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Flygt 3201

Xylem Flygt 3201 Installation Operation & Maintenance

Installation,
Operation, and
Maintenance Manual
Flygt 3201
Table of Contents
Introduction and Safety.........................................................................................................................3
Safety.....................................................................................................................................................3
User health and safety......................................................................................................................4
Safety regulations for Ex-approved products in potentially explosive atmospheres..............6
Environmental safety........................................................................................................................7
Product warranty.................................................................................................................................7
Spare parts........................................................................................................................................8
Transportation and Storage..................................................................................................................9
Inspect the unit upon delivery...........................................................................................................9
Receive the unit.................................................................................................................................9
Unpack the unit.................................................................................................................................9
Lifting guidelines.................................................................................................................................9
Store the unit.....................................................................................................................................10
Product Description.............................................................................................................................11
Pump design......................................................................................................................................11
Parts....................................................................................................................................................12
Monitoring equipment.....................................................................................................................13
Optional sensors.............................................................................................................................13
The data plate....................................................................................................................................14
Approvals...........................................................................................................................................14
Product denomination......................................................................................................................15
Table of Contents
Installation.............................................................................................................................................17
Install the pump.................................................................................................................................17
Install with P-installation.................................................................................................................17
Install with S-installation.................................................................................................................18
Install with T/Z-installation.............................................................................................................19
Make the electrical connections......................................................................................................21
General precautions.......................................................................................................................21
Requirements..................................................................................................................................21
Cables..............................................................................................................................................21
Earthing (Grounding).....................................................................................................................22
Connect the motor cable to the pump........................................................................................22
Connect the motor cable to the starter and monitoring equipment.......................................23
Cable charts....................................................................................................................................24
Check the impeller rotation.............................................................................................................29
Operation..............................................................................................................................................31
Distance to wet areas........................................................................................................................31
Start the pump...................................................................................................................................31
Maintenance.........................................................................................................................................32
Maintenance guidelines...................................................................................................................32
Torque values....................................................................................................................................32
Change the oil...................................................................................................................................33
Replace the wear rings.....................................................................................................................34
Replace the wear ring in the pump housing, diffuser ring, or suction cover..........................34
Replace the impeller wear ring.....................................................................................................35
Replace the impeller.........................................................................................................................35
Flygt 3201 Installation, Operation, and Maintenance Manual 1
Table of Contents
Remove the impeller and the wear protections ........................................................................36
Install the impeller and the wear protections.............................................................................36
Adjust the lower wear protection.................................................................................................37
Service the pump..............................................................................................................................37
Intermediate service.......................................................................................................................37
Major service...................................................................................................................................38
Service in case of alarm.................................................................................................................39
Troubleshooting...................................................................................................................................40
Introduction.......................................................................................................................................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.............................................................................42
The pump delivers too little or no water........................................................................................42
Technical reference.............................................................................................................................44
Application limits...............................................................................................................................44
Motor data..........................................................................................................................................44
2 Flygt 3201 Installation, Operation, and Maintenance Manual
Introduction and Safety
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact an Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem representative.
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
NOTICE:
For information about how to transport and store the pump, see Transportation and Storage in the Installation, Operation and Maintenance manual.
Introduction and Safety
Safety message levels
Definitions
Safety message level Indication
DANGER:
WARNING:
CAUTION:
Electrical Hazard:
A hazardous situation which, if not avoided, will result in death or serious injury
A hazardous situation which, if not avoided, could result in death or serious injury
A hazardous situation which, if not avoided, could result in minor or moderate injury
The possibility of electrical risks if instructions are not followed in a proper manner
Flygt 3201 Installation, Operation, and Maintenance Manual 3
Introduction and Safety
Safety message level Indication
NOTICE:
User health and safety
General precautions
The product is designed for use in liquids that can be hazardous to health. Observe these rules when working with the product:
• Make sure that all personnel who work with sewage systems are vaccinated against
diseases to which they may be exposed.
• Observe strict personal cleanliness.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work area:
• Helmet
• Safety goggles (with side shields)
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• A potential situation which, if not avoided, could result in an undesirable result or state
• A practice not related to personal injury
NOTICE:
The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may be exceeded in some installations and at certain operating points on the performance curve. Make sure that you understand the noise level requirements in the environment where the pump is installed. Failure to do so may result in hearing loss or violation of local laws.
The work area
Observe these regulations and warnings in the work area:
• 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.
Product and product positioning requirements
Observe these requirements for the product and the product positioning:
• Vent the tank of a sewage station in accordance with local plumbing codes.
• Never operate a pump unless safety devices are installed.
Electrical connections regulations
Electrical connections must be made by certified electricians in compliance with all international, national, state, and local regulations.
Observe these guidelines and warnings for electrical connections:
• Make sure that the product is isolated from the power supply and cannot be energized by mistake. This guideline also applies to the control circuit.
