892409 03 en gb vhb3085-3102-31 - infota.siss.clinfota.siss.cl/concesiones/empresas/aguaschañar/10...

Workshop manual3085, 3102, 3127

892409/03

3085, 3102, 31272

In order to minimize the risk of accidentsin connection with service work, thefollowing rules should be followed:

– Before starting work on the pump,make sure that the pump is isolatedfrom the power supply and cannot beenergized.

Follow all other health and safety regulations, localcodes and ordinances.

ITT Flygt disclaims all responsibility for work doneby untrained, unauthorized personnel.

– Bear in mind the risk of accidents. Make sure thatthe machine or parts of the machine cannot rollor fall over and injure people or damage property.

– Make sure that the lifting equipment can handlethe weight you want to lift and that it is in goodcondition.

– Make continuously sure that, in the course of thework, the pump and / or pump components standsteadily and cannot fall down and cause damage.

– Don't work under suspended load.

– Carry out the work on a sturdy workbench.

– Bear in mind the danger of electrical accidents.

– Bear in mind health hazards. Observe strictcleanliness. When carrying out repair work takecare to avoid injury by cutting or pinching.

– Make sure you have a first-aid box near at hand.

– Check that tools and other equipment are in goodcondition.

General rulesWash the outside of the pump thoroughly.

Before assembly:

- Clean all parts thoroughly, particularly O-ring grooves.

- Always change all O-rings, gaskets, washers andseals.

- Lubricate all springs, screws and O-rings with grease.

CONTENTS

Safety ________________________ 2Guarantee ____________________ 3How to use the workshop manual 4Products included _____________ 4Data plate interpretation ________ 5Technical data ________________ 7

Tools_________________________ 8Electrical connections__________ 11Monitoring equipment _______________________ 11

Dismantling _________________ 15

Assembly ___________________ 30Replacing/Installing/Trimming the impeller,

Grinder _________________________________ 52F-impeller _______________________________ 58Swirl (vortex) impeller _____________________ 64N-type impeller __________________________ 68

Exploded views ______________ 74

Service log __________________ 88

Specially approved pumps ____ 89

Notes _______________________ 94

SAFETY

33085, 3102, 3127

— Only Ex-approved pumps may be used in anexplosive or flammable environment.

— Do not open the pump when an explosive gasatmosphere may be present.

— Before starting work on the pump, make surethat the pump and the control panel are isolatedfrom the power supply and can not be energized.This applies to the control circuit as well.

— All mechanical work on the explosion-proofmotor section must be performed by personnelauthorized by ITT Flygt.

— Electrical connection on the explosion-proofmotor must be made by authorized personnel.

— Thermal contacts must be connected to protec-tion circuit intended for that purpose accordingto the approval of the product.

— The pump may be used only in accordance withthe approved motor data stated on the dataplates.

— Intrinsically safe circuits are normally required(Ex i) for the automatic level control system bylevel regulator if mounted in zone 0.

SAFETY

NOTES FOR EX-PRODUCTS

— This equipment must be installed in conformityto prescriptions in international or national rules( IEC/EN 60079-14 ).

— The maintenance operation must be made inconformity to the international or national stan-dards ( IEC/EN 60079-17).

— The yield stress of fastener elements in the prod-uct must be in conformity with the value speci-fied in the table for “Material of fastener” on theapproval drawing or the parts specified in thepart list for the product.

— According to the ATEX directive the Ex-pumpmust never run dry or snore. Permitted mini-mum water level, see dimensional drawing forthe pump.Dry running at service and inspection is onlypermitted outside the Ex area.

— The user must know about the risks due theelectric current and the chemical and physicalcharacteristics of the gas and/or vapours presentin hazardous areas.

— ITT Flygt disclaims all responsibility for workdone by untrained, unauthorized personnel.

GUARANTEE

Flygt undertakes to remedy faults in products sold byITT Flygt provided:

— that the fault is due to defects in design,materials or workmanship;

— that the faults are reported to ITT Flygt or ITTFlygt's representative during the guaranteeperiod;

— that the product is used only under conditiondescribed in the Installation, Care and Mainte-nance manual and in applications for which it isintended;

— that the monitoring equipment incorporated inthe product is correctly connected and in use;

— that all service and repair work is done by awork shop authorized by ITT Flygt;

— that genuine ITT Flygt parts are used.Hence, the guarantee does not cover faults caused bydeficient maintenance, improper installation, incorrectlyexecuted repair work or nomal wear and tear.ITT Flygt assumes no liability for either bodily injuries,material damages or economic losses beyond what isstated above.ITT Flygt guarantees that spare parts will be kept for 15years after that the manufacture of this product has beendiscontinued.

3085, 3102, 31274

3085.182: Standard

3085.092: EEx d IIB T4FM: Class I Div. 1 Grp. C and DClass II Div. 1 Grp. E, F and GSuitable for use in Class III Div. 1

3085.172: Grinder Standard

3085.891: GrinderEEx d IIB T4FM: Class I Div. 1 Grp. C and DClass II Div. 1 Grp. E, F and GSuitable for use in Class III Div. 1

3085.980: Industrial version

3102.180: Standard





PRODUCTS INCLUDED

This workshop manual describes how to dismantle andassemble products 3085, 3102 and 3127 in connectionwith repair and reconditioning work. The operative part ofthe manual begins with numbered illustrations of differentwork operations. At the end of the manual you will findexploded views of the different pump models.

Most of the operations apply to all three pump types.However, in some procedures the instructions may differbetween the pumps. Here we have pointed this out with apicture or explained this in the text.

Details are also provided of the special tools which notonly facilitate repair work, but which are sometimes nec-essary in order to carry out a particular operation.

HOW TO USE THE WORKSHOP MANUAL

We would also point out that the practical work involved incompiling this manual has been performed under extremelyfavourable conditions. We have dismantled and assemblednew products. A pump which has been in use for a longerperiod of time has acquired a “patina” and other workingmethods besides those recommended here will sometimeshave to be used.

If the pump is specially approved, please read the chapter“Specially approved pumps” in the end of this manual.

ITT Flygt disclaims all responsibility forwork done by untrained, unauthorizedpersonnel.

3127.180: Standard





53085, 3102, 3127

DATA PLATE INTERPRETATION

H

A

ML N

V

U

TR SQPO

I

J K

H

G

F

E

D

B C

X

General data plate

A Serial number

B Product code + Number

C Curve code / Propeller code

D Country of origin

E Product number

F Additional information

G Phase; Type of current; Frequency

H Rated voltage

I Thermal protection

J Thermal class

K Rated shaft power

L International standard

M Degree of protection

N Rated current

O Rated speed

P Max. submergence

Q Direction of rotation: L=left, R=right

R Duty class

S Duty factor

T Product weight

U Locked rotor code letter

V Power factor

X Max. ambient temperature

3085, 3102, 31276

DATA PLATE INTERPRETATION

EN: European NormATEX DirectiveEuropean standards EN 50014, EN 50018 and EN 1127-1EEx d II B T3 for ambient temperatures ≤ 40°C

Approval platesThese approval plates apply to an explosion proof submersible Flygt pump andare used together with the general data plate on the pump.

