MANUAL de INSTALC. FUNC. y MANTENIMIENTO Flygt 2201
MANUAL de INSTALC. FUNC. y MANTENIMIENTO Flygt 2201
MANUAL de INSTALC. FUNC. y MANTENIMIENTO Flygt 2201
Operation, and
Maintenance Manual
Flygt 2201
Table of Contents
Table of Contents
Introduction and Safety.........................................................................................................................3
Introduction..........................................................................................................................................3
Safety terminology and symbols.......................................................................................................3
Product warranty.................................................................................................................................4
Spare parts........................................................................................................................................5
Safety.....................................................................................................................................................5
User safety............................................................................................................................................5
Hazardous liquids.............................................................................................................................6
Wash the skin and eyes....................................................................................................................6
Ex-approved products........................................................................................................................6
Guidelines for compliance..............................................................................................................7
Permitted liquid level for ATEX.......................................................................................................7
Monitoring equipment.....................................................................................................................7
MSHA requirements............................................................................................................................7
Environmental safety...........................................................................................................................8
Product Description.............................................................................................................................11
Products included.............................................................................................................................11
Pump design......................................................................................................................................11
Monitoring equipment.....................................................................................................................12
The data plate....................................................................................................................................12
The Ex approval plate....................................................................................................................13
The MSHA approval plate.............................................................................................................14
Product denomination......................................................................................................................14
Installation.............................................................................................................................................15
Install the pump.................................................................................................................................15
Sedimentation prevention.............................................................................................................15
Discharge line requirements.........................................................................................................15
Fasteners.........................................................................................................................................16
Install with S-installation.................................................................................................................16
Make the electrical connections......................................................................................................17
General precautions.......................................................................................................................17
Requirements..................................................................................................................................17
Cables..............................................................................................................................................18
Earthing (Grounding).....................................................................................................................18
Operation..............................................................................................................................................26
Precautions.........................................................................................................................................26
Distance to wet areas........................................................................................................................26
Noise level..........................................................................................................................................26
Start the pump...................................................................................................................................26
Clean the pump.................................................................................................................................27
Maintenance.........................................................................................................................................28
Precautions.........................................................................................................................................28
Maintenance guidelines...................................................................................................................28
Torque values....................................................................................................................................28
Service................................................................................................................................................29
Inspection........................................................................................................................................29
Major overhaul................................................................................................................................31
Change the oil...................................................................................................................................31
Empty the oil...................................................................................................................................31
Fill with oil........................................................................................................................................32
Replace the impeller.........................................................................................................................32
Remove the impeller......................................................................................................................32
Install the impeller..........................................................................................................................33
Adjust the impeller.........................................................................................................................34
Replace the diffuser.......................................................................................................................35
Troubleshooting...................................................................................................................................37
Introduction.......................................................................................................................................37
The pump does not start..................................................................................................................37
The pump does not stop when a level sensor is used.................................................................38
The pump starts-stops-starts in rapid sequence...........................................................................38
The pump runs but the motor protection trips.............................................................................39
The pump delivers too little or no water........................................................................................39
Technical Reference............................................................................................................................41
Application limits...............................................................................................................................41
Motor data..........................................................................................................................................41
Specific motor data: Version code 011 .........................................................................................41
Specific motor data: Version code 320/590/690 .........................................................................43
Dimensions and weights..................................................................................................................44
Performance curves..........................................................................................................................46
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.
Hazard categories
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:
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
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 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 Ex-
approved products.
Limitations
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
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 10 years after the manufacture of
this product has been discontinued.
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.
User safety
General safety rules
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:
• 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.
Condition Action
Chemicals or hazardous 1. Hold your eyelids apart forcibly with your fingers.
fluids in eyes 2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
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.
• You must fully submerge the Ex-approved product 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 authorized Xylem
representative.
• Only use parts that are provided by an authorized Xylem representative.
