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Xylem Flygt Concertor 6020, Installation, Operation And Maintenance Manual

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Xylem Flygt Concertor 6020 Installation, Operation And Maintenance Manual Download Page 16

Illustrations

WS009987A

8

10

11

12

13

9

5

4

3

15

2

1

6

7

RS485

DI

1

2

3

4

GND

A

AI

AO

HMI

1

2

3

4

5

B

GND

24VDC

+

_

+

_

+

_

PWR

DI1

DI2

DI3

DI4

DO1

DO2

DO3

DO4

ALARM A

ALARM B

PUMP RUN/CLEAN

PUMP COMMS

RS485

USB

NODE
ADDRESS

ON

OFF

MASTER

SLAVE

TERM

RS485

DO1

NO

COM

NO

GND

T4

T3

GND

DO2

DO1

NO

COM

NO

GND

DO2

ETHERNET

Concertor™

FPG411

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 2

 

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Figure 1: N 6020.180 MT/100, iron

4  Product Description

14

Concertor

™

 6020 Installation, Operation, and Maintenance Manual

Summary of Contents for Flygt Concertor 6020

Page 1: ...Installation Operation and Maintenance Manual Concertor 6020 ...

Page 2: ......

Page 3: ...or DP 11 4 Product Description 13 4 1 The pump 13 4 1 1 Pump design 13 4 1 2 The data plate 16 4 1 3 Product denomination 16 4 2 The gateways 17 4 2 1 Product design 17 4 2 2 Approvals 17 4 2 3 Parts 18 4 2 4 The data plate 18 5 Mechanical Installation 19 5 1 Precautions 19 5 2 Requirements 20 5 3 Make the mechanical installation 20 5 3 1 Prepare the site new P installation 20 5 3 2 Install the pu...

Page 4: ...er 41 8 5 2 Install the impeller 41 9 Troubleshooting 44 9 1 The pump does not start 44 9 2 The impeller does not rotate 45 9 3 The pump starts but stops after 10 seconds 45 9 4 The pump stops 45 9 5 The pump does not receive commands from the gateway 46 9 6 The pump starts stops starts in rapid sequence 46 9 7 The pump delivers too little or no water 46 10 Technical Reference 48 10 1 The pump 48 ...

Page 5: ...s 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 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 pro...

Page 6: ...res on the product are functioning and in use at all times when the unit is being operated 1 4 Special hazards Biological hazards 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 may come into contact with biological hazards are vaccinated against diseases to which they may be exposed...

Page 7: ... to Xylem if it has been exposed to nuclear radiation unless Xylem has been informed and appropriate actions have been agreed upon 1 6 Spare parts CAUTION Only use the manufacturer s original spare parts to replace any worn or faulty components The use of unsuitable spare parts may cause malfunctions damage and injuries as well as void the warranty 1 7 Warranty For information about warranty see t...

Page 8: ...ure to do so could result in death or serious injury 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 2 2 1 Lifting Always inspect the lifting equipment and tackle before starting any work WARNING Crush Hazard 1 Always lift the unit by its designated lifting points 2 ...

Page 9: ...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...

Page 10: ... cable entry The impeller propeller must be rotated every other month to prevent the seals from sticking together Packaging material stacking limit If the packaging material has an 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 Storage 8 Concertor 602...

Page 11: ...e Concertor system series 2 Components outside of the Concertor system Contactors fuses relays Control system Level sensors Cloud services Pump sum alarm I O 3 PC application Dirigo Service Tool gives access to settings and log files Connection is made through T3 and T4 Functions Pump clog detection Pump cleaning Soft start Constant power Always correct rotation Pump sum alarm I O Change pump perf...

Page 12: ... All the alarms are sent back to the external control system The operator changes the pump settings through the gateway Data is logged by and stored in the gateway 4 HMI FOP 312 The HMI is handheld or mounted inside the cabinet or in the cabinet door The HMI is optional Functions Pump clog detection Pump cleaning Soft start Soft stop Constant power Always correct rotation Set up wizard Set pump pe...

Page 13: ...gnal from the external control system Digital input signal Analog input signal Modbus All the alarms are sent back to the external control system The operator changes the pump settings through the gateway Data is logged by and stored in the gateway 4 HMI FOP 312 The HMI is handheld or mounted inside the cabinet or in the cabinet door The HMI is optional Functions Pump clog detection Pump cleaning ...

Page 14: ...ic pump performance 4 20 mA or Modbus Pump alarms with priority A or B I O Pump and motor control alarms HMI or Modbus Alarm handling Status and history 3 System Description 12 Concertor 6020 Installation Operation and Maintenance Manual ...

Page 15: ...llow the limits given in Technical Reference on page 48 If there is a question regarding the intended use of the equipment please contact a local sales and service representative before proceeding DANGER Explosion Fire Hazard Special rules apply to installations in explosive or flammable atmospheres Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explo...

