Xylem FLYGT Concertor User manual

Installation, Operation, and
Maintenance Manual
886211_9.0
6020.180/090
Concertor™

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........................................................................................................... 7
2.1.1 Examine the package................................................................................................... 7
2.1.2 Examine the unit............................................................................................................7
2.2 Transportation guidelines...................................................................................................7
2.2.1 Lifting..............................................................................................................................7
2.3 Temperature ranges for transportation, handling and storage.....................................8
2.4 Storage guidelines...............................................................................................................9
3 Product Description................................................................................................................. 10
3.1 Pump design...................................................................................................................... 10
3.2 Monitoring equipment......................................................................................................13
3.3 The data plate.................................................................................................................... 13
3.4 Approvals............................................................................................................................14
3.5 Product 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-installation..................................................................................19
4.3.3 Install the pump: S-installation..................................................................................20
4.3.4 Install the pump: T-installation..................................................................................21
4.3.5 Install the pump: Z-installation..................................................................................22
5 Electrical Installation................................................................................................................ 24
5.1 Precautions......................................................................................................................... 24
5.2 Requirements..................................................................................................................... 25
5.3 Make the electrical connections...................................................................................... 26
5.3.1 Prepare the SUBCAB®cables....................................................................................26
5.3.2 Connect the motor cable to the pump.................................................................... 28
5.3.3 Connect the motor cable to mains and to the monitoring equipment............... 28
5.4 Cable charts........................................................................................................................29
6 Operation.................................................................................................................................. 33
6.1 Precautions......................................................................................................................... 33
6.2 Start the pump....................................................................................................................33
6.3 Alarm handling...................................................................................................................34
6.3.1 Alarms and messages................................................................................................ 34
Table of Contents
6020.180/090 Installation, Operation, and Maintenance Manual 1

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.................................... 42
7.5.2 Remove the impeller.................................................................................................. 44
7.5.3 Install the impeller...................................................................................................... 44
8 Troubleshooting....................................................................................................................... 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 receive commands from the controller / RTU / PLC.................. 52
8.7 The pump starts-stops-starts in rapid sequence............................................................52
8.8 The pump delivers too little or no water.........................................................................53
8.9 Dirigo™Service Tool: The communication with the unit fails.......................................54
9 Technical Reference.................................................................................................................55
9.1 Motor data.......................................................................................................................... 55
9.2 Application limits............................................................................................................... 55
9.3 Minimum permitted liquid level...................................................................................... 55
Table of Contents
2 6020.180/090 Installation, Operation, and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide necessary information for working with the unit.
Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the
unit.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment and the
surroundings. 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.
Other manuals
See also the safety requirements 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 problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
WARNING:
A hazardous situation which, if not avoided, could result
in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result
in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
1 Introduction and Safety
6020.180/090 Installation, Operation, and Maintenance Manual 3

Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical Hazard: CAUTION:
1.3 User safety
All regulations, codes, and health and safety directives must be observed.
The site
• Observe lockout/tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by
the site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves
and shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.
1.4 Ex-approved products
Follow these special handling instructions if you have an Ex-approved unit.
Personnel requirements
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.
• Any maintenance for Ex-approved products must conform to international and national
standards (for example, IEC/EN 60079-17).
Xylem disclaims all responsibility for work done by untrained and unauthorized personnel.
Product and product handling requirements
These are the product and product handling requirements for Ex-approved products in
potentially explosive atmospheres:
• Only use the product in accordance with the approved motor data.
• The Ex-approved product must never run dry during operation. The volute must be
filled with liquid during operation. Dry running during service and inspection is only
permitted outside the classified area.
• Before you start work on the product, make sure that the product and the control
panel are isolated from the power supply and the control circuit, so they cannot be
energized.
• Do not open the product while it is energized or in an explosive gas atmosphere.
1 Introduction and Safety
4 6020.180/090 Installation, Operation, and Maintenance Manual

• Intrinsically safe circuits are normally required for the automatic level-control system by
the level regulator if mounted in zone 0.
• The yield stress of fasteners must be in accordance with the approval drawing and the
product specification.
• 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. The detectors disconnect the
power supply to the motor timely. This action prevents the rise of temperatures above
the temperature value for the approval classification.
• The width of flameproof joints is more than the values specified in the tables of the IEC
60079–1 standard.
• The gap of flameproof joints is less than the values specified in Table 1 of the IEC
60079–1 standard.
• The flameproof joints are NOT intended to be repaired.
Guidelines for compliance
Compliance is fulfilled only when you operate the unit within its intended use. Do not
change the conditions of the service without the approval of an Ex-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 level
The approval for explosion proof products is predicated on a minimum permitted liquid
level. See Technical Reference on page 55.
Monitoring equipment
For additional safety, use condition-monitoring devices. Examples of condition-
monitoring devices include, but are not limited to, the following:
• Level indicators
• Temperature detectors in addition to the stator thermal detectors
Any thermal detectors or thermal protection devices delivered with the pump must be
installed and in use at all times.
1.5 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.
• Observe strict personal cleanliness.
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
1 Introduction and Safety
6020.180/090 Installation, Operation, and Maintenance Manual 5

Condition Action
Chemicals or hazardous fluids in
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.
1.6 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting 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 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
components. The use of unsuitable spare parts may cause malfunctions, damage, and
injuries as well as void the warranty.
1.8 Warranty
For information about warranty, see the sales contract.
1 Introduction and Safety
6 6020.180/090 Installation, Operation, and Maintenance Manual

