FLYGT 3085 Installation, Operation And Maintenance Manual

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Page 1

Installation, Operation,

and Maintenance Manual

Flygt 3085

Page 2

Page 3

Table of Contents

1 Introduction and Safety..............................................................................................................3

1.1 Introduction.......................................................................................................................... 3

1.2 Safety terminology and symbols........................................................................................3

1.3 User safety.............................................................................................................................4

1.4 Ex-approved products.........................................................................................................4

1.5 Special hazards.....................................................................................................................5

1.6 Protecting the environment................................................................................................6

1.7 Spare parts............................................................................................................................6

1.8 Warranty................................................................................................................................6

2 Transportation and Storage...................................................................................................... 7

2.1 Inspect the delivery..............................................................................................................7

2.1.1 Inspect the package..................................................................................................... 7

2.1.2 Inspect the unit..............................................................................................................7

2.2 Transportation guidelines...................................................................................................7

2.2.1 Lifting..............................................................................................................................7

2.3 Temperature ranges for transportation, handling and storage.....................................8

2.4 Storage guidelines...............................................................................................................8

Table of Contents

3 Product Description................................................................................................................. 10

3.1 Pump design...................................................................................................................... 10

3.2 Monitoring equipment......................................................................................................12

3.3 The data plate.................................................................................................................... 12

3.4 Approvals............................................................................................................................14

3.5 Product denomination...................................................................................................... 15

4 Installation................................................................................................................................. 17

4.1 Install the pump................................................................................................................. 17

4.1.1 Install with P-installation.............................................................................................18

4.1.2 Install with S-installation.............................................................................................19

4.1.3 Install with T/Z-installation......................................................................................... 20

4.1.4 Install with F-installation.............................................................................................21

4.1.5 Install with H-installation............................................................................................ 22

4.1.6 Install with X-installation.............................................................................................22

4.2 Make the electrical connections...................................................................................... 23

4.2.1 Prepare the SUBCAB® cables....................................................................................25

4.2.2 Connect the motor cable to the pump.................................................................... 26

4.2.3 Connect the motor cable to the starter and monitoring equipment...................27

4.2.4 Cable charts.................................................................................................................28

4.3 T-installation: Bleed air before starting pump............................................................... 35

4.4 Check the impeller rotation..............................................................................................36

5 Operation.................................................................................................................................. 38

5.1 Estimate zinc anode replacement intervals....................................................................38

5.2 Start the pump....................................................................................................................39

6 Maintenance..............................................................................................................................40

6.1 Torque values.....................................................................................................................40

6.2 Change the oil....................................................................................................................41

6.3 Service the pump...............................................................................................................43

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Table of Contents

6.3.1 Inspection.................................................................................................................... 43

6.3.2 Major overhaul............................................................................................................ 44

6.3.3 Service in case of alarm..............................................................................................44

6.4 Replace the impeller......................................................................................................... 44

6.4.1 Replace the C-, D-, or L-impeller.............................................................................. 45

6.4.2 Replace the F-impeller...............................................................................................49

6.4.3 Replace the M-impeller..............................................................................................54

6.4.4 Replacing the Adaptive N-impeller..........................................................................57

7 Troubleshooting....................................................................................................................... 63

7.1 The pump does not start...................................................................................................63

7.2 The pump does not stop when a level sensor is used..................................................64

7.3 The pump starts-stops-starts in rapid sequence............................................................64

7.4 The pump runs but the motor protection trips..............................................................65

7.5 The pump delivers too little or no water.........................................................................66

8 Technical Reference.................................................................................................................67

8.1 Motor data.......................................................................................................................... 67

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1 Introduction and Safety

1.1 Introduction

Purpose of the manual

The purpose of this manual is to provide 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.

1 Introduction and Safety

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:

WARNING:

A hazardous situation which, if not avoided, will result in death or serious injury

A hazardous situation which, if not avoided, could result in death or serious injury

NOTICE:

Flygt 3085 Installation, Operation, and Maintenance Manual 3

CAUTION:

A hazardous situation which, if not avoided, could result in minor or moderate injury

Notices are used when there is a risk of equipment damage or decreased performance, but not personal injury.

Page 6

1 Introduction and Safety

Special symbols

Some hazard categories have speciﬁc symbols, as shown in the following table.

Electrical Hazard Permanent-magnet hazard

Electrical Hazard:

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.

CAUTION:

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 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 Ex-approved product must never run dry during normal 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.

• Make sure that thermal contacts are connected to a protection circuit according to the approval classiﬁcation of the product, and that they are in use.

certiﬁed electricians and Xylem

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• 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.

• Do not modify the equipment without approval from an Ex-approved Xylem representative.

• Only use parts that are provided by an Ex-approved Xylem representative.

• The thermal detectors ﬁtted to the stator windings shall be connected into the motor control circuit in such a manner as to disconnect the supply to the motor in order to prevent the Temperature Class T3.

• The width of ﬂameproof joints is more than the values speciﬁed in the tables of the IEC 60079–1 standard.

• The gap of ﬂameproof joints is less than the values speciﬁed in Table 1 of the IEC 60079–1 standard.

• The equipment must be submerged during normal operation.

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).

1 Introduction and Safety

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. Condition-monitoring devices include but are not limited to the following:

• Level indicators

• Temperature detectors

1.5 Special hazards

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.

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

Flygt 3085 Installation, Operation, and Maintenance Manual 5

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.

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1 Introduction and Safety

Condition Action Chemicals or hazardous ﬂuids on

skin

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 Spare parts

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least 1 minute.

3. Seek medical attention, if necessary.

1.8 Warranty

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.

For information about warranty, see the sales contract.

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2 Transportation and Storage

2.1 Inspect the delivery

2.1.1 Inspect the package

1. Inspect the package for damaged or missing items upon delivery.

2. Note any damaged or missing items on the receipt and freight bill.

3. File a claim with the shipping company if anything is out of order. If the product has been picked up at a distributor, make a claim directly to the

distributor.

2.1.2 Inspect the unit

1. Remove packing materials from the product. Dispose of all packing materials in accordance with local regulations.

2. Inspect the product to determine if any parts have been damaged or are missing.

3. If applicable, unfasten the product by removing any screws, bolts, or straps. For your personal safety, be careful when you handle nails and straps.

4. Contact the local sales representative if there is any issue.

2.2 Transportation guidelines

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 securely fastened during transportation, and cannot roll or fall over.

2.2.1 Lifting

Always inspect the lifting equipment and tackle before starting any work.

WARNING: Crush Hazard

1) Always lift the unit by its designated lifting points. 2) Use suitable lifting equipment and

ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4) Stay clear of cables and suspended loads.

NOTICE:

Never lift the unit by its cables or hose.

Lifting equipment

Lifting equipment is always required when handling the unit. It must fulﬁll the following requirements:

• The minimum height (contact your local sales and service representative for information) between the lifting hook and the ﬂoor must be sufﬁcient to lift the unit.

• 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 securely anchored and in good condition.

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2 Transportation and Storage

• The lifting equipment must support the weight of the entire assembly and must only be used by authorized personnel.

• 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

Over-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.

Units equipped with an internal 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.

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.

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.

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NOTICE:

Do not place heavy weights on the packed product.

Long-term storage

If the unit is stored more than six months, then the following apply:

• Before operating the unit after storage, it must be inspected with special attention to the seals and the cable entry.

• The impeller/propeller must be rotated every other month to prevent the seals from sticking together.

Packaging material stacking limit

If the packaging material has an indicated stacking limit, then it is valid for 23° C (73° F) and 50% relative humidity. Depending on the material, other temperature and humidity ranges can reduce the stacking limit.

2 Transportation and Storage

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3 Product Description

Products included

Pump

C-hydraulic

High Efﬁciency motor

(LSPM)

Explosion proof drive unit

Non-explosion proof drive unit

3085.092 X X X X X X

3085.160 X X

3085.172 X X

3085.183 X X X X X X

3085.190 X X

3085.760 X X *

3085.770 X X *

3085.800 X X X

3085.810 X X X

3085.820 X X X

3085.830 X X X

3085.891 X X

3085.900 X X X

3085.910 X X X

3085.960 X X X *

3085.970 X X X * * Stainless steel Adaptive-N hydraulics

D-hydraulic

F-hydraulic

G-hydraulic

M-hydraulic

(Grinder)

N hydraulic

(Hard-Iron)

Adaptive-N hydraulic

Pump-speciﬁc information

For the speciﬁc weight, current, voltage, power ratings, and speed of the pump, see the data plate of the pump.

