Xylem FLYGT 2640.181 Service And Repair Instructions
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Xylem FLYGT 2640.181 Service And Repair Instructions

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Service and Repair Instructions
885618_3.0
2640.181/.281

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Summary of Contents for Xylem FLYGT 2640.181

  • Page 1 Service and Repair Instructions 885618_3.0 2640.181/.281...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents 1 Introduction and Safety......................3 1.1 Introduction.......................... 3 1.2 Safety terminology and symbols..................3 1.3 User safety..........................4 1.4 Special hazards........................4 1.4.1 Working in temporary installations................4 1.4.2 Biological hazards......................4 1.4.3 Wash the skin and eyes....................5 1.5 Protecting the environment....................5 1.6 End of life product disposal....................5 1.7 Spare parts..........................6 1.8 Warranty..........................
  • Page 4 Table of Contents 4.6 Assemble the pump......................37 4.6.1 Assembly overview..................... 37 4.6.2 Install the stator......................38 4.6.3 Install the electrical connections................39 4.6.4 Install the pump top....................39 4.6.5 Install the bearings..................... 40 4.6.6 Install the shaft unit.....................42 4.6.7 Install the mechanical seal: Drainage versions............44 4.6.8 Install the mechanical seal: Sludge versions............

  • 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 a Xylem representative before proceeding.

  • Page 6: User Safety

    1 Introduction and Safety Special symbols Some hazard categories have specific symbols, as shown in the following table. Electrical hazard Magnetic fields hazard Electrical Hazard: CAUTION: 1.3 User safety All regulations, codes, and health and safety directives must be observed. The site •...

  • Page 7: Wash The Skin And Eyes

    • Clean-up of spills Exceptional sites CAUTION: Radiation Hazard Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon. 1.6 End of life product disposal Handle and dispose of all waste in compliance with local laws and regulations.

  • Page 8: Spare Parts

    1 Introduction and Safety 1.7 Spare parts CAUTION: Only use the manufacturer’s original spare parts to replace any worn or faulty components. The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as void the warranty. 1.8 Warranty For information about warranty, see the sales contract.

  • Page 9: Product Description

    2 Product Description 2 Product Description 2.1 Products included Pump model Standard MSHA Drainage Sludge 2640.181 2640.281 2.2 Pump design The pump is submersible, and driven by an electric motor. Intended use The product is intended for moving waste water, sludge, raw and clean water. Always follow the limits given in Technical Reference on page 61.

  • Page 10: Monitoring Equipment

    2 Product Description Impeller type Version code 181: K Clog resistant ® Version code 181: B Wear resistant with Dura-Spin Version code 281: D Sludge 2.3 Monitoring equipment The following applies to the monitoring equipment of the pump: • The stator incorporates thermal contacts connected in series that activate the alarm at overtemperature.
  • Page 11 2 Product Description Y = digit The different types of codes are marked up with a, b and c. Code parameters are marked up with numbers. Codes and parameters XXYYYY YYY YYY YYYY Type of Callout Number Indication Type of code Sales denomination Product code Serial number...

  • Page 12: Installation

    3 Installation 3 Installation 3.1 Hazardous atmospheres DANGER: Explosion/Fire Hazard Special rules apply to installations in explosive or flammable atmospheres. Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explosion- 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 actions.

  • Page 13: Grounding (Earthing)

    3 Installation • if the pump will be connected to the public mains, then the supply authority must be notified before installing the pump. When the pump is connected to the public power supply, it can cause flickering of incandescent lamps when started. •...

  • Page 14: Product-Specific Precautions

    3 Installation WARNING: Electrical Hazard Risk of electrical shock or burn. You must connect an additional ground- (earth-) fault protection device to the grounded (earthed) connectors if persons are likely to come into contact with liquids that are also in contact with the pump or pumped liquid. Ground (earth) conductor length The ground (earth) conductor must be longer than the phase conductors in the junction box of the unit.

  • Page 15: Connect The Motor Cable To The Pump

    3 Installation Figure 2: Aluminum foil on control element. b) Put a white shrink hose over the drain wire and the cable terminal. c) Fit a cable lug on the drain wire. d) Twist T1+T2 and T3+T4. e) Put a shrink hose over the control element. Make sure that the conductive aluminum foil and drain wire is covered.

