Zenit Blue Series Installation instructions

blue - bluePRO
-Ex
(ATEX - IECEx)
better together
use and maintenance booklet
safety instructions

EU DECLARATION OF CONFORMITY
Year Type
Version
Serial nr. Code
QUALITY CHECK PASSED
Zenit Italia s.r.l.
www.zenit.com
[email protected]
Modena - Made in Italy www.zenit.com
Ex ec nC h IIC T3 Gc
IECEX EUT 16.YYYYX
Manufacturer:
Plant: ZENIT Italia S.r.l.
Via dell’Industria,11 41018 S.Cesario s.P., Modena - (ITALIA)
Zenit Pumps (China) Co., Ltd.
26 Wupu Road, Suzhou Industrial Park, Jiangsu Province, P.R. China
ZENIT Italia S.r.l.
Via dell’Industria,11 41018 S.Cesario s.P., Modena - (ITALIA)
Declare that the submersible electric pump, series blue and bluePRO, -Ex versions with marking
meet the Essential Health and Safety Requirements applicable to them in terms of the following directives and subsequent amendments and
additions:
MACHINERY DIRECTIVE 2006/42/EU
LOW VOLTAGE DIRECTIVE 2014/35/EU
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 2014/30/EU
RoHS DIRECTIVE 2011/65/EU and 2015/863/EU
ATEX DIRECTIVE 2014/34/EU
The following main standards are applied: CEI EN 60034-1:2015; CEI EN 60034-5:2007; CEI EN 50581:2013, CEI EN 60335-1:2013;
IEC 60335-2-41:2012; IEC 60079-0:2017 / EN 60079-0:2018, IEC 60079-7:2015 / EN 60079-7:2015+A1:2018,
IEC 60079-15:2017 / EN 60079-15:2019, ISO IEC 80079-36:2016 / EN ISO 80079-36:2016, ISO IEC 80079-37:2016 / EN ISO 80079-37:2016
The aforesaid equipment has been approved by the following certification procedures:
- ATEX type: examination certificate (Volountary request of Directive 2014/34/EU) No. EPT 16 ATEX 0228 X;
- IECEx type: Certificate of Conformity (CoC) No. IECEX EUT 16.0006X issued by Eurofins Product Testing Italy s.r.l. via Cuorgnè 21 10156 Turin (Italy).
IECEx Quality Assessment Report (QAR):
Zenit Italia S.r.l. N° DNV/QAR10.0002 performed by DNV - DNV (DNV Nemko Presafe AS)
Zenit pumps (China) Co., Ltd N° CN/CQM/QAR10.0003 performed by CQM - China Quality Mark Certification Group Co., Ltd.
The manufacturer ZENIT ITALIA S.r.l. operates in accordance with Quality Control System procedures which comply with the UNI EN ISO 9001
standard, accredited by DNV with certificate No. CERT-00660-95-AQ-IND-SINCERT.
The plant Zenit Pumps (China) Co., Ltd operates in accordance with Quality Control System procedures which comply with the ISO 9001
standard, accredited by CQC with Certificate No. 00119Q310038R3M/3200.
We also declare that the technical file for the electric pump is available at:
Zenit Italia S.r.l.
Via dell’Industria,11 - 41018 S.Cesario s.P. Modena - (ITALIA)
Modena, __________________ Signed
Massimiliano Volta
(Director)
II 3G (only for ATEX)
Ex ec nC h IIC T3 Gc (Atex and IECEx)
II 3G (only for ATEX)
Ex ec h IIC T3 Gc (Atex and IECEx)
Three phase
(NAE version: models without thermal protection)
Single phase
(all version with thermal protection)

