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Xylem Flygt 3060, Installation, Operation And Maintenance Manual

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Xylem Flygt 3060 Installation, Operation And Maintenance Manual Download Page 4

View of terminal board and sensor connections........................................................................21
Motor cable, stator leads and thermal contacts connection to terminal board.....................22

Check the impeller rotation.............................................................................................................23

Operation..............................................................................................................................................24

Precautions.........................................................................................................................................24
Distance to wet areas........................................................................................................................24
Noise level..........................................................................................................................................24
Start the pump...................................................................................................................................24
Clean the pump.................................................................................................................................25

Maintenance.........................................................................................................................................26

Precautions.........................................................................................................................................26
Maintenance guidelines...................................................................................................................26
Torque values....................................................................................................................................26
Service................................................................................................................................................27

Inspection........................................................................................................................................27
Major overhaul................................................................................................................................29

Change the oil...................................................................................................................................29

Empty the oil...................................................................................................................................29
Fill with oil........................................................................................................................................29

Replace the impeller.........................................................................................................................30

Remove the impeller......................................................................................................................30
Install the impeller..........................................................................................................................30
Adjust the impeller.........................................................................................................................30

Troubleshooting...................................................................................................................................31

Introduction.......................................................................................................................................31
The pump does not start..................................................................................................................31
The pump does not stop when a level sensor is used.................................................................32
The pump starts-stops-starts in rapid sequence...........................................................................32
The pump runs but the motor protection trips.............................................................................33
The pump delivers too little or no water........................................................................................34

Technical Reference............................................................................................................................35

Application limits...............................................................................................................................35
Motor data..........................................................................................................................................35
Specific motor data...........................................................................................................................35
Dimensions and weights..................................................................................................................38
Performance curves..........................................................................................................................42

Table of Contents

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Flygt 3060 Installation, Operation, and Maintenance Manual

Summary of Contents for Flygt 3060

Page 1: ...Flygt 3060 Installation Operation and Maintenance Manual ...

Page 2: ......

Page 3: ...he unit out of liquid 8 Storage guidelines 8 Storage location 8 Long term storage 8 Product Description 9 Products included 9 Pump design 9 Monitoring equipment 9 The data plate 10 Product denomination 10 Installation 12 Install the pump 12 Sedimentation prevention 12 Discharge line requirements 12 Fasteners 13 Install with P installation 13 Install with S installation 14 Install with T Z installa...

Page 4: ...29 Empty the oil 29 Fill with oil 29 Replace the impeller 30 Remove the impeller 30 Install the impeller 30 Adjust the impeller 30 Troubleshooting 31 Introduction 31 The pump does not start 31 The pump does not stop when a level sensor is used 32 The pump starts stops starts in rapid sequence 32 The pump runs but the motor protection trips 33 The pump delivers too little or no water 34 Technical R...

Page 5: ...out 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 Hazard levels Hazard level Indication DANGER A hazardous situation which if not avoided will result in death or se...

Page 6: ... only under the conditions described in this manual The monitoring equipment incorporated in the product is correctly connected and in use All service and repair work is done by Xylem authorized personnel Genuine Xylem parts are used Only Ex approved spare parts and accessories authorized by an EX approved Xylem representative are used in Ex approved products Limitations The warranty does not cove...

Page 7: ...to Trapped liquid can rapidly expand and result in a violent explosion and injury Never apply heat to impellers propellers or their retaining devices to aid in their removal 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 del...

Page 8: ... eyes 1 Hold your eyelids apart forcibly with your fingers 2 Rinse the eyes with eyewash or running water for at least 15 minutes 3 Seek medical attention Chemicals or hazardous fluids on skin 1 Remove contaminated clothing 2 Wash the skin with soap and water for at least 1 minute 3 Seek medical attention if necessary Environmental safety The work area Always keep the station clean to avoid and or...

Page 9: ...ING 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 The unit and the components can be heavy Use proper lifting methods and wear steel toed shoes at all times ...

Page 10: ... 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 p...

Page 11: ... warm media liquid version has certain operational limitations which are stated on a plate on the pump For applicability see Application limits page 35 Particle size The pump can handle liquid containing particles that correspond to the holes in the strainer Number of holes Hole dimensions MT 81 HT 896 MT 15 15 mm 0 6 0 6 in HT Diameter 5 mm 0 2 in Pressure class LT Low head MT Medium head HT High...

Page 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 1 The data plate Product denomination Sales denomination The sales denominati...

Page 13: ...ination 2 Version Serial number The serial number is used for identification of an individual product and is divided into four parts This is an example of a serial number and an explanation of its parts 1 NP 3085 183 951 0163 2 3 4 WS006269A 1 Product code 2 Production year 3 Production cycle 4 Running number Product Description Flygt 3060 Installation Operation and Maintenance Manual 11 ...

Page 14: ...l debris from the inlet piping system before you install the pump Always check the impeller rotation before lowering the pump into the pumped liquid Sedimentation prevention In order to avoid sedimentation when the pumped liquid contains solid particles the velocity of the liquid in the discharge line must exceed a certain value Choose applicable minimum velocity from the table and choose proper d...

