Xylem GK GV User Manual
Installation,
Operation, and
Maintenance Manual
GK, GV (8204, 8204X)
Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Safety.....................................................................................................................................................3
Safety terminology and symbols....................................................................................................3
Environmental safety........................................................................................................................4
User safety.........................................................................................................................................5
Ex-approved products.....................................................................................................................6
Product warranty...............................................................................................................................7
Transportation and Storage..................................................................................................................8
Inspect the delivery.............................................................................................................................8
Inspect the package.........................................................................................................................8
Inspect the unit..................................................................................................................................8
Transportation guidelines..................................................................................................................8
Precautions........................................................................................................................................8
Position and fastening......................................................................................................................8
Lifting..................................................................................................................................................8
Temperature ranges for transportation, handling and storage....................................................9
Handling at freezing temperature..................................................................................................9
Unit in as-delivered condition.........................................................................................................9
Lifting the unit out of liquid...........................................................................................................10
Storage guidelines............................................................................................................................10
Storage location.............................................................................................................................10
Long-term storage..........................................................................................................................10
Table of Contents
Product Description.............................................................................................................................11
Pump design......................................................................................................................................11
Parts: standard version ....................................................................................................................11
Parts: Ex-version ...............................................................................................................................12
Monitoring Equipment.....................................................................................................................13
Optional sensors.............................................................................................................................13
The data plate....................................................................................................................................13
Approvals...........................................................................................................................................15
Installation.............................................................................................................................................16
Install the pump.................................................................................................................................16
Authority regulation.......................................................................................................................16
Fasteners.........................................................................................................................................16
Install with guide rail......................................................................................................................17
Install with stand.............................................................................................................................18
Make the electrical connections......................................................................................................19
General precautions.......................................................................................................................19
Requirements..................................................................................................................................19
Cables..............................................................................................................................................20
Earthing (Grounding).....................................................................................................................20
Connect the motor cable to the pump: standard version ........................................................20
Connect the motor cable to the pump: Ex-version ...................................................................21
Connect the motor cable to the starter and monitoring equipment.......................................21
Cable charts....................................................................................................................................22
Check the impeller rotation.............................................................................................................29
GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual 1
Table of Contents
Operation..............................................................................................................................................30
Precautions.........................................................................................................................................30
Distance to wet areas........................................................................................................................30
Noise level..........................................................................................................................................30
Start the pump...................................................................................................................................30
Maintenance.........................................................................................................................................32
Precautions.........................................................................................................................................32
Maintenance guidelines...................................................................................................................32
Torque values....................................................................................................................................32
Change the oil: standard version ...................................................................................................33
Empty the oil...................................................................................................................................33
Fill with oil........................................................................................................................................34
Change the coolant: Ex-version .....................................................................................................35
Empty the coolant..........................................................................................................................35
Fill with coolant...............................................................................................................................37
Service the pump..............................................................................................................................38
Inspection........................................................................................................................................38
Major overhaul................................................................................................................................39
Service in case of alarm.................................................................................................................39
Replace the impeller.........................................................................................................................40
Remove the impeller......................................................................................................................40
Install the impeller..........................................................................................................................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 GK, GV (8204, 8204X) 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 a Xylem
representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in
physical injury, damage, or delays.
Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
• Personal accidents and health problems
• Damage to the product
• Product malfunction
GK, GV (8204, 8204X) 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 GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual
Electrical installation
Recycling guidelines
User safety
General safety rules
Safety equipment
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 follow local laws and regulations regarding recycling.
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
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:
• 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.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual 5
Introduction and Safety
Condition Action
Chemicals or hazardous
fluids in eyes
Chemicals or hazardous
fluids on skin
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.
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
• All work on the product must be carried out by certified electricians and Xylem
authorized mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example, IEC/EN 60079-17).
Xylem disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during normal operation. Dry running
during service and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be
energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the
approval classification of the product, and that they are in use.
• Intrinsically safe circuits are normally required for the automatic level-control system by
the level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an Ex-approved Xylem
representative.
• Only use parts that are provided by an Ex-approved Xylem representative.
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not
change the conditions of the service without the approval of an Ex-approved Xylem
representative. When you install or maintain explosion proof products, always comply with
the directive and applicable standards (for example, IEC/EN 60079–14).
6 GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual
Minimum permitted liquid level
See the dimensional drawings of the product for the minimum permitted liquid level
according to the approval for explosion proof products. If the information is missing on the
dimensional drawing, the product must be fully submerged. Level-sensing equipment
must be installed if the product can be operated at less than the minimum submersion
depth.
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices
include but are not limited to the following:
• Level indicators
• Temperature detectors
Product warranty
Coverage
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 local sales and service 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 an EX-approved Xylem
representative are used in Ex-approved products.
Introduction and Safety
Limitations
Warranty claim
Spare parts
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 an
Xylem authorized representative
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your local sales and
service representative.
Xylem guarantees that spare parts will be available for 15 years after the manufacture of
this product has been discontinued.
GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual 7
Transportation and Storage
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 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.
8 GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual
Lifting eyebolts
Lifting equipment
Transportation and Storage
When lifting eyebolts are used for lifting the unit, the following guidelines apply:
• they always have to be screwed in firmly against the base
• they must be level with each other
• the angle between them must not be greater then 90°
Lifting equipment is always required when handling the unit. It must fulfill the following
requirements:
• The minimum height (contact your local sales and service representative for
information) between the lifting hook and the floor must be sufficient to lift the unit.
• The lifting equipment must be able to hoist the unit straight up and down, preferably
without the need for resetting the lifting hook.
• The lifting equipment must be securely anchored and in good condition.
• The lifting equipment must support weight of the entire assembly and must only be
used by authorized personnel.
• Two sets of lifting equipment must be used to lift the unit for repair work.
• The lifting equipment must be dimensioned to lift the unit with any remaining pumped
media in it.
• The lifting equipment must not be oversized.
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).
GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual 9
Transportation and Storage
If the unit has been exposed to freezing temperatures, then allow it to reach the ambient
temperature of the sump before operating.
Lifting the unit out of liquid
The unit is normally protected from freezing while operating or immersed in liquid, but the
impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a
surrounding temperature below freezing.
Units equipped with an internal cooling system are filled with a mixture of water and 30%
glycol. This mixture remains a flowing liquid at temperatures down to –13°C (9°F). Below –
13°C (9°F), the viscosity increases such that the glycol mixture will lose its flow properties.
However, the glycol-water mixture will not solidify completely and thus cannot harm the
product.
Follow these guidelines to avoid freezing damage:
1. Empty all pumped liquid, if applicable.
2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for
the presence of 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.
Long-term storage
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
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.
10 GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual
Product Description
1
2
3
4
5
6
7
8
9
WS006107A
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 a local sales and service
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.
The pump is not suitable to pump abrasive solids.
Product Description
Spare parts
Parts: standard version
• 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.
GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual 11
5
10
9
2
1
3
4
6
8
7
WS006190A
Product Description
PositionPart Description
1 Shaft Stainless steel with an integrated rotor
2 Stator housing Cooled by ambient liquid
3 Motor For information about the motor, see Motor data (page 49).
4 Mechanical seal
5 Oil housing Includes coolant that lubricates and cools the seals; acts as a buffer between the
6 Impeller
Type: Mechanical face seal
pumped fluid and the electric motor
K-impeller
Parts: Ex-version
7
8
9
Main bearing
Thermal contact If the pump is equipped with a thermal contact, see Monitoring Equipment (page 13) .
Support bearing
Two-row angular contact ball bearing
Single-row ball bearing
Position Part Description
1 Shaft The shaft is made of stainless steel, with an integrated rotor.
2 Impeller
12 GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual
K-impeller
Position Part Description
Product Description
3 Mechanical seals
4
5 Main bearing
6 Motor For information about the motor, see .Motor data (page 49).
7 Stator housing The pump is cooled by the ambient liquid/air.
8 Support bearing
9 Inspection
10 FLS 10 For information about FLS 10, see Monitoring Equipment (page 13).
Seal housing Includes a coolant that lubricates and cools the seals; the housing acts as a buffer between the
chamber
Monitoring Equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates thermal contacts connected in series that activates the alarm at
overtemperature.
• The thermal contacts open at 140°C (285°F).
• Ex-approved pumps must have thermal contacts connected to the control panel.
• The sensors must be connected to either the SMR 311 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
Type: Mechanical face seal
pumped fluid and the electric motor.
The bearing consisting of a two-row angular contact ball bearing.
The bearing consisting of a two-row ball bearing.
Equipped with an FLS 10 leakage sensor to prevent damages to the motor.
Optional sensors
LD
The data plate
The data plate
The data plate is a metal label located on the main body of the pump. The data plate lists
key product specifications.
LD 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 LD sensor is installed in the
bottom of the stator housing.
GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual 13
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
3
1
WS000351A
1
2 3 4 5 6
9
8
7
WS000104B
Product Description
The name plate
Ex- and MSHA-approved products also have approval plates. They are described below, if
applicable.
1. Curve code/Propeller code
2. Serial number
3. Product number
4. Country of origin
5. Additional information
6. Phase; type of current; frequency
7. Rated voltage
8. Thermal protection
9. Thermal class
10. Rated shaft power
11. International standard
12. Degree of protection
13. Rated current
14. Rated speed
15. Maximum submergence
16. Direction of rotation: L=left, R=right
17. Duty class
18. Duty factor
19. Product weight
20. Locked rotor code letter
21. Power factor
22. Maximum ambient temperature
The name plate is a metal label located on the main body of the pump. This plate lists key
product specifications for the branded pump.
1. Model
2. Horse power
3. R.P.M.
4. Phase Volts
5. KVA code
14 GK, GV (8204, 8204X) Installation, Operation, and Maintenance Manual
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