FLYGT P7030, P7035, P7040 Installation, Operation And Maintenance Manual

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Page 1

Installation, Operation

and Maintenance

Manual

Flygt P7030, P7035, P7040

Page 2

Page 3

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

Introduction..........................................................................................................................................3

Safety.....................................................................................................................................................3

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

Environmental safety........................................................................................................................4

User safety.........................................................................................................................................5

Product warranty...............................................................................................................................6

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

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

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

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

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

Precautions........................................................................................................................................7

Position and fastening......................................................................................................................7

Lifting..................................................................................................................................................7

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

Handling at freezing temperature..................................................................................................8

Unit in as-delivered condition.........................................................................................................8

Lifting the unit out of liquid.............................................................................................................8

Storage guidelines..............................................................................................................................9

Storage location................................................................................................................................9

Long-term storage............................................................................................................................9

Table of Contents

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

Pump Design.....................................................................................................................................10

Intended Use...................................................................................................................................10

Parts....................................................................................................................................................11

The monitoring equipment..............................................................................................................12

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

Approvals...........................................................................................................................................13

Product approvals for hazardous locations.................................................................................13

EN approval plate...........................................................................................................................13

IEC approval plate..........................................................................................................................14

FM approval plate..........................................................................................................................14

Product denomination......................................................................................................................14

Installation.............................................................................................................................................16

Fasteners............................................................................................................................................16

Requirements for the cable handling system................................................................................16

Install the pump.................................................................................................................................16

Make the electrical connections......................................................................................................20

General precautions.......................................................................................................................20

Requirements..................................................................................................................................20

Cables..............................................................................................................................................20

Earthing (Grounding).....................................................................................................................21

Cable entry parts............................................................................................................................21

Connect the motor cable to the pump........................................................................................21

Connect the motor cable to the starter and monitoring equipment.......................................22

Power cable phase sequence.......................................................................................................23

Cable charts....................................................................................................................................23

Cable bending radius, weight and diameter..............................................................................30

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 1

Page 4

Table of Contents

Check the impeller rotation.............................................................................................................32

Operation..............................................................................................................................................33

Precautions.........................................................................................................................................33

Distance to wet areas........................................................................................................................33

Noise level..........................................................................................................................................33

Start the pump...................................................................................................................................33

Maintenance.........................................................................................................................................35

Precautions.........................................................................................................................................35

Torque values....................................................................................................................................35

Changing the coolant.......................................................................................................................36

Empty the coolant..........................................................................................................................36

Fill with coolant...............................................................................................................................37

Preparing for work on the hydraulic end.......................................................................................38

Remove the entrance cover..........................................................................................................38

Attach the assembly and dismantling stand...............................................................................39

Replacing the propeller....................................................................................................................40

Measure the clearance...................................................................................................................41

Remove the propeller....................................................................................................................42

Install the propeller........................................................................................................................43

Replace the bell mouth....................................................................................................................45

Replace the zinc anodes...................................................................................................................46

Service the pump..............................................................................................................................47

Inspection........................................................................................................................................47

Major overhaul................................................................................................................................49

Service in case of alarm.................................................................................................................49

Troubleshooting...................................................................................................................................50

Introduction.......................................................................................................................................50

The pump does not start..................................................................................................................50

The pump does not stop when a level sensor is used.................................................................51

The pump starts-stops-starts in rapid sequence...........................................................................51

The pump runs but the motor protection trips.............................................................................52

The pump delivers too little or no water........................................................................................52

Technical Reference............................................................................................................................54

Product overview...............................................................................................................................54

Materials.............................................................................................................................................54

Mounting-related data......................................................................................................................55

Operational data...............................................................................................................................56

Application limits............................................................................................................................56

Motor Data......................................................................................................................................56

The monitoring equipment...........................................................................................................56

P7030 Motor rating and performance, 50 Hz...................................................................................57

Low voltage........................................................................................................................................57

P7030 Motor rating and performance, 60 Hz...................................................................................58

Low voltage........................................................................................................................................58

2 Flygt P7030, P7035, P7040 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 an Xylem representative before proceeding.

• This manual clearly identiﬁes accepted methods for disassembling units. These methods must be adhered to. Trapped liquid can rapidly expand and result in a violent explosion and injury. Never apply heat to impellers, propellers, or their retaining devices to aid in their removal.

• 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

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Introduction and Safety

Hazard levels

Hazard level Indication

Hazard categories

DANGER:

WARNING:

CAUTION:

NOTICE:

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:

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

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

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

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 to avoid and/or discover emissions.

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.

4 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 7

Electrical installation

Recycling guidelines

User safety

General safety rules

Introduction and Safety

WARNING:

Do NOT send the product to the Xylem manufacturer if it has been contaminated by any nuclear radiation. Inform Xylem so that accurate actions can take place.

For electrical installation recycling requirements, consult your local electric utility.

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 Xylem

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.

Safety equipment

Use safety equipment according to the company regulations. Use this safety equipment within the work area:

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:

• Hard hat

• Safety goggles, preferably with side shields

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

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.

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Introduction and Safety

Wash the skin and eyes

Follow these procedures for chemicals or hazardous ﬂuids that have come into contact with your eyes or your skin:

Condition Action

Product warranty

Coverage

Limitations

Chemicals or hazardous ﬂuids in eyes

Chemicals or hazardous ﬂuids on skin

Xylem undertakes to remedy defects in products from Xylem under these conditions:

• The faults are due to defects in design, materials, or workmanship.

