Related Manuals for Xylem FLYGT Concertor
Summary of Contents for Xylem FLYGT Concertor
- Page 1 Installation, Operation, and Maintenance Manual 886211_9.0 6020.180/090 ™ Concertor...
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Page 3: Table Of Contents
Table of Contents Table of Contents 1 Introduction and Safety......................3 1.1 Introduction.......................... 3 1.2 Safety terminology and symbols..................3 1.3 User safety..........................4 1.4 Ex-approved products......................4 1.5 Special hazards........................5 1.6 Protecting the environment....................6 1.7 Spare parts..........................6 1.8 Warranty..........................6 2 Transportation and Storage...................... 7 2.1 Examine the delivery...................... - Page 4 Table of Contents 6.3.2 Service in case of alarm....................34 7 Maintenance..........................35 7.1 Torque values........................36 7.2 Maintenance intervals....................... 37 7.2.1 Inspection........................37 7.2.2 Overhaul........................38 7.3 Drain the liquid from the stator housing.................38 7.4 Change the oil........................39 7.5 Replace the impeller: P, S, T, Z installations..............42 7.5.1 Remove the pump from the installation: T, Z installations........
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Page 5: Introduction And Safety
This includes any modification to the equipment or use of parts not provided by Xylem. If there is a question regarding the intended use of the equipment, please contact a Xylem representative before proceeding. -
Page 6: User Safety
These are the personnel 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 to installations in explosive atmospheres. • All users must know about the risks of electric current and the chemical and physical characteristics of the gas, the vapor, or both present in hazardous areas. -
Page 7: Special Hazards
• Do not modify the equipment without approval from an Ex-approved Xylem representative. • Only use original Xylem spare parts that are provided by an Ex-approved Xylem representative. • The thermal detectors that are fitted to the stator windings must be connected correctly to a separate motor control circuit and in use. -
Page 8: Protecting The Environment
• Clean-up of spills Exceptional sites CAUTION: Radiation Hazard Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless Xylem has been informed and appropriate actions have been agreed upon. 1.7 Spare parts CAUTION: Only use the manufacturer’s original spare parts to replace any worn or faulty... -
Page 9: Transportation And Storage
2 Transportation and Storage 2 Transportation and Storage 2.1 Examine the delivery 2.1.1 Examine the package 1. Examine the package for damaged or missing items upon delivery. 2. Record any damaged or missing items on the receipt and freight bill. 3. -
Page 10: Temperature Ranges For Transportation, Handling And Storage
• The minimum height between the lifting hook and the floor must be sufficient to lift the unit. Contact a Xylem representative for more information. • The lifting equipment must be able to hoist the unit straight up and down, preferably without the need for resetting the lifting hook. -
Page 11: Storage Guidelines
2 Transportation and Storage 2.4 Storage guidelines Storage location The product must be stored in a covered and dry location free from heat, dirt, and vibrations. NOTICE: Protect the product against humidity, heat sources, and mechanical damage. NOTICE: Do not place heavy weights on the packed product. Long-term storage If the unit is stored more than six months, then the following apply: •... -
Page 12: Product Description
3 Product Description 3 Product Description Products included Product Approvals 6020.180 Standard 6020.090 Ex-approved 3.1 Pump design The pump is submersible, and driven by a control system that is connected to a permanent-magnet synchronous motor. For motor data, see Technical Reference on page Intended use The product is intended for moving waste water, sludge, raw and clean water. - Page 13 3 Product Description Illustrations Figure 1: Outer casing of drive unit: Gray iron 6020.180/090 Installation, Operation, and Maintenance Manual...
- Page 14 3 Product Description Figure 2: Outer casing of drive unit: Aluminum Parts Position Part Insert ring with a guide pin Pump housing, without flush valve connection Seal housing cover Stator housing unit with a leakage sensor Cooling jacket / outer casing Connection housing with integrated control system Lifting handle Cable entry...
