Installation,
Operation, and
Maintenance Manual
Flygt 5520
Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Safety.....................................................................................................................................................3
Safety terminology and symbols....................................................................................................3
Environmental safety........................................................................................................................4
User safety.........................................................................................................................................5
Product warranty...............................................................................................................................6
Transportation and Storage..................................................................................................................7
Inspect the delivery.............................................................................................................................7
Inspect the package.........................................................................................................................7
Inspect the unit..................................................................................................................................7
Transportation guidelines..................................................................................................................7
Precautions........................................................................................................................................7
Position and fastening......................................................................................................................7
Lifting..................................................................................................................................................7
Temperature ranges for transportation, handling and storage....................................................8
Handling at freezing temperature..................................................................................................8
Unit in as-delivered condition.........................................................................................................8
Lifting the unit out of liquid.............................................................................................................8
Storage guidelines..............................................................................................................................9
Storage location................................................................................................................................9
Long-term storage............................................................................................................................9
Table of Contents
Product Description.............................................................................................................................10
Pump design......................................................................................................................................10
Parts....................................................................................................................................................11
Monitoring equipment.....................................................................................................................12
Optional sensors.............................................................................................................................12
The data plate....................................................................................................................................13
Product denomination......................................................................................................................14
Installation.............................................................................................................................................15
Install the pump.................................................................................................................................15
Authority regulation.......................................................................................................................15
Fasteners.........................................................................................................................................15
Install with P-installation.................................................................................................................16
Install with S-installation.................................................................................................................17
Install with T/Z-installation.............................................................................................................17
Make the electrical connections......................................................................................................19
General precautions.......................................................................................................................19
Requirements..................................................................................................................................19
Cables..............................................................................................................................................19
Earthing (Grounding).....................................................................................................................20
Connect the motor cable to the pump........................................................................................20
Connect the motor cable to the starter and monitoring equipment.......................................21
Cable charts....................................................................................................................................22
Check the impeller rotation.............................................................................................................30
Operation..............................................................................................................................................32
Precautions.........................................................................................................................................32
Distance to wet areas........................................................................................................................32
Flygt 5520 Installation, Operation, and Maintenance Manual 1
Table of Contents
Noise level..........................................................................................................................................32
Start the pump...................................................................................................................................32
Maintenance.........................................................................................................................................34
Precautions.........................................................................................................................................34
Maintenance guidelines...................................................................................................................34
Torque values....................................................................................................................................34
Change the oil...................................................................................................................................35
Service the pump..............................................................................................................................36
Inspection........................................................................................................................................36
Major overhaul................................................................................................................................37
Service in case of alarm.................................................................................................................38
Replace the hydraulic parts.............................................................................................................38
Replace the impeller......................................................................................................................38
Replace the wear parts..................................................................................................................41
Troubleshooting...................................................................................................................................45
Introduction.......................................................................................................................................45
The pump does not start..................................................................................................................45
The pump does not stop when a level sensor is used.................................................................46
The pump starts-stops-starts in rapid sequence...........................................................................46
The pump runs but the motor protection trips.............................................................................47
The pump delivers too little or no water........................................................................................47
Technical Reference............................................................................................................................49
Motor data..........................................................................................................................................49
Application limits...............................................................................................................................49
2 Flygt 5520 Installation, Operation, and Maintenance Manual
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
Introduction and Safety
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment. This includes
any modification to the equipment or use of parts not provided by Xylem. If there is a
question regarding the intended use of the equipment, please contact an Xylem
representative before proceeding.
• This manual clearly identifies accepted methods for disassembling units. These methods
must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion
and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in
their removal.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in
physical injury, damage, or delays.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
Flygt 5520 Installation, Operation, and Maintenance Manual 3
Introduction and Safety
Hazard levels
Hazard level Indication
Hazard categories
DANGER:
WARNING:
CAUTION:
NOTICE:
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
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
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary hazard
levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
4 Flygt 5520 Installation, Operation, and Maintenance Manual
Electrical installation
Recycling guidelines
User safety
General safety rules
Introduction and Safety
WARNING:
Do NOT send the product to the Xylem manufacturer if it has been contaminated by any
nuclear radiation. Inform Xylem so that accurate actions can take place.
For electrical installation recycling requirements, consult your local electric utility.
Always recycle according to these guidelines:
1. Follow local laws and regulations regarding recycling if the unit or parts are
accepted by an authorized recycling company.
2. If the first guideline is not applicable, then return the unit or parts to your Xylem
representative.
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
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:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
• Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
Flygt 5520 Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition Action
Product warranty
Coverage
Limitations
Chemicals or hazardous
fluids in eyes
Chemicals or hazardous
fluids on skin
Xylem undertakes to remedy defects in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an Xylem representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in
use.
• All service and repair work is done by Xylem-authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by Xylem are used in Exapproved products.
The warranty does not cover defects caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting
Xylem
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
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.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
Warranty claim
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your Xylem
representative.
Spare parts
Xylem guarantees that spare parts will be available for 15 years after the manufacture of
this product has been discontinued.
6 Flygt 5520 Installation, Operation, and Maintenance Manual
Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Transportation and Storage
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Position and fastening
The unit can be transported either horizontally or vertically. Make sure that the unit is
securely fastened during transportation, and cannot roll or fall over.
Lifting
WARNING:
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods
and wear steel-toed shoes at all times.
• Lift and handle the product carefully, using suitable lifting equipment.
• The product must be securely harnessed for lifting and handling. Use eyebolts or lifting
lugs if available.
• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the
hose.
• Do not attach sling ropes to shaft ends.
Flygt 5520 Installation, Operation, and Maintenance Manual 7
Transportation and Storage
Lifting equipment
Lifting equipment is always required when handling the unit. It must fulfill the following
requirements:
• The minimum height (contact Xylem for information) between the lifting hook and the
• The lifting equipment must be able to hoist the unit straight up and down, preferably
• The lifting equipment must be securely anchored and in good condition.