• The faults are reported to an Xylem representative within the warranty period.

• The product is used only under the conditions described in this manual.

• The monitoring equipment incorporated in the product is correctly connected and in use.

• All service and repair work is done by Xylem-authorized personnel.

• Genuine Xylem parts are used.

• Only Ex-approved spare parts and accessories authorized by Xylem are used in Exapproved products.

The warranty does not cover defects caused by these situations:

• Deﬁcient maintenance

• Improper installation

• Modiﬁcations or changes to the product and installation made without consulting

Xylem

• Incorrectly executed repair work

• Normal wear and tear

Xylem assumes no liability for these situations:

• Bodily injuries

• Material damages

• Economic losses

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.

1. Remove contaminated clothing.

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

3. Seek medical attention, if necessary.

Warranty claim

Xylem products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your Xylem representative.

Spare parts

Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued.

6 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 9

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 your sales representative if anything is out of order.

Transportation and Storage

Transportation guidelines

Precautions

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. The unit and the components can be heavy. Use proper lifting methods

and wear steel-toed shoes at all times.

• Lift and handle the product carefully, using suitable lifting equipment.

• The product must be securely harnessed for lifting and handling. Use eyebolts or lifting

lugs if available.

• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the

hose.

• Do not attach sling ropes to shaft ends.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 7

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Transportation and Storage

Lifting equipment

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

• The minimum height (contact Xylem for information) between the lifting hook and the

• The lifting equipment must be able to hoist the unit straight up and down, preferably

• 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

• 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

• The lifting equipment must not be oversized.

ﬂoor must be sufﬁcient to lift the unit.

without the need for resetting the lifting hook.

used by authorized personnel.

media in it.

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 ﬂame to thaw the unit.

Unit in as-delivered condition

If the unit is still in the condition in which it left the factory - all packing materials are undisturbed - then the acceptable temperature range during transportation, handling and storage is: –50°C (–58ºF) to +60°C (+140ºF).

If the unit has been exposed to freezing temperatures, then allow it to reach the ambient temperature of the sump before operating.

Lifting the unit out of liquid

The unit is normally protected from freezing while operating or immersed in liquid, but the impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding temperature below freezing.

Units equipped with an internal cooling system are ﬁlled with a mixture of water and 30% glycol. This mixture remains a ﬂowing liquid at temperatures down to –13°C (9°F). Below – 13°C (9°F), the viscosity increases such that the glycol mixture will lose its ﬂow properties. However, the glycol-water mixture will not solidify completely and thus cannot harm the product.

Follow these guidelines to avoid freezing damage:

8 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 11

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.

Storage guidelines

Storage location

The product must be stored in a covered and dry location free from heat, dirt, and vibrations.

NOTICE:

• Protect the product against humidity, heat sources, and mechanical damage.

• Do not place heavy weights on the packed product.

Long-term storage

If the unit is stored more than 6 months, 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.

Transportation and Storage

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 9

Page 12

Product Description

Pump Design

Intended Use

The product is intended for moving wastewater, sludge, raw and clean water. Always follow the limits that are given in Application limits (page 56). If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.

WARNING:

In explosive or ﬂammable environments, only use Ex- or MSHA-approved pumps.

NOTICE:

Do NOT use the pump in highly corrosive liquids.

10 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 13

Parts

WS003673A

Product Description

Figure 1: Section view, top view and exploded view of hydraulic parts.

Position Part Description 1 Terminal board 2 Support bearing Two-row ball bearing 3 Shaft Stainless steel, with an integrated rotor 4 Rotor 5 Main bearings Two-row angular contact ball bearing in O-arrangement 6 Seal housing Contains inner and outer mechanical seals. Includes a coolant that lubricates

and cools the seals; the housing acts as a buffer between the pumped ﬂuid and the electric motor

7 Propeller 8 Seal ring 9 Bell mouth With integrated relief groove

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 11

Page 14

1312 14

17 18 1916159 10 11

Product Description

Position Part Description 10 Pump housing 11 Stator Equipped with temperature sensors in windings 12 Electrical lead-through

unit 13 Cable entry 14 Lifting handle 15 Guide vanes

Spare part requirements

The following applies when servicing or repairing the pump:

• Modiﬁcations to the unit or installation should only be carried out after consulting with

Xylem.

• Original spare parts and accessories 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.

The monitoring equipment

MiniCAS II

The table below shows the parameters which can be tracked with the MiniCAS II monitoring system.

Parameter Sensor Standard or optional Stator winding temperature One of the following choices:

Standard

• 3 thermal switches (standard), or

• 3 PTC-thermistors (optional)

Leakage in the inspection chamber Float Switch Leakage Sensor (FLS) Standard Leakage in the junction box Float Switch Leakage Sensor (FLS) Optional

The data plate

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

12 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

1. Curve code/Propeller code

2. Serial number, see Product denomination (page 14)

3. Product number

4. Country of origin

Page 15

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 2: The data plate

Approvals

Product approvals for hazardous locations

Pump Approval

Product Description

EN approval plate

7030.090 European Norm (EN)

• ATEX Directive

• EN 60079-0, EN 60079-1, EN 1127-1

• II 2 G Ex d IIB T3

IEC

• IECEx scheme

• IEC 60079–0, IEC 60079–1

• Ex d IIB T3

EN approval for cable entry:

• Certiﬁcate number: INERIS 02ATEX9008 U

• II 2 G Ex d IIC or I M2 Ex d I

Factory Mutural (FM)

• 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

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

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 13

Page 16

1 2 3

6 7

9 10

WS003972A

WS001279B

876

5 9

WS003973A

Product Description

IEC approval plate

1. Approval

2. Approval authority + approval number

3. Approval for Class I

4. Approved drive unit

5. Stall time

6. Starting current/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 contained in its ﬁelds.

International Norm; not for EU member countries.

