Zenit Blue Series User manual

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Safety, Installation and Operations Manual
Submersible electric pumps

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/EC
• 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: EN ISO 12100:2010; EN 809:1998+A1:2009+AC:2010. EN 60034-1:2010+AC:2010, EN 60034-
5:2001+A1:2007; EN 60335-1:2012+AC:2014+A11:2014+A13:2017+A1:2019+A14:2019+A2:2019+A15:2021, EN IEC 60335-2-41: 2021+
A11:2021. EN IEC 63000:2018. EN 60079-0:2018 and IEC 60079-0:2017, EN 60079- 7:2015+A1:2018 and IEC 60079-7:2015, EN 60079-
15:2019 and IEC 60079-15:2017, EN ISO 80079-36:2016 and ISO IEC 80079-36:2016, EN ISO 80079-37:2016 and ISO IEC 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. EPTI 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 Product Assurance AS)
Zenit pumps (China) Co., Ltd N° CN/CQM/QAR10.0003 performed by PCET - PCEC (Tianjin) Certification Services 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, __________________
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)
NAE version: models without thermal protection All version with thermal protection
EU DECLARATION OF CONFORMITY
Signed: Massimiliano Volta
Managing Director Zenit Italia s.r.l.
Person empowered to sign the UE declaration of conformity

Zenit Italia s.r.l.
www.zenit.com
[email protected]
Year
Type
VersionSerial nr.
Code
QUALITY CHECK
Ex db IIB T4 Gb
II 2G Ex h IIB T4 Gb
WARNING: Flameproof joints cannot be repaired
WARNING: See user manual
XXXX
EPT XX ATEX XXXX X
Zenit Italia s.r.l.
via dell’Industria, 11
I-41018 S.Cesario s.P. (MO)
zenit.com
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 Key to the symbols used in the manual........................................................................................................................... 4
1.3 General safety regulations............................................................................................................................................... 4
1.3.1 Training of installation and maintenance staff .............................................................................................................. 4
1.3.2 Personal protective equipment (PPE) to use................................................................................................................ 4
1.3.3 Residual risks ............................................................................................................................................................... 4
1.4 Storage............................................................................................................................................................................ 4
1.5 Disposal........................................................................................................................................................................... 5
2. PRODUCT DESCRIPTION - INTENDED USE ................................................................................................................. 5
2.1 Operating conditions........................................................................................................................................................ 5
2.2 Equipment explanation to -Ex approval........................................................................................................................... 5
2.2.1 Suitability of the pump to the location of installation..................................................................................................... 5
2.2.2 Places subject to the presence of inflammable gas, mist or steam.............................................................................. 5
2.3 Nameplate safety data..................................................................................................................................................... 6
2.4 Code designation............................................................................................................................................................. 6
2.5 Dataplate ......................................................................................................................................................................... 7
2.6 Electrical features............................................................................................................................................................ 8
2.7 Installation ....................................................................................................................................................................... 8
2.7.1 Mobile post (Fig. 1)....................................................................................................................................................... 8
2.7.2 Fixed post (Fig. 2)......................................................................................................................................................... 8
2.7.3 With the joining foot (fig. 3)........................................................................................................................................... 9
2.8 Checking the impeller rotation direction (three-phase models only)................................................................................ 9
2.9 Electrical connections...................................................................................................................................................... 9
2.10 Thermal protection......................................................................................................................................................... 10
2.11 Starting capacitor........................................................................................................................................................... 10
2.12 Floating switch............................................................................................................................................................... 10
2.13 Earthing connection....................................................................................................................................................... 10
2.14 Maintenance.................................................................................................................................................................. 11
2.14.1 General safety precautions ........................................................................................................................................ 11
2.14.2 Daily and periodic inspection...................................................................................................................................... 11
2.15 Troubleshooting guide................................................................................................................................................... 12
2.16 Parts nomenclature ....................................................................................................................................................... 13

