Installation, Operation, and Maintenance Manual Flygt 3171 Table of Contents Table of Contents Introduction and Safety.........................................................................................................................3 Introduction..........................................................................................................................................3 Safety.....................................................................................................................................................3 Safety terminology and symbols....................................................................................................3 Environmental safety........................................................................................................................4 User safety.........................................................................................................................................5 Ex-approved products.....................................................................................................................6 Product warranty...............................................................................................................................7 Transportation and Storage..................................................................................................................8 Inspect the delivery.............................................................................................................................8 Inspect the package.........................................................................................................................8 Inspect the unit..................................................................................................................................8 Transportation guidelines..................................................................................................................8 Precautions........................................................................................................................................8 Position and fastening......................................................................................................................8 Lifting..................................................................................................................................................8 Temperature ranges for transportation, handling and storage....................................................9 Handling at freezing temperature..................................................................................................9 Unit in as-delivered condition.........................................................................................................9 Lifting the unit out of liquid.............................................................................................................9 Storage guidelines............................................................................................................................10 Storage location.............................................................................................................................10 Freezing precautions.....................................................................................................................10 Long-term storage..........................................................................................................................10 Product Description.............................................................................................................................11 Pump design......................................................................................................................................11 Parts....................................................................................................................................................12 Monitoring equipment.....................................................................................................................13 Optional sensors.............................................................................................................................13 The data plate....................................................................................................................................13 Approvals...........................................................................................................................................14 Product approvals for hazardous locations.................................................................................14 EN approval plate...........................................................................................................................14 IEC approval plate..........................................................................................................................15 FM approval plate..........................................................................................................................15 Product denomination......................................................................................................................16 Installation.............................................................................................................................................17 Install the pump.................................................................................................................................17 Authority regulation.......................................................................................................................17 Fasteners.........................................................................................................................................17 Install with P-installation.................................................................................................................18 Install with S-installation.................................................................................................................19 Install with T/Z-installation.............................................................................................................20 Make the electrical connections......................................................................................................21 General precautions.......................................................................................................................21 Requirements..................................................................................................................................21 Cables..............................................................................................................................................21 Earthing (Grounding).....................................................................................................................22 Connect the motor cable to the pump........................................................................................22 Flygt 3171 Installation, Operation, and Maintenance Manual 1 Table of Contents Connect the motor cable to the starter and monitoring equipment.......................................23 Cable charts....................................................................................................................................24 Sensor-connection.........................................................................................................................29 Check the impeller rotation.............................................................................................................31 Operation..............................................................................................................................................33 Precautions.........................................................................................................................................33 Distance to wet areas........................................................................................................................33 Noise level..........................................................................................................................................33 Start the pump...................................................................................................................................33 Maintenance.........................................................................................................................................35 Precautions.........................................................................................................................................35 Maintenance guidelines...................................................................................................................35 Torque values....................................................................................................................................35 Change the coolant..........................................................................................................................36 Empty the coolant..........................................................................................................................36 Fill with coolant...............................................................................................................................38 Service the pump..............................................................................................................................39 Inspection........................................................................................................................................40 Major overhaul................................................................................................................................41 Service in case of alarm.................................................................................................................41 Replace the impeller.........................................................................................................................41 Replace the impeller for wet