ITT Industries FLYGHT 3153 Maintenance manual

Installation, Care and Maintenance
3153
893544/06

23153
The pictures in this manual may differ somewhat from the delivered pump depending on the hydraulic end configuration.
CONTENTS
Safety ____________________________ 2
Data plate interpretation _______________ 3
Guarantee _________________________ 4
Product description ____________________ 4
Introduction _______________________________ 4
Application ________________________________ 4
Motordata _______________________________ 5
Design of the pump_________________ 6
Transportation and storage ____________ 8
Installation _________________________ 8
Handlingequipment ________________________ 8
Safetyprecautions __________________________ 9
Installationalternatives _____________________ 10
Electrical connections ________________ 10
Connectionofstatorandmotorleads _________ 11
Sensorconnections _______________________ 16
Operation ______________________________ 18
Beforestarting ____________________________ 18
Care and Maintenance _________________ 19
Service/Inspection _________________________ 19
Changingthecoolant ______________________ 21
Removing the impeller _____________________ 22
Installing the impeller _____________________ 23
Fault tracing ___________________________ 24
Service log ____________________________ 27
General Danger:
Non-observancegiventosafety
instructions in this manual, which
could cause danger to life have
beenspecificallyhighlightedwith
thisgeneraldangersymbol.
HighVoltage:
Thepresence ofa dangerous volt-
age is identified with this safety
symbol.
Non-observancetothiswarning
could damage the unit or affect its
function
This manual contains basic information on the installa-
tion,operatingandmaintenanceandshouldbefollowed
carefully. It is essential that these instructions are
carefullyread before installation or commissioning by
both the installation crew as well as those responsible
foroperationormaintenance.Theoperatinginstruc-
tions should always be readily available at the location
of the unit.
WARNING!
Qualificationsofpersonnel
Anauthorized (certified) electricianand mechanic shall
carry out all work.
Safetyregulationsfortheowner/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
supplycompany).
Unilateralmodificationandspareparts manu-
facturing
Modifications or changes to the unit/installation should
only be carried out after consulting with ITT Flygt.
Originalspare 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,
personnelandenvironmentarenotendangered.
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.
Allgovernmentregulationsshall beobserved.
Identificationofsafetyandwarningsymbols
SAFETY

3
3153
DATAPLATE INTERPRETATION
Generaldataplate
M
LN
V
U
T
RS
Q
P
O
I
JK
H
G
F
E
D
BC
X
A
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
Approvalplates
These approval plates apply to an explosion-proof submersible Flygt pump.
The plates are used together with the general data plate on the pump.
D
A
N
K
L
M
CB
F
E
GIJ
H
O
A Approval
B Approval authority + Approval Number
C Approval for Class I
D Approved drive unit
E Stalltime
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
EN: EuropeanNorm
ATEX Directive
EN50014,EN50018,EN1127-1
II 2 G EEx dII B T3 for ambient temperatures < 40°C
EEx dII B T4 for ambient temperatures < 25°C
FM: FactoryMutual
Class I Div. I Grp C and D
Class II and III Div. I Grp E, F and G

