope of the planned application must be approved by Sulzer Pump
Solutions (Kunshan) Co, Ltd.
In the case of any faults arising, the Sulzer units should immediately be taken out of use and secured. The fault
shouldbeimmediatelyrectied,orifnecessary,contactyourSulzerServiceCentre.
1.3 Application restrictions of RW / RCP
The RW 300 can be supplied both in standard and in explosion-proof versions (ATEX II 2G Ex h db IIB T4 Gb) for
50 Hz according to the standards EN ISO 12100:2010, EN 809:1998 + A1:2009 + AC:2010, EN 60079-0:2012 +
A11:2018, EN 60079-1:2014, EN ISO 80079-36, EN ISO 80079-37.
Limitations: The ambient temperature range is 0 °C to + 40 °C (32 °F to 104 °F)
Immersion depth maximum 20 m /( 65 ft)
ATTENTION In special cases an immersion depth greater than 20 m / 65 ft is possible. However,
the maximum number of starts according to the motor datasheet may not be
exceeded. In order to do this you need the written approval from the manufacturer
Sulzer.
Pumping of ammable or explosive liquids with these pumps is not allowed!
Only explosion-proof executions may be used in hazardous areas!
ATTENTION Leakage of lubricants could result in pollution of the medium being pumped.

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Operation of RW 300 Ex:
In hazardous areas care must be taken that during switching on and operation of the unit it is submerged or
under water. Other types of operation e.g. snore operation or dry running are not allowed!
ATTENTION RW 300 with Ex h d IIB T4 approval is not equipped with a DI in the oil chamber.!
The temperature monitoring of the RW 300 Ex has to be carried out by bimetallic temperature limiters
orthermistorsaccordingtoDIN44081-150connectedtoasuitablereleasedevicewhichiscertiedin
accordance with EC directive 2014/34/EU.
Operation of RW 300 Ex with frequency inverter:
Motorsmusthavedirectthermalprotectiondevicestted.Theseconsistoftemperaturesensors(PTCDIN
44081-150)embeddedinthewindings.Thesemustbeconnectedtoasuitablereleasedevicewhichiscertied
in accordance with EC directive 2014/34/EU.
Machines designated as Ex machines may never, without exception, be operated using a mains frequency that
is greater than the maximum of 50 Hz or 60 Hz as indicated on the nameplate.
ATTENTION Repair work on explosion-proof motors may only be carried out in authorized
workshops by qualied personnel using original parts supplied by the manufacturer.
Otherwise the Ex-approvals are no longer valid. All Ex-relevant components and
dimensions can be found in the modular workshop manual and the spare parts list.
ATTENTION After repair work in unauthorized workshops by unqualied personnel the Ex
approvals are no longer valid. After such repair the unit must not be operated in
hazardous areas. The Ex nameplate has to be removed.
1.4 Application areas
1.4.1 Application areas RW
The ABS submersible mixer RW 300, with a water pressure-tight encapsulated submersible motor, is a high
class quality product with the following range of applications in municipal treatment plants, in industry and in
agriculture:
• Mixing
• Stirring
• Agitation
1.4.2 Application areas RCP
TheABSsubmersiblerecirculationpumpRCP250isttedwithawaterpressuretightencapsulatedmotorsand
is a quality product suitable for use in the following areas:
• Pumpingandrecirculationofactivesludgeintreatmentplantswithnitrogenremoval(nitrication/
denitrication).
• Pumping of rain and surface water.

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1.5 Nameplate
We recommend that you record the data from the original nameplate Figure 1 so that you can refer to the data
at any time.
:epyT
:NP :NS
.xam INA
PN1 Wk P N2 Wk
TAC°xam
ND Q h H
bd07 thgieW 86PI
lC.ffErotoM
mprn Ø
.xamH
.lC.lusnI
.nimH
anihCnIdelbmessA
3
zH
UN~3
:V:
:::
:m : : m
:gk
.dtL,.oC)nahsnuK(snoituloSpmuPrezluS
,daoRgnefnehCtseW,8.oN
003512,anihC,ecnivorPusgnaJ,nahsnuK
28
27
26 25
24
23
22
21
201918
17
Nema Code
16
15
141312
11
10
987
6
5
4
3
2
1
Figure 1: Nameplate
Legend
1 Address  15 Max.ambienttemperature[exibleunit]
2 Type designation 16 Nema Code Letter (only at 60 Hz)
3 Art. no. 17 Min. pumping height
4 Serial number 18 Nominal width
5 Order number 19 Pumping quantity
6 Yearofmanufacture[month/year]  20 Pumpingheight
7 Nominal voltage 21 Max. pumping height
8 Max. immersion depth 22 Weight (without attached parts)
9 Nominalcurrent  23 Motore󰀩ciencyclass
10 Frequency 24 Motor shaft direction of rotation
11 Power (consumption) 25 Insulation Class
12 Power (output) 26 Sound level
13 Rotation speed 27 Phase connection
14 Propeller ø 28 Protection method
NOTE In all communication please state type of the unit, item and serial number.
1.6 Tightening torque
Tightening torque for Sulzer stainless steel screws A4-70:
Thread M6 M8 M10 M12 M16 M20 M24
Tightening torque 6.9 Nm 17 Nm 33 Nm 56 Nm 136 Nm 267 Nm 460 Nm
1.6.1 Fitting position of the Nord-Lock® securing washers
Outer side of the two securing washers
Inner side of the two securing washers
Figure 2: Correct tting position of the Nord-Lock® securing washers

