Sulzer RCP 250 User manual

www.sulzer.com
Submersible Recirculation Pump Type ABS RCP 250
1024-00
15975086EN (05/2019)
en
Installation and Operating Instructions

Sulzer reserves the right to alter specications due to technical developments !
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Contents
1 General................................................................................................................................................... 3
1.1 Application areas..................................................................................................................................... 3
1.2 Technical data ......................................................................................................................................... 3
1.3 Nameplate............................................................................................................................................... 3
2 Safety ..................................................................................................................................................... 4
3 Transport................................................................................................................................................ 4
4 Mounting and installation..................................................................................................................... 5
4.1 Installation example ................................................................................................................................ 5
4.2 Installation of the guide tube ................................................................................................................... 5
4.3 Fitting and removal of the recirculation pump ......................................................................................... 6
4.4 Lowering of the recirculation pump along the guide tube........................................................................ 6
4.5 Laying of the power cables ..................................................................................................................... 7
4.6 Electrical connection ............................................................................................................................... 8
4.7 Wiring diagram ........................................................................................................................................ 9
4.7.1 Checking direction of rotation.................................................................................................................. 9
4.7.2 Changing direction of rotation .............................................................................................................. 10
4.8 Connection of the seal monitor ............................................................................................................. 10
5 Commissioning ................................................................................................................................... 11
6 Types of operation .............................................................................................................................. 11
7 Maintenance ........................................................................................................................................ 11
7.1 General maintenance hints ................................................................................................................... 12
7.2 Oilllingandchanging .......................................................................................................................... 12
7.3 Filling oil into the oil chamber................................................................................................................ 12
7.4 Cleaning ................................................................................................................................................ 12
ABS submersible recirculation pump RCP
2533
2534
2535

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1 General
1.1 Application areas
The Sulzer recirculation pumps with water pressure-tight encapsulated submersible motors are reliable
quality products designed for the following applications:
• Pumping and circulation of activated sludge in treatment plants with removal of nitrogen
(nitrication/denitrication).
• Pumping of storm or surface water.
1.2 Technical data
Maximumnoiselevel≤70dB.Thismaybeexceedediscertaincircumstances.
1.3 Nameplate
We recommend that you record the data from the original nameplate 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theeld“Nr/SN”inallcommunications.
Baseefa 03ATEX07..X II 2G Ex db IIB T4 Gb
Legend
1001-04
Type Pump type
Nr./SN ItemNo./SerialNo.
xx/xxxx Productiondate(Week/Year)
UN Rated Voltage V
IN Rated Current A
Frequency Hz
P1N Rated Input Power kW
P2N Rated Output Power kW
nSpeed min-1
Qmax Max. Flow m3/h
Hmax Max. Head m
Ø Imp. Impeller diameter mm
DN Discharge diameter mm
IP68 Protection type
Figure 1: Nameplate Ex Version
Legend
1002-02
Model Pumptype/ItemNo.
SN Serial No.
UN Rated Voltage
P2 Rated Output Power HP
F. L. A mps Full Load Amps
Hz Frequency
Phase Three/SinglePhase
RPM Speed min-1
Imp. dia Impeller diameter mm
Max. ▽Max submersible depth Ft
Flow Max. Rated Discharge GPM
Head Max. Max. Head Ft
Figure 2: Nameplate FM Version

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Legend
1004-02
Model Pumptype/ItemNo.
SN Serial No.
UN Rated Voltage
P2 Rated Output Power HP
F. L. A mps Full Load Amps
Hz Frequency
Phase Three/SinglePhase
RPM Speed min-1
Imp. dia Impeller diameter mm
Max. ▽Max submersible depth Ft
Flow Max. Rated Discharge GPM
Head Max. Max. Head Ft
Figure 3: Nameplate Standard Version
Legend
1003-03
Type Pump type
Nr./SN ItemNo./SerialNo.
xx/xxxx Productiondate(Week/Year)
UN Rated Voltage V
IN Rated Current A
Frequency Hz
P1N Rated Input Power kW
P2N Rated Output Power kW
nSpeed min-1
Qmax Max. Flow m3/h
Hmax Max. Head m
Ø Imp. Impeller diameter mm
DN Discharge diameter mm
IP68 Protection type
Figure 4: Nameplate Standard Version
2 Safety
ThegeneralandspecichealthandsafetyguidelinesaredescribedindetailintheSafetyInstructionsfor
SulzerProductsTypeABS.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 unit should not be dropped or thrown.
The unit should never be raised or lowered by the power cable.
Theunitisttedwithaliftingdevicetowhichachainandshacklemaybeattachedfortransportpurposes.
Any hoist used must be adequately dimensioned for the weight of the unit.
All relevant safety regulators as well as general good technical practice must be complied with.

