FLYGT 3153 Installation, Operation And Maintenance Manual

Flygt 3153

Installation,

Operation, and

Maintenance Manual

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..................................................................................................................9

Inspect the delivery.............................................................................................................................9

Inspect the package.........................................................................................................................9

Inspect the unit..................................................................................................................................9

Transportation guidelines..................................................................................................................9

Precautions........................................................................................................................................9

Position and fastening......................................................................................................................9

Lifting..................................................................................................................................................9

Temperature ranges for transportation, handling and storage..................................................10

Handling at freezing temperature................................................................................................10

Unit in as-delivered condition.......................................................................................................10

Lifting the unit out of liquid...........................................................................................................10

Storage guidelines............................................................................................................................11

Storage location.............................................................................................................................11

Freezing precautions.....................................................................................................................11

Long-term storage..........................................................................................................................11

Product Description.............................................................................................................................12

Pump design......................................................................................................................................12

Parts....................................................................................................................................................13

Monitoring equipment.....................................................................................................................14

Optional sensors.............................................................................................................................14

The data plate....................................................................................................................................14

Approvals...........................................................................................................................................15

Product approvals for hazardous locations.................................................................................15

EN approval plate...........................................................................................................................15

IEC approval plate..........................................................................................................................16

FM approval plate..........................................................................................................................16

Product denomination......................................................................................................................17

Installation.............................................................................................................................................18

Install the pump.................................................................................................................................18

Authority regulation.......................................................................................................................18

Fasteners.........................................................................................................................................18

Install with P-installation.................................................................................................................19

Install with S-installation.................................................................................................................20

Install with T/Z-installation.............................................................................................................21

Make the electrical connections......................................................................................................22

General precautions.......................................................................................................................22

Requirements..................................................................................................................................22

Cables..............................................................................................................................................23

Earthing (Grounding).....................................................................................................................23

Connect the motor cable to the pump........................................................................................23

Flygt 3153 Installation, Operation, and Maintenance Manual 1

Table of Contents

Connect the motor cable to the starter and monitoring equipment.......................................24

Cable charts....................................................................................................................................25

Sensor-connection.........................................................................................................................31

Check the impeller rotation.............................................................................................................33

Operation..............................................................................................................................................35

Precautions.........................................................................................................................................35

Distance to wet areas........................................................................................................................35

Noise level..........................................................................................................................................35

Start the pump...................................................................................................................................35

Maintenance.........................................................................................................................................37

Precautions.........................................................................................................................................37

Maintenance guidelines...................................................................................................................37

Torque values....................................................................................................................................38

Change the coolant..........................................................................................................................39

Empty the coolant..........................................................................................................................39

Fill with coolant...............................................................................................................................41

Service the pump..............................................................................................................................42

Inspection........................................................................................................................................43

Major overhaul................................................................................................................................44

Service in case of alarm.................................................................................................................44

Replace the impeller.........................................................................................................................44

Replace the impeller for wet installation.....................................................................................44

Replace the impeller for dry installation......................................................................................52

Troubleshooting...................................................................................................................................62

Introduction.......................................................................................................................................62

The pump does not start..................................................................................................................62

The pump does not stop when a level sensor is used.................................................................63

The pump starts-stops-starts in rapid sequence...........................................................................63

The pump runs but the motor protection trips.............................................................................64

The pump delivers too little or no water........................................................................................65

Technical Reference............................................................................................................................67

Application limits...............................................................................................................................67

Motor data..........................................................................................................................................67

2 Flygt 3153 Installation, Operation, and Maintenance Manual

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



Hazard levels

Hazard level

DANGER:

WARNING:

CAUTION:

Indication

A hazardous situation which, if not avoided, will result in death or serious injury

A hazardous situation which, if not avoided, could result in death or serious injury

A hazardous situation which, if not avoided, could result in minor or moderate injury

NOTICE:

• 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

Magnetic hazard

Magnetic hazards are indicated by a specific symbol that replaces the typical hazard level symbols:

CAUTION:

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.

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.

Wash the skin and eyes

Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin:

Action Condition

Chemicals or hazardous fluids in eyes

1. Hold your eyelids apart forcibly with your fingers.

2. Rinse the eyes with eyewash or running water for at least 15 minutes.

3. Seek medical attention.

Chemicals or hazardous fluids on skin

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least 1 minute.

