Flygt 3153 руководство

• 22, 7. Prepare for the level regulator: a) Bolt the cable holder to the access frame. b) Attach the level regulator cable to the cable holder and adjust the height of the level regulator. c) Protect bolts and nuts with a corrosion-preventive compound. 8. Lower the pump along the guide bars. 9. 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 …

• 68, Cause Remedy There are signs of wear on the impeller, pump, and casing. Replace the worn parts. 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 X…

• 4, Connect the motor cable to the starter and monitoring equipment…………………………………24 Cable charts……………………………………………………………………………………………………………………25 Sensor-connection………………………………………………………………………………………………………….31 Check the …

• 10, Spare parts Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued. Introduction and Safety 8 Flygt 3153 Installation, Operation, and Maintenance Manual
  …

• 12, 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 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 …

• 20, FLYGT 3153 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 hazard…

• 9, • Do not modify the equipment without approval from an authorized Xylem representative. • Only use parts that are provided by an authorized 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 Xylem representative. When you install or maintain explosion proof products, alwa…

• 33, WS003824A Screenflex and SUBCAB with functional ground * For screened SUBCAB T3 & T4 shall also be twisted separately T1 and T2 twisted* White insulation hose Screen GN/YE L1 L2 L3 T1 T2 BN BK GY T1 and T2 White insulation hose twisted* Screen BK BK BK BK BK BK GN/YE 1 2 3 4 5 6 T1 T2 Figure 17: Screenflex and SUBCAB with functional ground Sensor-connection Connection to the pump WS003843A Color and marking of control leads Control SUBCAB 4GX/7G and Screenfle…

• 69, FLYGT 3153 Technical Reference Application limits Data Description Liquid temperature 40°C (104°F) maximum For P- and S-installations without cooling jacket, the pump can be operated only when the sump level is at least 10 mm above the stator housing. Warm-liquid version (only with cooling jacket): 70°C (158°F) maximum Ex-approved pumps: 40°C (104°F) maximum Liquid density 1100 kg/m³ (9.2 lb per US gal) maximum pH of the pumped media (liquid)…

• 27, NOTICE: • Either thermal contacts or thermistors 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 MiniCAS II monitoring equipment. NOTICE: Ex-appro…

• 38, NOTICE: Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation. 1. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. 2. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms. 3. Check that the monitoring equipment works. 4. Start the pump. Operation 36 Flygt 3153 Installation, Operation, and Maintenance Manual
  …

• 14, Product Description Pump design The pump is submersible, and driven by an electric motor. For a list of pump version and corresponding motor type, see Motor data (page 67). 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 67). If there is a question regarding the intended use of the equipment, please contact an Xylem representative before proceeding. WARNING: In expl…

• 52, e) Adjust its position so that the inspection hole is on the same side as the flush valve. f) Tighten the screws in diagonal sequence. For tightening torque, see Torque values (page 38). WS006260A 4. Remove the impeller screw: a) Place the pump horizontally. b) Lock the impeller in place by inserting a rod through the hole. c) Remove the impeller screw and the washer. WS001482A 5. Adjust the impeller: a) Using a hexagon-bit adapter, turn the adjustment scr…

• 13, 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. Freezing precautions The unit is frost-proo…

• 42, WS001471A c) Replace the inspection plug and O-ring and tighten. Tightening torque: 44 Nm (33 ft-lbs) 2. Empty the coolant: a) Place the pump in a horizontal position, or leave it upright to use a pump to empty the coolant. WS001463A b) If the pump is laid in a horizontal position, place a container under the pump. c) Remove the coolant plugs and empty the coolant. Maintenance 40 Flygt 3153 Installation, Operation, and Maintenance Manual
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• Page 1
  Installation, Operation, and Maintenance Manual Flygt 3153…

