Installation, Operation,

and Maintenance Manual

Flygt 3202

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 Table of Contents

Table of Contents
Introduction and Safety..................................................................................................................3
Introduction..................................................................................................................................3
Safety.............................................................................................................................................3
Safety terminology and symbols........................................................................................... 3
Environmental safety...............................................................................................................4
User safety................................................................................................................................ 5
Ex-approved products............................................................................................................ 6
Product warranty......................................................................................................................7

Transportation and Storage.......................................................................................................... 8

Inspect the delivery..................................................................................................................... 8
Inspect the package................................................................................................................ 8
Inspect the unit........................................................................................................................ 8
Transportation guidelines.......................................................................................................... 8
Lifting.........................................................................................................................................8
Temperature ranges for transportation, handling and storage............................................ 9
Storage guidelines...................................................................................................................... 9

Product Description......................................................................................................................11
Pump design..............................................................................................................................11
Monitoring equipment............................................................................................................. 13
The data plate............................................................................................................................13
Approvals................................................................................................................................... 15
Product denomination..............................................................................................................16

Installation......................................................................................................................................18
Install the pump.........................................................................................................................18
Install with P-installation....................................................................................................... 18
Install with S-installation....................................................................................................... 20
Install with T/Z-installation....................................................................................................20
Make the electrical connections..............................................................................................22
Prepare the SUBCAB™ cables..............................................................................................23
Connect the motor cable to the pump...............................................................................24
Connect the motor cable to the starter and monitoring equipment..............................25
Cable charts........................................................................................................................... 26
Sensor-connection................................................................................................................ 32
Check the impeller rotation..................................................................................................... 37

Operation.......................................................................................................................................39
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

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 Table of Contents

Service in case of alarm........................................................................................................ 47

Replace the impeller.................................................................................................................47
Replace the impeller for wet installation............................................................................ 47
Replace the impeller for dry installation.............................................................................54

Troubleshooting........................................................................................................................... 63
The pump does not start.......................................................................................................... 63
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

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 Introduction and Safety

Introduction and Safety

Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance

CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.

NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.

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 Xylem. If
there is a question regarding the intended use of the equipment, please contact a
Xylem representative before proceeding.
• Do not change the service application without the approval of an authorized Xylem
representative.

CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result
in physical injury, damage, or delays.

Safety terminology and symbols

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

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 Introduction and Safety

Hazard levels
Hazard level Indication
DANGER: A hazardous situation which, if not avoided, will result in
death or serious injury

WARNING: A hazardous situation which, if not avoided, could result

in death or serious injury

CAUTION: A hazardous situation which, if not avoided, could result

in minor or moderate injury

NOTICE: • A potential situation which, if not avoided, could

result in undesirable conditions
• A practice not related to personal injury

Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:

Electrical Hazard:

These are examples of other categories that can occur. They fall under the ordinary
hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard

Environmental safety
The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• 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.

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 Introduction and Safety

Recycling guidelines
Always recycle according to these guidelines:
1. Follow local laws and regulations regarding recycling if the unit or parts are accepted
by an authorized recycling company.
2. If the first guideline is not applicable, then return the unit or parts to your local sales
and service representative.

User safety
General safety rules
These 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 arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• 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.

Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
• Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into
contact with your eyes or your skin:
Condition Action
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.

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 Introduction and Safety

Condition Action
Chemicals or hazardous fluids on 1. Remove contaminated clothing.
skin 2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.

Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
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 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.
• Any maintenance for Ex-approved products must conform to international and
national standards (for example, IEC/EN 60079-17).
Xylem disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• You must fully submerge the Ex-approved product during normal operation. Dry
running during service and inspection is only permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control
panel are isolated from the power supply and the control circuit, so they cannot be
energized.
• 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.
• Intrinsically safe circuits are normally required for the automatic level-control system
by the level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• Do not modify the equipment without approval from an Ex-approved Xylem
representative.
• Only use parts that are provided by an Ex-approved Xylem representative.
• Some gap and diametrical clearances could be less than the values specified in table
1 in the standard EN 60079-1. Contact Xylem for any maintenance on flameproof
joints.
Guidelines for compliance
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 Ex-approved Xylem
representative. When you install or maintain explosion proof products, always comply
with the directive and applicable standards (for example, IEC/EN 60079–14).
Minimum permitted liquid level
See the dimensional drawings of the product for the minimum permitted liquid level
according to the approval for explosion proof 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.

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 Introduction and Safety

Monitoring equipment
For additional safety, use condition-monitoring devices. Condition-monitoring devices
include but are not limited to the following:
• Level indicators
• Temperature detectors

Product warranty
Coverage
Xylem undertakes to remedy defects in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to a local sales and service representative within the warranty
period.
• The product is used only under the conditions that are described in this manual.
• The monitoring equipment that is incorporated in the product is correctly connected
and in use.
• All service and repair work that is done by Xylem authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories that are authorized by an Ex-approved
Xylem representative are used in Ex-approved products.
Limitations
The warranty does not cover defects that are caused by these situations:
• Deficient maintenance
• Improper installation
• Modifications or changes to the product and installation that are made without
consulting a Xylem authorized representative
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
Xylem products are high-quality products with expected reliable operation and long life.
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.

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 Transportation and Storage

Transportation and Storage

Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a 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 if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact the local sales representative if there is any issue.

Transportation guidelines
Precautions

DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.

WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.

Position and fastening

The unit can be transported either horizontally or vertically. Make sure that the unit is
securely fastened during transportation, and cannot roll or fall over.

Lifting
WARNING:
Crush Hazard.
• Always lift the unit by its designated lifting points.
• Use suitable lifting equipment and ensure that the product is properly harnessed.
• Wear personal protective equipment.
• 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:

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 Transportation and Storage

• The minimum height (contact your local sales and service representative for
information) between the lifting hook and the floor must be sufficient to lift the unit.
• 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.
• The lifting equipment must support weight of the entire assembly and must only be
used by authorized personnel.
• Two sets of lifting equipment must be used to lift the unit for repair work.
• The lifting equipment must be dimensioned to lift the unit with any remaining
pumped media in it.
• The lifting equipment must not be oversized.

NOTICE:
Oversized lifting equipment could cause damage if the unit should stick when being
lifted.

Temperature ranges for transportation, handling and storage

Handling at freezing temperature
At temperatures below freezing, the product and all installation equipment, including the
lifting gear, must be handled with extreme care.
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.

NOTICE:
Never use a naked flame to thaw the unit.

Unit in as-delivered condition

If the unit is still in the condition in which it left the factory - all packing materials are
undisturbed - then the acceptable temperature range during transportation, handling and
storage is: –50°C (–58ºF) to +60°C (+140ºF).
If the unit has been exposed to freezing temperatures, then allow it to reach the ambient
temperature of the sump before operating.
Lifting the unit out of liquid
The unit is normally protected from freezing while operating or immersed in liquid, but
the impeller/propeller and the shaft seal may freeze if the unit is lifted out of the liquid
into a surrounding temperature below freezing.
Units equipped with an internal cooling system are filled with a mixture of water and 30%
glycol. This mixture remains a flowing liquid at temperatures down to –13°C (9°F). Below –
13°C (9°F), the viscosity increases such that the glycol mixture will lose its flow properties.
However, the glycol-water mixture will not solidify completely and thus cannot harm the
product.
Follow these guidelines to avoid freezing damage:
1. Empty all pumped liquid, if applicable.
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.

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 Transportation and Storage

NOTICE:
• Protect the product against humidity, heat sources, and mechanical damage.
• Do not place heavy weights on the packed product.

