Safety 2 Guarantee 3 Data plate interpretation 4 Product description 5 Introduction 5 ‘Application — 5 Motor data 6 Design of the pump 7 Transportation and storage ° Installation 10 Handling equipment 10 Safety precautions 10 Installation alternatives. 10 Electrical connections Connection of stator and motor lead Sensorconnections Operation Bofore starting Care and Maintenance Servicelinspection Changing the coolant Removing the impeller Installing the impeller Installing the agitator Removing the agitator Fault tracing Service log ___ BBSRBRSBYN BBS HE This manual contains basic information on the installa- tion, operating and maintenance and should be followed carefully. I s essential that these instructions are Carefully read before installation or commissioning by both the installation crew as well as those responsible for operation or maintenance. The operating instruc- tions should always be readily available atthe location of the unit. Identification of safety and warning symbols General Dangor: Non-observance given to safety Instructions in this manual, which ‘could cause danger to life have been specifically highlighted with this general danger symbol, High Voltage: ‘The presence of a dangerous volt- age is identified with this safety symbol. WARNING! —_Non-observance tothis waming could damage the unit or affect its function Qualifications of personne! ‘An authorized (certified) electrician and mechanie shall carry out all work. Safety regulations for the owner/operator All government regulations, local health and safety ‘codes shall be complied with All dangers due to electricity must be avoided (for | details consult the regulations of your local electricity ‘supply company). Unilateral modification and spare parts manu- facturing Modifications or changes to the unitinstallation should only be carried out after consulting with Fiygt. Criginal spare parts and accessories authorized by the ‘manufacturer are essential for compliance. The use of other parts can invalidate any claims for warranty or ‘compensation. Dismantling and re-assembly lt the pump has been used to pump hazardous media, care must be taken that, when draining the leakage, personnel and environment arenot endangered. ‘All waste and emissions such as used coolant must be appropriately disposed of. Coolant spills must be clea- ned up and emissions tothe environment must be reported, ‘The pumping station must be kept tity and in good order at all times. | Allgovernment regulations shall be observed.NOTES FOR EX-PRODUCTS — Only Ex-approved pumps may be used in an explosive or flammable environment. — Donat open the pump when an explosive gas atmosphere may be present. — Before starting work on the pump, make sure that the pump and the control panel are iso- lated from the power supply and can not be energized. This applies to the control circuit as well. — All mechanical work on the explosion-proot ‘motor section must be performed by person- nel authorized by Flygt. — Electrical connection on the explosion-proot motor must be made by authorized person- rel. — Thermal contacts must be connected to pro- tection circuit intended for that purpose ac- cording to the approval of the product. — The pump may be used only in accordance with the approved motor data stated on the data plates. = Intrinsically safe circuits are normally re- quired (Exi) for the automatic level control system by level regulator if mounted in zone 0. — This equipment must be installed in confor- rity to prescriptions in international or na- tional rules ( IEC/EN 6079-14 ) — The maintenance operation must be made in conformity to the international or national standards (IEC/EN 60079-17).. — The yield stress of fastener elements in the product must be in conformity with the value ‘Specified in the table for “Material of fas- tener” on the approval drawing or the parts specified in the part list for the product. — According to the ATEX directive the Ex-pump ‘must never run dry or snore. Permitted mini ‘mum water level, see dimensional drawing for the pump. Dry running at service and inspection is only Permitted outside the Ex area. — The user must know about the risks due the electric current and the chemical and physi cal characteristics of the gas and/or vapours present in hazardous areas — Fiygt disclaims all responsibility for work done by untrained, unauthorized personnel. Flygt undertakes to remedy faults in products sold by Flygt provided: — thatthe fault is due to defects in design, ‘materials or workmanship; — that the faults are reported to Flyat or Flygt's representative during the guarantee petiog; — that the product is used only under condition described inthe Installation, Care and Mainte- nance manual and in applications for which itis intended; — that the monitoring equipment incorporated in the product is correctly connected and in use: — that al service and repair work is done by a work shop authorized by Fiyat; — that genuine Fiygt parts are used. Hence, the guarantee does not cover faults