Xylem FLYFT P7900 Installation, Operation And Maintenance Manual
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Xylem FLYFT P7900 Installation, Operation And Maintenance Manual

Xylem FLYFT P7900 Installation, Operation And Maintenance Manual

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Installation, Operation, and
Maintenance Manual
90028101_1.0
P7900

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Summary of Contents for Xylem FLYFT P7900

  • Page 1 Installation, Operation, and Maintenance Manual 90028101_1.0 P7900...

  • 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 Biological hazards....................4 1.4.2 Wash the skin and eyes..................4 1.5 Protecting the environment....................5 1.6 End of life product disposal................... 5 1.7 Spare parts........................
  • Page 4 Table of Contents 4.5 Make the electrical connections.................. 24 4.5.1 General precautions....................24 4.5.2 Grounding (earthing) ....................25 4.5.3 Connect the cables: Standard pumps with MAS 801..........25 4.5.4 Connect the cables: Pumps with MAS 711............28 4.5.5 Power cable phase sequence................33 4.5.6 Identifying signal leads connected to the PEM, thermal contacts, or thermistors.........................

  • 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 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 • Observe lockout/tagout procedures before starting work on the product, such as transportation, installation, maintenance, or service.

  • Page 7: Protecting The Environment

    • 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: Transportation And Storage

    2 Transportation and Storage 2 Transportation and Storage 2.1 Examine the delivery 2.1.1 Examine the package 1. Examine the package for damaged or missing items upon delivery. 2. Record any damaged or missing items on the receipt and freight bill. 3.

  • Page 9: Lifting

    • The minimum height between the lifting hook and the floor must be sufficient to lift the unit. Contact a Xylem representative for more information. • The lifting equipment must be able to hoist the unit straight up and down, preferably without the need for resetting the lifting hook.

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

    2 Transportation and Storage 2. Lift the pump by using the correct lifting equipment. 3. Put the pump upright on a rigid horizontal surface so that it cannot fall over. 4. Cut the transportation strap. 2.3 Temperature ranges for transportation, handling and storage Handling at freezing temperature At temperatures below freezing, the product and all installation equipment, including the lifting gear, must be handled with extreme care.

  • Page 11: Storage Guidelines

    2 Transportation and Storage Unit in as-delivered condition If the unit is still in the condition in which it left the factory - all packing materials are undisturbed - then the acceptable temperature range during transportation, handling and storage is: –50°C (–58ºF) to +60°C (+140ºF). If the unit has been exposed to freezing temperatures, then allow it to reach the ambient temperature of the sump before operating.

  • Page 12: Product Description

    • Modifications to the unit or installation must only be carried out after consulting with Xylem. • Original spare parts and accessories that are authorized by Xylem are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation.

  • Page 13: The Mas 801 Monitoring Equipment

    3 Product Description Voltage range Drive units Maximum number of starts per hour Up to 1 kV 3.4 The MAS 801 monitoring equipment 3.4.1 FLS: float switch sensor The float switches are leakage sensors. The float switches are located in the lower part of the stator housing and in the junction box. 3.4.2 Vibration in three directions A vibration sensor that is located in the PEM measures vibration speed in three directions.

  • Page 14: Stator Temperature Monitoring Methods

    3 Product Description • Early warning: “B”-alarm • Pump stop: “A”-alarm 3.4.4 Stator temperature monitoring methods The purpose of stator winding temperature monitoring is to make the motor shut off at high temperature. There are several monitoring methods, depending on the voltage of the motor, and types of thermal sensors chosen.

  • Page 15: Pump Current And Power Monitoring

    3 Product Description Table 4: Pt100 sensor Description Measured value Fault values The Pt100 sensor Resistance: > 200 ohm (approximate) can indicate is a resistor the following situations: • 100 ohm at 0ºC (32ºF) changing value • Broken sensor • 107.79 ohm at room temperature almost linearly with (20ºC, 68ºF) •...
  • Page 16 3 Product Description The system also includes a pump memory module, storing identity data of the pump. The parameters that are tracked are chosen by the customer, and may include the following: • Temperature: – Main bearing – Support bearing –...