Freezing precautions
The unit is frost-proof while operating or immersed in liquid, but the impeller/propeller
and the shaft seal may freeze if the unit is lifted out of the liquid into a surrounding
temperature below freezing.
Follow these guidelines to avoid freezing damage:
When Guideline
Before storage • The unit must be allowed to run for a short time after raising it to
discharge remaining pumped liquid.
This does not apply to impeller/propeller units.
• The discharge opening must be covered in a suitable way, or placed
facing down so that any still remaining pumped liquid runs out.
• If present, the cooling jacket must be drained manually by opening the
air vent screws at the top of the cooling jacket.
After storage If the impeller/propeller is frozen, it must be thawed by immersing the unit
in liquid before operating the unit.

NOTICE:
Never use a naked flame to thaw the unit.

Long-term storage
If the unit is stored more than six months, then the following apply:
• 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.

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 Product Description

Product Description
Pump design
The pump is submersible, and driven by an electric motor.
Intended use
The product is intended for moving wastewater, sludge, raw and clean water. Always
follow the limits that are given in Application limits (page 67). If there is a question
regarding the intended use of the equipment, please contact a local sales and service
representative before proceeding.

WARNING:
In explosive or flammable environments, only use Ex- or MSHA-approved products.

NOTICE:
Do NOT use the pump in highly corrosive liquids.

Spare parts
• 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. For more information contact your Xylem representative.
Pressure class
LT Low head
MT Medium head
HT High head
SH Super high head

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 Product Description

Parts

14 1
13
2

9 12
11 3
10 4

8 6 5

WS000850A

WS006171A
7
Figure 1: Without cooling jacket
Figure 2: With cooling jacket

Positio Denomination Description

n
1 Monitoring Optional sensor. For information about sensors, see Monitoring equipment (page
sensor 13).
2 Shaft Stainless steel, with an integrated rotor
3 Cooling without The pump is cooled by the ambient liquid.
jacket
4 Cooling with The motor is cooled by a closed loop system. An integrated coolant pump circulates the
jacket coolant whenever the pump is operated.
5 Flow diffuser Provides heat transfer from the coolant to the pumped fluid.
6 Seal housing Includes a coolant that lubricates and cools the seals; the housing acts as a buffer
between the pumped fluid and the electric motor
7 Impeller N-impeller, a semi-open, two-vane impeller
8 Inspection Equipped with an FLS10 leakage sensor to prevent damages to the motor
chamber
9 FLS10 For information about FLS10, see Monitoring equipment (page 13).
10 Mechanical seals Made of one of the following alternatives:
• Alternative 1
• Inner seal: corrosion-resistant cemented carbide WCCR/WCCR
• Outer seal: corrosion-resistant cemented carbide WCCR/WCCR
• Alternative 2
• Inner seal: corrosion-resistant cemented carbide WCCR/WCCR
• Outer seal: silicon carbide RSiC/RSiC
11 Main bearings Consisting of a two-row angular contact ball bearing
12 Motor For information about the motor, see Motor data (page 67).
13 Thermal contact/ For information about the thermal contact and thermistors, see Monitoring
Thermistors equipment (page 13).

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 Product Description

Positio Denomination Description

n
14 Support bearing Consisting of a two-row ball bearing

Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates three thermal contacts connected in series that activate the
alarm and stops the pump at overtemperature
• The thermal contacts open at 140°C (285°F).
• 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.
If optional sensors are installed it is recommended to use MAS 711 as monitoring
equipment or equivalent equipment.
• The monitoring equipment must be of a design that makes automatic restart
impossible.
• The pump is supplied with an inspection sensor FLS 10 for sensing the presence of
any liquid in the inspection chamber.
• Information in the junction box shows if the pump is equipped with optional sensors.
Optional sensors
Thermistor Thermistors are optional sensors for measuring the temperature. They are
connected in series in the stator and activate the alarm at overtemperature.
The sensors are only optional for standard pumps.

NOTICE:
Thermistor must never be exposed to voltages higher than 2.5 V. If the
voltage exceeds this value, for example when the control circuit is tested, the
thermistors will be destroyed.
FLS FLS is a miniature float switch for detection of liquid in the junction box.
Pt 100 Pt100 is a sensor that measures the temperature in the stator and in bearings.

NOTICE:
Never connect the Pt 100 transducer to a voltage higher than 2.5 V.
VIS 10 VIS 10 is a vibration sensor located in the junction box. It measures vibrations
in one direction.

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.

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 Product Description

3 2 1

4
24
5 23
22
6
21
7
20
8

WS006257A
9 10 11 12 13 14 15 16 17 18 19
1. Curve code or Propeller code
2. Serial number, see Product denomination (page 16)
3. Product number
4. Country of origin
5. Additional information
6. Phase; type of current; frequency
7. Rated voltage
8. Thermal protection
9. Thermal class
10. Rated shaft power
11. International standard
12. 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 factor
22. Maximum ambient temperature
23. Read installation manual
24. Notified body, only for EN-approved Ex products
Figure 3: The data plate

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 Product Description

Approvals
Product approvals for hazardous locations
Pump Approval
• 3202.090 European Norm (EN)
• 3202.095 • ATEX Directive
• 3202.390 • EN 60079-0:2009, EN 60079-1:2007, EN 13463-1:2009,
• 3202.670 EN 13463-5:2011
• 3202.810 •
I M2 c Ex d I Mb
• 3202.830
•
• 3202.850 II 2 G c Ex d IIB T3 Gb
• 3202.870 EN approval for cable entry:
• Certificate number: INERIS 02ATEX9008 U
•
II 2 G Ex d IIC Gb or I M2 Ex d I Mb
IEC
• IECEx scheme
• IEC 60079-0, IEC 60079-1
• Ex d I
• Ex d IIB T3
FM (FM Approvals)
• Explosionproof for use in Class I, Div. 1, Group C and D
• Dust ignition proof for use in Class II, Div. 1, Group E, F and
G
• Suitable for use in Class III, Div. 1, Hazardous Locations

EN approval plate
This illustration describes the EN approval plate and the information that is contained in
its fields.

1 2 3 1. Approval
2. Approval authority and
Approval number
3. Approval for Class I
4. Approved for drive unit
5. Stall time
15 6. Starting current or Rated
4 14 current
7. Duty class
13 8. Duty factor
9. Input power
12 10. Rated speed
11. Controller
11 12. Additional information
5 13. Maximum ambient
temperature
14. Serial number
6 7 8 9 10 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.

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 Product Description

1. Approval
1 2 2. Approval authority and
Approval number
3. Approved for drive unit
4. Stall time
5. Starting current or Rated
current
3 13 6. Duty class
7. Duty factor
12 8. Input power
9. Rated speed
11 10. Controller
11. Additional information
4 12. Maximum ambient
10 temperature
13. Serial number

5 6 7 8 9 WS001279B

FM approval plate
This illustration describes the FM approval plate and the information that is contained in
its fields.

1 1. Temperature class
2. Maximum ambient
temperature

2 WS003973A

Product denomination
Reading instruction
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.
Codes and parameters
XXYYYY . YYY YYY YYYY
1 2 3 4 5 6 7
a
WS006265B

b
c

Type of Callout Number Indication

Type of code a Sales denomination
b Product code
c Serial number

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 Product Description

Type of Callout Number Indication

Parameter 1 Hydraulic end
2 Type of installation
3 Sales code
4 Version
5 Production year
6 Production cycle
7 Running number

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 Installation

Installation
Install the pump
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.

WARNING:
• Note that special rules apply to installation in explosive atmospheres.
• Do not install the starter equipment in an explosive zone unless it is explosion-proof
rated.
• Do not install CSA-approved products in locations that are classified as hazardous in
the national electric code, ANSI/NFPA 70-2005.
• Make sure that the unit cannot roll or fall over and injure people or damage property.