Page 15: ...s 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 You can inspect the pump by hoisting it up along the guide bars without disconnecting it WS006259A F...

Page 16: ...e 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 8 Lower the pump along the guide bars When it reaches the bottom position the...

Page 17: ...tion see Check the impeller rotation page 23 Install with T Z 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 The pump for T installation has a watertight motor that is protected in the event of flooding in the pump roo...

Page 18: ...lectrical 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 ...

Page 19: ... 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 Earthing Grounding Electrical Hazard You must earth ground all electrical equipment This applies to the pump equipm...

Page 20: ... sure that any thermal contacts incorporated in the pump are properly connected to the terminal board 6 Install the cover 7 Fasten the screws on the entrance flange so that the cable insertion assembly bottoms out After you have connected the motor cable to the pump connect the motor cable and the control cable to the starter equipment WARNING Do not install the starter equipment in an explosive z...

Page 21: ... regulator 6 Diode 18 Contactor start relay or thermal relay 7 Motor cable minimum 20 m 66 ft 19 Thermal detector in stator 8 Screen 20 Thermal detector in main bearing 9 Pump 21 Jumper 10 Crimp connection 22 Terminal board terminal plate 11 Crimp isolation 23 Leakage sensor 12 Motor protector 24 Stator leads U1 U2 U5 U6 V1 V2 V5 V6 W1 W2 W5 W6 Z1 Z5 Z6 Color code standard Code Description BN Brow...

Page 22: ...Code Description GNYE Green Yellow RD Red GY Grey BU Blue YE Yellow Installation 20 Flygt 3060 Installation Operation and Maintenance Manual ...

Page 23: ...ctional ground Jumper Crimp connection Crimp isolation SYMBOLS AND DENOMINATIONS Connection plate W1 V1 U1 W2 V2 U2 2071 MAIN TERMINAL BOARD SENSOR TERMINALS Y STAR JUMPERS D DELTA JUMPERS T1 T2 3060 T1 T2 T1 T2 MAIN TERMINAL BOARD Y STAR JUMPERS D DELTA JUMPERS W1 V1 U1 W2 V2 U2 SENSOR TERMINALS 2075 3080 B U W V Y X Z B W1 W V1 V U1 U W2 Z V2 Y U2 X T1 B T2 B W1 3 V1 2 U1 1 T1 4 T2 5 MAIN TERMIN...

Page 24: ...3xA 3 S 4x0 5 4GA 2x1 5 GY BN BK GNYE WH RD BK GNYE A AWG 7 A AWG 3 2 1 GC T1 WH T2 WH OR BU YE MOTOR CABLE CONNECTION TO TERMINALBOARD 3 PH L3 L1 L2 L3 L1 L2 7GA 2x1 5 BK 3 BK 1 BK 2 BK 6 BK 4 BK 5 T1 WH T2 WH GNYE Y D HCR 6xA 3 WH 1 WH 2 WH 5 WH 4 WH 6 WH GNYE 4GA GY BN BK GNYE GY BN BK FGB 3xA Screen as ground conductor FGB 6xA 2x1 5 3 WH 1 WH 2 WH 6 WH 4 WH 5 WH T1 WH T2 WH 3 P H A S E 3 Y D G...

Page 25: ...tion L2 L1 L2 L3 L3 L1 WS001397A Figure 5 Start reaction For T installations the direction of rotation can also be checked through the inlet elbow access cover 4 If the impeller rotates in the wrong direction then do the following If the motor has a 1 phase connection then contact the local sales and service representative If the motor has a 3 phase connection then transpose two phase conductors a...

Page 26: ...ct with the pumped or mixed liquid Electrical Hazard 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 perfo...

Page 27: ...ler is correct For more information see Check the impeller rotation 1 Check the oil level in the oil housing 2 Remove the fuses or open the circuit breaker and check that the impeller can be rotated freely 3 Check that the monitoring equipment if any works 4 Check that the impeller rotation is correct 5 Start the pump Clean the pump The pump must be cleaned if it has been running in very dirty wat...

Page 28: ...ssembly 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 and O rings with grease During reassembly always make sure that existing index markings are in line Torque values All screws and nuts must be lubricated to achieve correct tightening torque Screws that are screwed into stainl...

Page 29: ... 1 000 hours Major overhaul To secure a long operating lifetime for the product It includes replacement of key components and the measures taken during an inspection Every year under normal operating conditions 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...

Page 30: ...s oil in the inspection chamber then check that the inner mechanical seal is not damaged If necessary contact an authorized service shop 5 If there is water in the inspection chamber then do the following a Check that the O ring is not damaged b Check that the cable entry does not have any leakage Cable 1 If the outer jacket is damaged replace the cable 2 Check that the cables do not have any shar...

Page 31: ...can be used Empty the oil 1 Lay the pump on its side Lock the pump with supports to prevent it from rolling over 2 Remove the oil screw WARNING The oil housing may be pressurized Hold a rag over the oil plug to prevent oil from spraying out 3 Turn the pump so that the oil hole faces downwards and let the oil run out In order to get all the oil out the pump must be raised upright for a short while ...