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices
include but are not limited to the following:
• Level indicators
• Temperature detectors
MSHA requirements
According to the Code of Federal Regulations, the following requirements must be fulfilled
to maintain permissibility of this equipment:
Subject area Requirements
General safety • Frequent inspections must be made.
• All electrical parts, portable cable, and wiring must be kept in a safe condition.
• There must not be any openings into the casings of the electrical parts.
• The machine frame must be effectively earthed (grounded).
• Power wires must not be used for earthing (grounding).
• The operating voltage must match the voltage rating of the motor.
DANGER:
Failure to restore the permissible equipment to its original
state of safety will void the MSHA approval. The creation of a
safety hazard will subject the owner / operator of a mine to
citations and penalties under the law.
Fastenings All bolts, nuts, screws, and threaded covers must be properly tightened and secured.
Operation Poly-Life® equipped products must not be operated dry in hazardous areas.
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.
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.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
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.
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.
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.
Product Description
Products included
Pump model Approvals
2201.011 Standard
2201.320
Pump design
The pump is submersible, and driven by an electric motor.
Intended use
The product is intended for moving waste water, sludge, raw and clean water. Always
follow the limits given in Application limits (page 41). 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.
Pressure class
Version code 011: LT Low head
MT Medium head
HT High head
Impeller type
B Wear resistant
Poly-Life®
Version code 011/320: The pump is available with Poly-Life® polyurethane wear parts for
extra resistance.
Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates thermal contacts connected in series that activate the alarm at
overtemperature.
• The thermal contacts open at 125°C (257°F) and close at 70°C (160°F).
4
24
5 23
22
6
21
7
20
8
WS006257A
9 10 11 12 13 14 15 16 17 18 19
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
15
4 14
13
12
5 11
6 7 8 9 10 WS003972A
1. Approval
2. Approval authority and 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 speed
11. Controller
12. Additional information
13. Maximum ambient temperature
14. Serial number
15. ATEX marking
Figure 2: EN
1 2
3 13
12
11
4 10
5 6 7 8 9 WS001279B
Figure 3: IEC
1. Approval
2. Approval authority + approval number
3. Approved for drive unit
4. Stall time
5. Starting current/Rated current
6. Duty class
7. Duty factor
8. Input power
9. Rated speed
10. Controller
WS006211A
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.
NP 3085
WS006265A
1 2 3
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.
NP 3085.183
WS006262A
1 2
1. Sales denomination
2. Version
Serial number
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
WS006269A
1 2 3 4
1. Product code
2. Production year
3. Production cycle
4. Running number
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.
• 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:
• Never force piping to make a connection with a pump.
Sedimentation prevention
In order to avoid sedimentation when the pumped liquid contains solid particles, the
velocity of the liquid in the discharge line must exceed a certain value. Choose applicable
minimum velocity from the table, and choose proper dimension of the discharge line
accordingly.
Mixture Minimum velocity, meter per second (feet per second)
Water + coarse gravel 4 (13)
Water + gravel 3.5 (11)
Water + sand, particle size <0.6 mm (0.024 in) 2.5 (8.2)
Water + sand, particle size <0.1 mm (0.004 in) 1.5 (4.9)
For more permanent installations with a heavily contaminated pumped liquid, a settling
pump-sump is recommended.
WS001380B
WS001346A
WS001379A
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.
Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local codes and
regulations.
• Before starting work on the unit, make sure that the unit and the control panel are
isolated from the power supply and cannot be energized. This applies to the control
circuit as well.
• Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep
the end of the motor cable above the liquid level.
• Make sure that all unused conductors are insulated.
• There is a risk of electrical shock or explosion if the electrical connections are not
correctly carried out or if there is fault or damage on the product.
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
WS006209A
Requirements
These general requirements apply for electrical installation:
• The supply authority must be notified before installing the pump if it will be connected
to the public mains. When the pump is connected to the public power supply, it may
cause flickering of incandescent lamps when started.
• The mains voltage and frequency must agree with the specifications on the data plate.
If the pump can be connected to different voltages, then the connected voltage is
specified by a yellow sticker close to the cable entry.
