Xylem FLYGT 3045 Wartungshandbuch

Xylem Water Solutions AB (the Company) was previously named ITT Water &

Wastewater AB. The name change took place in November 2011. This is document is

(i) a document that relates to a product of the Company phased out prior to the name

change; or (ii) an old version of documentation relating to a product that is still being

produced by the Company but which document was published prior to the 1st of

January 2012 . This document may therefore still be marked "ITT". Xylem Water

Solutions AB is no longer an ITT company and the fact that "ITT" may appear on this

document shall not be interpreted as a reference by the Company to "ITT" in the

Company's current business activities. Any use or reference to “ITT” by you is strictly

prohibited. In no event will we be liable for any incidental, indirect, consequential,

punitive or special damages of any kind, or any other damages whatsoever, including,

without limitation, those resulting from loss of profit, loss of contracts, loss of reputation,

goodwill, data, information, income, anticipated savings or business relationships for any

use by you of “ITT”. This disclaimer notice shall be interpreted and governed by Swedish

law, and any disputes in relation to it are subject to the jurisdiction of the courts in Sweden.

If you do not agree to these terms and conditions you should not print this document and

immediately stop accessing it.

End of Disclaimer text.

3045

892769/12

Installation, Care and Maintenance

CONTENTS

Safety __________________________________ 2

Data plate interpretation ________________ 4

Product description ____________________ 5

General design of a Flygt pump ________ 5

Installation _____________________________ 6

Electrical connections __________________ 7

Cable chart _____________________________ 9

Transportation and storage ___________ 13

Operation ______________________________ 13

Care and maintenance ________________ 14

Oil change _____________________________ 15

Hydraulic ends ________________________ 16

SAFETY

General Danger:

Safety instructions in this manual,

which could cause danger to life if

not observed, have been specifi-

cally highlighted with this general

dangersymbol.

HighVoltage:

The presence of a dangerous volt-

age is identified with this safety

symbol.

Non-observance to this warning

could damage the unit or affect its

function

This manual contains basic information on the installa-

tion, operating and maintenance and should be fol-

lowed carefully. It is essential that these instructions

are carefully read before installation or commissioning

by both the installation crew as well as those respon-

sible for operation or maintenance. The operating

instructions should always be readily available at the

location of the unit.

WARNING!

Qualificationsof personnel

An authorized (certified) electrician and mechanic

shall carry out all work.

Safety regulations for the owner/operator

All government regulations, local health and safety

codes shall be complied with.

All dangers due to electricity must be avoided (for

details consult the regulations of your local electricity

supply company).

Unilateral modification and spare parts manu-

facturing

Modifications or changes to the unit/installation should

only be carried out after consulting with 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.

Dismantlingandre-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 coolant must

be appropriately disposed of. Coolant spills must be

cleaned up and emissions to the environment must be

reported.

The pumping station must be kept tidy and in good

order at all times.

All government regulations shall be observed.

Identification of safety and warning symbols

NOTES FOR EX-PRODUCTS

SAFETY

ITT Flygt undertakes to remedy faults in products sold

by Flygt provided:

— that the fault is due to defects in design, materials or

workmanship;

— that the fault is reported to Flygt or Flygt’s represen-

tativeduring theguarantee period;

— that the product is used only under conditions de-

scribed in the care and maintenance instructions and

in applications for which it is intended;

— that the monitoring equipment incorporated in the

product is correctly connected;

— that all service and repair work is done by a work-

shop authorized by Flygt;

— that genuine Flygt parts are used.

GUARANTEE

— Only Ex-approved pumps may be used in an explo-

sive or flammable environment.

— Do not open the pump when an explosive gas atmo-

sphere may be present.

— Before starting work on the pump, make sure that

the pump and the control panel are isolated from

the power supply and can not be energized. This

applies to the control circuit as well.

— All mechanical work on the explosion-proof motor

section must be performed by personnel authorized

by Flygt.

— Electrical connection on the explosion-proof motor

must be made by authorized personnel.

