Page 1
Installation, Operation,
and Maintenance Manual
Flygt 3202
Page 2
Page 3
Table of Contents
Introduction and Safety..................................................................................................................3
Introduction..................................................................................................................................3
Safety.............................................................................................................................................3
Safety terminology and symbols........................................................................................... 3
Environmental safety...............................................................................................................4
User safety................................................................................................................................ 5
Ex-approved products............................................................................................................ 6
Product warranty......................................................................................................................7
Transportation and Storage.......................................................................................................... 8
Inspect the delivery.....................................................................................................................8
Inspect the package................................................................................................................8
Inspect the unit........................................................................................................................ 8
Transportation guidelines.......................................................................................................... 8
Lifting.........................................................................................................................................8
Temperature ranges for transportation, handling and storage............................................ 9
Storage guidelines...................................................................................................................... 9
Table of Contents
Product Description......................................................................................................................11
Pump design..............................................................................................................................11
Monitoring equipment............................................................................................................. 13
The data plate............................................................................................................................13
Approvals................................................................................................................................... 15
Product denomination..............................................................................................................16
Installation......................................................................................................................................18
Install the pump.........................................................................................................................18
Install with P-installation....................................................................................................... 18
Install with S-installation....................................................................................................... 20
Install with T/Z-installation....................................................................................................20
Make the electrical connections..............................................................................................22
Prepare the SUBCAB™ cables..............................................................................................23
Connect the motor cable to the pump...............................................................................24
Connect the motor cable to the starter and monitoring equipment..............................25
Cable charts........................................................................................................................... 26
Sensor-connection................................................................................................................ 32
Check the impeller rotation..................................................................................................... 37
Operation.......................................................................................................................................39
Estimate zinc anode replacement intervals........................................................................... 39
Start the pump...........................................................................................................................40
Maintenance..................................................................................................................................41
Torque values............................................................................................................................ 41
Change the coolant.................................................................................................................. 42
Empty the coolant................................................................................................................. 42
Fill with coolant......................................................................................................................44
Service the pump...................................................................................................................... 45
Inspection...............................................................................................................................45
Major overhaul.......................................................................................................................46
Flygt 3202 Installation, Operation, and Maintenance Manual 1
Page 4
Table of Contents
Service in case of alarm........................................................................................................ 47
Replace the impeller.................................................................................................................47
Replace the impeller for wet installation............................................................................47
Replace the impeller for dry installation.............................................................................54
Troubleshooting........................................................................................................................... 63
The pump does not start..........................................................................................................63
The pump does not stop when a level sensor is used......................................................... 64
The pump starts-stops-starts in rapid sequence...................................................................64
The pump runs but the motor protection trips..................................................................... 65
The pump delivers too little or no water................................................................................65
Technical Reference..................................................................................................................... 67
2 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 5
Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
Introduction and Safety
Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• 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. 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.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result
in physical injury, damage, or delays.
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
• Product malfunction
Flygt 3202 Installation, Operation, and Maintenance Manual 3
Page 6
Introduction and Safety
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
Hazard categories
WARNING:
CAUTION:
NOTICE:
A hazardous situation which, if not avoided, could result
in death or serious injury
A hazardous situation which, if not avoided, could result
in minor or moderate injury
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary
hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Environmental safety
The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any
nuclear radiation.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
4 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 7
Recycling guidelines
User safety
General safety rules
Safety equipment
Introduction and Safety
Always recycle according to these guidelines:
1. Follow local laws and regulations regarding recycling if the unit or parts are accepted
by an authorized recycling company.
2. If the first guideline is not applicable, then return the unit or parts to your local sales
and service representative.
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
Wash the skin and eyes
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
• Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
Follow these procedures for chemicals or hazardous fluids that have come into
contact with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in
eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Flygt 3202 Installation, Operation, and Maintenance Manual 5
Page 8
Introduction and Safety
Condition Action
Chemicals or hazardous fluids on
skin
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.
• You must fully submerge the Ex-approved product 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.
• 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.
• Some gap and diametrical clearances could be less than the values specified in table
1 in the standard EN 60079-1. Contact Xylem for any maintenance on flameproof
joints.
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
certified electricians and Xylem
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not
change the conditions of the service without the approval of an Ex-approved Xylem
representative. When you install or maintain explosion proof products, always comply
with the directive and applicable standards (for example, IEC/EN 60079–14).
Minimum permitted liquid level
See the dimensional drawings of the product for the minimum permitted liquid level
according to the approval for explosion proof products. If the information is missing on
the dimensional drawing, the product must be fully submerged. Level-sensing equipment
must be installed if the product can be operated at less than the minimum submersion
depth.
6 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 9
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices
include but are not limited to the following:
Product warranty
Coverage
Xylem undertakes to remedy defects in products from Xylem under these conditions:
Introduction and Safety
• Level indicators
• Temperature detectors
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to a local sales and service representative within the warranty
period.
• The product is used only under the conditions that are described in this manual.
• The monitoring equipment that is incorporated in the product is correctly connected
and in use.
• All service and repair work that is done by Xylem authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories that are authorized by an Ex-approved
Xylem representative are used in Ex-approved products.
Limitations
Warranty claim
Spare parts
The warranty does not cover defects that are caused by these situations:
Deficient maintenance
•
• Improper installation
• Modifications or changes to the product and installation that are made without
consulting a Xylem authorized representative
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need for a warranty claim arise, contact your local sales and service
representative.
Xylem guarantees that spare parts will be available for 15 years after the manufacture of
this product has been discontinued.
Flygt 3202 Installation, Operation, and Maintenance Manual 7
Page 10
Transportation and Storage
Transportation and Storage
Inspect the delivery
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.
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.
Transportation guidelines
Precautions
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
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.
Lifting
WARNING:
Crush Hazard.
• Always lift the unit by its designated lifting points.
• Use suitable lifting equipment and ensure that the product is properly harnessed.
• Wear personal protective equipment.
• Stay clear of cables and suspended loads.
Lifting equipment and tackle should always be inspected before starting work.
Lifting equipment
Lifting equipment is always required when handling the unit. It must fulfill the following
requirements:
8 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 11
Transportation and Storage
• 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.
• The lifting equipment must support 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.
NOTICE:
Oversized lifting equipment could cause damage if the unit should stick when being
lifted.
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
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
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 water. Change if needed.
flame to thaw the unit.
filled with a mixture of water and 30%
Storage guidelines
Storage location
The product must be stored in a covered and dry location free from heat, dirt, and
vibrations.
Flygt 3202 Installation, Operation, and Maintenance Manual 9
Page 12
Transportation and Storage
NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.
Freezing precautions
The unit is frost-proof while operating or immersed in liquid, but the impeller/propeller
and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding
temperature below freezing.
Follow these guidelines to avoid freezing damage:
When Guideline
Before storage • The unit must be allowed to run for a short time after raising it to
After storage If the impeller/propeller is frozen, it must be thawed by immersing the unit
discharge remaining pumped liquid.
