Xylem FLYGT 2640.181 Setup guide

Service and Repair Instructions
885618_3.0
2640.181/.281

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 Special hazards.....................................................................................................................4
1.4.1 Working in temporary installations.............................................................................4
1.4.2 Biological hazards.........................................................................................................4
1.4.3 Wash the skin and eyes................................................................................................5
1.5 Protecting the environment................................................................................................5
1.6 End of life product disposal................................................................................................5
1.7 Spare parts............................................................................................................................6
1.8 Warranty................................................................................................................................6
2 Product Description....................................................................................................................7
2.1 Products included................................................................................................................ 7
2.2 Pump design.........................................................................................................................7
2.3 Monitoring equipment........................................................................................................ 8
2.4 The data plate.......................................................................................................................8
2.5 Product denomination........................................................................................................ 8
3 Installation................................................................................................................................. 10
3.1 Hazardous atmospheres................................................................................................... 10
3.2 Make the electrical connections...................................................................................... 10
3.2.1 General precautions...................................................................................................10
3.2.2 Grounding (earthing) ................................................................................................ 11
3.2.3 Product-specific precautions.....................................................................................12
3.2.4 Prepare the SUBCAB™cables................................................................................... 12
3.2.5 Connect the motor cable to the pump.................................................................... 13
3.2.6 Cable charts.................................................................................................................14
3.3 Check the impeller rotation..............................................................................................17
4 Maintenance..............................................................................................................................18
4.1 Precautions......................................................................................................................... 18
4.2 The fault-tracing process.................................................................................................. 19
4.2.1 Trace faults in the drive..............................................................................................19
4.2.2 Check the stator..........................................................................................................19
4.2.3 Trace faults in the wet end.........................................................................................20
4.3 Torque values.....................................................................................................................20
4.4 Change the oil....................................................................................................................21
4.5 Disassemble the pump..................................................................................................... 22
4.5.1 Disassembly overview................................................................................................22
4.5.2 Remove the discharge connection or cover........................................................... 23
4.5.3 Remove the impeller: Drainage version.................................................................. 23
4.5.4 Remove the impeller: Sludge version......................................................................25
4.5.5 Remove the mechanical seal: Drainage versions................................................... 26
4.5.6 Remove the mechanical seal: Sludge versions.......................................................28
4.5.7 Remove the shaft unit.................................................................................................30
4.5.8 Remove the bearings................................................................................................. 34
4.5.9 Remove the pump top............................................................................................... 35
4.5.10 Disconnect the electrical connections................................................................... 36
4.5.11 Remove the stator.................................................................................................... 37
Table of Contents
2640.181/.281 Service and Repair Instructions 1

4.6 Assemble the pump.......................................................................................................... 37
4.6.1 Assembly overview.....................................................................................................37
4.6.2 Install the stator...........................................................................................................38
4.6.3 Install the electrical connections...............................................................................39
4.6.4 Install the pump top................................................................................................... 39
4.6.5 Install the bearings..................................................................................................... 40
4.6.6 Install the shaft unit.....................................................................................................42
4.6.7 Install the mechanical seal: Drainage versions....................................................... 44
4.6.8 Install the mechanical seal: Sludge versions........................................................... 47
4.6.9 Check the seal tightness............................................................................................ 49
4.6.10 Install the impeller: Drainage version.................................................................... 49
4.6.11 Install the impeller: Sludge version........................................................................52
4.6.12 Install the discharge connection or cover............................................................. 54
4.7 Service.................................................................................................................................55
4.7.1 Inspection.................................................................................................................... 55
4.7.2 Overhaul...................................................................................................................... 56
5 Troubleshooting....................................................................................................................... 57
5.1 Electrical troubleshooting.................................................................................................57
5.2 The pump does not start...................................................................................................57
5.3 The pump does not stop when a level sensor is used.................................................. 58
5.4 The pump starts-stops-starts in rapid sequence............................................................59
5.5 The pump runs but the motor protection trips..............................................................59
5.6 The pump delivers too little or no water.........................................................................60
6 Technical Reference.................................................................................................................61
6.1 Application limits............................................................................................................... 61
6.2 Motor data.......................................................................................................................... 61
6.3 Specific motor data............................................................................................................61
6.4 Dimensions and weights...................................................................................................63
6.5 Tools.................................................................................................................................... 64
6.6 Winding data......................................................................................................................67
Table of Contents
2 2640.181/.281 Service and Repair Instructions

