Xylem FLYGT P7030 Series User manual

Installation, Operation, and
Maintenance Manual
882901_15.0
P7030, P7035, P7040

Table of Contents
1 Introduction and Safety........................................................................................................ 4
1.1 Introduction....................................................................................................................4
1.2 Safety terminology and symbols....................................................................................4
1.3 User safety.................................................................................................................... 5
1.4 Ex-approved products................................................................................................... 5
1.5 Special hazards............................................................................................................. 7
1.5.1 Biological hazards...................................................................................................7
1.5.2 Wash the skin and eyes..........................................................................................7
1.6 Protecting the environment............................................................................................7
1.7 End of life product disposal........................................................................................... 7
1.8 Spare parts.................................................................................................................... 8
1.9 Warranty........................................................................................................................ 8
2 Transportation and Storage................................................................................................. 9
2.1 Examine the delivery..................................................................................................... 9
2.1.1 Examine the package............................................................................................. 9
2.1.2 Examine the unit..................................................................................................... 9
2.2 Transportation guidelines.............................................................................................. 9
2.2.1 Precautions............................................................................................................. 9
2.2.2 Lifting...................................................................................................................... 9
2.3 Temperature ranges for transportation, handling and storage.................................... 10
2.4 Storage guidelines.......................................................................................................11
3 Product Description............................................................................................................12
3.1 Products included........................................................................................................ 12
3.2 Pump design................................................................................................................12
3.3 Parts............................................................................................................................ 13
3.4 Monitoring equipment.................................................................................................. 14
3.5 The MAS 801 monitoring equipment .......................................................................... 14
3.5.1 MAS 801............................................................................................................... 14
3.5.2 FLS: float switch sensor........................................................................................15
3.5.3 Vibration in three directions.................................................................................. 15
3.5.4 Bearing temperature measurement...................................................................... 16
3.5.5 Stator temperature monitoring methods............................................................... 16
3.5.6 Pump current and power monitoring.....................................................................17
3.6 Monitoring with MAS 711.............................................................................................17
3.6.1 MAS 711............................................................................................................... 18
3.6.2 Sensors.................................................................................................................18
3.6.3 Stator temperature monitoring methods............................................................... 19
3.6.4 Pump memory.......................................................................................................20
3.7 Monitoring with MiniCAS II.......................................................................................... 20
3.7.1 MiniCAS II............................................................................................................. 20
3.8 Column adapters......................................................................................................... 20
3.9 The data plate..............................................................................................................22
3.10 Motor regulation.........................................................................................................22
3.11 Approvals...................................................................................................................22
3.12 Product denomination................................................................................................24
4 Installation.......................................................................................................................... 26
4.1 Precautions..................................................................................................................26
4.1.1 Hazardous atmospheres.......................................................................................26
Table of Contents
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 1

