FLYGT Flygt 3069 Installation, Operation And Maintenance Manual Download

Page: 33 / 64

4.2.6.5 Screened cable connection

Screened connection SUBCAB & FGB Screened

Cable without sep. ground conductor
Screen as ground conductor

GN/YE shrink hose

Screen

Mini CAS

Mini CAS+AUX

FGB Screened

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)

T3 (WH)

T4 (WH)

T1 (WH)

T2 (WH)

Screen - SUBCAB and Screenflex

T1 and T2
twisted

White insulation hose

Screen

together

GN/YE

T1 T2

T1 and T2
twisted
together

White insulation hose

Screen

GN/YE

T1 T2

L1 L2 L3

WS004132A

Sensors connection

Not all charts are applicable for every product.
These sensor connections are applicable for 3–phase and 1–phase without built-in starter:

Control

SUBCAB 7GX & 4GX
Screenflex

SUBCAB AWG

SUBCAB

screened

WH T1

WH T2

WH T3

WH T4

SENSORS

(Thermal Contacts)

+ FLS

+ CLS

+ FLS+CLS

FLS

Max. 250V Max.5A
Max. 1.6A,cos =0.6
Max. 2.5A,cos =1

WH/YE

Control leads

WH/YE

T1/*OG/4

*SUBCAB AWG

T2/*OG/5

FLS

Max 12 V

WH
YE

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

CLS

Max 12 V

WH
YE

BN/RD

WH/YE

T1 Control leads

T1/*OG/4

Mini

*SUBCAB AWG

T2/*BU/5

-5

CAS

CLS

FLS

Max 12 V

RD/BN

WH/YE

T1 Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

Temp > 40° T1,T2 thermal

FLS

contacts not connected

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

T2/*BU/5

*SUBCAB AWG

Control

SUBCAB 7GX & 4GX
Screenflex

SUBCAB AWG

SUBCAB

screened

WH T1

WH T2

WH T3

WH T4

SENSORS

(Thermal Contacts)

+ FLS

+ CLS

+ FLS+CLS

FLS

Max. 250V Max.5A
Max. 1.6A,cos =0.6
Max. 2.5A,cos =1

WH/YE

Control leads

WH/YE

T1/*OG/4

*SUBCAB AWG

T2/*OG/5

FLS

Max 12 V

WH
YE

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

CLS

Max 12 V

WH
YE

BN/RD

WH/YE

T1 Control leads

T1/*OG/4

Mini

*SUBCAB AWG

T2/*BU/5

-5

CAS

CLS

FLS

Max 12 V

RD/BN

WH/YE

T1 Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

Temp > 40° T1,T2 thermal

FLS

contacts not connected

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

T2/*BU/5

*SUBCAB AWG

Control

SUBCAB 7GX & 4GX
Screenflex

SUBCAB AWG

SUBCAB

screened

WH T1

WH T2

WH T3

WH T4

SENSORS

WS004130B

Control

SUBCAB 7GX & 4GX
Screenflex

SUBCAB AWG

SUBCAB

screened

WH T1

WH T2

WH T3

WH T4

SENSORS

(Thermal Contacts)

+ FLS

+ CLS

+ FLS+CLS

FLS

Max. 250V Max.5A
Max. 1.6A,cos =0.6
Max. 2.5A,cos =1

WH/YE

Control leads

WH/YE

T1/*OG/4

*SUBCAB AWG

T2/*OG/5

FLS

Max 12 V

WH
YE

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

CLS

Max 12 V

WH
YE

BN/RD

WH/YE

T1 Control leads

T1/*OG/4

Mini

*SUBCAB AWG

T2/*BU/5

-5

CAS

CLS

FLS

Max 12 V

RD/BN

WH/YE

T1 Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

Temp > 40° T1,T2 thermal

FLS

contacts not connected

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

T2/*BU/5

*SUBCAB AWG

Control

SUBCAB 7GX & 4GX
Screenflex

SUBCAB AWG

SUBCAB

screened

WH T1

WH T2

WH T3

WH T4

SENSORS

(Thermal Contacts)

