FLYGT 2125 Installation, Operation And Maintenance Manual

Installation,

Operation, and

Maintenance Manual

2125

Table of Contents

Introduction and Safety.........................................................................................................................3

Introduction..........................................................................................................................................3

Safety terminology and symbols.......................................................................................................3

Inspect the delivery.............................................................................................................................4

Inspect the package.........................................................................................................................4

Inspect the unit..................................................................................................................................4

Product warranty.................................................................................................................................4

Spare parts........................................................................................................................................5

Safety.....................................................................................................................................................5

User safety............................................................................................................................................6

Hazardous liquids.............................................................................................................................6

Wash the skin and eyes....................................................................................................................6

Ex-approved products........................................................................................................................7

ATEX guidelines................................................................................................................................7

Permitted liquid level for ATEX.......................................................................................................7

Monitoring equipment.....................................................................................................................7

MSHA requirements............................................................................................................................8

Environmental safety...........................................................................................................................8

Table of Contents

Transportation and Storage................................................................................................................10

Transportation guidelines................................................................................................................10

Precautions......................................................................................................................................10

Position and fastening...................................................................................................................10

Lifting...............................................................................................................................................10

Storage guidelines............................................................................................................................10

Storage location.............................................................................................................................10

Freezing precautions.....................................................................................................................10

Long-term storage..........................................................................................................................11

Product Description.............................................................................................................................12

Products included.............................................................................................................................12

Pump design......................................................................................................................................12

Monitoring equipment.....................................................................................................................13

The data plate....................................................................................................................................13

The Ex approval plate....................................................................................................................14

The MSHA approval plate.............................................................................................................14

Product denomination......................................................................................................................14

Installation.............................................................................................................................................16

Install the pump.................................................................................................................................16

Sedimentation prevention.............................................................................................................16

Discharge line requirements.........................................................................................................16

Fasteners.........................................................................................................................................17

Install with S-installation.................................................................................................................17

Make the electrical connections......................................................................................................18

General precautions.......................................................................................................................18

Requirements..................................................................................................................................18

Cables..............................................................................................................................................18

Earthing (Grounding).....................................................................................................................19

Earth (ground) conductor length.................................................................................................19

Connect the motor cable to the pump........................................................................................19

Cable charts....................................................................................................................................20

2125 Installation, Operation, and Maintenance Manual 1

Table of Contents

Check the impeller rotation.............................................................................................................27

Operation..............................................................................................................................................28

Precautions.........................................................................................................................................28

Distance to wet areas........................................................................................................................28

Noise level..........................................................................................................................................28

Start the pump...................................................................................................................................28

Clean the pump.................................................................................................................................29

Maintenance.........................................................................................................................................30

Precautions.........................................................................................................................................30

Maintenance guidelines...................................................................................................................30

Torque values....................................................................................................................................30

Service................................................................................................................................................31

Inspection........................................................................................................................................31

Major overhaul................................................................................................................................33

Change the oil...................................................................................................................................33

Empty the oil...................................................................................................................................33

Fill with oil........................................................................................................................................34

Replace the impeller.........................................................................................................................34

Remove the impeller......................................................................................................................34

Install the impeller..........................................................................................................................36

Troubleshooting...................................................................................................................................38

Introduction.......................................................................................................................................38

The pump does not start..................................................................................................................38

The pump does not stop when a level sensor is used.................................................................39

The pump starts-stops-starts in rapid sequence...........................................................................39

The pump runs but the motor protection trips.............................................................................40

The pump delivers too little or no water........................................................................................40

Technical Reference............................................................................................................................42

Application limits...............................................................................................................................42

Motor data..........................................................................................................................................42

Specific motor data...........................................................................................................................42

Dimensions and weights..................................................................................................................46

Performance curves..........................................................................................................................50

2 2125 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.

Introduction and Safety

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:

WARNING:

A hazardous situation which, if not avoided, will result in
death or serious injury

A hazardous situation which, if not avoided, could result
in death or serious injury

2125 Installation, Operation, and Maintenance Manual 3

CAUTION:

A hazardous situation which, if not avoided, could result
in minor or moderate injury

Introduction and Safety

Hazard categories

Hazard level Indication

• A potential situation which, if not avoided, could

NOTICE:

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

result in undesirable conditions

• A practice not related to personal injury

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 your sales representative if anything is out of order.

Product warranty

Coverage

Xylem undertakes to remedy faults in products from Xylem under these conditions:

• The faults are due to defects in design, materials, or workmanship.

• The faults are reported to an Xylem 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.

4 2125 Installation, Operation, and Maintenance Manual

Limitations

Warranty claim

Introduction and Safety

• Genuine Xylem parts are used.

• Only Ex-approved spare parts and accessories authorized by Xylem are used in Ex­approved products.

The warranty does not cover faults caused by these situations:

• Deficient maintenance

• Improper installation

• Modifications or changes to the product and installation made without consulting

Xylem

• Incorrectly executed repair work

• Normal wear and tear

Xylem assumes no liability for these situations:

• Bodily injuries

• Material damages

• Economic losses

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 Xylem
representative.

Spare parts

Safety

Xylem guarantees that spare parts will be available for 10 years after the manufacture of
this product has been discontinued.

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 an Xylem
representative before proceeding.

• Installation, Operation, and Maintenance manuals clearly identify accepted methods for
disassembling units. These methods must be adhered to. Trapped liquid can rapidly
expand and result in a violent explosion and injury. Never apply heat to impellers,
propellers, or their retaining devices to aid in their removal.

• Do not change the service application without the approval of an authorized Xylem
representative.

CAUTION:

You must observe the instructions for installation, operation, and maintenance contained
in this manual. Failure to do so could result in physical injury, damage, or delays.

2125 Installation, Operation, and Maintenance Manual 5

Introduction and Safety

User safety

General safety rules

Safety equipment

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.

Use safety equipment according to the company regulations. Use this safety equipment
within the work area:

• Helmet

• Safety goggles, preferably with side shields

• Protective shoes

• Protective gloves

• Gas mask

• Hearing protection

• First-aid kit

• Safety devices

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:

•

• Observe strict personal cleanliness.

Wash the skin and eyes

NOTICE:

Never operate a unit unless safety devices are installed. Also see specific information
about safety devices in other chapters of this manual.

Make sure that all personnel who work with biologically hazardous liquids are
vaccinated against diseases to which they may be exposed.

Do the following if chemicals or hazardous fluids have come into contact with your
eyes or your skin:

If you need to wash your... Then...

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.

Skin

6 2125 Installation, Operation, and Maintenance Manual

1. Remove contaminated clothing.

2. Wash the skin with soap and water for at least one minute.

3. Seek medical attention, if required.

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 (including 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.

• You must fully submerge the Ex-approved product during normal 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.