3. 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).

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.


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.



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:



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 • 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.

After storage 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.


Product Description

Product Description

Pump design

The pump is submersible, and driven by an electric motor.

For a list of pump version and corresponding motor type, see Motor data (page 67).

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 67). 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

Pressure class

LT

MT

HT

SH

• 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.

Low head

Medium head

High head

Super high head


Product Description

Parts

13 14

9

8

12

11

10

2

1

3

6

5

4

7

Figure 1: Without cooling jacket

Figure 2: With cooling jacket

2

3

Positio n

1

4

7

8

5

6

9

10

11

12

Part

Monitoring sensor

Shaft

Cooling without jacket

Cooling with jacket

Flow diffuser

Seal housing

Description

Optional sensor. For information about sensors, see

Stainless steel, with an integrated rotor

The pump is cooled by the ambient liquid.

coolant whenever the pump is operated.

Monitoring equipment

The motor is cooled by a closed loop system. An integrated coolant pump circulates the

Provides heat transfer from the coolant to the pumped fluid.

Main bearings Consisting of a two-row angular contact ball bearing

Motor For information about the motor, see Motor data (page 67).

(page 14).

Impeller

Inspection chamber

Includes a coolant that lubricates and cools the seals; the housing acts as a buffer between the pumped fluid and the electric motor

N-impeller, a semi-open, two-vane impeller

Equipped with an FLS10 leakage sensor to prevent damages to the motor

FLS10 For information about FLS10, see Monitoring equipment (page 14).

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/Aluminum oxide WCCR/Al

2

• Outer seal: silicon carbide RSiC/RSiC

O

3


Product Description

Positio n

13

14

Part

Thermal contact/

Thermistors

Description

For information about the thermal contact and thermistors, see

(page 14).

Support bearing Consisting of a two-row ball bearing

Monitoring equipment

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

5

6

7

8

9 10 11 12 13 14 15 16

1.

Curve code/Propeller code

2.

Serial number, see Product denomination (page 17)

3.

Product number

17 18 19

24

23

22

21

20


Product Description

4.

Country of origin

5.

Additional information

6.

Phase; type of current; frequency

7.

Rated voltage

8.

Thermal protection

9.

Thermal class

10. Rated shaft power

11. International standard

12. Degree of protection

13. Rated current

14. Rated speed

15. Maximum submergence

16. Direction of rotation: L=left, R=right

17. Duty class

18. Duty factor

19. Product weight

20. Locked rotor code letter

21. Power factor

22. Maximum ambient temperature

23. Read installation manual

24. Notified body. Only for EN-approved Ex-products

Figure 3: The data plate

Approvals

Product approvals for hazardous locations

Pump

• 3153.091

• 3153.095

• 3153.390

• 3153.810

• 3153.830

• 3153.850

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.


Product Description

4

5

6 7 8

1

9

2

10

3

15

14

13

12

11

WS003972A

1.

Approval

2.

Approval authority + approval number

3.

Approval for Class I

4.

Approved drive unit

5.

Stall time

6.

Starting current/Rated current

7.

Duty class

8.

Duty factor

9.

Input power

10. Rated speed

11. Controller

12. Additional information

13. Maximum ambient temperature

14. Serial number

15. 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.

3

4

5 6 7

1

8

2

9

13

12

11

10

WS001279B

1.

Approval

2.

Approval authority + approval number

3.

Approved for drive unit

4.

Stall time

5.

Starting current/Rated current

6.

Duty class

7.

Duty factor

8.

Input power

9.

Rated speed

10. Controller

11. Additional information

12. Max. ambient temperature

13. Serial number

FM approval plate

This illustration describes the FM approval plate and the information contained in its fields.

1 1.

Temperature class

2.

Maximum ambient temperature

2

WS003973A


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.

NP 3085

Product code

Serial number

1 2 3

1.

Hydraulic part

2.

Installation type

3.

Sales 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.

NP 3085.183

1 2

1.

Sales denomination

2.

Version

The serial number is used for identification of an individual product, and is divided into four parts.

This is an example of a serial number, and an explanation of its parts.

NP 3085.183 - 951 0163

1 2 3 4

1.

Product code

2.

Production year

3.

Production cycle

4.

Running number


18

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.