Modena - Made in Italy www.zenit.com
Ex ec nC h IIC T3 Gc
IECEX EUT 16.YYYYX
Year Type
Version
Serial nr. Code
QUALITY CHECK PASSED
Zenit Italia s.r.l.
www.zenit.com
[email protected]
The images are indicative only and may not match the actual product.
Details given here may dier from the actual product.
Zenit reserves the right to modify the product without prior warning.
For more information, consult the website www.zenit.com.
AFFIX HERE
TABLE OF CONTENT
1. SAFETY INSTRUCTIONS ...................................................................................................................................................................4
1.1 INTRODUCTION ..............................................................................................................................................................................4
1.2 EQUIPMENT: EXPLANATION TO -EX APPROVAL .....................................................................................................................4
1.2.1 Suitability of the pump to the location of installation........................................................................................................................4
1.2.2 Places subject to the presence of inflammable gas, mist or steam.................................................................................................4
1.3 NAMEPLATE SAFETY DATA..........................................................................................................................................................4
1.4 SAFETY.............................................................................................................................................................................................5
1.4.1 Training of installation and maintenance staff .................................................................................................................................5
1.4.2 Personal protective equipment (PPE) to use...................................................................................................................................5
1.4.4 Residual risks ..................................................................................................................................................................................5
1.5 STORAGE .........................................................................................................................................................................................5
1.6 DISPOSAL..........................................................................................................................................................................................5
2. USE AND MAINTENANCE INSTRUCTIONS ......................................................................................................................................6
2.1 HOW TO IDENTIFY THE PRODUCT ............................................................................................................................................6
2.2 CONDITIONS OF USE.....................................................................................................................................................................6
2.3 ELECTRICAL FEATURES............................................................................................................................................................... 7
2.4. INSTALLATION ...............................................................................................................................................................................7
2.4.1 Mobile post ......................................................................................................................................................................................7
2.4.2 Fixed post........................................................................................................................................................................................7
2.4.3 With the joining foot.........................................................................................................................................................................8
2.5 CHECKING THE IMPELLER ROTATION DIRECTION (three-phase models only)......................................................................8
2.6 ELECTRICAL CONNECTIONS .......................................................................................................................................................8
2.7 THERMAL PROTECTION..................................................................................................................................................................9
2.8 STARTING CAPACITOR ...............................................................................................................................................................9
2.9 FLOATING SWITCH ..........................................................................................................................................................................9
2.10 EARTHING CONNECTION .......................................................................................................................................................... 9
2.11 MAINTENANCE..............................................................................................................................................................................10
2.11.1 General safety precautions ...........................................................................................................................................................10
2.11.2 Daily and periodic inspection.........................................................................................................................................................10
2.12 TROUBLESHOOTING GUIDE ......................................................................................................................................................11
2.13 PARTS NOMENCLATURE ............................................................................................................................................................12
2.14 OVERALL DIMENSIONS ..............................................................................................................................................................14

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For correct installation and safe use of the product, read this manual carefully and keep it safe in a clean, easily accessible place
for future reference.
Misuse of the product may cause even serious injury and damage, cause malfunctions and lead to loss of warranty cover.
1. SAFETY INSTRUCTIONS
1.1 INTRODUCTION
These safety instructions refer to the installation, operation and maintenance of the pump IECEx and ATEX Blue Standard and Professional
Series for use in places with an explosive gas atmosphere other than mines (-Ex).
Before installing and using the pump, read the instructions given below carefully.
Check that the box and its contents are in perfect condition and stop the installation in the event that any defects or anomalies are found,
then inform the supplier.
1.2 EQUIPMENT: EXPLANATION TO -EX APPROVAL
The electrical pumps BLUE series are suitable for professional use, heavy duty with clean and dirty water. They have the types of protection
“Ex ec” and “Ex h” and are suitable for gas group IIC.
The equipment is manufactured with cables permanently connected to it.
The IECEx and ATEX Blue pumps have the following explosion protection classification
1.2.1 Suitability of the pump to the location of installation
II 3G (only for ATEX)
Ex ec nC h IIC T3 Gc (Atex and IECEx)
II 3G (only for ATEX)
Ex ec h IIC T3 Gc (Atex and IECEx)
Three phase
(NAE version: models without thermal protection)
Single phase
(all version with thermal protection)
The user shall check that pump is suitable to the area classification and to the characteristics of the flammable substances present.
National Law, local Rules and Standards establish the essential safety requirements against the risk of explosion in classified areas.
1.2.2 Places subject to the presence of inflammable gas, mist or steam
The classification criteria for areas subject to the risk of explosion are laid down in the IEC 60079-10 standard.
The technical requirements for electrical plants located in classified areas are established by the IEC 60079-14 standard.
The choice of type of pump, according to these technical and legislative provisions, must take into account the following factors:
• Type of plant: above ground plants
• Zone classification: 0, 1, 2
• Characteristics of the flammable substances present in the form of gases, vapours or mists:
-Sub-group: IIA, IIB, IIC
-Temperature class: T3 (defines the ignition temperature of the gases)
1.3 NAMEPLATE SAFETY DATA
In addition to operating data, the information provided on the nameplate, includes:
• Information necessary to identify the appropriate type of pump and for the correct installation of the pump itself.
• References to the notified bodies responsible for certification.
The specific marking of explosion protection given in the Annex II of the Directive 2014/34/EU
II Group of the equipment. Group II: electrical equipment for use in places with an explosive gas atmosphere other than mines
3G Category of the equipment subject of certification, in presence of potentially explosive atmospheres of Gas, Vapors, Mist (G).
The equipment can be installed in ZONE 2
Ex ec h IIC The types of protection for the Ex equipment correspond to increased safety “ec” and through liquid immersion “h”, suitable
for Gas Group IIC, IIB and IIA.
Ex ec nC h IIC The types of protection for the Ex equipment correspond to increased safety “ec” with encapsulated thermal protection devi-
ce “nC” and through liquid immersion “h”, suitable for Gas Group IIC, IIB and IIA.
T3 Temperature Class of the equipment (maximum surface temperature 200°C)
Gc Equipment for explosive gas atmospheres, having a “enhanced” level of protection (EPL Gc), which is not a source of ignition
in normal operation and which may have some additional protection to ensure that it remains inactive as an ignition source in
the case of regular expected occurrences. Suitable for use in ZONE 2. Equipment category 3G.
Certificates number:
IECEx EUT 16.0006X
IECEx EUT: laboratory that issued the IECEx certificate of conformity
16: year in which the certificate was issued
0006: IECEx certificate number
EPT 16 ATEX 0228 X
EPT: laboratory that issued the ATEX certificate of conformity
16: year in which the certificate was issued
ATEX 0228: ATEX certificate number