1. Approval

2. Approval authority + approval number

3. Approved for drive unit

4. Stall time

5. Starting current/Rated current

6. Duty class

7. Duty factor

8. Input power

9. Rated speed

10. Controller

11. Additional information

12. Max. ambient temperature

13. Serial number

FM approval plate

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

1. Temperature class

2. Maximum ambient temperature

Product denomination

14 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 17

Sales denomination

NP 3085

2 3

3085.183

1 2

NP 3085.183 - 951 0163

2 3 4

Product code

Serial number

Product Description

The sales denomination consists of the four-digit sales code and two letters that indicate the hydraulic end and type of installation.

This is an example of a sales denomination, and an explanation of its parts.

1. Hydraulic part

2. Installation type

3. Sales code

The product code consists of nine characters divided into two parts. This is an example of a product code, and an explanation of its parts.

1. Sales denomination

2. Version

The serial number is used for identiﬁcation of an individual product, and is divided into four parts.

This is an example of a serial number, and an explanation of its parts.

1. Product code

2. Production year

3. Production cycle

4. Running number

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 15

Page 18

Installation

Fasteners

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.

Requirements for the cable handling system

When the pump is installed in a discharge tube, it is critically important that a proper cable support and protection system is used, especially with long power cables and closed discharge tubes.

Checklist

This table shows the requirements to be fulﬁlled by the cable handling system.

Requirement Check Cables must be supported in such a way, so that they do not come in contact with any hard

surface which could abrade the cable sheathing. Examples of surfaces include pump and tube components, lifting cables or wires and any other hardware.

Cables should be bundled together, using components that will not cut or abrade the cables. Proper strain relief and support at prescribed intervals should be provided. Spring-controlled tensioning and an integrated guide wire system is recommended for long

cables, to protect the cable from movement which can cause damage.

Install the pump

Consult the nearest Xylem representative regarding the following topics:

• Sizing of the pump, piping station, and access frame

• Choice of auxiliary equipment

• Other aspects of installation

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.

• Check the explosion risk before welding or using electric hand tools.

• Provide a suitable barrier around the work area, e.g. a guard rail.

• Before installing the pump, check that the cable and cable entry have not been damaged during transportation.

• A certiﬁed electrician must supervise all electrical work. Comply with all local codes and

regulations.

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

NOTICE:

• Do not run the pump dry.

• Never force piping to make a connection with a pump.

16 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 19

WS001675A

Installation

The pump is usually installed in a vertical discharge tube on a pump seat, which is incorporated in the lower end of the tube. No anchoring is required because the weight of the pump is sufﬁcient to keep it in place. The pumps are equipped with anti-rotation devices.

Figure 3: Pump in discharge tube (generic propeller pump shown)

When the pump is installed in a discharge tube, the following must be considered:

• A suitable cable support and protection system must be used.

Before installation, check the following:

• The propeller must rotate in the correct direction.

If the rotation is not in the correct direction, then the pump may lift and start rotating inside the tube. This can seriously damage the equipment.

• The rubber seal ring underneath the pump is in place.

• There is no damage to, or debris on, the pump seat.

• There is no large construction debris under the pump tube (at the pump intake). If

debris is present then there is a risk that it can get sucked into the pump and cause propeller damage.

• The pump control is set to turn the pump off at or above the minimum operating water

level for this pump installation.

1. After cable preparation, lower the pump into the pump column.

Make sure that the pump does not tilt on the stop vanes, which are at the bottom of the column.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 17

Page 20

WS001677A

WS001678A

WS003676A

Installation

Correct Incorrect

1 Discharge column

2 Antirotation gusset (stop vanes)

3 Pump seat

2. Lower the pump to its bottom position, at the same time carefully moving it back and

forth between the nearest anti-rotation gusset.

Figure 4: Lowering pump while moving between anti-rotation gussets (generic propeller pump shown)

3. Lift the pump slightly again, approximately 2-3 cm (1 in.), and turn it counterclockwise

until the anti-rotation device on the hydraulic end lands against the nearest adjacent vanes.

18 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 21

2–3 cm (0.8–1.2 in.)

WS003677A

Figure 5: Turning pump until anti-rotation device is in place (generic propeller pump shown)

WS001680A

4. Lower the pump to its ﬁnal bottom position.

No additional anchoring of the pump is required. Maximum permissible submersion depth is 20 m (65 ft).

Installation

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 19

Figure 6: Lowering pump to ﬁnal bottom position (generic propeller pump shown)

5. If the recommended cable handling system is used, then follow the instructions for

ﬁnishing the cable connection. See the document "Mounting Instructions, Flygt Cable Handling System."

6. If the recommended cable handling system is not used, then fasten the power cables

on the cable holder, and run them to the electric junction box.

Make sure that the cables have no sharp bends, are not pinched, and do not disturb the water ﬂow.

Page 22

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

Cables

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.

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 minimum bending radius must not be below the accepted value.

• 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.

20 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 23

Earthing (Grounding)

WS003675A

Cable entry parts

Installation

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.