4.1.2 Falling................................................................................................................... 26
4.2 Cables......................................................................................................................... 27
4.3 Requirements for the cable handling system.............................................................. 29
4.4 Install the diffuser adapter........................................................................................... 30
4.5 Install the pump........................................................................................................... 32
4.6 Make the electrical connections.................................................................................. 37
4.6.1 General precautions..............................................................................................37
4.6.2 Grounding (earthing) ............................................................................................38
4.6.3 Cable entry parts...................................................................................................39
4.6.4 Prepare the SUBCAB™ cables..............................................................................39
4.6.5 Connect the cables: Standard pumps with MAS 801............................................41
4.6.6 Connect the cables: Ex-proof pumps with MAS 801.............................................42
4.6.7 Connect the cables: Pumps with MiniCAS or MAS 711........................................45
4.6.8 Power cable phase sequence...............................................................................47
4.6.9 Cable bending radius, weight and diameter..........................................................48
4.7 Cable charts................................................................................................................ 48
4.7.1 Colors and markings of leads............................................................................... 50
4.7.2 Motor connection.................................................................................................. 50
4.7.3 MAS 711 connections........................................................................................... 53
4.7.4 Sensor connection: MiniCAS................................................................................ 54
4.7.5 MiniCAS connections............................................................................................54
4.8 Check the impeller rotation..........................................................................................57
5 Operation........................................................................................................................... 59
5.1 Precautions..................................................................................................................59
5.2 Estimate zinc anode replacement intervals................................................................. 59
5.3 Start the pump............................................................................................................. 60
6 Maintenance.......................................................................................................................61
6.1 Precautions..................................................................................................................61
6.1.1 Rotating propeller..................................................................................................61
6.1.2 Falling................................................................................................................... 62
6.2 Torque values..............................................................................................................62
6.3 Check the temperature sensors.................................................................................. 63
6.4 Check the leakage sensors......................................................................................... 64
6.4.1 FLS....................................................................................................................... 64
6.5 Changing the oil...........................................................................................................64
6.5.1 Empty the oil......................................................................................................... 65
6.5.2 Fill with oil............................................................................................................. 66
6.6 Pumps with MAS 801: Replace the PEM.................................................................... 66
6.7 Preparing for work on the hydraulic end......................................................................67
6.7.1 Remove the entrance cover..................................................................................68
6.7.2 Attach the assembly and dismantling stand..........................................................68
6.8 Replacing the propeller................................................................................................69
6.8.1 Measure the clearance......................................................................................... 70
6.8.2 Remove the propeller............................................................................................72
6.8.3 Install the propeller................................................................................................73
6.9 Replace the bellmouth.................................................................................................75
6.10 Replace the zinc anodes........................................................................................... 76
6.11 Service the pump.......................................................................................................76
6.11.1 Inspection............................................................................................................77
6.11.2 Major overhaul.................................................................................................... 78
6.11.3 Service in case of alarm......................................................................................78
7 Troubleshooting................................................................................................................. 80
7.1 Electrical troubleshooting............................................................................................ 80
7.2 The pump does not start..............................................................................................80
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2 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

7.3 The pump does not stop when a level sensor is used.................................................81
7.4 The pump starts-stops-starts in rapid sequence......................................................... 81
7.5 The pump runs but the motor protection trips..............................................................82
7.6 The pump delivers too little or no water.......................................................................83
8 Technical Reference.......................................................................................................... 84
8.1 Application limits..........................................................................................................84
8.2 Pt100 resistance..........................................................................................................84
Table of Contents
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 3

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide the necessary information for working with the unit.
Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the unit.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment and the
surroundings. This includes any modification to the equipment or use of parts not provided
by Xylem. If there is a question regarding the intended use of the equipment, please contact
a Xylem representative before proceeding.
Other manuals
See also the safety requirements and information in the original manufacturer's manuals for
any other equipment furnished separately for use in this system.
1.2 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will
result in death or serious injury
WARNING:
A hazardous situation which, if not avoided, could
result in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could
result in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not
personal injury.
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
1 Introduction and Safety
4 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

Electrical hazard Magnetic fields hazard
Electrical Hazard: CAUTION:
1.3 User safety
All regulations, codes, and health and safety directives must be observed.
The site
•Observe lockout/tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by the
site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves and
shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.
1.4 Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive
atmospheres:
• All work on the product must be carried out by certified electricians and Xylem authorized
mechanics. Special rules apply to installations in explosive atmospheres.
• All users must know about the risks of electric current and the chemical and physical
characteristics of the gas, the vapor, or both present in hazardous areas.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example, IEC/EN 60079-17).
Xylem disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The equipment must never run dry during operation. The volute must be filled with liquid
during operation. Dry running during service and inspection is only permitted outside the
classified area.
• Before you start work on the product, make sure that the product and the control panel
are isolated from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Intrinsically safe circuits are normally required for the automatic level-control system by
the level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
1 Introduction and Safety
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 5

