Xylem FLYGT P7030 Series Installation, Operation And Maintenance Manual Download Page 58

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WS003876C

FLS + Thermistor

Control leads

T1/1

Thermistor

T2/2

relay

T15

Max

FLS

BN/BU

T3/3

Mini

12 V

BN/BU

T16

T4/4

CAS

-5

Figure 30: 1 FLS + thermistor

Max

12 V

Max

12 V

Max

2.5 V

FLS + FLS + Thermistor

FLS

Control leads

T15

T16

T1/1

T2/2

T3/3

T4/4

*SUBCAB AWG

-5

Mini

CAS

Thermistor

relay

WS008808A

Figure 31: 2 FLS + thermistor

Thermal detectors; FLS disconnected

WS003869C

Thermal detectors FLS Disconnected

FLS

Max 12 V

WH/YE

T1 Control leads

T1/*OG/1

Mini

CAS

T2/*BU/2

-5

WH/YE

T15

**T3

**T4

*SUBCAB AWG

**Screened SUBCAB

Figure 32: Thermal detectors connected, and FLS disconnected

4 Installation

P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

Summary of Contents for FLYGT P7030 Series

Page 1: ...Installation Operation and Maintenance Manual 882901_15 0 P7030 P7035 P7040...

Page 2: ......

Page 3: ...cription 12 3 1 Products included 12 3 2 Pump design 12 3 3 Parts 13 3 4 Monitoring equipment 14 3 5 The MAS 801 monitoring equipment 14 3 5 1 MAS 801 14 3 5 2 FLS float switch sensor 15 3 5 3 Vibrati...

Page 4: ...5 1 Precautions 59 5 2 Estimate zinc anode replacement intervals 59 5 3 Start the pump 60 6 Maintenance 61 6 1 Precautions 61 6 1 1 Rotating propeller 61 6 1 2 Falling 62 6 2 Torque values 62 6 3 Che...

Page 5: ...tarts in rapid sequence 81 7 5 The pump runs but the motor protection trips 82 7 6 The pump delivers too little or no water 83 8 Technical Reference 84 8 1 Application limits 84 8 2 Pt100 resistance 8...

Page 6: ...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 follow the...

Page 7: ...mechanics Special rules apply to installations in explosive atmospheres All users must know about the risks of electric current and the chemical and physical characteristics of the gas the vapor or b...

Page 8: ...s must be of quality higher than or equal to A4 80 Guidelines for compliance Compliance is fulfilled only when you operate the unit within its intended use Do not change the conditions of the service...

Page 9: ...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 1 6 Protecting the environment Emissions and waste disposal Obse...

Page 10: ...and electronic equipment can be returned to the producer or distributor 1 8 Spare parts CAUTION Only use the manufacturer s original spare parts to replace any worn or faulty components The use of un...

Page 11: ...issue then contact a sales representative 2 2 Transportation guidelines 2 2 1 Precautions DANGER Crush Hazard Moving parts can entangle or crush Always disconnect and lock out power before servicing t...

Page 12: ...s 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...

Page 13: ...hts on the packed product Long term storage If the unit is stored for more than six months then the following apply Before operating the unit after storage it must be inspected Special attention must...

Page 14: ...a Xylem representative before proceeding DANGER Explosion Fire Hazard Special rules apply to installations in explosive or flammable atmospheres Do not install the product or any auxiliary equipment i...

Page 15: ...tor 4 Rotor 5 Main bearings Two row angular contact ball bearing in O arrangement 6 Mechanical seals Inner and outer mechanical seals Seal housing The housing acts as a buffer between the pumped fluid...

Page 16: ...ore monitoring channels are required MAS 711 requires a separate signal cable with 12 or 24 leads MAS 801 This is the most advanced monitoring system With the MAS 801 the analog signals from the senso...

Page 17: ...e leakage sensors The float switches are located in the junction box and in the lower part of the stator housing or leakage chamber 3 5 3 Vibration in three directions A vibration sensor that is locat...

Page 18: ...windings Three thermistors PTC connected in series are incorporated in the coil ends of the stator windings TRef 140 C 285 F One Pt100 sensor is incorporated in one of the windings By using an analogu...

Page 19: ...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 transformers in the control cabinet The PAN 312 power an...

Page 20: ...l switch is a normally closed contact 0 3 ohm unless the wires are very long An infinite value open circuit indicates either high temperature or a fault a wire is broken or there is a bad contact in a...

Page 21: ...ring VIS10 Table 9 Vibration sensor VIS10 Description Measured value Fault values The vibration sensor located in the junction box measures vibrations in one direction The output is a 4 20 mA signal p...

