ABS 80C-CB1, 80E-CB1, 100G-CB1, 150G-VX, 80C-VX Installation, Operating And Maintenance Instructions
...Page 1
ABS submersible sewage pump XFP 80C - 201G
www.absgroup.com
08/2011
Installation, Operating and Maintenance Instructions
Page 2
2 Installation, Operating and Maintenance Instructions (Original Instructions)
ABS reserves the right to alter specifi cations due to technical developments
ABS submersible sewage pump XFP 80C - 201G
Contents
1 Application areas .......................................................................................................................................................3
1.1 Explosion-proof Approvals ...........................................................................................................................................3
2 Safety ...........................................................................................................................................................................3
2.1 Use of explosion-proof pumps in explosive zones. ......................................................................................................3
3 Technical data .............................................................................................................................................................4
3.1 Nameplates ...................................................................................................................................................................4
4 General design features .......................................................................................................................................... 5
4.1 Design features PE1 & PE2 ..........................................................................................................................................5
4.2 Design features PE3 ..................................................................................................................................................... 6
5 Transport and Storage ...............................................................................................................................................7
5.1 Transport ......................................................................................................................................................................7
5.2 Storage .........................................................................................................................................................................7
5.2.1 Moisture protection of motor connection cable ............................................................................................................7
6 Mounting and Installation .........................................................................................................................................8
6.1 Installation examples .................................................................................................................................................... 8
6.1.1 Submerged in concrete sump....................................................................................................................................... 8
6.1.2 Dry-installed .................................................................................................................................................................9
6.2 Discharge Line ............................................................................................................................................................ 10
7 Electrical Connection ..............................................................................................................................................10
7.1 Temperature monitoring .............................................................................................................................................10
7.2 Seal monitoring ...........................................................................................................................................................10
7.3 Wiring Diagrams ......................................................................................................................................................... 11
8 Commissioning ........................................................................................................................................................ 12
8.1 Types of operation and frequency of starting .............................................................................................................12
8.2 Checking direction of rotation .....................................................................................................................................12
8.3 Changing direction of rotation .................................................................................................................................... 13
9 Maintenance .............................................................................................................................................................. 13
9.1 General maintenance instructions .............................................................................................................................. 13
9.2 Maintenance of Lifting Stations in accordance with EN 12056. ................................................................................. 13
9.3 Lubricant changing (PE1 & PE2) ................................................................................................................................ 14
9.4 Lubricant changing (PE3 - version without cooling jacket) ......................................................................................... 15
9.5 Coolant changing (PE3 - version with cooling jacket) ................................................................................................16
9.6 Oil and glycol quantities (litres) ................................................................................................................................... 17
9.7 Bottom plate adjustment ............................................................................................................................................. 18
9.7.1 Instructions on how to adjust the bottom plate ........................................................................................................... 18
9.8 Bearings and Mechanical Seals .................................................................................................................................19
9.9 Changing the power cable (PE1 & PE2) ..................................................................................................................... 19
9.10 Cleaning ......................................................................................................................................................................19
9.11 Venting of the volute ...................................................................................................................................................19
10 Troubleshooting Guide ............................................................................................................................................20
EC Declaration of Conformity ..............................................................................................................................................21
ABS submersible sewage pump XFP
PE1 (50 Hz) PE2 (50 Hz) PE3 (50 Hz) PE1 (60 Hz) PE2 (60 Hz) PE3 (60 Hz)
80C-CB1 80E-CB1 100G-CB1 150G-VX 80C-CB1 80E-CB1 100G-CB1 150G-VX
80C-VX 81E-VX 100G-VX 200G-CB1 80C-VX 81E-VX 100G-VX 200G-CB1
81C-VX 100E-CB1 101G-CB1 201G-CB2 81C-VX 100E-CB1 101G-CB1 201G-CB2
100C- CB1 100E-VX 101G-V X 100C- CB1 100E-VX 101G-V X
100C-VX 150E-CB1 150G-CB1 100C-VX 150E-CB1 150G-CB1
Page 3
3Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
Symbols and notices used in this booklet:
Presence of dangerous voltage.
Non-compliance may result in personal injury.
Hot surface - danger of burn injury.
Danger of an explosion occurring.
ATTENTION! Non-observance may result in damage to the unit or negatively affect its performance.
NOTE: Important information for particular attention.
1 Application areas
The following guidelines must be observed when setting the lowest switch off point for XFP pumps:
When switching on and operating the pump, the hydraulic section of dry installation pumps must always be
fi lled with water.
The minimum submergence allowed for specifi c pumps can be found on the dimension installation sheets
available from your local ABS representative.