A ApprovalB Approval authority + Approval NumberC Approval for Class ID Approved drive unitE Stall timeF Starting current / Rated currentG Duty classH Duty factorI Input power

J Rated speedK ControllerL Additional informationM Max. ambient temperatureN Serial numberO ATEX marking

FM: Factory Mutual according to standard 3615 as:Class I Div. I Grp C and DClass II and III Div. I Grp E, F and G

73085, 3102, 3127

LubricantsLubricate all screws with oil before assembly.

Part No Description

90 17 52 Oil for the oil housing;Paraffin oil Mobil Whiterex 307-309,(alternative: Esso Marcol 82, Shell Ondina orsimilar oil which meets the standard FDA172.878).Oil volume;

3085 1.0 l (1.1 US quarts)3102 1.0 l (1.1 US quarts)3127 2.0 l (2.1 US quarts)

The pump is delivered from the factory withparaffin oil with a viscosity close to ISO VG15.In applications where poisonous properties areof less concern, a mineral oil with a viscosityup to ISO VG32 can be used. Other types ofnormal existing oil can be used, for examplean ordinary type of hydraulic oil.

90 20 61 Bearing grease cartridge, Esso Unirex N3

Recommended amount of bearing grease inthe bearings (weight in kg).

3085 3102 3127

Main bearing 0.025 0.025 0.020Support bearing Pregreased 0.012 0.010

NOTE ! Don't inject more grease thanrequired since overheating may otherwiseoccur.

TECHNICAL DATA

WeightsThe weight varies depending on the version:

3085 44 - 80 kg ( 97 - 176 lb)

3102 75 - 159 kg ( 165 - 350 lb)

3127 103 - 221 kg ( 227 - 487 lb)

For the pump's specific weight, current, voltage, powerratings and speed, please refer to the data plate of thepump.

Special tightening torques:

3085 3102 3127Nm (ft-lb)

Impeller screw 34 (25) 60 (44.2) 80 (59)

Impeller screw, F version 30 (22.1) 33 (24.3) 40 (29.5)

Impeller screw, M version 34 (25) 60 (44.2) 75 (55.3)

Oil, (inspection) screws 20 (14.7) 20 (14.7) 20 (14.7)

All ITT Flygt standard screws are made of stainlesssteel. Size M6 belongs to Property class 70 while allother sizes belong to class 80.

RECOMMENDED TIGHTENING TORQUE FOR ITT FLYGTSTANDARD SCREWS IN Nm AND ft-lbChart valid only for lubricated screws. Use assembly oil (type polypropyleneglycol) as lubricant.

Tightening torques

Stainless (A2, A4)

Property class

70 80

Nm ft-lb Nm ft-lb Nm ft-lb

M5

M6

M8

M10

M12

M16

M20

M24

Type of screw

4,1 3 2,0 1,5 5,4 4

7 5,2 4,1 3 9,3 6,9

17 12,5 7 5,2 22 16

33 24,3 17 12,5 44 32

57 42 33 24,3 76 56

140 103 57 42 187 138

273 201 100 74 364 268

472 348 140 103 629 464

Material

Thread

3085, 3102, 31278

TOOLS

Special toolsSee also the catalogue “Tools for the Flygt service workshop”, where you find all the recommended standard and specialtools.

Users connected to ITT Flygt’s on-line computer system can find the complete service tool list under the dialogue D001,Technical Information. Use the subdialogues D6488 and D6501.

3085

Part No Denomination Range of use

82 04 90 Socket head screw Together with 841362 for NEVACLOG84 08 10 Circlip plier Outer seal seat84 08 67 Cable lug pliers Stator connection84 10 16 Ratchet handle Sockets84 11 56 Combination wrench Cable entry

84 13 04 Hexagon bit adapter (N= 6 mm) Impeller screw, stator housing84 13 06 Hexagon bit adapter (N= 10 mm) Pump housing84 13 60 Impeller puller D impellers, curves 276-284, 470-47784 13 62 Impeller puller MT impellers NEVACLOG, curves 432-43684 13 84 Socket wrench (N= 10 mm) GF-base

84 13 87 Socket wrench (N= 13 mm) Suction cover (F-version)84 13 95 Socket wrench (N= 16 mm) Oil plug, HT-strainer84 14 76 Hex.bit adapter (N= 5 mm, long) Bearing cover, bearing housing, earthing screw84 15 45 SKF bearing mounting kit Seal assembly, stationary seal ring84 15 55 Extension bar Impeller screw

84 15 66 Torque wrench 0-137 Nm Torque tightening84 16 73 Screw driver CLS-sensor84 20 48 Bearing puller Support bearing

216 68 00 Sleeve puller Rotating seal unit249 92 03 Impeller puller LT impellers, curves 620-622

251 35 02 Impeller puller G impellers, curves 242-244251 35 03 Impeller puller HT impellers, curves 250-252303 60 00 Impeller puller MT impellers, curves 438-440, 473-477, 632-636394 69 00 Stator puller Stator handling, I.D.=130-170 mm395 81 05 Tap Protection pin, bearing puller,

398 71 00 Impeller puller, unit LT impellers, curves 412-414, 612-614403 90 00 Stator puller unit Stator handling426 34 00 Mounting socket Stationary seal ring fitting, L=110 mm462 30 00 LP gas set Heating stator housing

463 78 02 Seal tool Seal type: 397 90 0X, 593 75 0X

466 97 01 Bearing puller Main bearing479 92 00 Seal tool Grip ring, seal type: 476 27 0X

93085, 3102, 3127

3102


82 04 90 Socket head screw Together with 841362 for NEVACLOG84 08 67 Cable lug pliers Connection sleeves84 10 16 Ratchet handle Sockets84 11 35 Combination wrench N=8 mm Cable clamp (cable Ø 20-32 mm)84 11 56 Combination wrench N=41 mm Cable entry (cable Ø 10-20 mm)

84 13 04 Hexagon bit adapter (N= 6 mm) Junction box cover84 13 05 Hexagon bit adapter (N= 8 mm) Impeller screw, lifting handle84 13 06 Hexagon bit adapter (N= 10 mm) Stator housing, pump housing84 13 62 Impeller puller D impeller, MT impellers NEVACLOG, curves 430-43584 13 87 Socket wrench (N= 13 mm) Suction cover (F-version)

84 13 95 Socket wrench (N= 16 mm) Oil plug84 14 76 Hex.bit adapter (N= 5 mm, long) Oil housing bottom, terminal holder84 15 45 SKF bearing mounting kit Seal assembly, stationary seal ring84 15 55 Extension bar Impeller screw84 15 66 Torque wrench 0-137 Nm Torque tightening