• Page 3: Table Of Contents

  Installation………………………..18 Install the pump……………………..18 Authority regulation……………………18 Fasteners……………………….18 Install with P-installation…………………….19 Install with S-installation…………………….20 Install with T/Z-installation………………….21 Make the electrical connections………………….22 General precautions……………………22 Requirements……………………..22 Cables…………………………23 Earthing (Grounding)……………………23 Connect the motor cable to the pump………………23 Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 4
  The pump does not stop when a level sensor is used…………..63 The pump starts-stops-starts in rapid sequence…………….63 The pump runs but the motor protection trips…………….64 The pump delivers too little or no water………………65 Technical Reference……………………..67 Application limits……………………..67 Motor data……………………….67 Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 5: Introduction And Safety

  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 3153 Installation, Operation, and Maintenance Manual…

• Page 6: Environmental Safety

  Magnetic hazard Magnetic hazards are indicated by a specific symbol that replaces the typical hazard level symbols: CAUTION: Environmental safety The work area Always keep the station clean to avoid and/or discover emissions. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 7: User Safety

  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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 8: Ex-Approved Products

  • 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 9: Product Warranty

  • Material damages • Economic losses 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 10
  Introduction and Safety Spare parts Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 11: Transportation And Storage

  • 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 3153 Installation, Operation, and Maintenance Manual…

• Page 12: Temperature Ranges For Transportation, Handling And Storage

  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: Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 13: Storage Guidelines

  • 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 14: Product Description

  • 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 Low head Medium head High head Super high head Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 15: Parts

  • Inner seal: corrosion-resistant cemented carbide/Aluminum oxide WCCR/Al • Outer seal: silicon carbide RSiC/RSiC Main bearings Consisting of a two-row angular contact ball bearing Motor For information about the motor, see Motor data (page 67). Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 16: Monitoring Equipment

  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. Curve code/Propeller code Serial number, see Product denomination (page 17) Product number Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 17: Approvals

  • Dust ignition proof for use in Class II. Div 1. Group E, F and G • Suitable for use in Class III. Div 1. Hazardous Locations EN approval plate This illustration describes the EN approval plate and the information contained in its fields. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 18: Iec Approval Plate

  11. Additional information 12. Max. ambient temperature 13. Serial number WS001279B FM approval plate This illustration describes the FM approval plate and the information contained in its fields. Temperature class Maximum ambient temperature WS003973A Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 19: Product Denomination

  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. NP 3085.183 — 951 0163 Product code Production year Production cycle Running number Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 20: Installation

  Fasteners 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 3153 Installation, Operation, and Maintenance Manual…

• Page 21: Install With P-Installation

  Secure the guide bars in the bracket. b) Check that the guide bars are placed vertically. Use a level or a plumb line. 6. Connect the discharge pipe to the discharge connection. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 22: Install With S-Installation

  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 33). Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 23: Install With T/Z-Installation

  Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 33). 5. Make sure that the weight of the pump does not put strain on the piping. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 24: Make The Electrical Connections

  • If stated on the data plate, then the motor is convertible between different voltages. • The thermal contacts/thermistors must be in use. • For FM-approved pumps, FLS must be connected and in use in order to meet approval requirements. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 25: Cables

  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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 26: Connect The Motor Cable To The Starter And Monitoring Equipment

  9. 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 3153 Installation, Operation, and Maintenance Manual…

• Page 27: Cable Charts

  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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 28
  Motor cable leads L1 L2 L3 T1 T2 T3 T4 Stator (internal connection illustrated) U1 V1 W1 W2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 L2 L3 Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 29
  * * Ground conductor is stranded around core Screen (WH) Screen (WH) Screen (WH) GC=Ground check 773 29 00/2 Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 30
  If a separate control cable is used, then the control cores in the motor cable are never used. One cable (left) and two cables (right) Y-connection. Two cables One cable V1 U2 U1 W2 W1 V2 Figure 10: Y-connection One cable (left) and two cables (right) D-connection. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 31
  Figure 13: Y or D-connection 9-leads connection If a separate control cable is used, then the control cores in the motor cable are never used. One cable (left) and two cables (right) Y-parallel connection. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 32
  Cable without sep. ground conductor Screen as ground conductor GN/YE shrink hose FGB Screened Mini CAS Mini CAS+AUX Figure 16: Screened SUBCAB and FGB Screened * For screened SUBCAB T3 and T4 shall also be twisted separately. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 33: Sensor-Connection