XFP pumps have been designed for economic and reliable pumping in commercial, industrial and municipal
installations and are suitable for pumping of the following liquids:
clear and wastewater, and for sewage containing solids and fi brous material
faecal matter
In combination with the ABS automatic coupling system, the below ground level wet installation is a particularly
economical and environmentally friendly solution. The pumps are also suitable for horizontal or vertical dry
installation (except XFP 80E-CB1-PE125/2 and XFP 81E-VX-PE125/2, 60 Hz).
The regulations of DIN 1986 as well as local regulations should be observed when installing the pumps
.
ATTENTION! The maximum allowable temperature of the medium pumped is 40 °C
1.1 Explosion-proof approvals
Explosion-proof as standard, in accordance with international standards Ex d IIB T4, ATEX 94/9/EC and FM (60
Hz US).
2 Safety
The general and specifi c health and safety guidelines are described in detail in the ABS Products Safety
Instructions booklet. If anything is not clear or you have any questions as to safety make certain to contact the
manufacturer ABS.
2.1 Use of explosion-proof pumps in explosive zones.
1. Explosion-proof submersible pumps may only be operated with the thermal sensing system connected.
2. If ball type fl 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 submersible explosion-proof motors may only be carried out by approved
personnel in specially approved work shops.
4. In the event that the pump is to be operated in explosive atmospheres using a variable speed drive,
please contact your local ABS representative for technical advice regarding the various Approvals and
Standards concerning thermal overload protection.
•
•
•
•
Page 4
4
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
3 Technical data
Maximum noise level 70 dB. This may be exceeded in certain circumstances.
Detailed technical information is available in the technical data sheet ABS submersible sewage pump XFP 80C
- 201G which can be downloaded from www.absgroup.com > Downloads.
3.1 Nameplates
XFP pumps are rated for use in hazardous locations (Ex) as standard, and are fi tted with a standard nameplate
containing technical data and a secondary nameplate to certify that the pump is Ex rated (examples below).
If an XFP pump is serviced or repaired in a workshop that is not Ex approved then it must no longer be used in
hazardous locations and the Ex nameplate must be removed.
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 no. and serial no. in all communications.
Standard nameplate
Ex nameplate
Legend
Typ Pump type
Nr Item No.
Sn Serial No.
xx/xxxx Production date (Week/Year)
U
N
Rated voltage V
I
N
Rated current A
Ph Number of phases
Hz Frequency Hz
P1 Rated input power kW
P2 Rated output power kW
1/min Speed r/min
Cos ij Power factor pf
NEMA NEMA code
Qmax Max. Flow m
3
/h
Hmax Max. Head m
Ø Imp. Impeller diameter mm
DN Discharge diameter mm
Legend
Typ Pump type
Nr Item No.
Sn Serial No.
xx/xxxx Production date (Week/Year)
U
N
Rated voltage V
I
N
Rated current A
Ph Number of phases
Hz Frequency Hz
P1 Rated input power kW
P2 Rated output power kW
1/min Speed r/min
Cos ij Power factor pf
NEMA NEMA code
Qmax Max. Flow m
3
/h
Hmax Max. Head m
Ø Imp. Impeller diameter mm
DN Discharge diameter mm
Typ
Nr Sn xx/xxxx
UN IN Ph Hz
P1: P2: 1/min
Cos φ NEMA IP68
Qmax Hmax ØImp
DN Hmin Weight
EN 12050-1
Typ
Nr Sn xx/xxxx
UN IN Ph Hz
P1: P2: 1/min
Cos φ NEMA IP68
Qmax Hmax ØImp
DN Hmin Weight
EN 12050-1
2G k Ex d B T4
0102
Do not open while energized
Nicht unter Spannung öffnen
2G k Ex d B T4
0102
Do not open while energized
Nicht unter Spannung öffnen
Page 5
5Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
4 General design features
XFP is a submersible sewage and wastewater pump with a Premium Effi ciency motor.
The water-pressure-tight, encapsulated, fl ood-proof motor and the pump section form a compact, robust,
modular construction.