84 16 50 Screw driver Cable clamp (cable Ø 20-32 mm)84 16 58 Screw driver Terminal84 16 73 Screw driver CLS-sensor84 20 48 Bearing puller Support bearing

216 68 00 Sleeve puller Rotating seal unit

249 92 02 Impeller puller LT impellers, curves 440-442295 72 02 Impeller puller LT impellers, curves 410-412303 60 00 Impeller puller MT impellers, curves 436-438344 13 00 Impeller puller HT impellers389 25 02 Hexagon head screw F impellers

394 69 00 Stator puller Stator handling, I.D.=130-170 mm395 81 05 Tap Protection pin, bearing puller,398 21 00 Mounting socket Stationary seal ring457 89 00 Mounting tool, grip ring Seals462 30 00 LP gas set Heating stator housing

466 97 01 Bearing puller Main bearing

H

A

ML N

V

U

TR SQPO

I

J K

H

G

F

E

D

B C

X

Impeller code / curve code, see thepump data plate

XXX

3085, 3102, 312710

3127


82 06 60 Socket head screw Together with 841362 for NEVACLOG84 10 16 Ratchet handle Sockets84 11 35 Combination wrench N=8 mm Cable clamp (cable Ø 20-32 mm)84 11 37 Combination wrench N=18 mm Suction cover HD, inlet PL84 11 56 Combination wrench N=41 mm Cable entry (cable Ø 10-20 mm)

84 13 04 Hexagon bit adapter (N= 6 mm) Junction box cover84 13 05 Hexagon bit adapter (N= 8 mm) Stator housing, lifting handle84 13 06 Hexagon bit adapter (N= 10 mm) Impeller screw, pump housing84 13 62 Impeller puller D impeller, HT impellers 254-259 and NEVACLOG 480-48584 13 95 Socket wrench (N= 16 mm) Oil plug, protective plug

84 14 76 Hex.bit adapter (N= 5 mm, long) Bearing cover, bearing housing, earth screw84 15 45 SKF bearing mounting kit Seal assembly, stationary seal ring84 15 55 Extension bar Sockets84 15 66 Torque wrench 0-137 Nm Torque tightening84 16 50 Screw driver Cable entry (cable Ø 20-32 mm)

84 16 58 Screw driver Terminal84 16 73 Screw driver CLS-sensor84 20 48 Bearing puller Support bearing

216 68 00 Sleeve puller Rotating seal unit249 92 04 Impeller puller LL, LT, MT impellers, curves 410-412, 441-442, 430-436

303 58 00 Hexagon head screw HD impellers309 39 00 Impeller puller HT impellers, curves 250, 461-467394 69 00 Stator puller Stator handling, I.D.=130-170 mm395 81 05 Tap Protection pin, bearing puller,396 70 00 Puller screw, compl. N impellers LT curves X20-X22

400 39 00 Mounting socket Stationary seal ring436 97 00 Mounting tool, grip ring Seals438 58 00 Hexagon head screw F impellers462 30 00 LP gas set Heating stator housing466 98 01 Bearing puller Main bearing

113085, 3102, 3127

Electrical connections

NOTE for Ex version page 3

Connect the stator leads and the motor cable as shownin the wiring diagrams.

NOTE! For safety reasons, the earth conductor shouldbe approx. 50 mm (2.0") longer than the phase conduc-tors. If the motor cable is jerked loose by mistake, theearth conductor should be the last conductor to comeloose from its terminal. This applies to both ends of thecable.

ELECTRICAL CONNECTIONS

Monitoring equipmentThermal switches are incorporated into the stator. Thethermal switches may be used for voltages up to 250 V,rated current 10 A (cos ϕ = 1) / 6.3 A (cos ϕ = 0.6). ITTFlygt recommends that they be connected to 24 V overseparate fuses to protect the other automatic equipment.

A plate in the junction box shows whether the pump isequipped with optional sensors.

CLS-30 is a leakage sensor for sensing water in the oilhousing and initiates an alarm when the oil contains 30%water. Oil change is recommended after the alarm. If thesensor initiates an alarm soon after the oil has beenchanged, contact your nearest ITT Flygt representative.

The CLS-30 sensor is installed in the bearing housingand goes down into the oil housing. The sensor is notapplicable to Ex-approved pumps.

The FLS sensor consists of a small float switch forsensing water in the stator housing. Its design makes itsuitable for pumps in vertical installations.

The FLS sensor is installed in the bottom of the statorhousing.

The two sensors, CLS-30 and FLS, can be used in thesame pump. They are connected in parallel. Follow theinstructions for monitoring equipment.

Check:

— signals and tripping function.

— that relays, lamps, fuses and connections are intact.

Replace defective equipment.

Stator lead colours

U1/U5 Red

V1/V5 Brown

W1/W5 Yellow

U2/U6 Green

V2/V6 Blue

W2/W6 Black

Number of conductors

SUBCAB 4Gx + 2x1.5

Including earth conduc-tor e.g. 4G4 mm2

Number of conductors

Conductor area

Flygt SUBCAB® cable

3085, 3102, 312712

3-phase, direct on-line starting

Conductors Connectionstarter

SUBCAB® 4Gxbrown L1blue L2black L3yellow/green earth

SUBCAB 4Gx+2x1.5brown L1blue L2black L3yellow/green earthblack T1*black T1*


For Canada/USA

SUBCAB xAWG/4red L1white L2black L3yellow/green earth

SUBCAB xAWG/7red L1white L2black L3yellow GC**yellow/green earthorange T1*blue T2*

D

SUBCABS

UB

CA

B

GC

GC

T1

T2

W2 V2U2

L2 L3 T1 T2L1GC

3~

V1 W1

T2

U1

L1 L3

T1

W2 V2 W1U2

T1 T2

L2

V1U1

1000

3

* Terminal for connection of thermal switches in the motor andmonitoring equipment.

** GC = Ground Check

SUBCAB is a registered trademark of ITT Flygt AB for electriccables.