Position Part 1 Entrance cover 2 O-ring 3 O-ring 4 Washer 5 Seal sleeve 6 Spacer ring 7 Entrance ﬂange 8 Cable

Connect the motor cable to the pump

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 21

Page 24

Installation

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.

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 the applicable

cable chart. The earth (ground) lead must be 120 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, and twist the leads

together.

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

WARNING:

Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.

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

conductors to the MiniCAS II monitoring equipment. Twist the monitoring wires together.

2. If thermistors are included in the pump installation, and screened or auxiliary cable is

used, then connect T1(1) and T2(2) to thermistor relay, and T3(3) and T4 (4) to MiniCAS II.

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

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

charts (page 23).

4. Check the functionality of the monitoring equipment:

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

Replace any defective equipment.

22 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 25

Power cable phase sequence

L1 L2 L3

L3L1

WS000578B

T2T1

In the following ﬁgure, the triangle marked “L1,” “L2” and “L3” shows the phase sequence.

Figure 7: Correct phase sequence

Item Description Color of cable lead

1 L1 cable lead Brown Brown 2 L2 cable lead Black Black 3 L3 cable lead Grey Grey 4 Earth PE or Ground cable lead Green/Yellow Screen from leads 5 Functional ground In cables with both power cores

6 T1 cable lead (control

7 T2 cable lead (control

8 Power cable to pump

element)

and control element.

In cables with both power cores

and control element.

In cables with both power cores

and control element.

Installation

SUBCAB SUBCAB

(screened)

—

Cable charts

Connection locations

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

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 23

Page 26

L1 L2 L3

T3 T4T1 T2

*YE

GN/YE

WS004133B

L1 L2 L3

T3 T4T1 T2

CLS

FLS

FLS 10

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

24 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 27

Colors and markings of leads

WS003909A

Terminal clamps 6 stator leads

Motor Connection

Colors and marking of the main leads

773 29 00/1

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

Screenflex 7GX

Screenflex 4GX

SUBCAB AWG

SUBCAB Screened

BK 1

BK 2

BK 3

BK 4

BK 5

BK 6

GN/YE

**Screen/PE from cores

Screen (WH)

Motor Connection

773 29 00/1

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

Installation

See Color code standard (page 25).

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

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 25

Page 28

WS003903A

Terminal clamps 6 stator leads

One cable

Two cables

GN/YE

*YE

WS003803A

One cable

Two cables

GN/YE

*YE

WS003804A

Installation

Motor connection

6 leads

Figure 8: Terminal clamps, 6 stator leads

One cable (left) and two cables (right) Y-connection.

Figure 9: Y-connection

One cable (left) and two cables (right) D-connection.

26 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Figure 10: D-connection

One cable (left) and two cables (right) Y/D-connection.

Page 29

WS003805A

Y/D

One cable

Two cables

L1:1

L3:1

L2:1

L1:2

L3:2

L2:2

GN/YE

*YE

9 leads

WS003826A

One cable

Two cables

Y-

GN/YE

*YE

WS003837A

Y-SER

One cable

Two cables

GN/YE

*YE

Installation

Figure 11: Y/D-connection

One cable (left) and two cables (right) Y-parallel connection.

Figure 12: Y-parallel connection

One cable (left) and two cables (right) Y-serial connection.

Figure 13: Y-serial connection

Screened cables

Cable without separate ground conductor. Screen as ground conductor.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 27

Page 30

WS003815A

Screened SUBCAB & FGB Screened

Cable without sep. ground conductor Screen as ground conductor

GN/YE shrink hose

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)

WS003824A

Screenflex and SUBCAB with functional ground

* For screened SUBCAB T3 & T4 shall also be twisted separately

T1 and T2 twisted*

White insulation hose

Screen

GN/YE

T1 and T2

White insulation hose

twisted*

Screen

GN/YE

WS003843A

Color and marking of control leads

Control

SUBCAB 4GX/7G and

Screenflex

SUBCAB AWG

SUBCAB Screened

WH T1

WH T2

WH T3

WH T4

Installation

Figure 14: Screened SUBCAB and FGB Screened

* For screened SUBCAB T3 and T4 shall also be twisted separately.

Figure 15: Screenﬂex and SUBCAB with functional ground

Sensor connection

28 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Figure 16: Color and marking of control leads

See Color code standard (page 25).

Page 31

WS003850A

Sensor terminal clamps

T15

T16

Figure 17: Sensor terminal clamps

WS003855A

FLS + Thermal detectors

FLS

Max 12 V

WH/YE

Control leads

T1/*OG/1

Mini

CAS

WH/YE

T2/*BU/2

-5

T15

**T3

*SUBCAB AWG

**T4

**Screened SUBCAB

Installation

∞ Ohm

Overtemperature 1200 Ohm OK 430 Ohm Leakage

The values have a 10 % tolerance.

