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Summary of Contents for Xylem Flygt SR 4320.011/091
- Page 1 Installation, Operation, and Maintenance Manual 90000101_8.0 Flygt SR 4320.011/091...
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Page 3: Table Of Contents
4.3.1 Install on a single guide bar.................. 21 4.3.2 Install on a tripod....................24 4.4 Position the mixer......................28 4.4.1 Propeller clearance....................28 4.4.2 Position parameters....................29 4.4.3 Set the horizontal angle..................29 4.4.4 Set the vertical angle.................... 31 Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 4 7.12.1 Remove the motor cable from the connection housing........59 7.12.2 Replace the I/O unit and the cable unit...............60 7.12.3 Install the motor cable in the connection housing..........60 7.12.4 Perform an insulation check on the motor cable..........63 Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
- Page 5 8.11 The installation equipment vibrates................70 8.12 DST 001: The communication with the unit fails............70 9 Technical Reference......................71 9.1 Drive unit data......................71 9.2 Application limits......................71 9.3 Minimum permitted liquid level..................71 Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 6: 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 7: User Safety
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, the vapor, or both present in hazardous areas. -
Page 8: Special Hazards
1 Introduction and Safety • Only use original Xylem spare parts that are provided by an Ex-approved Xylem representative. • The thermal contacts that are fitted to the stator windings must be connected correctly to a separate motor control circuit and in use. The thermal contacts shall be connected to a monitoring device, which disconnects the power supply immediately upon activation. -
Page 9: Drowning
• 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. 1.7 End-of-life product disposal Handle and dispose of all waste in compliance with local laws and regulations. -
Page 10: Spare Parts
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. 1.9 Warranty For information about warranty, see the sales contract. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 11: Transportation And Storage
Use suitable lifting equipment and ensure that the product is properly harnessed. Wear personal protective equipment. Stay clear of cables and suspended loads. NOTICE: Never lift the unit by its cables or hose. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 12: Prepare For Moving An Assembled Mixer
• If the blades are too long for safe transport, then the blades or the propeller must be removed. • If the blades are short, then the mixer can be securely fastened on pallets or equivalent. If stacked pallets are used, then they must be securely strapped together. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 13: Temperature Ranges For Transportation, Handling And Storage
However, the glycol-water mixture will not solidify completely and thus cannot harm the product. 2.4 Storage guidelines Storage location The product must be stored in a covered and dry location free from heat, dirt, and vibrations. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 14 • Before operating the unit after storage, it must be inspected. Special attention must be given to the seals and the cable entry. • The impeller or propeller must be rotated every other month to prevent the seals from sticking together. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 15: Product Description
Illustration Parts Position Part Description Connection housing Connection housing with integrated control system Junction box The connection plate is located on the VFD Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 16: Sensors
Explosion-proof version: The stator incorporates three thermal contacts connected in series. 3.3 Monitoring equipment The mixer can be connected to the following equipment: Monitoring equipment Illustration ADC system: APP 412 controller and FPG 415 gateway ADF system: FPG 415 gateway Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 17: The Data Plate
17. Power factor 18. Phase, type of current, frequency 19. Manufacturer 20. Country of origin 21. Brand 22. Sales denomination 23. WEEE-Directive symbol 24. Hydraulic end, type of installation 25. UKCA marking Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 18: Approvals
14. ATEX marking 15. Country of origin WS003972C IEC approval plate This illustration describes the IEC approval plate and the information that is contained in its fields. International Norm; not for EU member countries. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 19: Product Denomination
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 SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 20 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 SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 21: Mechanical Installation
• Make sure that equipment is in place so that the unit cannot roll or fall over during the installation process. • Vent the tank of a sewage station in accordance with the local plumbing codes. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 22: Rotation Test
The failure of the signal leads indicates that the other parts of the cable are vulnerable to damage. Continuing to operate the product can result in a hazardous situation. For a safe operation, the cable must be replaced and the support for the cable must be enhanced. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 23: Install The Mixer
Use one or two shackles as needed. See the following figure. WS012521A 2. Prepare the power cable: a) Use the M6 screw and lock nut to attach the cable holder to the mixer. The cable must not have any sharp bends. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 24 Attach the top cable holder to the power cable. This cable holder is supplied with the mixer. f) Attach the remainder of the cable coil to the davit, so that it cannot fall into the basin. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
- Page 25 Lower the mixer onto the guide bar. 5. Put the mixer on the support at the given height “H”. For information about the correct angle setting, see Position the mixer on page 28. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 26: Install On A Tripod