+ FLS

+ CLS

+ FLS+CLS

FLS

Max. 250V Max.5A
Max. 1.6A,cos =0.6
Max. 2.5A,cos =1

WH/YE

Control leads

WH/YE

T1/*OG/4

*SUBCAB AWG

T2/*OG/5

FLS

Max 12 V

WH
YE

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

CLS

Max 12 V

WH
YE

BN/RD

WH/YE

T1 Control leads

T1/*OG/4

Mini

*SUBCAB AWG

T2/*BU/5

-5

CAS

CLS

FLS

Max 12 V

RD/BN

WH/YE

T1 Control leads

T1/*OG/4

Mini

-5

CAS

*SUBCAB AWG

T2/*BU/5

Temp > 40° T1,T2 thermal

FLS

contacts not connected

WH/YE

Control leads

T1/*OG/4

Mini

-5

CAS

T2/*BU/5

*SUBCAB AWG

(Thermal Contacts)

Max. 250V Max.5A
Max. 1.6A,cos =0.6
Max. 2.5A,cos =1

WH/YE

Control leads

WH/YE

T1/*OG/4

*SUBCAB AWG

T2/*OG/5

WS011184A

4 Installation

Flygt 3069 Installation, Operation, and Maintenance Manual

Summary of Contents for Flygt 3069

Page 1: ...Installation Operation and Maintenance Manual 885842_10 0 Flygt 3069...

Page 2: ......

Page 3: ...guidelines 10 3 Product Description 12 3 1 Pump design 12 3 2 Sensors and monitoring equipment 13 3 3 The data plate 14 3 4 Approvals 15 3 5 Product denomination 16 4 Installation 17 4 1 Precautions...

Page 4: ...eller 47 6 7 4 Install the cutting wheel 48 6 8 Replace the N impeller 49 6 8 1 Remove the N impeller 49 6 8 2 Install the N impeller 50 7 Troubleshooting 54 7 1 Electrical troubleshooting 54 7 2 The...

Page 5: ...ents and information in the original manufacturer s manuals for any other equipment furnished separately for use in this system 1 2 Safety terminology and symbols About safety messages It is extremely...

Page 6: ...nnel 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...

Page 7: ...s 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 dire...

Page 8: ...less Xylem has been informed and appropriate actions have been agreed upon 1 7 End of life product disposal Handle and dispose of all waste in compliance with local laws and regulations Correct dispos...

Page 9: ...1 9 Warranty For information about warranty see the sales contract 1 Introduction and Safety Flygt 3069 Installation Operation and Maintenance Manual 7...

Page 10: ...any issue then contact a sales representative 2 2 Transportation guidelines 2 2 1 Precautions DANGER Crush Hazard Moving parts can entangle or crush Always disconnect and lock out power before servici...

Page 11: ...formation 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 correctly anchored and in g...

Page 12: ...liquid into a surrounding temperature below freezing Follow these guidelines to avoid freezing damage 1 Empty all pumped liquid if applicable 2 Check all liquids used for lubrication or cooling both o...

Page 13: ...n indicated stacking limit then it is valid for 23 C 73 F and 50 relative humidity Depending on the material other temperature and humidity ranges can reduce the stacking limit 2 Transportation and St...

Page 14: ...ludge raw and clean water Always follow the limits given in Technical Reference on page 58 If there is a question regarding the intended use of the equipment please contact a local sales and service r...

Page 15: ...WCCR For information see Parts List 4 Impeller 5 Pump housing The pump housing includes a coolant that lubricates and cools the seals the housing acts as a buffer between the pumped fluid and the driv...

Page 16: ...e 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 WS011207A 8 7...

Page 17: ...ber 3 Approved drive unit 4 Cable entry temperature 5 Stall time 6 Starting current or Rated current 7 Duty class 8 Duty factor 9 Input power 10 Rated speed 11 Additional information 12 Maximum ambien...

Page 18: ...etter 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 b c WS006265B Type of Callou...

Page 19: ...nformation in the safety chapter before taking any further actions General requirements These requirements apply Use the pump dimensional drawing in order to ensure proper installation Before installi...

Page 20: ...e requirements and instructions only apply when the installation is made according to the dimensional drawing 1 Run the cable so that it has no sharp bends Make sure that it is not pinched and cannot...

Page 21: ...are required Discharge connection Pipe For installation instructions see appropriate mechanical accessories 4 1 2 3 P installation WS009505A P Semipermanent wet well arrangement with the pump install...