4.1 Design features PE1 & PE2
1
2
3
4
5
7
8
9
10
12
13
14
15
14
16
17
11
18
6
1
2
3
4
5
7
8
9
10
12
13
14
15
14
16
17
11
18
6
1 Pressure release screw
2 10-pole terminal block
3 Moisture sensor (DI)
4 Seal chamber
5 Seal chamber drain plug/
pressure test point
6 Venting plug
1 Pressure release screw
2 10-pole terminal block
3 Moisture sensor (DI)
4 Seal chamber
5 Seal chamber drain plug/
pressure test point
6 Venting plug
7 Stainless steel lifting hoop
8 Upper bearing - single row
9 Motor with thermal sensors
10 Stainless steel shaft
11 Motor chamber
12 Lower bearing - double row
7 Stainless steel lifting hoop
8 Upper bearing - single row
9 Motor with thermal sensors
10 Stainless steel shaft
11 Motor chamber
12 Lower bearing - double row
13 Bearing housing
14 Mechanical seals
15 Seal holding plate
16 Motor chamber drain plug/
pressure test point
17 Impeller - Contrablock version
18 Bottom plate adjustment screw
13 Bearing housing
14 Mechanical seals
15 Seal holding plate
16 Motor chamber drain plug/
pressure test point
17 Impeller - Contrablock version
18 Bottom plate adjustment screw
Page 6
6
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
4.2 Design features PE3 (version with cooling jacket)
1
2
3
4
5
6
7
8
9
13
14
5
16
20
17
18
12
19
24
23
22
21
25
10
11
15
1
2
3
4
5
6
7
8
9
13
14
5
16
20
17
18
12
19
24
23
22
21
25
10
11
15
1 Stainless steel lifting hoop
2 Lid assembly
3 Cable gland
4 Upper bearing - single row
5 Coolant fi ll plug
6 Cooling jacket
7 Motor housing
8 Lower bearing housing
9 Lower bearing - double row
1 Stainless steel lifting hoop
2 Lid assembly
3 Cable gland
4 Upper bearing - single row
5 Coolant fi ll plug
6 Cooling jacket
7 Motor housing
8 Lower bearing housing
9 Lower bearing - double row
10 Seal holding plate
11 Mechanical seals
12 Venting plug
13 Terminal block*
14 Pressure test point
15 Upper bearing housing
16 Motor with thermal sensors
17 Stainless steel shaft
18 Moisture sensor (DI)
10 Seal holding plate
11 Mechanical seals
12 Venting plug
13 Terminal block*
14 Pressure test point
15 Upper bearing housing
16 Motor with thermal sensors
17 Stainless steel shaft
18 Moisture sensor (DI)
19 Dry chamber
20 Coolant impeller
21 Flow defl ector
22 Coolant drain plug /
pressure test point
23 Seal chamber
24 Impeller - Contrablock version
25 Bottom plate adjustment screw
* Fitted to bearing housing when two cables connected.
19 Dry chamber
20 Coolant impeller
21 Flow defl ector
22 Coolant drain plug /
pressure test point
23 Seal chamber
24 Impeller - Contrablock version
25 Bottom plate adjustment screw
* Fitted to bearing housing when two cables connected.
Page 7
7Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
5 Transport and Storage
5.1 Transport
During transport, care should be taken that the pump is not dropped or thrown.
The pumps of the XFP series are fi tted with a lifting hoop to which a chain and shackle may be attached for
transport or for suspension of the pump.
The pump must be raised only by the lifting hoop and never by the power cable.
Take note of the weight of the entire unit. The hoist and chain must be adequately dimensioned for
that weight and must comply with the current valid safety regulations.
All relevant safety regulations as well as general good technical practice must be complied with.
5.2 Storage
During long periods of storage the pump should be protected from moisture and extremes of cold or heat.
To prevent the mechanical seals from sticking it is recommended that occasionally the impeller is rotated by
hand.
If the pump is being taken out of service the oil should be changed before storage.
After storage the pump should be inspected for damage, the oil level should be checked, and the impeller
checked to ensure it rotates freely.
5.2.1 Moisture protection of motor connection cable
The motor connection cables are protected against the ingress of moisture along the cable by having the ends
sealed at the factory with protective covers.
ATTENTION! The ends of the cables should never be immersed in water as the protective covers
only provide protection against water spray or similar (IP44) and are not a water tight
seal. The covers should only be removed immediately prior to connecting the pumps
electrically.
During storage or installation, prior to the laying and connection of the power cable, particular attention should
be given to the prevention of water damage in locations which could fl ood.
ATTENTION! If there is a possibility of water ingress then the cable should be secured so that the
end is above the maximum possible fl ood level. Take care not to damage the cable or
its insulation when doing this.
1.
2.
3.
4.
Page 8
8
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
6 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 off 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.
For the XFP transportable version, arrange the cable run so that the cables will not be kinked or nipped.
Connect the discharge pipe and cable (see section ”Electrical Connection”). Place the pump on a fi rm surface
which will prevent it from overturning or burrowing down. The pump can also be bolted down to the base or
suspended slightly by the lifting handle. Hoses, pipes and valves must be sized to suit the pump performance.