WARNING:

A permanent-magnet motor generates voltage when the shaft is rotating. Ensure that the shaft can not rotate before performing any electrical installation.

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.

• If the unit has a permanent magnet motor, ensure that you have read and understood all safety instructions regarding permanent magnet motors.

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 3153 Installation, Operation, and Maintenance Manual

Installation

Install with P-installation

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.


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 33).

Clean all debris from the sump before starting the pump.

Install with S-installation

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.

20

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.



Installation

Install with T/Z-installation

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.


5. Make sure that the weight of the pump does not put strain on the piping.


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.

• A permanent-magnet motor generates voltage when the shaft is rotating. Ensure that the shaft can not rotate before performing any electrical installation.

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.


Installation

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.

• 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.


Installation

1

2

1.

Entrance cover

2.

O-ring

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.


Installation

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 25).

4. Ensure that the warning label is attached to the cable end. In case the label is missing, attach the spare label to the cable end.

The label is delivered with the pump.

5. 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.

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.


Installation

L1 L2 L3

L1

L2

L3

T1 T2

Figure 8: Phase sequence

Connection locations

The figures in this section illustrate how to interpret the connection strip symbols.

L1 L2 L3 T1 T2 T3 T4

1.

Stator leads

2.

Terminal board

3.

Motor cable leads

4.

Stator (internal connection illustrated)

U1 V1 W1

U2

W2 V2

U1 V1 W1 W2 U2 V2

U1 V1 W1 W2 U2 V2

L1 L2 L3

GC

L3

W1

W2

L1

U1

U2

V2

V1

L2

L2

L1 L3

L1 L2 L3


5

1

L1 L2 L3

2 3 4

T1 T2 T3 T4

9

Installation

1.

Starter equipment and mains leads (L1, L2, L3)

2.

Earth (ground)

3.

Functional ground

4.

Control leads (T1, T2, T3, T4)

5.

Thermal contact

6.

FLS

7.

FLS 10

8.

CLS

9.

Thermistor

10. Level sensor

11. Capacitor

6

7

FLS

10

FLS 10

11

8 CLS

Colors and markings of leads

Motor Connection

Colors and marking of the main leads

COLOR STANDARD STATOR LEADS

BN = Brown

BK = Black

WH = White

OG = Orange

GN = Green

GN/YE = Green-Yellow

RD = Red

GY = Grey

BU = Blue

YE = Yellow

U1,U5 = RD

U2 = GN

V1,V5 = BN

V2 = BU

W1,W5 = YE

W2 = BK

T1,T2 = WH or YE

*SUBCAB AWG

* * Ground conductor is stranded around core

GC=Ground check 773 29 00/2

Mains

3

L1

L2

L3

L1

L2

L3

GC

SUBCAB 7GX SUBCAB 4GX

Screenflex 7GX Screenflex 4GX SUBCAB AWG

BK 1 BN RD

BK 2

BK 3

BK 4

BK 5

BK 6

GN/YE

BK

GY

-

-

-

GN/YE

Screen (WH) Screen (WH)

-

BK

WH

-

-

-

GN/YE

-

YE

SUBCAB

Screened

BN

BK

GY

-

-

-

**Screen/PE from cores

Screen (WH)

-

Color code standard

Code

BN

BK

WH

OG

GN

GNYE


Motor Connection

COLOR STANDARD STATOR LEADS

BN = Brown

BK = Black

WH = White

OG = Orange

RD = Red

GY = Grey

BU = Blue

YE = Yellow

U1,U5 = RD

U2 = GN

V1,V5 = BN

V2 = BU

W1,W5 = YE

W2 = BK

T1,T2 = WH or YE

* * Ground conductor is stranded around core

GC=Ground check

773 29 00/2

L1

L2

L3

L1

L2

L3

Colors and marking of the main leads

SUBCAB 4GX

GC

BK 1

BK 2

BK 3

BK 4

BK 5

BK 6

GN/YE

BN

BK

GY

-

-

-

GN/YE

Screen (WH) Screen (WH)

-

RD

BK

WH

-

-

-

GN/YE

-

YE

-

-

BN

BK

GY

-

Screen (WH)

-

Terminal clamps 6 stator leads

U1 W2 V1 U2 W1 V2

One cable

U1 W2 V1 U2 W1 V2

U2 W1

L1 L3 L2

Description

Brown

Black

White

Orange

Green

Green-Yellow

27

Installation

Motor connection

Code

RD

GY

BU

YE

Description

Red

Grey

Blue

Yellow

Terminal clamps 6 stator leads

U1 W2 V1 U2 W1 V2

Figure 9: Terminal clamps, 6 stator leads

Connections included

• 6–leads connection (page 28)

• 9-leads connection (page 29)

• Screened cable connection (page 30)

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.

