FLYGT 3126.290 Installation, Operation And Maintenance Manual

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Page 1

Installation, Operation,

and Maintenance Manual

Flygt 3126.290

Page 2

Page 3

Table of Contents

Introduction and Safety..................................................................................................................3

Introduction..................................................................................................................................3

Safety.............................................................................................................................................3

Safety terminology and symbols........................................................................................... 3

Environmental safety...............................................................................................................4

User safety................................................................................................................................ 5

Ex-approved products............................................................................................................ 6

Product warranty......................................................................................................................7

Transportation and Storage.......................................................................................................... 8

Inspect the delivery.....................................................................................................................8

Inspect the package................................................................................................................8

Inspect the unit........................................................................................................................ 8

Transportation guidelines.......................................................................................................... 8

Lifting.........................................................................................................................................8

Temperature ranges for transportation, handling and storage............................................ 9

Storage guidelines...................................................................................................................... 9

Table of Contents

Product Description......................................................................................................................11

Pump design..............................................................................................................................11

External cooling.........................................................................................................................12

Monitoring equipment............................................................................................................. 13

The data plate............................................................................................................................13

Approvals................................................................................................................................... 14

Product denomination..............................................................................................................15

Installation......................................................................................................................................17

Install the pump.........................................................................................................................17

Install with P-installation....................................................................................................... 18

Install with S-installation....................................................................................................... 19

Install with T-installation....................................................................................................... 19

Make the electrical connections..............................................................................................20

Prepare the SUBCAB™ cables..............................................................................................22

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

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

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

T-installation: Bleed air before starting pump.......................................................................27

Check the impeller rotation..................................................................................................... 27

Operation.......................................................................................................................................29

Estimate zinc anode replacement intervals........................................................................... 29

Start the pump...........................................................................................................................30

Maintenance..................................................................................................................................31

Torque values............................................................................................................................ 31

Change the oil........................................................................................................................... 32

Service the pump...................................................................................................................... 33

Inspection...............................................................................................................................33

Major overhaul.......................................................................................................................34

Service in case of alarm........................................................................................................ 34

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Table of Contents

Replace the impeller.................................................................................................................34

Replace the C- or D-impeller............................................................................................... 35

Install the impeller: C, D....................................................................................................... 36

Install the F-impeller..............................................................................................................37

Troubleshooting........................................................................................................................... 40

The pump does not start..........................................................................................................40

The pump does not stop when a level sensor is used......................................................... 41

The pump starts-stops-starts in rapid sequence...................................................................41

The pump runs but the motor protection trips..................................................................... 41

The pump delivers too little or no water................................................................................42

Technical Reference..................................................................................................................... 44

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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

WARNING:

• The operator must be aware of safety precautions to prevent physical injury.

• 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 a Xylem representative before proceeding.

• 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 Indication

Flygt 3126.290 Installation, Operation, and Maintenance Manual 3

DANGER:

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

Page 6

Introduction and Safety

Hazard level Indication

WARNING:

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

Hazard categories

CAUTION:

NOTICE:

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

• A potential situation which, if not avoided, could result in undesirable conditions

• A practice not related to personal injury

Hazard categories can either fall under hazard levels or let speciﬁc symbols replace the ordinary hazard level symbols.

Electrical hazards are indicated by the following speciﬁc symbol:

Electrical Hazard:

These are examples of other categories that can occur. They fall under the ordinary hazard levels and may use complementing symbols:

• Crush hazard

• Cutting hazard

• Arc ﬂash hazard

Environmental safety

The work area

Always keep the station clean.

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.

CAUTION: Radiation Hazard

Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon.

Electrical installation

For electrical installation recycling requirements, consult your local electric utility.

Recycling guidelines

Always recycle according to these guidelines:

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User safety

General safety rules

Safety equipment

Introduction and Safety

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 local sales and service representative.

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:

• Hard hat

• 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:

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.

• Observe strict personal cleanliness.

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

Condition Action Chemicals or hazardous ﬂuids in

eyes

1. 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.

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Introduction and Safety

Condition Action Chemicals or hazardous ﬂuids on

skin

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 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 (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.

• The Ex-approved product must never run dry 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 Ex-approved Xylem representative.

• Only use parts that are provided by an Ex-approved Xylem representative.

• The thermal detectors ﬁtted to the stator windings shall be connected into the motor control circuit in such a manner as to disconnect the supply to the motor in order to prevent the Temperature Class T3.

• The width of ﬂameproof joints is more than the values speciﬁed in the tables of the IEC 60079–1 standard.

• The gap of ﬂameproof joints is less than the values speciﬁed in Table 1 of the IEC 60079–1 standard.

• The equipment must be submerged during normal operation.