6.1 Installation examples
6.1.1 Submerged in concrete sump
1 Sump cover
2 Venting line
3 Sump cover
4 Sleeve for cable ducting to
the control panel as well as
for aeration and venting
5 Chain
6 Infl ow line
7 Ball-type fl oat switch
8 Submersible pump
9 Concrete sump
10 Pedestal
11 Guide rail
12 Discharge line
13 Non-return valve
14 Gate valve
15 Power cable to motor
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Page 9
9Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
6.1.2 Dry-installed
Horizontal
Vertical
1 Control panel
2 Discharge line
3 Gate valve
4 Non-return valve
5 Power cable from motor to
control panel
6 Pump
7 Collection sump
8 Infl ow line
9 Ball-type fl oat switch
10 Gate valve
ATTENTION! PE3 pumps must not be dry-installed without a cooling jacket.
Under continuous running conditions the pump motor housing may become hot.
To avoid burn injury allow to cool down before handling.
1
2
3
4
5
6
8
7
9
10
1
2
3
4
5
6
8
7
9
10
1
2
3
4
5
6
8
7
9
10
1
2
3
4
5
6
8
7
9
10
Page 10
10
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
6.2 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 fi tted with a backwash loop (180° bend) located above
the backwash level and should then fl ow by gravity into the collection line or sewer.
- The discharge line should not be connected to a down pipe.
- No other infl ows or discharge lines should be connected to this discharge line.
ATTENTION! The discharge line should be installed so that it is not affected by frost.
7 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 qualifi 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 qualifi ed person.
All relevant safety regulations 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 used outdoors must be fi tted with a power cable of at least 10 metre length. Other
regulations may apply in different countries.
For pumps intended to be used in outdoor fountains, garden ponds and similar places, the pump is to be
supplied through a residual current device (RCD) having a rated residual operating current not exceeding
30 mA.
Please consult your electrician.
7.1 Temperature monitoring
Thermal sensors in the stator windings protect the motor from overheating.
XFP motors are fi tted with bimetallic thermal sensors in the stator as standard, or as an option with a PTC
thermistor (in accordance with DIN 44082). PTC relays for use in control panels must also be in accordance
with this standard.
7.2 Seal monitoring
XFP pumps are supplied as standard with a moisture sensor (DI), to detect and alert to the ingress of water into
the motor and seal chambers (PE1 & PE2), or motor and dry chambers (PE3).
NOTE: Running the pump with the thermal and/or moisture sensors disconnected will invalidate
related warranty claims.
Page 11
11Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
7.3 Wiring Diagrams
U1 V1 W1 F1 FO Di PE
123 4 5 6
U1 V1 W1 F1 FO Di PE
123 4 5 6
U1 V1 W1 V2 W2 U2 F1 FO Di PE
12 3 45
6
78 9
U1 V1 W1 V2 W2 U2 F1 FO Di PE
12 3 45
6
78 9
PE F1 F0 U1 V1 W1 U2 V2 W2 DI PE
M
3
PE F1 F0 U1 V1 W1 U2 V2 W2 DI PE
M
3
112233
T1 T2 T3 1 2 3 PET1 T2 T3 1 2 3 PE
RSC
(U1 W1 V1)*
12 3PE
1
RSC
(U1 W1 V1)*
12 3PE
1
Explosion-proof pumps may
only be used in explosive
zones with the thermal sensors
connected (leads F0 & F1).
Explosion-proof pumps may
only be used in explosive
zones with the thermal sensors
connected (leads F0 & F1).
