Xylem Flygt 2860.180 Installation, Operation And Maintenance Manual Download Page 1

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Installation, Operation,

and Maintenance Manual

Flygt 2860.180

Summary of Contents for Flygt 2860.180

Page 1: ...Installation Operation and Maintenance Manual Flygt 2860 180...

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Page 3: ...mination 10 Installation 12 Install the pump 12 Install with S installation 13 Make the electrical connections 14 Connect the motor cable to the pump 15 Cable charts 16 Check the impeller rotation 19...

Page 4: ...2 The pump delivers too little or no water 43 The pump does not start when a softstarter is used 43 Technical Reference 46 Application limits 46 Specific motor data 46 Dimensions and weights 47 Perfor...

Page 5: ...d 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 Pro...

Page 6: ...e and repair work is done by Xylem authorized personnel Genuine Xylem parts are used Only Ex approved spare parts and accessories authorized by an EX approved Xylem representative are used in Ex appro...

Page 7: ...tion to the risks presented by gas and vapors in the work area Avoid all electrical dangers Pay attention to the risks of electric shock or arc flash hazards Always bear in mind the risk of drowning e...

Page 8: ...en using the unit in rugged applications the following conditions must be met If electrical cables must be located such that they are at risk of being run over by heavy equipment then provide mechanic...

Page 9: ...local sales representative if there is any issue Transportation guidelines Precautions DANGER Disconnect and lock out electrical power before installing or servicing the unit WARNING Stay clear of su...

Page 10: ...f the unit is lifted out of the liquid into a surrounding temperature below freezing Units equipped with an internal cooling system are filled with a mixture of water and 30 glycol This mixture remain...

Page 11: ...n highly corrosive liquids For information about pH see Application limits page 46 The warm media liquid version has certain operational limitations which are stated on a plate on the pump For applica...

Page 12: ...on 6 Phase type of current frequency 7 Rated voltage 8 Thermal protection 9 Thermal class 10 Rated shaft power 11 International standard 12 Degree of protection 13 Rated current 14 Rated speed 15 Maxi...

Page 13: ...ber 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 n...

Page 14: ...tallation Provide a suitable barrier around the work area for example a guard rail Check the explosion risk before you weld or use electric hand tools Remove all debris from the inlet piping system be...

Page 15: ...rged in the pumped liquid The pump is equipped with a connection for hose or pipe These requirements and instructions only apply when the installation is made according to the dimensional drawing 1 Ru...

Page 16: ...ation 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 inca...

Page 17: ...e 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 co...

Page 18: ...iode 18 Contactor start relay or thermal relay 7 Motor cable 19 Thermal detector in stator 8 Screen 20 Thermal detector in main bearing 9 Pump 21 Jumper 10 Crimp connection 22 Terminal board terminal...

Page 19: ...Y 12 leads D 12leads D serial V1 T1 T2 V5 U2 V2 W2 U6 V6 W6 T1 T2 V1 V5 U2 U6 U2 V2 W2 U5 V5 W5 V1 U6 T1 T2 STATOR LEADS AND THERMAL CONTACTS W2 U1 U1 U1 U1 U5 U U1 U5 U1 U5 W2 W6 U1 W6 V2 W1 W1 W1 W1...

Page 20: ...1 T2 Terminal plate U W 1 2 3 4 5 6 Thermal O L relay Setting I Pump Pump Contactor BK GY BN WH BU Float switch Optional EU Max 400V US CDN Max 250V BU WH BN BK GNYE GN GC 5 BU T2 In serial with BU le...

Page 21: ...p will react in the opposite direction to the impeller rotation Pumps with softstarter will not start if the phase sequence is incorrect L2 L1 L2 L3 L3 L1 WS001397A Figure 3 Start reaction 4 If the im...

Page 22: ...isk 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 t...

Page 23: ...there is no physical damage to the pump or cables 2 Check the oil level in the oil housing 3 Remove the fuses or open the circuit breaker and check that the impeller can be rotated freely 4 Check tha...

Page 24: ...hat the product and its components have been thoroughly cleaned Do not open any vent or drain valves or remove any plugs while the system is pressurized Make sure that the pump is isolated from the sy...

Page 25: ...114 84 277 204 541 399 935 689 1840 1357 12 9 4 9 3 6 9 7 7 2 17 13 40 30 79 58 136 100 333 245 649 480 1120 825 1 2210 1630 Hexagon screws with countersunk heads For hexagon socket head screws with c...

Page 26: ...be firmly tightened into its bottom most position The seal sleeve and the washers must conform to the outside diameter of the cables 2 Cut off a piece of the cable so that the seal sleeve closes aroun...

Page 27: ...is delivered from the factory with this type of oil In applications where poisonous properties are of less concern a mineral oil with viscosity up to ISO VG32 can be used 1 2 WS006203A 1 Inspection s...

Page 28: ...with new oil Fill until the oil level reaches the inlet hole Quantity 1 45 L 1 53 qt 4 Put the oil screw back and tighten it Replace the impeller Remove the impeller MT HT WARNING A worn impeller and...