• The lifting equipment must support weight of the entire assembly and must only be
• 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.
floor must be sufficient to lift the unit.
without the need for resetting the lifting hook.
used by authorized personnel.
media in it.
NOTICE:
Oversized lifting equipment could cause damage if the unit should stick when being
lifted.
Temperature ranges for transportation, handling and storage
Handling at freezing temperature
At temperatures below freezing, the product and all installation equipment, including the
lifting gear, must be handled with extreme care.
Make sure that the product is warmed up to a temperature above the freezing point before
starting up. Avoid rotating the impeller/propeller by hand at temperatures below the
freezing point. The recommended method to warm the unit up is to submerge it in the
liquid which will be pumped or mixed.
NOTICE:
Never use a naked flame to thaw the unit.
Unit in as-delivered condition
If the unit is still in the condition in which it left the factory - all packing materials are
undisturbed - then the acceptable temperature range during transportation, handling and
storage is: –50°C (–58ºF) to +60°C (+140ºF).
If the unit has been exposed to freezing temperatures, then allow it to reach the ambient
temperature of the sump before operating.
Lifting the unit out of liquid
The unit is normally protected from freezing while operating or immersed in liquid, but the
impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a
surrounding temperature below freezing.
Units equipped with an internal cooling system are filled with a mixture of water and 30%
glycol. This mixture remains a flowing liquid at temperatures down to –13°C (9°F). Below –
13°C (9°F), the viscosity increases such that the glycol mixture will lose its flow properties.
However, the glycol-water mixture will not solidify completely and thus cannot harm the
product.
Follow these guidelines to avoid freezing damage:
8 Flygt 5520 Installation, Operation, and Maintenance Manual
1. Empty all pumped liquid, if applicable.
2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for
the presence of water. Change if needed.
Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and
vibrations.
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Long-term storage
If the unit is stored more than 6 months, the following apply:
• Before operating the unit after storage, it must be inspected with special attention to
the seals and the cable entry.
• The impeller/propeller must be rotated every other month to prevent the seals from
sticking together.
Transportation and Storage
Flygt 5520 Installation, Operation, and Maintenance Manual 9
Product Description
Product Description
Pump design
The pump is submersible, and driven by an electric motor.
Intended use
The product is intended for moving wastewater, sludge, raw and clean water. Always
follow the limits that are given in Application limits (page 49). If there is a question
regarding the intended use of the equipment, please contact an Xylem representative
before proceeding.
WARNING:
In explosive or flammable environments, only use Ex- or MSHA-approved pumps.
NOTICE:
Do NOT use the pump in highly corrosive liquids.
Spare parts
• Modifications to the unit or installation should only be carried out after consulting with
Xylem.
• Original spare parts and accessories that are authorized by Xylem are essential for
compliance. The use of other parts can invalidate any claims for warranty or
compensation. For more information contact your Xylem representative.
Pressure class
MT
Medium head
10 Flygt 5520 Installation, Operation, and Maintenance Manual
Parts
12
11
10
6
9
7
8
1
2
4
3
5
WS006182A
Product Description
Position Part Description
1 Motor For information about the motor,
see Motor data (page 49).
2 Monitoring equipment For more information about the
monitoring equipment, see
3 Impeller The impeller is a shrouded three-
4 Flushing plug External flushing of the outer
5 Wear parts
Monitoring equipment (page 12).
channel H-impeller.
mechanical seal can be connected
to one of the holes. The other holes
must then be plugged during
flushing.
• Flushing flow: 1.5-4 l/min
(1.6-4.2 quarts/min)
• Pressure of 5m + shut-off
head
For more information, contact your
local Xylem representative.
• Wear lining
• Wear ring
Flygt 5520 Installation, Operation, and Maintenance Manual 11
Product Description
Position Part Description
• Wearing cover
• Suction cover
• Impeller
• Wear protection/plug
6 Gasket Functions as a sealing both between
the pump housing and the
discharge line and between the
pump housing and the wear lining.
7 Mechanical seals One inner and one outer seal in a
combination of materials:
• Tungsten carbide
• Silicon carbide RSiC
• Aluminium oxide Al2O
• Corrosion-resistant
cemented carbide WCCR
8 Oil casing A housing with oil that lubricates
and cools the seals, and acts as a
buffer between the pumped fluid
and the drive unit. Pressure buildup
within the oil casing is reduced by
means of a built in air volume.
3
9 Main bearing The bearing consists of a two row
10 Shaft The shaft is stainless steel, with an
11 Cooling The pump is cooled by the ambient
12 Support bearing The bearing consists of a single-row
Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates three thermal contacts connected in series that activate the
alarm and stops the pump at overtemperature
• The thermal contacts open at 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.
angular contact ball bearing.
integrated rotor.
liquid.
ball bearing.
Optional sensors
FLS
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.
12 Flygt 5520 Installation, Operation, and Maintenance Manual
CLS CLS is a sensor for detection of water in the oil housing. The sensor initiates an alarm
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
3
1
23
24
WS006257A
One CLS and one FLS sensor can be used in the same pump, if they are connected in
parallel.
The data plate
The data plate is a metal label located on the main body of the products. The data plate
lists key product specifications. Specially approved products also have an approval plate.
Product Description
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. The CLS sensor is not
applicable to Ex-approved pumps.
NOTICE:
The CLS sensor body is made of glass. Handle the sensor with care.
1. Curve code/Propeller code
2. Serial number, see Product denomination (page 14)
3. Product number
4. Country of origin
5. Additional information
6. Phase; type of current; frequency
7. Rated voltage
8. Thermal protection
9. Thermal class
10. Rated shaft power
11. International standard
12. Degree of protection
13. Rated current
14. Rated speed
15. Maximum submergence
16. Direction of rotation: L=left, R=right
17. Duty class
18. Duty factor
19. Product weight
20. Locked rotor code letter
21. Power factor
22. Maximum ambient temperature
23. Read installation manual
24. Notified body. Only for EN-approved Ex-products
Figure 1: The data plate
Flygt 5520 Installation, Operation, and Maintenance Manual 13
1
NP 3085
2 3
WS006265A
3085.183
1 2
NP
WS006262A
1
NP 3085.183 - 951 0163
2 3 4
WS006269A
Product Description
Product denomination
Sales denomination
The sales denomination consists of the four-digit sales code and two letters that indicate
the hydraulic end and type of installation.
