Xylem Flygt 2250 Installation, Operation And Maintenance Manual Download Page 21

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View of terminal board and sensor connections

775 13 00_1

2201

2250

2290

2400

Connection plate

2400

THERMAL

DETECTORS

IN STATOR

THERMAL

DETECTOR IN

MAIN BEARING

WH
WH
BK
BK

MAIN TERMINAL BOARD

SENSOR TERMINALS

SENSORS

T1
T2
T3
T4

CONNECTION AT 2 LEADER PILOT CABLE

CONNECTION AT 4 LEADER PILOT CABLE

THERMAL

DETECTORS

IN STATOR
THERMAL

DETECTOR IN

MAIN BEARING

T1
T2

MAX 2,5V

MAX 250v

MAX 6A, cos =0,6

MAX 10A, cos =1

MAX 2,5V

Y (STAR)

JUMPERS

D (DELTA)

JUMPERS

T1
T2
T3
T4

ALT.

T1
T2
T3
T4

2250

2290

MAX 250v

MAX 6A, cos =0,6

MAX 10A, cos =1

SENSORS

WH
WH

T1
T2

MAIN TERMINAL BOARD

THERMAL

DETECTORS

IN STATOR

Y (STAR)

JUMPERS

D (DELTA)

JUMPERS

SENSOR TERMINALS

2201.011

2201.320

TERMINAL BOARD

SEEN FROM OUTSIDE

TERMINAL BOARD

SEEN FROM INSIDE

Y (STAR)

JUMPERS

D (DELTA)

JUMPERS

MAX 250v

MAX 6A, cos =0,6

MAX 10A, cos =1

SENSORS

WH
WH

T1
T2

THERMAL

DETECTORS

IN STATOR

2201.590

2201.690

TERMINAL BOARD

SEEN FROM OUTSIDE

WITHOUT DIODE

TERMINAL BOARD

SEEN FROM OUTSIDE

WITH DIODE

DIODE

CONNECTION

OF DIODE

WH
WH

T1
T2

THERMAL

DETECTORS

IN STATOR

DIODE

WS004538A

Installation

Flygt 2250 Installation, Operation, and Maintenance Manual

Summary of Contents for Flygt 2250

Page 1: ...Flygt 2250 Installation Operation and Maintenance Manual ...

Page 2: ......

Page 3: ... guidelines 8 Storage location 8 Long term storage 8 Product Description 9 Products included 9 Pump design 9 Monitoring equipment 9 The data plate 10 Product denomination 10 Installation 12 Install the pump 12 Sedimentation prevention 12 Discharge line requirements 12 Fasteners 13 Install with S installation 13 Make the electrical connections 14 General precautions 14 Requirements 14 Cables 15 Ear...

Page 4: ... the impeller 28 Adjust the impeller 29 Replace the diffuser 30 Replace the upper diffuser 30 Troubleshooting 32 Introduction 32 The pump does not start 32 The pump does not stop when a level sensor is used 33 The pump starts stops starts in rapid sequence 33 The pump runs but the motor protection trips 34 The pump delivers too little or no water 34 Technical Reference 36 Application limits 36 Mot...

Page 5: ...out safety messages It is extremely important that you read understand and follow the safety messages and regulations carefully before handling the product They are published to help prevent these hazards Personal accidents and health problems Damage to the product Product malfunction Hazard levels Hazard level Indication DANGER A hazardous situation which if not avoided will result in death or se...

Page 6: ...nty 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 cove...

Page 7: ...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 del...

Page 8: ... eyes 1 Hold your eyelids apart forcibly with your fingers 2 Rinse the eyes with eyewash or running water for at least 15 minutes 3 Seek medical attention Chemicals or hazardous fluids on skin 1 Remove contaminated clothing 2 Wash the skin with soap and water for at least 1 minute 3 Seek medical attention if necessary Environmental safety The work area Always keep the station clean to avoid and or...

Page 9: ...ions WARNING Stay clear of suspended loads Observe accident prevention regulations in force Position and fastening The unit can only be transported vertically Make sure that the unit is securely fastened during transportation and cannot roll or fall over 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 ...

Page 10: ... internal cooling system are filled with a mixture of water and 30 glycol This mixture remains a flowing liquid at temperatures down to 13 C 9 F Below 13 C 9 F the viscosity increases such that the glycol mixture will lose its flow properties However the glycol water mixture will not solidify completely and thus cannot harm the product Follow these guidelines to avoid freezing damage 1 Empty all p...

