Xylem FLYGT 3045 Maintenance manual

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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
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End of Disclaimer text.

3045
892769/12
Installation, Care and Maintenance

2
CONTENTS
Safety __________________________________ 2
Data plate interpretation ________________ 4
Product description ____________________ 5
General design of a Flygt pump ________ 5
Installation _____________________________ 6
Electrical connections __________________ 7
Cable chart _____________________________ 9
Transportation and storage ___________ 13
Operation ______________________________ 13
Care and maintenance ________________ 14
Oil change _____________________________ 15
Hydraulic ends ________________________ 16
SAFETY
General Danger:
Safety instructions in this manual,
which could cause danger to life if
not observed, have been specifi-
cally highlighted with this general
dangersymbol.
HighVoltage:
The presence of a dangerous volt-
age is identified with this safety
symbol.
Non-observance to this warning
could damage the unit or affect its
function
This manual contains basic information on the installa-
tion, operating and maintenance and should be fol-
lowed carefully. It is essential that these instructions
are carefully read before installation or commissioning
by both the installation crew as well as those respon-
sible for operation or maintenance. The operating
instructions should always be readily available at the
location of the unit.
WARNING!
Qualificationsof personnel
An authorized (certified) electrician and mechanic
shall carry out all work.
Safety regulations for the owner/operator
All government regulations, local health and safety
codes shall be complied with.
All dangers due to electricity must be avoided (for
details consult the regulations of your local electricity
supply company).
Unilateral modification and spare parts manu-
facturing
Modifications or changes to the unit/installation should
only be carried out after consulting with Flygt.
Original spare parts and accessories authorized by the
manufacturer are essential for compliance. The use of
other parts can invalidate any claims for warranty or
compensation.
Dismantlingandre-assembly
If the pump has been used to pump hazardous media,
care must be taken that, when draining the leakage,
personnel and environment are not endangered.
All waste and emissions such as used coolant must
be appropriately disposed of. Coolant spills must be
cleaned up and emissions to the environment must be
reported.
The pumping station must be kept tidy and in good
order at all times.
All government regulations shall be observed.
Identification of safety and warning symbols

3
NOTES FOR EX-PRODUCTS
SAFETY
ITT Flygt undertakes to remedy faults in products sold
by Flygt provided:
— that the fault is due to defects in design, materials or
workmanship;
— that the fault is reported to Flygt or Flygt’s represen-
tativeduring theguarantee period;
— that the product is used only under conditions de-
scribed in the care and maintenance instructions and
in applications for which it is intended;
— that the monitoring equipment incorporated in the
product is correctly connected;
— that all service and repair work is done by a work-
shop authorized by Flygt;
— that genuine Flygt parts are used.
GUARANTEE
— Only Ex-approved pumps may be used in an explo-
sive or flammable environment.
— Do not open the pump when an explosive gas atmo-
sphere may be present.
— Before starting work on the pump, make sure that
the pump and the control panel are isolated from
the power supply and can not be energized. This
applies to the control circuit as well.
— All mechanical work on the explosion-proof motor
section must be performed by personnel authorized
by Flygt.
— Electrical connection on the explosion-proof motor
must be made by authorized personnel.
— Thermal contacts must be connected to protection
circuit intended for that purpose according to the
approval of the product.
— The pump may be used only in accordance with the
approved motor data stated on the data plates.
— Intrinsically safe circuits are normally required
(Ex i) for the automatic level control system by
level regulator if mounted in zone 0.
— This equipment must be installed in conformity to
prescriptions in international or national rules ( IEC/
EN 60079-14 ).
— The maintenance operation must be made in con-
formity to the international or national standards (
IEC/EN 60079-17).
— The yield stress of fastener elements in the product
must be in conformity with the value specified in the
table for “Material of fastener” on the approval
drawing or the parts specified in the part list for the
product.
— According to the ATEX directive the Ex-pump must
never run dry or snore. Permitted minimum water
level, see dimensional drawing for the pump.
Dry running at service and inspection is only per-
mitted outside the Ex area.
— The user must know about the risks due the electric
current and the chemical and physical characteris-
tics of the gas and/or vapours present in hazardous
areas.
— Flygt disclaims all responsibility for work done by
untrained, unauthorized personnel.
Hence, the guarantee does not cover faults caused by
deficient maintenance, improper installation, incorrectly
executedrepairwork or normal wear andtear.
Flygt assumes no liability for bodily injuries, material dam-
ages or economic losses beyond what is stated above.
Flygt guarantees that a spare parts stock will be kept
for 15 years after the manufacture of this product has
beendiscontinued.

