FLYGT ITT Flygt Series User manual

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
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Solutions AB is no longer an ITT company and the fact that "ITT" may appear on this
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End of Disclaimer text.

Water & Wastewater
Installation, Operation and
Maintenance Manual
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351,
C3356, C3400, C3501, C3531, C3602, C3800

Table of Contents
Introduction and Safety...................................................................................................................................................5
Introduction.......................................................................................................................................................................5
Inspect the delivery........................................................................................................................................................5
Product warranty............................................................................................................................................................5
Safety...................................................................................................................................................................................6
Safety message levels.....................................................................................................................................................6
User safety.......................................................................................................................................................................7
Ex-approved products...................................................................................................................................................8
Environmental safety.....................................................................................................................................................9
Transportation and Storage..........................................................................................................................................10
Transportation guidelines...............................................................................................................................................10
Precautions....................................................................................................................................................................10
Position and fastening.................................................................................................................................................10
Horizontal position......................................................................................................................................................10
Vertical position...........................................................................................................................................................10
Lifting.............................................................................................................................................................................11
Lift pump from vertical position and remove transport pallet.............................................................................13
Lift pump from horizontal position and remove transport pallet........................................................................14
Install the guide claw (3800 only)..............................................................................................................................17
Storage guidelines............................................................................................................................................................18
Storage location............................................................................................................................................................18
Freezing precautions....................................................................................................................................................18
Long-term storage.......................................................................................................................................................19
Reinstall the locking device.........................................................................................................................................19
Product Description........................................................................................................................................................20
Pump Design...................................................................................................................................................................20
Intended Use.................................................................................................................................................................20
Approvals......................................................................................................................................................................20
Spare parts.....................................................................................................................................................................21
Drive units........................................................................................................................................................................21
The monitoring equipment ...........................................................................................................................................24
Monitoring alternatives: MAS and CAS overviews................................................................................................26
Sensors...........................................................................................................................................................................27
Stator temperature monitoring methods..................................................................................................................31
Pt100 resistance............................................................................................................................................................32
Pump memory..............................................................................................................................................................33
The cooling system.........................................................................................................................................................33
Direct cooling...............................................................................................................................................................33
Integrated cooling........................................................................................................................................................33
External Cooling..........................................................................................................................................................35
Fittings needed to drain cooling jacket.....................................................................................................................38
Seal Flushing....................................................................................................................................................................40
Applications for seal flushing.....................................................................................................................................41
Circuit diagram for seal flushing................................................................................................................................41
Connections for seal flushing.....................................................................................................................................43
The data plates.................................................................................................................................................................43
Installation.........................................................................................................................................................................45
Install the pump...............................................................................................................................................................45
Fasteners........................................................................................................................................................................45
The locking device.......................................................................................................................................................45
Install with P-installation............................................................................................................................................46
Install with S-installation.............................................................................................................................................47
Install with T/Z-installation.......................................................................................................................................48
Table of Contents
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
1

Make the electrical connections....................................................................................................................................49
General precautions.....................................................................................................................................................49
Requirements................................................................................................................................................................49
Cables.............................................................................................................................................................................49
Earthing (Grounding).................................................................................................................................................50
Connect the cables.......................................................................................................................................................50
Power cable phase sequence.......................................................................................................................................51
MAS sensor connections............................................................................................................................................53
CAS or MAS 711 + MRM-01 sensor connections.................................................................................................55
Cable charts...................................................................................................................................................................58
Prepare the medium-voltage cable............................................................................................................................66
Connect the coolant........................................................................................................................................................72
Connect the integrated cooling system.....................................................................................................................72
Connect the external cooling system........................................................................................................................72
