Xylem Flygt 2860.180 Installation, Operation And Maintenance Manual
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Xylem Flygt 2860.180 Installation, Operation And Maintenance Manual

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Installation, Operation,
and Maintenance Manual
Flygt 2860.180

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Summary of Contents for Xylem Flygt 2860.180

  • Page 1 Installation, Operation, and Maintenance Manual Flygt 2860.180...

  • Page 3: Table Of Contents

    Remove the impeller SH.......................28 Install the impeller MT, HT....................31 Install the impeller SH......................34 Troubleshooting........................... 40 The pump does not start......................40 The pump does not stop when a level sensor is used............41 Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 4 The pump delivers too little or no water................43 The pump does not start when a softstarter is used.............43 Technical Reference........................46 Application limits........................46 Specific motor data........................46 Dimensions and weights......................47 Performance curves........................49 Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 5: Introduction And Safety

    A hazardous situation which, if not avoided, could result CAUTION: in minor or moderate injury • A potential situation which, if not avoided, could NOTICE: result in undesirable conditions • A practice not related to personal injury Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 6: Product Warranty

    However, should the need arise for a warranty claim, then contact your local sales and service representative. Spare parts Xylem guarantees that spare parts will be available for 10 years after the manufacture of this product has been discontinued. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 7: 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 a Xylem representative before proceeding.

  • Page 8: Environmental Safety

    • Clean up all spills in accordance with safety and environmental procedures. • Report all environmental emissions to the appropriate authorities. WARNING: Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any nuclear radiation. Electrical installation For electrical installation recycling requirements, consult your local electric utility.

  • Page 9: Transportation And Storage

    • Wear personal protective equipment. • Stay clear of cables and suspended loads. Lifting equipment and tackle should always be inspected before starting work. Mechanical lifting When lifting the unit mechanically, always use the lifting eyes. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 10: Temperature Ranges For Transportation, Handling And Storage

    • Before operating the unit after storage, it must be inspected with special attention to the seals and the cable entry. • The impeller/propeller must be rotated every other month to prevent the seals from sticking together. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 11: Product Description

    For more information about the strainer, see Dimensions and weights. Pressure class Medium head High head Super head Impeller type Wear resistant Wear resistant Monitoring equipment The following applies to the monitoring equipment of the pump: Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 12: The Data Plate

    In this section, code characters are illustrated accordingly: X = letter Y = digit The different types of codes are marked up with a, b and c. Code parameters are marked up with numbers. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 13 XXYYYY YYY YYY YYYY Type of Callout Number Indication Type of code Sales denomination Product code Serial number Parameter Hydraulic end Type of installation Sales code Version Production year Production cycle Running number Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 14: Installation

    Water + sand, particle size <0.6 mm (0.024 in) 2.5 (8.2) Water + sand, particle size <0.1 mm (0.004 in) 1.5 (4.9) For more permanent installations with a heavily contaminated pumped liquid, a settling pump-sump is recommended. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 15: Install With S-Installation

    Alternatively, the pump can be suspended with a lifting chain just above the sump bottom. Make sure that the pump cannot rotate at startup or during operation. 5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 16: Make The Electrical Connections

    • If intermittent operation is prescribed, then the pump must be provided with monitoring equipment supporting such operation. • The thermal contacts/thermistors must be in use. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 17: Connect The Motor Cable To The Pump

    4. Firmly tighten the cable entry into its bottom-most position. The seal sleeve and the washers must conform to the outside diameter of the cables. WARNING: Do not install the starter equipment in an explosive zone unless it is explosion-proof rated. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 18: Cable Charts

    Motor protector Stator leads (U1, U2, U5, U6, V1, V2, V5, V6, W1, W2, W5, W6, Z1, Z5, Z6) Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Grey Blue Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 19 CONNECTION TERMINAL BOARD W2 (BK) CABLE SEAL V1 (BN) U2 (GN) W1 (YE) S T A T O R TERMINAL BOARD V2 (BU) T1 (WH/YE) T2 (WH/YE) Waterproof flat pin (8x) Terminal block (8x) Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 20 Softstarter settings: Ramp up 4sec. Ramp down N/A Torque 25% Motor Terminal cable plate Pump Softstarter L3 GY L3 - T3 L2 - T2 L2 BK L1 BN L1 - T1 GNYE Thermal O/L relay Setting= I Thermal contact Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 21: Check The Impeller Rotation

    • If the motor has a 3-phase connection, then transpose two phase conductors and repeat this procedure from step 1. For 3-phase pumps with external starters or without built-in motor protection, the phases must be shifted on the output terminal of the starter. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 22: Operation

    Failure to do so may result in hearing loss or violation of local laws. Start the pump DANGER: If you need to work on the pump, make sure that it is isolated from the power supply and cannot be energized. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 23: Clean The Pump

    Let the pump run for a while in clean water, or flush it through the discharge connection. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 24: Maintenance

    • Lubricate all springs, screws, O-rings with grease. For an optimal corrosion protection, all O-rings and adjacent surfaces must be coated with Exxon Mobil Unirex N3 or equivalent. Figure 4: Example of O-ring adjacent surfaces Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 25: Torque Values

    4,000 hours or 2 years, whichever comes overhaul includes replacement of key components and the first. These intervals apply to normal measures taken during an inspection. applications and operating conditions at media (liquid) temperatures < 40°C (104°F). Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 26: Inspection