Page 22: ...on see the MAS 711 Installation and User Manual 3 7 Monitoring with MiniCAS II This table shows the parameters which can be tracked with the MiniCAS II monitoring system Parameter Sensor Standard or o...

Page 23: ...0 27 6 769 73 10 7040 Long motor 800 31 5 769 73 03 700 27 6 769 73 02 Short motor 800 31 5 769 73 01 700 27 6 769 73 00 Flange adapter WS008931A The flange adapter is bolted to the bottom of the spec...

Page 24: ...nce 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 Not...

Page 25: ...s 8 Duty factor 9 Input power 10 Rated speed 11 Additional information 12 Maximum ambient temperature 13 Serial number 14 ATEX marking 15 Country of origin IEC approval plate This illustration describ...

Page 26: ...are illustrated accordingly X letter Y digit The different types of codes are marked up with a b and c Code parameters are marked up with numbers Codes and parameters XXYYYY YYY YYY YYYY 1 2 3 4 5 6...

Page 27: ...Type of Callout Number Indication 6 Production cycle 7 Running number 3 Product Description P7030 P7035 P7040 Installation Operation and Maintenance Manual 25...

Page 28: ...nd 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 the installation process Check the explosion risk before you weld or use...

Page 29: ...ace all corroded or damaged fasteners Make sure that all the fasteners are correctly tightened and that there are no missing fasteners 4 2 Cables General requirements The voltage drop in a long cable...

Page 30: ...t 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 exceed th...

Page 31: ...abrade the cable sheathing Examples of surfaces include pump and tube components lifting cables or wires and any other hardware Cables should be bundled together by using components that do not cut o...

Page 32: ...talling the cable handling system Instructions for installing the Flygt Lift Cable Handling System are given in the document Installation Operation and Maintenance Flygt Lift Cable Handling System For...

Page 33: ...hrough the triangular holes of the adapter from the inside 2 Lift the adapter without the pump WS009188A 3 Lower the adapter into the column until it bottoms out on the bottom of the column 4 Lower th...

Page 34: ...product is rated explosion proof or intrinsically safe then see the specific explosion proof information in the safety chapter before taking any further actions WARNING Explosion Fire Hazard Before s...

Page 35: ...ally installed in a vertical discharge tube on a pump seat which is incorporated in the lower end of the tube No anchoring is required because the weight of the pump is sufficient to keep it in place...

Page 36: ...If debris is present then there is a risk that it gets sucked into the pump and cause propeller damage 1 Make sure that the pump control is set to turn off the pump at or above the minimum operating w...

Page 37: ...on the stop vanes which are at the bottom of the column Correct Incorrect WS004613B WS004614B 6 Lower the pump to its bottom position at the same time carefully moving it back and forth between the n...

Page 38: ...device on the hydraulic end lands against the nearest adjacent vanes 2 3 cm 0 8 1 2 in WS003677B Figure 11 Turn the pump until the anti rotation device is in place 8 Lower the pump to its final bottom...

Page 39: ...precautions DANGER Electrical Hazard Before starting work on the unit make sure that the unit and the control panel are isolated from the power supply and cannot be energized This applies to the cont...

Page 40: ...he outside of the drive unit to meet approval requirements Motor and short circuit protection A qualified electrician must select the size of motor protection breakers and fuses so that it is sufficie...

Page 41: ...s that are also in contact with the pump or pumped liquid 4 6 3 Cable entry parts 1 2 WS003675A 3 4 5 5 4 4 4 6 7 8 Position Part 1 Entrance cover 2 O ring 3 O ring 4 Washer 5 Seal sleeve 6 Spacer rin...

Page 42: ...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 WS0043...

Page 43: ...t are integrated in the SUBCAB cable T1 and T2 to the MAS BU See the chapter Installation in the SIO Manual for the MAS 801 monitoring equipment b If it is not already connected then connect the funct...

Page 44: ...s 51 63 81 80 24 23 22 21 20 19 4 3 38 37 11 12 13 14 1 2 9 10 34 33 17 18 16 15 WS008193B Terminal Description Terminal Description 37 38 Temperature support bearing Pt100 13 14 Analog input 0 4 20 m...

Page 45: ...rmal contact status signals Thermistors Connect the leads to a SIL approved thermistor relay For more information see the SIO Manual for the MAS 801 4 To gain access to the terminal board remove the e...

