Zoeller 350 User manual

IL1962
CITY PRESSURE BOOSTER PUMP
INSTRUCTION MANUAL
MODEL # 350, 355
C
US
NSF/ANSI 372
600449
FM3168
0519
Supersedes
New
Product information presented
here reects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
TEL: [phone] • 1 (800) 928-PUMP • FAX: [phone]
Visit our website:
zoellerpumps.com

© Copyright 2019 Zoeller® Co. All rights reserved.
2
GENERAL SAFETY INFORMATION
Please read and understand this manual before attempting to
assemble, operate, or install this product. For questions, please
call customer service at 1-800-742-5044
(7:30am - 5:00pm ESDT Mon. - Fri.)
This is a SAFETY ALERT SYMBOL. When you see this
symbol on the pump or in the manual, look for one of
the following signal words and be alert to the
potential for personal injury or property damage.
DANGER
Warns of hazards that WILL cause serious
personal injury, death, or major property damage if ignored.
Warns of hazards that CAN cause serious
personal injury or death, if ignored.
Warns of hazards that MAY cause minor
personal injury, product or property damage if ignored.
IMPORTANT: Indicates factors concerned with operation,
installation, assembly, or maintenance which could result in
damage to the machine or equipment if ignored.
NOTE: Indicates special instructions which are important, but are
not related to hazards.
Customer Alert on Potential Water Damage: As with any product
subject to a continuous supply of incoming water, a water alarm
to monitor the pump area is strongly recommended to alert the
customer to the potential for water damage which may result from
water line failure, product damage, or incorrect installation.
PUMP SAFETY INFORMATION
Hazardous
voltage. Can
shock, burn
or cause
death. Ground
pump before
connecting to
power supply.
SHOCK HAZARD
1. Meet United States National Electrical Code
and local codes for all wiring.
2. Do not handle a pump or pump motor with wet
hands or when standing on a wet or damp
surface or in water.
3. Follow wiring instructions in this manual
when connecting to power lines.
4. Always disconnect power source before
performing any work on or near the motor or
its connected load.
5. Risk of electric shock - This pump has not
been investigated for use in swimming pool
areas or marine areas.
6. Protect electrical cord. Replace or repair damaged or worn
cords immediately.
7. To reduce the risk of electric shock, connect only to a properly
grounded, grounding-type receptacle.
Do not use to pump ammable or
explosive uids such as gasoline,
fuel oil, kerosene, etc. Do not use in ammable and/or
explosive environments.
Hazardous pressure! Install
pressure relief valve in discharge
pipe. Release all pressure on system before working on
any component.
GENERAL SAFETY
1. This pump has been evaluated to work with
water only.
2. Wear safety glasses when working with pumps.
3. Periodically inspect pump and system components.
4. Do not insert nger or any object into pump or motor openings.
5. Secure the discharge line before starting the pump. An
unsecured discharge line will whip, possibly causing personal
injury and/or property damage or puncture.
6. Do not touch an operating motor or engine. They are designed
to operate at high temperatures.
1/2 HP PERFORMANCE
See charts below for expected system pressure at various
incoming line pressure / ow rates.
Inlet
PSI
350 System Pressure (PSI)
at Flow Rates (GPM)
3 6 9 12 15 18 21
10 43 36 35 31 26
20 53 46 45 41 36
30 63 56 55 51 46
Do not exceed 30 input PSI for model 350
1 HP PERFORMANCE
Inlet
PSI
355 System Pressure (PSI)
at Flow Rates (GPM)
3 6 9 12 15 18 21
10 72 67 61 56 50 45 39
20 82 77 71 66 60 55 49
30 92 87 81 76 70 65 59
40 102 97 91 86 80 75 69
50 112 107 101 96 90 85 79
Do not exceed 50 input PSI for model 355
NAMEPLATE DATA
Model 350 355
HP 1/2 1
Volts 115 115
HZ/Ph 60/1 60/1
Amp 6.0 10.0
Amb 40C 40C
Class B B
Rating Cont Cont

