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Xylem FLYGT Concertor, Installation, Operation And Maintenance Manual

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Xylem FLYGT Concertor Installation, Operation And Maintenance Manual Download Page 14

WS009767B

8

10

11

12

13

9

5

4

3

14

2

1

6

7

Figure 2: Outer casing of drive unit: 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
/ outer casing

6

Connection housing with integrated control system

7

Lifting handle

8

Cable entry

9

Support bearing

10

Shaft unit with a permanent magnet rotor

11

Main bearing

3  Product Description

12

6020.180/090 Installation, Operation, and Maintenance Manual

Summary of Contents for FLYGT Concertor

Page 1: ...Installation Operation and Maintenance Manual 886211_9 0 6020 180 090 Concertor...

Page 2: ......

Page 3: ...uct denomination 15 4 Mechanical Installation 17 4 1 Precautions 17 4 2 Requirements 18 4 3 Make the mechanical installation 18 4 3 1 Prepare the site new P installation 18 4 3 2 Install the pump P in...

Page 4: ...ting 47 8 1 Dirigo Service Tool 47 8 2 The pump does not start 50 8 3 The impeller does not rotate 51 8 4 The pump starts but stops after 10 seconds 51 8 5 The pump stops 52 8 6 The pump does not rece...

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 im...

Page 6: ...equirements for Ex approved products in potentially explosive atmospheres All work on the product must be carried out by certified electricians and Xylem authorized mechanics Special rules apply to in...

Page 7: ...approved Xylem representative When you install or maintain explosion proof products always comply with the directive and applicable standards for example IEC EN 60079 14 Minimum permitted liquid leve...

Page 8: ...of emissions to the appropriate authorities Sorting recycling and disposal of solid or liquid waste Clean up of spills Exceptional sites CAUTION Radiation Hazard Do NOT send the product to Xylem if it...

Page 9: ...representative 2 2 Transportation guidelines Precautions DANGER Crush Hazard Moving parts can entangle or crush Always disconnect and lock out power before servicing to prevent unexpected startup Fail...

Page 10: ...s below the freezing point The recommended method to warm the unit up is to submerge it in the liquid which will be pumped or mixed NOTICE Never use a naked flame to thaw the unit Unit in as delivered...

Page 11: ...y Before operating the unit after storage it must be inspected with special attention to the seals and the cable entry The impeller propeller must be rotated every other month to prevent the seals fro...

Page 12: ...ce on page 55 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 ap...

Page 13: ...Illustrations WS009987B 8 10 11 12 13 9 5 4 3 14 2 1 6 7 Figure 1 Outer casing of drive unit Gray iron 3 Product Description 6020 180 090 Installation Operation and Maintenance Manual 11...

Page 14: ...flush valve connection 3 Seal housing cover 4 Stator housing unit with a leakage sensor 5 Cooling jacket outer casing 6 Connection housing with integrated control system 7 Lifting handle 8 Cable entry...

Page 15: ...duct denomination on page 15 2 Product number 3 Additional information 4 CE marking 5 Read installation manual 6 Notified body only for EN approved Ex products 7 Duty class 8 Degree of protection 9 Th...

Page 16: ...on proof for use in Class I Div 1 Group C and D EN approval plate This illustration describes the EN approval plate and the information that is contained in its fields 1 2 3 5 6 7 8 9 10 11 12 13 14 W...

Page 17: ...M approval plate and the information that is contained in its fields 1 2 WS003973A 1 Temperature class 2 Maximum ambient temperature CSA approval plate This illustration describes the CSA approval pla...

Page 18: ...ber Indication Type of code a Sales denomination b Product code c Serial number Parameter 1 Hydraulic end 2 Type of installation 3 Sales code 4 Version 5 Production year 6 Production cycle 7 Running n...

Page 19: ...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 spe...

Page 20: ...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 c...

Page 21: ...to the pump For example use a stainless steel lifting chain with shackles 3 Lower the pump along the guide bars 4 Attach the permanent lifting device to the sump structure 5 Secure the motor cable Ma...

Page 22: ...that the sump bottom is aligned horizontally 4 Put the pump in position on the sump bottom Make sure that the pump cannot fall over or sink 5 Connect the discharge line to the discharge connection 6 A...

Page 23: ...n to the suction and discharge piping These items are required Shutoff valves Air vent on the discharge side between the pump and the check valve WS010232A 1 2 3 4 1 Discharge line 2 Suction line 3 Li...

Page 24: ...ng to the separate instructions 4 Make sure that the weight of the pump does not put strain on the piping 5 Bleed air through the air vent Clean all the debris from the sump before the pump is started...

Page 25: ...Connect the suction line and the discharge line d Install the holder and the optional service cart and rail system For more information see the separate accessories documentation 2 Connect the motor c...

Page 26: ...WARNING Electrical Hazard 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 Visually inspect eq...

Page 27: ...s at both ends of the cable WARNING Electrical Hazard Risk of electrical shock or burn You must connect an additional ground earth fault protection device to the grounded earthed connectors if persons...

Page 28: ...ust be insulated The 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 gate...

