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FLYGT 3126.290, Installation, Operation And Maintenance Manual

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Table of Contents

Introduction and Safety..................................................................................................................3

Introduction..................................................................................................................................3
Safety.............................................................................................................................................3

Safety terminology and symbols........................................................................................... 3
Environmental safety...............................................................................................................4
User safety................................................................................................................................ 5
Ex-approved products............................................................................................................ 6
Product warranty......................................................................................................................7

Transportation and Storage.......................................................................................................... 8

Inspect the delivery..................................................................................................................... 8

Inspect the package................................................................................................................ 8
Inspect the unit........................................................................................................................ 8

Transportation guidelines.......................................................................................................... 8

Lifting.........................................................................................................................................8

Temperature ranges for transportation, handling and storage............................................ 9
Storage guidelines...................................................................................................................... 9

Product Description......................................................................................................................11

Pump design..............................................................................................................................11
External cooling.........................................................................................................................12
Monitoring equipment............................................................................................................. 13
The data plate............................................................................................................................13
Approvals................................................................................................................................... 14
Product denomination..............................................................................................................15

Installation......................................................................................................................................17

Install the pump.........................................................................................................................17

Install with P-installation....................................................................................................... 18
Install with S-installation....................................................................................................... 19
Install with T-installation....................................................................................................... 19

Make the electrical connections..............................................................................................20

Prepare the SUBCAB

™

 cables..............................................................................................22

Connect the motor cable to the pump...............................................................................23
Connect the motor cable to the starter and monitoring equipment..............................24
Cable charts........................................................................................................................... 25

T-installation: Bleed air before starting pump.......................................................................27
Check the impeller rotation..................................................................................................... 27

Operation.......................................................................................................................................29

Estimate zinc anode replacement intervals........................................................................... 29
Start the pump...........................................................................................................................30

Maintenance..................................................................................................................................31

Torque values............................................................................................................................ 31
Change the oil........................................................................................................................... 32
Service the pump...................................................................................................................... 33

Inspection...............................................................................................................................33
Major overhaul.......................................................................................................................34
Service in case of alarm........................................................................................................ 34

Table of Contents

Flygt 3126.290 Installation, Operation, and Maintenance Manual

1

Summary of Contents for 3126.290

Page 1: ...Installation Operation and Maintenance Manual Flygt 3126 290 ...

Page 2: ......

Page 3: ... Product denomination 15 Installation 17 Install the pump 17 Install with P installation 18 Install with S installation 19 Install with T installation 19 Make the electrical connections 20 Prepare the SUBCAB cables 22 Connect the motor cable to the pump 23 Connect the motor cable to the starter and monitoring equipment 24 Cable charts 25 T installation Bleed air before starting pump 27 Check the i...

Page 4: ...0 The pump does not start 40 The pump does not stop when a level sensor is used 41 The pump starts stops starts in rapid sequence 41 The pump runs but the motor protection trips 41 The pump delivers too little or no water 42 Technical Reference 44 Table of Contents 2 Flygt 3126 290 Installation Operation and Maintenance Manual ...

Page 5: ...equipment or use of parts not provided by Xylem If there is a question regarding the intended use of the equipment please contact a Xylem representative before proceeding Do not change the service application without the approval of an authorized Xylem representative CAUTION You must observe the instructions contained in this manual Failure to do so could result in physical injury damage or delays...

Page 6: ...tting hazard Arc flash hazard Environmental safety The work area Always keep the station clean 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 R...

Page 7: ... 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 fo...

Page 8: ...ile 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 a...

Page 9: ...t is done by Xylem authorized personnel Genuine Xylem parts are used Only Ex approved spare parts and accessories that are authorized by an Ex approved Xylem representative are used in Ex approved products Limitations The warranty does not cover defects that are caused by these situations Deficient maintenance Improper installation Modifications or changes to the product and installation that are ...