• Make sure that thermal contacts are connected to a protection circuit according to the

approval classification of the product, and that they are in use.

• 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 authorized Xylem

representative.

• Only use parts that are provided by an authorized Xylem representative.

Introduction and Safety

ATEX guidelines

ATEX 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 Xylem representative.
When you install or maintain ATEX-compliant equipment, always comply with the directive
and applicable standards in IEC/EN 60079–14.

Permitted liquid level for ATEX

ATEX-approved products must be fully submerged according to the ATEX approval. Level­sensing equipment must be installed if the product can be operated at less than the
minimum submersion depth.

Monitoring equipment

For additional safety, use condition-monitoring devices. Condition-monitoring devices
include but are not limited to the following:

• Level indicators

• Temperature detectors

2125 Installation, Operation, and Maintenance Manual 7

Introduction and Safety

MSHA requirements

According to the Code of Federal Regulations, the following requirements must be fulfilled
to maintain permissibility of this equipment:

Subject area Requirements
General safety

Service and repair

Fastenings All bolts, nuts, screws, and threaded covers must be properly tightened and secured.

Cables A flame-resistant portable cable must be used. It has to bear an MSHA-assigned

• Frequent inspections must be made.

• All electrical parts, portable cable, and wiring must be kept in a safe condition.

• There must not be any openings into the casings of the electrical parts.

• The machine frame must be effectively earthed (grounded).

• Power wires must not be used for earthing (grounding).

• The operating voltage must match the voltage rating of the motor.

• Inspections, service, and repairs are only allowed when the portable cable is
disconnected from the power supply.

• Work must be performed by trained personnel (preferably the manufacturer or

agent) to ensure that the pump is restored to its original state of safety in regards
to all flame-arresting paths.

• Replacement parts must be exactly equal to those provided by the manufacturer.

• When cable entries are disturbed on pump or control, they must be reassembled
in the approved manner.

DANGER:

Failure to restore the permissible equipment to its original
state of safety will void the MSHA approval. The creation of a
safety hazard will subject the owner / operator of a mine to
citations and penalties under the law.

identification number and be adequately protected by an automatic circuit-interrupting
device. Special care must be taken in handling the cable to avoid mechanical damage
and wear.

Operation Poly-Life® equipped products must not be operated dry in hazardous areas.

Environmental safety

The work area

Always keep the station clean to avoid and/or discover emissions.

Recycling guidelines

Always recycle according to these guidelines:

1. Follow local laws and regulations regarding recycling if the unit or parts are
accepted by an authorized recycling company.

2. If the first guideline is not applicable, then return the unit or parts to your Xylem

representative.

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.

8 2125 Installation, Operation, and Maintenance Manual

Electrical installation

Introduction and Safety

For electrical installation recycling requirements, consult your local electric utility.

2125 Installation, Operation, and Maintenance Manual 9

Transportation and Storage

Transportation and Storage

Transportation guidelines

Precautions

WARNING:

• Stay clear of suspended loads.

• Observe accident prevention regulations in force.

Position and fastening

The pump can be transported either horizontally or vertically. Make sure that the product is
securely fastened during transportation, and cannot roll or fall over.

Lifting

WARNING:

Crush hazard. The unit and the components can be heavy. Use proper lifting methods

•
and wear steel-toed shoes at all times.

• Lift and handle the product carefully, using suitable lifting equipment.

• The product must be securely harnessed for lifting and handling. Use eyebolts or lifting
lugs if available.

• Always lift the unit by its lifting handle. Never lift the unit by the motor cable or by the
hose.

• Do not attach sling ropes to shaft ends.

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.

Freezing precautions

The pump is frost-proof while operating or immersed in liquid, but the impeller/propeller
and the shaft seal may freeze if the pump is lifted out of the liquid into a surrounding
temperature below freezing.

Follow these guidelines to avoid freezing damage:

10 2125 Installation, Operation, and Maintenance Manual

Long-term storage

Transportation and Storage

When Guideline
Before storage

• The pump must be allowed to run for a short time after raising it to
discharge remaining pumped liquid.

• The discharge opening must be covered in a suitable way, or placed
facing down so that any still remaining pumped liquid runs out.

• If present, the cooling jacket must be drained manually by opening the
air vent screws at the top of the cooling jacket.

After storage If the impeller/propeller is frozen, it must be thawed by immersing the pump

in liquid before operating the pump.

NOTICE:

Never use a naked flame to thaw the unit.

If the pump is stored more than 6 months, the following apply:

• Before operating the pump 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.

2125 Installation, Operation, and Maintenance Manual 11

Product Description

Product Description

Products included

Pump model Approvals

Pump design

Intended use

2125.181

2125.320

2125.051 MSHA (Mine Safety and Health Administration, USA):

2125.690

The pump is submersible, and driven by an electric motor.

Pumps with MSHA (Mine Safety and Health Administration, USA) certifications are
designed to be used in explosive zones.

WARNING:

In explosive or flammable environments, only use Ex- or MSHA-approved pumps.

Standard

30CFR Part 18, Approval number X/P-3769-0

• European Norm

• ATEX Directive

• EN 1127-1, EN 50014, EN 50018

• I M2 EEx d I

Particle size

Pressure class

Impeller type

NOTICE:

Do NOT use the pump in highly corrosive liquids.

For information about pH, see Application limits (page 42).

The pump can handle liquid containing particles that correspond to the holes in the
strainer.

Number of holes Hole dimensions

186 6×50 mm (0.24× 1.96 in.)

For more information about the strainer, see Dimensions and weights (page 46).

MT Medium head

HT High head

ST Super head

B Wear resistant

12 2125 Installation, Operation, and Maintenance Manual

2

1312 14

22

21

20

17 18 1916159 10 11

8

7

6

5

4

3

1

23

24

Product Description

Poly-Life

®

Version code 051/181: The pump is available with Poly-Life® polyurethane wear parts for
extra resistance.

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 125°C (257°F).

The data plate

The data plate is a metal label located on the main body of the pump. The data plate lists
key product specifications.

Ex- and MSHA-approved products also have approval plates. They are described below, if
applicable.

1. Curve code/Propeller code

2. Serial number, see Product denomination (page 14)

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

2125 Installation, Operation, and Maintenance Manual 13

1 2 3

4

5

6 7

8

9 10

12

11

13

14

15

1

NP 3085

2 3

Product Description

The Ex approval plate

1. Approval

Approval authority and approval number

2.

3. Approval for Class I

4. Approved drive unit

5. Stall time

6. Starting current/Rated current

7. Duty class

8. Duty factor

9. Input power

10. Rated speed

11. Controller

12. Additional information

13. Maximum ambient temperature

14. Serial number

15. ATEX marking

The MSHA approval plate

Product denomination

Sales denomination

The sales denomination consists of the four-digit sales code and two letters that indicate
the hydraulic end and type of installation.

