Page 1
Water & Wastewater
Service and Repair Instructions
Flygt 3102
Page 2
Page 3
Table of Contents
Introduction and Safety...................................................................................................................................................3
Introduction.......................................................................................................................................................................3
Transportation and Storage..........................................................................................................................................3
Inspect the delivery........................................................................................................................................................3
Product warranty............................................................................................................................................................3
Safety...................................................................................................................................................................................4
Safety message levels.....................................................................................................................................................4
User safety.......................................................................................................................................................................5
Ex-approved products...................................................................................................................................................6
Environmental safety.....................................................................................................................................................7
Product Description..........................................................................................................................................................8
Products included..............................................................................................................................................................8
The data plate.....................................................................................................................................................................9
Approvals............................................................................................................................................................................9
Product denomination....................................................................................................................................................11
Installation.........................................................................................................................................................................12
General precautions........................................................................................................................................................12
Requirements...................................................................................................................................................................12
Cables................................................................................................................................................................................12
Earthing (Grounding).....................................................................................................................................................13
Connect the motor cable to the pump.........................................................................................................................13
Connect the motor cable to the starter and monitoring equipment.......................................................................14
Cable charts......................................................................................................................................................................15
Sensor-connection.......................................................................................................................................................20
Check the impeller rotation...........................................................................................................................................21
Table of Contents
Maintenance......................................................................................................................................................................22
Precautions.......................................................................................................................................................................22
Maintenance guidelines..................................................................................................................................................22
Torque values...................................................................................................................................................................22
Change the oil..................................................................................................................................................................23
Empty the oil................................................................................................................................................................23
Fill with oil....................................................................................................................................................................24
Disassemble the pump...................................................................................................................................................25
Remove the motor cable and the stator housing....................................................................................................25
Remove the pump housing.........................................................................................................................................26
Remove the mechanical seal.......................................................................................................................................27
Remove the stator from the stator housing.............................................................................................................30
Assemble the pump........................................................................................................................................................31
Install the stator in the stator housing......................................................................................................................31
Install the mechanical seal..........................................................................................................................................32
Install the motor cable in the stator housing...........................................................................................................35
Replace wear parts and cutting parts........................................................................................................................37
Install the pump housing............................................................................................................................................41
Replace the impeller........................................................................................................................................................42
Replace the C- or D-impeller.....................................................................................................................................43
Replace the F-impeller.................................................................................................................................................46
Replace the M-impeller...............................................................................................................................................51
Replace the N-impeller................................................................................................................................................55
Requirements for Ex-approved products....................................................................................................................57
Flygt 3102 Service and Repair Instructions 1
Page 4
Table of Contents
Service the pump.............................................................................................................................................................57
Intermediate service....................................................................................................................................................57
Major service................................................................................................................................................................58
Service in case of alarm...............................................................................................................................................58
Troubleshooting...............................................................................................................................................................60
Introduction.....................................................................................................................................................................60
The pump does not start................................................................................................................................................60
The pump does not stop when a level sensor is used...............................................................................................61
The pump starts-stops-starts in rapid sequence.........................................................................................................61
The pump runs but the motor protection trips..........................................................................................................61
The pump delivers too little or no water.....................................................................................................................62
Technical Reference........................................................................................................................................................64
Exploded view.................................................................................................................................................................64
Tools..................................................................................................................................................................................67
2 Flygt 3102 Service and Repair Instructions
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.
Transportation and Storage
For information about how to transport and store the pump, see Transportation and Storage in the
Installation, Operation and Maintenance manual.
Introduction and Safety
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.
Product warranty
Coverage
ITT undertakes to remedy faults in products from ITT under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an ITT 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 ITT-authorized personnel.
• Genuine ITT parts are used.
• Only Ex-approved spare parts and accessories authorized by ITT are used in Ex-approved products.
Flygt 3102 Service and Repair Instructions 3
Page 6
Introduction and Safety (Continued)
Limitations
The warranty does not cover faults caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation made without consulting ITT
• Incorrectly executed repair work
• Normal wear and tear
ITT assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
ITT products are high-quality products with expected reliable operation and long life. However, should the
need arise for a warranty claim, then contact your ITT representative.
Spare parts
ITT guarantees that spare parts will be available for 15 years after the manufacture of this product has
been discontinued.
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 ITT. If there is a question regarding the intended use of
the equipment, please contact an ITT representative before proceeding.
• Installation, Operation, and Maintenance manuals clearly identify 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 ITT representative.
CAUTION:
You must observe the instructions for installation, operation, and maintenance contained in this manual.
Failure to do so could result in physical injury, damage, or delays.
Safety message levels
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
4 Flygt 3102 Service and Repair Instructions
Page 7
Definitions
Safety message level Indication
A hazardous situation which, if not avoided, will
DANGER:
WARNING:
CAUTION:
Electrical Hazard:
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
The possibility of electrical risks if instructions are
not followed in a proper manner
Introduction and Safety (Continued)
User safety
General safety rules
Safety equipment
NOTICE:
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:
• Helmet
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
• A potential situation which, if not avoided,
could result in undesirable conditions
• A practice not related to personal injury
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information about safety
devices in other chapters of this manual.
Flygt 3102 Service and Repair Instructions 5
Page 8
Introduction and Safety (Continued)
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:
• 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.
Wash the skin and eyes
Do the following if chemicals or hazardous fluids have come into contact with your eyes or your skin:
If you need to wash your... Then...
Eyes
Skin
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 one minute.
3. Seek medical attention, if required.
Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
These are the personnel requirements for Ex-approved products in potentially explosive atmospheres:
• All work on the product must be carried out by certified electricians and ITT-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
(including IEC/EN 60079-17).
ITT disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in potentially
explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during normal operation. Dry running during service
and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control panel are isolated
from the power supply and the control circuit, so they cannot be energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
• Make sure that thermal contacts are connected to a protection circuit according to the approval
classification of the product, and that they are in use.
• 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 authorized ITT representative.
• Only use parts that are provided by an authorized ITT representative.
6 Flygt 3102 Service and Repair Instructions
Page 9
ATEX guidelines
ATEX 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 ITT representative. When you install or maintain ATEXcompliant equipment, always comply with the directive and applicable standards in IEC/EN 60079–14.
Permitted liquid level for ATEX
See the dimensional drawings of the product for the minimum permitted liquid level according to the
ATEX approval. If the information is missing on the dimensional drawing, the product must be fully
submerged. Level-sensing equipment must be installed if the product can be operated at less than the
minimum submersion depth.
Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices include but are not
limited to the following:
• Level indicators
• Temperature detectors
Environmental safety
The work area
Always keep the station clean to avoid and/or discover emissions.
