Zabel Environmental Technology PL-TE-10 User manual

OWNER’S MANUAL
4" SUBMERSIBLE PUMP
Model PL-TE-10 – 1/2 HP, 10 GPM
Model PL-TE-20 – 1/2 HP, 20 GPM
Installation • Operation
Zabel Environmental Technology™
P.O. Box 1520
Crestwood, KY 40014
Z370 (Rev. 5/12/08)
LIMITED WARRANTY
4” Submersible pumps are warranted against defects in material and workmanship
for a period of 3 years from the date of original installation, not to exceed 42 months
from the date of manufacture, whichever occurs first. In no event shall Zabel be liable
for any consequential damages or any labor, material, freight or expense required to
replace, correct or reinstall the product. Zabel’s liability is limited to repair or replace-
ment of the part. All warranties are void if the product has been improperly modified,
applied or installed, subjected to misuse or abuse. Except as stated herein, there are
no warranties express or implied, including the warranty of merchantability or warranty
of fitness for a specific purpose.
Zabel Environmental TechnologyTM • P.O. Box 1520 • Crestwood, KY 40014

TABLE OF CONTENTS
Warranty...........................................................................................1
Safety Instructions............................................................................2
General.............................................................................................2
Electrical........................................................................................2-3
Operation..........................................................................................3
Troubleshooting Guide .....................................................................4
Carefully read and follow all safety instructions in this manual
or on pump.
This is the safety alert symbol. When you see this symbol
on your pump or in this manual, look for one of the following
signal words and be alert to the potential for personal injury!
DANGER warns about hazards that will cause seri-
ous personal injury, death or major property damage if ignored.
WARNING warns about hazards that can cause
serious personal injury, death or major property damage if ignored.
CAUTION warns about hazards that will or can
cause minor personal injury or property damage if ignored.
The word NOTICE indicates special instructions which are impor-
tant but not related to hazards.
To avoid serious or fatal personal injury and possible property
damage, carefully read and follow the safety instructions.
1. Under certain conditions, submersible pumps
can develop extremely high pressure. Install
a pressure relief valve capable of passing
entire pump flow at 75 PSI.
Do not allow pump, piping, or any other system compo-
nent containing water to freeze. Freezing may damage
system, leading to injury or flooding. Allowing pump or system
components to freeze will void warranty.
2. Can shock, burn or cause death. To avoid
dangerous or fatal electric shock hazard, use
pump only in an effluent system. DO NOT
install pump in an open body of water ( a
lake, swimming pool, etc.).
Install, ground and wire pump according to local and Cana-
dian Electrical Code or National Electrical Code requirements
that apply.
Disconnect electrical power supply before installing or servic-
ing pump.
Make sure motor nameplate voltage and frequency match
line voltage and frequency of power supply.
1. Install pump according to all plumbing, pump and well code
requirements.
2. Install an all leg disconnect switch in the power supply near the
pump.
3. Two-wire motors are equipped with automatic thermal overload
protection which will open the circuit and stop the motor when a
thermal overload (excessive heating) exists. When motor cools,
overload will reset and motor will restart automatically. This can
cause the motor to start unexpectedly and without warning.
GENERAL
Inspect pump and motor for delivery damage. Report any damage
immediately to shipping carrier or to Zabel immediately.
Have any installation, repair, or service work done by your Zabel
dealer.
Never run pump dry.
During system operation, pump must be submerged at all times.
Pipe joint compound can cause cracking in plastics. Use only teflon
tape when sealing joints in plastic pipe.
Warranty is void in the following conditions:
• Water is highly corrosive.
• If entrained gas or air present in water being pumped reduce the
flow and cause cavitation (which can damage the pump).
• Pump has been operated with discharge valve closed (severe
internal damage will result).
ELECTRICAL
WIRING/GROUNDING
Can shock, burn, or cause death. Permanently
ground pump, motor and control box before
connecting power supply to motor.
Ground pump and motor in accordance with all codes and ordi-
nances that apply. All wiring must meet National Electrical Code and
Canadian Electrical Code (whichever applies). Use copper ground
wire at least as large as wires carrying current to motor.
