FLYGT 2125 Installation, Operation And Maintenance Manual
Installation,
Operation, and
Maintenance Manual
2125
Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Safety terminology and symbols.......................................................................................................3
Inspect the delivery.............................................................................................................................4
Inspect the package.........................................................................................................................4
Inspect the unit..................................................................................................................................4
Product warranty.................................................................................................................................4
Spare parts........................................................................................................................................5
Safety.....................................................................................................................................................5
User safety............................................................................................................................................6
Hazardous liquids.............................................................................................................................6
Wash the skin and eyes....................................................................................................................6
Ex-approved products........................................................................................................................7
ATEX guidelines................................................................................................................................7
Permitted liquid level for ATEX.......................................................................................................7
Monitoring equipment.....................................................................................................................7
MSHA requirements............................................................................................................................8
Environmental safety...........................................................................................................................8
Table of Contents
Transportation and Storage................................................................................................................10
Transportation guidelines................................................................................................................10
Precautions......................................................................................................................................10
Position and fastening...................................................................................................................10
Lifting...............................................................................................................................................10
Storage guidelines............................................................................................................................10
Storage location.............................................................................................................................10
Freezing precautions.....................................................................................................................10
Long-term storage..........................................................................................................................11
Product Description.............................................................................................................................12
Products included.............................................................................................................................12
Pump design......................................................................................................................................12
Monitoring equipment.....................................................................................................................13
The data plate....................................................................................................................................13
The Ex approval plate....................................................................................................................14
The MSHA approval plate.............................................................................................................14
Product denomination......................................................................................................................14
Installation.............................................................................................................................................16
Install the pump.................................................................................................................................16
Sedimentation prevention.............................................................................................................16
Discharge line requirements.........................................................................................................16
Fasteners.........................................................................................................................................17
Install with S-installation.................................................................................................................17
Make the electrical connections......................................................................................................18
General precautions.......................................................................................................................18
Requirements..................................................................................................................................18
Cables..............................................................................................................................................18
Earthing (Grounding).....................................................................................................................19
Earth (ground) conductor length.................................................................................................19
Connect the motor cable to the pump........................................................................................19
Cable charts....................................................................................................................................20
2125 Installation, Operation, and Maintenance Manual 1
Table of Contents
Check the impeller rotation.............................................................................................................27
Operation..............................................................................................................................................28
Precautions.........................................................................................................................................28
Distance to wet areas........................................................................................................................28
Noise level..........................................................................................................................................28
Start the pump...................................................................................................................................28
Clean the pump.................................................................................................................................29
Maintenance.........................................................................................................................................30
Precautions.........................................................................................................................................30
Maintenance guidelines...................................................................................................................30
Torque values....................................................................................................................................30
Service................................................................................................................................................31
Inspection........................................................................................................................................31
Major overhaul................................................................................................................................33
Change the oil...................................................................................................................................33
Empty the oil...................................................................................................................................33
Fill with oil........................................................................................................................................34
Replace the impeller.........................................................................................................................34
Remove the impeller......................................................................................................................34
Install the impeller..........................................................................................................................36
Troubleshooting...................................................................................................................................38
Introduction.......................................................................................................................................38
The pump does not start..................................................................................................................38
The pump does not stop when a level sensor is used.................................................................39
The pump starts-stops-starts in rapid sequence...........................................................................39
The pump runs but the motor protection trips.............................................................................40
The pump delivers too little or no water........................................................................................40
Technical Reference............................................................................................................................42
Application limits...............................................................................................................................42
Motor data..........................................................................................................................................42
Specific motor data...........................................................................................................................42
Dimensions and weights..................................................................................................................46
Performance curves..........................................................................................................................50
2 2125 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.
Introduction and Safety
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 Indication
DANGER:
WARNING:
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
2125 Installation, Operation, and Maintenance Manual 3
CAUTION:
A hazardous situation which, if not avoided, could result
in minor or moderate injury
Introduction and Safety
Hazard categories
Hazard level Indication
• A potential situation which, if not avoided, could
NOTICE:
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
result in undesirable conditions
• A practice not related to personal injury
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.
