REPAIR MANUAL 69 HD SERIES HEAVY DUTY SOLIDS HANDLING PUMPS. Safety Instructions. Table of Contents. To Order Replacement Parts. Short Term Storage

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1 NOTICE TO INSTALLER: Instructions must remain with installation. Product information presented here reflects conditions at time of publication. Consult factory regarding discrepancies or inconsistencies. MAIL TO: P.O. BOX Louisville, KY SHIP TO: 3649 Cane Run Road Louisville, KY (50) (800) 98-PUMP FAX (50) SECTION: Z Visit our web site: zoellerengineered.com ZM Supersedes New REPAIR MANUAL 69 HD SERIES HEAVY DUTY SOLIDS HANDLING PUMPS For over sixty years the name Zoeller has represented the standard for submersible dewatering and sewage pumps. The same high quality workmanship and easy maintenance design has been incorporated into this line of heavy-duty solids-handling submersible sewage pumps. This manual incorporates the parts list and repair instructions into one document to aid in the ownership of a Zoeller 69 HD submersible solids handling wastewater product. Please read and review this manual before repairing the product. Follow the steps and procedures listed on ZM1074 for a proper start-up upon installation. Many items contained within, when followed correctly, will not only ensure a long and problem-free life for the pump, but also save time and money during installation. Reference ZM319 for owner s manual on 69 HD Series Pumps. Should further assistance be necessary please call our Technical Service Department at PUMP (7867). Table of Contents Safety Instructions... 1 Motor Assembly...-3 Pump Housing and Impeller... 4 General Notes and Installation... 5 Start-up, Maintenance and Test Procedures... 6 Operation, Disassembly and Electrical Connections... 7 Repairs and Reassembly Specifications EASY-LIFT Assembly Service Checklist and Trouble Shooting... 1 To Order Replacement Parts PLEASE FURNISH THE FOLLOWING INFORMATION: Model Number Part Number of Pump Serial Number System Voltage Replacement Part Number and Description (refer to pages 6-9) Short Term Storage Storage of six months or less will not damage the submersible pump. However, to ensure the best possible protection, the following is advised: Store pump inside whenever possible or cover with some type of protective covering. Manually rotate the impeller every 30 days. Tape or seal in plastic bag the terminal ends of wire leads. Spray coat unpainted surfaces with rust-inhibiting oil. See ZM319 Owner s Manual before start-up. Safety Instructions TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA- JOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP. THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP. CAUTION This is a SAFETY ALERT SYMBOL. When you see this symbol on the pump or in the manual, look for one of the following signal words and be alert to the potential for personal injury or property damage. Warns of hazards that WILL cause serious personal injury, death or major property damage. Warns of hazards that CAN cause serious personal injury, death or major property damage. Warns of hazards that CAN cause personal injury or property damage. INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED. THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP. MAINTAIN ALL SAFETY DECALS. 1

2 69 HD MOTOR ASSEMBLY PARTS IDENTIFICATION DRAWING OIL LEVEL

3 69 HD Motor Assembly NO. DESCRIPTION 1 ROTOR STATOR 3 SHAFT 4 LOWER SEAL HOUSING 5 THRUST BEARING HOUSING 6 THRUST BEARING CAP OR SNAP RING 7 STATOR HOUSING 8 RADIAL BEARING HOUSING 9 CAP AND CABLE ASSEMBLY 10 THRUST BEARING 11 RADIAL BEARING 1 LOWER SEAL SNAP RING 13 LOWER SEAL ROTATING ELEMENT 14 LOWER SEAL STATIONARY SEAT 15 UPPER SEAL SNAP RING 16 UPPER SEAL ROTATING ELEMENT 17 UPPER SEAL STATIONARY SEAT 18 O-RING, THRUST BEARING HOUSING 19 O-RING, STATOR HOUSING 0 O-RING, CORD & CAP ASM. TO RADIAL BEARING HOUSING 1 MOISTURE PROBES SOCKET HEAD CAP SCREW 3 HEX HEAD/SOCKET HEAD CAP SCREW 4 HEX HEAD CAP SCREW 5 PIPE PLUG 6 HEX HEAD CAP SCREW 8 O-RING, LOWER SEAL HOUSING 30 POWER WIRING LEADS 3 PROBE WIRING LEADS 33 THERMAL PROTECTOR LEADS 37 RESISTOR (ACROSS PROBES 1) 40 DRAIN PLUG 44* SNAP RING - THRUST BEARING 45* LOCK NUT AND WASHER 46* HEX HEAD CAP SCREW 54 LIFTING BAIL 55 PIPE PLUG *NOTE - NOT APPLICABLE TO ALL FRAMES. 3

