www.grindex.

com EN
Installation, Operation, and
Maintenance Manual
90019401_3.0

8104.181 Major
 Table of Contents

Table of Contents
1 Introduction and Safety........................................................................................................ 3
1.1 Introduction....................................................................................................................3
1.2 Safety terminology and symbols....................................................................................3
1.3 User safety.................................................................................................................... 4
1.4 Special hazards............................................................................................................. 4
1.4.1 Working in temporary installations.......................................................................... 4
1.4.2 Biological hazards...................................................................................................4
1.4.3 Wash the skin and eyes..........................................................................................5
1.5 Protecting the environment............................................................................................5
1.6 End-of-life product disposal........................................................................................... 5
1.7 Spare parts.................................................................................................................... 5
1.8 Warranty........................................................................................................................ 5

2 Transportation and Storage................................................................................................. 6

2.1 Examine the delivery..................................................................................................... 6
2.1.1 Examine the package............................................................................................. 6
2.1.2 Examine the unit..................................................................................................... 6
2.2 Transportation guidelines.............................................................................................. 6
2.2.1 Precautions............................................................................................................. 6
2.2.2 Lifting...................................................................................................................... 6
2.3 Temperature ranges for transportation, handling and storage...................................... 7
2.4 Storage guidelines.........................................................................................................7

3 Product Description..............................................................................................................8
3.1 Products included.......................................................................................................... 8
3.2 Pump design..................................................................................................................8
3.3 Monitoring equipment.................................................................................................... 8
3.3.1 Level regulators...................................................................................................... 9
3.4 The data plate................................................................................................................9
3.5 Motor regulation...........................................................................................................10

4 Installation.......................................................................................................................... 11
4.1 Precautions..................................................................................................................11
4.1.1 Hazardous atmospheres.......................................................................................11
4.2 Requirements.............................................................................................................. 11
4.3 Install........................................................................................................................... 12
4.4 Make the electrical connections.................................................................................. 13
4.4.1 General precautions..............................................................................................13
4.4.2 Grounding (earthing) ............................................................................................14
4.4.3 Product-specific precautions.................................................................................15
4.4.4 Prepare the SUBCAB™ cables..............................................................................15
4.4.5 Connect the motor cable to the pump...................................................................16
4.4.6 Cable charts..........................................................................................................17
4.5 Check the impeller rotation: Pumps without built-in motor protection..........................20
4.6 Check the phase sequence: Pumps with built-in motor protection..............................20

5 Operation........................................................................................................................... 23
5.1 Precautions..................................................................................................................23
5.2 Start the pump............................................................................................................. 23
5.3 Clean the pump........................................................................................................... 24

8104.181 Major Installation, Operation, and Maintenance Manual 1

Table of Contents

6 Maintenance.......................................................................................................................25
6.1 Precautions..................................................................................................................25
6.2 Maintenance guidelines...............................................................................................25
6.3 Torque values..............................................................................................................26
6.4 Service.........................................................................................................................27
6.4.1 Inspection..............................................................................................................27
6.4.2 Overhaul............................................................................................................... 28
6.5 Change the oil............................................................................................................. 28
6.6 Replace the impeller....................................................................................................29
6.6.1 Remove the impeller............................................................................................. 30
6.6.2 Install the impeller................................................................................................. 31

7 Troubleshooting................................................................................................................. 34
7.1 General precautions.................................................................................................... 34
7.2 Electrical troubleshooting............................................................................................ 34
7.3 The pump does not start..............................................................................................34
7.3.1 Pumps with SMART™: The pump does not start...................................................35
7.4 The pump does not stop when a level sensor is used.................................................36
7.5 The pump starts-stops-starts in rapid sequence......................................................... 37
7.6 The pump runs but the motor protection trips..............................................................37
7.7 The pump delivers too little or no water.......................................................................38

8 Technical Reference.......................................................................................................... 40
8.1 Application limits..........................................................................................................40
8.2 Motor data................................................................................................................... 40
8.3 Specific motor data......................................................................................................40
8.4 Dimensions and weights..............................................................................................42
8.5 Performance curves.................................................................................................... 43

2 8104.181 Major Installation, Operation, and Maintenance Manual

 1 Introduction and Safety

1 Introduction and Safety

1.1 Introduction EN

Purpose of the manual

The purpose of this manual is to provide the necessary information for working with the unit.
Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the unit.
Intended use

WARNING:
Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment and the
surroundings. This includes any modification to the equipment or use of parts not provided
by Grindex. If there is a question regarding the intended use of the equipment, please
contact a Grindex representative before proceeding.

Other manuals
See also the safety requirements and information in the original manufacturer's manuals for
any other equipment furnished separately for use in this system.

1.2 Safety terminology and symbols

About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent these
hazards:
• Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels

Hazard level Indication

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

WARNING: A hazardous situation which, if not avoided, could

result in death or serious injury

CAUTION: A hazardous situation which, if not avoided, could

result in minor or moderate injury

NOTICE: Notices are used when there is a risk of equipment

damage or decreased performance, but not
personal injury.

8104.181 Major Installation, Operation, and Maintenance Manual 3

 1 Introduction and Safety

Special symbols
Some hazard categories have specific symbols, as shown in the following table.

Electrical hazard Magnetic fields hazard

EN Electrical Hazard: CAUTION:

1.3 User safety

All regulations, codes, and health and safety directives must be observed.
The site
• Observe lockout and tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by the
site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves and
shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.

1.4 Special hazards

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

1.4.2 Biological hazards

The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
• Make sure that all personnel who may come into contact with biological hazards are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.

WARNING: Biological Hazard

Infection risk. Rinse the unit thoroughly with clean water before working on it.

4 8104.181 Major Installation, Operation, and Maintenance Manual

 1 Introduction and Safety

1.4.3 Wash the skin and eyes

Follow these procedures for chemicals or hazardous fluids that have come into contact with
your eyes or your skin:
Condition Action
EN
Chemicals or hazardous 1. Hold your eyelids apart forcibly with your fingers.
fluids in eyes 2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous 1. Remove contaminated clothing.
fluids on skin 2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.

1.5 Protecting the environment

Emissions and waste disposal
Observe the local regulations and codes regarding:
• Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites

CAUTION: Radiation Hazard

Do NOT send the product to Grindex if it has been exposed to nuclear radiation, unless
Grindex has been informed and appropriate actions have been agreed upon.

1.6 End-of-life product disposal

Handle and dispose of all waste in compliance with local laws and regulations.
EU and UK only: Correct disposal of this product — waste electrical and electronic equipment
• EU: Directive 2012/19/EU on waste electrical and electronic equipment (WEEE)
• UK: SI 2013 No. 3113
WS009973B

This marking on the product, accessories or literature indicates that the product should not
be disposed of with other waste at the end of its working life.

1.7 Spare parts

CAUTION:
Only use the manufacturer’s original spare parts to replace any worn or faulty components.
The use of unsuitable spare parts may cause malfunctions, damage, and injuries as well as
void the warranty.

1.8 Warranty
For information about warranty, see the sales contract.

8104.181 Major Installation, Operation, and Maintenance Manual 5

 2 Transportation and Storage

2 Transportation and Storage

EN 2.1 Examine the delivery
2.1.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company.
If the product has been picked up at a distributor, make a claim directly to the distributor.

