Xylem Flygt 2830.180 User manual

Installation, Operation,
and Maintenance Manual
Flygt 2830.180

Table of Contents
Introduction and Safety..................................................................................................................3
Introduction..................................................................................................................................3
Safety terminology and symbols............................................................................................... 3
Product warranty......................................................................................................................... 4
Safety.............................................................................................................................................5
User safety.................................................................................................................................... 5
Environmental safety...................................................................................................................6
Transportation and Storage.......................................................................................................... 7
Inspect the delivery.....................................................................................................................7
Inspect the package................................................................................................................7
Inspect the unit........................................................................................................................ 7
Transportation guidelines.......................................................................................................... 7
Lifting.........................................................................................................................................7
Temperature ranges for transportation, handling and storage............................................ 8
Storage guidelines...................................................................................................................... 8
Product Description........................................................................................................................9
Pump design................................................................................................................................9
Monitoring equipment............................................................................................................... 9
The data plate............................................................................................................................10
Product denomination..............................................................................................................10
Installation......................................................................................................................................12
Install the pump.........................................................................................................................12
Install with S-installation....................................................................................................... 13
Make the electrical connections..............................................................................................14
Product-specific precautions............................................................................................... 15
Cable charts........................................................................................................................... 16
Check the impeller rotation..................................................................................................... 18
Operation.......................................................................................................................................20
Start the pump...........................................................................................................................20
Clean the pump.........................................................................................................................21
Maintenance..................................................................................................................................22
Torque values............................................................................................................................ 23
Service........................................................................................................................................ 23
Inspection...............................................................................................................................24
Major overhaul.......................................................................................................................25
Change the oil........................................................................................................................... 25
Replace the impeller.................................................................................................................26
Remove the impeller MT, HT............................................................................................... 26
Install the impeller MT, HT................................................................................................... 28
Troubleshooting........................................................................................................................... 32
The pump does not start..........................................................................................................32
The pump does not stop when a level sensor is used......................................................... 33
The pump starts-stops-starts in rapid sequence...................................................................33
The pump runs but the motor protection trips..................................................................... 34
Table of Contents
Flygt 2830.180 Installation, Operation, and Maintenance Manual 1

The pump delivers too little or no water................................................................................35
Technical Reference..................................................................................................................... 36
Application limits.......................................................................................................................36
Specific motor data...................................................................................................................36
Dimensions and weights.......................................................................................................... 38
Performance curves.................................................................................................................. 38
Table of Contents
2 Flygt 2830.180 Installation, Operation, and Maintenance Manual

Introduction and Safety
Introduction
Purpose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
Read this manual carefully before installing and using the product. Improper use of the
product can cause personal injury and damage to property, and may void the warranty.
NOTICE:
Save this manual for future reference, and keep it readily available at the location of the
unit.
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
• 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:
• A potential situation which, if not avoided, could
result in undesirable conditions
• A practice not related to personal injury
Introduction and Safety
Flygt 2830.180 Installation, Operation, and Maintenance Manual 3

Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols replace the
ordinary hazard level symbols.
Electrical hazards are indicated by the following specific symbol:
Electrical Hazard:
These are examples of other categories that can occur. They fall under the ordinary
hazard levels and may use complementing symbols:
• Crush hazard
• Cutting hazard
• Arc flash hazard
Product warranty
Coverage
Xylem undertakes to remedy defects in products from Xylem under these conditions:
• The faults are due to defects in design, materials, or workmanship.
• The faults are reported to an local sales and service representative within the warranty
period.
• The product is used only under the conditions described in this manual.
• The monitoring equipment incorporated in the product is correctly connected and in
use.
• All service and repair work is done by Xylem authorized personnel.
• Genuine Xylem parts are used.
• Only Ex-approved spare parts and accessories authorized by an EX-approved Xylem
representative are used in Ex-approved products.
Limitations
The warranty does not cover defects caused by these situations:
•Deficient maintenance
• Improper installation
•Modifications or changes to the product and installation made without consulting an
Xylem authorized representative
• Incorrectly executed repair work
• Normal wear and tear
Xylem assumes no liability for these situations:
• Bodily injuries
• Material damages
• Economic losses
Warranty claim
Xylem products are high-quality products with expected reliable operation and long life.
However, should the need arise for a warranty claim, then contact your local sales and
service representative.
Spare parts
Xylem guarantees that spare parts will be available for 10 years after the manufacture of
this product has been discontinued.
Introduction and Safety
4 Flygt 2830.180 Installation, Operation, and Maintenance Manual