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X: specific conditions of use
The certificate number indicated on the nameplate is followed by an “X”.
It means that the user must follow specific conditions of use described in this manual.
1. The submersible pump shall operate only completely submersed. A suitable separate protection device shall be installed to prevent the
pump from operating when not fully submersed.
2. The cable shall be protected against the risk of damage due to mechanical stresses. Do not use the feeding of the floating switch cable
to move the pump.
3. Do not expose permanently the plastic enclosure of floating switch to light of the sun or luminaires.
4. Do not expose permanently the plastic enclosure of the electropump to light of the sun or luminaires
5. The end connection of the feeding cables shall be made in safe area or in according to a type of protection listed in IEC 60079-0 standard
suitable for the installation hazardous area.
1.4 SAFETY
Do not allow the electric pump to be used by children or non-qualified persons.
If the electric pump is used in swimming pools and suchlike, people must not bath in or come into contact with the treated fluid until the pump
has been removed from the pool.
1.4.1 Training of installation and maintenance staff
The staff assigned to install and maintain the product must be trained in the inevitable residual risks related to electrical equipment
operating in contact with biological liquids.
They must also be capable of reading and understanding the contents of the technical documentation supplied with the product, especially the
electrical wiring diagrams.
1.4.2 Personal protective equipment (PPE) to use
Handle the electric pump while wearing personal protective equipment in conformity with the law.
Use is compulsory of protective gloves, safety footwear, protective goggles with the sides closed and leather aprons.
Before handling the already installed product, wash it with plenty of running water and/or detergents.
1.4.4 Residual risks
The product is designed and built to ensure safe, reliable use.
However, since it is intended for use with liquids that constitute a health hazard, the installation and maintenance staff must take great care
and always wear regulation personal protection equipment.
During all work on the product, users must take care not to drop the pump and must not underestimate the risks of burns, electrocution,
drowning and suffocation or poisoning due to the inhalation of toxic gases.
To reduce the risks associated with lightning, the user is required to install any necessary and adequate lightning protection measures.
Any intervention which modifies the pump components can create a DANGER of EXPLOSION.
The pumps MUST be used ONLY in areas compatible with the characteristics recorded on the label.
During handling, installation or removal operations the pump must be disconnected from the power supply panel.
1.5 STORAGE
During storage, the electric pump must be kept in a suitable place, out of the reach of children or those with diminished responsibility, suitably
secured against falling and protected from damp, dust, vibrations and extreme temperatures (below -5°C and above +40°C).
 Turn the impeller by hand occasionally (at least every month) through the outlet or intake, to prevent the mechanical
seals from sticking together.
Following storage, inspect the electric pump to make sure there is no damage, check the oil level in the mechanical seals chamber and make
sure the impeller spins freely.
If the electric pump needs to be stored for more than six months, prior to commissioning it, change the oil in the mechanical seals chamber
and take it to an authorised disposal centre.
Do not dispose of the oil as household waste.
1.6 DISPOSAL
The crossed bin symbol on the equipment, or its packaging, indicates that the product must be collected separately from other waste
at the end of its useful life and not with mixed urban waste.
Appropriate waste sorting for the subsequent recycling, treatment and disposal in an environmentally sound way of the disused equip-
ment avoids negative effects on the environment or human health and favours the re-use or recycling of the equipment’s materials.
Please contact your municipality, or local authority, for all information regarding the waste sorting systems available in the area.