WARNING:
Electrical shock hazard. Check that the cable and cable entry have not been damaged
during transport before installing the pump.

NOTICE:
• Do not run the pump dry.
• Never force piping to make a connection with a pump.
• Always remove all debris and waste material from the sump, inlet piping, and
discharge connection, before you install the pump.

These requirements apply:

• Use the pump dimensional drawing in order to ensure proper installation.
• In S-, T-, and Z-installations the pump must be equipped with cooling jacket
• Provide a suitable barrier around the work area, for example, a guard rail.
• Check the explosion risk before you weld or use electric hand tools.
• Vent the tank of a sewage station in accordance with local plumbing codes.
• Always check the impeller rotation before lowering the pump into the pumped liquid.
Authority regulation
Vent the tank of a sewage station in accordance with local plumbing codes.
Fasteners

WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing
fasteners.

Install with P-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.

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 Installation

WS006259A
Figure 4: P-installation

These items are required:

• Guide bars
• Guide bar bracket for attaching the guide equipment to the access frame or to the
upper part of the sump
• Level regulators or other control equipment for start, stop, and alarm
• Cable holder for holding the cable and regulating the height of the level regulators
• Access frame (with covers) to which the upper guide bar bracket and cable holder can
be attached
• Discharge connection for connecting the pump to the discharge line
The discharge connection has a flange which fits the pump casing flange and a
bracket for attaching the guide equipment.
• Fasteners for the discharge connection
• Anchor bolts
1. Run a cable between the sump and the stator and monitoring equipment.
Make sure that the cable is neither sharply bent, nor pinched.
2. Install the access frame:
a) Place the access frame in position and align it horizontally.
b) Grout the frame in place.
3. Grout the anchor bolts in place.
Be careful when you align and position the discharge connection in relation to the
access frame.
4. Place the discharge connection in position, and tighten the nuts.
5. Install the guide bars:
a) Secure the guide bars in the bracket.
b) Check that the guide bars are placed vertically. Use a level or a plumb line.
6. Connect the discharge pipe to the discharge connection.
7. Prepare for the level regulator:
a) 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.

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 Installation

8. Lower the pump along the guide bars.

9. Secure the motor cable:
a) Fasten the permanent lifting device to the pump and to the access frame. For
example, you can use a stainless-steel lifting chain with shackles.
b) Fasten the cable to the cable holder.
Make sure that the cable cannot be sucked into the pump inlet or that it is neither
sharply bent, or pinched. Support straps are required for deep installations.
c) Connect the motor cable and the starter and monitoring equipment according to
the separate instructions.
Make sure that the impeller rotation is correct. For more information, see Check
the impeller rotation (page 37).
Clean all debris from the sump before starting the pump.

Install with S-installation

In the S-installation, the pump is transportable and intended to operate either completely
or partially submerged in the pumped liquid. The pump is equipped with a connection for
hose or pipe and stands on a base stand.
These requirements and instructions only apply when the installation is made according
to the dimensional drawing. For information about the different installation types, see
Parts List.
WS006270A

Figure 5: S-installation

1. Run the cable so that it has no sharp bends. Make sure that it is not pinched, and
cannot be sucked into the pump inlet.
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.
Alternatively, the pump can be suspended with a lifting chain just above the sump
bottom. Make sure that the pump cannot rotate at startup or during operation.
5. Connect the motor cable and the starter and monitoring equipment according to the
separate instructions.
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

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 Installation

In the T-installation, the pump is installed in a vertical position in a dry well next to the wet
sump. These requirements and instructions only apply when the installation is made
according to the dimensional drawing.
In the Z-installation, the pump is installed in a horizontal position on a support stand in a
dry well next to the wet sump, and a bell-mouth is connected to the inlet pipe. These
requirements and instructions are for Z-installations that comply to the dimensional
drawing.

WS006273A
WS006272A

Figure 7: Z-installation

Figure 6: T-installation

These items are required:

• Support stand and anchor bolts for anchoring the pump to a base
• Inlet elbow for connecting the suction line and discharge line
• Shut-off valves that allow you to remove the pump from service
• Air vent on the discharge side between the pump and the check valve
• Level regulators or other control equipment for start, stop, and alarm

NOTICE:
The risk of freezing is particularly high in T- or Z-installations.

1. Fasten the pump:

a) Use the anchor bolts to bolt the support stand to the concrete base.
b) Bolt the pump to the support stand and the suction connection.
2. Make sure that the pump is vertical for the T-installation or horizontal for the Z-
installation.
3. Connect the suction line and discharge line.
4. Connect the motor cable and the starter and monitoring equipment according to the
separate instructions.
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.

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 Installation

Make the electrical connections

General precautions

Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local codes
and regulations.
• 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. This applies to the control
circuit as well.
• Leakage into the electrical parts can cause damaged equipment or a blown fuse.
Keep the end of the motor cable above the liquid level.
• Make sure that all unused conductors are insulated.
• There is a risk of electrical shock or explosion if the electrical connections are not
correctly carried out or if there is fault or damage on the product.

WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.

CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.

Requirements
These general requirements apply for electrical installation:
• The supply authority must be notified before installing the pump if it will be
connected to the public mains. When the pump is connected to the public power
supply, it may cause flickering of incandescent lamps when started.
• The mains voltage and frequency must agree with the specifications on the data plate.
If the pump can be connected to different voltages, then the connected voltage is
specified by a yellow sticker close to the cable entry.
• The fuses and circuit breakers must have the proper rating, and the pump overload
protection (motor protection breaker) must be connected and set to the rated current
according to the data plate and if applicable the cable chart. The starting current in
direct-on-line start can be up to six times higher than the rated current.
• The fuse rating and the cables must be in accordance with the local rules and
regulations.
• If intermittent operation is prescribed, then the pump must be provided with
monitoring equipment supporting such operation.
• If stated on the data plate, then the motor is convertible between different voltages.
• The thermal contacts/thermistors must be in use.
• For FM-approved pumps, a leakage sensor must be connected and in use in order to
meet approval requirements.
Cables
These are the requirements to follow when you install cables:
• The cables must be in good condition, not have any sharp bends, and not be pinched.
• The sheathing must not be damaged and must not have indentations or be embossed
(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.

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 Installation

• If using a cable which has been used before, a short piece must be peeled off when
refitting it so that the cable entry seal sleeve does not close around the cable at the
same point again. If the outer sheath of the cable is damaged, then replace the cable.
Contact a local sales and service representative.
• The voltage drop in long cables must be taken into account. The drive unit’s rated
voltage is the voltage measured at the cable connection point in the pump.
• 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 local sales
and service representative (VFD-supplier).
• For SUBCAB™ cables, the twisted pair copper foil must be trimmed.
Earthing (Grounding)

Electrical Hazard:
• You must earth (ground) all electrical equipment. This applies to the pump
equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to
verify that it is connected correctly.
• If the motor cable is jerked loose by mistake, the earth (ground) conductor should be
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 or burn. You must connect an additional earth- (ground-) fault
protection device to the earthed (grounded) connectors if persons are likely to come
into physical contact with the pump or pumped liquids.

Prepare the SUBCAB™ cables

This section applies to SUBCAB cables with twisted-pair control cores.
The prepared SUBCAB™ cable The prepared screened SUBCAB™ cable

1
1
5 2 5 2
3
2

3
2
T

1 1

4
T

4
T
3
T
4
T

SUBCAB 1000V Screened SUBCAB

6 8
WS004299C

WS004298B
6 7
1. T1+T2 twisted pairs in control element 1. T1+T2 and T3+T4 twisted pairs in control element
2. Drain wire in control element (bare copper wire) 2. Drain wire in control element (bare copper wire)
3. Screened copper pt-foil 3. Screened copper pt-foil
4. Insulation jacket/sheath for control element 4. Insulation jacket/sheath for control element
5. Power cores 5. Power cores
6. Earth (ground) core 6. Aluminum foil
7. Earth (ground) core with green/yellow shrink hose
8. Uncovered screen/braided wire

1. Peel off the outer sheath at the end of the cable.

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.