4
A Approval
B Approval authority + Approval Number
C Approval for Class I
D Approved drive unit
E Stall time
F Starting current; Rated current
G Duty class
H Duty factor
I Input power
J Rated speed
K Controller
L Additional information
M Max. ambient temperature
N Serial number
O ATEX marking
Approval plates
These approval plates apply to an explosion-proof submersible Flygt pump.
The plates are used together with the general data plate on the pump.
DATA PLATE INTERPRETATION
FM: Factory Mutual
Class I Div. I Grp C and D . . . . . . . . . . . . . . 3045.090
Class II and III Div. I Grp E, F and G . . . . . . 3045.090
D
A
N
K
L
M
CB
F
E
GIJ
H
O
EN: European Norm
ATEX Directive
EN 50014, EN 50018, EN 1127-1 . . . . . . . . 3045.090
II 2 G EEx dII T4
A
M
LN
V
U
TRSQPO
I
JK
H
G
F
E
D
BC
X
Y
Made in Germany
A Serial number
B Product code + Number
C Curve code / Propeller code
D Country of origin
E Product number
F Additional information
G Phase;Type of current; Frequency
H Rated voltage
I Thermal protection
J Thermal class
K Rated shaft power
L International standard
M Degree of protection
N Rated current
O Rated speed
P Max. submergence
Q Direction of rotation: L=left, R=right
R Duty class
S Duty factor
T Product weight
U Locked rotor code letter
V Power factor
X Max. ambient temperature
Y Notified body/ Only for EN-apparoved
Ex-products
General data plate
EN approval for the Cable entry
Certificate number: INERIS 03ATEX9008 U
II 2 G or IM2 EEx d IIC or EEx d I

5
Generaltechnicaldata
Liquid temperature: max. 40°C(104°F).The pump
can be operated at full load only if at least half the
stator housing is submerged.
Liquid density: max. 1100 kg/m3(9.2 lb per US gal.)
The pH of the pumped liquid: 5.5 - 14 (cast iron
pumps).
Depth of immersion: max. 20 m (65 ft).
— In some installations and at
certain operating points on the
performancecurve, thenoise
level of 70 dB or the noise level
specified for the actual pump
may be exceeded.
Warrantyclaim
Flygt pumps are high quality products with expected
reliable operation and long life. However, should the
need arise for a warranty claim, please contact your
Flygt representative.
PRODUCT DESCRIPTION
Introduction
Thank you for buying a submersible Flygt pump. In this
Installation, Care and Maintenance manual you will find
general information on how to install and service the
3045 pump to give it a long and reliable life.
Application
This Installation, Care and Maintenance manual
applies to a submersible Flygt pump. If you have
bought an Ex-approved pump (please see approval
plate on your pump) special handling instructions
apply as described in this document.
Depending on the hydraulic end, the pump is intended
to be used for:
— pumping of waste water,
— pumping of sludge,
— pumping of ground water.
The pumps must not be used in highly corrosive liquids.
See pH limits below.
The pump is available for permanent installation in a
sump or portable installation with hose connection and
stand.
For further information on applications, contact your
nearest Flygt representative.
Specifictechnicaldata
For specific technical data regarding your pump, please
see the data plate.
GENERAL DESIGN OF AN FLYGT PUMP
Design
The pump is a submersible, electric motor-driven
product.
1. Impeller
The pump is available with a single channel or
a vortex impeller.
2. Shaft seals
The pump has two mechanical face seals – one inner
and one outer, with an intermediate oil housing.
3. Shaft
The shaft is delivered with the rotor as an integral part.
Shaft material: stainless steel.
4.Bearings
The bearings of the shaft consist of single-row ball
bearings.
5. Oil housing
The oil lubricates and cools the seals and acts as a
buffer between the pump housing and the electric
motor.
6. Motor
Squirrel-cage1-phaseor3-phaseinductionmotorfor
50 Hz or 60 Hz.
The motor can be started by direct on-line or star-
delta starting.
The motor can be run continuously or intermittently
with a maximum of 30 evenly spaced starts per
hour.
Flygt motors are tested in accordance with IEC 34-1.
Recycling
Localand/orprivatelawsand regulationsregarding
recycling must be followed. If there are no laws or regu-
lations, or the product is not accepted by an authorized
recycling company, the product or it’s parts can be
returned to the nearest Flygt sales company or service
workshop.

