FLYGT 3202 Installation, Operation And Maintenance Manual
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FLYGT 3202 Installation, Operation And Maintenance Manual

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Installation, Operation,
and Maintenance Manual
Flygt 3202

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Summary of Contents for FLYGT 3202

  • Page 1 Installation, Operation, and Maintenance Manual Flygt 3202...

  • Page 3: Table Of Contents

    Estimate zinc anode replacement intervals................39 Start the pump........................... 40 Maintenance..........................41 Torque values..........................41 Change the coolant........................42 Empty the coolant......................... 42 Fill with coolant........................44 Service the pump........................45 Inspection..........................45 Major overhaul........................46 Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 4 The pump does not stop when a level sensor is used............64 The pump starts-stops-starts in rapid sequence..............64 The pump runs but the motor protection trips..............65 The pump delivers too little or no water................65 Technical Reference........................67 Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 5: Introduction And Safety

    It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product. They are published to help prevent these hazards: • Personal accidents and health problems • Damage to the product • Product malfunction Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 6: Environmental Safety

    • Report all environmental emissions to the appropriate authorities. WARNING: Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any nuclear radiation. Electrical installation For electrical installation recycling requirements, consult your local electric utility. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 7: User Safety

    Condition Action Chemicals or hazardous fluids in Hold your eyelids apart forcibly with your fingers. eyes Rinse the eyes with eyewash or running water for at least 15 minutes. Seek medical attention. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 8: Ex-Approved Products

    If the information is missing on the dimensional drawing, the product must be fully submerged. Level-sensing equipment must be installed if the product can be operated at less than the minimum submersion depth. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 9: Product Warranty

    However, should the need for a warranty claim arise, contact your local sales and service representative. Spare parts Xylem guarantees that spare parts will be available for 15 years after the manufacture of this product has been discontinued. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 10: Transportation And Storage

    • Stay clear of cables and suspended loads. Lifting equipment and tackle should always be inspected before starting work. Lifting equipment Lifting equipment is always required when handling the unit. It must fulfill the following requirements: Flygt 3202 Installation, Operation, and Maintenance Manual...

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

    2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for the presence of water. Change if needed. Storage guidelines Storage location The product must be stored in a covered and dry location free from heat, dirt, and vibrations. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 12 • Before operating the unit after storage, it must be inspected with special attention to the seals and the cable entry. • The impeller/propeller must be rotated every other month to prevent the seals from sticking together. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 13: Product Description

    • Original spare parts and accessories that are authorized by Xylem are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation. For more information contact your Xylem representative. Pressure class Low head Medium head High head Super high head Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 14 Consisting of a two-row angular contact ball bearing Motor For information about the motor, see Motor data (page 67). Thermal contact/ For information about the thermal contact and thermistors, see Monitoring Thermistors equipment (page 13). Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 15: Monitoring Equipment

    The data plate The data plate is a metal label that is located on the main body of the products. The data plate lists key product specifications. Specially approved products also have an approval plate. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 16 18. Duty factor 19. Product weight 20. Locked rotor code letter 21. Power factor 22. Maximum ambient temperature 23. Read installation manual 24. Notified body, only for EN-approved Ex products Figure 3: The data plate Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 17: Approvals

    14. Serial number WS003972A 15. ATEX marking IEC approval plate This illustration describes the IEC approval plate and the information that is contained in its fields. International Norm; not for EU member countries. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 18: Product Denomination

    The different types of codes are marked up with a, b and c. Code parameters are marked up with numbers. Codes and parameters XXYYYY YYY YYY YYYY Type of Callout Number Indication Type of code Sales denomination Product code Serial number Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 19 Product Description Type of Callout Number Indication Parameter Hydraulic end Type of installation Sales code Version Production year Production cycle Running number Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 20: Installation

    In the P-installation, the pump is installed on a stationary discharge connection, and operates either completely or partially submerged in the pumped liquid. These requirements and instructions only apply when the installation is made according to the dimensional drawing. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 21 Bolt the cable holder to the access frame. b) Attach the level regulator cable to the cable holder and adjust the height of the level regulator. c) Protect bolts and nuts with a corrosion-preventive compound. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 22: Install With S-Installation

    Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 37). Install with T/Z-installation This installation is not applicable for these versions: • .660 • .670 • .860 • .870 Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 23 Make sure that the impeller rotation is correct. For more information, see Check the impeller rotation (page 37). 5. Make sure that the weight of the pump does not put strain on the piping. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 24: Make The Electrical Connections

    (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. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 25: Prepare The Subcab ™ Cables

    2. Prepare the control element: a) Peel the sheath (if applicable) and the copper foil. The copper foil is a screen and is conductive. Do not peel more than necessary, and remove the peeled foil. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 26: Connect The Motor Cable To The Pump

    Peel the insulation from each power core. Connect the motor cable to the pump CAUTION: Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the end of the motor cable above the liquid level. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 27: Connect The Motor Cable To The Starter And Monitoring Equipment