caused by deficient maintenance, improper installation, incor- rectly executed repair work or nomal wear and tea, Flygt assumes no liabity for elther bodily injuries, ‘material damages or economic losses beyond what is stated above. Flygt guarantees that spare parts willbe kept for 15 ‘years after that the manufacture ofthis product has beendiscontinued.wD s150.050/060 g ce Zz General data plate ‘Sori! nunber Product code = Number ‘Guve code / Proper code (County of origin Product nomber ‘tena oration Phase; Type of curon;Froquency Rated volage “Thermal protection ‘Thermal clase Fatod shat powor Intomatonal standars Degree of protection Rated curent Fated Spaos Max submergence Drecon of rola: Lie, Reight Duty class Duty factor Product weight ‘Loked voor code lator Power factor Max. ambien temperature NotitedbodOnyy for ENvapproved Exiproduete Approval plates ‘These approval plates apply to an explosion-proof submersible Flygt pump. The plates are used together with the general data plate on the pump. EN: —EuropeanNormn ATEX Directive EN 50014, EN 60018, EN 1127-1 ® 1126 EEx dll BT3 for ambient temperatures < 40°C. ‘Aoprows ‘Roprovalsutorty + Approval Number ‘eprval for Clas | ‘eprved ave unt Star eme Starting curt Rated curent uty cass Dury fact Canter atonal infomation Max ambient temperature Seria sure. TEX marking FoGHI J EN approval or the Cable entry Certificate number: INERIS O2ATEX9008 U @ 2G or M2 EExd IIC or EExd! ozerxe-zo7moom> Temperature class Tax Operaing Tere 37 Explosion proot for Usa Class Bw trp ond D (us gnitlon pret for use. APPROVED] lo tow! bvfgreeaes Ol Suto oye in Oa Dy | sazoeue Lest ee bin is q ‘DO NOT OPEN WHILE ENERGIZED | CONNECT THERUAL CONTACTS 3 Wok. ambient temperatureIntroduction ‘Thank you for buying a submersible ITT Flygt pump. In this Installation, Care and Maintenance manual you wil find general information on how to install and service the pump to give ita long and reliable life. Applications This installation, Care and Maintenance manual applies to a submersible Flygt pumps: -5150.350 ~5180,360 | you have bought an Ex-approved pump (please see approval plate on your pump or Parts List) special handling instructions apply as described in this docu- ment, ‘The pump is intended to be used for: — pumping of water containing abrasive particles — pumping of sludge — pumping of ground water — pumping of surtes. Installation alternatives SS = transportable version with hose connection or flange for connection to discharge pipeline, For further information on applications, contact your nearest Fiygt representative Liquid temperature:max. 40°C (104°) ‘Also available in an execution for liquid temperature up 10 70°C (158°F) only with cooling jacket. Higher temperatures than 40° C (104° F) are not permit- ted for the Ex-approved pumps. Liquid density: depending on the size of the impeller. ‘The pH of the pumped liquid: 5:5—14. Lowest liquid level: See illustration on page 7. Depth of immersion: max. 20 m (65) Weights Weight including connections, but without motor cable, without | — with agitator | agitator Without cooling | 8i7kg | 845kg jacket with cooling | 880kg | 908kg jacket rear 5150.950/960 Recycling ‘Local and/or private laws and regulations regarding recycling must be followed. f there are no laws or regulations, or the product is not accepted by an au- thorized recycling company, the product or i's parts can be returned to the nearest Flygt sales company or service.IRE 5150.280/060 Motor data 50 He, 55.0 KW, 1475 r/min {60 Hz, 85 hp (63 KW), 1775 r/min 3:phase, ¢-pole S-phase, 4-pole Vonage | Rated | Staring | Votage | Rated | Staring v lourent A] current A | Vv lcurrent | current A 380D tos | 410 3800 127 | 600 400D wo | 45 | 4600 wor | 430 4150 ve | 400 575D a) 3 4400 | 490 6000 73 | 350 500D we | 35 690 Y so | 250 50 He, 70.0 KW, 1480 r/min {60 Hz, 105 hp (78 kW), 1780 r/min S-phase, 4-pole 3-phase,4-pole Votage | Rated | Staring Votage | Ratod | Starting v lcurent Al curent A v lourrent A| current A 3800 ia | 875 380 149 | 1095 400 132 | 565 460 125 | 560 aso | tat | 745 5750 ror | 445 aod | 119 | 00 6000 oo | 465 500 12 | 640 690 % | 355150 is a submersible, electric motor-driven slury pump. 1.Motor ‘Squirrel-cage 3-phase induction motor for 50 Hz or 60 Hz, ‘The motors started by means of direct on-line or star-detta stat. ‘The motor can be run continuously or intermittently with ‘a maximum of 30 evenly spaced starts per hour. Flygt motors are tested in accordance with IEC 34-1 ‘The stator is insulated in accordance with class H (180°C, 360°F). The motor is designed to supply its rated output at 25 % variation ofthe rated voltage, Without overheating the motor, #10 % variation of the rated voltage can be accepted provided that the motor does not run continuously at full load. The motor is. designed to operate with a voltage imbalance of up to 2% between the phases. 