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Xylem FLYGT 2640.181, Service And Repair Instructions, Page: 48 / 72

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Xylem FLYGT 2640.181 Service And Repair Instructions Download Page 48

5. Use a screwdriver to check that the retaining ring is properly seated in its groove.

WS008545A

6. Fit new greased O-rings to the seal housing cover.
7. Install new pressure equalizer(s).

WS002976A

8. Mount the seal housing cover.

Fasten the two bolts to the correct torque.

9. Fit the protection plugs.
10.Mount the diffuser.

Fasten the four bolts to the correct torque.

4  Maintenance

46

2640.181/.281 Service and Repair Instructions

Summary of Contents for FLYGT 2640.181

Page 1: ...Service and Repair Instructions 885618_3 0 2640 181 281...

Page 2: ......

Page 3: ...repare the SUBCAB cables 12 3 2 5 Connect the motor cable to the pump 13 3 2 6 Cable charts 14 3 3 Check the impeller rotation 17 4 Maintenance 18 4 1 Precautions 18 4 2 The fault tracing process 19 4...

Page 4: ...e version 52 4 6 12 Install the discharge connection or cover 54 4 7 Service 55 4 7 1 Inspection 55 4 7 2 Overhaul 56 5 Troubleshooting 57 5 1 Electrical troubleshooting 57 5 2 The pump does not start...

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: ...ct is rated explosion proof or 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 corrosi...

Page 10: ...19 16 15 9 10 11 22 21 20 2 3 1 1 Curve code or Propeller code 2 Serial number 3 Product number 4 Country of origin 5 Additional information 6 Phase type of current frequency 7 Rated voltage 8 Therma...

Page 11: ...YYY 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 c...

Page 12: ...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 13: ...on not have any sharp bends and not be pinched The cables must not be damaged and must not have indentations or be embossed with markings etc at the cable entry The cable entry seal sleeve and washers...

Page 14: ...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 15: ...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 16: ...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 17: ...E 3 V T1 T2 Terminal plate STATOR LEADS AND THERMAL CONTACTS 1 PHASE 2640 9 leads T1 T2 V1 V5 W5 W2 U2 V2 U U1 U5 W W1 WH YE WH YE BN BN YE BK GN BU RD RD YE 1 P H A S E 1 EU Max 500V Max 1 3A cos 0...

Page 18: ...TER 1 PHASE WITHOUT INTERNAL CONTACTOR GC GNYE Motor cable 4 4 7 conductors YE EXTERNAL STARTER INTERNAL CONTACTOR 1 PHASE A1 A2 OR BU V C T1 T2 Terminal plate U M W A 1 2 3 4 5 6 BU GY WH BK BK BN RD...

Page 19: ...from above When started the pump will react in the opposite direction to the impeller rotation L2 L1 L2 L3 L3 L1 WS001397A Figure 3 Start reaction 4 If the impeller rotates in the wrong direction the...

Page 20: ...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 21: ...ult tracing process 4 2 1 Trace faults in the drive Check the stator See Check the stator on page 19 Check inspection chamber stator housing Abnormal leakage Yes Basic Repair Kit BRK Mechanical seals...

Page 22: ...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 23: ...5 1 2210 1630 Hexagon screws 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 4...

Page 24: ...ches the inlet hole Pump Oil Quantity L qt 2640 181 0 88 0 93 2640 281 0 59 0 62 4 Put the oil screw back and tighten it 4 5 Disassemble the pump Before the pump is disassembled the pump has to be dra...

Page 25: ...r Suction cover Impeller Seals Seal housing Diffuser Rotor unit with bearing housing Remove bearings from bearing housing 4 5 2 Remove the discharge connection or cover 1 Place the pump in its upright...

Page 26: ...the impeller screw and the washer WS001332A 5 Remove the impeller a Lock the impeller to prevent rotation Use pliers a screwdriver or similar b Turn the adjustment screw counterclockwise until the imp...