This does not apply to impeller/propeller units.
• The discharge opening must be covered in a suitable way, or placed
facing down so that any still remaining pumped liquid runs out.
• If present, the cooling jacket must be drained manually by opening the
air vent screws at the top of the cooling jacket.
in liquid before operating the unit.
Long-term storage
NOTICE:
Never use a naked flame to thaw the unit.
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.
10 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 13
Product Description
Pump design
The pump is submersible, and driven by an electric motor.
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.
WARNING:
In explosive or flammable environments, only use Ex- or MSHA-approved products.
NOTICE:
Do NOT use the pump in highly corrosive liquids.
Product Description
Spare parts
Pressure class
• 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.
LT
MT Medium head
HT High head
SH Super high head
Low head
Flygt 3202 Installation, Operation, and Maintenance Manual 11
Page 14
1
11
10
9
8
7
2
3
6
12
13
14
WS000850A
4
5
WS006171A
Product Description
Parts
Figure 1: Without cooling jacket
Figure 2: With cooling jacket
PositionDenomination Description
1 Monitoring
sensor
2 Shaft Stainless steel, with an integrated rotor
3 Cooling without
jacket
4 Cooling with
jacket
5 Flow diffuser Provides heat transfer from the coolant to the pumped fluid.
6 Seal housing Includes a coolant that lubricates and cools the seals; the housing acts as a buffer
7 Impeller N-impeller, a semi-open, two-vane impeller
8 Inspection
chamber
9 FLS10
10 Mechanical seals Made of one of the following alternatives:
11 Main bearings Consisting of a two-row angular contact ball bearing
12 Motor
13 Thermal contact/
Thermistors
Optional sensor. For information about sensors, see Monitoring equipment (page
13).
The pump is cooled by the ambient liquid.
The motor is cooled by a closed loop system. An integrated coolant pump circulates the
coolant whenever the pump is operated.
between the pumped fluid and the electric motor
Equipped with an FLS10 leakage sensor to prevent damages to the motor
For information about FLS10, see Monitoring equipment (page 13).
• Alternative 1
• Inner seal: corrosion-resistant cemented carbide WCCR/WCCR
• Outer seal: corrosion-resistant cemented carbide WCCR/WCCR
• Alternative 2
• Inner seal: corrosion-resistant cemented carbide WCCR/WCCR
• Outer seal: silicon carbide RSiC/RSiC
For information about the motor, see Motor data (page 67).
For information about the thermal contact and thermistors, see Monitoring
equipment (page 13).
12 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 15
PositionDenomination Description
14 Support bearing Consisting of a two-row ball bearing
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 140°C (285°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.
If optional sensors are installed it is recommended to use MAS 711 as monitoring
equipment or equivalent equipment.
• The monitoring equipment must be of a design that makes automatic restart
impossible.
• The pump is supplied with an inspection sensor FLS 10 for sensing the presence of
any liquid in the inspection chamber.
• Information in the junction box shows if the pump is equipped with optional sensors.
Product Description
Optional sensors
Thermistor
FLS FLS is a miniature float switch for detection of liquid in the junction box.
Pt 100 Pt100 is a sensor that measures the temperature in the stator and in bearings.
VIS 10 VIS 10 is a vibration sensor located in the junction box. It measures vibrations
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
plate.
Thermistors are optional sensors for measuring the temperature. They are
connected in series in the stator and activate the alarm at overtemperature.
The sensors are only optional for standard pumps.
NOTICE:
Thermistor must never be exposed to voltages higher than 2.5 V. If the
voltage exceeds this value, for example when the control circuit is tested, the
thermistors will be destroyed.
NOTICE:
Never connect the Pt 100 transducer to a voltage higher than 2.5 V.
in one direction.
specifications. Specially approved products also have an approval
Flygt 3202 Installation, Operation, and Maintenance Manual 13
Page 16
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
3
1
23
24
WS006257A
Product Description
1. Curve code or Propeller code
2. Serial number, see Product denomination (page 16)
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 3: The data plate
14 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 17
Approvals
1 2 3
4
5
6 7
8
9 10
12
11
13
14
15
WS003972A
Product approvals for hazardous locations
Pump Approval
• 3202.090
• 3202.095
• 3202.390
• 3202.670
• 3202.810
• 3202.830
• 3202.850
• 3202.870
Product Description
European Norm (EN)
• ATEX Directive
• EN 60079-0:2009, EN 60079-1:2007, EN 13463-1:2009,
EN 13463-5:2011
•
I M2 c Ex d I Mb
•
II 2 G c Ex d IIB T3 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 I
• Ex d IIB T3
FM (FM Approvals)
• Explosionproof 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
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
its fields.
International Norm; not for EU member countries.
Flygt 3202 Installation, Operation, and Maintenance Manual 15
Page 18
WS001279B
21
876
3
4
5 9
10
11
12
13
1
2
WS003973A
XXYYYY YYY YYY YYYY
1
2
3
4
5
6
7
a
b
c
WS006265B
.
Product Description
FM approval plate
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
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.
Codes and parameters
Type of Callout Number Indication
16 Flygt 3202 Installation, Operation, and Maintenance Manual
Type of code a Sales denomination
b Product code
c Serial number
Page 19
Type of Callout Number Indication
Parameter 1 Hydraulic end
2 Type of installation
3 Sales code
4 Version
5 Production year
6 Production cycle
7 Running number
Product Description
Flygt 3202 Installation, Operation, and Maintenance Manual 17
Page 20
Installation
Installation
Install the pump
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.
WARNING:
• Note that special rules apply to installation in explosive atmospheres.
• Do not install the starter equipment in an explosive zone unless it is explosion-proof
rated.
• Do not install CSA-approved products in locations that are classified as hazardous in
the national electric code, ANSI/NFPA 70-2005.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
WARNING:
Electrical shock hazard. Check that the cable and cable entry have not been damaged
during transport before installing the pump.
Authority regulation
Fasteners
NOTICE:
• Do not run the pump dry.
• Never force piping to make a connection with a pump.
• Always remove all debris and waste material from the sump, inlet piping, and
discharge connection, before you install the pump.
These requirements apply:
• Use the pump dimensional drawing in order to ensure proper installation.
• In S-, T-, and Z-installations the pump must be equipped with cooling jacket
• Provide a suitable barrier around the work area, for example, a guard rail.
• Check the explosion risk before you weld or use electric hand tools.
• Vent the tank of a sewage station in accordance with local plumbing codes.
• Always check the impeller rotation before lowering the pump into the pumped liquid.
Vent the tank of a sewage station in accordance with local plumbing codes.
WARNING:
• 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.
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.
18 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 21
WS006259A
Installation
Figure 4: 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
• Level regulators or other control equipment for start, stop, and alarm
• Cable holder for holding the cable and regulating the height of the level regulators
• 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 casing flange and a
bracket for attaching the guide equipment.