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Page 15: Monitoring Equipment
3 Product Description Position Part Mechanical seal Plug in seal with active seal design. Adaptive-N impeller Pressure class, discharge connection LT/150 Low head MT/100 Medium head HT/80 High head 3.2 Monitoring equipment • Leakage sensor in the stator housing (FLS) •... -
Page 16: Approvals
3 Product Description 3.4 Approvals Product approvals for hazardous locations Pump Approval 6020.090 European Norm (EN) • ATEX Directive • EN 60079-0:2012/A11:2013, EN 60079-1:2014, EN 13463-1:2009, EN 13463-5:2011 • II 2 G c Ex db IIB T4 Gb • IECEx scheme •... -
Page 17: Product Denomination
3 Product Description 1. Approval 2. Approval authority and Approval number 3. Approved for 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 ambient temperature 13.Serial number... - Page 18 3 Product Description Codes and parameters XXYYYY YYY YYY YYYY Type of Callout Number Indication Type of code Sales denomination Product code Serial number Parameter Hydraulic end Type of installation Sales code Version Production year Production cycle Running number 6020.180/090 Installation, Operation, and Maintenance Manual...
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Page 19: Mechanical Installation
4 Mechanical Installation 4 Mechanical Installation 4.1 Precautions General precautions Before starting work, make sure that the safety instructions in the chapter Introduction and Safety on page 3 have been read and understood. Electrical precautions DANGER: Electrical Hazard Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. -
Page 20: Requirements
4 Mechanical Installation 4.2 Requirements General requirements • Use the dimensional drawing to make sure that the installation is correct. • Always remove all debris and waste materials from the sump and piping before installation. Piping requirements NOTICE: Never force piping to make a connection with a pump. 4.3 Make the mechanical installation 4.3.1 Prepare the site: new P-installation For more information, see the separate accessories documentation. -
Page 21: Install The Pump: P-Installation
4 Mechanical Installation 4.3.2 Install the pump: P-installation P Semipermanent, wet well arrangement with the pump installed on two guide bars. The connection to the discharge is automatic. 1. Install the sliding bracket unit on the pump. For more information, see the separate accessories documentation. 2. -
Page 22: Install The Pump: S-Installation
4 Mechanical Installation 4.3.3 Install the pump: S-installation S Portable semipermanent, wet well arrangement with hose coupling or flange for connection to the discharge pipeline. 1. Install the discharge connection unit on the pump. For more information, see the separate accessories documentation. 2. -
Page 23: Install The Pump: T-Installation
4 Mechanical Installation 4.3.4 Install the pump: T-installation T Vertical permanent, dry well arrangement with flange connection 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 1. -
Page 24: Install The Pump: Z-Installation
4 Mechanical Installation NOTICE: The risk of freezing is particularly high in T- or Z-installations. 1. Install the pump: a) Bolt the pipe suction unit to the concrete base. b) Bolt the pump to the pipe suction unit. For more information, see the separate accessories documentation. 2. - Page 25 4 Mechanical Installation 3. Line to drain 4. Drainage plug NOTICE: The risk of freezing is particularly high in T- or Z-installations. 1. Install the pump: Make sure that the drainage plug faces downwards. a) Bolt the suction connection to the concrete base. b) Bolt the pump to the suction connection.
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Page 26: Electrical Installation
5 Electrical Installation 5 Electrical Installation 5.1 Precautions General precautions Before starting work, make sure that the safety instructions in the chapter Introduction and Safety on page 3 have been read and understood. Electrical precautions DANGER: Electrical Hazard Before starting work on the unit, make sure that the unit and the control panel are isolated from the power supply and cannot be energized. -
Page 27: Requirements
5 Electrical Installation DANGER: Inhalation Hazard Before entering the work area, make sure that the atmosphere contains sufficient oxygen and no toxic gases. 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 explosion- proof or intrinsically-safe. -
Page 28: Make The Electrical Connections
5 Electrical Installation NOTICE: Do not use Variable Frequency Drive (VFD) with this unit. NOTICE: Do not use any type of soft start equipment with this unit. Cable requirements NOTICE: Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the cable ends dry at all times. - Page 29 5 Electrical Installation 1. T1+T2 and T3+T4 twisted pairs in control element 2. Drain wire in control element (bare aluminum wire) 3. Screened aluminum pt-foil 4. Insulation sheath (jacket) for control element 5. Power cores 6. Aluminum foil 7. Ground (earth) core with green/yellow shrink hose 8.