Page 27: ...rts can have sharp edges Wear protective clothing 1 Remove the stand and the lower pump housing WS001393A 2 Loosen the impeller a Lock the impeller to prevent rotation Use pliers a screwdriver or simi...

Page 28: ...eller breaks free from the shaft Use an 8 mm hexagon bit adapter Allen socket with a 100 mm 4 in extension WS001394A c Pull off the impeller 4 5 5 Remove the mechanical seal Drainage versions 1 2 3 4...

Page 29: ...not use any method where the shaft is used as counterstay as this may displace the shaft in relation to the main bearing 5 Remove the pressure equalizers 6 Remove the O ring on the seal housing cover...

Page 30: ...ear protection The upper wear protection sits inside the upper pump housing It is not held by fasteners 3 Remove the gasket between the upper pump housing and seal housing cover 4 Remove the guide pla...

Page 31: ...g WS002949B Figure 8 Removing the retaining ring Generic seal shown 9 Remove the mechanical seal WS002950B Figure 9 Removing the mechanical seal Generic seal shown 4 Maintenance 2640 181 281 Service a...

Page 32: ...g 8 Retaining ring 9 Outer casing Generic outer casing shown 10 Seal ring 11 Adapter Select one of the following instructions Use the Flygt pullers on page 30 Use a Dent puller on page 33 4 5 7 1 Use...

Page 33: ...en the screws until the heads are below the surface of the adapter Use M8 60 screws with hexagon socket heads WS009673A d Attach the pullers to the top of the adapter with the cylinders facing upwards...

Page 34: ...s loose when the outer casing is loosened from the adapter or the pump top 3 Remove the outer casing Use a rubber mallet and tap gently on the outer casing close to where it is attached The outer casi...

Page 35: ...d Lock the nut with a wrench and tighten the screw for each puller Alternate between the screws until the shaft assembly breaks free WS009700A 5 Remove the pullers 6 Attach an eyebolt into the shaft 7...

Page 36: ...ng is evenly supported during the removal of the main bearing NOTICE Only use a puller with three claws Otherwise the bearing housing can be damaged WS002957A Figure 10 Removing the bearing housing Ge...

Page 37: ...that the power from the mains is physically disconnected and locked out 3 Check that the discharge connection drainage pumps or cover sludge pumps has been removed WS008550A 4 Remove the cable entranc...

Page 38: ...or Figure 12 Configurations Left With starter unit Right Without starter unit 1 Check that the power from the mains is physically disconnected and locked out 2 Disconnect the power leads a Configurati...

Page 39: ...azard Allow surfaces to cool before starting work or wear heat protective clothing WS002667A 4 When the stator is released and has dropped down allow the stator housing and the stator to cool If the n...

Page 40: ...or leads downwards in the stator 2 Heat the stator housing to maximum 150 C 302 F 3 Quickly lower the stator housing onto the stator until it bottoms Make sure the stator leads connection point is cen...

Page 41: ...Mount the terminal plate unit 2 1 WS008551A 1 Terminal plate unit 2 Starter unit 4 Configuration with starter unit Mount the starter unit 5 Connect the ground earth cable 6 Configuration with starter...

Page 42: ...e 6 If the pump handle was removed then fit the pump handle 4 6 5 Install the bearings 1 Assemble the main bearing in the bearing housing a Place the bearing housing on the work bench WS002962A b Fit...

Page 43: ...a press or a soft hammer to press down the bearing housing For further details see the assembly tool description WS002965A WS002966A 4 Fit new greased O ring s WS002967A 5 Assemble the support bearin...

Page 44: ...10 11 3 4 5 6 7 8 2 1 1 Shaft assembly shaft unit bearings and bearing housing 2 Support bearing 3 Shaft unit 4 Bearing housing 5 O ring 6 O ring 7 Main bearing 8 Retaining ring 9 Cooling jacket Gene...

Page 45: ...the bearing housing clockwise to the index mark WS002968A 5 If the pump is equipped with an FLS 10 sensor then check that the switch is between the coil end and the stator housing 6 Fit a new greased...