3.1 Pump design

The pump is submersible, and driven by an electric motor. For a list of pump version and corresponding motor type, see Motor data (page 67).

Intended use

The product is intended for moving wastewater, sludge, raw and clean water. Always follow the limits that are given in Application limits (page 67). If there is a question regarding the intended use of the equipment, please contact a local sales and service 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 explosionproof or intrinsically-safe. If the product is EN/ATEX-, MSHA- or FM-approved, then see the speciﬁc EX information in the Safety chapter before taking any further actions.

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NOTICE:

WS006127A

Do NOT use the unit in highly corrosive liquids.

Spare parts

• 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 contact your Xylem representative.

Pressure class

LT Low head MT Medium head HT High head SH Super high head

Experior® product concept

Experior® is a product concept including N-technology, Premium efﬁciency motor, and the intelligent control SmartRun®.

Parts

3 Product Description

Position Denomination Description 1 Shaft The shaft is made of stainless steel, with an integrated rotor.

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3 Product Description

Position Denomination Description 2 Impeller There are multiple types of impellers. For information about the pumps

3 Mechanical seals One inner and one outer seal in a combination of materials:

4 Oil housing The oil housing includes a coolant that lubricates and cools the seals; the

5 Main bearing The bearing consisting of a two-row angular contact ball bearing. 6 Motor 7 Stator housing The pump is cooled by the ambient liquid/air. 8 Support bearing The bearing consisting of a single-row ball bearing.

3.2 Monitoring equipment

The following applies to the monitoring equipment of the pump:

• The stator incorporates three thermal contacts connected in series that activate the alarm and stops the pump at overtemperature

• The thermal contacts open at 125°C (257°F).

• Ex-approved pumps must have thermal contacts connected to the control panel.

• The sensors must be connected to either the MiniCAS II monitoring equipment or an equivalent equipment.

• The monitoring equipment must be of a design that makes automatic restart impossible.

• Information in the junction box shows if the pump is equipped with optional sensors.

impellers, see Parts List.

• Aluminium oxide Al2O

• Silicon carbide RSiC

• Corrosion-resistant cemented carbide WCCR

For information about the pumps mechanical seals, see Parts List.

housing acts as a buffer between the pumped ﬂuid and the drive unit.

For information about the motor, see Motor data (page 67)..

Optional sensors

FLS is a miniature ﬂoat switch for detection of liquid in the stator housing. Due to its

FLS

design it is best suited for pumps in a vertical position. The FLS sensor is installed in the bottom of the stator housing.

CLS CLS is a sensor for detection of water in the oil housing. The sensor initiates an alarm

when the oil contains approximately 35% water. The sensor is installed in the bearing housing/bearing holder with its sensing part in the oil housing. The CLS sensor is not applicable to Ex-approved pumps.

NOTICE:

The CLS sensor body is made of glass. Handle the sensor with care.

One CLS and one FLS sensor can be used in the same pump, if they are connected in parallel.

3.3 The data plate

The data plate is a metal label that is located on the main body of the products. The data plate lists key product speciﬁcations. Specially approved products also have an approval plate.

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1312 14

17 18 1916159 10 11

WS006257A

1. Curve code or Propeller code

2. Serial number

3. Product number

4. Country of origin

5. Additional information

6. Phase; type of current; frequency

7. Rated voltage

8. Thermal protection

9. Thermal class

10.Rated shaft power

11.International standard

12.Degree of protection

13.Rated current

14.Rated speed

15.Maximum submergence

16.Direction of rotation: L=left, R=right

17.Duty class

18.Duty factor

19.Product weight

20.Locked rotor code letter

21.Power factor

22.Maximum ambient temperature

23.Read installation manual

24.Notiﬁed body, only for EN-approved Ex products

Figure 1: The data plate

3 Product Description

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1 2 3

6 7

9 10

WS003972A

3 Product Description

3.4 Approvals

Product approvals for hazardous locations

Pump Approval

• 3085.092

• 3085.190

• 3085.770

• 3085.810

• 3085.830

• 3085.891

• 3085.910

• 3085.970

European Norm (EN)

• ATEX Directive

• EN 60079-0:2009, EN 60079-1:2007, EN 13463-1:2009, EN 13463-5:2011

•

II 2 G c Ex d IIB T4 Gb

EN approval for cable entry:

• Certiﬁcate number: INERIS 02ATEX9008 U

•

II 2 G Ex d IIC Gb or I M2 Ex d I Mb

IEC

• IECEx scheme

• IEC 60079-0, IEC 60079-1

• Ex d IIB T4

FM (FM Approvals)

• Explosion proof for use in Class I, Div. 1, Group C and D

• Dust ignition proof for use in Class II, Div. 1, Group E, F and G

• Suitable for use in Class III, Div. 1, Hazardous Locations

CSA Ex

• Explosion proof for use in Class I, Div. 1, Group C and D

EN approval plate

IEC approval plate

This illustration describes the EN approval plate and the information that is contained in its ﬁelds.

1. Approval

2. Approval authority and Approval number

3. Approval for Class I

4. Approved for drive unit

5. Stall time

6. Starting current or Rated current

7. Duty class

8. Duty factor

9. Input power

10.Rated speed

11.Controller

12.Additional information

13.Maximum ambient temperature

14.Serial number

15.ATEX marking

This illustration describes the IEC approval plate and the information that is contained in

ﬁelds.

its International Norm; not for EU member countries.

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WS001279B

876

5 9

FM approval plate

WS003973A

WS009401A

3 Product Description

1. Approval

2. Approval authority and Approval number

3. Approved for drive unit

4. Stall time

5. Starting current or Rated current

6. Duty class

7. Duty factor

8. Input power

9. Rated speed

10.Controller

11.Additional information

12.Maximum ambient temperature

13.Serial number

This illustration describes the FM approval plate and the information that is contained in its ﬁelds.

1. Temperature class

2. Maximum ambient temperature

CSA approval plate

This illustration describes the CSA approval plate and the information that is contained in its ﬁelds.

1. Temperature class

3.5 Product denomination

Reading instruction

In this section, code characters are illustrated accordingly: X = letter Y = digit The different types of codes are marked up with a, b and c. Code parameters are marked

up with numbers.

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Page 18

XXYYYY YYY YYY YYYY

WS006265B

3 Product Description

Codes and parameters

Type of Callout Number Indication Type of code a Sales denomination

Parameter 1 Hydraulic end

b Product code c Serial number

2 Type of installation 3 Sales code 4 Version 5 Production year 6 Production cycle 7 Running number

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4 Installation

4.1 Install the pump

Before starting work, make sure that the safety instructions in the chapter Introduction and

Safety (page 3) have been read and understood.

DANGER: Electrical Hazard

Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. This applies to the control circuit as well.

DANGER: Inhalation Hazard

Before entering the work area, make sure that the atmosphere contains sufﬁcient oxygen and no toxic gases.

WARNING: Electrical Hazard

The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate.

4 Installation

Hazardous atmospheres

DANGER: Explosion/Fire Hazard

WARNING: Explosion/Fire Hazard

Do not install CSA-approved products in locations that are classiﬁed as hazardous in the National Electric Code(TM), ANSI/NFPA 70-2005.

General requirements

These requirements apply:

• Use the pump dimensional drawing in order to ensure proper installation.

Before installing the pump, do the following:

• Provide a suitable barrier around the work area, for example, a guard rail.

• Make sure that equipment is in place so that the unit cannot roll or fall over during the

• Check the explosion risk before you weld or use electric hand tools.

• Check that the cable and cable entry have not been damaged during transport.

• Always remove all debris and waste material from the sump, inlet piping, and

• If the unit has a permanent magnet motor, then ensure that you have read and

installation process.

discharge connection, before you install the pump.

understood all safety instructions regarding permanent magnet motors.

NOTICE:

Do not run the pump dry.

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WS006259A

4 Installation

NOTICE:

Never force piping to make a connection with a pump.

Authority regulation

Vent the tank of a sewage station in accordance with local plumbing codes.

Fasteners

• Only use fasteners of the proper size and material.

• Replace all corroded fasteners.

• Make sure that all fasteners are properly tightened and that there are no missing fasteners.