Page 16: ...O 3 DO 4 ALA RM A ALA RM B PUM P RUN CL EAN PUM P CO MM S RS4 85 USB NO DE AD DR ESS ON OF F MA STE R SLA VE TERM RS4 85 DO 1 NO CO M NO GN D T4 T3 GN D DO 2 DO 1 NO CO M NO GN D DO 2 ETH ERN ET Co nc ert or FP G4 11 1 2 3 4 5 6 7 8 9 0 14 Figure 1 N 6020 180 MT 100 iron 4 Product Description 14 Concertor 6020 Installation Operation and Maintenance Manual ...

Page 17: ...RN ET Co nc ert or FP G4 11 1 2 3 4 5 6 7 8 9 0 14 Figure 2 N 6020 180 LT 150 aluminum Parts Position Part 1 Insert ring with a guide pin 2 Pump housing without flush valve connection 3 Seal housing cover 4 Stator housing unit with a leakage sensor 5 Cooling jacket 6 Connection housing with integrated control system 7 Lifting handle 8 Cable entry 9 Support bearing 10 Shaft unit with a permanent ma...

Page 18: ...mergence 11 Product weight 12 Direction of rotation L left R right 13 Nominal motor speed 14 Minimum rated voltage rated current maximum rated voltage rated current 15 Maximum ambient temperature 2 rated shaft power 2 16 Maximum ambient temperature 1 rated shaft power 1 17 Power factor 18 Phase type of current frequency 19 Manufacturer 20 Country of origin 21 Brand 4 1 3 Product denomination Readi...

Page 19: ...12 HMI through I O or through Modbus RTU Product name Part number Description FPG 411 8012100 Gateway for Concertor EA FPG 412 8012000 Gateway for Concertor DP FPG 411 The gateway allows control of the pump through digital input The pump performance curve can be changed when the pump is stopped through the HMI or through Modbus RTU An external HMI can be connected to monitor all pump data FPG 412 ...

Page 20: ...NO COM NO COM DO4 ETH ERNET Concertor FPG 411 WS009747A 1 2 3 4 5 1 2 3 4 5 6 7 8 9 0 1 Front connections 2 Status LEDs 3 Top connections 4 Back plane bus 5 Bottom connections 4 2 4 The data plate WS009750A 4 2 3 5 1 6 7 8 1 Brand 2 Product 3 Batch number Edition number 4 Country of origin Manufacturer 5 Approvals 6 Serial number 7 Part number 8 Software version 4 Product Description 18 Concertor ...

Page 21: ...heres Do not install the product or any auxiliary equipment in an explosive zone unless it is rated explosion proof or intrinsically safe If the product is EN ATEX MSHA or FM approved then see the specific EX information in the Safety chapter before taking any further actions WARNING Explosion Fire Hazard Do not install CSA approved products in locations that are classified as hazardous in the Nat...

Page 22: ...all the upper guide bar holder 2 Prepare the base for the discharge connection Make sure that the following requirements are fulfilled The base is aligned horizontally The anchor bolts are installed correctly The integrated lower guide bar support that is part of the discharge connection can be vertically aligned with the upper guide bar holder 3 Put the discharge connection in position and tighte...

Page 23: ...tomatic 1 Install the sliding bracket unit on the pump For more information see the separate accessories documentation WS009896A 2 Attach a permanent lifting device to the pump For example use a stainless steel lifting chain with shackles 3 Lower the pump along the guide bars 5 Mechanical Installation Concertor 6020 Installation Operation and Maintenance Manual 21 ...

Page 24: ...semipermanent wet well arrangement with hose coupling or flange for connection to the discharge pipeline 1 Install the discharge connection on the pump For more information see the separate accessories documentation WS009897A 2 Attach a permanent lifting device to the pump For example use a stainless steel lifting chain with shackles 3 Make sure that the sump bottom is aligned horizontally 4 Put t...

Page 25: ... cable Make sure that the cable cannot be sucked into the pump inlet and that it is not sharply bent or pinched 8 Connect the motor cable according to the separate instructions Clean all the debris from the sump before the pump is started 5 3 4 Install the gateway Snap the unit onto the DIN rail WS009751A 5 Mechanical Installation Concertor 6020 Installation Operation and Maintenance Manual 23 ...

Page 26: ...explosion if the electrical connections are not correctly carried out or if there is fault or damage on the product Visually inspect equipment for damaged cables cracked casings or other signs of damage Make sure that electrical connections have been correctly made WARNING Crush Hazard Risk of automatic restart CAUTION Electrical Hazard Prevent cables from becoming sharply bent or damaged Permanen...