1. Remove contaminated clothing.

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

3. Seek medical attention, if necessary.

certiﬁed electricians and Xylem

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 Ex-approved 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

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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:

Product warranty

Coverage

Xylem undertakes to remedy defects in products from Xylem under these conditions:

Introduction and Safety

• Level indicators

• Temperature detectors

• The faults are due to defects in design, materials, or workmanship.

• The faults are reported to a local sales and service representative within the warranty period.

• The product is used only under the conditions that are described in this manual.

• The monitoring equipment that is incorporated in the product is correctly connected and in use.

• All service and repair work that is done by Xylem authorized personnel.

• Genuine Xylem parts are used.

• Only Ex-approved spare parts and accessories that are authorized by an Ex-approved Xylem representative are used in Ex-approved products.

Limitations

Warranty claim

Spare parts

The warranty does not cover defects that are caused by these situations:

• Deﬁcient maintenance

• Improper installation

• Modiﬁcations or changes to the product and installation that are made without consulting a Xylem authorized representative

• 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 for a warranty claim arise, contact your local sales and service representative.

Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued.

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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 the local sales representative if there is any issue.

Transportation guidelines

Precautions

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

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

Always inspect the lifting equipment and tackle before starting any work.

WARNING: Crush Hazard

1) Always lift the unit by its designated lifting points. 2) Use suitable lifting equipment and

ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4) Stay clear of cables and suspended loads.

NOTICE:

Never lift the unit by its cables or hose.

Lifting equipment

Lifting equipment is always required when handling the unit. It must fulﬁll the following requirements:

• The minimum height (contact your local sales and service representative 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.

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Transportation and Storage

• The lifting equipment must support the 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.

CAUTION: Crush Hazard

Over-dimensioned lifting equipment can lead to injury. A site-speciﬁc risk analysis must be done.

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 unacceptable amounts 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.

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Transportation and Storage

Long-term storage

If the unit is stored more than six months, then the following apply:

• Before operating the unit after storage, it must be inspected with special attention to

• The impeller/propeller must be rotated every other month to prevent the seals from

the seals and the cable entry.

sticking together.

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Product Description

Pump design

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

Intended use

The product is intended for moving wastewater, sludge, raw and clean water. Always follow the limits that are given in Application limits (page 44). If there is a question regarding the intended use of the equipment, please contact a local sales and service representative before proceeding.

DANGER: Explosion/Fire Hazard

Special rules apply to installations in explosive or ﬂammable atmospheres. Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explosionproof or intrinsically-safe. If the product is EN/ATEX-, MSHA- or FM-approved, then see the speciﬁc EX information in the Safety chapter before taking any further actions.

NOTICE:

Do NOT use the pump in highly corrosive liquids.

Product Description

Spare parts

Pressure class

• 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.

MT HT High head

Medium head

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WS003611A

Product Description

Parts

External cooling

Requested items

Position Denomination Description 1 Shaft The shaft is made of stainless steel, with an integrated rotor. 2 Mechanical seals One inner and one outer seal in a combination of materials:

• Silicon carbide RSiC

• Corrosion-resistant cemented carbide WCCR

For information about the pumps mechanical seals, see Parts List.

3 Monitoring sensor

Optional sensor. For information about the sensors, see Optional

sensors (page 13).

4 Oil housing The oil housing includes a coolant that lubricates and cools the seals; the

housing acts as a buffer between the pumped ﬂuid and the drive unit.

5 Impeller There are multiple types of impellers. For information about the pumps

impellers, see Parts List. 6 Main bearing The bearing consisting of a two-row angular contact ball bearing. 7 Motor

For information about the motor, see Motor data (page 44). 8 Cooling Cooling without jacket: The pump is cooled by the ambient liquid.

Cooling with jacket: The motor is cooled by the circulation of a portion of the

pumped liquid in the space between the stator housing and the cooling

jacket. The cooling jacket can also be used with an external cooling system.

Fore more information, see External cooling (page 12). 9 Support bearing The bearing consisting of a single-row ball bearing.

The following items are requested in order to use external cooling:

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Parts

WS003622A

Connection type 1

Product Description

• Cooling jacket

• Solid plugs

• External cooling system (hose, water source, etc.) including hose coupling nipples with thread R1/4 “

Contact your local Xylem representative for more information.

1. Plug

2. Sleeve

3. Solid plug

The external cooling ﬂuid enters through the hole in the stator housing marked “cool in”. This requires that the plug is replaced by a hose coupling nipple and hose. The ﬂuid exits at the impeller and the lower seal. For this type of connection, one of the sleeves between the oil housing and the stator housing must be replaced with a solid plug.

Connection type 2

The external cooling ﬂuid enters through the hole in the stator housing marked “cool in”. This requires that the plug is replaced by a hose coupling nipple and hose. The ﬂuid exits through the hole in the stator housing market “cool out”. This requires that the plug is replaced by a hose coupling nipple and hose. For this type of connection, both of the sleeves between the oil housing and the stator housing must be replaced with solid plugs.