• Fasteners for the discharge connection
• Anchor bolts
1. Run a cable between the sump and the stator and monitoring equipment.
Make sure that the cable is neither sharply bent, nor pinched.
2. Install the access frame:
a) Place the access frame in position and align it horizontally.
b) Grout the frame in place.
3. Grout the anchor bolts in place.
Be careful when you align and position the discharge connection in relation to the
access frame.
4. Place the discharge connection in position, and tighten the nuts.
5. 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.
6. Connect the discharge pipe to the discharge connection.
7. Prepare for the level regulator:
a) Bolt the cable holder to the access frame.
b) Attach the level regulator cable to the cable holder and adjust the height of the
level regulator.
c) Protect bolts and nuts with a corrosion-preventive compound.
Flygt 3202 Installation, Operation, and Maintenance Manual 19
Page 22
WS006270A
Installation
8. Lower the pump along the guide bars.
9. Secure the motor cable:
a) Fasten the permanent lifting device to the pump and to the access frame. For
b) Fasten the cable to the cable holder.
c) Connect the motor cable and the starter and monitoring equipment according to
Clean all debris from the sump before starting the pump.
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.
example, you can use a stainless-steel lifting chain with shackles.
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.
the separate instructions.
Make sure that the impeller rotation is correct. For more information, see Check
the impeller rotation (page 37).
Figure 5: 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.
Alternatively, the pump can be suspended with a lifting chain just above the sump
bottom. Make sure that the pump cannot rotate at startup 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 37).
Install with T/Z-installation
This installation is not applicable for these versions:
• .660
• .670
• .860
• .870
20 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 23
WS006272A
WS006273A
Installation
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, and a bell-mouth is connected to the inlet pipe. These
requirements and instructions are for Z-installations that comply to the dimensional
drawing.
Figure 7: Z-installation
Figure 6: T-installation
These items are required:
• Support stand and anchor bolts for anchoring the pump to a base
• Inlet elbow for connecting the suction line and discharge line
• Shut-off valves that allow you to remove the pump from service
• Air vent on the discharge side between the pump and the check valve
• Level regulators or other control equipment for start, stop, and alarm
NOTICE:
The risk of freezing is particularly high in T- or Z-installations.
1. Fasten the pump:
a) Use the anchor bolts to bolt the support stand to the concrete base.
b) Bolt the pump to the support stand and 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 37).
5. Make sure that the weight of the pump does not put strain on the piping.
Flygt 3202 Installation, Operation, and Maintenance Manual 21
Page 24
Installation
Make the electrical connections
General precautions
Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local codes
and regulations.
• 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.
• Leakage into the electrical parts can cause damaged equipment or a blown fuse.
Keep the end of the motor cable above the liquid level.
• Make sure that all unused conductors are insulated.
• 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.
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
Requirements
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
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 sheathing 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.
22 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 25
Earthing (Grounding)
SUBCAB 1000V
T
1
T
2
WS004299C
2
3
4
5
1
6
T
4
T
3
Screened SUBCAB
T
1
T
2
2
3
4
1
5
8
6
7
WS004298B
Installation
• 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).
• For SUBCAB™ cables, the twisted pair copper foil must be trimmed.
Electrical Hazard:
• You must earth (ground) all electrical equipment. This applies to the pump
equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to
verify that it is connected correctly.
• If the motor cable is jerked loose by mistake, the earth (ground) conductor should be
the last conductor to come loose from its terminal. Make sure that the earth (ground)
conductor is longer than the phase conductors. This applies to both ends of the motor
cable.
• Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault
protection device to the earthed (grounded) connectors if persons are likely to come
into physical contact with the pump or pumped liquids.
Prepare the SUBCAB™ cables
This section applies to SUBCAB cables with twisted-pair control cores.
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 jacket/sheath for control element
5. Power cores
6. Earth (ground) core
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.
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 jacket/sheath for control element
5. Power cores
6. Aluminum foil
7. Earth (ground) core with green/yellow shrink hose
8. Uncovered screen/braided wire
Flygt 3202 Installation, Operation, and Maintenance Manual 23
Page 26
WS004313B
Screened SUBCAB
T
1
T
2
T
3
T
4
Installation
Figure 8: 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 an insulating hose and insulating tape over the control element.
Make sure that the copper foil is covered.
3. Prepare the earth (ground) core for SUBCAB™ cable:
a) Peel the yellow-green insulation from the earth (ground) core.
b) Check that the earth (ground) core is at least 10% longer than the phase cores in
the cabinet.
4. Prepare the earth (ground) core for screened SUBCAB™ cable:
a) Untwist the screens around the power cores.
b) Put a yellow-green shrink hose over the earth (ground) core.
Leave a short piece uncovered.
c) Twist all power core screens together to create a earth (ground) core and
cable terminal to the end.
d) Check that the earth (ground) core is at least 10% longer than the phase cores in
the cabinet.
5. How is the connection to earth (ground) made?
• Screw: Fit cable terminals to the earth (ground) 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
Connect the motor cable to the pump
CAUTION:
Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep
the end of the motor cable above the liquid level.
24 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 27
1
2
WS006002B
Installation
1. Entrance cover
2. O-ring
For more information about the cable entry, see the Parts list.
1. Remove the entrance cover and the O-ring from the stator housing.
This provides access to the terminal board.
2. Check the data plate to see which connections are required for the power supply.
3. Arrange the connections on the terminal board in accordance with the required
power supply.
Links (jumper strips) are not used with the Y/D start.
4. Connect the mains leads (L1, L2, L3, and earth (ground)) according to applicable
cable chart.
The earth (ground) lead must be120 mm (4.8 in.) longer than the phase leads in the
junction box of the unit.
5. Make sure that the pump is correctly connected to earth (ground).
6. Connect the control leads to the applicable terminal board.
7. Make sure that any thermal contacts incorporated in the pump are properly
connected to the terminal board.
8. Install the entrance cover and the O-ring on the stator housing.
9. Fasten the screws on the entrance
flange so that the cable insertion assembly bottoms
out.
Connect the motor cable to the starter and monitoring equipment
If there are two power cables, then the cable that is connected to T1 and T2 is labeled. If a
separate control cable is used, then the control leads in the power cable are never
connected.
WARNING:
Do not install the starter equipment in an explosive zone or in the sump.
NOTICE:
• Either thermal contacts or thermistors are incorporated in the pump.
• Thermal contacts must never be exposed to voltages higher than 250 V, breaking
Flygt 3202 Installation, Operation, and Maintenance Manual 25
current maximum 4 A. It is recommended that they are connected to 24 V over
separate fuses to protect other automatic equipment.
Page 28
WS000509C
L2
L3L1
L1
L3L2
T1
T2
Installation
1. If thermal contacts are included in the pump installation, then connect the T1 and T2
control conductors to the MiniCAS II monitoring equipment.
