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Installation and Operating Instructions

1. cccccccecccceeceeececeeeeeeeeesusaeaeaessaeseeeeaeeseeeeeeess 21 Installation examples umnie ne na kun ed 21 Wet installation of the AFP submersible pump unnnnnnnnnnnnnnnnnannnnnnnnnnnenenenennnennnnnnnnnnnnnnnnnnn 24 Installation of the AFP submersible pump in a dry SUMP 222422222244nnnnnnnneenennnnnnnnnnnnnne nn anennrn nen 25 Fitting the pedestales naaa a an aa A rer neh ee nee ir 25 Pedestal for DN 100 to 200 light version inserting the seal 22444usssnnnnnnnnnnnnnnennennnnnnnne nenn 25 4 Installation and Operating Instructions Sal AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 5 3 2 HD pedestal fitting of O ring and guide piece uur4224444Hnnnsnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnernnnnnnnn nenn 26 5 4 Installation of the AFL and VUP submersible PUMPS cccceceeeeeeeeeeeeceeaeceeeeeeeeeeeeteseecsacaeeaeeeeeees 27 5 4 1 Types of installation of the AFL and VUP submersible DUMDS e cccceceeeeeeeeeeeeeteaeeeeeeeeeeeteteees 27 5 4 2 Installations examples with AFL and VUP submersible pumps rsssssssssnnnnnnnnnnnenennennnnn en 28 5 4 3 Installation of the AFL and VUP submersible PUMPS ccccecceceeeeeeeeeceeaecaeeeeeeeeeeeeeseecsncaeeaeeeeeees 29 5 4 4 Lowering of the AFL and VUP submersible pump into the coupling ring 2 00 ee eeeeeeeeeteeeeeeeenteeeeeeeaes 29 5 9 Electrical Connection u ae ine a
2. CJ J Figure 6 Transport in a horizontal manner AFL VUP ATTENTION a max lt 45 The angle a between the centre line of the unit and the lifting tools should not exceed 45 0562 0005 0562 0007 0563 B 12 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs AN The safety hints in the previous sections must be observed Submersible pumps are only transported in a horizontal position ifthey have been built for horizontal installation The submersible pump can be placed on the mounting frame fitted on the pump and transported ATTENTION Avoid point loading If necessary place the pump on a secure robust pallet and tie down using steel bands or other fixing methods Only lift up the submersible pump if it is suspended horizontally on the crane hooks If necessary adjust the chain accordingly 3 2 Transport securing devices 3 2 1 Motor connection cable moisture protection The motor connection cables are protected against the ingress of moisture along the cable by having the ends sealed at the works with protective covers ATTENTION These protective covers should only be removed immediately prior to connecting the pumps electrically Particular attention is necessary during storage or installation of pumps in locations which could fill with water prior to laying and connection of the power cable of the AFP motor Please note that the cable ends even where fitted with
3. A B Version with cooling jacket Version without cooling jacket ar N Legend 0562 0040 1 Cooling liquid filling 2 Cooling liquid emptying Initial filling ex works Glycol Frostox WS Partnr 11030083 TYFOROP Chemie Gmbh Alternative coolant released by ABS 1 Propylenglycol Code 27 Houghton Deutschland GmbH DOWCAL 20 G HEAT TRANSFER FLUID Dow Deutschland GmbH amp Co OHG DOWCAL brand of The Dow Chemical Company lt 1 7 gt 2 Bild 37 Cooling liquid filling and emptying Data is only valid for coolant used ex works Additional product information and safety data sheet are available on request When dealing with Frostox WS the general protective measures for chemicals must be observed The A information and hints in the safety data sheets covering this must be observed AFP ME 1077 1575 1576 AFP ME 1001 1002 1036 VUP ME4 0401 2 3 AFL ME4 Motor ME4 2073 2571 3071 3501 1501 2001 3003 0501 2 3 0604 2 0701 375mm 375mm 50 Hz 60 Hz A B A B ME 220 4 41 ME 250 4 41 60 34 0 8 0 38 3 12 3 ME 300 4 42 ME 350 4 42 60 34 0 8 0 38 3 12 3 ME 370 4 43 ME 430 4 43 60 28 5 8 0 32 8 12 3 ME 450 4 44 ME 520 4 44 60 28 5 8 0 32 8 12 3 ME 540 4 44 ME 650 4 44 60 ME 185 6 41 ME 210 6 41 60 34 0 8 0 38 3 12 3 ME 220 6 42 ME 250 6 42 60 28 5 8 0 32 8 12 3 ME 300 6 43 ME 350 6 43 60 28 5 8 0 32 8 12 3 ME 370 6 44 ME 430 6 44 60 28 5 8 0 32
4. L g Pump 3 6124007 6124008 ee ee S oO Figure 36 Electronic amplifier with collective signalling Electronic amplifier for 50 Hz 0562 0039 Electronic amplifier for 60 Hz 110 V Art Nr Part No 6 124 0113 115 V Art Nr Part No 6 124 0170 230 V Art Nr Part No 6 124 0114 230 V Art Nr Part No 6 124 0171 400 V Art Nr Part No 6 124 0115 460 V Art Nr Part No 6 124 0172 440 V Art Nr Part No 6 124 0116 575 V Art Nr Part No 6 124 0173 ATTENTION Maximum relay contact loading 2 Ampere 0563 B Installation and Operating Instructions 35 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 6 Commissioning N The safety hints in the previous sections must be observed Before commissioning the pump pump station should be checked and a functional test carried out Particular attention should be paid to the following In explosive zones care must be taken that during switching on and operation of the pumps the pump section is filled 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 e Have the electrical connections been carried out in accordance with regulations Have the thermal sensors been connected
5. e Is the seal monitoring device where fitted correctly installed e Is the motor overload switch correctly set Have the power and control circuit cables been correctly fitted e Was the sump cleaned out e Have the inflow and outflows of the pump station been cleaned and checked e Is the direction of rotation of the pump correct even if run via an emergency generator Are the level controls functioning correctly Are the required gates valves where fitted open AFP e Do the non return valves where fitted function easily e Have the hydraulics been vented in the case of dry installed pumps AFL VUP Have the steel riser pipe or concrete sump be cleaned thoroughly builder s rubble etc e Are any paint remnants are removed from the conical surfaces on the pumps or on the coupling ring Are these conical surfaces be greased 6 1 Starting frequency of the motors The allowable starting frequency per hour can be read from the table below where not otherwise specified from the works Motor power maximum starts per hour at interval in minutes 15 160 kW 15 4 gt 160 kW 10 6 ATTENTION The allowable starting frequency for any starting devices should be obtained from manufacturer of these devices 0563 B 36 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs Maintenance The safety hints in the previous sections must be observed Before commencing an
6. 2 4 0562 0034 ABS Germany V1 U2 0563 B 32 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 5 5 3 Checking direction of rotation N The safety hints in the previous sections must be observed When three phase units are being commissioned for the first time and also when used on a new site the direction of rotation must be carefully checked by a qualified person When checking the direction of rotation the submersible pump should be secured in such a manner A that no danger to personnel is caused by the rotating impeller or by the resulting air flow Do not place your hand into the hydraulic system A The direction of rotation should only be altered by a qualified person When carrying out the direction of rotation check as well as when starting the unit pay attention to the A START REACTION This can be very powerful 0562 0035 ATTENTION The direction of rotation is correct if the imeller propeller rotates in a clockwise manner when viewing down from the top of the placed unit The start reaction is anti clockwise RT REAc ar Oy amp O Ps ATTENTION a D 9 N Figure 32 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
