ITT Industries FLYGT B2060 Maintenance manual

INSTALLATION, CARE
AND MAINTENANCE
2060/3060
890169/09

GUARANTEE
Hence, the guarantee does not cover faults caused
by deficient maintenance, improper installation, in-
correctly executed repair work or normal wear and
tear.
Flygt assumes no liability for either bodily injuries,
material damages or economic losses beyond what is
stated above.
Flygt guarantees that a spare parts stock will be kept
for 10 years after the manufacture of this product has
been discontinued.
The manufacturer reserves the right to alter perfor-
mance, specification or design without notice.
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 repre-
sentative during the guarantee period;
— that the product is used only under conditions
described 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.
DATA PLATE INTERPRETATION
Product description_________________ 3
Applications _____________________________ 3
Dimensions and weights ___________________ 3
Design __________________________________ 3
Technical data ____________________________ 4
Transportation and storage________ 5
Installation ___________________________ 5
Safety precautions ________________________ 5
Installation alternatives ____________________ 5
Electrical connections _____________ 8
Before starting ___________________________ 11
Operation ____________________________ 11
Care and maintenance _____________ 12
Safety precautions ________________________ 12
Inspection _______________________________ 12
Changing the oil __________________________ 15
Replacing the diffuser (B 2060) _____________ 15
Replacing the impeller (B 2060) _____________ 15
Replacing the suction cover (C 3060) ________ 16
Replacing the impeller (C 3060) _____________ 16
Accessories and tools______________ 17
Fault tracing (Troubleshooting) ___ 18
Service log___________________________ 22
CONTENTS
Serial No.
Product No.
Product
code
Power factor
Curve No.
S-order No.
Rated current
Rated voltage
Stator connection
Shaft power
Special
Number of poles
Factory code
Consecu-
tive No.
Impeller/
propeller diam.
Number of phases,
type of current, frequence
Operating duty, cont./int.
Rotation speed
Weight
Insulation class
*Gear ratio*Direction of rotation
L = left R = right
*Rotation speed/blade angel
*propeller version *For mixers

3
PRODUCT DESCRIPTION
Design
B2060 and C3060 are submersible electric motor-
driven centrifugal pumps.
Impellers
The pump is available with the following types of
impellers:
B2060 — three-vane impeller of acid-proof steel or
stainless steel.
C3060 — two-vane impeller or vortex impeller of
stainless steel.
Shaft seals
The pump has two mechanical seals which provide
the isolation necessary between the electric motor and
the pumped liquid.
Materials:
Inner seal: ceramic—carbon.
Outer seal B2060: ceramic—tungsten carbide
C3060: ceramic—ceramic
Shaft
The shaft is delivered with the rotor as an integral part.
Shaft material: stainless steel.
Bearings
The pump bearings are designed for at least 15 000
hours of operation.
The lower bearing consists of a single-row ball bearing.
The upper bearing consists of a single-row ball bearing.
Oil casing
The oil lubricates and cools the seals and acts as a
buffer between the pump casing and the electric
motor.
Pressure build-up within the oil casing is reduced by
means of a built-in air volume.
Motor
Squirrel-cage 3-phase induction motor for 50 Hz or
60 Hz. The motor is also available for 1-phase, 60 Hz.
The motor is started by means of direct on-line start.
The motor can be run continuously or intermittently
with a maximum of 15 evenly spaced starts per hour.
The stator is insulated to class F, 155°C (310°F). The
motor is designed to supply its rated output at ± 5%
variation of the rated voltage. Without overheating the
motor, ± 10% variation of the rated voltage can be
accepted provided that the motor does not run
continuously at full load. The motor is designed to
operate with a voltage imbalance of up to 2% between
the phases.
Applications
B2060 and C3060 are designed for drainage respec-
tively pumping of industrial waste water, when high
demands regarding corrosion resistance are required.
Liquid temperature:
C2060 – max. 40°C (100°F).
C3060 – max. 70°C (160°F).
C3060 – max. 90°C (200°F) with external cooling.
Liquid density: Max. 1100 kg/m3(9.2 Ib per US gal).
The pumped liquid may contain particles up to a size
which corresponds to the openings in the strainer.
The pH of the pumped liquid: 5—11, depending of
the pumped liquid and its temperature. Contact your
nearest Flygt-representative for information.
Depth of immersion: max. 20 m (65 ft).
Pumps with a vortex impeller may not be operated at
a too low discharge head, since this causes overload-
ing of the motor. Contact your nearest Flygt-represen-
tative for information.
The pump shall not be used in
explosive or flammable environ-
ments or with flammable liquids.
For other applications, contact your nearest Flygt
representative for information.
Dimensions and weights
For dimensions see “Installation alternatives”.
Weight without motor cable:
B 2060 — 32 kg (70 Ibs)
C3060 — 41 kg (90 Ibs)