Connect the seal flushing...............................................................................................................................................77
Check the impeller rotation...........................................................................................................................................77
Operation...........................................................................................................................................................................79
Precautions.......................................................................................................................................................................79
Noise level........................................................................................................................................................................79
Start the pump.................................................................................................................................................................79
Modifications for freezing conditions..........................................................................................................................80
Maintenance......................................................................................................................................................................81
Precautions.......................................................................................................................................................................81
Service...............................................................................................................................................................................81
Inspection......................................................................................................................................................................82
Major overhaul..............................................................................................................................................................83
Check the junction box insulation, up to 1.1 kV drives............................................................................................84
Check the junction box insulation, 1.2-6.6 kV drives................................................................................................84
Check the temperature sensors.....................................................................................................................................84
Check the leakage sensors..............................................................................................................................................85
Empty the coolant (integrated cooling).......................................................................................................................85
Empty the coolant (external cooling)...........................................................................................................................86
Oil change.........................................................................................................................................................................87
Empty the oil................................................................................................................................................................88
Fill with oil....................................................................................................................................................................88
Horizontal lifting.............................................................................................................................................................89
Replace the wear parts....................................................................................................................................................90
Replace the pump housing wear ring........................................................................................................................90
Replace the impeller wear ring...................................................................................................................................91
Replace the impeller........................................................................................................................................................92
Remove the impeller....................................................................................................................................................92
Remove the locking assembly....................................................................................................................................94
Install the impeller.......................................................................................................................................................97
Install the locking assembly........................................................................................................................................97
Sequence for tightening or loosening locking assembly bolts..............................................................................99
Torque values.................................................................................................................................................................101
Tools................................................................................................................................................................................102
Technical Reference.....................................................................................................................................................105
Product overview..........................................................................................................................................................105
Materials..........................................................................................................................................................................105
Mounting-related data..................................................................................................................................................107
Drive units......................................................................................................................................................................108
Operational data............................................................................................................................................................110
Application limits.......................................................................................................................................................110
Motor Data.................................................................................................................................................................111
Monitoring with MAS...............................................................................................................................................111
Table of Contents
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C3231 Motor rating and performance, 50 Hz........................................................................................................113
Low voltage....................................................................................................................................................................113
C3240 Motor rating and performance, 50 Hz.......................................................................................................115
Low voltage....................................................................................................................................................................115
Medium voltage.............................................................................................................................................................116
C3300 Motor rating and performance, 50 Hz.......................................................................................................117
Low voltage....................................................................................................................................................................117
C3306 Motor rating and performance, 50 Hz.......................................................................................................119
Low voltage....................................................................................................................................................................119
C3312 Motor rating and performance, 50 Hz........................................................................................................120
Low voltage....................................................................................................................................................................120
Medium voltage.............................................................................................................................................................121
C3351 Motor rating and performance, 50 Hz........................................................................................................122
Low voltage....................................................................................................................................................................122
Medium voltage.............................................................................................................................................................123
C3356 Motor rating and performance, 50 Hz.......................................................................................................124
Low voltage....................................................................................................................................................................124
C3400 motor rating and performance, 50 Hz........................................................................................................125
Low voltage....................................................................................................................................................................125
Medium voltage.............................................................................................................................................................126
C3501 Motor rating and performance, 50 Hz........................................................................................................127
Low voltage....................................................................................................................................................................127
Medium voltage.............................................................................................................................................................128
C3531 Motor rating and performance, 50 Hz........................................................................................................129
Low voltage....................................................................................................................................................................129
Medium voltage.............................................................................................................................................................131
C3602 Motor rating and performance, 50 Hz.......................................................................................................134
Low voltage....................................................................................................................................................................134
