Xylem FLYGT Start 151 User manual

Installation and
Operation Manual
Start 151/161/156

Table of Contents
1 Introduction and Safety............................................................................................ 2
1.1 Introduction........................................................................................................2
1.2 Safety terminology and symbols..................................................................... 2
1.3 User safety.......................................................................................................... 3
1.4 End of life product disposal............................................................................. 4
1.5 Spare parts......................................................................................................... 5
1.6 Warranty..............................................................................................................5
1.7 Support............................................................................................................... 5
2 Product Description.................................................................................................. 6
2.1 Product design...................................................................................................6
2.2 The data plate.................................................................................................... 7
2.3 Technical data.................................................................................................... 7
3 Installation.................................................................................................................. 9
3.1 Facility requirements.........................................................................................9
3.2 Make the electrical connections...................................................................... 9
3.3 Wiring diagram................................................................................................10
3.4 External connections.......................................................................................11
3.5 Commissioning................................................................................................11
4 Troubleshooting......................................................................................................13
4.1 Common problems.........................................................................................13
4.2 Spare parts....................................................................................................... 14
Table of Contents
Start 151/161/156 Installation and Operation Manual 1

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide necessary information for installation,
operation, and maintenance of the unit.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the
location of the unit.
CAUTION:
Read this manual carefully before installing and using the
product. Improper use of the product can cause personal injury
and damage to property, and may void the warranty.
The equipment, and its functioning, may be impaired if used in a manner not
specified by the manufacturer.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is
not covered in this manual could cause death, serious personal
injury, or damage to the equipment and the surroundings. 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.
1.2 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety
messages and regulations carefully before handling the product. They are
published to help prevent these hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
1 Introduction and Safety
2 Start 151/161/156 Installation and Operation Manual

Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING:
A hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could
result in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not
personal injury.
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
Introduction
All government regulations, local health and safety directives must be observed.
Prevent danger due to electricity
All danger due to electricity must be avoided. Electrical connections must
always be carried out in compliance with the following:
• The standard connections shown in the product documentation that is
delivered together with the product
• All international, national, state, and local regulations. (For details, consult
the regulations of your local electricity supplier.)
For more information about requirements, see sections dealing specifically with
electrical connections.
1 Introduction and Safety
Start 151/161/156 Installation and Operation Manual 3

Power lock-out
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. This applies to the control circuit as well.
Qualification of personnel
WARNING: Electrical Hazard
Risk of electrical shock or burn. A certified electrician must
supervise all electrical work. Comply with all local codes and
regulations.
All work on the product must be carried out by certified electricians or Xylem
authorized mechanics.
Xylem disclaims all responsibility for work done by untrained, unauthorized
personnel.
1.4 End of life product disposal
Handle and dispose of all waste in compliance with local laws and regulations.
EU only: Correct disposal of this product — WEEE Directive on waste electrical and electronic
equipment
WS009973A
This marking on the product, accessories or literature indicates that the product
should not be disposed of with other waste at the end of its working life.
To prevent possible harm to the environment or human health from
uncontrolled waste disposal, please separate these items from other types of
waste and recycle them responsibly to promote the sustainable reuse of
material resources.
Waste from electrical and electronic equipment can be returned to the
producer or distributor.
1 Introduction and Safety
4 Start 151/161/156 Installation and Operation Manual

EU only: Correct disposal of batteries in this product
WS009974A
This marking on the battery, manual or packaging indicates that the batteries in
this product should not be disposed of with other waste at the end of its
working life. Where marked, the chemical symbols Hg, Cd or Pb indicate that
the battery contains mercury, cadmium or lead above the reference levels in EC
Directive 2006/66. If batteries are not properly disposed of, these substances
can cause harm to human health or the environment.
To protect natural resources and to promote material re-use, please separate
batteries from other types of waste and recycle them through your local, free
battery return system.
1.5 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.
1.6 Warranty
For information about warranty, see the sales contract.
1.7 Support
Xylem only supports products that have been tested and approved. Xylem does
not support unapproved equipment.
1 Introduction and Safety
Start 151/161/156 Installation and Operation Manual 5