NOTICE:
Ex-approved products must always have the thermal contacts connected irrespective
of the ambient temperature.
2. If thermistors are included in the pump installation, and screened or auxiliary cable is
used, then connect T1(1) and T2(2) to the thermistor relay or MAS 711, and T3(3) and
T4 (4) to MiniCAS II or MAS 711.
3. If the pump is prepared for MAS, then the separate sensor connection unit in the
pump is connected via SUBCAB 12×1.5 according to Connection to the monitoring
equipment (page 37).
4. 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 26).
5. 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.
Replace any defective equipment.
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.
Figure 9: Phase sequence
Connection locations
The figures in this section illustrate how to interpret the connection strip symbols.
26 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 29
1
2
3
4
L1 L2 L3
T3 T4T1 T2
U1
V1
W1
U2
W2
V2
U1
V1
W1
W2
U2
V2
U1
V1
W1
GC
W2
U2
V2
L1
L2
L3
*YE
GN/YE
WH
L1
U1
U2
W2
V2
W1
V1
L3
L2
WS004133D
L1 L2 L3
T3 T4T1 T2
43
21
5
10
8
CLS
6
FLS
7
FLS 10
11
9
WS004134A
Installation
1. Stator leads
2. Terminal board
3. Motor cable leads
4. Stator (internal connection illustrated)
1. Starter equipment and mains leads (L1, L2, L3)
2. Earth (ground)
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
Flygt 3202 Installation, Operation, and Maintenance Manual 27
Page 30
6 LEADS
Terminal clamps 6 stator leads
Motor Connection
Colors and marking of the main leads
773 29 00
One cable
COLOR STANDARD
STATOR LEADS
BN = Brown
U1,U5 = RD
BK = Black
U2 = GN
WH = White
V1,V5 = BN
OG = Orange
V2 = BU
GN = Green
W1,W5 = YE
GN/YE = Green-Yellow
W2 = BK
RD = Red
T1,T2 = WH or YE
GY = Grey
BU = Blue
YE = Yellow
*SUBCAB AWG
* * Ground conductor is stranded around core
GC=Ground check
U1
W2
V1
U2
W1
V2
Mains
SUBCAB 7GX
SUBCAB 4GX
3
Screenflex 7GX
Screenflex 4GX
SUBCAB AWG
SUBCAB
Screened
L1
BK 1
BN
RD
BN
L2
BK 2
BK
BK
BK
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)
GC
-
-
YE
-
L1
U1
RD
U1
W2
L3
W2
BK
V1
BN
V1
GN
U2
L2
U2
W1
YE
W1
V2
BU
V2
WS004551C
Motor Connection
Colors and marking of the main leads
773 29 00
( 5)
REV
COLOR STANDARD
STATOR LEADS
BN = Brown
U1,U5 = RD
BK = Black
U2 = GN
WH = White
V1,V5 = BN
OG = Orange
V2 = BU
GN = Green
W1,W5 = YE
GN/YE = Green-Yellow
W2 = BK
RD = Red
T1,T2 = WH or YE
GY = Grey
BU = Blue
YE = Yellow
*SUBCAB AWG
* * Ground conductor is stranded around core
GC=Ground check
Mains
SUBCAB 7GX
SUBCAB 4GX
3
Screenflex 7GX
Screenflex 4GX
SUBCAB AWG
SUBCAB
Screened
L1
BK 1
BN
RD
BN
L2
BK 2
BK
BK
BK
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)
GC
-
-
YE
-
( 5)
REV
Installation
Colors and markings of leads
Color code standard
Code Description
BN Brown
BK Black
WH White
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow
28 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 31
Motor connection
WS003903A
Terminal clamps 6 stator leads
U1
W2
V1
U2
W1
V2
WS003803B
Y
One cable
Two cables
L1
U1
U2
W2
V2
W1
V1
L2
L3
L1
RD
U1
1
L1
U1
L3
2
V1
L3
V1
BN
1
L2
2
W1
YE
W1
1
L2
2
GN
U2
W2
BK
BU
V2
GN/YE
*YE
GC
WH
L1
U1
RD
U1
BK
W2
L3
W2
V1
V1
BN
GN
U2
L2
U2
W1
W1
YE
BU
V2
V2
Figure 10: Terminal clamps, 6 stator leads
Connections included
• 6–leads connection (page 29)
• 9-leads connection (page 31)
• Screened cable connection (page 31)
Installation
6–leads connection
One cable (left) and two cables (right) Y-connection.
Figure 11: Y-connection
Flygt 3202 Installation, Operation, and Maintenance Manual 29
Page 32
WS003804B
D
One cable
Two cables
L1
U1
V2
U2
V1
W1
W2
L2
L3
L1
U1
RD
U1
W2
L3
W2
BK
V1
V1
BN
GN
U2
L2
U2
W1
YE
W1
V2
BU
V2
L1
1
L1
U1
RD
U1
BK
W2
L3
2
W2
V1
BN
V1
1
L3
GN
U2
L2
2
U2
W1
YE
W1
1
L2
2
V2
BU
V2
GN/YE
*YE
GC
WH
WS003805B
Y/D
One cable
Two cables
L1:1
L3:1
L2:1
L1:2
L3:2
L2:2
U1
V1
W1
U2
V2
W2
1
L1
RD
U1
2
4
L1
U1
W2
BK
W2
2
3
L3
BN
1
V1
V1
6
L3
GN
U2
2
U2
2
L2
YE
W1
1
5
W1
L2
BU
V2
2
V2
1
L1
1
4
L1
U1
U1
RD
BK
W2
2
W2
3
L3
V1
BN
V1
1
6
L3
GN
U2
2
L2
U2
2
W1
YE
W1
1
5
L2
2
V2
BU
V2
GN/YE
*YE
GC
WH
WS003813A
Y
D
Only applicable to 70mm2 terminal clamp
L1
1
U1
RD
U1
L3
V1
BN
V1
1
L2
YE
W1
1
W1
GN
U2
BU
V2
BK
L1
U1
1
U1
RD
BK
W2
L3
W2
BN
V1
1
V1
U2
U2
GN
L2
W1
YE
W1
1
BU
V2
V2
GN/YE
*YE
GC
WH
Installation
One cable (left) and two cables (right) D-connection.
Figure 12: D-connection
One cable (left) and two cables (right)Y/ D-connection.
Figure 13: Y/D-connection
Y and D-connection, only applicable to 70 mm2 terminal clamp.