© Copyright 2019 Zoeller® Co. All rights reserved.
3
FIG 1 TYPICAL INSTALLATIONS
IL1213
Ball
Valve
#2
(Open)
City Water Main
only Union
Home or Irrigation
1" Dia. Suction
Optional
Water
Tank
1" Dia. Discharge
Ball
Valve
#1
(Open)
Union
Ball Valve #3
(Closed)
IN
OUT
By-Pass
Drain
Pressure
Relief
Valve
(PRV)
Adjustable
Pressure
Regulator
(APR)
Adjustable
Pressure
Regulator
(APR)
#2
#1
#3
GENERAL PUMP INSTALLATION / SETUP (FIG 1)
City booster pump installation is shown per
FIG 1. During pump use, ensure ball valves #1 and #2 are open,
and ball valve #3 is closed.
#1 An Adjustable Pressure Regulator
(APR#1) is required on the suction side of the pump (see g 1)
if the incoming water pressure can exceed the maximum input
pressure.
#2 An Adjustable Pressure Regulator (APR#2)
is required on the Discharge (See g 1) to ensure maximum water
pressure does not exceed local plumbing codes.
#3 A Pressure Relief Valve (PRV) connected
to a drain is required (see g 1) to safe guard plumbing from
exceeding max pressures if the Pressure Regulators fail.
Typically the PRV would be set 5 psi higher than the APR#2.
NOTE: Optional external water tank can be used to decrease the
on/off cycle rate of the pump system, which can extend the life of
the pump. (Typical tank 3 gallon draw down.) Set tank PSI equal to
pump tank PSI.
The entire system must be air and water tight
to maintain prime. Use thread tape on all connections to ensure
no leaks. Hand tighten all threads and then add additional half
turn with wrench.
FOR NEW PUMP INSTALLATION
1. The inlet and outlet anges are tightened to the pump casing
before shipment. For new pump installations, do not remove
the anges (FIG 2). Because of the use of self-tapping
screws, please use extra care when you have to remove the
anges for future maintenance.
2. Install unions on inlet and outlet piping prior to attaching
them to the pump anges. (FIG 3).
3. The pump foundation should be rigid enough to absorb any
vibration from the motor, and the pump should be securely
bolted to the foundation.
4. Please provide an adequate draining system to avoid damage
in case of leakage, particularly when installed indoors. When
the pump is installed outdoors, it should be covered by a
weather-proof, well ventilated housing.
5. The pump and all piping must be protected from freezing.
When the pump will be exposed to temperatures less than
32°F (0°C), relocate it to a heated area.
FIG 2 DO NOT REMOVE FLANGES
FIG 3 INSTALL UNIONS

© Copyright 2019 Zoeller® Co. All rights reserved.
4
Indoor/outdoor area – ensure draining through pressure relief
valve is available in order to avoid damage in case of leakage.
Outdoor area – unit should be covered by a weather proof housing,
ensure adequate ventilation.
FREEZING (OR REMOVING PUMP FOR MAINTENANCE)
The pump and all piping must be protected
from freezing. If freezing weather is forecast, and the unit will be
exposed to temperatures less than 32 ºF (0 ºC), remove the pump by
closing off ball valves #1 and #2, (see FIG 1) and removing the pump
using the union connections. Store pump in a heated area. Open
ball valve #3 to allow city water to pass forward if desired. Ensure
the piping is adequately protected from the cold environment.
OPERATING CONDITIONS
Ambient temperature range 32 ºF (0 ºC) to 104 ºF (40 ºC).
PRIMING
After installation (with the pump OFF), open ball valves #1 and #2,
and slowly unthread the air relief plug (FIG 4). Allow inlet water
pressure to ll the pump cavity and remove in-line air pockets.
After the pump cavity lls with water, retighten the air relief plug.
FIG 4 PRIMING ILLUSTRATION
a. Open ball valves #1 and #2, close 3.
d. Tighten the air
relief plug.
c. Ensure water fills
chamber from city water.
Replace plug immediately
to avoid excess moisture
on pump.
IL1207
b. Loosen the air relief plug.
#1
#2
#3
Torque : 22 in-lb
22
in-lb
Suction
22
in-lb
If unit is shut down for an extended period of
time or air enters into the system, it may be necessary to repeat
the above priming instructions to ensure the internal pump cavity
is running with water to avoid dry running damage to the internal
seals.