installation.....................................................................................42 Replace the impeller for dry installation......................................................................................49 Troubleshooting...................................................................................................................................59 Introduction.......................................................................................................................................59 The pump does not start..................................................................................................................59 The pump does not stop when a level sensor is used.................................................................60 The pump starts-stops-starts in rapid sequence...........................................................................60 The pump runs but the motor protection trips.............................................................................61 The pump delivers too little or no water........................................................................................61 Technical Reference............................................................................................................................63 Application limits...............................................................................................................................63 Motor data..........................................................................................................................................63 2 Flygt 3171 Installation, Operation, and Maintenance Manual Introduction and Safety Introduction and Safety Introduction Purpose of this manual The purpose of this manual is to provide necessary information for: • Installation • Operation • Maintenance CAUTION: Read this manual carefully before installing and using the product. Improper use of the product can cause personal injury and damage to property, and may void the warranty. NOTICE: Save this manual for future reference, and keep it readily available at the location of the unit. Safety WARNING: • The operator must be aware of safety precautions to prevent physical injury. • Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized. Take all necessary measures to avoid over-pressurization. • Operating, installing, or maintaining the unit in any way that is not covered in this manual could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact an Xylem representative before proceeding. • This manual clearly identifies accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal. • Do not change the service application without the approval of an authorized Xylem representative. CAUTION: You must observe the instructions contained in this manual. Failure to do so could result in physical injury, damage, or delays. Safety terminology and symbols About safety messages It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards: • Personal accidents and health problems • Damage to the product • Product malfunction Flygt 3171 Installation, Operation, and Maintenance Manual 3 Introduction and Safety Hazard levels Hazard level NOTICE: Indication DANGER: A hazardous situation which, if not avoided, will result in death or serious injury WARNING: A hazardous situation which, if not avoided, could result in death or serious injury CAUTION: A hazardous situation which, if not avoided, could result in minor or moderate injury • A potential situation which, if not avoided, could result in undesirable conditions • A practice not related to personal injury Hazard categories Hazard categories can either fall under hazard levels or let specific symbols replace the ordinary hazard level symbols. Electrical hazards are indicated by the following specific symbol: Electrical Hazard: These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols: • Crush hazard • Cutting hazard • Arc flash hazard Environmental safety The work area Always keep the station clean to avoid and/or discover emissions. Waste and emissions regulations Observe these safety regulations regarding waste and emissions: • Appropriately dispose of all waste. • Handle and dispose of the processed liquid in compliance with applicable environmental regulations. • Clean up all spills in accordance with safety and environmental procedures. • Report all environmental emissions to the appropriate authorities. 4 Flygt 3171 Installation, Operation, and Maintenance Manual Introduction and Safety WARNING: Do NOT send the product to the Xylem manufacturer if it has been contaminated by any nuclear radiation. Inform Xylem so that accurate actions can take place. Electrical installation For electrical installation recycling requirements, consult your local electric utility. Recycling guidelines Always recycle according to these guidelines: 1. Follow local laws and regulations regarding recycling if the unit or parts are accepted by an authorized recycling company. 2. If the first guideline is not applicable, then return the unit or parts to your Xylem representative. User safety General safety rules These safety rules apply: • Always keep the work area clean. • Pay attention to the risks presented by gas and vapors in the work area. • Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards. • Always bear in mind the risk of drowning, electrical accidents, and burn injuries. Safety equipment Use safety equipment according to the company regulations. Use this safety equipment within the work area: • Hard hat • Safety goggles, preferably with side shields • Protective shoes • Protective gloves • Gas mask • Hearing protection • First-aid kit • Safety devices NOTICE: Never operate a unit unless safety devices are installed. Also see specific information about safety devices in other chapters of this manual. Electrical connections Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations. For more information about requirements, see sections dealing specifically with electrical connections. Hazardous liquids The product is designed for use in liquids that can be hazardous to your health. Observe these rules when you work with the product: • Make sure that all personnel who work with biologically hazardous liquids are vaccinated against diseases to which they may be exposed. • Observe strict personal cleanliness. Flygt 3171 Installation, Operation, and Maintenance Manual 5 Introduction and Safety Wash the skin and eyes Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin: Condition Action Chemicals or hazardous fluids in eyes 1. 2. 3. Hold your eyelids apart forcibly with your fingers. Rinse the eyes with eyewash or running water for at least 15 minutes. Seek medical attention. Chemicals or hazardous fluids on skin 1. 2. 3. Remove contaminated clothing. Wash the skin with soap and water for at least 1 minute. Seek medical attention, if necessary. Ex-approved products Follow these special handling instructions if you have an Ex-approved unit. Personnel requirements These are the personnel requirements for Ex-approved products in potentially explosive atmospheres: • All work on the product must be carried out by certified electricians and Xylemauthorized mechanics. Special rules apply to installations in explosive atmospheres. • All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas. • Any maintenance for Ex-approved products must conform to international and national standards (for example, IEC/EN 60079-17). Xylem disclaims all responsibility for work done by untrained and unauthorized personnel. Product and product handling requirements These are the product and product handling requirements for Ex-approved products in potentially explosive atmospheres: • Only use the product in accordance with the approved motor data. • You must fully submerge the Ex-approved product during normal operation. Dry running during service and inspection is only permitted outside the classified area. • Before you start work on the product, make sure that the product and the control panel are isolated from the power supply and the control circuit, so they cannot be energized. • Do not open the product while it is energized or in an explosive gas atmosphere. • Make sure that thermal contacts are connected to a protection circuit according to the approval classification of the product, and that they are in use. • Intrinsically safe circuits are normally required for the automatic level-control system by the level regulator if mounted in zone 0. • The yield stress of fasteners must be in accordance with the approval drawing and the product specification. • Do not modify the equipment without approval from an authorized Xylem representative. • Only use parts that are provided by an authorized Xylem representative. Guidelines for compliance Compliance is fulfilled only when you operate the unit within its intended use. Do not change the conditions of the service without the approval of an Xylem representative. When you install or maintain explosion proof products, always comply with the directive and applicable standards (for example, IEC/EN 60079–14). 6 Flygt 3171 Installation, Operation, and Maintenance Manual Introduction and Safety Minimum permitted liquid level See the dimensional drawings of the product for the minimum permitted liquid level according to the approval for explosion proof products. If the information is missing on the dimensional drawing, the product must be fully submerged. Level-sensing equipment must be installed if the product can be operated at less than the minimum submersion depth. Monitoring equipment For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to the following: • Level indicators • Temperature detectors Product warranty Coverage Xylem undertakes to remedy defects in products from Xylem under these conditions: • The faults are due to defects in design, materials, or workmanship. • The faults are reported to an Xylem representative within the warranty period. • The product is used only under the conditions described in this manual. • The monitoring equipment incorporated in the product is correctly connected and in use. • All service and repair work is done by Xylem-authorized personnel. • Genuine Xylem parts are used. • Only Ex-approved spare parts and accessories authorized by Xylem are used in Exapproved products. Limitations The warranty does not cover defects caused by these situations: • Deficient maintenance • Improper installation • Modifications or changes to the product and installation made without consulting Xylem • Incorrectly executed repair work • Normal wear and tear Xylem assumes no liability for these situations: • Bodily injuries • Material damages • Economic losses Warranty claim Xylem products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your Xylem representative. Spare parts Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued. Flygt 3171 Installation, Operation, and Maintenance Manual 7 Transportation and Storage Transportation and Storage Inspect the delivery Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the distributor. Inspect the unit 1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations. 