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide the 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
2640.181/.281 Service and Repair Instructions 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 Special hazards
1.4.1 Working in temporary installations
Certain industries, such as mining or construction, have a dynamic nature and require
temporary installation of equipment. Due to the rugged nature of these applications,
normal use of electrical equipment causes wear and tear that can result in insulation
breaks, short-circuits, and exposed wires. To maximize safety when using the unit in
rugged applications, the following conditions must be met:
• If electrical cables must be located such that they are at risk of being run over by heavy
equipment, then provide mechanical protection to prevent physical damage to the
cables.
• Visually inspect electrical equipment before use. Remove from service any equipment
with exposed wires or visible damage.
• Use ground-fault circuit interrupters on all receptacles, or have an assured equipment
grounding conductor program.
1.4.2 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.
1 Introduction and Safety
4 2640.181/.281 Service and Repair Instructions

WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
1.4.3 Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
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.
1.5 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.
1.6 End of life product disposal
Handle and dispose of all waste in compliance with local laws and regulations.
EU only: Correct disposal of this product — WEEE Directive on waste electrical and electronic equipment
WS009973A
This marking on the product, accessories or literature indicates that the product should
not be disposed of with other waste at the end of its working life.
To prevent possible harm to the environment or human health from uncontrolled waste
disposal, please separate these items from other types of waste and recycle them
responsibly to promote the sustainable reuse of material resources.
Waste from electrical and electronic equipment can be returned to the producer or
distributor.
1 Introduction and Safety
2640.181/.281 Service and Repair Instructions 5

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 2640.181/.281 Service and Repair Instructions

2 Product Description
2.1 Products included
Pump model Standard EX MSHA Drainage Sludge
2640.181 X X
2640.281 X X
2.2 Pump design
The pump is submersible, and driven by an electric motor.
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 61. If there is a question regarding
the intended use of the equipment, then contact a sales or authorized 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 rated explosion-proof or intrinsically-safe, then
see the specific explosion-proof information in the safety chapter before taking any
further actions.
NOTICE:
Do NOT use the unit in highly corrosive liquids.
For information about pH, see Technical Reference on page 61.
The warm media (liquid) version has certain operational limitations, which are stated on a
plate on the pump. For applicability, see Technical Reference on page 61.
Particle size: Drainage pump
The pump can handle liquid containing particles that correspond to the holes in the
strainer.
Pump Number of holes Hole dimensions
Diameter, mm (in)
2640.181 300 10 (0.39)
Particle size: Sludge pump
The pump can handle liquid containing particles with a maximum diameter as shown in
the table.
Pump Particle size
Diameter, mm (in)
2640.281 MT 46 (1.81)
2640.281 HT 31 (1.22)
Pressure class
MT Medium head
HT High head
2 Product Description
2640.181/.281 Service and Repair Instructions 7

