FLYGT 3085 Installation, Operation And Maintenance Manual
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FLYGT 3085 Installation, Operation And Maintenance Manual

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Installation, Operation,
and Maintenance Manual
Flygt 3085

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Summary of Contents for FLYGT 3085

  • Page 1 Installation, Operation, and Maintenance Manual Flygt 3085...

  • Page 3: Table Of Contents

    4.3 T-installation: Bleed air before starting pump............... 35 4.4 Check the impeller rotation....................36 5 Operation..........................38 5.1 Estimate zinc anode replacement intervals..............38 5.2 Start the pump........................39 6 Maintenance..........................40 6.1 Torque values........................40 6.2 Change the oil........................41 6.3 Service the pump.......................43 Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 4 7.3 The pump starts-stops-starts in rapid sequence............64 7.4 The pump runs but the motor protection trips.............. 65 7.5 The pump delivers too little or no water.................66 8 Technical Reference......................... 67 8.1 Motor data.......................... 67 Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 5: Introduction And Safety

    A hazardous situation which, if not avoided, could result CAUTION: in minor or moderate injury Notices are used when there is a risk of equipment NOTICE: damage or decreased performance, but not personal injury. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 6: User Safety

    • 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. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 7: Special Hazards

    Chemicals or hazardous fluids in 1. Hold your eyelids apart forcibly with your fingers. eyes 2. Rinse the eyes with eyewash or running water for at least 15 minutes. 3. Seek medical attention. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 8: Protecting The Environment

    Only use the manufacturer’s original spare parts to replace any worn or faulty components. The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as void the warranty. 1.8 Warranty For information about warranty, see the sales contract. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 9: Transportation And Storage

    • The lifting equipment must be able to hoist the unit straight up and down, preferably without the need for resetting the lifting hook. • The lifting equipment must be securely anchored and in good condition. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 10: Temperature Ranges For Transportation, Handling And Storage

    2.4 Storage guidelines Storage location The product must be stored in a covered and dry location free from heat, dirt, and vibrations. NOTICE: Protect the product against humidity, heat sources, and mechanical damage. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 11 If the packaging material has an indicated stacking limit, then it is valid for 23° C (73° F) and 50% relative humidity. Depending on the material, other temperature and humidity ranges can reduce the stacking limit. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 12: Product Description

    If the product is EN/ATEX-, MSHA- or FM-approved, then see the specific EX information in the Safety chapter before taking any further actions. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 13 ® Experior is a product concept including N-technology, Premium efficiency motor, and ® the intelligent control SmartRun Parts Position Denomination Description Shaft The shaft is made of stainless steel, with an integrated rotor. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 14: Monitoring Equipment

    3.3 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 3085 Installation, Operation, and Maintenance Manual...
  • Page 15 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 Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 16: Approvals

    13.Maximum ambient temperature 14.Serial number 15.ATEX marking WS003972A 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 3085 Installation, Operation, and Maintenance Manual...

  • Page 17: Product Denomination

    In this section, code characters are illustrated accordingly: X = letter Y = digit The different types of codes are marked up with a, b and c. Code parameters are marked up with numbers. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 18 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 3085 Installation, Operation, and Maintenance Manual...

  • Page 19: Installation

    • If the unit has a permanent magnet motor, then ensure that you have read and understood all safety instructions regarding permanent magnet motors. NOTICE: Do not run the pump dry. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 20: Install With P-Installation

    • Fasteners for the discharge connection • Anchor bolts 1. Install the access frame: a) Place the access frame in position and align it horizontally. b) Grout the frame in place. 2. Grout the anchor bolts in place. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 21: Install With S-Installation

    2. Connect the discharge line. 3. Lower the pump into the sump. 4. Place the pump on the base and make sure it cannot fall over or sink. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 22: Install With T/Z-Installation

    Figure 5: Z-installation Figure 4: T-installation These items are required: • Anchor bolts for anchoring the pump to a base. • Shut-off valves that allow you to remove the pump from service Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 23: Install With F-Installation

    3. Lower the pump into the sump. 4. Place the pump on the sump bottom and make sure it cannot fall over. 5. Connect the motor cable and the starter and monitoring equipment according to the separate instructions. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 24: Install With H-Installation

    (page 36). Clean all debris from the sump before you start the pump. 4.1.6 Install with X-installation In the X-installation, the pump has no pre-determined mechanical connection. The flange is drilled. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 25: Make The Electrical Connections

    WARNING: Electrical Hazard The permanent-magnet motor generates voltage when the shaft rotates, even if power sources are disconnected. Never perform any electrical work if the shaft could rotate. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 26 (VFD-supplier). • Make sure that the cable is long enough for maintenance work. ® • For SUBCAB cables, the twisted pair copper foil must be trimmed. • All unused conductors must be insulated. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 27: 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 3085 Installation, Operation, and Maintenance Manual...