Figure 18: FLS and thermal detectors

T=25°C (77°F) T=135°C (275°F) (T T=145°C (293°F) (T

–5°C (23°F)) R ≤ 550 Ohm

REF

+5°C (41°F)) R ≤ 1330 Ohm

REF

R ≤ 100 Ohm

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 29

Page 32

WS003876A

FLS + Thermistor

Control leads

Max

T1/1

Thermistor

2.5 V

T2/2

relay

T15

Max

FLS

BN/BU

T3/3

Mini

12 V

BN/BU

T16

T4/4

CAS

-5

WS003869A

Thermal detectors FLS Disconnected

FLS

Max 12 V

WH/YE

Control leads

T1/*OG/1

Mini

CAS

T2/*BU/2

-5

WH/YE

T15

**T3

*SUBCAB AWG

**T4

**Screened SUBCAB

24 V AC/DC

102

7 +T1

T15

FLS10

5 -

12 VDC

10S

WS002623B

Installation

Figure 19: FLS and thermistor

MiniCAS II

Cable bending radius, weight and diameter

Before cycle 20128

30 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Figure 20: Thermal detectors, and with FLS disconnected

C Pump contactor CC Control circuit L1 Caution light (leakage) L2 Caution light (stator over-temperature) P Pump main supply R Reset switch

This section applies to cables delivered before 13 November 2012.

Page 33

Installation

This table shows the minimum bending radius, weight and outer diameter for 4 core SUBCAB® cables with control cores.

Table 1: SUBCAB® cables with control cores

Cable Minimum bending

radius in mm

Weight in kg/m Outer diameter,

minimum-maximum in mm

4G4 + 2x1.5 200 0.63 Ø 20.0–22.0

4G6 + 2x1.5 230 0.83 Ø 23.0–25.0

4G10 + 2x1.5 260 1.15 Ø 26.0–28.0

4G16 + 2x1.5 260 1.35 Ø 26.0–28.0

4G25 + 2x1.5 320 2.00 Ø 32.5–34.5

4G35 + 2x1.5 360 2.60 Ø 36.5–38.5

This table shows the minimum bending radius, weight and outer diameter for 4 core SUBCAB® screened cables.

Table 2: SUBCAB® screened cables

Cable Minimum bending

radius in mm

Weight in kg/m Outer diameter,

minimum-maximum in mm

S3 x 6 + 3 x 6/3 + 4 x 1.5 200 0.70 Ø 20.0–23.0

S3 x 10 + 3 x 10/3 + 4 x 1.5 230 1.00 Ø 23.0–26.0

S3 x 16 + 3 x 16/3 + 4 x 1.5 290 1.50 Ø 29.0–32.0

S3 x 25 + 3 x 16/3 + 4 x 1.5 300 1.60 Ø 30.0–33.0

S3 x 35 + 3 x 16/3 + 4 x 1.5 320 2.10 Ø 32.0–35.0

From cycle 20128 (13 November 2012)

This section applies to cables delivered from 13 November 2012.

Table 3: SUBCAB

Cable Minimum bending

4G4 + 2x1.5 200 0.63 Ø 20.0–22.0 4G6 + 2x1.5 240 0.83 Ø 24–26 4G10 + S(2x0.5) 240 0.85 Ø 24–26 4G16 + S(2x0.5) 260 1.13 Ø 26–28 4G25 + S(2x0.5) 320 1.70 Ø 32–34 4G35 + S(2x0.5) 350 2.24 Ø 35–37

Table 4: SUBCAB® screened cables

Cable Minimum bending

radius in mm

Weight in kg/m Outer diameter,

minimum-maximum in mm

Weight in kg/m Outer diameter,

minimum-maximum in mm

S3x6 + 3x6/3 + S(4x0.5) 200 0.55 Ø 20–22

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 31

Page 34

WS000580A

A B

Installation

Cable Minimum bending

S3x10 + 3x10/3 + S(4x0.5) 240 0.95 Ø 24–26 S3x16 + 3x16/3 + S(4x0.5) 240 1.1 Ø 24–26 S3x25 + 3x16/3 + S(4x0.5) 290 1.4 Ø 29–31 S3x35 + 3x16/3 + S(4x0.5) 320 2.0 Ø 32–34

Check the impeller rotation

WARNING:

The starting jerk can be powerful.

If the propeller rotates in the wrong direction, then the pump lifts up and rotates, which can damage the cables.

1. Start the motor.

2. Stop the motor after a few seconds.

3. Check the propeller rotation. The correct direction of propeller rotation is clockwise when you look at the pump

from above.

radius in mm

Weight in kg/m Outer diameter,

minimum-maximum in mm

Direction of propeller rotation. Generic pump shown.

Figure 21: Top view (A) and side view (B)

4. If the impeller/propeller rotates in the wrong direction, check that the phase leads are correctly connected. See Power cable phase sequence (page 23).

After re-connecting phase leads, do this procedure again.

32 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 35

Operation

Precautions

WARNING:

• Never operate the pump without safety devices installed.

• Never operate the pump with 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.

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.

Start the pump

WARNING:

• If you need to work on the pump, make sure that it is isolated from the power supply and

cannot be energized.

• 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.

NOTICE:

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

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 33

Page 36

Operation

3. Check that the monitoring equipment works.

4. Start the pump.

34 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 37

Maintenance

Precautions

WARNING:

• Always follow safety guidelines when working on the product. See Introduction and

Safety (page 3).

• Disconnect and lock out electrical power before installing or servicing the pump.

• 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

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 a sales representative.

Screws and nuts

Table 5: 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

100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) 115 (84.8) 248 (183) 481 (355) — —

Table 6: Steel, torque Nm (ft-lbs)

Property 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

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

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

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

(915)

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

(966.2)

(1357) 2210

(825.1)

(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.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 35

Page 38

WS003631A

WS003633A

Maintenance

Changing the coolant

This ﬁgure shows where the plugs for change of coolant are placed on the unit.