One cable Two cables

Y

U1 W2 V1 U2 W1 V2 U1 V1 W1 U2 V2

L1

U1

GC

W2

U2

V2

W1

L1 L3 L2 L1

1

L1

2

L3

1

L3

2

L2

1

L2

2

W2

L2

V1

L3

Figure 10: Y-connection

One cable (left) and two cables (right) D-connection.


One cable Two cables D

L1

U1W2 V1 U2 W1 V2 U1 W2 V1 U2 W1 V2

U1

V2

L1 L3 L2

GC

U2

L1

1

L1

2

L3

1

L3

2

L2

1

L2

2

L2

W1 W2

V1

L3

Figure 11: D-connection

One cable (left) and two cables (right)Y/ D-connection.

One cable Two cables

U1 W2 V1 U2 W1 V2

GC

L1:1

L1:2

L3:1

L3:2

Y/D

L2:1

L2:2

U1 V1 W1

U2 V2 W2

L1

2

1

L1

2

4

L3

1

3

L3

2

6

L2

1

2

L2

2

5

U1 W2 V1 U2 W1 V2

L1

1

1

L1

2

4

L3

1

3

L3

2

6

L2

2

1

L2

2

5

Figure 12: Y/D-connection

Y and D-connection, only applicable to 70 mm 2 terminal clamp.

Y

U1 V1 W1 U2 V2 U1 W2 V1 U2 W1 V2

D

Installation

GC

L1

1

L3

1

L2

1

L1

1

L3

1

L2

1

Only applicable to 70mm2 terminal clamp

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.


Installation

One cable

U1 U5 V1 V5 W1 W5 U2 V2 W2

Two cables

U1 U5 V1 V5 W1 W5 U2 V2 W2

GC

L1 L3 L2 L1

1

L1

2

L3

1

L3

2

L2

1

L2

2

Figure 14: Y-parallel connection

One cable (left) and two cables (right) Y-serial connection.

One cable

U1 U5 U2 V1 V5 V2 W1 W5 W2

Two cables

U1 V1 W1 U2 U5 V2 V5 W2 W5

L1 L3 L2

L1

1

L1

2

L3

1

L3

2

L2

1

L2

2

GC

Y-

L1

L2

W1

W5

U1

W2

U2

U5

V2

V1

V5

L3

L2

W1

W2

W5

L1

Y-SER

U1

U2

U5

V5

V2

V1

L3

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

GN/YE shrink hose

L1 L2 L3

Mini CAS Mini CAS+AUX FGB Screened

Figure 16: Screened SUBCAB and FGB Screened

* For screened SUBCAB T3 and T4 shall also be twisted separately.


Screenflex and SUBCAB with functional ground

T1 and T2 twisted*

White insulation hose

Screen

Screen

T1 and T2 twisted*

White insulation hose

Installation

L1

BN

L2

BK

L3

GY

T1 T2 1 2 3 4 5 6 T1 T2

* 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

Control

T1

T2

T3

T4

SUBCAB 4GX/7G and

Screenflex

SUBCAB AWG

WH T1

WH T2

-

-

OG

BU

-

-

Figure 18: Color and marking of control leads

SUBCAB

Screened

WH T1

WH T2

WH T3

WH T4

Sensor terminal clamps

T15 T16 T1 T2

Figure 19: Sensor terminal clamps


Installation

FLS 10 and Thermal detectors

FLS + Thermal detectors

FLS TC

Max 12 V

WH/YE

BN

WH/YE

BN

T1 Control leads

T1/*OG/1

T2

T2/*BU/2

T15

+7

-5

Mini

CAS

**T3

**T4

*SUBCAB AWG

**Screened SUBCAB

∞ Ohm

1200 Ohm

430 Ohm

FLS 10 and Thermistor

FLS + Thermistor

Overtemperature

OK

Leakage

Max

2.5 V

RD

RD

T1

T2

Control leads

T1/1

T2/2

Thermistor relay

Max

12 V

FLS

BN/BU

BN/BU

T15

T16

T3/3

T4/4

+7

Mini

CAS

-5

T=25°C (77°F)