2. Bearings The support and main bearing of the shaft are both double row angular contact ball bearings. ‘3. Mechanical seal unit ‘The pump has one shaft mechanical seal unit consist- ing of two independently operating seals. All| Innerseal: Corrosion resistant tungsten carbide WCCRIWCCR Outer seal: Corrosion resistant tungsten carbide WCCRWCCR Alt Innerseal: _Corrosionresistant tungsten carbide WCCRWCCR Outer seal: Silicon Carbide RSICIRSIC AS Lowest liquid level 4, Monitoring equipment ‘The stator incorporates throe thermal contacts conn- ‘ected in series that activate an alarm at overtempe- rature, | The thermal contacts: open at 140°C (285°F). The ‘sensors shall be connected to Fiygts monitoring Unit MiniCAS Il or equivalent unit. ‘The monitoring equipment shall be of a design that ‘makes automatic restart impossible. ‘The pump is supplied with inspection sensor FLS10 for sensing the presence of any liquid in the inspection chamber. 5. Cooling (without cooling jacket) ‘The pump is cooled by the ambient liquid. For lowest liquid level, see ilustration below. 6. Seal housing ‘A.coolant fluid lubricates and cools the mechanical ‘seal unit and acts as a buffer between the pumped. media and the electric motor. | 7. Inspection chamber ‘The inspection chamber is equipped with a FLS10 leakage sensor to prevent damages on the motor. 8, Seal housing cover Provides heat transfer from the coolant to the pumped ‘media. 9.Shatt The shattis delivered with the rotor as an integral part Shaft material; stainless steel. 10. Cooling (with cooling jacket) The motor is cooled by a closed loop cooling system. An integrated coolant pump circulates the coolant ‘whenever the pumps operated. 11. Impeller ‘The pump is available with a shrouded three-channel type of High Chrome alloyed white cast iron (HC).BES 5150:250/960 Without cooling jacket With cooling jacket“The pump may be transported and stored in a vertical or horizontal position. Make sure that the pump cannot, roll or fall ove. WARNING! Always lft the pump by its liting handle never by the motor cable or the hose, ‘The pump is frostproot as long as itis operating or is immersed. Ifthe pump is hoisted from the sump when the temperature is below the freezing point, the impeller and shaft seal may freeze. ‘A frozen impeller and shaft seal can be thawed by allowing the pump to stand immersed in the liquid for a short period before itis started. Never use a naked flame to thaw the pump. “The pump should run fora few seconds ater being taken up in order to expel all remaining water from the hydraulic ond. 5150.950/960 For longer periods of storage, the pump must be pro- tected against moisture and heat. The impeller should be rotated by hand occasionally (for example every ‘ther month) to prevent the shaft seals from sticking together. If the pump Is stored for more than 6 months, this rotation is mandatory. ‘After a long period of storage, the pump should be inspected before its put into operation. Pay special attention to the shaft seal and the cable entry. Follow the instructions under the heading "Before start ing’Handling equipment ‘Always pay extra attention to safety aspects when work- ing wth iting equipment. Ling equipments required for hanaing the pump. ‘The litng chain and the schackle should be in stain- less steel and inspected every year. — Stay clear of suspended loads. — Always lift the pump by its lifting handle - never by the motor cable or the hose. ‘The minimum height between the lifting hook and the floor shall be sufficient to lit the pump out of the sump. The liting equipment shal be able to hoist the pump straight up and down in the sump, preferably without the need for resetting the liting hook. Oversized liting equipment could cause damage it the ump should stick when being lifted. Make sure that the lifting equipment is securely anchored and in good condition, CCheck that the liting handle and chain are in good ‘condition To ensure proper installation, please see the dimen- sions on the dimensional drawing WARNING! The end of the cable must not be submer- ‘ged. It must be above flood level, as water could pene- trate through the cable into the junction box or the ‘motor. For automatic operation ofthe pump (level contro), itis recommended thatthe level regulators should be used at low voltage. The data sheet delivered with the regulators gives the permissible voltage Local rules may specity otherwise. Clean out all debris from the sump before the pump is. lowered down and the station is started, NOTE for Ex version page 3. — Minimum stop level should be according to the dimensional drawing. — The pump must never run dry or ALLA Safety precautions In order to minimize the risk of accidents in connection with service and installation work, the following rules, shouldbe followed: Never work alone, Use aliting hamess, safety line and a resprator as required. Do nt ignore the risk ofdrowning Make sure there are no dangerous gases within the work area Check the explosion risk bofore welding or using electric hand tools Before the pump is installed check thatthe cable and cable entry have not been damaged during the transportation Observe strict cleanliness. Do not ignore heath hazards, Bear in mind the risk of electrical accidents, Make sure thatthe liting equipment is in good conaition and comply to local ordinances. Provide a suitable barier around the work area guardrail Make sure you have a clear path of retreat. Use safety het, aety goggles and protective A first-aid kt must be close at hand, Note that epecial rules apply to installation in expiosiveathmosphere. Follow all health and safety rules and local codes and ordinances. 