  Screenflex WH T1 WH T1 WH T2 WH T2 WH T3 WH T4 Figure 18: Color and marking of control leads Sensor terminal clamps T15 T16 T1 T2 Figure 19: Sensor terminal clamps Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 34
  T=145°C (293°F) (T +5°C (41°F)) R ≤ 1330 Ohm Thermal detectors, FLS disconnected Thermal detectors FLS Disconnected Max 12 V T1 Control leads WH/YE Mini T1/*OG/1 T2/*BU/2 WH/YE **T3 **T4 *SUBCAB AWG **Screened SUBCAB Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 35: Check The Impeller Rotation

  Check the impeller rotation 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 36
  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 3153 Installation, Operation, and Maintenance Manual…

• Page 37: Operation

  • 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 38
  1. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. 2. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms. 3. Check that the monitoring equipment works. 4. Start the pump. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 39: Maintenance

  • 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 40: Torque Values

  2210 (825.1) (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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 41: Change The Coolant

  1. Empty the coolant in the inspection chamber: a) Remove the inspection plug. Figure 22: Without a cooling jacket Figure 23: With a cooling jacket b) Pump out any coolant from the inspection chamber, as shown here. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 42
  Place the pump in a horizontal position, or leave it upright to use a pump to empty the coolant. b) If the pump is laid in a horizontal position, place a container under the pump. c) Remove the coolant plugs and empty the coolant. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 43: Fill With Coolant

  1. Fill with coolant until it overflows through the opposite hole, as shown here. Quantity: approximately • 2.2 L (2.3 qt.) without cooling jacket • 10.5 L (11.2 qt.) with cooling jacket Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 44: Service The Pump

  (liquid) temperatures <40°C. 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). Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 45: Inspection

  Check that the connections are properly tightened. Thermal contacts Normally closed circuit; interval 0–1 ohm. Thermistor Check the resistance is between 20–250 ohms and the measured voltage is maximum 2 V DC. Voltage and amperage Check the running values. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 46: Major Overhaul

  Remove the impeller: wet installation CAUTION: Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury. 1. Place the pump in a horizontal position. 2. Remove the impeller: Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 47
  Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. e) Hand-tighten the impeller screw to prevent it from falling off. WS001490A f) Remove the rod. 3. Raise the pump. 4. Remove the drive unit from the pump housing: Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 48
  Maintenance a) Remove the pump housing screws. b) Remove the drive unit from the pump housing. 5. Remove the impeller: a) Place the drive unit horizontally. b) Remove the impeller screw. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 49
  Polish off any flaws with a fine emery cloth. b) Grease the shaft end. NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 50
  Adjust the adjustment screw so that it is flush with the sleeve. WS001759A e) Fit the sleeve and impeller to the shaft. f) Hand-tighten the impeller screw to prevent it from falling off. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 51
  3. Fit the pump housing: a) Fit a new and greased O-ring on the seal housing cover. b) Grease the pump housing screws. c) Raise the drive unit. d) Place the drive unit into the pump housing. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 52
  Using a hexagon-bit adapter, turn the adjustment screw clockwise until the impeller makes contact with the pump housing. For tightening torque, see Torque values (page 38). b) Tighten it a further 1/8 turn (45°). Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 53
  Check that the impeller can rotate freely. CAUTION: Beware of the pinch point hazard between the rotating impeller and the guide pin. 7. Check that the clearance between the impeller and the insert ring is 0.1–0.5 mm (0.004–0.02 in.). Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 54: Replace The Impeller For Dry Installation