Introduction and Safety (Continued)
Recycling guidelines
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 ITT representative.
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.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Flygt 3102 Service and Repair Instructions 7
Page 10
Product Description
Product Description
Products included
Pump model Feature
3102.090 EN
• II 2 G EEx d IIB T4
FM
• FM: Class I Div. 1 groups C and D
• Class II Div. 1 groups E, F and G
• Suitable for use in Class III Div.1
3102.095
3102.170
3102.181
3102.185
3102.890
Hard Iron
EN
• II 2 G EEx d IIB T4
FM
• FM: Class I Div. 1 groups C and D
• Class II Div. 1 groups E, F and G
• Suitable for use in Class III Div.1
Grinder
Standard
Hard Iron
Grinder
EN
™
™
• II 2 G EEx d IIB T4
FM
• FM: Class I Div. 1 groups C and D
• Class II Div. 1 groups E, F and G
• Suitable for use in Class III Div.1
8 Flygt 3102 Service and Repair Instructions
Page 11
The data plate
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
3
1
23
24
The data plate is a metal label located on the main body of the pump. The data plate lists key product
specifications. Explosion-proof products also have an approval plate. Both are described below.
1. Curve code/Propeller code
2. Serial number, see Product denomination (page 11)
3. Product number
4. Country of origin
5. Additional information
6. Phase; type of current; frequency
7. Rated voltage
8. Thermal protection
9. Thermal class
10. Rated shaft power
11. International standard
12. Degree of protection
13. Rated current
14. Rated speed
15. Maximum submergence
16. Direction of rotation: L=left, R=right
17. Duty class
18. Duty factor
19. Product weight
20. Locked rotor code letter
21. Power factor
22. Maximum ambient temperature
23. Read installation manual
24. Notified body/only for EN-approved Ex-products
Figure 1: The data plate
Product Description (Continued)
Approvals
This section describes the EN and FM approvals that explosion-proof products have. For more
information, please contact your ITT representative. In addition to the data plate, explosion-proof
products also have either an EN or a FM approval plate.
EN
• European Norm
• ATEX Directive
• EN 50014, EN 50018, EN 1127-1
•
Flygt 3102 Service and Repair Instructions 9
II 2 G EEx d IIB T4
Page 12
1 2 3
4
5
6 7
8
9 10
12
11
13
14
15
1
2
Product Description (Continued)
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
Figure 2: EN approval plate
EN approval for cable entry:
• Certificate number: INERIS 02ATEX9008 U
II 2 G or IM2 EEx d IIC or EEx dI
•
FM
This illustration describes the approval plate for Factory Mutual (FM) and the information contained in its
fields.
1. Temperature class
2. Maximum ambient temperature
Figure 3: FM approval plate
10 Flygt 3102 Service and Repair Instructions
Page 13
Product denomination
1
NP 3085
2 3
3085.183
1 2
NP
1
NP 3085.183 - 951 0163
2 3 4
Sales denomination
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
Product 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.
Product Description (Continued)
Serial number
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 3102 Service and Repair Instructions 11
Page 14
Installation
Installation
General precautions
Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local codes and regulations.
• Before starting work on the pump, make sure that the pump 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.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a risk of sudden
restart.
Requirements
These general requirements apply for electrical installation:
Cables
These are the requirements to follow when you install cables:
• 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, the connected voltage is specified by a yellow sticker close to the
cable entry.
• The fuses, short-circuit, 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 starting 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, the pump must be provided with monitoring equipment
supporting such operation.
• The motor is convertible between different voltages, as stated on the data plate. This conversion is
done on the terminal board.
• 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.
• 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 an ITT service shop.
12 Flygt 3102 Service and Repair Instructions
Page 15
• The voltage drop in long cables must be taken into account. The drive unit’s rated voltage is the
2
2
1
voltage measured at the terminal board in the upper part of 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 ITT representative (VFD-supplier).
Earthing (Grounding)
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.
Connect the motor cable to the pump
Installation (Continued)
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.
1. Entrance cover
2. O-ring
For information about the cable entry, see the Parts list.
1. Remove the entrance cover and the O-ring from the stator housing.
This provide access to the terminal board/closed end splices.
Flygt 3102 Service and Repair Instructions 13
Page 16
Installation (Continued)
2. Check the data plate to see which connections are required for the power supply:
• Y
• D
• Y serial
• Y parallel
• Y/D
3. Arrange the connections on the terminal board/closed end splices in accordance with the required
power supply.
4. Connect the motor conductors (U1, V1, W1, and earth (ground)) according to applicable cable chart.
The earth (ground) conductor must be 50 mm ( 2.0 in.) longer than the phase conductors in the
junction box of the unit.
5. Make sure that the pump is correctly connected to earth (ground).
6. Make sure that any thermal contacts incorporated in the pump are properly connected to the terminal
block/closed end splices.
7. Install the entrance cover and the O-ring on the stator housing.
8. 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 or in the sump.
NOTICE:
• Thermal contacts are incorporated in the pump.
• Thermal contacts must never be exposed to voltages higher than 250 V, breaking current maximum
4 A. It is recommended that they are connected to 24 V over separate fuses to protect other
automatic equipment.
The single phase pumps must be equipped with a starter which has start and run capacitors.
A specially Flygt designed starter is required for the operation of single phase pumps. The connection of
the motor cable to the starter is shown in the wiring diagram.
1. If thermal contacts are included in the pump installation, connect the T1 and T2 control conductors
to the monitoring equipment.
Do not connect the T1 and T2 leads to thermal contacts if the temperature of the pumped liquid is
above 40°C (104°F).
NOTICE:
Ex-approved products must always have the thermal contacts connected irrespective of the ambient
temperature.
2. 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
15).
3. 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.