Page 46: ...t torque d Insert four long bolts in the outermost holes Use the bolts that normally hold the diffuser in place e Tighten the outer fasteners to the correct torque Use a piece of wood to help WS008548...

Page 47: ...ve groove in the shaft WS008542A c Lower the seal onto the shaft d Press the seal gently into place Do not force the seal down into its final position 3 Fit the retaining ring WS008543A 4 Press down t...

Page 48: ...ed O rings to the seal housing cover 7 Install new pressure equalizer s WS002976A 8 Mount the seal housing cover Fasten the two bolts to the correct torque 9 Fit the protection plugs 10 Mount the diff...

Page 49: ...ket 9 Upper pump housing 10 Upper wear protection 1 Grease the shaft 2 Fit the mechanical seal a Oil the new mechanical seal b Check that the drive pin engages in the drive groove in the shaft WS00854...

Page 50: ...erly seated in its groove WS008545A 6 Install new pressure equalizer s 7 Fit new greased O rings to the seal housing cover 8 Mount the seal housing cover 9 Mount the guide plate 10 Fit a new greased g...

Page 51: ...nutes V the volume of the oil chamber usually 1 2 oil volume liter WARNING Compressed Gas Hazard Compressed air gas may cause parts to be propelled with force Never apply compressed air gas to any cav...

Page 52: ...is clean and easy to screw into the shaft end This is to prevent the shaft from rotating with the impeller screw 5 Assemble the conical sleeve in the impeller Make sure that the conical sleeve bottom...

Page 53: ...e next step Use an 8 mm hexagon bit adapter Allen socket with a 100 mm 4 in extension WS001336A 9 Fasten the impeller a Place the washer on the impeller screw b Lock the impeller to prevent rotation U...

Page 54: ...with a fine 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 Th...

Page 55: ...s etc for example Kluber ALTEMP Q NB 50 or equivalent 4 Check that the impeller screw is clean and easy to screw into the shaft end This is to prevent the shaft from rotating with the impeller screw 5...

Page 56: ...mpeller can rotate freely 8 Mount the pump housing and the stand WS001391B 4 6 12 Install the discharge connection or cover 1 Place the pump in its upright position 2 Mount the discharge connection dr...

Page 57: ...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 N...

Page 58: ...If there is water in the inspection volume then check that the inspection screw O ring is not damaged Cable 1 If the outer jacket is damaged then replace the cable 2 Check that the cables do not have...

Page 59: ...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 60: ...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 61: ...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 62: ...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 63: ...sales 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...

Page 64: ...4 3 30 0 89 3 phase 60 Hz Motor type 3 500 rpm 6 6 kW 8 8 hp Voltage V Rated current A Starting current A Power factor cos 200 D 24 185 0 91 208 D 24 194 0 88 220 D 22 159 0 93 220 Y parallel 22 158...

Page 65: ...4 0 91 575 Y 8 4 58 0 92 600 D 8 5 67 0 88 600 Y 8 4 61 0 88 6 4 Dimensions and weights All measurements in the illustrations are in millimeters if not otherwise specified Figure 16 BS KS MT DN 100 Fi...

Page 66: ...T DN 100 tandem Figure 21 BS HT DN 75 tandem 6 5 Tools List of tools To avoid possible damages to the unit make sure that you have the following special tools available before servicing the unit 6 Tec...

Page 67: ...te 84 20 48 Remove the support bearing 4 Mounting kit 84 15 45 Install the bearing housing Install the support bearing 5 Puller 807 90 00 Remove the shaft unit Bearing puller See table below Used toge...

Page 68: ...housing on the shaft unit using the mounting kit WS004615A D A WS004618A Disassembly and assembly tools for the main bearing Removing the main bearing from the bearing housing Installing the main bea...

Page 69: ...d 60 Hz Stator number Resistance Ohm per phase 6945301 3 86 6945302 4 72 6945303 2 61 6945304 0 664 per half phase 6945305 1 33 6945306 0 965 6945307 0 762 6945308 6 22 6945309 7 61 6945310 8 59 69453...

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Page 72: ...nologies 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 combina...

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