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WS004361B

1. Fall protection harness

2. Anchoring point

• Make sure that all safety guards are in place and secure, and that there is a suitable

barrier around the work area.

• Wear clean slip-resistant shoes.
• Make sure that any ladders or climbing equipment that 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

6.2 Service

Regular inspection and service of the pump makes sure that operation will be more reliable.
Every time the site is visited, visually examine the accessories and sump for corrosion, wear

or damage.

Table 10: Service intervals

Type of service

Purpose

Interval

Initial inspection

To make a check up of the

pump condition by an

authorized Xylem service

representative and, based

on the result and findings

from these measures, to

determine the intervals for

periodical inspection and

major overhaul for the

specific installation.

In the first year of operation.

6 Maintenance

P7900 Installation, Operation, and Maintenance Manual

Содержание FLYFT P7900

Страница 1: ...Installation Operation and Maintenance Manual 90028101_1 0 P7900...

Страница 2: ......

Страница 3: ...10 3 1 Pump design 10 3 1 1 Spare part requirements 10 3 2 Major hydraulic parts 10 3 3 Drive units 10 3 4 The MAS 801 monitoring equipment 11 3 4 1 FLS float switch sensor 11 3 4 2 Vibration in three...

Страница 4: ...vice 48 6 2 1 Inspection 49 6 2 2 Major overhaul 50 6 2 3 Checking insulation and sensors 51 6 3 Check the insulation up to 1 kV drives or generators 51 6 4 Check the temperature sensors 51 6 5 Check...

Страница 5: ...turer 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 foll...

Страница 6: ...all times when the unit is being operated 1 4 Special hazards 1 4 1 Biological hazards The product is designed for use in liquids that can be hazardous to your health Observe these rules when you work...

Страница 7: ...A This marking on the product accessories or literature indicates that the product should not be disposed of with other waste at the end of its working life To prevent possible harm to the environment...

Страница 8: ...ng examine the product 3 If applicable unfasten the product by removing any screws bolts or straps Use care around nails and straps 4 If there is any issue then contact a sales representative 2 2 Tran...

Страница 9: ...uipment must be able to hoist the unit straight up and down preferably without the need for resetting the lifting hook The lifting equipment must be correctly anchored and in good condition The liftin...

Страница 10: ...duct and all installation equipment including the lifting gear must be handled with extreme care Make sure that the product is warmed up to a temperature above the freezing point before starting up Av...

Страница 11: ...ezing Follow these guidelines to avoid freezing damage When Guideline Before storage The unit must be allowed to run for a short time after raising it to discharge remaining pumped liquid This does no...

Страница 12: ...o the unit or installation must 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 ca...

Страница 13: ...e 2 Vibration directions with reference to the PEM The definitions of X Y and Z are the same whether or not the pump is in a vertical or horizontal position 3 4 3 Bearing temperature measurement Pt100...

Страница 14: ...s incorporated in one of the windings Optional Three thermal contacts connected in series are incorporated in the coil ends of the stator winding The contacts are normally closed and open at 140 C 285...

Страница 15: ...h the MAS 801 Pump current in three phases Pump current 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...

Страница 16: ...ntrol or pilot cable mounted The following SUBCAB signal cables are available 12x1 5 mm2 unscreened also known as unshielded Conductors 1 12 24x1 5 mm2 unscreened also known as unshielded Conductors 1...

Страница 17: ...output is a 4 20 mA signal proportional to the vibration level Current 4 20 mA 20 mA indicates a short circuit 4 mA indicates a fault A zero value indicates a broken wire or bad contact in a connecto...

Страница 18: ...d in the windings 3 5 4 1 Temperature sensors Table 7 Thermal contact Description Measured value Fault values The thermal contact is a normally closed contact 0 3 ohm unless the wires are long An infi...

Страница 19: ...ion Service log with a maximum of 200 lines of text Conditions to prompt for service based on for example running time number of starts and stops or specific dates For more information see the MAS 711...

Страница 20: ...r code 10 Rated speed 11 Pressure class 12 Column diameter or Inlet and outlet diameter 13 Product number 14 Country of origin Figure 4 The hydraulic unit plate 3 7 Motor regulation This product is su...

Страница 21: ...umber 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 Drive unit 5 Production year 6 Production cycle 7 Runn...

Страница 22: ...re installing the pump do the following Provide a suitable barrier around 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 t...

Страница 23: ...xplosion proof or intrinsically safe If the product is rated explosion proof or intrinsically safe then see the specific explosion proof information in the safety chapter before taking any further act...

Страница 24: ...ds must 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 exc...

Страница 25: ...llowing Sizing of the pump piping station and access frame Choice of auxiliary equipment Other aspects of installation NOTICE Do not run the pump dry NOTICE Never force piping to make a connection wit...

Страница 26: ...or damage on the product Visually inspect equipment for damaged cables cracked casings or other signs of damage Make sure that electrical connections have been correctly made WARNING Crush Hazard Ris...

Страница 27: ...urrent See the data plate and if applicable the cable chart for the rated current The starting current in direct on line start can be up to six times higher than the rated current 4 5 2 Grounding eart...

