ITT FLYGT BWS Series Maintenance manual

Self-priming centrifugal pumps
Installation, Care and Maintenance

CONTENTS
Safety ................................................................ 2
Warranty ............................................................ 4
Product description .......................................... 4
Transportation and storage ............................. 5
Installation ........................................................ 5
Operation .......................................................... 7
Care and Maintenance ..................................... 9
Inspection .......................................................... 9
Replacing worn-out parts............................... 10
Fault tracing ................................................... 13
Service log ...................................................... 14
SAFETY
This manual contains basic information on the
installation, operation and maintenance and should
be followed carefully. It is essential that these
instructions are carefully read before installation or
commissioning by both the installation crew as
well as those responsible for operation or
maintenance. The operating instructions should
always be readily available at the location of the
unit.
This manual provides general information
concerning the pumping unit but does not
include detailed instructions for the drive
units (diesel or electric motor); these
instructions can be found on the specific
manuals which must be provided with this
manual and form an integral part of it.
Identification of safety and warning symbols
General Danger:
Non-observance given to safety
instructions in this manual,
which could cause danger to
life have been spefically
highlighted with this general
danger symbol.
WARNING ! Non-observance to this warning
could damage the unit or affect
its function
Qualifications of personnel
All activities must be carried out by authorized
(certified) instructed personnel.
Safety regulations for the owner/operator
All safety and hygiene rules and
local regulations must be
observed.
All dangers related to
mechanical equipment and
moving parts must be avoided.
WARNING! Follow all the warning labels
fixed on the unit
When operating near the
pumping unit, avoid wearing
loose-fitting clothes, or other
things that could get caught (like
armlet, chains, etc.) and gather
any long hair.
Periodically check the presence
and readability of the warning
labels.
Check the presence, correct
fixing and perfect condition of the
fixed protections applied.
When the machine is running, do
not put anything into the pump
through the inlet/outlet or from
the inspection cover as there is
the risk of contact with moving
parts (impeller).
In order to avoid danger to the
personnel operating near the
pumping unit, check correct
connection and tightening of the
inlet/outlet before starting up.
2

The pumping unit must not be
used in places where there is the
danger of explosion and/or fire,
in mines and tunnels and in
places with poor ventilation
unless special precautions are
taken by the user.
The pumping unit must never
be used to treat liquids
intended for human or animal
consumption (alimentary use).
The pumping unit is provided
with a bolt for earth connection
to ensure equipotentiality and
prevent static electricity.
The pumping unit must be
installed in a workplace with
sufficient lighting for the task to
be performed; the lighting must
permit correct identification of
the controls and optical signals
on machine board in addition to
performance of the cleaning,
adjustment and maintenance
operations and topping up of
liquids.
The pumping units equipped with
diesel engine and/or with vacuum
pump are provided with oil vent
pipes. Suitable devices must be
provided to prevent dispersion in
the ground.
Unilateral modification and spare parts
manufacturing
Modifications or changes to the
unit/installation should only be
carried out after consulting ITT
Flygt.
Original spare parts and
accessories authorized by the
manufacturer are essential for
compliance.
The use of other parts can
invalidate any claims for
warranty or compensation.
WARNING!
Dismantiling and re-assembly
If the pump has been used to
pump hazardous media, care
must be taken that, when
draining the leakage, personnel
and environment are not
endangered.
All waste and emissions such
as used oil must be
appropriately disposed of. Oil
spills must be cleaned up and
emissions to the environment
must be reported.
The working area must be kept
in good order at all times.
All government regulations
shall be observed.
WARNING!
3