This is an example of a sales denomination, and an explanation of its parts.
1. Hydraulic part
2. Installation type
3. Sales code
Product code
The product code consists of nine characters divided into two parts.
This is an example of a product code, and an explanation of its parts.
Serial number
1. Sales denomination
2. Version
The serial number is used for identification of an individual product, and is divided into
four parts.
This is an example of a serial number, and an explanation of its parts.
1. Product code
2. Production year
3. Production cycle
4. Running number
14 Flygt 5520 Installation, Operation, and Maintenance Manual
Installation
Install the pump
WARNING:
• Electrical shock hazard. Check that the cable and cable entry have not been damaged
during transport before installing the pump.
• Note that special rules apply to installation in explosive atmospheres.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• Do not install CSA-approved products in locations that are classified as hazardous in the
national electric code, ANSI/NFPA 70-2005.
• Do not install the starter equipment in an explosive zone unless it is explosion-proof
rated.
NOTICE:
• Do not run the pump dry.
• Never force piping to make a connection with a pump.
• Always remove all debris and waste material from the sump, inlet piping, and
discharge connection, before you install the pump.
Installation
Authority regulation
Fasteners
These requirements apply:
• Use the pump dimensional drawing in order to ensure proper installation.
• Provide a suitable barrier around the work area, for example, a guard rail.
• Check the explosion risk before you weld or use electric hand tools.
• Always check the impeller rotation before lowering the pump into the pumped liquid.
Vent the tank of a sewage machine station in accordance with local plumbing codes.
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing
fasteners.
Flygt 5520 Installation, Operation, and Maintenance Manual 15
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 casing 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.
Make sure the rubber gasket in the discharge connection is correctly positioned.
6. Lower the pump along the guide bars.
16 Flygt 5520 Installation, Operation, and Maintenance Manual
When it reaches the bottom position, the pump automatically connects to the
WS006270A
discharge connection.
7. Secure the motor cable:
a) Fasten the permanent lifting device to the pump and to the access frame. For
example, you can use a stainless-steel lifting chain with shackles.
b) Fasten the cable to the cable holder.
Make sure that the cable cannot be sucked into the pump inlet or that it is neither
sharply bent, or pinched. Support straps are required for deep installations.
c) Connect the motor cable and the starter and monitoring equipment according to
the separate instructions.
Make sure that the impeller rotation is correct. For more information, see Check the
impeller rotation (page 30).
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
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 startup or during operation.
5. Connect the motor cable and the starter and monitoring equipment according to the
separate instructions.
Make sure that the impeller rotation is correct. For more information, see Check the
impeller rotation (page 30).
Install with T/Z-installation
In the T-installation, the pump is installed in a vertical position in a dry well next to the wet
sump. These requirements and instructions only apply when the installation is made
according to the dimensional drawing.
Flygt 5520 Installation, Operation, and Maintenance Manual 17
WS006272A
WS006273A
Installation
In the Z-installation, the pump is installed in a horizontal position on a support stand in a
dry well next to the wet sump. The following requirements and instructions are for Zinstallations that comply to the dimensional drawing.
Figure 5: Z-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 for the T-installation or horizontal for the Z-
installation.
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 30).
5. Make sure that the weight of the pump does not put strain on the piping.
18 Flygt 5520 Installation, Operation, and Maintenance Manual
Make the electrical connections
General precautions
Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local codes and
regulations.
• Before starting work on the unit, make sure that the unit and the control panel are
isolated from the power supply and cannot be energized. This applies to the control
circuit as well.
• Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep
the end of the motor cable above the liquid level.
• Make sure that all unused conductors are insulated.
• There is a risk of electrical shock or explosion if the electrical connections are not
correctly carried out or if there is fault or damage on the product.
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
Installation
Requirements
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
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.
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.
Flygt 5520 Installation, Operation, and Maintenance Manual 19
Installation
Earthing (Grounding)
• The minimum bending radius must not be below the accepted value.
• If using a cable which has been used before, a short piece must be peeled off when
refitting it so that the cable entry seal sleeve does not close around the cable at the
same point again. If the outer sheath of the cable is damaged, then replace the cable.
Contact an Xylem service shop.
• The voltage drop in long cables must be taken into account. The drive unit’s rated
voltage is the voltage measured at the cable connection point in the pump.
• The screened cable must be used according to the European CE requirements if a
Variable Frequency Drive (VFD) is used. For more information, contact your Xylem
representative (VFD-supplier).
Electrical Hazard:
• You must earth (ground) all electrical equipment. This applies to the pump equipment,
the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is
connected correctly.
• If the motor cable is jerked loose by mistake, the earth (ground) conductor should be the
last conductor to come loose from its terminal. Make sure that the earth (ground)
conductor is longer than the phase conductors. This applies to both ends of the motor
cable.
• Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault
protection device to the earthed (grounded) connectors if persons are likely to come
into physical contact with the pump or pumped liquids.
Connect the motor cable to the pump
CAUTION:
Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the
end of the motor cable above the liquid level.
20 Flygt 5520 Installation, Operation, and Maintenance Manual
2
1
WS003625A
3
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 earth (ground)) according to applicable cable
chart.
The earth (ground) lead must be 50 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 earth (ground).
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
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
Flygt 5520 Installation, Operation, and Maintenance Manual 21
WS000509C
L2
L3L1
L1
L3L2
T1
T2
Installation
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.
1. If thermal contacts are included in the pump installation, connect the T1 and T2 control
conductors to the monitoring equipment.