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Page 30: Connect The Motor Cable To The Pump
5 Electrical Installation – Screw: Fit cable terminals to the ground (earth) core and the power cores. – Terminal block: Leave the core ends as they are. 5. Prepare the main leads: a) Remove the aluminum foil around each power core. b) Peel the insulation from each power core. -
Page 31: Cable Charts
5 Electrical Installation Type of installation Connections Pump with gateway or controller 1. For a standard pump, isolate T1 and T2. 2. For an Ex-approved pump, connect T1 and T2 to the external controller. 3. Connect T3 and T4 to the gateway. 2. - Page 32 5 Electrical Installation 6020.090 U, V, W 1 - 15 6020.020 L1, L2, L3 (2x) 791 48 01_12 Figure 6: Explosion-proof version Connections Connection V1 W1 Earth/Ground continuity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 U V W Screen as ground conductor...
- Page 33 5 Electrical Installation Connection V1 W1 Earth/Ground continuity U V W 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Screen as ground conductor Shrink hose GNYE T3 T4 T1 T2 Gateway / Controller Sum Alarm Figure 8: Explosion-proof version Symbols and denominations...
- Page 34 5 Electrical Installation Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Grey Blue Yellow 6020.180/090 Installation, Operation, and Maintenance Manual...
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Page 35: Operation
6 Operation 6 Operation 6.1 Precautions Before taking the unit into operation, check the following: • All recommended safety devices are installed. • The cable and cable entry have not been damaged. • All debris and waste material has been removed. NOTICE: Never operate the pump with the discharge line blocked, or the discharge valve closed. -
Page 36: Alarm Handling
6 Operation WARNING: Crush Hazard Never put your hand into the pump housing. 2. Turn on the power supply for the system. Make sure that the external controller, the gateways, and the pump receive power. The pump runs at preset values. For more information about the operation of the system, see the System Installation and Operation Manual. -
Page 37: Maintenance
7 Maintenance 7 Maintenance Precautions Before starting work, make sure that the safety instructions in the chapter Introduction and Safety on page 3 have been read and understood. DANGER: Crush Hazard Moving parts can entangle or crush. Always disconnect and lock out power before servicing to prevent unexpected startup. -
Page 38: Torque Values
7 Maintenance CAUTION: Crush Hazard The rotor is a permanent magnet. Do not use tools which can be attracted to magnetic fields near the rotor, and do not allow the rotor to come near steel items. Assembly and disassembly of permanent magnet synchronous motors must be performed by qualified personnel and according to relevant instructions. -
Page 39: Maintenance Intervals
7.2 Maintenance intervals Type of Purpose Inspection interval maintenance Initial inspection A Xylem-authorized personnel checks the pump condition. Within the first year of From the results, the personnel recommends the intervals for operation. the periodical inspection and overhaul for the installation. Periodical... -
Page 40: Overhaul
7 Maintenance Service item Action Corrosion Check for corrosion and paint damages. If necessary, touch up. If applicable, install zinc anodes. Zinc anodes If applicable, replace the zinc anodes. Anodes are replaced when the anode mass is reduced to a selected fraction of its initial mass. -
Page 41: Change The Oil
7 Maintenance 3. Replace the O-ring and install the inspection plug. Tightening torque: 22 Nm (16 ft-lb). 7.4 Change the oil Item Label Description OIL OUT Oil plug for the oil drainage OIL IN Oil plug for the oil refill Figure 10: Oil plugs Empty the oil CAUTION: Compressed Gas Hazard... - Page 42 7 Maintenance 2. Put a container under the pump and turn the pump. Remove the oil plug, OIL IN, to simplify the process. Fill with oil The oil must be a medical white oil of paraffin type that fulfills FDA Sec. 172.878 (a) requirements.