This is an example of a sales denomination, and an explanation of its parts.

1. Hydraulic part

2.

Installation type

3. Sales code

14 2125 Installation, Operation, and Maintenance Manual

Product code

3085.183

1 2

NP

1

NP 3085.183 - 951 0163

2 3 4

Serial number

Product Description

The product code consists of nine characters divided into two parts.
This is an example of a product code, and an explanation of its parts.

1. Sales denomination

2. Version

The serial number is used for identification of an individual product, and is divided into
four parts.

This is an example of a serial number, and an explanation of its parts.

1. Product code

2. Production year

3. Production cycle

4. Running number

2125 Installation, Operation, and Maintenance Manual 15

Installation

Installation

Install the pump

WARNING:

• Before installing the pump, check that the cable and cable entry have not been
damaged during transportation.

• Make sure that the pump cannot roll or fall over and injure people or damage property.

• Do not install CSA-approved products in locations that are classified as hazardous in the

national electric code, ANSI/NFPA 70-2005.

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.

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.

Figure 2: Settling pump-sump

Discharge line requirements

The discharge line can be run vertically or horizontally, but must be without sharp bends.

16 2125 Installation, Operation, and Maintenance Manual

Fasteners

Installation

Proper horizontal and vertical installation Improper installation with a sharp

bend

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, 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.
Make sure that the impeller rotation is correct. For more information, see Check the

impeller rotation (page 27).

2125 Installation, Operation, and Maintenance Manual 17

Installation

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 pump, make sure that the pump 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.

CAUTION:

If the pump is equipped with automatic level control and/or internal contactor, there is a
risk of sudden restart.

Requirements

Cables

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, the connected voltage is specified
by a yellow sticker close to the cable entry.

• The fuses, short-circuit, 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 starting 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, the pump must be provided with monitoring

equipment supporting such operation.

• The thermal contacts must be in use.

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 sheathing must not be damaged and must not have indentations or be embossed

(with markings, etc.) at the cable entry.

18 2125 Installation, Operation, and Maintenance Manual

Earthing (Grounding)

Installation

• 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 an Xylem service shop.

• The voltage drop in long cables must be taken into account. The drive unit’s rated

voltage is the voltage measured at the terminal board in the upper part of the pump.

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 200 mm ( 7.9 in.) longer than the phase conductors
in the junction box of the unit.

Connect the motor cable to the pump

CAUTION:

Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the
end of the motor cable above the liquid level.

1. Check the data plate to see which connections are required for the power supply:

Y

•

• D

• Y serial

• Y parallel

• Y/D

2. Arrange the connections on the terminal board in accordance with the required power

supply.
Do not use links (jumper strips) with the Y/D start.
Do not use links (jumper strips) with the 9 stator leads tandem-coupling.

3. Connect the motor conductors (U1, V1, W1, and earth (ground)) to the terminal board.

4. Make sure that the pump is correctly connected to earth (ground).

5. Make sure that any thermal contacts incorporated in the pump are properly connected

to the terminal board.

6. Install the cover.

7. Fasten the screws on the entrance flange so that the cable insertion assembly bottoms

out.

8. Tighten the clamping screws.

2125 Installation, Operation, and Maintenance Manual 19

U2W2 V2

V1U1 W1

1 3 5 13 A2

2 4 6 14 A1

A2 44 32 22 14

A1 43 31 21 13

L1GC L2 L3

1

2

4

3

5

6

Installation

Cable charts

Connection locations

After you have connected the motor cable to the pump, connect the motor cable and the
control cable to the starter equipment.

WARNING:

Do not install the starter equipment in an explosive zone or in the sump.

Three thermal contacts are incorporated in the stator. They are normally closed.
Thermal contacts must never be exposed to voltages higher than 250 V, breaking current

maximum 6 A at a power factor 0.6. It is recommended that the thermal contacts are
connected to 24 V over a separate fuse to protect any other automatic equipment.

Colors and marking of the mains leads

1. Starter equipment

Mains and control leads

2.

3. Motor cable (or cables)

4. Contactor unit on the pump (if any)

5. Terminal board on the pump (if any)

6. Stator leads

Mains SUBCAB 7GX SUBCAB 4GX SUBCAB AWG SUBCAB Screened
L1 Black 1 Brown Red Brown
L2 Black 2 Black Black Black
L3 Black 3 Grey White Grey
L1 Black 4 - - ­L2 Black 5 - - ­L3 Black 6 - - -

20 2125 Installation, Operation, and Maintenance Manual

Mains SUBCAB 7GX SUBCAB 4GX SUBCAB AWG SUBCAB Screened

Groundcheck (GC) - - Yellow -

Colors and marking of the control leads

Mains SUBCAB 7GX and

T1 White T1 Orange White T1
T2 White T2 Blue White T2
T3 - - White T3
T4 - - White T4

Colors of the stator leads

Stator connection Lead color
U1 Red

U2 Green

U5 Red

Installation

Yellow / Green Yellow / Green Yellow / Green Screen from leads

SUBCAB AWG SUBCAB Screened

SUBCAB 4GX

U6 Green

V1 Brown

V2 Blue

V5 Brown

V6 Blue

W1 Yellow

W2 Black

W5 Yellow

W6 Black

2125 Installation, Operation, and Maintenance Manual 21

SUBCAB

®

7x#

SUBCAB

®

4Gx#
# AWG/4
# AWG/7

GC

1 2 3 4 T1 T2 L1 L2 L3

1 2 3 4 5 6 7 1 2 L1 L2 L3 GC

T1 T2

U1 W2 V1 U2T16 T15 T2 T1 W1 V2

U2V1W2U1 W1 V2

SUBCAB

®

7x1.5

SUBCAB

®

4Gx___
# AWG/4
# AWG/7

GC

1 2 3 4 T1 T2 L1 L2 L3

1 2 3 4 5 6 7 1 2 L1 L2 L3 GC

U1 W2 V1 U2

T16 T15 T2 T1

W1 V2

U2V1W2U1 W1 V2

T1 T2

5 6 7

U2W2 V2

V1U1 W1

T1

T2

GC L2L1 L3

T1 T2

T1 T2

T1

T2

T1 T2

U1 V1 U2 V2

SUBCAB

®

SUBCAB

®

GC

L1 L2

L3

W1W2

U2

W2

V2

V1U1 W1

T1

T2

GC L2L1 L3

T1 T2

T1 T2

T1

T2

T1 T2

U1 V1 U2 V2

SUBCAB

®

SUBCAB

®

GC

L1 L2

L3

W1W2

Installation

SUBCAB 4GX / SUBCAB AWG, 6 stator leads, Y and D connection (terminal board)

Y connection D connection

Y connection D connection

22 2125 Installation, Operation, and Maintenance Manual

SUBCAB 4GX / SUBCAB AWG, 6-leads, Y and D connections (contactor unit)