Page 32: ...n the shaft 2 Fit the impeller onto the shaft Check that the impeller is firmly seated 3 Tighten the impeller nut The impeller clearance should be minimal when the impeller is tightened Use the adjusting washers to adjust the clearance 4 Check that the impeller can rotate easily Adjust the impeller In order for the pump to perform at maximum capacity the impeller must be adjusted regularly The imp...

Page 33: ...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 automatically but can be started manually Check that The start level regulator is functioning Clean or replace if necessary All connections are intact The relay and contactor coils are ...

Page 34: ...place all defective items The stop level is set too low Raise the stop level If the problem persists contact the local sales and service representative Always state the serial number of your product see Product Description page 9 The pump starts stops starts in rapid sequence Cause Remedy The pump starts due to back flow which fills the sump to the start level again Check that The distance between...

Page 35: ... The insulation between the phases and ground in the stator is defective 1 Use an insulation tester With a 1000 V DC megger check that the 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 high Make sure that the maximum density is 1100 kg m3 9 2 lb US gal...

Page 36: ...y Check that all valves are correctly installed according to media flow Check that all valves open correctly The impeller is difficult to rotate by hand Clean the impeller 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 impeller pum...

Page 37: ...wer rating and speed of the pump see the data plate on the pump For starting current see Motor data page 35 For other applications contact the local sales and service representative for information Motor data Feature Description Motor type Squirrel cage induction motor Frequency Standard version 50 or 60 Hz Supply 1 phase or 3 phase Starting method Direct on line Maximum starts per hour 30 evenly ...

Page 38: ...43 230 D 8 5 45 346 Y 5 7 28 350 Y 5 6 28 380 D 5 2 24 380 Y 5 2 25 400 D 4 9 26 400 Y 4 9 26 400 Y 5 1 21 400 Y serial 4 9 25 415 Y 4 8 22 440 Y 4 5 23 500 Y 3 9 21 550 Y 3 5 18 660 Y 3 14 690 Y 2 9 15 3 phase 60 Hz Motor type Rated output 2 7 kW 3 6 hp Voltage V Rated current A Starting current A 200 Y 11 56 208 Y 10 58 220 Y 9 8 62 220 Y parallel 9 9 51 230 D 9 48 230 Y parallel 9 4 50 Technica...

Page 39: ...9 55 260 D 8 3 49 380 D 5 7 32 400 Y 5 4 30 440 Y 4 9 27 440 Y serial 4 9 26 460 Y 4 7 26 460 Y serial 4 7 25 550 Y 4 22 575 Y 3 7 18 575 Y 3 8 21 600 Y 3 5 21 660 Y 3 3 19 Technical Reference Flygt 3060 Installation Operation and Maintenance Manual 37 ...

Page 40: ...Dimensions and weights All measurements in the illustrations are in millimeters if not otherwise specified Figure 6 HT CP Technical Reference 38 Flygt 3060 Installation Operation and Maintenance Manual ...

Page 41: ...Figure 7 MT CP DP Technical Reference Flygt 3060 Installation Operation and Maintenance Manual 39 ...

Page 42: ...Figure 8 HT CS Technical Reference 40 Flygt 3060 Installation Operation and Maintenance Manual ...

Page 43: ...Figure 9 MT CS DS Technical Reference Flygt 3060 Installation Operation and Maintenance Manual 41 ...

Page 44: ...T DT Weight without motor cable 41 kg 90 lbs Performance curves Test standard Pumps are tested in accordance with ISO 9906 HI level A Technical Reference 42 Flygt 3060 Installation Operation and Maintenance Manual ...

Page 45: ...1 5 2 0 2 5 274 274 272 LT Q l s H m P1 kW 272 WS006420A Figure 11 50 Hz LT 0 2 4 6 8 10 0 2 4 6 8 10 12 14 0 1 2 3 LT Q l s H m P1 kW 274 276 276 274 WS006421A Figure 12 60 Hz LT Technical Reference Flygt 3060 Installation Operation and Maintenance Manual 43 ...

Page 46: ... l s H m P1 kW WS006418A Figure 13 50 Hz MT 0 2 4 6 8 10 12 14 16 0 5 10 15 20 25 0 1 2 3 MT Q l s H m P1 kW Trifase 222 Trifase 222 Trifase 226 Trifase 226 Monofase 226 Monofase 226 WS006419A Figure 14 60 Hz MT Technical Reference 44 Flygt 3060 Installation Operation and Maintenance Manual ...

Page 47: ...3 252 252 250 250 HT Q l s H m P1 kW WS006416A Figure 15 50 Hz HT 0 1 2 3 4 5 6 7 8 0 5 10 15 20 25 30 35 0 1 2 3 252 252 HT Q l s H m P1 kW WS006417A Figure 16 60 Hz HT Technical Reference Flygt 3060 Installation Operation and Maintenance Manual 45 ...

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Page 50: ...ldings 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 AB Gesällvägen 33 174 87 Sundbyberg Sweden Tel 46 8 475 60 00 Fax 46 8 47...

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