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Use and maintenance booklet - Safety instructions
Modena - Made in Italy www.zenit.com
Ex ec nC h IIC T3 Gc
IECEX EUT 16.YYYYX
better together
3
1
42
7 8
5
6
9 10 11
12 13
15
16
14
18
17
19
20
2.USE AND MAINTENANCE INSTRUCTIONS
2.1 HOW TO IDENTIFY THE PRODUCT
2.2 CONDITIONS OF USE
The electric pump normally works completely immersed in the fluid in order to prime itself and to pump out and so that the latter can cool the
motor sufficiently.
These submersible pumps shall be installed only in vertical position (with vertical rotational axis). This way the inlet will not take in air and the
pump will operate correctly.
DR blue, DG blue, DR bluePRO, DGbluePRO Series:
drainage and evacuation of sewage water and/or with oil also with solid parts, in potentially explosive atmosphere.
GR bluePRO Series:
drainage and evacuation of sewage water and/or with oil with solid parts to be cutted, in potentially explosive atmosphere.
AP bluePRO Series:
drainage and evacuation of sewage clean, sandy, muddy water, with small solid parts, in potentially explosive atmosphere.
Not suitable for fluids for alimentary use
Duty type: S1
Degree of protection: IP 68 (10m – 168 h)
Maximum immersion depth: 7 m
Ambient temperature. 0 ÷ +40 °C
Temperature of the liquid 0 ÷ +40 °C
Density of fluid treated: maximum of 1.1 Kg/ dm³;
PH of fluid to be pumped: between 6 and 14;
The equipment is not intended to be supplied through inverter.
The pump has been designed to operate at the speeds indicated on the identification plate.
The submersible electric pumps feature an acoustic pressure level of below 70dB(A) when immersed and below 80dB(A) in the air.
1. Product name
2. Serial number
3. Year of manufacture
4. Motor phases
5. Frequency
6. Rated voltage
7. Motor power output - P2
8. Motor insulation class
9. Rated current
10. Running capacitor
11. Rpm
12. Minimum and maximum flow-rate
13. Maximum and minimum head
14. Ingress Protection rating
15. Maximum ambient temperature
16. Motor reference standard
17. Maximum immersion depth
18. Duty type
19. -Ex protection classification
20. -Ex certification number