Impeller type
Version code 181: K Clog resistant
Version code 181: B Wear resistant with Dura-Spin®
Version code 281: D Sludge
2.3 Monitoring equipment
The following applies to the monitoring equipment of the pump:
• The stator incorporates thermal contacts connected in series that activate the alarm at
overtemperature.
• The thermal contacts open at 140°C (284°F) and close at 105°C (221°F).
2.4 The data plate
The data plate is a metal label that is located on the main body of the products. The data
plate lists key product specifications. Specially approved products also have an approval
plate.
WS006257C
24
23
25
8
7
6
5
4
1312 14 17 18 19 16159 10 11
22
21
20
2
31
1. Curve code or Propeller code
2. Serial number
3. Product number
4. Country of origin
5. Additional information
6. Phase; type of current; frequency
7. Rated voltage
8. Thermal protection
9. Thermal class
10.Rated shaft power
11.International standard
12.Degree of protection
13.Rated current
14.Rated speed
15.Maximum submergence
16.Direction of rotation: L=left, R=right
17.Duty class
18.Duty factor
19.Product weight
20.Locked rotor code letter
21.Power factor
22.Maximum ambient temperature
23.Read installation manual
24.Notified body, only for EN-approved Ex products
25.WEEE-Directive symbol
Figure 1: The data plate
2.5 Product denomination
Reading instruction
In this section, code characters are illustrated accordingly:
X = letter
2 Product Description
8 2640.181/.281 Service and Repair Instructions

Y = digit
The different types of codes are marked up with a, b and c. Code parameters are marked
up with numbers.
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
2 Product Description
2640.181/.281 Service and Repair Instructions 9

3 Installation
3.1 Hazardous atmospheres
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 rated explosion-proof or intrinsically-safe, then
see the specific explosion-proof information in the safety chapter before taking any
further actions.
3.2 Make the electrical connections
3.2.1 General 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.
WARNING: Electrical Hazard
Risk of electric shock or burn. A certified electrician must supervise all the electrical work.
All the local codes and regulations must be obeyed.
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 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.
NOTICE:
Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep
the cable ends dry at all times.
Requirements
These general requirements apply for the electrical installation:
3 Installation
10 2640.181/.281 Service and Repair Instructions

• if the pump will be connected to the public mains, then the supply authority must be
notified before installing the pump. When the pump is connected to the public power
supply, it can cause flickering of incandescent lamps when started.
• The mains voltage and frequency must agree with the specifications on the data plate.
If the pump can be connected to different voltages, then follow the specified voltage
on the yellow sticker close to the cable entry.
• If the operation can be intermittent, then the pump must be supplied with monitoring
equipment supporting such operation.
• The thermal contacts or thermistors must be in use.
Motor and short-circuit protection
A qualified electrician must select the size of motor protection breakers and fuses, so that
it is sufficient for the specific motor data such as rated current and starting current.
It is important that the short-circuit protection is not over-dimensioned. Over-
dimensioned fuses and motor protection breakers decrease the protection for the motor.
• The fuse rating and the cables must be in accordance with the local rules and
regulations.
• The fuses and circuit breakers must have the correct rating. The pump overload
protection must be connected and set to the rated current. See the data plate and if
applicable the cable chart for the rated current. The starting current in direct-on-line
start can be up to six times higher than the rated current.
Cables
These are the requirements to follow when you install cables:
• The cables must be in good condition, not have any sharp bends, and not be pinched.
• The cables must not be damaged and must not have indentations or be embossed
(with markings, etc.) at the cable entry.
• The cable entry seal sleeve and washers must conform to the outside diameter of the
cable.
• The minimum bending radius must not be below the accepted value.
• If using a cable which has been used before, a short piece must be peeled off when
refitting it so that the cable entry seal sleeve does not close around the cable at the
same point again. If the outer sheath of the cable is damaged, then replace the cable.
Contact a sales or authorized service representative.
• The voltage drop in long cables must be taken into account. The drive unit’s rated
voltage is the voltage measured at the cable connection point in the pump.
• The screened cable must be used according to the European CE and EMC
requirements if a Variable Frequency Drive (VFD) is used. For more information,
contact a sales or authorized service representative (VFD-supplier).
• For SUBCAB®cables, the twisted pair copper foil must be trimmed.
• All unused conductors must be insulated.
3.2.2 Grounding (earthing)
Grounding (earthing) must be done in compliance with all local codes and regulations.
DANGER: Electrical Hazard
All electrical equipment must be grounded (earthed). Test the ground (earth) lead to
verify that it is connected correctly and that the path to ground is continuous.
WARNING: Electrical Hazard
If the power cable is jerked loose, then the ground (earth) conductor must be the last
conductor to come loose from its terminal. Make sure that the ground (earth) conductor is
longer than the phase conductors at both ends of the cable.
3 Installation
2640.181/.281 Service and Repair Instructions 11

