Xylem Flygt 3085 Maintenance 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
produced by the Company but which document was published prior to the 1st of
January 2012 . This document may therefore still be marked "ITT". Xylem Water
Solutions AB is no longer an ITT company and the fact that "ITT" may appear on this
document shall not be interpreted as a reference by the Company to "ITT" in the
Company's current business activities. Any use or reference to “ITT” by you is strictly
prohibited. In no event will we be liable for any incidental, indirect, consequential,
punitive or special damages of any kind, or any other damages whatsoever, including,
without limitation, those resulting from loss of profit, loss of contracts, loss of reputation,
goodwill, data, information, income, anticipated savings or business relationships for any
use by you of “ITT”. This disclaimer notice shall be interpreted and governed by Swedish
law, and any disputes in relation to it are subject to the jurisdiction of the courts in Sweden.
If you do not agree to these terms and conditions you should not print this document and
immediately stop accessing it.

End of Disclaimer text.

Installation, care and maintenance
3085/3102/3127
892062/17

CONTENTS
Safety __________________________________ 2
Data plate interpretation ________________ 4
Product description ____________________ 5
General design of a Flygt pump _________ 6
Installation ______________________________ 7
Electrical connections __________________ 8
Cable chart ____________________________ 10
Transportation and storage ____________ 14
Operation ______________________________ 14
Care and maintenance _________________ 15
Oil change _____________________________ 17
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.
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 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
— Only Ex-approved pumps may be used in an
explosive or flammable environment.
— Do not open the pump when an explosive gas
atmosphere may be present.
— Before starting work on the pump, make sure
that the pump and the control panel are iso-
lated 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 a pro-
tection circuit intended for that purpose ac-
cording 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.
SAFETY
NOTES FOR EX-PRODUCTS
— This equipment must be installed in conformity
to international or national standards ( IEC/EN
60079-14 ).
— The maintenance operation must be made in
conformity to the international or national stan-
dards ( 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. For permitted
minimum water level, see dimensional drawing
for the pump.
Dry running at service and inspection is only
permitted outside the Ex area.
— The user must know about the risks due to the
electrical current and the chemical and physi-
cal characteristics of the gas and/or vapours
present in hazardous areas.
— Flygt disclaims all responsibility for work done
by untrained, unauthorized personnel.
GUARANTEE
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 faults are reported to Flygt or Flygt's repre-
sentative during the guarantee period;
— that the product is used only under condition
described in the Installation, Care and Mainte-
nance manual and in applications for which it is
intended;
— that the monitoring equipment incorporated in
the 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
deficient maintenance, improper installation, incorrectly
executed repair work or nomal wear and tear.
Flygt assumes no liability for either bodily injuries,
material damages or economic losses beyond what is
stated above.
Flygt guarantees that spare parts will be kept for 15
years after that the manufacture of this product has
beendiscontinued.

4
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
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
A
M
LN
V
U
TRSQPO
I
JK
H
G
F
E
D
BC
X
EN approval for the Cable entry
Certificate number: INERIS 03ATEX9008 U
II 2 G or IM2 EEx d IIC or EEx d I

5
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 (cast iron
pumps).
The pH of the pumped liquid: 3—14 (stainless steel
pumps).
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.
— NOTE for Ex-version page 3.
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 ITT Flygt pump. In
this Installation, Care and Maintenance manual you will
find general information on how to install and
service the 3085, 3102 or 3127 pump to give it a long
and reliable life. In the Parts List you will find all the
specific technical data for your pump.
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 or Parts List) 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.
In some applications, the pump is also available for a
dry stationary installation on a base stand directly
connected to the inlet and outlet lines.
For further information on applications, contact your
nearest Flygt representative.
Specific technical data
For specific technical data regarding your pump,
please see Parts List.

6
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 support bearing of the rotor consists of a single-
row ball bearing.
The main bearing of the rotor consists of a two-row
angular contact ball bearing.
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 30 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 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 sensors for sensing
water in the oil* and/or stator housing.
*Not applicable to Ex-approved pumps.
4
2
1
6
3
5

7
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 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.
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.
NOTE for Ex version page 3.
— Minimum stop level should be
according to the dimensional
drawing.
— The pump must never run dry.

8
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 ener-
gized.
— 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 acci-
dent. 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) con-
nected.
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 page 3.
- 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 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 in order to fulfil European CE requirements. Con-
tact your Flygt representative and ask your VFD-suppli-
er for electrical limitations.