Xylem FLYFT P7900 Installation, Operation And Maintenance Manual Download Page 40

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The following figure shows screened SUBCAB with a functional ground. T1 and T2 are

twisted together.

Screened SUBCAB - ground

Functional ground

Cable with sep. ground conductor

WH shrink hose

T1/T2 & T3/T4 (if applicable)

Twisted together

Bare wire

GN/YE

WS004341B

Figure 18: With functional ground

4.6.1 Colors and markings of leads

773 30 00/3

LV, 6 pole terminal; 1,2,3 or 4

cables

LV, 6 pole terminal; 1,2,3 or

GN/YE

COLOR STANDARD

BK - Black

BN - Brown

BU - Blue

GN - Green

GN/YE - Green/Yellow

GY - Grey

OG - Orange

RD - Red

WH - White

YE - Yellow

STATOR LEAD COLORS

SUBCAB SUBCAB AWG

SUBCAB

S6x95+95+S(4x0.5) MV cables

L1
L2
L3

T1, T2
T3, T4

BN
BK
GY
WH
WH

GN/YE

RD
BK
WH

1 WH , 4 WH
2 WH , 5 WH
3 WH , 6 WH

GN/YE

BK
BK
BK

WH
WH

LV Stators MV Stators

U1 - RD

U2 - GN

V1 - BN

V2 - BU

W1 - YE

W2 - BK

U - BK

V - BK

W - BK

VOLTAGE DENOMINATIONS
LV - Low voltage

MV - Medium voltage

MOTOR CONNECTION

COLORS AND MARKING OF MAIN LEADS

MOTOR CABLE LEAD COLORS AND MARKING

WH
WH

GN/YE

773 30 00 (

REV

COLOR STANDARD

BK - Black

BN - Brown

BU - Blue

GN - Green

GN/YE - Green/Yellow

GY - Grey

OG - Orange

RD - Red

WH - White

YE - Yellow

STATOR LEAD COLORS

SUBCAB SUBCAB AWG

SUBCAB

S6x95+95+S(4x0.5) MV cables

L1
L2
L3

T1, T2
T3, T4

BN
BK
GY
WH
WH

GN/YE

RD
BK
WH

1 WH , 4 WH
2 WH , 5 WH
3 WH , 6 WH

GN/YE

BK
BK

WH
WH

LV Stators

MV Stators

U1 - RD

U2 - GN

V1 - BN

V2 - BU

W1 - YE

W2 - BK

U - BK

V - BK

W - BK

VOLTAGE DENOMINATIONS

LV - Low voltage

MV - Medium voltage

MOTOR CONNECTION

COLORS AND MARKING OF MAIN LEADS

MOTOR CABLE LEAD COLORS AND MARKING

WH
WH

GN/YE

WS004335C

Color code standard

Code

Description

Brown

Black

White

Orange

Green

GNYE

Green-Yellow

Red

Grey

Blue

Yellow

4 Installation

P7900 Installation, Operation, and Maintenance Manual

Summary of Contents for FLYFT P7900

Page 1: ...Installation Operation and Maintenance Manual 90028101_1 0 P7900...

Page 2: ......

Page 3: ...10 3 1 Pump design 10 3 1 1 Spare part requirements 10 3 2 Major hydraulic parts 10 3 3 Drive units 10 3 4 The MAS 801 monitoring equipment 11 3 4 1 FLS float switch sensor 11 3 4 2 Vibration in three...

Page 4: ...vice 48 6 2 1 Inspection 49 6 2 2 Major overhaul 50 6 2 3 Checking insulation and sensors 51 6 3 Check the insulation up to 1 kV drives or generators 51 6 4 Check the temperature sensors 51 6 5 Check...

Page 5: ...turer s manuals for any other equipment furnished separately for use in this system 1 2 Safety terminology and symbols About safety messages It is extremely important that you read understand and foll...

Page 6: ...all times when the unit is being operated 1 4 Special hazards 1 4 1 Biological hazards The product is designed for use in liquids that can be hazardous to your health Observe these rules when you work...

Page 7: ...A This marking on the product accessories or literature indicates that the product should not be disposed of with other waste at the end of its working life To prevent possible harm to the environment...

Page 8: ...ng examine the product 3 If applicable unfasten the product by removing any screws bolts or straps Use care around nails and straps 4 If there is any issue then contact a sales representative 2 2 Tran...

Page 9: ...uipment must be able to hoist the unit straight up and down preferably without the need for resetting the lifting hook The lifting equipment must be correctly anchored and in good condition The liftin...

Page 10: ...duct and all installation equipment including the lifting gear must be handled with extreme care Make sure that the product is warmed up to a temperature above the freezing point before starting up Av...

