Xylem Flygt 3102 Series Installation, Operation And Maintenance Manual
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Xylem Flygt 3102 Series Installation, Operation And Maintenance Manual

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Installation, Operation, and
Maintenance Manual
90016001_2.0
Flygt 3102

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  • Page 1 Installation, Operation, and Maintenance Manual 90016001_2.0 Flygt 3102...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents 1 Introduction and Safety......................3 1.1 Introduction.......................... 3 1.2 Safety terminology and symbols..................3 1.3 User safety..........................4 1.4 Ex-approved products......................4 1.5 Special hazards........................5 1.5.1 Biological hazards......................5 1.5.2 Wash the skin and eyes....................6 1.6 Protecting the environment....................6 1.7 End of life product disposal....................6 1.8 Spare parts..........................6 1.9 Warranty..........................
  • Page 4 Table of Contents 5 Operation..........................41 5.1 Precautions......................... 41 5.2 Estimate zinc anode replacement intervals..............41 5.3 Start the pump........................42 6 Maintenance..........................43 6.1 Precautions......................... 43 6.2 Torque values........................44 6.3 Change the oil........................44 6.4 Service the pump.......................46 6.4.1 Inspection........................47 6.4.2 Overhaul........................48 6.4.3 Service in case of alarm....................48 6.5 Replace the impeller......................

  • Page 5: Introduction And Safety

    This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding.

  • Page 6: User Safety

    These are the personnel requirements for Ex-approved products in potentially explosive atmospheres: • All work on the product must be carried out by certified electricians and Xylem authorized mechanics. Special rules apply to installations in explosive atmospheres. • All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas.

  • Page 7: Special Hazards

    • Do not modify the equipment without approval from an Ex-approved Xylem representative. • Only use original Xylem spare parts that are provided by an Ex-approved Xylem representative. • The thermal contacts that are fitted to the stator windings must be connected correctly to a separate motor control circuit and in use.

  • Page 8: Wash The Skin And Eyes

    • Clean-up of spills Exceptional sites CAUTION: Radiation Hazard Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon. 1.7 End of life product disposal Handle and dispose of all waste in compliance with local laws and regulations.

  • Page 9: Warranty

    1 Introduction and Safety 1.9 Warranty For information about warranty, see the sales contract. Flygt 3102 Installation, Operation, and Maintenance Manual...

  • Page 10: Transportation And Storage

    2 Transportation and Storage 2 Transportation and Storage 2.1 Examine the delivery 2.1.1 Examine the package 1. Examine the package for damaged or missing items upon delivery. 2. Record any damaged or missing items on the receipt and freight bill. 3.

  • Page 11: Temperature Ranges For Transportation, Handling And Storage

    • The minimum height between the lifting hook and the floor must be sufficient to lift the unit. Contact a Xylem representative for more information. • The lifting equipment must be able to hoist the unit straight up and down, preferably without the need for resetting the lifting hook.

  • Page 12: Storage Guidelines

    2 Transportation and Storage 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.

  • Page 13: Product Description

    3 Product Description 3 Product Description Products included Pump 3102.060 3102.070 3102.090 3102.160 3102.170 3102.181 3102.190 3102.760 3102.770 3102.890 3102.900 3102.910 3102.920 3102.930 3102.960 3102.970 Hard-Iron ™ Stainless steel Cast iron, gray Pump-specific information For the specific weight, current, voltage, power ratings, and speed of the pump, see the data plate of the pump.
  • Page 14 • Modifications to the unit or installation should only be carried out after consulting with Xylem. • Original spare parts and accessories that are authorized by Xylem are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation.

  • Page 15: Sensors And Monitoring Equipment

    3 Product Description Parts Position Denomination Description Shaft The shaft is made of stainless steel with an integrated rotor. Impeller There are multiple types of impellers. For information about the pumps impellers, see Parts List. Mechanical seals One inner and one outer seal in a combination of materials: •...

  • Page 16: The Data Plate

    3 Product Description • Ex-approved pumps must have thermal contacts connected to the control panel. • The sensors must be connected to either the MiniCAS II monitoring equipment or an equivalent equipment. • The monitoring equipment must be of a design that makes automatic restart impossible.

