Xylem Flygt 5520 Installation, Operation And Maintenance Manual Download Page 32

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+ FLS+CLS

CLS

FLS

Max 12 V

RD/BN

WH/YE

T1 Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

FLS

Temp > 40° T1,T2 thermal

FLS

contacts not connected

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

T2/*BU/5

*SUBCAB AWG

WS004131A

Sensor connection characteristics

The values have a 10 % tolerance.

Sensors

Value (mA)

Definition

FLS and thermal contact

Overtemperature

7.8

Leakage

CLS and thermal contact

Overtemperature

5.5

Leakage (5 seconds delay)

CLS, FLS and thermal contact

Overtempterature

13.3

36–42

Leakage (0/5 seconds delay)

Check the impeller rotation

WARNING:

The starting jerk can be powerful.

1. Start the motor.
2. Stop the motor after a few seconds.
3. Check that the impeller rotates according to this illustration.

Installation

Flygt 5520 Installation, Operation, and Maintenance Manual

Summary of Contents for Flygt 5520

Page 1: ...Flygt 5520 Installation Operation and Maintenance Manual ...

Page 2: ......

Page 3: ...location 9 Long term storage 9 Product Description 10 Pump design 10 Parts 11 Monitoring equipment 12 Optional sensors 12 The data plate 13 Product denomination 14 Installation 15 Install the pump 15 Authority regulation 15 Fasteners 15 Install with P installation 16 Install with S installation 17 Install with T Z installation 17 Make the electrical connections 19 General precautions 19 Requiremen...

Page 4: ...lace the impeller 38 Replace the wear parts 41 Troubleshooting 45 Introduction 45 The pump does not start 45 The pump does not stop when a level sensor is used 46 The pump starts stops starts in rapid sequence 46 The pump runs but the motor protection trips 47 The pump delivers too little or no water 47 Technical Reference 49 Motor data 49 Application limits 49 Table of Contents 2 Flygt 5520 Insta...

Page 5: ...to the equipment or use of parts not provided by Xylem If there is a question regarding the intended use of the equipment please contact an Xylem representative before proceeding This manual clearly identifies accepted methods for disassembling units These methods must be adhered to Trapped liquid can rapidly expand and result in a violent explosion and injury Never apply heat to impellers propell...

Page 6: ...ds are indicated by the following specific symbol Electrical Hazard These are examples of other categories that can occur They fall under the ordinary hazard levels and may use complementing symbols Crush hazard Cutting hazard Arc flash hazard Environmental safety The work area Always keep the station clean to avoid and or discover emissions Waste and emissions regulations Observe these safety reg...

Page 7: ...burn injuries Safety equipment Use safety equipment according to the company regulations Use this safety equipment within the work area Hard hat Safety goggles preferably with side shields Protective shoes Protective gloves Gas mask Hearing protection First aid kit Safety devices NOTICE Never operate a unit unless safety devices are installed Also see specific information about safety devices in o...

Page 8: ...ring 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 cover defects caused by these situations Deficient maintenance Improper installation Modificatio...

Page 9: ... straps 4 Contact your sales representative if anything is out of order Transportation guidelines Precautions WARNING Stay clear of suspended loads Observe accident prevention regulations in force 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 WARNING Crush ...

Page 10: ...before starting up Avoid rotating the impeller propeller by hand at temperatures below the freezing point The recommended method to warm the unit up is to submerge it in the liquid which will be pumped or mixed NOTICE Never use a naked flame to thaw the unit Unit in as delivered condition If the unit is still in the condition in which it left the factory all packing materials are undisturbed then ...

Page 11: ...E Protect the product against humidity heat sources and mechanical damage Do not place heavy weights on the packed product Long term storage If the unit is stored more than 6 months the following apply Before operating 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 fro...

Page 12: ... In explosive or flammable environments only use Ex or MSHA approved pumps 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 parts and accessories that are authorized by Xylem are essential for compliance The use of other parts can invalidate any claims for warranty or c...