  8. If applicable, adjust clearance to 0.1–0.5 mm (0.004–0.02 in.) between the guide pin and the impeller. Replace the impeller for dry installation Remove the impeller: dry installation 1. Remove the drive unit from the pump housing: a) Remove the pump housing screws. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 55
  Remove the drive unit from the pump housing. 2. Remove the impeller: a) Place the drive unit horizontally. b) Lock the impeller as shown in the figure. c) Remove the impeller screw. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 56
  Polish off any flaws with a fine emery cloth. b) Grease the shaft end. NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 57
  Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw. Always use a new impeller screw. d) Unscrew the adjustment screw approximately 5 mm (0.2 in.). WS002106A e) Measure and note the distance A. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 58
  Maintenance 2. Mount the impeller: a) Fit the sleeve and the impeller to the shaft. b) Fit the impeller screw and washer and tighten. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 59
  Make sure that the drive unit is parallel with the pump housing by hand-tightening the pump housing screws. b) Check the distance between the seal housing cover and the pump housing with a feeler gauge. Check diagonally at four points. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 60
  Lift the drive unit out of the pump housing and remove the impeller and conical sleeve. 5. Trim to the correct distance: a) Calculate the measure C according to the formula shown in the image. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 61
  7. If applicable, check that the clearance between the impeller and the insert ring is maximum 1 mm (0.04 in.) radial. If not, send the pump for service. The insert ring is pressed into the seal housing cover. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 62
  Maintenance 8. Install the drive unit in the pump housing: a) Fit a new and greased O-ring to the seal housing cover. WS002056A b) Place the drive unit in the pump housing. Flygt 3153 Installation, Operation, and Maintenance Manual…
• Page 63
  Tighten the greased screws diagonally. For tightening torque, see Torque values (page 38). WS001478A If you need to adjust the impeller, redo the replace the impeller procedure from the beginning. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 64: Troubleshooting

  • 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. Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 65: The Pump Does Not Stop When A Level Sensor Is Used

  • 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, Product Description (page 12).

• Page 66: The Pump Runs But The Motor Protection Trips

  • 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, Product Description (page 12).

• Page 67: The Pump Delivers Too Little Or No Water

  Replace the overload protection. 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, Product Description (page 12).

• Page 68
  • 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, Product Description (page 12).

• Page 69: Technical Reference

  Code compliance IEC 60034-1 Rated output variation ±10% Voltage variation without ±10%, provided that it does not run continuously at full load overheating Voltage imbalance tolerance Stator insulation class H (180°C [360°F]) Flygt 3153 Installation, Operation, and Maintenance Manual…

• Page 72
  Gesällvägen 33 174 87 Sundbyberg The original instruction is in English. All non- English instructions are translations of the original Sweden instruction. Tel. +46-8-475 60 00 © 2012 Xylem Inc. Fax +46-8-475 69 00 http://tpi.xyleminc.com 895381_13.0_en.US_2012-08_IOM.3153.091/.095/.181/.185/.350/.390/.800/.810/.820/.830/.840/.850…

Summary of Contents:

[Page 1] FLYGT 3153 Flygt 3153 Installation, Operation, and Maintenance Manual …

[Page 2] FLYGT 3153 …

[Page 3] FLYGT 3153 Table of Contents Introduction and Safety………………………………………………………………………………………………………….3 Introduction…………………………………………………………………..

[Page 4] FLYGT 3153 Connect the motor cable to the starter and monitoring equipment…………………………………24 Cable charts……………………………………………………………………………………………………………………2…

[Page 5] FLYGT 3153 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…

[Page 6] FLYGT 3153 Hazard levels Hazard level Indication DANGER: A hazardous situation which, if not avoided, will result in death or serious injury WARNING: A hazardous situation which, if not avoided, could result in death or serious injury CAUTION: A hazardous…

[Page 7] FLYGT 3153 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 …

[Page 8] FLYGT 3153 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 agains…

[Page 9] FLYGT 3153 • Do not modify the equipment without approval from an authorized Xylem representative. • Only use parts that are provided by an authorized Xylem representative. Guidelines for compliance Compliance is fulfilled only when you operate the unit wi…

[Page 10] FLYGT 3153 Spare parts Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued. Introduction and Safety 8 Flygt 3153 Installation, Operation, and Maintenance Manual …

[Page 11] FLYGT 3153 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 …

[Page 12] FLYGT 3153 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 floor must be sufficient to lift the…

[Page 13] FLYGT 3153 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 cove…

[Page 14] FLYGT 3153 Product Description Pump design The pump is submersible, and driven by an electric motor. For a list of pump version and corresponding motor type, see Motor data (page 67). Intended use The product is intended for moving wastewater, sludge, raw and c…