14 Flygt 3102 Service and Repair Instructions
Page 17
Cable charts
1 2 3 4 5 6 7
1 2 L1 L2 L3 GC
U1 W2 V1 U2T16 T15 T2 T1 W1 V2
1
2
3
6
5
4
7
Installation (Continued)
L2
L3L1
L1 L2 L3
1. Control leads
2. Starter equipment
3. Mains leads
4. Motor cable
5. Terminal blocks on pump
6. Stator leads
7. Control cable
Figure 4: Connection locations
Figure 5: Phase sequence
Colors and marking of the mains leads
Color and marking of the control leads
Colors of the stator leads
Mains SUBCAB 7GX SUBCAB 4GX SUBCAB AWG SUBCAB
Screened
SI-SLBIHFSIH-J
L1 Black 1 Brown Red Brown Brown
L2 Black 2 Black Black Black Black
L3 Black 3 Grey White Grey Grey
L1 Black 4 – – – –
L2 Black 5 – – – –
L3 Black 6 – – – –
Yellow/Green Yellow/Green Yellow/Green Screen from
Yellow/Green
leads
Groundcheck
– – Yellow – –
(GC)
Control SUBCAB 7GX and
SUBCAB 4GX
SUBCAB AWG SUBCAB screened
T1 White T1 Orange White T1
T2 White T2 Blue White T2
T3 – – White T3
T4 – – White T4
Stator connection Lead color
U1 Red
U2
Green (Brown if 1 phase stator 4 leads is used)
U5 Red
Flygt 3102 Service and Repair Instructions 15
Page 18
GC
T1 T2
Installation (Continued)
Stator connection Lead color
U6 Green
V1 Brown
V2 Blue
V5 Brown
V6 Blue
W1 Yellow
W2 Black
W5 Yellow
W6 Black
SUBCAB 4GX/SUBCAB AWG/SI-SL-BIHF, 4 stator leads, 1 phase
This table shows the connection diagrams for example the SUBCAB 4GX.
SUBCAB 4GX/SUBCAB AWG/SI-SL-BIHF, 12 stator leads, 230V, 1 phase
This table shows the connection diagrams for example the SUBCAB 4GX.
16 Flygt 3102 Service and Repair Instructions
Page 19
T1
T2
GC
U2W2 V2
V1U1 W1
T1
T2
GC L2L1 L3
T1 T2
T1 T2
T1
T2
T1 T2
U1 V1 U2 V2
SUBCAB
®
SUBCAB
®
GC
L1 L2
L3
W1W2
U2
W2
V2
V1U1 W1
T1
T2
GC L2L1 L3
T1 T2
T1 T2
T1
T2
T1 T2
U1 V1 U2 V2
SUBCAB
®
SUBCAB
®
GC
L1 L2
L3
W1W2
Installation (Continued)
SUBCAB 4GX/SUBCAB AWG, 6 stator leads, Y and D connection
This table shows the connection diagrams for example the SUBCAB 4GX (3-phase power cable), with Y
and D connection.
Y serial connection D serial connection
SUBCAB 7GX, 2 motor cables, 6 stator leads, D connection
This table shows the connection diagrams for the SUBCAB 7GX (3-phase power cables), with D serial
connection.
Flygt 3102 Service and Repair Instructions 17
Page 20
W2 U1 V1 U2 V2
W1
U2W2 V2
V1U1 W1
T1
T2
L1 L2 L3
T1 T2
1 4 2 5 3 6
1 4 2
T1 T2
T1
T2
SUBCAB
®
5 3 6
V1W1 U1
U2V2 W2
T1
T2
L1 L2 L3 L1 L2 L3
T1 T2
1 42 53 6
123
T1 T2
T1 T2
W1 V1
SUBCAB
®
U1
V2
U2 W2
456
Installation (Continued)
Y serial connection
SUBCAB 7GX, 6 stator leads, Y/D connection
This table shows the connection diagrams for the SUBCAB 7GX (3-phase power cable), with Y/D serial
connection.
Y/D serial connection
SUBCAB 4GX/SUBCAB AWG, 9-leads, 230/460 V, Y connection
18 Flygt 3102 Service and Repair Instructions
This table shows the connection diagrams for example the SUBCAB 4GX (3-phase power cables), with Y
parallel/serial connection (60 Hz only).
Page 21
Y parallel connection (230 V) Y serial connection (460 V)
U2W2 V2
V1U1 W1
T1
T2
GC L2L1 L3
T1 T2
T1 T2
T1
T2
T1 T2
SUBCAB
®
SUBCAB
®
GC
L1 L3
L2
W2
U1 V1
U2 V2
W1
U5 V5 W5
L1
L2
L3
L3
V1 W1
T1
T2
U1
T1
W2
U1V1U2
W1
V2
SUBCAB
®
SUBCAB
®
G C L1 L 2
T 1 T 2
3 ~
V2
W2
U2
G C
T2
T1
T2
G C
U5
V5
W5
U2W2 V2
V1U1 W1
T1
T2
GC L2L1 L3
T1 T2
T1 T2
T1
T2
T1 T2
SUBCAB
®
SUBCAB
®
GC
L1 L3
L2
W2
U1 U2
V2
W1
U5 V1 W5V5
W6
V6
U6
L2 L3
L3
V1 W1
T1
T2
U1
T1
W2
U1
V1
U2
W1
V2
SUBCAB
®
SUBCAB
®
G C L 1 L 2
T 1 T 2
3 ~
V2
W2
U2
G C
T2
T1
T2
G C
U5
V5
W5
W6U6V6
L1
Installation (Continued)
SUBCAB 4GX/SUBCAB AWG, 12 stator leads, 220/230:440/460 V, Y connection
This table shows the connection diagrams for example the SUBCAB 4GX (3-phase power cable), with Y
parallel/serial connection (60 Hz only).
Y parallel connection (220/230 V) Y serial connection (440/460 V)
SUBCAB Screened S3X2.5+3X2.5/3+4X1.5, 6 stator leads, Y and D connection
Flygt 3102 Service and Repair Instructions 19
This table shows the connection diagrams for the SUBCAB Screened (3-phase power cable), with Y parallel/
serial connection (60 Hz only).
Page 22
U2W2 V2
V1U1 W1
T1
T2
32
L2L1 L3
T1 T2
T1 T2
T1
T3
T3
T4
T4
1 T2
SUBCAB
®
1 3
2
W2 U1 V1 U2 V2
W1
U2W2 V2
V1U1 W1
T1
T2
W2 U1 V1 U2 V2
W1
32
L2L1 L3
T1 T2
T1 T2
T1
T3
T3
T4
T4
1 T2
SUBCAB
®
1 3
2
Installation (Continued)
Y serial connection D serial connection
Sensor-connection
Thermal contact
FLS and Thermal contact Value
0 mA Overtemperature
7.8 mA OK
36 mA Leakage
The values have a 10 % tolerance
CLS and Thermal contact (only standard version) Value
0 mA Overtemperature
5.5mA OK
29mA Leakage (5 second delay)
The values have a 10 % tolerance
20 Flygt 3102 Service and Repair Instructions
Page 23
Installation (Continued)
CLS, FLS, and Thermal contact (only standard
version)
Check the impeller rotation
WARNING:
The starting jerk can be powerful.
1. Start the motor.
2. Stop the motor.
3. Check that the impeller rotates according to this illustration.
Value
0 mA Overtemperature
13.3 mA OK
36-42mA Leakage (0/5 seconds delay)
The values have a 10 % tolerance
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, do one of these steps:
• If the motor has a 1-phase connection, contact the local ITT shop.