9. 10, n 12, | Installation alternatives & eS In the S- instalation, the pump is transportable and intended to operate completely or partially submerged inthe pumped liquid. The pump is equipped with a ‘connection for hose or pipe, see "Parts list’ ‘The pump stands on a base stand. 10— Before starting work on the pump, ‘make sure that the pump and the control panel are isolated from the power supply and cannot be energized. earthed (grounded). This applies to both pump equipment and any ‘monitoring equipment. Failure to heed this warning may cause a lethal accident. Make sure that the earth (ground) lead is correctly connected by testing it. p NOTE for Ex version page 3. - All electrical work shall be carried out under the super- Vision of an authorized electrician, Local codes and regulations shall be complied with. = Check the data plate to determine which voltage sup- ply is valid for your pump. ~ Check that the main voltage and frequency agree with the specifications on the pump data plate - Ifthe pump can be connected to different voltages, the connected voltage is specified by a yellow sticker. Connect the motor cable tothe starter equipment as ilustrated in the wiring diagrams. When the pump is connected to the public mains it ‘may cause flicker of incandescent lamps when starting. In this case the supply authority should be notified before installing the pump. Leads that are not in use must be isolated. “The cable should be replaced if the outer sheath is. damaged. Contact a Fiygt service shop. Make sure thatthe cable does not have any sharp bends and is not pinched. Under no circumstances may the starter equipment be installed inthe sump. WARNING! For safety reasons, the earth (ground) lead ‘should be approx. 150 mm (6.0) longer than the phase lead. if the motor cable is jerked loose by mistake, the ‘earth (ground) lead should be the last lead to come. | toose from its terminal. This applies to both ends of the | cable. The motor is convertible between different voltages as stated on the data plate. This conversion is done on the terminal board or the contactor. — Bear in mind the risk of electrical shock and the risk of explosion if the electrical connections are not correctly carried out. When using a variable-frequency-drive (VFD) the shielded cable (type NSSHOU...SE+St) should be Used in order to full European CE requirements. Con- tact your Flygt representative and ask your VED-suppli- €r for electrical imitations. Also please see VFD-rec- ‘ommendation Fiygt article no. 893472 "=ERBES 5150.9501960 Connection of stator and motor leads ~ Check on the data plate which connection, ¥, D or YD, is valid for the voltage supply. Then, depending ‘on voltage, arrange the connection on the terminal board in accordance with Y, D or YD. See figure. = Connect the motor cable to the connection block, U1, V1, W1 and earth (ground). Connect the leads from the motor control circuit = It star-detta statis used, motor cables are connected as shown in the figure. Links (umper strips) are not Used with star-delta star. Make sure that the purmpis correctly earthed (grounded). + Install the O-ring (83) and connection cover (32). + Tighten the screws and the gland nut so thatthe ca- ble entry unt bottoms out. = Connect the motor cable to the starter equipment. ‘Check the direction of rotation, see "Before starting’. «Ifthe direction of rotation is wrong, transpose two of the phase leads. = Remember thatthe starting surge withthe direct-on line start can be up to six times higher than the rated current. Make sure that the fuses and circu breakers are ofthe proper amperage. ~The incorporated thermal contacts must be connect- ed and in use. The pump must be connected to an ‘overload protection which must be set to rated power. 1251503801300 SE SUBCAB?® 4GX/SUBCAB® AWG, SUBCAB® 4GX/SUBCAB® AWG, 6-leads, Y 6-leads, D 5150 5150OE 51s0.280/060 Ene: SUBCAB?