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2.0 Technical data
Themaximumnoiseleveloftheunitsofthisseriesis≤70dB(A).Insometypesofinstallationitispossiblethat
the noise level of 70 dB(A) or the measured noise level will be exceeded.
ATTENTION The maximum uid temperature for continuous operation is 40 °C / 104 °F for a
submerged unit.
2.1 Technical data RW 300
Propeller Motor Installation
Mixer type
Propeller diameter
Speed
Version with ow ring
Motor type
Rated power input P1
Rated power output P2
Starting: Direct (D.O.L)
Starting: Star/Delta
Rated current
Starting current
Temperature monitoring
Seal monitoring
Ex
Guide tube □ 60
Total weight (without flow ring)
Total weight (with flow ring)
50 Hz 400 V
[mm] [1/min] [kW] [kW] [A] [A] [kg] [kg]
RW 3021 300 904 ○A 15/6 2.21 1.5 ●-4.6 16.8 ● ● ○ ● 47 53
RW 3022 300 904 ○A 15/6 2.21 1.5 ●-4.6 16.8 ● ● ○ ● 47 53
RW 3031 300 904 ○A 15/6 2.21 1.5 ●-4.6 16.8 ● ● ○ ● 47 53
RW 3032 300 894 ○A 28/6 4.09 2.8 ●-8.4 30.4 ● ● ○ ● 51 57
RW 3033 300 894 ○A 28/6 4.09 2.8 ●-8.4 30.4 ● ● ○ ● 51 57
RW 3034 300 894 ○A 28/6 4.09 2.8 ●-8.4 30.4 ● ● ○ ● 51 57
60 Hz
460 V
RW 3021 300 1111 ○A 17/6 2.36 1.7 ●-4.3 15.5 ● ● -●47 53
RW 3022 300 1111 ○A 17/6 2.36 1.7 ●-4.3 15.5 ● ● -●47 53
RW 3031 300 1097 ○A 32/6 4.4 3.2 ●-8.8 24.8 ● ● -●51 57
RW 3032 300 1097 ○A 32/6 4.4 3.2 ●-8.8 24.8 ● ● -●51 57
P1= Power input. P2=Poweroutput.●=Standard.○=Option.Cabletype:1x7G1.5.10mcablewithfreecableendsasstandard.
2.2 Technical data RCP 250
Propeller Motor
RCP hydraulics type
Propeller diameter
Propeller speed
Hmax
Qmax
Motor type
Rated input
power P1
Rated motor power P2
Starting: Direct (D.O.L)
Rated current
Starting current
Temperature monitoring
Seal monitoring
Total weight
(Complete unit)
50 Hz 400 V
[mm] [1/min] [m] [l/s] [kW] [kW] [A] [A] [kg]
RCP 2533 246 980 1,1 85 A 15/6 2,21 1,5 ●4,6 16,8 ● ● 61
RCP 2534 246 980 1,6 120 A 28/6 4,09 2,8 ●8,4 30,4 ● ● 66
RCP 2535 246 980 1,8 160 A 28/6 4,09 2,8 ●8,4 30,4 ● ● 66
60 Hz
460 V
RCP 2533 246 1180 1,1 100 A 17/6 2,36 1,7 ●4,3 15,5 ● ● 61
RCP 2534 246 1180 1,6 145 A 32/6 4,39 3,2 ●8,8 24.8 ● ● 66
RCP 2535 246 1180 1,4 180 A 32/6 4,39 3,2 ●8,8 24,8 ● ● 66
P1= Power input. P2=Poweroutput.●=Standard.○=Option.Cabletype:1x7G1.5.10mcablewithfreecableendsasstandard.
NOTE Data applies also for versions with ow ring. Other voltages available on request.

8
3.0 Dimensions (mm)
3.1 Dimensions RW 300
± 15°/22°/30°
min. 725
90
610
*A15/6 and A17/6 motor sizes
**A28/6 and A32/6 motor sizes
63
29
60
610
*217
**237
264
Ø300
Ø462
264
Ø158
220
min. 700
min. 50
min. 190
90
63
29
Figure 3: Dimensions RW 300

9
3.2 Dimension RCP 250
788
31
85
3.3
125
4.9
620
24.4
210
8.3
267
10.5
min
265
10
250
9.8
min 500 mm
19.7
GUIDE TUBE 2" EN10255-M
10" ANSI B16.1 CLASS 125
Flange PN6 Type 11 DN250 DIN EN 1092-1
Figure 4: RCP 250
NOTE The weights of the units can be obtained from the nameplate of the unit or from the
tables in Section 2.0 Technical Data.

10
3.3 Flange dimension check RCP 250 (mm)
ange PN6 DIN EN1092-1 Typ 11
ange Class125 ANSI B16.1-2010
22 +0.5
Figure 5: Flange dimensions
ATTENTION Before installing the recirculation pump, check the dimension of the ange. Make
sure that the dimension specied in the drawing is adhered to, otherwise the ange
will need to be reworked.