4 69 HD Pump Housing and Impeller ITEM DESCRIPTIVE NAME MAT'L ILLUSTRATION A 1 MOTOR ZEP HEX HD CAP SCREW - MTR TO UNIT STN STL 76 3 GASKET - MTR ADAPTER PLATE - (WHEN REQ'D) NEOPRENE 4 ADAPTER PLATE - MTR TO PUMP (WHEN REQ'D) CAST IRON 5 GASKET - MTR/ADAPTER PLATE/VOLUTE NEOPRENE 6 SOCKET HD CAP SCREW - ADPTR PLT TO PUMP STN STL STANDARD CONSTRUCTION 7 VOLUTE (DISCHARGE CASING) CAST IRON 8 IMPELLER CAST IRON 1 IMPELLER WASHER STN STL 1A IMPELLER LOCK SCREW WITH NYLON INSERT STN STL 1B SPRING LOCKWASHER - IMPELLER STN STL 1C HEAVY HEX NUT - IMPELLER STN STL 13 KEY - IMPELLER DRIVE STN STL 14 SPACER BUSHING - IMPELLER (WHEN REQ'D) STN STEEL 75 WEARING RING - IMPELLER STN STL 76 WEARING RING - CASING POLY 76A WEARING RING - CASING STN STL 77 FLAT HD MACHINE SCREW - W/R LOCKING STN STL REPAIR KIT CONSTRUCTION WHEN IMPELLER WEAR RING IS FURNISHED 76A A 77 CONSTRUCTION WHEN WEAR RINGS ARE FURNISHED ON PUMP MODELS OTHER THAN THOSE LISTED ON ILLUSTRATION A B A BHP STANDARD CONSTRUCTION ON PUMP MODELS OTHER THAN THOSE LISTED IN ILLUSTRATION A 100 BHP 1C 4

5 General Notes and Installation GENERAL NOTES 1. Motor - The Zoeller Engineered Products (ZEP) 69 HD Submersible Motors are totally enclosed non ventilated (TENV), air filled, tandem seal design, with an oil chamber separate from the motor windings. To insure the integrity of sealing surfaces and fits when servicing these motors, all parts should be handled with utmost care.. Wound Stators - 69 HD Submersible Motors have Class H stator insulation systems specifically designed for the temperature and electrical ratings involved. If motor failure is analyzed to encompass a winding failure, it is required that a replacement wound stator be ordered from ZEP. 3. Cap & Cable Assembly The cap & cable system is supplied with modular cable units and a modular rail-mounted terminal board. The cap & cable assembly can be removed from the motor in order to perform normal inspection and repairs. Should the cap & cable assembly or individual cable modules be damaged or the integrity of the sealing components be in question, repair or replacement is required. Complete assemblies and individual cable units are available as replacement parts. Rebuild kits for field repair of the cable modules are also available as replacement parts. When rebuilding the cable modules with non- OEM cable, care should be taken to use only cable meeting original factory specifications and dimensions. When replacing the assembly or individual cable modules, care should be taken not to nick or damage the O-ring seals. Replace any damaged or nicked O-rings. Please refer to instructions supplied with the replacement parts for complete details. 4. WHEN REPLACEMENT PARTS ARE REQUIRED, BE SURE TO ORDER FROM ZEP USING MOTOR NAMEPLATE IDENTIFICATION NUMBERS. 5. Hardware - All hardware is stainless steel and, if necessary, should be replaced with the same type. FACTORY MUTUAL RESEARCH APPROVED MOTORS ZEP manufactures both Factory Mutual (FM) Approved motors and non-fm Approved motors. FM motors are explosion proof and approved for Class 1, Division 1, Groups C and D/T3A. The motor nameplate carries the FM logo when FM motors are purchased. The repair of FM ZEP submersible motors by independent repair shops is permissible. However, to maintain the approved status, strict guidelines for the repair must be adhered to. They are as follows: 1. ZEP must first be notified prior to any work being done to motor, the nature of the work, and who will complete the work.. No machining, rework, or redesign to any part or assembly is permitted. There are no exceptions. 3. All new replacement parts required to reconstruct the motor back to operating condition must be ordered from ZEP. 4. No changes to or removal of motor nameplates, warning plates, and/or instruction labels is permitted. Replacements are available from ZEP. (Damaged plates must be returned to ZEP.) Disregarding these guidelines will result in voiding the Factory Mutual Research Approved status of the motor. NO CHANGES TO THIS DOCUMENT ARE PERMITTED WITHOUT PRIOR FM APPROVAL. LONG TERM STORAGE INSTRUCTIONS The equipment is shipped from the factory with adequate protection for transportation in covered trucks, and for indoor storage at the job site for a limited time between receipt and installation. If the equipment is not put into service within 90 days, it should be stored in a cool, clean, and dry indoor location. The equipment should be removed from shipping packaging and inspected