® 4GX/SUBCAB® AWG, 60 Hz only, 9-leads, 460 V, Y ser. 5150 peed * SUBCAB® 4GX/SUBCAB® AWG, 60 Hz only, 9-leads, 230 V, Y // 5150 alo} TITS Ut US V4 Vs wa ws Suna auecarane tee te tesa [Temi bors 3 yen See cones ___| Cale ed 2 2 sir eas cameron Stato od Us ea Uz geen 2 bin 5 Wyte |e We ytor ws Termin! boars ins ens end ur ca red UF a | asa Hs wi eo ytenigcen —|ytowsroon | Vasouer U2, geene “Cermecod ater aorSUBCAB® 7GX, 6-leads, Y/D 5150 SUBCAB® 4GX/SUBCAB® AWG, 60 Hz only, 2 motor cables in- parallel, 9-leads, 230 V, Y // 5150 yallyeeueed| vifesade frat ander . hl ofall 7 seca cane | tne tose tad | emi oa a rom ra or @ tx ok ws a [eae ima 6 ory ‘ie “ a 1 or 2 yetonireen | etonironn | D a 2 wt Seandock 60 ator & 5 wn wens] Suncare : 4 « he conwat___| cabot [Eni nd |e boa B 7 ie 2 2 ti 2 2 tone 2 Sioa conaton E ea oe et a ee “eminl bod 2 i 2 ||| ose os ‘Stor wage eonrecton z Vi bon “ Stor ad “amin! bors V6 bown 6 We we We, yon ws Vitro ie Wb vy “ U2 ene we “Canc paw eT'5150.950/960 = ‘SUBCAB® 4GX/SUBCAB® AWG, SUBCAB® 4GX/SUBCAB® AWG, 60 Hz only, 2 motor cables in- 2 motor cables in parallel, 6-leads, Y parallel, 9-leads, 460 V, Y ser 5180 5150 nivel Giles | i | | ‘suBCAs® ‘SUBCABY sien iSien : waver ro Reo ee]eIIo] mp) alle elelalelolalo eee ame ne tose teed {ria nore 7 coe ra cr & vr ce " ° Fatowarer [jionsenn | Sones oon acs | senna connot —|eomtees [esas |rorial bom 2 2 ie 2 ean 3 fe ‘eral oes wpe ™ Ce gee ee aneiaeemee }5150,250/960 SE SUBCAB® 4GX/SUBCAB® AWG, 2 motor cables in parallel, 6-leads, SUBCAB® 4Gx, 5150 2 motor cables, Y/D, 6-leads ‘Saachar | SaBCA AWe i mare | tess re terminal boars ra oe rs ut ne Ta Tenino a ‘ace tack ws tr own ur 2 ace Back ws 2 dis ws a omy vate vt 3 ey wu a sey si vt u fom we 2 retowireen —|yetowgenn |p 2 Bea ve Guns co le a ‘wr je ‘suecass | suacaRe aN || yeowareon 2 Convsi___| cabin ions _|cale fad | Terminal beara | | [Coniel canis nad Terni board 2 2 he R 2 fe 2 ‘Stotor eds connection ce ‘Site ads conection Stator ead _Tombalboord Sao eed “Tein board Ui Ur or] ur vebown “ wa, ae we Wi, ylow wt Vi.bown w 2, aren| We. geen ve vate geo wi 12, Vath we 7WEEE 5150250060 Sensorconnections Monitoring equipment FLS10 is a small float switch and itis installed in the inspection chamber. FLS is connected to max 12 V. Thermal switches are incorporated into the stator and are rated 250 V, 2,5 A (cosp=1) /6,3 A (cos =06). ‘The sensors are connected as standard to the Flygt ‘monitoring relay MiniCAS II (see diagrams below). Incase optional sensors are used the more advanced monitoring relay MAS 711 can be used. Thermal contacts/ Thermistors FLS10 Fora PTC-thermistor (PTC = Positive Temperature Coefficient), there is a significant increase in resistance at a certain temperature that can be utlized for monitoring the temperature, PTC-thermistor 35°C R.<1000hm 195°C (Tyep5°O) F< 550 Ohm [2145 °C (Tree +5°C) R12 1390 Ohm ‘Three thermistors are connected in series and have a resistance of approx. 150-300 ohms at room tempe- rature, ‘The label in the junction box shows if the pump is ‘equipped with optional sensors, Optional Pump without cooling jacket ‘Sensor connection for standard configuration ‘The pump is as standard equipped with either thermal contacts or thermistors. ‘AyThetmal contacts, B)Thermistors BA eine Cara The hay Tet og q — a ia = 5 ev BSUS) ore pg il 185150950060 SE A smal contacts 0 mA= Overtemperatire 10 m= OK 23 mA= Leckage Tolerance 10% a a Circuits shown de-energised —. pumenansurny —al = ‘Sensor Connection Table (For unter information pease contact Flat represetatve) ‘Sensor ‘Sensor Thermal Control Connected lead connection | cable to Thermal | White Ti TiPOrange CAST contacts | Brown rR Ta'Bue Mini CAS It + WhitesBrown | T15 ‘SubCab FLsio /SubCabAWG I | Thermistors | Fed 7 OT Theristor relay + Red wm 2 Thermistorrelay FLsto Brown 15 3 Mini CAS IL Brown M16 4 Mini CAS IL 19= Before starting — Before starting work on the pump, make sure that the pump is Isolated from the power supply and cannot be energized. This applies to the control circuit as well. In some installations the pum surface and the surronding li may be hot. Bear in mind the risk of burn injuries. In some installations and at level of 70 d8 or the noise level specified for the actual pump may beexceeded. ‘Make sure that the pump cannot roll or fall over and injure people ‘or damage property. NOTE for Ex version page 3. = Check thatthe visible parts of the pump and installation are undamaged and in good consition. = Remove the fuses or open the circuit breaker and ‘check thatthe impeller can be rotated by hand, - Verity that the supply voltage matches the pump data plate voltage rating. = Conduct insulation integrity check. ~ Conduct phase to phase resistant check. Check that the monitoring equipment works. = Check the direction of rotation. The impeller shall rotate clockwise, as viewed from above. When start- ed, the pump will jerk in the opposite direction to the: direction in which the impeller rotates. See figure. - In case of dry installation, check the direction of rota- tion through the inlet elbow access cover. + Transpose two phase leads ifthe impeller rotates in the wrong direction (3-phase). Cleaning Ifthe pump has to be stopped after it has been running inheayy slurry, et itrun for a while in clean water, or ‘lush it through the discharge connection. I clay, ce- ment or other similar dir islet in the pump it may clog the impeller and seal, hampering the pumps operation. During a longer period out of operation, the pump must be test run every other month to prevent the mechani- cal seals from sticking together. NOTE for Ex