Xylem Flygt 5530, Installation, Operation And Maintenance Manual

Page 1: ...Flygt 5530 Installation Operation and Maintenance Manual...

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Page 3: ...Storage location 9 Long term storage 9 Product Description 10 Pump design 10 Parts 11 Monitoring equipment 13 Optional sensors 13 The data plate 13 Product denomination 14 Installation 15 Install the...

Page 4: ...Replace the wear parts 40 Replace the agitator 43 Troubleshooting 45 Introduction 45 The pump does not start 45 The pump does not stop when a level sensor is used 46 The pump starts stops starts in ra...

Page 5: ...o 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 id...

Page 6: ...s 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 Cr...

Page 7: ...urn 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 s...

Page 8: ...ing 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...

Page 9: ...straps 4 Contact your sales representative if anything is out of order Transportation guidelines Precautions WARNING Stay clear of suspended loads Observe accident prevention regulations in force Posi...

Page 10: ...efore 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...

Page 11: ...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...

Page 12: ...In explosive or flammable environments only use Ex or MSHA approved pumps NOTICE Do NOT use the pump in highly corrosive liquids Spare parts Modifications to the unit or installation should only be ca...

Page 13: ...rmation about the motor see Motor data page 49 2 Monitoring equipment For more information about the monitoring equipment see Monitoring equipment page 13 3 Impeller The impeller is a shrouded three c...

Page 14: ...Tungsten carbide Silicon carbide RSiC Aluminium oxide Al2O3 Corrosion resistant cemented carbide WCCR 8 Oil casing A housing with oil that lubricates and cools the seals and acts as a buffer between t...

Page 15: ...of the stator housing CLS CLS is a sensor for detection of water in the oil housing The sensor initiates an alarm when the oil contains approximately 35 water The sensor is installed in the bearing ho...

Page 16: ...raulic end and type of installation This is an example of a sales denomination and an explanation of its parts 1 NP 3085 2 3 WS006265A 1 Hydraulic part 2 Installation type 3 Sales code Product code Th...

Page 17: ...a pump Always remove all debris and waste material from the sump inlet piping and discharge connection before you install the pump These requirements apply Use the pump dimensional drawing in order t...

Page 18: ...e discharge connection has a flange which fits the pump casing flange and a bracket for attaching the guide equipment Fasteners for the discharge connection Anchor bolts 1 Install the access frame a P...

Page 19: ...etely or partially submerged in the pumped liquid The pump is equipped with a connection for hose or pipe and stands on a base stand These requirements and instructions only apply when the installatio...

Page 20: ...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...

Page 21: ...zard 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 th...

Page 22: ...n longer than the phase leads in the junction box of the unit 5 Make sure that the pump is correctly connected to earth ground 6 Connect the control leads to the applicable terminal board 7 Make sure...

Page 23: ...e 2 Connect the mains leads L1 L2 L3 and earth ground to the starter equipment For information about the phase sequence and the color codes of the leads see Cable charts page 21 3 Check the functional...

Page 24: ...1 T2 4 3 2 1 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...

Page 25: ...LOUR STANDARD STATOR LEADS BN Brown U1 U5 RD BK Black U2 U6 GN WH White V1 V5 BN OG Orange V2 V6 BU GN Green W1 W5 YE GN YE Green Yellow W2 W6 BK RD Red T1 T2 WH YE GY Grey BU Blue YE Yellow SUBCAB AW...

Page 26: ...L1 L2 L3 L1 1 L2 1 L3 1 L1 2 L2 2 L3 2 U1 V1 W1 U2 V2 W2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 GC 1 2 3 4 5 6 GN YE YE WH WS004126A 6 Leads Y U1 V1 W1 U2 W2 V2 U1 V1 W1 W2 U2 V2 U1 V1...

Page 27: ...YE GN YE WH WS004127A 12 Leads Y L1 U1 U5 U2 W 2 U6 W 1 V 6 W 6 V 2 V 5 W 5 L 3 V 1 L 2 U1 V1 W1 U2 V6 U5 V5 W5 V2 W2 U6 W6 U1 V1 W1 W2 U2 V2 W2 U2 V2 GC U1 V1 W1 L1 L2 L3 YE WH GN YE Y SER L1 U1 U2...

Page 28: ...W2 U5 V5 W5 U6 V6 W6 WS004129A 1 PHASE 4 Leads 1 Z2 U2 U1 Z1 T1 T2 BK BN RD YE GC 1 BN RD 2 BK BK 3 GY WH 4 T1 OG 5 T2 BU 6 WH GN YE YE Starter 4 Leads with level regulator 1 1 1 2 3 Z2 U2 Z1 U1 Z2 U2...