  • Page 28: Connect The Motor Cable To The Pump

    5. Arrange the connections on the terminal board/closed end splices in accordance with the required power supply. 6. Connect the mains leads (L1, L2, L3, and ground (earth) ) according to applicable cable chart. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 29: Connect The Motor Cable To The Starter And Monitoring 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.

  • Page 30: Cable Charts

    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 Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 31 For markings on sensor leads, see Sensors connection (page 34). 4.2.4.2 Connections included • 3-phase connection (page 30) • 1-phase connection (page 32) • Sensors connection (page 34) • Screened cable connection (page 33) Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 32 U1 V1 W1 W2 U2 V2 L1 L2 L3 L3:1 L2:1 L1:1 U1 V1 W1 W2 U2 V2 L3:2 L2:2 L1:2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 L1 L2 L1 L2 L3 Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 33 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 Y-SER U1 V1 W1 W2 U2 V2 W5 U5 V5 U6 W6 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 WS004128A Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 34 4 Installation 4.2.4.4 1-phase connection 4 Leads Starter 4 Leads with level regulator U1 Z1 Starter 12 Leads U1 V1 U6 Starter Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 35 Mini CAS+AUX FGB Screened Mini CAS Screen - SUBCAB and Screenflex T1 and T2 T1 and T2 twisted White insulation hose White insulation hose twisted together Screen together Screen T1 T2 L2 L3 Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 36 T1/*OG/4 WH/YE T2/*OG/5 *SUBCAB AWG + 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 Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 37: T-Installation: Bleed Air Before Starting Pump

    Leakage (5 seconds delay) CLS, FLS and thermal contact Overtempterature 13.3 36–42 Leakage (0/5 seconds delay) 4.3 T-installation: Bleed air before starting pump 1. Open valve D and bleed out the air. See the following figure. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 38: Check The Impeller Rotation

    The starting jerk can be powerful. Make sure nobody is close to the unit when it is started. 1. Start the motor. 2. Stop the motor after a few seconds. 3. Check that the impeller rotates according to this illustration. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 39 – If the motor has a 1-phase connection, then contact the local sales and service representative. – If the motor has a 3-phase connection, then transpose two phase leads and do this procedure again. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 40: Operation

    The recommended interval for the selection fraction is 0.25–0.50 (25–50%). 1. Remove, weigh, and reinstall one or more of the exterior zinc anodes before starting up the pump. 2. After two months, remove and weigh the same zinc anode or anodes again. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 41: Start The Pump

    Never put your hand into the pump housing. 3. Conduct insulation test phase to ground. To pass, the value must exceed 5 megaohms. 4. Check that the monitoring equipment works. 5. Start the pump. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 42: Maintenance

    If there is a question regarding the tightening torques, please contact the local sales and service representative. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 43: Change The Oil

    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 3085 Installation, Operation, and Maintenance Manual...
  • Page 44 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 L (1.1 qt). Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 45: Service The Pump

    1. Check the impeller clearance. 2. Adjust the impeller, if necessary. Stator housing 1. Drain all liquid, if any. 2. Check the resistance of the leakage sensor. Normal value approximately1500 ohms, alarm approximately 430 ohms. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 46: Major Overhaul

    • 6 mm hexagon bit adapter with an extension of at least 125 mm (4.92 in) • Impeller puller If applicable, contact your local sales and service representative for correct type and size. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 47: Replace The C-, D-, Or L-Impeller

    If you fail with the impeller installation, then you must redo the installation procedure from the beginning. 6.4.1 Replace the C-, D-, or L-impeller Figure 13: C-Impeller Figure 14: D-impeller Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 48 6.4.1.1 Remove the C-, D-, or L-impeller CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. 1. Remove the pump housing. WS001966A 2. Remove the impeller screw. If applicable, use the rod. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 49 The proper lubrication is grease for bearings, for example Exxon Mobil Unirex N3, Mobil Mobilith SHC 220 or equivalent. NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 50 Tighten a further 1/8 turn, 45° after tightening to the correct torque. If applicable, use the rod. WS001941A Check that the impeller can rotate freely. 4. Mount the pump housing: a) Fit the pump housing. b) Fit and tighten the lubricated screws. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 51: Replace The F-Impeller