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 Installation

1 2T
T
3 4
T T

WS004313B
Screened SUBCAB
Figure 8: Copper foil on control element.
b)Put a white shrink hose over the drain wire and the cable terminal.
c)Fit a cable lug on the drain wire.
d)Twist T1+T2 and T3+T4.
e)Put an insulating hose and insulating tape over the control element.
Make sure that the copper foil is covered.
3. Prepare the earth (ground) core for SUBCAB™ cable:
a) Peel the yellow-green insulation from the earth (ground) core.
b) Check that the earth (ground) core is at least 10% longer than the phase cores in
the cabinet.
4. Prepare the earth (ground) core for screened SUBCAB™ cable:
a) Untwist the screens around the power cores.
b) Put a yellow-green shrink hose over the earth (ground) core.
Leave a short piece uncovered.
c) Twist all power core screens together to create a earth (ground) core and fit a
cable terminal to the end.
d) Check that the earth (ground) core is at least 10% longer than the phase cores in
the cabinet.
5. How is the connection to earth (ground) made?
• Screw: Fit cable terminals to the earth (ground) core and the power cores.
• Terminal block: Leave the core ends as they are.
6. Prepare the main leads:
a) Remove the aluminum foil around each power core.
b) 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.

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WS006002B
1. Entrance cover
2. O-ring
For more information about the cable entry, see the Parts list.
1. Remove the entrance cover and the O-ring from the stator housing.
This provides access to the terminal board.
2. Check the data plate to see which connections are required for the power supply.
3. Arrange the connections on the terminal board in accordance with the required
power supply.
Links (jumper strips) are not used with the Y/D start.
4. Connect the mains leads (L1, L2, L3, and earth (ground)) according to applicable
cable chart.
The earth (ground) lead must be120 mm (4.8 in.) longer than the phase leads in the
junction box of the unit.
5. Make sure that the pump is correctly connected to earth (ground).
6. Connect the control leads to the applicable terminal board.
7. Make sure that any thermal contacts incorporated in the pump are properly
connected to the terminal board.
8. Install the entrance cover and the O-ring on the stator housing.
9. Fasten the screws on the entrance flange so that the cable insertion assembly bottoms
out.

Connect the motor cable to the starter and monitoring equipment

If there are two power cables, then the cable that is connected to T1 and T2 is labeled. If a
separate control cable is used, then the control leads in the power cable are never
connected.

WARNING:
Do not install the starter equipment in an explosive zone or in the sump.

NOTICE:
• Either thermal contacts or thermistors are incorporated in the pump.
• 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.

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 Installation

1. If thermal contacts are included in the pump installation, then connect the T1 and T2
control conductors to the MiniCAS II monitoring equipment.

NOTICE:
Ex-approved products must always have the thermal contacts connected irrespective
of the ambient temperature.
2. If thermistors are included in the pump installation, and screened or auxiliary cable is
used, then connect T1(1) and T2(2) to the thermistor relay or MAS 711, and T3(3) and
T4 (4) to MiniCAS II or MAS 711.
3. If the pump is prepared for MAS, then the separate sensor connection unit in the
pump is connected via SUBCAB 12×1.5 according to Connection to the monitoring
equipment (page 37).
4. Connect the mains leads (L1, L2, L3, and ground (earth)) to the starter equipment.
For information about the phase sequence and the color codes of the leads, see
Cable charts (page 26).
5. 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.

Cable charts
Description
This topic contains general connection information. It also provides cable charts that show
connection alternatives for use with different cables and power supply.

L2

L1 L3

L1 L2 L3 T1 T2
WS000509C

Figure 9: Phase sequence

Connection locations
The figures in this section illustrate how to interpret the connection strip symbols.

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1. Stator leads
2. Terminal board
L1 L2 L3 T1 T2 T3 T4
3. Motor cable leads
4. Stator (internal connection illustrated)

1
L1
U1 V1 W1 U2

2
U1
W2 V2

U1 V1 W1 W2 U2 V2 U2
GC

W2

V2
U1 V1 W1 W2 U2 V2

GN/YE

W1
*YE

V1
WH
L1 L2 L3
L3 L2

4
3

WS004133D
1 2 3 4 1. Starter equipment and mains leads (L1, L2, L3)
2. Earth (ground)
3. Functional ground
4. Control leads (T1, T2, T3, T4)
L1 L2 L3 T1 T2 T3 T4 5. Thermal contact
6. FLS
7. FLS 10
8. CLS
9. Thermistor
5 9 10. Level sensor
11. Capacitor

6 FLS 10

7 FLS 10 11
WS004134A

8
CLS

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 Installation

Colors and markings of leads

Motor Connection Colors and marking of the main leads

Mains SUBCAB 7GX SUBCAB 4GX SUBCAB
COLOR STANDARD STATOR LEADS 3 Screenflex 7GX Screenflex 4GX
SUBCAB AWG
Screened

BN = Brown U1,U5 = RD L1 BK 1 BN RD BN
BK = Black U2 = GN
WH = White L2 BK 2 BK BK BK
V1,V5 = BN
OG = Orange V2 = BU L3 BK 3 GY WH GY
GN = Green W1,W5 = YE
GN/YE = Green-Yellow W2 = BK L1 BK 4 - - -
RD = Red T1,T2 = WH or YE L2 BK 5 - - -
GY = Grey
BU = Blue L3 BK 6 - - -
YE = Yellow
GN/YE **Screen/PE
GN/YE GN/YE
*SUBCAB AWG from cores
* * Ground conductor is stranded around core Screen (WH) Screen (WH) - Screen (WH)
GC=Ground check
773 29 00 ( 5) REV GC - - YE -

Motor Connection Colors and marking of the main leads Terminal clamps 6 stator leads One cable
Mains SUBCAB 7GX SUBCAB 4GX SUBCAB
COLOR STANDARD STATOR LEADS 3 Screenflex 7GX Screenflex 4GX
SUBCAB AWG
Screened

BN = Brown U1,U5 = RD L1 BK 1 BN RD BN U1 W2 V1 U2 W1V2

6 LEADS
BK = Black U2 = GN

WS004551C
WH = White L2 BK 2 BK BK BK
V1,V5 = BN

GN
RD

BN

BU
BK

YE
OG = Orange V2 = BU L3 BK 3 GY WH GY U1 W2 V1 U2 W1 V2
GN = Green W1,W5 = YE
GN/YE = Green-Yellow W2 = BK L1 BK 4 - - -
RD = Red T1,T2 = WH or YE

W1
W2
L2 BK 5 - - -

U2
U1

V1

V2
GY = Grey
BU = Blue L3 BK 6 - - -
YE = Yellow
GN/YE **Screen/PE
GN/YE GN/YE
*SUBCAB AWG from cores
* * Ground conductor is stranded around core Screen (WH) Screen (WH) - Screen (WH)
GC=Ground check L1 L3 L2
773 29 00 ( REV
5) GC - - YE -

Color code standard

Code Description
BN Brown
BK Black
WH White
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow

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Motor connection

Terminal clamps 6 stator leads

U1 W2 V1 U2 W1 V2

WS003903A
Figure 10: Terminal clamps, 6 stator leads

Connections included
• 6–leads connection (page 29)
• 9-leads connection (page 31)
• Screened cable connection (page 31)
6–leads connection
One cable (left) and two cables (right) Y-connection.