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2.3 ELECTRICAL FEATURES
Pump type DR/DG blue 40/2
DR/DG bluePRO 40/2
DR/DG blue 50/2
DR/DG bluePRO 50/2
DR/DG blue 75/2
DR/DG bluePRO 75/2
DR/DG blue 100/2
DR/DG bluePRO 100/2
Rated power [kW] 0.3 (50Hz)
0.28 (60Hz) 0.37 (50/60Hz) 0.55 (50/60Hz) 0.74 (50/60Hz)
N° of phases 1 1 3 1 3 1 3
Connection - - Y - Y - Y
Rated voltage [V] 230
(50/60 Hz)
230
(50/60 Hz)
400
(50/60 Hz)
230
(50/60 Hz)
400
(50/60 Hz)
230
(50/60 Hz)
400
(50/60 Hz)
Rated current [A] 2.3 2.8 1.15 4.1 1.45 5.6 2.15
Starting-Rated current Ratio 1.9 (50Hz)
2.3 (60Hz)
1.9 (50Hz)
2.7 (60Hz)
3.2 (50Hz)
4.2 (60Hz)
2.0 (50Hz)
2.3 (60Hz)
3.5 (50Hz)
4.5 (60Hz)
2 (50Hz)
2.1 (60Hz)
3.4 (50Hz)
3.9 (60Hz)
Running capacitor [µF] 10 (50Hz)
10 (60Hz)
10 (50Hz)
10 (60Hz) -14 (50Hz) 14 (60Hz) -20 (50Hz) 20 (60Hz) -
Rated frequency [Hz] 50 / 60
rpm 2900 (50Hz)
3400 (60Hz)
Insulation class F
Pump type GR bluePRO 100/2 (*)
AP bluePRO 100/2
DR/DG bluePRO 150/2
GR bluePRO 150/2 (*)
AP bluePRO 150/2
DR/DG bluePRO 200/2
GR bluePRO 200/2 (*)
AP bluePRO 200/2
Rated power [kW] 0.74 (50/60Hz) 1.1 (50/60Hz) 1.5 (50/60Hz)
N° of phases 1 3 1 3 1 3
Connection - Y - Y - Y
Rated voltage [V] 230 400 230 400 230 400
Rated current [A] 5.5 2.7 7.5 3.2 10 4.3
Starting-Rated current Ratio 2.3 (50Hz)
2.7 (60Hz)
3.6 (50Hz)
4.8 (60Hz)
2.4 (50Hz)
3.1 (60Hz)
4.5 (50Hz)
5.7 (60Hz)
1.9 (50Hz)
2.5 (60Hz)
4.3 (50Hz)
5.7 (60Hz)
Running capacitor [µF] 25 (50Hz)
25 (60Hz) -30 (50Hz) 40 (60Hz) -30 (50Hz) 40 (60Hz) -
Rated frequency [Hz] 50 / 60
rpm 2900 (50Hz)
3400 (60Hz)
Insulation class F
(*): GR bluePRO pumps require starting capacitor. See Point 2.8 .
NOTE: Refer to the technical data sheet and to the data on the nameplate for rated voltage different from the standard versions.
The equipment could be designed also with different voltages (≤400V) maintaining the same current density in the winding and the same
induction in the magnetic core. The rated power, losses, temperatures and insulation class have to remain unchanged.
2.4 INSTALLATION
If the pump is installed in a well, this must have the following minimum dimensions: 350mm x 350mm x 350mm.
However, the manufacturer recommends the use of wells which are no smaller than 500mm x 500mm x 500mm.
 All of the follo wing operations must be carried out in safety area, in absence of potentially explosive atmospheres.
 Check that the submersible pump has been primed. In some cases, an air bubble may form in the upper part of the
pump body, which prevents liquid pumping.
2.4.1 Mobile post (Fig. 1)
Using a hose union, connect the delivery pipe to a hose with an internal
reinforcement coil and a diameter which is the same size as or larger than the
electric pump outlet.
2.4.2 Fixed post (Fig. 2)
Connect the electric pump to a metal piping, fitting a non-return valve and
an interception gate valve on the said metal piping. This ensures the pump
stability is guaranteed by the piping.
The pump can also be connected to polyethylene piping, using the relative
union. Connect the electric pump to the earth using the PVC insulated fork.

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N L
PE
M
1~
~1 50/60Hz
~3 50/60Hz
NAE version
L1 L3
PE
M
3~
L2
All versions
L - N L1 - L2 - L3 PE
Single-phase
power supply
Three-phase
power supply Ground Black Brown Grey Blue Yellow/Green
N GM B GV
2.4.3 With the joining foot (fig. 3)
Designed for the horizontal outlet models. Fix the joining foot to the bottom of
the tank first, using expansion plugs. Install the delivery pipe with the relative
non-return valve and gate valve.
Engage two guide pipes on the joining foot, fixing them in the upper part using
the spacer bracket provided by the manufacturer.
This way, the pump can be lowered supported with a galvanised chain or cable
hooked around the handle and, thanks to the two guide pipes it will fit perfectly
in place on the foot.
2.5 CHECKING THE IMPELLER ROTATION DIRECTION (three-phase models only)
Before making the three-phase electrical connection, make sure the rotation direction is correct.
To check the rotation direction, proceed as follows:
1. Lay the pump horizontal on one side and leave it free;
2. Temporarily connect the yellow-green wire to ground and then connect the power supply wires to the contactor;
3. Make sure there are no people or objects within a radius of at least 1 metre of the pump;
4. Turn on the start switch for a few moments;
5. Watch the impeller as it stops through the intake port and check that it turns anticlockwise.
If the pump is rotating in the wrong direction, invert two of the power supply wires in the contactor and try again.
Once the correct rotation direction has been obtained, MARK the power supply wire connection positions, REMOVE the temporary electrical
connections and install the pump in the planned position.
2.6 ELECTRICAL CONNECTIONS
• All operations connected to the mains must be performed by qualified personnel, in compliance with the local regulations.
• To ensure safety the pump is to be supplied through a residual current device (RCD) having a rated residual operating current not excee-
ding 30 mA.
• The electrical connection of the models without plug must be performed by connecting first the yellow-green to the ground, then the other
wires.
• Appliances without plug are intended to be permanently connected to fixed wiring; a switch that ensure the all-pole disconnection incorpo-
rated in the fixed wiring is to be provided. The switch shall be directly connected to the supply terminals and shall have a contact separation
in all poles, providing full disconnection under overvoltage category III (4000V).
• The pump motor must be protected from overload by installing in the main control circuit or power line of pump an overload protection
(motor protection breaker). The protection must be adequately dimensioned according to the rated pump data.
• The starting current in direct-on-line start can be up to six times higher than the rated current.
• Refer to the technical data sheet for the correct value of staring current of pumps with rated voltage different from the standard versions.