7. 30 lt 25 lt 6 VUP 0500 lt 40 VUP 0600 lt 50 VUP 0800 lt 60 VUP 1000 lt 80 VUP 1200 lt 80 If larger bar spacings are required please contact ABS ATTENTION When setting the switching off level the minimum cover as given in the installation documents must be adhered to 0563 B 28 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 5 4 2 Installations examples with AFL and VUP submersible pumps 5_ _ Ai IA H Figure 27 VUP AFL in a steel discharge pipe Legend AON B Tank cover Discharge pipe riser pipe Concrete sump AFL VUP submersible pump 0562 0028 CONDO 0562 0029 4 ll gt a Figure 28 VUP AFL in a concrete sump Coupling ring Minimum water level see installation drawings Connection cable Cable support for fixing the power cable 0563 B Installation and Operating Instructions 29 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 5 4 3 Installation of the AFL and VUP submersible pumps N The safety hints in the previous sections must be observed ATTENTION The power cables should be handl
8. 66 0 16 0 72 0 22 0 ME 300 10 51 ME 350 10 51 60 66 0 16 0 72 0 22 0 6 6 ME 370 10 52 ME 430 10 52 60 66 0 16 0 72 0 22 0 6 6 ME 450 10 53 ME 520 10 53 60 66 0 16 0 72 0 22 0 6 6 A Version with cooling jacket B Version without cooling jacket only version B Filling volumes in Litres Coolant 33 Glycol und 67 Water Frost resistant up to 20 C 4 F AFP ME 2002 AFP ME 4004 AFP ME 5001 AFP ME 6003 2501 2503 3001 Motor ME6 3002 3502 4001 475 mm 530 mm 670 mm 850 mm 50 Hz 60 Hz A B A B A B A B ME 1320 4 61 ME 1500 4 61 60 95 3 ME 1600 4 62 ME 1850 4 62 60 95 3 ME 2000 4 63 ME 2200 4 63 60 95 3 ME 2500 4 44 ME 2800 4 64 60 108 3 ME 1100 6 61 ME 1250 6 61 60 95 3 ME 1320 6 62 ME 1500 6 62 60 95 3 ME 1600 6 63 ME 1850 6 63 60 108 3 ME 2000 6 64 ME 2200 6 64 60 ME 900 8 61 ME 1040 8 61 60 ME 1100 8 62 ME 1250 8 62 60 ME 1320 8 63 ME 1500 8 63 60 ME 1600 8 64 ME 1850 8 64 60 ME 750 10 61 ME 860 10 61 60 ME 900 10 62 ME 1040 10 62 60 ME 1100 10 63 ME 1250 10 63 60 ME 1320 10 64 ME 1500 10 64 60 ME 750 12 61 ME 860 12 61 60 ME 900 12 62 ME 1040 12 62 60 A Version with cooling jacket B Version without cooling jacket Filling volumes in Litres Coolant 33 Glycol und 67 Water F
9. a hoist to the submersible pump e The ABS submersible pump is suspended on the guide tube by means of the pedestal bracket on the pressure connection and carefully lowered vertically or at a slight inclination max 3 It couples automatically at the pedestal and seals the pressure connection at the pedestal leak tight by means of its own weight and a seal e Make electrical connection as described in section 5 5 1o gt 0562 0023 0562 0024 Figure 22 Retaining bracket assembly HD pedestal assembled at the factory lt u 0562 0025 Figure 23 Lowering the submersible pump Figure 24 Retaining bracket assembly pedestal ME4 ATTENTION The lifting hoop is assembled at the factory only ME4 for the version A with the HD pedestal See Figure 22 and Figure 23 If the pedestal is used in the light version B see Figure 24 and Figure 25 the lifting hoop must be rotated as shown in Figure 24 by 180 Tightening torque of the screws 267 Nm 0563 B u Installation and Operating Instructions 25 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 5 2 2 Installation of the AFP submersible pump in a dry sump N The safety hints in the previous sections must be observed e Fit a hoist to the submersible pump e With the aid of the hoist pl
10. installed e Close off the gate valves on the inlet and discharge sides Empty the volute and if necessary the discharge line e If fitted dismantle the venting line above the discharge e Install lifting gear see 3 1 on the submersible pump e Disconnect the suction inlet by opening the bolts on the bottom plate of the hydraulics e Dismantle the discharge line by opening the bolts on the discharge flange of the volute If necessary remove the fastening bolts at the ground support ring and carefully lift off the pump with the hoist e Place the pump on an even firm flat surface 7 4 3 e If present the discharge pipe cover should be removed and the water pressure tight cable inlet opened Removal of the AFL and VUP submersible pump e Raise the submersible pump out of the concrete sump or the steel discharge pipe with the hoist While doing this the connection cables should be drawn out as the pump itself is being raised e Place the submersible pump with propeller housing vertically on a solid surface taking care that it cannot tip over 0563 B 40 Installation and Operating Instructions on AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 8 Assembling the gearbox AFL VUP 8 1 Assembling the motor and the gearbox hydraulic unit N The safety hints in the previous sections must be observed Pay close attention to the assembly instructions and work in the indicated sequence in order to guarantee that both main
11. motor shaft should only be removed immediately prior to installation or connecting up to the pump 0562 0011 il X amp g FL 1 TTT 1 Figure 10 Removal of the transport devices on VUP and AFL pumps e Remove the transport securing device 10 1 0563 B Installation and Operating Instructions 15 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 3 3 Storage of the units ATTENTION NOTE The ABS products must be protected from weather influences such as UV from direct sunlight high humidity aggressive dust emissions mechanical damage frost etc The ABS original packaging with the relevant transport securing devices where used ensures optimum protection of the unit If the units are exposed to temperatures under 0 C 32 F check that there is no water in the hydraulics cooling system or other spaces In the case of heavy frosts the units and cable should not be moved if possible When storing under extreme conditions e g in tropical or desert conditions suitable additional protective steps should be taken We would be glad to advise you further ABS units do not generally require any particular maintenance d
12. parts 38 1 and 38 2 are perfectly assembled First check that all required additional parts as well as LOCTITE type 243 and suitable hoisting devices are available 0562 0041 Figure 38 Assembling the motor and the gearbox hydraulic unit Legend 1 Motor with transport securing device 7 Swivel connection 2 Gearbox hydraulic unit with transportation lock 8 Hex screws 3 O ring for motor gearbox assembly 9 Fixing screws 4 3x stud with nuts and spring washers 11 LOCTITE type 243 6 Transport securing device 0563 B Installation and Operating Instructions 41 en abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 8 2 Remove transport securing device Connect a suitable hoist of adequate capacity to the lifting hoop 39 1 of the motor and hoist it e Loosen the hex screw 39 2 in the center shaft lock Loosen the hex screw 39 3 at the motor flange Remove the transportation securing device 39 6 Store the motor 39 7 on a suitable support 39 8 e g two thick planks of hardwood in such a way that the motor shaft is not damaged N For safety reasons the hoist must always remain connected during all assembly steps 0562 0042 Figure 39 Remove transport securing device 0563 B 42 Installation and Operating Instructions See AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 8 3 Remove transport securing device of the gearbox ATTENTION When removing the tr
13. protective sleeves cannot be immersed in water ATTENTION These protective covers only provide protection against water spray or similar and are not a water tight seal The ends of the cables should not be immersed in water otherwise moisture could enter the connection chamber of the motor NOTE If there is a possibility of water ingress then the cables should be secured so that the ends are above the maximum possible flood level ATTENTION Take care not to damage the cable or its insulation when doing this 3 2 2 Transport securing device for AFP submersible pump shafts NOTE Does not apply to all models In order to avoid damage to the pump shaft or the bearings during horizontal transport the shaft is clamped in an axial direction when leaving the works ATTENTION The transport securing device on the pump shaft should only be removed immediately before installation or connecting up the pump 0563 B Installation and Operating Instructions 13 AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Bl 0562 0008 LOCTITE 243 Figure 7 Removal of the transport securing devices AFP without holes on the suction side Before commissioning remove securing device 7 1 6 Fit impeller washer with securing pin 7 7 and impeller screw 7 9 complete with lock washers 7 8 ATTENTION Hold the impeller washer 7 7 in position when unscrewing the threaded rod 7 2 The impeller screws of the M4 motors are in addition secured