Do not connect the T1 and T2 leads to thermal contacts if the temperature of the
pumped liquid is above 40°C (104°F).
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 earth [ground]) to the starter equipment.
For information about the phase sequence and the color codes of the leads, see Cable
charts (page 22).
3. Check the functionality of the monitoring equipment:
a) Check that the signals and the tripping function work properly.
b) Check that the relays, lamps, fuses, and connections are intact.
Replace any defective equipment.
Cable charts
Description
This topic contains general connection information. It also provides cable charts that show
connection alternatives for use with different cables and power supply.
Figure 6: Phase sequence
Connection locations
The figures in this section illustrate how to interpret the connection strip symbols.
22 Flygt 5520 Installation, Operation, and Maintenance Manual
L1 L2 L3
T3 T4T1 T2
U1
V1
W1
U2
W2
V2
U1
V1
W1
W2
U2
V2
U1
V1
W1
GC
W2
U2
V2
L1
L2
L3
*YE
GN/YE
WH
L1
U1
U2
W2
V2
W1
V1
L3
L2
WS004133C
L1 L2 L3
T3 T4T1 T2
43
21
5
10
8
CLS
6
FLS
7
FLS 10
11
9
WS004134A
Installation
1. Stator leads
2. Terminal board
3. Motor cable leads
4. Stator (internal connection illustrated)
1. Starter equipment and mains leads (L1, L2, L3)
2. Earth (ground)
3. Functional ground
4. Control leads (T1, T2, T3, T4)
5. Thermal contact
6. FLS
7. FLS 10
8. CLS
9. Thermistor
10. Level sensor
11. Capacitor
Color code standard
Code Description
BN Brown
BK Black
WH White
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow
Flygt 5520 Installation, Operation, and Maintenance Manual 23
1 L1 BK 1 BN RD BN
2 L2 BK 2 BK BK BK
3 L3 BK 3 GY WH GY
L1 BK 4
- - -
L2 BK 5
- - -
L3 BK 6
- - -
GN/YE GN/YE GN/YE
**Screen/PE
from cores
Screen (WH) Screen (WH)
-
Screen (WH)
Mains
1~ 3~
SUBCAB 7GX
Screenflex 7GX
SUBCAB 4GX
Screenflex 4GX
SUBCAB AWG
SUBCAB
Screened
GC
- -
YE
-
772 17 00/1
Motor connection
Colours and marking of main leads
COLOUR STANDARD
STATOR LEADS
BN=Brown
U1,U5 RD
BK=Black
U2,U6 GN
WH=White
V1,V5 BN
OG=Orange
V2,V6 BU
GN=Green
W1,W5 YE
GN/YE=Green-Yellow
W2,W6 BK
RD=Red
T1,T2 WH/YE
GY=Grey
BU=Blue
YE=Yellow
*SUBCAB AWG
* * Ground Conductor is stranded around cores
GC=Ground Check
WS004125A
Installation
Colors and markings of leads
For markings on sensor leads, see Sensors connection (page 29).
Connections included
• 3-phase connection (page 25)
• 1-phase connection (page 27)
• Sensors connection (page 29)
• Screened cable connection (page 28)
24 Flygt 5520 Installation, Operation, and Maintenance Manual
3-phase connection
D
L1
W2
U1
W1
U2
L3
V2
V1
L2
U1
V1
W1
W2
U2
V2
U1
V1
W1
W2
U2
V2
U1
V1
W1
W2
U2
V2
GC
L1
L2
L3
*YE
GN/YE
WH
Y/D
L1
L2
L3
L1
L2
L3
L1:1
L2:1
L3:1
L1:2
L2:2
L3:2
U1
V1
W1
U2
V2
W2
U1
V1
W1
W2
U2
V2
U1
V1
W1
W2
U2
V2
U1
V1
W1
W2
U2
V2
GC
1
2
3
4
5
6
GN/YE
*YE
WH
WS004126A
6 Leads
Y
U1
V1
W1
U2
W2
V2
U1
V1
W1
W2
U2
V2
U1
V1
W1
GC
W2
U2
V2
L1
L2
L3
*YE
GN/YE
WH
L1
U1
U2
W2
V2
W1
V1
L3
L2
Installation
Flygt 5520 Installation, Operation, and Maintenance Manual 25
9 Leads
Y-
L3
W1
U1
L1
W2
U2
W5
U5
V2
V1
V5
L2
U1
V1
W1
V2
U5
V5
W5
U2
W2
U1
V1
W1
U1
V1
W1
GC
L1
L2
L3
*YE
GN/YE
WH
Y-SER
L1
U1
U2
U5
W2
W5
W1
V5
V2
V1
L3
L2
U5
U2
V1
V5
V2
W1
W5
W2
U1
U1
U5
V1
V5
W1
W5
GC
L1
L2
L3
*YE
GN/YE
WH
WS004127A
12 Leads
Y-
L1
U1
U5
U2
W2
U6
W1
V6
W6
V2
V5
W5
L3
V1
L2
U1
V1
W1
U2
V6
U5
V5
W5
V2
W2
U6
W6
U1
V1
W1
W2
U2
V2
W2
U2
V2
GC
U1
V1
W1
L1
L2
L3
*YE
WH
GN/YE
Y-SER
L1
U1
U2
U5
W6
U6
W2
W5
V6
W1
V5
V2
V1
L3
L2
U1
V1
W1
W2
U2
V2
V6
W5
U5
V5
U6
W6
U1
V1
W1
W2
U2
V2
W1
W2
GC
U1
V1
U2
V2
L1
L2
L3
*YE
GN/YE
WH
WS004128A
Installation
26 Flygt 5520 Installation, Operation, and Maintenance Manual
1-phase connection
12 Leads
U1
V1
U6
U2
W2
V6
V5
W1
W5
U5
V2
W6
U1
V1
W1
W2
U2
V2
GC
U1
V1
W1
W2
U2
V2
BN
*RD
BK
GY
WH
1
3
*BK
2
*WH
6
GN/YE
*YE
Starter
1 ~
1 ~
U1
V1
W1
U2
V2
W2
U5
V5
W5
U6
V6
W6
WS004129A
1 PHASE
4 Leads
1 ~
Z2
U2
U1
Z1
T1
T2
BK
BN
RD
YE
GC
1/BN
*RD
2/BK
*BK
3/GY
*WH
4/T1
*OG
5/T2
*BU
6
WH
GN/YE
*YE
Starter
4 Leads with level regulator
1 ~
1 ~
1
2
3
Z2
U2
Z1
U1
Z2
U2
U1
Z1
T1
T2
BK
BN
RD
YE
GC
BN
BU
1/BN
*RD
2/BK
*BK
3/GY
*WH
4/T1
*OG
5/T2
*BU
6
WH
GN/YE
*YE
Starter