2 Product Description
2.1 Product design
This unit is a manual starter that is well suited for rugged applications such as
building sites. Design features include a robust plastic casing and ON and OFF
buttons inset into the front, for manually starting and stopping the pump.
Automatic operation of the pump, for example with level control equipment, is
not possible.
Maximum number of starts
The starter includes a start capacitor in order to increase the starting torque
during start-up. The start capacitor is not designed for many repeated start
cycles in a short time. Always observe the limitations described under
Commissioning.
Pumps
These starters have been developed for use with single-phase capacitor motor
with one main winding and one auxiliary winding. The auxiliary winding is
connected in series with a running capacitor. At the instant of starting, a starting
capacitor supplements the running capacitor to provide extra starting torque.
Every variant of the starter is tested for the respective pump, so that the
capacitors and the starting relay are matched to the rating and voltage of the
pump. A starter must not be transferred and used on two different pumps, even
if they have similar electrical data.
Overload protection
The built-in motor protection switch, which has a thermal tripping function,
protects both the pump and its cable against overload. If the pump is
overloaded, then it is stopped and remains blocked until it is reset manually.
Current ranges
The starter is available for all current ranges from 1.0 - 16 A, and can be
supplied in two versions:
• Type A for pumps without built-in thermal contacts
• Type B for pumps with built-in thermal contacts
Cable connections
The starters are fully equipped with terminal blocks and cable glands for all
cable connections.
2 Product Description
6 Start 151/161/156 Installation and Operation Manual

2.2 The data plate
V Hz
5
24
6
3
7
1
A
max A
MFD MFD
89
WS000676B
1. Degree of protection
2. Part number
3. Type designation
4. Maximum fuse rating
5. Voltage
6. Frequency
7. Current range
8. Run capacitor
9. Start capacitor
2.3 Technical data
Table 1: Electrical characteristics
Parameter Value
Supply voltage/frequency * 115 V / 60 Hz
230 V / 60 Hz
110 V / 50 Hz
230–240 V / 50 Hz
Rated current* 16 A maximum
Maximum power supply fuse rating See the data plate.
Mains connection: 115–230 V / 60 Hz: 2 m cable with NA-plug
230–240 V / 50Hz: 2 m cable with schuco plug
Pump connection Cable gland PG21, 13–18 mm
* See the technical data that is supplied with the starter.
Table 2: Physical characteristics
Parameter Value
Material Polycarbonate
Dimensions (H x W x D) 280 x 178 x 120 mm (11 x 7 x 4.7 in)
Weight Approximately 3.5 kg (7.9 lb)
Table 3: Features
Feature Value
Thermal trip Yes
Magnetic trip No
Temperature compensation Yes, automatic between –25°C to +50°C (–13°F to
+122°F)
Motor temperature monitoring Type A: No
Type B: Yes
Degree of protection IP44/NEMA 3R
2 Product Description
Start 151/161/156 Installation and Operation Manual 7

Feature Value
Ambient temperature –25° to +40°C (–13°F to +104°F)
Table 4: Maximum connection area
Conductor Maximum
Solid conductor 1 x 1....10.0 mm2
2 x 1.... 4.0 mm2
Multiple-strand conductor 1 x 1....6.0 mm2
2 x 1....2.5 mm2
2 Product Description
8 Start 151/161/156 Installation and Operation Manual

3 Installation
3.1 Facility requirements
Exposure to water or physical damage
The starter has a high degree of protection against moisture and dirt, but it
should always be installed so that it will not be unnecessarily exposed to water
or the risk of external physical damage.
Explosive zones
Do not install the starter equipment in an explosive zone.
NOTICE:
Do not use this unit in environments that may contain
flammable/explosive or chemically aggressive gases or
powders.
3.2 Make the electrical connections
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. This applies to the control circuit as well.
WARNING: Electrical Hazard
There is a risk of electrical shock or explosion if the electrical
connections are not correctly carried out, or if there is fault or
damage on the product. Visually inspect equipment for
damaged cables, cracked casings or other signs of damage.
Make sure that electrical connections have been correctly
made.
WARNING: Electrical Hazard
Risk of electrical shock or burn. A certified electrician must
supervise all electrical work. Comply with all local codes and
regulations.
3 Installation
Start 151/161/156 Installation and Operation Manual 9

DANGER: Electrical Hazard
All electrical equipment must be grounded (earthed). Test the
ground (earth) lead to verify that it is connected correctly and
that the path to ground is continuous.
The current for the motor protection switch is preset, and has been matched at
the factory to the rated current of the motor. It cannot be adjusted.
1. Check that the starter rating agrees with the pump rating and with the
current, voltage and frequency of the power supply system.
2. Check that the fuse in the power supply agrees with the maximum
permissible fuse rating.
3. Make the electrical connections in accordance with the connection diagram.
For single-phase motors, it is particularly important that the pump cable
should be connected in accordance with the specified color sequence. If
incorrectly connected, a single-phase motor can damage both the starter
and the motor itself.
4. For type B starter: If the pump has motor temperature monitoring, then do
the following:
a) At the terminals marked T1–T2, remove the jumper fitted at the factory.
b) Connect the two conductors marked T1–T2 for motor temperature
monitoring to the terminals marked T1–T2
If the pump does not have this function, then do not remove the jumper at
terminals T1–T2.
5. Check that all connections have been securely tightened. Give particular
attention to the protective conductors.
3.3 Wiring diagram
M
°C
L1 L2 M1 M2 M3 PEPE T1 T2
1~
x)
WS000672A
European Version North American Version
Terminal Cable Color Terminal Cable Color
L1 1–phase supply L1 1–phase supply
L2 1–phase supply L2 1–phase supply
3 Installation
10 Start 151/161/156 Installation and Operation Manual