14. with LOCTITE Type 243 LOCTITE will be supplied if required Insert the impeller washer 7 7 so that the securing pin of the washer fits into the drilled hole of the shaft Fasten the socket head screw 7 9 together with the lock washers 7 8 ATTENTION Ensure that the fitting position and tightening torque of the Nord Lock securing washers is correct as in Figure 8 and table for tightening torque u 0562 0009 Outer side of the 2 securing washers Inner side of the 2 securing washers Figure 8 Correct fitting position of the Nord Lock securing washers Tightening torque for ABS stainless steel screws A4 70 Thread me ms mo mz me M20 m24 0563 B 14 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 0562 0010 4 2 3 4 Figure 9 Removal of the transport securing devices AFP with holes on suction side Before commissioning remove the transport securing devices 9 1 ATTENTION After fitting of the impeller washer check that the impeller can be turned by hand 3 2 3 Transport securing device for submersible pump shafts AFL VUP NOTE Does not apply to all models In order to avoid damage to the pump shaft or bearings during horizontal transport the shaft is clamped in an axial direction when leaving the works N The safety hints in the previous sections must be observed ATTENTION The transport securing device on the
15. 1 3 1 1 3 1 2 3 2 3 2 1 3 2 2 3 2 3 3 3 4 1 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 3 5 1 5 1 1 5 2 5 2 1 5 2 2 5 3 5 3 1 LOJ 1111 Al sicciccccsccccccstecsccecsccaseccees edcececes casescees seasaceoes sadcecees soa seceees sas cacseessecaaetonsceceassen va ssaaeeesseteactesseesaanses eases 6 Introduetiona ae anemae 6 Comect usage Of the Products u A a0 222 0400ER a ag nn Haaren energie 6 Application restrictions of the submersible pumps cecceceeeeeeeeeeeeeeeaecaeceeeeeeeeeeeseecsncaeeaeeeeeeeeeees 6 Application areas for the submersible PUMPS ccccseesceeseceecececececeeeeeeeeeeeeaeseseaesesseesaeeeeseseeeeeeeseseees T Application areas for the series AFP c ecccccececeeeeeeeeeeneeaeceeeeeeeeeeesecceaaeaeceeeeseeeeseseecenssaceeeeeeeeeeess 7 Application areas for the series AFL uuesessssesnensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnenenenenennnnnnnnnnnnnnnnnnnnnennnnn 7 Application areas for the series VUP uuuusussssssssnnennnnnnnnennnnnnnnnnnnnnennnnnnnnennnnnnnnn nenne nnnnnnannnnrnnrnn nenn 8 Identification Coding u a ae ee 8 Technical data man einen 9 Dimensions and weights c cecccceceeeeeeeeeeeeceeaaeaeeeeeeeeeeeeeceeeaaeaaeaeeeeeeeeeeeseceaeaaeaaeeeeeeeeeeeeeseeseesieaeees 9 Namepl teranucn O E E ANNEE AT EEES EO EN SEEE 9 EEE 17 E A E E A SE N E A S AN E E E T A 10 Transportand Strago SRERRPREEPRAPPEFERPEFFBEFRREREESTPEELPOFHEREFEEPEFPE
16. 1 597 0563 GB 08 2007 We know how water works ABS submersible sewage pumps AFP ME4 to ME6 and AFP ME SX ABS submersible mixed flow column pumps AFL ME4 to ME6 ABS submersible propeller pumps VUP ME4 to ME6 Installation and Operating Instructions www absgroup com 2 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Installation and Operating Instructions For submersible pumps AFP Hydraulics AFP 1001 AFP 1501 AFP 2001 AFP 2501 AFP 3001 AFP 1002 AFP 1552 AFP 2002 AFP 2503 AFP 3002 AFP 1036 AFP 1575 AFP 2073 AFP 2571 AFP 3003 AFP 1077 AFP 1576 AFP 3071 AFP SX Hydraulics AFP 1001 SX AFP 1501 SX AFP 2001 SX AFP 2501 SX AFP 1002 SX AFP 1575 SX AFP 2002 SX AFP 2503 SX AFP 1077 SX AFP 1576 SX AFP 2073 SX AFP 2571 SX AFL Hydraulics AFL 0701 AFL 0801 AFL 0802 AFL 1202 VUP Hydraulics VUP 0401 VUP 0501 VUP 0601 VUP 0801 VUP 0402 VUP 0502 VUP 0602 VUP 0802 VUP 0403 VUP 0503 ABS reserves the right to alter specifications due to technical developments abs AFP 3501 AFP 4001 AFP 5001 AFP 6003 AFP 3502 AFP 4004 AFP 3001 SX AFP 3002 SX AFP 3003 SX AFP 3071 SX AFL 1203 VUP 1001 VUP 1002 AFP 3501 SX AFP 4001 SX AFP 3502 SX AFL 1207 VUP 1201 VUP 1202 0563 B abs Installation and Operating Instructions 3 AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Table of contents 1 1 1 2 1 3 1 4 1 4 1 1 4 2 1 4 3 1 5 1 6 1 7 1 8 3
17. 8 12 3 ME 150 8 41 ME 170 8 41 60 28 5 8 0 32 8 12 3 ME 185 8 42 ME 210 8 42 60 28 5 8 0 32 8 12 3 ME 220 8 43 ME 250 8 43 60 28 5 8 0 32 8 12 3 ME 300 8 44 ME 350 8 44 60 28 5 8 0 32 8 12 3 A Version with cooling jacket B Version without cooling jacket only version B Filling volumes in Litres Coolant 33 Glycol und 67 Water Frost resistant up to 20 C 4 F 0563 B 38 Installation and Operating Instructions RI AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 AFP ME 1001 1002 AFP ME 1552 AFP ME 5001 VUP ME 1036 1077 1501 2002 2501 2503 0501 2 3 1575 1576 2001 3001 3002 3502 0601 2 0801 2 Motor MES 2073 2571 3003 4001 AFL ME 3071 0701 0801 2 375 mm 475 mm 670mm 50 Hz 60 Hz A B A B A B ME 550 4 51 ME 630 4 51 60 43 0 15 0 48 0 16 0 ME 750 4 52 ME 860 4 52 60 55 5 15 0 66 0 16 0 ME 900 4 53 ME 1040 4 53 60 55 5 15 0 66 0 16 0 ME 1100 4 54 ME 1250 4 54 60 55 5 15 0 66 0 16 0 ME 450 6 51 ME 520 6 51 60 43 0 15 0 48 0 16 0 6 6 ME 550 6 52 ME 630 6 52 60 55 5 15 0 66 0 16 0 6 6 ME 750 6 53 ME 860 6 53 60 55 5 15 0 66 0 16 0 72 0 22 0 6 6 ME 900 6 54 ME 1040 6 54 60 55 5 15 0 66 0 16 0 72 0 22 0 6 6 ME 370 8 51 ME 430 8 51 60 66 0 16 0 72 0 22 0 6 6 ME 450 8 52 ME 520 8 52 60 66 0 16 0 72 0 22 0 6 6 ME 550 8 53 ME 630 8 53 60 66 0 16 0 72 0 22 0 6 6 ME 730 8 53 ME 840 8 53 60
18. ELEEEFESBERPLTEFEFFELRLEPEFESLEREPEEFSLFPEEFEFPPLRFTERERFCFEFELERNN 10 Transport aaa ai ee ae a a aaa A aaa aa aa ear Aaa aerie 10 Standing transponira aa naen nennen ar aaan b aeaaaioii aeaaaee EE a aa an a a aE E 11 Transport in a horizontal manner eniinn n e a a E aa Ra 11 Transport securing devices u nee 12 Motor connection cable moisture Protectio sedre onana aa aaa A EAE aaa i 12 Transport securing device for AFP submersible pump shafts eccceceeeeeeeeeeeeeeneecaeeeeeeeeeeeeeetees 12 Transport securing device for submersible pump shafts AFL VUP 222222240440snnanennnnnenneennnne nn 14 Storage Of the UNItS n nee nase ETO EE R 15 Product description 54 44544sun020E aa aaar aa aeaa Eaa a Ban dae aa na BEI na nam nah AR soaneeaangass 16 Structural designen ne een ale 16 Motor m nitoring system u se an han be ne Teenie 17 Temperature monitoring of the Stator 4444444444Hnnnnennnnnnnnnnnnnnnnnnnnennennnnnnnnnnnnnnnnnnnennennrnnr nn 17 DIPBIG CHOC sirrinin EAEEREN EE EEEE ETE E A 17 Temperature monitoring of the bearings Option ME4 ME5 essssseseessessrrssssrrrssrerrrsssrerrrssrrrrrssreeens 18 Temperature indications sesine eilig 19 Operation with frequency inverters sererai a aeaa a Eaa Aaaa n ia A aa aaae Ranai nn 20 ELE el 3 e E E E 21 Installation of the AFP submersible PUMPS neraino a E 21 Installation options for the AFP Submersible DUMPS
19. ace the submersible pump carefully into the prepared mounting frame and fasten Fit the suction and discharge ports to the volute e If required fit the vent line to the volute Open the gate valves on the suction and discharge side 5 3 Fitting the pedestal 5 3 1 Pedestal for DN 100 to 200 light version inserting the seal ATTENTION The seal 25 2 must be inserted into the pedestal bracket 25 3 The larger outer diameter of the seal must point in direction of the discharge flange of the pump 0562 0026 Figure 25 Pedestal light version only ME4 DN 100 150 200 Legend 1 Bracket is fitted to the pump 2 Seal 3 Pedestal 0563 B 26 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 5 3 2 HD pedestal fitting of O ring and guide piece N Care ensure that adhesive does not come into contact with skin or eyes Wear goggle and gloves The groove of the guide piece and O ring must be clean and free of grease The instant adhesive LOCTITE type 406 supplied with the unit is spread evenly on the base of the groove in the bracket 26 1 and the O ring inserted immediately NOTE The hardening time of the adhesive is only about 10 seconds The guide piece 26 3 must be screwed on as shown in the drawing Fasten the guide piece 26 3 with the two M12 screws 26 2 Tighten the screws with a torque of 56 Nm 0562 0027 26 HD Pedestal DN 100 500 Legend 1 Bra