Page 11: ...y corrosive liquids For information about pH see Application limits page 36 Particle size The pump can handle liquid containing particles that correspond to the holes in the strainer Number of holes Hole dimensions 508 15 45 mm 0 6 1 77 in Pressure class MT Medium head HT High head Impeller type B Wear resistant Poly Life The pump is available with Poly Life polyurethane wear parts for extra resis...

Page 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 22 Maximum ambient temperature 23 Read installation manual 24 Notified body Only for EN approved Ex products Figure 1 The data plate Product denomination Sales denomination The sales denominati...

Page 13: ...ination 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 1 NP 3085 183 951 0163 2 3 4 WS006269A 1 Product code 2 Production year 3 Production cycle 4 Running number Product Description Flygt 2250 Installation Operation and Maintenance Manual 11 ...

Page 14: ...l debris from the inlet piping system before you install the pump Always check the impeller rotation before lowering the pump into the pumped liquid 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 d...

Page 15: ...when the installation is made according to the dimensional drawing 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 fall over or sink Alternatively the pump can be suspended with a lifting chain just above the sump b...

Page 16: ...ral 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 ...

Page 17: ... 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 ...

Page 18: ... 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 Fasten the nuts and the gland nut on the entrance flange so that the cable insertion ...

Page 19: ...3 T4 T1 T2 15 13 14 4 2 3 1 7 10 5 9 8 6 11 12 17 16 24 22 23 19 20 21 18 1 Starter equipment and main leads L1 L2 L3 13 Coil 2 Earth ground 14 Transformer 3 Functional ground 15 Capacitor 4 Control leads T1 T2 T3 T4 16 Softstarter 5 Phase shifter 17 Level regulator 6 Diode 18 Contactor start relay or thermal relay 7 Motor cable minimum 20 m 66 ft 19 Thermal detector in stator 8 Screen 20 Thermal ...

Page 20: ...lor code standard Code Description BN Brown BK Black WH White OG Orange GN Green GNYE Green Yellow RD Red GY Grey BU Blue YE Yellow Installation 18 Flygt 2250 Installation Operation and Maintenance Manual ...

Page 21: ...2290 MAX 250v MAX 6A cos 0 6 MAX 10A cos 1 SENSORS WH WH T1 T2 MAIN TERMINAL BOARD THERMAL DETECTORS IN STATOR Y STAR JUMPERS D DELTA JUMPERS W1 V1 U1 W2 V2 U2 T1 T2 T1 T2 SENSOR TERMINALS 2201 011 2201 320 TERMINAL BOARD SEEN FROM OUTSIDE TERMINAL BOARD SEEN FROM INSIDE W1 V1 U1 W2 V2 U2 T1 T2 T1 T2 W1 V1 U1 W2 V2 U2 Y STAR JUMPERS D DELTA JUMPERS MAX 250v MAX 6A cos 0 6 MAX 10A cos 1 SENSORS WH ...

Page 22: ...W2 ALT T1 ALT T2 Terminal board T3 T4 ALT ALT GC GC GY BN BK T1 WH T2 WH T3 WH T4 WH GNYE GC Screen as ground conductor Functional ground to GC S3xA 3xA 3 S 4x0 5 GY BN BK T1 WH T2 WH Functional ground to GC 4GA S 2x0 5 4GA 2x1 5 GY BN BK GNYE WH RD BK GNYE A AWG 3 2 1 GC T1 WH T2 WH OR BU YE MOTOR CABLE CONNECTION TO TERMINAL BOARD DIRECT ON LINE DOL MOTOR CABLE CONNECTION TO TERMINAL BOARD GNYE ...

Page 23: ...of the strainer apertures 3 Place a support under the rod 4 Using the rod as a lever tilt the pump slightly 5 Start the motor 6 Stop the motor 7 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 L2 L3 L3 L1 WS0...

Page 24: ...ct 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 perfo...

Page 25: ...ler 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 3 Check that the monitoring equipment if any works 4 Check that the impeller rotation is correct 5 Start the pump Clean the pump The pump must be cleaned if it has been running in very dirty wat...

Page 26: ...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 Torque values All screws and nuts must be lubricated to achieve correct tightening torque Screws that are screwed i...

Page 27: ...ratures 40 C 104 F Major overhaul To secure a long operating lifetime for the product It includes replacement of key components and the measures taken during an inspection 4 000 hours or 2 years whichever comes first These intervals apply to normal applications and operating conditions at media liquid temperatures 40 C 104 F NOTICE Shorter intervals may be required when the operating conditions ar...