SUBCAB

®

L1

L2

L3

W2

U1

V1

U2

W1

V2

G C

G C

L3

G C

3 ~

L2L1

T2

T1

1

Y

14642

A1

135

3

A2

13213143A1

14

2232

44

A2

1 3 5 13 A2

2 4 6 14 A1

A2 44 32 22 14

A1 43 31 21 13

SUBCAB

®

GC

L1

U1

W2V1U2

V2

W1

T1

T2

L3 L2

L1GC L2 L3

U2W2 V2

V1U1 W1

1 3 5 13 A2

2 4 6 14 A1

A2 44 32 22 14

A1 43 31 21 13

SUBCAB

®

GC

L1 L3 L2

T2T1

W2 U1 V1 U2 W1 V2

L1GC L2 L3

1 3 5 13 A2

2 4 6 14 A1

A2 44 32 22 14

A1 43 31 21 13

U2W2 V2

V1U1 W1

T1

T2

SUBCAB

®

GC

L1 L3 L2

T2T1

W2 U1 V1 U2 W1 V2

L1GC L2 L3

Y connection D connection

Installation

SUBCAB 4GX / SUBCAB AWG, 6 stator leads, Y and D connection (terminal board and contactor unit)

2125 Installation, Operation, and Maintenance Manual 23

Stator leads W2, U2, and V2 are connected together at a
separate Y terminal.

Y connection D connection

V1W1 U1

U2V2 W2

T1

T2

L1 L2 L3 L1 L2

L3

1 2 43 5 6

11223

3

T1T1T2

T2

W1 V1

SUBCAB

®

SUBCAB

®

SUBCAB

®

U1 V2

U2

44556 T1 T2 T1 T2

6

W2

V1

W1

U1

U2

V2

W2

T1 T2

L 1

L3

L2 L1

L2

L3

1

14642

A2

135

3

A2

13213143A1

14

2232

44

A1

1 2

3 4

5

6

4

5

6

3

2

1

SUBCAB

SUBCAB

W1V1U1 W2U2V2

SUBCAB

®

7x1.5

SUBCAB

®

4Gx___
# AWG/4
# AWG/7

GC

1 2 3 4

L1T1 T2 L2 L3

T2T1

1 2 3 4 5 6 7

1 2 L1 L2 L3 GC

U1 U5 V1 V5

T16 T15 T2 T1

W1 W5

V5

V1

U5

U1 W1

W5

5

6 7

W2

U2

V2

SUBCAB

®

7x1.5

SUBCAB

®

4Gx___
#AWG/4
#AWG/7

GC

1 2 3 4 L1

T1 T2 L2 L3

T2T1

1 2 3 4 5 6 7 1 2 L1 L2 L3 GC

U1 U5 V1 V5T16 T15 T2 T1 W1 W5

V5

V1

U5

U1

W1

W5W2V2

U2

5

6 7

Installation

SUBCAB 4GX, 6 stator leads, Y/D connection

Terminal board Terminal board and contactor unit

SUBCAB 4GX / SUBCAB AWG, 60 Hz only, 9 stator leads, Y serial and Y parallel connection

Y serial connection (460 V) Y parallel connection (230 V)

Stator leads W2, U2, and V2 are connected together on
the terminal.

24 2125 Installation, Operation, and Maintenance Manual

SUBCAB 4GX / SUBCAB AWG, 60 Hz only, 9 stator leads, Y serial and Y parallel connection

L1 L2L3

L3

V1

W1

T1

T2

U1

T1

W2

U1

V1

U2

W1

V2

SUBCAB

®

SUBCAB

®

GC L1 L2

T1 T2

3~

V2

W2

U2

GC

T2

T1

T2

GC

U5

V5

W5

L1

L2L3

L3

V1

W1

T1

T2

U1

T1

W2

U1

V1 U2

W1

V2

SUBCAB

®

SUBCAB

®

GC L1 L2

T1 T2

3~

V2

W2

U2

GC

T2

T1

T2

GC

U5

V5

W5

L1

L2L3

L3

V1 W1

T1

T2

U1

T1

W2

U1

V1

U2

W1

V2

SUBCAB

®

SUBCAB

®

G C L 1 L 2

T 1 T 2

V2

W2

U2

G C

T2

T1

T2

G C

U5

V5

W5

W6U6V6

L1

L2L3

L3

V1 W1

T1

T2

U1

T1

U2

U1

V1

V2

W1

W2

SUBCAB

®

SUBCAB

®

G C L 1 L 2

T 1 T 2

3 ~

V2

W2

U2

G C

T2

T1

T2

G C

U5

V5

W5

W6

U6

V6

Y serial connection (460 V) Y parallel connection (230 V)

Installation

Stator leads W2, U2, and V2 are connected together on
the terminal board.

SUBCAB 4GX / SUBCAB AWG, 60 Hz only, 12 stator leads, Y serial and Y parallel connection

Stator leads W6, U6, and V6 are connected together in an insulated closed-end splice.

Y serial connection (460 V) Y parallel connection (230 V)

2125 Installation, Operation, and Maintenance Manual 25

SUBCAB

®

7x1.5

SUBCAB

®

7Gx ___

T1

T1 T2 11 2 3 4 5 6 7

T2

2 3 4 5 6

1 2 3 4 5 6 7

1 2

L1 L2 L1L3 L2 L3

U1 W2 V1 U2T16 T15 T2 T1 W1 V2

U2V1W2U1 W1 V2

T1

W2U1

V1

U2

W1

V2

SUBCAB

®

T1 T 2

3~

T2

L1

1

3

4

2

6

5

1

2 3 4 5 6

L3L2 L1 L2L3

T1

T2

V1

U1

W1

V2

U2

W2

V1

W1

U1

U2

V2

W2

T2

L 1

L3

L2 L1

L2

L3

SUBCAB

1

14642

A2

135

3

A2

13213143A1

14

2232

44

A1

1 2

3 4

5

6

4

5

6

3

2

1

W1V1U1 W2U2V2

T1

Installation

SUBCAB 7GX, 6 stator leads, Y/D connection (terminal board)

Alternative 1 Alternative 2

SUBCAB 7GX, 6 stator leads, Y/D connection (terminal board and contactor unit)

26 2125 Installation, Operation, and Maintenance Manual

Check the impeller rotation

L2

L1 L2 L3

L3L1

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.
Stop the motor.

2.

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.

Installation

Figure 3: Start reaction

If the impeller rotates in the wrong direction, then do the following:

4.

• 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.

2125 Installation, Operation, and Maintenance Manual 27

Operation

Operation

Precautions

• Never operate the pump without safety devices installed.

• Never operate the pump with the discharge valve closed.

• Make sure that all safety guards are in place and secure.