version page 3. | Starting jerk ‘Watch the starting jerk which can be powerful 20Service/Inspection Flygt recommends a preventive maintenance program based on Intermediate and Major Services at regular intervals, For standard applications where the temperature of the pumped liquid is 40° C (104° F) or less an Intermediate Service should be performed. ‘Service intervals depends on duty conditions. A first check of inspection chamber and cootant level should be made after 1 month of duty. — a ‘The time between Major Service could vary con- siderably depending on operating conditions and the ‘need for a Major Service will be determind during the regular Intermediate Services Pump intermediate Service Pumpstation Intermediate Service Junction box Check thattis clean and dy Electrical Check that they are clean and dry Terminalboard Check that the connections are cabinets/panels roperiytightened Connectonto Check thatthe connections are Insulation check Check that the resistance | " Property tightened. betweenearthandphaseleadis | | Overloadand Check correc settings. more than 5M. Conduct phase to || etherprotections (et Personnel safety Check guard rails, covers and other | Cable Check thatthe rubbersheatng ack protections Se ecoares Levelregulators Check condition and function. Sealhousing _Filup with new coolant f neces sary. Check freezing point lowerthan-13°C ("| 6 Ol Pump ‘Major Service Inspection Drain liquid any. Check chamber the resistance of FLS0. Normal value approx.1200.0, alarm | | Suppontand Replace wihnew bearings approx. 4300. mainboaring rings ‘Always replace the O-ings of the || \lochanical sal Replace with new seal units. filing plugs and at the junction cov- | | unit ad cr Always grease new O-rings ‘Thermal Check the resistance. eae ecation eerie xe Nilerrnecaate a contacts Normally closed ercut: intervalO=1 0 ‘Thermistor Check the resistance 20 - 250.0, (measuring voltage max 2 V DC). Impeller Check impeller clearance and adjust it necessary. Liting handle Check the serews and the coniton of the liting handle Rotation Check the rotation of the rection impel. Liting device Check that local safety regu: lations ae flowed. Voltageand Check runing values. amperage 21ABE 51502500060 any indication of | Actions alarm between in- spections, please seeinstructions bolow. Fisto Drain the fluid in the inspect- ion chamber. Fill with new coolant if necessary. Check freezing point lower than | 13°C (@°F)) | ‘Check the inspection chamber again after one week of ope- ration. Ifleakage has occured, drain the tuid and change the ‘mechanical seal unit and replace with new coolant. Thermistor Thermal | Check coolant level contact (pump with cooting jacket) (Check stat and stop levels. Overtoadprotection | Check thatthe impeller can rotate freely NOTE for Ex version page 3. Safety precautions WARNING! Before starting work on the pump, ‘make sure that the pump is isolat- ‘ed from the power supply and cannot be energized. The following points are important in connection with ‘work on the pump: — Make sure that the pump cannot roll o fll over, andiinjure people of damage property. —Check every year that the liting equipment is in {good condition “The pump is designed for use in liquids which can be a healthrsk. In order to prevent injury to the eyes and ‘skin, observe the following points when working on the pump: '— Make sure that the pump has been thoroughly, cleaned. — Beware ofthe risk of infection — Follow local safety regulations — Always wear goggles and rubber gloves. — Rinse the pump thoroughly with clean water before starting work. — Rinse the components in water atter dismantling — The coolant chamber may be under pressure. Hold a rag over the fling plug to prevent splatter. Proceed as follows if fluids have splashed into your eyes: — Rinse your eyes immediately in running water for 15 minutes. Hold your eyelids apart with your fingers — Contact an eye specialist (On your skin — Remove contaminated clothes. —Wash your skin with soap and water. — Seek medical attention, if required.Changing the coolant Emptying coolant (without cooling jacket) Filling plugs in/out 44Nm (33 ftlb) Rte table yg part na. 96 77 00 Filling coolant Filing plug Inout 44 Nm (33 ft) INSP Pump without cooling jacket Filing plug invout 44 Nm = (@3rt) Pump with cooling jacket 23 s1s0.50%60 SE Emptying coolant (with cooling jacket) Filling plugs in/out 44 Nm (33 Rib) Lift the pump horizontally with two overhead cranes ‘and place on a reli table, ‘Turn the pump so that one of the filing plugs holes faces downwards. WARNING! Ifthe mechanical seal unit leaks, the ‘seal housing may be under pressure. Hold a rag Cover the fling plug to prevent splatter. Unscrew the filing plug. Itis easier to drain the wa- ter-alyco! ifthe other filing plug is also removed. |. Raise the pump to an upright positon. Fill wth cool ant to the same level as the filing plugs Pump without cooling jacket ‘approx. 11 litres (11.6 US quarts). Pump with cooling jacket ‘approx. 