Monitoring equipment

The following applies to the monitoring equipment of the pump:

Optional sensors

FLS

The data plate

The data plate is a metal label that is located on the main body of the products. The data plate lists key product speciﬁcations. Specially approved products also have an approval plate.

• The stator incorporates three thermal contacts connected in series that activate the alarm and stops the pump at overtemperature

• The thermal contacts open at 125°C (257°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.

• Information in the junction box shows if the pump is equipped with optional sensors.

FLS is a miniature ﬂoat switch for detection of liquid in the stator housing. Due to its design it is best suited for pumps in a vertical position. The FLS sensor is installed in the bottom of the stator housing.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 13

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1312 14

17 18 1916159 10 11

WS006257A

Product Description

1. Curve code or Propeller code

2. Serial number

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

Approvals

Product approvals for hazardous locations

Pump Approval

3126.290 European Norm (EN)

14 Flygt 3126.290 Installation, Operation, and Maintenance Manual

• ATEX Directive

• EN 60079-0:2009, EN 60079-1:2007, EN 13463-1:2009, EN 13463-5:2011

•

II 2 G c Ex d IIB T4 Gb

EN approval for cable entry:

• Certiﬁcate number: INERIS 02ATEX9008 U

•

II 2 G Ex d IIC Gb or I M2 Ex d I Mb

IEC

• IECEx scheme

• IEC 60079-0, IEC 60079-1

• Ex d IIB T4

FM (FM Approvals)

• Explosionproof for use in 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

Page 17

EN approval plate

1 2 3

6 7

9 10

WS003972A

WS001279B

876

5 9

WS003973A

IEC approval plate

Product Description

This illustration describes the EN approval plate and the information that is contained in its ﬁelds.

1. Approval

2. Approval authority and Approval number

3. Approval for Class I

4. Approved for drive unit

5. Stall time

6. Starting current or 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

This illustration describes the IEC approval plate and the information that is contained in its ﬁelds.

International Norm; not for EU member countries.

FM approval plate

1. Approval

2. Approval authority and Approval number

3. Approved for drive unit

4. Stall time

5. Starting current or Rated current

6. Duty class

7. Duty factor

8. Input power

9. Rated speed

10. Controller

11. Additional information

12. Maximum ambient temperature

13. Serial number

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

1. Temperature class

2. Maximum ambient temperature

Product denomination

Reading instruction

In this section, code characters are illustrated accordingly:

Flygt 3126.290 Installation, Operation, and Maintenance Manual 15

Page 18

XXYYYY YYY YYY YYYY

WS006265B

Product Description

X = letter Y = digit The different types of codes are marked up with a, b and c. Code parameters are marked

up with numbers.

Codes and parameters

Type of Callout Number Indication Type of code a Sales denomination

Parameter 1 Hydraulic end

b Product code c Serial number

2 Type of installation 3 Sales code 4 Version 5 Production year 6 Production cycle 7 Running number

16 Flygt 3126.290 Installation, Operation, and Maintenance Manual

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Installation

Install the pump

Before starting work, make sure that the safety instructions in the chapter Introduction and

Safety (page 3) have been read and understood.

DANGER: Electrical Hazard

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.

DANGER: Inhalation Hazard

Before entering the work area, make sure that the atmosphere contains sufﬁcient oxygen and no toxic gases.

Hazardous atmospheres

DANGER: Explosion/Fire Hazard

Installation

General requirements

Authority regulation

WARNING: Explosion/Fire Hazard

Do not install CSA-approved products in locations that are classiﬁed as hazardous in the National Electric Code(TM), ANSI/NFPA 70-2005.

These requirements apply:

• Use the pump dimensional drawing in order to ensure proper installation.

• In T-installation, the pump must be equipped with cooling jacket.

Before installing the pump, do the following:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that equipment is in place so that the unit cannot roll or fall over during the installation process.

• Check the explosion risk before you weld or use electric hand tools.

• Check that the cable and cable entry have not been damaged during transport.

• Always remove all debris and waste material from the sump, inlet piping, and discharge connection, before you install the pump.

NOTICE:

• Never force piping to make a connection with a pump.

Vent the tank of a sewage station in accordance with local plumbing codes.

Fasteners

• 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.

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Page 20

WS006259A

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 2: 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

• Cable holder for holding the cable

• 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 housing ﬂange and a

bracket for attaching the guide equipment.

• Fasteners for the discharge connection

• Anchor bolts

1. Install the access frame: a) Place the access frame in position and align it horizontally.

b) Grout the frame in place.

2. Grout the anchor bolts in place. Be careful when you align and position the discharge connection in relation to the

access frame.

3. Place the discharge connection in position, and tighten the nuts.

4. 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.