— Thermal contacts must be connected to protection

circuit intended for that purpose according to the

approval of the product.

— The pump may be used only in accordance with the

approved motor data stated on the data plates.

— Intrinsically safe circuits are normally required

(Ex i) for the automatic level control system by

level regulator if mounted in zone 0.

— This equipment must be installed in conformity to

prescriptions in international or national rules ( IEC/

EN 60079-14 ).

— The maintenance operation must be made in con-

formity to the international or national standards (

IEC/EN 60079-17).

— The yield stress of fastener elements in the product

must be in conformity with the value specified in the

table for “Material of fastener” on the approval

drawing or the parts specified in the part list for the

product.

— According to the ATEX directive the Ex-pump must

never run dry or snore. Permitted minimum water

level, see dimensional drawing for the pump.

Dry running at service and inspection is only per-

mitted outside the Ex area.

— The user must know about the risks due the electric

current and the chemical and physical characteris-

tics of the gas and/or vapours present in hazardous

areas.

— Flygt disclaims all responsibility for work done by

untrained, unauthorized personnel.

Hence, the guarantee does not cover faults caused by

deficient maintenance, improper installation, incorrectly

executedrepairwork or normal wear andtear.

Flygt assumes no liability for bodily injuries, material dam-

ages or economic losses beyond what is stated above.

Flygt guarantees that a spare parts stock will be kept

for 15 years after the manufacture of this product has

beendiscontinued.

A Approval

B Approval authority + Approval Number

C Approval for Class I

D Approved drive unit

E Stall time

F Starting current; Rated current

G Duty class

H Duty factor

I Input power

J Rated speed

K Controller

L Additional information

M Max. ambient temperature

N Serial number

O ATEX marking

Approval plates

These approval plates apply to an explosion-proof submersible Flygt pump.

The plates are used together with the general data plate on the pump.

DATA PLATE INTERPRETATION

FM: Factory Mutual

Class I Div. I Grp C and D . . . . . . . . . . . . . . 3045.090

Class II and III Div. I Grp E, F and G . . . . . . 3045.090

GIJ

EN: European Norm

ATEX Directive

EN 50014, EN 50018, EN 1127-1 . . . . . . . . 3045.090

II 2 G EEx dII T4

TRSQPO

Made in Germany

A Serial number

B Product code + Number

C Curve code / Propeller code

D Country of origin

E Product number

F Additional information

G Phase;Type of current; Frequency

H Rated voltage

I Thermal protection

J Thermal class

K Rated shaft power

L International standard

M Degree of protection

N Rated current

O Rated speed

P Max. submergence

Q Direction of rotation: L=left, R=right

R Duty class

S Duty factor

T Product weight

U Locked rotor code letter

V Power factor

X Max. ambient temperature

Y Notified body/ Only for EN-apparoved

Ex-products

General data plate

EN approval for the Cable entry

Certificate number: INERIS 03ATEX9008 U

II 2 G or IM2 EEx d IIC or EEx d I

Generaltechnicaldata

Liquid temperature: max. 40°C(104°F).The pump

can be operated at full load only if at least half the

stator housing is submerged.

Liquid density: max. 1100 kg/m3(9.2 lb per US gal.)

The pH of the pumped liquid: 5.5 - 14 (cast iron

pumps).

Depth of immersion: max. 20 m (65 ft).

— In some installations and at

certain operating points on the

performancecurve, thenoise

level of 70 dB or the noise level

specified for the actual pump

may be exceeded.

Warrantyclaim

Flygt pumps are high quality products with expected

reliable operation and long life. However, should the

need arise for a warranty claim, please contact your

Flygt representative.

PRODUCT DESCRIPTION

Introduction

Thank you for buying a submersible Flygt pump. In this

Installation, Care and Maintenance manual you will find

general information on how to install and service the

3045 pump to give it a long and reliable life.