  • Page 17: Fls: Float Switch Sensor

    3 Product Description Signal Cable, Standard or Parameter Monitored Sensor Number of Optional Leads Required Leakage in the stator housing or Float switch leakage sensor Standard inspection chamber (FLS) Water in oil: standard drive units only. (Not applicable for drive Capacitive leakage sensor (CLS) 24 Optional units with internal closed-loop...
  • Page 18 3 Product Description monitoring the stator winding temperature depend upon the voltage range of the drive unit. Drive units on page 10 for the voltage range for each drive unit. Up to 1 kV drive units Table 6: Stator temperature monitoring configuration, up to 1 kV Standard / Optional Monitoring configuration description Standard...

  • Page 19: Pump Memory

    3 Product Description NOTICE: Never connect the Pt100 transducer to a voltage higher than 2.5 V. For information on the various configurations of contacts, thermistors and sensors that are Stator temperature monitoring methods used to monitor stator winding temperature, see page 15.

  • Page 20: Motor Regulation

    3 Product Description 21. Rated voltage 22. Phase; Type of current; Frequency 23. Additional information 24. Product number 25. Country of origin Figure 3: The drive unit plate valid from 990101 Hydraulic unit 1. Serial number 2. Product code and number 3.
  • Page 21 3 Product Description Codes and parameters 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 Drive unit Production year Production cycle Running number P7900 Installation, Operation, and Maintenance Manual...

  • Page 22: Installation

    4 Installation 4 Installation 4.1 Precautions Before starting work, make sure that the safety instructions have been read and understood. DANGER: Electrical Hazard Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized.

  • Page 23: Hazardous Atmospheres

    4 Installation 1. Fall protection harness 2. Anchoring point • Make sure that all safety guards are in place and secure, and that there is a suitable barrier around the work area. • Wear clean slip-resistant shoes. • Make sure that any ladders or climbing equipment that is used is correctly sized and in good working condition.
  • Page 24 4 Installation Figure 5: Kinked cable Figure 6: Pinched cable • If the outer jacket of the cable is damaged, then replace the cable. • The cable must not be damaged and must not have indentations or be embossed at the cable entry.

  • Page 25: Rotate The Pump

    4 Installation 4.3 Rotate the pump 1. Crane hook 2. Lifting straps 3. Pump housing 4. Frame 1. Attach a crane hook to the pump handle. 2. Attach straps between the pump housing and a second crane. 3. Lift the pump in the pump handle. 4.

  • Page 26: Make The Electrical Connections

    4 Installation • There is no large amount of unwanted construction material under the pump tube, or at the pump intake. If unwanted material is present, then there is a risk that it can get sucked into the pump and cause propeller damage. •...

  • Page 27: Grounding (Earthing)

    4 Installation • The thermal contacts must be connected to a protection circuit in accordance with the product approvals. • The thermal contacts or thermistors must be in use. • The environment must be appropriate for medium-voltage (1.2–10 kV) cables and electrical work.
  • Page 28 4 Installation 1. PEM communication terminals 2. PEM control terminals 3. Functional ground 4. Cable tie 5. Terminal plate 6. Index arrow. The index arrow on the terminal plate is aligned with the cable inlet. 1. Install the monitoring equipment. See the System Installation and Operation (SIO) Manual for the MAS 801 monitoring equipment.
  • Page 29 4 Installation 1. Protective sleeve 2. Washer 3. Connection flange 4. Washer 5. Seal sleeve 6. Washer 7. O-ring 8. Spacer ring 9. Washer 10. Seal sleeve 11. Washer Figure 8: Drive unit Pumps with drive units 705–776 are also equipped with a cable holder illustrated here.

  • Page 30: Connect The Cables: Pumps With Mas 711

    4 Installation 4.5.3.1 Terminals used in standard applications Terminal Description Terminal Description 37, 38 Temperature support bearing, 13, 14 Analog input 0/4 -20 mA, Pt100 +12 VDC, GND 3, 4 Temperature main bearing, Pt100 1, 2 Leakage: Inspection chamber or stator housing, FLS/FLS10 19, 20 Temperature stator winding 1,...
  • Page 31 4 Installation a) Check that the communication between the pump and the MAS base unit is activated. b) Upload the factory settings of sensors and related parameters by choosing the command "copy all from pump memory to MAS". For more information about the MAS installation, see the Installation and User Manual for the MAS 711 monitoring equipment.
  • Page 32 4 Installation Figure 12: Cable holder b) Fit the protective rubber sleeve onto the cable where it leaves the connection housing. The rubber sleeve must have the correct size to give the correct compression around the cable. c) Attach the connection flange to the entrance flange. Make sure that the seal sleeve is not misaligned with the rubber sleeve.
  • Page 33 4 Installation 4.5.4.1 MAS 711 sensor connections TEMP TEMP 3 TEMP 2 SUPPO RT WINDNING WINDNING BEARING THERMAL FLOAT SWI TCH SWI T CH CLS LEA KAGE PT 100 - SENSOR SENSOR VIB RATION TEMP TEMP 1 PTC - THERMIS TOR LEA KAGE LEA KAGE SENSOR...
  • Page 34 4 Installation 15 4 17 16 13 8 19 7 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 Ethernet Ext.1 Ext.2 Local Power Link LAN TD RD Monitoring and Status MAS 711 37 36 35 FOO126A...