4455
50 Hz
12 3
13/6
15/4
22/4
29/4
30/2
D01,D14,
D07
-
-
40/2 -
D05,D08,
D20
30/6
D01,D14,
D07
D05
-
40/4
49/4
60/4
90/4
55/2
70/2
110/2
-
D05,D08,
D20
90/6
110/6
140/6
-
D05,D08 D20
110/4
D05,D08,
D20
-
140/4
160/4
185/4
D05,D08 D20
220/4 D08 D05,D20
150/2
185/2
D05,D08 D20
250/2 D08 D05,D20
D01 = 400 V 3~, DOL D05 = 400 V 3~, Yǻ
D14 = 230 V 3~, DOL D20 = 230 V 3~, Yǻ
D07 = 500 V 3~, DOL D08 = 500 V 3~, Yǻ
50 Hz
12 3
13/6
15/4
22/4
29/4
30/2
D01,D14,
D07
-
-
40/2 -
D05,D08,
D20
30/6
D01,D14,
D07
D05
-
40/4
49/4
60/4
90/4
55/2
70/2
110/2
-
D05,D08,
D20
90/6
110/6
140/6
-
D05,D08 D20
110/4
D05,D08,
D20
-
140/4
160/4
185/4
D05,D08 D20
220/4 D08 D05,D20
150/2
185/2
D05,D08 D20
250/2 D08 D05,D20
D01 = 400 V 3~, DOL D05 = 400 V 3~, Yǻ
D14 = 230 V 3~, DOL D20 = 230 V 3~, Yǻ
D07 = 500 V 3~, DOL D08 = 500 V 3~, Yǻ
60 Hz
12 3 4 5
20/6
22/4
28/4
35/4
D63,D68,
D79,D80
-
-
D66,D62,D77,D85
-
45/2
D63,D79,
D80
D64,D81 D66,D62,D77,D85,D86
18/4W
28/4W
20/6W*
-- -
W60,
W62
35/6
45/4
56/4
75/4
90/4
105/4
80/2
125/2
D63,D79,
D80
D64,D81 - D66,D62,D77,D85,D86 -
120/8
90/6
110/6
130/6
-
D64,D79 D63,D80,D81 D66,D62,D77,D85,D86
-
160/6
-
D63,D64,D79,D80,D81
D66,D62,D77,D85,D86
200/6
D64,D79
130/4
D64,D79 D63,D80,D81
150/4
185/4
-
D63,D64,D79,D80,D81
210/4
250/4
185/2
200/2
300/2
D64,D79
D62 = 230 V 3~, DOL D68 = 380 V 3~, Yǻ D81 = 220 V 3~, Yǻ W60 = 230 V 1~
D63 = 220 V 3~, DOL D77 = 460 V 3~, DOL D85 = 600 V 3~, DOL W62 = 208 V 1~
D64 = 380 V 3~, Yǻ D79 = 380 V 3~, Yǻ D86 = 460 V 3~, DOL
D66 = 208 V 3~, DOL D80 = 220 V 3~, DOL
60 Hz
12 3 4 5
20/6
22/4
28/4
35/4
D63,D68,
D79,D80
-
-
D66,D62,D77,D85
-
45/2
D63,D79,
D80
D64,D81 D66,D62,D77,D85,D86
18/4W
28/4W
20/6W*
-- -
W60,
W62
35/6
45/4
56/4
75/4
90/4
105/4
80/2
125/2
D63,D79,
D80
D64,D81 - D66,D62,D77,D85,D86 -
120/8
90/6
110/6
130/6
-
D64,D79 D63,D80,D81 D66,D62,D77,D85,D86
-
160/6
-
D63,D64,D79,D80,D81
D66,D62,D77,D85,D86
200/6
D64,D79
130/4
D64,D79 D63,D80,D81
150/4
185/4
-
D63,D64,D79,D80,D81
210/4
250/4
185/2
200/2
300/2
D64,D79
D62 = 230 V 3~, DOL D68 = 380 V 3~, Yǻ D81 = 220 V 3~, Yǻ W60 = 230 V 1~
D63 = 220 V 3~, DOL D77 = 460 V 3~, DOL D85 = 600 V 3~, DOL W62 = 208 V 1~
D64 = 380 V 3~, Yǻ D79 = 380 V 3~, Yǻ D86 = 460 V 3~, DOL
D66 = 208 V 3~, DOL D80 = 220 V 3~, DOL
Page 12
12
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
8 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?
- Does the pump sit correctly on the pedestal?
- Is the direction of rotation of the pump correct - even if run via an emergency
generator?
- Are the switching ON and switching OFF levels set correctly?
- Are the level control switches functioning correctly?
- Are the required gate valves (where fi tted) open?
- Do the non-return valves (where fi tted) function easily?
8.1 Types of operation and frequency of starting
All pumps of the XFP series have been designed for continuous operation S1 when either submerged or dryinstalled.
8.2 Checking direction of rotation
When three phase units are being commissioned for the fi rst time, and also when used on a new site, the
direction of rotation must be carefully checked by a qualifi 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 fl ow. Do not place your hand into
the hydraulic system!
When checking the direction of rotation, or when starting the unit, pay attention to the
START
REACTION
. This can be very powerful and cause the pump to jerk in the opposite direction to the
direction of rotation.
ATTENTION:
When viewed from above, the
direction of rotation is correct
if the impeller rotates in a
clockwise manner.
NOTE:
The start reaction is
anti-clockwise.
ATTENTION! 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.
Page 13
13Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
8.3 Changing direction of rotation
The direction of rotation should only be altered by a qualifi 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.
9 Maintenance
Before commencing any maintenance work the pump should be completely disconnected from the mains
by a qualifi 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.
Under continuous running conditions the pump motor housing can become very hot. To prevent burn
injury allow to cool down before handling.
ATTENTION! The maintenance instructions given here are not designed for “do-it-yourself” repairs as
special technical knowledge is required.
9.1 General maintenance instructions
ABS submersible pumps are reliable quality products, each being subjected to careful fi 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. However, should a
malfunction occur, do not improvise, but ask your ABS Customer Service Department for assistance.
