ITT Industries Flygt 3067 Maintenance manual

Installation, Care and Maintenance
3067
892397/08

CONTENTS
Operation ______________________________ 11
Care and maintenance _________________ 12
Oil change _____________________________ 13
Available motors ______________________ 14
Hydraulic ends ____________________ 15
Dimensions and weights ____________ 17
Service log ________________________ 22
Safety __________________________________ 2
Data plate interpretation ________________ 3
Product description ____________________ 4
General design of a Flygt pump _________ 5
Installation ______________________________ 6
Electrical connections __________________ 7
Cable chart _____________________________ 9
Transportation and storage ____________ 11
SAFETY
General Danger:
Non-observance given to safety
instructions in this manual, which
could cause danger to life have
been specifically highlighted with
this general danger symbol.
High Voltage:
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 followed
carefully. It is essential that these instructions are
carefully read before installation or commissioning by
both the installation crew as well as those responsible
for operation or maintenance. The operating instruc-
tions should always be readily available at the location
of the unit.
WARNING!
Qualifications of 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 ITT 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.
Dismantling and re-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.
All government regulations shall be observed.
Identification of safety and warning symbols
The pictures in this manual may differ somewhat from the delivered pump depending on the hydraulic end configuration.

3
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
Class II and III Div. I Grp E, F and G
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
D
A
N
K
L
M
CB
F
E
GIJ
H
O
EN: EuropeanNorm
ATEX Directive
EN 50014, EN 50018, EN 1127-1
II 2 G EEx dII T4 . . . . . 3067.090,3067.590,3067.890
I M 2 EEx dI . . . . . . . . 3067.690
General data plate 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
M
LN
V
U
T
RS
Q
P
O
I
JK
H
G
F
E
D
BC
X
A
Made in Germany

4
General technical data
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.
The pump can be equipped for operation at tempera-
tures up to 90°C (195°F). At increased temperatures,
the pump must be completely submerged when
operated at full load.
Higher temperatures than 40°C (104°F) are not per-
mitted for Ex-approved pumps.
Liquid density: max. 1100 kg/m3(9.2 lb per US gal.)
The pH of the pumped liquid: 5.5—14
Depth of immersion: max. 20 m (65 ft).
— In some installations and at
certain operating points on the
performance curve, the noise
level of 70 dB or the noise level
specified for the actual pump
may be exceeded.
— Only Ex-approved pumps may be
used in an explosive or flammable
environment.
Warranty claim
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 3067 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 light liquid manure and urine
— pumping of sludge
— pumping of ground water
— pumping of sewage if the solids need to be cut into
small pieces.
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.
Specific technical data
For specific technical data regarding your pump,
please see the data plate.

5
GENERAL DESIGN OF A FLYGT PUMP
Design
The pump is a submersible, electric motor-driven
product.
1. Impeller
The pump is available with a wide range of impellers
for different applications and capacities.
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-cage 1-phase or 3-phase induction motor for
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 15 evenly spaced starts per hour.
Flygt motors are tested in accordance with IEC 34-1.
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.
The pump can be equipped with a sensor (FLS) for
sensing water in the stator housing (not applicable
to Ex-approved pumps).

6
INSTALLATION
Handling equipment
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.
General recommendations
To ensure proper installation, please see the dimen-
sions on the dimensional drawing.
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.
Special rules apply to installation in
explosive atmosphere.
— Intrinsically safe circuits are
normally required (Ex i) for the
automatic level control system by
level regulators.
— Minimum stop level should be
according to the dimensional
drawing.
— The pump must never run dry.
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.

7
ELECTRICAL CONNECTIONS
— Before starting work on the
pump, make sure that the pump
is 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) socket must
have an additional earth-(ground-)
fault protection device (GFI)
connected.
When pumping near a lake (jetties,
beaches, ponds, fountains etc)
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
— Electrical connections on the
explosion-proof motor must be
made by authorized personnel.
Flygt disclaims all responsibility
for work done by untrained, un-
authorized personnel.
— The pump may be used only in
accordance with the approved
motor data stated on the pump’s
plates.
— Thermal contacts must be
connected to protection circuit
intended for that purpose
according to the approval of the
product.
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 cable charts.
Conductors that are not in use must be isolated.
The cable should be replaced if the outer sheath is
damaged. Contact a 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. 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 equipment.
Make sure that the pump is correctly earthed (grounded).
When using a variable-frequency-drive (VFD) the
shielded cable (type NSSHÖU.../3E+St) should be
used. Contact your Flygt representative and ask your
VFD-supplier for electrical limitations.

8
ELECTRICAL CONNECTIONS
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.
Single phase operation
The Flygt single phase pumps must be equipped with
a starter which has start and run capacitors.
A special Flygt designed starter is required for the
operation of single phase 3067 pumps. The connec-
tion 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.
Monitoring equipment
The FLS sensor consists of a small float switch for
sensing water in the stator housing. Its design makes
it suitable for pumps in vertical installations.
The FLS sensor is installed in the bottom of the stator
housing.
The sensor is not applicable to Ex-approved pumps.
Check:
— signals and tripping function.
— that relays, lamps, fuses and connections are
intact.
Replace defective equipment.