prior to storage. To help prevent rusting, any paint scratches or chips incurred during handling should be touched up prior to storage. Store the equipment in the vertical shaft down position. Electrical cables must be properly supported and protected from moisture. The rotating assembly must be spun for approximately one (1) minute monthly to insure proper distribution of lubricant and to prevent damage to the shaft, bearings or seals. INSTALLATION NOTES Maximum submergence of motor is not to exceed 150 feet in depth and/or 150 P.S.I. working pressure at the motor lower seal. Thermal Protectors (Leads marked P1 and P) must be connected. See page #7. Moisture Sensing Probes (Leads marked W1 and W) must be connected. See page #7. Check power supply against final nameplate connection voltage. This equipment is intended to operate using a supply of quality power with normally accepted characteristics of voltage unbalance, voltage variations, expected number of voltage sags/interruptions and harmonic distortion levels. The IEEE and the International Electrotechnical Commission (IEC) have developed standards to provide further guidance regarding these areas. When installing pump or other machine to motor shaft, care must be taken to properly fit shaft and key. If required, the impeller hub should be heated slightly before sliding it onto the shaft. UNDER NO CIRCUMSTANCES SHOULD THE IMPELLER BE DRIVEN ON BY POUNDING. THIS WILL DAMAGE THE SEALS AND BEARINGS. The key must be fit to shaft keyway to avoid impeller from riding on key. The fastener must employ locking means to prevent loosening. When fastener is removed, it is recommended fastener be replaced with a similar device available from ZEP. When the submersible motor leaves the factory it is ready for installation, however, during shipping and handling, fasteners may loosen. Verify tightness before installation. No further adjusting, venting or oil filling is required. The motor will operate successfully when the following conditions are met: Voltage variation: 10% above or below nameplate data. Frequency variation: 5% above or below nameplate data. Voltage unbalance: 1% maximum between any two () incoming power legs. Performance within these ranges will not necessarily be the same as the established performance at exact rated voltage and frequency. The motor should be rechecked for proper rotation on initial start-up, prior to installation. All 3-phase submersible pump motors will operate in either direction of rotation. To reverse direction of a 3-phase motor, interchange any two motor leads at the starter. A lifting bail is supplied for the purpose of installation and servicing. DO NOT USE MOTOR CABLES FOR LIFTING. THIS WILL RESULT IN PERMANENT DAMAGE TO THE CAP AND CABLE ASSEMBLY AND WILL VOID THE WARRANTY. Normal care should be exercised to prevent mechanical damage to the seal, the frame, and the insulated cable. Control leads should not be installed in the same conduit as power leads. 5

6 CAUTION Induced voltage can cause false moisture detection signals. Additionally, junction boxes installed inside wet wells are subject to moisture and condensation. These conditions may produce false moisture detection warnings. Start-up, Maintenance and Test Procedures MOISTURE DETECTION SYSTEM IMPORTANT ZEP SUBMERSIBLE MOTORS ARE EQUIPPED WITH MOISTURE DETECTION DEVICES. FAILURE TO PROPERLY CONNECT OR UTILIZE THIS SYSTEM VOIDS THE MOTOR WARRANTY. START-UP ZEP Submersible motors are designed to run continuously in water or 15 minutes in air. During normal operation, the water level should not be lower than the top of the stator housing of the motor. The unit is designed to protect all power connections against moisture. All ZEP Submersible Motors have a lead connection chamber. Three phase, dual voltage motors have 9 stator leads. In addition, all submersible motors have thermal protector leads and moisture sensing probe leads in this chamber. Leads are tagged for easy identification. Appropriate connection diagrams can be found on Page 7. MAINTENANCE With proper installation and employment of monitoring devices, frequent inspection of motor seals is not required. Should a malfunction occur, the motor has been equipped with a moisture detection system and thermal protection that will provide advance warning of impending failure, allowing the user to plan corrective maintenance before total failure occurs. THERMAL