Safety
WARNING:
• The operator must be aware of safety precautions to prevent physical injury.
• Any pressure-containing device can explode, rupture, or discharge its contents if it is
over-pressurized. Take all necessary measures to avoid over-pressurization.
• 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. 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.
• Do not change the service application without the approval of an authorized Xylem
representative.
CAUTION:
You must observe the instructions contained in this manual. Failure to do so could result
in physical injury, damage, or delays.
User safety
General safety rules
These safety rules apply:
• Always keep the work area clean.
• Pay attention to the risks presented by gas and vapors in the work area.
• Avoid all electrical dangers. Pay attention to the risks of electric shock or arc flash
hazards.
• Always bear in mind the risk of drowning, electrical accidents, and burn injuries.
Safety equipment
Use safety equipment according to the company regulations. Use this safety equipment
within the work area:
• Hard hat
• Safety goggles, preferably with side shields
• Protective shoes
• Protective gloves
• Gas mask
• Hearing protection
• First-aid kit
• Safety devices
NOTICE:
Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.
Electrical connections
Electrical connections must be made by certified electricians in compliance with all
international, national, state, and local regulations. For more information about
requirements, see sections dealing specifically with electrical connections.
Hazardous liquids
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
Introduction and Safety
Flygt 2830.180 Installation, Operation, and Maintenance Manual 5

• Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
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.
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.
Environmental safety
The work area
Always keep the station clean.
Waste and emissions regulations
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
WARNING:
Radiation Hazard. Do NOT send the product to Xylem if it has been exposed to any
nuclear radiation.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Introduction and Safety
6 Flygt 2830.180 Installation, Operation, and Maintenance Manual

Transportation and Storage
Inspect the delivery
Inspect the package
1. Inspect the package for damaged or missing items upon delivery.
2. Note any damaged or missing items on the receipt and freight bill.
3. File a claim with the shipping company if anything is out of order.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
Inspect the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. Inspect the product to determine if any parts have been damaged or are missing.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
For your personal safety, be careful when you handle nails and straps.
4. Contact the local sales representative if there is any issue.
Transportation guidelines
Precautions
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.
WARNING:
• Stay clear of suspended loads.
• Observe accident prevention regulations in force.
Position and fastening
The unit can be transported either horizontally or vertically. Make sure that the unit is
securely fastened during transportation, and cannot roll or fall over.
Lifting
WARNING:
Crush Hazard.
• Always lift the unit by its designated lifting points.
• Use suitable lifting equipment and ensure that the product is properly harnessed.
• Wear personal protective equipment.
• Stay clear of cables and suspended loads.
Lifting equipment and tackle should always be inspected before starting work.
Mechanical lifting
When lifting the unit mechanically, always use the lifting eyes.
Transportation and Storage
Flygt 2830.180 Installation, Operation, and Maintenance Manual 7

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: –50°C (–58ºF) 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.
Units equipped with an internal 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.
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 water. Change if needed.
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.
• 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.
Transportation and Storage
8 Flygt 2830.180 Installation, Operation, and Maintenance Manual

Product Description
Products included
Pump model Approvals
2830.180 Standard
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 Application limits (page 36). If there is a question regarding the
intended use of the equipment, please contact a local sales and service representative
before proceeding.
WARNING:
In explosive or flammable environments, only use Ex- or MSHA-approved products.
NOTICE:
Do NOT use the pump in highly corrosive liquids.
For information about pH, see Application limits (page 36).
The warm media (liquid) version has certain operational limitations, which are stated on a
plate on the pump. For applicability, see Application limits (page 36).
Particle size
The pump can handle liquid containing particles that correspond to the holes in the
strainer.
Number of holes Hole dimensions
376 Diameter 10.0 mm (0.39 in)
For more information about the strainer, see Dimensions and weights.
Pressure class
MT Medium head
HT High head
Impeller type
KWear resistant
B Wear resistant
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).
Product Description
Flygt 2830.180 Installation, Operation, and Maintenance Manual 9