4
Monitoring equipment
The stator incorporates two thermal switches
connected in series.
The thermal switches open at 125°C (260°F) and
close at 70°C (160°F).
The monitoring equipment shall be of a design that
makes automatic restart impossible.
See also “Electrical connections” and separate
instructions for starters.
Cooling
B 2060
The stator is cooled by the pumped liquid passing
through the space between the stator casing and the
outer casing.
C 3060
The stator is cooled by the circulation of a portion of
the pumped liquid in the space between the stator
casing and the cooling jacket.
Under severe operating conditions and/or at high
temperatures of the pumped liquid, internal cooling
can be replaced by external cooling. Special rules
apply for connecting external cooling to fresh water
systems.
C3060 can also be operated without the outer casing,
in which case the lowest liquid level shall be above the
upper edge of the stator casing.
Technical data
B 2060
The pump curves show:
— input power at various operating points.
— flow rate versus total head.
C 3060
For information about the capacity of the pump, con-
tact your nearest Flygt-representative.
Capacity
50 Hz
Capacity
60 Hz
Input (kW)
Head (m)
Capacity (l/s)
Input (kW)
Head (m)
Capacity (l/s)
1-phase
3-phase
1-phase
3-phase

5
TRANSPORTATION AND STORAGE
The pump may be transported and stored in a vertical
or horizontal position. Make sure that it is securely
fastened and cannot roll or fall over.
Always lift the pump by its carrying handle or lifting
eyes, never by the motor cable or the hose.
The pump is frostproof as long as it is operating or is
immersed in the liquid. If the pump is taken up when
the temperature is below freezing, the impeller may
freeze. The pump shall be operated for a short period
after being taken up in order to expel 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 an open flame to thaw
the pump.
For longer periods of storage, the pump must be
protected against moisture and heat. The impeller
should be rotated by hand occasionally (for example
every other month) to prevent the seals 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 seals and the cable entry.
Follow the instructions under the heading “Before
starting”.
CP 3060
With discharge connection assembly
Control equipment for start, stop and alarm.
Cable holder for holding the cable and regulating the
height of the level sensors.
Access frame (with covers) to which the upper guide
bar bracket and cable holder can be attached.
Discharge connection for connecting the pump to
the discharge line. The discharge connection has a
flange which fits the flange on the station piping. The
pump casing mates with the discharge connection,
which also has bosses for holding the guide bars.
Safety precautions
In order to minimize the risk of accidents in connection
with the service and installation work, the following
rules should be followed:
1.Make sure the lifting equipment is in good condi-
tion.
2.Be aware of the risk of electrical accidents.
3.Use a safety helmet, safety goggles and protective
shoes.
4.Do not ignore the risk of drowning.
5.A first-aid kit must be handy.
Follow all other health and safety rules and local
codes and ordinances.
At certain installations and
operation points on the pump
curve the noise level 70 dB, or
for the actual pump specified
noise level, can be exceeded.
INSTALLATION
Installation alternatives
C3060
CP version
In the CP version, the pump is installed on a station-
ary discharge connection and operates completely or
partially submerged in the pumped liquid.
In addition to the pump, the following items are
required:
Guide bars consisting of two stainless steel pipes.
Upper guide bar bracket for attaching the guide bars
to the access cover or top of the station.

6
CP installation
All dimensions are in mm (in).
Provide a barrier around the pump pit, for example a
guard rail.
Arrange for a cable between the sump and the electric
control box. Make sure that the cables are not sharply
bent or pinched.
NOTE!
The end of the cable must not be
submerged. Leads have to be
above flood level, as water may
penetrate through the cable into
the junction box or the motor.
Place the access frame in position. Align the frame so
that it is horizontal and then grout it in place. Check
that the guide bars will be vertical using a level or
plumb line.
Install the anchor bolts in place. Be careful when
aligning and positioning the discharge connection in
relation to the access frame.
Place the discharge connection in position and tighten
it. Secure the guide bars in the brackets and dis-
charge bosses. Connect the discharge pipe to the
discharge connection.
Bolt the cable holder to the access frame.
Protect bolts and nuts with corrosion-preventive
compound.
Lower the pump along the guide bars. On reaching its
bottom position, the pump will automatically connect to
the discharge connection. Fasten the lifting chain on
the access frame eyebolt provided and the cables on
the cable holder. Cable supports are required for deep
installations. 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
undone.
CS version
In the CS version, the pump is transportable and
intended to operate completely or partially submerged
in the pumped liquid.
The pump is equipped with a connection for pipe, see
“Parts list”.
The pump stands on a strainer with a support plate.
CS installation
Run the cables so that they have no sharp bends, are
not pinched and cannot be sucked into the pump inlet.
Connect the discharge line and the motor cable. See
“Electrical connections”.
Lower the pump into the sump.
Place the pump on a base which prevents it from
sinking into a soft sump bottom.
Alternatively, the pump can be suspended from above
by its handle just above the bottom of the sump.
CS 3060
Portable