• If the motor has a 3-phase connection, transpose two phase leads and do this procedure again.
Flygt 3102 Service and Repair Instructions 21
Page 24
Maintenance
Maintenance
Precautions
WARNING:
• Always follow safety guidelines when working on the pump. See Introduction and Safety (page 3).
• Disconnect and lock out electrical power before installing or servicing the pump.
• Make sure that the pump cannot roll or fall over and injure people or damage property.
• Rinse the pump thoroughly with clean water before working on the pump.
• 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 guidelines
During 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, and O-rings with grease.
During 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 testrun before normal operation.
Torque values
Screw and nuts
Stainless steel, A2 and A4
Property
class
Torque,
Nm (ftlbs)
Carbon steel and alloyed steel
70 +8012.7 (2) 5.4 (4) 9.3 (6.9) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) 629 (464) 1240
M4 M5 M6 M8 M10 M12 M16 M20 M24 M30
(915)
1
Property class 70 is torque tightened as class 80.
22 Flygt 3102 Service and Repair Instructions
Page 25
11
Maintenance (Continued)
Torque,
Nm (ftlbs)
Screws with countersunk heads
Stainless steel, A2 and A4
Torque,
Nm (ft-lbs)
Carbon steel and alloyed steel
Torque,
Nm (ft-lbs)
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
12.9
Property
class
70 +8011.2 (0.9) 2.7 (2) 5.4 (4) 9.3 (6.9) 22 (16) 44 (32) 76 (56) 120 (88) 187 (138)
8.8 2.3 (1.7) 4.6 (3.4) 7.8 (5.8) 19 (14) 38 (28) 65 (48) 158 (116) 308 (228) 532 (392)
10.9
12.9
4.0 (2.9) 8.1 (6) 14 (10.3) 33 (24.3) 65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840
4.9 (3.6) 9.7 (7.2) 17 (12.5) 40 (30) 79 (58) 136 (100) 333 (245) 649 (480) 1120
M4 M5 M6 M8 M10 M12 M16 M20 M24
3.2 (2.4) 6.5 (4.8) 11(8) 26 (19) 52 (38) 91 (67) 222 (164) 433 (320) 748 (552)
3.9 (2.9) 7.8 (5.8) 14 (10.3) 32 (23.6) 63 (46) 109 (80) 266 (196) 519 (383) 896 (661)
(825)
(966)
(1357)
2210
(1630)
Change the oil
This image shows the plugs that are used to change the oil.
1. Oil plug
Empty the oil
WARNING:
The oil housing may be pressurized. Hold a rag over the oil plug to prevent oil from spraying out.
1. Place the pump in a horizontal position and unscrew the oil plug.
If the pump has a hole with the markings "oil out" it is important that this hole is used for drainage.
Flygt 3102 Service and Repair Instructions 23
Page 26
Maintenance (Continued)
2. Place a container under the pump and turn the pump.
3. Unscrew the other oil plug.
If this hole has the markings "oil in", raise the pump upright for a short period of time during
drainage in order to drain all the oil.
Fill with oil
The oil should be a paraffin oil with viscosity close to ISO VG32.
1. Replace the O-rings of the oil plugs.
2. Refit an oil plug in the hole that faces downwards or is marked "oil out", and tighten.
Tightening torque: 10-40 Nm (7.5-29.5 ft-lbs)
3. Fill with oil through the hole on the opposite side or the hole marked "oil in".
If the hole is marked "oil in", slightly tilt the pump and lower it again in order to fill the pump with
the correct quantity.
Quantity: approximately 1.0 liters (1.1 quarts)
24 Flygt 3102 Service and Repair Instructions
Page 27
4. Refit the oil plug and tighten.
Tightening torque: 10-40 Nm (7.5-29.5 ft-lbs)
Disassemble the pump
Before the pump is disassembled the pump has to be drained of all coolant. For information, see Empty the
oil (page 23).
For specially approved drive units, follow the instructions in Specially approved drive units during the disassembly.
Follow the applicable instructions when removing the mechanical seal.
• Griploc seals: Remove the inner mechanical seal: Griploc (page 29)
• For seals type T, see information included in the spare part.
• Other seals: Remove the mechanical seal (page 27)
1. Remove the motor cable and the stator housing (page 25)
2. Remove the pump housing (page 26)
3. Remove the mechanical seal (page 27)
a) Remove the outer mechanical seal: Griploc (page 27)
b) Remove the outer mechanical seal (page 27)
c) Remove the oil housing bottom (page 28)
d) Remove the inner mechanical seal: Griploc (page 29)
e) Remove the inner mechanical seal (page 29)
4. Remove the bearings
5. Remove the stator from the stator housing (page 30)
Maintenance (Continued)
Remove the motor cable and the stator housing
1. Remove the stator housing:
a) Remove the stator housing screws.
b) Lift of the stator housing from the oil housing.
2. Open the entrance cover.
Flygt 3102 Service and Repair Instructions 25
Page 28
Maintenance (Continued)
3. Disconnect the motor cable and the stator leads from the terminal board.
4. Pull out the stator leads through the cable lead trough in the stator housing.
5. Undo the cable entry and pull the motor cable out of the entrance cover.
Inspect the cable for damage, especially close to the cable entry.
Remove the pump housing
1. Remove the pump housing screws.
2. Fasten lifting eye bolts in the oil housing screw holes.
Use M10 eye bolts.
3. Lift of the rotor assembly with the oil housing and impeller from the pump housing.
26 Flygt 3102 Service and Repair Instructions
Page 29
For instructions about how to remove the impeller, see Replace the impeller (page 42).
Remove the mechanical seal
Remove the outer mechanical seal: Griploc
1. Loosen the seal locking screw.
Use a 8 mm flat bladed screwdriver
2. Remove the rotating seal unit.
3. Remove the stationary seal ring including its O-ring.
Maintenance (Continued)
Remove the outer mechanical seal
1. Remove the grip ring:
a) Fit the mounting tool and turn the allen key to release the grip ring.
Use the mounting tool.
b) Remove the grip ring.
Flygt 3102 Service and Repair Instructions 27
Page 30
Maintenance (Continued)
2. Remove the outer rotating seal ring.
Use special pliers.
3. Remove the outer stationary seal ring.
Remove the oil housing bottom
1. Undo the socket hexagon screws which hold the oil housing together.
28 Flygt 3102 Service and Repair Instructions
Page 31
2. Lift off the rotor unit together with the bearing holder.
Maintenance (Continued)
Remove the inner mechanical seal: Griploc
Use the instructions in Remove the outer mechanical seal: Griploc (page 27) to remove the inner mechanical seal.