4.1.1 Install with P-installation

In the P-installation, the pump is installed on a stationary discharge connection, and operates either completely or partially submerged in the pumped liquid. These requirements and instructions only apply when the installation is made according to the dimensional drawing.

Figure 2: P-installation

These items are required:

• Guide bars

• Guide bar bracket for attaching the guide equipment to the access frame or to the upper part of the sump

• Cable holder for holding the cable

• 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 pump housing ﬂange and a

bracket for attaching the guide equipment.

• Fasteners for the discharge connection

• Anchor bolts

1. Install the access frame: a) Place the access frame in position and align it horizontally.

b) Grout the frame in place.

2. Grout the anchor bolts in place.

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WS006270A

4 Installation

Be careful when you align and position the discharge connection in relation to the access frame.

3. Place the discharge connection in position, and tighten the nuts.

4. Install the guide bars: a) Secure the guide bars in the bracket.

b) Check that the guide bars are placed vertically. Use a level or a plumb line.

5. Connect the discharge pipe to the discharge connection.

6. Lower the pump along the guide bars. When it reaches the bottom position, the pump automatically connects to the

discharge connection.

7. Secure the motor cable: a) Fasten the permanent lifting device to the pump and to the access frame. For

example, you can use a stainless-steel lifting chain with shackles.

b) Fasten the cable to the cable holder.

Make sure that the cable cannot be sucked into the pump inlet or that it is neither sharply bent, or pinched. Support straps are required for deep installations.

c) Connect the motor cable and the starter and monitoring equipment according to

the separate instructions. Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 36).

Clean all debris from the sump before starting the pump.

4.1.2 Install with S-installation

In the S-installation, the pump is transportable and intended to operate either completely or partially submerged in the pumped liquid. The pump is equipped with a connection for hose or pipe and stands on a base stand.

These requirements and instructions only apply when the installation is made according to the dimensional drawing. For information about the different installation types, see Parts List.

Figure 3: S-installation

1. Run the cable so that it has no sharp bends. Make sure that it is not pinched, and cannot be sucked into the pump inlet.

2. Connect the discharge line.

3. Lower the pump into the sump.

4. Place the pump on the base and make sure it cannot fall over or sink.

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WS008385A

WS006273A

WS008403B

4 Installation

Alternatively, the pump can be suspended with a lifting chain just above the sump bottom. Make sure that the pump cannot rotate at start-up or during operation.

5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions.

Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 36).

4.1.3 Install with T/Z-installation

This installation is not applicable for these versions:

• .172

• .891

In the T-installation, the pump is installed in a vertical position in a dry well next to the wet sump. These requirements and instructions only apply when the installation is made according to the dimensional drawing.

In the Z-installation, the pump is installed in a horizontal position on a support stand in a dry well next to the wet sump. The following requirements and instructions are for Zinstallations that comply to the dimensional drawing.

Figure 4: T-installation

These items are required:

• Anchor bolts for anchoring the pump to a base.

• Shut-off valves that allow you to remove the pump from service

20 Flygt 3085 Installation, Operation, and Maintenance Manual

Figure 5: Z-installation

Page 23

1. Outlet line

WS006255A

2. Inlet line

3. Line to drain

4. Air vent

Figure 6: T-, Z-installation shutoff and air vent valves (generic pumps shown)

NOTICE:

The risk of freezing is particularly high in T- or Z-installations.

1. Fasten the pump: a) Bolt the stationary suction connection to the concrete base.

b) Bolt the pump to the suction connection.

2. Make sure that the pump is vertical for the T-installation or horizontal for the Zinstallation.

3. Connect the suction line and discharge line.

4. Connect the motor cable and the starter and monitoring equipment according to the separate instructions.

Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 36).

5. Make sure that the weight of the pump does not put strain on the piping.

4.1.4 Install with F-installation

4 Installation

In the F-installation, the pump is free standing and installed primarily in a small sump on a ﬁrm surface. The pump is intended to operate completely or partially submerged in the pumped liquid. The pump is equipped with a connection for hose or pipe and with supporting legs and/or a strainer. These requirements and instructions are for Finstallations that comply to the dimensional drawing.

Figure 7: F-installation

These items are required:

• Nipple pipe/Flange/Coupling

• Pipe or hose

1. Run the cable so that is has no sharp bends, is not pinched, and cannot be sucked into the pump inlet.

2. Fit the nipple pipe/ﬂange/coupling.

3. Lower the pump into the sump.

4. Place the pump on the sump bottom and make sure it cannot fall over.

5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions.

Flygt 3085 Installation, Operation, and Maintenance Manual 21

Page 24

WS006258A

4 Installation

Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 36).

4.1.5 Install with H-installation

This installation is only applicable for the following versions:

• 172

• 891

In the H-installation, the pump is installed with a permanent, quick-connection, suspended arrangement that incorporates an integral non-return valve. The pump is intended to operate completely or partially submerged in the pumped liquid. These requirements and instructions are for H-installations that comply to the dimensional drawing.

Figure 8: H-installation

These items are required:

• Discharge connection

• Pipe

1. Run the cable so that is has no sharp bends, is not pinched, and cannot be sucked into the pump inlet.

2. Fit the pipe and connect the discharge connection.

3. Lower the pump into the sump.

4. Make sure that the pump is hanging just above the sump bottom.

5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions.

Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 36).

Clean all debris from the sump before you start the pump.

4.1.6 Install with X-installation

In the X-installation, the pump has no pre-determined mechanical connection. The ﬂange is drilled.

22 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 25

WS001278A

Equipment

locked out by

Name .......................

DANGER

4 Installation

Figure 9: X-installation

NOTICE:

A pump prepared for X-installation is only approved to be used in P- or S-installation. Never use it in T- or Z-installation

For installation instructions, see appropriate mechanical accessories.

4.2 Make the electrical connections

General precautions

DANGER: Electrical Hazard

Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. This applies to the control circuit as well.

WARNING: Electrical Hazard

Risk of electrical shock or burn. A certiﬁed electrician must supervise all electrical work. Comply with all local codes and regulations.

WARNING: Electrical Hazard

There is a risk of electrical shock or explosion if the electrical connections are not correctly carried out, or if there is fault or damage on the product. Visually inspect equipment for damaged cables, cracked casings or other signs of damage. Make sure that electrical connections have been correctly made.

WARNING: Electrical Hazard

The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate.

Flygt 3085 Installation, Operation, and Maintenance Manual 23

Page 26

4 Installation

Requirements

WARNING: Crush Hazard

Risk of automatic restart.

CAUTION: Electrical Hazard

Prevent cables from becoming sharply bent or damaged.

NOTICE:

Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the cable ends dry at all times.

These general requirements apply for electrical installation:

• The supply authority must be notiﬁed before installing the pump if it will be connected to the public mains. When the pump is connected to the public power supply, it may cause ﬂickering of incandescent lamps when started.

• The mains voltage and frequency must agree with the speciﬁcations on the data plate. If the pump can be connected to different voltages, then the connected voltage is speciﬁed by a yellow sticker close to the cable entry.

• The fuses and circuit breakers must have the proper rating, and the pump overload protection (motor protection breaker) must be connected and set to the rated current according to the data plate and if applicable the cable chart. The starting current in direct-on-line start can be up to six times higher than the rated current.

• The fuse rating and the cables must be in accordance with the local rules and regulations.

• If intermittent operation is prescribed, then the pump must be provided with monitoring equipment supporting such operation.

• If stated on the data plate, then the motor is convertible between different voltages.

• The thermal contacts/thermistors must be in use.

• For FM-approved pumps, a leakage sensor must be connected and in use in order to meet approval requirements.

Cables

These are the requirements to follow when you install cables:

• The cables must be in good condition, not have any sharp bends, and not be pinched.

• The cables must not be damaged and must not have indentations or be embossed (with markings, etc.) at the cable entry.

• The cable entry seal sleeve and washers must conform to the outside diameter of the cable.

• The minimum bending radius must not be below the accepted value.

• If using a cable which has been used before, a short piece must be peeled off when reﬁtting it so that the cable entry seal sleeve does not close around the cable at the same point again. If the outer sheath of the cable is damaged, then replace the cable. Contact a local sales and service representative.

• The voltage drop in long cables must be taken into account. The drive unit’s rated voltage is the voltage measured at the cable connection point in the pump.

• The screened cable must be used according to the European CE requirements if a Variable Frequency Drive (VFD) is used. For more information, contact your local sales and service representative (VFD-supplier).