• Make sure that the thermal contacts are connected to a protection circuit according to the product approvals, and that they are in use.
4 Flygt 3201 Installation, Operation, and Maintenance Manual
Earthing (grounding)
Introduction and Safety
• Make sure that the cable and the cable entry have not been damaged during shipping.
• Use only the screened cable when using a variable-frequency drive (VFD). The
screened cable is necessary to fulfill European CE requirements. Contact your Xylem representative and ask your VFD supplier for electrical limitations. See also VFD recommendation in article no. 893472.
Observe the following regulations for earthing (grounding) connections.
Earthing (grounding) regulation Comment All electric equipment must be earthed (grounded). This rule applies to pumps and mixers as well as
monitoring equipment.
The earthing (grounding) conductors must be correctly connected.
The earthing (grounding) conductors should always be longer than the phase conductor/conductors.
Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault protection device to the earthed (grounded) connectors if persons are likely to come into physical contact with the pump or pumped liquids.
Precautions before work
Observe these safety precautions before you work with the product or are in connection with the product:
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that all safety guards are in place and secure.
• Allow all system and pump components to cool before you handle them.
• Make sure that you have a clear path of retreat.
• Make sure that the product cannot roll or fall over and injure people or damage
• Make sure that the lifting equipment is in good condition.
• Use a lifting harness, a safety line, and a breathing device as required.
• Make sure that the product is thoroughly clean.
• Make sure that there are no poisonous gases within the work area.
• Make sure that you have quick access to a first-aid kit.
• Disconnect and lock out power before servicing.
• Check the explosion risk before you weld or use electric hand tools.
Failure to follow this rule could result in a fatal accident.
If the motor cable is disconnected by mistake, the earthing (grounding) conductor needs to be disconnected last from its terminal. This rule applies to both ends of the cable.
—
property.
Precautions during work
Observe these safety precautions when you work with the product or are in connection with the product:
• Never work alone.
• Always wear protective clothing and hand protection.
• Stay clear of suspended loads.
• Always lift the product by its lifting device.
• Never lift the product by its motor cable or hose.
• Beware of the risk of a sudden start if the product is used with an automatic level control.
• Beware of the starting jerk, which can be powerful.
• Rinse the components in water after you disassemble the pump.
Flygt 3201 Installation, Operation, and Maintenance Manual 5
Introduction and Safety
• Do not open any vent or drain valve 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.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Clean chemicals from the eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes for at least 15 minutes. Use an eyewash or running water.
3. Seek medical attention.
Clean chemicals from the body
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least one minute.
3. Seek medical attention, if required.
Safety regulations for Ex-approved products in potentially explosive atmospheres
General guidelines
ATEX compliance is only fulfilled when the pump is operated within its intended use, for example within its intended hydraulic range. The conditions of the service must not be changed without approval of an authorized Xylem representative. When installing or maintaining ATEX-compliant pumps, follow these guidelines:
• Always install ATEX-approved equipment in compliance with the directive and applicable standards (IEC/EN 60079–14).
• Always install FM-approved products according to ANSI/NFPA 70-2005.
WARNING:
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.
If there are any questions regarding these requirements, the intended use, or if the equipment requires modification, contact an Xylem representative before you proceed.
Personnel requirements
Xylem disclaims all responsibility for work done by untrained and unauthorized personnel. 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 and/or vapor present in hazardous areas.
• The maintenance operation for Ex-approved products must be made in conformity to the international or national standards (IEC/EN 60079-17).
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 stated on the nameplates.
• The Ex-approved product must never run dry during normal operation. Dry running
during service and inspection is only permitted outside the classified area.
6 Flygt 3201 Installation, Operation, and Maintenance Manual
• See the dimensional drawings of the product for the minimum permitted water level according to the ATEX approval. Level-sensing equipment must be installed if the product can be operated at less than the minimum submersion depth.
• Before you start working with 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.
• 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 have been provided by an authorized Xylem representative.
Equipment for monitoring
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices:
• Level indicators
• Temperature detectors
Introduction and Safety
Environmental safety
The work area
Always keep the pump station clean to avoid and/or discover emissions.
Recycling guidelines
Always recycle according to these guidelines:
1. If the unit or parts are accepted by an authorized recycling company, then follow
local recycling laws and regulations.
2. If the unit or parts are not accepted by an authorized recycling company, then return
them to the nearest Xylem representative.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Dispose appropriately of all waste.
• Handle and dispose of the pumped fluid 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.
Reference for electrical installation
For electrical installation requirements, consult your local electric utility.
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.
Flygt 3201 Installation, Operation, and Maintenance Manual 7
Introduction and Safety
Limitations
Warranty claim
• All service and repair work is done by Xylem-authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by Xylem are used in Ex­approved products.
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
Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued.
8 Flygt 3201 Installation, Operation, and Maintenance Manual
Transportation and Storage
Inspect the unit upon delivery
Receive the unit
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.