    • 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. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 28: Cable Charts

    This topic contains general connection information. It also provides cable charts that show connection alternatives for use with different cables and power supply. T1 T2 Figure 9: Phase sequence Connection locations The figures in this section illustrate how to interpret the connection strip symbols. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 29 Starter equipment and mains leads (L1, L2, L3) Earth (ground) Functional ground Control leads (T1, T2, T3, T4) L1 L2 L3 T1 T2 T3 T4 Thermal contact FLS 10 Thermistor 10. Level sensor 11. Capacitor FLS 10 Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 30 * * Ground conductor is stranded around core Screen (WH) Screen (WH) Screen (WH) GC=Ground check ( 5) 773 29 00 Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Grey Blue Yellow Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 31 9-leads connection (page 31) • Screened cable connection (page 31) 6–leads connection One cable (left) and two cables (right) Y-connection. Two cables One cable V1 U2 U1 W2 W1 V2 Figure 11: Y-connection Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 32 L2:1 L3:1 L1:1 U1W2 L2:2 L3:2 L1:2 Figure 13: Y/D-connection Y and D-connection, only applicable to 70 mm terminal clamp. U2 V2 Only applicable to 70mm2 terminal clamp Figure 14: Y or D-connection Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 33 Cable without separate ground conductor. Screen as ground conductor. Screened SUBCAB & FGB Screened Cable without sep. ground conductor Screen as ground conductor GN/YE shrink hose FGB Screened Mini CAS Mini CAS+AUX Figure 17: Screened SUBCAB and FGB Screened Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 34: Sensor-Connection

    Screenflex WH T1 WH T1 WH T2 WH T2 WH T3 WH T4 Figure 19: Color and marking of control leads Sensor terminal clamps T15 T16 T1 T2 Figure 20: Sensor terminal clamps Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 35 Thermal detectors FLS Disconnected Max 12 V T1 Control leads WH/YE Mini T1/*OG/1 T2/*BU/2 WH/YE **T3 **T4 *SUBCAB AWG *Screened SUBCAB MAS 711 The following sensors can be used together with MAS 711: Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 36 VIS 10 The vibration sensor located in Current, 4-20 mA > 20 mA the junction box measures vibrations in one direction. The output is a 4-20 mA signal proportional to the vibration level. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 37 • pump top, and • electrical cabinet If the sensor cable contains a green-yellow lead, that lead should not be connected. Communication port 37-38 for RS-485 is common to both pump memory and operator panel. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 38 If the sensor cable contains a green-yellow lead, that lead should not be connected. VIS 10 is not applicable to pump type 3153 Communication port 37-38 for RS-485 is common to both pump memory and operator panel. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 39: Check The Impeller Rotation

    Check the impeller rotation WARNING: The starting jerk can be powerful. 1. Start the motor. 2. Stop the motor after a few seconds. 3. Check that the impeller rotates according to this illustration. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 40 The correct direction of impeller rotation is clockwise when you look at the pump from above. 4. If the impeller rotates in the wrong direction, transpose two phase leads (3-phase) and do this procedure again. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 41: Operation

    2. After two months, remove and weigh the same zinc anode or anodes again. 3. Divide the lapsed time in days (between steps 1 and 2) by the anode weight loss in grams to get the calculated anode consumption rate (days/gram). Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 42: Start The Pump

    1. Remove the fuses or open the circuit breaker, and check that the impeller can be rotated freely. 2. Conduct insulation test phase to ground. To pass, the value must exceed 5 megohms. 3. Check that the monitoring equipment works. 4. Start the pump. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 43: Maintenance

    15 (11) 27 (20) 65 (48) 127 (93.7) 220 (162) 434 (320) 70, 80 2.7 (2) 5.4 (4) 9.0 (6.6) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) 629 (464) 1240 (915) Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 44: Change The Coolant

    Empty the coolant WARNING: The seal housing may be pressurized. Hold a rag over the inspection/ filling plugs to prevent splatter. 1. Empty the coolant in the inspection chamber: a) Remove the inspection plug. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 45 Place the pump in a horizontal position, or leave it upright to use a pump to empty the coolant. b) If the pump is laid in a horizontal position, place a container under the pump. c) Remove the coolant plugs and empty the coolant. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 46: Fill With Coolant

    1. Fill with coolant until it overflows through the opposite hole, as shown here. Quantity: approximately • 5.9 L (6.2 qt.) without cooling jacket • 25 L (26.4 qt.) with cooling jacket, versions 3202.090/.095/.180./185/.350/.390/.660/.670 • 41 L (43.3 qt.) with cooling jacket, versions 3202.800/.810/.820/.830/.840/.850/.860/.870 Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 47: Service The Pump

    Check that the cables do not have any sharp bends and are not pinched. Connection to power Check that the connections are properly tightened. Electrical cabinets Check that they are clean and dry. Impeller Check the impeller clearance. Adjust the impeller, if necessary. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 48: Major Overhaul