The support wire must not be overtightened. The mixer must rest on the guide bar. 4.3.2 Install on a tripod For greater clarity, the power cable is not shown in some of the illustrations. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 27 Insert cable holders on the power cable at every 1.5 m (4.9 ft) distance. d) Attach the cable holders to the support wire. For more information, see the separate mounting instruction 85 05 29. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
- Page 28 4. Install the mixer: a) Lift the mixer. b) Use the operating bar on the davit to pivot the mixer. NOTICE: The lifting chain or wire must be vertically aligned with the guide bars. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
- Page 29 The support wire must be tightly installed and there must be no tension in the power cable. NOTICE: The support wire must not be overtightened. The mixer must rest on the support unit. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 30: Position The Mixer
750 mm (30 in) blade to the liquid level Exception: In thick media and good flow condition or with lower motor load, the distance can be shorter. Propeller blade to the back wall Propeller diameter Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 31: Position Parameters
1. Rotate the guide bar to set the horizontal angle. 2. Place the indexing screw in the corresponding hole to fasten the angle. Propeller clearance Make sure to maintain the propeller clearance, see on page 28. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 32 – – – – – – – – – – – – 3. Place the cable holders in position on the power cable. 4. Attach the cable holders to the support wire. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 33: Set The Vertical Angle
2. Check and correct the position of the lifting equipment. The M measurement identifies the correct position. See the dimensional drawings for the product. If further fine-tuning is needed for horizontal alignment, then different lifting holes can be selected. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 34: Electrical Installation
Visually inspect equipment for damaged cables, cracked casings or other signs of damage. Make sure that electrical connections have been correctly made. WARNING: Crush Hazard Risk of automatic restart. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 35: Grounding (Earthing)
Risk of electrical shock. The ground (earth) lead must be sufficiently longer than the phase leads to make sure that the ground lead is the last to become disconnected if the cable is jerked loose. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 36: Requirements
Table 3: Motor rating, 380–480 V, 50–60 Hz, 3-phase Maximum rotations per Rated Power, kW Rated power, hp Rated Current, A Power factor minute, rpm 2800 0.71 2800 0.90 2800 0.94 2800 0.94 Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 37: Power Isolation
EN 61800-3 category C3. • With a 3–phase VFD mains filter installed, the unit complies with EN 61800-3, category C2. The filter is available from Xylem on part number 85 03 11. For more information, contact the sales and service representative. - Page 38 Untwist the screens around the power conductors. b) Twist all the power conductor screens together to create a ground (earth) conductor. c) Put a yellow-green shrink tube over the ground (earth) conductor. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 39: Connect The Motor Cable To The Mixer
The T1 and T2 leads must always be connected to a protection circuit that disconnects the power supply to the mixer when the contact opens. NOTICE: Thermal contacts must never be exposed to voltages higher than 250 V, breaking current maximum 5 A. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 40 1. T1+T2 and T3+T4 twisted pairs in control element 2. Drain wire in control element (bare aluminum wire) 3. Aluminum foil, screen 4. Insulation jacket (plastic jacket) for control element 5. Power conductors 6. Aluminum foil, screen Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 41: Cable Charts
2. Ground (earth) 3. Functional ground (earth) 4. Terminal block 5. Electrical filter: toroid core 6. Leakage sensor 7. Thermal contacts Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 42 5 Electrical installation Code Description Grey Blue Yellow Connection plates Figure 5: 4320.011 Figure 6: 4320.091 Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
- Page 43 5 Electrical installation Connections Figure 7: 4320.011 Figure 8: 4320.091 Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 44: Operation
An external switch or circuit breaker must be provided near the installation to enable the mixer to be isolated from the power supply. 6.2.4 Mixer reposition Before the mixer is repositioned on the guide bar, the power supply must be turned off. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 45: Units With Integrated Intelligent Drives: Start And Restart
6.4.2 Start the mixer Connect the mixer to power. The mixer runs counterclockwise at the pre-set speed. The rotation is not dependent on the connection to the phases, and cannot be changed. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 46: Alarm Handling
– Check the cooling effect of the surrounding environment. – If applicable, then check the start and stop levels. Thermal contacts, for Ex- approved versions The overload protection Check that the propeller can rotate freely. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 47: Maintenance
7.2 Inspect the work area before permit-required hot work WARNING: Explosion/Fire Hazard Before starting any permit-required hot work such as welding, gas cutting, grinding, or using electrical handtools, do the following: 1. Check the explosion risk. 2. Provide sufficient ventilation. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 48: Rotating Propeller
Table 4: Stainless steel, A2 and A4, torque Nm (lbf·ft) (0.74) (1.5) (2.2) (5.9) (11) (20) (48) (93.7) (162) (320) 70, 80 1240 (6.6) (16) (32) (56) (138) (268) (464) (915) — — (10) (25) (49) (84.8) (183) (355) Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 49: Maintenance Intervals
Heavy duty Others Normal duty Table 9: Biogas and agriculture applications Application Operating condition Fluid manure Normal duty Digestate Normal duty Digester Heavy duty • For example, energy crops and solid manure Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 50: Maintenance Schedule
If the periodic inspections are not performed according to the schedule, then shorten the interval of the overhaul. For more information, contact the sales and service representative. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 51: Service Actions