2. Inspect the product to determine if any parts have been damaged or are missing. 3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps. 4. Contact your sales representative if anything is out of order. Transportation guidelines Precautions WARNING: • Stay clear of suspended loads. • Observe accident prevention regulations in force. Position and fastening The unit can be transported either horizontally or vertically. Make sure that the unit is securely fastened during transportation, and cannot roll or fall over. Lifting WARNING: • Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-toed shoes at all times. • Lift and handle the product carefully, using suitable lifting equipment. • The product must be securely harnessed for lifting and handling. Use eyebolts or lifting lugs if available. • Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the hose. • Do not attach sling ropes to shaft ends. 8 Flygt 3171 Installation, Operation, and Maintenance Manual Transportation and Storage Lifting equipment Lifting equipment is always required when handling the unit. It must fulfill the following requirements: • The minimum height (contact Xylem for information) between the lifting hook and the floor must be sufficient to lift the unit. • The lifting equipment must be able to hoist the unit straight up and down, preferably without the need for resetting the lifting hook. • The lifting equipment must be securely anchored and in good condition. • The lifting equipment must support weight of the entire assembly and must only be used by authorized personnel. • Two sets of lifting equipment must be used to lift the unit for repair work. • The lifting equipment must be dimensioned to lift the unit with any remaining pumped media in it. • The lifting equipment must not be oversized. NOTICE: Oversized lifting equipment could cause damage if the unit should stick when being lifted. Temperature ranges for transportation, handling and storage Handling at freezing temperature At temperatures below freezing, the product and all installation equipment, including the lifting gear, must be handled with extreme care. Make sure that the product is warmed up to a temperature above the freezing point before starting up. Avoid rotating the impeller/propeller by hand at temperatures below the freezing point. The recommended method to warm the unit up is to submerge it in the liquid which will be pumped or mixed. NOTICE: Never use a naked flame to thaw the unit. Unit in as-delivered condition If the unit is still in the condition in which it left the factory - all packing materials are undisturbed - then the acceptable temperature range during transportation, handling and storage is: –50°C (–58ºF) to +60°C (+140ºF). If the unit has been exposed to freezing temperatures, then allow it to reach the ambient temperature of the sump before operating. Lifting the unit out of liquid The unit is normally protected from freezing while operating or immersed in liquid, but the impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding temperature below freezing. Units equipped with an internal cooling system are filled with a mixture of water and 30% glycol. This mixture remains a flowing liquid at temperatures down to –13°C (9°F). Below – 13°C (9°F), the viscosity increases such that the glycol mixture will lose its flow properties. However, the glycol-water mixture will not solidify completely and thus cannot harm the product. Follow these guidelines to avoid freezing damage: Flygt 3171 Installation, Operation, and Maintenance Manual 9 Transportation and Storage 1. Empty all pumped liquid, if applicable. 2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for the presence of water. Change if needed. Storage guidelines Storage location The product must be stored in a covered and dry location free from heat, dirt, and vibrations. NOTICE: • Protect the product against humidity, heat sources, and mechanical damage. • Do not place heavy weights on the packed product. Freezing precautions The unit is frost-proof while operating or immersed in liquid, but the impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding temperature below freezing. Follow these guidelines to avoid freezing damage: When Guideline Before storage After storage • The unit must be allowed to run for a short time after raising it to discharge remaining pumped liquid. This does not apply to impeller/propeller units. • The discharge opening must be covered in a suitable way, or placed facing down so that any still remaining pumped liquid runs out. • If present, the cooling jacket must be drained manually by opening the air vent screws at the top of the cooling jacket. If the impeller/propeller is frozen, it must be thawed by immersing the unit in liquid before operating the unit. NOTICE: Never use a naked flame to thaw the unit. Long-term storage If the unit is stored more than 6 months, the following apply: • Before operating the unit after storage, it must be inspected with special attention to the seals and the cable entry. • The impeller/propeller must be rotated every other month to prevent the seals from sticking together. 10 Flygt 3171 Installation, Operation, and Maintenance Manual Product Description Product Description Pump design The pump is submersible, and driven by an electric motor. Intended use The product is intended for moving wastewater, sludge, raw and clean water. Always follow the limits that are given in Application limits (page 63). If there is a question regarding the intended use of the equipment, please contact an Xylem representative before proceeding. WARNING: In explosive or flammable environments, only use Ex- or MSHA-approved pumps. NOTICE: Do NOT use the pump in highly corrosive liquids. Spare parts • Modifications to the unit or installation should only be carried out after consulting with Xylem. • Original spare parts and accessories that are authorized by Xylem are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation. For more information contact your Xylem representative. Pressure class LT Low head MT Medium head HT High head SH Super high head Flygt 3171 Installation, Operation, and Maintenance Manual 11 Product Description Parts 14 13 2 12 11 9 1 3 4 10 7 5 WS000850A 6 WS006171A 8 Figure 1: Without cooling jacket Figure 2: With cooling jacket 12 Positio Part n Description 1 Monitoring sensor Optional sensor. For information about sensors, see Monitoring equipment (page 13). 2 Shaft Stainless steel, with an integrated rotor 3 Cooling without jacket The pump is cooled by the ambient liquid. 4 Cooling with jacket The motor is cooled by a closed loop system. An integrated coolant pump circulates the coolant whenever the pump is operated. 5 Flow diffuser Provides heat transfer from the coolant to the pumped fluid. 6 Seal housing Includes a coolant that lubricates and cools the seals; the housing acts as a buffer between the pumped fluid and the electric motor 7 Impeller N-impeller, a semi-open, two-vane impeller 8 Inspection chamber Equipped with an FLS10 leakage sensor to prevent damages to the motor 9 FLS10 For information about FLS10, see Monitoring equipment (page 13). 10 Mechanical seals Made of one of the following alternatives: • Alternative 1 • Inner seal: corrosion-resistant cemented carbide WCCR/WCCR • Outer seal: corrosion-resistant cemented carbide WCCR/WCCR • Alternative 2 • Inner seal: corrosion-resistant cemented carbide WCCR/WCCR • Outer seal: silicon carbide RSiC/RSiC 11 Main bearings Consisting of a two-row angular contact ball bearing 12 Motor For information about the motor, see Motor data (page 63). Flygt 3171 Installation, Operation, and Maintenance Manual Product Description Positio Part n Description 13 Thermal contact/ For information about the thermal contact and thermistors, see Monitoring equipment Thermistors (page 13). 14 Support bearing Consisting of a two-row ball bearing Monitoring equipment The following applies to the monitoring equipment of the pump: • The stator incorporates three thermal contacts connected in series that activate the alarm and stops the pump at overtemperature • The thermal contacts open at 140°C (285°F). • Ex-approved pumps must have thermal contacts connected to the control panel. • The sensors must be connected to either the MiniCAS II monitoring equipment or an equivalent equipment. • The monitoring equipment must be of a design that makes automatic restart impossible. • The pump is supplied with an inspection sensor FLS 10 for sensing the presence of any liquid in the inspection chamber. • Information in the junction box shows if the pump is equipped with optional sensors. Optional sensors Thermistor Thermistors are optional sensors for measuring the temperature. They are connected in series in the stator and activate the alarm at overtemperature. Thermistors are not applicable to Ex-approved pumps. NOTICE: Thermistor must never be exposed to voltages higher than 2.5 V. If the voltage exceeds this value, for example when the control circuit is tested, the thermistors will be destroyed. The data plate The data plate is a metal label located on the main body of the products. The data plate lists key product specifications. Specially approved products also have an approval plate. 3 2 1 4 24 23 5 22 6 21 7 9 1. 2. 3. 