20. an ae herr haha han wien iia ee 30 5 5 1 Standard connection diagrams mains voltage 380 420 V at 50 Hz 460 V at 60 HZ u 30 5 5 2 Lead designations uss 222444eesessnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnrsn nen 31 5 5 3 GHECKING GIFECHLON OF folation zen ee een 32 5 5 4 Changing direction Of rotation 22 eigene 32 5 5 5 Connection fthe control cireultleadsu uenaeenne ee ea ad 33 5 5 6 Connection of the seal monitoring unit to the control panel cece cette eerste eter eteteeeeeetneeeeee 33 6 COMMISSIONING 5 5 sccccciiccsccceccsctecees cnc ccctccseeccteeeeecasdeceascasscceceseescoceeescasuecescasceates ses assaeeyecscaseteecacasaeeeceas 35 6 1 StartingTreguency or the molors aussehen st ovata 35 7 Maintenance oasa ee bee heen se ee lees eevee aden Yet raeg 2 Vest eee eu cteg Neca OR 36 7 1 General maintenance MIMS wciivctistecatubissetodestaydedatvedeiecborudiesee Medesdbicacgest shad otubladec Aebdead chseentebedceeudelachseuued 36 7 2 Maintenance hints if the submersible pump is out of use for a considerable period 36 7 2 1 Before installation ccceceencceeseeecceeeesecceneeeeeencneeensnacnseeeseacnseeeseanseenseeaanseneesecnsseeseecenseeneessneneeeeees 36 7 2 2 After installation an ee aan 36 7 3 Coolant filling Lubrication oil filling only VUP AFL MEB6 uu 222444s444snnnnnnnnnnnnnnennnnnnnnnnnnnnn
21. and motor e g AFP 1001 SX ME 370 4 43 0563 B Installation and Operating Instructions 9 a abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 1 6 Technical data The electrical data is dependent on the operating point for which the unit was designed Please take the technical data from the name plate or from the ABSEL data files The maximum noise level of the units of this series is lt 70 dB A In some types of installation and at certain operating points on the performance curve it is possible that the noise level of 70 dB A or the measured noise level will be exceeded 1 7 Dimensions and weights The dimensions of the unit can be found on the relevant dimensional sheet The hydraulic curves and impeller type can be found on the ABSEL hydraulics curve sheet Please take the technical data and the weight of the units from the nameplate 1 8 Nameplate We recommend that you record the data from the original nameplate Figure 2 so that you can refer to the data at any time 0562 0003 42240223 Oper Temp 2 Amb eet max a LA Weight Made in 9 80 Do not open while energized EPB u gt E Nicht unter Spannung ffnen Figure 2 Nameplate 42240223 Legend 1 Address 16 Speed 1 min rpm 2 Logo approval 17 Nominal delivery head m mm in ft 3 Model designation 18 Service factor only applied to 60 Hz orders e g 1 15 4 Year of manufacture 19 Nema Co
22. ange to 20 30 cm e Push the slightly greased O ring 41 4 over the centring seat of the intermediate flange e Carefully centre the motor over the gearbox and lower it slowly until the studs of the gearbox flange are in the holes of intermediate flange 0520 0022 KR NA Figure 41 Assembly instructions gearbox motor housing ATTENTION Before lowering the motor check the position of the DI or in case of Ex pumps the sealing washer in relation to the hole in the gearbox flange e Now carefully lower the motor until the teeth of the motor shaft lock in the relevant slots of the gearbox shaft NOTE Should the teeth not interlock teeth between teeth then the motor should again be lifted slightly and the incorrect position remedied by rotating the propeller by hand about a few degrees e When the motor shaft is correctly centred or interlocked lower the motor all the way and securely bolt it and the gearbox into position observe the tightening torque NOTE The propeller should be capable of being turned by hand 0563 B We know how water works ABS Production Lohmar GmbH Scheiderh her Stra e 30 38 D 53797 Lohmar Germany I Tel 49 22 46 900 0 Fax 49 22 46 900 200 www absgroup com 0563 B
23. ansport securing device and when assembling the parts ensure that these are absolutely clean Ensure that no contaminants enter the gear box e Remove the transport securing device for pump shafts according to para 3 2 3 NOTE There is a threaded hole in the middle of the cover 40 6 into which an eye bolt can be inserted e Loosen the securing screws 40 8 and screw an eye bolt M12 into the central threaded hole of the transport securing device 40 6 e Connect a suitable hoist to the eye bolt e Loosen the nuts 40 3 of the studs and loosen the swivel connection 40 5 NOTE The 3 locked screws 40 1 not on all versions need not be loosened e Using the hoist carefully lift off the transport securing device 40 6 e Moisten the missing studs 40 7 with LOCTITE type 243 medium strength and screw them in all the way 0520 0021 Figure 40 Remove transport securing device of gearbox 0563 B Installation and Operating Instructions 43 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 8 4 Assembly instructions for gearbox motor housing Use a suitable hoist to position the motor over the gearbox hydraulic part in such a way that the DI probe 41 6 with the counter pole 41 7 or in case of Ex pumps the sealing washer 41 12 is in position aligned with the drilling in the intermediate flange e Lower the motor just so far as to reduce the distance between the gearbox housing and the intermediate fl
24. ature Switching Taking care not to exceed the allowable switching current these can be fitted directly into Temperature the control circuit Figure 15 Curve showing principle of operation of bimetallic temperature limiter 0562 0018 Resistance Application Option Function Temperature dependent resistance no switch curve with stepwise behaviour Switching Cannot be installed direct into the control circuit Evaluation of the signal must be carried out by Temperature suitable electronic equipment gt Figure 16 Curve showing principle of operation of thermistor Resistance 0562 0019 Application Option not for Ex Function Function temperature dependent resistance no switch The linear curve allows continuous measurement and indication of the temperature Switching Cannot be installed direct into the control circuit Evaluation of Temperature the signal must be carried out by suitable electronic equipment Figure 17 Curve showing principle of operation of PT 100 0563 B 20 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 4 3 Operation with frequency inverters The stator design and the insulation grade of the motors from ABS means that they suita
25. ble for usage with fre quency inverters It is however essential that the following conditions are met when the motors are used with frequency inverters The guidelines for EMC electromagnetic compatibility are complied with e Explosion proof motors must be equipped with thermistors PTC temperature sensors e Machines designated as Ex machines may never without exception be operated using a mains frequency that is greater than the maximum of 50 or 60 Hz as indicated on the type plate e Machines that are not designated as Ex machines may only be operated using the mains frequency indicated on the type plate Greater frequencies can be used but only after consulting with and receiving permission from the ABS manufacturing plant e For operation of ex motors on frequency inverters special requirements in relation to the tripping times of the thermo control elements must be observed The lowest frequency must be set so that the minimum fluid velocity of 1 m s is present in the volute The maximum frequency must be set so the rated power of the motor is not exceeded Modern frequency inverters are using higher wave frequencies and a steeper rise on the flanks of the voltage wave This means that motors losses and motor noise is reduced Unfortunately these inverter output signals cause higher voltage spikes in the stator Experience has shown that depending on rated voltage and the length of the cable between the inverter and the mo