    Worn parts can have sharp edges. Wear protective clothing. 1. Remove the suction cover. If necessary, then pry off the suction cover. 2. Remove the impeller screw, the ring, and the washers. If applicable, use the rod. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 52 Fit the conical sleeve onto the shaft. b) Fit one adjustment washer with a thickness of 0.25 mm (0.01 in) and two adjustment washers with a thickness of 1 mm (0.04 in) onto the impeller. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 53 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. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 54 Use Loctite 603 locking liquid in order to secure the studs. b) Fit two adjustment washers with a thickness of 1 mm (0.04 in) and six adjustment washers with a thickness of 0.25 mm (0.01 in) onto each stud. WS002014A Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 55 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. WS002105A b) Tighten the nuts. Tightening torque: 17 Nm (13 ft-lb). WS001937A 8. Raise the pump to a vertical position. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 56: Replace The M-Impeller

    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. Refit the impeller screw. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 57 Coat the inner conic, the outer cylindrical surfaces, and the thread of the conical sleeve with a thin layer of grease. The proper lubrication is grease for bearings, for example Exxon Mobil Unirex N3, Mobil Mobilith SHC 220 or equivalent. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 58 The correct distance for pressure class LT and HT is 43.5±0.3 mm (1.71±0.01 in.). b) Slide the impeller on to the shaft until you reach the correct distance. Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 59: Replacing The Adaptive N-Impeller

    Fit the pump housing. b) Fit and tighten the lubricated screws. Tightening torque: 57 Nm (42 ft-lb). WS002018A 6.4.4 Replacing the Adaptive N-impeller To see which pumps are Adaptive-N, see Product Description (page 10). Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 60 6.4.4.1 Prepare the pump for removal: T-, Z-installations The pump must be removed from the installation to change the impeller. 1. Close valves A and B on the inlet and outlet lines. See the following figures. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 61 Use the impeller puller or the crowbars. d) Remove the impeller screw, the washer, and the conical sleeve. 6.4.4.3 Install the Adaptive-N impeller: P, S, T, Z installations To see which pumps are Adaptive-N, see Product Description (page 10). Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 62 3. Mount the impeller sleeve and impeller, and secure the impeller in place with the screw. 4. Check that the impeller is in its lowest position: a) Insert two screwdrivers as shown in the following figure, and push the impeller downwards. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 63 WARNING: Crush Hazard Beware of the pinch point hazard between the rotating impeller and the guide pin. 9. Check with an extended feeler gauge that the impeller clearance is 0.1 – 0.3 mm. Flygt 3085 Installation, Operation, and Maintenance Manual...
  • Page 64 6 Maintenance 10.Fit the lubricated plug and tighten it. Tightening torque: 15-30 Nm (11-22 ft-lb). 11.Re-install the pump. T-installations: See the instructions in T-installation: Bleed air before starting pump (page 35). Flygt 3085 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 3085 Installation, Operation, and Maintenance Manual...

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

    • The distance between the start and stop levels is sufficient. again. • The non-return valve(s) work(s) properly. • The length of the discharge pipe between the pump and the first non- return valve is sufficiently short. Flygt 3085 Installation, Operation, and Maintenance Manual...

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

    • Contact the local sales and service representative. There is a malfunction in the overload Replace the overload protection. protection. Always state the serial number of your product, see Product Description (page 10). Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 68: The Pump Delivers Too Little Or No Water

    • 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 10). Flygt 3085 Installation, Operation, and Maintenance Manual...

  • Page 69: Technical Reference

    40°C (104°F) maximum The pump can be operated at full load only if at least half the stator housing is submerged. Warm-liquid version: 70°C (158°F) maximum (3085.160, 3085.183, 3085.760) Ex-approved pumps: 40°C (104°F) maximum Liquid density 1100 kg/m³ (9.2 lb per US gal) maximum pH of the pumped media 5.5–14...
  • Page 72 Visit our Web site for the latest version of this document and more information Services 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 © 2011 Xylem Inc Fax: +46-471-24 47 01 http://tpi.xyleminc.com 898548_6.0_en-US_2016-01_IOM.3085...

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