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START
STOP
ON
OFF
2.7 THERMAL PROTECTION
“Ex ec nC” pumps are equipped with encapsulated thermal protection devices installed within the stator winding.
These protection device interrupts the power supply in conditions of overheating of the motor when abnormal operation occurs.
The user must protect the motor of Ex nC pumps (without thermal protector) by an overload protection (motor protection breaker) having rated
or setting current equal to or below the value of the rated motor power supply current (In) (see also point 2.11).
2.8 STARTING CAPACITOR
GR BluePRO single phase pumps are equipped with a special connection box. This plastic box can receive all the electrical components and
in particular an 80 µF starting capacitor, which works in parallel to the running capacitor. The connection box is equipped with a power cable
with or without plug at the end. Positioning and connection of connection box is at user care and must be performed in safe area according
manufacturer’s instructions.
2.9 FLOATING SWITCH
The electric pump can be supplied with a floating switch and its functioning is completely automatic.
The floating switch has an adjustable stroke to allow regulation of the on and off levels.
Make sure that there is nothing around that could obstruct the movement.
It is important that the cables do not get in each other’s way, twisted up or stuck in any jutting parts or grips inside the tank
If the pump does not have a start/stop floating switch, one or more start/stop floating switches should be installed inside the tank to control
starting and stopping and for any alarms.
In the event of strong turbulence, floating switches should be installed on a rigid rod mounted inside the tank
Make sure that the minimum level does not fall below the pump’s top.
2.10 EARTHING CONNECTION
The pump is provided with two earthing terminals: one inside the pump envelope and the other on the pump frame.
Depending on the cross-section of the line conductor, the earthing conductor cross-section must be:
S - Line conductor section H - Earth conductor section
S ≤ 16 mm2H = S
The earth connection is made in the sequence indicated in the figures.

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2.11.2 Daily and periodic inspection
󰀨
form its normal operating condition, refer to section “Troubleshooting” and take appropriate measures at an early stage.
Interval Inspection Item
Daily Measuring the operating current To be within the rated current
Measuring the power voltage Power supply voltage variation within ± 5% of the rated voltage
Monthly Measuring the insulation resistan-
ce
Insulation resistance reference value = 20 MΩ minimum
NOTE: The motor must be inspected if the insulation resistance is considerably lower than the last inspection.
Half-yearly Inspection of lifting chain or rope Replace if damage, corrosion, or wear has occurred to the chain or rope.
Remove if foreign object is attaching to it.
Yearly Inspecting cables, oil, mechanical seals, bearings, wearing parts (impeller, suction ange….).
NOTE: rubber parts need to be replaced if disassembled during inspection
Once every 2 ye-
ars or 9000 hours
for heavy duty
Changing oil 9,000 hours (for heavy duty) or 24 months, whichever comes rst.
Changing the mechanical seals
NOTE: The inspection and replacement of these parts require specialized equipment. To have this operation per-
formed, contact the dealer where this equipment was purchased, or the ZENIT sales oce in your area.
Once every 2 to 5
years
Overhaul The pump must be overhauled even if the pump appears normal during
operation. Especially, the pump may need to be overhauled earlier if it is used
continuously.
NOTE: To overhaul the pump, contact the dealer where it was purchased, or the ZENIT sales office in your area.
2.11 MAINTENANCE
Any interventions of the pump in -Ex versions must be carried out by an Ex-Certified Service Centre (according with international and/or
local standards and rules) or by a Zenit Service Centre by trained technicians using only original spare parts.
Failure to comply with this rule causes loss of -Ex approval.
2.11.1 General safety precautions
All of the following operations must be carried out in safety area, in absence of potentially explosive atmospheres.
• Before cleaning and/or maintenance procedures, a skilled technician must disconnect the pump from the power supply and ensure that it
cannot start up accidentally.
• Always disconnect the phase wires first and then the yellow-green ground wire.
• Ensure that the pump cannot fall or roll, causing injury or damage.
• Wash the surface of the pump thoroughly with clean water and/or specific detergent before doing any work on it.
• After prolonged use, the surface of the pump may become very hot: allow it to cool sufficiently to avoid burns.
• Always comply with the safety regulations in force in the place of installation, any local regulations and the dictates of common sense.