– Check that the resistance between the ground (earth) and phase lead is more than 5 megohms. Other actions Inspections on page 49. 7.7.3 Service in case of alarm Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 52: Change The Oil
The oil quality is not the same for oil housing and gear housing. NOTICE: Mixing lubricating oils can result in equipment damage. Always use the same type of oil when replacing the oil in the gear box. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 53: Change The Propeller
Fill according to the table. If the mixer is installed in an angle more than 10° offset from the horizontal plane, then more oil is needed in the gear housing. Contact the local Xylem service shop. b) Replace the O-ring of the filling plug. -
Page 54: Handle The Screw Unit
Figure 9: Star pattern for peripheral screws b) Repeat this procedure until there is no more load on the peripheral screws. Three or four repetitions are normally enough. c) Remove the center screw. 2. Fit the screw unit. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 55: Remove The Propeller Blades
2. Carefully tap a mandrel, or a piece of wood, with a mallet until the blade comes out of its slot. Figure 12: Two–bladed propeller Figure 13: Three–bladed propeller 3. Carefully twist the blade back and forth to loosen it from the hub. Pull out the blade without dropping it. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 56: Remove The Propeller Hub
Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical sleeve with a thin layer of grease. The correct lubrication is grease for bearings, for example Exxon Mobil Unirex N3, Mobil Mobilith SHC 220 or equivalent. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 57 4. Press the conical sleeve into the hub. 5. Press the hub onto the shaft. 6. Mount the hub screw, washer, and the O-ring. Handle the screw unit Follow the procedure in on page 52. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 58: Assemble The Propeller Blades
1. Make sure that the slots are free from excessive paint and burrs. 2. Lubricate the shaft and the slots. Lubricate with grease. 3. Install the damper (a) and the key (b) on the blade shaft. 4. Install the blade on the hub. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 59: Remove The Lifting Bracket
Before starting this procedure, remove the propeller according to the instructions in the propeller on page 51. For better stability, do not remove the propeller hub at this stage unless it is necessary. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 60: Remove The Connection Housing
CAUTION: Crush Hazard Make sure that the unit cannot roll or fall over and injure people or damage property. 4. Tilt and put the connection housing on top of the stator housing. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 61: Replace The Motor Cable
Remove the connection 2. Remove the connection housing. For more information, see housing on page 58. If only the motor cable is replaced, then do not drain the oil. 3. Loosen the cable entry. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 62: Replace The I/O Unit And The Cable Unit
At delivery from the factory, the motor cable is usually already connected to the mixer. NOTICE: The control leads T3 and T4 must never be extended or broken up in sections. Spliced control leads can result in interference and signal loss. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 63 3. Ground (earth) and screen 4. T1, T2 b) Pull the cable to the final position. The marking must be aligned with the entrance of the cable entry. 70 mm (2.8 in) Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
- Page 64 8. Connect the motor leads and the control leads. To decrease the risk for disturbance of the communication, separate the motor leads from the control leads. Use cable ties to secure the leads to the plastic lid. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 65: Perform An Insulation Check On The Motor Cable
See the applicable steps in on page 59. 1. Put a new and lubricated O-ring on the stator housing. 2. Reconnect the grounding cable between the stator housing and the connection housing. See the following figure. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 66: Mount The Lifting Bracket
3. Tighten the four screws on the upper side through the lifting bracket, and on the lower side through the seat. 4. Ensure that the two parts of the lock washer are correctly mounted. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - Page 67 7 Maintenance 5. Fasten the cable clamp. Fill the oil Before mounting the propeller, follow the instructions in on page 50. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual...
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Page 68: Troubleshooting
DST 001 is a computer software application that is used to configure settings, upgrade software, and troubleshoot Flygt products. The DST 001 application communicates with the product through a USB converter, PCM 001. Technical Product Information The application and documentation is available at Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 69: The Mixer Does Not Start
Failure to do so could result in death or serious injury. WARNING: Electrical Hazard The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 70: The Mixer Starts But Stops After 10 Seconds
RTU / PLC. 3. Check T3 and T4. If the problem persists, then contact a sales or authorized service representative. Always state the product number and the serial number of the product. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 71: 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. Failure to do so could result in death or serious injury. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 72: The Installation Equipment Vibrates
8.12 DST 001: The communication with the unit fails See the separate documentation for DST 001. If the problem persists, then contact a sales or authorized service representative. Always state the product number and the serial number of the product. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... -
Page 73: Technical Reference
In hazardous areas, this information is critical for the safety of the installation of this product. This pump or mixer must always be totally submerged during operation or when it is energized. Flygt SR 4320.011/091 Installation, Operation, and Maintenance Manual... - 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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