© Copyright 2019 Zoeller® Co. All rights reserved.
5
Checking and Setting Tank PSI
Pressure Tank Charge – Pressure tank air charge should be
checked at regular intervals of every six months and after the
pump has not been used for a prolonged period. To check the
tank pressure, turn off power, open the tap on discharge line
to release pressure from the pump, unscrew the black plastic
cover, and place a pressure gauge on it as shown (FIG 5).
Pressure should be adjusted to the original pre-charge as follows:
350 1/2 HP - 25 psi (1.8 Kg/cm2)
355 1 HP - 35 psi (2.5 Kg/cm2)
FIG 5 SET TANK PRESSURE
IL1307
NOTE: If using optional water tank (FIG 1), set both tanks to the
same pressure.
GENERAL OPERATION GUIDELINES
1. What Causes The Unit To Start? – The pump will turn ON when
the ow rate is greater than 0.7 GPM or when the pressure
output is less than the pump pressure activation point
(approximately 25 psi - 1/2hp, 35 psi - 1hp).
2. Dry Run Protection - After the unit recognizes a continual low
ow of water, the unit will shut down to protect itself from
running dry. Hourly, it will turn on to sample the water ow
requirements, and return to shut down if running dry. The
home owner can x the run dry issue and return the pump to
normal operation by unplugging the pump for 5 seconds.
3. Dead Head Protection - If there is no water demand (discharge
is shut off), the unit will shut down to protect the pump from
damage. Once water ow is restarted, the pump will re-start
the power automatically.
4. Rapid Cycle Protection – If the unit cycles repeatedly on/off,
the unit will shut down to protect the pump life. The optional
water tank not maintaining pressure could be a potential
cause. Hourly, it will turn on to sample the water ow
requirements, and return to shut down if the problem persists.
The home owner can x the concern and return the pump to
normal operation by unplugging the pump for 5 seconds.
TROUBLESHOOTING
Before ANY work with the pump, SHUT OFF the electrical supply and ball valves #1 and #2 to prevent electrical shock and
water damage.
Problem Cause Correction
Pump does not start or shuts down. No power supply. Connect the electricity supply.
Incorrect voltage. Pump is 115 Volt only.
It will not start with 230V supply.
Incorrectly plumbed. Conrm FIG 1 installation is correct. Conrm ball valves
#1 and #2 are open in suction and discharge. Conrm ball
valve #3 is closed on bypass.
Blocked inlet Check if pump suction inlet screen is blocked.
See FIG 10.
Insufcient water supply Ensure water source is providing sufcient water.
Pump starts when no water is
consumed.
Pipe leaking. Ensure all threads have 3 wraps of Teon tape + hand tight
+ 1/2 turn with wrench.
Tank pressure is low. See FIG 5 to check and add air pressure to the tank.
Air in the system. Ensure all threads have 3 wraps of teon tape + hand tight +
1/2 turn with wrench. Re-prime unit.
Pump does not shut down when water
is not consumed.
Blocked check valve. See FIG 8. Conrm check valve is free of debris and
functions freely.

© Copyright 2019 Zoeller® Co. All rights reserved.
6
OPERATION AND MAINTENANCE REQUIREMENTS
1. Pump Operation – There are three indicator lights on the
terminal box: Power (Green), Failure (Red), and On (Yellow).
Pump operating conditions are indicated as below: (FIG 6)
a) Power (Green): It is always on when connected to power.
b) On (Yellow): Turns on when tap is open - indicates normal
operation.
c) Failure (Red): Turns on when tap is open - indicates pump
is run dry.
d) On (Yellow): Turns on intermittently when tap is closed -
indicates pipe leak.
FIG 6 – PUMP OPERATION INDICATORS
Green
Red
Yellow
CITY
PRESSURE
BOOSTER PUMP
Refer to Instruction Manual
before installing or operating pump
156388 A
2. Periodically check the condition of the check valve and
strainer (if used).
3. If the pump is to be inactive for long periods, it should be
rinsed thoroughly with clean water, then drained and stored
in a dry place.
4. If the pump shaft is seized up after periods of inactivity, place
a screwdriver in the motor end to rotate the shaft. This should
free the pump shaft. (See FIG 7). If this does not remedy the
problem, the pump will need to be dismantled.
FIG 7 – FREEING UP PUMP SHAFT
IL1964
5. Internal Check Valve – If Teon tape or debris enters into the
pump cavity, the operation of the internal check valve can be
restricted. This may create an erratic or poor performance
with the pump. To clean the check valve (FIG 8).
FIG 8 – INTERNAL CHECK VALVE
a. Remove the air relief
port and top cover
b. Conrm the spring
and check valve are
free of debris
c. Reassemble the top
cover and air relief
port
IL1308B
DO NOT apply any bonding material (such as silicon, glue,
etc.) to seal the chamber cover. (FIG 9)
FIG 9 – DO NOT GLUE CHAMBER
IL1968