9
CABLE CHART
3-phase, direct on-line starting
Conductors Connection starter
SUBCAB 4Gx 1 brown ***red L1
***SUBCAB xAWG/4 2 blue ***white L2
HØ7RN-F 4Gx 3 black ***black L3
BIHF 4Gx silicon yellow/green earth
SUBCAB 4Gx+2x1,5 1 brown L1
2 blue L2
3 black L3
yellow/green earth
T1 black T1*
T2 black T2*
SUBCAB 7Gx 1 black L1
HØ7RN-F 7Gx 2 black L2
SO7E6E5-F 7x2.5 3 black L3
4 black cut off
5 black T1*
6 black T2*
yellow/green earth
For Canada/USA red L1
***SUBCAB xAWG/7 white L2
black L3
yellow GC**
yellow/green earth
orange T1*
blue T2*
Stator leads V2 = blue
W2 = black
U2 = green
U1 = red
V1 = brown
W1 = yellow
7GX
3-phase, direct-on-line, ∆∆
∆∆
∆
Conductors Connection starter
SUBCAB7Gx 1 black L1
2 black L2
3 black L3
4 black L1
5 black L2
6 black L3
yellow/green earth
SUBCAB7Gx+2x1,5 1 black L1
2 black L2
3 black L3
4 black L1
5 black L2
6 black L3
T1 black T1*
T2 black T2*
yellow/green earth
* Terminalfor connection of thermal contactsinthe motor and monitoring equipment.
** GC = Ground Check
*** SUBCAB/AWG
SUBCAB is a registered trademark of ITT Flygt AB for electrical cables.
Stator leads V2 = blue
W2 = black
U2 = green
U1 = red
V1 = brown
W1 = yellow
V2
U2
W2
U1
V1
W1
10009b
SUBCAB
1356
2
4
T1
T2
W2 V2
U2
V1 W1
U1
DDD
L2 L3 T1 T2L1
3~
1236
4T1 T2
5
7GX
(7GX+2×1.5)

10
CABLE CHART
3-phase, star-delta starting
Conductors Connection starter
SUBCAB7Gx 1 black L1
SO7E6E5-F 7x2.5 2 black L2
3 black L3
4 black L1
5 black L2
6 black L3
yellow/green earth
SUBCAB 7Gx+2x1,5 1 black L1
2 black L2
3 black L3
4 black L1
5 black L2
6 black L3
T1 black T1*
T2 black T2*
yellow/green earth
* Terminalfor connection of thermal contactsinthe motor and monitoring equipment.
** GC = Ground Check
*** SUBCAB/AWG
SUBCAB is a registered trademark of ITT Flygt AB for electrical cables.
Stator leads V2 = blue
W2 = black
U2 = green
U1 = red
V1 = brown
W1 = yellow
Single phase
Conductors Connection starter
SUBCAB 4Gx 1 brown ***red 1
***SUBCAB xAWG/4 2 black ***black 2
HØ7RN-F 4Gx 3 blue ***white 3
BIHF 4Gx silicon yellow/green earth
SUBCAB 4Gx+2x1,5 1 brown 1
2 black 2
3 blue 3
yellow/green earth
T1 black T1*
T2 black T2*
SUBCAB 7Gx 1 black 1
2 black 2
3 black 3
4 black cut off
5 black T1*
6 black T2*
yellow/green earth
For Canada/USA red 1
***SUBCAB xAWG/7 black 2
white 3
yellow GC**
yellow/green earth
orange T1*
blue T2*
Stator leads U2 = brown
Z2 = black
U1 = red
Z1 = yellow
7GX

11
OPERATION
Before starting
— Before starting work on the pump,
make sure that the pump is
isolated from the power supply
and cannot be energized.
— Make sure that the pump cannot
roll or fall over and injure people
or damage property.
Check that the visible parts on the pump and
installation are undamaged and in good condition.
Check the oil level in the oil housing.
Remove the fuses or open the circuit breaker and
check that the impeller can be rotated freely.
Check that the monitoring equipment (if any) works.
Check the direction of rotation. The impeller shall
rotate clockwise, as viewed from above. When
started, the pump will jerk in the opposite direction to
the direction in which the impeller rotates. See the
figure.
In the case of dry installation, check the direction of
rotation through the inlet elbow access cover.
Transpose two phase leads if the impeller rotates in
the wrong direction (3 ~).
In some installations the pump
surface and the surrounding liquid
may be hot. Bear in mind the risk of
burn injuries.
Starting jerk
Watch out for the starting jerk,
which can be powerful.
The pump can be transported and stored in a vertical
or horizontal position.
— Always lift the pump by its lifting
handle – never by the motor cable
or the hose.
— Make sure that the pump cannot
roll or fall over and injure people
or damage property.
The pump is frostproof as long as it is operating or is
immersed in the liquid. If the pump is raised when
the temperature is below freezing, the impeller may
freeze.
The pump shall be run for a short period after being
raised in order to discharge all remaining water.
A frozen impeller 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.
For longer periods of storage, the pump must be
protected against moisture and heat. The impeller
should be rotated occasionally (for example every
other month) to prevent the seals from sticking
together.
After a long period of storage, the pump should be
inspected before it is taken into operation. Pay special
attention to the seals and the cable entry.
Follow the instructions under the heading “Before
starting”.
TRANSPORTATION AND STORAGE