Product warranty
Coverage
Xylem undertakes to remedy faults 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.
4 2125 Installation, Operation, and Maintenance Manual
Limitations
Warranty claim
Introduction and Safety
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by Xylem are used in Exapproved products.
The warranty does not cover faults 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
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
Safety
Xylem guarantees that spare parts will be available for 10 years after the manufacture of
this product has been discontinued.
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.
• Installation, Operation, and Maintenance manuals clearly identify 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 for installation, operation, and maintenance contained
in this manual. Failure to do so could result in physical injury, damage, or delays.
2125 Installation, Operation, and Maintenance Manual 5
Introduction and Safety
User safety
General safety rules
Safety equipment
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.
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
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:
•
• Observe strict personal cleanliness.
Wash the skin and eyes
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
Do the following if chemicals or hazardous fluids have come into contact with your
eyes or your skin:
If you need to wash your... Then...
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.
Skin
6 2125 Installation, Operation, and Maintenance Manual
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least one minute.
3. Seek medical attention, if required.
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 Xylem-
authorized 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 (including 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.
Introduction and Safety
ATEX guidelines
ATEX 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 ATEX-compliant equipment, always comply with the directive
and applicable standards in IEC/EN 60079–14.
Permitted liquid level for ATEX
ATEX-approved products must be fully submerged according to the ATEX approval. Levelsensing 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
2125 Installation, Operation, and Maintenance Manual 7
Introduction and Safety
MSHA requirements
According to the Code of Federal Regulations, the following requirements must be fulfilled
to maintain permissibility of this equipment:
Subject area Requirements
General safety
Service and repair
Fastenings All bolts, nuts, screws, and threaded covers must be properly tightened and secured.
Cables A flame-resistant portable cable must be used. It has to bear an MSHA-assigned
• Frequent inspections must be made.
• All electrical parts, portable cable, and wiring must be kept in a safe condition.
• There must not be any openings into the casings of the electrical parts.
• The machine frame must be effectively earthed (grounded).
• Power wires must not be used for earthing (grounding).
• The operating voltage must match the voltage rating of the motor.
• Inspections, service, and repairs are only allowed when the portable cable is
disconnected from the power supply.
• Work must be performed by trained personnel (preferably the manufacturer or
agent) to ensure that the pump is restored to its original state of safety in regards
to all flame-arresting paths.
• Replacement parts must be exactly equal to those provided by the manufacturer.
• When cable entries are disturbed on pump or control, they must be reassembled
in the approved manner.
DANGER:
Failure to restore the permissible equipment to its original
state of safety will void the MSHA approval. The creation of a
safety hazard will subject the owner / operator of a mine to
citations and penalties under the law.
identification number and be adequately protected by an automatic circuit-interrupting
device. Special care must be taken in handling the cable to avoid mechanical damage
and wear.
Operation Poly-Life® equipped products must not be operated dry in hazardous areas.
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
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.
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.
8 2125 Installation, Operation, and Maintenance Manual
Electrical installation
Introduction and Safety
For electrical installation recycling requirements, consult your local electric utility.
2125 Installation, Operation, and Maintenance Manual 9
Transportation and Storage
Transportation and Storage
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Position and fastening
The pump can be transported either horizontally or vertically. Make sure that the product 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.
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 pump is frost-proof while operating or immersed in liquid, but the impeller/propeller
and the shaft seal may freeze if the pump is lifted out of the liquid into a surrounding
temperature below freezing.
Follow these guidelines to avoid freezing damage:
10 2125 Installation, Operation, and Maintenance Manual
Long-term storage
Transportation and Storage
When Guideline
Before storage
• The pump must be allowed to run for a short time after raising it to
discharge remaining pumped liquid.
• 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 pump
in liquid before operating the pump.
NOTICE:
Never use a naked flame to thaw the unit.
If the pump is stored more than 6 months, the following apply:
• Before operating the pump 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.
2125 Installation, Operation, and Maintenance Manual 11
Product Description
Product Description
Products included
Pump model Approvals
Pump design
Intended use
2125.181
2125.320
2125.051 MSHA (Mine Safety and Health Administration, USA):
2125.690
The pump is submersible, and driven by an electric motor.