Page 22: ...e flange is drilled WS009508A 4 2 Make the electrical connections 4 2 1 General precautions DANGER Electrical Hazard Before starting work on the unit make sure that the unit and the control panel are...

Page 23: ...on the data plate then the motor is convertible between different voltages The thermal contacts or thermistors must be in use If the temperature of the pumped liquid is above 40 C 104 F then do not c...

Page 24: ...il must be trimmed All unused conductors must be insulated NOTICE Do not use external Variable Frequency Drive VFD with this unit 4 2 2 Grounding earthing Grounding earthing must be done in compliance...

Page 25: ...rol element a Peel the insulation jacket or plastic jacket b Peel the aluminum and textile layers The aluminum foil is a conductive screen Do not peel more than necessary and remove the peeled foil WS...

Page 26: ...ns WS009725A 3 Check the data plate to see which connections are required for the power supply 4 Arrange the connections in accordance with the required power supply 5 Connect the mains leads L1 L2 L3...

Page 27: ...tacts 2 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 3 Check the functionality...

Page 28: ...S 10 11 9 WS004134B 12 13 14 CT 1 Starter equipment and mains leads L1 L2 L3 2 Ground earth 3 Functional ground 4 Control leads T1 T2 T3 T4 5 Thermal contact 6 FLS 7 FLS 10 8 CLS 9 Thermistor 10 Level...

Page 29: ...YE GN YE Screen PE from cores Screen WH Screen WH Screen WH Mains 1 3 SUBCAB 7GX Screenflex 7GX SUBCAB 4GX Screenflex 4GX SUBCAB AWG SUBCAB Screened GC YE WS004125C Figure 7 3 phase and 1 phase witho...

Page 30: ...1 L2 1 L3 1 L1 2 L2 2 L3 2 U1 V1 W1 U2 V2 W2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 GC 1 2 3 4 5 6 GN YE YE WH WS004126A 6 Leads Y U1 V1 W1 U2 W2 V2 U1 V1 W1 W2 U2 V2 U1 V1 W1 GC W2 U2...

Page 31: ...YE GN YE WH WS004127A 12 Leads Y L1 U1 U5 U2 W 2 U6 W 1 V 6 W 6 V 2 V 5 W 5 L 3 V 1 L 2 U1 V1 W1 U2 V6 U5 V5 W5 V2 W2 U6 W6 U1 V1 W1 W2 U2 V2 W2 U2 V2 GC U1 V1 W1 L1 L2 L3 YE WH GN YE Y SER L1 U1 U2 U...

Page 32: ...3 GY U1 U2 V1 V2 U5 V5 W1 W2 W5 1 W6 V6 U6 T1 T2 Z2 U2 U1 Z1 BK BN RD YE Starter 1 BN RD 2 BK BK 3 GY WH 4 T1 OG 5 T2 BU 6 GN YE WH YE GC Starter 1 BN RD 2 BK BK 3 GY WH 4 T1 OG 5 T2 BU 6 GN YE WH YE...

Page 33: ...er White insulation hose Screen BK BK BK BK BK BK GN YE 1 2 3 4 5 6 T1 T2 L1 L2 L3 L1 L2 L3 WS004132A Sensors connection Not all charts are applicable for every product These sensor connections are ap...

Page 34: ...YE 6 BN RD WH YE T1 Control leads T1 OG 4 T2 7 BK Mini SUBCAB AWG T2 BU 5 5 CAS WS011186A SUBCAB screened WH T1 WH T2 WH T3 WH T4 Thermal Contacts FLS CLS TC Max 250V Max 5A Max 1 6A cos 0 6 Max 2 5A...

Page 35: ...stration WS006253B 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 then do one of these steps If the motor...

Page 36: ...exceed 70 dB A at certain operating points on the performance curve Make sure that you understand the noise level requirements in the environment where the product is installed Failure to do so may re...

Page 37: ...jerk can be powerful Make sure nobody is close to the unit when it is started NOTICE Make sure that the rotation of the impeller is correct For more information see Check the impeller rotation 1 Chec...

Page 38: ...dle them Make sure that the product and its components have been thoroughly cleaned Before starting work make sure that the work area is well ventilated Do not open any vent or drain valves or remove...

