Xylem Flygt 3069 Installation, Operation And Maintenance Manual
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Xylem Flygt 3069 Installation, Operation And Maintenance Manual

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Installation, Operation, and
Maintenance Manual
885842_25.0
Flygt 3069

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Summary of Contents for Xylem Flygt 3069

  • Page 1 Installation, Operation, and Maintenance Manual 885842_25.0 Flygt 3069...

  • Page 3: Table Of Contents

    4.2.5 Connect the motor cable to the starter and monitoring equipment....... 25 4.2.6 Cable charts......................26 4.3 Check the impeller rotation..................35 5 Operation........................... 36 5.1 Precautions........................36 5.2 Estimate zinc anode replacement intervals..............36 5.3 Start the pump......................37 Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 4 7.5 The pump runs but the motor protection trips..............59 7.6 The pump delivers too little or no water...............60 8 Technical Reference......................61 8.1 Motor data........................61 8.1.1 Thermal contacts, opening temperature............... 61 8.2 Application limits......................61 8.3 Minimum permitted liquid level..................61 Flygt 3069 Installation, Operation, and Maintenance Manual...

  • 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 • 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 width of flameproof joints is more than the values specified in the tables of the EN/ IEC 60079-1 standard.

  • Page 8: Special Hazards

    • 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 End-of-life product disposal Handle and dispose of all waste in compliance with local laws and regulations.

  • Page 9: Spare Parts

    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. 1.9 Warranty For information about warranty, see the sales contract. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 10: Transportation And Storage

    Never lift the unit by its cables or hose. Lifting points The following images show the lifting points for the different installation types. For more Installation information about the installation types, see on page 18. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 11 • 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 12: Temperature Ranges For Transportation, Handling And Storage

    • Before operating the unit after storage, it must be inspected. Special attention must be given to the seals and the cable entry. • The impeller or propeller must be rotated every other month to prevent the seals from sticking together. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 13 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. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 14: Product Description

    Corrosive liquids NOTICE: Do NOT use the unit in highly corrosive liquids. Pressure classes Low head Medium head High head Super high head Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 15: Sensors And Monitoring Equipment

    Support bearing Single-row deep-groove ball bearing — Screws and Property class 80 nuts Torque values on page 39. 3.2 Sensors and monitoring equipment The following applies to the monitoring equipment of the pump: Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 16: The Data Plate

    25. WEEE-Directive symbol 26. UKCA marking Figure 4: The data plate 3.4 Motor regulation This product is submersible and therefore exempted from the motor efficiency requirement, in accordance with EU commission regulation 2019/1781 Article 2(2)(e). Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 17: Approvals

    12. Maximum ambient temperature 13. Serial number 14. ATEX marking 15. Country of origin WS003972C IEC approval plate This illustration describes the IEC approval plate and the information that is contained in its fields. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 18: Product Denomination

    12. Maximum ambient temperature 13. Serial number 14. UKEx marking 15. Country of origin WS013146A 3.6 Product denomination Reading instruction In this section, code characters are illustrated accordingly: X = letter Y = digit Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 19 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 Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 20: Installation

    The maximum working pressure must not exceed the value in the approved performance curve for the pump. A closed valve or a clogged pipe can rapidly build up the pressure. A motor protector or a relief valve on the discharge line is always recommended. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 21: Install The Pump

    3. Connect the motor cable and the starter and monitoring equipment according to the separate instructions. 4.1.2.1 F-installation F Free standing semipermanent, wet well arrangement where the pump is placed on a firm surface. The pump is intended to operate completely submerged in the pumped liquid. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 22 4.1.2.3 P-installation P Semipermanent, wet well arrangement with the pump installed on two guide bars. The connection to the discharge is automatic. The pump is intended to operate completely submerged in the pumped liquid. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 23: Make The Electrical Connections

    Visually inspect equipment for damaged cables, cracked casings or other signs of damage. Make sure that electrical connections have been correctly made. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 24 • The cables must not be damaged and must not have indentations. • The cables must not be embossed at the cable entry. • The cable entry seal sleeve and washers must conform to the outer diameter of the cable. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 25: Grounding (Earthing)

    (earthed) connectors if persons are likely to come into contact with liquids that are also in contact with the pump or pumped liquid. 4.2.3 Prepare the SUBCAB ™ cables ™ This section applies to SUBCAB cables with twisted-pair control conductors. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 26 Untwist the screens around the power conductors. b) Twist all power conductor screens together to create a ground (earth) conductor. c) Put a yellow-green shrink tube over the ground (earth) conductor. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 27: Connect The Motor Cable To The Pump