Pumps with MSHA (Mine Safety and Health Administration, USA) certifications are
designed to be used in explosive zones.
WARNING:
In explosive or flammable environments, only use Ex- or MSHA-approved pumps.
Standard
30CFR Part 18, Approval number X/P-3769-0
• European Norm
• ATEX Directive
• EN 1127-1, EN 50014, EN 50018
• I M2 EEx d I
Particle size
Pressure class
Impeller type
NOTICE:
Do NOT use the pump in highly corrosive liquids.
For information about pH, see Application limits (page 42).
The pump can handle liquid containing particles that correspond to the holes in the
strainer.
Number of holes Hole dimensions
186 6×50 mm (0.24× 1.96 in.)
For more information about the strainer, see Dimensions and weights (page 46).
MT Medium head
HT High head
ST Super head
B Wear resistant
12 2125 Installation, Operation, and Maintenance Manual
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
3
1
23
24
Product Description
Poly-Life
®
Version code 051/181: The pump is available with Poly-Life® polyurethane wear parts for
extra resistance.
Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates thermal contacts connected in series that activate the alarm at
overtemperature.
• The thermal contacts open at 125°C (257°F).
The data plate
The data plate is a metal label located on the main body of the pump. The data plate lists
key product specifications.
Ex- and MSHA-approved products also have approval plates. They are described below, if
applicable.
1. Curve code/Propeller code
2. Serial number, see Product denomination (page 14)
3. Product number
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 1: The data plate
2125 Installation, Operation, and Maintenance Manual 13
1 2 3
4
5
6 7
8
9 10
12
11
13
14
15
1
NP 3085
2 3
Product Description
The Ex approval plate
1. Approval
Approval authority and approval number
2.
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
The MSHA approval plate
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.
1. Hydraulic part
2.
Installation type
3. Sales code
14 2125 Installation, Operation, and Maintenance Manual
Product code
3085.183
1 2
NP
1
NP 3085.183 - 951 0163
2 3 4
Serial number
Product Description
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. 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.
1. Product code
2. Production year
3. Production cycle
4. Running number
2125 Installation, Operation, and Maintenance Manual 15
Installation
Installation
Install the pump
WARNING:
• Before installing the pump, check that the cable and cable entry have not been
damaged during transportation.
• Make sure that the pump 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.
NOTICE:
• Never force piping to make a connection with a pump.
These requirements apply:
• Use the pump dimensional drawing in order to ensure proper installation.
• 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.
• Remove all debris from the inlet piping system before you install the pump.
Sedimentation prevention
In order to avoid sedimentation when the pumped liquid contains solid particles, the
velocity of the liquid in the discharge line must exceed a certain value. Choose applicable
minimum velocity from the table, and choose proper dimension of the discharge line
accordingly.
Mixture Minimum velocity, meter per second (feet per second)
Water + coarse gravel 4 (13)
Water + gravel 3.5 (11)
Water + sand, particle size <0.6 mm (0.024 in.) 2.5 (8.2)
Water + sand, particle size <0.1 mm (0.004 in.) 1.5 (4.9)
For more permanent installations with a heavily contaminated pumped liquid, a settling
pump-sump is recommended.
Figure 2: Settling pump-sump
Discharge line requirements
The discharge line can be run vertically or horizontally, but must be without sharp bends.
16 2125 Installation, Operation, and Maintenance Manual
Fasteners
Installation
Proper horizontal and vertical installation Improper installation with a sharp
bend
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.
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.
These requirements and instructions only apply when the installation is made according to
the dimensional drawing.
1. Run the cable so that it has no sharp bends, 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 27).
2125 Installation, Operation, and Maintenance Manual 17
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 pump, make sure that the pump 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.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
Requirements
Cables
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, the connected voltage is specified
by a yellow sticker close to the cable entry.
• The fuses, short-circuit, 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 starting 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, the pump must be provided with monitoring
equipment supporting such operation.
• The thermal contacts must be in use.
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.
18 2125 Installation, Operation, and Maintenance Manual
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