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 are likely to come into
contact with liquids that are also in contact with the pump or pumped liquid.
Ground (earth) conductor length
The ground (earth) conductor must be longer than the phase conductors in the junction
box of the unit.
The table shows how much longer, than the phase conductors, the ground (earth)
conductor must be.
Pump Extra length of ground conductor, mm (in.)
2640.181
2640.281
270 (10.6)
3.2.3 Product-specific precautions
This information is valid only for standard version products.
For a pump with a level regulator and a cable with ground (earth) check: Make sure that
the ground (earth) check connection is done at the GC-connection point with a cable lug
and one screw. Connect the ground cable from the level switch to the other screw at the
GC-connection point.
3.2.4 Prepare the SUBCAB™cables
This section applies to SUBCAB™cables with twisted-pair control cores.
The prepared SUBCAB™cable The prepared screened SUBCAB™cable, without cable lugs
SUBCAB 1000V
T
1
T
2
12
34
5
6
WS004299E
1. T1+T2 twisted pairs in control element
2. Drain wire in control element (bare aluminum wire)
3. Aluminum foil, screen
4. Insulation sheath (plastic jacket) or PT-foil for control element
5. Power cores
6. Ground (earth) core
WS004298F
Screened SUBCAB
1
5
6
7
8
2
9
3 4
1. T1+T2 and T3+T4 twisted pairs in control element
2. Drain wire in control element (tinned copper strands) with shrink hose
3. Aluminum and textile layers
4. Insulation sheath or plastic jacket, for the control element
5. Power cores
6. Plastic laminated aluminum foil, screen
7. Ground (earth) core with yellow-green shrink hose
8. Uncovered screen/braided wire
9. Shrink hose
1. Peel off the outer sheath at the end of the cable.
2. Prepare the control element:
a) Peel the sheath (if applicable) and the aluminum foil.
The aluminum foil is a screen and is conductive. Do not peel more than necessary,
and remove the peeled foil.
3 Installation
12 2640.181/.281 Service and Repair Instructions

WS004313F
Screened SUBCAB
T
1T
2
T
3T
4
Figure 2: 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 hose over the control element.
Make sure that the conductive aluminum foil and drain wire is covered.
3. Prepare the ground (earth) core for SUBCAB™cable:
a) Peel the yellow-green insulation from the ground (earth) core.
b) Check that the ground (earth) core is at least 10% longer than the phase cores in
the cabinet.
c) If applicable, put a cable lug on the ground core.
4. Prepare the ground (earth) core for screened SUBCAB™cable:
a) Untwist the screens around the power cores.
b) Put a yellow-green shrink 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.
5. Connect to ground (earth):
– Screw: Fit cable terminals to the ground (earth) core and the power cores.
– Terminal block: Leave the core ends as they are.
6. Prepare the main leads:
a) Remove the aluminum foil around each power core.
b) Peel the insulation from each power core.
3.2.5 Connect the motor cable to the pump
NOTICE:
Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep
the end of the motor cable dry at all times.
1. Check the data plate to see which connections are required for the power supply.
2. Connect the motor cable conductors, including ground (earth), to the terminal or
starter unit.
3. Make sure that the pump is correctly connected to ground (earth).
4. Tighten the cable entry into its bottom-most position.
The seal sleeve and the washers must conform to the outside diameter of the cables.
3 Installation
2640.181/.281 Service and Repair Instructions 13