6
GENERAL DESIGN OF A FLYGT PUMP
The stator is insulated in accordance with class F
(155°C, 310°F). The motor is designed to deliver its
rated output at ± 5% variation from the rated voltage.
Without overheating the motor, ± 10% variation from
the rated voltage can be accepted provided that the
motor does not run continuously at full load. The
motor is designed to operate at a voltage imbalance
of up to 2% between the phases.
4
5
1
3
2
6
Monitoring equipment
The stator incorporates thermal contacts connected in
series for some versions.
INSTALLATION
Handlingequipment
Lifting equipment is required for handling the pump.
— Stay clear of suspended loads.
— Always lift the pump by its lifting
handle - never by the motor cable
or the hose.
The minimum height between the lifting hook and the
floor shall be sufficient to lift the pump out of the
sump.
The lifting equipment shall be able to hoist the pump
straight up and down in the sump, preferably without
the need for resetting the lifting hook.
Oversize lifting equipment could cause damage if the
pump should stick when being lifted.
Make sure that the lifting equipment is securely
anchored.

7
INSTALLATION
Generalrecommendations
To ensure proper installation, please see the dimen-
sions on the dimensional drawing in the Parts List.
NOTE! The end of the cable must not be submerged.
It must be above flood level, as water may penetrate
through the cable into the junction box or the motor.
Check that the lifting handle and chain are in good
condition.
For automatic operation of the pump (level control),
it is recommended that the level regulators be used
at low voltage. The data sheet delivered with the regu-
lators gives the permissible voltage. Local rules may
specify otherwise.
Clean out all debris from the sump before the pump is
lowered down and the station is started.
— NOTE for Ex version page 3.
— Minimum stop level should be
according to the dimensional
drawing.
— The pump must never run dry or
on snore.
Safety precautions
In order to minimize the risk of accidents in connection
with the service and installation work, the following
rules should be followed:
11. Never work alone. Use a lifting harness, safety
line and a respirator as required. Do not ignore
the risk of drowning!
12. Make sure there are no poisonous gases within
the work area.
13. Check the explosion risk before welding or using
electric hand tools.
14. Do not ignore health hazards. Observe strict
cleanliness.
15. Bear in mind the risk of electrical accidents.
16. Make sure that the lifting equipment is in good
condition.
17. Provide a suitable barrier around the work area,
e.g. a guard rail.
18. Make sure you have a clear path of retreat.
19. Use safety helmet, safety goggles and protective
shoes.
10. All personnel who work with sewage systems
must be vaccinated against diseases to which
they may be exposed.
11. A first-aid kit must be close at hand.
12. Note that special rules apply to installation in
explosive athmosphere.
Follow all other health and safety rules and local
codes and ordinances.
ELECTRICAL CONNECTIONS
— Before starting work on the
pump, make sure that the pump
and the control panel are isolated
from the power supply and cannot
be energized.
— If the pump is equipped with
automatic level control, there is
a risk of sudden restart.
— All electrical equipment must be
earthed. This applies to both pump
equipment and any monitoring
equipment. Failure to heed this
warning may cause a lethal
accident. Make sure that the earth
lead is correctly connected by
testing it.
— If persons are likely to come into
physical contact with the pump or
pumped media (liquid), e.g on con-
struction sites and farms, the
earthed(grounded)socketmust
haveanadditionalearth-(ground-)
faultprotection device (GFI)
connected.
When pumping near a lake (jetties,
beaches,ponds,fountainsetc)
a safety-distance of at least 20 m
(65 ft) between the person and the
pump is applicable.
The pump must never be placed
directly into a swimming pool. If
used in connection with swimming
pools, special safety regulations
apply.
NOTE for Ex version page 3.