2.1.2 Examine the unit

1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
Use care around nails and straps.
4. If there is any issue, then contact a sales representative.

2.2 Transportation guidelines

2.2.1 Precautions
DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing
to prevent unexpected startup. Failure to do so could result in death or serious injury.

Position and fastening

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

2.2.2 Lifting
Always inspect the lifting equipment and tackle before starting any work.

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.

NOTICE:
Never lift the unit by its cables or hose.

6 8104.181 Major Installation, Operation, and Maintenance Manual

 2 Transportation and Storage

2.3 Temperature ranges for transportation, handling and storage

Handling at freezing temperature
At temperatures below freezing, the product and all installation equipment, including the
lifting gear, must be handled with extreme care. EN
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.
Follow these guidelines to avoid freezing damage:
1. Empty all pumped liquid, if applicable.
2. Check all liquids used for lubrication or cooling, both oil and water-glycol mixtures, for the
presence of unacceptable amounts of water. Change if needed.
Water-glycol mixtures: Units equipped with an internal closed-loop cooling system are filled
with a mixture of water and 30% glycol. This mixture remains a flowing liquid at temperatures
down to –13°C (9°F). Below –13°C (9°F), the viscosity increases such that the glycol mixture
will lose its flow properties. However, the glycol-water mixture will not solidify completely and
thus cannot harm the product.

2.4 Storage guidelines

Storage location
The product must be stored in a covered and dry location free from heat, dirt, and vibrations.

NOTICE:
Protect the product against humidity, heat sources, and mechanical damage.

NOTICE:
Do not place heavy weights on the packed product.

Long-term storage
If the unit is stored for more than six months, then the following apply:
• Before operating the unit after storage, it must be inspected. Special attention must be
given to the seals and the cable entry.
• The impeller or propeller must be rotated every other month to prevent the seals from
sticking together.

8104.181 Major Installation, Operation, and Maintenance Manual 7

 3 Product Description

3 Product Description
EN 3.1 Products included
Pump model Standard Ex-proof MSHA Drainage Sludge
version
Major 8104.181 X X

3.2 Pump design

The pump is submersible, and driven by an electric motor.
Intended use
The product is intended for moving waste water, sludge, raw and clean water. Always follow
the limits given in Technical Reference on page 40. If there is a question regarding the
intended use of the equipment, then contact a sales or authorized service representative
before proceeding.

DANGER: Explosion/Fire Hazard

Special rules apply to installations in explosive or flammable atmospheres. Do not install the
product or any auxiliary equipment in an explosive zone unless it is rated explosion-proof or
intrinsically-safe. If the product is rated explosion-proof or intrinsically-safe, then see the
specific explosion-proof information in the safety chapter before taking any further actions.

NOTICE:
Do NOT use the unit in highly corrosive liquids.

For information about pH, see Technical Reference on page 40.

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

Number of holes Hole dimensions

300 Diameter 10.0 mm (0.39 in)

For more information about the strainer dimensions, see Technical Reference on page 40.
Pressure class

N Medium head
H High head

Impeller type

Pump Impeller type

8104.181 Wear resistant

3.3 Monitoring equipment

The following applies to the monitoring equipment of the pump:
• The stator incorporates thermal contacts connected in series that activate the alarm at
overtemperature.
• The thermal contacts open at 140°C (284°F) and close at 105°C (221°F).
• The pump can also be equipped with level regulators.

8 8104.181 Major Installation, Operation, and Maintenance Manual

 3 Product Description

3.3.1 Level regulators

About level regulators
Starting and stopping the pump at different water levels can be manual or automatic. If
automatic start and stop is required, a level regulator can be ordered (as an option). The
option is only available for standard pumps. EN

Features
Below are some of the features of the level regulators:
• The level regulator can be set at different operating levels by adjusting the length of
cable.
• A clamping bracket situated at the lifting handle holds the level regulator cable in place.
• If continuous pumping is required, the level regulator can be placed in a special rubber
bracket on the discharge connection to eliminate the level regulator function.
Illustration
1. The pump turns on when the water level rises to this point.
1 2. The pump turns off when the water level has gone down to this point.
WS006210C

3.4 The data plate

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

1 3 2

20 4

18
6
19 21
17

16
15

14 13 12 11 10 9 7 8 5
WS011380C

1. Pump type number

2. Frequency
3. Phases, type of current
4. Rated shaft power
5. Thermal class
6. WEEE-Directive symbol
7. Locked rotor code-letter
8. Country of origin
9. Maximum power consumption
10. Product weight
11. Maximum submersion depth

8104.181 Major Installation, Operation, and Maintenance Manual 9

 3 Product Description

12. Degree of protection

13. Maximum capacity
14. Rated current
15. Direction of the start reaction
16. Direction of the impeller rotation
17. Maximum head
18. Serial number
EN 19. Rated voltage
20. Pump model
21. UKCA marking

3.5 Motor regulation

This product is submersible and therefore exempted from the motor efficiency requirement,
in accordance with EU commission regulation 2019/1781 Article 2(2)(e).

10 8104.181 Major Installation, Operation, and Maintenance Manual

 4 Installation

4 Installation
4.1 Precautions EN

Before starting work, make sure that the safety instructions have been read and understood.

DANGER: Electrical Hazard

Before starting work on the unit, make sure that the unit and the control panel are isolated
from the power supply and cannot be energized. This applies to the control circuit as well.

DANGER: Inhalation Hazard

Before entering the work area, make sure that the atmosphere contains sufficient oxygen
and no toxic gases.

4.1.1 Hazardous atmospheres

DANGER: Explosion/Fire Hazard
Special rules apply to installations in explosive or flammable atmospheres. Do not install the
product or any auxiliary equipment in an explosive zone unless it is rated explosion-proof or
intrinsically-safe. If the product is rated explosion-proof or intrinsically-safe, then see the
specific explosion-proof information in the safety chapter before taking any further actions.

Authority regulation
Vent the tank of a sewage station in accordance with local plumbing codes.

4.2 Requirements
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.

8104.181 Major Installation, Operation, and Maintenance Manual 11

 4 Installation

EN

WS001380B
Figure 1: 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

WS001346A
WS001379A

Fasteners
• Only use fasteners of the correct size and material.
• Replace all corroded or damaged fasteners.
• Make sure that all the fasteners are correctly tightened and that there are no missing
fasteners.

4.3 Install
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.
The discharge line can be run vertically or horizontally, but must be without sharp bends.
3. Lower the pump into the sump.
The cable must not be used for this purpose. You should attach a rope or similar to the
handle or the eye bolts for lowering and lifting the pump.
Heavier pumps must be lifted and lowered down by crane. Suspend the pump by the
lifting handle or the eye bolts with chains or wires.
4. Place the pump on the base and make sure it cannot fall over or sink.
The base should consist of a plank, a bed of coarse gravel, or a cut-down and perforated
oil drum.
Alternatively, the pump can be suspended with a lifting chain just above the sump
bottom. Make sure that the pump cannot rotate at start-up or during operation.
5. Connect the motor cable and the starter and monitoring equipment according to the
separate instructions.