Page 13: ...he impeller is a shrouded three channel H impeller 4 Flushing plug External flushing of the outer mechanical seal can be connected to one of the holes The other holes must then be plugged during flushing Flushing flow 1 5 4 l min 1 6 4 2 quarts min Pressure of 5m shut off head For more information contact your local Xylem representative 5 Wear parts Wear lining Wear ring Product Description Flygt ...

Page 14: ...mbient liquid 12 Support bearing The bearing consists of a single row ball bearing 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 co...

Page 15: ...ved products also have an approval plate 2 13 12 14 22 21 20 17 18 19 16 15 9 10 11 8 7 6 5 4 3 1 23 24 WS006257A 1 Curve code Propeller code 2 Serial number see Product denomination page 14 3 Product number 4 Country of origin 5 Additional information 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 ...

Page 16: ...de consists of nine characters divided into two parts This is an example of a product code and an explanation of its parts 3085 183 1 2 NP WS006262A 1 Sales denomination 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 WS0062...

Page 17: ...h a pump Always remove all debris and waste material from the sump inlet piping and discharge connection before you install the pump These requirements apply Use the pump dimensional drawing in order to ensure proper installation 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 Always check the impeller rot...

Page 18: ...he discharge connection has a flange which fits the pump casing 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...

Page 19: ...base stand These requirements and instructions only apply when 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 ...

Page 20: ...rticularly high in T or Z installations 1 Fasten the pump a Bolt the stationary suction connection to the concrete base b Bolt the pump to the suction connection 2 Make sure that the pump is vertical for the T installation or horizontal for the Z installation 3 Connect the suction line and discharge line 4 Connect the motor cable and the starter and monitoring equipment according to the separate i...

Page 21: ... 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 voltages then the connected voltage is specified by a yellow sticker close to the cable entry The fuses and circuit breakers must have the proper rating and the pump overload protection motor protection breaker must be connect...

Page 22: ...azard 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 the phase con...

Page 23: ... ground lead must be 50 mm 2 0 in longer than the phase leads in the junction box of the unit 5 Make sure that the pump is correctly connected to earth ground 6 Make sure that any thermal contacts incorporated in the pump are properly connected to the terminal block closed end splices 7 Install the entrance cover and the O ring on the stator housing 8 Fasten the screws on the entrance flange so th...

Page 24: ...re 2 Connect the mains leads L1 L2 L3 and earth ground to the starter equipment For information about the phase sequence and the color codes of the leads see Cable charts page 22 3 Check the functionality of the monitoring equipment a Check that the signals and the tripping function work properly b Check that the relays lamps fuses and connections are intact Replace any defective equipment Cable c...

Page 25: ...T1 T2 4 3 2 1 5 10 8 CLS 6 FLS 7 FLS 10 11 9 WS004134A 1 Starter equipment and mains leads L1 L2 L3 2 Earth ground 3 Functional ground 4 Control leads T1 T2 T3 T4 5 Thermal contact 6 FLS 7 FLS 10 8 CLS 9 Thermistor 10 Level sensor 11 Capacitor Color 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 Flygt 552...

Page 26: ...OLOUR STANDARD STATOR LEADS BN Brown U1 U5 RD BK Black U2 U6 GN WH White V1 V5 BN OG Orange V2 V6 BU GN Green W1 W5 YE GN YE Green Yellow W2 W6 BK RD Red T1 T2 WH YE GY Grey BU Blue YE Yellow SUBCAB AWG Ground Conductor is stranded around cores GC Ground Check WS004125A For markings on sensor leads see Sensors connection page 29 Connections included 3 phase connection page 25 1 phase connection pa...

Page 27: ... L1 L2 L3 L1 1 L2 1 L3 1 L1 2 L2 2 L3 2 U1 V1 W1 U2 V2 W2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 GC 1 2 3 4 5 6 GN YE YE WH WS004126A 6 Leads Y U1 V1 W1 U2 W2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 GC W2 U2 V2 L1 L2 L3 YE GN YE WH L1 U1 U2 W 2 V 2 W 1 V 1 L3 L2 Installation Flygt 5520 Installation Operation and Maintenance Manual 25 ...