10 11 12 13 14 15 16 17 18 19 WS006257A 20 8 Curve code/Propeller code Serial number, see Product denomination (page 16) Product number Flygt 3171 Installation, Operation, and Maintenance Manual 13 Product Description 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Country of origin Additional information Phase; type of current; frequency Rated voltage Thermal protection Thermal class Rated shaft power International standard Degree of protection Rated current Rated speed Maximum submergence Direction of rotation: L=left, R=right Duty class Duty factor Product weight Locked rotor code letter Power factor Maximum ambient temperature Read installation manual Notified body. Only for EN-approved Ex-products Figure 3: The data plate Approvals Product approvals for hazardous locations Pump • • • • • • 3171.091 3171.095 3171.390 3171.810 3171.830 3171.850 Approval European Norm (EN) • ATEX Directive • EN 60079-0, EN 60079-1, EN 1127-1 • I M2 Ex d I • II 2 G Ex d IIB T3 EN approval for cable entry: • Certificate number: INERIS 02ATEX9008 U • II 2 G Ex d IIC or I M2 Ex d I IEC • • • • IECEx scheme IEC 60079–0, IEC 60079–1 Ex d I Ex d IIB T3 Factory Mutural (FM) • Class I. Div 1. Group C and D • Dust ignition proof for use in Class II. Div 1. Group E, F and G • Suitable for use in Class III. Div 1. Hazardous Locations EN approval plate This illustration describes the EN approval plate and the information contained in its fields. 14 Flygt 3171 Installation, Operation, and Maintenance Manual Product Description 1 2 3 1. 2. 15 14 13 4 12 11 5 6 7 8 9 10 WS003972A 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Approval Approval authority + approval number Approval for Class I Approved drive unit Stall time Starting current/Rated current Duty class Duty factor Input power Rated speed Controller Additional information Maximum ambient temperature Serial number ATEX marking IEC approval plate This illustration describes the IEC approval plate and the information contained in its fields. International Norm; not for EU member countries. 1 1. 2. 2 3. 4. 5. 3 13 12 11 4 10 5 6 7 8 9 6. 7. 8. 9. 10. 11. 12. 13. Approval Approval authority + approval number Approved for drive unit Stall time Starting current/Rated current Duty class Duty factor Input power Rated speed Controller Additional information Max. ambient temperature Serial number WS001279B FM approval plate This illustration describes the FM approval plate and the information contained in its fields. 1 2 Flygt 3171 Installation, Operation, and Maintenance Manual 1. 2. Temperature class Maximum ambient temperature WS003973A 15 Product Description Product denomination Sales denomination The sales denomination consists of the four-digit sales code and two letters that indicate the hydraulic end and type of installation. This is an example of a sales denomination, and an explanation of its parts. WS006265A NP 3085 1 2 3 1. 2. 3. Hydraulic part Installation type Sales code Product code The product code consists of nine characters divided into two parts. This is an example of a product code, and an explanation of its parts. 1 1. 2. WS006262A NP 3085.183 2 Sales denomination Version Serial number The serial number is used for identification of an individual product, and is divided into four parts. 1 1. 2. 3. 4. 16 2 3 4 WS006269A This is an example of a serial number, and an explanation of its parts. NP 3085.183 - 951 0163 Product code Production year Production cycle Running number Flygt 3171 Installation, Operation, and Maintenance Manual Installation Installation Install the pump WARNING: • Electrical shock hazard. Check that the cable and cable entry have not been damaged during transport before installing the pump. • Note that special rules apply to installation in explosive atmospheres. • Make sure that the unit cannot roll or fall over and injure people or damage property. • Do not install CSA-approved products in locations that are classified as hazardous in the national electric code, ANSI/NFPA 70-2005. • Do not install the starter equipment in an explosive zone unless it is explosion-proof rated. NOTICE: • Do not run the pump dry. • Never force piping to make a connection with a pump. • Always remove all debris and waste material from the sump, inlet piping, and discharge connection, before you install the pump. These requirements apply: • Use the pump dimensional drawing in order to ensure proper installation. • In S-, T-, and Z-installations the pump must be equipped with cooling jacket • Provide a suitable barrier around the work area, for example, a guard rail. • Check the explosion risk before you weld or use electric hand tools. • Always check the impeller rotation before lowering the pump into the pumped liquid. Authority regulation Vent the tank of a sewage machine station in accordance with local plumbing codes. Fasteners WARNING: • Only use fasteners of the proper size and material. • Replace all corroded fasteners. • Make sure that all fasteners are properly tightened and that there are no missing fasteners. Flygt 3171 Installation, Operation, and Maintenance Manual 17 Installation Install with P-installation WS006259A In the P-installation, the pump is installed on a stationary discharge connection, and operates either completely or partially submerged in the pumped liquid. These requirements and instructions only apply when the installation is made according to the dimensional drawing. Figure 4: P-installation These items are required: • Guide bars • Guide bar bracket for attaching the guide equipment to the access frame or to the upper part of the sump • Level regulators or other control equipment for start, stop, and alarm • Cable holder for holding the cable and regulating the height of the level regulators • Access frame (with covers) to which the upper guide bar bracket and cable holder can be attached • Discharge connection for connecting the pump to the discharge line The discharge connection has a flange which fits the pump casing flange and a bracket for attaching the guide equipment. • Fasteners for the discharge connection • Anchor bolts 1. Run a cable between the sump and the stator and monitoring equipment. Make sure that the cable is neither sharply bent, nor pinched. 2. Install the access frame: a) Place the access frame in position and align it horizontally. b) Grout the frame in place. 3. Grout the anchor bolts in place. Be careful when you align and position the discharge connection in relation to the access frame. 4. Place the discharge connection in position, and tighten the nuts. 5. Install the guide bars: a) Secure the guide bars in the bracket. b) Check that the guide bars are placed vertically. Use a level or a plumb line. 6. Connect the discharge pipe to the discharge connection. 18 Flygt 3171 Installation, Operation, and Maintenance Manual Installation 7. Prepare for the level regulator: a) Bolt the cable holder to the access frame. b) Attach the level regulator cable to the cable holder and adjust the height of the level regulator. c) Protect bolts and nuts with a corrosion-preventive compound. 8. Lower the pump along the guide bars. 9. Secure the motor cable: a) Fasten the permanent lifting device to the pump and to the access frame. For example, you can use a stainless-steel lifting chain with shackles. b) Fasten the cable to the cable holder. Make sure that the cable cannot be sucked into the pump inlet or that it is neither sharply bent, or pinched. Support straps are required for deep installations. c) Connect the motor cable and the starter and monitoring equipment according to the separate instructions. Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 31). Clean all debris from the sump before starting the pump. Install with S-installation WS006270A In the S-installation, the pump is transportable and intended to operate either completely or partially submerged in the pumped liquid. The pump is equipped with a connection for hose or pipe and stands on a base stand. These requirements and instructions only apply when the installation is made according to the dimensional drawing. For information about the different installation types, see Parts List. Figure 5: S-installation 1. Run the cable so that it has no sharp bends. Make sure that it is not pinched, and cannot be sucked into the pump inlet. 2. Connect the discharge line. 3. Lower the pump into the sump. 4. Place the pump on the base and make sure it cannot fall over or sink. Alternatively, the pump can be suspended with a lifting chain just above the sump bottom. Make sure that the pump cannot rotate at startup or during operation. 5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions. Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 31). Flygt 3171 Installation, Operation, and Maintenance Manual 19 Installation Install with T/Z-installation WS006272A WS006273A In the T-installation, the pump is installed in a vertical position in a dry well next to the wet sump. These requirements and instructions only apply when the installation is made according to the dimensional drawing. In the Z-installation, the pump is installed in a horizontal position on a support stand in a dry well next to the wet sump, and a bell-mouth is connected to the inlet pipe. These requirements and instructions are for Z-installations that comply to the dimensional drawing. Figure 7: Z-installation Figure 6: T-installation These items are required: • Support stand and anchor bolts for anchoring the pump to a base • Inlet elbow for connecting the suction line and discharge line • Shut-off valves that allow you to remove the pump from service • Air vent on the discharge side between the pump and the check valve • Level regulators or other control equipment for start, stop, and alarm NOTICE: The risk of freezing is particularly high in T- or Z-installations. 1. Fasten the pump: a) Use the anchor bolts to bolt the support stand to the concrete base. b) Bolt the pump to the support stand and the suction connection. 2. Make sure that the pump is vertical for the T-installation or horizontal for the Zinstallation. 3. Connect the suction line and discharge line. 4. Connect the motor cable and the starter and monitoring equipment according to the separate instructions. Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 31). 5. Make sure that the weight of the pump does not put strain on the piping. 20 Flygt 3171 Installation, Operation, and Maintenance Manual Installation Make the electrical connections General precautions Electrical Hazard: • A certified electrician must supervise all electrical work. Comply with all local codes and regulations. • Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. This applies to the control circuit as well. • Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the end of the motor cable above the liquid level. • Make sure that all unused conductors are insulated. • There is a risk of electrical shock or explosion if the electrical connections are not correctly carried out or if there is fault or damage on the product. WARNING: Do not install the starter equipment in an explosive zone unless it is explosion-proof rated. CAUTION: If the pump is equipped with automatic level control and/or internal contactor, there is a risk of sudden restart. Requirements These general requirements apply for electrical installation: • The supply authority must be notified before installing the pump if it will be connected to the public mains. When the pump is connected to the public power supply, it may cause flickering of incandescent lamps when started. • The mains voltage and frequency must agree with the specifications on the data plate. If the pump can be connected to different voltages, then the connected voltage is specified by a yellow sticker close to the cable entry. • The fuses and circuit breakers must have the proper rating, and the pump overload protection (motor protection breaker) must be connected and set to the rated current according to the data plate and if applicable the cable chart. The starting current in direct-on-line start can be up to six times higher than the rated current. • The fuse rating and the cables must be in accordance with the local rules and regulations. • If intermittent operation is prescribed, then the pump must be provided with monitoring equipment supporting such operation. • If stated on the data plate, then the motor is convertible between different voltages. • The thermal contacts/thermistors must be in use. • For FM-approved pumps, FLS must be connected and in use in order to meet approval requirements. Cables These are the requirements to follow when you install cables: • The cables must be in good condition, not have any sharp bends, and not be pinched. • The sheathing must not be damaged and must not have indentations or be embossed (with markings, etc.) at the cable entry. Flygt 3171 Installation, Operation, and Maintenance Manual 21 Installation • The cable entry seal sleeve and washers must conform to the outside diameter of the cable. • The minimum bending radius must not be below the accepted value. • If using a cable which has been used before, a short piece must be peeled off when refitting it so that the cable entry seal sleeve does not close around the cable at the same point again. If the outer sheath of the cable is damaged, then replace the cable. Contact an Xylem service shop. • The voltage drop in long cables must be taken into account. The drive unit’s rated voltage is the voltage measured at the cable connection point in the pump. • The screened cable must be used according to the European CE requirements if a Variable Frequency Drive (VFD) is used. For more information, contact your Xylem representative (VFD-supplier). Earthing (Grounding) Electrical Hazard: • You must earth (ground) all electrical equipment. This applies to the pump equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is connected correctly. • If the motor cable is jerked loose by mistake, the earth (ground) conductor should be the last conductor to come loose from its terminal. Make sure that the earth (ground) conductor is longer than the phase conductors. This applies to both ends of the motor cable. • Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault protection device to the earthed (grounded) connectors if persons are likely to come into physical contact with the pump or pumped liquids. Connect the motor cable to the pump CAUTION: Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the end of the motor cable above the liquid level. 1 WS006002A 2 1. 2. 22 Entrance cover O-ring Flygt 3171 Installation, Operation, and Maintenance Manual Installation For more information about the cable entry, see the Parts list. 1. Remove the entrance cover and the O-ring from the stator housing. This provides access to the terminal board. 2. Check the data plate to see which connections are required for the power supply. 3. Arrange the connections on the terminal board in accordance with the required power supply. Links (jumper strips) are not used with the Y/D start. 4. Connect the mains leads (L1, L2, L3, and earth (ground)) according to applicable cable chart. The earth (ground) lead must be 100 mm ( 4.0 in.) longer than the phase leads in the junction box of the unit. 5. Make sure that the pump is correctly connected to earth (ground). 6. Connect the control leads to the applicable terminal board. 7. Make sure that any thermal contacts incorporated in the pump are properly connected to the terminal board. 8. Install the entrance cover and the O-ring on the stator housing. 9. Fasten the screws on the entrance flange so that the cable insertion assembly bottoms out. Connect the motor cable to the starter and monitoring equipment WARNING: Do not install the starter equipment in an explosive zone unless it is explosion-proof rated. NOTICE: • Either thermal contacts or thermistors are incorporated in the pump. • Thermal contacts must never be exposed to voltages higher than 250 V, breaking current maximum 4 A. It is recommended that they are connected to 24 V over separate fuses to protect other automatic equipment. 1. If thermal contacts are included in the pump installation, connect the T1 and T2 control conductors to the MiniCAS II monitoring equipment. NOTICE: Ex-approved products must always have the thermal contacts connected irrespective of the ambient temperature. 2. If thermistors are included in the pump installation, and screened or auxiliary cable is used, then connect T1(1) and T2(2) to thermistor relay or MAS 711, and T3(3) and T4 (4) to MiniCAS II or MAS 711. 3. Connect the mains leads (L1, L2, L3, and earth [ground]) to the starter equipment. For information about the phase sequence and the color codes of the leads, see Cable charts (page 24). 4. Check the functionality of the monitoring equipment: a) Check that the signals and the tripping function work properly. b) Check that the relays, lamps, fuses, and connections are intact. Replace any defective equipment. Flygt 3171 Installation, Operation, and Maintenance Manual 23 Installation Cable charts Description This topic contains general connection information. It also provides cable charts that show connection alternatives for use with different cables and power supply. L2 L1 L3 L1 L2 L3 WS000509C T1 T2 Figure 8: Phase sequence Connection locations The figures in this section illustrate how to interpret the connection strip symbols. T1 T2 T3 T4 U1 V1 W1 L1 U2 U1 W2 V2 L3 L2 WS004133C *YE WH GN/YE W1 L3 W2 U1 V1 W1 W2 U2 V2 L2 U2 GC V1 U1 V1 W1 W2 U2 V2 L1 Stator leads Terminal board Motor cable leads Stator (internal connection illustrated) V2 L1 L2 L3 1. 2. 3. 4. 24 Flygt 3171 Installation, Operation, and Maintenance Manual Installation 1 2 3 9 10 7 FLS 10 11 8 CLS Starter equipment and mains leads (L1, L2, L3) Earth (ground) Functional ground Control leads (T1, T2, T3, T4) Thermal contact FLS FLS 10 CLS Thermistor Level sensor Capacitor WS004134A FLS 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. T1 T2 T3 T4 L1 L2 L3 5 4 Colors and markings of leads Motor Connection SUBCAB 7GX Screenflex 7GX 3 BK 1 BN RD BN L2 BK 2 BK BK BK L3 BK 3 GY WH GY L1 BK 4 - - - L2 BK 5 - - - L3 BK 6 - - GN/YE *SUBCAB AWG * * Ground conductor is stranded around core GC=Ground check GN/YE - U1,U5 = RD U2 = GN V1,V5 = BN V2 = BU W1,W5 = YE W2 = BK T1,T2 = WH or YE Colors and marking of the main leads Mains 3 773 29 00/2 SUBCAB 4GX SUBCAB AWG Screenflex 4GX BN RD BN BK BK BK L3 L1 L2 BK 3 BK 4 - - Screen (WH) Screen (WH) GC - - - - GN/YE U1 W2 V1 U2 W1 V2 - - - BK 6 GY WH GY BK 5 GN/YE - GN/YE - **Screen/PE from cores Screen (WH) YE - - One cable Terminal clamps 6 stator leads SUBCAB Screened BK 1 BK 2 L3 *SUBCAB AWG * * Ground conductor is stranded around core GC=Ground check SUBCAB 7GX Screenflex 7GX L1 L2 U1 W2 V1 U2 W1V2 BK STATOR LEADS RD BN = Brown BK = Black WH = White OG = Orange GN = Green GN/YE = Green-Yellow RD = Red GY = Grey BU = Blue YE = Yellow **Screen/PE from cores Screen (WH) YE BN GN YE Motor Connection COLOR STANDARD - - GC - GN/YE Screen (WH) Screen (WH) 773 29 00/2 SUBCAB Screened L1 BU U1,U5 = RD U2 = GN V1,V5 = BN V2 = BU W1,W5 = YE W2 = BK T1,T2 = WH or YE SUBCAB 4GX SUBCAB AWG Screenflex 4GX L1 L3 L2 WS004551B Mains U1 W2 V1 U2 W1 V2 BN = Brown BK = Black WH = White OG = Orange GN = Green GN/YE = Green-Yellow RD = Red GY = Grey BU = Blue YE = Yellow STATOR LEADS 6 LEADS COLOR STANDARD Colors and marking of the main leads Color code standard Code Description BN Brown BK Black WH White OG Orange GN Green GNYE Green-Yellow Flygt 3171 Installation, Operation, and Maintenance Manual 25 Installation Code Description RD Red GY Grey BU Blue YE Yellow Motor connection Terminal clamps 6 stator leads WS003903A U1 W2 V1 U2 W1 V2 Figure 9: Terminal clamps, 6 stator leads Connections included • 6–leads connection (page 26) • 9-leads connection (page 27) • Screened cable connection (page 28) 6–leads connection If a separate control cable is used, then the control cores in the motor cable are never used. One cable (left) and two cables (right) Y-connection. U1 BU YE BN L1 U2 V2 GN W1 V1 U1 RD BU BK BN GN YE U1 W2 V1 U2 W1V2 RD Y Two cables One cable L3 1 L21 W2 L2 V2 V1 WH BK W1 V1 U1 L11 L3 WS003803A L2 *YE L3 GN/YE L1 L22 L32 W1 L12 GC W2 U1 W2 V1 U2 W1 V2 U2 Figure 10: Y-connection One cable (left) and two cables (right) D-connection. 