Medium voltage.............................................................................................................................................................135
C3800 Motor rating and performance, 50 Hz.......................................................................................................137
Low voltage....................................................................................................................................................................137
Medium voltage.............................................................................................................................................................138
C3231 Motor rating and performance, 60 Hz........................................................................................................139
Low voltage....................................................................................................................................................................139
C3240 Motor rating and performance, 60 Hz.......................................................................................................140
Low voltage....................................................................................................................................................................140
Medium voltage.............................................................................................................................................................141
C3300 Motor rating and performance, 60 Hz.......................................................................................................142
Low voltage....................................................................................................................................................................142
C3306 Motor rating and performance, 60 Hz.......................................................................................................144
Low voltage....................................................................................................................................................................144
Table of Contents
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
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C3312 Motor rating and performance, 60 Hz........................................................................................................145
Low voltage....................................................................................................................................................................145
Medium voltage.............................................................................................................................................................146
C3351 Motor rating and performance, 60 Hz........................................................................................................147
Low voltage....................................................................................................................................................................147
Medium voltage.............................................................................................................................................................148
C3356 Motor rating and performance, 60 Hz.......................................................................................................149
Low voltage....................................................................................................................................................................149
C3400 motor rating and performance, 60 Hz........................................................................................................150
Low voltage....................................................................................................................................................................150
Medium voltage.............................................................................................................................................................151
C3501 Motor rating and performance, 60 Hz........................................................................................................153
Low voltage....................................................................................................................................................................153
Medium voltage.............................................................................................................................................................154
C3531 Motor rating and performance, 60 Hz........................................................................................................156
Low voltage....................................................................................................................................................................156
Medium voltage.............................................................................................................................................................158
C3602 Motor rating and performance, 60 Hz.......................................................................................................160
Low voltage....................................................................................................................................................................160
Medium voltage.............................................................................................................................................................161
C3800 Motor rating and performance, 60 Hz.......................................................................................................163
Low voltage....................................................................................................................................................................163
Medium voltage.............................................................................................................................................................164
Table of Contents
4 C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual

Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
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.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the unit.
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact your sales representative if anything is out of order.
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT representative within the warranty period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in use.
• All service and repair work is done by ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
Introduction and Safety
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
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• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should the
need arise for a warranty claim, then contact your ITT representative.
Spare parts
ITT guarantees that spare parts will be available for 20 years after the manufacture of this product has
been discontinued.
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is over-pressurized.
Take all necessary measures to avoid over-pressurization.
• 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. This includes any modification to the
equipment or use of parts not provided by ITT. If there is a question regarding the intended use of
the equipment, please contact an ITT representative before proceeding.
• This manual clearly identify accepted methods for disassembling units. These methods must be
adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply
heat to impellers, propellers, or their retaining devices to aid in their removal.
• Do not change the service application without the approval of an authorized ITT representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result in physical injury,
damage, or delays.
Safety message levels
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
• Product malfunction
Definitions
Safety message level Indication
DANGER:
A hazardous situation which, if not avoided, will
result in death or serious injury
Introduction and Safety
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Safety message level Indication
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
Electrical Hazard:
The possibility of electrical risks if instructions are
not followed in a proper manner
NOTICE: • A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment within the work
area:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety
devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all international, national,
state, and local regulations. For more information about requirements, see sections dealing specifically with
electrical connections.
Introduction and Safety
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
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Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe these rules when
you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are vaccinated against
diseases to which they may be exposed.
• Observe strict personal cleanliness.
Wash the skin and eyes
Do the following if chemicals or hazardous fluids have come into contact with your eyes or your skin:
If you need to wash
your...
Then...
Eyes 1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Skin 1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least one minute.
3. Seek medical attention, if required.
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:
• All work on the product must be carried out by certified electricians and ITT-authorized mechanics.
Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical characteristics of
the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national standards
(for example, IEC/EN 60079-17).
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially
explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during normal operation. Dry running during service
and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel are isolated
from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the approval
classification of the product, and that they are in use.
• Intrinsically safe circuits are normally required for the automatic level-control system by the level
regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the product
specification.
• Do not modify the equipment without approval from an authorized ITT representative.
• Only use parts that are provided by an authorized ITT representative.
Introduction and Safety
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Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not change the
conditions of the service without the approval of an ITT representative. When you install or maintain
explosion proof products, always comply with the directive and applicable standards (for example, IEC/
EN 60079–14).
Minimum permitted liquid level
See the dimensional drawings of the product for the minimum permitted liquid level according to the
approval for explosion proof products. If the information is missing on the dimensional drawing, the
product must be fully submerged. Level-sensing equipment must be installed if the product can be
operated at less than the minimum submersion depth.
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not
limited to the following:
• Level indicators
• Temperature detectors
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Introduction and Safety
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
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Transportation and Storage
Transportation guidelines
Precautions
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Position and fastening
The pump can be transported either horizontally or vertically. Make sure that the product is securely
fastened during transportation, and cannot roll or fall over.
