Xylem Flygt 2620.172, Service And Repair Instructions

Page 1: ...Service and Repair Instructions 885611_2 0 2620 172 281...

Page 2: ......

Page 3: ...specific precautions 13 3 2 4 Prepare the SUBCAB cables 13 3 2 5 Connect the motor cable to the pump 14 3 2 6 Cable charts 15 3 3 Check the impeller rotation 19 4 Maintenance 20 4 1 Precautions 20 4 2...

Page 4: ...inage version only 57 4 6 11 Install the cover Sludge version only 58 4 7 Service 58 4 7 1 Inspection 59 4 7 2 Overhaul 60 5 Troubleshooting 61 5 1 Electrical troubleshooting 61 5 2 The pump does not...

Page 5: ...quirements and information in the original manufacturer s manuals for any other equipment furnished separately for use in this system 1 2 Safety terminology and symbols About safety messages It is ext...

Page 6: ...4 1 Working in temporary installations Certain industries such as mining or construction have a dynamic nature and require temporary installation of equipment Due to the rugged nature of these applica...

Page 7: ...solid or liquid waste Clean up of spills Exceptional sites CAUTION Radiation Hazard Do NOT send the product to Xylem if it has been exposed to nuclear radiation unless Xylem has been informed and app...

Page 8: ...ace any worn or faulty components The use of unsuitable spare parts may cause malfunctions damage and injuries as well as void the warranty 1 8 Warranty For information about warranty see the sales co...

Page 9: ...intrinsically safe then see the specific explosion proof information in the safety chapter before taking any further actions NOTICE Do NOT use the unit in highly corrosive liquids For information abo...

Page 10: ...dard pumps Features Below are some of the features of the level regulators The level regulator can be set at different operating levels by adjusting the length of cable A clamping bracket situated at...

Page 11: ...uct weight 20 Locked rotor code letter 21 Power factor 22 Maximum ambient temperature 23 Read installation manual 24 Notified body only for EN approved Ex products 25 WEEE Directive symbol Figure 2 Th...

Page 12: ...Number Indication Parameter 1 Hydraulic end 2 Type of installation 3 Sales code 4 Version 5 Production year 6 Production cycle 7 Running number 2 Product Description 10 2620 172 281 Service and Repai...

Page 13: ...uit as well WARNING Electrical Hazard Risk of electric shock or burn A certified electrician must supervise all the electrical work All the local codes and regulations must be obeyed WARNING Electrica...

Page 14: ...nt 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 cables must not be damaged and must not have...

Page 15: ...Prepare the SUBCAB cables This section applies to SUBCAB cables with twisted pair control cores The prepared SUBCAB cable The prepared screened SUBCAB cable without cable lugs SUBCAB 1000V T 1 T 2 1 2...

Page 16: ...e screens together to create a ground earth core and fit a cable terminal to the end e Check that the ground earth core is at least 10 longer than the phase cores in the cabinet 5 Connect to ground ea...

Page 17: ...11 12 17 16 24 22 23 19 20 21 18 25 1 Starter equipment and main leads L1 L2 L3 14 Transformer 2 Ground earth 15 Capacitor 3 Functional ground 16 Softstarter 4 Control leads T1 T2 T3 T4 17 Level regul...

Page 18: ...nge GN Green GNYE Green Yellow RD Red GY Grey BU Blue YE Yellow Terminal plate markings 1 phase Marking Description A Auxiliary winding C Common M Main winding 3 Installation 16 2620 172 281 Service a...

Page 19: ...M Main winding U1 Z5 U6 U2 Z6 U5 Z1 4 leads Z1 8 leads Z2 T1 T2 STATOR LEADS 1 ph RD GN BN YE YE BU BK WH YE STATOR LEADS 3 ph RD GN BN BU YE BK WH or YE U1 U5 U2 U6 V1 V5 V2 V6 W1 W5 W2 W6 T1 T2 U2 V...

Page 20: ...as ground conductor FGB 3 S T1 WH T2 WH T3 WH T4 WH T1 alt T2 alt L3 L2 L1 BK GY BN V C alt 3 U M alt 1 W A alt 5 Motor cable alt Pump Pump BU BK BN GY WH GC Subcab S3 3 3 S4 Float switch Optional BU...

Page 21: ...from above When started the pump will react in the opposite direction to the impeller rotation L2 L1 L2 L3 L3 L1 WS001397A Figure 4 Start reaction 4 If the impeller rotates in the wrong direction the...

Page 22: ...e you handle them Make sure that the product and its components have been thoroughly cleaned Before starting work make sure that the work area is well ventilated Do not open any vent or drain valves o...

Page 23: ...ult tracing process 4 2 1 Trace faults in the drive Check the stator See Check the stator on page 21 Check inspection chamber stator housing Abnormal leakage Yes Basic Repair Kit BRK Mechanical seals...

Page 24: ...ly uniform Yes Clean and dry stator and BRK No New stator and BRK Basic Repair Kit BRK Mechanical seals bearings and O rings 4 2 3 Trace faults in the wet end Check the status of the wet end component...

