Zenit Group | 31 Mar 2023

UNIQA - ZUG OC DRY

Complete assembly ZUG OC model DRY version

Step by step operations

Mark the position of the cables on the stator with a marker pen
Fit the drivers into the stator, taking care not to crush the cables
Secure the drivers with the threaded rod
With the aid of a hoist, lift the stator and place it in the case
IMPORTANT: keep the mark on the stator in this position
Using a press and a suitable driver, insert the stator into the case
Remove the drivers from the stator
Turn the motor over and find the stator groove nearest to the winding terminals
Insert the sensor cable into the groove in the stator
Fix the lug onto the sensor cable
Place the bearing in the seat in the bottom support
Overturn the bottom support and place the bearing on a suitable driver
Using a hoist, fit the shaft into the seat of the bearing
Fit the top bearing on the top of the shaft and insert with the aid of a press
Fix the sensor cable gland to the bottom bearing support
Fit the sensor into the cable gland and tighten the nut to fix it in position
Lift the shaft using a hoist and a sling
Place the O-ring in the seat
Fit the shaft into the stator, leaving about 10 cm between the bottom bearing support and the case
Fix the cable to the sensor with the nut
Use Loctite 243 threadlocker or equivalents
Slowly lower the shaft until the bottom bearing support mates with the case.
Secure the bottom bearing support to the case with the screws
Fit the O-ring into the shaft seat and grease
Fully fit the stop bushing into the shaft
Tighten the fixing stud bolts of the stop bushing.
Use Loctite 243 threadlocker or equivalents
Use a gauge to check that the eccentricity of the stop bushing is less than 0.1 mm
Fit the O-rings into the seats in the bottom bearing flange
Use a smooth, rounded tool to press gently on the bottom lip of the PTFE lip seal to aid its insertion
Use the tapered insert to check the tightness of the PTFE lip seal
Wet the flange with alcohol and fit the PTFE lip seal in the seat with the driver
Lubricate the PTFE lip seal and the O-ring with plenty of grease
Fit the tapered insert to avoid damaging the rubber edges of the PTFE lip seal
Place the flange in the seat and fit it correctly with the driver.
Remove the tapered insert
Fix the bottom bearing flange with the snap ring
Fit the tightness testing device in place and secure it by tightening the screw
Connect the compressed air hose to the union and test for tightness at a pressure of about 2 bar
Disconnect the compressed air hose and remove the device
Fit the cooling impeller and secure it with the fixing stud bolts.
Use Loctite 243 threadlocker or equivalents
Lubricate the V-ring with plenty of grease and fit it onto the cooling impeller
Draw a line on the bushing to mark the position of the hole
Fit the O-ring into the seat on the bushing and grease it
Fit the bushing into the seat, taking care to align the mark with the hole in the base of the bottom diffuser
Use the driver to put the bushing in position and check that it is correctly aligned
Overturn the bottom diffuser
Fix the bushing to the bottom diffuser with the fixing stud bolt.
Use Loctite 243 threadlocker or equivalents
Fit the bottom diffuser
Insert the rubber gasket and secure the sensor with the cable gland
Fit the O-rings into the seats in the bottom diffuser
Clean the surface of the first counterface with a paper towel and wet it with alcohol
Place the first counterface in the seat and fit it with the driver
Remove any residues from the shaft with a paper towel
Lubricate the first counterface slightly
Clean the surface of the first mechanical seal with a paper towel and wet it with alcohol
Place the first mechanical seal on the shaft and fit it with the driver
Fix the first mechanical seal with the snap ring
Fit the shim rings into the seat
Fit the top diffuser, positioning the holes for the plugs as shown
With the aid of a hoist and a sling, lift the oil chamber and fit the O-ring into the seat
Place the oil chamber on the motor and secure it with the screws, then remove the eye-bolts
Fit the cooling circuit plugs and screw them down
Fit the O-rings into the oil chamber seats
Clean the surface of the second mechanical seal with a paper towel and wet it with alcohol
Place the second mechanical seal on the shaft and fit it with the driver
Remove any residues from the shaft and the mechanical seal with a paper towel
Wet the second counterface with alcohol and place it in the seat with the driver