One cable Two cables Y

L1
U1 W2 V1 U2 W1V2 U1 V1 W1 U2 V2
U1
BU
GN
GN
RD

RD

BN
BN

BU
BK

YE

YE

U2

GC
W1
W2

W1

W2
U2
U1

U1
V1

V2

V1

V2
W1

V1

WS003803B
BK

GN/YE

L12 L32 L22

WH
*YE

L2 L3
L1 L3 L2 L11 L3 1 L21 W2

Figure 11: Y-connection

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 Installation

One cable (left) and two cables (right) D-connection.

One cable Two cables D

L1
U1W2 V1 U2 W1 V2 U1W2 V1 U2 W1 V2

U1

GN
RD

GN
BU
BN

RD
BK

YE

BU
BN
BK

YE
V2

W1
W1
GC U2

W2
W2

V1
U1
U1

V1

U2
U2

V2
V1

V2
W1 W2

GN/YE

WS003804B
L12 L22

WH
L32

*YE
L2 L3
L1 L3 L2 L11 L3 1 L2 1

Figure 12: D-connection

One cable (left) and two cables (right)Y/ D-connection.

One cable Two cables Y/D

L1:1 L3:1 L2:1
U1W2 V1 U2 W1V2 U1W2 V1 U2 W1V2 L2:2
L1:2 L3:2
RD

YE
BN
GN
RD

GN
BN

BU
YE
BK

BU
BK

U1 V1 W1
W1

GC
W1
W2

W2
V1
U2
U1

U2
V1

V2

U1

V2

L12 L32 L22 U2 V2 W2

L12 L32 L2 2

WS003805B
GN/YE

4 6 5 4 6 5
WH
*YE

L12 L31 L21 L11 L3 1 L2 1

1 3 2 1 3 2

Figure 13: Y/D-connection

Y and D-connection, only applicable to 70 mm2 terminal clamp.

Y D
U1 V1 W1 U2 V2 U1 W2 V1 U2 W1 V2
GN

RD
RD

BU

BN
BN

YE

GN

BU
YE
BK
BK

GC
W1
W1

W2

U2
U1
U1

V1

V2
V1

GN/YE

WH
*YE

L11 L3 L2 1 L11 L3 1 L2 1
1
WS003813A

Only applicable to 70mm2 terminal clamp

Figure 14: Y or D-connection

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9-leads connection
One cable (left) and two cables (right) Y-parallel connection.

One cable Two cables Y-

L1
U1U5 V1 V5 W1W5 U2 V2 W2 U1U5 V1 V5 W1W5 U2 V2 W2
U1

GN

RD
RD

GN
BN

BK
RD

BU
BN
RD

YE
U5

YE
BN

BU

YE
BN

BK

YE
U2

GC

W1

W1
W5

W5
U1

W
U5
U1

V1
V5

U5

V5
V1

V5

WS003826B
W

V2
1
GN/YE

WH
L1 2 L3 2 L2 2

V1
*YE

L3
5
L2
L1 L3 L2 L11 L3 1 L2 1

Figure 15: Y-parallel connection

One cable (left) and two cables (right) Y-serial connection.

One cable Two cables Y-SER

U1 V1 W1 U2 U5 V2V5W2W5 L1
U1 U5 U2 V1 V5 V2 W1 W5 W2

GN
RD
RD

BU
BN

BN
RD

YE
RD

GN

BK
YE
BN
BN
BU

BK
YE
YE

U1
U2
U5
W1 GC
U1

V1
W1
W5
U1

V5
U5
V1

W5

V5
W2

V2
GN/YE

W1
L12 L32 L22

WS003837B
V1
WH
*YE
L11 L31 L2 1 L2 L3
L1
L3 L2

Figure 16: Y-serial connection

Screened cable connection

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

GY
BK
BN

Mini CAS Mini CAS+AUX FGB Screened

L1 L2 L3
WS003815B
T1 (WH)

T2 (WH)

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)
T4 (WH)
T3 (WH)

Figure 17: Screened SUBCAB and FGB Screened

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 Installation

* For screened SUBCAB T3 and T4 shall also be twisted separately.

Screenflex and SUBCAB with functional ground

T1 and T2 White insulation hose T1 and T2 White insulation hose
twisted* twisted*
Screen Screen

BK

BK
BK
BK

BK

BK
GN/YE
GN/YE L1 L2 L3 T1 T2 1 2 3 4 5 6 T1 T2
BN BK GY

WS003824B
* For screened SUBCAB T3 & T4 shall also be twisted separately

Figure 18: Screenflex and SUBCAB with functional ground

Sensor-connection
Connection to the pump

Color and marking of control leads

SUBCAB
Control SUBCAB 4GX/7G and SUBCAB AWG
Screened
Screenflex

T1 WH T1 OG WH T1

T2 WH T2 BU WH T2

T3 - - WH T3

T4 - - WH T4 WS003843B

Figure 19: Color and marking of control leads

Sensor terminal clamps

WS003850B

T15 T16 T1 T2

Figure 20: Sensor terminal clamps

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FLS 10 and Thermal detectors

FLS + Thermal detectors

FLS TC
Max 12 V

WH/YE T1 Control leads

+7
T1/*OG/1 Mini
BN T2 CAS
-5
T2/*BU/2
WH/YE

BN T15 **T3

WS003855B
**T4
*SUBCAB AWG
*Screened SUBCAB

∞ Ohm Overtemperature
1200 Ohm OK
430 Ohm Leakage
FLS 10 and Thermistor

FLS + Thermistor
T1 Control leads
Max RD T1/1 Thermistor
2.5 V RD T2 T2/2 relay

T15
+7
Max FLS BN/BU T3/3 Mini
CAS

WS003876B
12 V BN/BU T16 T4/4
-5

T=25°C (77°F) R ≤ 100 Ohm

T=135°C (275°F) (TREF –5°C (23°F)) R ≤ 550 Ohm
T=145°C (293°F) (TREF +5°C (41°F)) R ≤ 1330 Ohm
Thermal detectors, FLS disconnected

Thermal detectors FLS Disconnected

FLS TC
Max 12 V

WH/YE T1 Control leads

+7
T1/*OG/1 Mini
BN T2 CAS
-5
T2/*BU/2
WH/YE
T15
BN **T3
WS003869B

**T4
*SUBCAB AWG
*Screened SUBCAB

MAS 711
The following sensors can be used together with MAS 711:

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 Installation

• FLS 10/FLS
• Pump memory
• PT 100
• Thermal contacts
• VIS 10
Sensor type Description Measured value Fault values
Thermal contact The thermal contact is a 0-3 ohm, unless the wires are An infinite value (open circuit)
normally closed contact. very long. indicates either high
temperature or a fault (a wire is
broken or there is a bad contact
in a connector).
Thermistor The thermistor is a Resistance at normal • Above the tripping point,
semiconductor device. temperature: TRef, the resistance
• 50-100 ohm (150-300 increases dramatically to
ohm for three in a series). several Kohm.
• An infinite value (open
circuit) indicates a fault (a
wire is broken or there is a
bad contact in a
connector).
• A value close to zero
indicates a short circuit in
the wiring.
Pt 100 sensor The Pt 100 sensor is a resistor Resistance: • An infinite value (open
changing value almost linearly • 100 ohm at 0ºC (32ºF) circuit) indicates a fault (a
with temperature. • 107.79 ohm at room wire is broken or there is a
temperature (20ºC, 68ºF) bad contact in a
connector).
• 138.5 ohm at 100ºC
(212ºF) • A value close to zero
indicates a short circuit in
The resistance increases with the wiring.
0.385 ohm for each degree
centigrade.