8
ELECTRICAL CONNECTIONS
- All electrical work shall be carried out under the super-
vision of an authorized electrician.
- Local codes and regulations shall be complied with.
- Check on the data plate which voltage supply is valid
for your pump.
- Check that the main voltage and frequency agree with
the specifications on the pump data plate.
- If the pump can be connected to different voltages,
the connected voltage is specified by a yellow sticker.
- Connect the motor cable to the starter equipment as
illustrated in the wiring diagrams.
- When the pump is connected to the public mains it
may cause flicker of incandescent lamps when start-
ing. In this case the supply authority should be noti-
fied before installing the pump.
Conductors that are not in use must be isolated.
The cable should be replaced if the outer sheath is
damaged. Contact an Flygt service shop.
Make sure that the cable does not have any sharp
bends and is not pinched.
Under no circumstances may the starter equipment be
installed in the sump.
NOTE! For safety reasons, the earth conductor
should be approx. 50 mm (2.0") longer than the phase
conductors. If the motor cable is jerked loose by
mistake, the earth conductor should be the last
conductor to come loose from its terminal. This
applies to both ends of the cable.
Thermal contacts are incorporated in the stator for
some versions. The thermal contacts can be
connected to max 250 V, breaking current max 4 A.
Flygt recommends that they be connected to 24 V over
separate fuses to protect the other automatic equip-
ment.
Make sure that the pump is correctly earthed (grounded).
Whenusing a variable-frequency-drive(VFD) the
shielded cable (type NSSHÖU.../3E+St) should be
used in order to fulfil European CE requirements. Con-
tact your Flygt representive and ask your VFD-supplier
for electrical limitations.
Remember that the starting current in direct on-line
starting can be up to six times higher than the rated
current. Make sure that the fuses or circuit breakers
are of the proper rating.
The data plate gives rated current. Fuse rating and
cable shall be selected in accordance with local rules
and regulations. Note that with long cables, the
voltage drop in the cable must be taken into consider-
ation, since the motor’s rated voltage is the voltage
that is measured at the terminal board in the pump.
The overload protection (motor protection breaker) for
direct on-line starting shall be set to the motor rated
current as given on the data plate.
Check the phase sequence in the mains with the
phase sequence indicator.
If intermittent operation is prescribed (see data plate),
the pump shall be provided with control equipment
that provides such operation.
Singlephaseoperation
The Flygt single phase pumps must be equipped with a
starter which has a capacitor.
A special Flygt designed starter is required for the
operation of single phase pumps. The connection of
the motor cable to the starter is shown in the wiring
diagram.
NOTE! It is not possible to change the direction of
rotation of a single phase pump by changing the cable
conductors on the starter. Please contact your nearest
Flygt representative.

9
Stator leads U1 = red
V1 = brown
W1 = yellow
U2 = green
V2 = blue
W2 = black
U5 = red
V5 = brown
W5 = yellow
U6 = green
V6 = blue
W6 = black
Single phase with level regulator
Conductors Connection
starter
Motorcable
Conductor See specification
identification singlephaseabove
Levelregulator brown 4
blue 5
Statorleads Z2, black 6
U2, brown 7
U1, red 8
Z1, yellow 9
CABLE CHART

10
CABLE CHART
Single phase
Conductors Connection starter
SUBCAB 4Gx 1brown ***red 1
***SUBCABxAWG/4 2 black ***black 2
HØ7RN-F4Gx 3 blue/ alt. grey***white 3
BIHF4Gxsilicon yellow/green earth
SUBCAB4Gx+2x1,5 1brown 1
2 black 2
3 blue/alt. grey 3
yellow/green earth
T1 black T1*
T2 black T2*
SUBCAB7Gx 1 black 1
2 black 2
3 black 3
4 black T1*
5 black T2*
6 black cut off
yellow/green earth
ForCanada/USA red 1
***SUBCABxAWG/7 black 2
white 3
yellow GC**
yellow/green earth
orange T1*
blue T2*
Stator leads U2 = brown
Z2 = black
U1 = red
Z1 = yellow
* Terminal for connection of thermal contacts in the motor and monitoring equipment.
** GC = Ground Check
*** SUBCAB/AWG
7GX