• Make sure you have a clear path of retreat.

• Never work alone.

• Beware of the risk of a sudden start if the product is used with an automatic level
control and/or internal contactor.

Distance to wet areas

Electrical Hazard:

Risk of electrical shock when pumping or mixing near a lake, jetties, beaches, ponds,
fountains, or similar. There must be a safety distance of at least 20 m (65 ft.) between the
person and the product if the person is in contact with the pumped or mixed liquid.

Electrical Hazard:

Risk of electrical shock. This pump has not been investigated for use in swimming pools. If
used in connection with swimming pools special safety regulations apply.

Noise level

NOTICE:

The noise level of the product is lower than 70 dB. However, the noise level of 70 dB may
be exceeded in some installations and at certain operating points on the performance
curve. Make sure that you understand the noise level requirements in the environment
where the pump is installed. Failure to do so may result in hearing loss or violation of local
laws.

Start the pump

WARNING:

If you need to work on the pump, make sure that it is isolated from the power supply and

•
cannot be energized.

• Make sure that the pump cannot roll or fall over and injure people or damage property.

• In some installations, the pump and the surrounding liquid may be hot. Bear in mind the
risk of burn injuries.

• Make sure nobody is close to the pump when it is started. The pump will jerk in the
opposite direction of the impeller rotation.

NOTICE:

Make sure that the rotation of the impeller is correct. For more information, see Check the
impeller rotation.

1. Check the oil level in the oil housing.

28 2125 Installation, Operation, and Maintenance Manual

2. Remove the fuses or open the circuit breaker, and check that the impeller can be

rotated freely.

3. Check that the monitoring equipment (if any) works.

4. Check that the impeller rotation is correct.

5. Start the pump.

Clean the pump

The pump must be cleaned if it has been running in very dirty water. If clay, cement or
other similar dirt is left in the pump it may clog the impeller and seal, preventing the pump
from working.

Let the pump run for a while in clean water, or flush it through the discharge
connection.

Operation

2125 Installation, Operation, and Maintenance Manual 29

Maintenance

Maintenance

Precautions

WARNING:

• Always follow safety guidelines when working on the pump. See Introduction and Safety
(page 3).

• Disconnect and lock out electrical power before installing or servicing the pump.

• Make sure that the pump cannot roll or fall over and injure people or damage property.

• Rinse the pump thoroughly with clean water before working on the pump.

• Rinse the components in water after dismantling.

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.

• 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.

Maintenance guidelines

During 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, and O-rings with grease.

During reassembly, always make sure that existing index markings are in line.

Torque values

Screw and nuts

Stainless steel, A2 and A4
Property

class

Torque,
Nm (ft­lbs)

Carbon steel and alloyed steel

70 +80 2.7 (2) 5.4 (4) 9.3 (6.9) 22 (16) 44 (32) 76 (56) 187 (138) 364 (268) 629 (464) 1240

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

(915)

1

Property class 70 is torque tightened as class 80.

30 2125 Installation, Operation, and Maintenance Manual

Maintenance

Torque,
Nm (ft­lbs)

Screws with countersunk heads

Stainless steel, A2 and A4
Property

Torque,
Nm (ft-lbs)

Carbon steel and alloyed steel
Torque,

Nm (ft-lbs)

8.8 2.9 (2.1) 5.7 (4.2) 9.8 (7.2) 24 (18) 47 (35) 81(60) 194 (143) 385 (285) 665 (490) 1310

10.9

12.9

class
70 +8011.2 (0.9) 2.7 (2) 5.4 (4) 9.3 (6.9) 22 (16) 44 (32) 76 (56) 120 (88) 187 (138)

8.8 2.3 (1.7) 4.6 (3.4) 7.8 (5.8) 19 (14) 38 (28) 65 (48) 158 (116) 308 (228) 532 (392)

10.9

12.9

4.0 (2.9) 8.1 (6) 14 (10.3) 33 (24.3) 65 (48) 114 (84) 277 (204) 541 (399) 935 (689) 1840

4.9 (3.6) 9.7 (7.2) 17 (12.5) 40 (30) 79 (58) 136 (100) 333 (245) 649 (480) 1120

M4 M5 M6 M8 M10 M12 M16 M20 M24

3.2 (2.4) 6.5 (4.8) 11(8) 26 (19) 52 (38) 91 (67) 222 (164) 433 (320) 748 (552)

3.9 (2.9) 7.8 (5.8) 14 (10.3) 32 (23.6) 63 (46) 109 (80) 266 (196) 519 (383) 896 (661)

(825)

(966)

(1357)
2210

(1630)

Service

Regular inspection and service of the pump ensures more reliable operation.

Type of service Purpose Inspection interval

Inspection To prevent operational interruptions

and machine breakdown. Measures
to secure performance and pump
efficiency are defined and decided
for each individual application. It
can include such things as impeller
trimming, wear part control and
replacement, control of zinc-anodes
and control of the stator.

Major overhaul To secure a long operating lifetime

for the product. It includes
replacement of key components
and the measures taken during an
inspection.

NOTICE:

Shorter intervals might be required for tough operating conditions such as very abrasive
and corrosive applications and media (liquid) temperatures >40°C.

Twice a year

Every year, under normal operating
conditions

Inspection

Regular inspection and service of the pump ensures more reliable operation.

2125 Installation, Operation, and Maintenance Manual 31

Maintenance

Service item Action

Visible parts on
the pump and
installation

1. Check that all screws, bolts, and nuts are properly tightened.

2. Check the condition of lifting handles, eyebolts, ropes, chains, and wires.

3. Check for worn or damaged parts.

4. Adjust and/or replace if necessary.

Pipes, valves, and
other peripheral
equipment

Pump casing and
impeller

1. Check for worn or damaged parts.

2. Adjust and/or replace if necessary.

1. Check for worn or damaged parts.

2. Adjust and/or replace if necessary.

Wear on the impeller or surrounding parts necessitates fine adjustments of the impeller
or replacement of worn parts. See Replace the impeller (page 34).

Oil Check the water and oil mixture as follows:

1. Insert a tube or hose into the oil hole.

2. Cover the top end of the tube.

3. Take up a little oil from the bottom.
(Air/oil mixture can be confused with water/oil mixture.)

4. If the mixture contains too much water, in other words if it is heavily emulsified

(creamlike) or if the water has settled out, then change the oil. See Change the

oil (page 33). Check again one week after changing the oil.

Cable entry

1. Check that the following requirements are met:

• The cable clamps must be properly tightened.

• The cable entry must be firmly tightened into its bottom-most position.

• The seal sleeve and the washers must conform to the outside diameter of the

cables.