• Make sure that the cable is long enough for maintenance work.

• For SUBCAB® cables, the twisted pair copper foil must be trimmed.

• All unused conductors must be insulated.

24 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 27

Grounding (earthing)

SUBCAB 1000V

WS004299E

WS004298C

Screened SUBCAB

Grounding (earthing) must be done in compliance with all local codes and regulations.

DANGER: Electrical Hazard

All electrical equipment must be grounded (earthed). Test the ground (earth) lead to verify that it is connected correctly. Frequently inspect electrical systems to ensure that the path to ground is continuous.

WARNING: Electrical Hazard

If the power cable is jerked loose, then the ground (earth) conductor must be the last conductor to come loose from its terminal. Make sure that the ground (earth) conductor is longer than the phase conductors at both ends of the cable.

WARNING: Electrical Hazard

Risk of electrical shock or burn. You must connect an additional ground- (earth-) fault protection device to the grounded (earthed) connectors if persons are likely to come into contact with liquids that are also in contact with the pump or pumped liquid.

4.2.1 Prepare the SUBCAB

This section applies to SUBCAB® cables with twisted-pair control cores.

cables

4 Installation

The prepared SUBCAB® cable The prepared screened SUBCAB® cable

1. T1+T2 twisted pairs in control element

2. Drain wire in control element (bare copper wire)

3. Screened copper pt-foil

4. Insulation sheath (jacket) or PT-foil for control element

5. Power cores

6. Ground (earth) core

1. T1+T2 and T3+T4 twisted pairs in control element

2. Drain wire in control element (bare copper wire)

3. Screened copper pt-foil

4. Insulation sheath (jacket) for control element

5. Power cores

6. Aluminum foil

7. Ground (earth) core with green/yellow shrink hose

8. Uncovered screen/braided wire

1. Peel off the outer sheath at the end of the cable.

2. Prepare the control element: a) Peel the sheath (if applicable) and the copper foil.

The copper foil is a screen and is conductive. Do not peel more than necessary, and remove the peeled foil.

Flygt 3085 Installation, Operation, and Maintenance Manual 25

Page 28

WS004313C

4 Installation

Figure 10: Copper foil on control element.

b) Put a white shrink hose over the drain wire and the cable terminal. c) Fit a cable lug on the drain wire. d) Twist T1+T2 and T3+T4. e) Put a shrink hose over the control element.

Make sure that the conductive copper foil and drain wire is covered.

3. Prepare the ground (earth) core for SUBCAB™ cable: a) Peel the yellow-green insulation from the ground (earth) core.

b) Check that the ground (earth) core is at least 10% longer than the phase cores in

the cabinet.

c) If applicable, put a cable lug on the ground core.

4. Prepare the ground (earth) core for screened SUBCAB™ cable: a) Untwist the screens around the power cores.

b) Put a yellow-green shrink hose over the ground (earth) core.

Leave a short piece uncovered. c) If applicable, put a cable lug on the screened ground core. d) Twist all power core screens together to create a ground (earth) core and

terminal to the end. e) Check that the ground (earth) core is at least 10% longer than the phase cores in

the cabinet.

5. How is the connection to ground (earth) made? – Screw: Fit cable terminals to the ground (earth) core and the power cores.

– Terminal block: Leave the core ends as they are.

6. Prepare the main leads:

a) Remove the aluminum foil around each power core. b) Peel the insulation from each power core.

ﬁt a cable

4.2.2 Connect the motor cable to the pump

NOTICE:

Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the end of the motor cable dry at all times.

1. Remove the entry gland screw from the stator housing.

2. Remove the stator housing.

This provides access to the terminal board/closed end splices.

3. Remove the terminal board.

4. Check the data plate to see which connections are required for the power supply.

5. Arrange the connections on the terminal board/closed end splices in accordance with

the required power supply.

26 Flygt 3085 Installation, Operation, and Maintenance Manual

6. Connect the mains leads (L1, L2, L3, and ground (earth) ) according to applicable

cable chart.

Page 29

The ground (earth) lead must be 50 mm (2.0 in.) longer than the phase leads in the

WS003681A

junction box of the unit.

7. Make sure that the pump is correctly connected to ground (earth) .

8. Make sure that any thermal contacts incorporated in the pump are properly connected

to the terminal block/closed end splices.

9. Install the stator housing.

10.Install the entry gland screw.

4.2.3 Connect the motor cable to the starter and monitoring equipment

DANGER: Explosion/Fire Hazard

NOTICE:

Thermal contacts are incorporated in the pump.

NOTICE:

Thermal contacts must never be exposed to voltages higher than 250 V, breaking current maximum 4 A. It is recommended that they are connected to 24 V over separate fuses to protect other automatic equipment.

4 Installation

The single phase pumps must be equipped with a starter which has start and run capacitors.

A specially 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.

1. If thermal contacts are included in the pump installation, then connect the T1 and T2

control conductors to the monitoring equipment. If the temperature of the pumped liquid is above 40°C (104°F), do not connect the T1

and T2 leads to thermal contacts.

NOTICE:

The thermal contacts are incorporated in the stator. Connect them to 24 V over separate fuses to protect other automatic equipment.

2. Connect the mains leads (L1, L2, L3, and ground (earth)) to the starter equipment.

For information about the phase sequence and the color codes of the leads, see Cable

charts (page 28).

3. Applicable for permanent magnet motor; ensure that the warning label is attached to

the cable end. In case the label is missing, attach the spare label to the cable end. The label is delivered with the pump.

4. Check the functionality of the monitoring equipment:

a) Check that the signals and the tripping function work properly. b) Check that the relays, lamps, fuses, and connections are intact.

Flygt 3085 Installation, Operation, and Maintenance Manual 27

Page 30

WS000509E

L3L1

L3L2

L1 L2 L3

T3 T4T1 T2

*YE

GN/YE

WS004133D

4 Installation

4.2.4 Cable charts

Description

This topic contains general connection information. It also provides cable charts that show connection alternatives for use with different cables and power supply.

Replace any defective equipment.

Connection locations

Figure 11: Phase sequence

ﬁgures in this section illustrate how to interpret the connection strip symbols.

The

1. Stator leads

2. Terminal board

3. Power cable leads

4. Stator (internal connection illustrated)

28 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 31

L1 L2 L3

T3 T4T1 T2

CLS

FLS

FLS 10

WS004134A

Color code standard

772 17 00

( 6)

REV

COLOUR STANDARD

BN=Brown BK=Black WH=White OG=Orange GN=Green GN/YE=Green-Yellow RD=Red GY=Grey BU=Blue YE=Yellow

STATOR LEADS

U1,U5 RD U2,U6 GN V1,V5 BN V2,V6 BU W1,W5 YE W2,W6 BK T1,T2 WH/YE

*SUBCAB AWG * * Ground Conductor is stranded around cores GC=Ground Check

Colours and marking of main leads

Motor connection

1 L1 BK 1 BN RD BN

2 L2 BK 2 BK BK BK

3 L3 BK 3 GY WH GY

L1 BK 4

- - -

L2 BK 5

- - -

L3 BK 6

- - -

GN/YE GN/YE GN/YE

**Screen/PE

from cores

Screen (WH) Screen (WH)

Screen (WH)

Mains

1~ 3~

SUBCAB 7GX

Screenflex 7GX

SUBCAB 4GX

Screenflex 4GX

SUBCAB AWG

SUBCAB Screened

- -

WS004125B

4 Installation

1. Starter equipment and mains leads (L1, L2, L3)

2. ground (earth)

3. Functional ground

4. Control leads (T1, T2, T3, T4)

5. Thermal contact

6. FLS

7. FLS 10

8. CLS

9. Thermistor

10.Level sensor

11.Capacitor

Code Description BN Brown BK Black WH White OG Orange GN Green GNYE Green-Yellow RD Red GY Grey BU Blue YE Yellow

4.2.4.1 Colors and markings of leads

4.2.4.2 Connections included

Flygt 3085 Installation, Operation, and Maintenance Manual 29

For markings on sensor leads, see Sensors connection (page 34).