This applies particularly if the pump is continually switched off 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. Service intervals vary for XFP
pumps depending on installation and application. For recommended service interval details contact your local
ABS Service Centre. A maintenance contract with our Service Department will guarantee the best technical
service.
When carrying out repairs, only original spare parts supplied by the manufacturer should be used.
ABS warranty conditions are only valid provided that any repair work has been carried out in an ABS approved
workshop and where original ABS spare parts have been used.
NOTE: XFP pumps are rated for use in hazardous locations (Ex) as standard and feature a
secondary Ex nameplate containing EX data. If an XFP pump is serviced or repaired
in a workshop that is not Ex approved then it must no longer be used in hazardous
locations and the Ex nameplate must be removed.
9.2 Maintenance of Lifting Stations in accordance with EN 12056.
It is recommended that a lifting station is inspected monthly and its function checked.
In accordance with EN regulations, the lifting station should be maintained by a qualifi ed person at the following
intervals:
in commercial premises - every three months.
in apartment blocks - every six months.
in a single family home - once a year.
In addition we recommend that a maintenance contract be taken out with a qualifi ed company.
•
•
•
Page 14
14
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
9.3 Lubricant changing (PE1 & PE2)
The seal chamber between the motor and the hydraulic section has been fi lled with oil at manufacture.
An oil change is only necessary:
At specifi ed service intervals (for details contact your local ABS Service Centre).
If the DI moisture sensor detects an ingress of water into the seal chamber or motor chamber.
After repair work that requires draining of the oil.
If the pump is being taken out of service the oil should be changed before storage.
9.3.1 Instructions on how to drain and fi ll the seal chamber
Loosen the drain plug screw (a) enough to release any pressure that may have built-up, and re-tighten.
Before doing so, place a cloth over the plug screw to
contain any possible spray of oil as the pump de-pressurises.
Place the pump in a horizontal position, sitting on its discharge fl ange,
with the motor housing supported from underneath.
To prevent the pump from toppling over ensure it is supported
to lie fl at on its discharge fl ange.
Position an adequate container to receive the waste oil.
Remove the plug screw and seal ring (a) from the drain hole.
After the oil is fully drained lay the pump fl at, and rotate so that
the drain hole is positioned to the top.
When in this position the pump must be held by hand,
or supported at both sides, to prevent it from toppling over.
Select the required volume of oil from the quantities table (p.17) and
slowly pour into the drain hole.
Refi t the plug screw and seal ring.
(a) Drain plug screw
DRAIN FILL
•
•
•
•
1.
2.
3.
4.
5.
6.
7.
(a)(a)
Page 15
15Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
9.4 Lubricant changing (PE3 - version without cooling jacket)
The seal chamber between the motor and the hydraulic section has been fi lled with glycol at manufacture. The
water and propylene glycol is frost resisting down to -15 °C / 5 °F.
A glycol change is only necessary:
At specifi ed service intervals (for details contact your local ABS Service Centre).
If the DI moisture sensor detects an ingress of water into the seal chamber or dry chamber.
After repair work that requires draining of the glycol.
If the pump is being taken out of service the glycol should be changed before storage.
In the 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.
9.4.1 Instructions on how to drain and fi ll the seal chamber
Loosen the drain plug screw (a) enough to release any pressure that may have built-up, and re-tighten.
Before doing so, place a cloth over the plug screw to contain
any possible spray of glycol as the pump de-pressurises.
Secure a hoist to the lifting hoop. Lay the pump on its side and
rotate until the drain plug is underneath.
Note: because there is insuffi cient space to place a waste
container underneath the drain plug the waste must be drained
into a sump.
Remove the plug screw and seal ring (a) from the drain hole.
After the glycol is fully drained, place the pump in a horizontal
position sitting on its discharge fl ange with the motor housing
supported from underneath.
To prevent the pump from toppling over ensure it is
supported to lie fl at on its discharge fl ange.
Select the required volume of glycol from the quantities table (p.17)
(a) Drain plug screw
and slowly pour into the drain hole.
Refi t the plug screw and seal ring.
DRAIN FILL
•
•
•
•
•
1.
2.
3.
4.
5.
6.
(a)(a)
Page 16
16
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
9.5 Coolant changing (PE3 - version with cooling jacket)
The cooling system (seal chamber and cooling jacket) has been fi lled with glycol at manufacture. The water and
propylene glycol is frost resisting down to -15 °C / 5 °F.
A glycol change is only necessary:
At specifi ed service intervals (for details contact your local ABS Service Centre).
If the DI moisture sensor detects an ingress of water into the seal chamber or dry chamber.