12 8104.181 Major Installation, Operation, and Maintenance Manual

 4 Installation

Make sure that the phase sequence is correct. For more information, see Check the
phase sequence: Pumps with built-in motor protection on page 20.

4.4 Make the electrical connections

EN
4.4.1 General precautions
DANGER: Electrical Hazard
Before starting work on the unit, make sure that the unit and the control panel are isolated
from the power supply and cannot be energized. This applies to the control circuit as well.

WARNING: Electrical Hazard

Risk of electrical shock or burn. A certified electrician must supervise all electrical work.
Comply with all local codes and regulations.

WARNING: Electrical Hazard

There is a risk of electrical shock or explosion if the electrical connections are not correctly
carried out, or if there is fault or damage on the product. Visually inspect equipment for
damaged cables, cracked casings or other signs of damage. Make sure that electrical
connections have been correctly made.

WARNING: Crush Hazard

Risk of automatic restart.

CAUTION: Electrical Hazard

Prevent cables from becoming sharply bent or damaged.

NOTICE:
Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the
cable ends dry at all times.

Requirements
These general requirements apply for the electrical installation:
• If the pump will be connected to the public mains, then the supply authority must be
notified before installing the pump. When the pump is connected to the public power
supply, it can cause flickering of incandescent lamps when started.
• The mains voltage and frequency must agree with the specifications on the data plate. If
the pump can be connected to different voltages, then follow the specified voltage on the
yellow sticker close to the cable entry.
• If the operation can be intermittent, such as S3 periodic duty, then the pump must be
supplied with monitoring equipment supporting such operation.
• The thermal contacts or thermistors must be in use.

8104.181 Major Installation, Operation, and Maintenance Manual 13

 4 Installation

Motor and short-circuit protection

NOTICE:
A qualified electrician must select the size of motor protection breakers and fuses. The size
must be chosen for the specific motor data such as rated current and starting current.
EN
It is important that the short-circuit protection is not over-dimensioned. Over-dimensioned
fuses or motor protection breakers decrease the protection for the motor.

• The fuse rating and the cables must be in accordance with the local rules and
regulations.
• The fuses and circuit breakers must have the correct rating.
• The pump overload protection must be connected and set to the rated current.
The starting current in direct-on-line start can be up to six times higher than the rated
current.
For more information, see the data plate and if applicable, the cable chart for the rated
current.
Cables
When cables are installed, these requirements must be followed:
• The cables must be in good condition, not have any sharp bends, and not be pinched.
• The cables must not be damaged and must not have indentations.
• The cables must not be embossed at the cable entry.
• The cable entry seal sleeve and washers must conform to the outer diameter of the
cable.
• The minimum bend radius must not be smaller than the accepted value.
• If a cable is reused, a short piece at the end must be peeled off when the cable is refitted.
This action is necessary so that the seal sleeve of the cable entry does not close around
the cable at the same point again. If the outer jacket of the cable is damaged, then the
cable must be replaced.
Contact a sales or authorized service representative.
• The voltage drop in long cables must be considered. The rated voltage of the drive unit is
the voltage that is measured at the cable connection point in the pump.
• If a variable frequency drive (VFD) is used, the screened cable must be used according
to the European CE and EMC requirements. For more information, contact a sales or
authorized service representative.
• For SUBCAB™ cables, the twisted pair copper foil must be trimmed.
• All unused conductors must be insulated.

4.4.2 Grounding (earthing)

Grounding (earthing) must be done in compliance with all local codes and regulations.

DANGER: Electrical Hazard

All electrical equipment must be grounded (earthed). Test the ground (earth) lead to verify
that it is connected correctly and that the path to ground is continuous.

WARNING: Electrical Hazard

Risk of electrical shock. The ground (earth) lead must be sufficiently longer than the phase
leads to make sure that the ground lead is the last to become disconnected if the cable is
jerked loose.

WARNING: Electrical Hazard

Risk of electrical shock or burn. You must connect an additional ground- (earth-) fault
protection device to the grounded (earthed) connectors if persons are likely to come into
contact with liquids that are also in contact with the pump or pumped liquid.

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 4 Installation

Ground (earth) conductor length

The ground (earth) conductor must be longer than the phase conductors in the junction box
of the unit. The table shows how much longer, than the phase conductors, the ground (earth)
conductor must be.
EN
Pump Extra length of ground conductor
mm in.
8104.181 270 10.6

4.4.3 Product-specific precautions

This information is valid only for standard version products.
For a pump with a level regulator and a cable with ground (earth) check: Make sure that the
ground (earth) check connection is done at the GC-connection point with a cable lug and
one screw. Connect the ground cable from the level switch to the other screw at the GC-
connection point.

4.4.4 Prepare the SUBCAB™ cables

This section applies to SUBCAB™ cables with twisted-pair control conductors.

The prepared SUBCAB™ cable The prepared screened SUBCAB™ cable, without cable lugs
3 4
1
5 2 2
1
3
2

5
T

1
T

4
9

SUBCAB 1000V

Screened SUBCAB

6
WS004299E

WS004298F
6
7
1. T1+T2 twisted pairs in control element
2. Drain wire in control element (tinned copper strands) with shrink tube 1. T1+T2 and T3+T4 twisted pairs in control element
3. Aluminum and textile layers 2. Drain wire in control element (tinned copper strands) with shrink tube
4. Insulation jacket or plastic jacket, for the control element 3. Aluminum and textile layers
5. Power conductors 4. Insulation jacket or plastic jacket, for the control element
6. Ground (earth) conductor with yellow-green shrink tube 5. Power conductors
6. Plastic laminated aluminum foil, screen
7. Ground (earth) conductor with yellow-green shrink tube
8. Uncovered screen/braided wire
9. shrink tube

1. Peel off the outer jacket at the end of the cable.

2. Prepare the control element:
a) Peel the insulation jacket or plastic jacket.
b) Peel the aluminum and textile layers.
The aluminum foil is a conductive screen. Do not peel more than necessary, and
remove the peeled foil.

8104.181 Major Installation, Operation, and Maintenance Manual 15

 4 Installation

1 2T
T
EN

3 4
T T

WS004313F
Screened SUBCAB
Figure 2: Aluminum foil on the control element.
c) Put a white shrink tube over the drain wire.
d) Twist T1+T2 and T3+T4.
e) Put a shrink tube over the control element.
Make sure that the conductive aluminum foil and drain wire are covered.
3. Prepare the ground (earth) conductor of the SUBCAB™ cable:
a) Peel the yellow-green insulation from the ground (earth) conductor.
b) Check that the ground (earth) conductor is at least 10% longer than the phase
conductors in the cabinet.
c) If applicable, put a cable lug on the ground conductor.
4. Prepare the ground (earth) conductor of the screened SUBCAB™ cable:
a) Untwist the screens around the power conductors.
b) Twist all power conductor screens together to create a ground (earth) conductor.
c) Put a yellow-green shrink tube over the ground (earth) conductor.
Leave a short piece uncovered.
d) Check that the connected ground (earth) conductor has sufficient slack. The
conductor must stay connected even if the power conductors are pulled loose.
5. Prepare the power conductors:
a) Remove the aluminum foil around each power conductor.
b) Peel the insulation from each power conductor.
6. Prepare the ends of the ground (earth) conductor, the power conductors, and the drain
wire:
Connection type Action
Screw Fit cable lugs to the ends.
Terminal block Fit end sleeves or leave the ends as they are.