• Do not modify the equipment without approval from an Ex-approved Xylem
representative.
•Only use original Xylem spare parts that are provided by an Ex-approved Xylem
representative.
• The thermal contacts that are fitted to the stator windings must be connected correctly to
a separate motor control circuit and in use. The thermal contacts shall be connected to a
monitoring device, which disconnects the power supply immediately upon activation. This
action prevents the rise of temperatures above the temperature value for the approval
classification.
• The width of flameproof joints is more than the values specified in the tables of the EN/
IEC 60079-1 standard. For information contact the manufacturer.
• The gap of flameproof joints is less than the values specified in Table 2 of the EN/
IEC 60079-1 standard. For information contact the manufacturer.
• It is NOT allowed to repair the flameproof joints.
ATEX and IECEx
Pump Minimum Ambient Temperature Maximum Ambient Temperature
7020 –20°C 60°C
7030, 7035, 7040 –20°C 60°C
FM
Pump Maximum Ambient Temperature
7020 40°C
7030, 7035, 7040 40°C
Fasteners
The screws used for the assembly of the various parts of explosion-proof enclosures must
be of quality higher than or equal to A4–80.
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not change
the conditions of the service without the approval of an Ex-approved Xylem representative.
When you install or maintain explosion proof products, always comply with the directive and
applicable standards (for example, IEC/EN 60079–14).
Minimum permitted liquid level
See the dimensional drawings of the product for the minimum permitted liquid level
according to the approval for explosion proof products. If the information is missing on the
dimensional drawing, the product must be fully submerged. Level-sensing equipment must
be installed if the product can be operated at less than the minimum submersion depth.
Monitoring equipment
For additional safety, use condition-monitoring devices. Examples of condition-monitoring
devices include, but are not limited to, the following:
•Level indicators
• Temperature detectors in addition to the stator thermal detectors
Any thermal detectors or thermal protection devices delivered with the pump must be
installed and in use at all times.
The site owner is responsible for selection, installation, and proper maintenance of functional
monitoring equipment for motor protection.
1 Introduction and Safety
6 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

1.5 Special hazards
1.5.1 Biological hazards
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
•Make sure that all personnel who may come into contact with biological hazards are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
1.5.2 Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition Action
Chemicals or hazardous
fluids in eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least
15 minutes.
3. Seek medical attention.
Chemicals or hazardous
fluids on skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.6 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
•Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem
has been informed and appropriate actions have been agreed upon.
1.7 End of life product disposal
Handle and dispose of all waste in compliance with local laws and regulations.
Correct disposal of this product — WEEE Directive on waste electrical and electronic equipment
WS009973A
This marking on the product, accessories or literature indicates that the product should not
be disposed of with other waste at the end of its working life.
1 Introduction and Safety
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 7

To prevent possible harm to the environment or human health from uncontrolled waste
disposal, please separate these items from other types of waste and recycle them
responsibly to promote the sustainable reuse of material resources.
Waste from electrical and electronic equipment can be returned to the producer or
distributor.
1.8 Spare parts
CAUTION:
Only use the manufacturer’s original spare parts to replace any worn or faulty components.
The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as
void the warranty.
1.9 Warranty
For information about warranty, see the sales contract.
1 Introduction and Safety
8 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

2 Transportation and Storage
2.1 Examine the delivery
2.1.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company.
If the product has been picked up at a distributor, make a claim directly to the distributor.
2.1.2 Examine the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
Use care around nails and straps.
4. If there is any issue, then contact a sales representative.
2.2 Transportation guidelines
2.2.1 Precautions
DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing
to prevent unexpected startup. Failure to do so could result in death or serious injury.
Position and fastening
The unit can be transported either horizontally or vertically. Make sure that the unit is
correctly fastened during transportation, and cannot roll or fall over.
2.2.2 Lifting
Always inspect the lifting equipment and tackle before starting any work.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
NOTICE:
Never lift the unit by its cables or hose.
2 Transportation and Storage
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 9