T=135°C (275°F) (T

REF

–5°C (23°F))

T=145°C (293°F) (T

REF

+5°C (41°F))

Thermal detectors, FLS disconnected

Thermal detectors FLS Disconnected

R ≤ 100 Ohm

R ≤ 550 Ohm

R ≤ 1330 Ohm

FLS TC

Max 12 V

WH/YE

BN

WH/YE

BN

T1 Control leads

T1/*OG/1

T2

T2/*BU/2

T15

+7

-5

Mini

CAS

**T3

**T4

*SUBCAB AWG

**Screened SUBCAB


Connection to the monitoring equipment

MiniCAS II

24 V AC/DC

FLS10

T15

CC

2

R

T1

T2

6

7 +

12 VDC

5 -

11

1

10S

10

9

8

4

3

P

L1

L2

C

WS002623B

Check the impeller rotation

WARNING:

The starting jerk can be powerful.

C Pump contactor

CC Control circuit

L1 Caution light (leakage)

L2 Caution light (stator over-temperature)

P Pump main supply

R Reset switch

1. Start the motor.

2. Stop the motor after a few seconds.

3. Check that the impeller rotates according to this illustration.

Installation


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.


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

Electrical Hazard:

A permanent-magnet motor generates voltage when the shaft is rotating. Ensure that the shaft can not rotate before performing any electrical installation.

WARNING:

• If you need to work on the pump, make sure that it is isolated from the power supply and cannot be energized.


• 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.


Operation

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.

3. Check that the monitoring equipment works.

4. Start the pump.


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.


• Rinse the unit thoroughly with clean water before working on the unit.

• Rinse the components in water after dismantling.

WARNING:

Electrical hazard. A permanent magnet motor produces voltage when the shaft is rotating.

The conductors must be insulated.

CAUTION:

• Magnetic stray fields may damage cardiac pacemaker and other medical implants. Stay clear of any magnetic stray fields that can occur near an open or disassembled permanent-magnet synchronous motor, or near a separate rotor of such a motor. Keep magnetic media away, including credit cards and watches.

• Crush hazard during disassembly or assembly of a permanent-magnet synchronous motor. Fingers or other body parts can be trapped and injured. Magnetic items such as tools attracted to the rotor can also cause personal injury.

• Assembly and disassembly of permanent-magnet synchronous motors must be performed by qualified personnel and according to relevant instructions.

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.

• If the unit has a permanent magnet motor, ensure that you have read and understood all safety instructions regarding permanent magnet motors.

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.


Maintenance

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

50

70, 80

100

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

1.0 (0.74)

2.7 (2)

4.1 (3)

2.0 (1.5)

5.4 (4)

8.1 (6)

3.0 (2.2)

9.0 (6.6)

14 (10)

8.0 (5.9)

22 (16)

34 (25)

15 (11)

44 (32)

27 (20)

76 (56)

65 (48) 127 (93.7) 220 (162) 434 (320)

187 (138) 364 (268) 629 (464) 1240

(915)

66 (49) 115 (84.8) 248 (183) 481 (355) — —

Table 2: Steel, torque Nm (ft-lbs)

Property class

8.8

M4

2.9 (2.1)

M5

5.7 (4.2)

M6

9.8 (7.2)

M8

24 (18)

M10 M12 M16 M20 M24 M30

10.9

12.9

4.0 (2.9)

4.9 (3.6)

8.1 (6)

9.7 (7.2)

14 (10)

17 (13)

33 (24)

40 (30)

47 (35) 81(60) 194 (143) 385 (285) 665 (490) 1310

(966.2)

65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840

(1357)

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.


Maintenance

Change the coolant

This image shows the plugs that are used to change the coolant.

2 2

1

1

2

Figure 21: Without a cooling jacket

Figure 20: With a cooling jacket

1.

Inspection plug

2.

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.

2

Figure 22: Without a cooling jacket Figure 23: With a cooling jacket b) Pump out any coolant from the inspection chamber, as shown here.


Maintenance 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.

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.


Maintenance

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.