• The fuses and circuit breakers must have the proper rating, and the pump overload
protection (motor protection breaker) must be connected and set to the rated current
according to the data plate and if applicable the cable chart. The starting current in
direct-on-line start can be up to six times higher than the rated current.
• The fuse rating and the cables must be in accordance with the local rules and
regulations.
• If intermittent operation is prescribed, then the pump must be provided with
monitoring equipment supporting such operation.
• The thermal contacts/thermistors must be in use.
Cables
These are the requirements to follow when you install cables:
• The cables must be in good condition, not have any sharp bends, and not be pinched.
• The sheathing must not be damaged and must not have indentations or be embossed
(with markings, etc.) at the cable entry.
• The cable entry seal sleeve and washers must conform to the outside diameter of the
cable.
• The minimum bending radius must not be below the accepted value.
• If using a cable which has been used before, a short piece must be peeled off when
refitting it so that the cable entry seal sleeve does not close around the cable at the
same point again. If the outer sheath of the cable is damaged, then replace the cable.
Contact an Xylem service shop.
• The voltage drop in long cables must be taken into account. The drive unit’s rated
voltage is the voltage measured at the cable connection point in the pump.
Earthing (Grounding)
Electrical Hazard:
• You must earth (ground) all electrical equipment. This applies to the pump equipment,
the driver, and any monitoring equipment. Test the earth (ground) lead to verify that it is
connected correctly.
• If the motor cable is jerked loose by mistake, the earth (ground) conductor should be the
last conductor to come loose from its terminal. Make sure that the earth (ground)
conductor is longer than the phase conductors. This applies to both ends of the motor
cable.
• Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault
protection device to the earthed (grounded) connectors if persons are likely to come
into physical contact with the pump or pumped liquids.
12
36
75
86 70
88
87 77
88 72
73
83 74
84 73
83
WS001319A
Part Description
12 Screws
72 Gland nut
125 Cover
Figure 5: Cable entry for version code 320
1. Check the data plate to see which connections are required for the power supply:
• Y
• D
• Y serial
• Y parallel
• Y/D
2. Arrange the connections on the terminal board in accordance with the required power
supply.
Do not use links (jumper strips) with the Y/D start.
Do not use links (jumper strips) with the 9 stator leads tandem-coupling.
3. Connect the motor conductors (U1, V1, W1, and earth (ground)) to the terminal board.
4. Make sure that the pump is correctly connected to earth (ground).
5. Make sure that any thermal contacts incorporated in the pump are properly connected
to the terminal board.
6. Install the cover.
7. Version code 011: Fasten the nuts on the entrance flange so that the cable insertion
assembly bottoms out.
8. Version code 320: Fasten the screws and the gland nut on the entrance flange so that
the cable insertion assembly bottoms out.
After you have connected the motor cable to the pump, connect the motor cable and the
control cable to the starter equipment.
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
Three thermal contacts are incorporated in the stator. They are normally closed.
Thermal contacts must never be exposed to voltages higher than 250 V, breaking current
maximum 6 A at a power factor 0.6. It is recommended that the thermal contacts are
connected to 24 V over a separate fuse to protect any other automatic equipment.
WS002604B
Part Description
5 Screw
50 Lock washer
90 Cable entry
92 Gland flange
93 Seal sleeve
Figure 6: Cable entry
a) Fit it with the largest diameter of the hole facing the inside of the cover.
b) Tighten the screws, but leave 1 mm (0.04 in.) of clearance between the cover and
the gland flange.
c) Lock the screws with the lock washers.
5. Connect the leads.
6. Connect the control cable between the terminal board (H1 and H2) and the control
circuit of the starter.
7. Fit and tighten the cover.
Check, through the inspection hole, that no leads are pinched.
8. Fit and tighten the inspection cover.
9. Connect the pump to earth (ground) with an external earth (ground) lead on the top of
the cover.