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Safety, Installation and Operations Manual - Original instructions
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 Professio-
nal 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 Key to the symbols used in the manual
Warning - Hazard for operators and pump
Warning - Electrical risk
Warning - Very hot surfaces with burn hazard
Warning - These instruction must be observed for Explosion-proof pumps (-Ex models).
Failure to comply with this instruction may cause danger of an explosion occurring.
It is recommended to follow these instruction also for standard pump.
CAUTION Important information to be read with special care
1.3 General safety regulations
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.
1.3.1 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 opera-
ting 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.
1.3.2 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.
1.3.3 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.
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.
To reduce the risks associated with lightning, the user is required to install any necessary and adequate
lightning protection measures.
1.4 Storage
During storage, the electric pump must be kept in a suitable place, out of the reach of children or those with diminished responsibility, suita-
bly secured against falling and protected from damp, dust, vibrations and extreme temperatures (below -5°C and above +40°C).
CAUTION 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.

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Safety, Installation and Operations Manual - Original instructions
1.5 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.
2. PRODUCT DESCRIPTION - INTENDED USE
The electrical pumps Blue series are suitable for professional use, heavy duty with clean and dirty water. Blue submersible pumps are
classified depending on the hydraulic type as follow:
DRblue, DGblue, DRbluePRO, DGbluePRO Series: drainage and evacuation of sewage water and/or with oil also with solid parts.
GRbluePRO Series: drainage and evacuation of sewage water and/or with oil with solid parts to be cutted.
APbluePRO Series: drainage and evacuation of sewage clean, sandy, muddy water, with small solid parts.
The equipment is manufactured with cables permanently connected to it.
This electric pump is a fixed appliance intended to be used while fastened to a support or while secured in a specific location.
This appliance is not intended to be held in the hand during normal use.
This electric pump may not be used with liquids for human consumption
Blue submersible pumps must under no circumstances be used to pump explosive, flammabile or comustible liquids
-Ex models are certified for use in potentially explosive atmosphere according to the marking string recorded on the dataplate
2.1 Operating conditions
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.
For correct use, comply with the following operating conditions:
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 dataplate.
The submersible electric pumps feature an acoustic pressure level of below 70dB(A) when immersed and below 80dB(A) in the air.
2.2 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 protec-tion
“Ex ec” and “Ex h” and are suitable for gas group IIC. Models with thermal protectors have also the type of protection “nC”. The equipment is
manufactured with cables permanently connected to it.
The IECEx and ATEX Blue pumps have the following explosion protection classification
2.2.1 Suitability of the pump to the location of installation
Models without thermal protection
(Electrical variant: NAE)
Models with thermal protection
(Electrical variant: T, TC, TCD, TCG, TCDT, TCDGT)
II 3G (only for ATEX)
Ex ec h IIC T3 Gc (Atex and IECEx)
II 3G (only for ATEX)
Ex ec nC h IIC T3 Gc (Atex and IECEx)
The user shall check that pump is suitable to the area classification and to the characteristics of the flammable substances present. Natio- nal
Law, local Rules and Standards establish the essential safety requirements against the risk of explosion in classified areas.
2.2.2 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)

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DG bluePRO 50/2/G40V A1BM5
TC 10 AU 230 D CX NN
(A) (B) (C)
1
10
5
14
3
12
7
16
2
11
6
15
4
13
8 9
1
10
5
14
3
12
7
16
2
11
6
15
4
13
8
9
Safety, Installation and Operations Manual - Original instructions
2.3 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 igni
tion 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
EPTI 16 ATEX 0228 X
EPTI: laboratory that issued the ATEX certificate of conformity
16: year in which the certificate was issued
ATEX 0228: ATEX certificate number
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. For models provided without float switch 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.
2.4 Code designation
The pump can be identified by the “type” and the “version” designations stated on the pump dataplate. Below an example with the legend:
Hydraulic Family
DG = Vortex
DR = Channels
GR = Grinder
AP = High head
Series
BLUE = Blue STANDARD
BLUEPRO = Blue PROFESSIONAL
Electrical variant
NAE = No electrical accessory
T = Thermal protection
TC = Thermal protection and capacitor
TCD = Thermal protection, starting and run capacitor
TCG = Thermal protection, capacitor and oat switch
TCDT = Thermal protection, starting and run capacitor,
overolad protection
TCDGT = Thermal protection, starting and run
capacitor, oat switch, overload protection
Power (HPx100) / motor poles
Pump outlet
(A) TYPE (GAS thread/Flanged)
(B) DIAMETER (mm)
(C) POSITION
V = vertical H = horizontal
Hydraulic model
Sequential number (0...n).
Refers to the pump evolution.
Cable length
Plug type
NN = No plug
AU = Australian plug
... = Other
Rated Voltage
Starting
D = DOL
Y = star/delta
Motor size
Motor phases
M = Single-phase T = Three-phase
Frequency
5 = 50Hz 6 = 60Hz
Certication
NN = standard
EX = ATEX, ATEX + IECEx
CX = IECEX only
Customization
Type
Version