Page 29: ...CAS AUX FGB Screened T1 WH T2 WH T3 WH T4 WH T1 WH T2 WH T3 WH T4 WH T1 WH T2 WH Screen SUBCAB and Screenflex T1 and T2 twisted White insulation hose Screen together GN YE L1 L2 L3 T1 T2 T1 and T2 twi...

Page 30: ...6A cos 0 6 Max 2 5A cos 1 6 WH YE T1 Control leads WH YE T2 T1 OG 4 SUBCAB AWG T2 OG 5 FLS FLS TC Max 12 V BU BU WH YE 6 BU WH YE T1 Control leads BU T2 T1 OG 4 7 Mini 5 CAS SUBCAB AWG T2 BU 5 CLS CLS...

Page 31: ...10 tolerance Sensors Value mA Definition FLS and thermal contact 0 Overtemperature 7 8 OK 36 Leakage CLS and thermal contact 0 Overtemperature 5 5 OK 29 Leakage 5 seconds delay CLS FLS and thermal co...

Page 32: ...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 30 Flygt 5530 In...

Page 33: ...d 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 Start the pump WARNING If you need to work on the p...

Page 34: ...uct insulation test phase to ground To pass the value must exceed 5 megohms 4 Check that the monitoring equipment works 5 Start the pump Operation 32 Flygt 5530 Installation Operation and Maintenance...

Page 35: ...intenance 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...

Page 36: ...ll property classes must be 80 of the values for property class 8 8 above Change the oil The following items are needed for this procedure New oil plugs New O rings Oil that should be a medical white...

Page 37: ...efined and decided for each individual application It can include such things as impeller trimming wear part control and replacement control of zinc anodes and control of the stator Up to twice a year...

Page 38: ...local safety regulations are followed Lifting handle 1 Check the screws 2 Check the condition of the lifting handle 3 Replace if necessary O rings 1 Replace the oil plug O rings 2 Replace the O rings...

Page 39: ...Replace the hydraulic parts Replace the impeller Required tools Impeller puller If applicable contact your Xylem representative for correct type and size Rod wooden or plastic for locking the impelle...

Page 40: ...ve the pump housing screws b Remove the drive unit from the pump housing 2 Place the drive unit horizontally 3 Remove the impeller a Remove the wear protection plug b Remove the impeller screw If appl...

Page 41: ...0 2 in the wearing cover must be replaced 3 Mount the impeller a Fit the expeller and the wearing cover onto the shaft Use a rubber mallet in order to knock the wearing cover in to place b Press the...

Page 42: ...ng 15 Wear ring 16 Trimming flange 17 Stud 18 Suction cover 19 Screw Remove the wear parts The pump housing and the impeller have to be removed before the wear parts can be removed For more informatio...

Page 43: ...er screws b Remove the suction cover Use two crowbars if needed WS002422A 7 Remove the trimming flange unit trimming flange and wear ring and its two O rings 8 Remove the O ring on the inside of the p...

Page 44: ...mp housing a Fit the new greased O ring on the top of the pump housing b Place the drive unit in the pump housing c Grease the pump housing screws d Tighten the screws in a diagonal sequence For tight...

Page 45: ...ver screw and tighten Tightening torque 100 Nm 74 ft lbs Replace the agitator WS006183A 1 Impeller screw 2 Key 3 Barrel nut 4 Propeller shaft 5 Agitator propeller 6 Washer 7 Retaining ring Maintenance...

Page 46: ...parts to make the agitator area accessible 1 Lock the impeller If applicable use a rod wooden or plastic to lock the impeller in place 2 Install the propeller shaft a Fit the agitators parallel key in...

Page 47: ...t The impeller rotates freely The sensor indicators do not indicate an alarm The overload protection is not tripped If the problem still persists Contact the local Xylem service shop The pump does not...

Page 48: ...f the level regulators Check the contactor and the control circuit Replace all defective items The stop level is set too low Raise the stop level If the problem persists refer to the Flygt Service Gui...

Page 49: ...ed electrician The phase currents vary or they are too high Contact the local Xylem service shop The insulation between the phases and ground in the stator is defective 1 Use an insulation tester With...

Page 50: ...cult to rotate by hand Clean the impeller Clean out the sump Check that the impeller is properly trimmed The pipes are obstructed Clean out the pipes to ensure a free flow The pipes and joints leak Fi...

Page 51: ...sulation class H 180 C 360 F Application limits Data Description Liquid temperature 40 C 104 F maximum The pump must work fully submerged under full load operation Warm liquid version 70 C 158 F maxim...

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Page 54: ...dings factories and farms In more than 150 countries we have strong long standing relationships with customers who know us for our powerful combination of leading product brands and applications exper...