- Page 43 7 Maintenance 4. Turn the pump so that OIL IN faces upwards. 5. Fill with oil. Quantity: 1.0 L (1.1 quarts) 6. Refit and tighten the oil plug, OIL IN. Tightening torque: 22 Nm (16 ft-lb) 6020.180/090 Installation, Operation, and Maintenance Manual...
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Page 44: Replace The Impeller: P, S, T, Z Installations
7 Maintenance 7.5 Replace the impeller: P, S, T, Z installations CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. NOTICE: When laying the pump on its side, do not allow the weight of the pump to rest on any portion of the impeller. - Page 45 7 Maintenance 1. Discharge line 2. Suction line 3. Line to drain 4. Air vent Figure 11: T installation 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.
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Page 46: Remove The Impeller
7 Maintenance 7.5.2 Remove the impeller 1. Put the pump in a horizontal position on the workbench. 2. Loosen the impeller screw until the impeller is free from the clamping sleeve. Prevent the impeller from rotating. Insert a rod through the pump housing outlet. 3. - Page 47 7 Maintenance NOTICE: Surplus grease can cause the impeller to become loose. Remove surplus grease from conical and/or cylindrical surfaces of shafts and/or sleeves. 3. Lubricate the shaft and the impeller screw. 4. Install the clamping sleeve, washer, and impeller screw on the shaft. Do not tighten the screw.
- Page 48 7 Maintenance T installation: Bleed air through the air vent. 6020.180/090 Installation, Operation, and Maintenance Manual...
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Page 49: Troubleshooting
8 Troubleshooting 8 Troubleshooting Introduction DANGER: Electrical Hazard Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical troubleshooting must be done by a qualified electrician. Follow these guidelines when troubleshooting: • Disconnect and lock out the power supply except when conducting checks that require voltage. - Page 50 8 Troubleshooting The software application The interface consists of drop-down menus and tabs. The menus are used for application settings and maintenance. The tabs are used for the monitoring and control of the pump. Overview Control The tab contains quick control buttons and shows the current operation.
- Page 51 8 Troubleshooting 1. Turn off and lock out the power supply to the pump. 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. 2.
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Page 52: The Pump Does Not Start
8 Troubleshooting WARNING: Crush Hazard Risk of automatic restart. If the communication fails and the unit continues to operate, then turn off the power supply to the pump. For more information, see Troubleshooting on page 47. 4. Use the software application interface to read and write data. The software application on page 48. -
Page 53: The Impeller Does Not Rotate
8 Troubleshooting Always state the product number and the serial number of the product. 8.3 The impeller does not rotate 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. -
Page 54: The Pump Stops
8 Troubleshooting Cause Remedy The FLS triggers the sum alarm because of leakage into Check that the FLS triggers the sum alarm: the drive unit. 1. Turn off and on the power to start the pump again. 2. If the pump runs for 10 seconds and then stops, then disconnect the pump and empty the liquid from the drive unit. -
Page 55: The Pump Delivers Too Little Or No Water
8 Troubleshooting WARNING: Electrical 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 pump starts due to back-flow. The Check the following: back-flow fills the sump to the start •... -
Page 56: Dirigo ™ Service Tool: The Communication With The Unit Fails
8 Troubleshooting Cause Remedy One or more of the valves are set in • Reset the valves that are set in the incorrect position. the incorrect positions. • If necessary, replace the valves. • Check that all the valves are installed correctly according to the media flow. -
Page 57: Technical Reference
9 Technical Reference 9 Technical Reference 9.1 Motor data The drive unit includes a synchronous motor with IE4 equivalent efficiency. NOTICE: Do not connect a starter or a Variable Frequency Drive (VFD) to this unit. Feature Description Input frequency 50–60 Hz Input supply 3-phase •... - Page 60 For more information on how Xylem can help you, go to www.xylem.com Xylem Water Solutions Global Visit our Web site for the latest version of this document...