2. Cut off a piece of the cable so that the seal sleeve closes around a new position
on the cable.

3. Replace the seal sleeve, if necessary.

Inspection
chamber

2

1. Drain all liquid.

2. If there is water in the stator casing, then do the following:
a. Check that the inspection screw is properly tightened.
b. Check that the O-ring is not damaged.
c. Check that the cable entry does not have any leakage.

3. If there is oil in the inspection chamber, then check that the inner mechanical
seal is not damaged. If necessary, contact an authorized service shop.

Cable

1. If the outer jacket is damaged, replace the cable.

2. Check that the cables do not have any sharp bends and are not pinched.

Cooling system Rinse and clean if the flow through the system has been partly restricted.

Level sensors or
other sensor
equipment

1. Check the functionality.

2. Repair or replace any damaged equipment.

3. Clean and adjust the equipment.

2

Regardless of individual applications, the inspection chamber should not be inspected less frequently than the intervals for normal
applications and operating conditions at media (liquid) temperatures <40°C.

32 2125 Installation, Operation, and Maintenance Manual

Service item Action

Maintenance

Major overhaul

Change the oil

A paraffin oil with viscosity close to ISO VG32 is recommended. The pump is delivered
from the factory with this type of oil. In applications where poisonous properties are of less
concern, a mineral oil with viscosity up to ISO VG32 can be used.

Starter
equipment

Insulation
resistance in the
stator

For a major overhaul, take this action, in addition to the tasks listed under Inspection.

Service item Action

Support and main bearing Replace the bearings with new bearings.

Mechanical seal Replace with new seal units.

1. Check the condition and functionality.

2. Contact an electrician, if necessary.

1. Check the insulation between:

• Phase–phase on the stator

• Phase–earth (ground)
The insulation should be > 1 megohm. Use a 1000 VDC megger to test the

insulation.

2. If the resulting value is < 1 megohm, then contact an authorized service shop.

Empty the oil

1. Lay the pump on its side.
Lock the pump with supports to prevent it from rolling over.

2. Remove the oil screw.
There are two oil screws. Either can be used for drainage, but it is easier to drain the oil

if both oil screws are removed.

WARNING:

The oil housing may be pressurized. Hold a rag over the oil plug to
prevent oil from spraying out.

3. Turn the pump so that the oil hole faces downwards and let the oil run out.

2125 Installation, Operation, and Maintenance Manual 33

Maintenance

Fill with oil

1. Replace the oil screw O-ring.

2. Put one of the oil screws back and tighten it.

3. Turn the pump so that the oil hole faces upwards and fill with new oil.
Quantity for version code 181/051: 2 L (2.1 qt.)
Quantity for version code 320/690: 1.7 L (1.8 qt.)

4. Put the oil screw back and tighten it.
Tightening torque: 10–40 Nm (7.4–30 ft-lbs)

Replace the impeller

Remove the impeller

WARNING:

A worn impeller and/or pump housing can have very sharp edges. Wear protective gloves.

1. Lay the pump on its side.

34 2125 Installation, Operation, and Maintenance Manual

2. Remove the items in the illustrations:
a) Remove the nuts and the strainer.

b) Remove the nuts and the suction cover.

Maintenance

c) Remove the nuts and the diffuser.

3. Remove the impeller:

Lock the impeller to prevent rotation.

a)

2125 Installation, Operation, and Maintenance Manual 35

Maintenance

Use pliers, screwdriver, or similar.

b) Remove the impeller nut.

c) Pull off the impeller.

Use an impeller puller or pry off carefully with two strong screwdrivers or bars.

4. If the diffuser is to be replaced, the oil has to be drained first.

5. Remove the studs and the diffuser.

Install the impeller

Make sure that the upper diffuser is properly mounted before you begin.

1. Prepare the shaft:

2. Install the impeller:

a) Polish off any flaws with a fine emery cloth.

The end of the shaft must be clean and free from burrs.
b) Grease the end of the shaft.
c) Insert the key in the keyway of the shaft.
d) Fit an appropriate number of adjusting washers on the shaft.

a) Fit the impeller onto the shaft.
b) Lock the impeller to prevent rotation.

Use pliers, screwdriver, or similar.
c) Tighten the impeller nut.

Tightening torque: 60 Nm (44 ft-lbs).

36 2125 Installation, Operation, and Maintenance Manual

The impeller clearance should be minimal when the impeller is tightened. Use the

adjusting washers to adjust the clearance.

3. Check that the impeller can rotate easily.

4. Install the lower diffuser.

Maintenance

5. Install the suction cover:
a) Press the suction cover against the impeller.

The impeller clearance should be minimal when the impeller is tightened. Use the
inner nuts to adjust the clearance.

b) Place the nuts on the studs. Tighten the nuts evenly all around.

6. Check that the impeller can rotate easily.
Install the strainer.

7.

In order for the pump to perform at maximum capacity, the impeller must be adjusted
regularly.

2125 Installation, Operation, and Maintenance Manual 37

Troubleshooting

Troubleshooting

Introduction

Follow these guidelines when troubleshooting the pump:

• Disconnect and lock out the power supply except when conducting checks that
require voltage.

• Make sure that no one is near the pump when the power supply is reconnected.

• When troubleshooting electrical equipment, use the following:

• Universal instrument multimeter

• Test lamp (continuity tester)

• Wiring diagram

The pump does not start

WARNING:

Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.

Cause Remedy

An alarm signal has been triggered
on the control panel.

The pump does not start
automatically, but can be started
manually.

The installation is not receiving
voltage.

Check that:

The impeller rotates freely.

•

• The sensor indicators do not indicate an alarm.

• The overload protection is not tripped.
If the problem still persists:
Contact the local Xylem service shop.

Check that:

• The start level regulator is functioning. Clean or replace if necessary.

• All connections are intact.

• The relay and contactor coils are intact.

• The control switch (Man/Auto) makes contact in both positions.
Check the control circuit and functions.

Check that:

• The main power switch is on.

• There is control voltage to the start equipment.

• The fuses are intact.

• There is voltage in all phases of the supply line.

• All fuses have power and that they are securely fastened to the fuse
holders.

• The overload protection is not tripped.

• The motor cable is not damaged.

The impeller is stuck. Clean:

38 2125 Installation, Operation, and Maintenance Manual

Cause Remedy

• The impeller

• The sump in order to prevent the impeller from clogging again.

If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 12).

The pump does not stop when a level sensor is used

WARNING:

Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

Cause Remedy

Troubleshooting

The pump is unable to empty the
sump to the stop level.

There is a malfunction in the level­sensing equipment.

The stop level is set too low. Raise the stop level.

If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 12).

Check that:

There are no leaks from the piping and/or discharge connection.

•

• The impeller is not clogged.

• The non-return valve(s) are functioning properly.

• The pump has adequate capacity. For information:
Contact the local Xylem service shop.

• Clean the level regulators.

• Check the functioning of the level regulators.

• Check the contactor and the control circuit.

• Replace all defective items.