11
Use and maintenance booklet - Safety instructions
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2.12 TROUBLESHOOTING GUIDE
Problem Possible cause Solution
1
The pump doesn’t start
No power supply Check power supply line.
Damaged or disconnected cable Check the cable connections and make sure that it’s not dama-
ged.
Fuses blown Check fuses type and rating and replace them with correct ones.
Tripped circuit breaker Refer to Point 3.
Tripped thermal protector Refer to Point 2.
Damaged or wrongly connected capa-
citor (single phase motor) Replace the capacitor and check that it’s correctly connected.
Tripped level control Check that the level sensor is correctly connected and functio-
ning
Broken, burned or disconnected wiring Check the status of wiring and connections.
2
The thermal protection trips
after a short operating time
The pump is immersed in a liquid
which is too hot Cool down the liquid.
Clogged hydraulic Clean the hydraulic parts and remove the blocking material
Blocked rotor Contact an authorised service center.
Incorrect voltage Check that the supplied voltage matches with the one on the
pump’s nameplate
Fault in bearings Contact an authorised service center.
Starts per hour exceed the permitted
number Refer to Point 6
3
Tripped circuit breaker
High drop voltage Reestablish the correct voltage supply.
Low voltage supply Measure the voltage supply. Reestablish the correct voltage
supply.
Clogged hydraulic Clean the hydraulic parts and remove the blocking material
Blocked rotor Contact an authorised service center.
Short circuit in the motor winding Contact an authorised service center.
Wrong electrical connection Check and correct the electrical installation.
Low setting of the thermal relay Set the relay in accordance with the rated current on the name-
plate
4Tripped residual current device
(RCD)
Low motor winding insulation Contact an authorised service center.
Fault in cable Have the cable checked and repaired by a qualified electrician.
5
The pump operates but the flow
is low or null
Clogged hydraulic Clean the hydraulic parts and remove the blocking material
Clogged outlet pipe Clean the outlet pipe.
Blocked non-return valve Clean the non-return valve.
Outlet valve blocked or closed Open and/or clean the outlet valve.
Wrong direction of rotation Check the direction of rotation, interchange any two of the
phases.
Leakage in the pipeline Check the pipeline and fix the leakage causes.
Wrong pump selection Replace the pump with a suitable one.
6
Starts per hour exceed the
permitted number
(see technical data sheet)
Wrong setting of the level control Correct the level control setting.
Level control malfunction check the level sensors functionality.
Turbolence near the level sensors Remove the causes of turbulence or change the positioning of
the level sensors.
Undersized tank Adjust the tank dimension.
7
Noisy operation and excessive
vibrations
Fault in bearings Contact an authorised service center.
Damaged impeller Contact an authorised service center.
Blocked impeller Clean the hydraulic parts and remove the blocking material
Wrong direction of rotation of the
impeller
Check the direction of rotation, interchange any two of the pha-
ses.
8
The pump works correctly but
absorbed current is too high
Wrong duty point Make sure the pump operates within its operative range
Wrong voltage supply Reestablish the correct voltage supply.
Clogged hydraulic Clean the hydraulic parts and remove the blocking material
Fault in bearings Contact an authorised service center.
Wrong direction of rotation of the
impeller
Check the direction of rotation, interchange any two of the pha-
ses.

12
Use and maintenance booklet - Safety instructions
21 21
24
DR blue - DR bluePRO
DG blue - DG bluePRO
DR blue DG blueDR bluePRO DG bluePRO
better together
Component Material
1 Handle Plastic
2 Plate Stainless steel
3 Cable Cupper, rubber
3.1 Cable clamp Steel
4 Float switch Plastic, rubber
5 Screws Stainless steel
6 O-Ring Rubber
7 Cable gland Plastic, rubber
8 Cable fastener Plastic
9 Cable gland support Plastic
10 Capacitor Plastic, metal, rubber
11 Motor case Cast iron
12 Bleeder valve (*) Plastic, rubber
13 Stator Cupper, iron
14 Support washer Rubber
15 Bearing Stainless steel
16 Shaft with rotor Stainless steel/Aluminium
17 Lower bearing holder Aluminium
18 Mechanical seal Rubber, iron, SiC
19 Sealing flange Cast iron
20 Impeller bushing Brass
21 Impeller Plastic/Cast iron (*)
22 Suction flange Stainless steel
23 Foot base support Cast iron
24 Grid Plastic
(*) PRO version only
2.13 PARTS NOMENCLATURE