5. Connect the discharge pipe to the discharge connection.

6. Lower the pump along the guide bars. When it reaches the bottom position, the pump automatically connects to the

discharge connection.

7. Secure the motor cable:

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a) Fasten the permanent lifting device to the pump and to the access frame. For

WS006270A

b) Fasten the cable to the cable holder.

c) Connect the motor cable and the starter and monitoring equipment according to

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.

Installation

example, you can use a stainless-steel lifting chain with shackles.

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.

the separate instructions. Make sure that the impeller rotation is correct. For more information, see Check

the impeller rotation (page 27).

Figure 3: 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 start-up 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).

Install with T-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.

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WS008385A

Installation

Figure 4: T-installation

These items are required:

• Anchor bolts for anchoring the pump to a base.

• Shut-off valves that allow you to remove the pump from service

NOTICE:

The risk of freezing is particularly high in T- or Z-installations.

1. Fasten the pump: a) Bolt the stationary suction connection to the concrete base.

b) Bolt the pump to the suction connection.

2. Make sure that the pump is vertical.

3. Connect the suction line and discharge line.

4. Connect the motor cable and the starter and monitoring equipment according to the separate instructions.

Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 27)

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

Make the electrical connections

General precautions

DANGER: Electrical Hazard

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.

WARNING: Electrical Hazard

Risk of electrical shock or burn. A certiﬁed electrician must supervise all electrical work. Comply with all local codes and regulations.

20 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 23

Requirements

Installation

WARNING: Electrical Hazard

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. Visually inspect equipment for damaged cables, cracked casings or other signs of damage. Make sure that electrical conections have been correctly made.

WARNING: Crush Hazard

Risk of automatic restart.

CAUTION: Electrical Hazard

Prevent cables from becoming sharply bent or damaged.

NOTICE:

Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the cable ends dry at all times.

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, a leakage sensor must be connected and in use in order to meet approval requirements.

Cables

These are the requirements to follow when you install cables:

• The cables must be in good condition, not have any sharp bends, and not be pinched.

• The sheathing must not be damaged and must not have indentations or be embossed (with markings, etc.) at the cable entry.

• 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 a local sales and service representative.

• 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.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 21

Page 24

SUBCAB 1000V

WS004299E

WS004298C

Screened SUBCAB

Installation

• Make sure that the cable is long enough for maintenance work.

• For SUBCAB™ cables, the twisted pair copper foil must be trimmed.

Grounding (earthing)

Grounding (earthing) must be done in compliance with all local codes and regulations.

DANGER: Electrical Hazard

All electrical equipment must be grounded (earthed). Test the ground (earth) lead to verify that it is connected correctly. Frequently inspect electrical systems to ensure that the path to ground is continuous.

WARNING: Electrical Hazard

If the power cable is jerked loose, then the ground (earth) conductor must be the last conductor to come loose from its terminal. Make sure that the ground (earth) conductor is longer than the phase conductors at both ends of the cable.

WARNING: Electrical Hazard

Risk of electrical shock or burn. You must connect an additional ground- (earth-) fault protection device to the grounded (earthed) connectors if persons are likely to come into contact with liquids that are also in contact with the pump or pumped liquid.

Prepare the SUBCAB™ cables

This section applies to SUBCAB™ cables with twisted-pair control cores.

The prepared SUBCAB™ cable The prepared screened SUBCAB™ cable

1. T1+T2 twisted pairs in control element

2. Drain wire in control element (bare copper wire)

3. Screened copper pt-foil

4. Insulation sheath (jacket) or PT-foil for control element

5. Power cores

6. Ground (earth) core

1. T1+T2 and T3+T4 twisted pairs in control element

2. Drain wire in control element (bare copper wire)

3. Screened copper pt-foil

4. Insulation sheath (jacket) for control element

5. Power cores

6. Aluminum foil

7. Ground (earth) core with green/yellow shrink hose

8. Uncovered screen/braided wire

1. Peel off the outer sheath at the end of the cable.

2. Prepare the control element: a) Peel the sheath (if applicable) and the copper foil.

The copper foil is a screen and is conductive. Do not peel more than necessary, and remove the peeled foil.

22 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 25

WS004313C

Figure 5: Copper foil on control element.

b) Put a white shrink hose over the drain wire and the cable terminal. c) Fit a cable lug on the drain wire. d) Twist T1+T2 and T3+T4. e) Put a shrink hose over the control element.

Make sure that the conductive copper foil and drain wire is covered.

3. Prepare the ground (earth) core for SUBCAB™ cable: a) Peel the yellow-green insulation from the ground (earth) core.

b) Check that the ground (earth) core is at least 10% longer than the phase cores in

the cabinet.

c) If applicable, put a cable lug on the ground core.

4. Prepare the ground (earth) core for screened SUBCAB™ cable: a) Untwist the screens around the power cores.

b) Put a yellow-green shrink hose over the ground (earth) core.