Horizontal position
Figure 1: Horizontal position for transport
The impeller must be locked during transportation, if the pump is transported in the horizontal position.
Vertical position
Transportation and Storage
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Figure 2: Vertical position for transport
The impeller/propeller must also be locked during transportation.
Lifting
WARNING:
• Crush hazard. The unit and the components can be heavy. Use proper lifting methods and wear steel-
toed shoes at all times.
• Lift and handle the product carefully, using suitable lifting equipment.
• The product must be securely harnessed for lifting and handling. Use eyebolts or lifting lugs if
available.
• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the hose.
• Do not attach sling ropes to shaft ends.
Lifting equipment
Lifting equipment is always required when handling the pump. It must fulfill the following requirements:
• The minimum height (contact ITT for information) between the lifting hook and the floor must be
sufficient to lift the pump.
• The lifting equipment must be able to hoist the pump straight up and down, preferably without the
need for resetting the lifting hook.
• The lifting equipment must be securely anchored and in good condition.
• The lifting equipment must support weight of the entire assembly and must only be used by
authorized personnel.
• Two sets of lifting equipment must be used to lift the pump for repair work.
• The lifting equipment must be dimensioned to lift the pump with any remaining pumped media in it.
• The lifting equipment must not be oversized.
NOTICE:
Oversized lifting equipment could cause damage if the unit should stick when being lifted.
Lifting link placement for vertical lifting
Use the following lifting link configurations to lift the pump in the vertical position.
Transportation and Storage
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
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The left arrow indicates placement of the lifting link when lifting the complete pump with 605–675 drive
units. The right arrow indicates placement for lifting the drive unit only.
Figure 3: Drive units 605–675
Placement for lifting drive unit only, or complete pump C3231-C3356, with 705–775 drive units:
Placement for lifting complete pump C3400-C3602, with 705–775 drive units:
Figure 4: Drive units 705–775
When lifting only the drive unit for C3400–C3602 pumps, the lifting cover must be turned 180°.
Transportation and Storage
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WS000014A
Figure 5: Drive units 805–995
For 805–995 drive units, the lifting link must be positioned so that the complete pump hangs forward with
an incline of 0–2° in relation to the vertical axis.
Lift pump from vertical position and remove transport pallet
1. Fasten a suitable lifting strap/sling to the lifting eye on the top of the drive unit.
See Lifting (page 11).
2. Cut the transportation strap.
3. Lift up the pump using proper lifting equipment.
4. Place the pump upright on a rigid horizontal surface so that it cannot fall over.
Transportation and Storage
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
Operation and Maintenance Manual
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Lift pump from horizontal position and remove transport pallet
WARNING:
• An assembled pump must never be lifted by the holes in the hydraulic unit.
• Stay clear of suspended loads.
NOTICE:
• When handling the pump to and from horizontal position, the pump should always be lifted by the
lifting link. Use a suitable lifting sling/strap.
Lift with single-hook equipment
1. Fasten a suitable lifting sling/strap to the lifting eye on the top of the drive unit.
See Lifting (page 11).
2. Raise the pump approximately halfway to its upright position.
The pump is still be attached to the transport pallet.
3. Slide a pallet or similar object under the inlet section.
This will minimize the jolt which may occur later in the lifting, when the pump is almost fully upright.
Transportation and Storage
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For C3231: Make sure that the support columns on C3231 are outside the pallet, as they may break if
used as support when raising. See figure below.
4. Continue raising the pump until it is in an upright position.
The pump may jolt or sway near the end of the lifting operation.
WARNING:
Keep a safe distance while the unit is moving.
5. Remove the straps holding the pump to the transport pallet.
Transportation and Storage
C3300/6x5, C/R3231, C3240, C3306, C3312, C3351, C3356, C3400, C3501, C3531, C3602, C3800 Installation,
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6. Remove the transport pallet.
7. Lift the pump and remove the support pallet.
8. Place the pump upright on a rigid horizontal surface so that it cannot fall over.
Transportation and Storage
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