Страница 28: ...connect the T1 and T2 leads integrated in the SUBCAB cable to the PEM See the illustration and table in Terminals used in standard applications on page 28 4 If they are not already connected then conn...

Страница 29: ...The rubber sleeve must have the correct size to give the correct compression around the cable c Attach the connection flange to the entrance flange Make sure that the seal sleeve is not misaligned wi...

Страница 30: ...2 power supply and communication 51 63 Temperature stator winding Thermal contact or thermistor TC 17 Not used 11 12 Vout 12 VDC GND 18 Not used 4 5 4 Connect the cables Pumps with MAS 711 1 Connect t...

Страница 31: ...tion U1 U2 V1 V2 W1 W2 and ground earth according to the cable chart See Cable charts on page 36 d If control elements are present and not used then cut and cap them 5 Install the entrance flange a Fi...

Страница 32: ...e entrance flange Make sure that the seal sleeve is not misaligned with the rubber sleeve Check that the entrance flange supports the cable so that it cannot be excessively bent 6 Connect the starter...

Страница 33: ...RMAL SWI TCH OIL F LOW SENSOR LEA KAGE S TATOR LEA KAGE CONNECTION HOUSING TEMP MAIN BEARING TEMP 1 WINDING WINDING TEMP TEMP SUPPO RT BEARING TEMP 3 WINDNING TEMP 2 WINDNING WS000508A Figure 13 Conne...

Страница 34: ...Conductor for 24 lead cable Float switch in the stator house1 1 1 1 2 2 2 Float switch in the junction box 9 7 7 2 Pt100 in the main bearing2 3 3 3 4 4 4 Pt100 in the support bearing 37 17 38 18 Therm...

Страница 35: ...4 T2 T1 7 6 5 8 Figure 15 Correct phase sequence Item Description 1 L1 cable lead Brown 2 L2 cable lead Black 3 L3 cable lead Gray 4 Earth PE or ground lead cable 5 T1 cable lead control element In c...

Страница 36: ...2 Measure both polarities T1 T2 resistance T1 T2 resistance Opposite polarity Conclusion 70 130 kilohms ohm The PEM is connected to this cable ohm infinite resistance ohm The PEM is not connected to t...

Страница 37: ...ntrol 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...

Страница 38: ...he electrical parts can cause damaged equipment or a blown fuse Keep the end of the motor cable dry at all times Stator leads connection to terminal board Terminal board Stator leads connection to ter...

Страница 39: ...used then the control conductors in the power cable are never used The following figure shows screened SUBCAB cable without a separate ground conductor The ground conductor is made of stranded ground...

Страница 40: ...WH GC WH YE LV Stators MV Stators U1 RD U2 GN V1 BN V2 BU W1 YE W2 BK U BK V BK W BK VOLTAGE DENOMINATIONS LV Low voltage MV Medium voltage MOTOR CONNECTION COLORS AND MARKING OF MAIN LEADS MOTOR CABL...

Страница 41: ...D LV 3 pole terminal 1 or 2 cables L2 V2 V1 W1 U1 U2 L3 L1 W2 U V W L1 L3 L2 GN YE YE WH GC WS004349D Drive units with small connection housing U1 V1 W1 L2 L3 L1 GC WS001040C Drive units with large c...

Страница 42: ...L2 GN YE YE WH GC WS003911B Drive units with small connection housing L2 L3 L1 U1 V1 W1 GC WS001041C 4 6 2 3 D connection 6 pole terminal 2 cables Schematic diagram D LV 6 pole terminal 1 2 3 or 4 cab...

Страница 43: ...with large connection housing L2 L3 L1 V2 W1 U2 V1 U1 W2 WS008998B 4 6 2 4 Y connection Schematic diagram Y LV 6 pole terminal 1 or 2 cables L2 L3 L1 U2 V 2 W 2 V 1 W 1 U1 W2 U2 V2 U1 V1 W1 L1 L3 L2 G...

Страница 44: ...powerful Make sure nobody is close to the unit when it is started If the propeller rotates in the wrong direction then the pump lifts up and rotates which can damage the cables 1 Start the motor 2 Sto...

Страница 45: ...in the wrong direction then check that the phase leads are correctly connected See Power cable phase sequence on page 33 After reconnecting phase leads do this procedure again 4 Installation P7900 Ins...

Страница 46: ...UTION Electrical Hazard Risk of electrical shock or burn The equipment manufacturer has not evaluated this unit for use in swimming pools If used in connection with swimming pools then special safety...

Страница 47: ...et the calculated anode consumption rate days gram If multiple anodes were weighed then use the anode which has lost the most weight for this calculation 4 Calculate future replacement intervals so th...

Страница 48: ...temperatures at or below the freezing point that is the pump is not totally submerged then special modifications must be made to the pump and the installation For more information please contact your...

Страница 49: ...process Make sure that you have a clear path of retreat Never work alone Check the explosion risk before you weld or use electrical hand tools Before starting work make sure that the work area is wel...

Страница 50: ...ice Regular inspection and service of the pump makes sure that operation will be more reliable Every time the site is visited visually examine the accessories and sump for corrosion wear or damage Tab...