Application

This Installation, Care and Maintenance manual

applies to a submersible Flygt pump. If you have

bought an Ex-approved pump (please see approval

plate on your pump) special handling instructions

apply as described in this document.

Depending on the hydraulic end, the pump is intended

to be used for:

— pumping of waste water,

— pumping of sludge,

— pumping of ground water.

The pumps must not be used in highly corrosive liquids.

See pH limits below.

The pump is available for permanent installation in a

sump or portable installation with hose connection and

stand.

For further information on applications, contact your

nearest Flygt representative.

Specifictechnicaldata

For specific technical data regarding your pump, please

see the data plate.

GENERAL DESIGN OF AN FLYGT PUMP

Design

The pump is a submersible, electric motor-driven

product.

1. Impeller

The pump is available with a single channel or

a vortex impeller.

2. Shaft seals

The pump has two mechanical face seals – one inner

and one outer, with an intermediate oil housing.

3. Shaft

The shaft is delivered with the rotor as an integral part.

Shaft material: stainless steel.

4.Bearings

The bearings of the shaft consist of single-row ball

bearings.

5. Oil housing

The oil lubricates and cools the seals and acts as a

buffer between the pump housing and the electric

motor.

6. Motor

Squirrel-cage1-phaseor3-phaseinductionmotorfor

50 Hz or 60 Hz.

The motor can be started by direct on-line or star-

delta starting.

The motor can be run continuously or intermittently

with a maximum of 30 evenly spaced starts per

hour.

Flygt motors are tested in accordance with IEC 34-1.

Recycling

Localand/orprivatelawsand regulationsregarding

recycling must be followed. If there are no laws or regu-

lations, or the product is not accepted by an authorized

recycling company, the product or it’s parts can be

returned to the nearest Flygt sales company or service

workshop.

GENERAL DESIGN OF A FLYGT PUMP

The stator is insulated in accordance with class F

(155°C, 310°F). The motor is designed to deliver its

rated output at ± 5% variation from the rated voltage.

Without overheating the motor, ± 10% variation from

the rated voltage can be accepted provided that the

motor does not run continuously at full load. The

motor is designed to operate at a voltage imbalance

of up to 2% between the phases.

Monitoring equipment

The stator incorporates thermal contacts connected in

series for some versions.

INSTALLATION

Handlingequipment

Lifting equipment is required for handling the pump.

— Stay clear of suspended loads.

— Always lift the pump by its lifting

handle - never by the motor cable

or the hose.

The minimum height between the lifting hook and the

floor shall be sufficient to lift the pump out of the

sump.

The lifting equipment shall be able to hoist the pump

straight up and down in the sump, 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.

INSTALLATION

Generalrecommendations

To ensure proper installation, please see the dimen-

sions on the dimensional drawing in the Parts List.

NOTE! The end of the cable must not be submerged.

It must be above flood level, as water may penetrate

through the cable into the junction box or the motor.

Check that the lifting handle and chain are in good

condition.

For automatic operation of the pump (level control),

it is recommended that the level regulators be used

at low voltage. The data sheet delivered with the regu-

lators gives the permissible voltage. Local rules may

specify otherwise.

Clean out all debris from the sump before the pump is

lowered down and the station is started.

— NOTE for Ex version page 3.

— Minimum stop level should be

according to the dimensional

drawing.

— The pump must never run dry or

on snore.

Safety precautions

In order to minimize the risk of accidents in connection

with the service and installation work, the following

rules should be followed:

11. Never work alone. Use a lifting harness, safety

line and a respirator as required. Do not ignore

the risk of drowning!

12. Make sure there are no poisonous gases within

the work area.

13. Check the explosion risk before welding or using

electric hand tools.

14. Do not ignore health hazards. Observe strict

cleanliness.

15. Bear in mind the risk of electrical accidents.

16. Make sure that the lifting equipment is in good

condition.

17. Provide a suitable barrier around the work area,

e.g. a guard rail.

18. Make sure you have a clear path of retreat.

19. Use safety helmet, safety goggles and protective

shoes.