[Page 15] FLYGT 3153 Parts 1 11 10 9 8 7 2 3 6 12 13 14 WS000850A Figure 1: Without cooling jacket 4 5 WS006171A Figure 2: With cooling jacket Positio n Part Description 1 Monitoring sensor Optional sensor. For information about sensors, see Monitoring equipment (pag…

[Page 16] FLYGT 3153 Positio n Part Description 13 Thermal contact/ Thermistors For information about the thermal contact and thermistors, see Monitoring equipment (page 14). 14 Support bearing Consisting of a two-row ball bearing Monitoring equipment The following appli…

[Page 17] FLYGT 3153 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…

[Page 18] FLYGT 3153 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 WS003972A 1. Approval 2. Approval authority + approval number 3. Approval for Class I 4. Approved drive unit 5. Stall time 6. Starting current/Rated current 7. Duty class 8. Duty factor 9. Input power 10. Rated sp…

[Page 19] FLYGT 3153 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…

[Page 20] FLYGT 3153 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. �…

[Page 21] FLYGT 3153 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 install…

[Page 22] FLYGT 3153 7. Prepare for the level regulator: a) Bolt the cable holder to the access frame. b) Attach the level regulator cable to the cable holder and adjust the height of the level regulator. c) Protect bolts and nuts with a corrosion-preventive compound. 8….

[Page 23] FLYGT 3153 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. I…

[Page 24] FLYGT 3153 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…

[Page 25] FLYGT 3153 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 mar…

[Page 26] FLYGT 3153 1 2 WS006002A 1. Entrance cover 2. O-ring For more information about the cable entry, see the Parts list. 1. Remove the entrance cover and the O-ring from the stator housing. This provides access to the terminal board. 2. Check the data plate to see…

[Page 27] FLYGT 3153 NOTICE: • Either thermal contacts or thermistors 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 f…

[Page 28] FLYGT 3153 L2 L1 L2 L3 L3L1 WS000509B WS000509C L2 L3L1 L1 L3L2 T1 T2 Figure 8: Phase sequence Connection locations The figures in this section illustrate how to interpret the connection strip symbols. L1 L2 L3 T3 T4T1 T2 U1 V1 W1 U2 W2 V2 U1 V1 W1 W2 U2 V2 …

[Page 29] FLYGT 3153 L1 L2 L3 T3 T4T1 T2 43 21 5 10 8 CLS 6 FLS 7 FLS 10 11 9 WS004134A 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…

[Page 30] FLYGT 3153 Code Description RD Red GY Grey BU Blue YE Yellow Motor connection WS003903A Terminal clamps 6 stator leads U1 W2 V1 U2 W1 V2 Figure 9: Terminal clamps, 6 stator leads Connections included • 6–leads connection (page 28) • 9-leads connection (…

[Page 31] FLYGT 3153 D One cable Two cables L1 U1 V2 U2 V1 W1 W2 L2 L3 L1 U1 RD U1 W2 L3 W2 BK V1 BN V1 GN U2 L2 U2 W1 YE W1 V2 BU V2 L1 U1 1 L1 U1 RD BK W2 L3 2 W2 V1 BN V1 1 L3 GN U2 L2 2 U2 W1 YE 1 W1 L2 2 V2 BU V2 GN/YE *YE GC WH WS003804A Figure 11: D-connection On…

[Page 32] FLYGT 3153 WS003826A One cable Two cables Y- L1 U1 U5 U2 W2 W1 V2 V5 L2 W5 V1 L3 L1 U1 U1 RD U5 RD U5 L3 BN V1 V1 BN V5 L2 V5 W1 YE W1 YE W5 W5 GN U2 BU V2 BK W2 L1 RD U1 1 L1 U1 RD U5 L3 2 U5 BN V1 1 L3 V1 BN V5 L2 2 V5 YE W1 1 L2 W1 W5 YE W5 2 GN U2 BU V2 BK …

[Page 33] FLYGT 3153 WS003824A Screenflex and SUBCAB with functional ground * For screened SUBCAB T3 & T4 shall also be twisted separately T1 and T2 twisted* White insulation hose Screen GN/YE L1 L2 L3 T1 T2 BN BK GY T1 and T2 White insulation hose twisted* Screen BK…

