Xylem Flygt 5520, Flygt 5530 Installation, Operation And Maintenance Manual
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
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