Figure 14: Y or D-connection
30 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 33
9-leads connection
WS003826B
One cable
Two cables
Y-
L1
U1
U5
U2
W2
W1
V5
V2
L2
W5
V1
L3
L1
U1
RD
U1
RD
U5
L3
U5
BN
V1
V1
BN
V5
L2
V5
YE
W1
W1
W5
W5
YE
GN
U2
BU
V2
BK
W2
L1
RD
U1
1
L1
U1
RD
U5
L3
2
U5
BN
V1
1
L3
V1
BN
V5
L2
2
V5
YE
W1
1
L2
W1
YE
W5
2
W5
GN
U2
BU
V2
BK
W2
GN/YE
*YE
GC
WH
WS003837B
Y-SER
One cable
Two cables
L1
U1
U2
U5
W2
W5
W1
V5
V2
V1
L2
L3
L1
RD
U1
U1
RD
U5
L3
U5
GN
U2
V1
BN
V1
L2
V5
BN
V5
W1
BU
V2
W5
YE
W1
YE
W5
BK
W2
L1
RD
U1
1
U1
L1
L3
2
BN
V1
1
L3
V1
L2
2
YE
W1
1
L2
W1
2
GN
U2
RD
U5
BU
V2
BN
V5
BK
W2
YE
W5
GN/YE
*YE
GC
WH
WS003815B
Screened SUBCAB & FGB Screened
Cable without sep. ground conductor
Screen as ground conductor
GN/YE shrink hose
BN
BK
GY
L1
L2
L3
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)
One cable (left) and two cables (right) Y-parallel connection.
Figure 15: Y-parallel connection
One cable (left) and two cables (right) Y-serial connection.
Installation
Figure 16: Y-serial connection
Screened cable connection
Cable without separate ground conductor. Screen as ground conductor.
Flygt 3202 Installation, Operation, and Maintenance Manual 31
Figure 17: Screened SUBCAB and FGB Screened
Page 34
WS003824B
Screenflex and SUBCAB with functional ground
* For screened SUBCAB T3 & T4 shall also be twisted separately
T1 and T2
White insulation hose
twisted*
Screen
GN/YE
L1
L2
L3
T1
T2
BN
BK
GY
T1 and T2
White insulation hose
twisted*
Screen
BK
BK
BK
BK
BK
BK
GN/YE
1
2
3
4
5
6
T1
T2
WS003843B
Color and marking of control leads
SUBCAB 4GX/7G and
SUBCAB
Control
Screenflex
SUBCAB AWG
Screened
T1
WH T1
OG
WH T1
T2
WH T2
BU
WH T2
T3
-
-
WH T3
T4
-
-
WH T4
WS003850B
Sensor terminal clamps
T15
T16
T1
T2
Installation
* For screened SUBCAB T3 and T4 shall also be twisted separately.
Figure 18: Screenflex and SUBCAB with functional ground
Sensor-connection
Connection to the pump
Figure 19: Color and marking of control leads
Figure 20: Sensor terminal clamps
32 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 35
FLS 10 and Thermal detectors
WS003855B
FLS + Thermal detectors
FLS
TC
Max 12 V
WH/YE
T1
Control leads
+7
T1/*OG/1
Mini
BN
T2
CAS
WH/YE
T2/*BU/2
-5
BN
T15
**T3
**T4
*SUBCAB AWG
*Screened SUBCAB
WS003876B
FLS + Thermistor
T1
Control leads
Max
RD
T1/1
Thermistor
2.5 V
RD
T2
T2/2
relay
T15
Max
FLS
BN/BU
T3/3
+7
Mini
12 V
BN/BU
T16
T4/4
CAS
-5
WS003869B
Thermal detectors FLS Disconnected
FLS
TC
Max 12 V
WH/YE
T1
Control leads
+7
T1/*OG/1
Mini
BN
T2
CAS
T2/*BU/2
-5
WH/YE
T15
BN
**T3
**T4
*SUBCAB AWG
*Screened SUBCAB
∞ Ohm Overtemperature
1200 Ohm OK
430 Ohm Leakage
FLS 10 and Thermistor
Installation
T=25°C (77°F)
T=135°C (275°F) (T
T=145°C (293°F) (T
Thermal detectors, FLS disconnected
MAS 711
Flygt 3202 Installation, Operation, and Maintenance Manual 33
The following sensors can be used together with MAS 711:
REF
REF
R ≤ 100 Ohm
–5°C (23°F)) R ≤ 550 Ohm
+5°C (41°F)) R ≤ 1330 Ohm
Page 36
Installation
• FLS 10/FLS
• Pump memory
• PT 100
• Thermal contacts
• VIS 10
Sensor type Description Measured value Fault values
Thermal contact The thermal contact is a
normally closed contact.
0-3 ohm, unless the wires are
very long.
An infinite value (open circuit)
indicates either high
temperature or a fault (a wire is
broken or there is a bad contact
in a connector).
Thermistor The thermistor is a
semiconductor device.
Resistance at normal
temperature:
• 50-100 ohm (150-300
ohm for three in a series).
• Above the tripping point,
T
, the resistance
Ref
increases dramatically to
several Kohm.
• An infinite value (open
circuit) indicates a fault (a
wire is broken or there is a
bad contact in a
connector).
• A value close to zero
indicates a short circuit in
the wiring.
Pt 100 sensor The Pt 100 sensor is a resistor
changing value almost linearly
with temperature.
Resistance:
• 100 ohm at 0ºC (32ºF)
• 107.79 ohm at room
temperature (20ºC, 68ºF)
• 138.5 ohm at 100ºC
(212ºF)
The resistance increases with
0.385 ohm for each degree
• An infinite value (open
circuit) indicates a fault (a
wire is broken or there is a
bad contact in a
connector).
• A value close to zero
indicates a short circuit in
the wiring.
centigrade.
Float switch (FLS) The float switches are leakage
sensors located in the
inspection chamber and in the
junction box.
VIS 10 The vibration sensor located in
the junction box measures
vibrations in one direction. The
output is a 4-20 mA signal
proportional to the vibration
level.
NOTICE:
Never connect the Pt 100
transducer to a voltage higher
than 2.5 V.
Resistance. 2 sensor variants:
FLS:
• Normal: 1530 ohm
• Alarm: 330 ohm
FLS-10:
• Normal: 1200 ohm
• Alarm: 430 ohm
Current, 4-20 mA > 20 mA
34 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 37
WS003882B
Conn. for MAS 711, FLS option
Control leads
Connection leads
MAS
SUBCAB
FLS 10
BN 1
1
1
1
BN 2
2
17
2
2
16
RD 3
Main bearing
WH 3
3
3
3
8
PT 100
4
4
4
4
TC
YE 5
5
5
5
1
YE 6
6
6
6
2
FLS
BU 9
7
7
7
BU 2
8
15
8
8
3
RD 19
9
9
9
Stator winding
PT 100 (Phase 1)
WH 4
38
10
10
10
37
RS485 B GY 74
Pump memory
RS485 A YE 75
11
11
11
12
12
12
36
Ground BK 76
35
12V+ RD 77
Installation
Figure 21: Connection for MAS 711, FLS option
Sensor/Component Sensor cable,
no
FLS 10 — Leakage in inspection
chamber
Pt 100 — Temperature measurement,
main bearing
Thermal switches — Temperature guard
stator windings
1 17
2 16
3 8
4 4
5 1
6 2
FLS — Leakage in junction box 7 15
(2) (16)
Pt 100 — Temperature measurement,
stator winding ph 1
Pump memory:
RS–485 B 9 38
RS-485 A 10 37
Supply, ground 11 36
Supply, 12V+ 12 35
1
If the sensor cable contains a green-yellow lead, that lead should not be connected.
