ITT Flygt 3102 Service And Repair Instructions
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ITT Flygt 3102 Service And Repair Instructions

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Service and Repair Instructions
Flygt 3102

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Summary of Contents for ITT Flygt 3102

  • Page 1 Water & Wastewater Service and Repair Instructions Flygt 3102...

  • Page 3: Table Of Contents

    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...
  • Page 4 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 Flygt 3102 Service and Repair Instructions...

  • Page 5: Introduction And Safety

    • 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...

  • Page 6: Safety

    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.

  • Page 7: User Safety

    • Gas mask • Hearing protection • First-aid kit • Safety devices 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...

  • Page 8: Ex-Approved Products

    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.

  • Page 9: Environmental Safety

    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 ATEX- compliant equipment, always comply with the directive and applicable standards in IEC/EN 60079–14.

  • Page 10: Product Description

    II 2 G EEx d IIB T4 • 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 Flygt 3102 Service and Repair Instructions...

  • Page 11: The Data Plate

    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. • European Norm •...
  • Page 12 II 2 G or IM2 EEx d IIC or EEx dI This illustration describes the approval plate for Factory Mutual (FM) and the information contained in its fields. Temperature class Maximum ambient temperature Figure 3: FM approval plate Flygt 3102 Service and Repair Instructions...

  • Page 13: Product Denomination

    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. NP 3085.183 - 951 0163 Product code Production year Production cycle Running number Flygt 3102 Service and Repair Instructions...

  • Page 14: Installation

    If the outer sheath of the cable is damaged, then replace the cable. Contact an ITT service shop. Flygt 3102 Service and Repair Instructions...

  • Page 15: Earthing (Grounding)

    • 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: •...

  • Page 16: Connect The Motor Cable To The Starter And Monitoring Equipment

    15). 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. Flygt 3102 Service and Repair Instructions...

  • Page 17: Cable Charts

    White T1 White T2 Blue White T2 – – White T3 – – White T4 Colors of the stator leads Stator connection Lead color Green (Brown if 1 phase stator 4 leads is used) Flygt 3102 Service and Repair Instructions...
  • Page 18 SUBCAB 4GX/SUBCAB AWG/SI-SL-BIHF, 4 stator leads, 1 phase This table shows the connection diagrams for example the SUBCAB 4GX. T1 T2 SUBCAB 4GX/SUBCAB AWG/SI-SL-BIHF, 12 stator leads, 230V, 1 phase This table shows the connection diagrams for example the SUBCAB 4GX. Flygt 3102 Service and Repair Instructions...
  • Page 19 T1 T2 T1 T2 T1 T2 V1 U2 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...
  • Page 20 SUBCAB T1 T2 U2 W2 SUBCAB 4GX/SUBCAB AWG, 9-leads, 230/460 V, Y connection This table shows the connection diagrams for example the SUBCAB 4GX (3-phase power cables), with Y parallel/serial connection (60 Hz only). Flygt 3102 Service and Repair Instructions...
  • Page 21 T1 T2 T1 T2 SUBCAB Screened S3X2.5+3X2.5/3+4X1.5, 6 stator leads, Y and D connection This table shows the connection diagrams for the SUBCAB Screened (3-phase power cable), with Y parallel/ serial connection (60 Hz only). Flygt 3102 Service and Repair Instructions...

  • Page 22: Sensor-Connection

    36 mA Leakage The values have a 10 % tolerance CLS and Thermal contact (only standard version) Value 0 mA Overtemperature 5.5mA 29mA Leakage (5 second delay) The values have a 10 % tolerance Flygt 3102 Service and Repair Instructions...

  • Page 23: Check The Impeller Rotation

    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.

  • Page 24: Maintenance

    5.4 (4) 9.3 (6.9) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) 629 (464) 1240 Nm (ft- (915) lbs) Carbon steel and alloyed steel Property class 70 is torque tightened as class 80. Flygt 3102 Service and Repair Instructions...

  • Page 25: Change The Oil

    The oil housing may be pressurized. Hold a rag over the oil plug to prevent oil from spraying out. 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...

  • Page 26: Fill With Oil

    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) Flygt 3102 Service and Repair Instructions...

  • Page 27: Disassemble The Pump

    (page 30) Remove the motor cable and the stator housing Remove the stator housing: a) Remove the stator housing screws. b) Lift of the stator housing from the oil housing. Open the entrance cover. Flygt 3102 Service and Repair Instructions...

  • Page 28: Remove The Pump Housing

    Remove the pump housing screws. Fasten lifting eye bolts in the oil housing screw holes. Use M10 eye bolts. Lift of the rotor assembly with the oil housing and impeller from the pump housing. Flygt 3102 Service and Repair Instructions...

  • Page 29: Remove The Mechanical Seal

    Remove the stationary seal ring including its O-ring. Remove the outer mechanical seal 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...
  • Page 30 Maintenance (Continued) Remove the outer rotating seal ring. Use special pliers. Remove the outer stationary seal ring. Remove the oil housing bottom Undo the socket hexagon screws which hold the oil housing together. Flygt 3102 Service and Repair Instructions...
  • Page 31 (page 27) to remove the inner mechanical seal. Remove the inner mechanical seal 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...

  • Page 32: Remove The Stator From The Stator Housing

    Remove the stator from the stator housing NOTICE: Make sure that the lifting device is suitable for use near heat and open flames. Lift the stator. Place a suitable protecting device under the stator. Flygt 3102 Service and Repair Instructions...

  • Page 33: Assemble The Pump

    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 Heat the stator housing to about 150°C (302°F). Flygt 3102 Service and Repair Instructions...