Installation
Flygt 5520 Installation, Operation, and Maintenance Manual 27
Screened connection SUBCAB & FGB Screened
Cable without sep. ground conductor
Screen as ground conductor
L1
BN
L2
BK
L3
GY
GN/YE shrink hose
Screen
Mini CAS
Mini CAS+AUX
FGB Screened
T1 (WH)
T2 (WH)
T3 (WH)
T4 (WH)
T1 (WH)
T2 (WH)
T3 (WH)
T4 (WH)
T1 (WH)
T2 (WH)
Screen - SUBCAB and Screenflex
T1 and T2
twisted
White insulation hose
Screen
together
GN/YE
L1
L2
L3
T1
T2
T1 and T2
twisted
together
White insulation hose
Screen
BK
BK
BK
BK
BK
BK
GN/YE
1
2
3
4
5
6
T1
T2
L1
L2
L3
L1
L2
L3
WS004132A
Installation
Screened cable connection
28 Flygt 5520 Installation, Operation, and Maintenance Manual
Sensors connection
Control
SUBCAB 7GX & 4GX
Screenflex
SUBCAB AWG
SUBCAB
screened
T1 WH T1 OG WH T1
T2 WH T2 BU WH T2
T3
- -
WH T3
T4
- -
WH T4
SENSORS
(Thermal Contacts)
TC
Max. 250V Max.5A
Max. 1.6A,cos =0.6
Max. 2.5A,cos =1
6
WH/YE
T1
Control leads
WH/YE
T2
T1/*OG/4
*SUBCAB AWG
T2/*OG/5
+ FLS
FLS
TC
Max 12 V
BU
BU
WH
YE
6
BU
WH/YE
T1
Control leads
BU
T2
T1/*OG/4
+7
Mini
-5
CAS
*SUBCAB AWG
T2/*BU/5
+ CLS
CLS
TC
Max 12 V
BK
BN
WH
YE
6
BN/RD
WH/YE
T1
Control leads
T1/*OG/4
T2
+7
BK
Mini
*SUBCAB AWG
T2/*BU/5
-5
CAS
WS004130A
Installation
Flygt 5520 Installation, Operation, and Maintenance Manual 29
+ FLS+CLS
CLS
FLS
TC
Max 12 V
BK
BN
BU
BU
WH
6
YE
RD/BN
BU
RD/BN
WH/YE
T1
Control leads
BU
T1/*OG/4
+7
Mini
BK
T2
-5
CAS
*SUBCAB AWG
T2/*BU/5
FLS
Temp > 40° T1,T2 thermal
FLS
TC
contacts not connected
WH/YE
6
WH/YE
Control leads
BU
T1/*OG/4
+7
Mini
-5
CAS
BU
T2/*BU/5
*SUBCAB AWG
WS004131A
Installation
Sensor connection characteristics
Check the impeller rotation
The values have a 10 % tolerance.
Sensors Value (mA) Definition
FLS and thermal contact 0 Overtemperature
CLS and thermal contact 0 Overtemperature
CLS, FLS and thermal contact 0 Overtempterature
WARNING:
The starting jerk can be powerful.
1. Start the motor.
2. Stop the motor after a few seconds.
3. Check that the impeller rotates according to this illustration.
7.8 OK
36 Leakage
5.5 OK
29 Leakage (5 seconds delay)
13.3 OK
36–42 Leakage (0/5 seconds delay)
30 Flygt 5520 Installation, Operation, and Maintenance Manual
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, transpose two phase leads (3-phase) and
do this procedure again.
Flygt 5520 Installation, Operation, and Maintenance Manual 31
Operation
Operation
Precautions
WARNING:
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• Make sure you have a clear path of retreat.
• Never work alone.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
Distance to wet areas
Electrical Hazard:
Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to the unit when
being in contact with the pumped or mixed liquid.
Noise level
NOTICE:
The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may
be exceeded in some installations and at certain operating points on the performance
curve. Make sure that you understand the noise level requirements in the environment
where the pump is installed. Failure to do so may result in hearing loss or violation of local
laws.
Start the pump
WARNING:
• If you need to work on the pump, make sure that it is isolated from the power supply and
cannot be energized.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• In some installations, the pump and the surrounding liquid may be hot. Bear in mind the
risk of burn injuries.
• Make sure nobody is close to the unit when it is started. The unit will jerk in the opposite
direction of the impeller rotation.
NOTICE:
Make sure that the rotation of the impeller is correct. For more information, see Check the
impeller rotation.
1. Check the oil level in the oil housing.
2. Remove the fuses or open the circuit breaker, and check that the impeller can be
rotated freely.
32 Flygt 5520 Installation, Operation, and Maintenance Manual
Operation
3. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms.
4. Check that the monitoring equipment works.
5. Start the pump.
Flygt 5520 Installation, Operation, and Maintenance Manual 33
Maintenance
Maintenance
Precautions
WARNING:
• Always follow safety guidelines when working on the product. See Introduction and
Safety (page 3).
