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Xylem Lowara e-IXPSA, Additional Installation, Operation And Maintenance Instructions

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Xylem Lowara e-IXPSA Additional Installation, Operation And Maintenance Instructions Download Page 27

en – Original instructions 

 

 

e-IXPSA – Additional Installation, Operation and Maintenance Manual  

27

 

 

 

WARNING: Hot surface hazard 

Be aware of the extreme heat generated by the unit. 

 

 

WARNING: 

It is prohibited to place flammable materials near the unit. 

 

 

NOTE: 

Check that the shaft can turn smoothly. 

 

 

NOTE: 

The maximum pressure delivered by the unit at the discharge side, determined by the 

pressure available on the suction side, must not exceed the maximum pressure (PN). 

5.2

 

Checking the rotation direction 

Preparing the unit 

 

WARNING: Temperature increase due to contact between rotating and fixed components 

Checking the direction of rotation by running the unit dry is strictly forbidden. 

1.

 

Check that all the operations described in the previous paragraphs have been completed 

correctly. 

2.

 

Fill and vent the unit and the suction pipe. 

3.

 

Shut off the discharge on-off valve almost completely. 

4.

 

Fully open the suction on-off valve. 

Checking the rotation direction 

 

WARNING: 

Loose pump parts and pump damage due to incorrect pump and motor 

rotation

 

Pay attention to the arrow indicating the rotation direction of the pump. Check the rotation 

direction. In case of wrong rotation direction, switch 2 phases of the electrical connection. 

1.

 

Locate the arrow on the adapter, the coupling or the cover, to determine the correct 

direction of rotation of the motor. 

2.

 

Start the unit. 

3.

 

Check the rotation direction through the motor cover. 

4.

 

Stop the unit. 

5.

 

In case of incorrect rotation direction: 

•

 

Disconnect the power supply 

•

 

Invert two of the three wires of the power supply cord. 

6.

 

Check the direction of rotation again. 

5.3

 

Start-up 

 

DANGER: Explosion hazard due to excessive temperature 

Do not keep the on-off valve on the discharge side in the closed position in order to throttle 

the pump for more than 5 seconds. If the unit has to operate longer with closed discharge 

valve or for a longer period below the minimum flow, a bypass circuit must be installed that is 

either permanently active or controlled by a minimum flow valve, to prevent overheating of the 

fluid in the pump. 

 

Summary of Contents for Lowara e-IXPSA

Page 1: ...ps according to ISO 2858 and ISO 5199 ATEX II 2G Ex h IIC T5 T3 Gb Additional Installation Operation and Maintenance Manual Applicare qui l adesivo con il codice a barre Apply the adhesive bar code nameplate here ...

Page 2: ... and Storage 11 2 1 Unit inspection upon delivery 11 2 1 1 Package inspection 11 2 1 2 Unpacking and inspection of the unit 11 2 2 Guidelines for transport 11 2 2 1 Handling of the packed unit using a forklift truck 12 2 2 2 Lifting with a crane 12 2 3 Storage 13 2 3 1 Storage of the packed unit 13 2 3 2 Long term storage of the unit 14 2 3 3 Return 14 3 Description of the product 15 3 1 Features ...

Page 3: ...g 31 6 5 Tightening torques 31 7 Troubleshooting 33 7 1 Precautions 33 7 2 The unit does not start 33 7 3 The differential protection device RCD has tripped 33 7 4 The unit produces excessive noise and or vibrations 33 7 5 The thermal overload protection triggers or the fuses trip 34 7 6 The thermal overload protection triggers 34 7 7 The motor becomes excessively hot 34 7 8 Little or no hydraulic...

Page 4: ...ntenance data 38 8 8 Section drawings and list of components 39 8 8 1 Drawings 39 8 8 2 List of components 41 9 Disposal 43 9 1 Precautions 43 9 2 WEEE EU EEA 43 9 3 WEEE UK 43 10 Declarations 44 10 1 EC Declaration of Conformity Original 44 10 2 EU Declaration of Conformity n 67 44 11 Warranty 46 11 1 Information 46 ...