  • Page 17: Approvals

    3 Product Description 24.Notified body, only for EN-approved Ex products 25.WEEE-Directive symbol Figure 5: The data plate 3.4 Approvals Product approvals for hazardous locations Pump Approval • 3102.070 European Norm (EN) • 3102.090 • ATEX Directive • 3102.190 • EN 60079-0:2012/A11:2013, EN 60079-1:2014, EN ISO 80079-36:2016, •...

  • Page 18: Product Denomination

    3 Product Description 1. Approval 2. Approval authority and Approval number 3. Approved drive unit 4. Cable entry temperature 5. Stall time 6. Starting current or Rated current 7. Duty class 8. Duty factor 9. Input power 10.Rated speed 11.Additional information 12.Maximum ambient temperature 13.Serial number 14.ATEX marking...
  • Page 19 3 Product Description Codes and parameters XXYYYY YYY YYY YYYY Type of Callout Number Indication Type of code Sales denomination Product code Serial number Parameter Hydraulic end Type of installation Sales code Version Production year Production cycle Running number Flygt 3102 Installation, Operation, and Maintenance Manual...

  • Page 20: Installation

    4 Installation 4 Installation 4.1 Precautions Before starting work, make sure that the safety instructions have been read and understood. DANGER: Electrical Hazard Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized.

  • Page 21: Install With P-Installation

    4 Installation NOTICE: Never force piping to make a connection with a pump. Authority regulation Vent the tank of a sewage station in accordance with local plumbing codes. Fasteners • Only use fasteners of the correct size and material. • Replace all corroded or damaged fasteners. •...

  • Page 22: Install With S-Installation

    4 Installation Be careful when you align and position the discharge connection in relation to the access frame. 3. Place the discharge connection in position, and tighten the nuts. 4. Install the guide bars: a) Secure the guide bars in the bracket. b) Check that the guide bars are placed vertically.

  • Page 23: Install With T-Installation

    4 Installation Alternatively, the pump can be suspended with chains just above the sump bottom. Make sure that the pump cannot rotate at start-up or during operation. 5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions.

  • Page 24: Install With Z-Installation

    4 Installation NOTICE: The risk of freezing is particularly high in T- or Z-installations. 1. Fasten the pump: a) Bolt the stationary suction connection to the concrete base. b) Bolt the pump to the suction connection. 2. Make sure that the pump is vertical for the T-installation. 3.

  • Page 25: Install With F-Installation

    4 Installation 1. Fasten the pump: a) Bolt the stationary suction connection to the concrete base. b) Bolt the pump to the suction connection. 2. Make sure that the pump is vertical for the T-installation or horizontal for the Z- installation.

  • Page 26: Install With L-Installation

    4 Installation 4.7 Install with L-installation In the L-installation, the pump is installed in a vertical, semipermanent, wet well column pipe arrangement. The well is divided into a suction part and a discharge part. The pump end is equipped with guide vanes. These requirements and instructions only apply when the installation is made according to the dimensional drawing.

  • Page 27: Install With X-Installation

    4 Installation Make sure that the cable is kept taut in the center of the column pipe and that it is not sharply bent or pinched. b) If the discharge column is pressurized, then install a cable entry seal unit in the side of the column.

  • Page 28: Make The Electrical Connections

    4 Installation NOTICE: A pump prepared for X-installation is only approved to be used in P- or S-installation. Never use it in T- or Z-installation For installation instructions, see appropriate mechanical accessories. 4.9 Make the electrical connections 4.9.1 General precautions DANGER: Electrical Hazard Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized.

  • Page 29: Grounding (Earthing)

    4 Installation • If the pump will be connected to the public mains, then the supply authority must be notified before installing the pump. When the pump is connected to the public power supply, it can cause flickering of incandescent lamps when started. •...

  • Page 30: Prepare The Subcab ™ Cables

    4 Installation WARNING: Electrical Hazard If the power cable is jerked loose, then the ground (earth) conductor must be the last conductor to come loose from its terminal. Make sure that the ground (earth) conductor is longer than the phase conductors at both ends of the cable. WARNING: Electrical Hazard Risk of electrical shock or burn.

  • Page 31: Connect The Motor Cable To The Pump

    4 Installation d) Twist T1+T2 and T3+T4. e) Put a shrink tube over the control element. Make sure that the conductive aluminum foil and drain wire are covered. ™ 3. Prepare the ground (earth) conductor of the SUBCAB cable: a) Peel the yellow-green insulation from the ground (earth) conductor. b) Check that the ground (earth) conductor is at least 10% longer than the phase conductors in the cabinet.