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.
2
1312 14
22
21
20
17 18 1916159 10 11
8
7
6
5
4
31
23
24
WS006257A
1. Curve code or Propeller code
2. Serial number, see Product denomination (page 10)
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
Figure 1: The data plate
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.
Codes and parameters
XXYYYY YYY YYY YYYY
1234567
a
b
c
WS006265B
.
Product Description
10 Flygt 2830.180 Installation, Operation, and Maintenance Manual

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
Product Description
Flygt 2830.180 Installation, Operation, and Maintenance Manual 11

Installation
Install the pump
DANGER:
Disconnect and lock out electrical power before installing or servicing the unit.
WARNING:
• Do not install the starter equipment in an explosive zone unless it is explosion-proof
rated.
• Do not install CSA-approved products in locations that are classified as hazardous in
the national electric code, ANSI/NFPA 70-2005.
• Vent the tank of a sewage station in accordance with local plumbing codes.
• Make sure that the unit cannot roll or fall over and injure people or damage property.
WARNING:
Electrical shock hazard. Check that the cable and cable entry have not been damaged
during transport before installing the pump.
NOTICE:
• Never force piping to make a connection with a pump.
These requirements apply:
• Use the pump dimensional drawing in order to ensure proper installation.
• Provide a suitable barrier around the work area, for example, a guard rail.
• Check the explosion risk before you weld or use electric hand tools.
• Remove all debris from the inlet piping system before you install the pump.
• Always check the impeller rotation before lowering the pump into the pumped liquid.
Sedimentation prevention
In order to avoid sedimentation when the pumped liquid contains solid particles, the
velocity of the liquid in the discharge line must exceed a certain value. Choose applicable
minimum velocity from the table, and choose proper dimension of the discharge line
accordingly.
Mixture Minimum velocity, meter per second (feet per second)
Water + coarse gravel 4 (13)
Water + gravel 3.5 (11)
Water + sand, particle size <0.6 mm (0.024 in) 2.5 (8.2)
Water + sand, particle size <0.1 mm (0.004 in) 1.5 (4.9)
For more permanent installations with a heavily contaminated pumped liquid, a settling
pump-sump is recommended.
Installation
12 Flygt 2830.180 Installation, Operation, and Maintenance Manual

WS001380B
Figure 2: Settling pump-sump
Discharge line requirements
The discharge line can be run vertically or horizontally, but must be without sharp bends.
Proper horizontal and vertical installation Improper installation with a sharp
bend
WS001379A
WS001346A
Fasteners
WARNING:
• Only use fasteners of the proper size and material.
• Replace all corroded fasteners.
• Make sure that all fasteners are properly tightened and that there are no missing
fasteners.
Install with S-installation
In the S-installation, the pump is transportable and intended to operate either completely
or partially submerged in the pumped liquid. The pump is equipped with a connection for
hose or pipe.
These requirements and instructions only apply when the installation is made according
to the dimensional drawing.
1. Run the cable so that it has no sharp bends. Make sure that it is not pinched, and
cannot be sucked into the pump inlet.
2. Connect the discharge line.
3. Lower the pump into the sump.
4. Place the pump on the base and make sure it cannot fall over or sink.
Alternatively, the pump can be suspended with a lifting chain just above the sump
bottom. Make sure that the pump cannot rotate at startup or during operation.
5. Connect the motor cable and the starter and monitoring equipment according to the
separate instructions.
Installation
Flygt 2830.180 Installation, Operation, and Maintenance Manual 13