4.4.5 Connect the motor cable to the pump

NOTICE:
Leakage into the electrical parts can cause damaged equipment or a blown fuse. Keep the
end of the motor cable dry at all times.

1. Check the data plate to see which connections are required for the power supply.
2. Connect the motor cable conductors, including ground (earth), to the terminal or starter
unit.
3. Make sure that the pump is correctly connected to ground (earth).
4. Tighten the cable entry into its bottom-most position.
The seal sleeve and the washers must conform to the outside diameter of the cables.

16 8104.181 Major Installation, Operation, and Maintenance Manual

 4 Installation

DANGER: Explosion/Fire Hazard

Special rules apply to installations in explosive or flammable atmospheres. Do not install the
product or any auxiliary equipment in an explosive zone unless it is rated explosion-proof or
intrinsically-safe. If the product is rated explosion-proof or intrinsically-safe, then see the
specific explosion-proof information in the safety chapter before taking any further actions. EN

4.4.6 Cable charts

Connection locations
1 2 3 4 12
19 25
20
L1 L2 L3 T1 T2 T3 T4
13
21
CT
5 14 22
26

23
6
7 15
24
8
16

17
9

WS001021E
10 18
11

1 Starter equipment and main leads (L1, L2, 14 Transformer

L3)
2 Ground (earth) 15 Capacitor
3 Functional ground 16 Softstarter
4 Control leads (T1, T2, T3, T4) 17 Level regulator
5 Phase shifter 18 Contactor, start relay or thermal relay
6 Diode 19 Thermal detector in stator
7 Motor cable 20 Thermal detector in main bearing
8 Screen 21 Jumper
9 Pump 22 Terminal board, terminal plate
10 Crimp connection 23 Leakage sensor
11 Crimp isolation 24 Stator leads (U1, U2, U5, U6, V1, V2, V5,
V6, W1, W2, W5, W6, Z1, Z5, Z6)
12 Motor protector 25 Current transformer
13 Coil 26 Terminal block

Color code standard

Code Description
BN Brown
BK Black

8104.181 Major Installation, Operation, and Maintenance Manual 17

 4 Installation

Code Description
WH White
OG Orange
GN Green
EN
GNYE Green-Yellow
RD Red
GY Grey
BU Blue
YE Yellow

Stator leads and thermal contacts connection to the terminal plate

Terminal
plate

8103.181
8104.181
8110.281
8111.281

STATOR LEADS AND THERMAL CONTACTS

Terminal 3 leads 6 leads 6 leads 9 leads 9 leads 12 leads 12leads 12 leads STATOR LEADS
plate Y D Y Y serial Y // Y // D serial D //
W1
U1,U5 RD
W W W1 V2 W1 W1 W5 W1 W5 W1 V6 W1 W5 V2 V6
V V1 U2 V1 V1 V5 V1 V5 V1 U6 V1 V5 U2 U6
U2,U6 GN
V V1
U U U1 W2 U1 U1 U5 U1 U5 U1 W6 U1 U5 W2 W6 V1,V5 BN
U1
T1 T1 T1 T1 T1 T1 T1 T1 V2,V6 BU
T1
T2 T2 T2 T2 T2 T2 T2 T2 T2 W1,W5 YE
W2,W6 BK

WS004924D
W2 W2 W5 W2 W2 W6 W2 W5
V2 V2 V5 V2 V2 V6 V2 V5 T1,T2 WH/YE
U2 U2 U5 U2 U2 U6 U2 U5

18 8104.181 Major Installation, Operation, and Maintenance Manual

 4 Installation

Motor cable and starter unit connection to the terminal plate

Terminal SYMBOLS AND DENOMINATIONS

plate BN=Brown =Terminal plate

BK=Black =Screen
WH=White
8103.181 OG=Orange =Ground EN
GN=Green =Functional ground
8104.181 GNYE=Green-Yellow =Crimp isolation
8110.281 RD=Red
GY=Grey =Socket - Plug
8111.281 BU=Blue
YE=Yellow =Inside pump
Pump

*SUBCAB AWG/CSA
**GC= Ground check

PHASE SHIFTER ON MOTOR CABLE SCREENED MOTOR CABLES

Shrink hose GNYE Screen as ground conductor

Pump Pump

1-0-1 Motor cable

Motor cable from grid Motor cable to pump

Contactor unit
(4/4* conductors) (4/4* conductors) L3 GY
L3 min 20m L2 BK
L3 GY/WH* W
L3 GY/WH* L1 BN
L2
L2 BK/BK* V GNGY
L1 L2 BK/BK* T1 WH -
L1 BN/RD* U T2 WH -
L1 BN/RD* T3 WH - -
GNYE/GNYE* T4 WH - -
GNYE/GNYE*
(GC) (GC)
Subcab Subcab Subcab FGB
(3+S2) (S3+S4) (S3+4) (S3)
CONTACTOR UNIT Current over 19A no CONTACTOR UNIT, 3-PHASE, FLOAT SWITCH. EU OVER 400V, US/CDN OVE R 250V
FLOAT SWITCH OPTIONAL BN=500-600V
EU: MAX 400V Isolate not used leader with
SMART US/CDN: MAX 250V SMART RD=380-460V
Motor cable F Motor cable F
(4/4*/7* Terminal (4/4*/7* Terminal
conductors) Pump G plate conductors) Pump G plate
Contactor Contactor
H 5-6 W/A H 5-6 W/A
L3 GY/WH* BK BK L3 GY/WH* BK BK
L2 BK/BK* GY 3-4 GY V/C L2 BK/BK* GY 3-4 GY V/C
L1 BN/RD* BN 1-2 BN U/M L1 BN/RD* BN 1-2 BN U/M
GNYE/* A1 WH T1 GNYE/* A1 WH T1
YE* GC** A2
BN/BK*
YE* GC** A2 A2
BU
T2 A2 BU T2

WS004925D
OG* 16 OG* 16 BU/WH*
BU/WH* BN/BK* 15
BU* 15 BU BU*
14 14
WH
GY
RD

YE
BK
BN

BU

13 Float switch
GNYE/GN*
13 Float switch GNYE/GN*
Optional GC** SUPERVISION RELAY GC**

Thermal contact ratings

IEC/EN UL/CSA
Maximum voltage 500 V 250 V
Maximum current 1.3 A 2.5 A
Phase factor, cos φ 0.6 1

Terminal board ratings

All copper conductors must be stranded.

Table 1: Power terminal

IEC/EN UL/CSA
Maximum voltage 1000 V 600 V
Maximum current 70 A 70 A
Wire size 0.75–16 mm2 18–6 AWG
Torque 8 Nm (6 lbf·ft) 8 Nm (6 lbf·ft)

Table 2: Signal terminal

IEC/EN UL/CSA
Maximum voltage 500 VAC / 24 VDC 250 VAC / 24 VDC
Maximum current 2.5 A 2.5 A

8104.181 Major Installation, Operation, and Maintenance Manual 19

 4 Installation

IEC/EN UL/CSA
Wire size 0.5–6 mm2 20–10 AWG
Torque 3 Nm (2 lbf·ft) 3 Nm (2 lbf·ft)

EN
4.5 Check the impeller rotation: Pumps without built-in motor
protection
Follow this procedure if your product does not have the rotation control SMART™.