Quantity: approximately

• 2.2 L (2.3 qt.) without cooling jacket

• 10.5 L (11.2 qt.) with cooling jacket


Maintenance

Figure 26: With 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

Initial inspection

Periodical inspection

Major overhaul

Figure 27: Without cooling jacket

Purpose

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.

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.

To secure a long operating lifetime for the product. It includes replacement of key components and the measures taken during an inspection.

Inspection interval

Within the first year of operation.

Up to 12,000 hours or 3 years, whichever comes first.

Applies to normal applications and operating conditions at media

(liquid) temperatures <40°C.

Up to 24,000 hours or 6 years, whichever comes first.

Applies to normal applications and operating conditions at media

(liquid) temperatures <40°C.

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

Maintenance

Service item

Cable

Connection to power

Electrical cabinets

Impeller

Inspection chamber

Insulation

Junction box

Level regulators

Lifting device

Lifting handle

O-rings

Overload protection and other protections

Personnel safety devices

Rotation direction

Seal housing

Terminal board

Thermal contacts

Thermistor

Voltage and amperage

Action

1. If the outer jacket is damaged, replace the cable.

2. Check that the cables do not have any sharp bends and are not pinched.

Check that the connections are properly tightened.

Check that they are clean and dry.

1. Check the impeller clearance.

2. Adjust the impeller, if necessary.

1. Drain all liquid, if any.

2. Check the resistance of the leakage sensor.

Normal value approx.1200 ohms, alarm approx. 430 ohms.

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.

Check that it is clean and dry.

Check the condition and functionality.

Check that local safety regulations are followed.

1. Check the screws.

2. Check the condition of the lifting handle.

3. Replace if necessary.

1. Replace the oil plug O-rings.

2. Replace the O-rings at the entrance or junction cover.

3. Grease the new O-rings.

Check the correct settings.

Check the guard rails, covers, and other protections.

Check the impeller rotation.

1. Fill with new coolant, if necessary.

2. Check that the freezing point is lower than -13°C (9°F).

Check that the connections are properly tightened.

Normally closed circuit; interval 0–1 ohm.

Check the resistance is between 20–250 ohms and the measured voltage is maximum 2 V DC.

Check the running values.


Maintenance

Major overhaul

For a major overhaul, take this action in addition to the tasks listed under Inspection.

Service item Action

Support and main bearing

Mechanical seal

Replace the bearings with new bearings.

Replace with new seal units.

Service in case of alarm

For information about indication values for sensors, see Sensor-connection (page 31).

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. Check the coolant level (pump with cooling jacket).

2. 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.

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.

Maintenance

WS001482A d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft.

e) Hand-tighten the impeller screw to prevent it from falling off.

f) Remove the rod.

3. Raise the pump.

4. Remove the drive unit from the pump housing:

WS001490A


Maintenance a) Remove the pump housing screws.

b) Remove the drive unit from the pump housing.

5. Remove the impeller: a) Place the drive unit horizontally.

b) Remove the impeller screw.


Maintenance c) Remove the impeller and the conical sleeve.

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.


Maintenance

WS002057A c) Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw.

Always use a new impeller screw.

d) Adjust the adjustment screw so that it is flush with the sleeve.

48

WS001759A e) Fit the sleeve and impeller to the shaft.

f) Hand-tighten the impeller screw to prevent it from falling off.


Maintenance

2. If applicable, check that the clearance between the impeller and the insert ring is maximum 1 mm (0.04 in.) radial. If not, send the pump for service.

The insert ring is pressed into the seal housing cover.

3. 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.


Maintenance 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 38).

4. 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.

50

WS001482A

5. Adjust the impeller: a) Using a hexagon-bit adapter, turn the adjustment screw clockwise until the impeller makes contact with the pump housing.


b) Tighten it a further 1/8 turn (45°).


Maintenance

6. Fasten the impeller: a) Fit the greased washer and impeller screw.

b) Tighten the impeller screw.


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.


f) Check that the impeller can rotate freely.

CAUTION:

Beware of the pinch point hazard between the rotating impeller and the guide pin.

7. Check that the clearance between the impeller and the insert ring is 0.1–0.5 mm

(0.004–0.02 in.).


Maintenance

WS003731A

8. 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.


Maintenance 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.


Maintenance

WS001494A 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.


Maintenance

WS002057A 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.


Maintenance

2. Mount the impeller: a) Fit the sleeve and the impeller to the shaft.

56 b) Fit the impeller screw and washer and tighten.