  • Page 32: Connect The Motor Cable To The Starter And Monitoring Equipment

    4 Installation 1. Entrance cover 2. O-ring 3. Entrance flange 1. Remove the entrance cover and the O-ring from the stator housing. This provide access to the terminal board/closed end splices. 2. Check the data plate to see which connections are required for the power supply. 3.

  • Page 33: Cable Charts

    4 Installation 4. Check the functionality of the monitoring equipment: a) Check that the signals and the tripping function work correctly. b) Check that the relays, lamps, fuses, and connections are intact. Replace any defective equipment. 4.9.6 Cable charts Description This topic contains general connection information.
  • Page 34 4 Installation 1. Stator leads 2. Terminal board 3. Power cable leads L1 L2 L3 T1 T2 T3 T4 4. Stator (internal connection illustrated) U1 V1 W1 W2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 L2 L3 1.
  • Page 35 4 Installation 4.9.6.1 Colors and markings of leads Motor connection Mains SUBCAB SUBCAB 7GX SUBCAB 4GX SUBCAB AWG Screenflex 7GX Screenflex 4GX Screened Colours and marking of main leads BK 1 COLOUR STANDARD STATOR LEADS BK 2 U1,U5 RD BN=Brown U2,U6 GN BK=Black BK 3...
  • Page 36 4 Installation 6 Leads U1 V1 W1 W2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 L1 L2 L3 U1 V1 W1 W2 U2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 L1 L2 L3 L3:1 L2:1...
  • Page 37 4 Installation 9 Leads U1 V1 W1 U5 V5 W5 U2 W2 U1 V1 W1 U1 V1 W1 L1 L2 Y-SER U5 U2 V1 V5 V2 W1 W5 W2 12 Leads V1 W1 W5 V2 W2 U6 W6 U5 V5 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2...
  • Page 38 4 Installation 4.9.6.4 1-phase connection 4 Leads Starter 4 Leads with level regulator U1 Z1 Starter 12 Leads U1 V1 U6 Starter Figure 17: Without built-in starter For more information, see Colors and markings of leads on page 33. Flygt 3102 Installation, Operation, and Maintenance Manual...
  • Page 39 4 Installation 4.9.6.5 Screened cable connection Screened connection SUBCAB & FGB Screened Cable without sep. ground conductor Screen as ground conductor GN/YE shrink hose Screen Mini CAS+AUX FGB Screened Mini CAS Screen - SUBCAB and Screenflex T1 and T2 T1 and T2 twisted White insulation hose White insulation hose...
  • Page 40 4 Installation + FLS Max 12 V Control leads WH/YE Mini T1/*OG/4 T2/*BU/5 *SUBCAB AWG + CLS Max 12 V T1 Control leads BN/RD WH/YE Mini T1/*OG/4 T2/*BU/5 *SUBCAB AWG + FLS+CLS Max 12 V T1 Control leads WH/YE RD/BN RD/BN Mini T1/*OG/4...

  • Page 41: T-Installation: Bleed Air Before Starting Pump

    4 Installation Sensors Value (mA) Definition CLS and thermal contact Overtemperature Leakage (5 seconds delay) CLS, FLS and thermal contact Overtempterature 13.3 36–42 Leakage (0/5 seconds delay) 4.10 T-installation: Bleed air before starting pump 1. Open the valve on the air vent line and bleed out the air. See the following figure. WS008391C 1.
  • Page 42 4 Installation The correct direction of impeller rotation is clockwise when you look at the pump from above. 4. If the impeller rotates in the wrong direction, then do one of these steps: – If the motor has a 1-phase connection, then contact a sales or authorized service representative.

  • Page 43: Operation

    5 Operation 5 Operation 5.1 Precautions Before taking the unit into operation, check the following: • All recommended safety devices are installed. • The cable and cable entry have not been damaged. • All debris and waste material has been removed. NOTICE: Never operate the pump with the discharge line blocked, or the discharge valve closed.

  • Page 44: Start The Pump

    5 Operation 3. Divide the lapsed time in days (between steps 1 and 2) by the anode weight loss in grams to get the calculated anode consumption rate (days/gram). If multiple anodes were weighed, then use the anode which has lost the most weight for this calculation.