Page 11: ...ezing Follow these guidelines to avoid freezing damage When Guideline Before storage The unit must be allowed to run for a short time after raising it to discharge remaining pumped liquid This does no...

Page 12: ...o the unit or installation must only be carried out after consulting with Xylem Original spare parts and accessories that are authorized by Xylem are essential for compliance The use of other parts ca...

Page 13: ...e 2 Vibration directions with reference to the PEM The definitions of X Y and Z are the same whether or not the pump is in a vertical or horizontal position 3 4 3 Bearing temperature measurement Pt100...

Page 14: ...s incorporated in one of the windings Optional Three thermal contacts connected in series are incorporated in the coil ends of the stator winding The contacts are normally closed and open at 140 C 285...

Page 15: ...h the MAS 801 Pump current in three phases Pump current in three phases is also possible with the MAS 801 To track pump current in three phases with the MAS 801 the following are needed Three current...

Page 16: ...ntrol or pilot cable mounted The following SUBCAB signal cables are available 12x1 5 mm2 unscreened also known as unshielded Conductors 1 12 24x1 5 mm2 unscreened also known as unshielded Conductors 1...

Page 17: ...output is a 4 20 mA signal proportional to the vibration level Current 4 20 mA 20 mA indicates a short circuit 4 mA indicates a fault A zero value indicates a broken wire or bad contact in a connecto...

Page 18: ...d in the windings 3 5 4 1 Temperature sensors Table 7 Thermal contact Description Measured value Fault values The thermal contact is a normally closed contact 0 3 ohm unless the wires are long An infi...

Page 19: ...ion Service log with a maximum of 200 lines of text Conditions to prompt for service based on for example running time number of starts and stops or specific dates For more information see the MAS 711...

Page 20: ...r code 10 Rated speed 11 Pressure class 12 Column diameter or Inlet and outlet diameter 13 Product number 14 Country of origin Figure 4 The hydraulic unit plate 3 7 Motor regulation This product is su...

Page 21: ...umber 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 Drive unit 5 Production year 6 Production cycle 7 Runn...

Page 22: ...re installing the pump do the following Provide a suitable barrier around the work area for example a guard rail Make sure that equipment is in place so that the unit cannot roll or fall over during t...

Page 23: ...xplosion proof or intrinsically safe If the product is rated explosion proof or intrinsically safe then see the specific explosion proof information in the safety chapter before taking any further act...

Page 24: ...ds must be protected from water during storage Cable handling To install cables follow these requirements Start at the pump and carefully roll out the cable WS011247A When pulling the cable do not exc...

Page 25: ...llowing Sizing of the pump piping station and access frame Choice of auxiliary equipment Other aspects of installation NOTICE Do not run the pump dry NOTICE Never force piping to make a connection wit...

Page 26: ...or damage on the product Visually inspect equipment for damaged cables cracked casings or other signs of damage Make sure that electrical connections have been correctly made WARNING Crush Hazard Ris...

Page 27: ...urrent See the data plate and if applicable the cable chart for the rated current The starting current in direct on line start can be up to six times higher than the rated current 4 5 2 Grounding eart...

Page 28: ...connect the T1 and T2 leads integrated in the SUBCAB cable to the PEM See the illustration and table in Terminals used in standard applications on page 28 4 If they are not already connected then conn...

Page 29: ...The rubber sleeve must have the correct size to give the correct compression around the cable c Attach the connection flange to the entrance flange Make sure that the seal sleeve is not misaligned wi...

Page 30: ...2 power supply and communication 51 63 Temperature stator winding Thermal contact or thermistor TC 17 Not used 11 12 Vout 12 VDC GND 18 Not used 4 5 4 Connect the cables Pumps with MAS 711 1 Connect t...

Page 31: ...tion U1 U2 V1 V2 W1 W2 and ground earth according to the cable chart See Cable charts on page 36 d If control elements are present and not used then cut and cap them 5 Install the entrance flange a Fi...

Page 32: ...e entrance flange Make sure that the seal sleeve is not misaligned with the rubber sleeve Check that the entrance flange supports the cable so that it cannot be excessively bent 6 Connect the starter...

Page 33: ...RMAL SWI TCH OIL F LOW SENSOR LEA KAGE S TATOR LEA KAGE CONNECTION HOUSING TEMP MAIN BEARING TEMP 1 WINDING WINDING TEMP TEMP SUPPO RT BEARING TEMP 3 WINDNING TEMP 2 WINDNING WS000508A Figure 13 Conne...

Page 34: ...Conductor for 24 lead cable Float switch in the stator house1 1 1 1 2 2 2 Float switch in the junction box 9 7 7 2 Pt100 in the main bearing2 3 3 3 4 4 4 Pt100 in the support bearing 37 17 38 18 Therm...