[Page 34] FLYGT 3153 FLS 10 and Thermal detectors WS003855A FLS + Thermal detectors FLS TC Max 12 V WH/YE T1 Control leads T1/*OG/1 +7 Mini BN T2 CAS WH/YE T2/*BU/2 -5 BN T15 **T3 *SUBCAB AWG **T4 **Screened SUBCAB ∞ Ohm Overtemperature 1200 Ohm OK 430 Ohm Leakage FL…

[Page 35] FLYGT 3153 Connection to the monitoring equipment MiniCAS II 24 V AC/DC R CC P C L2 L1 102 6 7 +T1 T15 T2 FLS10 5 — 11 1 12 VDC 9 8 10S 4 3 WS002623B C Pump contactor CC Control circuit L1 Caution light (leakage) L2 Caution light (stator over-temperature) P P…

[Page 36] FLYGT 3153 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. Installation 34 Flygt 3153 Installation,…

[Page 37] FLYGT 3153 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 equi…

[Page 38] FLYGT 3153 NOTICE: Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation. 1. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. 2. Conduct insulation test phas…

[Page 39] FLYGT 3153 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 …

[Page 40] FLYGT 3153 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 tig…

[Page 41] FLYGT 3153 Change the coolant This image shows the plugs that are used to change the coolant. 1 2 2 Figure 20: With a cooling jacket 1 2 2 WS001480A Figure 21: Without a cooling jacket 1. Inspection plug 2. Coolant plugs Empty the coolant WARNING: The seal …

[Page 42] FLYGT 3153 WS001471A c) Replace the inspection plug and O-ring and tighten. Tightening torque: 44 Nm (33 ft-lbs) 2. Empty the coolant: a) Place the pump in a horizontal position, or leave it upright to use a pump to empty the coolant. WS001463A b) If the pum…

[Page 43] FLYGT 3153 WS001411A Figure 24: With a cooling jacket WS001412A Figure 25: Without a cooling jacket Fill with coolant Use a coolant that is a mixture of 70% water and 30% monopropylene glycol. The coolant should prevent corrosion and be nonpoisonous (general…

[Page 44] FLYGT 3153 WS000966A Figure 26: With cooling jacket WS001469A Figure 27: Without cooling jacket 2. Replace the O-rings. 3. Tighten the coolant plugs. Tightening torque: 44 Nm (33 ft-lbs) Service the pump Type of service Purpose Inspection interval Initial in…

[Page 45] FLYGT 3153 Inspection Service item Action Cable 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. Connection to power Check that the connections are properly tightened. Electrical cab…

[Page 46] FLYGT 3153 Major overhaul For a major overhaul, take this action in addition to the tasks listed under Inspection. Service item Action Support and main bearing Replace the bearings with new bearings. Mechanical seal Replace with new seal units. Service in case …

[Page 47] FLYGT 3153 a) Remove the flush valve cover and its O-ring. b) Lock the impeller in place by inserting a rod through the hole. c) Remove the impeller screw. WS001482A d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft….

[Page 48] FLYGT 3153 a) Remove the pump housing screws. WS006264A b) Remove the drive unit from the pump housing. WS001477A 5. Remove the impeller: a) Place the drive unit horizontally. b) Remove the impeller screw. Maintenance 46 Flygt 3153 Installation, Operation, …

[Page 49] FLYGT 3153 WS006263A c) Remove the impeller and the conical sleeve. WS001461B Install the impeller: wet installation 1. Mount the impeller: a) Make sure that the end of the shaft is free from burrs. Polish off any flaws with a fine emery cloth. b) Grease t…

[Page 50] FLYGT 3153 WS002057A c) Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw. Always use a new impeller screw. WS002058A d) Adjust the adjustment screw so that it is flush with the sleeve. WS001759A e) Fit the…

[Page 51] FLYGT 3153 WS006256A 2. If applicable, check that the clearance between the impeller and the insert ring is maximum 1 mm (0.04 in.) radial. If not, send the pump for service. The insert ring is pressed into the seal housing cover. WS003664A WS003665A 3. Fit…