1. Coolant plug

2. Inspection plug

3. Coolant plug

4. Outer screw

Figure 22: With a cooling jacket

Empty the coolant

WARNING:

The seal housing may be pressurized. Hold a rag over the inspection/ ﬁlling plugs to prevent splatter.

1. Remove the outer screw and the inner screw of both coolant plugs, and the inspection plug, on the hydraulic part.

1. Outer screw

2. Inner screw

36 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 39

WS003632A

Maintenance

2. Thread the hose of the hand-pump through the inner and outer holes into the seal chamber.

3. Pump out any coolant from the seal chamber.

4. Remove the inspection plug.

5. Pump out any leakage from the inspection chamber.

6. Reassemble the inspection plug with a new O-ring. Remount the plug and tighten. Tightening torque: 44 Nm (33 ft-lbs)

7. Remount the outer screw for the inspection plug. Tightening torque: 76 Nm (57 ft-lbs)

Fill with coolant

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. Thread the hose of the hand-pump through both of the holes into the seal chamber.

2. Pump coolant into the seal chamber until it overﬂows through the opposite hole.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 37

Page 40

WS003634A

WS003635A

Maintenance

Quantity: approximately 2 L (2.2 qt.).

3. Replace the O-rings with new ones.

4. Remount the oil plugs and tighten. Tightening torque: 44 Nm (33 ft-lbs)

5. Remount the outer screws for the coolant plug. Tightening torque: 76 Nm (57 ft-lbs)

Preparing for work on the hydraulic end

Some maintenance work on the hydraulic end of the pump, such as changing the impeller or replacing zinc anodes, requires that the pump be turned upside-down. This section provides instructions for removing the connection house and attaching an assembly and dismantling stand in its place.

Remove the entrance cover

1. Remove the entrance cover screws.

2. Disconnect the motor cable leads.

3. Lift off the entrance cover.

38 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 41

WS003636A

Attach the assembly and dismantling stand

WS003637A

WS003666A

Two lifting devices are required for this task.

1. Bolt the assembly/dismantling stand (605 70 00) in position. Secure it using the screws for the entrance cover.

Maintenance

2. Attach lifting straps as shown in the following ﬁgure, and lift the pump.

3. Place the drive unit upside down on the stand.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 39

Page 42

WS003638A

WS003614A

Maintenance

Replacing the propeller

Required tools:

• Stand 605 70 00

• 14 mm hexagon bit adapter with an extension bar

• Trim tool (17 mm hexagon bit adapter with an extension bar)

• Rod (wood or plastic) for locking the impeller in place.

WARNING:

A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.

During this procedure the pump is upside down. The stand 605 70 00 is used to support the pump in the upside down position. For instructions for attaching the stand, see

Preparing for work on the hydraulic end (page 38).

The propeller parts are shown in the following ﬁgure.

1. Propeller screw

2. Washer

3. Propeller

4. Adjustment screw

40 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 43

5. Conical sleeve

WS000587A

6. Conical shaft end

Measure the clearance

Depending on the type of media that is being pumped the pump will more or less be exposed to wear, mainly in the gap between the propeller blades and the pump housing.

The clearance between the propeller blades and the pump housing will increase. The effect of this is that the capacity as well as the efﬁciency will drop. It should be noted that these effects are not linearly proportional to the size of the clearance, but progressive.

Operating the pump when the blade–housing clearance has reached or exceeded the clearance threshold will result in a loss of capacity (ﬂow) and pump efﬁciency.

It is therefore recommended that the blade–housing clearance be checked at routine inspections and worn parts be replaced as necessary. If the measured blade–housing clearance exceeds the critical limit, then we recommend that the efﬁciency drop be evaluated and replacement of worn parts be considered.

1. Measure the clearance between the propeller blades and the pump housing in a few places to get an average value.

The blade–housing clearance can vary slightly as the propeller might not be perfectly centered due to manufacturing tolerances.

Maintenance

1. Propeller

2. Pump housing

3. Critical clearance

Figure 23: Critical clearance

Pump Clearance threshold for efﬁciency drop, mm (in) 7030 1.3 (0.051)

7035 1.2 (0.047)

7040 1.6 (0.063)

If the measured clearance is less than the threshold value given in the table above, then the rest of the steps in this section can be omitted. If the measured clearance is greater than the threshold value in the table above, then proceed as follows:

2. Measure the wear in the pump housing with a thickness gauge by placing the edge of a ruler across the surface of the housing.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 41

Page 44

WS000589A

WS003620A

Maintenance

1. Ruler

2. Wear

3. Replace parts according to the table.

Pump Wear measured, mm (in) Action 7030 0.3 (0.012) Replace the propeller

7035 0.3 (0.012) Replace the propeller

7040 0.4 (0.016) Replace the propeller

Remove the propeller

CAUTION:

Wear heavy work gloves when you handle impellers. The sharp edges can cause physical injury.

1. Lock the propeller in place by inserting a rod or piece of wood through the pump housing outlet.

1.0 (0.039) Replace the bell mouth

0.9 (0.035) Replace the bell mouth

1.2 (0.047) Replace the bell mouth

2. Loosen the propeller: a) Remove the propeller screw and washer.

42 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 45

WS003615A

WS003619A

WS003617A

Maintenance

b) Turn the adjustment screw counterclockwise until the propeller breaks free from the

shaft. Use the trim tool.

3. Remove the propeller and the propeller sleeve.

Install the propeller

1. Mount the propeller:

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 43

Page 46

WS003613A

WS003612A

WS003621A

1.5 mm

Maintenance

a) Make sure that the end of the shaft is free from burrs.