Leave a short piece uncovered. c) If applicable, put a cable lug on the screened ground core. d) Twist all power core screens together to create a ground (earth) core and

cable terminal to the end. e) Check that the ground (earth) core is at least 10% longer than the phase cores in

the cabinet.

5. How is the connection to ground (earth) made?

• Screw: Fit cable terminals to the ground (earth) core and the power cores.

• Terminal block: Leave the core ends as they are.

6. Prepare the main leads: a) Remove the aluminum foil around each power core.

b) Peel the insulation from each power core.

Installation

ﬁt a

Connect the motor cable to the pump

NOTICE:

Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the end of the motor cable dry at all times.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 23

Page 26

WS003623A

Installation

1. Entrance cover

2. O-ring

3. Entrance ﬂange

1. Remove the entrance cover and the O-ring from the stator housing. This provide access to the terminal board/closed end splices.

2. Check the data plate to see which connections are required for the power supply.

3. Arrange the connections on the terminal board/closed end splices in accordance with the required power supply.

4. Connect the mains leads (L1, L2, L3, and ground (earth) ) according to applicable cable chart.

The ground (earth) lead must be50 mm (2.0 in.) longer than the phase leads in the junction box of the unit.

5. Make sure that the pump is correctly connected to ground (earth) .

6. Make sure that any thermal contacts incorporated in the pump are properly connected to the terminal block/closed end splices.

7. Install the entrance cover and the O-ring on the stator housing.

8. 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

DANGER: Explosion/Fire Hazard

24 Flygt 3126.290 Installation, Operation, and Maintenance Manual

NOTICE:

• Thermal contacts 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.

The single phase pumps must be equipped with a starter which has start and run capacitors.

Page 27

Cable charts

WS000509D

L3L1

L3L2

WS008530A

Description

Installation

A specially Flygt designed starter is required for the operation of single phase pumps. The connection of the motor cable to the starter is shown in the wiring diagram.

1. If thermal contacts are included in the pump installation, then connect the T1 and T2 control conductors to the monitoring equipment.

NOTICE:

Ex-approved products must always have the thermal contacts connected irrespective of the ambient temperature.

2. Connect the mains leads (L1, L2, L3, and ground (earth)) to the starter equipment. For information about the phase sequence and the color codes of the leads, see

Cable charts (page 25).

This topic contains general connection information. It also provides cable charts that show connection alternatives for use with different cables and power supply.

Figure 6: Phase sequence

Connections

Flygt 3126.290 Installation, Operation, and Maintenance Manual 25

Figure 7: 6 leads

Page 28

WS008531A

WS002440A

Installation

Figure 8: 12 leads

Denomination, stator leads Color Marking text U1 Red Black V1 Brown Black W1 Yellow Black U2 Green Black V2 Blue Black W2 Black White U5 Red Yellow V5 Brown Yellow W5 Yellow Red U6 Green Yellow V6 Blue Yellow W6 Black Yellow

Sensor connection

Denomination, motor leads Color RED Red BROWN Brown WHITE White GREY Grey BLACK Black YELLOW Yellow GREEN Green

Code Color BU Blue GY Grey WH White YE Yellow

26 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 29

Sensors Value (mA) Deﬁnition

WS008391B

FLS and thermal contact 0 Overtemperature

7.8 OK 36 Leakage

The values have a 10% tolerance.

T-installation: Bleed air before starting pump

Installation

1. Open valve D and bleed out the air. See the following

1. Outlet line

2. Inlet line

3. Line to drain

4. Air vent

Figure 9: T-installation, valves A—D

2. Close valve D before the pump is started.

ﬁgure.

Check the impeller rotation

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

1. Start the motor.

2. Stop the motor after a few seconds.

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

Flygt 3126.290 Installation, Operation, and Maintenance Manual 27

Page 30

WS006253A

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, then transpose two phase leads (3phase) and do this procedure again.

28 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 31

Operation

Precautions

Before taking the unit into operation, check the following:

• All recommended safety devices are installed.

• The cable and cable entry have not been damaged.

• All debris and waste material has been removed.

NOTICE:

Never operate the pump with the discharge line blocked, or the discharge valve closed.

WARNING: Crush Hazard

Risk of automatic restart.

Distance to wet areas

WARNING: Electrical Hazard

Operation

CAUTION: Electrical Hazard

Risk of electrical shock or burn. The equipment manufacturer has not evaluated this unit for use in swimming pools. If used in connection with swimming pools then special safety regulations apply.

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 product is installed. Failure to do so may result in hearing loss or violation of local laws.

Estimate zinc anode replacement intervals

The mass and surface area of the zinc anodes are designed to protect the pump surface for 1 year in sea water with an average temperature of 20°C (68°F). Shorter inspection intervals and anode replacement can be required, depending upon the water temperature and the chemical composition as well as the presence of other metals in the vicinity of the pump.