13
Use and maintenance booklet - Safety instructions
21
GR bluePRO - AP bluePRO
GR bluePRO AP bluePRO
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Component Material
1 Handle Plastic
2 Plate Stainless steel
3 Cable Cupper, rubber
3.1 Cable clamp Steel
4 Screws Stainless steel
5 O-Ring Rubber
6 Cable gland Plastic, rubber
7 Cable fastener Plastic
8 Cable gland support Plastic
9 Capacitor Plastic, metal, rubber
10 Motor case Cast iron
11 Stator Cupper, iron
12 Support washer Stainless steel
13 Bearing Stainless steel
14 Shaft with rotor Stainless steel/Aluminium
15 Lower bearing holder Aluminium
16 Mechanical seal Rubber, iron, SiC
17 Sealing flange Paper
18 Impeller Cast iron
19 Gasket Paper
20 Foot base support Cast iron
21 Cutting disk NiCr steel
22 Grid Plastic
23 Cutter Stainless steel

14
Use and maintenance booklet - Safety instructions
2.14 OVERALL DIMENSIONS
DR blue
DG blue
DR bluePRO
DG bluePRO
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C
A
D
F
B
E
C
A
D
F
B
E
C
A
D
F
B
E
C
A
D
F
B
E
A
mm
B
mm
C
mm
D
mm
E F
mm
DG blue 40/2/G40V 265 115 335 140 G 1½” 190
DG blue 50/2/G40V 265 115 335 140 G 1½” 190
DG blue 75/2/G40V 265 115 365 140 G 1½” 190
DG blue 100/2/G40V 265 115 365 140 G 1½” 190
A
mm
B
mm
C
mm
D
mm
E F
mm
DR blue 40/2/G40V 255 115 295 110 G 1¼” 150
DR blue 50/2/G40V 255 115 295 110 G 1¼” 150
DR blue 75/2/G40V 255 115 325 110 G 1¼” 150
DR blue 100/2/G40V 255 115 325 110 G 1¼” 150
A
mm
B
mm
C
mm
D
mm
E F
mm
DG bluePRO 50/2/G40V 265 115 335 140 G 1½” 190
DG bluePRO 75/2/G40V 265 115 365 140 G 1½” 190
DG bluePRO 100/2/G40V 265 115 365 140 G 1½” 190
DG bluePRO 150/2/G50V 295 125 465 195 G 2” 200
DG bluePRO 200/2/G50V 295 125 465 195 G 2” 200
A
mm
B
mm
C
mm
D
mm
E F
mm
DR bluePRO 50/2/G32V 255 115 290 110 G 1¼” 150
DR bluePRO 75/2/G32V 255 115 320 110 G 1¼” 150
DR bluePRO 100/2/G32V 255 115 320 110 G 1¼” 150
DR bluePRO 150/2/G50V 295 125 420 170 G 2” 200
DR bluePRO 200/2/G50V 295 125 420 170 G 2” 200

15
Use and maintenance booklet - Safety instructions
GR bluePRO
AP bluePRO
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C
A
D
F
B
E
H G
J1
J
C
A
D
F
B
E
H G
J1
J
A
mm
B
mm
C
mm
D
mm
E F
mm
G
mm
H
mm
J J1
GR bluePRO 100/2/G40H 270 130 365 95 G 1½” 220 14 90 90° 180°
GR bluePRO 150/2/G40H 285 125 410 100 G 1½” 230 14 90 90° 180°
GR bluePRO 200/2/G40H 285 125 410 100 G 1½” 230 14 90 90° 180°
A
mm
B
mm
C
mm
D
mm
E F
mm
G
mm
H
mm
J J1
AP bluePRO 100/2/G40H 270 130 365 95 G 1½” 220 14 90 90° 180°
AP bluePRO 150/2/G40H 270 130 365 95 G 1½” 220 14 90 90° 180°
AP bluePRO 200/2/G40H 270 130 365 95 G 1½” 220 14 90 90° 180°

zenit.com Cod. 27270100700400000
Rev. 4 - 29/05/20
better together