• Disconnect and lock out electrical power before installing or servicing the pump.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• Rinse the unit thoroughly with clean water before working on the unit.
• Rinse the components in water after dismantling.
Make sure that you follow these requirements:
• Check the explosion risk before you weld or use electrical hand tools.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product and its components have been thoroughly cleaned.
• Do not open any vent or drain valves or remove any plugs while the system is
pressurized. Make sure that the pump is isolated from the system and that pressure is
relieved before you disassemble the pump, remove plugs, or disconnect piping.
Maintenance guidelines
During maintenance and before reassembly, always remember to perform these tasks:
• Clean all parts thoroughly, particularly O-ring grooves.
• Change all O-rings, gaskets, and seal washers.
• Lubricate all springs, screws, and O-rings with grease.
During reassembly, always make sure that existing index markings are in line.
The reassembled drive unit must always be insulation-tested and the reassembled pump
must always be test-run before normal operation.
Torque values
All screws and nuts must be lubricated to achieve correct tightening torque. Screws that
are screwed into stainless steel must have the threads coated with suitable lubricants to
prevent seizing.
If there is a question regarding the tightening torques, please contact a sales
representative.
Screws and nuts
Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)
Property
class
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
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
(915)
34 Flygt 5520 Installation, Operation, and Maintenance Manual
WS002420A
Maintenance
Property
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
class
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.
WARNING:
The oil housing may be pressurized. Hold a rag over the oil plug to
prevent oil from spraying out.
4. Drain the pump.
Unscrew the other oil plug for easier drainage.
Flygt 5520 Installation, Operation, and Maintenance Manual 35
WS001517A
Maintenance
5. Fill the housing with new oil.
Quantity: approximately 1 liters (1.1 US quarts)
6. Insert and tighten the new O-rings and plugs.
Tightening torque: 20 Nm (18.8 ft-lbs)
Service the pump
Type of service Purpose Inspection interval
Initial inspection To make a check up of the pump
condition by an authorized Xylem
service representative and, based
on the result and findings from
these measures, to determine the
intervals for periodical inspection
and major overhaul for the specific
installation.
Periodical inspection To prevent operational interruptions
and machine breakdown. Measures
to secure performance and pump
efficiency are defined and decided
for each individual application. It
can include such things as impeller
trimming, wear part control and
replacement, control of zinc-anodes
and control of the stator.
Major overhaul To secure a long operating lifetime
for the product. It includes
replacement of key components
and the measures taken during an
inspection.
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).
Within the first year of operation.
Up to twice a year
Applies to normal applications and
operating conditions at media
(liquid) temperatures <40°C.
Up to every second year or 10,000
hours, whichever comes first.
Applies to normal applications and
operating conditions at media
(liquid) temperatures <40°C.
Inspection
36 Flygt 5520 Installation, Operation, and Maintenance Manual
Service item Action
Maintenance
Cable
Connection to power Check that the connections are properly tightened.
Electrical cabinets Check that they are clean and dry.
Impeller
Stator housing
Insulation Use a megger maximum 1000 V.
Junction box Check that it is clean and dry.
Level regulators Check the condition and functionality.
Lifting device Check that local safety regulations are followed.
1. If the outer jacket is damaged, replace the cable.
2. Check that the cables do not have any sharp bends and are not
pinched.
1. Check the impeller clearance.
2. Adjust the impeller, if necessary.
1. Drain all liquid, if any.
2. Check the resistance of the leakage sensor.
Normal value approx.1500 ohms, alarm approx. 430 ohms.
1. Check that the resistance between the earth (ground) and
phase lead is more than 5 megohms.
2. Conduct a phase-to-phase resistance check.
Major overhaul
Lifting handle
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.
For a major overhaul, take this action in addition to the tasks listed under Inspection.
1. Check the screws.
2. Check the condition of the lifting handle.
3. Replace if necessary.
1. Replace the oil plug O-rings.
2. Replace the O-rings at the entrance or junction cover.
3. Grease the new O-rings.
Check the correct settings.
Service item Action
Support and main bearing Replace the bearings with new bearings.
Mechanical seal Replace with new seal units.
Flygt 5520 Installation, Operation, and Maintenance Manual 37
Maintenance
Service in case of alarm
For information about indication values for sensors, see Sensors connection (page 29).
Alarm source Action
CLS Check for water in the oil housing. If the oil contains too much water:
1. Drain the oil and water.
2. Replace with new oil.
FLS
Thermal contact Check the start and stop levels.
The overload protection Check that the impeller can rotate freely.
Replace the hydraulic parts
Replace the impeller
Required tools:
• Impeller puller
If applicable, contact your Xylem representative for correct type and size
• Rod (wooden or plastic) for locking the impeller in place
• Two crowbars, if applicable
WARNING:
• If you fail with the impeller installation, you must redo the installation procedure from the
beginning.
• A worn impeller and/or pump housing can have very sharp edges. Wear protective
gloves.
• When laying the pump on its side, do not allow the weight of the pump to rest on any
portion of the impeller. The impeller must not be allowed to make contact with the
concrete floor or other hard and rough surfaces.
1. Check for liquid in the stator housing.
2. Drain all liquid, if any.
3. Check the mechanical seal unit, the O-rings, and the cable
entry, if liquid was found.
38 Flygt 5520 Installation, Operation, and Maintenance Manual
1
2
3
4
5
7
8
9
10
11
12
13
15
16
18
17
19
20
21
22
14
6
WS006085A
1. O-ring
2. Ring
3. Sleeve
4. Expeller
5. Wearing cover
6. O-ring
7. Screw
8. Pump housing, upper
9. O-ring
10. Impeller
11. Impeller screw
12. Wear protection/plug
13. Pump housing lining
14. Gasket
15. O-ring
16. Pump housing, lower
17. O-ring
18. Wear ring
19. Trimming flange
20. Stud
21. Suction cover
22. Screw
Maintenance
Remove the impeller
1. Remove the drive unit from the pump housing:
a) Remove the pump housing screws.
b) Remove the drive unit from the pump housing.