The rate of zinc consumption, and the appropriate inspection intervals, can be estimated by measuring how much zinc is consumed during the ﬁrst two months following installation.

Anodes are replaced when the anode mass is reduced to a selected fraction of its initial mass. The recommended interval for the selection fraction is 0.25–0.50 (25–50%).

1. Remove, weigh, and reinstall one or more of the exterior zinc anodes before starting up the pump.

2. After two months, remove and weigh the same zinc anode or anodes again.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 29

Page 32

Operation

3. Divide the lapsed time in days (between steps 1 and 2) by the anode weight loss in

4. Calculate future replacement intervals so that they occur when the selected fraction of

Start the pump

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

NOTICE:

Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation.

1. Check the oil level in the oil housing.

2. Remove the fuses or open the circuit breaker, and check that the impeller can be

grams to get the calculated anode consumption rate (days/gram). If multiple anodes were weighed, then use the anode which has lost the most weight

for this calculation.

zinc is remaining.

rotated freely.

WARNING: Crush Hazard

Never put your hand into the pump housing.

3. Conduct insulation test phase to ground. To pass, the value must exceed 5 megaohms.

4. Check that the monitoring equipment works.

5. Start the pump.

30 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 33

Maintenance

Precautions

Before starting work, make sure that the safety instructions in the chapter Introduction and

Safety (page 3) have been read and understood.

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

WARNING: Biological Hazard

Infection risk. Rinse the unit thoroughly with clean water before working on it.

CAUTION: Crush Hazard

Make sure that the unit cannot roll or fall over and injure people or damage property.

Maintenance

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.

Ground continuity veriﬁcation

A ground (earth) continuity test must always be performed after service.

Maintenance guidelines

During the 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, O-rings with grease.

During the reassembly, always make sure that existing index markings are in line. The reassembled drive unit must always be insulation-tested and the reassembled pump

must always be test-run before normal operation.

Torque values

All screws and nuts must be lubricated to achieve correct tightening torque. Screws that are screwed into stainless steel must have the threads coated with suitable lubricants to prevent seizing.

If there is a question regarding the tightening torques, please contact the local sales and service representative.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 31

Page 34

WS001519A

Maintenance

Screws and nuts

Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)

Property

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class 50 1.0 (0.74) 2.0 (1.5) 3.0 (2.2) 8.0 (5.9) 15 (11) 27 (20) 65 (48) 127 (93.7) 220 (162) 434 (320) 70, 80 2.7 (2) 5.4 (4) 9.0 (6.6) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) 629 (464) 1240 (915) 100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) 115 (84.8) 248 (183) 481 (355) — —

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

Property

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class

8.8 2.9 (2.1) 5.7 (4.2) 9.8 (7.2) 24 (18) 47 (35) 81(60) 194 (143) 385 (285) 665 (490) 1310 (966.2)

10.9 4.0 (2.9) 8.1 (6) 14 (10) 33 (24) 65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840 (1357)

12.9 4.9 (3.6) 9.7 (7.2) 17 (13) 40 (30) 79 (58) 136 (100) 333 (245) 649 (480) 1120

(825.1)

2210 (1630)

Hexagon screws with countersunk heads

For hexagon socket head screws with countersunk head, maximum torque for all property classes must be 80% of the values for property class 8.8 above.

Change the oil

The following items are needed for this procedure:

• New oil plugs

• New O-rings

• Oil that should be a medical white oil of

parafﬁn type that fulﬁlls FDA 172.878 (a) and

viscosity close to VG32.

1. Place the pump in a horizontal position.

2. Turn the pump so that the oil hole faces downwards.

3. Unscrew the oil plug. If the pump has a hole with the markings "oil out" it is important that this hole is used

for drainage.

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Hold a rag over the plug to prevent liquid from spraying out.

32 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 35

1. Inspection plug

WS001517A

2. Oil plug

4. Drain the pump. Unscrew the other oil plug for easier drainage.

5. Fill the housing with new oil. Quantity: approximately 2 liters (2.1 US quarts)

6. Insert and tighten the new O-rings and plugs. Tightening torque: 10-20 Nm (7.4-14.8 ft-lbs)

Maintenance

Service the pump

Type of service Purpose Inspection interval Initial

inspection

Periodical inspection

Major overhaul

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

To make a check up of the pump condition by a Xylem authorized 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 the replacement of key components and the measures that are taken during an inspection.

Within the ﬁrst year of operation.

Up to every year Applies to normal applications

and operating conditions at media (liquid) temperatures <40°C (104°F).

Up to every 3 year Applies to normal applications

and operating conditions at media (liquid) temperatures <40°C (104°F).