NOTICE:
Never connect the Pt 100
transducer to a voltage higher
than 2.5 V.
Float switch (FLS) The float switches are leakage Resistance. 2 sensor variants:
sensors located in the FLS:
inspection chamber and in the
• Normal: 1530 ohm
junction box.
• Alarm: 330 ohm
FLS-10:
• Normal: 1200 ohm
• Alarm: 430 ohm
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.

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Conn. for MAS 711, FLS option

Control leads MAS
Connection leads SUBCAB
FLS 10 BN 1 1
1 1 17
BN 2 2
2 2 16
RD 3 3
Main bearing 3 3 8
PT 100 WH 3 4
4 4 4
YE 5 5
1
TC 5 5
YE 6 6
6 6 2
FLS BU 9
7 7
7
15
8
BU 2 8 8 3
RD 19 9 9
9
Stator winding 38
PT 100 (Phase 1) WH 4 10 10
10
37
RS485 B GY 74 11
11 11 36
Pump memory RS485 A YE 75 12

WS003882B
12 12 35
Ground BK 76
12V+ RD 77

Figure 21: Connection for MAS 711, FLS option

Sensor/Component Sensor cable, Base unit terminal block, no

no
FLS 10 — Leakage in inspection 1 17
chamber 2 16
Pt 100 — Temperature measurement, 3 8
main bearing 4 4
Thermal switches — Temperature guard 5 1
stator windings 6 2
FLS — Leakage in junction box 7 15
(2) (16)
Pt 100 — Temperature measurement, 8 3
stator winding ph 1 (4) (4)
Pump memory:
RS–485 B 9 38
RS-485 A 10 37
Supply, ground 11 36
Supply, 12V+ 12 35
(Screen) If applicable, attach screen to ground terminals in the
• pump top, and
• electrical cabinet

1 If the sensor cable contains a green-yellow lead, that lead should not be connected.
2 Communication port 37-38 for RS-485 is common to both pump memory and operator panel.

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 Installation

Conn. for MAS 711,VIS 10 option

Connection leads
Control leads MAS
SUBCAB
FLS 10 BN 1 1
1 1 17
BN 2 2
2 2 16
RD 3 3
Main bearing 3 3 8
PT 100 WH 3 4
4 4 4
YE 5 5
1
TC 5 5
YE 6 6
6 6 2
BU 9 7
7 7 15
VIS 10 BN 2 8 8
8
3
RD 19 9 9
9
Stator winding 38
PT 100 (Phase 1) WH 4 10 10
10
37
RS485 B GY 74 11
11 11 36
Pump memory RS485 A YE 75 12

WS003892B
Ground BK 76 12 12 35
12V+ RD 77

Figure 22: Connection for MAS 711, VIS 10 option

Sensor/Component Sensor cable, Base unit terminal block, no

no3
FLS 10 — Leakage in inspection 1 17
chamber 2 16
Pt 100 — Temperature measurement, 3 8
main bearing 4 4
Thermal switches — Temperature 5 1
guard stator windings 6 2
VIS 10 — Vibration sensor4 7 18
-2 -16
Pt 100 — Temperature measurement, 8 3
stator winding ph 1 -4 -4
Pump memory:
RS–485 B 9 38
RS-485 A 10 37
Supply, ground 11 36
Supply, 12V + 12 35
(Screen) If applicable, attach screen to ground terminals in the
• pump top, and
• electrical cabinet

3 If the sensor cable contains a green-yellow lead, that lead should not be connected.
4 VIS 10 is not applicable to pump type 3153
5 Communication port 37-38 for RS-485 is common to both pump memory and operator panel.

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 Installation

1 2

WS001113A
1. Electric connection, sensor cables
2. Electric connection, 12-lead cable
Figure 23: Pin setting connector unit

Connection to the monitoring equipment

MiniCAS II

24 V AC/DC C Pump contactor

CC Control circuit
2 10
L1 Caution light (leakage)
R
6 L2 Caution light (stator over-temperature)
T15 T1 7+
12 VDC
P Pump main supply
FLS10
T2 5- R Reset switch
11
L1
9

10S 8
L2
4

CC
1 3

P
WS002623B

MAS 711
For information on how to connect to MAS 711, see MAS 711 Installation and Operation
manual.

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.

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 Installation

WS006253A
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.

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 Operation

Operation
Precautions

WARNING:
• Never operate the pump without safety devices installed.
• Never operate the pump with the discharge line blocked, or the discharge valve
closed.
• Make sure you have a clear path of retreat.
• Never work alone.

CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.

Distance to wet areas

Electrical Hazard:
• Risk of electrical shock. Make sure no one gets closer than 20 m (65 ft.) to the unit
when being in contact with the pumped or mixed liquid.
• Risk of electrical shock. This unit has not been investigated for use in swimming pools.
If used in connection with swimming pools special safety regulations apply.

Noise level

NOTICE:
The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may
be exceeded in some installations and at certain operating points on the performance
curve. Make sure that you understand the noise level requirements in the environment
where the pump is installed. Failure to do so may result in hearing loss or violation of local
laws.

Estimate zinc anode replacement intervals

The mass and surface area of the zinc anodes are designed to protect the pump surface
for 1 year in sea water with an average temperature of 20°C (68°F). Shorter inspection
intervals and anode replacement can be required, depending upon the water
temperature and the chemical composition as well as the presence of other metals in the
vicinity of the pump.
The rate of zinc consumption, and the appropriate inspection intervals, can be estimated
by measuring how much zinc is consumed during the first two months following
installation.
Anodes are replaced when the anode mass is reduced to a selected fraction of its initial
mass. 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.
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).

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 Operation

If multiple anodes were weighed, then use the anode which has lost the most weight
for this calculation.
4. Calculate future replacement intervals so that they occur when the selected fraction of
zinc is remaining.

Start the pump

DANGER:
If you need to work on the pump, make sure that it is isolated from the power supply and
cannot be energized.

WARNING:
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• In some installations, the pump and the surrounding liquid may be hot. Bear in mind
the risk of burn injuries.
• Make sure nobody is close to the unit when it is started. The unit will jerk in the
opposite direction of the impeller rotation.

NOTICE:
Make sure that the rotation of the impeller is correct. For more information, see Check the
impeller rotation.

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.

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 Maintenance

Maintenance
Precautions

DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.

WARNING:
• Always follow safety guidelines when working on the product. See Introduction and
Safety (page 3).
• Make sure that the unit cannot roll or fall over and injure people or damage property.
• Rinse the unit thoroughly with clean water before working on the unit.
• Rinse the components in water after dismantling.

Make sure that you follow these requirements:

• Check the explosion risk before you weld or use electrical hand tools.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product and its components have been thoroughly cleaned.
• Do not open any vent or drain valves or remove any plugs while the system is
pressurized. 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.
Earth continuity verification
An earth continuity test must always be performed after service.
Maintenance guidelines
During the maintenance and before reassembly, always remember to perform these
tasks:
• Clean all parts thoroughly, particularly O-ring grooves.
• Change all O-rings, gaskets, and seal washers.
• Lubricate all springs, screws, O-rings with grease.
During the reassembly, always make sure that existing index markings are in line.
The reassembled drive unit must always be insulation-tested and the reassembled pump
must always be test-run before normal operation.

