4
© Copyright 2013 Zoeller Co. All rights reserved.
DISASSEMBLY PROCEDURES
DUAL VOLTAGE MOTORS
230/460V pump stators are wound so they can be wired for either 230 or 460 volts. New
pumps are shipped connected for the specific voltage ordered.
To change the voltage, remove the six screws (2) that secure the cover. Lift off the cover
(4) being careful not to damage the seal ring (9). Change the wiring as required per the
following diagram.
THREE PHASE STANDARD MOTOR,
VOLTAGE OPTIONS WIRING DIAGRAM
After changing the leads, lightly oil the seal ring (9). Ensure that the wire leads will not be pinched
and position the cover (4) on the upper bearing housing (15), securing with screws (2).
Before installing a pump into a pit for operation, check the pump rotation, ensure that
the wiring has been completed to proper power source and that the green lead of the
power and sensor cords (see Power and Sensor Cord Lead identification illustration) is
connected to a valid ground. Momentarily energize the pump, observing the direction of
kick back due to starting torque. Rotation is correct if kick back is in the opposite direction
of rotation arrow on the pump casing. If rotation is not correct, switching of any two power
leads should provide the proper rotation (three phase only).
Single phase models are available in 230 volts / 60 Hz only and will only run in the proper
direction. Therefore, it will not be necessary to remove the lead wire housing.
OPERATION
Before putting the pump into operation, the following items should be checked to ensure
that the pump is installed correctly.
• Electrical connections
• Pump rotation
Loss of performance is usually an indication of wear between the impeller and the casing.
The gap created by this wear can be reduced by adding shims as instructed in disassembly
and assembly sections of this manual.
DISASSEMBLY PROCEDURES
A. Before you begin...
1. Shut off pump.
2. Disconnect power source.
3. Remove pump from system.
B. When removing impeller (44)...
1.
Complete
section
A.
2.
Remove the eight screws (32) and lock washers (3)
from the flange of the
adapter
housing
(34).
3. Remove the pump housing (48) and gasket (47) (dry pit only).
4. Immobilize the impeller (44) by holding the vanes with a pipe wrench. Using a
socket, remove the impeller bolt (46), lock washer (50) and impeller washer (45).
5. Using two pry bars, carefully pry the impeller (44) from the shaft.
6.
Remove the square key (43) and any impeller shims (42) which are on the shaft.
Note
the number of shims removed so the same amount can be installed upon reassembly.
NOTE: Impeller hub serves as lower seal retainer. When impeller is removed, seal
spring will fall free.
C. When removing rotary seals (36 & 41)...
1. Complete sections A and B.
Pump should be at room temperature. Seal and motor housing may
be pressurized. Care should be used in removing pipe plugs so that oil is not sprayed.
CAUTION
Do not touch sealing face of the rotating section or the stationary
section of the rotary seals (36 & 41) when removing or installing seal. Seal replacement
should be done in shop atmosphere if possible.
2. Remove the spring of the lower rotary seal (41) from the shaft. See rotary seal
component placement diagram for part identification.
3. Remove the pipe plug (1) in the side of the adapter (34) and drain the oil from
the chamber with the pump laying on its side.
4. Remove the eight socket head screws (40) from the seal retainer (39).
5. Use two screw drivers to lightly pry the seal retainer (39) from the adapter (34).
The remaining part of the lower seal assembly will also be removed.
6. Press seal seat out of the seal retainer (39).
7. Remove the seal ring (38) from the seal retainer (39) and inspect for damage.
8.
Slowly remove the oil plug (1) from the side of the motor housing (17) (see
warning
above).
9. Turn the pump on it’s side to drain the motor chamber oil.
10. Remove the upper seal retainer ring (37) from the shaft and remove the spring
holder and seal spring of the upper rotary seal (36) from the shaft.
11. Using a bearing puller or other suitable tools, pull the rotating section of the
upper rotary seal (36) from the rotor shaft. If needed, carefully pry rotating
section loose and pull off by hand.