  • Page 45: Maintenance

    6 Maintenance 6 Maintenance 6.1 Precautions Before starting work, make sure that the safety instructions have been read and understood. DANGER: Crush Hazard Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. Failure to do so could result in death or serious injury.

  • Page 46: Torque Values

    6 Maintenance 6.2 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, then contact a sales or authorized service representative.
  • Page 47 6 Maintenance 1. Oil plug Empty the oil CAUTION: Compressed Gas Hazard Air inside the chamber may cause parts or liquid to be propelled with force. Be careful when opening. Allow the chamber to de-pressurize before removal of the plug. 1.

  • Page 48: Service The Pump

    6.4 Service the pump Type of Purpose Inspection interval maintenance Initial inspection A Xylem-authorized personnel checks the pump condition. Within the first year of operation. From the results, the personnel recommends the intervals for the periodical inspection and overhaul for the installation.

  • Page 49: Inspection

    6 Maintenance Type of Purpose Inspection interval maintenance Periodical The inspection prevents operational interruptions and Up to every year inspection machine breakdowns. The measures to increase Applies to normal applications and performance and pump efficiency are decided for each operating conditions at media application.

  • Page 50: Overhaul

    6 Maintenance Service item Action Voltage and amperage Check the running values. 6.4.2 Overhaul The basic repair kit includes O-rings, seals, and bearings. For an overhaul, do the following in addition to the tasks listed under Inspection. Service item Action Support and main bearing Replace the bearings with new bearings.

  • Page 51: Replace The Impeller: D

    6 Maintenance 6.5.1 Replace the impeller: D Figure 19: D-impeller 6.5.1.1 Remove the impeller: D CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. 1. Remove the pump housing or the suction cover. WS001966A 2. Remove the impeller screw. If applicable, use the rod.
  • Page 52 6 Maintenance WS001982A Figure 20: D-impeller 3. Remove the washer. 4. Remove the impeller. Use the impeller puller or the crowbars. WS001978A Figure 21: D-impeller 5. Remove the conical sleeve. 6.5.1.2 Install the impeller: D 1. Prepare the shaft: a) Polish off any flaws with a fine emery cloth. The end of the shaft must be clean and free from burrs.
  • Page 53 6 Maintenance 2. Mount the impeller: a) Fit the conical sleeve onto the shaft. WS002022A b) Lubricate the impeller screw threads and contact surface. Ensure that all parts are clean. c) Fit the washer on the lubricated impeller screw. d) Press the impeller onto the shaft with the impeller screw. NOTICE: The impeller may get jammed against the oil housing bottom.

  • Page 54: Replace The F-Impeller

    6 Maintenance 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-lb). WS002018A 6.5.2 Replace the F-impeller 6.5.2.1 Remove the F-impeller CAUTION: Cutting Hazard Worn parts can have sharp edges.
  • Page 55 6 Maintenance WS001976A 3. Remove the impeller. Use the impeller puller or the crowbars. Use the impeller screw to push the impeller. 4. Remove the conical sleeve. 6.5.2.2 Install the F-impeller 1. Prepare the shaft: a) Polish off any flaws with a fine emery cloth. The end of the shaft must be clean and free from burrs.
  • Page 56 6 Maintenance WS002021A c) Lubricate the impeller screw threads and contact surface. Ensure that all parts are clean. d) Press the impeller onto the shaft with the impeller screw. 3. Fasten the impeller: a) Prevent the impeller from rotating by inserting the rod through the pump housing outlet.
  • Page 57 6 Maintenance WS002107A b) Tighten the impeller screw. If applicable, use the rod. Tightening torque: 65 Nm (48 ft-lb). Check that the impeller can rotate freely. 5. Fit a new lubricated O-ring to the into the groove in the pump housing. WS002080A 6.
  • Page 58 6 Maintenance d) Fit the lock nuts onto the studs. e) Tighten the nuts. Tightening torque: 17 Nm (13 ft-lb) WS001937A 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.