26. cket is fitted to the pump 4 O ring 2 Screws 2 off 5 Pedestal 3 Guide piece 0563 B Installation and Operating Instructions 27 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 5 4 Installation of the AFL and VUP submersible pumps A The safety hints in the previous sections must be observed 5 4 1 Types of installation of the AFL and VUP submersible pumps There are two main types of installation possible with the AFL VUP submersible pumps 1 Installation in a steel discharge pipe in accordance with Figure 27 2 Installation in a concrete sump in accordance with Figure 28 The inflow to the sump for AFL pumps must be fitted with a screen The maximum bar spacing depends on the type of hydraulics fitted to the pump and can be obtained from the table below Type of hydraulics Clean water Runoff water river water used water rain water pre screened liquid recirculation Bar spacing in mm Bar width in mm AFL 0700 lt 40 lt 20 AFL 0800 lt 60 lt 30 AFL 1200 lt 100 lt 50 If larger bar spacings are required please contact ABS The inflow to the sump for VUP pumps must be fitted with a screen The maximum bar spacing depends on the type of hydraulics fitted to the pump and can be obtained from the table below Type of hydraulics Clean water Runoff water river water pre screened liquid used water rain water recirculation Bar spacing in mm Bar spacing in mm Bar spacing in mm VUP 0400 lt
27. de Letter only at 60 Hz e g H 5 Item no 20 Insulation class e g F 6 Customer order no 21 Impeller Propeller angle mm 7 Pump no 22 Temperature class only with FM e g T3C 8 Nominal voltage and phase switching 23 Max ambient temperature C F 9 Frequency 24 Max immersion depth m ft 10 Nominal discharge diameter 25 Sound level 11 Free reserve field 26 Ex symbol only with Ex pumps 12 Power uptake kW 27 Ex FM designation 13 Power delivery kW hp 28 Weight without attached parts kg Ibs 14 Nominal flow rate I s m h gpm 29 Country of manufacture 15 Nominal current 30 Direction of rotation of motor shaft NOTE In all communication please state type of the unit item and serial number NOTE Additional country specific nameplates possible ae 10 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 2 Safety The general and specific health and safety hints are described in detail in the separate booklet Safety Hints If anything is not clear or you have any questions as to safety make certain to contact the manufacturer ABS 3 Transport and storage 3 1 Transport A The unit must never be raised by the power cable Depending on model and mode of installation the units are prepared at the factory for vertical or horizontal transportation Depending on the version the units are fitted with a lifting hoop series for vertical installation eyebolt
28. diagram and lead designations the direction of rotation will be correct 5 5 4 Changing direction of rotation A The safety hints in the previous sections must be observed A The direction of rotation should only be altered by a qualified 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 0563 B Installation and Operating Instructions 33 abs 5 5 5 Connection of the control circuit leads N The safety hints in the previous sections must be observed PE X of 1 12 13 Abschalten Switch off Motor berwachung Motor monitoring Fr j Adem Kennzeichnung Steuerkabel Cable core marking control cable PTC Heal 41 TA off Wicklung Winding Lager oben Upper bearing Lager unten 44 Lower bearing Abschalten Switch HTA 43 T II 45 Zh Temperaturmessung Temperat measurement DI Anschlu raum Connection chamber DI Motorraum Motor chamber x DI lraum DI l berwachungsraum DI Oil Separation chamber Oil chamber EH 10K Q H 22 1 10K 2212 AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 42240220 NOTE 5 5 6 Connection of the seal monitorin
29. e and to assist you in solving your pumping problems NOTE The ABS warranty conditions are only valid provided that any repair work has been carried out in ABS approved workshops and where original ABS spare parts have been used 7 2 Maintenance hints if the submersible pump is out of use for a considerable period NOTE If the pumps have remained idle for more than 12 months then we recommend that you ask ABS or an approved distributor for advice 7 2 1 Before installation The covers giving moisture protection of the cables see section 3 2 1 should be only removed immediately before actual installation of the pump After the removal of the transport securing devices and before connecting up the pump electrically the motor shaft should be rotated a number of times by turning the impeller or propeller by hand 7 2 2 After installation If after installation of the submersible pump it remains out of use for prolonged periods for example in storm water holding tanks then we recommend that the pump be run for a maximum of 1 minute every 3 months in order to check both its functioning and availability 0563 B u Installation and Operating Instructions 37 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 p Attention Dry running of Ex units located in areas where an explosion could occur Is not allowed 7 3 Coolant filling Lubrication oil filling only VUP AFL ME6 ATTENTION Only coolants released by the manufacturer should be used
30. ed carefully during installation and removal of the pumps in order to avoid damage to the insulation The coupling ring required for installation of the AFL ME VUP ME submersible pump must already be installed as shown in Figure 27 and 28 Before installation of the pump a suitable support hook for the chain as well as an opening and suspension cable sock for the cable must be provided in the sump or riser pipe NOTE In the case of AFL VUP submersible pumps with gearbox the submersible motor and hydraulics mounted to the gearbox are supplied separately Before or during the installation the motor connection cables should be fitted on site with suitable strain relief e g cable socks Particular care should be taken that the cable insulation is not crushed or damaged by the weight of the hanging cable especially in the area of the cable inlet ATTENTION When raising the submersible pump out of the concrete sump or the steel discharge pipe with the hoist ensure that the connection cables are lifted out simultaneously as the pump itself is being raised 5 4 4 Lowering of the AFL and VUP submersible pump into the coupling ring ATTENTION Before lowering the pump a direction of rotation check should be carried out see section 5 5 3 e Draw the cable hose over the end of the connection cable ATTENTION The steel riser pipe or concrete sump must be cleaned thoroughly builder s rubble etc Before fitting the pump into a sump or into a st
31. eel discharge pipe care should be taken that any paint remnants are completely removed from the conical surfaces on the pumps or on the coupling ring These conical surfaces must then be greased To optimise the inflow and to reduce the noise level it is important that one pair of fins of the suction pipe are in line with the main flow direction of the inflow chamber This must be observed when fitting the pump into a sump or into a steel discharge pipe e Carefully lower the submersible pump with the aid of a hoist into the coupling ring in the sump Take care that the cable is lowered simultaneously and cannot snag e Attach the lifting chain to the hook provided so that it cannot strike either the pump cable or the sump wall e Tension the pump cable and fasten to the hook provided with the aid of the cable sock Where a steel pressure pipe is used the connection cable should be brought through the connection cable inlet and sealed off in a watertight manner The connection cable should only be tightened sufficiently so that no tension acts at the cable inlet in A the head of the pump The connection cable should not strike the chain or the sump wall If necessary the steel riser pipe is sealed off in a watertight manner 0563 B 30 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 5 5 Electrical connection N The safety hints in the previous sections must be observed Before commissioni