Page 10: ...do so could result in death or serious injury Position and fastening The unit can be transported either horizontally or vertically Make sure that the unit is securely fastened during transportation and cannot roll or fall over Lifting Always inspect the lifting equipment and tackle before starting any work WARNING Crush Hazard 1 Always lift the unit by its designated lifting points 2 Use suitable ...

Page 11: ...g transportation handling and storage is 50 C 58ºF to 60 C 140ºF If the unit has been exposed to freezing temperatures then allow it to reach the ambient temperature of the sump before operating Lifting the unit out of liquid The unit is normally protected from freezing while operating or immersed in liquid but the impeller propeller and the shaft seal may freeze if the unit is lifted out of the l...

Page 12: ...rating 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 Transportation and Storage 10 Flygt 3126 290 Installation Operation and Maintenance Manual ...

Page 13: ...ment in an explosive zone unless it is rated explosion proof or intrinsically safe If the product is EN ATEX MSHA or FM approved then see the specific EX information in the Safety chapter before taking any further actions NOTICE Do NOT use the pump in highly corrosive liquids Spare parts Modifications to the unit or installation should only be carried out after consulting with Xylem Original spare...

Page 14: ...iple types of impellers For information about the pumps impellers see Parts List 6 Main bearing The bearing consisting of a two row angular contact ball bearing 7 Motor For information about the motor see Motor data page 44 8 Cooling Cooling without jacket The pump is cooled by the ambient liquid Cooling with jacket The motor is cooled by the circulation of a portion of the pumped liquid in the sp...

Page 15: ...oil housing and the stator housing must be replaced with solid plugs Monitoring equipment The following applies to the monitoring equipment of the pump The stator incorporates three thermal contacts connected in series that activate the alarm and stops the pump at overtemperature The thermal contacts open at 125 C 257 F Ex approved pumps must have thermal contacts connected to the control panel Th...

Page 16: ...ient temperature 23 Read installation manual 24 Notified body only for EN approved Ex products Figure 1 The data plate Approvals Product approvals for hazardous locations Pump Approval 3126 290 European Norm EN ATEX Directive EN 60079 0 2009 EN 60079 1 2007 EN 13463 1 2009 EN 13463 5 2011 II 2 G c Ex d IIB T4 Gb EN approval for cable entry Certificate number INERIS 02ATEX9008 U II 2 G Ex d IIC Gb ...

Page 17: ...tion that is contained in its fields International Norm not for EU member countries WS001279B 2 1 8 7 6 3 4 5 9 10 11 12 13 1 Approval 2 Approval authority and Approval number 3 Approved for drive unit 4 Stall time 5 Starting current or Rated current 6 Duty class 7 Duty factor 8 Input power 9 Rated speed 10 Controller 11 Additional information 12 Maximum ambient temperature 13 Serial number FM app...

Page 18: ...Y YYY YYYY 1 2 3 4 5 6 7 a b c WS006265B Type of Callout Number Indication Type of code a Sales denomination b Product code c Serial number Parameter 1 Hydraulic end 2 Type of installation 3 Sales code 4 Version 5 Production year 6 Production cycle 7 Running number Product Description 16 Flygt 3126 290 Installation Operation and Maintenance Manual ...

Page 19: ...ns that are classified as hazardous in the National Electric Code TM ANSI NFPA 70 2005 General requirements These requirements apply Use the pump dimensional drawing in order to ensure proper installation In T installation the pump must be equipped with cooling jacket Before installing the pump do the following Provide a suitable barrier around the work area for example a guard rail Make sure that...

Page 20: ... has a flange which fits the pump housing flange and a bracket for attaching the guide equipment Fasteners for the discharge connection Anchor bolts 1 Install the access frame a Place the access frame in position and align it horizontally b Grout the frame in place 2 Grout the anchor bolts in place Be careful when you align and position the discharge connection in relation to the access frame 3 Pl...

