Table of Contents
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Table of Contents
Related Manuals for Xylem Flygt 3201
Summary of Contents for Xylem Flygt 3201
- Page 1 Installation, Operation, and Maintenance Manual Flygt 3201...
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Page 3: Table Of Contents
Maintenance............................32 Maintenance guidelines........................32 Torque values............................32 Change the oil...........................33 Replace the wear rings........................34 Replace the wear ring in the pump housing, diffuser ring, or suction cover......34 Replace the impeller wear ring.....................35 Replace the impeller.........................35 Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 4 The pump does not stop when a level sensor is used..............41 The pump starts-stops-starts in rapid sequence................41 The pump runs but the motor protection trips................42 The pump delivers too little or no water..................42 Technical reference..........................44 Application limits..........................44 Motor data............................44 Flygt 3201 Installation, Operation, and Maintenance Manual...
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Page 5: Introduction And Safety
This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact an Xylem representative before proceeding. -
Page 6: User Health And Safety
This guideline also applies to the control circuit. • Make sure that the thermal contacts are connected to a protection circuit according to the product approvals, and that they are in use. Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 7 • Make sure that the cable and the cable entry have not been damaged during shipping. • Use only the screened cable when using a variable-frequency drive (VFD). The screened cable is necessary to fulfill European CE requirements. Contact your Xylem representative and ask your VFD supplier for electrical limitations. See also VFD recommendation in article no.
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Page 8: Safety Regulations For Ex-Approved Products In Potentially Explosive Atmospheres
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres: • All work on the product must be carried out by certified electricians and Xylem- authorized 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 and/or vapor present in hazardous areas. -
Page 9: Environmental Safety
• Do not modify the equipment without approval from an authorized Xylem representative. • Only use parts that have been provided by an authorized Xylem representative. Equipment for monitoring For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not limited to these devices: •... -
Page 10: Spare Parts
However, should the need arise for a warranty claim, then contact your Xylem representative. Spare parts Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 11: Transportation And Storage
1. Remove packing materials from the unit. Dispose of all packing materials in accordance with local regulations. 2. Inspect the unit to determine if any parts have been damaged or are missing. 3. Contact your Xylem representative if anything is out of order. Lifting guidelines General The following are general guidelines for lifting the unit: •... -
Page 12: Store The Unit
• The minimum height between the lifting hook and the floor must be sufficient to lift the unit out of the sump. Contact Xylem for information. • The lifting equipment must be able to hoist the unit straight up and down in the sump, preferably without the need for resetting the lifting hook. -
Page 13: Product Description
• Modifications to the unit or installation should only be carried out after consulting with Xylem. • Original spare parts and accessories authorized by Xylem are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation. For more information contact your Xylem representative. -
Page 14: Parts
(liquid) and the drive unit. Cooling The stator is cooled by either the surrounding media (liquid) or by forced circulation in a cooling jacket. Motor For information about the motor, see Motor data. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 15: Monitoring Equipment
NOTICE: The CLS sensor body is made of glass. Handle with care. Two FLS sensors or one CLS and one FLS sensor can be used in the same pump, connected in parallel. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 16: The Data Plate
Approvals This section describes the EN and FM approvals that explosion-proof products have. For more information, please contact your Xylem representative. In addition to the data plate, explosion-proof products also have either an EN or a FM approval plate. • European Norm •... -
Page 17: Product Denomination
II 2 G or IM2 EEx d IIC or EEx dI This illustration describes the approval plate for Factory Mutual (FM) and the information contained in its fields. Temperature class Maximum ambient temperature Figure 3: FM approval plate Product denomination Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 18 The serial number is used for identification of an individual product, and is divided into four parts. This is an example of a serial number, and an explanation of its parts. NP 3085.183 - 951 0163 Product code Production year Production cycle Running number Flygt 3201 Installation, Operation, and Maintenance Manual...
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Page 19: Installation
In the P-installation, the pump is installed on a stationary discharge connection, and operates either completely or partially submerged in the pumped liquid. These requirements and instructions only apply when the installation is made according to the dimensional drawing. Figure 4: P-installation Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 20: Install With S-Installation
In the S-installation, the pump is transportable and intended to operate either completely or partially submerged in the pumped liquid. The pump is equipped with a connection for hose or pipe and stands on a base stand. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 21: Install With T/Z-Installation
• In the Z-installation, the pump is installed in a horizontal position on a support stand in a dry well next to the wet sump, and a bell-mouth is connected to the inlet pipe. These requirements and instructions are for Z-installations that comply to the dimensional drawing. Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 22 Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 29). 5. Make sure that the weight of the pump does not put strain on the piping. Flygt 3201 Installation, Operation, and Maintenance Manual...