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Ex ec h IIC T3 Gc
IECEX EUT 16.0006X
Made in P.R.C.
VERS
Hz
TYPE
S.N.
S1
YW
I.CL. F
Kg
IEC/EN 60034-1
Class IA
V rpm
kWP2IP68
CR
m
zenit.comZenit Italia s.r.l.
Via dell’Industria, 11
I-41018 S.Cesario s.P. - MO
0°C≤Tamb≤40°C
l/min
l/min
Qmin
Hmin
Qmax
Hmax m
m
µF
II 3G
EPTI 16 ATEX 0228 X
Ex ec nC h IIC T3 Gc
Made in P.R.C.
VERS
Hz
TYPE
S.N.
S1
YW
I.CL. F
Kg
IEC/EN 60034-1
Class IA
V rpm
kWP2IP68
CR
m
zenit.comZenit Italia s.r.l.
Via dell’Industria, 11
I-41018 S.Cesario s.P. - MO
0°C≤Tamb≤40°C
l/min
l/min
Qmin
Hmin
Qmax
Hmax m
m
µF
IECEX EUT 16.0006X
II 3G
EPTI 16 ATEX 0228 X
3 3
1 1
4 4
7 78 8
5 56 6
9 910 10
12 12
13 13
18 1817 17
20 20
23 23
21 21
24 24
22 22
25 25
Electrical variant:
NAE
Electrical variant:
T, TC, TCD, TCG, TCDT, TCDGT
16 16
15 15
14 14
19 19
11 11
2 2
29 29
26 26
27 27
28 28
Safety, Installation and Operations Manual - Original instructions
2.5 Dataplate
On the top of the electropump you find the dataplate which states the operating data and approvals applying to the pumps.
Below is an example with the legend.
1. Manufacturer name and address
2. Country of manufacture
3. Pump type
4. Year and week of production
5. Pump version
6. Serial number
7. Rated voltage
8. Motor phases
9. Frequency
10.Speed (revolutions per minute)
11.Insulation class
12.Rated current
13.Motor output power P2
14.Duty type
15.IEC protection class against electric shock
16.IP code (degree of protection provided by enclosure)
17.Run capacitor
18.Ambient temperature (liquid)
19.Motor reference standards
20.Minimum flow-rate
21.Maximum head
22.Maximum immersion depth
23.Maximum flow-rate
24.Minimum head
25.Weight
26.Atex and/or IECEx marking string
27.Atex and/or IECEx certification number
28.Conformity mark
29.WEE mark
2.6 Electrical features
Models 50Hz (60Hz)
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 (0.28) 0.37 (0.37) 0.55 (0.55) 0.74 (0.74)
N° of phases 1 1 3 1 3 1 3
Connection - - Y - Y - Y
Rated voltage [V] 230 (230) 230 (230) 400 (400) 230 (230) 400 (400) 230 (230) 400 (400)
Rated current [A] 2.3 2.8 1.15 4.1 1.45 5.6 2.15
Starting-Rated current Ratio 1.9 (2.3) 1.9 (2.7) 3.2 (4.2) 2.0 (2.3) 3.5 (4.5) 2.0 (2.1) 3.4 (3.9)
Running capacitor [µF] 10 (10) 10 (10) - 14 (14) - 20 (20) -
Rated frequency [Hz] 50 / 60
rpm 2900 (3400)
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 (0.74) 1.1 (1.1) 1.5 (1.5)
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 (2.7) 3.6 (4.8) 2.4 (3.1) 4.5 (5.7) 1.9 (2.5) 4.3 (5.7)
Running capacitor [µF] 25 (25) - 30 (40) - 30 (40) -
Rated frequency [Hz] 50 / 60
rpm 2900 (3400)
Insulation class F
(*): GR bluePRO pumps require starting capacitor. See Point 2.11 .