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 rated explosion-proof or intrinsically-safe, then
see the specific explosion-proof information in the safety chapter before taking any
further actions.
3.2.6 Cable charts
Connection locations
WS001021C
L1 L2 L3 T3 T4T1 T2
15
13
14
42 31
7
10
5
9
8
6
11
12
17
16
24
22
23
19 20
21
18
25
1 Starter equipment and main leads (L1, L2, L3) 14 Transformer
2 Ground (earth) 15 Capacitor
3 Functional ground 16 Softstarter
4 Control leads (T1, T2, T3, T4) 17 Level regulator
5 Phase shifter 18 Contactor, start relay or thermal relay
6 Diode 19 Thermal detector in stator
7 Motor cable 20 Thermal detector in main bearing
8 Screen 21 Jumper
9 Pump 22 Terminal board, terminal plate
10 Crimp connection 23 Leakage sensor
11 Crimp isolation 24 Stator leads (U1, U2, U5, U6, V1, V2, V5, V6, W1,
W2, W5, W6, Z1, Z5, Z6)
12 Motor protector 25 Current transformer
13 Coil
Color code standard
Code Description
BN Brown
BK Black
WH White
3 Installation
14 2640.181/.281 Service and Repair Instructions

Code Description
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow
Stator leads and thermal contacts connection to the terminal plate
WS004922C
773 48 04_6
2630.181
2630.281
2640.181
2640.281
2830.180
2840.180
W
VU
T1
T2
Terminal
plate
STATOR LEADS
RD
GN
BN
BU
YE
BK
WH/YE
U1,U5
U2,U6
V1,V5
V2,V6
W1,W5
W2,W6
T1,T2
U2V1 V1
U2
V2
W2
U5
V5
W5
6 leads
D
T1
T2
U2
V2
W2
T1
T2
9 leads
Y serial
9 leads
Y //
V1
T1
T2
V1
T1
T2
V5
U2
V2
W2
V
3 leads
Y
T1
T2
12 leads
Y //
12 leads
D //
12leads
D serial
V1
T1
T2
V5
U2
V2
W2
U6
V6
W6
T1 *
T2 *
*
V1 V5 U2 U6
U2
V2
W2
U5
V5
W5
V1 U6
T1
T2
STATOR LEADS AND THERMAL CONTACTS
W2U1 U1 U1 U1 U5 UU1 U5 U1 U5 W2 W6U1 W6
V2W1 W1 W1 W1 W5 WW1 W5 W1 W5 V2 V6W1 V6
V
T1
T2
Terminal
plate
U
W
6 leads
Y
3 - P H A S E (3~)
V
T1
T2
Terminal
plate
STATOR LEADS AND THERMAL CONTACTS
1-PHASE (2640)
9 leads
T1
T2
V1 V5
W5 W2
U2 V2
UU1 U5
WW1
WH/YE
WH/YE
BN-BN
YE-BK
GN-BU
RD-RD
YE
1 - P H A S E (1~)
EU: Max 500V Max 1,3A cos =0,6
US/CDN: Max 250V Max 2,5A cos =1
EU: Max 500V Max 1,3A cos =0,6
US/CDN: Max 250V Max 2,5A cos =1
3 - P H A S E (3~)
CABLE SEAL FOR Y/D STARTER
CABLE SEAL
REPLACES TERMINAL PLATE
STATOR
C A B L E S E A L
TERMINAL
BOARD
V1 (BN)
U2 (GN)
V2 (BU)
W2 (BK)
T2 (WH/YE)
T1 (WH/YE)
U1 (RD)
W1 (YE)
CONNECTION TERMINAL BOARD
Waterproof flat pin (8x)
Terminal block (8x)
Terminal block (8x)
BN
GN
BU
BK
WH
WH
RD
YE
U1
W2
V1
U2
W1
V2
T1
T2
SYMBOLS AND DENOMINATIONS
BN=Brown
BK=Black
WH=White
OG=Orange
GN=Green
GNYE=Green-Yellow
RD=Red
GY=Grey
BU=Blue
YE=Yellow
*SUBCAB AWG/CSA
**GC= Ground check
=Terminal plate
=Screen
=Ground
=Functional ground
=Crimp isolation for
cable, if not in use
=Thermal relay
=Socket - Plug
=Inside pump
Pump
TR
3 Installation
2640.181/.281 Service and Repair Instructions 15