Polish off any ﬂaws with a ﬁne emery cloth.

b) Grease the shaft end.

NOTICE:

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

c) Grease the conical sleeve and the threads of the adjustment screw.

d) Turn the adjustment screw 3/4 of a turn, so that it juts out from the sleeve 1.5 mm.

Use the trim tool.

e) Fit the sleeve onto the shaft. f) Carefully ﬁt the propeller to the shaft.

44 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 47

Make sure that the sleeve and propeller are pushed on straight onto the shaft. If not

WS003618A

WS003616A

they might get stuck part way on.

2. Fit the propeller screw and washer.

Maintenance

3. Tighten the propeller screw.

4. Tighten the propeller screw a further 1/8 turn (45°).

5. Check that the propeller can rotate freely.

Replace the bell mouth

1. Remove the 3 hexagonal screws securing the bell mouth. If there are zinc anodes, then 6 hexagonal screws must be removed.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 45

Page 48

WS003763A

WS003667A

Maintenance

1. Hexagonal screws

2. Bell mouth

3. Pump housing

2. Lift off the bell mouth.

3. Put the new bell mouth in place.

4. If zinc anodes are used, then remount them.

5. Fasten the screws.

Replace the zinc anodes

1. Loosen the hexagonal screws securing the zinc anodes at the inlet.

2. Replace the zinc anodes and fasten the screws.

3. Loosen the hexagonal screws securing the anodes at the outlet.

46 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 49

WS003668A

4. Replace the zinc anodes and fasten the screws.

Service the pump

Maintenance

Type of service Purpose Inspection interval

Initial inspection To make a check up of the pump

condition by an authorized Xylem service representative and, based on the result and ﬁndings from these measures, to determine the intervals for periodical inspection and major overhaul for the speciﬁc installation.

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 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.

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).

Within the ﬁrst year of operation.

Up to 12,000 hours or 3 years, whichever comes ﬁrst.

Applies to normal applications and operating conditions at media (liquid) temperatures <40°C.

Up to 24,000 hours or 6 years, whichever comes ﬁrst.

Applies to normal applications and operating conditions at media (liquid) temperatures <40°C.

Inspection

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 47

Page 50

Maintenance

Service item Action

Cable

1. If the outer jacket is damaged, replace the cable.

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

Connection to power Check that the connections are properly tightened.

Electrical cabinets Check that they are clean and dry.

Propeller

1. Check the propeller clearance.

2. Replace the propeller, if necessary.

Inspection chamber

1. Drain all liquid, if any.

2. Check the resistance of the leakage sensor. Normal value approx. 1200 ohms, alarm approx. 430 ohms.

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. General: Check that it is clean and dry. If it is wet: a. Check the cable entry. b. Replace the O-rings. (New O-rings should be ﬁtted to all

O-ring seal joints opened during inspection.)

2. Terminal board: Check that the connections are properly tightened.

Level regulators Check the condition and functionality.

Lifting device Check that local safety regulations are followed.

O-rings

1. Replace the coolant 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 propeller 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.

Thermal contacts Normally closed circuit; interval 0–1 ohm.

Thermistor Check the resistance is between 20–250 ohms and the measured

voltage is maximum 2 V DC.

Voltage and amperage Check the running values.

48 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

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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.

Mechanical seal Replace with new seal unit.

Service in case of alarm

Alarm source Action

Maintenance

FLS10

The thermistor/thermal contact Check the start and stop levels.

The overload protection Check that the propeller can rotate freely.

1. Drain the ﬂuid in the inspection chamber. Fill with new coolant

if 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.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 49

Page 52

Troubleshooting

Introduction

Follow these guidelines when troubleshooting the pump:

• 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

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.

The installation is not receiving voltage.

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 Xylem service shop.

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.

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 is stuck. Clean:

50 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

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Cause Remedy

• The impeller

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

If the problem persists, refer to the Flygt Service Guide on the web or contact the local Xylem service shop. Always state the serial number of your pump when you contact Xylem, see Product Description (page 10).

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

Troubleshooting

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.

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 Xylem service shop.

• 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.

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.

The self-holding function of the contactor malfunctions.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 51

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.

Page 54

Troubleshooting

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 the clearance between the propeller and the pump housing.

• Check the fuses. Replace fuses that have tripped.

• If the fuses are intact, notify a certiﬁed electrician.

Contact the local Xylem service shop.

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 Xylem service shop.

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 Xylem service shop.

Replace the overload protection.

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.

52 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

Page 55

Troubleshooting

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

See Check the impeller rotation (page 32).

direction.

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 the clearance between the propeller and the pump housing.

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.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 53

Page 56

Technical Reference

Product overview

Axial-ﬂow pump for transportation of large volumes of water and wastewater at low heads.

Installation

L-installation

Accessories

Mechanical accessories which are available include the following:

• Cable handling system

• Lifting equipment

Electrical accessories which are available include the following:

• Pump controller

• Control panels

• Starters

• MiniCAS-II monitoring

See your Xylem representative for further information.