Page 39: ...1240 915 100 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 class M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 8 8 2 9 2 1 5 7 4 2 9 8 7 2 24 18 47 35 81 60 194...

Page 40: ...propelled with force Be careful when opening Allow the chamber to de pressurize before removal of the plug 1 Put the pump in a horizontal position and unscrew the oil plug WS009604A 2 Put a container...

Page 41: ...le oil types are the following Statoil MedicWay 32 BP Enerpar M 004 Shell Ondina 927 Shell Ondina X430 1 Replace the O ring of the oil plug 2 Fill with oil Quantity approximately 0 6 L 0 6 quarts WS00...

Page 42: ...eratures 40 C 104 F Overhaul The overhaul lengthens the operating lifetime of the product It includes the replacement of key components and the measures that are taken during an inspection Up to every...

Page 43: ...ctions Rotation direction Check the impeller rotation Oil housing If necessary fill with new oil Electrical connections Check that the connections are properly secured Thermal contacts Normally closed...

Page 44: ...WS009622A 1 2 3 4 5 6 1 Pump housing 2 Impeller screw 3 Impeller 4 Spacer 5 Sleeve 6 Screws Figure 10 Abrasive resistant variant 6 5 1 Remove the D impeller CAUTION Cutting Hazard Worn parts can have...

Page 45: ...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 2 Prepare the impeller For the s...

Page 46: ...w Prevent the impeller from rotating 3 Remove the impeller and the sleeve 6 6 2 Install the F impeller 1 Prepare the shaft a Polish off any flaws with a fine emery cloth The end of the shaft must be c...

Page 47: ...e Torque values on page 37 3 Install the suction cover a Fit the studs on the pump housing Use Loctite 603 locking liquid to secure the studs WS009625A b Fit the seal sleeves the suction cover and the...

Page 48: ...nt unexpected startup Failure to do so could result in death or serious injury CAUTION Cutting Hazard Worn parts can have sharp edges Wear protective clothing 1 Prevent the cutting wheel from rotating...

Page 49: ...hafts and or sleeves 2 Mount the impeller a Insert the sleeve into the impeller b Fit the impeller to the shaft c Coat the cylindrical surface of the pump housing with a thin layer of grease The prope...

Page 50: ...sher 811 62 50 2 Fit the cutting wheel to the adjustment screw until the wheel touches the plastic shim 3 Fit and tighten the set screw Tightening torque 55 Nm 41 ft lb 4 Make sure that the impeller a...

Page 51: ...ICE 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 a...

Page 52: ...out again If the sleeve does not move freely or does not come fully out then replace the impeller unit WS009595A 2 Prepare the shaft a Polish off any flaws with a fine emery cloth The end of the shaft...

Page 53: ...te the threads of the impeller screw Always use a new screw b Adjust the adjustment screw so that it is flush in the sleeve WS009596A c Insert the sleeve into the impeller WS009597C d Fit the arrangem...

Page 54: ...n page 37 Prevent the impeller from rotating Insert a screwdriver or similar through the pump housing outlet WS009502A c Tighten the screw a further 1 8 turn 45 d Check that the impeller can rotate fr...

Page 55: ...WS009599A 6 Maintenance Flygt 3069 Installation Operation and Maintenance Manual 53...

Page 56: ...ush 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...

Page 57: ...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 sump to the stop leve...

Page 58: ...nd 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...

Page 59: ...se two phase leads If it is a 1 phase pump then do the following Contact a sales or authorized service representative One or more of the valves are set in the wrong positions Reset the valves that are...

Page 60: ...3 08 4BB 13 10 2BB 13 10 2BB 13 10 4BB 140 C 284 F T3 13 10 4BB 8 2 Application limits Data Description Liquid temperature Maximum 40 C 104 F The pump can be operated at full load only if at least hal...

Page 61: ...less steel version of the pump can be operated at full load only if the complete stator housing is submerged WS010481A 1 2 1 2 8 Technical Reference Flygt 3069 Installation Operation and Maintenance M...

Page 62: ......

Page 63: ......

Page 64: ...rn water to the environment in public utility industrial residential and commercial building services settings Xylem also provides a leading portfolio of smart metering network technologies and advanc...

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