Fit the locking ring and fix it with the screws
Use Loctite 243 threadlocker or equivalents
Fit the O-rings into the seats
Clean the surface of the second counterface with a paper towel
Lubricate the second counterface slightly
Overturn the pump plate and place it on the oil chamber
Tighten 2 opposite screws by hand to allow the pump plate to position correctly
Secure the pump plate by tightening the screws
Fix an eye-bolt to the top of the shaft to allow it to be turned by hand
Pour in a little alcohol to check for leaks from the bottom seal
Seal one of the oil chamber holes with the plug
Use a union to connect the oil chamber to the compressed air system
Test for tightness at a maximum pressure of 1 bar
If there are no air bubbles, the mechanical seal has been assembled correctly
Remove the union
Fit the O-ring into the seat on the suction flange and grease it
Overturn the suction flange and fit it into the seat in the pump body
IMPORTANT position the suction flange with the ends of the groove facing towards the discharge
Fix the suction flange to the pump body with the screws
Lie the motor on the bench
Fill the mechanical seal chamber with oil
Refer to the documentation for the correct amount
Fit the plug on the oil chamber
Use Loctite 243 threadlocker or equivalents
Fix the adjuster ring-nut to the impeller
CAUTION: left-hand thread
Fully fit the bronze bushing into the impeller seat
Couple the impeller to the shaft and secure it with the fixing washer and screw
With the aid of a hoist and a sling, lift the motor and place it on the pump body
Fix the motor to the pump body with the screws
Fit the seal in the bottom bearing support seat
Undo the 3 fixing screws of the oil chamber which are at 120° to each other
Fit the internal cooling jacket
Secure the internal cooling jacket with the screws
Use Loctite 243 threadlocker or equivalents
Fit the external cooling jacket, with one of the filling holes facing towards the discharge
Protect the cables of the thermal protections and the sensor with sheaths
Fit the O-ring into the seat in the top bearing support and grease
Fit the top bearing support on the motor case
Fit the cables through the hole in the support
Fit the terminal board bar and fix the bar with the screws
Use Loctite 243 threadlocker or equivalents
Connect the motor terminals to the terminal board
Fit the O-ring into the seat in the top bearing support
Fit the O-ring into the seat in the motor cover and grease
Fit the seal into the cooling jacket locking ring seat
Fit the cooling jacket locking ring onto the motor cover
Fit the cable into the cable gland and the rubber gasket
Fit the cable into the motor cover and place the rubber gasket in the seat
Fit the cable stop and fix it in place
Fit a lug to the ground cable
Connect the motor terminals to the terminal board, referring to the diagram provided in the documentation
Secure the ground cable to the motor cover with the screw
Fit the motor case O-rings into the seats.
Use a little grease to hold them in place
Fit the motor cover onto the case and fix it with the screws
Fit the rubber cable gland gasket into the seat in the motor cover and fix the cable gland with the screws
Using a union, connect the compressed air system to the motor cover
Test for tightness at a maximum pressure of 1 bar
Disconnect the compressed air hose and remove the union
Seal the motor cover with the plug
Use Loctite 243 threadlocker or equivalents
Temporarily fix the cooling jacket locking ring to the motor cover with the screws
Seal the top hole of the cooling jacket with the plug
Use Teflon or similar products to ensure an airtight seal
Using a union, connect the compressed air system to the cooling jacket
Test for tightness at a maximum pressure of 1 bar
Disconnect the compressed air hose and remove the union
Permanently fix the cooling jacket locking ring to the motor cover. Use Loctite 243 threadlocker or equivalents
Fill the cooling jacket with the water-glycol mixture
Refer to the documentation for the correct amount
Seal the holes in the cooling jacket with the plugs
Use Loctite 243 threadlocker or equivalents
Lift the pump with the aid of a hoist
Remove the impeller fixing screw and washer
Screw down the ring nut until the impeller fits snug against the suction flange
CAUTION: Left-hand thread
Secure the impeller to the shaft with the fixing screw and washer
The impeller must now turn freely.
Repeat the operation if necessary
Use a feeler gauge to check that the clearance between the blade and the flange is 0.4-0.6 mm