  • Page 16: Cable Charts

    3 Installation DANGER: Explosion/Fire Hazard Special rules apply to installations in explosive or flammable atmospheres. Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explosion- 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 actions.
  • Page 17 3 Installation Code Description Orange Green GNYE Green-Yellow Grey Blue Yellow Stator leads and thermal contacts connection to the terminal plate SYMBOLS AND DENOMINATIONS 2630.181 Terminal 2630.281 BN=Brown plate =Terminal plate BK=Black 2640.181 =Screen WH=White =Ground OG=Orange 2640.281 GN=Green =Functional ground 2830.180 GNYE=Green-Yellow =Crimp isolation for...
  • Page 18 3 Installation Motor cable and starter unit connection to the terminal plate Terminal GENERAL SYMBOLS AND DENOMINATIONS 2630.181 plate BN=Brown =Terminal plate 2630.281 BK=Black =Screen WH=White 2640.181 =Ground OG=Orange 2640.281 GN=Green =Functional ground 2830.180 GNYE=Green-Yellow =Crimp isolation for cable (all cables not in use) RD=Red 2840.180 =Thermal relay...

  • Page 19: Check The Impeller Rotation

    3 Installation 3.3 Check the impeller rotation CAUTION: Crush Hazard The starting jerk can be powerful. Make sure nobody is close to the unit when it is started. Check the direction of rotation each time the cable has been re-connected and after phase or total supply failure.

  • Page 20: Maintenance

    4 Maintenance 4 Maintenance 4.1 Precautions Before starting work, make sure that the safety instructions in the chapter Introduction and Safety on page 3 have been read and understood. DANGER: Crush Hazard Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup.

  • Page 21: The Fault-Tracing Process

    4 Maintenance Figure 4: Example of O-ring adjacent surfaces During the reassembly, always make sure that existing index markings are in line. The reassembled drive unit must always be insulation-tested and the reassembled pump must always be test-run before normal operation. 4.2 The fault-tracing process 4.2.1 Trace faults in the drive Check the stator.

  • Page 22: Trace Faults In The Wet End

    4 Maintenance Parameter Measurement — ground — ground — ground — V — W — W 2. With an ohm meter, check that R — R are reasonably uniform. Parameter Measurement — U — V — W 3. Use the following flowchart to determine the action needed. Insulation test →...

  • Page 23: Change The Oil

    4 Maintenance If there is a question regarding the tightening torques, then contact a sales or authorized service representative. Screws and nuts Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs) Property class 1.0 (0.74) 2.0 (1.5) 3.0 (2.2) 8.0 (5.9) 15 (11) 27 (20)

  • Page 24: Disassemble The Pump

    4 Maintenance CAUTION: Compressed Gas Hazard Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Allow the chamber to de-pressurize before removal of the plug. 3. Turn the pump so that the oil hole faces downwards and let the oil run out into a container.

  • Page 25: Remove The Discharge Connection Or Cover

    4 Maintenance Suction cover Impeller Diffuser Seal housing → → → ↓ Remove bearings Stator with stator Rotor unit with from bearing Seals ← ← ← house bearing housing housing Dismantling to replace wear parts, seals and bearings The following flowchart shows the general workflow when dismantling in order to access the wear parts, seals and bearings.
  • Page 26 4 Maintenance 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 the washer. 5. Remove the impeller: a) Lock the impeller to prevent rotation.

  • Page 27: Remove The Impeller: Sludge Version

    4 Maintenance c) Pull off the impeller. 4.5.4 Remove the impeller: Sludge version CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. 1. Remove the stand and the lower pump housing. 2. Loosen the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar.

  • Page 28: Remove The Mechanical Seal: Drainage Versions

    4 Maintenance 3. Remove the impeller: a) Lock the impeller to prevent rotation. Use pliers, a screwdriver, or similar. b) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in.) extension. c) Pull off the impeller.
  • Page 29 4 Maintenance 1. Check that the oil has been emptied. 2. Remove the diffuser. 3. Remove the O-ring between the diffuser and the seal housing cover. Only polyurethane diffusers have this O-ring. NBR-diffusers do not have this O-ring. 4. Remove the seal housing cover. NOTICE: Do not use any method where the shaft is used as counterstay as this may displace the shaft in relation to the main bearing.