26 Flygt 3171 Installation, Operation, and Maintenance Manual Installation One cable D Two cables BU *YE WH YE L2 1 L3 1 L11 GN/YE L2 L3 U2 GC L22 L32 V2 V1 W2 W1 L3 L2 WS003804A GN RD L12 L1 U1 U1 W2 V1 U2 W1 V2 BK BN BU YE U1 W2 V1 U2 W1 V2 BK BN RD U1W2 V1 U2 W1 V2 GN L1 U1W2 V1 U2 W1 V2 Figure 11: D-connection One cable (left) and two cables (right)Y/ D-connection. Y/D Two cables One cable L2 2 5 L32 6 L3 1 3 U1 V1 W1 U2 V2 W2 BU YE GN RD L11 1 L2:2 L2 1 2 WS003805A L21 2 L12 4 L3:2 WH L31 3 L22 5 *YE L12 1 L32 6 L1:2 GC GN/YE L12 4 BK BN U1 W2 V1 U2 W1 V2 BU YE GN BN U1 W2 V1 U2 W1 V2 RD BK U1W2 V1 U2 W1V2 L2:1 L3:1 L1:1 U1W2 V1 U2 W1V2 Figure 12: Y/D-connection Y and D-connection, only applicable to 70 mm2 terminal clamp. D Y BU L11 L3 1 L2 1 Only applicable to 70mm2 terminal clamp WS003813A L2 1 1 WH L3 *YE L1 1 GC GN/YE YE U1 W2 V1 U2 W1 V2 BK BN GN W1 RD U1 W2 V1 U2 W1 V2 V1 BU BK U2 V2 GN W1 YE BN V1 U1 RD U1 Figure 13: Y or D-connection 9-leads connection If a separate control cable is used, then the control cores in the motor cable are never used. One cable (left) and two cables (right) Y-parallel connection. Flygt 3171 Installation, Operation, and Maintenance Manual 27 Installation One cable Two cables BU BK GN YE YE BN BN RD RD U1U5 V1 V5 W1W5 U2 V2 W2 BK GN BU YE YE BN BN RD RD U1U5 V1 V5 W1W5 U2 V2 W2 YL1 U1 U5 WS003826A V5 V2 L3 WH *YE GN/YE V1 U1 U5 V1 V5 W1 W5 L2 1 L3 1 L11 5 W L2 L2 2 L3 2 L2 L3 L1 1 W L1 2 GC 2 W U1 U5 V1 V5 W1 W5 U2 Figure 14: Y-parallel connection One cable (left) and two cables (right) Y-serial connection. One cable Two cables Y-SER W1 U2 U5 V2V5W2W5 YE BN V1 L1 U1 GN RD BU BN BK YE U1 RD BK YE YE BU BN BN GN RD RD U1 U5 U2 V1 V5 V2 W1 W5 W2 U2 V2 V1 L3 L2 WS003837B WH *YE L2 1 V5 W1 V1 U1 L2 GN/YE L3 L31 W1 L1 L22 L32 L12 L11 W5 W2 U1 U5 V1 V5 W1 W5 U5 GC Figure 15: Y-serial connection Screened cable connection Cable without separate ground conductor. Screen as ground conductor. Screened SUBCAB & FGB Screened Cable without sep. ground conductor Screen as ground conductor GY WS003815A T1 (WH) FGB Screened T2 (WH) T4 (WH) T3 (WH) T1 (WH) Mini CAS+AUX T2 (WH) T4 (WH) T3 (WH) Mini CAS L3 T2 (WH) L2 T1 (WH) L1 BK BN GN/YE shrink hose Figure 16: Screened SUBCAB and FGB Screened * For screened SUBCAB T3 and T4 shall also be twisted separately. 28 Flygt 3171 Installation, Operation, and Maintenance Manual Installation Screenflex and SUBCAB with functional ground T1 and T2 twisted* T1 and T2 twisted* White insulation hose Screen T1 T2 1 2 5 BK BK BK BK 4 3 6 T1 T2 WS003824A L3 GY BK BK L2 BK GN/YE GN/YE L1 BN White insulation hose Screen * For screened SUBCAB T3 & T4 shall also be twisted separately Figure 17: Screenflex and SUBCAB with functional ground Sensor-connection Connection to the pump Color and marking of control leads SUBCAB 4GX/7G and SUBCAB AWG Screenflex SUBCAB Screened T1 WH T1 OG WH T1 T2 WH T2 BU WH T2 T3 - - WH T3 T4 - - WH T4 WS003843A Control Figure 18: Color and marking of control leads T15 T16 T1 T2 WS003850A Sensor terminal clamps Figure 19: Sensor terminal clamps Flygt 3171 Installation, Operation, and Maintenance Manual 29 Installation FLS 10 and Thermal detectors FLS + Thermal detectors TC Max 12 V WH/YE BN WH/YE T1 Control leads T1/*OG/1 T2 T2/*BU/2 +7 -5 Mini CAS T15 BN **T3 **T4 *SUBCAB AWG WS003855A FLS **Screened SUBCAB ∞ Ohm Overtemperature 1200 Ohm OK 430 Ohm Leakage FLS 10 and Thermistor FLS + Thermistor RD Max 12 V BN/BU Control leads T1/1 T2 RD Thermistor relay T2/2 T15 FLS +7 T3/3 T16 BN/BU T4/4 Mini CAS -5 T=25°C (77°F) R ≤ 100 Ohm T=135°C (275°F) (TREF –5°C (23°F)) R ≤ 550 Ohm T=145°C (293°F) (TREF +5°C (41°F)) R ≤ 1330 Ohm WS003876A T1 Max 2.5 V Thermal detectors, FLS disconnected Thermal detectors FLS Disconnected TC Max 12 V WH/YE BN WH/YE BN *SUBCAB AWG **Screened SUBCAB 30 T1 Control leads T1/*OG/1 T2 T2/*BU/2 T15 +7 -5 Mini CAS **T3 **T4 WS003869A FLS Flygt 3171 Installation, Operation, and Maintenance Manual Installation Connection to the monitoring equipment MiniCAS II 24 V AC/DC 2 C CC L1 L2 P R 10 R 6 T15 T1 7+ 12 VDC T2 FLS10 511 L1 9 10S 8 L2 4 CC 1 Pump contactor Control circuit Caution light (leakage) Caution light (stator over-temperature) Pump main supply Reset switch 3 C P WS002623B Check the impeller rotation WARNING: The starting jerk can be powerful. WS006253A 1. Start the motor. 2. Stop the motor after a few seconds. 3. Check that the impeller rotates according to this illustration. Flygt 3171 Installation, Operation, and Maintenance Manual 31 Installation The correct direction of impeller rotation is clockwise when you look at the pump from above. 4. If the impeller rotates in the wrong direction, transpose two phase leads (3-phase) and do this procedure again. 32 Flygt 3171 Installation, Operation, and Maintenance Manual Operation Operation Precautions WARNING: • Never operate the pump without safety devices installed. • Never operate the pump with the discharge valve closed. • Make sure you have a clear path of retreat. • Never work alone. CAUTION: If the pump is equipped with automatic level control and/or internal contactor, there is a risk of sudden restart. Distance to wet areas Electrical Hazard: Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to the unit when being in contact with the pumped or mixed liquid. Noise level NOTICE: The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may be exceeded in some installations and at certain operating points on the performance curve. Make sure that you understand the noise level requirements in the environment where the pump is installed. Failure to do so may result in hearing loss or violation of local laws. Start the pump WARNING: • If you need to work on the pump, make sure that it is isolated from the power supply and cannot be energized. • Make sure that the unit cannot roll or fall over and injure people or damage property. • In some installations, the pump and the surrounding liquid may be hot. Bear in mind the risk of burn injuries. • Make sure nobody is close to the unit when it is started. The unit will jerk in the opposite direction of the impeller rotation. NOTICE: Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation. 1. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. 2. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms. Flygt 3171 Installation, Operation, and Maintenance Manual 33 Operation 3. Check that the monitoring equipment works. 4. Start the pump. 34 Flygt 3171 Installation, Operation, and Maintenance Manual Maintenance Maintenance Precautions WARNING: • Always follow safety guidelines when working on the product. See Introduction and Safety (page 3). • Disconnect and lock out electrical power before installing or servicing the pump. • Make sure that the unit cannot roll or fall over and injure people or damage property. • Rinse the unit thoroughly with clean water before working on the unit. • Rinse the components in water after dismantling. Make sure that you follow these requirements: • Check the explosion risk before you weld or use electrical hand tools. • Allow all system and pump components to cool before you handle them. • Make sure that the product and its components have been thoroughly cleaned. • Do not open any vent or drain valves or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping. Maintenance guidelines During maintenance and before reassembly, always remember to perform these tasks: • Clean all parts thoroughly, particularly O-ring grooves. • Change all O-rings, gaskets, and seal washers. • Lubricate all springs, screws, and O-rings with grease. During reassembly, always make sure that existing index markings are in line. The reassembled drive unit must always be insulation-tested and the reassembled pump must always be test-run before normal operation. Torque values All screws and nuts must be lubricated to achieve correct tightening torque. Screws that are screwed into stainless steel must have the threads coated with suitable lubricants to prevent seizing. If there is a question regarding the tightening torques, please contact a sales representative. Screws and nuts Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs) Property class M4 M5 M6 M8 M10 M12 M16 M20 50 1.0 (0.74) 2.0 (1.5) 3.0 (2.2) 8.0 (5.9) 15 (11) 27 (20) 65 (48) 127 (93.7) 220 (162) 434 (320) 70, 80 2.7 (2) 5.4 (4) 9.0 (6.6) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) Flygt 3171 Installation, Operation, and Maintenance Manual M24 M30 629 (464) 1240 (915) 35 Maintenance Property class M4 M5 M6 M8 M10 M12 100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) M16 M20 M24 M30 115 (84.8) 248 (183) 481 (355) — — M30 Table 2: Steel, torque Nm (ft-lbs) Property class M4 M5 M6 M8 M10 M12 M16 M20 M24 8.8 2.9 (2.1) 5.7 (4.2) 9.8 (7.2) 24 (18) 47 (35) 81(60) 194 (143) 385 (285) 665 (490) 1310 (966.2) 10.9 4.0 (2.9) 8.1 (6) 14 (10) 33 (24) 65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840 (1357) 12.9 4.9 (3.6) 9.7 (7.2) 17 (13) 40 (30) 79 (58) 136 (100) 333 (245) 649 (480) 1120 (825.1) 2210 (1630) Hexagon screws with countersunk heads For hexagon socket head screws with countersunk head, maximum torque for all property classes must be 80% of the values for property class 8.8 above. Change the coolant This image shows the plugs that are used to change the coolant. 2 2 1 1 2 WS001480A 2 Figure 21: Without a cooling jacket Figure 20: With a cooling jacket 1. 2. Inspection plug Coolant plugs Empty the coolant WARNING: The seal housing may be pressurized. Hold a rag over the inspection/ filling plugs to prevent splatter. 1. Empty the coolant in the inspection chamber: a) Remove the inspection plug. 36 Flygt 3171 Installation, Operation, and Maintenance Manual Figure 22: Without a cooling jacket WS002122A WS001505A Maintenance Figure 23: With a cooling jacket WS001471A b) Pump out any coolant from the inspection chamber, as shown here. c) Replace the inspection plug and O-ring and tighten. Tightening torque: 44 Nm (33 ft-lbs) 2. Empty the coolant: a) Place the pump in a horizontal position, or leave it upright to use a pump to empty the coolant. Flygt 3171 Installation, Operation, and Maintenance Manual 37 WS001463A Maintenance WS001411A WS001412A b) If the pump is laid in a horizontal position, place a container under the pump. c) Remove the coolant plugs and empty the coolant. Figure 24: With a cooling jacket Figure 25: Without a cooling jacket Fill with coolant Use a coolant that is a mixture of 70% water and 30% monopropylene glycol. The coolant should prevent corrosion and be nonpoisonous (generally recognized as safe by the FDA as food additives under part 184 and 182). NOTICE: Clean water with an anti-corrosive is an acceptable coolant when there is no risk of freezing. 