Make sure that the impeller rotation is correct. For more information, see Check the
impeller rotation (page 18).
Make the electrical connections
General precautions
Electrical Hazard:
• A certified electrician must supervise all electrical work. Comply with all local codes
and regulations.
• 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.
• Leakage into the electrical parts can cause damaged equipment or a blown fuse.
Keep the end of the motor cable above the liquid level.
• Make sure that all unused conductors are insulated.
• 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.
WARNING:
Do not install the starter equipment in an explosive zone unless it is explosion-proof rated.
CAUTION:
If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.
WS006209A
Requirements
These general requirements apply for electrical installation:
• The supply authority must be notified before installing the pump if it will be
connected to the public mains. When the pump is connected to the public power
supply, it may 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 the connected voltage is
specified by a yellow sticker close to the cable entry.
• The fuses and circuit breakers must have the proper rating, and the pump overload
protection (motor protection breaker) must be connected and set to the rated current
according to the data plate and if applicable the cable chart. The starting current in
direct-on-line start can be up to six times higher than the rated current.
• The fuse rating and the cables must be in accordance with the local rules and
regulations.
• If intermittent operation is prescribed, then the pump must be provided with
monitoring equipment supporting such operation.
• The thermal contacts/thermistors must be in use.
Cables
These are the requirements to follow when you install cables:
Installation
14 Flygt 2830.180 Installation, Operation, and Maintenance Manual

• The cables must be in good condition, not have any sharp bends, and not be pinched.
• The sheathing 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 local sales and 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 requirements if a
Variable Frequency Drive (VFD) is used. For more information, contact your local sales
and service representative (VFD-supplier).
• For SUBCAB cables, the twisted pair copper foil must be trimmed.
Earthing (Grounding)
Electrical Hazard:
• You must earth (ground) all electrical equipment. This applies to the pump
equipment, the driver, and any monitoring equipment. Test the earth (ground) lead to
verify that it is connected correctly.
• If the motor cable is jerked loose by mistake, the earth (ground) conductor should be
the last conductor to come loose from its terminal. Make sure that the earth (ground)
conductor is longer than the phase conductors. This applies to both ends of the motor
cable.
• Risk of electrical shock or burn. You must connect an additional earth- (ground-) fault
protection device to the earthed (grounded) connectors if persons are likely to come
into physical contact with the pump or pumped liquids.
Earth (ground) conductor length
The earth (ground) conductor must be 270mm (10.6 in) longer than the phase conductors
in the junction box of the unit.
Product-specific precautions
Electrical Hazard:
This information is valid only for standard version products:
For a pump with a level regulator and a cable with earth (ground) check: Make sure that
the earth (ground) 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.
Installation
Flygt 2830.180 Installation, Operation, and Maintenance Manual 15

Cable charts
Connection locations
WS001021B
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
1 Starter equipment and main leads (L1, L2, L3) 13 Coil
2 Earth (ground) 14 Transformer
3 Functional ground 15 Capacitor
4 Control leads (T1, T2, T3, T4) 16 Softstarter
5 Phase shifter 17 Level regulator
6 Diode 18 Contactor, start relay or thermal relay
7 Motor cable 19 Thermal detector in stator
8 Screen 20 Thermal detector in main bearing
9 Pump 21 Jumper
10 Crimp connection 22 Terminal board, terminal plate
11 Crimp isolation 23 Leakage sensor
12 Motor protector 24 Stator leads (U1, U2, U5, U6, V1, V2, V5, V6, W1,
W2, W5, W6, Z1, Z5, Z6)
Color code standard
Code Description
BN Brown
BK Black
WH White
OG Orange
GN Green
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
Installation
16 Flygt 2830.180 Installation, Operation, and Maintenance Manual

Code Description
YE Yellow
Stator leads and thermal contacts connection to the terminal plate
WS004922B
773 48 02_4
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~)
Installation
Flygt 2830.180 Installation, Operation, and Maintenance Manual 17

Motor cable and starter unit connection to the terminal plate
WS004923B
773 48 02_4
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
W
V
U
T1
T2
Terminal
plate =Terminal plate
=Screen
=Ground
=Functional ground
=Crimp isolation for
cable, if not in use
=Thermal relay
=Socket - Plug
=Inside pump
Pump
TR
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)
-
-
-
-
-
-
-
-
-
-
-
----
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*
Motor protection
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
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)
Check the impeller rotation
WARNING:
The starting jerk can be powerful.
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.
Installation
18 Flygt 2830.180 Installation, Operation, and Maintenance Manual