Page 28: ...3 YE GN YE WH WS004127A 12 Leads Y L1 U1 U5 U2 W 2 U6 W 1 V 6 W 6 V 2 V 5 W 5 L 3 V 1 L 2 U1 V1 W1 U2 V6 U5 V5 W5 V2 W2 U6 W6 U1 V1 W1 W2 U2 V2 W2 U2 V2 GC U1 V1 W1 L1 L2 L3 YE WH GN YE Y SER L1 U1 U2 U5 W 6 U6 W 2 W 5 V 6 W 1 V 5 V 2 V 1 L3 L2 U1 V1 W1 W2 U2 V2 V6 W5 U5 V5 U6 W6 U1 V1 W1 W2 U2 V2 W1 W2 GC U1 V1 U2 V2 L1 L2 L3 YE GN YE WH WS004128A Installation 26 Flygt 5520 Installation Operation...

Page 29: ... W2 U5 V5 W5 U6 V6 W6 WS004129A 1 PHASE 4 Leads 1 Z2 U2 U1 Z1 T1 T2 BK BN RD YE GC 1 BN RD 2 BK BK 3 GY WH 4 T1 OG 5 T2 BU 6 WH GN YE YE Starter 4 Leads with level regulator 1 1 1 2 3 Z2 U2 Z1 U1 Z2 U2 U1 Z1 T1 T2 BK BN RD YE GC BN BU 1 BN RD 2 BK BK 3 GY WH 4 T1 OG 5 T2 BU 6 WH GN YE YE Starter Installation Flygt 5520 Installation Operation and Maintenance Manual 27 ...

Page 30: ... CAS AUX FGB Screened T1 WH T2 WH T3 WH T4 WH T1 WH T2 WH T3 WH T4 WH T1 WH T2 WH Screen SUBCAB and Screenflex T1 and T2 twisted White insulation hose Screen together GN YE L1 L2 L3 T1 T2 T1 and T2 twisted together White insulation hose Screen BK BK BK BK BK BK GN YE 1 2 3 4 5 6 T1 T2 L1 L2 L3 L1 L2 L3 WS004132A Installation 28 Flygt 5520 Installation Operation and Maintenance Manual ...

Page 31: ... 6A cos 0 6 Max 2 5A cos 1 6 WH YE T1 Control leads WH YE T2 T1 OG 4 SUBCAB AWG T2 OG 5 FLS FLS TC Max 12 V BU BU WH YE 6 BU WH YE T1 Control leads BU T2 T1 OG 4 7 Mini 5 CAS SUBCAB AWG T2 BU 5 CLS CLS TC Max 12 V BK BN WH YE 6 BN RD WH YE T1 Control leads T1 OG 4 T2 7 BK Mini SUBCAB AWG T2 BU 5 5 CAS WS004130A Installation Flygt 5520 Installation Operation and Maintenance Manual 29 ...

Page 32: ...a 10 tolerance Sensors Value mA Definition FLS and thermal contact 0 Overtemperature 7 8 OK 36 Leakage CLS and thermal contact 0 Overtemperature 5 5 OK 29 Leakage 5 seconds delay CLS FLS and thermal contact 0 Overtempterature 13 3 OK 36 42 Leakage 0 5 seconds delay Check the impeller rotation WARNING The starting jerk can be powerful 1 Start the motor 2 Stop the motor after a few seconds 3 Check t...

Page 33: ...r rotation is clockwise when you look at the pump from above 4 If the impeller rotates in the wrong direction transpose two phase leads 3 phase and do this procedure again Installation Flygt 5520 Installation Operation and Maintenance Manual 31 ...

Page 34: ...nd the noise level requirements in the environment where the pump is installed Failure to do so may result in hearing loss or violation of local laws Start the pump WARNING If you need to work on the pump make sure that it is isolated from the power supply and cannot be energized Make sure that the unit cannot roll or fall over and injure people or damage property In some installations the pump an...

Page 35: ...duct insulation test phase to ground To pass the value must exceed 5 megohms 4 Check that the monitoring equipment works 5 Start the pump Operation Flygt 5520 Installation Operation and Maintenance Manual 33 ...

Page 36: ...aintenance guidelines During maintenance and 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 The reassembled drive unit must always be insulation tested and the re...

Page 37: ...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 horizontal position 2 Turn the pump so that the oil hole faces downwards 3 Unscrew the oil plug If t...