    Check the running values. Major overhaul For a major overhaul, take this action in addition to the tasks listed under Inspection. Service item Action Support and main bearing Replace the bearings with new bearings. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 49: Service In Case Of Alarm

    1. Place the pump in a horizontal position. 2. Remove the impeller: a) Remove the flush valve cover and its O-ring. b) Lock the impeller in place by inserting a rod through the hole. c) Remove the impeller screw. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 50 Hand-tighten the impeller screw to prevent it from falling off. WS001490A Remove the rod. 3. Raise the pump. 4. Remove the drive unit from the pump housing: a) Remove the pump housing screws. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 51 Maintenance b) Remove the drive unit from the pump housing. 5. Remove the impeller: a) Place the drive unit horizontally. b) Remove the impeller screw. c) Remove the impeller and the conical sleeve. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 52 Fit an M12 lifting eyebolt into the shaft end and place the drive unit in a horizontal position. b) Lubricate the threads of the impeller screw and the washer. Always use a new impeller screw. c) Adjust the adjustment screw so that it is flush with the sleeve. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 53 Place the drive unit into the pump housing. e) Adjust its position so that the inspection hole is on the same side as the flush valve. Tighten the screws in diagonal sequence. For tightening torque, see Torque values (page 41). Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 54 Using a hexagon-bit adapter, turn the adjustment screw clockwise until the impeller makes contact with the pump housing. For tightening torque, see Torque values (page 41). b) Tighten it a further 1/8 turn (45°). Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 55 Fit the O-ring and flush valve cover and fasten it with screws. For tightening torque, see Torque values (page 41). Check that the impeller can rotate freely. 7. Check that the clearance between the impeller and the insert ring is 0.1–0.5 mm (0.004–0.02 in). Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 56: Replace The Impeller For Dry Installation

    Replace the impeller for dry installation Remove the impeller: dry installation 1. Remove the drive unit from the pump housing: a) Remove the pump housing screws. b) Remove the drive unit from the pump housing. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 57 Lock the impeller as shown in the figure. c) Remove the impeller screw. WS001494A d) Turn the adjustment screw counterclockwise until the impeller breaks free from the shaft. e) Remove the impeller and the conical sleeve. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 58 Lubricate the threads of the impeller screw and the washer. Always use a new impeller screw. b) Unscrew the adjustment screw approximately 5 mm (0.2 in.). WS002106A c) Measure and note the distance A. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 59 Maintenance d) Fit the sleeve and the impeller to the shaft. e) Fit the impeller screw and washer and tighten. 3. Make sure that the O-ring is removed from the seal housing cover. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 60 Make sure that the drive unit is parallel with the pump housing by hand-tightening the pump housing screws. b) Check the distance between the seal housing cover and the pump housing with a feeler gauge. Check diagonally at four points. c) Note the largest distance B. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 61 Lift the drive unit out of the pump housing and remove the impeller and conical sleeve. 5. Trim to the correct distance: a) Calculate the measure C according to the formula shown in the image. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 62 For tightening torque, see Torque values (page 41). c) Tighten it further 1/8 turn (45°). 7. Install the drive unit in the pump housing: a) Fit a new and lubricated O-ring to the seal housing cover. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 63 Adjust the position of the drive unit so that the inspection hole is on the same side as the flush valve. d) Tighten the lubricated screws diagonally. For tightening torque, see Torque values (page 41). Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 64 Maintenance WS001478A If you need to adjust the impeller, redo the replace the impeller procedure from the beginning. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 65: Troubleshooting

    • The start level regulator is functioning. Clean or replace if necessary. manually. • All connections are intact. • The relay and contactor coils are intact. • The control switch (Man/Auto) makes contact in both positions. Check the control circuit and functions. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 66: The Pump Does Not Stop When A Level Sensor Is Used

    • 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. Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 67: The Pump Runs But The Motor Protection Trips

    Remedy The impeller rotates in the wrong • If it is a 3-phase pump, transpose two phase leads. direction. • If it is a 1-phase pump: Contact the local sales and service representative. Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 68 • Check that the level sensor is set correctly. • Depending on the installation type, add a means for priming the pump, such as a foot valve. Always state the serial number of your product, see Product Description (page 11). Flygt 3202 Installation, Operation, and Maintenance Manual...

  • Page 69: Technical Reference

    Maximum starts per hour 30 evenly spaced starts per hour Code compliance IEC 60034-1 Rated output variation ±10% Voltage variation without ±10%, provided that it does not run continuously at full load overheating Voltage imbalance tolerance Stator insulation class H (180°C [360°F]) Flygt 3202 Installation, Operation, and Maintenance Manual...
  • Page 72 Visit our Web site for the latest version of this document and more information Manufacturing AB 361 80 Emmaboda The original instruction is in English. All non-English instructions are translations of the original instruction. Sweden Tel: +46-471-24 70 00 © 2012 Xylem Inc Fax: +46-471-24 47 01 http://tpi.xyleminc.com 894445_22.0_en-US_2013-11_IOM.3202...

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