12
CARE AND MAINTENANCE
Before starting work on the pump,
make sure that the pump is isolated
from the power supply and cannot
be energized.
This applies to the control circuit
as well.
NOTE for Ex version
All work on the explosion-proof
motor section must be performed by
personnel authorized by Flygt.
Flygt disclaims all responsibility for
work done by untrained, unauthorized
personnel.
Make sure that the pump cannot
roll or fall over and injure people
or damage property.
The following points are important in connection with
work on the pump:
— Make sure that the pump has been thoroughly
cleaned.
— Beware of the risk of infection.
— Follow local safety regulations.
The pump is designed for use in liquids which can be
hazardous to health. In order to prevent injury to the
eyes and skin, observe the following points when
working on the pump:
— Always wear goggles and rubber gloves.
— Rinse the pump thoroughly with clean water before
starting work.
— Rinse the components in water after dismantling.
— The oil housing may be under pressure. Hold a rag
over the oil screw (oil plug) to prevent splatter.
Proceed as follows if hazardous chemicals have
splashed into your eyes:
— Rinse your eyes immediately in running water
for 15 minutes. Hold your eyelids apart with your
fingers.
— Contact an eye specialist.
On your skin:
— Remove contaminated clothes.
— Wash your skin with soap and water.
— Seek medical attention, if required.
Inspection
Regular inspection and preventive maintenance
ensure more reliable operation.
The pump should be inspected at least once a year,
but more frequently under severe operating
conditions.
Under normal operating conditions, the pump should
have a major overhaul in a service shop at least every
third year for permanent installation and every year for
portable pumps. This requires special tools and should
be done by an authorized service shop.
If the seals have been replaced, an inspection of the
oil is recommended after one week of operation.
NOTE! Regular check of the condition of the lifting
handle and chain is important.
Inspection of hot water applications
Pumps in hot water applications shall undergo
inspection or overhaul at a service shop as follows,
depending on the time they have been submerged in
the hot water:
Temp. Mode of Inspection Shop
operation overhaul
<_70°C Continuous 1000 hours 4000 hours
(160°F)
<_70°C Intermittent twice a year once a year
(160°F)
<_90°C Cont./Int. 6 times a year twice a year
(195°F)

13
OIL CHANGE
A check of the condition of the oil can show whether
there has been leakage. Note! Air/oil mixture can be
confused with water/oil mixture.
Insert a tube (or hose) into the oil hole. Cover the top
end of the tube and take up a little oil from the bottom.
Change the oil if it contains too much water, i.e. if it is
heavily emulsified (cream-like), or if the oil housing
contains free water. Check again one week after
changing the oil.
The oil housing may be under
pressure. Hold a rag over the oil
plug to prevent splatter.
1. Lay the pump on its side on a bench or over two
supports. Unscrew the oil housing screw (oil plug)
and drain the oil.
2. Fill with oil.
A paraffin oil with viscosity close to ISO VG15 is
recommended (e.g. Mobil Whiterex 309). The
pump is delivered from factory with this type of oil.
In applications where poisonous properties are of
less concern, a mineral oil with viscosity up to ISO
VG32 can be used.
3. Replace the O-rings under the oil housing screws
(plugs) with new ones.
10 Nm (7 ft lb)
▲▲
▲▲
▲
0,4 l (0,42 US quarts)

14
AVAILABLE MOTORS
Motor For version with product code:
3 ~ 3067 .090 .180 .250 .590 .690 .170 .890
50 Hz 1.2 kW 2840 rpm × × × × × × ×
60 Hz 1.4 kW 3400 rpm × × × × × × ×
50 Hz 1.2 kW 1350 rpm × × – – – – –
60 Hz 1.3 kW 1650 rpm × × – – – – –
1 ~
50 Hz 0.9 kW 2800 rpm – – × – – – –
50 Hz 1.0 kW 2840 rpm – × – – – × –
60 Hz 1.2 kW 3450 rpm × × × × – × ×
50 Hz 0.8 kW 1400 rpm – × – – – – –
60 Hz 1.0 kW 1700 rpm × × – – – – –

15
HYDRAULIC ENDS
CM
BF

16
HYDRAULIC ENDS
DD
D

17
DIMENSIONS AND WEIGHTS
C 3067.090
.180
All dimensions in mm (in).

18
DIMENSIONS AND WEIGHTS
D 3067.090
.180
All dimensions in mm (in).

19
DIMENSIONS AND WEIGHTS
B/D 3067.250
.590
.690
All dimensions in mm (in).

20
DIMENSIONS AND WEIGHTS
M 3067.170
.890
All dimensions in mm (in).