• 3-phase connection (page 30)

• 1-phase connection (page 32)

• Sensors connection (page 34)

• Screened cable connection (page 33)

Page 32

3 PHASE

3 Leads

*YE

GN/YE

WS009162A

*YE

GN/YE

Y/D

L1:1

L2:1

L3:1

L1:2

L2:2

L3:2

GN/YE

*YE

WS004126A

6 Leads

*YE

GN/YE

4 Installation

4.2.4.3 3-phase connection

30 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 33

9 Leads

Y-

*YE

GN/YE

Y-SER

*YE

GN/YE

WS004127A

12 Leads

Y-

*YE

GN/YE

Y-SER

*YE

GN/YE

WS004128A

4 Installation

Flygt 3085 Installation, Operation, and Maintenance Manual 31

Page 34

1 PHASE

4 Leads

4 Leads with level regulator

12 Leads

1 ~

*YE

*RD

*BK

*WH

Starter

GN/YE

1 ~

1/BN

2/BK

3/GY

1 ~

Starter

1/BN

*RD

2/BK

*BK

3/GY

*WH

4/T1

*OG

5/T2

*BU

GN/YE

*YE

Starter

1/BN

*RD

2/BK

*BK

3/GY

*WH

4/T1

*OG

5/T2

*BU

GN/YE

*YE

WS004129B

4 Installation

4.2.4.4 1-phase connection

32 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 35

4.2.4.5 Screened cable connection

Screened connection SUBCAB & FGB Screened

Cable without sep. ground conductor Screen as ground conductor

GN/YE shrink hose

Screen

Mini CAS

Mini CAS+AUX

FGB Screened

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)

Screen - SUBCAB and Screenflex

T1 and T2 twisted

White insulation hose

Screen

together

GN/YE

T1 and T2 twisted together

White insulation hose

Screen

GN/YE

WS004132A

4 Installation

Flygt 3085 Installation, Operation, and Maintenance Manual 33

Page 36

Control

SUBCAB 7GX & 4GX Screenflex

SUBCAB AWG

SUBCAB screened

T1 WH T1 OG WH T1

T2 WH T2 BU WH T2

- -

WH T3

- -

WH T4

SENSORS

(Thermal Contacts)

Max. 250V Max.5A Max. 1.6A,cos =0.6 Max. 2.5A,cos =1

WH/YE

Control leads

WH/YE

T1/*OG/4

*SUBCAB AWG

T2/*OG/5

+ FLS

FLS

Max 12 V

WH YE

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

+ CLS

CLS

Max 12 V

WH YE

BN/RD

WH/YE

Control leads

T1/*OG/4

Mini

*SUBCAB AWG

T2/*BU/5

-5

CAS

WS004130A

4 Installation

4.2.4.6 Sensors connection

34 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 37

+ FLS+CLS

CLS

FLS

Max 12 V

RD/BN

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

FLS

Temp > 40° T1,T2 thermal

FLS

contacts not connected

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

T2/*BU/5

*SUBCAB AWG

WS004131A

4 Installation

Sensor connection characteristics

4.3 T-installation: Bleed air before starting pump

The values have a 10 % tolerance.

Sensors Value (mA) Deﬁnition FLS and thermal contact 0 Overtemperature

7.8 OK 36 Leakage

CLS and thermal contact 0 Overtemperature

5.5 OK 29 Leakage (5 seconds delay)

CLS, FLS and thermal contact 0 Overtempterature

13.3 OK 36–42 Leakage (0/5 seconds delay)

1. Open valve D and bleed out the air. See the following ﬁgure.

Flygt 3085 Installation, Operation, and Maintenance Manual 35

Page 38

WS008391B

WS006253A

4 Installation

1. Outlet line

2. Inlet line

3. Line to drain

4. Air vent

Figure 12: T-installation, valves A—D

2. Close valve D before the pump is started.

4.4 Check the impeller rotation

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

1. Start the motor.

2. Stop the motor after a few seconds.

3. Check that the impeller rotates according to this illustration.

36 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 39

4 Installation

The correct direction of impeller rotation is clockwise when you look at the pump from above.

4. If the impeller rotates in the wrong direction, then do one of these steps: – If the motor has a 1-phase connection, then contact the local sales and service

representative.

– If the motor has a 3-phase connection, then transpose two phase leads and do this

procedure again.

Flygt 3085 Installation, Operation, and Maintenance Manual 37

Page 40

5 Operation

Precautions

Before taking the unit into operation, check the following:

• All recommended safety devices are installed.

• The cable and cable entry have not been damaged.

• All debris and waste material has been removed.

NOTICE:

Never operate the pump with the discharge line blocked, or the discharge valve closed.

WARNING: Crush Hazard

Risk of automatic restart.

Distance to wet areas

WARNING: Electrical Hazard

CAUTION: Electrical Hazard

Risk of electrical shock or burn. The equipment manufacturer has not evaluated this unit for use in swimming pools. If used in connection with swimming pools then special safety regulations apply.

Noise level

NOTICE:

The sound power level of the product is lower than 70 dB(A). However, in some installations the resulting sound pressure level may exceed 70 dB(A) at certain operating points on the performance curve. Make sure that you understand the noise level requirements in the environment where the product is installed. Failure to do so may result in hearing loss or violation of local laws.

5.1 Estimate zinc anode replacement intervals

The mass and surface area of the zinc anodes are designed to protect the pump surface for 1 year in sea water with an average temperature of 20°C (68°F). Shorter inspection intervals and anode replacement can be required, depending upon the water temperature and the chemical composition as well as the presence of other metals in the vicinity of the pump.

The rate of zinc consumption, and the appropriate inspection intervals, can be estimated by measuring how much zinc is consumed during the ﬁrst two months following installation.

Anodes are replaced when the anode mass is reduced to a selected fraction of its initial mass. The recommended interval for the selection fraction is 0.25–0.50 (25–50%).

1. Remove, weigh, and reinstall one or more of the exterior zinc anodes before starting

up the pump.

2. After two months, remove and weigh the same zinc anode or anodes again.

38 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 41

3. Divide the lapsed time in days (between steps 1 and 2) by the anode weight loss in

grams to get the calculated anode consumption rate (days/gram). If multiple anodes were weighed, then use the anode which has lost the most weight

for this calculation.

4. Calculate future replacement intervals so that they occur when the selected fraction of

zinc is remaining.

5.2 Start the pump

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

NOTICE:

Make sure that the rotation of the impeller is correct. For more information, see Check the impeller rotation.

1. Check the oil level in the oil housing.

2. Remove the fuses or open the circuit breaker, and check that the impeller can be

rotated freely.

5 Operation

WARNING: Crush Hazard

Never put your hand into the pump housing.

3. Conduct insulation test phase to ground. To pass, the value must exceed

5 megaohms.

4. Check that the monitoring equipment works.

5. Start the pump.

Flygt 3085 Installation, Operation, and Maintenance Manual 39

Page 42

Equipment

locked out by

Name .......................

DANGER

6 Maintenance

Precautions

Before starting work, make sure that the safety instructions in the chapter Introduction and

Safety (page 3) have been read and understood.

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.

WARNING: Biological Hazard

Infection risk. Rinse the unit thoroughly with clean water before working on it.

CAUTION: Crush Hazard

Make sure that the unit cannot roll or fall over and injure people or damage property.

Make sure that you follow these requirements:

• Check the explosion risk before you weld or use electrical hand tools.

• Allow all system and pump components to cool before you handle them.

• Make sure that the product and its components have been thoroughly cleaned.

• Make sure that the work area is well-ventilated before you open any vent or drain valves, remove any plugs, or disassemble the unit.

• Do not open any vent or drain valves or remove any plugs while the system is pressurized. Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump, remove plugs, or disconnect piping.

Ground continuity veriﬁcation

A ground (earth) continuity test must always be performed after service.

Maintenance guidelines

During the maintenance and before reassembly, always remember to perform these tasks:

• Clean all parts thoroughly, particularly O-ring grooves.

• Change all O-rings, gaskets, and seal washers.

• Lubricate all springs, screws, O-rings with grease.

During the reassembly, always make sure that existing index markings are in line. The reassembled drive unit must always be insulation-tested and the reassembled pump

must always be test-run before normal operation.

6.1 Torque values

All screws and nuts must be lubricated to achieve correct tightening torque. Screws that are screwed into stainless steel must have the threads coated with suitable lubricants to prevent seizing.

If there is a question regarding the tightening torques, please contact the local sales and service representative.