2. Place the drive unit horizontally.
3. Remove the impeller:
a) Remove the wear protection/plug.
b) Remove the impeller screw.
If applicable us a rod to lock the impeller in place.
c) Remove the washer.
d) Remove the impeller.
Use the impeller puller or crowbars. Place a protector between the shaft end and
the impeller puller. Do not pry off the impeller, since it can easily be damaged.
4. Remove the wearing cover.
If applicable use a crowbar.
5. Remove the sleeve.
Flygt 5520 Installation, Operation, and Maintenance Manual 39
Maintenance
Install the impeller
6. Remove the expeller.
1. Prepare the shaft:
a) Make sure that the end of the shaft is free from burrs.
Polish off any flaws with a fine emery cloth.
b) Grease the shaft end and the inside of the impeller hub.
NOTICE:
• Do not grease the conical part of the shaft.
• Surplus grease can cause the impeller to become loose. Remove surplus grease
from conical and/or cylindrical surfaces of shafts and/or sleeves.
2. Check the clearance:
a) Place the wearing cover on the impeller.
b) Measure the distance between the outside of the impeller hub and the inside of the
wearing cover hole.
If the clearance exceeds 3.0 mm (0.12 in.), the wearing cover must be replaced.
3. Mount the impeller:
a) Fit the sleeve onto the shaft.
b) Fit the expeller and the wearing cover onto the shaft.
Use a rubber mallet in order to knock the wearing cover in to place.
c) Press the impeller onto to the shaft.
4. Fasten the impeller:
a) Fit the washer on the impeller screw.
b) Fit the impeller screw.
c) Tighten the impeller screw.
Tightening torque: 60 Nm (42 ft-lbs.)
d) Check that the impeller can rotate freely.
5. Mount the pump housing:
a) Make sure the ring is seated against the oil housing.
b) Fit the pump housing.
c) Fit and tighten the lubricated screws.
For tightening torque, see Torque values (page 34).
6. Check that the impeller can rotate freely.
Make sure that there is no friction between the impeller and the wear ring and that the
clearance is 0.3 mm (0.01in.).
40 Flygt 5520 Installation, Operation, and Maintenance Manual
Replace the wear parts
1
2
3
4
5
7
8
9
10
11
12
13
15
16
18
17
19
20
21
22
14
6
WS006085A
WS002412A
Maintenance
1. O-ring
2. Ring
3. Sleeve
4. Expeller
5. Wearing cover
6. O-ring
7. Screw
8. Pump housing, upper
9. O-ring
10. Impeller
11. Impeller screw
12. Wear protection/plug
13. Pump housing lining
14. Gasket
15. O-ring
16. Pump housing, lower
17. O-ring
18. Wear ring
19. Trimming flange
20. Stud
21. Suction cover
22. Screw
Remove the wear parts
The pump housing and the impeller have to be removed before the wear parts can be
removed. For more information, see Remove the impeller (page 39).
1. Remove the wearing cover and the expeller.
Use a crowbar, if applicable.
2. Remove the gasket from the pump housing outlet.
3. Remove the lining from the pump housing:
Flygt 5520 Installation, Operation, and Maintenance Manual 41
WS002423A
WS002425A
WS002422A
Maintenance
a) Undo the screws that keep the pump housing parts together.
b) Use two crowbars in order to separate the two pump housing parts.
c) Lift off the upper part of the pump housing.
d) Remove the lining from the lower part.
4. Remove the O-rings from both parts of the pump housing.
Install the wear parts
5. Turn the lower part of the pump housing upside down.
6. Remove the suction cover:
a) Unscrew the suction cover screws.
b) Remove the suction cover.
Use two crowbars if needed.
7. Remove the trimming flange unit (trimming flange and wear ring) and its two O-rings.
8. Remove the O-ring on the inside of the pump housing.
1. Make sure all parts are clean and free of burrs.
Polish off any flaws with a fine emery cloth.
2. Fit the expeller, wearing cover and the impeller. For more information, see Install the
impeller (page 40).
3. Fit the inner lining:
a) Fit the new greased O-rings to the lower part of the pump housing.
42 Flygt 5520 Installation, Operation, and Maintenance Manual
WS002426A
WS002424A
b) Fit the pump housing lining in the lower part of the pump housing.
WS002427A
4. Assemble the pump housing:
a) Place the upper part of the pump housing on the lower part.
Make sure to leave some distance between the parts in order to fit the new greased
O-ring.
b) Fit the new greased O-ring between the upper pump housing part and the inner
lining.
Use a screwdriver in order to lift the upper pump housing part which makes it easier
to fit the new greased O-ring.
Maintenance
c) Fit the gasket to the discharge outlet.
Make sure the gasket is fitted correctly to ensure that no leaks will occur.
d) Fit the screws that hold the pump housing together and tighten.
For tightening torque, see Torque values (page 34).
5. Fit the drive unit in the pump housing:
a) Fit the new greased O-ring on the top of the pump housing.
b) Place the drive unit in the pump housing.
c) Grease the pump housing screws.
d) Tighten the screws in a diagonal sequence.
For tightening torque, see Torque values (page 34).
6. Install the trimming flange unit:
a) Place the pump in a horizontal position.
b) Fit a washer to each stud.
c) Fit the trimming flange unit and its two new greased O-rings.
d) Fit a washer to each stud.
e) Fit a nut to each stud.
f) Tighten the trimming flange nuts.
For tightening torque, see Torque values (page 34).
7. Adjust the trimming flange unit:
a) Measure the distance between the impeller and the trimming flange unit.
The correct distance is 0.3 mm (0.01 in.).
b) Adjust the nuts along the studs to achieve the correct distance.
c) Tighten the trimming flange nuts.
For tightening torque, see Torque values (page 34).
8. Install the suction cover:
Flygt 5520 Installation, Operation, and Maintenance Manual 43
Maintenance
a) Fit the suction cover.
b) Fit a washer on each suction cover screw and tighten.