Remove the inner mechanical seal
1. Remove the grip ring:
a) Fit the mounting tool and turn the allen key to release the grip ring.
Use the mounting tool.
b) Remove the grip ring.
Flygt 3102 Service and Repair Instructions 29
Page 32
Maintenance (Continued)
2. Remove the rotating seal ring.
Use two screwdrivers.
3. Remove the O-ring.
Remove the stator from the stator housing
NOTICE:
Make sure that the lifting device is suitable for use near heat and open flames.
1. Lift the stator.
2. Place a suitable protecting device under the stator.
30 Flygt 3102 Service and Repair Instructions
Page 33
Use a protective material that will protect the stator from breaking when released.
3. Quickly heat the stator housing in order to loosen the stator.
Use an LP gas set. When the stator has released and dropped down, extinguish the burners and allow
the stator housing and the stator to cool.
Assemble the pump
Maintenance (Continued)
For specially approved drive units, follow the instructions in Empty the oil (page 23)during the assembly.
1. Install the stator in the stator housing (page 31)
2. Install the bearings
3. Install the mechanical seal (page 32)
a) Install the inner mechanical seal: Griploc (page 32)
b) Install the oil housing bottom (page 34)
c) Install the outer mechanical seal: Griploc (page 35)
4. Install the motor cable in the stator housing (page 35)
5. Replace wear parts and cutting parts (page 37)
a) Replace the wear ring: C-impeller (page 37)
b) Replace the wear protection: H-impeller (page 39)
c) Replace the insert ring (page 39)
d) Replace and adjust the removable guide pin
e) Replace the cutting ring (page 39)
f) Replace the pump housing cover (page 40)
After the pump is assembled it has to be filled with coolant. For more information, see Fill with oil.
Install the stator in the stator housing
1. Heat the stator housing to about 150°C (302°F).
Flygt 3102 Service and Repair Instructions 31
Page 34
Maintenance (Continued)
2. Then quickly lower the stator into the stator housing until it bottoms.
Use a lifting device.
NOTICE:
The stator must be oriented in the stator housing so that the stator leads reach the motor cable
connection.
3. Connect the leads according to applicable cable chart.
Install the mechanical seal
Install the inner mechanical seal: Griploc
The following items are needed for these procedures:
• Oil
• Grease
• 8 mm flat bladed screwdriver
• Mounting tool (included)
1. Mount the stationary seal ring:
a) Lubricate the O-ring.
If the stationary seal ring has a mechanical torque lock the O-ring can be lubricated with oil or grease.
32 Flygt 3102 Service and Repair Instructions
Page 35
b) Press the stationary seal ring into its seat.
Make sure that the highly polished surface is facing out.
Maintenance (Continued)
2. Clean the seal face on the shaft.
3. Fit the mechanical seal:
a) Apply oil to the seal surface.
b) Lubricate the shaft with grease.
c) Fit the rotating seal unit to the shaft using the mounting tool.
Flygt 3102 Service and Repair Instructions 33
Page 36
Maintenance (Continued)
4. Fasten the seal using a screwdriver.
d) Compress the seal unit with the mounting tool.
Press the seal as far as it will go without forcing it.
Do not put pressure on the screwdriver while fastening the screw. Tightening torque: 5.4 Nm (4.0 ftlbs.)
5. Remove the mounting tool.
Install the oil housing bottom
1. Install the oil housing.
Check that the sleeve for the oil refill can pass unobstructed from the cutouts in the bearing holder.
34 Flygt 3102 Service and Repair Instructions
Page 37
2. Replace the old sealing washers with new ones.
Maintenance (Continued)
3. Fit the 3 self-tapping screws.
Tightening torque: 7 Nm (5 ft-lbs.)
If you have bought an oil housing as a spare part, there will not be any threads in the 3 holes for the
screws (self-tapping screws).
Install the outer mechanical seal: Griploc
Use the instructions in Install the inner mechanical seal: Griploc (page 32) to install the outer mechanical seal.
Install the motor cable in the stator housing
1. Pull the cable into the junction box.
Flygt 3102 Service and Repair Instructions 35
Page 38
Maintenance (Continued)
2. Pull the stator leads into the junction box through the cable-lead-trough in the stator housing.
3. Connect the leads to the terminal board as shown in appropriate cable chart.
4. Assemble and fasten the cable entry.
Check the insulation for the connections with a Megger. The insulation between the phases and
between any phase and earth must be > 5 MΩ.
Make sure that the gland screw bottoms out when fasten.
Cable entry for cables with the
outside diameter of 12–20 mm
Cable entry for cables with the outside diameter of (20)–32
mm ((0.79)–1.26 in.)
(0.47–0.79 in.)
5. Lubricate and fit the O-ring on the bearing holder.
Push it down to the oil housing bottom.
36 Flygt 3102 Service and Repair Instructions
Page 39
6. Install the stator housing.
Maintenance (Continued)
7. Fit and tighten the lubricated screws.
Tightening torque: Torque values (page 22)
Replace wear parts and cutting parts
Replace the wear ring: C-impeller
This procedure only applies to the following pumps:
• 3102.090
• 3102.181
Flygt 3102 Service and Repair Instructions 37
Page 40
Maintenance (Continued)
1. Bend out the wear ring at a suitable point.
2. Knock out the wear ring.
Use a crowbar.
Use a chisel and a hammer.
3. Check that the surface intended for the wear ring is clean and undamaged.
4. Drive in the new wear ring.
To prevent deformation use either a rubber mallet or a wooden block and a hammer.
38 Flygt 3102 Service and Repair Instructions
Page 41
Replace the wear protection: H-impeller
This procedure only applies to the following pumps:
• 3127.090
• 3127.181
1. Remove the wear protection from the oil housing bottom.
2. Check that the surface intended for the wear protection is clean and undamaged.
3. Fit the new wear protection.
To prevent deformation use either a rubber mallet or a wooden block and a hammer.
Replace the insert ring
This procedure does not apply to the following pumps:
• 3102.170
• 3102.890
1. Turn the pump housing upside down.
2. Press out the insert.
3. Turn back the pump housing.
4. Check the surface intended for the insert ring is clean and undamaged.
5. Press in a new insert ring until it bottoms out.
Replace the cutting ring
Maintenance (Continued)
This procedure only applies to the following pumps:
• 3102.170
• 3102.890
When the impeller and cutter wheel are replaced, also replace the cutting ring.