10. All personnel who work with sewage systems

must be vaccinated against diseases to which

they may be exposed.

11. A first-aid kit must be close at hand.

12. Note that special rules apply to installation in

explosive athmosphere.

Follow all other health and safety rules and local

codes and ordinances.

ELECTRICAL CONNECTIONS

— Before starting work on the

pump, make sure that the pump

and the control panel are isolated

from the power supply and cannot

be energized.

— If the pump is equipped with

automatic level control, there is

a risk of sudden restart.

— All electrical equipment must be

earthed. This applies to both pump

equipment and any monitoring

equipment. Failure to heed this

warning may cause a lethal

accident. Make sure that the earth

lead is correctly connected by

testing it.

— If persons are likely to come into

physical contact with the pump or

pumped media (liquid), e.g on con-

struction sites and farms, the

earthed(grounded)socketmust

haveanadditionalearth-(ground-)

faultprotection device (GFI)

connected.

When pumping near a lake (jetties,

beaches,ponds,fountainsetc)

a safety-distance of at least 20 m

(65 ft) between the person and the

pump is applicable.

The pump must never be placed

directly into a swimming pool. If

used in connection with swimming

pools, special safety regulations

apply.

NOTE for Ex version page 3.

ELECTRICAL CONNECTIONS

- All electrical work shall be carried out under the super-

vision of an authorized electrician.

- Local codes and regulations shall be complied with.

- Check on the data plate which voltage supply is valid

for your pump.

- Check that the main voltage and frequency agree with

the specifications on the pump data plate.

- If the pump can be connected to different voltages,

the connected voltage is specified by a yellow sticker.

- Connect the motor cable to the starter equipment as

illustrated in the wiring diagrams.

- When the pump is connected to the public mains it

may cause flicker of incandescent lamps when start-

ing. In this case the supply authority should be noti-

fied before installing the pump.

Conductors that are not in use must be isolated.

The cable should be replaced if the outer sheath is

damaged. Contact an Flygt service shop.

Make sure that the cable does not have any sharp

bends and is not pinched.

Under no circumstances may the starter equipment be

installed in the sump.

NOTE! For safety reasons, the earth conductor

should be approx. 50 mm (2.0") longer than the phase

conductors. If the motor cable is jerked loose by

mistake, the earth conductor should be the last

conductor to come loose from its terminal. This

applies to both ends of the cable.

Thermal contacts are incorporated in the stator for

some versions. The thermal contacts can be

connected to max 250 V, breaking current max 4 A.

Flygt recommends that they be connected to 24 V over

separate fuses to protect the other automatic equip-

ment.

Make sure that the pump is correctly earthed (grounded).

Whenusing a variable-frequency-drive(VFD) the

shielded cable (type NSSHÖU.../3E+St) should be

used in order to fulfil European CE requirements. Con-

tact your Flygt representive and ask your VFD-supplier

for electrical limitations.

Remember that the starting current in direct on-line

starting can be up to six times higher than the rated

current. Make sure that the fuses or circuit breakers

are of the proper rating.

The data plate gives rated current. Fuse rating and

cable shall be selected in accordance with local rules

and regulations. Note that with long cables, the

voltage drop in the cable must be taken into consider-

ation, since the motor’s rated voltage is the voltage

that is measured at the terminal board in the pump.

The overload protection (motor protection breaker) for

direct on-line starting shall be set to the motor rated

current as given on the data plate.

Check the phase sequence in the mains with the

phase sequence indicator.

If intermittent operation is prescribed (see data plate),

the pump shall be provided with control equipment

that provides such operation.

Singlephaseoperation

The Flygt single phase pumps must be equipped with a

starter which has a capacitor.

A special Flygt designed starter is required for the

operation of single phase pumps. The connection of

the motor cable to the starter is shown in the wiring

diagram.

NOTE! It is not possible to change the direction of

rotation of a single phase pump by changing the cable

conductors on the starter. Please contact your nearest

Flygt representative.

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