47 litres (49.7 US quarts). Coolant: a mix of water and stabilized monopropy- leneglycol ina mixture ratio of 70/30 % volume part. known trade marks of monopropyleneglycol are: Dowcal N (individual components are approved by FDA), Doweal 20. These ate non-poisonous, heat- ‘and-cold resistant and inhibiting of corrosion. Use of other type of glycol jeopardize the function of the pump. If there is no risk of freezing even clean water with ant-cortosive is acceptable as coolant. ‘Always replace the O-rings of the filing plugs. Put the plugs back and tighten them.ARSE 5150.250/960 Removing the impeller Worn impelier and/or pump hous- ing can have very sharp edges Use protective gloves! a 1. Lock the impeller. Place the pump horizontally, Don't remove the liting sing, ‘Thread a chain through the impeller and pump outlet. ‘Connect the chain ends so that the impeller canttrotate, a 2. Loosen the impeller from the shatt. Remove the wear protection. Remove the impeller sorew. ‘Turn the gland screw counter clockwise until the impeller breaks free from the shat. Tool: 17 mm hexagon bit adaptor (allen socket) with @ 100 mm (4") extension. Fit the impeller screw and tighten lightly by ‘hand, just o prevent the impeller from falling oft, 3, Remove the pump housing Remove the chain from the impeller and pump housing Raise the pump. Remove the screws. Using a crane, lit the drive unit out off the pump housing. Remove the two O-rings. 244. Secure the wear cover. a. Place the drive unit horizontally. WARNING! When laying the pump on its side do ‘ot allow the weight of the pump to rest on any portion ofthe impeller. The impeller must not be allowed to make contact with the concrete floor oF ‘other hard and rough surfaces. b. Prevent the wear cover from falling off when removing the impeller by attaching a liting sting, ‘The impeller can have very sharp edges. Use protectivegioves! Remove the impeller. a. Remove the impeller screw, b. Remove the impeller. ¢. lomove the wear cover. 6. Remove the conical sleeve from the impeller.EES 51509501060 Installing the impeller 1. Setting he gland screw. ‘Make sure that the end of the shalt is clean and free from burrs. Polish off any flaws with fine emery clot. Grease the end ofthe shatt, conical sleeve, the threads of the gland screw and the impel- ler screw. Align the edge ofthe gland screw with the ledge of the conical sleeve so that they are ‘lush. Check thatthe impeller screw is clean and easy to screw into the shaft end. This fs to prevent the shatt to rotate wit the impeller screw. S OO a 2. Assemble the impeller. Fit the wear cover to the drive unit and secure it with aliting sting. Fit the conical sleeve and the impeller onto the shatt. Fit the washer (or barrel nut agitators used) and impeller screw. Tighten the screw lightly byhand. omove the sling and fit new O-rings to the ‘wear cover. 3. Fitthe drive unto the pump housing Raise the drive unit and fititto the pump housing, Tighten the screws diametrically.5150,350/360 4. Lock the impeller in place. a. Place the pump horizontally. b. Thread chain through the impeller and pump outlet. c, Lock the chain ends. 5. Adjust the play between impeller and pump hous- ing. Remove the impeller screw and washer/ (barrel nut) and tur gently the gland screw clockwise towards the pump housing. 1 screw. 6. Tighten the impo ‘a. Fitthe washeri(barrel nut) and impeller screw {and tighten it. Check that the impeller rotates freely. The clearance should be 0,4- 1,3 mm between the impeller and the pump housing, b. Remove the chain. arDEE s150.0500060 Agitator ‘The agitator consists of a propeller onto a shaft, This hat is fixed to the impeller as an extension of the ump shatt WARNING! Watch out for the propeller in rotation. Installing the agitator 1. Carty out item 1-5 in chapter "Removing the impeller 2. Fitthe barrel-nut (4) and cylinder pin (2) to the impeller. 3. Carry out tem 1-6 in chapter “Installing the impeller. ‘Note! An impeller screw for agitator «applications shouldbe used. 4. Apply some grease on the contact surfaces between the shaft (6) and the barrel-nut (4). 5. Fitthe agitastor shaft (5) into the barrel nut (4) {and tighten itto a torque of 187 Nm (138 ft lb) Using the key handle on the shaft. 6 Fitthe stand and the strainer. 7. Apply grease into the tapered hole in the agitator propeller 6). 8. Fitthe propeller (6) to the shaft end. 9. Fitthe retaining ring (8) washer (7) and screw (9) into the place and tighten 10. Fitthe protection plug (10) onto the propeller. Removing the agitator Remove the protection plug (10). Untighten and remove the agitator screw (9). Remove the retaining ring (8) and washer (7). Refit the agitator screw (9), Place the washer (7) on top ofthe screw (9) and inset the retaining ring (8) nto the groove inthe propeller (6). 6. Remove the propelierby unscrewing the agita tor screw (9). Puller operation is obtained by the head of the screw pressing the propeller ‘outwards, Undo the screws holding the stand wth trainer and remove it. & Lock the impeller. See item 1 in chapter "Re- ‘moving the impeller 9. Undo and remove the shatt (5). 