43153
GUARANTEE
Flygt undertakes to remedy faults in products sold by
Flygtprovided:
— that the fault is due to defects in design, materials
orworkmanship;
— that the faults are reported to Flygt or Flygt's repre-
senatativeduringtheguaranteeperiod;
— that the product is used only under condition de-
scribedin the Installation,Care and Maintenance
manual and in applications for which it is intended;
— thatthemonitoringequipmentincorporatedinthe
product is correctly connected and in use;
— that all service and repair work is done by a work
shop authorized by Flygt;
— that genuine Flygt parts are used.
Hence, the guarantee does not cover faults caused by
deficientmaintenance,improperinstallation,incorrectly
executedrepairworkornomalwearandtear.
Flygt assumes no liability for either bodily injuries,
material damages or economic losses beyond what is
statedabove.
Flygt guarantees that spare parts will be kept for 15
years after that the manufacture of this product has
beendiscontinued.
Application
ThisInstallation,CareandMaintenancemanual
applies to a submersible Flygt pump.
Ifyou have bought an Ex-approved pump (please see
approval plate on your pump or Parts List) special
handling instructions apply as described in this docu-
ment.
The pump is intended to be used for;
— pumpingofwastewater
— pumpingofrawor cleanwater
— pumpingofsludge
Installationalternatives
P = semipermanentwet well arrangement with pump
installed by means of twin guide bars with automatic
connectiontodischarge.
S = transportable version with hose connection or
flangeforconnection todischarge pipeline.
T= permanent drywell orin-line arrangementwith
flangeconnectiontosuctionand dischargepipework;
verticalmounting.
Z = Permanentdry wellor in-line arrangement with
flangeconnection to suction and dischargepipe-
work;horizontal mounting.
In T, Z and S installations the pump must be equipped
with cooling jacket.
Forfurther information on applications, contactyour
nearestFlygtrepresentative.
PRODUCTDESCRIPTION
Introduction
Thank you for buying a submersible Flygt pump. In this
Installation,Care and Maintenancemanual you willfind
general information on how to install and service the
3153 pump to give it a long and reliable life.
Pumpversions
LT = low head execution
MT = medium head execution
HT = high head execution
Liquidtemperature:max.40°C(104°F)
alsoavailable in an execution for liquid temperature up
to 70°C (158°F) only with cooling jacket.
Highertemperaturesthan40°C(104°F)arenotpermit-
tedfor the Ex-approved pumps.
Liquid density: max. 1100 kg/m³ (9.2 lb per US gal.)
The pH of the pumped liquid: 5.5—14.
Lowest liquid level: See illustration on page 6.
Depth of immersion: max. 20 m (65 ft).
Weights
Weightincluding connections, butwithoutmotor cable
in kg (lb).
Pump type With Without Discharge
cooling cooling connection
jacket jacket
NP 3153 LT 239 (528) 226 (499) 78 (172)
NP 3153 LT 6-pole 298 (657) 285 (628) 98 (217)
NP3153 MT 203 (448) 190 (419) 54 (119)
NP 3153 HT 189 (417) 176 (388) 42 (93)
NS 3153 LT 257 (567) —
NS 3153 LT 6-pole 361 (796) —
NS 3153 MT 232 (511) —
NS 3153 HT 209 (461) —
NT 3153 LT 326 (719) —
NT 3153 LT 6-pole 417 (919) —
NT 3153 MT 272 (600) —
NT 3153 HT 235 (518) —
NZ 3153 LT 327 (721) —
NZ 3153 LT 6-pole 386 (853) —
NZ 3153 MT 256 (566) —
NZ 3153 HT 232 (511) —

5
3153
Motordata
50 Hz, 7.5 kW, 1460 r/min, 3~, 4-pole
Voltage Rated Starting
V current A currentA
230VD 29 168
380VD 17 96
380VY 17 102
400VD 16 91
400VY 17 98
415VD 15 86
500VD 13 70
50 Hz, 9.0kW, 1460 r/min, 3~, 4-pole
Voltage Rated Starting
V current A currentA
230VD 32 181
380VD 20 114
380VY 19 110
400VD 19 107
400VY 19 105
415VD 18 105
500VD 15 86
50 Hz, 11.0kW, 1465 r/min, 3~, 4-pole
Voltage Rated Starting
V current A currentA
230VD 40 244
380VD 25 148
380VY 25 152
400VD 24 146
400VY 23 141
415VD 23 141
500VD 19 111
50 Hz, 9.0kW, 955 r/min, 3~, 6-pole
Voltage Rated Starting
V current A currentA
230VD 36 151
380VD 22 95
380VY 22 90
400VD 21 90
400VY 21 88
415VD 20 81
440VD 20 87
500VD 17 73
60 Hz, 12 hp, (8.9 kW) 1760 r/min,
3~, 4-pole
60 Hz, 15 hp, (11.2 kW) 1760 r/min,
3~, 4-pole
Voltage Rated Starting
V current A current A
230Y// 39 228
460VD 19 112
575VD 15 90
600VD 15 95
60 Hz, 18 hp, (13.4 kW) 1760 r/min,
3~, 4-pole
Voltage Rated Starting
V current A current A
230Y// 47 296
460VD 24 153
575VD 19 116
600VD 19 123
60 Hz, 15 hp, (11.2 kW) 1150 r/min,
3~, 6-pole
230Y// 46 212
460VD 21 95
575VD 17 76
600VD 17 81
Voltage Rated Starting
V current A current A
230Y// 32 204
460VD 16 95
575VD 12 73
600VD 12 78
Voltage Rated Starting
V current A current A