  • Page 30: Remove The Mechanical Seal: Sludge Versions

    4 Maintenance 4.5.6 Remove the mechanical seal: Sludge versions 1. Mechanical seal and retaining ring 2. Pressure equalizers 3. O-ring 4. O-ring 5. O-ring 6. Seal housing cover 7. Guide plate 8. Gasket 9. Upper pump housing 10.Upper wear protection 1.
  • Page 31 4 Maintenance 8. Remove the retaining ring. Figure 8: Removing the retaining ring. Generic seal shown. 9. Remove the mechanical seal. Figure 9: Removing the mechanical seal. Generic seal shown. 2640.181/.281 Service and Repair Instructions...

  • Page 32: Remove The Shaft Unit

    4 Maintenance 4.5.7 Remove the shaft unit 1. Shaft assembly: shaft unit, bearings, and bearing holder 2. Support bearing 3. Shaft unit 4. Bearing holder 5. O-ring 6. O-ring 7. Main bearing 8. Retaining ring 9. Outer casing. Generic outer casing shown. 10.Seal ring 11.Adapter Select one of the following instructions:...
  • Page 33 4 Maintenance 1. Inner fasteners 2. Outer fasteners 3. Outermost holes a) Remove the outer fasteners. b) Remove the inner fasteners. c) Install two screws through the adapter into the stator housing. Tighten the screws until the heads are below the surface of the adapter. Use M8×60 screws with hexagon socket heads.
  • Page 34 4 Maintenance e) Turn the lower screws counterclockwise to push the pullers upwards. Alternate between the screws until the adapter breaks free. Use an Allen key through the center holes of the pullers. f) Remove the pullers. g) Remove the adapter. Depending on friction, the outer casing stays with the adapter or the pump top.
  • Page 35 4 Maintenance WS009699A b) Install a screw through the center hole of each puller and through a nut on the other side of the puller. Use M10 screws and nuts. Minimum thread length: 40 mm (1.6 in) c) Put protective sheets of metal between the screws and the stator to prevent damage.

  • Page 36: Remove The Bearings

    4 Maintenance 3. Remove the shaft assembly (shaft unit, bearing holder, bearings). 4.5.8 Remove the bearings 1. Remove the retaining ring. 2. Remove the bearing housing. Use a press or the dismantling tool and make sure that the bearing housing is evenly supported during the removal of the main bearing.

  • Page 37: Remove The Pump Top

    4 Maintenance Figure 11: Removing the main bearing. Generic pump shown. 4. Remove the support bearing. Use a bearing puller. WS002956A 4.5.9 Remove the pump top 1. Place the pump in its upright position. 2. Check that the power from the mains is physically disconnected and locked out. 3.

  • Page 38: Disconnect The Electrical Connections

    4 Maintenance 6. Remove the fasteners securing the pump top. The fasteners are located inside the pump top. 7. Remove the pump top and the O-ring under the pump top. 4.5.10 Disconnect the electrical connections 1. Incoming power 2. Ground (earth) leads 3.

  • Page 39: Remove The Stator

    4 Maintenance 1. Terminal plate unit 2. Starter unit 6. Disconnect the stator leads. 4.5.11 Remove the stator 1. Lift the stator housing. 2. Place a protective material underneath to prevent the stator from breaking when released. 3. Use an LP gas set to heat the stator housing quickly and evenly, until the stator drops. Do not allow the stator housing temperature to exceed 150°C (302°F).

  • Page 40: Install The Stator

    4 Maintenance Pump top ↓ Bearings ↓ Shaft unit ↓ Seals ↓ Impeller ↓ Discharge connection or cover 4.6.2 Install the stator 1. O-ring 2. O-ring 3. Stator housing 4. O-ring 5. O-ring 6. Stator 1. Place the stator on a support no wider than the stator. Position the stator leads downwards in the stator.

  • Page 41: Install The Electrical Connections

    4 Maintenance 4.6.3 Install the electrical connections 1. Incoming power 2. Ground (earth) leads 3. Starter unit 4. Leads between starter unit and terminal plate unit 5. Terminal plate unit 6. Stator leads 7. Stator Figure 13: Configurations. Left: With starter unit. Right: Without starter unit. 1.

  • Page 42: Install The Bearings

    4 Maintenance Make sure that no cables are pinched. 3. Tighten the fasteners securing the pump top. The fasteners are located inside the pump top. 4. Mount the cover, and a new gasket under the cover. 5. Fit the cable entrance flange. 6.
  • Page 43 4 Maintenance 3. Fit the bearing housing: a) Place the shaft-rotor unit on the work bench. b) Install the bearing housing on the shaft. Use a press or a soft hammer to press down the bearing housing. For further details, see the assembly tool description. WS002965A 4.