Motor is supplied with copper ground wire. Splice to copper conduc-
tor that matches motor wire size specified in Table 2. Use only cop-
per wire for connections to pump.
Permanently ground pump and motor before connecting power
cable to power supply. Connect ground wire to approved ground
first, then connect to equipment being installed.
Do not ground to a gas supply line.
Float switches or any other approved motor control must match
motor input in full load amperes.
For more information, contact your local code officials.
INSTALLATION WIRING INSTRUCTIONS
Single Phase, 2 Wire
2-Wire pumps have two power supply wires (Red/Black) and one
ground wire (Green).
1. Fasten power supply wire leads securely to pump discharge sec-
tion; leave 4-5" of slack in leads at this point. Securely fasten
leads to plastic pipe within 6" of the pump discharge section.
2. Ground wire must be as large as wires supplying current to
motor. Consult current National Electrical Code or Canadian
Electrical Code (as applicable) and local codes for grounding
information.
3. Use only submersible power supply wires supplied by pump man-
ufacturer. When installing pump, secure supply wires to discharge
pipe with Scotch #33 electrical tape. DO NOT damage pump
wires.
NOTICE: To avoid dropping pump or damaging wires or splices,
NEVER allow pump wires to support weight of pump.
EFFLUENT APPLICATIONS
Effluent applications must meet the following:
Risk of electrical shock. Do not remove cord and
strain relief. Do not connect conduit to pump.
1. Only qualified personnel should install the pump and associated
control equipment.
2. Vent sewage tank according to local code.
3. Do not install pump in any location classified as hazardous by
National Electrical Code, ANSI/NFPA 70-1984.
4. These pumps are intended for permanent connection only.
Provide strain relief at control box for power supply cord connec-
tion to box. All control components must be UL listed and suitable
for end use application.
PUMP INSTALLATION
1. Make sure that pump and motor are free to rotate by turning the
shaft by hand.
2. To prevent dropping pump, lower it by the drop pipe, not by the
cables. The electrical cables will not hold the pump weight.
3. Discharge outlet is 1-1/4" NPT threaded.
NOTICE: Pump discharge is left-hand thread into pump shell. If
installing external check valve, hold discharge with pipe wrench to
prevent loosening discharge in shell.
4. If pump is to be operated with an open discharge, a discharge
valve must be installed.ˆ Before startup, open this valve about 1/3
Hazardous
voltage
Hazardous
voltage
2

open. Start pump. Slowly open valve until the desired flow rate is
reached. Final setting must be within pump’s recommended oper-
ating range.
OPERATION
1. The pump must be submerged at all times during normal opera-
tion. Do not run pump dry.
2. Make sure that the float switches are set so that the pump stops
before the pump runs dry or breaks suction. If necessary, adjust
float switches to achieve this.
3. The motor bearings are lubricated internally. No maintenance is
required or possible on the pump or the motor.
3
Volts HP 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 3 AWG 2 AWG 1 AWG 0 AWG
115 1/2 99 158 247 387 603 921 1138 1403 1677 1893
Table 2: Power Supply Wire (Cable) Length in Feet
1 Phase, 2 Wire Cable, 60 Hz (Copper Wire Size - Service to motor)
Hazardous voltage. Can shock, burn,
or kill. To reduce the risk of electrical
shock during pump operation, ground and bond the pump and
motor as follows:
A. To reduce risk of electrical shock from metal parts of the assembly
other than the pump, bond together all metal parts accessible at the
tank top (including metal discharge pipe, metal tank top, and the
like). Use a metal bonding conductor at least as large as the power
cable conductors running down the well to the pump's motor.
B. Clamp or weld (or both if necessary) this bonding conductor to the
grounding means provided with the pump, which will be the equip
ment-grounding terminal, the grounding conductor on the pump
housing, or an equipment-grounding lead. The equipment-grounding
lead, when provided, will be the conductor having green insulation; it
may also have one or more yellow stripes.
C. Ground the pump, motor, and any metallic conduit that carries power
cable conductors. Ground these back to the service by connecting a
copper conductor from the pump, motor, and conduit to the ground-
ing screw provided within the supply-connection box wiring compart-
ment. This conductor must be at least as large as the circuit conduc-
tors supplying the pump.