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4 Mounting and installation
NOTE We recommend that original Sulzer installation accessories be used for mounting
and installation of the pump.
Particular attention must be paid to the safety regulations covering work in closed areas in sewage
plants as well as good general technical practices.
4.1 Installation example
1Lifting frame with hoist
1025-00
2 Socket type support frame
3 Concrete tank
4Guide tube
5Chain
6BracketforDINange
7Submersible motor
8Flange
Figure 5: Installation example
4.2 Installation of the guide tube
ATTENTION Thedischargelineaswellastherequiredangeshouldbeinstalledonsitebefore
commencingtheinstallationoftheguidetube.Theangeshouldbeinstalledinsuch
amannerthattheangeholesaresymmetricallyoneithersideoftheverticalaxisof
theange,i.e.averticallineshouldnotpassthroughanyoftheholes.Careshould
betakenthattheangeisadequatelyfastenedtotheconcrete.
1026-00
Figure 6: Installation of guide tube

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Placebracket(5)attheangeanddeterminenalposition.DrillandtaptwoM12holesinange.Again,place
bracket(5)atangeandfastentightlyusingcylinderbolts(6)includingwashers.
Fixthepositionofthepiperetainer(1)verticallyabovethebracket(5)andtusingmasonryplugs(3).Donot
yetfullytightenscrews(2).
Placeguidetube(4)alongsidethesupportconeonthebracket(5)anddeterminethenalguidetubelength.
Themeasurementistakentotheupperedgeoftheconeonthepiperetainer(1).
Shortenguidetube(4)tothecorrectlengthandplaceontheconeonthebracket(5).
Presspiperetainer(1)upwardsintotheguidetube(4)sothatthereisnoplayinaverticaldirection.Tightenhex
screws(2)includingspringwashers.
4.3 Fitting and removal of the recirculation pump
The lifting device must be adequately dimensioned to suit the weight of the recirculation pump.
The safety regulations as well as general good technical practice should be observed.
4.4 Lowering of the recirculation pump along the guide tube
The recirculation pump together with guide piece is connected into the guide tube as shown in Figure 8,
andloweredalongituntilitautomaticallysitsinitsnalposition.
When doing this feed the power cable downwards at the same time.
To ensure the RCP will tilt enough to lower correctly on the guide tube, the angle of the pump created by the
lifting hook when suspended by the hoist has to be checked prior to lowering. For this purpose, begin lifting the
pumpfromahorizontalsurfaceandcheckthattherearendofthexingsupportrises2-to4-cmfromtheoor
beforethefrontendbeginstoliftclear(seedrawingbelow).
1027-00
Figure 7: Checking installation angle of pump

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ATTENTION The power cable should be connected to the chain or wire rope in such a manner that
itcannotbecomeentangledinthepropellerandthatitisnotsubjectedtoanystrain.
After lowering of the recirculation pump the chain or wire rope should have the tension released.
1028-00
Figure 8: Lowering into position
4.5 Laying of the power cables
NOTE The cable brackets here are not supplied as standard with the recirculation pump.
1
2
4
3
1
6
5
7
1029-00
Figure 9: Laying of power cable
Placecableholder(2)withrubbersleeve(3)ashortdistanceabovetherecirculationpumpontheconnection
cableandtightenusinghexbolt(1).
Connectthesnaphook(4)tothecableholder(2)andchainorwirerope(5).

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The connection cable should be laid in such a manner that it cannot become entangled in the
propeller and is not subjected to strain.
Locateasecondcableholderdirectlyabovetheshackle(6)inasimilarmanner.
Mount the other cable holders in a similar manner. As the distance from the pump increases it is possible to
increase the distance between the cable holders.
Suspendthecablebymeansofstrainrelief(7)tothecablehook.
The electrical connection is carried out in accordance with Section 3.7.
4.6 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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.
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.
ATTENTION Foruseintheopenair,thefollowingVDEregulationsapply:
Submersiblepumps/recirculatorsusedoutdoorsmustbettedwithapowercableofatleast10mlength.Other
regulationsmayapplyindi󰀨erentcountries.
Pumps for use in swimming pools, garden ponds and similar, must comply with European Standard 60335, Part
2, protection class I.
NOTE Pleaseconsultyourelectrician.