Page 5: ...mps may be supplied with supplementary instruction manuals For situations not considered in the manual or in the commercial documentation contact Xylem or the Authorised Distributor 1 2 Hazard levels and safety symbols Before using the unit the user must read understand and comply with the indications of the danger warnings in order to avoid the following risks Injuries and health hazards Damage t...

Page 6: ...uring installation use and maintenance of the unit 1 4 Explosion protection The installation operation and maintenance of the unit in potentially explosive atmospheres are regulated by EU Directive 2014 34 EU ATEX and UK Regulation of 2016 regarding Equipment and Protective Systems Intended For Use in Potentially Explosive Atmospheres S I 2016 1107 DANGER Potentially explosive atmosphere hazard Ma...

Page 7: ...of the liquid Expect extremely high temperatures On the pump casing surface On the shaft sealing On the bearings area During the quotation stage handled either by sales the technical department appointed representatives or the supplier of the mechanical seal check the heating of the liquid at the shaft NOTE If the pump surface temperature exceeds that of the liquid check that the temperature class...

Page 8: ...00 min 1 T4 135 275 120 248 20 40 4 104 T3 200 392 140 284 20 40 4 122 The maximum operating temperature of the pump is shown In the data sheet or the order confirmation or both In the name plate on the pump 1 4 2 Operation of the pump Filling During pump operation fill with the pumped liquid The suction system The pressure pipe The pump itself Also carefully fill All the sealing chambers The auxi...

Page 9: ... explosion protection 1 4 4 Intended use Speed pressure temperature The speed pressure and temperature of the pump and the shaft sealing should not exceed the limit values given in the data sheet and or order confirmation As they can occur with too fast shut down keep them under control for example by installing a non return valve on the pressure side fly wheel or air tanks They can cause temperat...

Page 10: ...tion hazard If the unit has been exposed to ionizing radiations implement the necessary safety measures for the protection of people If the unit needs to be dispatched inform the carrier and the recipient accordingly so that appropriate safety measures can be put in place 1 6 Spare parts WARNING Replace all worn or faulty components with original spare parts to prevent unit malfunction and persona...

Page 11: ...of the unit CAUTION Cut and abrasion hazard Always wear personal protective equipment 1 Remove the packaging 2 Ensure sorting of all packaging materials in accordance with the applicable regulations 3 Release the unit by removing the screws and or cutting the straps if fitted 4 Check the unit for integrity and to make sure that there are no missing components 5 In case of damage or missing compone...

Page 12: ...and or slings hereinafter referred to as ropes hooks and or clasps hereinafter referred to as hooks shackles or eyebolts that comply with the applicable directives and are suitable for use WARNING It is forbidden to use the shaft end and or the motor eyebolts to move the unit NOTE Make sure that the harnessing does not hit and or damage the unit WARNING Lift and handle the unit slowly to avoid sta...

Page 13: ... Lifting and positioning 1 Lift and move the unit slowly 2 Set the unit down slowly 3 Release the harness 2 3 Storage Precautions WARNING risk of injury Pay attention to liquids that are excessively hot or cold WARNING Make sure that the drained liquid cannot cause damage or injuries WARNING It is prohibited to dispose of lubricant liquids and other hazardous substances in the environment 2 3 1 St...

Page 14: ...essential in environments with cold temperatures Otherwise any residual liquid in the unit could have an adverse effect on its condition and performance For more information on long term storage contact the Xylem sales company or Authorised Distributor 2 3 3 Return 1 Correctly empty the unit 2 Wash and clean the unit especially if used to process harmful explosive hot or potentially hazardous liqu...

Page 15: ...Galvanic processes and painting systems Cleaning of tanks and cisterns Mixing of liquids Water movement in water parks Observe the operating limits in Technical Information on page 36 DANGER Potentially explosive atmosphere hazard It is prohibited to operate non EX approved units in environments with potentially explosive atmospheres or with combustible dusts Pumped liquids Water Sea water Salt wa...

Page 16: ... 2 Size from 40 25 160 to 300 250 315 3 Impeller with full A reduced B C or D standard or special X diameter 4 Motor power in kWx10 5 WEG W ABB A or other motor manufacturer X 6 2 pole 2 4 pole 4 or 6 pole 6 motor 7 Frequency 50 Hz 5 or 60 Hz 6 8 Standard operating pressure discharge side PN 16 bar B PN 25 bar C class 150 R or class 300 S 9 Cast ductile iron D stainless steel N or duplex R pump bo...