Save these instructions.
NOTE: Sizes given are for copper wire. For aluminum wire go two
sizes larger (i.e., if table lists #12 copper wire, use #10 aluminum
wire.)
Condition of Motor and Leads Ohm Value Megohm Value
New motor, without power cable 20,000,000 (or more) 20.0
Used motor, which can be reinstalled in tank 10,000,000 (or more) 10.0
Motor in Tank – Readings are Power Cable plus Motor
Do not pull pump for these reasons:
New Motor 2,000,000 (or more) 2.0
Motor in reasonably good condition 500,000 to 2,000,000 0.5–2.0
Motor which may be damaged or have damaged power cable 20,000 to 500,000 0.02–0.5
Pull pump; replace pump or cable:
Motor definitely damaged or with damaged power cable 10,000 to 20,000 0.01–0.02
Failed motor or power cable Less than 10,000 0–0.01
Motor Insulation Resistance Readings
Normal Ohm/Megohm readings for all motors, between all leads and ground. Set ohmmmeter to 100K scale.
Table 1: Recommended Fusing Data
60 Hz/1 Phase 2-Wire Cable
Motor Winding Max Locked Fuse Size
Voltz/Hz/ Resistance Load Rotor Standard/
HP Phase Ohms Amps Amps Dual Element
1/2 115/60/1 1.0-1.3 12.0 64.8 30/15
Important Electrical Grounding Information

PROBLEM CHECK CORRECTIVE ACTION
Motor will not start but fuses do not blow
No voltage. No voltage at disconnect switch. Replace blown fuses or bad cable, reset circuit breakers.
Electrical cable bad. Consult licensed electrician or serviceman.
Fuses blow or overload protector trips when motor starts
Wrong size fuse, Check fuse or circuit breaker size against chart, Page 2. Install correct fuse, time delay fuse, or circuit breaker.
time delay fuse,
or circuit breaker.
Wire size too small. Check wire size against chart, Page 3. Install correct size wire.
Low or high voltage. Check that line voltage is within ±10% of nameplate If voltage variation is greater than ±10%, call power
rated voltage while motor is running. company or local hydro authority to adjust voltage.
Pump or motor stuck or Check for locked shaft in pump. If necessary, pull pump (make all possible above ground
binding. checks first). If pump is locked, replace it. Clean tank
of all sand, lime, and solids before reinstalling pump.
Power supply wires or Consult licensed electrician or qualified serviceman. Have a qualified serviceman or electrician make necessary
motor leads grounded, cable repairs.
shorted, or open.
Fuses blow or overload protector trips when motor is running
Low or high voltage. Check that line voltage is within ±10% of rated nameplate If voltage variation is more than ±10%, call power
voltage while motor is running. company to adjust voltage.
High ambient (atmospheric) Check temperature of tank Protect tank from direct sunlight.
temperature.
Wire size too small. Check wire size against chart, Page 3. Install correct wire size.
Pump starts too frequently
Leaks in system. Check plumbing for leaks.
Level switch. Check for defective switch or switch out of adjustment. Re-adjust or replace level switch.
Check valves leaking. Make sure check valves are not leaking back. Replace check valves if necessary.
Little or no water delivered
Check valve stuck. Examine valve. If stuck, free valve.
Low voltage. Check voltage at circuit breaker with pump running. Install larger wire from meter to circuit breaker. Install
Check incoming wire size and power supply wire size larger wire from circuit breaker to pump. If necessary,
against chart, Page 3. have power company raise supply voltage.
Plugged intake screen. Pull pump and check condition of screen. Clean or replace as necessary.
Check valve at pump Pull pump and examine check valve. Free check valve.
discharge stuck.
Worn impellers and Make sure system is clear of obstructions and pump is in Replace pump.
diffusers. solid water and operating normally.
Pump doesn’t develop Check pump curve against operating conditions. Replace pump with “higher head” pump.
enough pressure (“head”).
Plugged impellers. Pull pump. Replace pump.
TROUBLESHOOTING GUIDE