Service item Action Cable 1. If the outer jacket is damaged, replace the cable.

Connection to power Check that the connections are properly tightened. Electrical cabinets Check that they are clean and dry.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 33

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

Page 36

Maintenance

Service item Action Impeller 1. Check the impeller clearance.

2. Adjust the impeller, if necessary.

Stator housing 1. Drain all liquid, if any.

2. Check the resistance of the leakage sensor. Normal value approximately1500 ohms, alarm approximately

430 ohms.

Insulation Use a megger maximum 1000 V.

1. Check that the resistance between the ground (earth) and phase lead is more than 5 megaohms.

2. Conduct a phase-to-phase resistance check.

Junction box Check that it is clean and dry. Lifting device Check that local safety regulations are followed. Lifting handle 1. Check the screws.

2. Check the condition of the lifting handle.

3. Replace if necessary.

O-rings 1. Replace the oil plug O-rings.

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

3. Grease the new O-rings.

Overload protection and other protections

Personnel safety devices Check the guard rails, covers, and other protections. Rotation direction Check the impeller rotation. Oil housing Fill with new oil, if necessary. Terminal block/closed end splice Check that the connections are properly tightened. Thermal contacts Normally closed circuit; interval 0–1 ohm. Voltage and amperage Check the running values.

Check the correct settings.

Major overhaul

For a major overhaul, do the following in addition to the tasks listed under Inspection.

Service item Action Support and main bearing Replace the bearings with new bearings. Mechanical seal Replace with new seal units.

Service in case of alarm

For information about indication values for sensors, see Sensors connection.

Alarm source Action FLS 1. Check for liquid in the stator housing.

Thermal contact Check the start and stop levels.

Replace the impeller

Required tools:

2. Drain all liquid, if any.

3. Check the mechanical seal unit, the O-rings, and the cable entry, if liquid was found.

Check that the cooling jacket is not clogged. Clean if necessary.

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

2. Check the start and stop levels.

34 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 37

• 10 mm hexagon bit adapter with an extension of at least 125 mm (4.92 in.)

WS003639A

WS003640A

• Impeller puller If applicable, contact your local sales and service representative for correct type and

size.

• Two crowbars, if applicable

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

NOTICE:

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.

If you fail with the impeller installation, then you must redo the installation procedure from the beginning.

Replace the C- or D-impeller

Maintenance

Figure 10: C-impeller

Remove the impeller: C, D

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

1. Remove the pump housing or the suction cover.

2. Remove the impeller screw. If applicable, use the rod.

Figure 11: D-impeller

Flygt 3126.290 Installation, Operation, and Maintenance Manual 35

Page 38

WS001988A

WS001982A

WS001978A

Maintenance

Figure 12: C-impeller

3. Remove the washer.

4. Remove the impeller. Use the impeller puller or the crowbars.

Figure 14: D-impeller

Install the impeller: C, D

1. Mount the impeller: a) Lubricate the impeller screw threads and contact surface.

b) Fit the washer on the lubricated impeller screw. c) Press the impeller onto the shaft with the impeller screw.

2. Tighten the impeller screw. If applicable, use the rod. Tightening torque: 90 Nm (66 ft-lbs)

Figure 13: D-impeller

Ensure that all parts are clean.

Check that the impeller can rotate freely.

3. Mount the suction cover (if applicable): a) Fit a new lubricated O-ring to the suction cover.

36 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 39

WS002015A

b) Fit the suction cover.

WS001940A

c) Fit and tighten the lubricated screws.

For tightening torque, see Torque values (page 31).

4. Mount the pump housing: a) Fit the pump housing.

b) Fit and tighten the lubricated screws.

Tightening torque: 57 Nm (42 ft-lb).

Maintenance

Install the F-impeller

1. Mount the impeller:

2. Fasten the impeller:

a) Lubricate the impeller screw threads and contact surface.

Ensure that all parts are clean.

b) Press the impeller onto the shaft with the impeller screw.

a) Prevent the impeller from rotating by inserting the rod through the pump housing

outlet.

b) Tighten the impeller screw.

If applicable, use the rod.

Check that the impeller can rotate freely.

3. Adjust the impeller: a) Measure the distance between the edge of the impeller and the pump housing

cover. The correct distance should be 0.5-1.5 mm (0.02-0.06 in). Add or remove the

appropriate number of adjusting washers in order to achieve correct distance.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 37

Page 40

WS002107A

WS001937A

Maintenance

b) Tighten the impeller screw.

If applicable, use the rod. Check that the impeller can rotate freely.

4. Mount the suction cover: a) Fit the studs on the pump housing.

Use Loctite 603 locking liquid in order to secure the studs. b) Fit the suction cover to the studs. c) Fit the lock nuts onto the studs. d) Tighten the nuts.

5. Adjust the suction cover: a) Measure the distance between the impeller and the suction cover.

38 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 41

WS002105A

b) Tighten the nuts.