2
Communication port 37-38 for RS-485 is common to both pump memory and operator panel.
Flygt 3202 Installation, Operation, and Maintenance Manual 35
8 3
(4) (4)
(Screen) If applicable, attach screen to ground terminals in the
Base unit terminal block, no
• pump top, and
• electrical cabinet
Page 38
WS003892B
Conn. for MAS 711,VIS 10 option
Connection leads
Control leads
MAS
SUBCAB
FLS 10
BN 1
1
1
1
BN 2
2
17
2
2
16
RD 3
Main bearing
WH 3
3
3
3
8
PT 100
4
4
4
4
TC
YE 5
5
5
5
1
YE 6
6
6
6
2
BU 9
VIS 10
7
7
7
BN 2
8
15
8
8
3
RD 19
9
9
9
Stator winding
PT 100 (Phase 1)
WH 4
38
10
10
10
37
RS485 B GY 74
Pump memory
RS485 A YE 75
11
11
11
12
12
12
36
Ground BK 76
35
12V+ RD 77
Installation
Figure 22: Connection for MAS 711, VIS 10 option
Sensor/Component Sensor cable,
FLS 10 — Leakage in inspection
chamber
Pt 100 — Temperature measurement,
main bearing
Thermal switches — Temperature
guard stator windings
VIS 10 — Vibration sensor
4
3
no
1 17
2 16
3 8
4 4
5 1
6 2
7 18
Base unit terminal block, no
-2 -16
Pt 100 — Temperature measurement,
3
If the sensor cable contains a green-yellow lead, that lead should not be connected.
4
VIS 10 is not applicable to pump type 3153
5
Communication port 37-38 for RS-485 is common to both pump memory and operator panel.
36 Flygt 3202 Installation, Operation, and Maintenance Manual
stator winding ph 1
Pump memory:
RS–485 B 9 38
RS-485 A 10 37
Supply, ground 11 36
Supply, 12V + 12 35
8 3
-4 -4
(Screen) If applicable, attach screen to ground terminals in the
• pump top, and
• electrical cabinet
Page 39
WS001113A
2
1
1. Electric connection, sensor cables
24 V AC/DC
R
CC
P
C
L2
L1
102
6
7 +T1
T15
T2
FLS10
5 -
11
1
12 VDC
9
8
10S
4
3
WS002623B
2. Electric connection, 12-lead cable
Figure 23: Pin setting connector unit
Installation
Connection to the monitoring equipment
MiniCAS II
MAS 711
For information on how to connect to MAS 711, see MAS 711 Installation and Operation
manual.
Check the impeller rotation
WARNING:
Flygt 3202 Installation, Operation, and Maintenance Manual 37
The starting jerk can be powerful.
1. Start the motor.
2. Stop the motor after a few seconds.
3. Check that the impeller rotates according to this illustration.
Pump contactor
C
CC Control circuit
L1 Caution light (leakage)
L2 Caution light (stator over-temperature)
P Pump main supply
R Reset switch
Page 40
WS006253A
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, transpose two phase leads (3-phase) and
do this procedure again.
38 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 41
Operation
Precautions
WARNING:
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge line blocked, or the discharge valve
closed.
• Make sure you have a clear path of retreat.
• Never work alone.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
Distance to wet areas
Electrical Hazard:
• Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to the unit
when being in contact with the pumped or mixed liquid.
• Risk of electrical shock. This unit has not been investigated for use in swimming pools.
If used in connection with swimming pools special safety regulations apply.
Operation
Noise level
NOTICE:
The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may
be exceeded in some installations and at certain operating points on the performance
curve. Make sure that you understand the noise level requirements in the environment
where the pump is installed. Failure to do so may result in hearing loss or violation of local
laws.
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
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.
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).
first two months following
Flygt 3202 Installation, Operation, and Maintenance Manual 39
Page 42
Operation
4. Calculate future replacement intervals so that they occur when the selected fraction of
Start the pump
DANGER:
If you need to work on the pump, make sure that it is isolated from the power supply and
cannot be energized.
WARNING:
NOTICE:
Make sure that the rotation of the impeller is correct. For more information, see Check the
impeller rotation.
If multiple anodes were weighed, then use the anode which has lost the most weight
for this calculation.
zinc is remaining.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• In some installations, the pump and the surrounding liquid may be hot. Bear in mind
the risk of burn injuries.
• Make sure nobody is close to the unit when it is started. The unit will jerk in the
opposite direction of the impeller rotation.
1. Remove the fuses or open the circuit breaker, and check that the impeller can be
rotated freely.
2. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms.
3. Check that the monitoring equipment works.
4. Start the pump.
40 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 43
Maintenance
Precautions
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.
WARNING:
• Always follow safety guidelines when working on the product. See Introduction and
Safety (page 3).
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• Rinse the unit thoroughly with clean water before working on the unit.
• Rinse the components in water after dismantling.
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.
• 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.
Maintenance
Earth continuity verification
An 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.
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.
Screws and nuts
Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)
Property
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)
Flygt 3202 Installation, Operation, and Maintenance Manual 41
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
Page 44
1
2
2
1
2
2
WS001480A
Maintenance
Property
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
class
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.
Change the coolant
This image shows the plugs that are used to change the coolant.
Figure 24: With a cooling jacket
1. Inspection plug
2. Coolant plugs
Empty the coolant
WARNING:
The seal housing may be pressurized. Hold a rag over the inspection/ filling plugs to
prevent splatter.
42 Flygt 3202 Installation, Operation, and Maintenance Manual
1. Empty the coolant in the inspection chamber:
a) Remove the inspection plug.
Figure 25: Without a cooling jacket
Page 45
WS001505A
WS002122A
Figure 27: With a cooling jacket
WS001471A
WS001463A
Figure 26: Without a cooling jacket
b) Pump out any coolant from the inspection chamber, as shown here.
Maintenance
c) Replace the inspection plug and O-ring and tighten.
Tightening torque: 44 Nm (33 ft-lbs)
2. Empty the coolant:
a) Place the pump in a horizontal position, or leave it upright to use a pump to empty
the coolant.
b) If the pump is laid in a horizontal position, place a container under the pump.
c) Remove the coolant plugs and empty the coolant.
Flygt 3202 Installation, Operation, and Maintenance Manual 43
Page 46
WS001425A
WS001426A
Maintenance
Fill with coolant
Figure 28: With a cooling jacket
Figure 29: Without a cooling jacket
Use a coolant that is a mixture of 70% water and 30% monopropylene glycol. The coolant
should prevent corrosion and be nonpoisonous (generally recognized as safe by the FDA
as food additives under part 184 and 182).