32. g unit to the control panel 0562 0036 Control circuit leads for submersible pumps 10 Common lead 11 Stator upper 12 Bearing upper 13 Bearing lower 20 DI connection chamber 21 DI Motor chamber 22 DI Oil chamber PE green yellow Figure 33 Designation of control circuit leads The available connections can be obtained from the relevant connection diagram The submersible pumps are supplied as standard with DI probes for seal monitoring In order to integrate this seal monitoring function into the control panel of the pump it is necessary to fit an ABS DI module and connect this in accordance with the circuit diagrams below ATTENTION If the DI seal monitoring is activated the unit must be immediately taken out of service Please contact your ABS service centre 0563 B 34 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Lene O 1 W N oO A Q O Q a N XT S v N us 5 2 x2 m 2 m L Figure 34 Electronic amplifier with signal lamp MAINS O 3 Dl p PE bO M2 J M1 Electrode 0562 0037 gt Zz n 3 DI p PE M2 Electrode 0562 0038 4 KB ZT T nen hrs Ihe l DR 6124009 es ee Figure 35 Electronic amplifier with floating contact cd Pump 2 er
33. hat specified 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 ABS In the case of any faults arising the ABS units should immediately be taken out of use and secured The fault should be immediately rectified or if necessary contact your ABS service centre 1 3 Application restrictions of the submersible pumps The submersible pumps can be supplied both as standard versions and in explosion proof execution with ATEX II 2Gk EEx dll B T4 for 50 Hz or FM NEC 500 Class I Division 1 Group C amp D T3C approval for 60 Hz Limitations Fluid temperature maximum 40 C 104 F Immersion depth maximum 20 m 65 ft ATTENTION If cable length is less than 20 m 65 ft the max immersion depth reduces accordingly In special cases an immersion depth greater than 20 m 65 ft is possible In order to do this you need the written approval from the manufacturer ABS 0563 B Installation and Operating Instructions 7 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 A Pumping of flammable or explosive liquids with these pumps is not allowed amp Only explosion proof executions may be used in hazardous areas For the operation of units as explosion proof execution the following applies In hazardous areas care must be taken that during switching on and ope
34. ion chamber 21 Contrablock CB bottom plate 5 Cable gland 22 Release screw horizontal dry installation 6 Seal monitoring DI connection chamber option 23 Adjusting screw for bottom plate 7 Temperature monitoring upper bearing option 24 Connection for pressure monitoring venting 8 Filling and venting screw 25 Discharge outlet 9 Cooling jacket 26 Volute 10 Cooling liquid 27 Impeller closed multi channel version 11 Stator 28 Wear ring in the volute 12 Rotor shaft 29 Wear ring on the impeller option 13 Temperature monitoring lower bearing Option 30 Bellmouth 14 Mechanical seal medium side 31 Wear ring not for all versions 15 Seal monitoring DI separation chamber 32 Guide ring 16 Separation chamber 33 Propeller VUP impeller AFL 17 Mechanical seal motor side 34 Adjusting screw for gap between impeller and wall AFL 4 2 Motor monitoring system Motor equipment Motors ME4 ME5 ME6 standard Ex Monitoring Stator Bimetallic Thermistors PTC o o PT 100 o Seal monitor Separation chamber O Motor chamber o e only ME6 o e only ME6 Connection chamber o e only ME6 o e only ME6 o e only ME6 Bearing temperature Upper lower Bimetallic o e only ME6 o e only ME6 o e only ME6 Thermistors PTC O O O PT 100 O O O e Standard o Option not possible 4 2 1 Temperature monitoring of the s
35. mp should be erected on site before the pump itself is installed The specified concrete quality min B25 must be used 0563 B Installation and Operating Instructions 23 Bl AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 9 4 11 8 1 5 were Be Ei l 3 5 23 z 24 a 1 14 6 3 16 21 Figure 21 Horizontal dry installation with closed cooling system Legend 1 Venting 13 Inflow line 3 Shut off valve 14 ABS submersible pump 4 Outflow line 15 Automatic level control 5 Non return valve 16 Concrete benching after installation of suction pipe 6 Fitting for removal valves 20 Collection sump 7 Cable duct 21 Suction line 8 Holder for float switches 23 Compensation piece 9 Pump sump 24 Diffuser 11 Discharge line 25 Head support volute support 12 Inflow chamber with impact wall NOTE Any support frame needed for the submersible pump should be erected on site before the pump itself is installed The specified concrete quality min B25 must be used 0563 B 24 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Bl 5 2 1 Wet installation of the AFP submersible pump N The safety hints in the previous sections must be observed ATTENTION Submersible pumps should be installed in accordance with Figure 23 e Fit
36. nd 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 Safety Instructions which might cause danger to life in case of non observance have been specifically A highlighted with the general danger symbol A The presence of a dangerous voltage is identified with this safety symbol A This symbol indicates the danger of an explosion occurring ATTENTION Appears at safety hints the non observance of which could damage the unit or affect its functioning NOTE Used for important pieces of information Illustrations code e g 3 2 The first digit refers to the figure no and the second digit to the position in that figure 1 2 Correct usage of the products The ABS products have been designed and built in accordance with the latest technology and taking into account 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 ABS 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 t
37. ng an expert should check that one of the necessary electrical protective devices is avail able Earthing neutral earth leakage circuit breakers etc must comply with the regulations of the local electric ity supply authority and a qualified 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 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 qualified person The power supply cable must be protected by an adequately dimensioned slow blow fuse corresponding to the rated power of the pump ATTTENTION The unit should only be operated with the overload relay and thermal sensors limiters connected 5 5 1 Standard connection diagrams mains voltage 380 420 V at 50 Hz 460 V at 60 Hz Cable 1 3 Cable 1 3 CD i 8 g Di e i PE lt n u1 uo EEE u yo e w1 we E Bei M3 pay ae Sl PE Ho i w2 Cable 2 t o U2 Cable 3 o V2 u 55 PE FO FO F1 a Cable 2 ni 4 Figure 29 Two power cables each with integrated con
38. ng system Legend 1 Venting 10 Guide tube 2 Valve chamber 11 Discharge line 3 Shut off valve 12 Inflow chamber with impact wall 4 Outflow line 13 Inflow line 5 Non return valve 14 ABS submersible sewage pump 6 Fitting for valve removal 15 Automatic level control 7 Cable duct 16 Concrete benching 8 Bracket for float switches 17 Pedestal 9 Collection sump 18 Bracket 0563 B 22 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs NOTE The pedestal and guide tube for the submersible pump must be fitted on site before installation of the pump On request we can send you detailed installation and foundation drawings The specified concrete quality min B25 must be used Ti 9 7 8 1 0562 0021 6 3 16 21 Figure 20 Installation in a dry sump with ground support ring with closed cooling system Legend 1 Venting 12 Inflow chamber with impact wall 3 Valve chamber 13 Inflow line 4 Outflow line 14 ABS submersible pump 5 Non return valve 15 Automatic level control 6 Fitting for removal valves 16 Concrete benching after installation of suction pipe 7 Cable duct 18 Flexible pipe connector 8 Holder for float switches 19 Ground support ring 9 Pump sump 20 Collection sump 11 Discharge line 21 Suction line NOTE Any support frame needed for the submersible pu