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4.7 Wiring diagram
1015-00
Figure 10: Wiring diagram
Legend
U1, V1, W1 =Live F1/FO =Thermal sensor
PE = Earth S = Start
Gr/ Yel =Green/Yellow R = Run
Di =Seal Monitor C = Neutral(common)
4.7.1 Checking direction of rotation
The safety hints in the previous sections must be observed!
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 unit 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 as this can be very powerful
ATTENTION
The direction of rotation is correct
if the propeller rotates in a
clockwise manner when viewing
down from the top of the placed
unit.
1019-00
ATTENTION
The start reaction is
anti-clockwise.
Figure 11: Rotor rotation
NOTE If a number of units 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.

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4.7.2 Changing direction of rotation
The safety hints in the previous sections must be observed!
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.
NOTE Thedirectionofrotationmeasuringdevicemonitorsthedirectionofrotationofthe
mainssupplyorthatofanemergencygenerator.
4.8 Connection of the seal monitor
In order to integrate the seal monitor into a control panel supplied by the customer it is necessary to use an
ABSDI-moduleandconnectthisinaccordancewiththecircuitdiagramsbelow.
NOTE DI-modulesareavailableforthevoltages110V,220V,380V,and440V.DI-modules
are not supplied as standard.
1022-00 1023-00
Figure 12: DI Module (connection of neon bulb) Figure 13: DI Module with relay for individual signaling
ATTENTION Maximumrelaycontactloading:2Ampere

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5 Commissioning
In explosive zones care must be taken that during switching on and operation of the pumps the pump
sectionislledwithwater(dryrunning)oralternativelyissubmergedorunderwater(wetinstallation).
Ensure in this case that the minimum submergence given in the data sheet is observed, Other types
of operation e.g. snore operation or dry running are not allowed.
The safety hints in the previous sections must be observed!
Beforecommissioning,theunit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(wheretted)correctlyinstalled?
- Is the motor overload switch correctly set?
- Havethepowerandcontrolcircuitcablesbeencorrectlytted?
- Was the sump cleaned out?
- Havetheinowandoutowsofthepumpstationbeencleanedandchecked?
- Is the direction of rotation correct - even if run via an emergency generator?
- Are the level controls functioning correctly?
- Dothenon-returnvalves(wheretted)functioneasily?
- Have the hydraulics been vented in the case of dry installed pumps?
6 Types of operation
Recirculation pumps may only be operated fully submerged.
ATTENTION Theminimumwatercoverabovetheunitmustbeatleast1m.Duringoperationnoair
mustbedrawninbythepropeller.Aquietowingactioninthemediummustoccur.
Theunitmustnotvibrateexcessively.
7 Maintenance
Before commencing any maintenance work the unit 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.
NOTE Themaintenancehintsgivenherearenotdesignedfor“do-it-yourself”repairsas
special technical knowledge is required.
NOTE AmaintenancecontractwithourServiceDepartmentwillguaranteeyouthebest
technicalserviceunderallcircumstances.

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7.1 General maintenance hints
Sulzersubmersiblerecirculation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unit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.
NOTE 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approvedworkshopandwhereoriginalSulzerspare
partshavebeenused.
7.2 Oilllingandchanging
Waste oil must be disposed of in the proper manner.
7.3 Filling oil into the oil chamber
Therecirculationpumpshavebeenlledatmanufacturewithoil.Theseoilsarenotinjurioustothe
environment. An oil change is only necessary if a fault occurs.
When carrying out repairs only original spare parts, supplied by the manufacturer, should be used.
7.4 Cleaning
ATTENTION Makecertainthepropellerhascompletelystoppedrotatingbefore
approaching the pump.
If the recirculation pump is to be taken out of commission then it should be cleaned by hosing it down with clear
water. If the unit is to remain out of service for a prolonged period then it should be stored in a dry and
frost-proof location.
If the unit is to be reinstalled after a prolonged period out of use then proceed as per Section 4.

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