12. The stationary seal can be pried with a screw driver. Be careful not to chip as
chips may fall into motor.
NOTE: If the adapter and motor housing are going to be separated to work on the motor,
it may be easier to do so before removing the upper seal. When the rotor and bearing are
pulled from the adapter, it will strip the seal off the shaft on the lower side.
D. When removing the power and sensor cord assembly (6)...
1.
Complete
section
A.
2. Remove the six screws (2) and lock washers (3) that secure the cover (4) to
the motor housing (17).
3. Pry the cover (4) off using two pry bars.
4. Remove the power and sensor cord lead connections from the thru-wall
terminals (10 & 11) and in upper bearing housing (15). Set cover and cord
assembly
aside.
5. Remove seal ring (9) from the cover and inspect for damage.
6. To replace cord assembly. Remove four screws (8) and lock washers (7).
7. Using a small pry bar, pry around the edges of the cord clamp area of the cord
and clamp assembly (6) to loosen it.
8. Remove the ground screw and disconnect the ground wire from the inside of
the cover (4).
9. Pulling on the power leads on the inside of the cover, remove the cord and
clamp assembly (6) and seal (5) from the cover. The entire length of the
power and sensor cords will be pulled through the cover.
NOTE: It may take some wiggling and prying to loosen this assembly, because the rubber
seal will have taken a set.
10. Inspect the cord seal for damage.
E. When removing motor rotor (27)...
1. Complete sections A, B, and C. Section D may or may not be completed first.
If the cord and cover assembly has been removed, two 9.5 mm (
3
/
8
") eye
bolts will be required when lifting the motor housing and stator off the unit.
2. Place the pump vertical on the work surface. The pump must be blocked or
set back in pump housing (48) to allow shaft to extend out the bottom.
3. Remove eight screws (32) and lock washers (3) between motor housing (17)
and adapter (34).
4. Lift the motor housing, upper bearing housing and stator (17) up off the
adapter (34) high enough to reach the moisture sensor wires (31) and
unplug terminals from moisture sensors (35).
5. Finish lifting the motor (17) housing off the adapter (34). Be careful to lift the
motor housing straight up, so as not to damage the stator windings or bearings.
6. Remove seal ring (33) from adapter (34) and inspect.
7. Using 90° retaining ring pliers, release the retaining ring (29) which secures
the double row bearing (30) in the adapter (34).
8. Remove rotor assembly (27) from adapter (34).
9. Using a bearing puller, against the inner race, remove the lower bearing (30)
and upper bearing (26) from the shaft. Replace the bearings if needed.
NOTE: Bearings should be cleaned with volatile mineral spirits and relubricated with
proper lubricants immediately after cleaning. Never dry bearings with compressed air,
and never spin unlubricated bearings.
F. Motor Stator (18)...
1. Complete sections A, D and E.
NOTE: The six screws that hold the cover in place also hold the upper bearing housing
to the motor housing.
2. Use two screwdrivers to pry the upper bearing housing (15) from the motor
housing
(17).
3. Turn the upper bearing housing (15) over and remove the hex nuts (20) which
secure the motor leads to the thru-wall terminals (10) tagging each as it is
disconnected. Disconnect the sensor wires from the thru-wall terminals (11).
460 VOLT 3PH/60 Hz
TWO PLATES ARE STACKED ON THESE CONNECTIONS
(FROM THE FACTORY) SO THAT THERE ARE 4 PLATES
AVAILABLE. 4 PLATES ARE REQUIRED FOR 230 VOLT.
X
XXXXXX-X
T2
M1M2
2
8
3
9
T1
1
7
6 5 4
230 VOLT 3PH/60 Hz
M1
X
XXXXXX-X
2
M2
T1
T2
8
3
9 6
4
7
1
5
NOTE: ALL THREE PHASE CONNECTIONS
1. BLACK
2. WHITE
3. RED
380 VOLT 3PH/50 Hz
ZEPB0594