Page 28: ...any 4 If there is oil in the inspection chamber then check that the inner mechanical seal is not damaged If necessary contact an authorized service shop 5 If there is water in the inspection chamber then do the following a Check that the O ring is not damaged b Check that the cable entry does not have any leakage Cable 1 If the outer jacket is damaged replace the cable 2 Check that the cables do n...

Page 29: ...properties are of less concern a mineral oil with viscosity up to ISO VG32 can be used Empty the oil 1 Lay the pump on its side Lock the pump with supports to prevent it from rolling over 2 Remove the oil screw There are two oil screws Either screw can be used for drainage but it is easier to drain the oil if both oil screws are removed WARNING The oil housing may be pressurized Hold a rag over th...

Page 30: ...its side 2 Remove the strainer a Remove the nuts b Remove the strainer 3 Remove the diffuser a Remove the nuts b Remove the washers c Remove the diffuser WS001833A d Remove the O ring 4 Remove the impeller a Remove the impeller screw b Remove the washer c Pull off the impeller Use an impeller puller or pry off carefully with two strong screwdrivers or bars Install the impeller 1 Prepare the shaft ...

Page 31: ... In order for the pump to perform at maximum capacity the impeller must be adjusted regularly The impeller clearance should be minimal when the impeller is tightened Use the adjusting washers to adjust the clearance Pumps equipped with polyurethane covering are extremely resistant to wear If the impeller does not rotate completely freely the friction will generate a lot of heat This can result in ...

Page 32: ...user 1 Remove the diffuser a Remove the impeller see Remove the impeller page 28 b Remove the sleeves c Remove the nuts and washers d Remove the diffuser WS001831A 2 Install the diffuser a Fit the sleeves b Fasten the diffuser in place with the nuts and washers Tightening torque 160 200 Nm 120 150 ft lbs c For further instructions see Install the impeller page 28 Replace the upper diffuser Remove ...

Page 33: ...user by reassembling in the reverse order to disassembly More extensive repairs require special tools and should be carried out by an authorized service technician Maintenance Flygt 2250 Installation Operation and Maintenance Manual 31 ...

Page 34: ...at 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 start automatically but can be started manually Check that The start level regulator is functioning Clean or replace if necessary All connections are intact The relay and contactor coils are intact ...

Page 35: ...defective items 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 9 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...

Page 36: ...ground in the stator is defective 1 Use an insulation tester With a 1000 V DC megger check that the insulation between the phases and between any phase and ground is 5 megohms 2 If the insulation is less Contact the local Xylem service shop The density of the pumped fluid is too high Make sure that the maximum density is 1100 kg m3 9 2 lb US gal Change the impeller or Change to a more suitable pum...

Page 37: ...tly The impeller is difficult 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 Find the leaks and seal them There are signs of wear on the impeller pump and casing Replace the worn parts The liquid level is too low Check that the level sensor is set correc...

Page 38: ...or information Motor data Feature Description Motor type Squirrel cage induction motor Frequency 50 or 60 Hz Supply 3 phase Starting method Direct on line Star delta Maximum starts per hour 30 evenly spaced starts per hour Code compliance IEC 60034 1 Rated output variation 10 Voltage variation without overheating 10 provided that it does not run continuously at full load Voltage imbalance toleranc...

Page 39: ...phase 60 Hz Motor type 1 770 rpm Input power 70 kW 94 hp Voltage V Rated current A Starting current A 200 D 245 1 100 220 D 220 1 200 380 Y 127 695 440 Y 110 585 440 D 110 585 460 D 105 560 575 D 84 460 Dimensions and weights Table 3 Dimensions A 1 144 mm 45 in B 771 mm 30 35 in Technical Reference Flygt 2250 Installation Operation and Maintenance Manual 37 ...

Page 40: ...with ISO 9906 HI level A 2250 011 P1 kW 15 0 0 40 80 120 160 200 240 280 5 10 15 20 25 30 35 40 45 50 55 25 35 45 H m Q l s WS006301A Figure 5 50 Hz 1 470 rpm P1 kW hp H m ft Q usgpm l s 40 0 0 0 50 100 150 200 250 1000 2000 3000 4000 5000 40 80 160 120 200 60 80 30 20 0 10 20 30 40 50 60 40 50 60 WS006302A Figure 6 60 Hz 1 770 rpm Technical Reference 38 Flygt 2250 Installation Operation and Maint...

Page 41: ......

Page 42: ...ldings 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 expertise backed by a legacy of innovation For more information on how Xylem can help you go to xyleminc com Xylem Water Solutions AB Gesällvägen 33 174 87 Sundbyberg Sweden Tel 46 8 475 60 00 Fax 46 8 47...

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