Y

SUBCAB

SU

BC

AB

GC

GC

T1

T2

W2 V2U2

L2 L3 T1 T2L1GC

3~

V1 W1

T2

U1

L1 L3

T1

W2 V2 W1U2

T1 T2

L2

V1U1

1000

7

133085, 3102, 3127


SUBCAB 7Gxblack 1 L1black 2 L2black 3 L3black 4 L1black 5 L2black 6 L3yellow/green earth

3-phase, star-delta starting

SUBCAB

T1 T2

1

3

2

W1

V1

U1

V2

U2

W2

3~

T2T1L3L2L1 L3L2L1

1 2 3 654 T1 T2

Y/D

65

4

U2

W2

W1

V1

U1

V2

1000

9


3-phase, direct-on-line ∆, ∆, ∆, ∆, ∆, 2 // connected cores


SUBCAB 7Gx+2x1.5black 1 L1black 2 L2black 3 L3black 4 L1black 5 L2black 6 L3

black T1 T1*black T2 T2*yellow/green earth

3085, 3102, 312714

SU

BC

AB

SUBCAB

GC

GC

T1

T2

W2 V2U2

T1 T2GC

T1 T2

V1 W1

T1

U1

T2

21

1~

1 2

3

3

230VU1

U5 V2

U2 V1

V5 W2

V6

W6

U6

W1

W5

1000

5

SU

BC

AB

SUBCAB

GC

GC

T1

T2

W2 V2U2

T1 T2GC

T1 T2

V1 W1

T1

U1

T2

21

1~

1 2

3

3

Z2 Z1

U2 U1

1001

5

Single phaseConductors Connection

starterSUBCAB 4Gx

brown 1black 2blue 3yellow/green earth

SUBCAB 4Gx+2x1.5brown 1black 2blue 3yellow/green earthblack T1*black T2*

For Canada/USA

SUBCAB xAWG/4Conductors Connection

starterred 1black 2white 3yellow/green earth

SUBCAB xAWG/7red 1black 2white 3yellow GC**yelllow/green earthorange T1*blue T2*


** GC = Ground Check

153085, 3102, 3127

1

2 “Oil in”screw

3

DISMANTLINGBefore starting the work on the pump, make sure that alltools are at hand and that O-rings and any other part thatare to be replaced are set out. Clean all parts carefully,especially the O-ring seats. Lubricate all screws that havebeen removed before refitting them. Make sure that thepump is isolated from the power supply before starting work.

If the pump is specially approved, first read through thesection “Specially approved pumps”.

1. C/N 3127. (The pictures below also apply to C/N3085 and C/N 3102).

2. Suspend or support the pump horizontally. Place asuitable vessel under the oil casing. Remove the“Oil in” screw.

Warning! If the seal leaks, the oil casing may beunder pressure. Hold a rag over the oil plug toprevent splatter.

3. Remove the “Oil out” screw.

3085, 3102, 312716

6

5

44. Empty the pump oil casing.

5. Remove the screws for the stator housing.

6. Lift off the stator housing from the oil housing.

173085, 3102, 3127

7

8

93085

7. Remove the screws for the oil housing.

3085 Cable connection

9. Remove the insulating hose from the stator leads.

8. Lift off the rotor assembly with the oil housing andthe impeller from the pump housing. Use two M10eye bolts.

3085, 3102, 312718

123085

113085

103085

10. Disconnect the motor cable from the stator leads bycutting the leads close to the closed end splice.

11. Undo the earth screw and the cable entry and pullthe motor cable out of the stator housing. Inspectthe cable for damage, specially close to the cableentry.

12. Cable entry.

193085, 3102, 3127

13

31023127

14

31023127

15

31023127

3102 and 3127 Junction box

13. Stator housing.

14. Open the junction box cover.

15. Disconnect the motor cable and the stator leadsfrom the terminal board.

3085, 3102, 312720

18 3102, 3127

Ø 20-32 mm(0.79"-1.26")

17

3102, 3127Ø 12-20 mm(0.47"-0.79")

16 3102, 312716. Pull out the stator leads through the cable lead-

through / hole into the stator housing. Undo thecable entry and pull the motor cable out of thecover. Inspect the cable in order to detect damage,specially close to the cable entry.

17. Cable entry for cable dia. 12-20 mm.

18. Cable entry for cable dia. 20-32 mm.

213085, 3102, 3127

19

20

21

Dismantling the impeller and outer seal unit

19. Undo the impeller screw.

20. Pull off the impeller with the aid of a puller (seespecial tool list).

21. Outer face seal.

3085, 3102, 312722

24

233127

223127

22. Remove the key with a hammer and chisel (only3127).

23. Remove the spacer ring (only 3127).

24. Use the seal tool (see special tool list) to removethe grip ring.

233085, 3102, 3127

25

26

27

25. Fit the seal tool and turn the allen key to releasethe grip ring.

26. Remove the grip ring.

27. Fit the seal remover tool to the outer rotating sealring.

3085, 3102, 312724

30

29

28

28. Remove the outer rotating seal ring.

29. Fit the seal remover tool to the outer stationary sealring.

30. Remove the outer stationary seal ring.

253085, 3102, 3127

33

32

313085

31. For 3085 it is possible to replace both the outerand the inner seal unit without dismantle the oilhousing. Remove the retaining ring.

Dismantling the oil casing and inner seal unit.

32. Undo the three socket hexagon screws which holdthe oil casing together.

33. Lift off the rotor unit together with the bearingholder.

3085, 3102, 312726

36

34

35

34. Dismantle the inner face seal in the same manneras for the outer face seal. Dismantle the grip ringwith the seal tool.

35. Remove the rotating seal ring.

36. Dismantle the stationary seal ring with two screwdrivers.

273085, 3102, 3127

39

38

3737. Remove the O-ring.

38. Undo the four inner hexagon screws.

39. Remove the bearing cover.

3085, 3102, 312728

42

40

41

Dismantling the upper and lower bearings

40. Insert a protection pin (Tap) in the hole in the end ofthe shaft in order to protect the thread.

41. Fit the bearing puller tool with the screws for thebearing cover.

42. Pull off the bearing holder with a combinationwrench (24 mm across flats) and an adjustablewrench.

293085, 3102, 3127

45

44

4343. Lift off the bearing holder.

44. Remove the distance sleeve from the hydraulic endof the shaft.

45. Knock out the bearing from the bearing holder witha suitable mandril.

3085, 3102, 312730

48

46

47

46. Pull off the upper bearing with a puller.

47. Remove the lifting handle and replace with two M10eye bolts. Lift up the stator using the eye bolts andplace a suitable protecting device under the stator.Heat the stator housing quickly in order to let thestator loosen. Use LP gas set. When the stator hasreleased and dropped down, extinguish the flamesand lift the stator housing.

ASSEMBLY

Assembling the stator with stator housing, upper andlower bearings

48. Heat the stator housing to about 150OC (302OF).

313085, 3102, 3127

51

5031023127

4949. Then quickly lower the stator into the stator

housing until it bottoms. Use Stator liftingdevice.Note! The stator must be oriented in such amanner in the stator housing that the leadsreach up to the motor cable connection orterminal board.

50. Pull the stator leads through the cable lead-through / hole from the stator housing intothe terminal board (3102, 3127). Connect theleads as shown in the charts in the chapter"Electrical connections".

51. Heat the upper bearing to about 100OC(212OF) (max 120OC, 248OF) in an oven, in oilor with a heating dowel. Place the heatedbearing on a smooth surface and insert theend of the shaft into the bearing. Allow thebearing to cool.

3085, 3102, 312732

54

52

53

52. Apply bearing grease. See lubricants, Technicaldata.

53. Fit the distance sleeve onto the shaft.

54. Lubricate the shaft with oil in order to allow thebearing to slide more easily into place.

333085, 3102, 3127

57

55

56

55. Lubricate the main bearing.

56. Fit the bearing into its holder.

57. Press the bearing into place. Use the bearing pullertool plus a rubber mallet.

Alternatives:

- Heat the bearing holder- Use a press.