Page 27: ... fault protection device to the grounded earthed connectors if persons are likely to come into contact with liquids that are also in contact with the pump or pumped liquid Time to zero energy state This product contains high voltage capacitors that take time to discharge after the power supply is disconnected Voltage is present at the terminals and in the motor control unit for up to one minute af...

Page 28: ...e cables must be run so that they cannot be sucked into the unit The cables must comply with the local regulations A screened SUBCAB cable must be used between the pump and the gateway For more information contact the sales and service representative Electromagnetic compatibility Make sure that the equipment or system in which the product is incorporated complies with the electromagnetic compatibi...

Page 29: ...hose over the ground earth core Leave a short piece uncovered c If applicable put a cable lug on the screened ground core d Twist all power core screens together to create a ground earth core and fit a cable terminal to the end e Check that the ground earth core is at least 10 longer than the phase cores in the cabinet 4 How is the connection to ground earth made Screw Fit cable terminals to the g...

Page 30: ...a sum alarm when the pump fails The contact is normally closed 2 Isolate T3 and T4 Concertor EA Concertor DP 1 Isolate T1 and T2 2 Connect T3 and T4 to the gateway 2 Connect the drain wire to functional ground earth 3 Connect the mains leads L1 L2 L3 and ground earth To prevent uncontrolled running of the pump if monitoring equipment failure occurs a contactor is recommended 4 Connect the uncovere...

Page 31: ...e separate documentation Cable Terminal Pump run DI1 DI1 is high Pump active DI1 is low Pump inactive Reference power AI 4 20 mA 4 mA Minimum power 20 mA Set power Alarm reset DI2 External Hand Off Auto control Hand on DI3 is high and DI4 is low Hand off DI3 is low and DI4 is high Auto DI3 is low and DI4 is low Pump run feedback DO1 Sum alarm A DO2 Sum alarm B DO3 Pump cleaning in progress DO4 Act...

Page 32: ...ound continuity WS009786A Symbols and denominations WS009787A GENERAL SYMBOLS AND DENOMINATIONS Screen Cable lead colors and marking Motor cable Control cores T1 WH T2 WH T3 WH T4 WH L1 BN L2 BK L3 GY Stator leads U1 RD V1 BN W1 YE BN Brown BK Black WH White OG Orange GN Green SUBCAB AWG CSA GC Ground check GNYE Green Yellow RD Red GY Grey BU Blue YE Yellow Ground Functional ground Leakage sensor ...

Page 33: ...round 4 Leakage sensor 5 Terminal block 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 6 Electrical Installation Concertor 6020 Installation Operation and Maintenance Manual 31 ...

Page 34: ...ection with swimming pools then special safety regulations apply Noise level NOTICE The sound power level of the product is lower than 70 dB A However in some installations the resulting sound pressure level may 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 ...

Page 35: ...ster accessible through the fieldbus with Modbus RTU protocol 7 3 2 Service in case of alarm Before any action is taken always use the Dirigo Service Tool application or a gateway together with an HMI to analyze the alarms Alarm source Action FLS 1 Check for liquid in the stator housing 2 If any drain all the liquid 3 If liquid was found check the mechanical seal unit the O rings and the cable ent...

Page 36: ...ted before you open any vent or drain valves remove any plugs or disassemble the unit 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 Precautions for handling permanent magnet motors WARNING Magnetic Hazard Magn...

Page 37: ...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 class M4 M5 M6 M8 M10 M12 M16 M20 M24 M30 50 1 0 0 74 2 0 1 5 3 0 2 2 8 0 5 9 15 11 27 20 65 48 127...

Page 38: ...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 Electrical connections Check that the connections are properly secured Electrical cabinets Check that they are clean and dry Impeller 1 Check the clearance 2 If necessary adjust Stator housing Drain any liquid For more information see Drain the liquid...

Page 39: ...earings For a major overhaul do the following in addition to the tasks listed under Inspection Service item Action Support and main bearing Replace the bearings with new bearings Mechanical seal Replace with new seal units 8 3 Drain the liquid from the stator housing 1 WS009970A Item Label Description 1 INSP Inspection plug for inspection and drainage Figure 5 Inspection plug 1 Remove the inspecti...

Page 40: ...r the oil refill Figure 6 Oil plugs Empty the oil CAUTION Compressed Gas Hazard Air inside the chamber may cause parts or liquid to be propelled with force Be careful when opening Hold a rag over the plug to prevent liquid from spraying out 1 Put the pump in a horizontal position so that OIL OUT faces upwards and unscrew the oil plug 8 Maintenance 38 Concertor 6020 Installation Operation and Maint...

Page 41: ...FDA Sec 172 878 a requirements The viscosity must be close to VG32 These oil types are suitable Statoil MedicWay 32 BP Enerpar M 004 Shell Ondina 927 Shell Ondina X430 1 Replace the O rings of the oil plugs 2 Turn the pump so that OIL OUT faces upwards 3 Refit and tighten the oil plug OIL OUT Tightening torque 44 Nm 33 ft lb 8 Maintenance Concertor 6020 Installation Operation and Maintenance Manua...