Page 17: ... combustible gases vapours or mists 5 Explosion protection for non electrical equipment 6 Gas explosion group standard IIC 7 Goods labelling for the British market 8 Maximum surface temperature standard T4 optional T3 or T5 9 System protection level EPL standard Gb 10 Operating ambient temperature standard 40 C 11 Control number of the ATEX conformity assessment institute 12 Control number of the ...

Page 18: ...Manual 3 5 Part names 1 Discharge body Volute casing 2 Bolt 3 Lifting lug 4 Motor adapter 5 Plug 6 Impeller 7 Wear ring 8 Impeller key 9 Impeller nut 10 Plug 11 Plug 12 O ring 13 Casing cover 14 Mechanical seal 15 Stub shaft 16 Motor XIPS_M0002_A_sc 2 3 1 5 6 8 10 11 7 12 13 14 9 15 4 16 ...

Page 19: ...e working tools 4 2 Mechanical installation 4 2 1 Precautions WARNING Risk of injury due to improper floor installation Install the unit on a concrete or metal foundation base sufficiently strong to ensure permanent and rigid support suitable for the size and weight of the unit and as flat and even as possible 4 2 2 Installation area 1 Follow the provisions in Operating environment on page 36 2 Pl...

Page 20: ...nd secure them with chemical anchors 3 Remove the caps of the suction and discharge ports 4 Place the unit on the foundation by inserting the tie rods into the holes in the plate 5 Level the unit with a spirit level on the shaft and discharge port the maximum permitted tolerance is 0 2 mm m 0 0024 in ft 6 Align the suction and discharge ports to their piping 7 If necessary insert levelling shims b...

Page 21: ...event them from weighing on the unit 2 Remove any welding residues deposits and impurities from the piping system in order to avoid damage to the unit the method and duration of the cleaning operation must be adapted to the materials of the unit and the gaskets 3 Install a filter if necessary 4 To reduce the transmission of vibrations between the unit and the system and vice versa install Anti vib...

Page 22: ...473 578 912 490 350 403 724 65 40 65 735 648 595 1146 525 385 420 775 40 385 350 438 680 455 315 368 664 80 65 80 875 788 718 1379 560 403 455 826 65 648 595 735 1146 525 385 420 775 80 50 80 875 788 718 1379 560 403 455 826 50 525 473 578 912 490 350 403 724 100 80 100 1173 1050 945 1836 613 438 508 908 80 788 718 875 1379 560 403 455 826 100 65 100 1173 1050 945 1836 613 438 508 908 65 648 595 7...

Page 23: ...thout shaft sleeve 1 11 Maintenance free mechanical seal 4 5 Electrical connection 4 5 1 Precautions Electrical measures DANGER Potentially explosive atmosphere hazard For the electrical connections make sure to comply with the requirements of the IEC 60079 14 standard DANGER Potentially explosive atmosphere hazard Only use motors that are EX certified for applications in zone 1 and zone 2 DANGER ...

Page 24: ...electric shocks 4 5 2 Guidelines for electrical connection 1 Check that the electrical leads are protected against High temperature Vibrations Collisions Liquids 2 Check that the power supply line is provided with A short circuit protection device of appropriate size 4 5 3 Motor connection 1 Open the terminal box cover 2 Insert the power cable in the cable gland 3 Unsheathe the conductors 4 Make s...

Page 25: ...losive atmospheres DANGER Potentially explosive atmosphere hazard Check if the electric motor is suitable to operate in potentially explosive atmospheres when connected to a frequency converter The converter exposes the insulation of the motor to a greater load determined by the length of the connecting cable observe the requirements of the Manufacturer of the frequency converter For applications ...

Page 26: ...supply and wait at least 10 minutes for the residual current to dissipate DANGER Explosion due to overheating Observe the operating limits for pressure temperature speed and pumped liquids DANGER Explosion The unit must be filled and vented properly before it can be started It is prohibited to operate the unit when dry not primed and below the rated flow rate DANGER Hot and or toxic liquid spillag...