PROTECTION SYSTEM IMPORTANT ZEP SUBMERSIBLE MOTORS ARE EQUIPPED WITH THERMAL PROTECTION DEVICES. FAILURE TO PROPERLY CONNECT OR UTILIZE THIS SYSTEM VOIDS THE MOTOR WARRANTY. Thermostat leads marked P1 and P should be connected in series with the stop button on the 3-wire pilot circuit of the magnetic motor controller, so that the thermostat will open the circuit before dangerous temperatures are reached. Refer to Page 7 for wiring diagram of Thermal Protector. MOTOR CONTROLLER MAY HAVE AUTOMATIC OR MANUAL OVERLOAD RESET. DISCONNECT ALL POWER LEADS TO MOTOR WHEN PERFORMING ANY WORK ON MOTOR. A MANUAL, MOMENTARY START SWITCH IS RECOMMENDED TO PREVENT AUTOMATIC RESTART OF THE MOTOR WHEN THERMOSTAT RESETS. If current through the thermostats exceeds the values listed in the table below, an intermediate control circuit relay must be used to reduce the current or the thermostats will not work properly. Table 1: Maximum Current Capacity of Motor Thermostat Volts (VAC) Continuous Amperes Inrush Amperes Moisture sensing probe leads marked W1 and W must be used in conjunction with an induction relay or similar device. This device will detect moisture entering the oil chamber due to leakage of the lower seal and/or a breach of the stator housing. When properly connected to a warning device, the moisture detection system will provide notification of needed corrective maintenance. Refer to Page 7 for a typical wiring diagram of Moisture Sensing Circuit. The integrity of the system requires periodic testing. It should be checked every month by the test button on the relay, or by measuring the resistance of the moisture sensing circuit. CONTROL LEADS SHOULD NOT BE INSTALLED IN THE SAME CONDUIT AS POWER LEADS. INDUCED VOLTAGE CAN CAUSE FALSE MOISTURE DETECTION SIGNALS. TEST PROCEDURES Moisture Seal Probe Test A normally closed push-button and neon indicating lamp may be provided as a means of checking the moisture sensing components. When the pushbutton is depressed, the indicating lamp will be illuminated to indicate: A) power is supplied to the control, B) the control is operative, C) wiring to the moisture sensing probes in the motor is intact. If a test button is not supplied, the integrity of the circuit may be checked with an ohmmeter by first disconnecting W1 and W from the relay. To avoid inaccurate readings, it is important to measure the resistance across the leads to the moisture seal probe and NOT across the relay. Measured resistance should be 330,000 ohms ( +/- 10%). Measured resistance below this level could indicate a moisture breach. Measured resistance above this level could indicate an interruption in the circuit and/or wiring. Signal Device(s) for Moisture Notification The signal device may be audible (bell, buzzer, horn or siren) or visible (incandescent or neon lamp) or both. Megger Test Meggers are normally used for trend analysis, whereby newly installed electrical equipment is measured to establish a base of values in resistance, which are recorded along with numerous other relevant variables. Thereafter, readings are periodically taken and recorded along with temperature, moisture, and the length of time the megger was connected to obtain readings. This procedure must be continued for an extended period of time in order to determine that the declining rate of insulation breakdown is not accelerating at an unacceptable level. This test should be taken between the power leads and ground and NEVER ACROSS THE MOISTURE DETECTION OR THERMAL PROTECTION CIRCUITS. With periodic monitoring of the moisture-sensing probe as part of a regular schedule of preventive maintenance, it is unnecessary to perform a megger test. However, if a megger test is performed, a resistance of megohms or less indicates maintenance is needed. System Operation 6