Cable charts
Connection locations
1 2 3 4 12
19
20
L1 L2 L3 T1 T2 T3 T4
13
21
5 14 22
23
6
7 15
24
8
16
17
9
WS001021B
10 18
11
12 Motor protector 24 Stator leads (U1, U2, U5, U6, V1, V2, V5, V6,
W1, W2, W5, W6, Z1, Z5, Z6)
Code Description
BN Brown
BK Black
WH White
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow
2290 W2 U2 V2
T1 T2 WH THERMAL
T1 DETECTORS
WH
T2
775 13 00_1
IN STATOR
2290
T1 T2
U1 V1 W1
2400
D (DELTA) Y (STAR)
JUMPERS JUMPERS
U1 W1
V1
V1
W1
U1
D (DELTA) Y (STAR)
JUMPERS JUMPERS
CONNECTION
OF DIODE
WH THERMAL
T2 T1 DETECTORS
WH
T2 IN STATOR
T1 T2 T1 DIODE
DIODE
ALT.
T1 CONNECTION AT 2 LEADER PILOT CABLE
T2 WH THERMAL
T1
MAX 2,5V BK DETECTORS
T3 T2
WS004538A
IN STATOR
T4
D (DELTA) Y (STAR) WH THERMAL
JUMPERS JUMPERS BK DETECTOR IN
MAIN BEARING
Motor cable, stator leads and thermal contacts connection to terminal board
WH=White =Screen
OG=Orange
2250 GN=Green =Ground
2290 GNYE=Green-Yellow
RD=Red =Functional ground
2400 GY=Grey
BU=Blue =Crimp connection
YE=Yellow
=Crimp isolation
GC= Ground check
A = Cable dimension in cable specification
GC
WS004539A
Check the direction of rotation each time the cable has been re-connected and after phase
or total supply failure.
1. Start the motor.
2. Stop the motor.
3. Check that the impeller rotates in the correct direction.
The correct direction of impeller rotation is clockwise when you look at the pump from
above. When started, the pump will react in the opposite direction to the impeller
rotation.
L2
L1 L3
L1 L2 L3
WS001397A
Operation
Precautions
WARNING:
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge valve closed.
• Make sure you have a clear path of retreat.
• Never work alone.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
WS006209A
Distance to wet areas
Electrical Hazard:
Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to the unit when
being in contact with the pumped or mixed liquid.
Electrical Hazard:
Risk of electrical shock. This unit has not been investigated for use in swimming pools. If
used in connection with swimming pools special safety regulations apply.
Noise level
NOTICE:
The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may
be exceeded in some installations and at certain operating points on the performance
curve. Make sure that you understand the noise level requirements in the environment
where the pump is installed. Failure to do so may result in hearing loss or violation of local
laws.
WARNING:
• If you need to work on the pump, make sure that it is isolated from the power supply and
cannot be energized.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• In some installations, the pump and the surrounding liquid may be hot. Bear in mind the
risk of burn injuries.
• Make sure nobody is close to the unit when it is started. The unit will jerk in the opposite
direction of the impeller rotation.
• During operation the Ex-approved product must be fully submerged.
NOTICE:
Make sure that the rotation of the impeller is correct. For more information, see Check the
impeller rotation.
Maintenance
Precautions
WARNING:
• Always follow safety guidelines when working on the product. See Introduction and
Safety (page 3).
• Disconnect and lock out electrical power before installing or servicing the pump.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• Rinse the unit thoroughly with clean water before working on the unit.
• Rinse the components in water after dismantling.
Maintenance guidelines
During maintenance and before reassembly, always remember to perform these tasks:
• Clean all parts thoroughly, particularly O-ring grooves.
• Change all O-rings, gaskets, and seal washers.
• Lubricate all springs, screws, and O-rings with grease.
During reassembly, always make sure that existing index markings are in line.
The reassembled drive unit must always be insulation-tested and the reassembled pump
must always be test-run before normal operation.
Torque values
All screws and nuts must be lubricated to achieve correct tightening torque. Screws that
are screwed into stainless steel must have the threads coated with suitable lubricants to
prevent seizing.
