2051-Flygt Care and Maintenance
2051-Flygt Care and Maintenance
080
INSTALLATION, CARE
AND MAINTENANCE
EXPLOSION-PROOF
CERCHAR MS
MSHA Permissible
890157/07
GUARANTEE
Flygt undertakes to remedy faults in products sold by
Official approval applies only providing:
Flygt provided:
— that the product is used under conditions de-
— that the fault is due to defects in design, materials
scribed in the care and maintenance instruc-
or workmanship;
tions and in applications for which it is
— that the fault is reported to Flygt or Flygt’s repre-
intended;
sentative during the guarantee period;
— that the product is used only under conditions de- — that all service and repair work is done by a
scribed in the care and maintenance instructions workshop authorized by Flygt;
and in applications for which it is intended; — that genuine Flygt parts are used.
— that all service and repair work is done by a work-
shop authorized by Flygt; Flygt guarantees that a spare parts stock will be kept
— that genuine Flygt parts are used. for 10 years after the manufacture of this product has
Hence, the guarantee does not cover faults caused been discontinued.
by deficient maintenance, improper installation, incor- The manufacturer reserves the right to alter perfor-
rectly executed repair work or normal wear and tear. mance, specification or design without notice.
Flygt assumes no liability for either bodily injuries,
material damages or economic losses beyond what
is stated above.
3085.181–0512 15
83/360123 436
CONTENTS
Product description _________________ 3 Electrical connections _____________ 6
Applications ______________________________ 3
Operation ____________________________ 11
Design _______________________ 3 Care and maintenance _____________ 12
Technical data _____________________________ 4 Safety precautions ________________________ 12
Inspection _______________________________ 12
Caution statement for MSHA _____ 4 Changing the oil __________________________ 14
Dimensions and weights ____________________ 5 Replacing the impeller _____________________ 14
2
PRODUCT DESCRIPTION
These care and maintenance instructions apply to Liquid temperature: max. 40°C (105°F).
an explosion-proof (permissible), submersible Liquid density: max. 1100 kg/m3 (9.2 lb per US gal.).
Flygt pump.
The pumped liquid may contain particles up to a size
which corresponds to the openings in the strainer
Applications (7x21 mm, 0.3"—0.8").
2151.080 is intended to be used for: The pH of the pumped liquid: 5—8.
— pumping of water which may contain abrasive Depth of immersion: max. 20 m (65 ft).
particles
For other applications, contact your nearest Flygt
— pumping of ground water. representative for information.
The pump is designed for use in explosive environ-
ments in accordance with the following approvals:
CARCHAR MS Centre d’Etudes et Recherches
des Charbonnages de France,
France
MSHA Permissible Mine Safety and Health Administ-
ration, USA
DESIGN
2051.080 is a submersible, electric motordriven pump. Motor
ELECTRICAL CONNECTIONS
WARNING! NOTE!
All electrical work shall be carried For safety reasons, the earth lead
out under the supervision of an should be approx. 70 mm (2.8")
authorized electrician. Local longer than the phase leads. If the
codes and regulations shall be motor cable is jerked loose by
complied with. mistake, the earth lead should be
the last lead to come loose from
Check that the main (line) voltage and frequency agree its terminal. This applies to both
with the specifications on the pump data plate. ends of the cable.
The motor can be connected for differant voltages as
shown on the data plate.
Under no circumstances may starter equipment be in- entrance cover. Check the direction of rotation, see
stalled in the explosion risk area. “Before starting” (page 10). Transpose two phase
leads if the impeller rotates in the wrong direction.
Install the motor cable as illustrated in the figure.
Connect the external protective earth.
To avoid leakage into the pump, check:
— that the cable entry seal sleeve and washers conform Connect the control leads, of any. from the motor
to the outside diameter of the cable, See the parts list control circuit to T1 and T2.