  • Page 35: Power Cable Phase Sequence

    4 Installation Sensor Terminal block Conductor Conductor for number for 12- 24-lead cable lead cable Pt100 in the stator winding 1 — — Pt100 in the stator winding 2 — — Pt100 in the stator winding 3 — — Memory module RS-485 B Memory module RS-485 A Memory module supply, ground (earth) Memory module supply, 12 VDC+...

  • Page 36: Prepare The Subcab ™ Cables

    4 Installation Labels are attached to the SUBCAB cable which is used for communication when there is more than one SUBCAB cable. This section gives instructions for identifying which cable is used for communication, when the label is missing. A multimeter can be used to identify the following: •...
  • Page 37 4 Installation The prepared SUBCAB ™ cable The prepared screened SUBCAB ™ cable, without cable lugs 1. T1+T2 twisted pairs in control element 2. Drain wire in control element (tinned copper strands) with shrink tube 1. T1+T2 and T3+T4 twisted pairs in control element 3.

  • Page 38: Cable Charts

    4 Installation Leave a short piece uncovered. d) Check that the connected ground (earth) conductor has sufficient slack. The conductor must stay connected even if the power conductors are pulled loose. 5. Prepare the power conductors: a) Remove the aluminum foil around each power conductor. b) Peel the insulation from each power conductor.
  • Page 39 4 Installation 1. Starter equipment and mains leads (L1, L2, L3) 2. Ground (earth) 3. Functional ground 4. Control leads (T1, T2, T3, T4) L1 L2 L3 T1 T2 T3 T4 5. Thermal contact 6. FLS 7. FLS 10 8. CLS 9.

  • Page 40: Colors And Markings Of Leads

    4 Installation The following figure shows screened SUBCAB with a functional ground. T1 and T2 are twisted together. Screened SUBCAB - ground T1/T2 & T3/T4 (if applicable) Functional ground Twisted together Cable with sep. ground conductor WH shrink hose Bare wire Figure 18: With functional ground 4.6.1 Colors and markings of leads 773 30 00 (...

  • Page 41: Power Wiring Diagrams: Drive Units Up To 1.1 Kv

    4 Installation 4.6.2 Power wiring diagrams: Drive units up to 1.1 kV 4.6.2.1 D-connection, 3-pole terminal Schematic diagram LV, 3 pole terminal; 1 or 2 cables Drive units with small connection housing WS001040C Drive units with large connection housing WS008999B P7900 Installation, Operation, and Maintenance Manual...
  • Page 42 4 Installation 4.6.2.2 D-connection, 6-pole terminal; 1 cable Schematic diagram LV, 6 pole terminal; 1,2,3 or 4 cables Drive units with small connection housing 4.6.2.3 D-connection, 6-pole terminal; 2 cables Schematic diagram LV, 6 pole terminal; 1,2,3 or 4 cables P7900 Installation, Operation, and Maintenance Manual...
  • Page 43 4 Installation Drive units with small connection housing Drive units with large connection housing WS008998B 4.6.2.4 Y-connection Schematic diagram LV, 6 pole terminal; 1 or 2 cables P7900 Installation, Operation, and Maintenance Manual...

  • Page 44: Check The Impeller Rotation

    4 Installation Drive units with small connection housing: 1 cable Drive units with large connection housing: 2 cables 4.7 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. If the propeller rotates in the wrong direction, then the pump lifts up and rotates, which can damage the cables.
  • Page 45 4 Installation 4. If the impeller/propeller rotates in the wrong direction, then check that the phase leads Power cable phase sequence are correctly connected. See on page 33. After reconnecting phase leads, do this procedure again. P7900 Installation, Operation, and Maintenance Manual...