63153
30720
DESIGN OFTHE PUMP
Monitoringequipment
Thestator incorporates threethermal contacts conn-
ected in series that activate an alarm at overtempe-
rature.
Thethermal contacts:open at 140°C(285°F). The
sensors shall be connected to Flygt's monitoring
unit MiniCAS II or equivalent unit.
The monitoring equipment shall be of a design that
makes automatic restart impossible.
The3153issuppliedwithinspection sensor FLS10 for
sensing the presence of any liquid in the inspection
chamber.
Withoutcoolingjacket
Motor
Squirrel-cage3-phaseinductionmotorfor50Hzor
60 Hz.
The motor is started by means of direct on-line or
star delta start.
The motor can be run continuously or intermittently
with a maximum of 15 evenly spaced starts per hour.
Flygt motors are tested in accordance with IEC 34-1.
The stator is insulated in accordance with class H
(180°C, 360 F). The motor is designed to supply its
rated output at ± 5% variation of the rated voltage.
Withoutoverheating the motor,±10% variation of the
ratedvoltagecan beacceptedprovided thatthemotor
does not run continuously at full load. The motor is
designedto operate with a voltage imbalance of up to 2
% between the phases.
Cooling (withoutcooling jacket)
The pump is cooled by the ambient liquid.
For lowest liquid level, see illlustration below*).
Seal housing
A coolant fluid lubricates and cools the mechanical
seal unit and acts as a buffer between the pumped
media and the electric motor.
Mechanicalsealunit
The pump has one shaft mechanical seal unit con-
sistingof two independently operating seals:
Alt I Innerseal: AluminumOxide/Carbon
Al2O3/CSb
Outerseal: Corrosionresistantcemented
carbideWCCR/WCCR
Alt II Innerseal: Corrosionresistantcemented
carbideWCCR/WCCR
Outerseal: Corrosionresistantcemented
carbideWCCR/WCCR
Alt III Innerseal: AluminumOxide/Corrosion
resistantcementedcarbide
Al2O3/WCCR
Outerseal: SiliconCarbideRSiC/RSiC
Bearings
The support bearing of the shaft is a single row ball
bearing. The main bearing of the shaft is a double
rowangularcontactballbearing.
30781
*) Lowest liquid level.

7
3153
30693
Withcooling jacket
Cooling (with cooling jacket)
The motor is cooled by a closed
loop cooling system. An inte-
gratedcoolantpumpcirculates
the coolant whenever the pump is
operated.
Impeller
Thepumpis equippedwith aN-impeller,
asemiopentwo-vaneimpeller.
Flowdiffusor
Provides heat transfer from the
coolantto the pumped media.
Inspectionchamber
The inspection chamber is
equippedwithaFLS10
leakagesensortoprevent
damagesonthe motor.
Seal housing
Thecoolant alsolubri-
cates and cools the
mechanical seal unit and
acts as a buffer between
thepumpedmediaand
the electric motor.
Shaft
The shaft is delivered with the
rotor as an integral part. Shaft
material; stainless steel.

83153
TRANSPORTATION AND STORAGE
Handlingequipment
Always pay extra attention to safety aspects when
workingwithliftingequipment.
Liftingequipmentisrequired forhandlingthe pump.
The lifting chain and the shackle should be in stainless
steel and inspected every year.
— Stayclearof 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
straightupanddown in the sump, preferably without
the need for resetting the lifting hook.
Oversized lifting equipment could cause damage if the
pump should stick when being lifted.
Make sure that the lifting equipment is securely
anchoredandingoodcondition.
Check that the lifting handle and chain are in good
condition.
INSTALLATION
The pump may be transported and stored in a vertical
or horizontal position. Make sure that the pump cannot
roll or fall over.
WARNING!
Always lift the pump by its lifting handle
never by the motor cable or the hose.
The pump is frostproof as long as it is operating or is
immersed. If the pump is hoisted from the sump
whenthe temperatureis belowthe freezingpoint,
the impeller and shaft seal may freeze.
A frozen impeller and shaft seal can be thawed by
allowing the pump to stand immersed in the liquid for a
short period before it is started. Never use a naked
flame to thaw the pump. The pump shall be run for a
short period after being taken up in order to expel all
remainingwater.
For longer periods of storage, the pump must be
protectedagainstmoisture andheat. Theimpeller
shouldberotated by hand occasionally (for example
every other month) to prevent the seal rings from
sticking together. If the pump is stored for more than 6
months, this rotation is mandatory.
After a long period of storage, the pump should be
inspected before it is put into operation. Pay special
attention to the shaft seal and the cable entry.
Followtheinstructionsunder theheading"Before
starting".
Toensureproper installation,please seethe dimen-
sionsonthedimensionaldrawing.
WARNING! The end of the cable must not be sub-
merged. It must be above flood level, as water may
penetrate through the cable into the junction box or the
motor.
Forautomatic operation of the pump (level control),
it is recommended that the level regulators should be
used at low voltage. The data sheet delivered with the
regulators 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.
Special rules apply to installation in
explosiveatmosphere;
— Intrinsicalllysafecircuitsare
normally required (Ex i) for the
automaticlevelcontrolsystemby
levelregulators.
— Minimum stop level should be
accordingto the dimensional
drawing.
— The pump must never run dry.