Maintenance

3. Make sure that the O-ring is removed from the seal housing cover.

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.


Maintenance c) Note the largest distance B.

d) Lift the drive unit out of the pump housing and remove the impeller and conical sleeve.

58

5. Trim to the correct distance: a) Calculate the measure C according to the formula shown in the image.


Maintenance 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.


c) Tighten it further 1/8 turn (45°).

7. If applicable, check that the clearance between the impeller and the insert ring is maximum 1 mm (0.04 in.) radial. If not, send the pump for service.

The insert ring is pressed into the seal housing cover.


Maintenance

8. Install the drive unit in the pump housing: a) Fit a new and greased O-ring to the seal housing cover.

60

WS002056A b) Place the drive unit in the pump housing.


Maintenance 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.


WS001478A

If you need to adjust the impeller, redo the replace the impeller procedure from the beginning.


62

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.

WARNING:



NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause

An alarm signal has been triggered on the control panel.

The pump does not start automatically, but can be started manually.

The installation is not receiving voltage.

Remedy

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.

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.

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.


Troubleshooting

Cause Remedy

• 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:

• 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 12).

The pump does not stop when a level sensor is used

WARNING:



WARNING:



Cause

The pump is unable to empty the sump to the stop level.

Remedy

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:


There is a malfunction in the levelsensing equipment.

• Clean the level regulators.

• Check the functioning of the level regulators.

• Check the contactor and the control circuit.

• Replace all defective items.

The stop level is set too low.

Raise the stop level.



The pump starts-stops-starts in rapid sequence

Cause Remedy

The pump starts due to back-flow which fills the sump to the start level again.

Check that:


Troubleshooting

Cause Remedy

• 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.



The pump runs but the motor protection trips

WARNING:



WARNING:



NOTICE:


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.

The phase currents vary, or they are too high.

• Check the fuses. Replace fuses that have tripped.

• If the fuses are intact, notify a certified electrician.



Troubleshooting

Cause

The insulation between the phases and ground in the stator is defective.

The density of the pumped fluid is too high.

Remedy

1. 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.

2. If the insulation is less:


Make sure that the maximum density is 1100 kg/m 3

• Change the impeller, or

(9.2 lb/US gal)

• Change to a more suitable pump.

• Contact the local Xylem service shop.

There is a malfunction in the overload protection.

Replace the overload protection.



The pump delivers too little or no water

WARNING:



WARNING:



NOTICE:


Cause

The impeller rotates in the wrong direction.

One or more of the valves are set in the wrong positions.

The impeller is difficult to rotate by hand.

The pipes are obstructed.

The pipes and joints leak.

Remedy

• If it is a 3-phase pump, transpose two phase leads.

• If it is a 1-phase pump:


• 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.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

Clean out the pipes to ensure a free flow.

Find the leaks and seal them.


Troubleshooting

Cause Remedy

There are signs of wear on the impeller, pump, and casing.

The liquid level is too low.

Replace the worn parts.

• 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.




Technical Reference

Technical Reference

Application limits

Data

Liquid temperature

Liquid density pH of the pumped media

(liquid)

Depth of immersion

Other

Description

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

1100 kg/m³ (9.2 lb per US gal) maximum

5.5–14

20 m (65 ft) maximum

For the specific weight, current, voltage, power ratings, and speed of the pump, see the data plate of the pump.

Motor data

Feature

Motor type

Frequency

Supply

Starting method

Description

• 3153.091/.095/.181/.185/.350/.390: Squirrel-cage induction motor

• 3153.800/.810/.820/.830/.840/.850: Line-started, permanent-magnet synchronous motor

50 or 60 Hz

3-phase

• Direct on-line

• Star-delta

• Soft starter

30 evenly spaced starts per hour Maximum starts per hour

Code compliance

Rated output variation

Voltage variation without overheating

Voltage imbalance tolerance

Stator insulation class

IEC 60034-1

±10%

±10%, provided that it does not run continuously at full load

2%

H (180°C [360°F])


Xylem |’zīl

ə

m|

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 non-

English instructions are translations of the original instruction.

© 2012 Xylem Inc.

895381_13.0_en.US_2012-08_IOM.3153.091/.095/.181/.185/.350/.390/.800/.810/.820/.830/.840/.850

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