Page 25: ...9 3 6 9 7 7 2 17 13 40 30 79 58 136 100 333 245 649 480 1120 825 1 2210 1630 Hexagon screws with countersunk heads For hexagon socket head screws with countersunk head maximum torque for all property...

Page 26: ...e Be careful when opening Allow the chamber to de pressurize before removal of the plug 3 Turn the pump so that the oil hole faces downwards and let the oil run out into a container Some oil will be l...

Page 27: ...620 172 0 44 0 46 2620 281 0 44 0 46 3 Put the oil screw back and tighten it 4 5 Disassemble the pump Before the pump is disassembled the pump has to be drained of all oil See Empty the oil on page 23...

Page 28: ...antling to replace wear parts seals and bearings The following flowchart shows the general workflow when dismantling in order to access the wear parts seals and bearings Strainer Suction cover Impelle...

Page 29: ...ts can have sharp edges Wear protective clothing 1 Remove the strainer WS004764A 2 Loosen the impeller a Lock the impeller to prevent rotation Use pliers a screwdriver or similar b Remove the impeller...

Page 30: ...to prevent rotation Use pliers a screwdriver or similar b Turn the adjustment screw counterclockwise until the impeller loosens from the shaft Use an 8 mm hexagon bit adapter Allen socket WS004767A c...

Page 31: ...sharp edges Wear protective clothing 1 Remove the stand and the lower pump housing WS004783A 2 Loosen the impeller a Lock the impeller to prevent rotation Use pliers a screwdriver or similar b Remove...

Page 32: ...rew counterclockwise until the impeller breaks free from the shaft Use an 8 mm hexagon bit adapter Allen socket with a 100 mm 4 in extension WS004785A c Pull off the impeller WS004786A 4 5 6 Remove th...

Page 33: ...nside the intermediate piece Use a syringe WS007771A 3 Remove the mechanical seal Use a screwdriver on each side to pry the mechanical seal off the shaft WS007770A 4 5 7 Remove the shaft unit 1 Reinst...

Page 34: ...WS007773A 3 Remove the diffuser 4 Remove the screws for the seal housing cover 5 Lift straight up and remove the intermediate piece and rotor shaft WS007774A 6 Remove the outer casing Use a rubber ma...

Page 35: ...ires WS002884A 4 5 8 Remove the bearings 1 Remove the small retaining ring WS007793A 2 Remove the shaft unit from the main bearing in the intermediate piece Use a press or the dismantling tool and mak...

Page 36: ...main bearing from the intermediate piece Use a press or the dismantling tool and make sure that the intermediate piece is evenly supported during the removal of the main bearing WS002958A 5 Remove the...

Page 37: ...Lift off the handle WS007779A 3 Remove the cover from the pump top a Remove the screws from the cover WS007780A b Remove the screws and washers from the entrance flange 4 Maintenance 2620 172 281 Ser...

Page 38: ...th a screwdriver d Remove the cover and the cable entrance from the pump top as far as the slack of the cable allows WS007782A e Disconnect the power leads WS007783A f Disconnect the ground earth lead...

Page 39: ...ews for the thermal protector and starter unit WS007784A 5 Remove the starter unit as far as the slack of the cables allows WS007785A 6 Disconnect the cables between the starter unit and the terminal...

Page 40: ...WS007786A 7 Remove the pump top a Remove the screws WS007787A WS007788A b Remove the pump top 4 Maintenance 38 2620 172 281 Service and Repair Instructions...

Page 41: ...as far as the slack of the cables allows WS007790A 2 Install a lifting eye bolt in the stator housing WS007791A 3 Remove the terminal plate unit a Disconnect the stator leads from the terminal plate...

Page 42: ...ng quickly and evenly until the stator drops CAUTION Thermal Hazard Allow surfaces to cool before starting work or wear heat protective clothing WS002667A 7 When the stator is released and has dropped...

Page 43: ...or housing cable throughlet CAUTION Thermal Hazard Allow surfaces to cool before starting work or wear heat protective clothing 4 Allow the stator housing and the stator to cool 5 Guide the leads thro...

Page 44: ...stall the terminal plate unit and O ring on top of the stator WS007790A 4 6 3 Install the pump top Standard version only 1 Install a new O ring on top of the stator housing Lubricate the O ring 4 Main...

Page 45: ...it through the hole WS007795A 3 Install the pump top a Guide the cables from the terminal plate unit through the pump top opening WS007789A b Install and tighten the screws The long screw is for the h...

Page 46: ...tion see Make the electrical connections on page 11 WS007786A 5 Install the starter unit in the pump top Install and tighten the screws for the starter unit and the thermal protector WS007784A 6 Insta...

Page 47: ...le in the cover Make sure that all parts of the cable entrance are in position WS007796A 1 2 3 1 Washer 2 Seal sleeve 3 Cable clip c Install the screws for the cable entrance Do not tighten the screws...

Page 48: ...th conductor must be Pump Extra length of ground conductor mm in 2620 172 2620 281 270 10 6 e Connect the power leads to the starter unit For more cable chart information see Make the electrical conne...