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, please contact the local sales and
service representative.
Screws and nuts

Table 1: Stainless steel, A2 and A4, torque Nm (ft-lbs)

Property M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class
50 1.0 (0.74) 2.0 (1.5) 3.0 (2.2) 8.0 (5.9) 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)

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 Maintenance

Property M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class
100 4.1 (3) 8.1 (6) 14 (10) 34 (25) 66 (49) 115 (84.8) 248 (183) 481 (355) — —

Table 2: Steel, torque Nm (ft-lbs)

Property M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

class
8.8 2.9 (2.1) 5.7 (4.2) 9.8 (7.2) 24 (18) 47 (35) 81(60) 194 (143) 385 (285) 665 (490) 1310
(966.2)
10.9 4.0 (2.9) 8.1 (6) 14 (10) 33 (24) 65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840
(1357)
12.9 4.9 (3.6) 9.7 (7.2) 17 (13) 40 (30) 79 (58) 136 (100) 333 (245) 649 (480) 1120 2210
(825.1) (1630)

Hexagon screws with countersunk heads

For hexagon socket head screws with countersunk head, maximum torque for all property
classes must be 80% of the values for property class 8.8 above.

Change the coolant

This image shows the plugs that are used to change the coolant.

2 2

1 2

1 2

WS001480A
Figure 25: Without a cooling jacket
Figure 24: With a cooling jacket

1. Inspection plug
2. Coolant plugs

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.

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WS002122A
WS001505A

Figure 27: With a cooling jacket

Figure 26: Without a cooling jacket
b) Pump out any coolant from the inspection chamber, as shown here.

c) Replace the inspection plug and O-ring and tighten. WS001471A

Tightening torque: 44 Nm (33 ft-lbs)

2. Empty the coolant:
a) Place the pump in a horizontal position, or leave it upright to use a pump to empty
the coolant.
WS001463A

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.

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 Maintenance

WS001426A
WS001425A
Figure 28: With a cooling jacket Figure 29: Without a cooling jacket

Fill with coolant

Use a coolant that is a mixture of 70% water and 30% monopropylene glycol. The coolant
should prevent corrosion and be nonpoisonous (generally recognized as safe by the FDA
as food additives under part 184 and 182).

NOTICE:
Clean water with an anti-corrosive is an acceptable coolant when there is no risk of
freezing.

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

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WS000966A

WS001469A
Figure 30: With cooling jacket

Figure 31: Without cooling jacket

2. Replace the O-rings.
3. Tighten the coolant plugs.
Tightening torque: 44 Nm (33 ft-lb)

Service the pump

Type of service Purpose Inspection interval
Initial To make a check up of the pump condition by a Xylem Within the first year of operation.
inspection authorized service representative and, based on the result and
findings from these measures, to determine the intervals for
periodical inspection and major overhaul for the specific
installation.
Periodical To prevent operational interruptions and machine breakdown. Up to 12,000 hours or 3 years,
inspection Measures to secure performance and pump efficiency are whichever comes first.
defined and decided for each individual application. It can Applies to normal applications and
include such things as impeller trimming, wear part control operating conditions at media
and replacement, control of zinc-anodes and control of the (liquid) temperatures <40°C.
stator.
Major To secure a long operating lifetime for the product. It includes Up to 24,000 hours or 6 years,
overhaul replacement of key components and the measures taken whichever comes first.
during an inspection. Applies to normal applications and
operating conditions at media
(liquid) temperatures <40°C.

NOTICE:
Shorter intervals may be required when the operating conditions are extreme, for
example with very abrasive or corrosive applications or when the liquid temperatures
exceed 40°C (104°F).

Inspection
Service item Action
Cable 1. If the outer jacket is damaged, replace the cable.
2. 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 1. Check the impeller clearance.
2. Adjust the impeller, if necessary.

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 Maintenance

Service item Action

Inspection chamber 1. Drain all liquid, if any.
2. Check the resistance of the leakage sensor.
If the pump is connected to the MAS 711 then it is recommended
that the sensors be checked in the MAS 711 unit. Otherwise, use a
multimeter.
For values, see Sensor-connection (page 32). Make sure to
select values for the appropriate monitoring equipment and sensor
combination.
Insulation Use a megger maximum 1000 V.
1. Check that the resistance between the earth (ground) and phase
lead is more than 5 megohms.
2. Conduct a phase-to-phase resistance check.
Junction box 1. Check that it is clean and dry.
2. Check the resistance of the leakage sensor.
If the pump is connected to the MAS 711 then it is recommended
that the sensors be checked in the MAS 711 unit. Otherwise, use a
multimeter.
Normal value approximately 1530 ohms, alarm approximately
330 ohms.
Level regulators Check the condition and functionality.
Lifting device Check that local safety regulations are followed.
Lifting handle 1. Check the screws.
2. Check the condition of the lifting handle.
3. Replace if necessary.
O-rings 1. Replace the oil plug O-rings.
2. Replace the O-rings at the entrance or junction cover.
3. Grease the new O-rings.
Overload protection and other Check the correct settings.
protections
Personnel safety devices Check the guard rails, covers, and other protections.
Rotation direction Check the impeller rotation.
Seal housing 1. Fill with new coolant, if necessary.
2. Check that the freezing point is lower than -13°C (9°F).
Terminal board Check that the connections are properly tightened.
Temperature sensors: If the pump is connected to the MAS 711 then it is recommended that the
• Thermal contact sensors be checked in the MAS 711 unit. Otherwise, use a multimeter.
• Thermistor Do not use a device applying a higher voltage than 2.5 V.
• Pt 100 1. Disconnect the sensor leads.
2. Measure the resistance to check the status of the sensor and leads
according to values in Sensor-connection (page 32). Make sure
to select values for the appropriate sensor, monitoring equipment
and sensor combination.
3. Measure between each sensor lead to earth (ground) to establish
that the resistance is infinite (or at least several Megaohm).
Voltage and amperage 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.

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Service item Action

Mechanical seal Replace with new seal units.

Service in case of alarm

For information about indication values for sensors, see Sensor-connection (page 32).
Alarm source Action
FLS10 1. Drain the fluid in the inspection chamber. Fill with new coolant if
necessary.
2. Check the freezing point (lower than -13°C or 9°F).
Check the inspection chamber again after one week of operation. If
leakage has occurred:
1. Drain the fluid.
2. Change the mechanical seal unit.
3. Replace with new coolant.
The thermistor/Thermal contact 1. Check the coolant level (pump with cooling jacket).
2. Check the start and stop levels.
The overload protection Check that the impeller can rotate freely.

Replace the impeller

Required tools:
• 17 mm hexagon bit adapter with an extension of at least a 100 mm (4 in.)
• Rod (wood or plastic) for locking the impeller in place.

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 edges. Wear protective
gloves.
• When laying the pump on its side, do not allow the weight of the pump to rest on any
portion of the impeller. The impeller must not be allowed to make contact with the
concrete floor or other hard and rough surfaces.

Replace the impeller for wet installation

Remove the impeller: wet installation

CAUTION:
Wear heavy work gloves when you handle impellers. The sharp edges can cause physical
injury.

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.

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 Maintenance

WS001482A

d) Turn the adjustment screw counterclockwise until the impeller breaks free from
the shaft.

WS001450A
e) Hand-tighten the impeller screw to prevent it from falling off.

WS001490A

f) Remove the rod.

3. Raise the pump.
4. Remove the drive unit from the pump housing:
a) Remove the pump housing screws.

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WS006264A
b) Remove the drive unit from the pump housing.
WS001477A

5. Remove the impeller:

a) Place the drive unit horizontally.
b) Remove the impeller screw.
WS006263A

c) Remove the impeller and the conical sleeve.

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 Maintenance

WS001461B
Install the impeller: wet installation
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.
b) 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.

NOTICE:
Surplus grease can cause the impeller to become loose. Remove surplus grease
from conical and/or cylindrical surfaces of shafts and/or sleeves.
WS006895A

2. Mount the impeller:

a) 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.

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WS001759A

d) Fit the sleeve and impeller to the shaft.

e) Hand-tighten the impeller screw to prevent it from falling off.