3085, 3102, 312734

60

58

59

58. Fit the bearing holder onto the shaft unit.

59. Fix the bearing puller.

60. Mount the screw and the washer that fits thethreaded hole for the impeller.

353085, 3102, 3127

63

6261

64

61. Press the bearing and bearing holder onto the shaft.Use a combination wrench (18 mm across flats for3127, 16 mm for 3085 and 3102) and an adjustablewrench. Make sure that the bearing is pressed allthe way to the bottom.

If the pump is specially approved, the gap betweenthe bearing holder and the distance sleeve shouldbe measured as described in the section “Speciallyapproved pumps”.

62. Grease the O-ring.

63. Assemble the bearing cover with the bearing holder.

64. Tighten the screws.

65. Mechanical face seal picture description. See nextpage.

3085, 3102, 312736

3085 outer / inner

601 26 00

PART NUMBER

593 75 00593 75 01593 75 02

463 78 02463 78 03

1.5 mm1/16"

50-100 N10-20 lbf

90°

601 22 00

PART NUMBER

592 01 00592 01 02592 01 04

457 89 00

50-100 N10-20 lbf

1.5 mm1/16"

90°

3102 outer

557 94 00

PART NUMBER

476 27 05476 27 08

479 92 00479 92 02

90°

50-100N10-20 lbf

557 95 00

PART NUMBER

476 27 04476 27 06476 27 07

479 92 00479 92 02

90°

50-100 N10-20 lbf

3085 outer,optional

3085 outer,optional65

373085, 3102, 3127

3127 outer / inner

601 24 00

PART NUMBER

593 70 00

436 97 00

1.5 mm1/16"

100-150 N20-30 lbf

90°

3102 inner

601 23 00

PART NUMBER

592 01 01592 01 03

457 89 00

1.5 mm1/16"

50-100 N10-20 lbf

90°

3127 inner

601 25 00

PART NUMBER

593 70 01

436 97 00

1.5 mm1/16"

100-150 N20-30 lbf

90°

577 47 00

PART NUMBER

549 07 01549 07 02

3127 outer,optional

3085, 3102, 312738

66

68

67

Assembling the inner seal unit and oil housing

66. Grease the O-ring and fit the O-ring into its seat inthe bearing cover.

67. Fit the inner stationary seal ring to its seat. Use asuitable plastic sleeve that fits outside the sealingsurface. Recommended sleeve: SKF bearingmounting kit. Make sure you fit the ring with thecorrect surface out (smooth, shining).

68. Stationary seal ring in place.

393085, 3102, 3127

71

70

69

69. Apply oil to the sealing surface.

70. Fit the inner rotating seal unit to the shaft.

71. Assemble the grip ring with the seal tool.

3085, 3102, 312740

72

73

74

72. Check the gap for the inner seal unit.Gap = 1.5 mm (1/16").

73. Assemble the oil housing. NOTE! Check that thesleeve for the oil refill can pass unobstructed fromthe cut outs in the bearing holder.

74. Replace the old sealing washers by new ones.

413085, 3102, 3127

77

76

7575. Fit the 3 self-tapping screws and tighten

them to a torque of 7 Nm.NOTE! If you have bought an oil housing asa spare part, there will be no threads in the 3holes for the screws (self-tapping screws).

Assembling the outer seal unit

76. Unpack a new outer seal unit.

77. Outer seal unit.

3085, 3102, 312742

78

79

80

78. Apply oil to the stationary seal ring.

79. Fit the seal ring together with its O-ring. Use theSKF bearing mounting kit (TMFT 33).

80. Clean the shaft and the stationary seal ring.

433085, 3102, 3127

83

82

8181. Apply oil to the rotating seal ring.

82. Grease the shaft.

83. Fit the rotating seal ring. Use the plastic sleeve inwhich the seal is wrapped.

3085, 3102, 312744

84

85

86

84. Push on the seal ring.

85. Grip ring.

86. Fit the grip ring in the seal tool. Prepare the grip ringin the tool.

453085, 3102, 3127

893085

88

8787. Fit the tool together with the grip ring to the shaft.

Press the tool to the bottom and turn the Allen key.The grip ring is now in position.

88. Check the gap for the outer seal unit.Gap = 1.5 mm (1/16").

3085 Cable connection

89. Pull the motor cable into the stator housing. Con-nect the yellow/green lead to the earth/ground connection using the specified cable lug.

3085, 3102, 312746

903085

913085

92

31023127

90. Connect the motor cable leads to the stator leads(see the diagrams in the chapter “Cable connec-tions”).

91. Apply a plastic protector hoose to the leads. Checkthe insulation for the connections with a Megger.The insulation between the phases and betweenany phase and earth shall be > 5 MΩ. Assemblethe junction box cover.

3102 and 3127 junction box

92. Pull the motor cable into the junction box. Connectthe leads to the terminal board as shown in thediagram in the chapter “Cable connections”. Checkthe insulation for the connections with a Megger.The insulation between the phases and betweenany phase and earth shall be > 5 MΩ.

473085, 3102, 3127

95

94

93Assembling the stator housing

93. Fit the O-ring.

94. Fit the stator housing to the oil casing.NOTE! In order to get the stator housing in thecorrect position, the junction box shall be positionedjust above the flange where there is no hole for thescrews connecting the hydraulic part. The groove forthe O-ring in the stator housing must be cleaned.

If the pump is specially approved, the gap betweenthe stator housing and the bearing cage should bemeasured as described in the section “Speciallyapproved pumps”.

95. Lubricate the 4 screws.

3085, 3102, 312748

96

97

983127


97. Remove the two lifting eyes and fit the standardlifting handle. Tighten the screws.NOTE! The highest point of the handle should beoriented away from the junction box.

Assembling the impeller

98. Fit the spacer ring (only 3127).

493085, 3102, 3127

101

100

993127

99. Fit the key in the keyway (only for 3127). Greasethe shaft (NOTE! for 3085 and 3102 not on theconical part of the shaft).

100. Fit the impeller and tighten the impeller screw.Check that the impeller rotates freely.NOTE! If you are mounting a C 3102 LT impeller,you have to pull out the impeller a couple of mm inorder for the impeller not to get jammed to the oilhousing bottom.

101. Fit the “oil out” screw. Fill the pump with the appro-priate type of oil and the correct volume.

3085, 3102, 312750

102

103

104

102. Fit a new O-ring on and tighten the “oil in” screw.

Replacing the wear ring

103. Bend out the wear ring at a suitable point with acrowbar.

104. Knock out the wear ring using a chisel.

513085, 3102, 3127

107

106

105105. Drive in the new wear ring. Use a rubber mallet or a

wooden block to prevent deformation.