© Copyright 2019 Zoeller® Co. All rights reserved.
7
6. Pump Suction Inlet Screen – If internal debris blocks or
restricts the inlet suction screen (FIG 10), manually clean with
hands.
FIG 10 – INLET SCREEN
IL1962
7. Flange Installation - When the anges are removed for
maintenance or for any reason, follow the instructions below
for replacement:
(FIG 11 & 12)
a. Place the gasket against the ange
b. Place the 4 screws in the ange. DO NOT tighten
at this time. When all 4 screws are in place, tighten
them diagonally onto the ange. DO NOT over-tighten.
(Recmmended torque is 18~22 in-lbs).
FIG 11 – PLACING GASKET ON FLANGE
FIG 12 – TIGHTENING FLANGE
Screws should be
tightened diagonally
Do not tighten the
screws unevenly
Pipe and ange
should be installed
in a straight line
IL1966
Screw torque is
18~22 in-lb.
Do not over-torque
the screws
Pipe must be straight
1
2
22
IN-LB
c. Install inlet and outlet piping to the unions and then
connect them to pump anges.

© Copyright 2019 Zoeller® Co. All rights reserved.
8
OUTLINE / DIMENSIONAL SIZE
IL1212
6.02
13.96
6.22
6.89
6.3
7.28
5.71
5.12
8.98 8.62
NPT1"
NPT1"
Outlet
Inlet
4.13 1.77
4- 0.4
8.07
NPT1"
6.3
7.28
5.12
NPT1"
6.35
16.11
6.55
6.89
8.62
5.71
8.98
4.13 1.77 Outlet
Inlet
4- 0.4
8.07
350 355
in lieu of all other warranties expressed or implied; and we do not authorize any
representative or other person to assume for us any other liability in connection
with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211, Attention:
Customer Support Department to obtain any needed repair or replacement of
part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF EXPRESSED
OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED TO THE
DURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied warranty, so
the above limitation may not apply to you. Some states do not allow the exclusion
or limitation of incidental or consequential damages, so the above limitation or
exclusion may not apply to you.
This warranty gives you specic legal rights and you may also have other rights
which vary from state to state.
LIMITED WARRANTY
Manufacturerwarrants,tothepurchaserandsubsequentownerduringthewarranty
period, every new product to be free from defects in material and workmanship
under normal use and service, when properly used and maintained, for a period
of one year from date of purchase. Proof of purchase is required. Parts that fail
within the warranty period that inspections determine to be defective in material
or workmanship will be repaired, replaced or remanufactured at Manufacturer's
option, provided however, that by so doing we will not be obligated to replace an
entire assembly, the entire mechanism or the complete unit. No allowance will
be made for shipping charges, damages, labor or other charges that may occur
due to product failure, repair or replacement.
This warranty does not apply to and there shall be no warranty for any material
or product that has been disassembled without prior approval of Manufacturer,
subjectedto misuse,misapplication,neglect,alteration,accident oruncontrollable
act of nature; that has not been installed, operated or maintained in accordance
with Manufacturer's installation instructions; that has been exposed to outside
substances including but not limited to the following: sand, gravel, cement, mud,
tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other
abrasive or corrosive substances, wash towels or feminine sanitary products,
etc. in all pumping applications. The warranty set out in the paragraph above is
In instances where property damages are incurred as a result of an alleged product failure, the property
owner must retain possession of the product for investigation purpose.