WS001937A

Maintenance

6. Raise the pump to a vertical position. Check that the impeller can rotate freely.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 39

Page 42

Troubleshooting

Introduction

DANGER: Electrical Hazard

Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualiﬁed electrician.

Follow these guidelines when troubleshooting:

• Disconnect and lock out the power supply except when conducting checks that require voltage.

• Make sure that no one is near the unit 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

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

NOTICE:

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

Cause Remedy An alarm signal has been triggered

on the control panel.

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

The installation is not receiving voltage.

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 sales and service representative.

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.

• 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.

40 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 43

Cause Remedy The impeller is stuck. Clean:

• The impeller

• The sump in order to prevent the impeller from clogging again.

Always state the serial number of your product, see Product Description (page 11).

The pump does not stop when a level sensor is used

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

Cause Remedy The pump is unable to empty the

sump to the stop level.

There is a malfunction in the levelsensing equipment.

The stop level is set too low. Raise the stop level.

Check that:

• There are no leaks from the piping and/or discharge connection.

• The impeller is not clogged.

• The non-return valve(s) are functioning properly.

• The pump has adequate capacity. For information:

Contact the local sales and service representative.

• Clean the level regulators.

• Check the functioning of the level regulators.

• Check the contactor and the control circuit.

• Replace all defective items.

Troubleshooting

Always state the serial number of your product, see Product Description (page 11).

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.

The self-holding function of the contactor malfunctions.

Always state the serial number of your product, see Product Description (page 11).

Check that:

• The distance between the start and stop levels is sufﬁcient.

• The non-return valve(s) work(s) properly.

• The length of the discharge pipe between the pump and the ﬁrst non-

return valve is sufﬁciently short.

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

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

Flygt 3126.290 Installation, Operation, and Maintenance Manual 41

Page 44

Troubleshooting

NOTICE:

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

Cause Remedy The motor protection is set too low. Set the motor protection according to the data plate and if applicable the

cable chart.

The impeller is difﬁcult to rotate by hand.

The drive unit is not receiving full voltage on all three phases.

The phase currents vary, or they are too high.

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

The density of the pumped ﬂuid is too high.

There is a malfunction in the overload protection.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

• Check the fuses. Replace fuses that have tripped.

• If the fuses are intact, then notify a certiﬁed electrician. Contact the local sales and service representative.

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 megaohms.

2. If the insulation is less, then do the following:

Contact the local sales and service representative.

Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)

• Change to a more suitable pump

• Contact the local sales and service representative. Replace the overload protection.

Always state the serial number of your product, see Product Description (page 11).

The pump delivers too little or no water

DANGER: Crush Hazard

Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

NOTICE:

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

Cause Remedy The 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. To ensure a free ﬂow, clean out the pipes. The pipes and joints leak. Find the leaks and seal them. There are signs of wear on the

impeller, pump, and casing.

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

• If it is a 1-phase pump, then do the following:

• 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.

Replace the worn parts.

42 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 45

Troubleshooting

Cause Remedy The liquid level is too low. • Check that the level sensor is set correctly.

• Depending on the installation type, add a means for priming the pump,

such as a foot valve.

Always state the serial number of your product, see Product Description (page 11).

Flygt 3126.290 Installation, Operation, and Maintenance Manual 43

Page 46

Technical Reference

Motor data

Feature Description Motor type Squirrel-cage induction motor Frequency 50 or 60 Hz Supply 3-phase Starting method • Direct on-line

• Star-delta

Star-delta Maximum starts per hour 30 evenly spaced starts per hour Code compliance IEC 60034-1 Voltage variation without

overheating Voltage imbalance

tolerance Stator insulation class H (180°C [360°F])

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

Application limits

Data Description Liquid temperature 40°C (104°F) maximum

The pump can be operated at full load only if at least half the stator housing is

submerged. Liquid density 1100 kg/m³ (9.2 lb per US gal) maximum pH of the pumped media

(liquid) Depth of immersion 20 m (65 ft) maximum Other For the speciﬁc weight, current, voltage, power ratings, and speed of the pump, see the

3–14 for stainless steel pumps

data plate of the pump.

44 Flygt 3126.290 Installation, Operation, and Maintenance Manual

Page 47

Page 48

Xylem |’zīləm|

1) The tissue in plants that brings water upward from the roots

2) A leading global water technology company

We're 12,500 people uniﬁed in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efﬁciently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation.

For more information on how Xylem can help you, go to xyleminc.com

Refer to www.xylemwatersolutions.com/contacts/ for contact details of your local sales and service representative.

Xylem Water Solutions Manufacturing AB 361 80 Emmaboda Sweden Tel: +46-471-24 70 00 Fax: +46-471-24 47 01 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.

2011 Xylem Inc

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