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1 2 3
Safety, Installation and Operations Manual - Original instructions
2.7 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.
CAUTION All of the following operations must be carried out in safety area, in absence of potentially explosive atmospheres.
CAUTION 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.
2.7.1 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.
2.7.2 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.
2.7.3 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.
2.8 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:
Lay the pump horizontal on one side and leave it free;
Temporarily connect the yellow-green wire to ground and then connect the power supply wires to the contactor;
Make sure there are no people or objects within a radius of at least 1 metre of the pump;
Turn on the start switch for a few moments;
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 electri-
cal connections and install the pump in the planned position.
2.9 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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N
3G1
L
PE
M
1~
L1 L3
PE
M
3~
L2
4G1
N L
PE
M
1~
CS
(AYC)
4G1
L1 L3
PE
M
3~
L2
TP TP
PE
B
3G1 4G1
~1 50/60Hz ~3 50/60Hz
Safety, Installation and Operations Manual - Original instructions
Electrical version: TC, TCG, TCDT, TCDGT
Electrical version: TCD
Electrical version: NAE
Electrical version: T
L - N L1 - L2 - L3 PE N M G B GV CSAYC
Single-phase
power supply
Three-phase
power supply Ground Black Brown Grey Blue Yellow/
Green
Start
capacitor At your care
CAUTION In case of discrepancies of the wires color, contact the dealer where this equipment was purchased, or the Zenit
sales office in your area.
2.10 Thermal protection
“Ex ec nC” pumps are protected against overheating by bimetal thermal protector/s (PTO) built into the windings head of the motor which open
its contact when the winding temperature exceeds the NST (nominal switching temperature). Once the temperature of the electric motor drops
below the safety limit, the thermal protector returns to its original position and the motor may suddenly restart.
Single-phase motors have the thermal protector connected in series to the main circuit to directly cutting off the motor supply in case of
overheating.
Three-phase motors have thermal protections connected to their own cable which must be connected to an external control panel set to shut
down the pump supply when the thermal protection intervenes.
2.11 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.
2.12 Earthing connection
The pump is provided with two earthing terminals: one inside the pump en-
velope 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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START
STOP
ON
OFF
Safety, Installation and Operations Manual - Original instructions
2.13 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.
2.14 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.
2.14.1 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.
2.14.2 Daily and periodic inspection
Regular maintenance and inspection are indispensable to maintaining the pump’s performance. If the pump behaves differently
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 resistance 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 years
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 perfor-
med, 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.

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Safety, Installation and Operations Manual - Original instructions
2.15 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 damaged
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 functioning
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 phases
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 phases

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4
1
6
6
3
8
2
7
5
9
10
14
12
16
11
15
15
17
18
6
19 20
21 21
23 23
24
22
13
3.1
DR blue DG blueDR bluePRO DG bluePRO
DR blue - DR bluePRO
DG blue - DG bluePRO
Safety, Installation and Operations Manual - Original instructions
2.16 Parts nomenclature
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

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1
2
3
3.1
10
11
4
5
5
5
12
13
13
6
7
14
15
18
19
20
21
22
23
8
9
16
17
GR bluePRO AP bluePRO
GR bluePRO - AP bluePRO
Safety, Installation and Operations Manual - Original instructions
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

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Safety, Installation and Operations Manual - Original instructions

zenit.com DS02: Cod. 27270100700400000 - Rev. 5 - 01/07/22
DS00: Cod. 2727NN00025 - Rev. 0 - 20/11/22
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