39. nnnnnnnnnn nn 37 7 4 Removal of the Submersible Pump yssen ea a a aaa aeaa aa a a aa aa 39 7 4 1 Removal of the AFP submersible pump from a wet SUMP uuusssesssssnesnnnnennnnnnenennnnnennennnene nennen 39 7 4 2 Removal of the AFP submersible pump when dry installed cccccceceeceeeeeeeeeeceeeeeeeeeeeeeeteteeeeeneaees 39 7 4 3 Removal of the AFL and VUP submersible pump 44444440onsnnennennennnnnnnnnnnennnnnnnnnneennennennn nen 39 8 Assembling the gearbox AFL VUP zunnssrnnesnnsnennnnonnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnnnn nennen 40 8 1 Assembling the motor and the gearbox hydraulic unit uursssessnnnnnnnnnnennnnnnnnennnnnnnnnnnnnnnnnnnnn nenn 40 8 2 Remove transpo rt sec ring device naar ae nn 41 8 3 Remove transport securing device of the gearbox uur sss4sunnnssnnnnnnnnennnnnnnnn nenn nee nnnnnnnnn nennen nn 42 8 4 Assembly instructions for gearbox motor housing 4msnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnennn nenn nenn 43 0563 B RI Installation and Operating Instructions 5 AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 0563 B 6 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs 1 General 1 1 Introduction These Installation and Operating Instructions and the separate booklet Safety Hints contain basic instructions and safety hints which must be observed during transport installation a
40. or the series VUP ABS submersible propeller pumps of the VUP series are designed for those applications where large water volumes must be pumped at low heads up to 10 m 33 ft They are suitable for the following liquids e Fresh and process water pumping e Raw water for drinking water supply e Surface and rain water The VUP pumps are installed in a concrete sump or in a steel pressure pipe using a suitable coupling ring ATTENTION The cooling liquid filled in at the factory in the ME series with the exception of the oil filled VUP and AFL using ME6 motors consists of 2 3 water and 1 3 glycol This mixture is frost proof down to temperatures of 20 C 4 F 1 5 Identification coding Hydraulics Motor AAA BB CC UU VVV W XY Z L Number of poles in motor Motor power P x 10 in kW 0562 0002 Motor designation e g ME Hydraulic number Discharge size DN cm Series Figure 1 Identification coding X Part of the manufacturing code for the motor size X gives the motor size y Part of the manufacturing code for the motor size Y indicates the stator length Selection here is between a motor frame size and number of poles 1 to n Z Information on the motor 50 Hz or FM 60 Hz for explosion proof versions NOTE The SX versions have an identical design to the AFP ME units They only differ in the materials used and are also only available in a cooling jacket version The designation SX will be added between hydraulics
41. ration of the pumps the pump section is filled with water dry installation or alternatively is submerged or under water wet installation with cooling jacket Other types of operation e g snore operation or dry running are not allowed ATTENTION The ex versions of the ME series are not fitted with a seal monitor DI in the monitoring chamber or in the oil chamber There is an option of an external seal monitor for the ex versions For the operation of explosion proof submersible pumps in wet well installation without cooling jacket applies It must be ensured that the motor of the ex submersible pump is always fully submerged during start up and operation For the operation of explosion proof submersible pumps applies The temperature monitoring of the explosion proof submersible pumps 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 certified in accordance with EC directive 94 9 EC For the operation of explosion proof submersible pumps with frequency inverter applies Motors must have direct thermal protection devices fitted These consist of temperature sensors PTC DIN 44081 150 embedded in the windings These must be connected to a suitable release device which is certified in accordance with EC directive 94 9 EC Machines designated as Ex machines may never without exception be operated using a mains frequency that is greater than
42. rost resistant up to 20 C 4 F 0563 B Installation and Operating Instructions 39 abs Filling volumes lubrication oil Hydraulics Filling volume oil chamber Filling volume gearbox AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Hydraulics Filling volume oil chamber Filling volume gearbox VUP 0600 2 5 VUP 0800 2 5 VUP 1000 7 0 VUP 1200 13 0 VUP 1000 G 7 0 VUP 1200 G 8 0 AFL 800 3 0 AFL 1200 2 5 AFL 1200 G 7 0 Motor ME6 7 4 Removal of the submersible pump A 7 4 1 Removal ofthe AFP submersible pump from a wet sump A e Fit a hoist to the pump in accordance to section 3 1 The safety hints in the previous sections must be observed Before removal of the unit the motor connection cables at the control panel should be completely disconnected by a qualified person from mains and care should be taken that it cannot be inadvertently switched back on Before removal of units in hazardous areas the sump and surrounding area must be adequately vented to avoid the danger of a spark causing an explosion e Raise the submersible pump out of the sump with the hoist While doing this the connection cables should be simultaneously drawn out of the sump as the pump itself is being raised e Place the pump with volute vertically on a solid surface and take care that it cannot fall over 7 4 2 Removal of the AFP submersible pump when dry
43. rs Activation must be by means of a thermistor protective relay device with PTB Approval number 4 2 3 Temperature monitoring of the bearings Option ME4 ME5 If bearing temperature monitoring is supplied the standard versions of the pump possess a bimetallic thermal limiter which opens at a pre set temperature and is fitted into the bearing block This allows switching off of the motor to take place in plenty of time e g where excessive bearing temperature due to wear occurs Switching temperature of motors of insulation class F Upper bearing 140 C 284 F e lower bearing 120 C 248 F As an alternative temperature dependent resistors thermistors PTC with non linear characteristics or PT 100 elements with linear characteristics can be fitted 0563 B Installation and Operating Instructions 19 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 4 2 4 Temperature indication A continuous indication of the temperature in the stator and the bearings is not possible using bimetallic thermal limiters or thermistors For this application it is necessary to fit thermal sensors of the type PT 100 with linear characteristics into the stator and bearing blocks This type of resistor has a linear characteristic i e the resistance rise is proportional to the temperature rise Resistance 0562 0017 Application Option Function Temperature switch using the bimetallic principle which opens at a rated temper
44. s option or attachment swivels horizontal installation to which a chain can be fastened by means of shackles to trans portation installation or removal Take note of the entire weight of the unit see nameplate Figure 2 The hoist and chain must be adequately dimensioned for the weight of the unit and must comply with the current valid safety regulations The unit should be protected from rolling over The unit is prepared for transportation by placing it on an adequately strong completely horizontal sur face taking care that it cannot topple over Do not stay or work in the swivel area of a suspended load The lifting hook height must take into consideration the entire height of the unit as well as the length of the lifting chain gt e Pe D 0563 B Installation and Operating Instructions 11 abs 3 1 1 Standing transport Figure 3 Standing transport AFP 0562 0004 AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Figure 4 Standing transport AFL and VUP N The safety hints in the section above must be observed 3 1 2 Transport in a horizontal manner H fe NS Figure 5 Transport in a horizontal manner AFP 0562 0006 2 1 Le