    If the product is rated explosion-proof or intrinsically-safe, then see the specific explosion-proof information in the safety chapter before taking any further actions. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 28: Cable Charts

    This topic contains general connection information. It also provides cable charts that show connection alternatives for use with different cables and power supply. T1 T2 Figure 6: Phase sequence Connection locations The figures in this section illustrate how to interpret the connection strip symbols. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 29 9. Thermistor 10. Level sensor 11. Capacitor 12. Crimp connection 13. Crimp isolation 14. Current transformer FLS 10 Color code standard Code Description Brown Black White Orange Green GNYE Green-Yellow Grey Blue Yellow Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 30 • 3-phase connection on page 28 1-phase connection • on page 32 Sensors connection • on page 33 Screened cable connection • on page 33 4.2.6.3 3-phase connection 3 Leads U1 V1 W1 Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 31 U1 V1 W1 W2 U2 V2 L1 L2 L3 L3:1 L2:1 L1:1 U1 V1 W1 W2 U2 V2 L3:2 L2:2 L1:2 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 L1 L2 L1 L2 L3 Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 32 4 Installation 9 Leads U1 V1 W1 U5 V5 W5 U2 W2 U1 V1 W1 U1 V1 W1 L1 L2 Y-SER U5 U2 V1 V5 V2 W1 W5 W2 Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 33 U1 V1 W1 W2 U2 V2 Y-SER U1 V1 W1 W2 U2 V2 W5 U5 V5 U6 W6 U1 V1 W1 W2 U2 V2 U1 V1 W1 W2 U2 V2 D-SER 460V 230V WS004128C Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 34 4 Leads Starter 4 Leads with level regulator U1 Z1 Starter 12 Leads U1 V1 U6 Starter Figure 8: Without built-in starter Colors and markings of leads For more information, see on page 28. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 35 SUBCAB Control SUBCAB AWG Screenflex screened WH T1 WH T1 WH T2 WH T2 WH T3 WH T4 *If Y/D-start, sensors not connected (Thermal Contacts) WH/YE Control leads T1/*OG/4 WH/YE T2/*OG/5 *SUBCAB AWG Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 36 For non Ex-pumps: Temp > 40° T1,T2 thermal contacts not connected WH/YE WH/YE 4.2.6.6 Sensor connection characteristics The values have a 10% tolerance. Sensors Value (mA) Definition FLS and thermal contact Overtemperature Leakage Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 37: Check The Impeller Rotation

    – If the motor has a 1-phase connection, then contact a sales or authorized service representative. – If the motor has a 3-phase connection, then transpose two phase leads and do this procedure again. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 38: Operation

    2. After two months, remove and weigh the same zinc anode or anodes again. 3. Divide the lapsed time in days (between steps 1 and 2) by the anode weight loss in grams to get the calculated anode consumption rate (days/gram). Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 39: Start The Pump

    Never put your hand into the pump housing. 3. Conduct insulation test phase to ground. To pass, the value must exceed 5 megaohms. 4. Check that the monitoring equipment works. 5. Start the pump. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 40: Maintenance

    • Lubricate all springs, screws, O-rings with grease. During the reassembly, always make sure that existing index markings are in line. The reassembled drive unit must always be insulation-tested and the reassembled pump must always be test-run before normal operation. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 41: Torque Values

    The torque values are only valid for the set screw, and not for the round nut. 18 (13) 35 (26) 6.4 Change the oil This image shows the plug that is used to change the oil. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 42 Allow the chamber to de-pressurize before removal of the plug. 1. Put the pump in a horizontal position and unscrew the oil plug. 2. Put a container under the pump and turn the pump. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 43 D-ARV* DN 50 0.5 (0.13) 3069.090 DN 50 0.5 (0.13) 3069.090 DN 65 0.4 (0.1) 3069.090 DN 65/80 0.4 (0.1) 3069.090 DN 40 0.4 (0.1) 3069.090 D-ARV* DN 50 0.4 (0.1) *Abrasion-resistant version Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 44: Service The Pump

    They can include such media (liquid) temperatures things as impeller trimming, wear part control and <40°C (104°F). replacement, control of zinc-anodes and control of the stator. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 45: Inspection

    Normally closed circuit; interval 0–1 ohm. Voltage and amperage Check the running values. 6.5.2 Overhaul The basic repair kit includes O-rings, seals, and bearings. For an overhaul, do the following in addition to the tasks listed under Inspection. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 46: Service In Case Of Alarm