— that the outer jacket on the cable is not damaged. Make sure that the pump is correctly earthed (ground-
When refitting a cable which has been used before, ed).
always cut off a short piece of the cable so that the Install the entrance cover.
cable entry seal sleeve does not close around the Remember that the starting surge with the direct-on
cable at the same point again. line start can be up to six times higher than the rated
Mount and tighten the cable entry in the junction box current. Make sure that the fuses or circuit breakers
cover, so that the seal sleeve is compressed and seals are of the proper amperage.
between the motor cable and the cover. Mount and The overload protection (motor protection breaker)
tighten the clamp. shall be set to the motor’s operating current, but no
Connect the motor cable to the terminal board connec- higher than the motor’s rated current as given on the
tions U1, V1, W1 and earth on the inside of the data plate.
6
50 Hz, 3~, 1.0 kW, 2850 r/min
220 3.9 25
230 3.8 24
380 2.3 15
400 2.2 24
500 1.7 11
550 1.6 11
115 14.0 60
230 7.1 35
440 2.4 14
460 2.3 14
575 1.7 12
7
50/60 Hz, 3~ with terminal board
SUBCAB/SUBCAB AWG*: The stator leads are connected to the terminal board
Mains Lead Pump terminal as follows:
board Stator lead Connection on terminal board
L1 Brown (Red*) U1 U1, red U1 (S1)
L2 Blue (White*) W1 V1, brown V1 (S2)
L3 Black (Black*) V1 W1, yellow W1 (S3)
Earth (PE) Yellow/Green PE U2, green U2 (S4)
Groundcheck Yellow* GC V2, blue V2 (S5)
T1 Black (Orange*) T1 W2, black W2 (S6)
T2 Black (Blue*) T2
Connect the control leads from the motor control
circuit to T1 and T2.
8
50/60 Hz, 3~ with terminal board
SUBCAB/SUBCAB AWG*: The stator leads are connected to the terminal board
Mains Lead Pump terminal as follows:
board Stator lead Connection on terminal board
L1 Brown (Red*) U1 U1, red U1 (S1)
L2 Blue (White*) W1 V1, brown V1 (S2)
L3 Black (Black*) V1 W1, yellow W1 (S3)
Earth (PE) Yellow/Green PE U2, green U2 (S4)
Groundcheck Yellow* GC V2, blue V2 (S5)
T1 Black (Orange*) T1 W2, black W2 (S6)
T2 Black (Blue*) T2 U5, red U5 (S7)
Connect the control leads from the motor control V5, brown V5 (S8)
circuit to T1 and T2. W5, yellow W5 (S9)
9
1 ~ operation The stator leads are connected to the terminal board
as follows:
SUBCAB AWG U1 = red
U2 = brown
No. Lead Pump terminal
U5 = yellow
board
U6 = green
1 Red U1 Z1 = blue
2 Black V1 Z2 = black
3 White W1 Z5 = red
Earth (PE) Yellow/Green PE Z6 = brown
10
OPERATION
Before starting
Starting jerk
Check the oil level in the oil casing.
Remove the fuses or open the circuit breaker and
check that the impeller can be rotated by hand.
Check that the monitoring equipment (if any) works.
Check the direction of rotation. See the figure. The
impeller shall rotate clockwise, as viewed from above.
When started, the pump will jerk in the opposite direc-
tion to the direction in which the impeller rotates. Be-
ware! The starting jerk on large pumps can be
powerful.
The above measures are described under ”Inspec-
tion”.
Cleaning
If the pump has been operating in very dirty water,
allow it to run for a short period in clean water or flush
clean water through the discharge connection. If clay,
cement or other types of dirt are left in the pump, they
may dry and clog the impeller and seal.
In order to avoid sedimentation when the pumped
medium contains solid particles, the velocity of the
medium in the discharge line should be:
The pump can be provided with level regulation in
Mixture Min. velocity in order tio prevent unnecessary wear on the hydraulic
discharge line components.
Water + sand
Sand particles <0.1 mm 1.5 m/s
(0.004") (4.9 ft/s)
Sand particles <0.6 mm 2.5 m/s
(0.024") (8.2 ft/s)
11
CARE AND MAINTENANCE
The figures in parentheses are item numbers and refer
to the exploded view on the last page. NOTE for Ex version
All work on the explosion-proof
(permissible) motor section must
be performed by authorized Flygt
Safety precautions personnel.