7 It is required that immediately upon indication (by warning light, etc.) of lower seal failure that the motor be removed from the installation and the oil and lower seal be replaced as soon as possible. If reconditioning is not performed within a 30-day period it is then recommended that the motor be thoroughly inspected and repaired/replaced as required. When ordering parts or reporting trouble, please provide complete motor nameplate data. DISASSEMBLY PROCEDURES Completely remove pump from the pit. Padlock motor safety switch and mark electrical leads to maintain correct rotation. Disconnect pump cable leads from control panel. Referring to Page 4, remove cap screws (part ) and lift motor with impeller out of volute. If gasket is destroyed, note its thickness for replacement. Note that an adapter plate (part 4) is shown. This may or may not be on your pump depending on the size of the motor. Lay this assembly on its side on a bench. For the applicable specific motor frame, remove impeller cap screw or heavy hex nut and washer (part 1). Pull the impeller off the motor shaft using a wheel puller or similar tool. Remove impeller key (part 13). If pump has a System Operation and Disassembly Procedures motor adapter plate, generally there is no need to remove it. On pump models equipped with polyurethane casing wear ring (See Illustration A for details and list of applicable models), ring may be removed by severing in half (semi-circle) and extracting. Replacement ring can then be drive fitted into place. Optional impeller wear ring (part 75) can also be removed by cutting off impeller eye outside diameter. Replacement impeller wear ring can be driven onto impeller eye outside diameter. (Slightly heating the wear ring may facilitate reinstallation.) All other models equipped with either casing wear ring (part 76) and/or impeller wear ring (part 75) are disassembled by removing machine screw (part 77). New replacement screws must be used and "loctited" in place upon reassembly. For the disassembly of the motor, refer to specific motor instruction manual. Note that stator repairs can be made with only partial motor disassembly. However, if complete disassembly is required, follow complete procedure in the motor instruction manual. After the motor is repaired and reassembled, again place it on its side on a bench. Assemble the pump in reverse order of disassembly. MOTOR MAY CONTAIN GAS UNDER PRESSURE DUE TO HIGH TEMPERATURES FROM OPERATION. DISASSEMBLY MAY CAUSE BODILY INJURY. 69 HD Electrical Connections WARNING! IF RECONNECTING MOTOR FOR DIFFERENT VOLTAGE, CHECK POWER CABLE SIZING CHART IN THE INSTRUCTION MANUAL TO AVOID OVERLOADING POWER CABLE. CONSULT FACTORY IF UNSURE BEFORE CONNECTING POWER TO MOTOR. POWER CABLE LOW VOL TAGE CONNECTION HIGH VOLTAGE CONNECTION T1 1 7 T T3 T DUAL VOLTAGE: NINE STATOR LEADS TO BE CONNECTED PER S.O. FOR EITHER HIGH OR LOW VOLTAGE SINGL E VOL TAGE: THREE STATOR LEADS MOTOR FRAME STATOR T1 T T3 1 3 T1 T T3 G (BLACK) (WHITE) (RED) (GREEN) (BLACK) P1 (WHITE) P (RED) W1 (ORANGE) W GROUND G T T3 P1 P W1 W P1 P W1 W 5 6 STATOR THERMOSTAT LEADS (SEE NOTE) RESISTOR CONTROL CABLE SEAL CAP MARKINGS ON TERMINALS OR WIRES TERMINAL S NOTE: THREE THERMOSTATS, NORMALLY CLOSED, AUTOMATIC RESET, CONNECTED IN SERIES, ONE PER EACH STATOR WINDING END COIL. MOISTURE PROBES IMPORTANT ZEP Submersible Motors are equipped with thermal protection & moisture detection devices. Failure to properly connect or utilize these systems voids the motor warranty. 7

8 ELECTRICAL REPAIRS Repairs and Reassembly 14. Using a suitable bearing puller, remove thrust bearing (10). Electrical repairs such as stator repair and/or replacement, or servicing of thermal protectors may be accomplished without disturbing the rotating assembly (i.e. rotor, thrust bearing housing, lower seal housing). Refer to Cross Section Drawing on Page. 1. Remove cap screws (6) securing cord and cap assembly (9). Disconnect all leads and grounding wire. Remove cord and cap assembly. 3. Remove bolts (3) securing thrust bearing housing (5) to stator housing (7). Using top lifting bail (54), lift stator assembly, being careful not to catch moisture probe leads (3) in wire channel. 4. Remove lifting bail (54) and lifting bail hardware, along with all hardware connecting the radial bearing housing (8) to the stator housing (7). NOTE: Pay particular attention to the location of lifting bail so that it is reassembled in the same position. 5. Remove radial bearing housing (8) if necessary. MECHANICAL REPAIRS Inspecting or Draining Oil: Lower seal cavity is oil filled. Oil can be drained by removing either pipe plug (5) or (40). Final Disassembly: 15. Remove moisture sensing probes (1) and resistor (37) if necessary. 16. For complete disassembly refer to Electrical Repairs Disassembly, Items Using suitable bearing puller, remove radial bearing (11) if necessary. 