European Version North American Version
Terminal Cable Color Terminal Cable Color
M1 Brown R Red
M2 Black B Black
M3 Grey W White
PE Green/yellow G Green/yellow
T1 T1/white * T1 Orange *
T2 T2/white * T2 Blue *
* Only for starter type B
3.4 External connections
3.5 Commissioning
WARNING: Explosion/Fire Hazard
The start capacitor is not designed for many repeated start
cycles in a short time. Always wait at least 15 seconds between
starting attempts. Maximum allowed: 30 starts per hour.
1. Check that the starter is closed before the power supply is turned on.
2. Switch on the main power supply or fit the main fuses.
3. Check the direction of rotation of the pump, by following the directions in
the Installation, Operation, and Maintenance Manual for the pump.
CAUTION: Crush Hazard
The starting jerk can be powerful. Make sure
nobody is close to the unit when it is started.
The pump will jerk in an anti-clockwise direction if the impeller is rotating
correctly.
3 Installation
Start 151/161/156 Installation and Operation Manual 11

WS001398B
Figure 1: Start reaction
3 Installation
12 Start 151/161/156 Installation and Operation Manual

4 Troubleshooting
Precautions
Before starting work, make sure that the safety instructions in the chapter
Introduction and Safety (page 2) have been read and understood.
DANGER: Electrical Hazard
Troubleshooting a live control panel exposes personnel to
hazardous voltages. Electrical troubleshooting must be done by
a qualified electrician.
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. This applies to the control circuit as well.
4.1 Common problems
Fault Reason Action
The pump fails to start No power supply to the pump Check the main fuses.
Check that the main switch is
closed.
The motor protection breaker
trips.
Let the motor cool down, and
then restart the pump.
The pump rotates in the wrong
direction
The internal connections of the
motor are wrong.
Contact a Xylem service
representative.
The pump starts but runs
unsatisfactorily
Low voltage Cables are too long or under-
dimensioned.
The motor cable phase
conductors are probably mixed
up.
Check that the connection agrees
with the connection diagram and
correct if necessary.
4 Troubleshooting
Start 151/161/156 Installation and Operation Manual 13

Fault Reason Action
The motor protection breaker
trips.
Incorrect setting range Check on the rating plates that
the rated current ranges of the
pump and starter agree.
Low voltage Cables are too long or under-
dimensioned.
Overloaded motor The impeller is binding due to
clogging. Leave the motor to cool
down and then reset the starter.
Then make a few short starting
attempts to clear the impeller of
any blockage.
If the starter initiates an alarm
again the pump must be taken
out of operation for service.
4.2 Spare parts
Spares are normally not necessary. However, abnormal conditions can result in
parts sustaining damage and requiring replacement. Examples of such
conditions include:
• Incorrect handling or installation
• Wrongly dimensioned fuses
• Undersized cables
• Low voltage
The following are examples of components that normally can sustain damage
under these conditions:
• Motor protection breaker
• Auxiliary relays
• Contactors
• Capacitors
• Start relays
If spare parts are required, then exact component data can be obtained from
the electrical documentation that is supplied with the starter. The parts can be
ordered through the nearest service office.
If the documentation is not available and spare parts are needed, then the
starter part number or the serial number on the data plate must be stated.
4 Troubleshooting
14 Start 151/161/156 Installation and Operation Manual

Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots
2) A leading global water technology company
We’re a global team unified in a common purpose: creating innovative
solutions to meet our world's water needs. Developing new technologies that
will improve the way water is used, conserved, and re-used in the future is
central to our work. We move, treat, analyze, and return water to the
environment, and we help people use water efficiently, in their homes,
buildings, factories and farms. In more than 150 countries, we have strong,
long-standing relationships with customers who know us for our powerful
combination of leading product brands and applications expertise, backed by
a legacy of innovation.
For more information on how Xylem can help you, go to xyleminc.com
Xylem Water Solutions Global
Services AB
361 80 Emmaboda
Sweden
Tel: [phone]
Fax: [phone]
http://tpi.xyleminc.com
Visit our Web site for the latest
version of this document and more
information
The original instruction is in English.
All non-English instructions are
translations of the original
instruction.
©2012 Xylem Inc
894504_4.0_en-US_2016-08_IOM.Start151_161_156