Tightening torque: 60 Nm (44 ft-lbs)
44 Flygt 5520 Installation, Operation, and Maintenance Manual
Troubleshooting
Introduction
Follow these guidelines when troubleshooting the pump:
• Disconnect and lock out the power supply except when conducting checks that
require voltage.
• Make sure that no one is near the pump when the power supply is reconnected.
• When troubleshooting electrical equipment, use the following:
• Universal instrument multimeter
• Test lamp (continuity tester)
• Wiring diagram
The pump does not start
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
Troubleshooting
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 Xylem service shop.
Check that:
• The start level regulator is functioning. Clean or replace if necessary.
• All connections are intact.
• The relay and contactor coils are intact.
• The control switch (Man/Auto) makes contact in both positions.
Check the control circuit and functions.
Check that:
• The main power switch is on.
• There is control voltage to the start equipment.
• The fuses are intact.
• There is voltage in all phases of the supply line.
• All fuses have power and that they are securely fastened to the fuse
holders.
• The overload protection is not tripped.
• The motor cable is not damaged.
The impeller is stuck. Clean:
Flygt 5520 Installation, Operation, and Maintenance Manual 45
Troubleshooting
Cause Remedy
• The impeller
• The sump in order to prevent the impeller from clogging again.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local
Xylem service shop. Always state the serial number of your pump when you contact Xylem,
see Product Description (page 10).
The pump does not stop when a level sensor is used
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
Cause Remedy
The pump is unable to empty the
sump to the stop level.
There is a malfunction in the levelsensing equipment.
The stop level is set too low. Raise the stop level.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local
Xylem service shop. Always state the serial number of your pump when you contact Xylem,
see Product Description (page 10).
Check that:
• There are no leaks from the piping and/or discharge connection.
• The impeller is not clogged.
• The non-return valve(s) are functioning properly.
• The pump has adequate capacity. For information:
Contact the local Xylem service shop.
• Clean the level regulators.
• Check the functioning of the level regulators.
• Check the contactor and the control circuit.
• Replace all defective items.
The pump starts-stops-starts in rapid sequence
Cause Remedy
The pump starts due to back-flow
which fills the sump to the start
level again.
Check that:
• 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.
The self-holding function of the
contactor malfunctions.
46 Flygt 5520 Installation, Operation, and Maintenance Manual
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.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local
Xylem service shop. Always state the serial number of your pump when you contact Xylem,
see Product Description (page 10).
The pump runs but the motor protection trips
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.
Cause Remedy
The motor protection is set too low. Set the motor protection according to the data plate and if applicable the
cable chart.
Troubleshooting
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.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local
Xylem service shop. Always state the serial number of your pump when you contact Xylem,
see Product Description (page 10).
• 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, notify a certified electrician.
Contact the local Xylem service shop.
1. Use an insulation tester. With a 1000 V DC megger, check that the
insulation between the phases and between any phase and ground is
> 5 megohms.
2. If the insulation is less:
Contact the local Xylem service shop.
Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)
• Change the impeller, or
• Change to a more suitable pump.
• Contact the local Xylem service shop.
Replace the overload protection.
The pump delivers too little or no water
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
Flygt 5520 Installation, Operation, and Maintenance Manual 47
Troubleshooting
NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.
Cause Remedy
The impeller rotates in the wrong
direction.
• If it is a 3-phase pump, transpose two phase leads.
• If it is a 1-phase pump:
Contact the local Xylem service shop.
One or more of the valves are set in
the wrong positions.
• 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.
The impeller is difficult to rotate by
hand.
• Clean the impeller.
• Clean out the sump.
• Check that the impeller is properly trimmed.
The pipes are obstructed. Clean out the pipes to ensure a free flow.
The pipes and joints leak. Find the leaks and seal them.
There are signs of wear on the
Replace the worn parts.
impeller, pump, and casing.
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.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local
Xylem service shop. Always state the serial number of your pump when you contact Xylem,
see Product Description (page 10).
48 Flygt 5520 Installation, Operation, and Maintenance Manual
Technical Reference
Motor data
Feature Description
Motor type
Frequency 50 or 60 Hz
Supply 3-phase
Technical Reference
Application limits
Starting method
Maximum starts per
hour
Code compliance IEC 60034-1
Rated output variation ±5%
Voltage variation without
overheating
Voltage imbalance
tolerance
Stator insulation class H (180°C [360°F])
Data Description
Liquid temperature 40°C (104°F) maximum
• Direct on-line
• Star-delta
30 evenly spaced starts per hour
±10%, provided that it does not run continuously at full load
2%
The pump must work fully submerged under full load operation.
Warm-liquid version : 70°C (158°F) maximum. These versions have certain operating
limitations which are stated on the plate on the pump.
Liquid density Contact the local Xylem representative
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
Flygt 5520 Installation, Operation, and Maintenance Manual 49
5.5–14
the data plate of the pump.
Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots
2) A leading global water technology company
We're 12,500 people unified in a common purpose: creating
innovative solutions to meet our world's water needs. Developing new
technologies that will improve the way water is used, conserved, and
re-used in the future is central to our work. We move, treat, analyze,
and return water to the environment, and we help people use water
efficiently, in their homes, buildings, factories and farms. In more than
150 countries, we have strong, long-standing relationships with
customers who know us for our powerful combination of leading
product brands and applications expertise, backed by a legacy of
innovation.
For more information on how Xylem can help you, go to xyleminc.com
Xylem Water Solutions AB
Gesällvägen 33
174 87 Sundbyberg
Sweden
Tel. +46-8-475 60 00
Fax +46-8-475 69 00
http://tpi.xyleminc.com
Visit our Web site for the latest version of this
document and more information
The original instruction is in English. All nonEnglish instructions are translations of the original
instruction.
©
2011 Xylem Inc.
890773_7.0_en.US_2012-08_IOM.5520.180
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