Motor cable and starter unit connection to the terminal plate
WS004923D
773 48 04_6
W
V
U
T1
T2
Terminal
plate
2630.181
2630.281
2640.181
2640.281
2830.180
2840.180
SCREENED MOTOR CABLES Shrink hose GNYE
(S3+S4) (S3)
T1 WH
T2 WH
T3 WH
T4 WH
-
-
-
-
L3 3 BK / GY
L2 2 BK / BK
L1 1 BK / BN
Motor cable Pump
(S3+4)(4+S2)
Screen as ground conductor
GNGY
-
-
(GC) (GC)
L3 6 BK
L2 5 BK
L1 4 BK
-
-
-
(7+S2) (S6+2)
-
-
(GC) Y/D Y/DDOL DOL
-
-
-
-
-
-
-
-
-
-
-
----
3 - P H A S E (3~)
Terminal plate or contactor unit
Current over
19A no
Use on T1-T2
when not in use
L3 GY/WH*
Motor cable
(6/7* conductors)
T1 WH/OG*
T2 WH/BU*
YE*
GNYE/*
GC**
L1 BN/RD*
L2 BK/BK*
EXTERNAL STARTER, DOL, 3-PHASE
V / C
T1
T2
Terminal
plate
U / M
W / A
Pump
BU
BK
BN
GY
WH
Float switch (Optional) BU/WH* BN/BK* GNYE/GN* GC**
EU: Max 400V
US/CDN: Max 250V
A1
A2
GC**
L1 BN/RD*
L3 GY/WH*
L2 BK/BK*
GNYE/GNYE*
YE*
BU*
OG*
V
T1
T2
Terminal
plate
U
W
Motor cable
(4/4*/7*
conductors)
H
A2
15
16
G
INTERNAL CONTACTOR, 3-PHASE
OVER 500V (CSA OVER 250V)
1 - 2
3 - 4
5 - 6
External
motor protection
Thermal O/L relay
Setting= I
Pump
Contactor
TR
BK
GY
BN
BU
WH
3 - P H A S E (3~)
Current over 19A no
A1 A2
INTERNAL CONTACTOR, 3-PHASE
MAX 500V (CSA MAX 250V)
GC**
L1 BN/RD*
L3 GY/WH*
L2 BK/BK*
GNYE/*
YE*
BU*
OG*
V / C
T1
T2
Terminal
plate
U / M
W / A
Motor cable
(4/4*/7*
conductors)
1 - 2
3 - 4
5 - 6
Thermal O/L
Setting= I
Pump Contactor
BK
GY
BN
WH
BK
GY
BN
BU/WH* BN/BK* GNYE/GN*
GC**
Float switch (Optional)
EU: Max 400V
US/CDN: Max 250V
BU
External
motor protection
3 - P H A S E (3~)
1 - P H A S E (1~)
EXTERNAL STARTER, 1-PHASE
WITHOUT INTERNAL
CONTACTOR
GC**
GNYE/*
Motor cable
(4/4*/7*
conductors)
YE*
EXTERNAL STARTER
INTERNAL CONTACTOR, 1-PHASE
A1 A2
OR*
BU*
V / C
T1
T2
Terminal
plate
U / M
W / A
1 - 2
3 - 4
5 - 6
BU
GY/WH*
BK/BK*
BN/RD*
Pump
Contactor
BN
GY
BK
WH
FGB Screened
motor cable. (3+S)
Screen as ground
conductor. Use
GNYE shrink hose Float switch
BU/WH* BN/BK*
GNYE/GN* GC**
(Optional)
BU GC**
GY/WH*
WH/OG*
WH/BU*
YE*
GNYE/*
BK/BK*
BN/RD*
Motor cable
(6/7* conductors)
V / C
T1
T2
Terminal
plate
U / M
W / A
Pump
BU
BN
GY
BK
WH
Float switch BU/WH* BN/BK* GNYE/GN* GC**
(Optional)
Motor cable
(9 conductors)
T1 WH
T2 WH
GNYE
EXTERNAL STARTER, 3-PHASE Y/D
WITHOUT
INTERNAL
CONTACTOR Pump
V1 (BN)
U2 (GN)
V2 (BU)
W2 (BK)
T2 (WH/YE)
T1 (WH/YE)
U1 (RD)
W1 (YE)
C A B L E S E A L
L3 BK 3
L2 BK 2
L1 BK 1
L3 BK 6
L2 BK 5
L1 BK 4
Connection
terminal board
V1
U2
V2
W2
U1
W1
T2
T1
STATOR
External Y/D starter
EXTERNAL STARTER
DCM711, 3-PHASE
Float switch
(Optional)
BU/WH*
BN/BK*
GNYE/GN*
L1 BN/RD*
L3 GY/WH*
L2 BK/BK*
GNYE/*
YE*
WH/BU*
WH/OG*
Motor cable
(6/6*/7*
conductors)
DCM711
PUMP
SENSOR
MODULE
Thermal
switch/
FLS
CCI
PT
100
Float
switch CT1 CT2
BN
BU
Pump
GC**
V / C
T1
T2
Terminal
plate
U / M
W / A
GC**
BK
GY
BN
STARTER
DCM711
Thermal O/L
Setting= I
BK
RD BK
RD
CT1
CT2
CT1/CT2
L1/L2
1000V & Current over 19A no
BU
WH
BU
WH
GENERAL SYMBOLS AND DENOMINATIONS
BN=Brown
BK=Black
WH=White
OG=Orange
GN=Green
GNYE=Green-Yellow
RD=Red
GY=Grey
BU=Blue
YE=Yellow
*SUBCAB AWG/CSA
**GC= Ground check Pump
TR
=Terminal plate
=Screen
=Ground
=Functional ground
=Crimp isolation for cable (all cables not in use)
=Thermal relay
=Socket - Plug
=Current transformer
=Inside pump
CT
3 Installation
16 2640.181/.281 Service and Repair Instructions