Lifting equipment
Lifting equipment is always required to handle the unit. The lifting equipment must fulfill the
following requirements:
•The minimum height between the lifting hook and the floor must be sufficient to lift the
unit. Contact a Xylem representative for more information.
• The lifting equipment must be able to hoist the unit straight up and down, preferably
without the need for resetting the lifting hook.
• The lifting equipment must be correctly anchored and in good condition.
• The lifting equipment must support the weight of the entire assembly. Only authorized
personnel may use the lifting equipment.
• Two sets of lifting equipment must be used to lift the unit for repair work.
• The lifting equipment must be dimensioned to lift the unit with any remaining pumped
media in it.
• The lifting equipment must not be oversized.
CAUTION: Crush Hazard
Improperly-dimensioned lifting equipment can lead to injury. A site-
specific risk analysis must be done.
2.3 Temperature ranges for transportation, handling and storage
Handling at freezing temperature
At temperatures below freezing, the product and all installation equipment, including the
lifting gear, must be handled with extreme care.
Make sure that the product is warmed up to a temperature above the freezing point before
starting up. Avoid rotating the impeller/propeller by hand at temperatures below the freezing
point. The recommended method to warm the unit up is to submerge it in the liquid which will
be pumped or mixed.
NOTICE:
Never use a naked flame to thaw the unit.
Unit in as-delivered condition
If the unit is still in the condition in which it left the factory - all packing materials are
undisturbed - then the acceptable temperature range during transportation, handling and
storage is: –50°C (–58ºF) to +60°C (+140ºF).
If the unit has been exposed to freezing temperatures, then allow it to reach the ambient
temperature of the sump before operating.
Lifting the unit out of liquid
The unit is normally protected from freezing while operating or immersed in liquid, but the
impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a
surrounding temperature below freezing.
Follow these guidelines to avoid freezing damage:
1. Empty all pumped liquid, if applicable.
2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for the
presence of unacceptable amounts of water. Change if needed.
Water-glycol mixtures: Units equipped with an internal closed-loop cooling system are filled
with a mixture of water and 30% glycol. This mixture remains a flowing liquid at temperatures
down to –13°C (9°F). Below –13°C (9°F), the viscosity increases such that the glycol mixture
will lose its flow properties. However, the glycol-water mixture will not solidify completely and
thus cannot harm the product.
2 Transportation and Storage
10 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

2.4 Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.
NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.
NOTICE:
Do not place heavy weights on the packed product.
Long-term storage
If the unit is stored for more than six months, then the following apply:
•Before operating the unit after storage, it must be inspected. Special attention must be
given to the seals and the cable entry.
• The impeller or propeller must be rotated every other month to prevent the seals from
sticking together.
2 Transportation and Storage
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 11

3 Product Description
3.1 Products included
Pump model Standard EX
7030.090 X
7030.180 X
7035.090 X
7035.180 X
7040.090 X
7040.180 X
3.2 Pump design
Intended Use
The product is intended for moving wastewater, sludge, raw and clean water. Always follow
the limits that are given in Application limits on page 84. If there is a question regarding the
intended use of the equipment, then contact a Xylem representative before proceeding.
DANGER: Explosion/Fire Hazard
Special rules apply to installations in explosive or flammable atmospheres. Do not install the
product or any auxiliary equipment in an explosive zone unless it is rated explosion-proof or
intrinsically-safe. If the product is rated explosion-proof or intrinsically-safe, then see the
specific explosion-proof information in the safety chapter before taking any further actions.
NOTICE:
Do NOT use the unit in highly corrosive liquids.
3 Product Description
12 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

3.3 Parts
1
2
3
8
7
6
5
4
12
11
10
9
13
WS003673A
15
7
9
14
14
13
Figure 1: Section view, top view and exploded view of hydraulic parts.
Position Part Description
1 Terminal board
2 Support bearing Two-row ball bearing
3 Shaft Stainless steel, with an integrated rotor
4 Rotor
5 Main bearings Two-row angular contact ball bearing in O-arrangement
6 Mechanical seals Inner and outer mechanical seals
– Seal housing The housing acts as a buffer between the pumped fluid and the
electric motor. It includes:
• Inner and outer seals
• An oil that lubricates the seals
7 Propeller
8 Seal ring
9 Bellmouth With integrated relief groove
10 Pump housing
3 Product Description
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 13