Page 38: ...defined and decided for each individual application It can include such things as impeller trimming wear part control and replacement control of zinc anodes and control of the stator Up to twice a year Applies to normal applications and operating conditions at media liquid temperatures 40 C Major overhaul To secure a long operating lifetime for the product It includes replacement of key components...

Page 39: ...t local safety regulations are followed Lifting handle 1 Check the screws 2 Check the condition of the lifting handle 3 Replace if necessary O rings 1 Replace the oil plug O rings 2 Replace the O rings at the entrance or junction cover 3 Grease the new O rings Overload protection and other protections Check the correct settings Personnel safety devices Check the guard rails covers and other protec...

Page 40: ...y Replace the hydraulic parts Replace the impeller Required tools Impeller puller If applicable contact your Xylem representative for correct type and size Rod wooden or plastic for locking the impeller in place Two crowbars if applicable WARNING If you fail with the impeller installation you must redo the installation procedure from the beginning A worn impeller and or pump housing can have very ...

Page 41: ...e pump housing a Remove the pump housing screws b Remove the drive unit from the pump housing 2 Place the drive unit horizontally 3 Remove the impeller a Remove the wear protection plug b Remove the impeller screw If applicable us a rod to lock the impeller in place c Remove the washer d Remove the impeller Use the impeller puller or crowbars Place a protector between the shaft end and the impelle...

Page 42: ...st be replaced 3 Mount the impeller a Fit the sleeve onto the shaft b Fit the expeller and the wearing cover onto the shaft Use a rubber mallet in order to knock the wearing cover in to place c Press the impeller onto to the shaft 4 Fasten the impeller a Fit the washer on the impeller screw b Fit the impeller screw c Tighten the impeller screw Tightening torque 60 Nm 42 ft lbs d Check that the imp...

Page 43: ...using lower 17 O ring 18 Wear ring 19 Trimming flange 20 Stud 21 Suction cover 22 Screw Remove the wear parts The pump housing and the impeller have to be removed before the wear parts can be removed For more information see Remove the impeller page 39 1 Remove the wearing cover and the expeller Use a crowbar if applicable WS002412A 2 Remove the gasket from the pump housing outlet 3 Remove the lin...

Page 44: ...ver screws b Remove the suction cover Use two crowbars if needed WS002422A 7 Remove the trimming flange unit trimming flange and wear ring and its two O rings 8 Remove the O ring on the inside of the pump housing Install the wear parts 1 Make sure all parts are clean and free of burrs Polish off any flaws with a fine emery cloth 2 Fit the expeller wearing cover and the impeller For more informatio...

Page 45: ...ump housing a Fit the new greased O ring on the top of the pump housing b Place the drive unit in the pump housing c Grease the pump housing screws d Tighten the screws in a diagonal sequence For tightening torque see Torque values page 34 6 Install the trimming flange unit a Place the pump in a horizontal position b Fit a washer to each stud c Fit the trimming flange unit and its two new greased ...

Page 46: ...a Fit the suction cover b Fit a washer on each suction cover screw and tighten Tightening torque 60 Nm 44 ft lbs Maintenance 44 Flygt 5520 Installation Operation and Maintenance Manual ...

Page 47: ...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 48: ...of the level regulators Check the contactor and the control circuit Replace all defective items The stop level is set too low Raise the stop level If the problem persists refer to the Flygt Service Guide on the web or contact the local Xylem service shop Always state the serial number of your pump when you contact Xylem see Product Description page 10 The pump starts stops starts in rapid sequence...

Page 49: ...ied electrician The phase currents vary or they are too high Contact the local Xylem service shop The insulation between the phases and 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 pump...

Page 50: ...icult 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 correctly Depending on the ins...

Page 51: ... H 180 C 360 F Application limits Data Description Liquid temperature 40 C 104 F maximum The pump must work fully submerged under full load operation Warm liquid version 70 C 158 F maximum These versions have certain operating limitations which are stated on the plate on the pump Liquid density Contact the local Xylem representative pH of the pumped media liquid 5 5 14 Depth of immersion 20 m 65 f...

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Page 54: ...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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