  • Page 44: Install The Shaft Unit

    4 Maintenance b) Tap the bearing in place. 4.6.6 Install the shaft unit 1. Shaft assembly: shaft unit, bearings, and bearing housing 2. Support bearing 3. Shaft unit 4. Bearing housing 5. O-ring 6. O-ring 7. Main bearing 8. Retaining ring 9.
  • Page 45 4 Maintenance 10.Seal ring 11.Intermediate piece 1. Make sure that the pump is in an upside-down position. 2. Screw the lifting eyebolt into the shaft end. WS002953A 3. Carefully lower the shaft-rotor unit with the bearing housing partly into the stator housing.

  • Page 46: Install The Mechanical Seal: Drainage Versions

    4 Maintenance 1. Inner fasteners 2. Outer fasteners 3. Outermost holes a) Mount the intermediate piece on the shaft. b) Insert the outer fasteners and finger-tighten. Install diametrically opposite bolts alternately. Do not apply torque. c) Insert the inner fasteners. Tighten to the correct torque.
  • Page 47 4 Maintenance 4. O-ring 5. Seal housing cover 6. O-ring 7. Diffuser 1. Grease the shaft. 2. Fit the mechanical seal: a) Oil the new mechanical seal. b) Check that the drive pin engages in the drive groove in the shaft. c) Lower the seal onto the shaft.
  • Page 48 4 Maintenance 5. Use a screwdriver to check that the retaining ring is properly seated in its groove. 6. Fit new greased O-rings to the seal housing cover. 7. Install new pressure equalizer(s). WS002976A 8. Mount the seal housing cover. Fasten the two bolts to the correct torque.

  • Page 49: Install The Mechanical Seal: Sludge Versions

    4 Maintenance 4.6.8 Install the mechanical seal: Sludge versions 1. Mechanical seal and retaining ring 2. Pressure equalizers 3. O-ring 4. O-ring 5. O-ring 6. Seal housing cover 7. Guide plate 8. Gasket 9. Upper pump housing 10.Upper wear protection 1.
  • Page 50 4 Maintenance 4. Press down the retaining ring by using a tube of suitable size. The seal will move down into its final position. 5. Use a screwdriver to check that the retaining ring is properly seated in its groove. 6.

  • Page 51: Check The Seal Tightness

    4 Maintenance The upper wear protection sits inside the upper pump housing. It is not held by fasteners. 4.6.9 Check the seal tightness After mounting a new seal, check that it is tight. Leakage can be detected by applying a vacuum in the seal housing, and monitoring any change of pressure over time.
  • Page 52 4 Maintenance WS001759A 3. Grease the threads of the impeller screw and the washer. The proper lubrication of the screw and washer is lubricating grease for assembly of bolts etc., for example, Kluber ALTEMP Q NB 50 or equivalent. 4. Check that the impeller screw is clean and easy to screw into the shaft end. This is to prevent the shaft from rotating with the impeller screw.
  • Page 53 4 Maintenance 8. Turn the adjustment screw clockwise until the impeller contacts the suction cover. Tighten a further 1/8 turn, 45°. The extra 1/8 turn will make sure that the clearance between the impeller and the suction cover is correct in the next step. Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in) extension.

  • Page 54: Install The Impeller: Sludge Version

    4 Maintenance 10.Mount the strainer and the nuts. Tightening torque: 22 Nm (16.2 ft-lb) 4.6.11 Install the impeller: Sludge version 1. Prepare the shaft: a) Polish off any flaws with a fine emery cloth. The end of the shaft must be clean and free from burrs. b) Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical sleeve with a thin layer of grease.
  • Page 55 4 Maintenance NOTICE: 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 adjustment screw with the edge of the conical sleeve so that they are flush.

  • Page 56: Install The Discharge Connection Or Cover

    4 Maintenance Tightening torque: 22 Nm (16.2 ft-lb) d) Tighten a further 1/8 turn, 45°. 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 freely. 8.

  • Page 57: Service

    4 Maintenance Figure 15: Discharge connection for sludge pumps. Generic pump shown. 4.7 Service Regular inspection and service of the pump ensures more reliable operation. Type of Purpose Inspection interval service Inspection To prevent operational interruptions and machine 2,000 hours or 1 year, whichever comes breakdown.