Page 21: ... the installation is made according to the dimensional drawing For information about the different installation types see Parts List WS006270A Figure 3 S installation 1 Run the cable so that it has no sharp bends Make sure that it is not pinched and cannot be sucked into the pump inlet 2 Connect the discharge line 3 Lower the pump into the sump 4 Place the pump on the base and make sure it cannot ...

Page 22: ...cording to the separate instructions Make sure that the impeller rotation is correct For more information see Check the impeller rotation page 27 5 Make sure that the weight of the pump does not put strain on the piping Make the electrical connections General precautions DANGER Electrical Hazard Before starting work on the unit make sure that the unit and the control panel are isolated from the po...

Page 23: ...e 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 If stated on the data plate then the motor is convertible between different volta...

Page 24: ... liquids that are also in contact with the pump or pumped liquid Prepare the SUBCAB cables This section applies to SUBCAB cables with twisted pair control cores The prepared SUBCAB cable The prepared screened SUBCAB cable SUBCAB 1000V T 1 T 2 1 2 3 4 5 6 WS004299E 1 T1 T2 twisted pairs in control element 2 Drain wire in control element bare copper wire 3 Screened copper pt foil 4 Insulation sheath...

Page 25: ...t a yellow green shrink hose over the ground earth core Leave a short piece uncovered c If applicable put a cable lug on the screened ground core d Twist all power core 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 How is the connection to ground earth made Screw Fit ...

Page 26: ... and the O ring on the stator housing 8 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 DANGER Explosion Fire Hazard Special rules apply to installations in explosive or flammable atmospheres Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explosio...

Page 27: ... irrespective of the ambient temperature 2 Connect the mains leads L1 L2 L3 and ground earth to the starter equipment For information about the phase sequence and the color codes of the leads see Cable charts page 25 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 sup...

Page 28: ...hite U5 Red Yellow V5 Brown Yellow W5 Yellow Red U6 Green Yellow V6 Blue Yellow W6 Black Yellow Denomination motor leads Color RED Red BROWN Brown WHITE White GREY Grey BLACK Black YELLOW Yellow GREEN Green Sensor connection WS002440A Code Color BU Blue GY Grey WH White YE Yellow Installation 26 Flygt 3126 290 Installation Operation and Maintenance Manual ...

Page 29: ...t line 2 Inlet line 3 Line to drain 4 Air vent Figure 9 T installation valves A D 2 Close valve D before the pump is started Check the impeller rotation CAUTION Crush Hazard The starting jerk can be powerful Make sure nobody is close to the unit when it is started 1 Start the motor 2 Stop the motor after a few seconds 3 Check that the impeller rotates according to this illustration Installation Fl...

Page 30: ...ation is clockwise when you look at the pump from above 4 If the impeller rotates in the wrong direction then transpose two phase leads 3 phase and do this procedure again Installation 28 Flygt 3126 290 Installation Operation and Maintenance Manual ...

Page 31: ... and at certain operating points on the performance curve Make sure that you understand the noise level requirements in the environment where the product is installed Failure to do so may result in hearing loss or violation of local laws Estimate zinc anode replacement intervals The mass and surface area of the zinc anodes are designed to protect the pump surface for 1 year in sea water with an av...

Page 32: ...k can be powerful Make sure nobody is close to the unit when it is started NOTICE Make sure that the rotation of the impeller is correct For more information see Check the impeller rotation 1 Check the oil level in the oil housing 2 Remove the fuses or open the circuit breaker and check that the impeller can be rotated freely WARNING Crush Hazard Never put your hand into the pump housing 3 Conduct...

Page 33: ... Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump remove plugs or disconnect piping Ground continuity verification A ground earth continuity test must always be performed after service Maintenance guidelines During the maintenance and before reassembly always remember to perform these tasks Clean all parts thoroughly particularly O r...

Page 34: ...ws 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 Change the oil The following items are needed for this procedure New oil plugs New O rings Oil that should be a medical white oil of paraffin type that fulfills FDA 172 878 a and viscosity close to VG32 1 Place the pump in a ho...