After repair work that requires draining of the glycol.
If the pump is being taken out of service the glycol should be changed before storage.
In the 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.
9.5.1 Instructions on how to drain and fi ll the cooling system
Loosen the plug screw (a) or (b), enough to release any pressure that
may have built-up, and re-tighten.
Before doing so, place a cloth over the plug screw to contain any
possible spray of glycol as the pump de-pressurises.
Secure a hoist to the lifting hoop. Tilt the pump to 45° with the drain
plug underneath.
Note: because there is insuffi cient space to place a waste container
underneath the drain plug by the completion of step 5, the waste
must be drained into a sump.
Remove the plug screw and seal ring (a) from the drain hole.
Glycol will drain from the cooling jacket chamber.
When the fl ow stops, continue to gradually tilt the pump until
horizontal. This will drain the remaining glycol from the seal
chamber.
Note: draining the glycol entirely with the pump in a horizontal
position would result in some glycol being retained in the cooling
jacket.
After the glycol is fully drained raise the pump into its upright position
and refi t the plug screw and seal ring (a).
Remove the plug screw and seal ring (b) from the fi ll hole.
Select the required volume of glycol from the quantities table and
slowly pour into the fi ll hole.
(a) Drain (b) Fill
Refi t the plug screw and seal ring (b).
DRAIN FILL
•
•
•
•
•
1.
2.
3.
4.
5.
6.
7.
8.
9.
(a)
(b)
(a)
(b)
2.5.2.
5.
Page 17
17Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
9.6 Oil and glycol quantities (litres)
XFP
Motor
Lubricant
(without cooling jacket)
Coolant
(with cooling jacket)
50Hz 60Hz Oil
Water and
propylene glycol
Water and
propylene glycol
PE 1
PE30/2
PE40/2
PE15/4
PE22/4
PE29/4
PE13/6
PE45/2
PE22/4
PE28/4
PE35/4
PE18/4W
PE28/4W
PE20/6
PE20/6W
0.43
--
PE 2
PE55/2
PE70/2
PE110/2
PE40/4
PE49/4
PE60/4
PE90/4
PE30/6
PE80/2
PE125/2
PE45/4
PE56/4
PE75/4
PE90/4
PE105/4
PE35/6
0.68
--
PE3
PE150/2
PE185/2
PE250/2
PE110/4
PE140/4
PE160/4
PE185/4
PE90/6
PE110/6
PE140/6
PE185/2
PE200/2
PE300/2
PE130/4
PE150/4
PE185/4
PE210/4
PE90/6
PE110/6
PE130/6
PE160/6
PE120/8
- 8.0
16.5
PE220/4 PE250/4
PE200/6
18.0
Volume ratio: 86% oil or water/propylene glycol : 14% air
Specifi cation:
Lubricant: white mineral oil VG8 FP153C or 70% water/30% glycol
Coolant: 70% water/30% glycol
Page 18
18
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
9.7 Bottom plate adjustment
At manufacture, the bottom plate is fi tted to the volute with the correct clearance gap set between the impeller
and the bottom plate (for optimum performance max 0.2 mm).
9.7.1 Instructions on how to adjust the bottom plate
To reset the clearance gap following wear:
(Note: when adjusting PE3 pumps, steps 1, 2 and 3 do not apply)
Check the position of the alignment notch (e) in the fi xing lug to determine if the bottom plate is in the factory pre-set position or if the clearance gap has been previously adjusted. If previously adjusted proceed to
Step 4.
Remo ve t he th re e s cr ews (c) s ecu ri ng th e bot to m pla te to th e vo lut e.
Attention: if, due to corrosion, the bottom plate does not release freely from the volute, DO NOT force it
free by tightening the adjusting grub screws (d) against the fi xing lugs on the volute as this could damage
the lugs on the bottom plate beyond repair! In that case, fi rst remove the volute from the motor housing by
releasing the three securing screws (f) and then remove the bottom plate by tapping it free from inside the
volute using a mallet and block of wood.
Rotate the bottom plate anti-clockwise through 45° from the pre-set position (a) to the secondary alignment
position (b) and refi t the securing screws.
Loosen the adjusting grub screws (d) and tighten the securing screws in the bottom plate evenly until the
impeller will lightly, but freely, rub against the bottom plate when rotated by hand.
Tighten the grub screws fully to secure the bottom plate in position (max. 33 Nm).
Factory pre-set position
Fixing lugs
Adjustment position
1.
2.
3.
4.
5.
(c)
(d)
(b)
(a)
(e)
(c)
(d)
(b)
(a)
(e)
(e)
(e)
(e)
(e)
(f)(f)
Page 19
19Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
9.8 Bearings and Mechanical Seals
XFP pumps are fi tted with lubricated-for-life ball bearings. Shaft sealing is by means of double mechanical
seals.