Before starting work on the pump, make sure that the Flygt renounces all responsibility
pump is isolated from the power supply and cannot be for work done by untrained, un-
energized. authorized personnel.
NOTE! This applies to the control circuit as well.
The following points are importat in connection with WARNING!
work on the pump: Before starting work on the
— make sure that the pump has been thoroughly pump, make sure that the pump
cleaned. is isolated from the power sup-
— follow local safety regulations. ply and cannot be energized.
Inspection
Regular inspection and preventive maintenance en-
sure more reliable operation.
The pump should be inspected at least every three
months, more frequently under severe operating con-
ditions.
Under normal operating conditions, the pump should
have a major overhaul in a service shop once a year.
This requires special tools and should be done by an
authorized service shop.
When the pump is new or when the seals have been
replaced, inspection is recommended after one week
of operation.
12
Recommended inspections:
Inspection of Action
Oil quantity
WARNING! If the seal leaks, the oil casing may be under
pressure. Hold a rag over the oil casing screw in order to
prevent splatter. See “Safety precautions” for additional in-
formation.
Check that the oil reaches up to the oil hole when the pump is lying down with the
oil hole up.
Add oil as needed. See ”Changing the oil”.
Condition of the oil A check of the condition of the oil can show whether there has been an leakage.
Maximum permissible leakage is 0.05 ml/h (0.0017 oz/h). (Note! Air/oil mixture can
be confused with water/oil mixture).
Insert a tube (or hose) into the oil hole. Cover the top end of the tube and take up a
little oil from the bottom.
Change the oil if it contains too much water, i.e., is heavily emulsified (cream-like),
or if the water has settled out. See “Changing the oil”. Check again one week after
changing the oil.
If the oil contains too much water again, the fault may be:
— that an oil screw (OIL) is not sufficiently tight.
— that the O-ring of the oil screw or its sealing surface is damaged.
— that the lower seal (48) is damaged. Contact a Flygt service shop.
Cable entry Make sure that the cable clamp is tight. If the cable entry leaks:
— check that the entry is sufficiently tightened.
— cut a piece of the cable off so that the seal sleeve (28) closes around a new
position on the cable.
— replace the seal sleeve (28).
— check that the seal sleeve (28) and the washers (18) conform to the outside
diameter of the cables.
Cables Replace the cable if the outer jacket is damaged. Make sure that the cables do not
have any sharp bends and are not pinched.
Level sensors or other Check function. Clean, adjust, replace or repair damaged level sensing equipment.
level equipment Follow the instructions for the level sensing equipment in question.
Starter equipment If faulty, contact an electrician.
Rotation direction Transpose two phase leads if the impeller does not rotate clockwise as viewed
of pump from above. Rotation in the wrong direction reduces the capacity of the pump and
(requires voltage) the motor may be overloaded. Check the direction of rotation every time the pump
is reconnected.
13
Changing the oil
Oil hole
WARNING!
If the seal leaks, the oil casing
may be under pressure. Hold
a rag over the oil plug to
prevent splatter.
14
15
ACCESSORIES AND TOOLS
Tandem operation See special brochure that describes the procedure for
The delivery head can be increased by connecting two tandem connection. The following complete connec-
or three pumps in tandem. tion units are available for tandem connection:
Max. permissible operating pressure is 0.4 MPa (57 Order No. Intended for
psi). 392 34 00 2" hose
The vertical distances between the pumps should be
approximately equal.
The connection unit for tandem operation replaces the Low suction attachment
strainer, see figure. Remove the strainer and fit the
connection (A) in its place. Don’t forget the O-ring (B).
Fit gasket (C), washer (D), locking washer (E) and
secure with nut (F).
Tandem operation
16
Low suction attachment
In order to get the pump to drain all the way down to Zinc anode set
the floor, the pump can be provided with a rubber
collar.
The low suction attachment replaces the strainer, see
figure. Remove the strainer and fit the low suction
attachment (H) in its place. Don’t forget the O-ring (I).
Fit gasket (J), washer (K), locking washer (L) and
secure with nut (M).