The pump starts-stops-starts in rapid sequence

Cause Remedy

The pump starts due to back-flow
which fills the sump to the start
level again.

Check that:

The distance between the start and stop levels is not too small.

•

• The non-return valve(s) work(s) properly.

• The rinser is not too long without a non-return valve.

The self-holding function of the
contactor malfunctions.

If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 12).

2125 Installation, Operation, and Maintenance Manual 39

Check:

• The contactor connections.

• The voltage in the control circuit in relation to the rated voltages on the
coil.

• The functioning of the stop-level regulator.

• Whether the voltage drop in the line at the starting surge causes the
contactor's self-holding malfunction.

Troubleshooting

The pump runs but the motor protection trips

WARNING:

Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.

Cause Remedy

The motor protection is set too low. Set the motor protection according to the data plate and if applicable the

cable chart.

The impeller is difficult to rotate by
hand.

The drive unit is not receiving full
voltage on all three phases.

The phase currents vary, or they are
too high.

The insulation between the phases
and ground in the stator is
defective.

The density of the pumped fluid is
too high.

The ambient temperature exceeds
the maximum ambient
temperature.

• Clean the impeller.
Clean out the sump.

•

• Check that the impeller is properly trimmed.

• Check the fuses. Replace fuses that have tripped.

• If the fuses are intact, notify a certified electrician.

Contact the local Xylem service shop.

1. Use an insulation tester. With a 1000 V DC megger, check that the

insulation between the phases and between any phase and ground is
> 5 megohms.

2. If the insulation is less:

Contact the local Xylem service shop.

Make sure that the maximum density is 1100 kg/m3 (9.2 lb/US gal)

• Change the impeller, or

• Change to a more suitable pump.

• Contact the local Xylem service shop.

The pump must not be used for such an application.

There is a malfunction in the
overload protection.

If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 12).

The pump delivers too little or no water

WARNING:

Always disconnect and lock out power before servicing to prevent unexpected startup.
Failure to do so could result in death or serious injury.

40 2125 Installation, Operation, and Maintenance Manual

Replace the overload protection.

Troubleshooting

NOTICE:

Do NOT override the motor protection repeatedly if it has tripped. Doing so may result in
equipment damage.

Cause Remedy

The impeller rotates in the wrong
direction.

• If it is a 3-phase pump, transpose two phase leads.

• If it is a 1-phase pump:
Contact the local Xylem service shop.

One or more of the valves are set in
the wrong positions.

• Reset the valves that are set in the wrong position.

• Replace the valves, if necessary.

• Check that all valves are correctly installed according to media flow.

• Check that all valves open correctly.

The impeller is difficult to rotate by
hand.

• Clean the impeller.

• Clean out the sump.

• Check that the impeller is properly trimmed.

The pipes are obstructed. Clean out the pipes to ensure a free flow.

The pipes and joints leak. Find the leaks and seal them.

There are signs of wear on the

Replace the worn parts.

impeller, pump, and casing.

The liquid level is too low.

• Check that the level sensor is set correctly.

• Depending on the installation type, add a means for priming the pump,
such as a foot valve.

If the problem persists, contact the local Xylem service shop. Always state the serial
number of your pump when you contact Xylem, see Product Description (page 12).

2125 Installation, Operation, and Maintenance Manual 41

Technical Reference

Technical Reference

Application limits

Data Description

Motor data

Media (liquid)
temperature

pH of the pumped media
(liquid)

Media (liquid) density Maximum density: 1100 kg/m3 (9.2 lb. per US gal.)

Depth of immersion 20 m (65 ft.)

Other For specific weight, current, voltage, power rating, and speed of the pump, see the data

Feature Description

Motor type Squirrel-cage induction motor

Frequency Version code 181/320/690: 50 or 60 Hz

Supply 3-phase

Starting method

Maximum temperature 40°C (104°F)

Version code 051 and 181: 5–8
Version code 320 and 690: 6–13

plate on the pump. For starting current, see Motor data (page 42).
For other applications, contact the nearest Xylem representative for information.

Version code 051: 60 Hz

• Direct on-line

• Star-delta

Maximum starts per
hour

Code compliance IEC 60034-1

Rated output variation ±10%

Voltage variation without
overheating

Voltage imbalance
tolerance

Stator insulation class H (180°C [360°F])

Specific motor data

Version code 181: 3-phase, 50 Hz

Motor type:

• 2,890 rpm

• Rated output 8.0 kW (11 hp)

30 evenly spaced starts per hour

±10%, provided that it does not run continuously at full load

2%

42 2125 Installation, Operation, and Maintenance Manual

Voltage (V) Rated current (A) Starting current (A)
220 D 27 200
230 D 27 211
380 D 16 113
380 Y 16 115
400 D 15 120
400 Y 15 122
415 D 15 113
440 D 15 121
500 D 12 98
525 D 12 104
550 D 11 80
660 Y 9.1 65
690 Y 8.9 69
1000 Y 6.2 49

Version code 181: 3-phase, 60 Hz

Motor type:

• 3,465 rpm

• Rated output 9.7 kW (13 hp)

Voltage (V) Rated current (A) Starting current (A)
208 D 35 247
220 D 33 264
220 Y parallel 33 243
230 D 32 278
230 Y parallel 32 256
260 D 28 216
380 D 19 149
380 Y 19 152
400 Y 19 161
440 D 16 119
440 Y 16 121
440 Y serial 16 121
460 D 16 125
460 Y 16 128
460 Y serial 16 128
480 D 15 131
575 D 13 102
600 D 12 107
1100 Y 6.6 49

Technical Reference

2125 Installation, Operation, and Maintenance Manual 43

Technical Reference

Version code 320: 3-phase, 50 Hz

Motor type:

• 2,890 rpm

• Rated output 8.0 kW (11 hp)

Voltage (V) Rated current (A) Starting current (A)
220 D 27 200
230 D 27 211
380 D 16 113
380 Y 16 115
400 D 15 120
400 Y 15 122
415 D 15 113
440 D 15 121
500 D 12 98
525 D 12 104
550 D 11 80
660 Y 9.1 65
690 Y 8.9 69
1000 Y 6.2 49

Version code 320: 3-phase, 60 Hz

Motor type:

• 3,465 rpm

• Rated output 9.7 kW (13 hp)

Voltage (V) Rated current (A) Starting current (A)
220 Y parallel 33 243
230 Y parallel 32 256
260 D 28 216
380 D 19 149
440 D 16 119
440 Y 16 121
440 Y serial 16 121
460 D 16 125
460 Y 16 128
460 Y serial 16 128
575 D 13 102
600 D 12 107
1100 Y 6.6 49

Version code 051: 3-phase, 60 Hz

Motor type:

• 3,485 rpm

• Rated output 9.7 kW (13 hp)