45. tator Thermal limiters protect the stator from overheating in the case of asymmetric phase loading or voltage continuous dry running or excessive temperatures in the medium itself The stator is equipped with three bimetallic thermal limiters which are connected in series Additionally it is possible to fit temperature dependent resistors PT 100 not for Ex with linear characteristics 4 2 2 DI Electrode The Dl electrodes carry out the seal monitoring function and signal the ingress of moisture into the motor by means of a special electronic device See also section 5 5 6 0563 B 18 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs ATTENTION Thermistors or PT 100 devices must never be directly connected into the control or power system They must always be connected to a suitable evaluation device Switch off temperature of the thermal sensors fitted to standard motors of Insulation Class F 140 C 284 F The temperature limiting switches may only be operated as specified by the manufacturer See table below Operating voltage AC DC 900 V 101 V Rated voltage AC 250 V Rated current AC cos 1 0 2 5A Rated current AC cos 0 6 1 6 A max switching current at I 5 0A ATTENTION The maximum switching ability of the thermal sensors is 5 A the rated voltage 250 V Explosion proof motors which are connected to static frequency inverters must be fitted with thermisto
46. the maximum of 50 or 60 Hz as indicated on the nameplate 1 4 Application areas for the submersible pumps 1 4 1 Application areas for the series AFP The ABS submersible sewage pumps of the AFP series have been designed for the economical and reliable pumping of commercial industrial and municipal sewage and can be installed dry or wet They are suitable for pumping of the following liquids e Clear and wastewater for sewage containing solids and fibrous material Faecal matter Sludge e Fresh and process water pumping e Raw water for drinking water supply Surface and rain water Sewage 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 1 4 2 Application areas for the series AFL The ABS mixed flow column pump of the AFL series have been developed for environmental protection water supply municipal sewage treatment and dewatering of polders 0563 B 8 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Bl They are suitable for the following liquids e Raw water with solid or fibrous material Sewage e Surface water rain water drainage water Sludge The AFL pumps are installed in a concrete sump or in a steel pressure pipe using a suitable coupling ring 1 4 3 Application areas f
47. tor these voltage spikes can adversely affect the life of the motor In order to avoid this inverters of this type must equipped with sinus filters when used in the critical zone see fig 18 The sinus filter chosen must be suitable for the inverter with regard to rated voltage inverter wave frequency rated current of the inverter and maximum inverter output frequency 0562 0012 230 10 50 100 150 L m L total length from frequency inverter to motor Figure 18 Critical non critical area 0563 B Installation and Operating Instructions 21 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 5 Installation N The safety hints in the previous sections must be observed 5 1 Installation of the AFP submersible pumps 5 1 1 Installation options for the AFP submersible pumps There are three main installation options for the submersible pumps 1 Wet installation vertical with ABS automatic coupling system 2 Dry installation with ground support ring with closed cooling system 3 Dry installation horizontal with closed cooling system NOTE The dimensional sheets and foundation plans for each type of installation are supplied either with the planning documents or your order confirmation 5 2 Installation examples 4 2 3 5 6 1 0562 0020 Figure 19 Wet installation vertical with ABS automatic coupli
48. trol Figure 30 Two power cables and one control cable leads 0563 B Installation and Operating Instructions 31 abs AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 Cable 1 Cable 3 8 PE mE ey ee 3 a u PEx U1 10 PTC 3 PT 100 TT vi l 5 L_ 44 winding 40 H 5 30 Mh e ie were ale wi s ol 42 S 134 u St ol 12 upper bearing 5 M 2 ae a we W Cacal l 2 _ o a 13 lower bearing 3 z 36 m Oo PE 45 4 37 l 3 K wa 5 ma 20 DI connection chamber U2 ma 21 DI motor chamber ol mm 22 Diol chamber D V2 Cable 2 X cable core marking control cable Figure 31 Special versions two power cables and one control cable for optional motor monitoring features ATTENTION The cable leads are routed out of the motor No switching takes place in the motor Any switching required use of bridges must be carried out in the control panel NOTE Information on the type of starting can be obtained from the nameplate of the pump 5 5 2 Lead designations Direct starting in star L2 Join North America 2 4 amp 58 amp 6 0562 0033 ABS Germany V1 U2 amp V2 amp W2 irect starting in delta L2 North America
49. uring storage After long storage periods after approx one year the transportation locking device on the motor shaft not with all versions should be disassembled By rotating the shaft several times by hand new lubricating oil or depending on the version a small amount of coolant which also serves to cool or lubricate the mechanical seals is applied to the sealing surfaces thus ensuring perfect operation of the mechanical seals The bearings supporting the motor shaft are maintenance free In the case of extreme ambient temperatures below 20 C 4 F during transportation storage or longer out of service periods the coolant must be drained to prevent damage to the unit In such cases please contact your ABS dealer 0563 B 16 Installation and Operating Instructions AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 4 Product description 4 1 Structural design 25 20 21 Figure 11 AFP ME4 3 ee 4 6 5 7 11 12 13 15 17 16 19 14 18 32 33 34 DIE Figure 13 AFL ME5 26 23 Bl 0562 0015 0562 0013 49 22 25 28 27 29 Figure 12 AFP ME 5 0562 0016 0562 0014 Figure 14 VUP ME4 0563 B Installation and Operating Instructions 17 AFP ME4 6 AFP ME SX AFL ME4 6 VUP ME4 6 abs Legend 1 Lifting hoop Standard 18 Release screw for cooling medium 2 Eyebolts Option 19 Plug screw separation chamber 3 Cable inlet 20 Contrablock CB impeller 4 Connect
50. y maintenance work the pump should be completely disconnected from the mains by a qualified person and care should be taken that it cannot be inadvertently switched back on 7 7 1 General maintenance hints NOTE The maintenance hints given here are not designed for do it yourself repairs as special technical knowledge is required Repair work on explosion proof motors may only be carried out in approved workshops by approved A personnel using original parts supplied by the manufacturer Otherwise the ex approvals no longer apply ABS submersible pumps are reliable quality products each being subjected to careful final inspection Lubri cated 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 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 limiters of the thermo control system or by the seal monitoring system DI ATTENTION The lifting tools like chains and shackles should be visually checked in regular intervals approx every 3 month for wear and corrosion These parts should be replaced if required The ABS service organisation would be pleased to advise you on any applications you may hav

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