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Page 23: Make The Electrical Connections
If the outer sheath of the cable is damaged, then replace the cable (contact an Xylem service shop). Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 24: Earthing (Grounding)
• The screened cable must be used according to the European CE requirements if a Variable Frequency Drive (VFD) is used. For more information, contact your Xylem representative (VFD-supplier). -
Page 25: Connect The Motor Cable To The Starter And Monitoring Equipment
4. Check the functionality of the monitoring equipment: a) Check that the signals and the tripping function work properly. b) Check that the relays, lamps, fuses, and connections are intact. Replace any defective equipment. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 26: Cable Charts
Color and marking of the control leads Control SUBCAB 7GX and SUBCAB 4GX SUBCAB AWG White T1 Orange White T2 Blue Colors of the stator leads Stator connection Lead color Green Brown Blue Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 27 ® SUBCAB T1 T2 T1 T2 W2 U1 V1 U2 SUBCAB 7GX, 6 stator leads, Y/D connection This table shows the connection diagrams for the SUBCAB 7GX (3-phase power cables), with Y/D connection. Flygt 3201 Installation, Operation, and Maintenance Manual...
- Page 28 T1 T2 T1 T2 T1 T2 T1 T2 V1 U2 SUBCAB 4GX, 6 stator leads, Y/D connection This table shows the connection diagrams for the SUBCAB 4GX (3-phase power cables), with Y/D connection. Flygt 3201 Installation, Operation, and Maintenance Manual...
- Page 29 T1 T2 SUBCAB ® SUBCAB ® SUBCAB 4GX/SUBCAB AWG, 9 stator leads, 460V This table shows the connection diagram for the SUBCAB 4GX/SUBCAB AWG (3-phase power cable), with Y serial connection (60 Hz only). Flygt 3201 Installation, Operation, and Maintenance Manual...
- Page 30 36 mA Leakage The values have a 10 % tolerance CLS and Thermal contact (only standard version) Value 0 mA Overtemperature 5.5mA 29mA Leakage (5 second delay) The values have a 10 % tolerance Flygt 3201 Installation, Operation, and Maintenance Manual...
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Page 31: Check The Impeller Rotation
Two FLS, and Thermal contact (only standard version) Thermal contact Check the impeller rotation WARNING: The starting jerk can be powerful. 1. Start the motor. 2. Stop the motor. 3. Check that the impeller rotates according to this illustration. Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 32 4. If the impeller rotates in the wrong direction, do one of these steps: • If the motor has a 1-phase connection, contact the local Xylem shop. • If the motor has a 3-phase connection, transpose two phase leads and do this procedure again.
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Page 33: Operation
2. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. 3. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms. 4. Check that the monitoring equipment works. 5. Start the pump. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 34: Maintenance
79 (58) 136 (100) 333 (245) 649 (480) 1120 2210 12.9 (825) (1630) Screws with countersunk heads Stainless steel, A2 and A4 Property class Property class 70 is torque tightened as class 80. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 35: Change The Oil
2. Drain the pump. Use the oil drainage pump. Make sure that the plastic tube goes all the way to the bottom of the oil housing. 3. Fill the housing with new oil. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 36: Replace The Wear Rings
Use a rubber mallet or a wooden block to prevent deformation. The work will proceed more easily if the pump housing , diffuser ring, or suction cover first is heated and/or the wear ring cooled. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 37: Replace The Impeller Wear Ring
5. Install the drive unit on the pump housing. Tightening torque, see Torque values (page 32). Replace the impeller WARNING: A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. Wear protection Lock nuts Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 38: Remove The Impeller And The Wear Protections
Not applicable for HS-, or LT-version. f) Press the impeller, impeller hub, or propeller onto the shaft with the impeller or propeller screw. Heat the impeller, impeller hub, or propeller to about 100°C (212°F), to ease the fitting. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 39: Adjust The Lower Wear Protection
6. Check that the impeller can easily be rotated by hand. For the pump to perform at maximum capacity, the impeller must be adjusted regularly. More extensive repairs require special tools and should be carried out by an Xylem authorized service technician. -
Page 40: Major Service
Check the running values. Major service For a major service, take this action, in addition to the tasks listed under intermediate service. Service of the... Action Support and main bearing Replace the bearings with new bearings. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 41: Service In Case Of Alarm
Replace with new seal units. Service in case of alarm Alarm source Action The thermistor/Thermal contact Check that the cooling jacket is not clogged. Clean if necessary. The overload protection Check that the impeller can rotate freely. Flygt 3201 Installation, Operation, and Maintenance Manual... -
Page 42: Troubleshooting
• The sump in order to prevent the impeller from clogging again. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, Product Description (page 11). -
Page 43: The Pump Does Not Stop When A Level Sensor Is Used
Raise the stop level. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, Product Description (page 11). -
Page 44: The Pump Runs But The Motor Protection Trips
Replace the overload protection. overload protection. If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, Product Description (page 11). - Page 45 If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, Product Description (page 11).
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Page 46: Technical Reference
Code compliance IEC 60034-1 Rated output variation ±5% Voltage variation without ±10%, provided that it does not run continuously at full load. overheating Voltage imbalance tolerance Stator insulation class H (180°C [360°F]). Flygt 3201 Installation, Operation, and Maintenance Manual... - Page 48 For more information on how Xylem can help you, go to xyleminc.com Xylem Water Solutions AB Visit our Web site for the latest version of this document and more information Gesällvägen 33...