  • Page 46: Operation

    5 Operation 5 Operation 5.1 Precautions Before taking the unit into operation, check the following: • All recommended safety devices are installed. • The cable and cable entry have not been damaged. • All debris and waste material has been removed. NOTICE: Never operate the pump with the discharge line blocked, or the discharge valve closed.

  • Page 47: Estimate Zinc Anode Replacement Intervals

    5 Operation 5.3 Estimate zinc anode replacement intervals The mass and surface area of the zinc anodes are designed to protect the pump surface for 1 year in sea water with an average temperature of 20°C (68°F). Shorter inspection intervals and anode replacement can be required, depending upon the water temperature and the chemical composition as well as the presence of other metals in the vicinity of the pump.

  • Page 48: Modifications For Freezing Conditions

    5 Operation 5.5 Modifications for freezing conditions If the pump is installed in such a way that it can be exposed to temperatures at or below the freezing point (that is, the pump is not totally submerged), then special modifications must be made to the pump and the installation.

  • Page 49: Maintenance

    6 Maintenance 6 Maintenance 6.1 Precautions Before starting work, make sure that the safety instructions 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. Failure to do so could result in death or serious injury. WARNING: Biological Hazard Infection risk.

  • Page 50: Service

    Interval Initial inspection To make a check up of the In the first year of operation. pump condition by an authorized Xylem service representative and, based on the result and findings from these measures, to determine the intervals for periodical inspection and major overhaul for the specific installation.

  • Page 51: Inspection

    6 Maintenance Type of service Purpose Interval Periodical inspection To prevent operational 12,000 hours or 3 years, whichever comes interruptions and machine first. Applies to normal applications and breakdown. Measures to operating conditions at media (liquid) secure performance and temperatures < 40°C (104°F). efficiency are defined and decided for each individual application.

  • Page 52: Major Overhaul

    6 Maintenance Part to service Action Stator housing 1. Check that it is clean and dry. Drive units with oil as – If there is oil in the stator housing, then drain and clean it. Check the the seal lubricant. stator housing again after one week of operation.

  • Page 53: Checking Insulation And Sensors

    6 Maintenance Part to service Action Sensors Check the following: 1. Stator temperature sensors 2. Bearing temperature sensors 3. FLS and CLS sensors Check the temperature sensors Check the leakage on page 51 and detectors on page 52. Impeller or propeller Check the general impeller or propeller status. Change if necessary. Check general wear ring status.

  • Page 54: Check The Leakage Detectors

    6 Maintenance The different types of temperature sensors are: • Thermal switches • PTC thermistors • Pt100 NOTICE: Do not use a megger or other device applying a higher voltage than 2.5 V. 1. Disconnect the sensor wires. 2. Check the status of the sensor and wiring by measuring the resistance according to the Product Description values in on page 10.
  • Page 55 6 Maintenance The amount of oil that is required is 5.6 L (5.9 quarts). Table 12: Spare part numbers Item Part number Oil plug 809 35 00 O-ring 82 72 95 1. Seal oil plugs, 3x 1. Seal oil drain plug 2.

  • Page 56: Change The Gear Oil

    6 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. Replace the O-rings. 4. When the oil has been emptied, then install the oil plugs. If new oil must be added directly, then only the oil drain plug must be installed now.
  • Page 57 6 Maintenance 1. Gear oil plugs, 3x 1. Gear oil drain plug 2. Gear oil fill plug 3. Gear oil level plug P7900 Installation, Operation, and Maintenance Manual...

  • Page 58: Replace The Hydraulic Parts

    6 Maintenance Empty the oil 1. Put a container under the oil drain hole. 2. Unscrew the oil plugs. 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.

  • Page 59: Disassemble The Pump

    6 Maintenance 6.8.2 Disassemble the pump 6.8.2.1 Remove the propeller 1. Lifting eye unit 2. Plug 3. Screws 4. O-ring 5. Propeller 1. Remove the plug. 2. Install the lifting eye unit. 3. Remove the screws. 4. Remove the propeller. 5.
  • Page 60 6 Maintenance 6.8.2.2 Remove the locking assembly 1. Locking assembly 2. Plug × 4 3. Screw × 12 4. Propeller hub 5. Shaft 1. Remove the screws. The locking assembly should become released. 2. If the assembly stays locked after loosening the screws, then do the following: a) Remove the four plugs.
  • Page 61 6 Maintenance Tool Illustration Basic repair kit 436 19 00 1. Screw unit 432 50 00 2. Washer 432 43 00 3. Puller screw unit 432 51 00 Hub tool 436 18 00 1. Cross piece 432 44 00 2. Screw 432 53 00, M16 3.