Page 35: ...4 T2 T1 7 6 5 8 Figure 15 Correct phase sequence Item Description 1 L1 cable lead Brown 2 L2 cable lead Black 3 L3 cable lead Gray 4 Earth PE or ground lead cable 5 T1 cable lead control element In c...

Page 36: ...2 Measure both polarities T1 T2 resistance T1 T2 resistance Opposite polarity Conclusion 70 130 kilohms ohm The PEM is connected to this cable ohm infinite resistance ohm The PEM is not connected to t...

Page 37: ...ntrol element a Peel the insulation jacket or plastic jacket b Peel the aluminum and textile layers The aluminum foil is a conductive screen Do not peel more than necessary and remove the peeled foil...

Page 38: ...he electrical parts can cause damaged equipment or a blown fuse Keep the end of the motor cable dry at all times Stator leads connection to terminal board Terminal board Stator leads connection to ter...

Page 39: ...used then the control conductors in the power cable are never used The following figure shows screened SUBCAB cable without a separate ground conductor The ground conductor is made of stranded ground...

Page 40: ...WH GC WH YE LV Stators MV Stators U1 RD U2 GN V1 BN V2 BU W1 YE W2 BK U BK V BK W BK VOLTAGE DENOMINATIONS LV Low voltage MV Medium voltage MOTOR CONNECTION COLORS AND MARKING OF MAIN LEADS MOTOR CABL...

Page 41: ...D LV 3 pole terminal 1 or 2 cables L2 V2 V1 W1 U1 U2 L3 L1 W2 U V W L1 L3 L2 GN YE YE WH GC WS004349D Drive units with small connection housing U1 V1 W1 L2 L3 L1 GC WS001040C Drive units with large c...

Page 42: ...L2 GN YE YE WH GC WS003911B Drive units with small connection housing L2 L3 L1 U1 V1 W1 GC WS001041C 4 6 2 3 D connection 6 pole terminal 2 cables Schematic diagram D LV 6 pole terminal 1 2 3 or 4 cab...

Page 43: ...with large connection housing L2 L3 L1 V2 W1 U2 V1 U1 W2 WS008998B 4 6 2 4 Y connection Schematic diagram Y LV 6 pole terminal 1 or 2 cables L2 L3 L1 U2 V 2 W 2 V 1 W 1 U1 W2 U2 V2 U1 V1 W1 L1 L3 L2 G...

Page 44: ...powerful Make sure nobody is close to the unit when it is started If the propeller rotates in the wrong direction then the pump lifts up and rotates which can damage the cables 1 Start the motor 2 Sto...

Page 45: ...in the wrong direction then check that the phase leads are correctly connected See Power cable phase sequence on page 33 After reconnecting phase leads do this procedure again 4 Installation P7900 Ins...

Page 46: ...UTION Electrical Hazard Risk of electrical shock or burn The equipment manufacturer has not evaluated this unit for use in swimming pools If used in connection with swimming pools then special safety...

Page 47: ...et the calculated anode consumption rate days gram If multiple anodes were weighed then use the anode which has lost the most weight for this calculation 4 Calculate future replacement intervals so th...

Page 48: ...temperatures at or below the freezing point that is the pump is not totally submerged then special modifications must be made to the pump and the installation For more information please contact your...

Page 49: ...process Make sure that you have a clear path of retreat Never work alone Check the explosion risk before you weld or use electrical hand tools Before starting work make sure that the work area is wel...

Page 50: ...ice Regular inspection and service of the pump makes sure that operation will be more reliable Every time the site is visited visually examine the accessories and sump for corrosion wear or damage Tab...

Page 51: ...es exceed 40 C 104 F 6 2 1 Inspection CAUTION Compressed Gas Hazard Air inside may cause parts or liquid to be propelled with force Be careful when opening Regular inspection and service of the pump m...

Page 52: ...cessary to the correct torque See Torque values on page 65 Electrical cabinets Check that it is clean and dry Connection to power Check that the connections are properly secured Level regulators Check...

Page 53: ...tion After any service involving the power connections check the rotation before operating the pump See Check the impeller rotation on page 42 6 2 3 Checking insulation and sensors It is important tha...

Page 54: ...C supply The sensor must have the correct polarity to be checked However a switched plus and minus does not damage the sensor b Use the multimeter as an ammeter and connect it in series with the senso...

Page 55: ...Part number Oil plug 809 35 00 O ring 82 72 95 1 WS013658C 1 Seal oil plugs 3x 1 2 WS013656A 1 Seal oil drain plug 2 Seal oil fill plug Empty the oil 1 Put a container under the oil drain hole 2 Unsc...