Page 27: ...the rotation direction WARNING Loose pump parts and pump damage due to incorrect pump and motor rotation Pay attention to the arrow indicating the rotation direction of the pump Check the rotation direction In case of wrong rotation direction switch 2 phases of the electrical connection 1 Locate the arrow on the adapter the coupling or the cover to determine the correct direction of rotation of th...

Page 28: ...t in operation check that No liquid is leaking from the unit or piping system The nominal pressure is higher than the maximum pressure delivered by the unit The current absorbed is within the rated limits Note an automatic restart may only take place if it is made sure that the pump remains filled with liquid when it is at a standstill Operation limits Flow min max If no other data are given in th...

Page 29: ...required DANGER Sparks can occur during servicing work Always perform maintenance work on explosion proof pumps away from potentially explosive atmospheres WARNING Always wear personal protective equipment CAUTION Always use suitable working tools DANGER Electrical hazard Before starting work check that the electric power supply is disconnected and locked out to avoid unintentional restart of the ...

Page 30: ...heck Check That there are no unwanted noise or vibrations The mechanical seal That there are no liquid leaks from the gaskets Tightness of the screws and bolts The motor adapter Clogging of the filter in the suction pipe clean if necessary Daily Control Check the temperature of the motor bearings Check the operation of the device in standby Every 2 weeks Check If the unit is subjected to chemical ...

Page 31: ...tect the unit against freezing 4 Before restarting the unit check that the shaft is rotating freely without mechanical impediments 6 4 Spare parts ordering Identify the spare parts with the product codes directly on the site www lowara com spark Contact Xylem or the Authorised Distributor for further technical information 6 5 Tightening torques Blocked pump with bolted casing cover XIPS_M0008_A_sc...

Page 32: ...901 12 M6 4 35 Standard wrench 901 13 M12 45 400 903 01 G1 2 60 530 903 02 04 06 07 G1 4 15 130 904 08 09 M8 15 130 Hex wrench M10 30 270 914 13 M12 45 400 Standard wrench 920 01 M12x1 5 50 440 Torque wrench M16x1 5 80 710 M20x1 5 120 1060 M24x2 0 170 1500 922 02 M16X1 5 80 710 Torque wrench M20X1 5 100 900 M24X2 130 1150 M30X2 180 1600 M36X2 220 1950 ...

Page 33: ...ion against the absence of liquid has tripped Check the liquid level in the tank and or Adjust the device If the problem continues replace the device Control panel faulty Check and repair or replace the control panel Unit faulty Contact Xylem or its Authorised Distributor 7 3 The differential protection device RCD has tripped Cause Solution Motor leaking Check and repair or replace the motor Diffe...

Page 34: ...ion value is too low in relation to the rated current of the motor Recalibrate Input voltage outside the rated limits Make sure the voltage values are correct Unbalanced input voltage Make sure the voltage of the three phases is balanced Wrong duty point flow rate above the permitted limits Bring the flow rate back within the permitted limits Liquid too thick Check the liquid Room temperature too ...

Page 35: ...r install an expansion vessel Oversized unit Contact Xylem or its Authorised Distributor 7 11 The unit does not stop The unit with automatic start and stop device never stops Cause Solution The required flow rate is greater than the one expected Reduce the required flow rate Discharge pipe leaking Eliminate the leaks Three phase motor turning in the wrong direction Check the direction of rotation ...

Page 36: ... motor manufacturer s instructions and catalogues to reduce the power output of the motor or replace the motor with a more powerful model Altitude m ft Power reduction coefficient 1000 1500 3300 4900 0 97 1500 2000 4900 6600 0 95 8 2 Temperature of pumped liquid The table shows the permitted liquid temperatures according to the material of the standard non balanced seal with elastomeric bellow Sea...

Page 37: ... TT RN 25 bar 363 psi only ASME B16 5 DN NN UU RR TT RN 25 bar 363 psi only 8 4 Electrical specifications See the motor data plate Permitted tolerances for the supply voltage Frequency Hz Phase No of conductors earth UN V 50 1 2 1 220 240 6 3 3 1 230 400 10 400 690 10 60 1 2 1 220 230 6 3 3 1 220 380 5 380 660 10 ...