  • Page 62: Assemble The Pump

    6 Maintenance 3. Install the threaded adapter. 4. Install the hydraulic pump into the cross piece. 5. Install the puller screw into the hydraulic pump. 6. By using the hydraulic pump, apply pressure until the propeller hub is released. 7. Remove the hydraulic pump and the cross piece. 8.
  • Page 63 6 Maintenance 1. Non-threaded adapter 2. Washer 3. Cross piece 4. Screw unit 5. Hydraulic pump 6. O-ring Figure 21: Overview 1. Install the O-ring. 2. Put the propeller hub on the shaft. 3. Put the cross piece over the propeller hub. 4.
  • Page 64 6 Maintenance Figure 22: Screw numbers Table 17: Screw sequence Order Screw numbers 1, 2 3, 4 5, 6 7, 8 9, 10 11, 12 a) Tighten the screws according to the sequence. Tightening torque: 70 Nm (52 lbf·ft) b) Tighten the screws again according to the sequence. Tightening torque: 154 Nm (114 lbf·ft) c) Tighten the screws again according to the sequence.
  • Page 65 6 Maintenance 6.8.3.3 Install the propeller 1. Lifting eye unit 2. Plug 3. Screws 4. O-ring 5. Propeller 1. Install the O-ring. 2. Remove the plug. 3. Install the lifting eye unit. 4. Lift the propeller. 5. Align the holes of the propeller hub with the holes of the propeller. 6.

  • Page 66: Pumps With Mas 801: Replace The Pem

    6 Maintenance Figure 23: Screw numbers Table 18: Screw sequence Order Screw numbers 1, 2 3, 4 5, 6 7, 8 9, 10 11, 12 a) Tighten the screws according to the sequence. Tightening torque: 62 Nm (46 lbf·ft) b) Tighten the screws again according to the sequence. Tightening torque: 125 Nm (93 lbf·ft) c) Tighten the screws again according to the sequence.

  • Page 67: Torque Values

    6 Maintenance 1. Disconnect the communication terminals. 2. Disconnect the control terminals on the PEM. For specially-approved pumps, do not disconnect T3 and T4 from the separate plinth. 3. Disconnect the functional ground. 4. Remove the two screws securing the PEM. 5.

  • Page 68: Tools

    6 Maintenance Table 21: Brass, torque Nm (lbf·ft) 2.7 (2.0) (8.1) (16.2) Hexagon screws with countersunk heads For hexagon socket head screws with countersunk head, maximum torque for all property classes must be 80% of the values for property class 8.8. 6.11 Tools Beside ordinary tools, the following tools are required to do the necessary maintenance of the pump.
  • Page 69 6 Maintenance Part number Denomination Parts Part number Denomination 14-57 21 04 Hydraulic pump 702 76 00 Lifting eye unit P7900 Installation, Operation, and Maintenance Manual...

  • Page 70: Troubleshooting

    7 Troubleshooting 7 Troubleshooting 7.1 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 71: The Pump Does Not Stop When A Level Sensor Is Used

    7 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 72: The Pump Runs But The Motor Protection Trips

    7 Troubleshooting Product Description Always state the serial number of the product, see on page 10. 7.5 The pump runs but the motor protection trips DANGER: Crush Hazard Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup.

  • Page 73: Technical Reference

    8 Technical Reference 8 Technical Reference 8.1 Application limits Data Description Liquid temperature Maximum 40°C (104°F) pH of the pumped media 5.5–14 Liquid density 1100 kg/m³ (9.2 lb per US gal) maximum Depth of immersion Maximum 20 m (65 ft) 8.2 Pt100 resistance This table shows the relationship between temperature (°C) and resistance (ohms).

  • Page 74: Cable Bending Radius, Weight And Diameter

    8 Technical Reference T, °C R, ohms T, °C R, ohms T, °C R, ohms T, °C R, ohms T, °C R, ohms 111.94 124.77 137.36 149.82 112.45 125.16 137.74 150.20 8.3 Cable bending radius, weight and diameter Control cables Table 22: SUBCAB ™...
  • Page 76 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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