Page 56: ...lled now Tightening torque 50 Nm 37 lbf ft Fill with oil 1 Fill up with the new oil 2 Replace the O rings 3 Install the oil plugs Tightening torque 50 Nm 37 lbf ft 6 7 Change the gear oil For the inte...

Page 57: ...1 WS013817A 1 Gear oil plugs 3x 1 2 3 WS013657A 1 Gear oil drain plug 2 Gear oil fill plug 3 Gear oil level plug 6 Maintenance P7900 Installation Operation and Maintenance Manual 55...

Page 58: ...rectly then only the oil drain plug must be installed now Tightening torque 50 Nm 37 lbf ft Fill with oil 1 Fill up with the new oil The oil level must be below the oil level hole 2 Replace the O ring...

Page 59: ...5 1 WS013659A 1 Lifting eye unit 2 Plug 3 Screws 4 O ring 5 Propeller 1 Remove the plug 2 Install the lifting eye unit 3 Remove the screws 4 Remove the propeller WS013660C 5 Discard the O ring 6 Maint...

Page 60: ...loosening the screws then do the following a Remove the four plugs b Install four of the screws that were removed c Tighten the screws evenly until the locking assembly is released d Remove the screw...

Page 61: ...ss piece 432 44 00 2 Screw 432 53 00 M16 3 Screw 432 55 00 M12 4 Washer 432 45 00 1 2 3 4 5 WS013665B 7 6 Figure 20 Overview 1 Threaded adapter 2 Hydraulic pump 3 Cross piece 4 Propeller hub 5 Puller...

Page 62: ...the O ring 6 8 3 Assemble the pump 6 8 3 1 Install the propeller hub Table 16 Tools Tool Illustration Hydraulic pump 14 57 21 04 1 2 WS013663A 1 Threaded adapter 2 Non threaded adapter Basic repair ki...

Page 63: ...pump 7 By using the hydraulic pump apply pressure until the propeller hub is seated 6 8 3 2 Install the locking assembly 1 Install the locking assembly over the shaft and into the base of the propelle...

Page 64: ...ening torque 70 Nm 52 lbf ft b Tighten the screws again according to the sequence Tightening torque 154 Nm 114 lbf ft c Tighten the screws again according to the sequence Tightening torque 230 Nm 170...

Page 65: ...ring 2 Remove the plug 3 Install the lifting eye unit 4 Lift the propeller WS013660C 5 Align the holes of the propeller hub with the holes of the propeller 6 Lubricate the screws Lubricant Loctite No...

Page 66: ...ng torque 125 Nm 93 lbf ft c Tighten the screws again according to the sequence Tightening torque 187 Nm 138 lbf ft d Tighten the screws a last time according to the sequence Tightening torque 187 Nm...

Page 67: ...torque Screws that are screwed into stainless steel must have the threads coated with applicable lubricants to prevent seizing If there is a question regarding the tightening torques then contact a s...

Page 68: ...Three jaw puller 1 84 15 17 C wrench 1 332 91 00 Spring puller tool 1 436 18 00 Hub tool 1 432 44 00 Cross piece 1 432 45 00 Washer 1 432 53 00 Screw M16 4 432 55 00 Screw M12 3 436 19 00 Basic repai...

Page 69: ...Part number Denomination Parts Qty Part number Denomination 14 57 21 04 Hydraulic pump 1 702 76 00 Lifting eye unit 1 6 Maintenance P7900 Installation Operation and Maintenance Manual 67...

Page 70: ...r 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 Doing so may result i...

Page 71: ...e stop level Check that There are no leaks from the piping and or discharge connection The impeller is not clogged The non return valve s are functioning properly The pump has adequate capacity For in...

Page 72: ...is properly trimmed The drive unit is not receiving full voltage on all three phases Check the fuses Replace fuses that have tripped If the fuses are intact then notify a certified electrician The pha...

Page 73: ...141 91 142 154 32 11 104 29 44 117 08 77 129 75 110 142 29 143 154 70 12 104 68 45 117 47 78 130 13 111 142 66 144 155 07 13 105 07 46 117 85 79 130 51 112 143 04 145 155 45 14 105 46 47 118 24 80 13...

Page 74: ...Screened SUBCAB Cable Minimum bending radius in mm Weight in kg m Outer diameter minimum maximum in mm S3x16 3x16 3 S 4x0 5 240 1 1 24 26 S3x25 3x16 3 S 4x0 5 290 1 4 29 31 S3x35 3x16 3 S 4x0 5 320 2...

Page 75: ......

Page 76: ...gies and advanced analytics solutions for water electric and gas utilities In more than 150 countries we have strong long standing relationships with customers who know us for our powerful combination...

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