Page 46: ...ly Thermistors must be wired to a Safety Integrity Level SIL approved thermistor relay T3 T4 WS008219C 51 63 81 80 24 23 22 21 20 19 4 3 38 37 11 12 13 14 1 2 9 10 34 33 17 18 16 15 Terminal Descripti...

Page 47: ...eads to the applicable terminal board and twist the leads together 7 Make sure that any thermal contacts incorporated in the pump are properly connected to the terminal board 8 Install the entrance co...

Page 48: ...4 6 7 3 Connect the SUBCAB cables to the starter and MAS 711 monitoring equipment This section provides connections for MAS 711 using 12 lead sensor cable and four power cable leads It is applicable t...

Page 49: ...the color codes of the leads see Cable charts on page 48 3 Check the functionality of the monitoring equipment a Check that the signals and the tripping function work properly b Check that the relays...

Page 50: ...S 2x0 5 350 2 24 35 37 3x50 2G35 2 S 2x0 5 350 2 6 35 37 3x70 2G35 2 S 2x0 5 380 3 3 38 41 Table 14 SUBCAB screened cables Cable Minimum bending radius in mm Weight in kg m Outer diameter minimum max...

Page 51: ...illustrated L1 L2 L3 T3 T4 T1 T2 4 3 2 1 5 10 8 CLS 6 FLS 7 FLS 10 11 9 WS004134B 12 13 14 CT 1 Starter equipment and mains leads L1 L2 L3 2 Ground earth 3 Functional ground 4 Control leads T1 T2 T3...

Page 52: ...BU V2 WS004551E Motor Connection Colors and marking of the main leads 773 29 00 9 REV COLOR STANDARD STATOR LEADS BN Brown U1 U5 RD BK Black U2 GN WH White V1 V5 BN OG Orange V2 BU GN Green W1 W5 YE G...

Page 53: ...GN YE YE GC WH L1 U1 RD U1 BK W2 L3 W2 V1 V1 BN GN U2 L2 U2 W1 W1 YE BU V2 V2 Figure 17 Y connection 4 50 mm2 One cable left and two cables right D connection Applicable to 4 50 mm2 WS003804D D One c...

Page 54: ...W1 V2 BK BN GN YE BU RD BK BN GN YE BU W2V1 U2W1V2 U1W2V1 U2W1V2 Two cables D Only applicable to 95 120 mm2 terminal clamp L11 L31 L21 L12 L32 L22 WS008919A GN YE YE WH GC Figure 20 D connection 95 12...

Page 55: ...U5 L3 U5 GN U2 V1 BN V1 L2 V5 BN V5 W1 BU V2 W5 YE W1 YE W5 BK W2 L1 RD U1 1 U1 L1 L3 2 BN V1 1 L3 V1 L2 2 YE W1 1 L2 W1 2 GN U2 RD U5 BU V2 BN V5 BK W2 YE W5 GN YE YE GC WH Figure 23 Y serial connect...

Page 56: ...ps T1 T2 T14 T15 T16 T15 T16 Only valid for 7020 connection FLS FLS Thermal detectors PT100 WS008805A Figure 26 Sensor terminal clamps Additional terminal clamps are shown at insert at lower right onl...

Page 57: ...S FLS WS008807A Figure 28 2 FLS thermal detectors FLS FLS Thermal detectors PT100 Max 12 V For 7020 PT100 connected in connection block outside rail Control leads T1 T2 T15 T14 T16 T1 1 7 5 T2 2 T3 3...

Page 58: ...1 T2 2 T3 3 T4 4 BN BN BN BN SUBCAB AWG BU BU 7 5 Mini CAS Thermistor relay WS008808A Figure 31 2 FLS thermistor Thermal detectors FLS disconnected WS003869C Thermal detectors FLS Disconnected FLS TC...

Page 59: ...contactor CC Control circuit L1 Caution light leakage L2 Caution light stator over temperature P Pump main supply R Reset switch 4 8 Check the impeller rotation CAUTION Crush Hazard The starting jerk...

Page 60: ...w B 4 If the impeller propeller rotates in the wrong direction then check that the phase leads are correctly connected See Power cable phase sequence on page 47 After reconnecting phase leads do this...

Page 61: ...e that you understand the noise level requirements in the environment where the product is installed Failure to do so may result in hearing loss or violation of local laws 5 2 Estimate zinc anode repl...

Page 62: ...y become hot during operation Allow surfaces to cool before starting work or wear heat protective clothing NOTICE Make sure that the rotation of the impeller is correct For more information see Check...

Page 63: ...explosion risk before you weld or use electrical hand tools Allow all system and pump components to cool before you handle them Make sure that the product and its components have been thoroughly clea...