1. Fill with coolant until it overflows through the opposite hole, as shown here. 38 Flygt 3171 Installation, Operation, and Maintenance Manual Maintenance Figure 26: With cooling jacket WS001469A WS000966A Quantity: approximately • 4.6 L (4.9 qt.) without cooling jacket • 16.7 L (17.6 qt.) with cooling jacket, versions 3171.091/.095/.181/.185/.350/.390 • 24 L (25.4 qt.) with cooling jacket, versions 3171.800/.810/.820/.830/.840/.850 Figure 27: Without cooling jacket 2. Replace the O-rings. 3. Tighten the coolant plugs. Tightening torque: 44 Nm (33 ft-lbs) Service the pump Type of service Purpose Inspection interval Initial inspection To make a check up of the pump condition by an authorized Xylem service representative and, based on the result and findings from these measures, to determine the intervals for periodical inspection and major overhaul for the specific installation. Within the first year of operation. Periodical inspection To prevent operational interruptions and machine breakdown. Measures to secure performance and pump efficiency are defined and decided for each individual application. It can include such things as impeller trimming, wear part control and replacement, control of zinc-anodes and control of the stator. Up to 12,000 hours or 3 years, whichever comes first. Applies to normal applications and operating conditions at media (liquid) temperatures <40°C. Major overhaul To secure a long operating lifetime for the product. It includes replacement of key components and the measures taken during an inspection. Up to 24,000 hours or 6 years, whichever comes first. Applies to normal applications and operating conditions at media (liquid) temperatures <40°C. Flygt 3171 Installation, Operation, and Maintenance Manual 39 Maintenance NOTICE: Shorter intervals may be required when the operating conditions are extreme, for example with very abrasive or corrosive applications or when the liquid temperatures exceed 40°C (104°F). Inspection Service item Cable 1. 2. If the outer jacket is damaged, replace the cable. Check that the cables do not have any sharp bends and are not pinched. Connection to power Check that the connections are properly tightened. Electrical cabinets Check that they are clean and dry. Impeller 1. 2. Check the impeller clearance. Adjust the impeller, if necessary. Inspection chamber 1. 2. Drain all liquid, if any. Check the resistance of the leakage sensor. Normal value approx.1200 ohms, alarm approx. 430 ohms. Insulation Use a megger maximum 1000 V. 1. Check that the resistance between the earth (ground) and phase lead is more than 5 megohms. 2. Conduct a phase-to-phase resistance check. Junction box Check that it is clean and dry. Level regulators Check the condition and functionality. Lifting device Check that local safety regulations are followed. Lifting handle 1. 2. 3. Check the screws. Check the condition of the lifting handle. Replace if necessary. O-rings 1. 2. 3. Replace the oil plug O-rings. Replace the O-rings at the entrance or junction cover. Grease the new O-rings. Overload protection and other protections Check the correct settings. Personnel safety devices Check the guard rails, covers, and other protections. Rotation direction Check the impeller rotation. Seal housing 40 Action 1. 2. Fill with new coolant, if necessary. Check that the freezing point is lower than -13°C (9°F). Terminal board Check that the connections are properly tightened. Thermal contacts Normally closed circuit; interval 0–1 ohm. Flygt 3171 Installation, Operation, and Maintenance Manual Maintenance Service item Action Thermistor Check the resistance is between 20–250 ohms and the measured voltage is maximum 2 V DC. Voltage and amperage Check the running values. Major overhaul For a major overhaul, take this action in addition to the tasks listed under Inspection. Service item Action Support and main bearing Replace the bearings with new bearings. Mechanical seal Replace with new seal units. Service in case of alarm For information about indication values for sensors, see Sensor-connection (page 29). Alarm source FLS10 Action 1. Drain the fluid in the inspection chamber. Fill with new coolant if necessary. 2. Check the freezing point (lower than -13°C or 9°F). Check the inspection chamber again after one week of operation. If leakage has occurred: 1. Drain the fluid. 2. Change the mechanical seal unit. 3. Replace with new coolant. The thermistor/Thermal contact The overload protection 1. 2. Check the coolant level (pump with cooling jacket). Check the start and stop levels. Check that the impeller can rotate freely. Replace the impeller Required tools: • 12 mm hexagon bit adapter with an extension of at least a 100 mm (4 in.) • Rod (wood or plastic) for locking the impeller in place. Flygt 3171 Installation, Operation, and Maintenance Manual 41 Maintenance WARNING: • If you fail with the impeller installation, you must redo the installation procedure from the beginning. • A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. • When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller. The impeller must not be allowed to make contact with the concrete floor or other hard and rough surfaces. Replace the impeller for wet installation Remove the impeller: wet installation CAUTION: Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury. 1. Place the pump in a horizontal position. 2. Remove the impeller: a) Remove the flush valve cover and its O-ring. b) Lock the impeller in place by inserting a rod through the hole. c) Remove the impeller screw. WS001482A d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. 42 Flygt 3171 Installation, Operation, and Maintenance Manual WS001450A Maintenance e) Hand-tighten the impeller screw to prevent it from falling off. WS001490A WS006264A f) Remove the rod. 3. Raise the pump. 4. Remove the drive unit from the pump housing: a) Remove the pump housing screws. b) Remove the drive unit from the pump housing. Flygt 3171 Installation, Operation, and Maintenance Manual 43 WS001477A Maintenance WS006263A 5. Remove the impeller: a) Place the drive unit horizontally. b) Remove the impeller screw. c) Remove the impeller and the conical sleeve. 44 Flygt 3171 Installation, Operation, and Maintenance Manual WS001461B Maintenance Install the impeller: wet installation 1. Mount the impeller: a) Make sure that the end of the shaft is free from burrs. Polish off any flaws with a fine emery cloth. b) Grease the shaft end. NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. WS002057A c) Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw. Always use a new impeller screw. Flygt 3171 Installation, Operation, and Maintenance Manual 45 WS002058A Maintenance d) Adjust the adjustment screw so that it is flush with the sleeve. WS001759A WS006256A e) Fit the sleeve and impeller to the shaft. f) Hand-tighten the impeller screw to prevent it from falling off. 2. Fit the pump housing: a) Fit a new and greased O-ring on the seal housing cover. b) Grease the pump housing screws. c) Raise the drive unit. d) Place the drive unit into the pump housing. 46 Flygt 3171 Installation, Operation, and Maintenance Manual Maintenance WS006260A e) Adjust its position so that the inspection hole is on the same side as the flush valve. f) Tighten the screws in diagonal sequence. For tightening torque, see Torque values (page 35). 3. Remove the impeller screw: a) Place the pump horizontally. b) Lock the impeller in place by inserting a rod through the hole. c) Remove the impeller screw and the washer. WS001482A 4. Adjust the impeller: a) Using a hexagon-bit adapter, turn the adjustment screw clockwise until the impeller makes contact with the pump housing. For tightening torque, see Torque values (page 35). b) Tighten it a further 1/8 turn (45°). Flygt 3171 Installation, Operation, and Maintenance Manual 47 WS001451A Maintenance 5. Fasten the impeller: a) Fit the greased washer and impeller screw. b) Tighten the impeller screw. For tightening torque, see Torque values (page 35). c) Tighten it a further 1/8 turn (45°). WS001486A d) Remove the rod used to lock the impeller. e) Fit the O-ring and flush valve cover and fasten it with screws. For tightening torque, see Torque values (page 35). f) Check that the impeller can rotate freely. CAUTION: Beware of the pinch point hazard between the rotating impeller and the guide pin. 6. Check that the clearance between the impeller and the insert ring is 0.1–0.5 mm (0.004–0.02 in.). 48 Flygt 3171 Installation, Operation, and Maintenance Manual WS003730A Maintenance WS003731A WS001504A 7. If applicable, adjust clearance to 0.1–0.5 mm (0.004–0.02 in.) between the guide pin and the impeller. Replace the impeller for dry installation Remove the impeller: dry installation 1. Remove the drive unit from the pump housing: a) Remove the pump housing screws. Flygt 3171 Installation, Operation, and Maintenance Manual 49 WS001539A Maintenance WS001477A b) Remove the drive unit from the pump housing. 2. Remove the impeller: a) Place the drive unit horizontally. b) Lock the impeller as shown in the figure. c) Remove the impeller screw. 50 Flygt 3171 Installation, Operation, and Maintenance Manual Maintenance WS001494A WS001461B d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. e) Remove the impeller and the conical sleeve. Install the impeller: dry installation 1. Prepare the sleeve: a) Make sure that the end of the shaft is free from burrs. Polish off any flaws with a fine emery cloth. b) Grease the shaft end. NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. Flygt 3171 Installation, Operation, and Maintenance Manual 51 Maintenance WS002057A WS002058A c) Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw. Always use a new impeller screw. d) Unscrew the adjustment screw approximately 5 mm (0.2 in.). WS002106A e) Measure and note the distance A. 52 Flygt 3171 Installation, Operation, and Maintenance Manual WS001472A A Maintenance WS006256A 2. Mount the impeller: a) Fit the sleeve and the impeller to the shaft. b) Fit the impeller screw and washer and tighten. Flygt 3171 Installation, Operation, and Maintenance Manual 53 WS001492A Maintenance WS002008A 3. Make sure that the O-ring is removed from the seal housing cover. WS001475A 4. Measure the trim distance: a) Place the drive unit in the pump housing. Make sure that the drive unit is parallel with the pump housing by hand-tightening the pump housing screws. b) Check the distance between the seal housing cover and the pump housing with a feeler gauge. Check diagonally at four points. 