18. Remove stationary seats of the upper (17) and lower (14) seals. NOTE: Rotor & Shaft assembly cannot be further disassembled. Stators on BHP models are secured in the housings by a pin or set screw located approximately at the center of the stator housing. The pin or set screw is sealed and covered by a pipe plug and cannot be serviced or removed. MOTOR ASSEMBLY - REASSEMBLY INSTRUCTIONS 1. FOR 0-40 BHP: Rotating Assembly-- Assemble radial bearing (11), thrust bearing snap ring (44) and thrust bearing (10) to rotor/shaft assembly. FOR BHP: Rotating Assembly-- Assemble radial bearing (11), thrust bearing cap (6), thrust bearing (10), lock washer and locknut (45) to rotor/shaft assembly. Pay particular attention to orientation of thrust bearings. Install with the wide outer races facing each other as shown on the attached drawing. Inspecting Lower Seal: 1. Place motor with output shaft in up position.. Remove lower seal snap ring (1). 3. Remove lower seal rotating element (13). 4. Thoroughly clean the recess and visually inspect seal. If mating faces do not show excessive wear, replacement is not required. Inspecting Upper Seal: 5. Remove pipe plug (5) and drain oil while in shaft up position. Remove lower seal as described above. 6. Remove cap screws () from thrust bearing housing (5) and remove lower seal housing (4). 7. Remove upper seal snap ring (15) and upper seal rotating element (16). 8. Thoroughly clean the chamber and visually inspect seal. If mating faces do not show excessive wear, replacement is not required. MOTOR ASSEMBLY - DISASSEMBLY INSTRUCTIONS Thrust Bearing Replacement: 9. Rotate motor to output shaft in down position. 10. Remove cord and cap assembly (9), stator housing (7), and stator () (Refer to Electrical Repairs Disassembly Items 1-3). 11. FOR 0-40 BHP: Remove thrust bearing retaining ring (6). Grasp rotor (1) below radial bearing (11) and lift rotor/shaft assembly. FOR BHP: Remove cap screw (46) and lift thrust bearing cap (6). Grasp rotor (1) below radial bearing (11) and lift rotor/shaft assembly. 1. Disconnect moisture sensing probe lead wires (3) at probes (1). 13. FOR 0-40 BHP: Remove thrust bearing snap ring (44). FOR BHP: Remove locknut and lock washer (45). 8 CAUTION WHEN INSTALLING BALL OR ROLLER BEARINGS, PRESS ONLY AGAINST INNER RACES OF BEARINGS. PRESSING ON OUTER RACES WILL DAMAGE ROLLING ELEMENTS AND DAMAGE THE BEARING. PRESS EVENLY ON BEARING INNER RACE, USING EXTREME CARE NOT TO SCORE SHAFT. It may be necessary to heat bearings to facilitate installation due to close tolerance fits. Bearings may be heated by either of the following methods: OIL BATH: Accomplished by submerging bearing in a tank of oil having a high flash point. The bearing should be suspended so as not to be in contact with the heat source, for 0 to 30 minutes at a temperature of approximately 00 F. Oil temperature must not exceed 50 F. INDUCTION HEATING: Accomplished by applying heat directly to the bearing (i.e., commercially available induction bearing heater). Extreme caution must be exercised to insure that bearing temperature does not exceed 00 F. The bearings should be quickly installed and positioned squarely against mating face while it is still hot, and secured with appropriate retaining ring or locknut. Retighten locknut after bearing has cooled. SUITABLE PROTECTIVE CLOTHING (I.E. GLOVES) MUST BE WORN WHEN HANDLING HEATED COMPONENTS.. Place O-rings (18), (19) & (8) on their register fits. Lightly coat all fits with a suitable lubricant (such as that listed on page 13). Alternatively, grease may be substituted (not excessive). 3. Thrust Bearing Housing Assembly-- A) Coat moisture sensor probe (1) pipe threads with sealant and screw into place, making sure they are tight. Clean excessive sealant from thrust bearing housing (5). B) Pre-pack thrust bearing (10) /3-3/4 full of lithium based grease. Do not over grease. C) Lightly lubricate upper seal stationary seat O-ring(17) with recommended seal lubricant (Page 10). Make certain lapped face is exposed. Now, using a suitable pressing tool, carefully press upper