7
CT version
In the CT version, the pump is installed in a stationary
position in a dry well next to the wet sump.
The pump has a watertight motor and will therefore
not be damaged in the event of flooding in the pump
room.
The pump is liquid-cooled. See “Cooling”.
In addition to the pump, the following items are
required:
Base stand and anchor bolts for setting up the
pump.
Shut-off valves to permit the pump to be removed for
repair.
Air vent on discharge side between the pump and the
check valve.
CT installation
The pump should be positioned low in the dry pit for
effective drainage.
Bolt the base stand to the concrete base by means of
four grouted-in anchor bolts.
Bolt the pump to the stand.
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.
NOTE! The risk of freezing is particularly great at
certain CT installations.
* Depending on the number of adjusting shims.
CT 3060
Dry installation
B2060
Pump installation
Run the cables so that they do not have any sharp
bends and are not pinched.
Connect the discharge connection and motor cable.
See “Electrical connections”.
Lower the pump into the sump.
Place the pump on a base which will prevent it from
sinking into a soft sump bottom. Alternatively, the
pump can be suspended by its handle just above the
sump bottom.
For tandem connection of pumps, see “Accessories
and tools”.
Consult your nearest Flygt representative regarding:
— sizing of sump, pumping station and access frame.
— choice of peripheral equipment.
— other problems in connection with installation.
B 2060

8
ELECTRICAL CONNECTIONS
6-lead stator
WARNING!
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.
Check that the main (line) voltage and frequency
agree with the specifications on the pump data plate.
The motor can be connected for different voltages as
shown on the data plate.
Install the motor cable as illustrated in the exploded
figure.
To avoid leakage into the pump, check:
— that the cable entry seal sleeve and washers
conform to the outside diameter of the cable. See
the parts list.
— that the outer jacket on the cable is not damaged.
When refitting a cable which has been used before,
always cut off a short piece of the cable so that the
cable entry seal sleeve does not close around the
cable at the same point again.
To protect the motor cable a stainless steel protection
hose can be ordered.
Please see under ACCESSORIES AND TOOLS (page
00). To prevent leakage thread tape should used
mounting the hose into the gland screw!
The stator leads are colour coded as follows:
6-and 9-lead stator 4-lead stator
U1 = Red U1 = Red
V1 = Brown U2 = Brown
W1 = Yellow Z1 = Yellow
U2 = Green Z2 = Black
V2 = Blue
W2 = Black
U5 = Red
V5 = Brown
W5 = YeIlow
The stator leads are connected to the terminal board
as illustrated in the figures.
Connect the motor cable to the terminal board as
follows. Check on the data plate which connection,
star or delta, is valid for used mains voltage.
Then, depending on mains voltage, mount the closing
links on the terminal board for star or delta connection,
see figure.

9
9-lead stator
* NOTE! When connecting pumps which
have 1 9-lead stator for 460V Y Ser. 60 Hz,
noclosinglinksshouldbeused.Forcorrect
connection,seeinsideofjunctionboxcover.

10
4-lead stator
(only 60 Hz, 1 phase)
Connect the control leads to the terminal board.
Make sure that the pump is correctly earthed
(grounded).
Install the cover (51).
Remember that the starting surge with the direct-on
line start can be up to six times higher than the rated
current.
Make sure that the fuses or circuit breakers are of the
proper amperage.
The tables give rated current. Fuse amperage 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)
shall be set to the motor’s operating current, but no
higher than the motor’s rated current as given on the
data plate.
NOTE!
For safety reasons, the earth
lead should be approx. 70 mm
(2.8") longer than the phase
leads. If the motor cable is jerked
loose by mistake, the earth lead
should be the last lead to come
loose from its terminal. This
applies to both ends of the cable.
B 2060/C 3060
60 Hz Rated current (A)
3-phase 220 V 380 V 460 V 575 V
2.7 kW (3.6 hp) 10 10 5.0 4.0
60 Hz Rated current (A)
1-phase 220 V 230 V — —
1.8 kW (2.5 hp) 11 11 — —
C 3060
50 Hz Rated current (A)
3-phase 220 V 380 V 440 V 550 V
2.4 kW 9.1 5.3 4.6 3.7
B 2060
50 Hz Rated current (A)
3-phase 220 V 380 V 440 V 550 V
2.2 kW 8.1 4.7 4.1 3.2