PRODUCT DESCRIPTION
Introduction
Thank you for buying an ITT Flygt pump.
In this Installation Care and Maintenance manual
you will find general information on how to install
and service the pumping unit to give it a long and
reliable life.
Applications
The pumping unit is intended to be used for:
- pumping of ground water
-lowering the groundwater level with Wellpoint
system (only for version with vacuum pump)
- pumping of raw or clean water
-pumping heavy, abrasive or saline liquids
- drainage
- dewatering
-water supply from wells and canals (only for
non-alimentary uses)
-pumping of liquids and mud with solid parts in
suspension (within the limits of the technical
specifications)
-transfer of bentonite slurry
WARRANTY
ITT Flygt undertakes to remedy faults in products
sold by ITT Flygt provided:
- that the fault is due to defects in design, materials
or workmanship.
- that the faults are reported to ITT Flygt or ITT Flygt’s
representative during the warranty period.
- that the product is used only under condition
described in the Installation, Care and Maintenance
manual and in applications for which it is intended
- that the monitoring equipment incorporated in the
product is correctly connected and in use.
- that all service and repair work is done by a work
shop ITT Flygt
- that genuine ITT Flygt parts are used.
Hence, the warranty does not cover faults caused
by deficient maintenance, improper installation,
incorrectly executed repair work or normal wear and
tear.
ITT Flygt assumes no liability for either bodily injuries,
material damages or economic losses beyond what
is stated above.
ITT Flygt guarantees that spare parts will be kept for
10 years after that the manufacture of this product
has been discontinued
For further information on applications, contact
your nearest ITT Flygt representative.
Liquid temperature : max. 70 °C.
Liquid density : max. 1100 kg/m3
The pH of the pumped liquid : 5,5 – 9
4

INSTALLATION
The pumping unit may be transported and stored in
a horizontal position.
Always lift the pumping unit
by its lifting system; never
use the delivery or suction
pipe or the hooks on the
pump and/or on motor unit.
WARNING! Make sure that
the pump cannot roll or fall
over and injure people or
damage property
During towing in the site,
check that the tow bar is fixed
by means of the stop pin and
that the latter is locked through
the locking device.
Although fitted on wheels, the
pumping unit is not approved
for use on roads.
Towing is therefore forbidden
on public roads.
On specific request, the
pumping unit can be fitted on a
trolley approved for road use.
During handling on site, ensure
that the diesel tank (fitted on
pumping unit base stand) is not
subjected to impact or abrasion
which can cause fuel leakage.
The pump is frost-proof as long as it is operating. If
the pump doesn’t work when the temperature is below
the freezing point, the water freezes and the pump
housing can break.
Never leave the water in the priming chamber if there
is the risk of freezing: empty the pump through the
inspection cover.
For longer periods of storage, the pump must be
protected against moisture and heat.
After a long period of storage, the pump should be
inspected before it is put into operation. Pay special
attention to the shaft seal and the drive unit.
Follow the instructions under the heading “Before
starting” in the chapter “Operation”.
TRANSPORTATION AND STORAGE
WARNING!
Handling equipment
Always pay extra attention to
safety aspects when working
with lifting equipment.
Suitable lifting equipment is
required for handling the pump.
The lifting equipment shall be
able to hoist the pumping unit
straight up and down preferably
without the need for resetting the
lifting hook.
Oversize lifting equipment could
cause damage if the pump
should stick when being lifted.
Make sure that the lifting
equipment is securely anchored
and in good condition.
Check that the lifting system is
in good condition.
- Stay clear of suspended
loads
- Always lift the pump by its
lifting handle
In order to guarantee adequate
stability of the pumping unit and
prevent it from accidentally
moving during operation, it must
be installed in a flat position
longitudinally and with a
maximum gradient of 10%
crosswise. You should therefore
avoid positioning it on steep
ground.
5
WARNING!