9 seal stationary seat into thrust bearing housing (5) until properly positioned. D) FOR 0-40 BHP: Lower reassembled rotating assembly (Reassembly Instruction 1, above) into thrust bearing housing (5) and secure thrust bearing retaining ring (6) in thrust bearing housing (5). FOR BHP: Lower reassembled rotating assembly (Reassembly Instruction 1, above) into thrust bearing housing (5) and secure thrust bearing cap (6) to thrust bearing housing (5) with cap screws (46). E) Attach resistor (37) and lead wires (3) marked W1 and W to probes (1). Re-install stator () and lower stator housing (7) over rotating assembly, pulling W1 and W lead wires (3) through cored channel in housing. Bolt stator housing (7) to thrust bearing housing (5) with cap screws (3), making sure the O-ring (18) is not damaged and is properly seated. 4. Top Cap/Radial Assembly-- A) Pre-pack radial bearing (11) /3 to 3/4 full of lithium based grease such as Mobilux EP or equal. Do not over-grease. B) Assemble radial bearing housing (8) to stator housing (7) by pulling all lead wires through one of the cored opening in radial bearing housing (8). Make sure O-ring (19) is seated properly before tightening all hardware previously removed. C) Replace lifting bail (54) to original position and secure with fastening hardware. 5. Lower Seal/Mounting Flange Assembly-- A) Place motor assembly with output shaft in up position. Thoroughly clean seal cavity and probes. Lightly lubricate rubber parts of upper seal rotating element (16) and shaft (3) with recommended seal lubricant. Slide complete upper seal rotating element (16) onto shaft (3). Firmly push into position and install upper seal snap ring (15) on shaft (3) using a suitable tool. Turn shaft by hand to make sure seal is properly seated. B) Reinstall lower stationary seat (14) and rubber mounting cup, making sure it is properly seated. Follow steps outlined in Paragraph 3 C) on previous page. C) Assemble lower seal housing (4) to thrust bearing housing (5) and secure with cap screws (). Make sure O-ring (8) is properly seated before tightening. Thoroughly clean seal cavity. Complete lower seal rotating element (13) and lower seal snap ring (1) following the procedure outlined in Paragraph 5 A) above. When complete, turn shaft by hand to make sure seals are properly seated. D) Add required quantity of recommended oil to lower seal cavity (Refer to Table for recommended oil quantities). This can be accomplished with the output shaft in the up position. Use pipe plugs (40) (one for filling and one for venting); or, in a shaft down position use plugs (5) similarly. The oil level should be checked after assembly is complete and motor is returned to shaft down position. Oil level should be even with the bottom of upper pipe plug (5). 6. Cord and Cap assembly -- A) Rotate motor to output shaft in down position. B) Thoroughly clean all O-ring fits. Place O-ring (0) over fit and lightly coat with grease (not excessive). C) Reconnect power and control wires using applicable connection diagram on pages 15 & 16. D) Secure cord and cap assembly (9) to radial bearing housing (8) using screws (6), making sure O-ring (0) is properly seated. Repairs and Reassembly (Continued) 9

10 RECOMMENDED OIL QUANTITIES MOTOR BHP QUANTITY QTS QTS QTS QTS Specifications Standard Food-Grade RECOMMENDED OIL MANUFACTURER BRAND NAME Petro Canada Petro Canada 10W Citgo Citgard 10W Petro Canada Purity FG White Mineral Oil Witco Freezene Heavy Recommended Grease for Bearings: CITGO Lithium EP- or equivalent MAINTENANCE DATA FOR MECHANICAL SEALS MOTOR BHP SIZE UPPER SEAL LOWER SEAL 0 1-3/ /4-1/ / / 3-1/4 Applicable Products: ZEP Submersible Motors Applicable Seals: Type 1 or equal. Cleaning Solvent: Denatured Ethyl Alcohol Solvent Formula CDA 19. Seal Installation Lubricant: Water or water based seal installation lubricant such as P-80 Rubber Lubricant. Do not use oil or grease as a seal lubricant. Model No. H.P. Full Load RPM Frame Size 69 HD SUBMERSIBLE MOTOR DATA VOLT / 3 PHASE Nominal Eff * Full Load Nominal Power Factor Full Load 460V Full Load Locked Rotor KVA Code Letter Full Load Torque (Ft Lbs) Typical motor data for Submersible 3 phase, 60 hertz, NEMA design B, 40 C ambient, normal torque motors. Amperes shown for 460 volt connection. If other connections are available, the amperes will vary inversely with rated voltage. All values nominal. *Efficiencies include all mechanical losses including mechanical seals. ** Above cable data for standard 460 Volt motors only, with cable length of 50'. Data is applicable through lengths of 100'. Cable size and dimensions may vary. Confirm with factory before final design or construction. 10 % Full Load Torque Locked Rotor Breakdown Power Cable** AWG Size O.D. (in.) Control Cable** F # # F # # G #4 1.5 # G # # F # # F #4 1.5 # G #4 1.5 # G # 1.45 # AWG Size O.D. (in.)

