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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

Introduction and Safety (Continued)

4

Flygt 3102 Service and Repair Instructions

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Содержание Flygt 3102

Страница 1: ...Water Wastewater Service and Repair Instructions Flygt 3102...

Страница 2: ......

Страница 3: ...er rotation 21 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 stato...

Страница 4: ...ump 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 litt...

Страница 5: ...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...

Страница 6: ...eath 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 equ...

Страница 7: ...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...

Страница 8: ...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 confo...

Страница 9: ...to the following Level indicators Temperature detectors Environmental safety The work area Always keep the station clean to avoid and or discover emissions Recycling guidelines Always recycle accordi...

Страница 10: ...5 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 3102 170 Grinder 3102 181 Standard 3102 185 Hard Iron 3102 890...

Страница 11: ...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...

Страница 12: ...on 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 Th...

Страница 13: ...uct code consists of nine characters divided into two parts This is an example of a product code and an explanation of its parts 3085 183 1 2 NP 1 Sales denomination 2 Version Serial number The serial...

Страница 14: ...ow 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...

Страница 15: ...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...

Страница 16: ...igher 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...

Страница 17: ...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 leads Yellow Gre...

Страница 18: ...SUBCAB AWG SI SL BIHF 4 stator leads 1 phase This table shows the connection diagrams for example the SUBCAB 4GX GC T1 T2 SUBCAB 4GX SUBCAB AWG SI SL BIHF 12 stator leads 230V 1 phase This table shows...

Страница 19: ...1 U1 W1 T1 T2 GC L2 L1 L3 T1 T2 T1 T2 T1 T2 T1 T2 U1 V1 U2 V2 SUBCAB SUBCAB GC L1 L2 L3 W1 W2 U2 W2 V2 V1 U1 W1 T1 T2 GC L2 L1 L3 T1 T2 T1 T2 T1 T2 T1 T2 U1 V1 U2 V2 SUBCAB SUBCAB GC L1 L2 L3 W1 W2 SU...

Страница 20: ...e power cable with Y D serial connection Y D serial connection V1 W1 U1 U2 V2 W2 T1 T2 L1 L2 L3 L1 L2 L3 T1 T2 1 4 2 5 3 6 1 2 3 T1 T2 T1 T2 W1 V1 SUBCAB U1 V2 U2 W2 4 5 6 SUBCAB 4GX SUBCAB AWG 9 lead...

Страница 21: ...r cable with Y parallel serial connection 60 Hz only Y parallel connection 220 230 V Y serial connection 440 460 V U2 W2 V2 V1 U1 W1 T1 T2 GC L2 L1 L3 T1 T2 T1 T2 T1 T2 T1 T2 SUBCAB SUBCAB GC L1 L3 L2...

Страница 22: ...T1 T2 T1 T2 T1 T3 T3 T4 T4 1 T2 SUBCAB 1 3 2 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...

Страница 23: ...r 3 Check that the impeller rotates according to this illustration The correct direction of impeller rotation is clockwise when you look at the pump from above 4 If the impeller rotates in the wrong d...

Страница 24: ...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 befor...

Страница 25: ...eel Torque Nm ft lbs 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 3 2 2 4 6 5 4 8 11 8 26 19 52 38 91 67 222 164 433 320 748 552 12 9 3 9 2 9 7 8 5 8 14 10 3 32 23 6 63 4...

Страница 26: ...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 th...

Страница 27: ...r 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...

Страница 28: ...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 h...

Страница 29: ...ing screw Use a 8 mm flat bladed screwdriver 2 Remove the rotating seal unit 3 Remove the stationary seal ring including its O ring Remove the outer mechanical seal 1 Remove the grip ring a Fit the mo...

Страница 30: ...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 Maintenance Continued 28 Flygt 3102...

Страница 31: ...emove 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 th...

Страница 32: ...g 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 stat...

Страница 33: ...nner 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...

Страница 34: ...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 too...

Страница 35: ...surface is facing out 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...

Страница 36: ...put pressure on the screwdriver while fastening the screw Tightening torque 5 4 Nm 4 0 ft lbs 5 Remove the mounting tool Install the oil housing bottom 1 Install the oil housing Check that the sleeve...

Страница 37: ...ot 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 o...

Страница 38: ...he phases and between any phase and earth must be 5 M 4 Assemble and fasten the cable entry Make sure that the gland screw bottoms out when fasten Cable entry for cables with the outside diameter of 1...

Страница 39: ...ted 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 Maintenanc...

Страница 40: ...ng 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...

Страница 41: ...ply 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 undam...

Страница 42: ...ng 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...

Страница 43: ...ing 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 tight...

Страница 44: ...e 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 edge...

Страница 45: ...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 2 Remove the impeller screw If applicable u...

Страница 46: ...eeve 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...

Страница 47: ...impeller with the pressure class LT 3 Tighten the impeller screw If applicable use the rod Tightening torque 65 Nm 48 ft lbs Check that the impeller can rotate freely 4 Mount the pump housing a T Z i...

Страница 48: ...orn 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 Maintenance...

Страница 49: ...cal 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...

Страница 50: ...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 l...

Страница 51: ...to 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...

Страница 52: ...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 Maintenance Continued 50 Flygt 3102 Service and Repair Instruction...

Страница 53: ...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 impelle...

Страница 54: ...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 impe...

Страница 55: ...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...

Страница 56: ...5 Mount the pump housing 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 Maintenance Continued 54 F...

Страница 57: ...emove 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 Fi...

Страница 58: ...rt 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 tor...

Страница 59: ...nts 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 Documents required Approva...

Страница 60: ...e O rings at the entrance or junction cover 3 Grease the new O rings Overload protection and other protections Check the correct settings Personnel safety devices Check the guard rails covers and othe...

Страница 61: ...quid 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 rot...

Страница 62: ...still persists Contact the local ITT service shop The pump does not start automatically but can be started manually Check that The start level regulator is functioning Clean or replace if necessary A...

Страница 63: ...in rapid sequence Cause Remedy The pump starts due to back flow which fills the sump to the start level again Check that The distance between the start and stop levels is not too small The non return...

Страница 64: ...fer 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 li...

Страница 65: ...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...

Страница 66: ...Technical Reference Exploded view Figure 12 3201 090 3201 095 Technical Reference 64 Flygt 3102 Service and Repair Instructions...

Страница 67: ...Figure 13 3201 170 Technical Reference Continued Flygt 3102 Service and Repair Instructions 65...

Страница 68: ...Figure 14 3201 180 3201 185 Technical Reference Continued 66 Flygt 3102 Service and Repair Instructions...

Страница 69: ...arts 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 flygtpu...

Страница 70: ...bottom terminal holder 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...

Страница 71: ......

Страница 72: ...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...

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