Options

The following options are available:

• Zinc anodes for corrosion protection in sea water

• Special coating system (with epoxy base coat) for demanding environments

Materials

Propeller

Pump housing

Mechanical face seals

Material Flygt material number Standard

Europe USA

Stainless steel (austenitic) M0344.2343.12 EN 10283:1998

Nos. 1.4408, 1.4412

Item Available materials Flygt material number Standard

Europe USA

Pump housing Cast iron M0314.0125.00 EN 1561:1997

No. JL 1040

Bell mouth Hard-Iron

High chromium cast iron

Seal Material, rotating ring Material, stationary ring Inner Wolfram Carbide Corrosion Resistant

M0344.0466 EN 12513:2011

No. 5.5610

WCCR

(WCCR)

ASTM A 743 CF-8M

ASTM-A 48 – No. 35 B

ASTM-A 532 – Alloy III A

Outer WCCR WCCR

54 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

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Motor shaft

Technical Reference

Available materials Flygt material number Standard

Europe USA

O-rings

Coating system

Stainless steel (martensitic) M0344.2321.03 EN 10088-3:1995

No. 1.4057

Available materials Flygt material number Standard

Europe USA

Nitrile rubber (NBR) 70⁰ IRH

Fluorinated rubber (FPM) M0516.2677.32 — —

The following table describes the two variants of paint systems available for the pump, Standard and Special. The choice of coating system depends upon the service environment.

Coating system Basecoat Topcoat Total dry ﬁlm thickness Standard Acrylic (waterborne)

Special (option) Epoxy, 2 layers Oxirane ester, 2–pack, 1

M0516.2637.04 — —

Oxirane ester, 2–pack 120–350 μm or alkyd (solventborne)

layer

ASTM/AISI 431

350–700 μm

Other coating systems are available for special requirements such as drinking water, high temperature or erosion applications. See the Xylem internal standard M0700.00.0001 (Coating Selection Guidelines).

Mounting-related data

Depth of immersion

The maximum depth of immersion is 20 m (65 ft.).

Weight

The P7030 weighs 450 kg, excluding cables.

Cables

SUBCAB

Engineering data

Performance curves, motor data and dimensional drawings are available from your Xylem representative.

Pump (ball-) throughlet

Table 7: P7030

Pump Throughlet

P7030 64 2.52

Maximum voltage 600–1000 V, intended for drive units up to 1.1 kV. To be dimensioned by Xylem.

mm in.

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 55

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Technical Reference

Pump Throughlet

P7035 P7040 79 3.11

Operational data

Application limits

Table 8: Process data

Parameter Value Liquid temperature Max. +40°C (+105°F) Depth of immersion Max. 20 m (65 ft.) pH of pumped liquid pH 5.5–14 Liquid density Max. 1100 kg/m3 (9.17 lb per gal.)

Motor Data

Motor characteristics

Insulation class H (+180°C, +356°F) Voltage variation Max. +/- 10% Voltage imbalance between phases Max. 2% Number of starts per hour Max. 30

mm in. 50 1.97

Frequency

Pump 50 Hz 60 Hz

7030.090, 7030.180 X X

7035.090, 7035.180 X X

7040.090, 7040.180 X X

The monitoring equipment

MiniCAS II

The table below shows the parameters which can be tracked with the MiniCAS II monitoring system.

Parameter Sensor Standard or optional Stator winding temperature One of the following choices:

Leakage in the inspection chamber Float Switch Leakage Sensor (FLS) Standard Leakage in the junction box Float Switch Leakage Sensor (FLS) Optional

Standard

• 3 thermal switches (standard), or

• 3 PTC-thermistors (optional)

56 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

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P7030 Motor rating and

0.0

0.6

1.2

1.8

2.4

3.0

3.6

4.2

4.8

5.4

200 250 300 350 400 450 500

550

l/s

WS003669A

performance, 50 Hz

Low voltage

Table 9: P7030, 50 Hz

P7030 Motor rating and performance, 50 Hz

Rotations per

minute

970 30–29–6A 400 40 76 415 0.85 965 30–23–6A 400 965 30–18–6A 400

Motor Voltage, V Rated power,kWRated current,

33 64 320 0.84 24 47 235 0.85

Starting

current, A

Power factor

cos φ

Figure 24: P7030, 50 Hz

Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual 57

Page 60

250 300 350 400 450 500 550 600 650 700

l/s

11,0009,000

7,000

5,000

GPM

WS003670A

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

0.0

24.0

4.0

8.0

12.0

16.0

20.0

ft.

8.0

P7030 Motor rating and performance, 60 Hz

Low voltage

Table 10: P7030, 60 Hz

Rotations

per minute

1165 30–29–6A 460 48 65 78 430 0.86 1165 30–23–6A 460 1165 30–18–6A 460 1170 30–29–6AA 600 1170 30–23–6AA 600 1170 30–18–6AA 600

Motor Voltage, V Rated

power, kW

37 50 61 330 0.86 28 38 46 243 0.87 48 65 61 365 0.84 37 50 48 274 0.84 28 38 36 208 0.84

Rated

power, HP

Rated

current, A

Starting

current, A

Power factor

cos φ

Figure 25: P7030, 60 Hz

58 Flygt P7030, P7035, P7040 Installation, Operation and Maintenance Manual

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Page 62

Xylem |’zīləm|

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

2) A leading global water technology company

We're 12,500 people uniﬁed in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efﬁciently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation.

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

Xylem Water Solutions AB Gesällvägen 33 174 87 Sundbyberg Sweden Tel. +46-8-475 60 00 Fax +46-8-475 69 00 http://tpi.xyleminc.com

882901_3.0_en.US_2012-06_IOM.7030.7035.7040

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

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

2012 Xylem Inc.