10. Perform item 2-5 in chapter "Removing the impeller’ 28‘A universal instrument multimeter (VOM), atest lamp (Continuity ester) and wiring diagram are required in ‘order to carry out fault tracing on the electrical equip- ment. Fault tracing shall be done with the power supply as- ‘connected and locked off, except for those checks which cannot be performed without voltage. ‘Atways make sure that there is no one near the pump ‘when the power supply is turned on. Use the following checklist as an aid to fault tracing, It Is assumed that the pump and installation have former- ly functioned satisfactory. Electrical work shall be performed by an authorized electrician, Follow local safety regulations and observe recommen- ded safety precautions. 1. Pump fails to start Yes Ts an alarm signal indicated on |___»- the control panet? No Yes Canthe pump be started |__p manually? | No Y ; No [1s the instalation receiving ‘voltage? Yes Y Is the impeller stuck? Yes WARNING: disconnectpower |__» before checking the impeller. No Y Contact Fiygt service shop. (Check the cause: — It the stator temperature is high, check that the impeller rotates freely. — It there isa fault in the thermistorsthermal contacts, contact a Fiygt service shop. — Ifthe FLS10 indicates an alarm, — Check that the overload protection is reset. 4) Faultin level equipment (start level regulator). Clean orreplace. ) Faultin control equipment. Check: — that the thermal contacts have not opened. — that all connections are intact. — relay and contactor cols — that the control switch *Mar/Auto" makes contact in both positions. ‘Check: — that the main power switch is on. — that there is control voltage tothe starter equipment and its fuses are intact. — that there is voltage in each phase of the supply line. — that all fuses have continuity and are — that the overload protection is reset. _— that there is no brake in the motor cable. ht. Clean, Clean the sump. 2POE 5150 2807060 2. Pump starts but motor protection trips Yes Is the motor protection set |» adjust. toolow? (Check with data plate) + Is the impeller difficult to es} Clean the impeller. rotate by hand? > WARNING: disconnectpower lean out the sump. No v ———_1_____ ww Is the installation receiving full |» Check the motor fuses. voltage onallthree phases? | Notty an electrician, y ves Yes ithe same value, or are they too high?| yw Yes phases and earth (ground) in the stator detective? Use insulation tester. With a 1000 V-DC megger, the insulation between the phases and between any phase and earth (ground) should be > 5 MOhm ,” | Yes isthe density ofthe pumped _|—"~> pitute the lquia liquid oo high? (Max deneiy 1500 kg/m*, 12.5 1b per US gal) cana i Fault on overload protection? Yes No before checking the impeller Check that the impeller is propery trimmed, It anything else is wrong, contact Flygt service shop. Have allthe phase currents |_——» Contact Flygt service shop. |s the insulation between the |» Contact Flygt service shop. ‘Change the impeller or to a more suitable pump. [> Replace the overload protection,5150950%60 | 5 3.The pump does not stop (when level control is used) -——_________ ww» Is the pump able to empty the |—— Check: station to the stop level? —for leakage in pipe and/or discharge connection. — that the impeller isnot clogged. y ves WARNING: disconnect power before checking the impeller. =the non-retum valve(s). — that the pump has adequate capacity. Contact Fiygt Yes Faultin level sensing equipment? |_—» Clean the level regulators. a a (Check the functioning of level regulators. No Check the contactor and contro circuit. v Replace defective items. Yes ‘Stop level set too low? |__» Raaise the stop level No. v Contact Fiygt service shop. 4.The pump starts-stops-starts in rapid sequence ———— 1 Does the pump stat due to |" » Check backow which fils sump —that the distance between the start and stop levels is {o start level again’? eote a top —the non-return vatve(s). y — that the riser is not too long without a non-return valve. Yes Does the contactors sel |» Check: holding function break? ee —the voltage in the controt circuit in relation to the rated No voltages on the col —the functioning of stop level regulator. y —the voltage drop in the line atthe starting surge makes the contactor’ seltholding break. Contact Fiygt service shop. 315. Pump runs but delivers too little or no water Check: — direction of rotation of pump, see "Before starting" —that valves are open and intact. — that pipes and impelier are not clogged. — that the impeller rotates freely — that the suction lt has not been altered. —for leakage in the pump installation, — for wear on the impeller, pump and casingfiange. ‘See also under “inspection”, Do not override the motor protection repeatedly iit has tripped.‘Most recent service date Pump No. Hours of operation Remarks Sign.wEIBES 5150.050/060 ‘Most recent Pump No, Hours of Remarks Sign. service date operationsis0.sso60rer wow fiygticom