40 Flygt 3085 Installation, Operation, and Maintenance Manual

Page 43

Screws and nuts

WS000089A

Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)

6 Maintenance

Property

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class 50 1.0 (0.74) 2.0 (1.5) 3.0 (2.2) 8.0 (5.9) 15 (11) 27 (20) 65 (48) 127 (93.7) 220 (162) 434 (320) 70, 80 2.7 (2) 5.4 (4) 9.0 (6.6) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) 629 (464) 1240 (915) 100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) 115 (84.8) 248 (183) 481 (355) — —

Table 2: Steel, torque Nm (ft-lbs)

Property

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class

8.8 2.9 (2.1) 5.7 (4.2) 9.8 (7.2) 24 (18) 47 (35) 81(60) 194 (143) 385 (285) 665 (490) 1310 (966.2)

10.9 4.0 (2.9) 8.1 (6) 14 (10) 33 (24) 65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840 (1357)

12.9 4.9 (3.6) 9.7 (7.2) 17 (13) 40 (30) 79 (58) 136 (100) 333 (245) 649 (480) 1120

(825.1)

2210 (1630)

Hexagon screws with countersunk heads

For hexagon socket head screws with countersunk head, maximum torque for all property classes must be 80% of the values for property class 8.8 above.

6.2 Change the oil

This image shows the plugs that are used to change the oil.

1. Oil plug

Empty the oil

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Hold a rag over the plug to prevent liquid from spraying out.

1. Place the pump in a horizontal position and unscrew the oil plug. If the pump has a hole with the markings "oil out" it is important that this hole is used

for drainage.

Flygt 3085 Installation, Operation, and Maintenance Manual 41

Page 44

WS001760A

WS001761A

6 Maintenance

2. Place a container under the pump and turn the pump.

3. Unscrew the other oil plug. If this hole has the markings "oil in", raise the pump upright for a short period of time

during drainage in order to drain all the oil.

Fill with oil

The oil should be a medical white oil of parafﬁn type that fulﬁlls FDA 172.878 (a) and viscosity close to VG32. Examples of suitable oil types are the following:

• Statoil MedicWay 32

• BP Enerpar M 004

• Shell Ondina 927

• Shell Ondina X430

™

1. Replace the O-rings of the oil plugs.

2. Reﬁt an oil plug in the hole that faces downwards or is marked "oil out", and tighten. Tightening torque: 10-40 Nm (7.5-29.5 ft-lb)

3. Fill with oil through the hole on the opposite side or the hole marked "oil in". If the hole is marked "oil in", slightly tilt the pump and lower it again in order to ﬁll the

pump with the correct quantity. Quantity: approximately 1.0 L (1.1 qt).

42 Flygt 3085 Installation, Operation, and Maintenance Manual

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WS001762A

4. Reﬁt the oil plug and tighten. Tightening torque: 10-40 Nm (7.5-29.5 ft-lb).

6.3 Service the pump

Type of service Purpose Inspection interval Initial

inspection

Periodical inspection

Major overhaul

To make a check up of the pump condition by a Xylem authorized service representative and, based on the result and ﬁndings from these measures, to determine the intervals for periodical inspection and major overhaul for the speciﬁc installation.

To prevent operational interruptions and machine breakdown. Measures to secure performance and pump efﬁciency are deﬁned and decided for each individual application. It can include such things as impeller trimming, wear part control and replacement, control of zinc-anodes and control of the stator.

To secure a long operating lifetime for the product. It includes the replacement of key components and the measures that are taken during an inspection.

6 Maintenance

Within the ﬁrst year of operation.

Up to every year Applies to normal applications

and operating conditions at media (liquid) temperatures <40°C (104°F).

Up to every 3 years Applies to normal applications

and operating conditions at media (liquid) temperatures <40°C (104°F).

NOTICE:

Shorter intervals may be required when the operating conditions are extreme, for example with very abrasive or corrosive applications or when the liquid temperatures exceed 40°C (104°F).

6.3.1 Inspection

Service item Action Cable 1. If the outer jacket is damaged, replace the cable.

Connection to power Check that the connections are properly tightened. Electrical cabinets Check that they are clean and dry. Impeller 1. Check the impeller clearance.

Stator housing 1. Drain all liquid, if any.

Flygt 3085 Installation, Operation, and Maintenance Manual 43

2. Check that the cables do not have any sharp bends and are not pinched.

2. Adjust the impeller, if necessary.

2. Check the resistance of the leakage sensor. Normal value approximately1500 ohms, alarm approximately

430 ohms.

Page 46

6 Maintenance

Service item Action Insulation Use a megger maximum 1000 V.

1. Check that the resistance between the ground (earth) and phase lead is more than 5 megohms.

2. Conduct a phase-to-phase resistance check.

Junction box Check that it is clean and dry. Lifting device Check that local safety regulations are followed. Lifting handle 1. Check the screws.

2. Check the condition of the lifting handle.

3. Replace if necessary.

O-rings 1. Replace the oil plug O-rings.

2. Replace the O-rings at the entrance or junction cover.

3. Grease the new O-rings.

Overload protection and other protections

Personnel safety devices Check the guard rails, covers, and other protections. Rotation direction Check the impeller rotation. Oil housing Fill with new oil, if necessary. Terminal block/closed end splice Check that the connections are properly tightened. Thermal contacts Normally closed circuit; interval 0–1 ohm. Voltage and amperage Check the running values.

Check the correct settings.

6.3.2 Major overhaul

For a major overhaul, do the following in addition to the tasks listed under Inspection.

Service item Action Support and main bearing Replace the bearings with new bearings. Mechanical seal Replace with new seal units.

6.3.3 Service in case of alarm

For information about indication values for sensors, see Sensors connection (page 34).

Alarm source Action CLS Check for water in the oil housing. If the oil contains too much water, then

FLS 1. Check for liquid in the stator housing.

Thermal contact Check the start and stop levels. The overload protection Check that the impeller can rotate freely.

6.4 Replace the impeller

do the following:

1. Drain the oil and water.

2. Replace with new oil.

2. Drain all liquid, if any.

3. Check the mechanical seal unit, the O-rings, and the cable entry, if liquid was found.

Required tools:

• 6 mm hexagon bit adapter with an extension of at least 125 mm (4.92 in)

• Impeller puller If applicable, contact your local sales and service representative for correct type and

size.

44 Flygt 3085 Installation, Operation, and Maintenance Manual

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• Rod (wood or copper) for locking the impeller in place, if applicable

WS006128A

WS006129A

• Two crowbars, if applicable

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

NOTICE:

When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller. The impeller must not be allowed to make contact with the concrete ﬂoor or other hard and rough surfaces.

If you fail with the impeller installation, then you must redo the installation procedure from the beginning.

6.4.1 Replace the C-, D-, or L-impeller

6 Maintenance

Figure 13: C-Impeller

Flygt 3085 Installation, Operation, and Maintenance Manual 45

Figure 14: D-impeller

Page 48

WS006131A

WS001966A

6 Maintenance

Figure 15: L-impeller

6.4.1.1 Remove the C-, D-, or L-impeller

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

1. Remove the pump housing.

2. Remove the impeller screw. If applicable, use the rod.

46 Flygt 3085 Installation, Operation, and Maintenance Manual

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WS001988A

WS001982A

WS001978A

6 Maintenance

Figure 16: C-impeller

3. For the L- and some C-impellers, remove the washer.

4. Remove the impeller. Use the impeller puller or the crowbars.

5. Remove the conical sleeve.

6.4.1.2 Install the C-, D-, or L-impeller

1. Prepare the shaft: a) Polish off any

The end of the shaft must be clean and free from burrs.

b) Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical

sleeve with a thin layer of grease. The proper lubrication is grease for bearings, for example Exxon Mobil Unirex N3,

Mobil Mobilith SHC 220 or equivalent.

ﬂaws with a ﬁne emery cloth.

Figure 17: D-impeller

NOTICE:

Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves.

Flygt 3085 Installation, Operation, and Maintenance Manual 47

Page 50

WS006895A

WS002022A

WS001941A

6 Maintenance

2. Mount the impeller: a) Fit the conical sleeve onto the shaft.

b) Lubricate the impeller screw threads and contact surface.

Ensure that all parts are clean. c) For the L- and some C-impellers, ﬁt the washer on the lubricated screw. d) Press the impeller onto the shaft with the impeller screw.

3. Tighten the impeller screw. Tightening torque: 34 Nm (25 ft-lb). Tighten a further 1/8 turn, 45° after tightening to the correct torque. If applicable, use the rod.