Page 29: ...T 2 T 3 T 4 Figure 4 Aluminum foil on control element b Put a white shrink hose over the drain wire and the cable terminal c Fit a cable lug on the drain wire d Twist T1 T2 and T3 T4 e Put a shrink h...

Page 30: ...th this unit NOTICE For insulation tests the test voltage must be maximum 250 V The resistance must be minimum 1 megohm Only measurements between phase and ground earth give valid results NOTICE The c...

Page 31: ...filter is used then connect the mains leads through the filter For more information see Electromagnetic compatibility on page 26 and separate documentation that is delivered with the filter 4 Connect...

Page 32: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 U V W V1 W1 U1 L3 L2 L1 BU BU FLS T1 T2 T3 T4 Shrink hose GNYE Screen as ground conductor Gateway Controller Connection WH WH WH WH PE Sum Alarm Earth Ground continu...

Page 33: ...hite Cable lead colors and marking Motor cable Stator leads L1 BN L2 BK L3 GY U1 RD V1 BN W1 YE Control cores T1 WH T2 WH T3 WH T4 WH RD Red GY Grey BU Blue YE Yellow GNYE Green Yellow Screen Ground F...

Page 34: ...standard Code Description BN Brown BK Black WH White OG Orange GN Green GNYE Green Yellow RD Red GY Grey BU Blue YE Yellow 5 Electrical Installation 32 6020 180 090 Installation Operation and Maintena...

Page 35: ...egulations 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...

Page 36: ...TU protocol 6 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 lea...

Page 37: ...ents to cool before you handle them Make sure that the product and its components have been thoroughly cleaned Make sure that the work area is well ventilated before you open any vent or drain valves...

Page 38: ...arkings are in line The reassembled drive unit must always be insulation tested and the reassembled pump must always be test run before normal operation 7 1 Torque values All screws and nuts must be l...

Page 39: ...eed 40 C 104 F 7 2 1 Inspection The list is valid for initial inspection and periodical inspection Service item Action Cable 1 If the outer jacket is damaged replace the cable 2 Check that the cables...

Page 40: ...l The basic repair kit includes O rings seals and bearings For an overhaul do the following in addition to the tasks listed under Inspection Service item Action Support and main bearing Replace the be...

Page 41: ...the oil refill Figure 10 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 Allow the chamber to...

Page 42: ...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...

Page 43: ...OIL IN faces upwards 5 Fill with oil Quantity 1 0 L 1 1 quarts WS009852A 6 Refit and tighten the oil plug OIL IN Tightening torque 22 Nm 16 ft lb WS009853A 7 Maintenance 6020 180 090 Installation Ope...

Page 44: ...allowed to make contact with the concrete floor or other hard and rough surfaces 1 2 3 4 5 6 7 8 WS009764B 1 Pump housing 2 Impeller 3 O ring 4 Impeller screw 5 Washer 6 Clamping sleeve 7 Washers Was...

Page 45: ...stallation WS010233B 1 2 3 4 1 Discharge line 2 Suction line 3 Line to drain 4 Drainage plug Figure 12 Z installation 1 Close the suction and discharge valves 2 Drain the pump 3 Remove the pump from t...

Page 46: ...screw the washer and the sleeve 7 5 3 Install the impeller 1 Before installation of the impeller push the sleeve to check that it moves freely up and down When the sleeve is released it must be fully...

Page 47: ...that the motor cable gland is turned away from the pump outlet c Tighten the drive unit to the pump housing 9 Suspend the pump in the lifting handle 10 Adjust the impeller a Put a rod through the out...

Page 48: ...T installation Bleed air through the air vent 7 Maintenance 46 6020 180 090 Installation Operation and Maintenance Manual...

Page 49: ...r up to one minute after the disconnection of the power supply The STOP function does not remove the voltages 8 1 Dirigo Service Tool Description Dirigo Service Tool is a software application with con...

Page 50: ...ormation The values that are typed are confirmed by pressing the Enter key on the PC Install the application and drivers 1 Contact the local sales and service representative for the latest version of...

Page 51: ...B port on the PC 4 Turn on the PC and start the software application See Run Dirigo Service Tool on page 49 Run Dirigo Service Tool Make sure to take all necessary precautions and to follow all applic...

Page 52: ...GER 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 E q u i...

Page 53: ...hat the impeller can be rotated Clean the impeller Clean the sump If the problem persists then contact a sales or authorized service representative Always state the product number and the serial numbe...

Page 54: ...art the controller 3 Check T3 and T4 If the problem persists then contact a sales or authorized service representative Always state the product number and the serial number of the product 8 6 The pump...

Page 55: ...ontactor or not The power supply is incorrect The sum alarm is active after ten cycles Contact a sales or authorized service representative or use the Dirigo Service Tool application to read the alarm...

Page 56: ...lve The Set Power or the Set Speed parameter is too low Change the settings For more information see the User Guide The impeller rotates in the incorrect direction The connections inside the connectio...

Page 57: ...rmittently running Maximum 10 Voltage imbalance between the phases Maximum of 2 Stator insulation class In accordance with class H 180 C 356 F 9 2 Application limits Data Description Liquid temperatur...

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Page 60: ...nologies and advanced analytics solutions for water electric and gas utilities In more than 150 countries we have strong long standing relationships with customers who know us for our powerful combina...

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