11 - Foundation and Guide Pipes With the easy lift arrangement the pump is supported by the base elbow, which also supports the discharge piping. The pit floor should be designed to carry the weight of the entire assembly of pump, base elbow, guide pipes, and discharge piping. The foundation bolts for the base elbow are located off the clear opening in the pit cover (refer to ZM31) and should be long enough to accommodate 1" of grout under the foot of the elbow. The base elbow should be shimmed from the rough concrete floor until the horizontal pipe flange is level in both directions. Then grout the base and allow the grout to harden before tightening the foundation bolt nuts. Slide the two guide pipes over their pins in the base elbow. At the top of the guide pipes, install the pipe spacer with the plugs entering the pipes. For pits deeper than 8 feet, special intermediate spacers may be provided to laterally support the guide pipes to the discharge pipe. Then the upper ends of the guide pipes are attached to the floor plate cover angle, or whatever method has been provided. (This attachment varies with installations and is the responsibility of the customer.) - Piping In most cases, the discharge piping arrangement has been established and a typical arrangement is shown on the installation drawing; however, there are several rules to follow. The pipe size should be no smaller than that of the base elbow. Gate and check valves should be provided in each discharge pipe with the check valve placed between the gate valve and the pump. The EASY-LIFT Assembly Dual Rail valves may be either inside or outside the pit. The base elbow supports the weight of the piping but long (10' or more) vertical sections may require lateral bracing from the pit wall. - Checking Rotation It will be necessary to check the rotation of the motor and pump impeller before installing the unit into the basin. CAUTION BE CAREFUL NOT TO HAVE HANDS, FEET, CLOTHING, OR OTHER OBJECTS IN OR NEAR THE PUMP SUCTION OPENING WHEN THE POWER IS ON! The motor leads should be marked, or the starter diagram located inside the starter should be marked, or both, so that the connections can be broken and remade with accuracy. It is important that the pump rotates in the direction for which it was designed. Lay the pump on its side and connect the motor lead to the permanent source of power. Quickly turn the power on and off to get the impeller spinning. Examine the impeller through the suction opening. It should be turning counterclockwise. If not, change any two of the motor leads and recheck. As soon as the motor is rotating in a counterclockwise direction, mark the leads and diagram as mentioned above. COMPONENT & MATERIALS LIST ITEM QTY DESCRIPTION NAME Submersible Pump & Motor Assembly Easy Lift Stationary Elbow STANDARD MATERIAL Cast Iron Cast Iron 3 1 Easy Lift Slide Clamp. Cast Iron 4 4 Hex Head Cap Screws Stainless Steel 5 4 Lockwasher Spring Type 6 " Rail Pipes Stainless Steel OPTIONS Bronze / Stainless SS or Galvanized, provided by others

12 Service Checklist and Trouble Shooting ELECTRICAL PRECAUTIONS Before servicing a pump, always shut off the main power breaker to the panel and then disconnect the pump - making sure you are wearing insulated protective sole shoes and are not standing in water. Under flooded conditions, contact your local electric company or a qualified licensed electrician for disconnecting electrical service prior to pump removal. Submersible pumps contain oils which become pressurized and hot under operating conditions - allow ½ hours after disconnecting before attempting service. CONDITION A. Pump will not start or run. Steps Check Voltage At If No Voltage If Voltage No. 1 No. Line terminals in pump's control panel L1 - L - L3 (3 Phase). Pump motor terminals in pump s control panel T1 - T - T3. Check Disconnect switch, line fuse, and/or circuit breakers in power supply circuit. Check for control circuit voltage. Check out magnetic starter contacts, thermal overloads & sensor, and float switches. Proceed to No.. Check pump for ground, and binding impeller. COMMON CAUSES B. Motor overheats and trips overload or blows fuse. - Incorrect Voltage - Unbalanced power source - Incorrect motor rotation - Negative or low head - Excessive water temperature - Impeller or seal mechanically bound - Motor shorted - Lost one line in a Three Phase unit C. Pumps starts and stops too often. - Check valve stuck open - Level controls out of adjustment - Temperature sensor tripping - Thermal overload switch out of adjustment or defective - Pit too small D. Pump will not shut off. - Debris under float switch - Float travel obstructed - Defective or damaged float switch - Magnetic starter contacts shorted - Air lock - check vent hole E. Pump operates but delivers little or no water. - Check for plugged Pump housing, discharge pipe or sticking check valve - Vent hole clogged or not drilled - Discharge head exceeds pumps capacity - Low or incorrect voltage - Incorrect motor rotation F. Drop in head and/or capacity after a period or use. - Increase Pipe Friction - Clogged line or check valve - Abrasive material & chemical, deteriorated impeller and pump housing If the above check list does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump. 1