NOTE! In order for pumps with low suction attach-
ments to start working, the pump casing
must be primed (filled with water).
Order No. 392 35 00
Level sensor
Flygt supplies level sensors suited for different liquid
densities and with different cable lengths. See sepa-
rate brochure.
Tools
The following tools are required in order to perform the
necessary care and maintenance of the pump:
84 11 39 Combination wrench, n = 13 mm
84 12 53 Socket-type screwdriver, n = 8 mm
84 13 87 Socket, n = 13 mm
84 13 90 Socket, n = 17 mm
84 14 31 Adjustable wrench, 18"
84 15 61 Swivel handle, ½"
84 15 66 Torque wrench, 0—137 Nm
84 16 72 Screwdriver, width 8 mm
84 16 74 Screwdriver, width 14 mm
84 17 30 Allen keys set
Screw M12x45 for pulling off the impeller
17
FAULT TRACING (TROUBLESHOOTING)
A universal instrument (VOM), a test lamp (continuity Use the following checklist as an aid to fault tracing. It
tester) and a wiring diagram are required in order to is assumed that the pump and installation have for-
carry out fault tracing on the electrical equipment. merly functioned satisfactorily.
Fault tracing shall be done with the power supply Electrical work shall be performed by an authorized
disconnected and locked off, except for those checks electrician.
which cannot be performed without voltage. Follow local safety regulations and observe recom-
Always make sure that there is no one near the pump mended safety precautions page 11.
when the power supply is turned on.
Yes
Can the pump be started manually? a) Fault in level equipment (start sensors).
Clean or replace.
No b) Fault in control equipment.
Check:
— the control current.
— that all connections are intact.
— relay and contactor coils.
— that the control switch “Man/Auto” makes contact in both
positions.
No
Is the installation receiving Check:
voltage? — that the main power switch is on.
— that there is voltage in each phase of the supply line.
Yes — that all fuses have continuity and are tight.
— that the overload protection is reset.
— that there is no break in the motor cable.
Yes
Is the impeller stuck? Clean.
Clean the sump.
No
WARNING: disconnect
power before checking
the impeller.
18
2. Pump starts but motor protection trips
Yes
Is the motor protection set Adjust.
too low?
(Check with data plate)
No
No
Is the impeller difficult to Clean the impeller.
rotate by hand? Clean out the sump.
Check that the impeller is not adjusted too tight.
Yes If anything else is wrong, contact Flygt service shop.
No
Is the installation receiving full Notify electrician.
voltage on all three phases?
Yes
Yes
Are the phase currents Contact Flygt service shop.
uneven or too high?
No
Yes
Is the insulation between the Contact Flygt service shop.
phases and earth (ground) in
the stator defective?
(Use insulation tester. With a
1000 V-DC megger, the insulation
between the phases and
between any phase and earth
(ground should be > 1 MW )
No
Yes
Is the density of the pumped Dilute the liquid.
liquid too high? (Max density Change to a more suitable pump.
1100 kg/m3, i.e. 70 lb/ft3)
Contact Flygt.
No
Yes
Fault in bimetals in motor Replace defective bimetals (over curent sensors).
protection?
No
Contact Flygt service shop.
WARNING: disconnect
power before checking
the impeller.
19
3. The pump does not stop
No
Is the pump able to empty the Check:
station to the stop level? — for leakage in pipe or hose.
— that the impeller is not clogged.
Yes — the non-return valve(s).
— that the pump has adequate capacity. Contact Flygt.
Yes
Fault in level sensing equipment? Clean the stop sensor.
Check the contactor and holding circuit.
No Replace defective items.
Yes
Stop level set too low? Raise the stop level.
No
Yes
Does the pump start due to Check:
backflow which fills sump
— that the distance between the start and stop levels is
to start level again?
not too small.
— the non-return valve(s).
No — that the riser is not too long without a non-return valve.
Yes
Does the contactor’s self- Check:
holding function break? — contactor connections.
— the voltage in the holding circuit in relation to the rated
No voltage on the coil.
21
SERVICE LOG
Most recent Pump No. Hours of Remarks Sign.
service date operation
22
Printed in Sweden KT 970339