1. Remove the cutter wheel from the pump housing.
2. Knock out the cutting ring from the inside of the pump housing.
Flygt 3102 Service and Repair Instructions 39
Page 42
Maintenance (Continued)
3. Turn the pump housing.
4. Check that the surface intended for the cutting ring is clean and undamaged.
5. Knock the new cutting ring in position.
6. Fit the cutter wheel on the outside of the pump housing.
7. Fit and tighten the lubricated screw.
Tightening torque: see Torque values (page 22)
Replace the pump housing cover
This procedure only applies to the following pumps:
• 3102.090
• 3102.181
To be able to replace the pump housing cover, the pump housing and impeller must have been removed.
1. Remove the pump housing cover and its O-ring.
40 Flygt 3102 Service and Repair Instructions
Page 43
2. Fit the new pump housing cover into the pump housing.
Check that the guide boss fits into the corresponding recess of the pump housing.
Maintenance (Continued)
3. Fit the new O-ring into its groove.
Install the pump housing
1. If used, fit the new lubricated O-ring between the oil housing bottom and the pump housing.
2. Install the pump housing.
3. Fit and tighten the lubricated screws.
Tightening torque: Torque values (page 22)
Flygt 3102 Service and Repair Instructions 41
Page 44
Maintenance (Continued)
4. If applicable, fit the sliding bracket.
Replace the impeller
Required tools:
• 8 mm hexagon bit adapter with an extension of at least 125 mm (4.92 in.)
• Impeller puller
If applicable, contact your local ITT representative for correct type and size.
• Rod (wooden or copper) for locking the impeller in place, if applicable.
• Two crowbars, if applicable
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.
42 Flygt 3102 Service and Repair Instructions
Page 45
Replace the C- or D-impeller
Maintenance (Continued)
Figure 6: C-impeller
Remove the C- or D-impeller
CAUTION:
A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.
1. Remove the pump housing or the suction cover.
Figure 7: D-impeller
2. Remove the impeller screw.
If applicable, use the rod.
Flygt 3102 Service and Repair Instructions 43
Page 46
Maintenance (Continued)
3. Remove the washer.
4. Remove the impeller.
Figure 8: C-impeller Figure 9: D-impeller
Use the impeller puller or the crowbars.
Figure 10: D-impeller
5. Remove the conical sleeve.
Install the C- or D-impeller
1. Prepare the shaft:
a) Make sure that the end of the shaft is clean and free from burrs.
Polish off any flaws with a fine emery cloth.
b) Lubricate the shaft.
NOTICE:
Do NOT grease the conical part of the shaft.
2. Mount the impeller:
a) Fit the conical sleeve onto the shaft.
44 Flygt 3102 Service and Repair Instructions
Page 47
b) Fit the washer on the lubricated impeller screw.
c) Press the impeller onto the shaft with the impeller screw.
NOTICE:
The impeller may get jammed against the oil housing bottom. Pull out the impeller a couple of
mm, when mounting a C impeller with the pressure class LT.
3. Tighten the impeller screw.
If applicable, use the rod.
Tightening torque: 65 Nm (48 ft-lbs)
Maintenance (Continued)
Check that the impeller can rotate freely.
4. Mount the pump housing:
a) T-, Z-installation only: Fit a new lubricated O-ring to the pump housing.
b) Fit the pump housing.
c) Fit and tighten the lubricated screws.
Tightening torque: 57 Nm (42 ft-lbs).
Flygt 3102 Service and Repair Instructions 45
Page 48
Maintenance (Continued)
Replace the F-impeller
Remove the F-impeller
CAUTION:
A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.
1. Remove the suction cover.
2. Remove the impeller screw, the ring, and the washers.
If applicable, use the rod.
46 Flygt 3102 Service and Repair Instructions
Page 49
3. Remove the impeller.
Use the impeller puller or the crowbars.
4. Remove the conical sleeve.
Install the F-impeller
1. Prepare the shaft:
a) Make sure that the end of the shaft is clean and free from burrs.
b) Lubricate the shaft.
Maintenance (Continued)
Polish off any flaws with a fine emery cloth.
NOTICE:
Do NOT grease the conical part of the shaft.
2. Mount the impeller:
a) Fit the conical sleeve onto the shaft.
b) Fit one plain washer with a thickness of 2 mm (0.08 in.), eight adjustment washers with a thickness
of 0.5 mm (0.02 in.), and eight adjustment washers with a thickness of 0.2 mm (0.008 in.) onto the
impeller.
c) Press the impeller onto the shaft with the impeller screw.
3. Fasten the impeller:
a) Prevent the impeller from rotating by inserting the rod through the pump housing outlet.
b) Tighten the impeller screw.
If applicable, use the rod.
Tightening torque: 65 Nm (48 ft-lbs)
Flygt 3102 Service and Repair Instructions 47
Page 50
Maintenance (Continued)
4. Adjust the impeller:
Check that the impeller can rotate freely.
a) Measure the distance between the edge of the impeller and the pump housing cover.
The correct distance should be 0.5-1.5 mm (0.02-0.06 in.). Add or remove the appropriate number
of adjusting washers in order to achieve correct distance.
b) Tighten the impeller screw.
If applicable, use the rod.
Tightening torque: 65 Nm (48 ft-lbs)
Check that the impeller can rotate freely.
5. Fit a new greased O-ring to the into the groove in the pump housing.
48 Flygt 3102 Service and Repair Instructions
Page 51
Maintenance (Continued)
6. Mount the suction cover:
a) Fit the studs on the pump housing.
Use Loctite 603 locking liquid in order to secure the studs.
b) Fit two adjustment washers with a thickness of 2 mm (0.08 in.) and 8-10 adjustment washers with
a thickness of 0.25 mm (0.01 in.), onto each stud.
c) Fit the suction cover to the studs.
d) Fit the lock nuts onto the studs.
e) Tighten the nuts.
Tightening torque: 17 Nm (13 ft-lbs)
7. Adjust the suction cover:
a) Measure the distance between the impeller and the suction cover.
The correct distance should be 0.5-1 mm (0.02-0.04 in.). Add or remove the appropriate number
of adjusting washers in order to achieve the correct distance.
Flygt 3102 Service and Repair Instructions 49
Page 52
Maintenance (Continued)
b) Tighten the nuts.
Tightening torque: 17 Nm (13 ft-lbs)
8. Raise the pump to a vertical position.
Check that the impeller can rotate freely.
50 Flygt 3102 Service and Repair Instructions
Page 53
Replace the M-impeller
Maintenance (Continued)
Figure 11: M-impeller
Remove the M-impeller
CAUTION:
A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.
1. Remove the pump housing.
2. Remove the impeller screw and outer sleeve.
If applicable, use the rod.