54 Flygt 3171 Installation, Operation, and Maintenance Manual WS002089A Maintenance WS001473A B c) Note the largest distance B. WS001477A d) Lift the drive unit out of the pump housing and remove the impeller and conical sleeve. 5. Trim to the correct distance: a) Calculate the measure C according to the formula shown in the image. Flygt 3171 Installation, Operation, and Maintenance Manual 55 WS001475A C=A-B-0.5 mm Maintenance WS001492A b) Turn the adjustment screw until C is reached. 6. Fasten the impeller: a) Fit the sleeve, impeller, greased washer with a greased impeller screw. b) Tighten the impeller screw. For tightening torque, see Torque values (page 35). c) Tighten it further 1/8 turn (45°). 7. Install the drive unit in the pump housing: a) Fit a new and greased O-ring to the seal housing cover. 56 Flygt 3171 Installation, Operation, and Maintenance Manual Maintenance WS002056A WS001475A b) Place the drive unit in the pump housing. c) Adjust the position of the drive unit so that the inspection hole is on the same side as the flush valve. d) Tighten the greased screws diagonally. For tightening torque, see Torque values (page 35). Flygt 3171 Installation, Operation, and Maintenance Manual 57 Maintenance WS001478A If you need to adjust the impeller, redo the replace the impeller procedure from the beginning. 58 Flygt 3171 Installation, Operation, and Maintenance Manual Troubleshooting Troubleshooting Introduction Follow these guidelines when troubleshooting the pump: • Disconnect and lock out the power supply except when conducting checks that require voltage. • Make sure that no one is near the pump when the power supply is reconnected. • When troubleshooting electrical equipment, use the following: • Universal instrument multimeter • Test lamp (continuity tester) • Wiring diagram The pump does not start WARNING: Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury. NOTICE: Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage. Cause Remedy An alarm signal has been triggered on the control panel. Check that: • The impeller rotates freely. • The sensor indicators do not indicate an alarm. • The overload protection is not tripped. If the problem still persists: Contact the local Xylem service shop. The pump does not start automatically, but can be started manually. Check that: • The start level regulator is functioning. Clean or replace if necessary. • All connections are intact. • The relay and contactor coils are intact. • The control switch (Man/Auto) makes contact in both positions. Check the control circuit and functions. The installation is not receiving voltage. Check that: • The main power switch is on. • There is control voltage to the start equipment. • The fuses are intact. • There is voltage in all phases of the supply line. • All fuses have power and that they are securely fastened to the fuse holders. • The overload protection is not tripped. • The motor cable is not damaged. The impeller is stuck. Clean: Flygt 3171 Installation, Operation, and Maintenance Manual 59 Troubleshooting Cause Remedy • The impeller • The sump in order to prevent the impeller from clogging again. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, see Product Description (page 11). The pump does not stop when a level sensor is used WARNING: Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury. Cause Remedy The pump is unable to empty the sump to the stop level. Check that: • There are no leaks from the piping and/or discharge connection. • The impeller is not clogged. • The non-return valve(s) are functioning properly. • The pump has adequate capacity. For information: Contact the local Xylem service shop. There is a malfunction in the levelsensing equipment. • • • • The stop level is set too low. Raise the stop level. Clean the level regulators. Check the functioning of the level regulators. Check the contactor and the control circuit. Replace all defective items. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, see Product Description (page 11). The pump starts-stops-starts in rapid sequence 60 Cause Remedy The pump starts due to back-flow which fills the sump to the start level again. Check that: • The distance between the start and stop levels is sufficient. • The non-return valve(s) work(s) properly. • The length of the discharge pipe between the pump and the first nonreturn valve is sufficiently short. The self-holding function of the contactor malfunctions. Check: • The contactor connections. • The voltage in the control circuit in relation to the rated voltages on the coil. • The functioning of the stop-level regulator. • Whether the voltage drop in the line at the starting surge causes the contactor's self-holding malfunction. Flygt 3171 Installation, Operation, and Maintenance Manual Troubleshooting If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, see Product Description (page 11). The pump runs but the motor protection trips WARNING: Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury. NOTICE: Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage. Cause Remedy The motor protection is set too low. Set the motor protection according to the data plate and if applicable the cable chart. The impeller is difficult to rotate by hand. • Clean the impeller. • Clean out the sump. • Check that the impeller is properly trimmed. The drive unit is not receiving full voltage on all three phases. • Check the fuses. Replace fuses that have tripped. • If the fuses are intact, notify a certified electrician. The phase currents vary, or they are too high. Contact the local Xylem service shop. The insulation between the phases and ground in the stator is defective. 1. 2. Use an insulation tester. With a 1000 V DC megger, check that the insulation between the phases and between any phase and ground is > 5 megohms. If the insulation is less: Contact the local Xylem service shop. The density of the pumped fluid is too high. Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal) • Change the impeller, or • Change to a more suitable pump. • Contact the local Xylem service shop. There is a malfunction in the overload protection. Replace the overload protection. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, see Product Description (page 11). The pump delivers too little or no water WARNING: Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury. Flygt 3171 Installation, Operation, and Maintenance Manual 61 Troubleshooting NOTICE: Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage. Cause Remedy The impeller rotates in the wrong direction. • If it is a 3-phase pump, transpose two phase leads. • If it is a 1-phase pump: Contact the local Xylem service shop. One or more of the valves are set in the wrong positions. • • • • The impeller is difficult to rotate by hand. • Clean the impeller. • Clean out the sump. • Check that the impeller is properly trimmed. The pipes are obstructed. Clean out the pipes to ensure a free flow. The pipes and joints leak. Find the leaks and seal them. There are signs of wear on the impeller, pump, and casing. Replace the worn parts. The liquid level is too low. • Check that the level sensor is set correctly. • Depending on the installation type, add a means for priming the pump, such as a foot valve. Reset the valves that are set in the wrong position. Replace the valves, if necessary. Check that all valves are correctly installed according to media flow. Check that all valves open correctly. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, see Product Description (page 11). 62 Flygt 3171 Installation, Operation, and Maintenance Manual Technical Reference Technical Reference Application limits Data Description Liquid temperature 40°C (104°F) maximum For P- and S-installations without cooling jacket, the pump can be operated only when the sump level is at least 10 mm above the stator housing. Warm-liquid version (only with cooling jacket): 70°C (158°F) maximum Ex-approved pumps: 40°C (104°F) maximum Liquid density 1100 kg/m³ (9.2 lb per US gal) maximum pH of the pumped media (liquid) 5.5–14 Depth of immersion 20 m (65 ft) maximum Other For the specific weight, current, voltage, power ratings, and speed of the pump, see the data plate of the pump. Motor data Feature Description Motor type Squirrel-cage induction motor Frequency 50 or 60 Hz Supply 3-phase Starting method • Direct on-line • Star-delta • Soft starter Maximum starts per hour 30 evenly spaced starts per hour Code compliance IEC 60034-1 Rated output variation ±10% Voltage variation without overheating ±10%, provided that it does not run continuously at full load Voltage imbalance tolerance 2% Stator insulation class H (180°C [360°F]) Flygt 3171 Installation, Operation, and Maintenance Manual 63 Xylem |’zīləm| 1) The tissue in plants that brings water upward from the roots 2) A leading global water technology company We're 12,500 people unified in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efficiently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation. For more information on how Xylem can help you, go to xyleminc.com Xylem Water Solutions AB Gesällvägen 33 174 87 Sundbyberg Sweden Tel. +46-8-475 60 00 Fax +46-8-475 69 00 http://tpi.xyleminc.com Visit our Web site for the latest version of this document and more information The original instruction is in English. All nonEnglish instructions are translations of the original instruction. © 2012 Xylem Inc. 895383_12.0_en.US_2012-08_IOM.3171.091/.095/.181/.185/.350/.390/.800/.810/.820/.830/.840/.850
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