Check that the impeller can rotate freely.

4. Mount the pump housing: a) Fit the pump housing.

b) Fit and tighten the lubricated screws.

48 Flygt 3085 Installation, Operation, and Maintenance Manual

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Tightening torque: 57 Nm (42 ft-lb).

WS002018A

WS006130A

6.4.2 Replace the F-impeller

6 Maintenance

6.4.2.1 Remove the F-impeller

Flygt 3085 Installation, Operation, and Maintenance Manual 49

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

1. Remove the suction cover. If necessary, then pry off the suction cover.

2. Remove the impeller screw, the ring, and the washers. If applicable, use the rod.

Page 52

WS001976A

WS006895A

6 Maintenance

3. Remove the impeller. Use the impeller puller or the crowbars.

4. Remove the conical sleeve.

6.4.2.2 Install the F-impeller

1. Prepare the shaft: a) Polish off any ﬂaws with a ﬁne emery cloth.

The end of the shaft must be clean and free from burrs.

b) Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical

sleeve with a thin layer of grease. The proper lubrication is grease for bearings, for example Exxon Mobil Unirex N3,

Mobil Mobilith SHC 220 or equivalent.

NOTICE:

Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves.

2. Mount the impeller: a) Fit the conical sleeve onto the shaft.

b) Fit one adjustment washer with a thickness of 0.25 mm (0.01 in) and two adjustment

washers with a thickness of 1 mm (0.04 in) onto the impeller.

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WS002021A

WS001940A

6 Maintenance

c) Lubricate the impeller screw threads and contact surface.

Ensure that all parts are clean.

d) Press the impeller onto the shaft with the impeller screw.

3. Fasten the impeller: a) Prevent the impeller from rotating by inserting the rod through the pump housing

outlet.

b) Tighten the impeller screw.

If applicable, use the rod. Tightening torque: 30 Nm (22 ft-lb). Tighten a further 1/8 turn, 45° after tightening to the correct torque.

Check that the impeller can rotate freely.

4. Adjust the impeller: a) Measure the distance between the edge of the impeller and the pump housing

cover. The correct distance should be 0.5-1.5 mm (0.02-0.06 in). Add or remove the

Flygt 3085 Installation, Operation, and Maintenance Manual 51

appropriate number of adjusting washers in order to achieve correct distance.

Page 54

WS002107A

WS002080A

WS002014A

6 Maintenance

b) Tighten the impeller screw.

If applicable, use the rod. Tightening torque: 30 Nm (22 ft-lb). Tighten a further 1/8 turn, 45° after tightening to the correct torque. Check that the impeller can rotate freely.

5. Fit a new lubricated O-ring to the into the groove in the pump housing.

6. Mount the suction cover: a) Fit the studs on the pump housing.

Use Loctite 603 locking liquid in order to secure the studs.

b) Fit two adjustment washers with a thickness of 1 mm (0.04 in) and six adjustment

washers with a thickness of 0.25 mm (0.01 in) onto each stud.

52 Flygt 3085 Installation, Operation, and Maintenance Manual

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c) Fit the suction cover to the studs.

WS001937A

WS002105A

WS001937A

d) Fit the lock nuts onto the studs. e) Tighten the nuts.

Tightening torque: 17 Nm (13 ft-lb)

7. Adjust the suction cover: a) Measure the distance between the impeller and the suction cover.

The correct distance should be 0.5-1 mm (0.02-0.04 in). Add or remove the appropriate number of adjusting washers in order to achieve the correct distance.

6 Maintenance

b) Tighten the nuts.

Tightening torque: 17 Nm (13 ft-lb).

8. Raise the pump to a vertical position.

Flygt 3085 Installation, Operation, and Maintenance Manual 53

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WS006132A

WS001977A

6 Maintenance

Check that the impeller can rotate freely.

6.4.3 Replace the M-impeller

Figure 18: M-impeller

6.4.3.1 Remove the M-impeller

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

1. Remove the pump housing.

2. Remove the impeller screw and outer sleeve. If applicable, use the rod.

3. Reﬁt the impeller screw.

54 Flygt 3085 Installation, Operation, and Maintenance Manual

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WS001993A

4. Fit the impeller puller and pull off the impeller and cutter wheel.

WS002006A

WS001987A

Place a protector between the screw head and the impeller puller.

6 Maintenance

5. Remove the conical sleeve.

6.4.3.2 Install the M-impeller

1. Prepare the shaft: a) Polish off any

The end of the shaft must be clean and free from burrs.

b) Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical

sleeve with a thin layer of grease. The proper lubrication is grease for bearings, for example Exxon Mobil Unirex N3,

Mobil Mobilith SHC 220 or equivalent.

ﬂaws with a ﬁne emery cloth.

Flygt 3085 Installation, Operation, and Maintenance Manual 55

Page 58

WS006895A

WS002081A

WS001943A

6 Maintenance

NOTICE:

Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves.

2. Mount the impeller: a) Fit the conical sleeve onto the shaft.

b) Fit the cutter wheel into the impeller. c) Fit the outer sleeve onto the lubricated impeller screw. d) Fit the impeller with the cutter wheel onto the shaft with the impeller screw.

Do not tighten the impeller screw.

3. Adjust the impeller: a) Use a straightedge and a vernier to measure the distance between the vanes of the

impeller and the shoulder for the pump housing on the oil housing bottom. The correct distance for pressure class LT and HT is 43.5±0.3 mm (1.71±0.01 in.).

b) Slide the impeller on to the shaft until you reach the correct distance.

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4. Tighten the impeller screw.

WS001939A

WS002018A

If applicable, use the rod. Tightening torque: 34 Nm (25 ft-lbs)

Check that the impeller can rotate freely.

5. Mount the pump housing: a) Fit the pump housing.

b) Fit and tighten the lubricated screws.

Tightening torque: 57 Nm (42 ft-lb).

6 Maintenance

6.4.4 Replacing the Adaptive N-impeller

To see which pumps are Adaptive-N, see Product Description (page 10).

Flygt 3085 Installation, Operation, and Maintenance Manual 57

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WS008398B

WS008391B

6 Maintenance

1. Conical sleeve

2. Washer

3. Impeller screw

4. Impeller

5. Plug

6. Insert ring

7. Pump housing

CAUTION: Cutting Hazard

Worn parts can have sharp edges. Wear protective clothing.

NOTICE:

6.4.4.1 Prepare the pump for removal: T-, Z-installations

The pump must be removed from the installation to change the impeller.

1. Close valves A and B on the inlet and outlet lines. See the following ﬁgures.

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1. Outlet line

WS008392B

WS008400A

2. Inlet line

3. Line to drain

4. Air vent

Figure 19: Valves A-D for T-installation (generic pump shown)

1. Outlet line

2. Inlet line

3. Line to drain

Figure 20: Valves A-C for Z-installation (generic pump shown)

2. Drain the pump by opening valve C on the drain line.

3. Remove the pump from the installation.

6 Maintenance

6.4.4.2 Remove the Adaptive-N impeller: P, S, T, Z installations

To see which pumps are Adaptive-N, see Product Description (page 10).

1. Remove the pump housing.

2. Remove the impeller. a) Remove the plug.

b) Loosen the impeller screw. c) Remove the impeller.

Use the impeller puller or the crowbars.

d) Remove the impeller screw, the washer, and the conical sleeve.

6.4.4.3 Install the Adaptive-N impeller: P, S, T, Z installations

To see which pumps are Adaptive-N, see Product Description (page 10).

Flygt 3085 Installation, Operation, and Maintenance Manual 59

Page 62

WS008396A

WS008329A

6 Maintenance

1. Before mounting the impeller, check that the sleeve moves freely up and down by pushing on it. See the following ﬁgure.

When the sleeve is released, it should be fully pushed out again. If the sleeve does not move freely, or does not come fully out, then replace the impeller unit.

2. Prepare the shaft: a) Polish off any ﬂaws with a ﬁne emery cloth.

The end of the shaft must be clean and free from burrs.

b) Coat the inner conic and the outer cylindrical surfaces of the sleeve with a thin layer

of grease.

The proper lubrication is grease for bearings, for example Exxon Mobil Unirex N3, Mobil Mobilith SHC 220 or equivalent.

NOTICE:

Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves.