Unpack the unit
1. Remove packing materials from the unit. Dispose of all packing materials in accordance with local regulations.
2. Inspect the unit to determine if any parts have been damaged or are missing.
3. Contact your Xylem representative if anything is out of order.
Lifting guidelines
General
The following are general guidelines for lifting the unit:
• Always use lifting equipment when handling the unit.
• When you use a lifting eyebolt or shackle for lifting the unit, make sure that the eyebolt
or shackle is fastened firmly before lifting.
• The unit can be transported either horizontally or vertically.
Transportation and Storage
Precautions
WARNING:
• The unit might get stuck if it hangs at any angle when lifting or lowering along guide
bars. Make sure the unit hangs straight up and down from the lifting hook.
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
• Do not attach sling ropes to shaft ends.
• Stay clear of suspended loads.
• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the
hose.
Flygt 3201 Installation, Operation, and Maintenance Manual 9
Transportation and Storage
Lifting equipment
The lifting equipment must fulfill the following requirements:
• The minimum height between the lifting hook and the floor must be sufficient to lift the
• The lifting equipment must be able to hoist the unit straight up and down in the sump,
• The lifting equipment must be securely anchored and in good condition.
• The lifting equipment must support the entire assembly and must only be used by
• 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
• The lifting equipment must not be oversized.
Store the unit
unit out of the sump. Contact Xylem for information.
preferably without the need for resetting the lifting hook.
authorized personnel.
media (liquid) in it.
NOTICE:
Oversized lifting equipment could cause damage if the unit should stick when being lifted.
1. After raising the unit, allow it to run for a short time to discharge all remaining pumped media (liquid).
The unit is frost-proof while operating or immersed in liquid, but the impeller and the shaft seal may freeze if the unit is raised in a temperature below freezing.
2. Store the unit in a covered and dry location free from heat, dirt, and vibrations.
3. If the unit is stored more than 6 months, rotate the shaft every other month to prevent the seals from sticking together.
4. Before operating the unit after storage:
If... Then…
the unit has been stored more than 6 months
the impeller is frozen thaw the impeller by immersing the unit in liquid.
inspect the unit with special attention to the seals and the cable entry.
NOTICE:
Never use a naked flame to thaw the unit.
10 Flygt 3201 Installation, Operation, and Maintenance Manual
Product Description
Pump design
The pump is submersible, and driven by an electric motor.
Intended use
WARNING:
Only use Ex- or MSHA-approved pumps in an explosive or flammable environment.
NOTICE:
Do NOT use the pump in highly corrosive liquids.
For information about pH, see Application limits (page 44).
Spare parts
• Modifications to the unit or installation should only be carried out after consulting with Xylem.
• Original spare parts and accessories 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.
Product Description
Flygt 3201 Installation, Operation, and Maintenance Manual 11
1
5
2
4
6
7
3
Product Description
Parts
PositionPart Description
1 Impeller A wide range of impellers are available for different applications and capacities. 2 Mechanical seal The seals are made of:
12 Flygt 3201 Installation, Operation, and Maintenance Manual
3 Shaft Stainless steel or carbon steel shaft with an integrated rotor. 4 Bearing
5 Oil housing A housing with oil that lubricates and cools the seals, and acts as a buffer between the
6 Cooling The stator is cooled by either the surrounding media (liquid) or by forced circulation in a
7 Motor For information about the motor, see Motor data.
• Inner seal: corrosion-resistant cemented carbide WCCR/WCCR
• Outer seal: corrosion-resistant cemented carbide WCCR/WCCR
• The main bearing consists of a two-row angular-contact ball bearing.
• The support bearing consists of a single-row roller bearing.
pumped media (liquid) and the drive unit.
cooling jacket.
Monitoring equipment
The following applies to the monitoring equipment of the pump:
• Normally the stator incorporates thermal contacts connected in series that activates the alarm 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 unit or an equivalent unit.
• The monitoring equipment must be of a design that makes automatic restart impossible.
• The label in the junction box shows if the pump is equipped with optional sensors.
Optional sensors
Product Description
Thermistor
FLS FLS is a miniature float switch for detection of liquid in the stator housing. Due
CLS CLS is a sensor for detection of water in the oil housing. The sensor initiates an
Two FLS sensors or one CLS and one FLS sensor can be used in the same pump, connected in parallel.
Thermistors are optional sensors for measuring the temperature. They are connected in series in the stator and activate the alarm at overtemperature. The sensors are only optional for standard pumps.
NOTICE:
Thermistor must never be exposed to voltages higher than 2.5 V. If the voltage exceeds this value, for example when the control circuit is tested, the thermistors will be destroyed.
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.
alarm when the oil contains approximately 35% water. The sensor is installed in the bearing housing/bearing holder with its sensing part in the oil housing.
NOTICE:
The CLS sensor body is made of glass. Handle with care.
Flygt 3201 Installation, Operation, and Maintenance Manual 13
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