Position Part Description
11 Stator Equipped with temperature sensors in windings
12 Electrical lead-
through unit
13 Cable entry
14 Lifting handle
15 Guide vanes
Spare part requirements
The following applies when servicing or repairing the pump:
•Modifications to the unit or installation should only be carried out after consulting with
Xylem.
• Original spare parts and accessories that are authorized by Xylem are essential for
compliance. The use of other parts can invalidate any claims for warranty or
compensation. For more information, please contact your local sales and service
representative.
3.4 Monitoring equipment
The following monitoring systems can be used:
• MiniCAS II
• MAS 801
• MAS 711
MiniCAS II This is the most-basic alternative. MiniCAS II can protect the pump against the
following:
•Over-temperature in the stator windings
• Leakage in the inspection chamber
MAS 711 This is a more advanced system, and is used when more monitoring channels
are required.MAS 711 requires a separate signal cable, with 12 or 24 leads.
MAS 801 This is the most advanced monitoring system. With the MAS 801, the analog
signals from the sensor are converted to digital signals inside the pump. The
digitalized monitoring signals are transmitted using the control cores in the
SUBCAB™ power cables. This allows a broad range of sensor signals, and
eliminates the need for a separate signal cable.
Ex-proof pumps
Ex-proof pumps must have the thermal contacts or the thermistors connected to the control
panel.
The sensors must be connected to either of the Flygt monitoring relays or an equivalent.
General
• The monitoring equipment must be of a design that prevents automatic restart.
• Information in the junction box of the pump indicates whether the pump is equipped with
optional sensors.
3.5 The MAS 801 monitoring equipment
3.5.1 MAS 801
With the MAS 801, one control unit can be used for several pumps, up to a maximum ten
pumps.
Each pump has a built-in PEM and has its own base unit.
3 Product Description
14 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

1
2
3
4
5
WS011254A
Figure 2: MAS 801
1. Pump electronic module (PEM)
2. Combined power and signal cable
3. Base unit (BU)
4. Central unit (CU)
5. Human-machine interface FOP 402
MAS 801 features include the following:
• Eight standard pump sensors
• SUBCAB® cables contain both signal leads and power leads.
• One central unit for maximum ten pumps
• One graphical touch panel shows information for multiple pumps.
3.5.2 FLS: float switch sensor
The float switches are leakage sensors.
The float switches are located in the junction box, and in the lower part of the stator housing
or leakage chamber.
3.5.3 Vibration in three directions
A vibration sensor that is located in the PEM measures vibration speed in three directions.
Two adjustable alarm limits can be applied for each measurement direction:
• Early warning: “B”-alarm
• Pump stop: “A”-alarm
X
XY
Y
Z
WS011503A
Figure 3: Vibration directions with reference to the PEM
The definitions of X, Y and Z are the same, whether or not the pump is in a vertical or
horizontal position.
3 Product Description
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 15

3.5.4 Bearing temperature measurement
Pt100 sensors monitor the bearing temperatures to protect the pump from the consequences
of a bearing failure.
Main bearing
Main bearing temperature monitoring is standard in the MAS 711 and MAS 801.
Support bearing
Support bearing temperature monitoring is an option in the MAS 711 and MAS 801.
Alarms
Two adjustable alarm limits can be used:
• Early warning: “B”-alarm
• Pump stop: “A”-alarm
3.5.5 Stator temperature monitoring methods
The purpose of stator-winding temperature monitoring is to make the motor shut off at high
temperature. There are two monitoring methods, depending on the types of thermal sensors
chosen.
Table 1: Stator temperature monitoring configuration
Configuration with thermal switches Configuration with thermistors
• Three thermal switches, connected in series, are
incorporated in the coil ends of the stator
winding. The switches are normally closed, and
open at 140°C (285°F).
• One Pt100 sensor is incorporated in one of the
windings.
• Three thermistors, PTC, connected in series, are
incorporated in the coil ends of the stator
windings. TRef=140°C (285°F).
• One Pt100 sensor is incorporated in one of the
windings.
By using an analogue sensor, two adjustable alarm limits can be used, one for warning (“B”-
alarm) and one for pump stop (“A”-alarm).
3.5.5.1 Temperature sensors
Table 2: Thermal contact
Description Measured value Fault values
The thermal
contact is a
normally closed
contact.
0–3 ohm, unless the wires are long. An infinite value (open circuit) indicates
either high temperature or a fault.
Examples of faults include a broken wire,
or a bad contact in a connector.
Table 3: PTC thermistor
Description Measured value Fault values
The PTC
thermistor is a
semiconductor
device.
Resistance at normal temperature:
• 50–100 ohm (150–300 ohm for three in
series).
• Above the tripping point, TRef, the
resistance increases dramatically to
several kilohm.
• An infinite value (open circuit)
indicates a fault. Examples of faults
include a broken wire, or a bad
contact in a connector.
• A value close to zero indicates a short
circuit in the wiring.
3 Product Description
16 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual

Table 4: Pt100 sensor
Description Measured value Fault values
The Pt100 sensor
is a resistor
changing value
almost linearly with
temperature.
Resistance:
• 100 ohm at 0ºC (32ºF)
• 107.79 ohm at room temperature
(20ºC, 68ºF)
• 138.5 ohm at 100ºC (212ºF)
For resistance data between 0–160ºC
(32–320ºF), see Pt100 resistance on
page 84.
> 200 ohm (approximate) can indicate
the following situations:
• Broken sensor
• Bad contact
• Broken lead
< 70 ohm (approximate) indicates:
• Short circuit
NOTICE:
Never connect the Pt100 transducer to a voltage higher than 2.5 V.
For information on the various configurations of contacts, thermistors and sensors that are
used to monitor stator winding temperature, see
Stator temperature monitoring methods .
3.5.6 Pump current and power monitoring
Pump current
Pump current is an important parameter in itself, which the MAS 801 can also use to record
running time, number of starts and other operating diagnostics. This information is
fundamental for monitoring operation, maintenance planning, and fault diagnosis.
Pump current in one phase is standard with the MAS 801.
Pump current in three phases
Pump current in three phases is also possible with the MAS 801. To track pump current in
three phases with the MAS 801, the following are needed:
• Three current transformers in the control cabinet
• The PAN 312 power analyzer
The current transformers are connected to the PAN 312. The PAN 312 transmits the data to
the CU and the PEM in the MAS 801 system.
Power monitoring: PAN 312
The optional Flygt power analyzer PAN 312 allows the following parameters to be monitored:
• Three-phase power
• Power factor
• System voltage
• Voltage imbalance
• Pump current in three phases
• Current imbalance
3.6 Monitoring with MAS 711
The MAS 711 monitoring equipment can be used with pump models P7030, P7035, and
P7040, in applications with only one (1) motor cable. The motor cable must be screened.
Pumps with the standard MAS 711 equipment use a 12-lead auxiliary cable, plus 4 leads
from the motor cable, for the following:
• Thermal switches for stator temperature monitoring (three in series) or PTC thermistors
• Leakage sensor in the inspection chamber
• Leakage sensor in the junction box
• Analogue temperature sensor (Pt100) for main bearing temperature monitoring
• Analogue temperature sensor (Pt100) for stator winding temperature in one phase
• Vibration sensor VIS 10
3 Product Description
P7030, P7035, P7040 Installation, Operation, and Maintenance Manual 17

• Analogue temperature sensor (Pt100) for support bearing temperature monitoring
•Pump memory
3.6.1 MAS 711
With MAS 711, a base unit and a display unit are required for each pump.
1
2
3
WS011255A
Figure 4: MAS 711
1. Separate cables for signal and power
2. Base unit
3. MAS 711 display unit
MAS 711 features include the following:
• Five standard pump sensors
• Separate SUBCAB® cables for power and signal
• Text display is dedicated to one pump.
3.6.2 Sensors
Temperature sensors
Table 5: Thermal switch
Description Measured value Fault values
The thermal switch
is a normally
closed contact.
0-3 ohm, unless the wires are very long. An infinite value (open circuit) indicates
either high temperature or a fault (a wire
is broken or there is a bad contact in a
connector).
Table 6: PTC-thermistor
Description Measured value Fault values
The PTC-
thermistor is a
semiconductor
device.
Resistance at normal temperature:
• 50-100 ohm (150-300 ohm for three in
series).
• Above the tripping point, TRef, the
resistance increases dramatically to
several kohm.
• An infinite value (open circuit)
indicates a fault (a wire is broken or
there is a bad contact in a connector).
• A value close to zero indicates a short
circuit in the wiring.
3 Product Description
18 P7030, P7035, P7040 Installation, Operation, and Maintenance Manual