3. Mount the impeller sleeve and impeller, and secure the impeller in place with the screw.

4. Check that the impeller is in its lowest position: a) Insert two screwdrivers as shown in the following ﬁgure, and push the impeller

downwards.

60 Flygt 3085 Installation, Operation, and Maintenance Manual

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WS008386A

6 Maintenance

5. Mount the pump housing: a) Fit the pump housing.

b) Fit and tighten the lubricated screws.

Tightening torque: 57 Nm (42 ft-lb).

6. Loosen the impeller screw and make sure that the impeller moves down towards the insert ring until they are in contact.

7. Tighten the impeller screw. Tightening torque: 34 Nm (25 ft-lb). Tighten a further 1/8 turn, 45°, after tightening to the correct torque.

8. Check that the impeller can rotate freely.

WARNING: Crush Hazard

Beware of the pinch point hazard between the rotating impeller and the guide pin.

9. Check with an extended feeler gauge that the impeller clearance is 0.1 – 0.3 mm.

Flygt 3085 Installation, Operation, and Maintenance Manual 61

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WS001449B

6 Maintenance

10.Fit the lubricated plug and tighten it. Tightening torque: 15-30 Nm (11-22 ft-lb).

11.Re-install the pump. T-installations: See the instructions in T-installation: Bleed air before starting pump

(page 35).

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7 Troubleshooting

Introduction

DANGER: Electrical Hazard

Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualiﬁed electrician.

Follow these guidelines when troubleshooting:

• Disconnect and lock out the power supply except when conducting checks that require voltage.

• Make sure that no one is near the unit when the power supply is reconnected.

• When troubleshooting electrical equipment, use the following:

– Universal instrument multimeter – Test lamp (continuity tester) – Wiring diagram

7.1 The pump does not start

7 Troubleshooting

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.

WARNING: Electrical Hazard

The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause Remedy An alarm signal has been triggered

on the control panel.

The pump does not start automatically, but can be started manually.

Check that:

• The impeller rotates freely.

• The sensor indicators do not indicate an alarm.

• The overload protection is not tripped. If the problem still persists: Contact the local sales and service representative.

Check that:

• The start level regulator is functioning. Clean or replace if necessary.

• All connections are intact.

• The relay and contactor coils are intact.

• The control switch (Man/Auto) makes contact in both positions. Check the control circuit and functions.

Flygt 3085 Installation, Operation, and Maintenance Manual 63

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7 Troubleshooting

Cause Remedy The installation is not receiving

voltage.

The impeller is stuck. Clean:

Always state the serial number of your product, see Product Description (page 10).

Check that:

• The main power switch is on.

• There is control voltage to the start equipment.

• The fuses are intact.

• There is voltage in all phases of the supply line.

• All fuses have power and that they are securely fastened to the fuse

holders.

• The overload protection is not tripped.

• The motor cable is not damaged.

• The impeller

• The sump in order to prevent the impeller from clogging again.

7.2 The pump does not stop when a level sensor is used

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.

WARNING: Electrical Hazard

The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate.

Cause Remedy The pump is unable to empty the

sump to the stop level.

There is a malfunction in the levelsensing equipment.

The stop level is set too low. Raise the stop level.

Always state the serial number of your product, see Product Description (page 10).

Check that:

• There are no leaks from the piping and/or discharge connection.

• The impeller is not clogged.

• The non-return valve(s) are functioning properly.

• The pump has adequate capacity. For information:

Contact the local sales and service representative.

• Clean the level regulators.

• Check the functioning of the level regulators.

• Check the contactor and the control circuit.

• Replace all defective items.

7.3 The pump starts-stops-starts in rapid sequence

Cause Remedy The pump starts due to back-ﬂow

which ﬁlls the sump to the start level again.

Check that:

• The distance between the start and stop levels is sufﬁcient.

• The non-return valve(s) work(s) properly.

• The length of the discharge pipe between the pump and the ﬁrst non-

return valve is sufﬁciently short.

64 Flygt 3085 Installation, Operation, and Maintenance Manual

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Cause Remedy The self-holding function of the

contactor malfunctions.

Always state the serial number of your product, see Product Description (page 10).

Check:

• The contactor connections.

• The voltage in the control circuit in relation to the rated voltages on the

coil.

• The functioning of the stop-level regulator.

• Whether the voltage drop in the line at the starting surge causes the

contactor's self-holding malfunction.

7.4 The pump runs but the motor protection trips

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.

WARNING: Electrical Hazard

The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate.

7 Troubleshooting

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause Remedy The motor protection is set too low. Set the motor protection according to the data plate and if applicable the

cable chart.

The impeller is difﬁcult to rotate by hand.

The drive unit is not receiving full voltage on all three phases.

The phase currents vary, or they are too high.

The insulation between the phases and ground in the stator is defective.

The density of the pumped ﬂuid is too high.

There is a malfunction in the overload protection.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

• Check the fuses. Replace fuses that have tripped.

• If the fuses are intact, then notify a certiﬁed electrician. Contact the local sales and service representative.

1. Use an insulation tester. With a 1000 V DC megger, check that the

insulation between the phases and between any phase and ground is > 5 megaohms.

2. If the insulation is less, then do the following:

Contact the local sales and service representative.

Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)

• Change the impeller, or

• Change to a more suitable pump

• Contact the local sales and service representative. Replace the overload protection.

Always state the serial number of your product, see Product Description (page 10).

Flygt 3085 Installation, Operation, and Maintenance Manual 65

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7 Troubleshooting

7.5 The pump delivers too little or no water

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.

WARNING: Electrical Hazard

The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in equipment damage.

Cause Remedy The impeller rotates in the wrong

direction.

One or more of the valves are set in the wrong positions.

The impeller is difﬁcult to rotate by hand.

The pipes are obstructed. To ensure a free ﬂow, clean out the pipes. The pipes and joints leak. Find the leaks and seal them. There are signs of wear on the

impeller, pump, and casing. The liquid level is too low. • Check that the level sensor is set correctly.

• If it is a 3-phase pump, then transpose two phase leads.

• If it is a 1-phase pump, then do the following:

Contact the local sales and service representative.

• Reset the valves that are set in the wrong position.

• Replace the valves, if necessary.

• Check that all valves are correctly installed according to media ﬂow.

• Check that all valves open correctly.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

Replace the worn parts.

• Depending on the installation type, add a means for priming the pump,

such as a foot valve.

Always state the serial number of your product, see Product Description (page 10).

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8 Technical Reference

8.1 Motor data

Feature Description Motor type • 3085.092/.160/.172/.183/.190/.760/.770/.891: Squirrel-cage induction motor

• 3085.800/.810/.820/.830/.900/.910/.960/.970: Line-started, permanent-magnet synchronous motor

Frequency 50 or 60 Hz Supply 1-phase or 3-phase Starting method • Direct on-line

• Star-delta

• Soft starter

Star-delta Maximum starts per hour 30 evenly spaced starts per hour Code compliance IEC 60034-1 Voltage variation without

overheating Voltage imbalance

tolerance Stator insulation class H (180°C [360°F])

±10%, provided that it does not run continuously at full load

8 Technical Reference

Application limits

Data Description Liquid temperature 40°C (104°F) maximum

The pump can be operated at full load only if at least half the stator housing is submerged.

Warm-liquid version: 70°C (158°F) maximum (3085.160, 3085.183, 3085.760)

Ex-approved pumps: 40°C (104°F) maximum Liquid density 1100 kg/m³ (9.2 lb per US gal) maximum pH of the pumped media

(liquid) Depth of immersion 20 m (65 ft) maximum Other For the speciﬁc weight, current, voltage, power ratings, and speed of the pump, see the

5.5–14

data plate of the pump.

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Page 71

Page 72

Xylem |’zīləm|

1) The tissue in plants that brings water upward from the roots

2) A leading global water technology company

We’re a global team uniﬁed in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efﬁciently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation.

For more information on how Xylem can help you, go to xyleminc.com

Refer to www.xylemwatersolutions.com/contacts/ for contact details of your local sales and service representative.

Xylem Water Solutions Global Services AB 361 80 Emmaboda Sweden Tel: +46-471-24 70 00 Fax: +46-471-24 47 01 http://tpi.xyleminc.com

Visit our Web site for the latest version of this document and more information

The original instruction is in English. All non-English instructions are translations of the original instruction.

2011 Xylem Inc

898548_6.0_en-US_2016-01_IOM.3085