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. If anything is out of order, then file a claim with the shipping company.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.1.2 Examine the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
Use care around nails and straps.
4. If there is any issue, then contact a sales 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. Failure to do so could result in death or serious
injury.
Equipment
locked out by
Name .......................
DANGER
Position and fastening
The unit can be transported either horizontally or vertically. Make sure that the unit is
correctly 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) Use suitable lifting equipment and
ensure that the product is properly harnessed. 3) Wear personal protective equipment. 4)
Stay clear of cables and suspended loads.
NOTICE:
Never lift the unit by its cables or hose.
2 Transportation and Storage
6020.180/090 Installation, Operation, and Maintenance Manual 7

Lifting equipment
Lifting equipment is always required to handle the unit. The lifting equipment must fulfill
the following requirements:
• 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.
• The lifting equipment must be correctly anchored and in good condition.
• The lifting equipment must support the weight of the entire assembly. Only authorized
personnel may use the lifting equipment.
• Two sets of lifting equipment must be used to lift the unit for repair work.
• The lifting equipment must be dimensioned to lift the unit with any remaining pumped
media in it.
• The lifting equipment must not be oversized.
CAUTION: Crush Hazard
Over-dimensioned lifting equipment can lead to injury. A site-specific
risk analysis must be done.
2.3 Temperature ranges for transportation, handling and storage
Handling at freezing temperature
At temperatures below freezing, the product and all installation equipment, including the
lifting gear, must be handled with extreme care.
Make sure that the product is warmed up to a temperature above the freezing point
before starting up. Avoid rotating the impeller/propeller by hand at temperatures 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 condition
If the unit is still in the condition in which it left the factory - all packing materials are
undisturbed - then the acceptable temperature range during transportation, handling and
storage is: –40°C (–40ºF) 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 is lifted out of the liquid
into a surrounding temperature below freezing.
Follow these guidelines to avoid freezing damage:
1. Empty all pumped liquid, if applicable.
2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for
the presence of unacceptable amounts of water. Change if needed.
Water-glycol mixtures: Units equipped with an internal closed-loop 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.
2 Transportation and Storage
8 6020.180/090 Installation, Operation, and Maintenance Manual

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:
• 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 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
6020.180/090 Installation, Operation, and Maintenance Manual 9

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
55.
Intended use
The product is intended for moving waste water, sludge, raw and clean water. Always
follow the limits given in Technical Reference 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 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. 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.
3 Product Description
10 6020.180/090 Installation, Operation, and Maintenance Manual

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

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

Position Part
12 Mechanical seal
Plug in seal with active seal design.
13 Adaptive-N impeller
14 Oil
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)
• Overtemperature sensors in the control system
Explosion-proof version: The stator incorporates three thermal contacts connected in
series.
3.3 The data plate
WS008366C
10
8
7
4
5
6
1516
9
14 1112
21
2
1
17
18
3
19
20
22
13
1. Serial number, see Product 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. Thermal class
10.Maximum submergence
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
22.Sales denomination
3 Product Description
6020.180/090 Installation, Operation, and Maintenance Manual 13

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
IEC
• IECEx scheme
• IEC 60079-0, IEC 60079-1
• Ex d IIB T4 Gb
FM (FM Approvals)
• FM 3600:2011
• FM 3615:2005
• FM 3650:2013
• FM 3810:2005
• ANSI/ISA 61010-1:2012
• ANSI/IEC 60529:2004
• Explosion proof for use in Class I, Div. 1, Group C and D
• Dust ignition proof for use in Class II, Div. 1, Group E, F and G
• Suitable for use in Class III, Div. 1, Hazardous Locations
CSA Ex
• Explosion 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 89 10
11
12
13
14
WS003972B
4
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
14.ATEX marking
IEC approval plate
This illustration describes the IEC approval plate and the information that is contained in
its fields.
International Norm; not for EU member countries.
3 Product Description
14 6020.180/090 Installation, Operation, and Maintenance Manual

1 2
3
5
6 7 89 10
11
12
13
14
4
WS001279C
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
14.ATEX marking
FM approval plate
This illustration describes the FM approval plate and the information that is contained in
its fields.
1
2WS003973A
1. Temperature class
2. Maximum ambient temperature
CSA approval plate
This illustration describes the CSA approval plate and the information that is contained in
its fields.
1 WS009401A
1. Temperature class
3.5 Product denomination
Reading instruction
In this section, code characters are illustrated accordingly:
X = letter
Y = digit
The different types of codes are marked up with a, b and c. Code parameters are marked
up with numbers.
3 Product Description
6020.180/090 Installation, Operation, and Maintenance Manual 15

Codes and parameters
XXYYYY YYY YYY YYYY
1234567
a
b
c
WS006265B
.
Type of Callout Number 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 number
3 Product Description
16 6020.180/090 Installation, Operation, and Maintenance Manual

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. This applies to the control circuit as well.
Equipment
locked out by
Name .......................
DANGER
Hazardous atmospheres
• Check the explosion risk before you weld or use electric hand tools.
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. 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
National Electric Code(TM), ANSI/NFPA 70-2005.
Site precautions
• Provide a suitable barrier around the work area, for example, a guard rail.
• Make sure that equipment is in place so that the unit cannot roll or fall over during the
installation process.
• Vent the tank of a sewage station in accordance with the local plumbing codes.
Fasteners
• Only use fasteners of the correct size and material.
• Replace all corroded or damaged fasteners.
• Make sure that all the fasteners are correctly tightened and that there are no missing
fasteners.
4 Mechanical Installation
6020.180/090 Installation, Operation, and Maintenance Manual 17

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.
1. Install 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 tighten the nuts.
4. Install the guide bars.
5. Connect the discharge pipe to the discharge connection.
6. Install the cable holders where they are needed.
4 Mechanical Installation
18 6020.180/090 Installation, Operation, and Maintenance Manual