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

Check the direction of rotation each time the cable has been re-connected and after phase
or total supply failure.
1. Start the motor.
2. Stop the motor.
3. Check that the impeller rotates in the correct direction.

L2

L1 L3

L1 L2 L3
WS001397A

Figure 3: Start reaction

4. If the impeller rotates in the wrong direction, then do the following:
– If the motor has a 3-phase connection, then transpose two phase conductors and
repeat this procedure from step 1.

4.6 Check the phase sequence: Pumps with built-in motor protection
Follow this procedure if your product is equipped with the rotation control SMART™.

CAUTION: Crush Hazard

The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

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.

20 8104.181 Major Installation, Operation, and Maintenance Manual

 4 Installation

L2

EN
L1 L3

L1 L2 L3

WS001397A
Figure 4: Start reaction

1. Connect the pump to power as follows:

Condition Action
The pump has a CEE plug with internal phase Connect the plug.
shifter.

WS006205A
The pump has a phase shifter with an on/off Turn the knob on the phase shifter in either
switch. direction.

WS006207A
The pump has neither a CEE plug with internal 1. Connect the pump to power.
phase shifter, nor a phase shifter with an on/off 2. Switch on the power.
switch.

The pump should start. If it does not, then continue to the next step.
2. If the pump does not start and the fuses are correct, then shift two phases:
Condition Action
The pump has a CEE plug with internal phase 1. Pull out the plug.
shifter. 2. Shift two phases.
3. Wait until the motor has stopped.
4. Connect the plug.
WS006206A

8104.181 Major Installation, Operation, and Maintenance Manual 21

 4 Installation

Condition Action
The pump has a phase shifter with an on/off 1. Turn the knob on the phase shifter to neutral
switch. position.
2. Wait until the motor has stopped.
EN 3. Turn the knob to the opposite position from
before.

WS006208A
The pump has neither a CEE plug with internal Transpose two phase leads on the output
phase shifter, nor a phase shifter with an on/off terminal of the starter.
switch.

NOTICE:
Do not reverse the phase sequence while the pump is running. Temporarily incorrect
rotation can occur, resulting in damage to motor electronics and rotating parts.

The pump should start. If it does not, then contact a certified electrician to check the
mains and the junctions.

22 8104.181 Major Installation, Operation, and Maintenance Manual

 5 Operation

5 Operation
5.1 Precautions EN
Before taking the unit into operation, check the following:
• All recommended safety devices are installed.
• The cable and cable entry have not been damaged.
• All debris and waste material has been removed.

NOTICE:
Never operate the pump with the discharge line blocked, or the discharge valve closed.

WARNING: Crush Hazard

Risk of automatic restart.

Distance to wet areas

WARNING: Electrical Hazard

Risk of electrical shock or burn. You must connect an additional ground- (earth-) fault
protection device to the grounded (earthed) connectors if persons are likely to come into
contact with liquids that are also in contact with the pump or pumped liquid.

CAUTION: Electrical Hazard

Risk of electrical shock or burn. The equipment manufacturer has not evaluated this unit for
use in swimming pools. If used in connection with swimming pools then special safety
regulations apply.

Noise level

NOTICE:
The sound power level of the product is lower than 70 dB(A). However, in some installations
the resulting sound pressure level may exceed 70 dB(A) at certain operating points on the
performance curve. Make sure that you understand the noise level requirements in the
environment where the product is installed. Failure to do so may result in hearing loss or
violation of local laws.

Do not allow the pump to snore or run dry

The equipment must never run dry during operation. The volute must be filled with liquid
during operation.
Dry running during service and inspection is only allowed less than one minute for each
occasion.

5.2 Start the pump

CAUTION: Crush Hazard
The starting jerk can be powerful. Make sure nobody is close to the unit when it is started.

8104.181 Major Installation, Operation, and Maintenance Manual 23

 5 Operation

CAUTION: Thermal Hazard

The surfaces or parts of the unit may become hot during operation. Allow surfaces to cool
before starting work, or wear heat-protective clothing.

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

1. Inspect the pump. Check that there is no physical damage to the pump or cables.
2. Check the oil level in the oil housing.
3. Remove the fuses or open the circuit breaker, and check that the impeller can rotate
freely.

WARNING: Crush Hazard

Never put your hand into the pump housing.

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

5. Check that the impeller rotation is correct.
6. Start the pump.

5.3 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.

24 8104.181 Major Installation, Operation, and Maintenance Manual

 6 Maintenance

6 Maintenance
6.1 Precautions EN
Before starting work, make sure that the safety instructions have been read and understood.

DANGER: Crush Hazard

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

DANGER: Inhalation Hazard

Before entering the work area, make sure that the atmosphere contains sufficient oxygen
and no toxic gases.

WARNING: Biological Hazard

Infection risk. Rinse the unit thoroughly with clean water before working on it.

CAUTION: Crush Hazard

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

Make sure that you follow these requirements:

• Check the explosion risk before you weld or use electrical hand tools.
• Allow all system and pump components to cool before you handle them.
• Make sure that the product and its components have been thoroughly cleaned.
• Before starting work, make sure that the work area is well-ventilated.
• Do not open any vent or drain valves or remove any plugs while the system is
pressurized. Make sure that the pump is isolated from the system and that pressure is
relieved before you disassemble the pump, remove plugs, or disconnect piping.
Ground continuity verification
A ground (earth) continuity test must always be performed after service.

6.2 Maintenance guidelines

During the maintenance and before reassembly, always remember to perform these tasks:
• Clean all parts thoroughly, particularly O-ring grooves.
• Change all O-rings, gaskets, and seal washers.
• Lubricate all springs, screws, O-rings with grease.
For an optimal corrosion protection, all O-rings and adjacent surfaces must be coated with
Exxon Mobil Unirex N3 or equivalent.

8104.181 Major Installation, Operation, and Maintenance Manual 25

 6 Maintenance

EN

WS006894A
Figure 5: Example of O-ring adjacent surfaces

During the reassembly, always make sure that existing index markings are in line.
The reassembled drive unit must always be insulation-tested and the reassembled pump
must always be test-run before normal operation.