NOTICE:
Clean water with an anti-corrosive is an acceptable coolant when there is no risk of
freezing.
1. Fill with coolant until it overflows through the opposite hole, as shown here.
Quantity: approximately
• 5.9 L (6.2 qt.) without cooling jacket
• 25 L (26.4 qt.) with cooling jacket, versions
3202.090/.095/.180./185/.350/.390/.660/.670
• 41 L (43.3 qt.) with cooling jacket, versions
3202.800/.810/.820/.830/.840/.850/.860/.870
44 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 47
Figure 30: With cooling jacket
WS001469A
2. Replace the O-rings.
3. Tighten the coolant plugs.
Tightening torque: 44 Nm (33 ft-lb)
Service the pump
Maintenance
Figure 31: Without cooling jacket
Inspection
Type of service Purpose Inspection interval
Initial
inspection
To make a check up of the pump condition by a Xylem
authorized service representative and, based on the result and
Within the first year of operation.
findings from these measures, to determine the intervals for
periodical inspection and major overhaul for the specific
installation.
Periodical
inspection
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
Up to 12,000 hours or 3 years,
whichever comes first.
Applies to normal applications and
operating conditions at media
(liquid) temperatures <40°C.
stator.
Major
overhaul
To secure a long operating lifetime for the product. It includes
replacement of key components and the measures taken
during an inspection.
Up to 24,000 hours or 6 years,
whichever comes first.
Applies to normal applications and
operating conditions at media
(liquid) temperatures <40°C.
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).
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.
Flygt 3202 Installation, Operation, and Maintenance Manual 45
2. Check that the cables do not have any sharp bends and are not
pinched.
2. Adjust the impeller, if necessary.
Page 48
Maintenance
Service item Action
Inspection chamber 1. Drain all liquid, if any.
2. Check the resistance of the leakage sensor.
If the pump is connected to the MAS 711 then it is recommended
that the sensors be checked in the MAS 711 unit. Otherwise, use a
multimeter.
For values, see Sensor-connection (page 32). Make sure to
select values for the appropriate monitoring equipment and sensor
combination.
Insulation Use a megger maximum 1000 V.
1. Check that the resistance between the earth (ground) and phase
lead is more than 5 megohms.
2. Conduct a phase-to-phase resistance check.
Junction box 1. Check that it is clean and dry.
2. Check the resistance of the leakage sensor.
If the pump is connected to the MAS 711 then it is recommended
that the sensors be checked in the MAS 711 unit. Otherwise, use a
multimeter.
Normal value approximately 1530 ohms, alarm approximately
330 ohms.
Level regulators Check the condition and functionality.
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
Check the correct settings.
protections
Personnel safety devices Check the guard rails, covers, and other protections.
Rotation direction Check the impeller rotation.
Seal housing 1. Fill with new coolant, if necessary.
2. Check that the freezing point is lower than -13°C (9°F).
Terminal board Check that the connections are properly tightened.
Temperature sensors:
• Thermal contact
• Thermistor
• Pt 100
If the pump is connected to the MAS 711 then it is recommended that the
sensors be checked in the MAS 711 unit. Otherwise, use a multimeter.
Do not use a device applying a higher voltage than 2.5 V.
1. Disconnect the sensor leads.
2. Measure the resistance to check the status of the sensor and leads
according to values in Sensor-connection (page 32). Make sure
to select values for the appropriate sensor, monitoring equipment
and sensor combination.
3. Measure between each sensor lead to earth (ground) to establish
that the resistance is infinite (or at least several Megaohm).
Voltage and amperage Check the running values.
Major overhaul
For a major overhaul, take this action in addition to the tasks listed under Inspection.
Service item Action
Support and main bearing Replace the bearings with new bearings.
46 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 49
Service item Action
Mechanical seal Replace with new seal units.
Service in case of alarm
For information about indication values for sensors, see Sensor-connection (page 32).
Alarm source Action
FLS10 1. Drain the fluid in the inspection chamber. Fill with new coolant if
The thermistor/Thermal contact 1. Check the coolant level (pump with cooling jacket).
The overload protection Check that the impeller can rotate freely.
Replace the impeller
Maintenance
necessary.
2. Check the freezing point (lower than -13°C or 9°F).
Check the inspection chamber again after one week of operation. If
leakage has occurred:
1. Drain the fluid.
2. Change the mechanical seal unit.
3. Replace with new coolant.
2. Check the start and stop levels.
Required tools:
• 17 mm hexagon bit adapter with an extension of at least a 100 mm (4 in.)
• Rod (wood or plastic) for locking the impeller in place.
WARNING:
• If you fail with the impeller installation, you must redo the installation procedure from
the beginning.
• A worn impeller and/or pump housing can have very sharp edges. Wear protective
gloves.
• 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.
Replace the impeller for wet installation
Remove the impeller: wet installation
CAUTION:
Wear heavy work gloves when you handle impellers. The sharp edges can cause physical
injury.
1. Place the pump in a horizontal position.
2. Remove the impeller:
a) Remove the flush valve cover and its O-ring.
b) Lock the impeller in place by inserting a rod through the hole.
c) Remove the impeller screw.
Flygt 3202 Installation, Operation, and Maintenance Manual 47
Page 50
WS001482A
WS001450A
WS001490A
Maintenance
d) Turn the adjustment screw counterclockwise until the impeller breaks free from
the shaft.
e) Hand-tighten the impeller screw to prevent it from falling off.
f) Remove the rod.
3. Raise the pump.
4. Remove the drive unit from the pump housing:
a) Remove the pump housing screws.
48 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 51
WS006264A
b) Remove the drive unit from the pump housing.
WS001477A
WS006263A
Maintenance
5. Remove the impeller:
a) Place the drive unit horizontally.
b) Remove the impeller screw.
c) Remove the impeller and the conical sleeve.
Flygt 3202 Installation, Operation, and Maintenance Manual 49
Page 52
WS001461B
WS006895A
Maintenance
Install the impeller: wet installation
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 an M12 lifting eyebolt into the shaft end and place the drive unit in a horizontal
position.
b) Lubricate the threads of the impeller screw and the washer.
Always use a new impeller screw.
c) Adjust the adjustment screw so that it is flush with the sleeve.
50 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 53
WS001759A
d) Fit the sleeve and impeller to the shaft.
WS006256A
e) Hand-tighten the impeller screw to prevent it from falling off.
Maintenance
3. Fit the pump housing:
a) Fit a new and lubricated O-ring on the seal housing cover.
b) Lubricate the pump housing screws.
c) Raise the drive unit.
d) Place the drive unit into the pump housing.
e) Adjust its position so that the inspection hole is on the same side as the flush
valve.
f) Tighten the screws in diagonal sequence.
For tightening torque, see Torque values (page 41).