Page 64: ...hat is used is correctly sized and in good working condition Never stand in coiled cables ropes or wires or between them and the open shaft or basin WS004315C Diffuser adapter When the pump is lifted...

Page 65: ...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 Table 17 Brass torque Nm lbf ft M5 M8 M10 2 7 2 0 11 8 1 22 16 2 Hexagon screws with countersunk heads For...

Page 66: ...e conditions below or both if the sensor is accessible 2 Check the float switch FLS in the junction box connection housing 6 4 1 FLS Table 18 Float switch sensor FLS Description Measured value Fault v...

Page 67: ...3A 1 Outer screw 2 Inner screw 2 Thread the hose of the hand pump through the inner and outer holes into the seal chamber WS003632A 3 Pump out any liquid from the seal chamber 4 Remove the inspection...

Page 68: ...lows through the opposite hole Table 19 Approximate oil quantities Pump Quantity L qt 7030 2 4 2 5 7035 3 6 3 8 7040 3 8 4 0 3 Replace the O rings with new ones 4 Remount the oil plugs and tighten Tig...

Page 69: ...e control terminals For Ex proof pumps do not use connections 51 and 63 on the PEM For Ex proof pumps T3 and T4 must be connected to the separate plinth d Connect the communication terminals T1 and T2...

Page 70: ...t off the entrance cover WS003636A 6 7 2 Attach the assembly and dismantling stand Two lifting devices are required for this task 1 Bolt the assembly dismantling stand 605 70 00 in position Secure it...

Page 71: ...the propeller Required tools Stand 605 70 00 14 mm hexagon bit adapter with an extension bar Trim tool 17 mm hexagon bit adapter with an extension bar Rod wood or plastic for locking the impeller in...

Page 72: ...efficiency will drop It should be noted that these effects are not linearly proportional to the size of the clearance but progressive Operating the pump when the blade housing clearance has reached or...

Page 73: ...s section can be omitted If the measured clearance is greater than the threshold value in the table above then proceed as follows 2 Measure the wear in the pump housing with a thickness gauge by placi...

Page 74: ...azard Sharp edges Wear protective clothing 1 Lock the propeller in place by inserting a rod or piece of wood through the pump housing outlet WS003620A 2 Loosen the propeller a Remove the propeller scr...

Page 75: ...nical sleeve with a thin layer of grease The correct lubrication is grease for bearings for example Exxon Mobil Unirex N3 Mobil Mobilith SHC 220 or equivalent NOTICE Surplus grease can cause the impel...

Page 76: ...l WS003621B c Fit the sleeve onto the shaft d Carefully fit the propeller to the shaft Make sure that the sleeve and propeller are pushed on straight onto the shaft If not they might get stuck part wa...

Page 77: ...curing the bellmouth If there are zinc anodes then six hexagonal screws must be removed 1 2 3 WS003763B 4 1 Hexagonal screws 2 Bellmouth 3 O ring optional 4 Pump housing 2 Lift off the bellmouth 3 Put...

Page 78: ...e anodes at the outlet WS003668A 4 Replace the zinc anodes and fasten the screws 6 11 Service the pump Type of maintenance Purpose Inspection interval Initial inspection A Xylem authorized personnel c...

Page 79: ...conditions are extreme for example with very abrasive or corrosive applications or when the liquid temperatures exceed 40 C 104 F 6 11 1 Inspection Service item Action Cable 1 If the outer jacket is...

Page 80: ...Terminal board Check that the connections are properly secured Temperature sensors MAS monitoring system Thermal contact Thermistor Pt100 If the pump is connected to the MAS monitoring system then it...

Page 81: ...one week of operation If leakage has occurred then do the following 1 Drain the fluid 2 Change the mechanical seal unit 3 Replace the oil with new oil The thermistor thermal contact Check the start a...

Page 82: ...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 repeatedly if i...

Page 83: ...p to the 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...

Page 84: ...able chart The impeller is difficult to rotate by hand Clean the impeller Clean out the sump Check the clearance between the propeller and the pump housing The drive unit is not receiving full voltage...

Page 85: ...essary Check that all valves are correctly installed 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 Chec...

Page 86: ...1 142 154 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 80 130 89 1...

Page 87: ...C R ohms T C R ohms T C R ohms T C R ohms 31 111 94 64 124 77 97 137 36 130 149 82 32 112 45 65 125 16 98 137 74 131 150 20 8 Technical Reference P7030 P7035 P7040 Installation Operation and Maintenan...

Page 88: ...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 of l...

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