ATTENTION! Once removed, bearings and seals must not be re-used, and must be replaced in
an approved workshop with genuine ABS spare parts.
9.9 Changing the power cable (PE1 & PE2)
To facilitate quick and easy changing or repair of the power cable, the connection between the cable and motor
is by means of an integrated 10-pole terminal block.
To be carried out only by a qualifi ed person, in strict adherence to relevant safety regulations.
9.10 Cleaning
If the pump is used for transportable applications, then in order to avoid deposits of dirt and encrustation it
should be cleaned after each usage by pumping clear water. In the case of fi xed installation, we recommend
that the functioning of the automatic level control system be checked regularly. By switching the selection switch
(switch setting “HAND”) the sump will be emptied. If deposits of dirt are visible on the fl oats then these should
be cleaned. After cleaning, the pump should be rinsed out with clear water and a number of automatic pumping
cycles carried out.
9.11 Venting of the volute
After lowering the pump into a sump full of water, an air lock may occur in the volute and cause pumping
problems. To clear the air lock, raise the pump in the medium and then lower it again. If necessary, repeat this
venting procedure.
We strongly recommend that dry-installed XFP pumps are vented back into the sump by means of the (drilled
and tapped) hole provided in the volute.
Page 20
20
Installation, Operating and Maintenance Instructions (Original Instructions)
ABS submersible sewage pump XFP 80C - 201G
10 Troubleshooting Guide
Fault Cause Fix
Pump does not
run
Moisture sensor shutdown. Check for loose or damaged oil plug, or locate and
replace faulty mechanical seal / damaged o-rings.
Change oil.
1)
Level control override. Check for fl oat switch that is faulty or tangled and
held in OFF position in sump.
Impeller jammed. Inspect and remove jammed object. Check gap
between impeller and bottom plate and adjust if
necessary.
Gate valve closed, non-return valve
blocked.
Open gate valve, clean blockage from non-return
valve.
Pump switching on/off
intermittently
Temperature sensor shutdown. Motor will restart automatically when pump cools
down.
Check thermal relay settings in control panel.
Check for impeller blockage.
If none of above, a service inspection is required.
1)
Low head or fl ow Wrong direction of rotation. Change rotation by interchanging two phases of
the power supply cable.
Gap too wide between impeller and
bottom plate
Reduce gap (see page 13).
Gate valve partially open. Open valve fully.
Excessive noise or
vibration
Defective bearing. Replace bearing.
1)
Clogged impeller. Remove and clean hydraulics.
Wrong direction of rotation. Change rotation by interchanging two phases of
the power supply cable.
High voltage Water inside motor. Replace stator.
1)
test failure
Stator insulation damaged. Replace stator.
1)
Power cable or lead damaged. Replace power cable.
1)
Ohms test
failure
Stator failure. Repair/replace stator.
1)
Before commencing any inspection or repair work the pump should be completely disconnected from the
mains by a qualifi ed person and care should be taken that it cannot be inadvertently switched back on.
1)
Pump must be taken to approved workshop.
Page 21
21
EC Declaration of Conformity
Manufacturer: Cardo Production Wexford Ltd
Address: Clonard Road, Wexford, Ireland
Name and address of the person authorised to compile the technical fi le to the authorities on request:
Frank Ennenbach,
Director Product Safety and Regulations,
Cardo Flow Solutions,
Roskildevägen 1,
Box 210,
S-210 22 Malmö,
Sweden.
Declare under our sole responsibility that the products: ABS submersible sewage pump XFP 80C - 201G
To which this declaration relates are in conformity with the following standards or other normative documents:
As defi ned by Machinery Directive 2006/42/EC, EMC-Directive 2004/108/EC, Low Voltage Directive 2006/95/EC,
ATEX 94/9/EC, Construction Products 89/106/EC
II 2G k Ex d IIB T4
DIN EN 12050-1, EN 60335, EN 60079-0:2006, EN 60079-1:2007, EN 13463-1:2009, EN 13463-8:2003, EN ISO 12100-1,
EN 809/A1, EN 60034, EN 61000-6, EN ISO 12100-2
15-09-2010
Sean Roche
Cardo Production Wexford Ltd.
Page 22
SERVICE LOG
Pump Type: Serial No:
Date Hours of
Operation
Comments Sign
Page 23
SERVICE LOG
Date Hours of
Operation
Comments Sign
Page 24
Cardo Production Wexford Ltd. Clonard Road, Wexford, Ireland
Tel. +353 53 91 63 200 Fax +353 53 91 42335. www.absgroup.com
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