6.3 Torque values

All screws and nuts must be lubricated to achieve correct tightening torque. Screws that are
screwed into stainless steel must have the threads coated with applicable lubricants to
prevent seizing.
If there is a question regarding the tightening torques, then contact a sales or authorized
service representative.
Screws and nuts

Table 3: Stainless steel, A2 and A4, torque Nm (lbf·ft)

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

Property
class

50 1.0 2.0 3.0 8.0 15 27 65 127 220 434

(0.74) (1.5) (2.2) (5.9) (11) (20) (48) (93.7) (162) (320)
70, 80 2.7 5.4 9.0 22 44 76 187 364 629 1240
(2) (4) (6.6) (16) (32) (56) (138) (268) (464) (915)
100 4.1 8.1 14 34 66 115 248 481 — —
(3) (6) (10) (25) (49) (84.8) (183) (355)

Table 4: Steel, torque Nm (lbf·ft)

M4 M5 M6 M8 M10 M12 M16 M20 M24 M30

Property
class

8.8 2.9 5.7 9.8 24 47 81 194 385 665 1310

(2.1) (4.2) (7.2) (18) (35) (60) (143) (285) (490) (966.2)
10.9 4.0 8.1 14 33 65 114 277 541 935 1840
(2.9) (6) (10) (24) (48) (84) (204) (399) (689) (1357)
12.9 4.9 9.7 17 40 79 136 333 649 1120 2210
(3.6) (7.2) (13) (30) (58) (100) (245) (480) (825.1) (1630)

Table 5: Brass, torque Nm (lbf·ft)

M5 M8 M10
2.7 (2.0) 11 22
(8.1) (16.2)

26 8104.181 Major Installation, Operation, and Maintenance Manual

 6 Maintenance

Hexagon screws with countersunk heads

For hexagon socket head screws with countersunk head, maximum torque for all property
classes must be 80% of the values for property class 8.8.
Round nuts with set screws
EN
Table 6: Set screw, torque Nm (lbf·ft)
The torque values are only valid for the set screw, and not for the round nut.
M8 M10
18 (13) 35 (26)

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

Type of Purpose Inspection interval

service
Inspection To prevent operational interruptions and machine breakdown. Twice a year
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.
Overhaul To secure a long operating lifetime for the product. It includes Every year, under
replacement of key components and the measures taken during normal operating
an inspection. conditions

NOTICE:
Shorter intervals may be required when the operating conditions are extreme, for example
with very abrasive or corrosive applications or when the liquid temperatures exceed 40°C
(104°F).

6.4.1 Inspection
Regular inspection and service of the pump ensures more reliable operation.
Service item Action
Visible parts on 1. Check that all screws, bolts, and nuts are properly tightened.
the pump and 2. Check the condition of the cooling jacket, strainer, cover, lifting handles, eye
installation bolts, ropes, chains, and wires.
3. Check for worn or damaged parts.
4. Adjust and/or replace if necessary.
Pipes, valves, 1. Check for worn or damaged parts.
and other 2. Adjust and/or replace if necessary.
peripheral
equipment
Impeller 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.
Oil Check the oil:
1. Take an oil sample.
2. If the oil contains particles, then replace the mechanical seal. Contact an
authorized service shop.
Make sure that the volume is filled to the correct level.
A smaller amount of water is not harmful for the mechanical seal.

8104.181 Major Installation, Operation, and Maintenance Manual 27

 6 Maintenance

Service item Action

Cable entry 1. Check that the following requirements are met:
– Standard pump version: The cable entry must be firmly tightened into its
bottom-most position.
EN – 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 1. Remove the inspection screw.
volume1 2. Drain all liquid, if any.
3. If there is oil in the inspection volume, then empty the oil and check again after
one week. If there is oil in the inspection volume again, then replace the
mechanical seal. Contact an authorized service shop.
4. If there is water in the inspection volume, then check that the inspection screw O-
ring is not damaged.
5. Check that the inspection screw is properly tightened.
Cable 1. If the outer jacket is damaged, then replace the cable.
2. Check that the cables do not have any sharp bends and are not pinched.
Cooling system If the flow through the system has been partly restricted, then rinse and clean.
Level sensors or 1. Check the functionality.
other sensor 2. Repair or replace any damaged equipment.
equipment 3. Clean and adjust the equipment.
Starter equipment 1. Check the condition and functionality.
2. Contact an electrician, if necessary.
Insulation 1. Check the insulation between:
resistance in the – Phase–phase on the stator
stator – Phase–ground (earth)
The insulation should be > 1 megaohm. Use a 1000-VDC megger to test the
insulation.
2. If the resulting value is < 1 megaohm, then contact an authorized service shop.

6.4.2 Overhaul
The basic repair kit includes O-rings, seals, and bearings.
For an overhaul, do the following in addition to the tasks listed under Inspection.
Service item Action
Support and main bearing Replace the bearings with new bearings.
Mechanical seal Replace with new seal units.

6.5 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. Examples of suitable oil types are the following:
• Statoil MedicWay 32
• BP Enerpar M 004
• Shell Ondina 927
• Shell Ondina X430
In applications where poisonous properties are of less concern, a mineral oil with viscosity
up to ISO VG32 can be used.

1 Regardless of individual applications, the inspection volume should not be inspected less frequently than the intervals for normal
applications and operating conditions at media (liquid) temperatures <40°C (104°F).

28 8104.181 Major Installation, Operation, and Maintenance Manual

 6 Maintenance

WS006203A
1 2
1. Inspection screw
2. Oil screw EN
Figure 6: Symbols

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 screw can be used for drainage, but it is easier to drain
the oil if both oil screws are removed.

CAUTION: Compressed Gas Hazard

Air inside the chamber may cause parts or liquid to be propelled with
force. Be careful when opening. Allow the chamber to de-pressurize
before removal of the plug.
3. Turn the pump so that the oil hole faces downwards and let the oil run out into a
container.
WS004250B

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 up and fill by using new oil.
Fill until the oil level reaches the inlet hole.

Pump Oil Quantity

Liters Quarts
8104.181 0.9 0.95
4. Put the oil screw back and tighten it.

6.6 Replace the impeller

8104.181 Major Installation, Operation, and Maintenance Manual 29

 6 Maintenance

6.6.1 Remove the impeller

CAUTION: Cutting Hazard
Worn parts can have sharp edges. Wear protective clothing.
EN

1. Remove the strainer.

WS001334C
2. Remove the suction cover.
3. Remove the O-ring.
4. Loosen the impeller:
a) Lock the impeller to prevent rotation.
Use pliers, a screwdriver, or similar.
b) Remove the impeller screw and the washer.

WS001332B

5. Remove the impeller:

a) Lock the impeller to prevent rotation.
Use pliers, a screwdriver, or similar.
b) Turn the adjustment screw counterclockwise until the impeller loosens from the shaft.
Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in) extension.
WS001335C

c) Pull off the impeller.

30 8104.181 Major Installation, Operation, and Maintenance Manual

 6 Maintenance

6.6.2 Install the impeller

1. Prepare the shaft:
a) Polish off any flaws by using a fine emery cloth.
The end of the shaft must be clean and free from burrs.
EN
b) Coat the inner conical, the outer cylindrical surfaces, and the thread of the conical
sleeve with a thin layer of grease.
The correct lubrication is grease for bearings, for example Exxon Mobil Unirex N3,
Mobil Mobilith SHC 220 or equivalent.

NOTICE:
Surplus grease can cause the impeller to become loose. Remove surplus grease from
conical and/or cylindrical surfaces of shafts and/or sleeves.

