Replacing Cooling Liquid

In Pumps with Cooling

Jackets

Flygt 3153, 3171,

3202, 3301, 3315,
5100, 5150
 Table of Contents

Table of Contents
1 Replace the Cooling Liquid....................................................................................................... 2
1.1 Prerequisites......................................................................................................................... 2
1.1.1 The water-glycol mixture..............................................................................................2
1.2 Coolant and inspection plugs............................................................................................ 2
1.3 Depressurize the cooling jacket.........................................................................................3
1.4 Empty the cooling jacket.....................................................................................................4
1.5 Empty the cooling liquid in the inspection chamber...................................................... 5
1.6 Fill with cooling liquid, alternative 1: complete pump....................................................6
1.7 Fill with cooling liquid, alternative 2: drive unit............................................................... 6

Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets 1
1 Replace the Cooling Liquid

1 Replace the Cooling Liquid

1.1 Prerequisites
• The old (spent) cooling liquid can be highly alkali. Use chemical eye goggles and
rubber gloves, and other appropriate personal protective equipment.
• For T- and Z-installations, the inlet and outlet lines must be closed off before starting
work, and the piping system must be depressurized. See the Installation, Operation
and Maintenance manual for the pump.
• Ensure adequate ventilation in the workspace.
• It is very important that the cooling system is depressurized before the drive unit is
separated from the pump housing. See Depressurize the cooling jacket (page 3).
For general safety
Before starting work, make sure that the safety instructions in the Installation, Operation
and Maintenance manual for the pump have been read and understood.

1.1.1 The water-glycol mixture

Composition
Use a cooling liquid that is a mixture of 70% deionized or distilled water, and 30%
DOWCAL 200™ monopropylene glycol. If DOWCAL 200™ from Dow Chemical Company
is not available, then contact your local Xylem representative.

NOTICE:
Deionized or distilled water must be used in the water-glycol mixture.

Applications for potable water or ingested substances

If the pumped liquid includes potable water or substances to be ingested, then contact
your local Xylem sales representative.
Volume of water-glycol mixture
Pump Quantity of water-glycol mixture, L (qt.)
3153 10.5 (11.2)
3171.091/.095/.181/.185/.350/.390/.660/.670 16.7 (17.6)
3171.800/.810/.820/.830/.840/.850/.860/.870 24 (25.4)
3202.090/.095/.180./185/.350/.390/.660/.670 25 (26.4)
3202.800/.810/.820/.830/.840/.850/.860/.870 41 (43.3)
3301.090/.095/.180/.185/.660/.670 47 (49.6)
3301.800/.810/.820/.830/.860/.870 54 (57)
3315 52 (54.9)
5100.211/.221 10.5 (11.2)
5100.251/.261 16.7 (17.6)
5100.300/.310 25 (26.4)
5150.300/.310 25 (26.4)
5150.350/.360 47 (49.6)

1.2 Coolant and inspection plugs

This image shows the plugs that are used to change the cooling liquid.

2 Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets
 1 Replace the Cooling Liquid

2 2

WS001479A
1. Inspection plug
2. Coolant plugs

1.3 Depressurize the cooling jacket

WARNING: Flammable Gas
The chamber might contain hydrogen gas, which is flammable. Avoid sparking, electrical
tools, and other sources of ignition.

CAUTION: Chemical Hazard

The old (spent) liquid can be highly alkali and cause caustic burns. Wear suitable gloves
and chemical eye goggles or face shield. In case of contact with eyes, rinse immediately
with plenty of water and seek medical advice.

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with force. Be careful
when opening. Do not stand in front of the plug.

1. Partially unscrew the uppermost coolant plug. Unscrew 2 turns only.

x2

WS009488A

2. Push inwards on the coolant plug. If there is resistance, then wait for the built-up
pressure inside the cooling jacket to vent.
WS009487B

Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets 3
1 Replace the Cooling Liquid

3. Push on the coolant plug again. If it is loose and has no resistance, then the pressure
has been vented. Continue with the next step.
4. Re-install the coolant plug.

1.4 Empty the cooling jacket

NOTICE:
It is important that all of the old (spent) cooling liquid is drained.
• For T- and Z-installations it is necessary to remove the drive unit from the pump
housing.
• For P- and S-installations the drive unit does not need to be separated from the pump
housing.

The quantity of cooling liquid can be significant. Have a container available to collect any
liquid coming out. For cooling liquid volumes, see The water-glycol mixture (page 2).
1. If it is necessary to separate the drive unit from the hydraulic unit, then follow this
procedure:
a) Relieve any built-up pressure inside the cooling jacket. See Depressurize the
cooling jacket (page 3).
b) Remove the pump housing screws.
c) Remove the drive unit from the pump housing.

NOTICE:
Do not allow the weight of the pump to rest on any portion of the impeller. The
impeller must not be allowed to make contact with the concrete floor or other hard
or rough surfaces.
2. Place the pump horizontally, so that one of the coolant plugs is at the lowest point of
the pump, to ensure that the cooling liquid will drain completely.
It is important to empty all of the cooling liquid.
3. Place a container under the pump.
4. Remove the coolant plugs and empty the cooling liquid.

4 Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets
 1 Replace the Cooling Liquid

WS001411A

1.5 Empty the cooling liquid in the inspection chamber

CAUTION: Compressed Gas Hazard
Air inside the chamber may cause parts or liquid to be propelled with force. Be careful
when opening. Hold a rag over the plug to prevent liquid from spraying out.

1. Place the pump in a vertical position. Secure it so that it cannot tip or fall.
2. Remove the inspection plug.
WS002122B

3. Pump out any cooling liquid from the inspection chamber, as shown here.

Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets 5
1 Replace the Cooling Liquid

WS009196B
4. Fit a new O-ring and re-install the inspection plug. Tighten the plug.
Tightening torque: 44 Nm (33 ft-lbs)

1.6 Fill with cooling liquid, alternative 1: complete pump

Follow these instructions if the drive unit has not been separated from the pump housing.
1. Put the pump in a vertical position. Secure the pump so that it cannot tip or fall.
2. Fill with cooling liquid until it overflows through the opposite hole, as shown here. For
cooling liquid amount, see The water-glycol mixture (page 2).

WS000966A

3. Fit new O-rings and re-install the coolant plugs. Tighten the plugs.
Tightening torque: 44 Nm (33 ft-lb)
4. Re-install the pump in its correct position.

1.7 Fill with cooling liquid, alternative 2: drive unit

If the drive unit has been separated from the pump housing then follow these instructions.
1. Put the drive unit in a vertical position. Secure the drive unit so that it cannot tip or fall.

NOTICE:
Do not allow the weight of the pump to rest on any portion of the impeller. The
impeller must not be allowed to make contact with the concrete floor or other hard or
rough surfaces.
2. Fill with cooling liquid until it overflows through the opposite hole, as shown here. For
cooling liquid amount, see The water-glycol mixture (page 2).

6 Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets
 1 Replace the Cooling Liquid

WS000966A
3. Fit new O-rings and reinstall the coolant plugs. Tighten the plugs.
Tightening torque: 44 Nm (33 ft-lb)
4. Reinstall the drive unit onto the pump housing.
5. Complete the reinstallation of the pump.

Flygt 3153, 3171, 3202, 3301, 3315, 5100, 5150 Replacing Cooling Liquid In Pumps with Cooling Jackets 7
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