If there is a question regarding the tightening torques, please contact a sales
representative.
Screws and nuts
Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)
Service
Regular inspection and service of the pump ensures more reliable operation.
Type of service Purpose Inspection interval
Major overhaul To secure a long operating lifetime Every year, under normal operating
for the product. It includes conditions
replacement of key components
and the measures taken during an
inspection.
NOTICE:
Shorter intervals may be required when the operating conditions are extreme, for example
with very abrasive or corrosive applications or when the liquid temperatures exceed 40°C
(104°F).
Inspection
Regular inspection and service of the pump ensures more reliable operation.
Visible parts on 1. Check that all screws, bolts, and nuts are properly tightened.
the pump and 2. Check the condition of lifting handles, eye bolts, ropes, chains, and wires.
installation
3. Check for worn or damaged parts.
4. Adjust and/or replace if necessary.
Cooling system If the flow through the system has been partly restricted, then rinse and clean.
1 Regardless of individual applications, the inspection chamber should not be inspected less frequently than the intervals for normal
applications and operating conditions at media (liquid) temperatures <40°C (104°F).
Major overhaul
For a major overhaul, take this action in addition to the tasks listed under Inspection.
Support and main bearing Replace the bearings with new bearings.
WARNING:
The oil housing may be pressurized. Hold a rag over the oil plug to
prevent oil from spraying out.
WS001318A
Fill with oil
1. Replace the oil screw O-ring.
2. Put one of the oil screws back and tighten it.
3. Put the corresponding oil plug back.
4. Turn the pump so that the oil hole faces upwards and fill with new oil.
Quantity: 5 L (5.3 qt.)
WS001827A
WS001822A
2. Check that the driving pin on the outer seal aligns with the key.
3. Without turning the shaft in relation to the driving ring, push the impeller carefully so
that the pin fits into the impeller keyway.
WS001819A
4. Fit the washer and the nut.
5. Tighten the impeller nut.
Tightening torque: 200 Nm (150 ft-lbs)
WS001824A
WS001823A
WS001828A
Troubleshooting
Introduction
Follow these guidelines when troubleshooting the pump:
• Disconnect and lock out the power supply except when conducting checks that
require voltage.
• Make sure that no one is near the pump when the power supply is reconnected.
• When troubleshooting electrical equipment, use the following:
• Universal instrument multimeter
• Test lamp (continuity tester)
• Wiring diagram
NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.
Cause Remedy
Cause Remedy
• The impeller
• The sump in order to prevent the impeller from clogging again.
If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 11).
Cause Remedy
The stop level is set too low. Raise the stop level.
If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 11).
If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 11).
NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.
Cause Remedy
The motor protection is set too low. Set the motor protection according to the data plate and if applicable the
cable chart.
The drive unit is not receiving full • Check the fuses. Replace fuses that have tripped.
voltage on all three phases. • If the fuses are intact, notify a certified electrician.
The phase currents vary, or they are Contact the local Xylem service shop.
too high.
The insulation between the phases 1. Use an insulation tester. With a 1000 V DC megger, check that the
and ground in the stator is insulation between the phases and between any phase and ground is
defective. > 5 megohms.
2. If the insulation is less:
Contact the local Xylem service shop.
The density of the pumped fluid is Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)
too high. • Change the impeller, or
• Change to a more suitable pump.
• Contact the local Xylem service shop.
The ambient temperature exceeds The pump must not be used for such an application.
the maximum ambient
temperature.
NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.
Cause Remedy
The impeller rotates in the wrong • If it is a 3-phase pump, transpose two phase leads.
direction. • If it is a 1-phase pump:
Contact the local Xylem service shop.
One or more of the valves are set in • Reset the valves that are set in the wrong position.
the wrong positions. • Replace the valves, if necessary.
• Check that all valves are correctly installed according to media flow.
• Check that all valves open correctly.
The pipes are obstructed. Clean out the pipes to ensure a free flow.
The pipes and joints leak. Find the leaks and seal them.
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, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 11).