WS006895A

2. Align the edge of the adjustment screw with the edge of the conical sleeve so that they
are flush.

WS001759A

3. Lubricate the threads of the impeller screw and the washer.

The correct lubrication of the screw and washer is lubricating grease for assembly of
bolts, and so forth. Example: Kluber ALTEMP Q NB 50.
4. Check that the impeller screw is clean and easy to screw into the shaft end.
This is to prevent the shaft from rotating with the impeller screw.
5. Assemble the conical sleeve in the impeller.
Make sure that the conical sleeve bottoms in the impeller.
WS001325C

6. Assemble the impeller with the conical sleeve onto the shaft.
7. Install the suction cover and its O-ring and tighten.
Tightening torque: 44 Nm (32.5 lbf·ft)

8104.181 Major Installation, Operation, and Maintenance Manual 31

 6 Maintenance

EN

WS001330B
8. Turn the adjustment screw clockwise until the impeller contacts the suction cover.
Tighten a further 1/8 turn, 45°. The extra 1/8 turn will make sure that the clearance
between the impeller and the suction cover is correct in the next step.
Use an 8 mm hexagon bit adapter (Allen socket) with a 100 mm (4 in) extension.

WS001336B

9. Attach the impeller screw:

a) Put the washer on the impeller screw.
b) Lock the impeller to prevent rotation.
Use pliers, a screwdriver, or similar.
c) Tighten the impeller screw.
Tightening torque: 22 Nm (16.2 lbf·ft)
d) Tighten a further 1/8 turn, 45°.
e) Check that the impeller can rotate freely.
WS001328B

10. Install the strainer and the nuts.

Tightening torque: 22 Nm (16.2 lbf·ft)

32 8104.181 Major Installation, Operation, and Maintenance Manual

 6 Maintenance

EN

WS001331B

8104.181 Major Installation, Operation, and Maintenance Manual 33

 7 Troubleshooting

7 Troubleshooting
EN 7.1 General precautions
Before starting work, make sure that the safety instructions have been read and understood.

DANGER: Inhalation Hazard

Before entering the work area, make sure that the atmosphere contains sufficient oxygen
and no toxic gases.

7.2 Electrical troubleshooting

DANGER: Electrical Hazard
Troubleshooting a live control panel exposes personnel to hazardous voltages. Electrical
troubleshooting must be done by a qualified electrician.

Follow these guidelines when troubleshooting:

• Disconnect and lock out the power supply except when conducting checks that require
voltage.
• Make sure that no one is near the unit when the power supply is reconnected.
• When troubleshooting electrical equipment, use the following:
– Universal instrument multimeter
– Test lamp (continuity tester)
– Wiring diagram

7.3 The pump does not start

DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing
to prevent unexpected startup. Failure to do so could result in death or serious injury.

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 Check that:
triggered on the control panel. • The impeller rotates freely.
• The sensor indicators do not indicate an alarm.
• The overload protection is not tripped.

34 8104.181 Major Installation, Operation, and Maintenance Manual

 7 Troubleshooting

Cause Remedy
The pump does not start Check that:
automatically, but can be started • The start level regulator is functioning. Clean or replace if
manually. necessary.
• All connections are intact. EN
• The relay and contactor coils are intact.
• The control switch (Man/Auto) makes contact in both positions.
Check the control circuit and functions.
The installation is not receiving Check that:
voltage. • 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:
• The impeller
• The sump in order to prevent the impeller from clogging again.

If the problem persists, then contact a sales or authorized service representative.

Always state the product number and the serial number of the pump, see Product
Description on page 8.
7.3.1 Pumps with SMART™: The pump does not start
This section is for pumps with SMART™. These steps are in addition to the remedies in The
pump does not start on page 34.

8104.181 Major Installation, Operation, and Maintenance Manual 35

 7 Troubleshooting

Cause Remedy
The phase sequence may be 1. Pull out the plug.
incorrect. 2. Do one of the following:
– Shift two phases by turning two contact pins with a
EN screwdriver

NOTICE:
Do not take the plug apart.

WS002614A

Figure 7: CEE plug

– Turn the knob to the opposite position 1, with 8 seconds
delay.

NOTICE:
Do not reverse the phase sequence while the motor is
running. Doing so may cause incorrect rotation resulting in
damage to the motor electronics and the rotating parts.
Respect the 8 seconds delay.

WS002616A

WS002615A
Figure 8: Phase shifter on/off switch
– If no glove or phase shifter is used, then shift two phase
conductors in the cabinet.

If the problem persists, then contact a sales or authorized service representative.

Always state the product number and the serial number of the pump, see Product
Description on page 8.

7.4 The pump does not stop when a level sensor is used
DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing
to prevent unexpected startup. Failure to do so could result in death or serious injury.

36 8104.181 Major Installation, Operation, and Maintenance Manual

 7 Troubleshooting

Cause Remedy
The pump is unable to empty the Check that:
sump to the stop level. • There are no leaks from the piping and/or discharge connection.
• The impeller is not clogged.
• The non-return valve(s) are functioning properly. EN
• The pump has adequate capacity. For information:
Contact a sales or authorized service representative.
There is a malfunction in the • Clean the level regulators.
level-sensing equipment. • Check the functioning of the level regulators.
• Check the contactor and the control circuit.
• Replace all defective items.
The stop level is set too low. Raise the stop level.

If the problem persists, then contact a sales or authorized service representative.

Always state the product number and the serial number of the pump, see Product
Description on page 8.

7.5 The pump starts-stops-starts in rapid sequence

Cause Remedy
The pump starts due to back-flow Check that:
which fills the sump to the start • The distance between the start and stop levels is sufficient.
level again. • The non-return valve(s) work(s) properly.
• The length of the discharge pipe between the pump and the first
non-return valve is sufficiently short.
The self-holding function of the Check:
contactor malfunctions. • 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.

If the problem persists, then contact a sales or authorized service representative.

Always state the product number and the serial number of the pump, see Product
Description on page 8.

7.6 The pump runs but the motor protection trips

DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing
to prevent unexpected startup. Failure to do so could result in death or serious injury.

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

8104.181 Major Installation, Operation, and Maintenance Manual 37

 7 Troubleshooting

Cause Remedy
The motor protection is set too Set the motor protection according to the data plate and if applicable
low. the cable chart.
The impeller is difficult to rotate • Clean the impeller.
EN by hand. • Clean out the wet well.
• Check that the impeller is correctly trimmed.
The drive unit cannot receive full • Check the fuses. Replace fuses that have tripped.
voltage on all three phases. • If the fuses are intact, then notify a certified electrician.
The phase currents change, or Contact a sales or authorized service representative.
they are too high.
The insulation between the 1. Use an insulation tester. Use a 1000 VDC insulation and
phases and ground in the stator is continuity tester to check that the insulation between the phases,
defective. and between any phase and ground, is > 5 megohms.
2. If the insulation is less, then do the following:
Contact a sales or authorized service representative.
The density of the pumped fluid is Make sure that the maximum density is 1100 kg/m³ (9.2 lb/US gal)
too high. • Change to a more applicable pump
• Contact a sales or authorized service representative.
The ambient temperature is more The pump must not be used for such an application.
than the maximum ambient
temperature.
There is a malfunction in the Replace the overload protection.
overload protection.
For pumps with SMART™: The Try one of the following:
SMART™ motor protection may • Reset the SMART™ motor protection by pulling and reinserting
need to be reset. the power plug.
• Or, disconnect and reconnect the power.
WS002610A

WS002612A
WS002611A

WARNING: Crush Hazard

Risk of automatic restart.

If the problem persists, then contact a sales or authorized service representative.

Always state the product number and the serial number of the pump, see Product
Description on page 8.