Page 38: ...74 1 90 74 8 73 8 79 7 74 8 8 7 Construction and maintenance data Model Diameter of ports mm in Shaft diameter mm in Mechanical seal mm in Suction Discharge 40 25 160 40 25 200 40 1 1 2 25 1 24 0 94 33 1 30 40 25 250 40 1 1 2 25 1 32 1 26 43 1 69 50 32 160 50 32 200 50 2 32 1 1 4 24 0 94 33 1 30 50 32 250 50 2 32 1 1 4 32 1 26 43 1 69 65 50 160 65 2 1 2 50 2 24 0 94 33 1 30 65 40 200 65 2 1 2 40 1...

Page 39: ... 150 250 200 8 150 6 42 1 65 53 2 09 200 150 315 200 150 400 200 8 150 6 48 1 89 65 2 56 250 200 250 250 200 315 250 10 200 8 48 1 89 65 2 56 300 250 315 300 12 250 10 48 1 89 65 2 56 8 8 Section drawings and list of components 8 8 1 Drawings To find the drawing corresponding to your model identify the type of mechanical seal see paragraph Identification code on page 16 S0 with clamped casing cove...

Page 40: ...al instructions 40 e IXPSA Additional Installation Operation and Maintenance Manual S0 with bolted casing cover Unbalanced single mechanical seal bolted casing cover and 1 piece motor adapter XIPS_M0009_A_sc ai ...

Page 41: ...et 411 05 Gasket 411 06 Gasket 411 07 Gasket 412 01 O Ring 433 01 Mechanical seal unbalanced 502 01 Wear ring 502 02 Wear ring 504 01 Spacer ring 554 01 Washer 554 02 Washer 554 09 Washer 554 13 Washer 561 01 Pin 681 01 Safety guard 800 00 Motor 900 01 Lifting lug 901 12 Hexagon head screw 901 13 Hexagon head screw 901 14 Hexagon head screw 902 01 Stud 902 02 Stud 902 09 Stud 902 14 Stud 903 01 Pl...

Page 42: ...nstructions 42 e IXPSA Additional Installation Operation and Maintenance Manual 914 13 Socket head cap screw 920 01 Hexagon nut 920 02 Hexagon nut 920 09 Hexagon nut 920 14 Hexagon nut 922 01 Impeller nut 940 01 Key ...

Page 43: ...er who wants to get rid of this equipment can then contact the producer and follow the system that it has adopted to allow the separate collection of equipment at the end of life or select a supply chain independently authorized to manage 9 3 WEEE UK INFORMATION TO USERS pursuant to art 44 of the The Waste Electrical and Electronic Equipment Regulations 2013 S I 2013 No 3113 The crossed bin symbol...

Page 44: ...irman of the Board of Directors rev 00 10 2 EU Declaration of Conformity n 67 1 ATEX Product model product IXP A see the label on first page EMC Apparatus model Product see the label on the first page RoHS Unique identification of the EEE IXP A 2 Name and address of the manufacturer Xylem Service Italia S r l Via Vittorio Lombardi 14 36075 Montecchio Maggiore VI Italyf 3 This declaration of confor...

Page 45: ...ecific conditions of use apply The equipment must be suitably grounded earthed prior to operation It is the user s responsibility to ensure the equipment does not run dry Any control system used to achieve this must comply with the relevant requirements of EN 80079 37 The equipment may only be operated when it is filled with the liquid to be pumped The liquid to be pumped must have conductivity 10...

Page 46: ...en Original instructions 46 e IXPSA Additional Installation Operation and Maintenance Manual 11Warranty 11 1 Information For information on the warranty refer to the commercial documentation ...

Page 47: ...en Original instructions e IXPSA Additional Installation Operation and Maintenance Manual 47 ...

Page 48: ...ons to meet our world s water needs Developing new technologies that will improve the way water is used conserved and re used in the future is central to our work We move treat analyze and return water to the environment and we help people use water efficiently in their homes buildings factories and farms In more than 150 countries we have strong long standing relationships with customers who know...

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