11
SUBCAB©SUBCAB©AWG
Mains Lead Lead Terminal board
L1 brown red U1
L2 black black V1
L3 grey white W1
yellow/green yellow/green
Groundcheck GC yellow
SUBCAB©SUBCAB©AWG
Control Cable lead Cable lead Terminal board
T1 T1 orange T1
T2 T2 blue T2
Stator leads connection:
Stator lead Terminal board
U1, red U1
W2, black W2
V1, brown V1
U2, green U2
W1, yellow W1
V2, blue V2
Bild 85a
U2W2 V2
V1U1 W1
T1
T2
GC L2L1 L3 T1 T2
T1 T2
T11
T2
T1 T2
SUBCAB®SUBCAB®
GC
1 3
2
W2 U1 V1 U2 V2
W1
32
Bild 85b
U2W2 V2
V1U1 W1
T1
T2
GC L2L1 L3 T1 T2
T1 T2
T11
T2
T1 T2
SUBCAB®SUBCAB®
GC
1 3
2
W2 U1 V1 U2 V2
W1
32
SUBCAB®4GX/SUBCAB®AWG,
6-leads, Y
3045
SUBCAB®4GX/SUBCAB®AWG,
6-leads, D
3045
CABLE CHART
SUBCAB©SUBCAB©AWG
Mains Lead Lead Terminal board
L1 brown red U1
L2 black black V1
L3 grey white W1
yellow/green yellow/green
Groundcheck GC yellow
SUBCAB©SUBCAB©AWG
Control Cable lead Cable lead Terminal board
T1 T1 orange T1
T2 T2 blue T2
Stator leads connection:
Stator lead Terminal board
U1, red U1
W2, black W2
V1, brown V1
U2, green U2
W1, yellow W1
V2, blue V2

12
Bild 93
W2 U1 V1 U2 V2
W1
U2W2 V2
V1U1 W1
T1
T2
L1 L2 L3 T1 T2
1 4 2 5 3 6
1 4 2
T1 T2
T1
T2
SUBCAB
®
5 3 6
SUBCAB®7GX
2 parallel cores connected together
6-leads, D
3045
Bild 94
V1W1 U1
U2V2 W2
T1
T2
L1 L2 L3 L1 L2 L3 T1 T2
1 42 53 6
123
T1 T2
T1 T2
W1 V1
SUBCAB
®
U1
V2
U2 W2
456
SUBCAB®7GX
6-leads, Y/D
3045
CABLE CHART
Mains Lead Terminal board
L1 1 U1
L1 4 U1
L2 2 V1
L2 5 V1
L3 3 W1
L3 6 W1
yellow/green
Control Cable lead Terminal board
T1 T1 T1
T2 T2 T2
Stator leads connection:
Stator lead Terminal board
U1, red U1
W2, black W2
V1, brown V1
U2, green U2
W1, yellow W1
V2, blue V2
Mains Lead Terminal board
L1 1 U1
L2 2 V1
L3 3 W1
L1 4 W2
L2 5 U2
L3 6 V2
yellow/green
Control Cable lead Terminal board
T1 T1 T1
T2 T2 T2
Stator leads connection:
Stator lead Terminal board
U1, red U1
W2, black W2
V1, brown V1
U2, green U2
W1, yellow W1
V2, blue V2

13
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
installationareundamaged and in goodcondition.
- 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.
- 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

14
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 page 3.
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)

15
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 new oil.
A paraffin oil with viscosity close to ISO VG32 is
recommended(e.g.Mobil Whiterex 309).Thepump
is delivered from factory with this type of oil.
3. Replace the O-rings under the oil housing screws
(plugs) with new ones.
10 Nm (7 ft lb)
3045:
0,4 l (0.42 US quarts)

16
HYDRAULIC ENDS
3045
CD

17

18