Page 42: ...IN faces upwards 5 Fill with oil Quantity approximately 1 L 1 quarts WS009852A 6 Refit and tighten the oil plug OIL IN Tightening torque 44 Nm 33 ft lb WS009853A 8 Maintenance 40 Concertor 6020 Installation Operation and Maintenance Manual ...

Page 43: ... Washers are not used for all configurations 7 Screws 8 5 1 Remove the impeller 1 Remove the pump housing 2 Remove the impeller a Loosen the impeller screw b Remove the impeller Use the impeller screw to push the impeller c Remove the impeller screw the washer and the sleeve 8 5 2 Install the impeller 1 Before installation of the impeller push the sleeve to check that it moves freely up and down W...

Page 44: ...e surplus grease from conical and or cylindrical surfaces of shafts and or sleeves 3 Put the pump housing in an upright position 4 Put the impeller in the insert ring 5 Install the clamping sleeve washer and impeller screw on the shaft Do not tighten the screw 6 Install the drive unit a Suspend the drive unit in the lifting handle b Lower the drive unit until it sits on top of the pump housing Mak...

Page 45: ...tate freely WARNING Crush Hazard Beware of the pinch point hazard between the rotating impeller and the guide pin 11 Use an extended feeler gauge to make sure that the impeller clearance is 0 1 0 7 mm 0 004 0 028 in WS009859A 8 Maintenance Concertor 6020 Installation Operation and Maintenance Manual 43 ...

Page 46: ... The STOP function does not remove the voltages 9 1 The pump does not start DANGER Crush Hazard Moving parts can entangle or crush Always disconnect and lock out power before servicing to prevent unexpected startup Failure to do so could result in death or serious injury WARNING Electrical Hazard The permanent magnet motor generates voltage when the shaft rotates even if power sources are disconne...

Page 47: ...Hazard The permanent magnet motor generates voltage when the shaft rotates even if power sources are disconnected Never perform any electrical work if the shaft could rotate Cause Remedy The FLS triggers the sum alarm because of leakage into the drive unit Check that the FLS triggers the sum alarm 1 Turn off and on the power to start the pump again 2 If the pump runs for 10 seconds and then stops ...

Page 48: ...again Check the following The distance between the start and stop levels is sufficient The non return valves work correctly The length of the discharge pipe between the pump and the first non return valve is sufficiently short The self holding function of the contactor malfunctions Check the following The contactor connections The voltage in the control circuit in relation to the rated voltages on...

Page 49: ...e impeller is trimmed correctly The pipes are obstructed To make sure that there is a free flow clean the pipes The pipes and joints leak Find the leaks and seal them There are signs of wear on the impeller pump and casing Replace the worn parts The liquid level is too low Check that the level sensor is set correctly Depending on the installation type provide equipment for the pump priming for exa...

Page 50: ...ta Description Liquid temperature Maximum 40 C 104 F Liquid density Maximum 1100 kg m3 9 2 lb per US gal pH of the pumped liquid 5 5 14 Depth of immersion Maximum 20 m 65 ft 10 2 The gateways 10 2 1 Dimensions RS485 DI 1 2 3 4 GND A AI AO HMI 1 2 3 4 5 B GND 24VDC _ _ _ PWR DI1 DI2 DI3 DI4 DO1 DO2 DO3 DO4 ALARM A ALARM B PUMP RUN CLEAN PUMP COMMS RS485 USB NODE ADDRESS ON OFF MASTER SLAVE TERM PUM...

Page 51: ... 48 5 US B NODE AD DR ES S ON OFF MAS TE R SL AV E TERM PU MP DO 1 NO CO M NO CO M T4 T3 GND DO 2 DO 3 NO CO M NO CO M DO 4 ET HE RN ET Conc ertor FP G411 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 1 2 4 5 3 6 14 WS009749A Section Terminal Description 1 NODE ADDRESS Node address 1 10 rotary switch 2 TERM 120 ohm termination on or off switch 3 USB Standard type A USB socket 4 MASTER SLAVE Switch for master ...

Page 52: ...250 VAC 5 A External fuse required 5 A COM 11 NO DO1 Potential free relay output Maximum 250 VAC 5 A External fuse required 5 A COM NO DO2 Potential free relay output Maximum 250 VAC 5 A External fuse required 5 A COM 12 T4 PUMP Pump interface RS485 T3 GND 13 Ethernet 14 Backplane bus DeviceNet 10 2 6 Source code BSD License for U8glib Code Universal 8bit Graphics Library http code google com p u8...

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Page 56: ...e 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 Refer to www xylemwatersolutions com contacts for contact details of your local sales and service representative Xylem Water Solutions Global Services...

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