3. Refit the impeller screw.
Flygt 3102 Service and Repair Instructions 51
Page 54
Maintenance (Continued)
4. Fit the impeller puller and pull off the impeller and cutter wheel.
Place a protector between the screw head and the impeller puller.
5. Remove the conical sleeve.
Install the M-impeller
1. Make sure that the end of the shaft is clean and free from burrs.
Polish off any flaws with a fine emery cloth.
2. Mount the impeller:
a) Fit the conical sleeve onto the shaft.
52 Flygt 3102 Service and Repair Instructions
Page 55
Maintenance (Continued)
b) Fit the cutter wheel into the impeller.
c) Fit the outer sleeve onto the lubricated impeller screw.
d) Fit the impeller with the cutter wheel onto the shaft with the impeller screw.
Do not tighten the impeller screw.
3. Adjust the impeller:
a) Use a straightedge and a vernier to measure the distance between the vanes of the impeller and the
shoulder for the pump housing on the oil housing bottom.
Pressure class Phase Hz Distance
LT 1 60 43.5±0.3 mm
(1.71±0.01 in.)
LT 3 50, 60 46.0±0.3 mm
(1.81±0.01 in.)
HT 1,3 50, 60 43.5±0.3 mm
(1.71±0.01 in.)
b) Slide the impeller on to the shaft until you reach the correct distance.
4. Tighten the impeller screw.
If applicable, use the rod.
Tightening torque: 65 Nm (48 ft-lbs)
Flygt 3102 Service and Repair Instructions 53
Page 56
Maintenance (Continued)
5. Mount the pump housing:
Check that the impeller can rotate freely.
a) Fit a new lubricated O-ring into the pump housing.
b) Fit the pump housing.
c) Fit and tighten the lubricated screws.
Tightening torque: 57 Nm (42 ft-lbs).
54 Flygt 3102 Service and Repair Instructions
Page 57
Replace the N-impeller
Maintenance (Continued)
Remove the N-impeller
CAUTION:
A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.
1. Remove the pump housing.
2. Remove the impeller screw.
Use the impeller puller or the crowbars.
3. Remove the impeller.
4. Remove the washer and the conical sleeve.
Install the N-impeller
1. Make sure that the end of the shaft is clean and free from burrs.
Polish off any flaws with a fine emery cloth.
2. Mount the impeller:
a) Fit the conical sleeve onto the shaft.
b) Fit the washer on the lubricated impeller screw.
c) Fit the impeller to the shaft.
d) Hand-tighten the impeller screw enough to prevent it from falling off.
Flygt 3102 Service and Repair Instructions 55
Page 58
Maintenance (Continued)
3. Mount the pump housing:
4. Adjust the impeller:
a) Fit the pump housing.
b) Fit and tighten the lubricated screws.
Tightening torque: 57 Nm (42 ft-lbs).
a) Measure the distance between the lower edge of the impeller and the insert ring.
The correct distance is 0.2-0.8 mm (0.084-0.032 in.).
b) Slide the impeller on the shaft until the correct clearance is reached.
5. Tighten the impeller screw.
If applicable, use the rod.
Tightening torque: 65 Nm (48 ft-lbs)
Check that the impeller can rotate freely.
CAUTION:
Beware of the pinch point hazard between the rotating impeller and the guide pin.
56 Flygt 3102 Service and Repair Instructions
Page 59
Requirements for Ex-approved products
Basic requirements
• Only personnel authorized by the manufacturer are allowed to repair, maintain and service Exapproved products.
• Always follow the information about repair, maintenance and service in the Ex manual while working
on an Ex-approved product. For the Ex manual, see the W&WW Intranet or contact your local Excoordinator.
• To ensure that the product complies with the regulations and approval of the authorities, use only
original spare parts.
• Always check the dimensions of vital parts before assembly, this applies to spare parts as well.
Failure to meet the above requirements may render the Ex-approval invalid.
Background
In an Ex-approved product the gaps between different parts, for example between the stator housing and
the junction box, must be tight enough and long enough to prevent any sparks from the interior of the
product from escaping out and igniting surrounding gases. To be able to measure these flameproof gaps
accurately all surfaces included in a gap must be clean and free from damages.
The approval drawings show the gaps, in these drawings also called joints, that must be measured and the
surfaces that must be inspected for damages. For approval drawings of the product, see the W&WW
Intranet or contact your local Ex-coordinator.
Maintenance (Continued)
Documents required
• Approval drawing of the pump at issue
• Ex manual
• Report of findings, measurements, tests, and similar, see examples in the Ex manual
Temporary storage guidelines
If a disassembled product has to await ordered spare parts, all parts have to be carefully lubricated and
covered. Store all parts separately to ensure that no damages will occur.
Service the pump
Regular inspection and service of the pump ensures more reliable operation, severe operating conditions
will require more frequent inspections.
If the seals have been replaced an inspection of the oil is recommended after one week of operation.
Type of service Inspection interval
Intermediate service
Major service in an
authorized service shop
• Every year (standard applications)
• For hot water applications (≤ 70°C [160°F]) with the following mode of
operation:
• Intermittent: twice a year
• Continuous: every 1000 hours
• Type of installation:
• Permanent: 3 years
• Portable: once a year
• For hot water applications (≤ 70°C [160°F]) with these mode of operation:
• Intermittent: once a year
• Continuous: every 4000 hours
Intermediate service
Flygt 3102 Service and Repair Instructions 57
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Maintenance (Continued)
Service of the... Action
Cable
Connection to power Check that the connections are properly tightened.
Electrical cabinets Check that they are clean and dry.
Impeller
Stator housing
Insulation
Junction box Check that it is clean and dry.
Lifting device Check that local safety regulations are followed.
Lifting handle
O-rings
Overload protection and other
protections
Personnel safety devices Check the guard rails, covers, and other protections.
Rotation direction Check the impeller rotation.
Oil housing Fill with new oil, if necessary.
Terminal block/closed end splice Check that the connections are properly tightened.
Thermal contacts Check the resistance of the leakage sensor.
Voltage and amperage Check the running values.
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.
1. Check the impeller clearance.
2. Adjust the impeller, if necessary.
1. Drain all liquid, if any.
2. Check the resistance of the leakage sensor.
Normal value approx.1500 ohms, alarm approx. 430 ohms.
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.
1. Check the screws.
2. Check the condition of the lifting handle.
3. Replace if necessary.
1. Replace the oil plug O-rings
2. Replace the O-rings at the entrance or junction cover.
3. Grease the new O-rings.
Check the correct settings.
Normally closed circuit; interval 0–1 ohm.
Major service
For a major service, take this action, in addition to the tasks listed under intermediate service.