Flygt 3202 Installation, Operation, and Maintenance Manual 51
Page 54
WS006260A
WS001482A
Maintenance
4. Remove the impeller screw:
a) Place the pump horizontally.
b) Lock the impeller in place by inserting a rod through the hole in the .
c) Remove the impeller screw and the washer.
5. Adjust the impeller:
a) Using a hexagon-bit adapter, turn the adjustment screw clockwise until the
impeller makes contact with the pump housing.
For tightening torque, see Torque values (page 41).
b) Tighten it a further 1/8 turn (45°).
52 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 55
WS001451A
6. Fasten the impeller:
WS001486A
a) Fit the lubricated washer and impeller screw.
b) Tighten the impeller screw.
For tightening torque, see Torque values (page 41).
c) Tighten it a further 1/8 turn (45°).
Maintenance
d) Remove the rod that is used to lock the impeller.
e) Fit the O-ring and flush valve cover and fasten it with screws.
For tightening torque, see Torque values (page 41).
f) Check that the impeller can rotate freely.
7. Check that the clearance between the impeller and the insert ring is 0.1–0.5 mm
(0.004–0.02 in).
Flygt 3202 Installation, Operation, and Maintenance Manual 53
Page 56
WS003730A
WS003731A
WS001539A
Maintenance
Replace the impeller for dry installation
Remove the impeller: dry installation
1. Remove the drive unit from the pump housing:
a) Remove the pump housing screws.
b) Remove the drive unit from the pump housing.
54 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 57
WS001477A
2. Remove the impeller:
WS001494A
WS001461B
a) Place the drive unit horizontally.
b) Lock the impeller as shown in the figure.
c) Remove the impeller screw.
Maintenance
d) Turn the adjustment screw counterclockwise until the impeller breaks free from
the shaft.
e) Remove the impeller and the conical sleeve.
Flygt 3202 Installation, Operation, and Maintenance Manual 55
Page 58
WS006895A
WS002106A
Maintenance
Install the impeller: dry installation
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) Lubricate the threads of the impeller screw and the washer.
Always use a new impeller screw.
b) Unscrew the adjustment screw approximately 5 mm (0.2 in.).
c) Measure and note the distance A.
56 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 59
A
WS001472A
WS006256A
WS001492A
Maintenance
d) Fit the sleeve and the impeller to the shaft.
e) Fit the impeller screw and washer and tighten.
3. Make sure that the O-ring is removed from the seal housing cover.
Flygt 3202 Installation, Operation, and Maintenance Manual 57
Page 60
WS002008A
WS001475A
WS002089A
Maintenance
4. Measure the trim distance:
a) Place the drive unit in the pump housing.
Make sure that the drive unit is parallel with the pump housing by hand-tightening
the pump housing screws.
b) Check the distance between the seal housing cover and the pump housing with a
feeler gauge.
Check diagonally at four points.
c) Note the largest distance B.
58 Flygt 3202 Installation, Operation, and Maintenance Manual
Page 61
B
WS001473A
WS001477A
Maintenance
d) Lift the drive unit out of the pump housing and remove the impeller and conical
sleeve.
5. Trim to the correct distance:
a) Calculate the measure C according to the formula shown in the image.
Flygt 3202 Installation, Operation, and Maintenance Manual 59
Page 62
C=A-B-0.5 mm
WS001475A
WS001492A
Maintenance
b) Turn the adjustment screw until C is reached.
6. Fasten the impeller:
a) Fit the sleeve, impeller, lubricated washer with a lubricated impeller screw.
b) Tighten the impeller screw.
For tightening torque, see Torque values (page 41).
c) Tighten it further 1/8 turn (45°).
7. Install the drive unit in the pump housing:
a) Fit a new and lubricated O-ring to the seal housing cover.
60 Flygt 3202 Installation, Operation, and Maintenance Manual
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WS002056A
b) Place the drive unit in the pump housing.
WS001475A
Maintenance
c) Adjust the position of the drive unit so that the inspection hole is on the same side
as the flush valve.
d) Tighten the lubricated screws diagonally.
For tightening torque, see Torque values (page 41).
Flygt 3202 Installation, Operation, and Maintenance Manual 61
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WS001478A
Maintenance
If you need to adjust the impeller, redo the replace the impeller procedure from the
beginning.
62 Flygt 3202 Installation, Operation, and Maintenance Manual
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Troubleshooting
Introduction
DANGER:
Personal injury hazard. Troubleshooting a live control panel exposes personnel to
hazardous voltages. Electrical troubleshooting must be done by a qualified electrician.
Failure to follow these instructions will result in serious personal injury, death, and/or
property damage.
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 pump when the power supply is reconnected.
• When troubleshooting electrical equipment, use the following:
• Universal instrument multimeter
• Test lamp (continuity tester)
• Wiring diagram
Troubleshooting
The pump does not start
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
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 3202 Installation, Operation, and Maintenance Manual 63
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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 11).
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.
The pump does not stop when a level sensor is used
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
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 11).
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.
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.
The self-holding function of the
contactor malfunctions.
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.
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.
64 Flygt 3202 Installation, Operation, and Maintenance Manual
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Always state the serial number of your product, see Product Description (page 11).
The pump runs but the motor protection trips
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
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, 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 megohms.
2. If the insulation is less:
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.
Troubleshooting
Always state the serial number of your product, see Product Description (page 11).
The pump delivers too little or no water
WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.
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.
Flygt 3202 Installation, Operation, and Maintenance Manual 65
• If it is a 3-phase pump, transpose two phase leads.
• If it is a 1-phase pump:
Contact the local sales and service representative.
Page 68
Troubleshooting
Cause Remedy
One or more of the valves are set in
the wrong positions.
• 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.
The impeller is difficult to rotate by
hand.
• Clean the impeller.
• Clean out the sump.
• Check that the impeller is properly trimmed.
The pipes are obstructed. Clean out the pipes to ensure a free flow.
The pipes and joints leak. Find the leaks and seal them.
There are signs of wear on the
Replace the worn parts.
impeller, pump, and casing.
The liquid level is too low. • Check that the level sensor is set correctly.
• 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 11).
66 Flygt 3202 Installation, Operation, and Maintenance Manual
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Technical Reference
Application limits
Data Description
Liquid temperature 40°C (104°F) maximum
For P- and S-installations without cooling jacket, the pump can be operated only when
the sump level is at least 10 mm above the stator housing.
Warm-liquid version (only with cooling jacket): 70°C (158°F) maximum
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.
Technical Reference
Motor data
Feature Description
Motor type Squirrel-cage induction motor
Frequency 50 or 60 Hz
Supply 3-phase
Starting method • Direct on-line
• Star-delta
• Soft starter
Maximum starts per hour 30 evenly spaced starts per hour
Code compliance IEC 60034-1
Rated output variation ±10%
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
2%
Flygt 3202 Installation, Operation, and Maintenance Manual 67
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Page 71
Page 72
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