106. Assemble the pump housing.

107. Lubricate the 5 screws.

3085, 3102, 312752

108

109

110


109. Fit the sliding bracket.

GrinderReplacing the impeller and the grinder device

110. M 3102. Warning! The impeller and the grinderdevice have very sharp edges.

533085, 3102, 3127

113

112

111111. Remove the 4 bolts

112. Lift off the driveunit from the pump housing.

113. Remove the impeller screw and washer.

3085, 3102, 312754

114

115

116

114. Fit the impeller screw back again.

115. Fit the impeller puller and place a protector betweenthe screw head and the puller. Pull off the impeller.

116. Cutter wheel, impeller and conical sleeve.

553085, 3102, 3127

119

118

117117. Mount the sleeve, a new impeller and the cutter

wheel. Make sure that the end of the shaft is cleanand free from burrs. Polish off any flaws with a fineemery cloth.

118. Fit the washer and impeller screw, but don't tightenthe screw. Measure the distance between the vanesof the impeller and the shoulder for the pumphousing on the oil housing bottom. Use astraightedge and a vernier.

Product Type Phases Hz Distance

3085 LT,HT 1/3 50,60 43.5 ± 0.3 mm

3102 LT 1 60 43.5 ± 0.3 mm3102 LT 3 50,60 46.0 ± 0.3 mm3102 HT 1/3 50,60 43.5 ± 0.3 mm

3127 LT,HT 3 50 65.0 ± 0.3 mm3127 LT,HT 3 60 65.0 ± 0.3 mm3127 LT 1 60 63.0 ± 0.3 mm3127 HT 1 60 65.0 ± 0.3 mm

119. At the right distance, tighten the screw quickly sothat the conical sleeve grips properly. Check thatthe impeller can be rotated by hand.

3085, 3102, 312756

120

121

122

120. When the impeller and cutter are replaced, thecutter ring in the pump housing should also bereplaced.

121. Remove the screws and dismantle the cover.

122. Knock out the cutter ring from the inside of thepump housing.

573085, 3102, 3127

125

124

123123. Replace the cutter ring with a new one. Knock the

new ring into its position. Mount the cover and thescrews and tighten the screws.

124. Assemble the drive unit and the pump housing.Don’t forget the O-ring, which must be lubricated.NOTE! The orientation of the pump housing.


3085, 3102, 312758

126

127

128

F-impellerReplacing and adjusting the F type impeller

126. F 3085. Warning! The impeller and the cover devicehave very sharp edges. The F-impellers require anadjustment in order to achieve correct cuttingability.

127. Remove the 4 bolts.

128. Lift off the drive unit from the pump housing.

593085, 3102, 3127

131

130

129129. Remove the impeller screw. It is advisable to use

industrial gloves as protection against sharp edges.

130. Impeller, screw, conical sleeve, washer and adjust-ing washers.

131. Remove the cover and the O-ring.

3085, 3102, 312760

132

133

134

132. Remove the 4 bolts which hold the pump housingbottom.

133. Remove the pump housing bottom. Use a crowbar.

134. Remove the O-ring and the adjusting washers.

613085, 3102, 3127

137

136

135135 Assembling. Start by placing the cover in the pump

housing. Check that the guide boss fits into thecorresponding recess of the pump housing.

136. Fit the O-ring into its groove.

137. Assemble the drive unit and the pump housing.

3085, 3102, 312762

138

139

140

138. Tighten the bolts.

139. Impeller, adjusting washers and conical sleeve. Theclearance is adjusted by adjusting washers, 1 mm(0.04") and 0.25 mm (0.01").

140. Fit the impeller and tighten the impeller screw.Prevent the impeller from rotating by using, forexample, a piece of wood in order not to damagethe sharp edges.

633085, 3102, 3127

143

142

141141. Measure the clearance. The clearance between the

tightened impeller's upper edge and the covershould be 0.5-1.5 mm (0.02"-0.06").

142. Fit a new lubricated O-ring into its groove.

143. Use adjusting washers for adjusting the pumphousing bottom.

3085, 3102, 312764

144

145

146

144. Fit the pump housing bottom and tighten thescrews.

145. Measure the clearance. The clearance between theimpeller and the pump housing bottom should be0.5 - 1mm (0.02"-0.04").

Swirl (vortex) impellerReplacing the impeller of swirl (vortex) type

146. D 3102. Remove the 4 bolts.

653085, 3102, 3127

149

148

147147. Lift off the drive unit from the pump housing.

148. Remove the impeller screw. Warning! Wornimpellers often have very sharp edges.

149. Pull off the impeller. Use, for example, two crow-bars.

3085, 3102, 312766

150

151

152

150. Impeller, conical sleeve, impeller screw and wash-ers.

151. Assembling. Make sure that the end of the shaft isclean and free from burrs. Polish off any flaws witha fine emerycloth. Fit the conical sleeve into theimpeller and fit the impeller on the shaft.

152. Tighten the impeller screw.

673085, 3102, 3127

155

154

153153. Fit a new lubricated O-ring in the groove on the oil

housing bottom.

154. Assemble the drive unit and the pump housing.


3085, 3102, 312768

157N3085/3102

N-type impellerReplacing the impeller and setting clearance

156. N 3085/N 3102. Remove the 4 screws for the pumphousing and lift off the drive unit from the pumphousing.

Warning!The impellers may have very sharp edges.

Use protective gloves.

156

157. Remove the stop screw in the impeller hub. Un-screw the impeller screw the whole way, that willremove the impeller from the shaft.

Installation:

Fit the conical sleeve, the washer, the impellerscrew and the impeller onto the shaft. Only handtighten the screw just to keep the impeller in place.

158N3085/3102

158. Lift the drive unit onto the pump housing and fit the4 screws. Measure and adjust the clearance be-tween the lower edge of the impeller and the insertring by sliding the impeller on the shaft to specifiedmeasurement. Tighten the impeller screw to speci-fied tightening torque.

693085, 3102, 3127

159N3085/3102

159. Reinstall the stop screw.

160. NP/NS/NL 3127. Remove the 5 screws and lift offthe drive unit from the pump housing.

161. Unscrew the impeller screw. Insert the impellerpuller screw and remove the impeller. 161

NP/NS/NL3127Warning!The impellers may have very sharp edges.


160

3085, 3102, 312770

164NP/NS/NL3127

(3x) 0,3 mm (0,012”) 298 62 00(1x) 1,5 mm (0,060”) 298 62 01(2x) 0,5 mm (0,020”) 298 62 02

3x 0,3 + 1x 1,5 +2x 0,5= 2,9 mm

162NP/NS/NL3127

163NP/NS/NL3127

162. The clearance is adjusted by adjusting washers, 0.3mm (0.012"), 0.5 mm (0.020") and 1.5 mm (0.060").Fit the washers acc. to the picture and install thenew impeller and the impeller screw.

163. Lift the drive unit onto the pump housing andmeasure the distance "B".

164. Lift off the drive unit and remove the impeller.Combine the washers so the distance correspondswith the formula acc. to the picture (see next picturefor the C-measure). Fit the impeller and tighten theimpeller screw to specified torque.