  • Page 58: Overhaul

    4 Maintenance Service item Action Impeller 1. Check for worn or damaged parts. 2. Adjust and/or replace if necessary. Wear on the impeller or surrounding parts necessitates fine adjustments of the impeller or replacement of worn parts. Check the oil: 1.

  • Page 59: Troubleshooting

    5 Troubleshooting 5 Troubleshooting 5.1 Electrical troubleshooting DANGER: Electrical Hazard Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician. Follow these guidelines when troubleshooting: • Disconnect and lock out the power supply except when conducting checks that require voltage.

  • Page 60: The Pump Does Not Stop When A Level Sensor Is Used

    5 Troubleshooting Cause Remedy The installation is not receiving Check that: voltage. • The main power switch is on. • There is control voltage to the start equipment. • The fuses are intact. • There is voltage in all phases of the supply line. •...

  • Page 61: The Pump Starts-Stops-Starts In Rapid Sequence

    5 Troubleshooting 5.4 The pump starts-stops-starts in rapid sequence Cause Remedy The pump starts due to back-flow Check that: which fills the sump to the start level • The distance between the start and stop levels is sufficient. again. • The non-return valve(s) work(s) properly. •...

  • Page 62: The Pump Delivers Too Little Or No Water

    5 Troubleshooting Cause Remedy The density of the pumped fluid is too Make sure that the maximum density is 1100 kg/m (9.2 lb/US gal) high. • Change the impeller, or • Change to a more suitable pump • Contact a sales or authorized service representative. The ambient temperature exceeds the The pump must not be used for such an application.

  • Page 63: Technical Reference

    6 Technical Reference 6 Technical Reference 6.1 Application limits Data Description Media (liquid) temperature Maximum 40°C (104°F) Standard version option, Warm media (liquid) version: Maximum temperature 70°C (158°F). Warm liquid has certain operational limitations, which are stated on a plate on the pump. pH of the pumped media (liquid) 5–8 Media (liquid) density...
  • Page 64 6 Technical Reference 3-phase, 50 Hz Motor type: • 2,895 rpm • 5.6 kW (7.5 hp) Voltage, V Rated current, A Starting current, A Power factor, cos φ 220 D 0.93 230 D 240 D 0.85 380 D 0.92 380 Y 0.91 400 D 0.87...

  • Page 65: Dimensions And Weights

    6 Technical Reference Voltage, V Rated current, A Starting current, A Power factor, cos φ 480 D 0.86 575 D 0.91 575 Y 0.92 600 D 0.88 600 Y 0.88 6.4 Dimensions and weights All measurements in the illustrations are in millimeters, if not otherwise specified. Figure 16: BS/KS MT, DN 100 Figure 17: BS HT, DN 75 2640.181/.281 Service and Repair Instructions...

  • Page 66: Tools

    6 Technical Reference Figure 18: DS, MT/HT, DN 75 Figure 19: DS, MT/HT, DN 100 Figure 20: BS, MT, DN 100, tandem Figure 21: BS, HT, DN 75, tandem 6.5 Tools List of tools To avoid possible damages to the unit, make sure that you have the following special tools available before servicing the unit.
  • Page 67 6 Technical Reference Position number Denomination Part number Range of use Mounting socket 398 38 00 Install the mechanical seal Puller complete 84 13 62 Used together with the bearing puller to: • Remove the bearing housing • Remove the main bearing •...
  • Page 68 6 Technical Reference Disassembly and assembly tools for the bearing housing Removing the bearing housing from the shaft unit Installing the bearing housing on the shaft unit, using the mounting kit Disassembly and assembly tools for the main bearing Removing the main bearing from the bearing housing Installing the main bearing in the bearing housing 2640.181/.281 Service and Repair Instructions...

  • Page 69: Winding Data

    6 Technical Reference 6.6 Winding data Prerequisites • Tolerance: ± 6% at the temperature 20°C (68°F) • Phase difference: ± 3% Standard version Table 3: Resistance per phase, 50 and 60 Hz Stator number Resistance (Ohm) per phase 6945301 3.86 6945302 4.72 6945303...
  • Page 72 For more information on how Xylem can help you, go to www.xylem.com Xylem Water Solutions Global Visit our Web site for the latest version of this document...

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