Service of the... Action
Support and main bearing Replace the bearings with new bearings.
Mechanical seal Replace with new seal units.
Service in case of alarm
For information about indication values for sensors, see Sensor connection.
Alarm source Action
CLS Check for water in the oil in the oil housing. If the oil contains to
much water:
1. Drain the oil and water.
2. Replace with new oil.
58 Flygt 3102 Service and Repair Instructions
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Alarm source Action
FLS
1. Check for liquid in the stator housing.
2. Drain all liquid, if any.
3. Check the mechanical seal unit, the O-rings, and the cable
entry, if liquid was found.
Thermal contact Check the start and stop levels.
The overload protection Check that the impeller can rotate freely.
Maintenance (Continued)
Flygt 3102 Service and Repair Instructions 59
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Troubleshooting
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.
The impeller is stuck. Clean:
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 ITT 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
• 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 ITT service shop.
Always state the serial number of your pump when you contact ITT, see Product Description (page 8).
60 Flygt 3102 Service and Repair Instructions
Page 63
Troubleshooting (Continued)
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.
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 ITT service shop.
• Clean the level regulators.
• Check the functioning of the level regulators.
• Check the contactor and the control circuit.
• Replace all defective items.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local ITT service shop.
Always state the serial number of your pump when you contact ITT, see Product Description (page 8).
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.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local ITT service shop.
Always state the serial number of your pump when you contact ITT, see Product Description (page 8).
Check that:
• The distance between the start and stop levels is not too small.
• The non-return valve(s) work(s) properly.
• The rinser is not too long without a non-return valve.
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.
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.
Flygt 3102 Service and Repair Instructions 61
Page 64
Troubleshooting (Continued)
Cause Remedy
The motor protection is set too low. Set the motor protection according to the data plate and if applicable
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.
the cable chart.
• 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 ITT 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 ITT 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 ITT service shop.
Replace the overload protection.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local ITT service shop.
Always state the serial number of your pump when you contact ITT, see Product Description (page 8).
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.
One or more of the valves are set
in the wrong positions.
The impeller is difficult to rotate
by hand.
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
impeller, pump, and casing.
• If it is a 3-phase pump, transpose two phase leads.
• If it is a 1-phase pump:
Contact the local ITT service shop.
• Reset the valves that are set in the wrong position.
• Replace the valves, if necessary.
• Check that all valves are correctly installed according to media flow.
• Check that all valves open correctly.
• Clean the impeller.
• Clean out the sump.
• Check that the impeller is properly trimmed.
Replace the worn parts.
62 Flygt 3102 Service and Repair Instructions
Page 65
Troubleshooting (Continued)
Cause Remedy
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.
If the problem persists, refer to the Flygt Service Guide on the web or contact the local ITT service shop.
Always state the serial number of your pump when you contact ITT, see Product Description (page 8).
Flygt 3102 Service and Repair Instructions 63
Page 66
Technical Reference
Technical Reference
Exploded view
Figure 12: 3201.090/3201.095
64 Flygt 3102 Service and Repair Instructions
Page 67
Technical Reference (Continued)
Figure 13: 3201.170
Flygt 3102 Service and Repair Instructions 65
Page 68
Technical Reference (Continued)
Figure 14: 3201.180/3201.185
66 Flygt 3102 Service and Repair Instructions
Page 69
Technical Reference (Continued)
Figure 15: 3201.890
For information about the different hydraulic ends and part names, see Parts List.
Tools
Service guide
The Flygt Service Guide (FSG) is a search engine for pump part numbers and spare parts. The service
guide is available at www.ittwww.com. For a valid password, contact flygtpumpar@flygt.com.
Flygt 3102 Service and Repair Instructions 67
Page 70
Technical Reference (Continued)
List of tools
Part number Denomination Range of use
820490 Socket head screw Together with 841362 for
840867 Press tong Connection sleeves
841016 Ratchet handle Sockets
841135 Combination wrench (8 mm) Cable clamp (cable OD 20-32 mm)
841156 Combination wrench (41 mm) Cable entry (cable OD 10-20 mm)
841304 Hexagon bit adapter (6 mm) Junction box cover
841305 Hexagon bit adapter (8 mm) Impeller screw, lifting handle
841306 Hexagon bit adapter (10 mm) Stator housing, pump housing
841362 Puller spread 250 mm /reach 200mmD-impeller, MT- impellers
841387 Socket wrench (13 mm) Suction cover (F-version)
841395 Socket wrench (16 mm) Oil plug
841476 Hexagon bit adapter (5 mm, long) Oil housing bottom, terminal
841555 Extension bar (L = 125 mm) Impeller screw
841566 Torque wrench 0-137 Nm Torque tightening
841650 Screw driver Cable clamp (20-32 mm)
841658 Screw driver Terminal
841673 Screw driver CLS-sensor removal/fitting
842048 Puller complete spread 100 mm /
2166800 Special pliers Rotating seal unit
2499202 Impeller puller LT-impellers, curves 440-442
2957202 Impeller puller unit LT-impeller, curves 410-412
3036000 Impeller puller unit MT-impeller, curves, 436-438
3441300 Impeller puller unit HT-impellers
3892502 Hexagon head screw F-impellers
3982100 Mounting socket Stationary seal ring
4578900 Mounting tool Grip ring seals
4669701 Bearing puller Main bearing removal/fitting
6572200 Mounting/dismounting tool Insert rings for N-impellers
6895401 Mounting/dismounting tool Stator
NEVACLOG
NEVACLOG, curves 430-435
holder
Inner bearing
reach 100mm
68 Flygt 3102 Service and Repair Instructions
Page 71
Page 72
What can ITT Water & Wastewater do for you?
Integrated solutions for fluid handling are offered by ITT Water &Wastewater as a
world leader in transport and treatment of wastewater. We provide a complete range
of water, wastewater and drainage pumps, equipment for monitoring and control,
units for primary and secondary biological treatment, products for filtration and
disinfection, and related services. ITT Water & Wastewater, headquartered in
Sweden, operates in some 140 countries across the world, with own plants in
Europe, China and North and South America. The company is wholly owned by the
ITT Corporation of White Plains, New York, supplier of advanced technology
products and services.
Visit our Web site for the latest version of this document and more information
www.ittwww.com
ITT Water & Wastewater AB
Gesällvägen 33
174 87Sundbyberg
Sweden
Tel. +46-8-475 60 00
Fax +46-8-475 69 00
© 2009 ITT Corporation. The original instruction is in English. All non-English instructions are translations of the original
instruction. 898245_1.0_en.US_2009-11_SR.3102.090/.095/.170/.181/.185/.890
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