7.7 The pump delivers too little or no water

DANGER: Crush Hazard
Moving parts can entangle or crush. Always disconnect and lock out power before servicing
to prevent unexpected startup. Failure to do so could result in death or serious injury.

38 8104.181 Major Installation, Operation, and Maintenance Manual

 7 Troubleshooting

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

Cause Remedy EN
™
The impeller rotates in the wrong • If it is a 3-phase pump without SMART , then transpose two
direction. phase leads.
• Pumps with SMART™ will not start if the phase sequence is not
correct.
• If it is a 1-phase pump, then do the following:
Contact a sales or authorized service representative.
One or more of the valves are set • Reset the valves that are set in the wrong position.
in the wrong positions. • 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 • Clean the impeller.
by hand. • Clean out the sump.
• Check that the impeller is properly trimmed.
The pipes are obstructed. To ensure a free flow, clean out the pipes.
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, then contact a sales or authorized service representative.

Always state the product number and the serial number of the pump, see Product
Description on page 8.

8104.181 Major Installation, Operation, and Maintenance Manual 39

 8 Technical Reference

8 Technical Reference
EN 8.1 Application limits
Data Description
Media (liquid) temperature Maximum 40°C (104°F)
pH of the pumped media (liquid) 5–8
Media (liquid) density 1100 kg/m³ (9.2 lb for each US gal) maximum
Depth of immersion Maximum 20 m (65 ft)
Maximum permissible working pressure 9 bar (131 psi)
Other For the specific weight, current, voltage, power
ratings, and speed of the pump, see the data plate
of the pump.
For other applications, contact a sales or
authorized service representative for information.

8.2 Motor data

Feature Description
Motor type Squirrel-cage induction
Frequency Standard version: 50 Hz or 60 Hz
Supply 3-phase
Starting method Direct on-line
Maximum starts for 30 evenly spaced starts for each hour
each hour
Code compliance IEC 60034-1
Rated output variation ±10%
Voltage variation ±10%, if it does not run continuously at full load
without overheating
Voltage imbalance 2%
tolerance
Maximum frequency ±3 Hz
variation (for pumps
with SMART™)
Stator insulation class H (180°C [356°F])

Motor encapsulation
Motor encapsulation is in accordance with IP68.

8.3 Specific motor data

3-phase, 50 Hz
Motor type:
• 2,895 rpm
• Rated output 5.6 kW (7.5 hp)
• Maximum power consumption 6.6 kW (8.9 hp)

Voltage, V Configuration Rated current, A Starting current, A Power factor, cos φ

220 D 19 123 0.93

40 8104.181 Major Installation, Operation, and Maintenance Manual

 8 Technical Reference

Voltage, V Configuration Rated current, A Starting current, A Power factor, cos φ

230 D 19 129 0.9
240 D 19 135 0.85
380 D 11 73 0.92
EN
380 Y 11 71 0.9
380 Y 11 68 0.91
400 D 11 78 0.87
400 Y 11 75 0.89
400 Y 11 72 0.86
415 D 10 67 0.92
415 Y 12 76 0.81
440 D 10 71 0.86
500 D 8.7 59 0.89
500 Y 8.6 53 0.9
525 D 8.2 51 0.9
550 D 7.9 55 0.88
660 Y 6.4 43 0.92
690 Y 6.3 45 0.88
1000 Y 4.3 30 0.89

3-phase, 60 Hz
Motor type:
• 3,470 rpm
• Rated output 6.6 kW (8.9 hp)
• Maximum power consumption 7.7 kW (10.3 hp)

Voltage, V Configuration Rated current, A Starting current, A Power factor, cos φ

200 D 24 185 0.91
208 D 24 194 0.88
220 D 22 159 0.93
220 D parallel 22 154 0.91
220 Y parallel 22 158 0.92
230 D 21 167 0.9
230 D parallel 21 167 0.9
230 Y parallel 22 166 0.89
240 D 21 175 0.86
240 Y parallel 22 174 0.85
380 Y 13 92 0.93
380 Y parallel 13 92 0.93
400 Y parallel 13 94 0.88
440 D 11 80 0.93
440 Y serial 11 79 0.92
440 D serial 11 77 0.91
440 Y 11 75 0.92
460 D 11 84 0.9
460 Y serial 11 83 0.89

8104.181 Major Installation, Operation, and Maintenance Manual 41

 8 Technical Reference

Voltage, V Configuration Rated current, A Starting current, A Power factor, cos φ

460 D serial 11 83 0.9
460 Y 11 79 0.89
480 D 11 88 0.86
EN
480 Y serial 11 87 0.85
480 Y 11 83 0.84
575 D 8.5 64 0.91
575 Y 8.4 58 0.92
600 D 8.4 67 0.88
600 Y 8.3 61 0.88

8.4 Dimensions and weights

All measurements in the illustrations are in millimeters, if not otherwise specified.
Standard version
ISO-G 4A ISO-G 4A
NPT 4-8 NPT 4-8
100 Hose size 229 100 Hose size 229
*Victaulic 4" *Victaulic 4"
768

732
621

963

927
112

253
286

45
286
9
37 Tandem connection
ISO-G 4A
45
NPT 4-8
23

9 100 Hose size

37 *Victaulic 4"
23
WS006731A

WS006733A

*Designed for "Victaulic Coupling, Weight (kg)

Weight (kg)
according to ANSI/AWWA C606-97 Total
*Designed for "Victaulic Coupling, Total
SCREEN OPENING 10 50 according to ANSI/AWWA C606-97 52.3

Figure 9: N Figure 10: N, tandem

42 8104.181 Major Installation, Operation, and Maintenance Manual

 8 Technical Reference

ISO-G 3A ISO-G 3A
NPT 3-8 189 NPT 3-8 189
75 Hose size 75 Hose size
*Victaulic 3" *Victaulic 3"

EN

732
615

895
893
112

221
286

45
286
Tandem connection
7 ISO-G 3A
33 45 NPT 3-8
75 Hose size
23

7
33 *Victaulic 3"

23

WS006732A
Weight (kg)
WS006730A

*Designed for "Victaulic Coupling, Weight (kg) *Designed for "Victaulic Coupling, Total
according to ANSI/AWWA C606-97 according to ANSI/AWWA C606-97
Total 52.3
SCREEN OPENING 10 50
Figure 12: H, tandem
Figure 11: H

8.5 Performance curves

Test standard
Pumps are tested in accordance with ISO 9906:2012, HI 11.6:2012.

8104.181 Major Installation, Operation, and Maintenance Manual 43

 8 Technical Reference

Standard pump version

P1 [kW] P1[hp] / [kW]

H H
10
6 7
EN N N
5 8 6

4 5
6
3 4

H [m] H [ft] / [m]

45 180

160 50
40
140
35 40
120
30
100 30
25
80
20 20
60
15
40 H
H 10
10
20
N
5
0 0
0
N
0 5 10 15 20 25 30 35 40
0 5 10 15 20 25 30 35 40 0 100 200 300 400 500 600 700
WS006728A Q [l/s] WS006729A Q [l/s] / [usgpm]

Figure 13: 50 Hz Figure 14: 60 Hz

44 8104.181 Major Installation, Operation, and Maintenance Manual

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90019401_3.0_en-US_2024-11_IOM_8104.181 Major