Page 49: ...trance WS007781A 7 Install the handle Tighten the screws WS007778A 8 Install a new O ring on the edge of the pump top Lubricate the O ring WS007801B 9 Install the outer casing Use a rubber mallet on t...

Page 50: ...liers 4 Lubricate the bearing surface of the shaft unit 5 Install the intermediate piece including main bearing onto the shaft unit Use a rubber mallet Use the SKF B20 52 fitting tool or a tube with t...

Page 51: ...O rings WS007804A 2 Drop the wave washer past the O ring into the upper bearing seat WS008335B 1 2 1 Wave washer 2 O ring 3 Put the shaft unit in position in the stator Make sure that the index markin...

Page 52: ...t and tap evenly on the intermediate piece WS007805A d Remove the alignment screw 4 6 6 Install the mechanical seal Standard versions only 1 Lubricate the shaft end with a few drops of water 2 Install...

Page 53: ...ng a vacuum in the seal housing and monitoring any change of pressure over time 1 Apply a negative differential pressure of about 0 5 0 7 bar 0 5 0 3 bar absolute pressure in the empty seal housing 2...

Page 54: ...emery cloth The end of the shaft must be clean and free from burrs b Coat the inner conic the outer cylindrical surfaces and the thread of the conical sleeve with a thin layer of grease The proper lub...

Page 55: ...e impeller with the conical sleeve onto the shaft 7 Mount the diffuser part and tighten Continuously check that the impeller can rotate easily Tightening torque 22 Nm 16 2 ft lb If the impeller cannot...

Page 56: ...k the impeller to prevent rotation Use pliers a screwdriver or similar c Tighten the impeller screw Tightening torque 22 Nm 16 2 ft lb d Tighten a further 1 8 turn 45 e Check that the impeller can rot...

Page 57: ...ith a thin layer of grease The proper lubrication is grease for bearings for example Exxon Mobil Unirex N3 Mobil Mobilith SHC 220 or equivalent NOTICE Surplus grease can cause the impeller to become l...

Page 58: ...the impeller Make sure that the conical sleeve bottoms in the impeller WS004787A 6 Assemble the impeller with the conical sleeve onto the shaft 7 Fasten the impeller a Place the washer on the impelle...

Page 59: ...using and stand WS004789A 4 6 10 Install the discharge connection Drainage version only 1 Fit a new O ring in the discharge connection WS000767 2 Install the discharge connection 4 Maintenance 2620 17...

Page 60: ...on To prevent operational interruptions and machine breakdown Measures to secure performance and pump efficiency are defined and decided for each individual application It can include such things as i...

Page 61: ...s of the impeller or replacement of worn parts Oil Check the oil 1 Take an oil sample 2 If the oil contains particles then replace the mechanical seal Contact an authorized service shop Make sure that...

Page 62: ...Contact an electrician if necessary Insulation resistance in the stator 1 Check the insulation between Phase phase on the stator Phase ground earth The insulation should be 1 megaohm Use a 1000 VDC me...

Page 63: ...or crush Always disconnect and lock out power before servicing to prevent unexpected startup Failure to do so could result in death or serious injury NOTICE Do NOT override the motor protection repea...

Page 64: ...lways disconnect and lock out power before servicing to prevent unexpected startup Failure to do so could result in death or serious injury Cause Remedy The pump is unable to empty the sump to the sto...

Page 65: ...ect and lock out power before servicing to prevent unexpected startup Failure to do so could result in death or serious injury NOTICE Do NOT override the motor protection repeatedly if it has tripped...

Page 66: ...mpeller rotates in the wrong direction If it is a 3 phase pump then transpose two phase leads If it is a 1 phase pump then do the following Contact a sales or authorized service representative One or...

Page 67: ...les or authorized service representative for information 6 2 Motor data Feature Description Motor type Squirrel cage induction motor Frequency Standard version 50 or 60 Hz MSHA version 60 Hz Supply 1...

Page 68: ...8 230 9 9 37 0 97 240 9 8 39 0 95 3 phase 60 Hz Motor type 3 410 rpm 2 6 kW 3 5 hp Voltage V Rated current A Starting current A Power factor cos 200 Y 11 61 0 88 208 Y 10 71 0 84 220 D 9 6 65 0 85 220...

Page 69: ...4 29 0 86 480 Y serial 4 9 34 0 78 575 Y 3 5 22 0 9 600 Y 3 5 23 0 88 6 4 Dimensions and weights All measurements in the illustration are in millimeters if not otherwise specified WS004703A 29 Figure...

Page 70: ...o the unit make sure that you have the following special tools available before servicing the unit Part number Denomination Range of use 841362 Puller Main bearing 841545 Mounting set Bearings 842048...

Page 71: ...Ohm 6389601 4 1 77 3 66 6389603 4 1 34 2 71 Table 4 3 phase Part number Number of stator leads Winding resistance Ohm 6389501 6 3 06 6389503 6 3 65 6389506 9 1 38 6389508 6 1 99 6389511 6 0 572 638951...

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