Страница 51: ...es exceed 40 C 104 F 6 2 1 Inspection CAUTION Compressed Gas Hazard Air inside may cause parts or liquid to be propelled with force Be careful when opening Regular inspection and service of the pump m...

Страница 52: ...cessary to the correct torque See Torque values on page 65 Electrical cabinets Check that it is clean and dry Connection to power Check that the connections are properly secured Level regulators Check...

Страница 53: ...tion After any service involving the power connections check the rotation before operating the pump See Check the impeller rotation on page 42 6 2 3 Checking insulation and sensors It is important tha...

Страница 54: ...C supply The sensor must have the correct polarity to be checked However a switched plus and minus does not damage the sensor b Use the multimeter as an ammeter and connect it in series with the senso...

Страница 55: ...Part number Oil plug 809 35 00 O ring 82 72 95 1 WS013658C 1 Seal oil plugs 3x 1 2 WS013656A 1 Seal oil drain plug 2 Seal oil fill plug Empty the oil 1 Put a container under the oil drain hole 2 Unsc...

Страница 56: ...lled now Tightening torque 50 Nm 37 lbf ft Fill with oil 1 Fill up with the new oil 2 Replace the O rings 3 Install the oil plugs Tightening torque 50 Nm 37 lbf ft 6 7 Change the gear oil For the inte...

Страница 57: ...1 WS013817A 1 Gear oil plugs 3x 1 2 3 WS013657A 1 Gear oil drain plug 2 Gear oil fill plug 3 Gear oil level plug 6 Maintenance P7900 Installation Operation and Maintenance Manual 55...

Страница 58: ...rectly then only the oil drain plug must be installed now Tightening torque 50 Nm 37 lbf ft Fill with oil 1 Fill up with the new oil The oil level must be below the oil level hole 2 Replace the O ring...

Страница 59: ...5 1 WS013659A 1 Lifting eye unit 2 Plug 3 Screws 4 O ring 5 Propeller 1 Remove the plug 2 Install the lifting eye unit 3 Remove the screws 4 Remove the propeller WS013660C 5 Discard the O ring 6 Maint...

Страница 60: ...loosening the screws then do the following a Remove the four plugs b Install four of the screws that were removed c Tighten the screws evenly until the locking assembly is released d Remove the screw...

Страница 61: ...ss piece 432 44 00 2 Screw 432 53 00 M16 3 Screw 432 55 00 M12 4 Washer 432 45 00 1 2 3 4 5 WS013665B 7 6 Figure 20 Overview 1 Threaded adapter 2 Hydraulic pump 3 Cross piece 4 Propeller hub 5 Puller...

Страница 62: ...the O ring 6 8 3 Assemble the pump 6 8 3 1 Install the propeller hub Table 16 Tools Tool Illustration Hydraulic pump 14 57 21 04 1 2 WS013663A 1 Threaded adapter 2 Non threaded adapter Basic repair ki...

Страница 63: ...pump 7 By using the hydraulic pump apply pressure until the propeller hub is seated 6 8 3 2 Install the locking assembly 1 Install the locking assembly over the shaft and into the base of the propelle...

Страница 64: ...ening torque 70 Nm 52 lbf ft b Tighten the screws again according to the sequence Tightening torque 154 Nm 114 lbf ft c Tighten the screws again according to the sequence Tightening torque 230 Nm 170...

Страница 65: ...ring 2 Remove the plug 3 Install the lifting eye unit 4 Lift the propeller WS013660C 5 Align the holes of the propeller hub with the holes of the propeller 6 Lubricate the screws Lubricant Loctite No...

Страница 66: ...ng torque 125 Nm 93 lbf ft c Tighten the screws again according to the sequence Tightening torque 187 Nm 138 lbf ft d Tighten the screws a last time according to the sequence Tightening torque 187 Nm...

Страница 67: ...torque Screws that are screwed into stainless steel must have the threads coated with applicable lubricants to prevent seizing If there is a question regarding the tightening torques then contact a s...

Страница 68: ...Three jaw puller 1 84 15 17 C wrench 1 332 91 00 Spring puller tool 1 436 18 00 Hub tool 1 432 44 00 Cross piece 1 432 45 00 Washer 1 432 53 00 Screw M16 4 432 55 00 Screw M12 3 436 19 00 Basic repai...

Страница 69: ...Part number Denomination Parts Qty Part number Denomination 14 57 21 04 Hydraulic pump 1 702 76 00 Lifting eye unit 1 6 Maintenance P7900 Installation Operation and Maintenance Manual 67...

Страница 70: ...r 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 result i...

Страница 71: ...e 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 For in...

Страница 72: ...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 then notify a certified electrician The pha...

Страница 73: ...141 91 142 154 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 13...

Страница 74: ...Screened SUBCAB Cable Minimum bending radius in mm Weight in kg m Outer diameter minimum maximum in mm S3x16 3x16 3 S 4x0 5 240 1 1 24 26 S3x25 3x16 3 S 4x0 5 290 1 4 29 31 S3x35 3x16 3 S 4x0 5 320 2...

Страница 75: ......

Страница 76: ...gies 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...

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