Page 35: ...as impeller trimming wear part control and replacement control of zinc anodes and control of the stator Up to every year Applies to normal applications and operating conditions at media liquid temperatures 40 C 104 F Major overhaul To secure a long operating lifetime for the product It includes the replacement of key components and the measures that are taken during an inspection Up to every 3 yea...

Page 36: ...ns Rotation direction Check the impeller rotation Oil housing Fill with new oil if necessary Terminal block closed end splice Check that the connections are properly tightened Thermal contacts Normally closed circuit interval 0 1 ohm Voltage and amperage Check the running values Major overhaul For a major overhaul do the following in addition to the tasks listed under Inspection Service item Actio...

Page 37: ... impeller The impeller must not be allowed to make contact with the concrete floor or other hard and rough surfaces If you fail with the impeller installation then you must redo the installation procedure from the beginning Replace the C or D impeller WS003639A Figure 10 C impeller WS003640A Figure 11 D impeller Remove the impeller C D CAUTION Cutting Hazard Worn parts can have sharp edges Wear pr...

Page 38: ... and contact surface Ensure that all parts are clean b Fit the washer on the lubricated impeller screw c Press the impeller onto the shaft with the impeller screw 2 Tighten the impeller screw If applicable use the rod Tightening torque 90 Nm 66 ft lbs Check that the impeller can rotate freely 3 Mount the suction cover if applicable a Fit a new lubricated O ring to the suction cover Maintenance 36 ...

Page 39: ...eller onto the shaft with the impeller screw 2 Fasten the impeller a Prevent the impeller from rotating by inserting the rod through the pump housing outlet b Tighten the impeller screw If applicable use the rod WS001940A Check that the impeller can rotate freely 3 Adjust the impeller a Measure the distance between the edge of the impeller and the pump housing cover The correct distance should be ...

Page 40: ... on the pump housing Use Loctite 603 locking liquid in order to secure the studs b Fit the suction cover to the studs c Fit the lock nuts onto the studs d Tighten the nuts WS001937A 5 Adjust the suction cover a Measure the distance between the impeller and the suction cover Maintenance 38 Flygt 3126 290 Installation Operation and Maintenance Manual ...

Page 41: ...WS002105A b Tighten the nuts WS001937A 6 Raise the pump to a vertical position Check that the impeller can rotate freely Maintenance Flygt 3126 290 Installation Operation and Maintenance Manual 39 ...

Page 42: ... may result in equipment damage Cause Remedy An alarm signal has been triggered on the control panel Check that 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 sales and service representative The pump does not start automatically but can be started manually Check that The start level ...

Page 43: ...too low Raise the stop level Always state the serial number of your product see Product Description page 11 The pump starts stops starts in rapid sequence Cause Remedy The pump starts due to back flow which fills the sump to the start level again Check that 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 t...

Page 44: ...epresentative There is a malfunction in the overload protection Replace the overload protection Always state the serial number of your product see Product Description page 11 The pump delivers too little or no water DANGER Crush Hazard Moving parts can entangle or crush Always disconnect and lock out power before servicing to prevent unexpected startup Failure to do so could result in death or ser...

Page 45: ...or is set correctly Depending on the installation type add a means for priming the pump such as a foot valve Always state the serial number of your product see Product Description page 11 Troubleshooting Flygt 3126 290 Installation Operation and Maintenance Manual 43 ...

Page 46: ... imbalance tolerance 2 Stator insulation class H 180 C 360 F Application limits Data Description Liquid temperature 40 C 104 F maximum The pump can be operated at full load only if at least half the stator housing is submerged Liquid density 1100 kg m 9 2 lb per US gal maximum pH of the pumped media liquid 3 14 for stainless steel pumps Depth of immersion 20 m 65 ft maximum Other For the specific ...

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Page 48: ... have strong long standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise backed by a legacy of innovation For more information on how Xylem can help you go to xyleminc com Refer to www xylemwatersolutions com contacts for contact details of your local sales and service representative Xylem Water Solutions Manufacturing AB...

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