44 2125 Installation, Operation, and Maintenance Manual

Voltage (V) Rated current (A) Starting current (A)
460 Y serial 16 128
575 D 13 102
950 Y 7.5 56

Version code 690: 3-phase, 50 Hz

Motor type:

• 2,890 rpm

• Rated output 8.0 kW (11 hp)

Voltage (V) Rated current (A) Starting current (A)
230 D 27 211
380 D 16 113
400 D 15 120
400 Y 15 122
415 D 15 113
440 D 15 121
500 D 12 98
550 D 11 80
660 Y 9.1 65
690 Y 8.9 69
1000 Y 6.2 49

Technical Reference

Version code 690: 3-phase, 60 Hz

Motor type:

• 3,465 rpm

• Rated output 9.7 kW (13 hp)

Voltage (V) Rated current (A) Starting current (A)
220 Y parallel 33 243
230 Y parallel 32 256
260 D 28 216
380 D 19 149
440 D 16 119
440 Y 16 121
440 Y serial 16 121
460 D 16 125
460 Y 16 128
460 Y serial 16 128
575 D 13 102
600 D 12 107
1100 Y 6.6 49

2125 Installation, Operation, and Maintenance Manual 45

Technical Reference

Dimensions and weights

All measurements in the illustrations are in millimeters, if not otherwise specified.

Figure 4: Version code: 181 HT

46 2125 Installation, Operation, and Maintenance Manual

Technical Reference

Figure 5: Version code: 320 HT

2125 Installation, Operation, and Maintenance Manual 47

Technical Reference

Figure 6: Version code: 320 MT

48 2125 Installation, Operation, and Maintenance Manual

Technical Reference

Figure 7: Version code: 051 HT

2125 Installation, Operation, and Maintenance Manual 49

Technical Reference

Figure 8: Version code: 690 SH

Performance curves

Standard

Pumps are tested in accordance with ISO 9906, HI level A.

50 2125 Installation, Operation, and Maintenance Manual

2125.181

Q [l/s]

H [m]

2

P [kW]

0 2 4 6 8 10 12 14 16

0

10

20

30

40

50

60

70

4

6

8

HT

233

234

233

234

Technical Reference

Figure 9: 50 Hz

2125 Installation, Operation, and Maintenance Manual 51

0 2 4 6 8 10 12 14 16 18

0 50 100 150 200 250 300

0

10

20

30

40

50

60

70

0

50

100

150

200

250

5

6

7

8

9

10

6

8

10

12

14

HT

234

234

P2 [hp] / [kW]

H [ft] / [m]

Q [l/s] / [usgpm]

Technical Reference

Figure 10: 60 Hz

52 2125 Installation, Operation, and Maintenance Manual

2125.320

Q [l/s]

H [m]

2

P [kW]

0 2 4 6 8 10 12 14 16 18

0

10

20

30

40

50

60

5

6

7

8

HT

233

233

Technical Reference

Figure 11: HT, 50 Hz

2125 Installation, Operation, and Maintenance Manual 53

0 4 8 12 16 20

0 50 100 150 200 250 300 350

0

10

20

30

40

50

60

70

0

50

100

150

200

250

6

8

10

6

8

10

12

14

16

HT

234

234

P2 [hp] / [kW]

H [ft] / [m]

Q [l/s] / [usgpm]

Technical Reference

Figure 12: HT, 60 Hz

54 2125 Installation, Operation, and Maintenance Manual

Q [l/s]

H [m]

2

P [kW]

0 10 20 30 40 50

0

5

10

15

20

25

7.0

7.5

8.0

8.5

9.0

MT

231

231

Technical Reference

Figure 13: MT, 50 Hz

2125 Installation, Operation, and Maintenance Manual 55

0 10 20 30 40 50

0 100 200 300 400 500 600 700 800 900

0

5

10

15

20

25

30

0

20

40

60

80

100

9

10

11

11

12

13

14

15

16

MT

P2 [hp] / [kW]

H [ft] / [m]

232

232

Q [l/s] / [usgpm]

Technical Reference

Figure 14: MT, 60 Hz

56 2125 Installation, Operation, and Maintenance Manual

2125.690

Q [l/s]

H [m]

2

P [kW]

0 2 4 6 8 10 12 14 16 18

0

10

20

30

40

50

60

4

6

8

HT

233

233

234

234

Technical Reference

Figure 15: HT, 50 Hz

2125 Installation, Operation, and Maintenance Manual 57

0 4 8 12 16 20

0 50 100 150 200 250 300 350

0

10

20

30

40

50

60

70

0

50

100

150

200

250

6

8

10

6

8

10

12

14

16

HT

234

234

P2 [hp] / [kW]

H [ft] / [m]

Q [l/s] / [usgpm]

Technical Reference

Figure 16: HT, 60 Hz

58 2125 Installation, Operation, and Maintenance Manual

Q [l/s]

H [m]

2

P [kW]

0 10 20 30 40 50

0

5

10

15

20

25

5

6

7

8

9

MT

232

232

231

231

Technical Reference

Figure 17: MT, 50 Hz

2125 Installation, Operation, and Maintenance Manual 59

0 10 20 30 40 50

0 100 200 300 400 500 600 700 800 900

0

5

10

15

20

25

30

0

20

40

60

80

100

9

10

11

11

12

13

14

15

16

MT

P2 [hp] / [kW]

H [ft] / [m]

232

232

Q [l/s] / [usgpm]

Technical Reference

Figure 18: MT, 60 Hz

60 2125 Installation, Operation, and Maintenance Manual

Q [l/s]

H [m]

2

P [kW]

0 2 4 6 8 10 12 14 16

0

10

20

30

40

50

60

70

80

8

9

10

ST

253

253

Technical Reference

Figure 19: ST

2125 Installation, Operation, and Maintenance Manual 61

Xylem |’zīləm|

1) The tissue in plants that brings water upward from the roots

2) A leading global water technology company

We're 12,000 people unified in a common purpose: creating
innovative solutions to meet our world's water needs. Developing new
technologies that will improve the way water is used, conserved, and
re-used in the future is central to our work. We move, treat, analyze,
and return water to the environment, and we help people use water
efficiently, in their homes, buildings, factories and farms. In more than
150 countries, we have strong, long-standing relationships with
customers who know us for our powerful combination of leading
product brands and applications expertise, backed by a legacy of
innovation.

For more information on how Xylem can help you, go to xyleminc.com

Xylem Water Solutions AB
Gesällvägen 33
174 87 Sundbyberg
Sweden
Tel. [phone]
Fax [phone]
http://tpi.xyleminc.com

898401_1.0_en.US_2009-12_IOM.2125.051/.181/.320/.690_XR

Visit our Web site for the latest version of this document and
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The original instruction is in English. All non-English
instructions are translations of the original instruction.

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2011 Xylem Inc