3.3 Check the impeller rotation
CAUTION: Crush Hazard
The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.
Check the direction of rotation each time the cable has been re-connected and after
phase or total supply failure.
1. Start the motor.
2. Stop the motor.
3. Check that the impeller rotates in the correct direction.
The correct direction of impeller rotation is clockwise when you look at the pump from
above. When started, the pump will react in the opposite direction to the impeller
rotation.
L2
L1 L2 L3
L3L1
WS001397A
Figure 3: Start reaction
4. If the impeller rotates in the wrong direction, then do the following:
– 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 conductors and
repeat this procedure from step 1.
For 3-phase pumps with external starters or without built-in motor protection, the
phases must be shifted on the output terminal of the starter.
3 Installation
2640.181/.281 Service and Repair Instructions 17

4 Maintenance
4.1 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. Failure to do so could result in death or serious
injury.
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or damage property.
Make sure that you follow these requirements:
•Check the explosion risk before you weld or use electrical hand tools.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product and its components have been thoroughly cleaned.
• Before starting work, make sure that the work area is well-ventilated.
• 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.
Ground continuity verification
A ground (earth) continuity test must always be performed after service.
Maintenance guidelines
During the maintenance and before reassembly, always remember to perform these
tasks:
• Clean all parts thoroughly, particularly O-ring grooves.
• Change all O-rings, gaskets, and seal washers.
• Lubricate all springs, screws, O-rings with grease.
For an optimal corrosion protection, all O-rings and adjacent surfaces must be coated
with Exxon Mobil Unirex N3 or equivalent.
4 Maintenance
18 2640.181/.281 Service and Repair Instructions