Technical Reference
Application limits
Data Description
pH of the pumped media Version code 320, 590, and 690: 6–11
(liquid) Version code 011: 5–8
Media (liquid) density Maximum density: 1100 kg/m3 (9.2 lb. per US gal.)
Other For specific weight, current, voltage, power rating, and speed of the pump, see the data
plate on the pump. For starting current, see Motor data (page 41).
For other applications, contact the nearest Xylem representative for information.
Motor data
Feature Description
Frequency 50 or 60 Hz
Supply 3-phase
Voltage variation without ±10%, provided that it does not run continuously at full load
overheating
Voltage imbalance 2%
tolerance
3-phase, 50 Hz, LT
Motor type:
• 1,465 rpm
• 30 kW (40 hp)
Voltage (V) Rated current (A) Starting current (A)
200 124 1020
220 111 880
230 98 745
380 62 505
400 56 430
415 56 410
500 46 325
3-phase, 60 Hz, LT
Motor type:
• 1,760 rpm
• 37 kW (50 hp)
Voltage (V) Rated current (A) Starting current (A)
220 128 1,062
380 78 655
440 64 495
460 63 525
575 48 335
3-phase, 60 Hz
Motor type:
• 3,400 rpm
• 42.7 kW (57.2 hp)
Voltage (V) Rated current (A) Starting current (A)
440 D 68 375
460 D 65 395
575 52 305
Figure 8: HT
Figure 9: LT, MT
A B
6 in. (152 mm) 1253 mm (49.3 in.)
8 in. (203 mm) 1253 mm (49.3 in.)
A B
R6 = BSP.Pl.6; NPT6 1153 mm (45.4 in.)
R8 = BSP.Pl.8; NPT8 1153 mm (45.4 in.)
Figure 10: MT
Figure 11: HT
Performance curves
Test standard
Pumps are tested in accordance with ISO 9906, HI level A.
36 40
32
36
28
32
24
20 28
H [m] H [m]
100
100
80
80
60
60
40 40
20 20
WS006294A
WS006293A
0 0
0 40 80 120 160 200 240 0 40 80 120 160 200 240
Q [l/s] Q [l/s]
0 0 0 0
H [ft] / [m] H [ft] / [m]
160
HT MT
80 45
250 140
40
70
120
35
200 60
100 30
50
150 80 25
40
20
60
100 30
15
40 231
20 10
50
253
20
10 5
254 232
0 0 0 0
0 10 20 30 40 50 60 0 20 40 60 80 100 120 140
WS006297A
WS006295A
0 200 400 600 800 1000 0 500 1000 1500 2000 2500
Q [l/s] / [usgpm]
Q [l/s] / [usgpm]
Figure 15: 50 Hz, MT
Figure 14: 50 Hz, HT
60 60
40 40
234 232
40 30 40 30
20 20
20 20
10 10
0 0 0 0
H [ft] / [m] H [ft] / [m]
160
HT MT
350 45
100 140
40
300
120
35
80
250
100 30
200 60 25
80
150 20
60
40
15
100 40
10
20
50 20 232
5
234
0 0 0 0
0 10 20 30 40 50 60 0 20 40 60 80 100 120 140 160 180
WS006298A
WS006296A
0 200 400 600 800 1000 0 500 1000 1500 2000 2500 3000
Q [l/s] / [usgpm] Q [l/s] / [usgpm]
28 36
24 32
20 28
H [m] H [m]
90 100
80 90
70 80
70
60
60
50
50
40
40
30
30
20 20
10 10
WS006299A
WS006300A
0 0
0 20 40 60 80 100 120 140 160 0 20 40 60 80 100 120 140 160 180
Q [l/s] Q [l/s]
Figure 18: 50 Hz, 37 kW Figure 19: 60 Hz, 42.7 kW (58 hp)
Xylem Water Solutions AB Visit our Web site for the latest version of this
document and more information
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 © 2011 Xylem Inc.
Fax +46-8-475 69 00
http://tpi.xyleminc.com
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