[Page 52] FLYGT 3153 e) Adjust its position so that the inspection hole is on the same side as the flush valve. f) Tighten the screws in diagonal sequence. For tightening torque, see Torque values (page 38). WS006260A 4. Remove the impeller screw: a) Place the pump ho…

[Page 53] FLYGT 3153 WS001451A 6. Fasten the impeller: a) Fit the greased washer and impeller screw. b) Tighten the impeller screw. For tightening torque, see Torque values (page 38). c) Tighten it a further 1/8 turn (45°). WS001486A d) Remove the rod used to lock th…

[Page 54] FLYGT 3153 WS003730A WS003731A 8. If applicable, adjust clearance to 0.1–0.5 mm (0.004–0.02 in.) between the guide pin and the impeller. WS001504A Replace the impeller for dry installation Remove the impeller: dry installation 1. Remove the drive unit f…

[Page 55] FLYGT 3153 WS001539A b) Remove the drive unit from the pump housing. WS001477A 2. Remove the impeller: a) Place the drive unit horizontally. b) Lock the impeller as shown in the figure. c) Remove the impeller screw. Maintenance Flygt 3153 Installation, Oper…

[Page 56] FLYGT 3153 WS001494A d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. e) Remove the impeller and the conical sleeve. WS001461B Install the impeller: dry installation 1. Prepare the sleeve: a) Make sure that the end…

[Page 57] FLYGT 3153 WS002057A c) Grease the conical sleeve, the threads of the adjustment screw, the washer, and the impeller screw. Always use a new impeller screw. WS002058A d) Unscrew the adjustment screw approximately 5 mm (0.2 in.). WS002106A e) Measure and no…

[Page 58] FLYGT 3153 A WS001472A 2. Mount the impeller: a) Fit the sleeve and the impeller to the shaft. WS006256A b) Fit the impeller screw and washer and tighten. Maintenance 56 Flygt 3153 Installation, Operation, and Maintenance Manual …

[Page 59] FLYGT 3153 WS001492A 3. Make sure that the O-ring is removed from the seal housing cover. WS002008A 4. Measure the trim distance: a) Place the drive unit in the pump housing. Make sure that the drive unit is parallel with the pump housing by hand-tightening …

[Page 60] FLYGT 3153 WS002089A c) Note the largest distance B. B WS001473A d) Lift the drive unit out of the pump housing and remove the impeller and conical sleeve. WS001477A 5. Trim to the correct distance: a) Calculate the measure C according to the formula shown…

[Page 61] FLYGT 3153 C=A-B-0.5 mm WS001475A b) Turn the adjustment screw until C is reached. 6. Fasten the impeller: a) Fit the sleeve, impeller, greased washer with a greased impeller screw. b) Tighten the impeller screw. For tightening torque, see Torque values (page …

[Page 62] FLYGT 3153 WS003664A WS003665A 8. Install the drive unit in the pump housing: a) Fit a new and greased O-ring to the seal housing cover. WS002056A b) Place the drive unit in the pump housing. Maintenance 60 Flygt 3153 Installation, Operation, and Maintenanc…

[Page 63] FLYGT 3153 WS001475A c) Adjust the position of the drive unit so that the inspection hole is on the same side as the flush valve. d) Tighten the greased screws diagonally. For tightening torque, see Torque values (page 38). WS001478A If you need to adjust t…

[Page 64] FLYGT 3153 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 r…

[Page 65] FLYGT 3153 Cause Remedy • 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: • The impeller • The sump in order to pre…

[Page 66] FLYGT 3153 Cause Remedy • 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-hold…

[Page 67] FLYGT 3153 Cause Remedy The insulation between the phases and ground in the stator is defective. 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 ins…

[Page 68] FLYGT 3153 Cause Remedy There are signs of wear on the impeller, pump, and casing. Replace the worn parts. 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, s…

[Page 69] FLYGT 3153 Technical Reference Application limits Data Description Liquid temperature 40°C (104°F) maximum For P- and S-installations without cooling jacket, the pump can be operated only when the sump level is at least 10 mm above the stator housing. Warm-li…

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