Put the pump in a horizontal
position. The suction pipe must
be the straightest possible. It’s
free end , at a distance of, at
least, twice the diameter from
the bottom of the excavation, is
attached to a strainer to avoid the
suction of materials which could
damage the pump.
Safety precautions
In order to minimize the risk of accidents in
connection with service and installation work, the
following rules should be followed :
1. Never work alone. Use a lifting harness, safety
line and a respirator as required. Do no ignore
the risk of drowning.
2. Make sure there are no dangerous gases within
the work area.
3. Check the explosion risk before welding or using
electric hand tools.
4. Before the pump is installed check that all the
parts have not been damaged during the
transportation.
5. Observe strict cleanliness. Do not ignore health
hazards.
6. Bear in mind the risk of mechanical accidents.
7. Make sure that the lifting equipment is in good
condition and comply to local ordinances.
8. Provide a suitable barrier around the work area,
eg. a guard rail.
9. Make sure you have a clear path of retreat.
10.Use safety helmet, safety goggles and protective
shoes.
11. A first-aid kit must be close at hand.
Follow all health and safety rules and local codes
and ordinances.
Pumping units with diesel engine
The pumping unit must be installed in adequately
ventilated environments in order to provide sufficient
air for combustion and dissipation of the heat
generated.
If the pumping unit provided
with diesel engine is installed
in a closed place, the exhaust
gases must be conveyed to
the outside. The pumping unit
must be installed at least at a
distance of 4 meters from
combustible and flammable
materials or from pressurised
containers.
Pumping unit with electric motor
The user must protect the
electrical power supply line
and the pumping unit against
short circuits and overloads by
connecting an adequate
thermal magnetic circuit
breaker.
In order to avoid the risk of electrocution due to
direct or indirect contacts with energized parts
the user must protect the pumping unit from
direct and indirect contacts, in compliance with
current regulations, taking account of the
ambient utilisation conditions that increase
electrical risks (e.g. differential circuit-breaker
Idn ≤≤
≤≤
≤30 mA on building sites); in particular the
pumping unit must not be positioned inside
narrow conducting environments, i.e. with good
earth connection (e.g. damp or wet
underground site or walls of a narrow
excavation) and reduced volume.
Damage to the power supply cable and housing
can involve contact with energized parts and
life risk;
before starting:
−Check the power cable and the control panel
condition.
−Check that the power cable size is right and
it’s protected against mechanical damage.
−If the power cable or unit is damaged, do
not operate!
−Replace the damaged power cable with a
new one.
−Use plugs with suitable protection rating
according to the environment where the unit
is operating (min. IP 55).
Check that the direction of rotation direction is
according to the direction indicated on the
electrical motor; if not, change the connection
of two phases (before this operation, make sure
that the electrical circuit is not energized).
6

OPERATION
Before starting
Check that the visible parts of the pump and
installation are undamaged and in good condition.
Before starting work on the
pump, make sure that the
pump cannot be energized
In case of emergency, stop the
pumping unit via the mushroom-
head push button on the control
panel (electrical motor) or via the
lever stop system (diesel
engine).
Make sure that the pump
cannot roll or fall over and
injure people or damage
property.
In some installations the
pump surface and the
surrounding liquid may be
hot. Bear in mind the risk of
burn injures
The noise level of 70 dB
may be exceeded
On specific request the
pumping unit can be
provided with soundproof
enclosure.
Before starting the unit, fill the pump casing with
water up to the lid (Tab.5 a page 10).
Then make sure there are no water leakages in the
mechanical seal or in the suction valve.
In the first case they would prevent the pump from
working properly and they would prolong pump-
priming times.
After this simple check, start the drive unit.
Remember that internal combustion engines must
be warmed up for some minutes till they reach the
optimum temperature.
Do not change or modify the
engine calibration in any
way.
Never operate the pump
without water.
Possible causes of unsuccessful pump-priming
- Pump-casing without water or with a level of the
water too low.
- Air passing through suction pipe, connectors etc.
- Broken or worn-out tang of the volute (see Tab.2,
part.4)
- Wrong number of drive unit revolutions.
- Broken or worn-out impeller.
7
1
2