  • Page 34: Install The Mechanical Seal

    • 8 mm flat bladed screwdriver • Mounting tool (included) 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. Flygt 3102 Service and Repair Instructions...
  • Page 35 Clean the seal face on the shaft. 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...
  • Page 36 Do not put pressure on the screwdriver while fastening the screw. Tightening torque: 5.4 Nm (4.0 ft- lbs.) Remove the mounting tool. Install the oil housing bottom Install the oil housing. Check that the sleeve for the oil refill can pass unobstructed from the cutouts in the bearing holder. Flygt 3102 Service and Repair Instructions...

  • Page 37: Install The Motor Cable In The Stator Housing

    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 Pull the cable into the junction box. Flygt 3102 Service and Repair Instructions...
  • Page 38 Cable entry for cables with the outside diameter of (20)–32 outside diameter of 12–20 mm mm ((0.79)–1.26 in.) (0.47–0.79 in.) Lubricate and fit the O-ring on the bearing holder. Push it down to the oil housing bottom. Flygt 3102 Service and Repair Instructions...

  • Page 39: Replace Wear Parts And Cutting Parts

    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...
  • Page 40 Check that the surface intended for the wear ring is clean and undamaged. Drive in the new wear ring. To prevent deformation use either a rubber mallet or a wooden block and a hammer. Flygt 3102 Service and Repair Instructions...
  • Page 41 • 3102.890 When the impeller and cutter wheel are replaced, also replace the cutting ring. Remove the cutter wheel from the pump housing. Knock out the cutting ring from the inside of the pump housing. Flygt 3102 Service and Repair Instructions...
  • Page 42 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. Remove the pump housing cover and its O-ring. Flygt 3102 Service and Repair Instructions...

  • Page 43: Install The Pump Housing

    Install the pump housing If used, fit the new lubricated O-ring between the oil housing bottom and the pump housing. Install the pump housing. Fit and tighten the lubricated screws. Tightening torque: Torque values (page 22) Flygt 3102 Service and Repair Instructions...

  • Page 44: Replace The Impeller

    • 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.

  • Page 45: Replace The C- Or D-Impeller

    Remove the C- or D-impeller CAUTION: A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. Remove the pump housing or the suction cover. Remove the impeller screw. If applicable, use the rod. Flygt 3102 Service and Repair Instructions...
  • Page 46 Polish off any flaws with a fine emery cloth. b) Lubricate the shaft. NOTICE: Do NOT grease the conical part of the shaft. Mount the impeller: a) Fit the conical sleeve onto the shaft. Flygt 3102 Service and Repair Instructions...
  • Page 47 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...

  • Page 48: Replace The F-Impeller

    Remove the F-impeller CAUTION: A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. Remove the suction cover. Remove the impeller screw, the ring, and the washers. If applicable, use the rod. Flygt 3102 Service and Repair Instructions...
  • Page 49 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...
  • Page 50 Tighten the impeller screw. If applicable, use the rod. Tightening torque: 65 Nm (48 ft-lbs) Check that the impeller can rotate freely. Fit a new greased O-ring to the into the groove in the pump housing. Flygt 3102 Service and Repair Instructions...
  • Page 51 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...
  • Page 52 Maintenance (Continued) b) Tighten the nuts. Tightening torque: 17 Nm (13 ft-lbs) Raise the pump to a vertical position. Check that the impeller can rotate freely. Flygt 3102 Service and Repair Instructions...

  • Page 53: Replace The M-Impeller

    A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves. Remove the pump housing. Remove the impeller screw and outer sleeve. If applicable, use the rod. Refit the impeller screw. Flygt 3102 Service and Repair Instructions...
  • Page 54 Make sure that the end of the shaft is clean and free from burrs. Polish off any flaws with a fine emery cloth. Mount the impeller: a) Fit the conical sleeve onto the shaft. Flygt 3102 Service and Repair Instructions...
  • Page 55 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. Tighten the impeller screw. If applicable, use the rod. Tightening torque: 65 Nm (48 ft-lbs) Flygt 3102 Service and Repair Instructions...
  • Page 56 Check that the impeller can rotate freely. 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). Flygt 3102 Service and Repair Instructions...

  • Page 57: Replace The N-Impeller

    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...
  • Page 58 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. Flygt 3102 Service and Repair Instructions...

  • Page 59: Requirements For Ex-Approved Products

    • 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...

  • Page 60: Major Service

    For information about indication values for sensors, see Sensor connection. Alarm source Action Check for water in the oil in the oil housing. If the oil contains to much water: Drain the oil and water. Replace with new oil. Flygt 3102 Service and Repair Instructions...
  • Page 61 Drain all liquid, if any. 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. Flygt 3102 Service and Repair Instructions...

  • Page 62: Troubleshooting

    • 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).

  • Page 63: The Pump Does Not Stop When A Level Sensor Is Used

    The stop level is set too low. Raise the stop level. 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).

  • Page 64: The Pump Delivers Too Little Or No Water

    Replace the overload protection. 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).
  • Page 65 • 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).

  • Page 66: Technical Reference

    Technical Reference Technical Reference Exploded view Figure 12: 3201.090/3201.095 Flygt 3102 Service and Repair Instructions...
  • Page 67 Technical Reference (Continued) Figure 13: 3201.170 Flygt 3102 Service and Repair Instructions...
  • Page 68 Technical Reference (Continued) Figure 14: 3201.180/3201.185 Flygt 3102 Service and Repair Instructions...

  • Page 69: Tools

    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...
  • Page 70 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 Flygt 3102 Service and Repair Instructions...
  • Page 72 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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