    Check the start and stop levels. The overload protection Check that the impeller can rotate freely. 6.6 Replace the D-impeller 1. Screws 2. Suction cover 3. Impeller screw 4. Impeller 5. Sleeve Figure 9: Standard variant Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 47: Remove The D-Impeller

    Coat the inner conic and the outer cylindrical surfaces of the sleeve with a thin layer of grease. The correct lubrication is grease for bearings, for example Exxon Mobil Unirex N3, Mobil Mobilith SHC 220 or equivalent. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 48: Replace The F-Impeller

    – For the abrasive resistant variant, install the pump housing. Tighten the screws. 6.7 Replace the F-impeller 1. Nuts 2. Suction cover 3. Seal sleeves 4. Studs 5. Impeller screw 6. Impeller 7. Sleeve Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 49: Remove The F-Impeller

    Prevent the impeller from rotating. Torque values For tightening torque, see on page 39. 3. Install the suction cover: a) Fit the studs on the pump housing. Use Loctite 603 locking liquid to secure the studs. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 50: Replace The M-Impeller And The Cutting Wheel

    Raise the pump to an upright position. b) Check that the impeller can rotate freely. If necessary, then loosen the nuts. c) Measure the clearance. Final clearance: 0.2–0.8 mm (0.008–0.03 in) 6.8 Replace the M-impeller and the cutting wheel Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 51: Remove The Cutting Wheel

    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. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 52 Tightening torque: 22 Nm (16 lbf·ft) i) Tighten the screw a further 1/8 turn (45°). j) Check that the impeller can rotate freely. 3. Measure the clearance. Final clearance: 0.1–0.5 mm (0.004–0.02 in) Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 53: Install The Cutting Wheel

    0.25 mm (0.010 in) for at least one of the wings. e) When the clearance is correct, tighten the set screw. Tightening torque: 55 Nm (41 lbf·ft) 6.9 Replace the N-impeller CAUTION: Cutting Hazard Worn parts can have sharp edges. Wear protective clothing. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 54: Remove The N-Impeller

    2. Remove and discard the impeller screw. 3. Insert a hexagon wrench and turn the adjustment screw clockwise until the impeller comes loose from the shaft and the adjustment screw is free from the threaded hole. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 55: Install The N-Impeller

    When the sleeve is released, it must be fully pushed out again. If the sleeve does not move freely, or does not come fully out, then replace the impeller unit. 2. Adjust the adjustment screw in the new impeller. The correct position is at the bottom without any tightening. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 56 4. Install the impeller sleeve and the impeller onto the shaft. 5. Fit the suction cover and tighten the screws. Point the guide pin towards the outlet. Torque values For tightening torque, see on page 39. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 57 When the sleeve is released, it should be fully pushed out again. If the sleeve does not move freely, or does not come fully out, then replace the impeller unit. 9. Check with a feeler gauge that the impeller clearance is 0.1–0.6 mm (0.004–0.02 in). Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 58 6 Maintenance Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 59: Troubleshooting

    • The start level regulator is functioning. Clean or replace if manually. necessary. • All connections are intact. • The relay and contactor coils are intact. • The control switch (Man/Auto) makes contact in both positions. Check the control circuit and functions. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 60: The Pump Does Not Stop When A Level Sensor Is Used

    • The distance between the start and stop levels is sufficient. level again. • The non-return valve(s) work(s) properly. • The length of the discharge pipe between the pump and the first non-return valve is sufficiently short. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 61: The Pump Runs But The Motor Protection Trips

    There is a malfunction in the Replace the overload protection. overload protection. If the problem persists, then contact a sales or authorized service representative. Product Description Always state the serial number of the product, see on page 12. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 62: The Pump Delivers Too Little Or No Water

    • Depending on the installation type, add a means for priming the pump, such as a foot valve. If the problem persists, then contact a sales or authorized service representative. Product Description Always state the serial number of the product, see on page 12. Flygt 3069 Installation, Operation, and Maintenance Manual...

  • Page 63: Technical Reference

    8.3 Minimum permitted liquid level In hazardous areas, this information is critical for the safety of the installation of this product. The pump must completely submerged in the pumped liquid during operation. Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 64 8 Technical Reference Flygt 3069 Installation, Operation, and Maintenance Manual...
  • Page 68 The original instruction is in English. All non-English instructions are translations of the original instruction. © 2016 Xylem Inc. Flygt is a trademark of Xylem Inc. or one of its subsidiaries. All other trademarks or registered trademarks are property of their respective owners. 885842_25.0_en-US_2024-08_IOM_Flygt 3069...

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