  • Page 59: Replace The M-Impeller

    6 Maintenance 6.5.3 Replace the M-impeller Figure 22: M-impeller 6.5.3.1 Remove the M-impeller CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. 1. Remove the pump housing. 2. Remove the impeller screw and outer sleeve. If applicable, use the rod. WS001977A 3.
  • Page 60 6 Maintenance WS001993A 4. Fit the impeller puller and pull off the impeller and cutting wheel. Place a protector between the screw head and the impeller puller. WS002006A 5. Remove the conical sleeve. WS001987A 6.5.3.2 Install the M-impeller 1. Prepare the shaft: a) Polish off any flaws with a fine emery cloth.
  • Page 61 6 Maintenance NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. 2. Mount the impeller: a) Fit the conical sleeve onto the shaft. WS002081A b) Fit the cutting wheel into the impeller. c) Fit the outer sleeve onto the lubricated impeller screw.
  • Page 62 6 Maintenance 4. Tighten the impeller screw. If applicable, use the rod. Tightening torque: 65 Nm (48 ft-lbs) Tighten a further 1/8 turn, 45° after tightening to the correct torque. WS001939A Check that the impeller can rotate freely. 5. Mount the pump housing: a) Fit a new lubricated O-ring into the pump housing.

  • Page 63: Replacing The Adaptive N Impeller

    6 Maintenance ™ 6.5.4 Replacing the Adaptive N impeller 1. Conical sleeve 2. Impeller screw 3. Impeller 4. Insert ring 5. Pump housing WS008398D 1. Shaft end 2. Conical sleeve 3. Impeller screw 4. Adjusting screw CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. NOTICE: When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller.
  • Page 64 6 Maintenance WS008392C WS008391C 1. Inlet line 2. Outlet line 1. Outlet line 3. Line to drain 2. Inlet line 3. Line to drain Figure 24: Z-installation (generic pump shown) 4. Air vent Figure 23: T-installation (generic pump shown) 2. Drain the pump by opening the valve on the drain line. 3.
  • Page 65 6 Maintenance ™ 6.5.4.3 Install the Adaptive N impeller: P, S, T, Z installations ™ To see which pumps are Adaptive N , see Product Description on page 11. 1. Before mounting the impeller, check that the sleeve moves freely up and down by pushing on it.
  • Page 66 6 Maintenance 5. Secure the impeller in place with the screw. 6. Check that the impeller is in its lowest position: a) Insert two screwdrivers as shown in the following figure, and push the impeller downwards. 7. Mount the pump housing: Flygt 3102 Installation, Operation, and Maintenance Manual...
  • Page 67 6 Maintenance a) Fit the pump housing. b) Fit and tighten the lubricated screws. Tightening torque: 57 Nm (42 ft-lb). 8. Loosen the impeller screw and turn the adjustment screw clockwise until the impeller makes contact with the insert ring. 9.

  • Page 68: Troubleshooting

    7 Troubleshooting 7 Troubleshooting 7.1 Electrical troubleshooting DANGER: Electrical Hazard Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician. Follow these guidelines when troubleshooting: • Disconnect and lock out the power supply except when conducting checks that require voltage.

  • Page 69: The Pump Does Not Stop When A Level Sensor Is Used

    7 Troubleshooting Cause Remedy The installation is not receiving Check that: voltage. • 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. •...

  • Page 70: The Pump Starts-Stops-Starts In Rapid Sequence

    7 Troubleshooting 7.4 The pump starts-stops-starts in rapid sequence Cause Remedy The pump starts due to back-flow Check that: which fills the sump to the start level • The distance between the start and stop levels is sufficient. again. • The non-return valve(s) work(s) properly. •...

  • Page 71: The Pump Delivers Too Little Or No Water

    7 Troubleshooting Cause Remedy The insulation between the phases 1. Use an insulation tester. With a 1000 V DC megger, check that the and ground in the stator is defective. insulation between the phases and between any phase and ground is > 5 megaohms.
  • Page 72 7 Troubleshooting Cause Remedy 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.

  • Page 73: Technical Reference

    8 Technical Reference 8 Technical Reference 8.1 Application limits Data Description Liquid temperature 40°C (104°F) maximum The pump can be operated at full load only if at least half the stator housing is submerged. 3102.060, 3102.160, 3102.181, 3102.760: • Warm-liquid version: 70°C (158°F) maximum pH of the pumped media (liquid) 5.5–14 Liquid density...
  • Page 76 For more information on how Xylem can help you, go to www.xylem.com 90016001_2.0_en-US_2020-06_IOM_Flygt 3102/BBE/0820...

This manual is also suitable for:

Flygt 3102.060Flygt 3102.070Flygt 3102.090Flygt 3102.160Flygt 3102.170Flygt 3102.181 ... Show all

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