713085, 3102, 3127

165NP/NS/NL3127

166NT3127

165. Mount the drive unit to the pump housing. Tightenthe screws and check the clearance between theimpeller and the insert ring.

166. NT 3127. Remove the 5 screws and lift off the driveunit from the pump housing. Unscrew the impellerscrew. Insert the impeller puller screw and removethe impeller.

Installation:

The clearance is adjusted by adjusting washers, 0.3mm (0.012"), 0.5 mm (0.020") and 1.5 mm (0.060").Fit three washers acc. to picture and fit the newimpeller and the impeller screw.

Warning!The impellers may have very sharp edges.


167. Lift the drive unit onto the pump housing andmeasure the clearance "B". 167

NT3127

3085, 3102, 312772

0,2

- 0,8

mm

(0,0

08 -

0,03

2")

168NT3127

169NT3127

168. Lift off the drive unit and remove the impeller.Combine the washers so the distance correspondswith the formula acc. to the picture. Fit the impellerand tighten the impeller screw to specified torque.

169. Mount the drive unit to the pump housing. Tightenthe screws.

733085, 3102, 3127

EXPLODED VIEW

24.424.524.4

24.124.2

3

23

22

3

4 5

99

9

11

9 15 24.624.7

24.624.7

24.8

18

19

17

3433 32

31

38

40

41

42

43

44

4733

45

48 49

50

51

52

53 57

1

20

21

678

2

1214

37

46

10

16

3085.092

3085, 3102, 312774

24.424.524.4

24.124.2

3

23

22

3

4 5

99

9

11

9 15 24.624.7

24.624.7

24.8

18

19

17

3433

38

40

41

42

43

44

4733

45

48 4950

5152

53 58

1

20

21

2

1213

37

46

35

36

39

60

64

66

67

68

6370

72

69

10

16

3085.172

EXPLODED VIEW

753085, 3102, 3127

24.424.524.4

24.124.2

3

23

22

3

4 5

99

9

11

9 15 24.624.7

24.624.7

24.8

18

19

17

3433

38

40

41

42

43

44

4733

45

48 49

50

51

52

53 57

1

20

21

2

1213

37

46

35

36

39

10

16

3085.182

EXPLODED VIEW

3085, 3102, 312776

24.424.524.4

24.124.2

3

23

22

3

4 5

99

9

11

9 1524.6

24.724.6

24.7

24.8

18

19

17

38

40

41

42

43

44

4733

45

48 4950

5152

53 58

1

20

21

2

1214

37

46

60

64

66

67

68

6370

72

69

876

33 32

31

34

10

16

3085.891

EXPLODED VIEW

773085, 3102, 3127

EXPLODED VIEW

3085, 3102, 312778

3

3

11

26

25

22

1214

2324.3

4 9 524.1

24.424.524.4

2

9

86

9

2724.6

24.7

2930

28

24.8

16

17

18

19

343332

31

38

40

41

42

43

44

4733

45

48 49

5357

37

46

1

10

15

3102.090

EXPLODED VIEW

793085, 3102, 3127

3

3

11

26

25

22

1213

23

4 9 5

24.1

24.424.524.4

2

9

9

2724.6

24.7

2930

28

24.816

17

18

19

34

33 38

40

41

42

43

44

473345

48 49

37

46

1 3536

39

3

222324.3

25

24.1

24.424.524.4

24.2

53 58

60

64

66

67

68

6370

72

69

10

15

3102.170

EXPLODED VIEW

3085, 3102, 312780

3

3

11

26

25

22

1213

23

4 9 5

24.1

24.424.524.4

2

9

9

2724.6

24.7

2930

28

24.816

17

18

19

34

3338

40

41

42

43

44

4733

45

48 49

5357

37

46

1 3536

39

3

222324.3

25

24.1

24.424.524.4

24.2

10

15

3102.180

EXPLODED VIEW

813085, 3102, 3127

3

3

11

2625

22

1214

23

4 9 5

24.1

24.424.524.4

2

9

9

2724.6

24.7

2930

28

24.816

17

18

19

3433 38

40

41

42

43

44

473345

48 49

37

46

1

53 58

60

64

66

67

68

6370

72

69

24.3

6

8

10

323115

3102.890

EXPLODED VIEW

3085, 3102, 312782

EXPLODED VIEW

833085, 3102, 3127

3

3

11

26

25

22

1214

2324.3

4 9 524.1

24.424.524.4

2

9

86

9

27

24.6

24.7

2930

28

24.8

16

17

18

19

34333231

38

40

41

42

43

44 4733

45

48 4953

57

37

46

1

10

15

59 75

3127.090

EXPLODED VIEW

3085, 3102, 312784

3

4

11

26

25

22

1213

23

4 9 5 24.1

24.424.524.4

2

9

9

27

24.6

24.7

2930

28

24.8

16

17

18

19

34

3338

40

41

42

43

44 4733

45

48 49

37

46

1

10

39

36

3

222324.3

25

24.1

24.424.524.4

35

53

60

64

66

67

68

63

70

72

69

15

24.2

59

65

3127.170

EXPLODED VIEW

853085, 3102, 3127

3

3

11

26

25

22

1213

23

4 9 5 24.1

24.424.524.4

2

9

9

27

24.6

24.7

2930

28

24.8

16

17

18

19

34

3338

40

41

42

43

44 4733

45

48 4953

57

37

46

1

10

39

36

3

222324.3

25

24.1

24.424.524.4

54

55

5675

59

15

24.2

35

3127.180

EXPLODED VIEW

3085, 3102, 312786

3

3

11

26

25

22

1214

23

4 9 5

24.124.424.524.4

2

9

9

27

24.6

24.7

2930

28

24.8

16

17

18

19

3433

38

40

41

42

43

44 47

33

45

48 49

37

46

1

10

53

5860

66

67

68

63

70

72

69

24.3

3231

68 15

65

64

3127.890

EXPLODED VIEW

873085, 3102, 3127

EXPLODED VIEW

3085, 3102, 312788

SERVICE LOG

Most recent Pump No. Hours of Remarks Sign.service date operation

893085, 3102, 3127

Specially approved pumps

NOTE!

Specially approved pumps may only be repairedor maintained by authorized ITT Flygt personnelor personnel authorized by ITT Flygt.

This workshop manual also describes the specially ap-proved pumps in the product series 3085, 3102 and3127. For identification, see the pump data plate andapproval plate.

To ensure that the pump complies with the regulationsand approval of the authorities, use only genuine ITTFlygt spare parts when carrying out repair work.

Always check the dimensions of vital parts before as-sembly. See picture below.

The assembled pumps shall always be insulation-testedand test-run before delivery.

GeneralIn a specially approved pump (Ex d), the gaps betweendifferent parts, for example between the stator housing andthe junction box, shall prevent any sparks from the interiorof the pump from getting out and igniting surrounding gases.