WS006256A
3. Fit the pump housing:
a) Fit a new and lubricated O-ring on the seal housing cover.
b) Lubricate the pump housing screws.
c) Raise the drive unit.
d) 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.
f) Tighten the screws in diagonal sequence.
For tightening torque, see Torque values (page 41).

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WS006260A
4. Remove the impeller screw:
a) Place the pump horizontally.
b) Lock the impeller in place by inserting a rod through the hole in the .
c) Remove the impeller screw and the washer.

WS001482A

5. Adjust the impeller:

a) 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°).

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WS001451A
6. Fasten the impeller:
a) Fit the lubricated washer and impeller screw.
b) Tighten the impeller screw.
For tightening torque, see Torque values (page 41).
c) Tighten it a further 1/8 turn (45°).

WS001486A

d) Remove the rod that is used to lock the impeller.

e) Fit the O-ring and flush valve cover and fasten it with screws.
For tightening torque, see Torque values (page 41).
f) 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).

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WS003731A

WS003730A
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. WS001539A

b) Remove the drive unit from the pump housing.

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WS001477A

2. Remove the impeller:

a) Place the drive unit horizontally.
b) 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.
WS001461B

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 Maintenance

Install the impeller: dry installation

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.
b) 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.

NOTICE:
Surplus grease can cause the impeller to become loose. Remove surplus grease
from conical and/or cylindrical surfaces of shafts and/or sleeves.

WS006895A
2. Mount the impeller:
a) 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.

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A WS001472A

d) Fit the sleeve and the impeller to the shaft.

WS006256A

e) Fit the impeller screw and washer and tighten.

WS001492A

3. Make sure that the O-ring is removed from the seal housing cover.

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WS002008A
4. Measure the trim distance:
a) Place the drive unit in the pump housing.
Make sure that the drive unit is parallel with the pump housing by hand-tightening
the pump housing screws.
WS001475A

b) Check the distance between the seal housing cover and the pump housing with a
feeler gauge.
Check diagonally at four points.
WS002089A

c) Note the largest distance B.

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B WS001473A
d) Lift the drive unit out of the pump housing and remove the impeller and conical
sleeve.
WS001477A

5. Trim to the correct distance:

a) Calculate the measure C according to the formula shown in the image.

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C=A-B-0.5 mm
WS001475A

b) Turn the adjustment screw until C is reached.

6. Fasten the impeller:
a) Fit the sleeve, impeller, lubricated washer with a lubricated impeller screw.
b) Tighten the impeller screw.
For tightening torque, see Torque values (page 41).
c) Tighten it further 1/8 turn (45°).

WS001492A

7. Install the drive unit in the pump housing:

a) Fit a new and lubricated O-ring to the seal housing cover.

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WS002056A

b) Place the drive unit in the pump housing.

WS001475A

c) 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).

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WS001478A

If you need to adjust the impeller, redo the replace the impeller procedure from the
beginning.

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 Troubleshooting

Troubleshooting
Introduction

DANGER:
Personal injury hazard. Troubleshooting a live control panel exposes personnel to
hazardous voltages. Electrical troubleshooting must be done by a qualified electrician.
Failure to follow these instructions will result in serious personal injury, death, and/or
property damage.

Follow these guidelines when troubleshooting:

• Disconnect and lock out the power supply except when conducting checks that
require voltage.
• Make sure that no one is near the pump when the power supply is reconnected.
• When troubleshooting electrical equipment, use the following:
• Universal instrument multimeter
• Test lamp (continuity tester)
• Wiring diagram

The pump does not start

WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.

Cause Remedy
An alarm signal has been triggered Check that:
on the control panel. • The impeller rotates freely.
• The sensor indicators do not indicate an alarm.
• The overload protection is not tripped.
If the problem still persists:
Contact the local sales and service representative.
The pump does not start Check that:
automatically, but can be started • 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.

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 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.
• All fuses have power and that they are securely fastened to the fuse
holders.
• The overload protection is not tripped.
• The motor cable is not damaged.
The impeller is stuck. Clean:
• The impeller
• The sump in order to prevent the impeller from clogging again.

Always state the serial number of your product, see Product Description (page 11).

The pump does not stop when a level sensor is used

WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

Cause Remedy
The pump is unable to empty the Check that:
sump to the stop level. • There are no leaks from the piping and/or discharge connection.
• The impeller is not clogged.
• The non-return valve(s) are functioning properly.
• The pump has adequate capacity. For information:
Contact the local sales and service representative.
There is a malfunction in the level- • Clean the level regulators.
sensing equipment. • Check the functioning of the level regulators.
• Check the contactor and the control circuit.
• Replace all defective items.
The stop level is set too low. Raise the stop level.

Always state the serial number of your product, see Product Description (page 11).

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.
• The length of the discharge pipe between the pump and the first non-
return valve is sufficiently short.
The self-holding function of the Check:
contactor malfunctions. • The contactor connections.
• 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.

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 Troubleshooting

Always state the serial number of your product, see Product Description (page 11).

The pump runs but the motor protection trips

WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.

Cause Remedy
The motor protection is set too low. Set the motor protection according to the data plate and if applicable the
cable chart.
The impeller is difficult to rotate by • Clean the impeller.
hand. • Clean out the sump.
• Check that the impeller is properly trimmed.
The drive unit is not receiving full • Check the fuses. Replace fuses that have tripped.
voltage on all three phases. • If the fuses are intact, notify a certified electrician.
The phase currents vary, or they are Contact the local sales and service representative.
too high.
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 megohms.
2. If the insulation is less:
Contact the local sales and service representative.
The density of the pumped fluid is too Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)
high. • Change the impeller, or
• Change to a more suitable pump.
• 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 11).

The pump delivers too little or no water

WARNING:
Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

NOTICE:
Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.

Cause 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.

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 Troubleshooting

Cause Remedy
One or more of the valves are set in • Reset the valves that are set in the wrong position.
the wrong positions. • Replace the valves, if necessary.
• Check that all valves are correctly installed according to media flow.
• Check that all valves open correctly.
The impeller is difficult to rotate by • Clean the impeller.
hand. • Clean out the sump.
• Check that the impeller is properly trimmed.
The pipes are obstructed. Clean out the pipes to ensure a free flow.
The pipes and joints leak. Find the leaks and seal them.
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.

Always state the serial number of your product, see Product Description (page 11).

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 Technical Reference

Technical Reference
Application limits

Data Description
Liquid temperature 40°C (104°F) maximum
For P- and S-installations without cooling jacket, the pump can be operated only when
the sump level is at least 10 mm above the stator housing.
Warm-liquid version (only with cooling jacket): 70°C (158°F) maximum
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
(liquid)
Depth of immersion 20 m (65 ft) maximum
Other For the specific weight, current, voltage, power ratings, and speed of the pump, see the
data plate of the pump.

Motor data

Feature Description
Motor type Squirrel-cage induction motor
Frequency 50 or 60 Hz
Supply 3-phase
Starting method • Direct on-line
• Star-delta
• Soft starter
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 2%
tolerance
Stator insulation class H (180°C [360°F])

Flygt 3202 Installation, Operation, and Maintenance Manual 67

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 Xylem |’zīləm|
1) The tissue in plants that brings water upward from the roots
2) A leading global water technology company

We're 12,000 people unified in a common purpose: creating innovative

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we help people use water efficiently, in their homes, buildings, factories and
farms. In more than 150 countries, we have strong, long-standing relationships
with customers who know us for our powerful combination of leading product
brands and applications expertise, backed by a legacy of innovation.

For more information on how Xylem can help you, go to xyleminc.com

Xylem Water Solutions 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.
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Tel: +46-471-24 70 00 © 2012 Xylem Inc

Fax: +46-471-24 47 01
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