Page 29: ...06951A 3 Remove the O ring 4 Loosen the impeller a Lock the impeller to prevent rotation Use pliers a screwdriver or similar b Remove the impeller screw and washer Maintenance Flygt 2860 180 Installat...

Page 30: ...he impeller breaks free from the shaft Use a 10 mm hexagon bit adapter Allen socket with a 100 mm 4 in extension WS006953A c Pull off the impeller Remove the impeller SH WARNING A worn impeller and or...

Page 31: ...ler screw and washer WS001347A 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 impeller breaks...

Page 32: ...the impeller a Lock the impeller to prevent rotation Use pliers a screwdriver or similar b Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft Use a 10 mm hexagon...

Page 33: ...r lubrication is grease for bearings for example Exxon Mobil Unirex N3 Mobil Mobilith SHC 220 or equivalent NOTICE Surplus grease can cause the impeller to become loose Remove surplus grease from coni...

Page 34: ...impeller WS006954A 6 Assemble the impeller with the conical sleeve onto the shaft Make sure that the conical sleeve bottoms in the impeller 7 Mount the suction cover with its O ring and tighten Tighte...

Page 35: ...r screw Tightening torque 44 Nm 32 5 ft lbs d Tighten a further 1 8 turn 45 The screw will be loaded to its yield point and the load capacity of the joint will be higher e Check that the impeller can...

Page 36: ...The proper lubrication is grease for bearings for example Exxon Mobil Unirex N3 Mobil Mobilith SHC 220 or equivalent NOTICE Surplus grease can cause the impeller to become loose Remove surplus grease...

Page 37: ...is clean and easy to screw into the shaft end a This is to prevent the shaft from rotating with the impeller screw a WS001344A 5 Assemble the upper conical sleeve and the upper impeller onto the shaf...

Page 38: ...n cover in the next step Use a 10 mm hexagon bit adapter Allen socket with a 100 mm 4 in extension WS001353A 9 Remove the suction cover 4x WS001350A 10 Remove the O ring 11 Align the edge of the lower...

Page 39: ...01343A 14 Turn the lower adjustment screw clockwise until the lower impeller makes contact with the suction cover Tighten a further 1 6 turn 60 This will ensure the correct clearance between the lower...

Page 40: ...its yield point and the load capacity of the joint will be higher e Check that both the upper and lower impeller can rotate easily WS001339A 16 Check that the impeller can rotate easily If not the ad...

Page 41: ...4x WS001341A Maintenance Flygt 2860 180 Installation Operation and Maintenance Manual 39...

Page 42: ...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 43: ...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 information Con...

Page 44: ...impeller 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 notify a certified electrician The...

Page 45: ...alled according to media flow Check that all valves open correctly The impeller is difficult to rotate by hand Clean the impeller Clean out the sump Check that the impeller is properly trimmed The pip...

Page 46: ...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 Doing so may...

Page 47: ...evel Refer to Motor data page 46 LED E is ON Check the power cable connections to L3 If either L1 or L2 is missing then LED A and LED E will be OFF LED F is ON Transpose two phase leads for L1 L2 L3 o...

Page 48: ...cations contact the local sales and service representative for information Motor data Feature Description Motor type Squirrel cage induction motor Frequency 50 or 60 Hz Supply 3 phase Starting method...

Page 49: ...220 Y 37 213 0 92 230 D 35 233 0 91 230 Y 35 224 0 91 240 D 35 245 0 88 240 Y 35 235 0 88 380 D 21 128 0 93 380 Y 21 128 0 93 400 D 20 136 0 9 400 Y 21 135 0 9 440 D 19 129 0 89 440 DSER 18 111 0 92 4...

Page 50: ...Figure 7 BS KS MT DN 150 Figure 8 BS KS MT HT DN 100 Figure 9 BS HT DN 75 Figure 10 BS SH DN 100 Technical Reference 48 Flygt 2860 180 Installation Operation and Maintenance Manual...

Page 51: ...igure 11 BS SH DN 75 Performance curves Test standard Pumps are tested in accordance with ISO 9906 2012 HI 11 6 2012 Technical Reference Flygt 2860 180 Installation Operation and Maintenance Manual 49...

Page 52: ...KS WS006971A Figure 12 BS KS MT Q l s H m 2 P kW 0 5 10 15 20 25 30 0 10 20 30 40 50 6 8 10 HT 251 BS 251 BS 255 255 BS 255 BS WS006972A Figure 13 BS HT Q l s H m 2 P kW 0 2 4 6 8 10 12 14 16 18 0 10...

Page 53: ...5 BS KS MT Q l s usgpm H ft m 2 P hp kW 0 5 10 15 20 25 30 0 100 200 300 400 500 0 10 20 30 40 50 60 0 40 80 120 160 200 6 8 10 12 8 12 16 HT 253 BS 253 BS 257 257 BS 257 BS WS006975A Figure 16 BS HT...

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Page 56: ...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...

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