All joint widths and gaps shall be measured with accurateand calibrated instruments. All joint surfaces shall be in-spected. No scratches, tool marks or the like are permissi-ble.

Failure to meet the above requirements may render thespecial approval invalid. Note that the work requires expe-rienced and specially trained personnel.

Workshop repairThe parts for which dimensions are to be checked aregiven in the parts list. It is important to ensure that thejoint surfaces for these parts are not damaged during dis-mantling.

The product must be thoroughly examined and a reportmust be preparred on all findings. Any measurements, di-mensional checks, test readings, details of materials, partsof windings which are found to require attention should becarefully noted.

If the products have been modified and do not complywith original approval, the owner must be informed andfurther information on the application must be requested.

If there are any doubts during the repair as to the resultsof measurements, tests, the continued integrity of partsor the possible reclamation of damage parts, referencemust be made to your local Ex Coordinator.

SPECIALLY APPROVED PUMPS

Guidelines for repairCare must be taken when dismantling Ex approved prod-ucts, as damage to flameproof faces can easily occur.For instance, if difficulties are found in separating spigotedjoints, draw studs should be used wherever possible ratherthan trying to wedge the components apart, as not onlywill damage occur at the point of wedging, but the wedgesare liable to be driven through and damage the flamepathsurface of the spigot. Similarly, care should be exercisedwhen removing the main bearing assembly and bearingcover to ensure that damage does not occur on the part ofthe shaft that constitutes the flamepath.

Unless obviously damaged through either mechanical in-jury or dry or wet burn out, the stator winding should notbe removed until preliminary testing has been done todetermine the condition of the stator winding and monitor-ing devices, i.e. overtemperature thermal switches. Themoisture detection device (FLS) in the stator housing isseparate and does not form part of the stator winding.

The user’s instruction should be consulted to verify whetherthe pump has been returned for repair because of electri-cal problems, such as operation of overload, short circuitor tripping out on an earth trip leakage device.

Once the pump has been completely dismantled, detailedexamination of all parts should be made and a conciserecord kept of all findings.

When assembling an Ex approved product, measure thegaps and the joint widths. Inspect the joint surfaces andsmear them with grease to prevent corrosion.

If a part does not meet the requirements on dimensionalaccuracy or surface finish, it must be discarded and anew specially approved part ordered. The new part mustalso be inspected.

Observe caution during assembly to prevent damage tothe joint surfaces.

FlamepathsBy referring to the spare parts list and dimensional draw-ings, the trained person can ascertain the parts of thepump motor that require special examination. Theflamepaths should be examined for any corrosive pittingor damage which may have occurred.

All castings should be examined for blow holes or hairlinecracks. If there is evidence that there has been an internalexplosion of gases, this may be confirmed by the userand will probably be evident by smoke and debris trackingacross the flamepaths.

Also violent damage will possibly have occurred to thestator windings, stator leads and terminal boards or bush-ings. In such cases, consideration should be given to therenewal of all parts forming the flameproof enclosure.

3085, 3102, 312790

Using the ITT FLYGT dimensional check information forEx approved products for the particular product under re-pair, the length of all flamepaths can be measured using avernier type gauge (the type incorporating a depth gaugeis particularly suitable for this purpose). When measuringflamepaths on spigoted parts, care should be taken tomeasure only from the outer edge of the flamepath to theouter edge of the “O” ring groove. It would, however, beunusual for these measurements to be wrong as any cor-rosive or mechanical damage affecting the length of theflamepath would be evident by visual inspection.

The flameproof gap is ascertained by measuring the out-side diameter (O.D.) of the spigoted or male part and theinside diameter (I.D.) of the female part of the casting intowhich it fits. Measurements should be taken at severalpoints on the circumference and the smaller (in the caseof O.D.) and the larger (in the case of I.D.) should be usedto calculate the diametral clearance. Micrometers shouldbe used for taking measurements.

The calculation is simply to subtract the O.D. of the malepart from the I.D. of the female part into which it fits. Careand experience is required when taking any of these meas-urements, as the tolerances are very fine.

For measuring the inside circumference of the stator coreor the outside diameters of rotors, special measuring toolsare required. Shaft outside diameter and inside diametersof bearing covers etc. can be measured using microm-eters.

The flameproof gaps should be calculated, recorded andchecked against the dimensional check list for the prod-uct under repair.

Stator and rotorPrior to examining the stator housing, preliminary elec-trical testing of the stator winding should be undertaken.This requires an insulation test between windings and earthand between windings, for sinlge phase also betweenwindings and auxiliaries.

The two monitoring cores should be short circuited togetherduring this test. A suitable test with a 100 volt meggerwould be 20 MΩ.The continuity of the thermal switches should be meas-ured to ensure their continued integrity. In the rare casewhen thermistors and PT100 elements are used, they canbe tested using a digital type high impedance instrument.


913085, 3102, 3127

Dimensional checks

With of joint Diameter (mm) Gap of joint (mm)(mm)

Min Max

1 ≥ 15.5 202 H7 0.122 0.168202 f8

2 ≥ 26 30 H7 0.255 0.29530

-0.274

3 65 89 ± 0.03 0.72 0.8888.2 ± 0.05

85 79 ± 0.03 0.61 0.79

78.3 ± 0.06

97 89 ± 0.03 0.72 0.8888.2 ± 0.05

4 65 (4-pole) 145 JS7145 +0.1

85 (2-pole) 145 JS7145 +0.083

97 (4-pole) 145 JS7 Shrink fit145 +0.1

97 (6-pole) 145 JS7145 +0.1

-0.255

+0.02

+0.02

+0.02

+0.02

3085.092 / .891

43

2

1

5


3085, 3102, 312792

43

2

1

5


Min Max

1 ≥ 25 205 H8 0.050 0.194202 f8

2 ≥ 25 30 H7 0.255 0.29630

-0.274

3 95 95.0 ± 0.030 0.72 0.8894.2 ± 0.050

110 110.0 ± 0.030 0.72 0.88

109.2 ± 0.050

4 91 (2-pole) 175 P7 Shrink fit106 (4-pole) 175 +0.050

5 ≥ 25 130 H8 0.043 0.169130 f8

-0.255

3102.090 / .890

-0.013


933085, 3102, 3127

43

2

1

5


Min Max

1 ≥ 25 244 H8 0.050 0.194244 f8

2 ≥ 25 45+0.170 0.250 0.300

45 d7

3 105 (2-pole) 114.1 - 115.0 0.87 1.03

95/115 (4 pole) 133.0 - 134.0 0.97 1.13

4 103 (2-pole) 210 P7 Shrink fit93/113 (4-pole) 210 +0.052

5 ≥ 25 130 H8 0.043 0.169130 f8

3127.090 / .890

-0.020

+0.195


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NOTES

3085, 3102, 312794

3085

/310

2/31

27. 3

3.03

. Eng

. 0,5

M. 1

1.03

© IT

T F

LYG

T A

B P

rinte

d in

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9240

9

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