9
3153
Safetyprecautions
In order to minimize the risk of accidents in connec-
tion with service and installation work, the following
rulesshouldbefollowed:
1. Never work alone. Use a lifting harness, safety
line anda respirator as required. Do not ignore
the risk of drowning.
2. Makesure there are no poisonous gases within
theworkarea.
3. Check the explosion risk before welding or using
electric hand tools.
4. Before the pump is installed check that the cable
andcableentryhavenotbeendamagedduring
thetransportation.
5. Observe strict cleanliness. Do not ignore health
hazards.
6. Bear in mind the risk of electrical accidents.
7. Make sure that the lifting equipment is in good
condition and comply to local ordinances.
8. Provideasuitablebarrieraroundtheworkarea,
e.g. a guard rail.
9. Make sure you have a clear path of retreat!
10. Use safety helmet, safety goggles and protective
shoes.
11. All personnel who work with sewage systems
must be vaccinated against diseases to which
they may be exposed.
12. A first-aid kit must be close at hand.
13. Note that special rules apply to installation in
explosiveatmosphere.
Follow all other health and safety rules and local
codesandordinances.
Installationalternatives
P- installation
In the P installation, the pump is installed on a
stationarydischargeconnectionandoperatescom-
pletelyor partially submerged inthe pumped liquid.
In addition to the pump the following items are
required:
Guide bars consisting of two hot dip galvanized or
stainless steel pipes.
Guide bar bracket for attaching the guide bars to the
access frame or the upper part of the sump.
Level regulators orothercontrol equipmentfor start,
stopand alarm.
Cable holder forholding the cableand regulating the
height of the level regulators.
Accessframe (with covers)towhichthe upperguide
barbracket and cable holder can be attached.
Discharge connection forconnecting thepump to the
dischargeline. The discharge connection has a flange
which fits the pump casing flange and a bracket for
attachingtheguideequipment.
Bushingsforvibrationdampingbetweentheguidebars
andthedischargeconnection.
Instructions
Providea barrieraroundthe pumppit, for example
aguardrail.
Arrange for a cable between the sump and the electric
control box. Make sure that the cables are not sharply
bentorpinched.
Place the access frame in position.
Align the frame so that it is horizontal and then grout it
in place.
Grout the anchor bolts in place. Be careful when align-
ingandpositioningthe dischargeconnection inrelation
to the access frame.
Place the discharge connection in position and tighten
the nuts.
Secure the guide bars in the bracket.
Check that the guide bars are placed vertically by using
a level or a plumb line.
Connectthe discharge pipeto the discharge conn-
ection.
Bolt the cable holder to the access frame. Thread the
level regulator cables through the holes in the cable
holder and adjust the height of the level regulators.
Protect bolts and nuts with corrosion preventive com-
pound.
Lowerthepumpalong theguidebars.
Fasten the lifting chain (stainless steel) on the access
frame and the cables on the cable holder. Make sure
that the cables cannot be sucked into the inlet of the
pump.Supportstrapsarerequired fordeepinstall-
ations.
Run the cables up to the electric control box.
Clean out debris from the sump before starting up the
station.
The pump can be hoisted up along the guide bars for
inspection without any connections having to be un-
done.
30747

10 3153
S-installation
In the S- installation, the pump is transportable and
intendedtooperatecompletelyorpartiallysubmerged
in the pumped liquid. The pump is equipped with a
connection for hose or pipe, see "Parts list".
The pump stands on a base stand.
WARNING! Watch for the starting jerk which can
bepowerful.
30784
30750
ELECTRICALCONNECTIONS
Instruction
Bolt the base stand to the concrete base by means of
the anchor bolts. Bolt the pump to the base stand and
the suction connection.
Check that the pump is vertical.
Connect the motor cable, suction line and discharge
line.
Make sure that the weight of the pump does not
bear on the system piping.
In the T- installation, the pump is installed in a station-
ary position in a dry well next to the wet sump.
In the Z- installation the pump is installed in a horizon-
tal position on a support stand and a bell-mouth is
connected to the inlet pipe.
T/Z-installation
— Beforestarting work onthepump,
makesure that the pump and the con-
trolpanel are isolatedfrom the power
supplyandcannotbeenergized.
— If the pump is equipped with
automaticlevel control, there is
ariskofsuddenrestart.
— If persons are likely to come into
physicalcontactwiththe pump or
pumped media (liquid), e.g on con-
structionsitesandfarms,theearthed
(grounded)socketmusthaveanaddi-
tionalearth-(ground-)faultprotection
device(GFI)connected.
All electrical work shall be carried out under the super-
vision of an authorized electrician. Local codes and
regulationsshall be compliedwith.
All electrical equipment must be
earthed(grounded). This applies to
both pump equipment and any
monitoring equipment. Failure to
heed this warning may cause a lethal
accident.Makesurethattheearth
(ground)leadiscorrectly connectedby
testingit.
TZ
Thepump has a watertight motor and will therefore not
be damaged in the event of flooding.
The pump is equipped with a cooling jacket.
Inadditionto thepumpthefollowingitems arerequired:
Support stand for anchoring the pump to a base.
Shut-off valves to permit the pump to be removed for
service.
Level regulators orothercontrol equipmentfor start,
stopand alarm.
WARNING! The risk of freezing is particularly great at
certain T or Z installations.