    Contact an electrician, if necessary. Regardless of individual applications, the inspection volume should not be inspected less frequently than the intervals for normal applications and operating conditions at media (liquid) temperatures <40°C (104°F). Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 27: Major Overhaul

    The oil housing may be pressurized. Hold a rag over the oil plug to prevent oil from spraying out. 4. Turn the pump so that the oil hole faces downwards and let the oil run out. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 28: Replace The Impeller

    4. Put the oil screw back and tighten it. Replace the impeller Remove the impeller MT, HT WARNING: A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. 1. Remove the strainer. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 29 2. Remove the suction cover. 3. Remove the O-ring. 4. Loosen the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Remove the impeller screw and washer. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 30: Remove The Impeller Sh

    Use a 10 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension. c) Pull off the impeller. Remove the impeller SH WARNING: A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. 1. Remove the strainer. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 31 Use pliers, a screwdriver, or similar. b) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. Use a 10 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 32 Use pliers, a screwdriver, or similar. b) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. Use a 10 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 33: Install The Impeller Mt, Ht

    2. Align the edge of the adjustment screw with the edge of the conical sleeve so that they are flush. WS001759A 3. Grease the threads of the impeller screw and the washer. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 34 8. Turn the adjustment screw clockwise until the impeller makes contact with the suction cover.Tighten a further 1/8 turn, 45°. This will ensure the correct clearance between the impeller and the suction cover in the next step. Use a 10 mm hexagon bit adapter (Allen socket). Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 35 The screw will be loaded to its yield point and the load capacity of the joint will be higher. e) Check that the impeller can rotate easily. 10. Mount the strainer and the nuts. Tightening torque: 44 Nm (32.5 ft-lbs) Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 36: Install The Impeller Sh

    Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. 2. Align the edge of the upper adjustment screw with the edge of the upper conical sleeve so that they are flush. WS001759A Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 37 5. Assemble the upper conical sleeve and the upper impeller onto the shaft. 6. Mount the diffuser parts and tighten. 7. Mount the suction cover with its O-ring and tighten. Tightening torque: 44 Nm (32.5 ft-lbs) Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 38 Use a 10 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension. 9. Remove the suction cover. 10. Remove the O-ring. 11. Align the edge of the lower adjustment screw with the edge of the lower conical sleeve so that they are flush. WS001759A Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 39 This will ensure the correct clearance between the lower impeller and the suction cover in the next step. Use a 10 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 40 If not, the adjustment screw and the conical sleeve have not been aligned, and the shaft may have been displaced relative to the main bearing. 17. Mount the strainer and the nuts. Tightening torque: 44 Nm (32.5 ft-lbs) Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 41 Maintenance Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 42: Troubleshooting

    • The start level regulator is functioning. Clean or replace if necessary. manually. • All connections are intact. • The relay and contactor coils are intact. • The control switch (Man/Auto) makes contact in both positions. Check the control circuit and functions. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 43: The Pump Does Not Stop When A Level Sensor Is Used

    • The distance between the start and stop levels is sufficient. again. • The non-return valve(s) work(s) properly. • The length of the discharge pipe between the pump and the first non- return valve is sufficiently short. Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 44: The Pump Runs But The Motor Protection Trips

    There is a malfunction in the overload Replace the overload protection. protection. If the problem persists, contact the local sales and service representative. Always state the serial number of your product, see Product Description (page 9). Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 45: The Pump Delivers Too Little Or No Water

    If the problem persists, contact the local sales and service representative. Always state the serial number of your product, see Product Description (page 9). The pump does not start when a softstarter is used Figure 6: Softstarter terminal layout Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 46 • The power cable and its connections to L1, L2, L3 (internal power supply is connected to L1, L2). • Fuses, contactors, switches and motor protection devices. • That line voltage is not too low. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 47 Transpose two phase leads for L1, L2, L3 outside the pump. If the problem persists, contact the local sales and service representative. Always state the serial number of your product, see Product Description (page 9). Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 48: Technical Reference

    • 2 pole • 2,880 rpm • 10 kW (13.4 hp) Voltage, V Rated current, A Starting current, A Power factor, cos φ 220 D 0.91 230 D 0.88 240 D 0.83 380 D 0.88 Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 49: Dimensions And Weights

    480 D 0.79 480 Y 480 YSER 0.88 575 D 575 Y 0.91 600 D 0.87 600 Y 0.89 Dimensions and weights All measurements in the illustrations are in millimeters, if not otherwise specified. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 50 Technical Reference Figure 8: BS/KS, MT/HT, DN 100 Figure 7: BS/KS, MT, DN 150 Figure 9: BS, HT, DN 75 Figure 10: BS, SH, DN 100 Flygt 2860.180 Installation, Operation, and Maintenance Manual...

  • Page 51: Performance Curves

    Technical Reference Figure 11: BS, SH, DN 75 Performance curves Test standard Pumps are tested in accordance with ISO 9906:2012, HI 11.6:2012. Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 52 226, BS 230, BS 234, KS 238, KS Q [l/s] Q [l/s] WS006971A WS006972A Figure 12: BS/KS, MT Figure 13: BS, HT P [kW] H [m] Q [l/s] WS006973A Figure 14: BS, SH Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 53 Q [l/s] / [usgpm] Q [l/s] / [usgpm] WS006974A WS006975A Figure 15: BS/KS, MT Figure 16: BS, HT P [hp] / [kW] H [ft] / [m] Q [l/s] / [usgpm] WS006976A Figure 17: BS, SH Flygt 2860.180 Installation, Operation, and Maintenance Manual...
  • Page 56 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...

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