- Clogged "re-circulation" pipe (Tab.1, part. 1),
Check through cleaning door (Tab. 1,
part. 2) with pump not working.
- Air passing through the mechanical seal. This can
be noticed thanks to water seepages from the
mechanical seal when the pump is not working.
Note: For any other cause, see "Fault tracing"
Vacuum pump (options)
No vacuum in the unit - possible causes
Air intake from the unit:
- Make sure that all unions are properly shut and
O-rings in perfect conditions.
Outlet valve (Tab.3, part.1) does not shut properly:
- Check if the seat is dirty (Tab.3, part.2) .
- Make sure that the seat and the valve itself are
not damaged. Should it be necessary, replace
them.
- The vacuum pump tank level is insufficient (top
up)
Vacuum pump does not run or runs slowly:
- The driving belt is broken (Tab.3, part. 3).Take off
the faulty links and install the belt again.
- The driving belt has loosened. Take off one more
links till you get the right state of tension once
again.
Vacuum pump blades are worn-out:
- Replace the 4 blades (Tab. 4, part.9).
3
How the pump works
Air
Water
1)Outletvalve
2) Valve seat
3) Driving belt
vacuum pump
self-priming centrifugal pump
float
intake
outlet
8

ITT Flygt recommends a preventive maintenance
program based on Intermediate and major Services at
regular intervals.
The time between Major Service could vary
considerably depending on operating conditions and
the need for a Major Service will be determine during
the regular Intermediate Services.
CARE AND MAINTENANCE
9
1) Pump casing
2) Impeller
3) Mechanical seal
4) Pump/motor coupling box
5) Vacuum pump oil tank
6) Complete vacuum pump
7) Outlet valve
4
8) Float to tank
9) Blade
10) Cock
11) Oil suction filter
12) Oil filter
13) Air filter
For routine maintenance of the diesel engine or
electric motor, follow the instructions in the manuals
provided.
Pumping units with diesel engine
During maintenance, ensure that
no metal or other conducting
object can short-circuit the
battery terminals with
consequent danger of explosion
of the battery.
If you have to isolate the battery,
first disconnect the negative pole
and then the positive pole (the
negative pole is earthed and if the
positive pole is disconnected
first, it increases the risk of
accidental short-circuit).
Pumping units with electric motor
During maintenance of the
pumping unit, isolate it by
disconnecting the socket from
the plug placed on the control
panel.
Inspection (version with oil vacuum
pump)
- Drain the condensate in the oil tank (Tab. 4,
part.10), through the cock at least once a day.
- For the suction pump use SAE 15W40 ENGINE
OIL.
- Every 1000 working hours wash oil suction filter
with gas/fuel oil (Tab. 4, part.11).
- Every 1000 working hours replace oil filter (Tab. 4,
part.12)
- Every 1000 working hours replace air filter (Tab. 4,
part.13)
Before starting work on the
pump make sure that it
cannot be started, even
accidentally.

REPLACING WORN-OUT PARTS
Disassembling pump-motor coupling box
(Tab 5)
Take off the pump casing by unscrewing assembling
nuts (part.4) and lever between pump and coupling
box.
The following points are important in connection
with work on the pump.
The pump is designed for use with liquids which
can be a health risk. In order to prevent injury to the
eyes and skin, observe the following points when
working on the pump:
WARNING! Make sure that the pump has been
thoroughly cleaned;
Beware of the risk of infection;
WARNING! Observe local safety regulations.
Always wear goggles and rubber gloves
Rinse the pump thoroughly with water before starting
work.
Rinse the components in water after dismantling.
10
5
WARNING! The oil chamber may be under pressure.
Hold a rag over the filling plug to prevent splatter.
WARNING! Proceed as follows if fluid have splashed
into your eyes:
- Rinse your eyes immediately in running water for
15 minutes. Hold your eyelids a part with your
fingers.
- Contact an eye specialist.
on your skin:
- Remove contaminated clothes
- Wash your skin with soap and water
- Seek medical attention, if required
Coperchio acqua