Zoeller 519 User manual

FM3081
0318
Supersedes
New
INSTALLATION INSTRUCTIONS
MODEL 519 Condensate Pump
NOTICE TO INSTALLER: Instructions must remain with installation.
P/N 155408
© Copyright 2018 Zoeller®Co. All rights reserved.
1. To help reduce the risk of electrical shock, a properly grounded
receptacle or control box of grounding type must be installed and
protected by a ground fault circuit interrupter (GFCI) in accordance
with the National Electrical Code and applicable local codes. If
pump is wired direct, a GFCI must be installed in the control box.
(SEE WARNING BELOW)
2. Make certain that the ground fault interrupter protected receptacle
or control box is within reach of the pump’s power supply cord.
DO NOT USE AN EXTENSION CORD. Extension cords that are
too long or too light do not deliver sufficient voltage to the pump
motor. But more important, they could present a safety hazard if
the insulation were to become damaged or the connection end
were to fall into a damp or wet area.
3. Make sure the pump's electrical supply circuit is equipped
with fuses or circuit breakers of proper capacity. A separate
branch circuit, sized according to the National Electrical Code
for the current shown on the pump name plate is recommended.
1. Inspect all materials. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using.
2.  Carefullyreadalltheliteratureprovidedtofamiliarizeyourselfwithspecicdetailsregardinginstallationandusebeforeattemptingtheinstallation.
These materials should be retained for future reference.
1. Check to be sure your power source is adequate to handle the
amperage requirements of the motor as indicated on the pump
or unit I.D. tag.
2. All plumbing (discharge and drain lines) must be installed to meet
local codes.
3. This pump has been evaluated for use with water only.
4. TESTING FOR GROUND. As a safety measure, each electrical
outlet should be checked for ground using an Underwriters
Laboratory Listed circuit analyzer which will indicate if the power,
neutral and ground wires are correctly connected to your outlet.
If they are not, call a qualified licensed electrician.
5. Installation and checking of electrical circuits and hardware should
only be performed by a qualified licensed electrician.
6. FOR YOUR PROTECTIONALWAYS DISCONNECT PUMP FROM
ITS POWER SOURCE BEFORE HANDLING.
7. Prop65 Warning for California residents: Cancer and Reproductive
Harm- www.P65Warnings.ca.gov.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
REFER TO WARRANTY ON PAGE 2.
NOTE: Pumps with the “UL” mark and pumps with the “US” mark are
testedtoULStandardUL778.CSACertiedpumpsarecertiedtoCSA
Standard C22.2 No. 108.
SEE BELOW FOR
LIST OF WARNINGS
Product information presented
here reflects 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 web site:
zoellerpumps.com
Register your
Zoeller Pump Company
Product on our website:
http://reg.zoellerpumps.com/

2
© Copyright 2018 Zoeller®Co. All rights reserved.
Performance Characteristics
155405
Zoeller Pump Company warrants, to the purchaser and
subsequent owner during the warranty period, every new
Zoeller Pump Company product to be free from defects in
material and workmanship under normal use and service,
when properly installed, used and maintained, for a period
of two years from date of installation or 30 months from
date of manufacturer, whichever comes rst. Parts that fail,
(within two years of installation or 30 months from date
of manufacturer, whichever comes rst) that inspections
determine to be defective in material or workmanship, will
be repaired, replaced or remanufactured at Zoeller Pump
Company’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 any material that has
been disassembled without prior approval of Zoeller Pump
Company, subjected to misuse, misapplication, neglect,
alteration, accident or act of God; that has not been installed,
operated or maintained in accordance with Zoeller Pump
Company installation instructions; that has been exposed
to but not limited to the following: sand, gravel, cement,
mud, tar, hydrocarbons or hydrocarbon derivatives (oil,
gasoline, solvents, etc), wash towels or feminine sanitary
products, etc. or other abrasive or corrosive substances.
Limited Warranty
This warranty is 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 Zoeller Pump Company, 3649 Cane Run Road,
Louisville, Kentucky 40211-1961, Attention: Customer
Service Department to obtain any needed repair or
replacement of part(s) or additional information pertaining
to our warranty.
ZOELLER PUMP COMPANY 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.
0
10 20
80
30 40
160
50
240
60 70 80
0
3
26
4
9
12
15
21
TOTAL DYNAMIC HEAD
METERS
FEET
PUMP PERFORMANCE CURVE
MODEL 519
FLOW PER HOUR
GALLONS
LITERS
18
6
90 100 110 120
320 400
MODEL
Feet
Shut-off Head:
519
Meters Gal. Liters
20 ft.(6.1m)
3 .9 110 416
61.8 93 352
9 2.7 77 291
12 3.7 59 223
15 4.6 38 144
TOTAL DYNAMIC HEAD/FLOW
PER HOUR
CONDENSATE
18 5.5 16 61

3
© Copyright 2018 Zoeller®Co. All rights reserved.
1. Read all instructions before beginning installation.
2. Be sure the installation does not exceed a maximum
of 15 feet of vertical lift.
3. Be sure the pump is level within 1/8" for the length of
the condensate pump.
4. Use soapy water when cleaning unit. Refer to
maintenance guidelines.
5. For best results, drain and discharge lines should have
a continuous downward slope.
1. DO read all installation material included with the pump.
2. DO inspect unit for any visible damage caused by
shipping. Contact dealer if unit appears to be damaged.
3. DO clean all debris from the pump reservoir.
4. DO always disconnect pump from power source before
handling. DO always connect to a separately protected
and properly grounded ground fault protected circuit.
DO NOT ever cut, splice or damage power cord. DO
NOT carry or lift pump by its power cord. DO NOT use
an extension cord with this condensate pump.
Ten Helpful Hints or Easy Installation
Do’s and Do Nots or Installing Unit
5. DO NOT use a discharge pipe smaller than the pump
discharge size.
6. DO test pump immediately after installation to be sure
that the system is working properly.
7. DO review all applicable local and national codes and
verify that the installation conforms to each of them.
8. Do not use Flexible tubing larger than 3/8".
6. Test operation of pump per STEP 5.
7. Do not overtighten check valve after cleaning. Refer
to maintenance guidelines.
8. Plug pump into a constant voltage source. Do not
plug into a device that runs intermittently.
9. The model number and date code can be found on
the pump I.D. label.
10. For best results, the highest point of the discharge
line should be higher than 5’ above oor.

4
© Copyright 2018 Zoeller®Co. All rights reserved.
1.1) Select a location for the pump that is below the evaporator drain and/or furnace drain.
1.2) The unit has two mounting brackets built into the deck so the pump can be attached to the wall or side of the
appliance. Refer to Figure 1.2.
2.1) To prevent pipe blockage, modify the end of the pipe or tubing as shown in Figure 2.1.
2.2) Plumb, exible tube or pipe, from the condensate drain and/or from the furnace drain to the inlet hole(s) on
the pump. Refer to Figure 2.2.
Figure 1.2
Figure 2.2Figure 2.1
Note: The drain line(s) should have a continuous downward slope to allow for gravity ow.
Note: Local codes may require the use of a condensate neutralizer when using this pump.
Note: Make sure the drain lines from the A.C. condenser are supported above the reservoir and no weight from the
drain line is directed to the bottom of the reservoir.
SK3177
SK1765
SK3178
STEP 1 Mounting Location
STEP 2 Installation of Condensate Drain Lines
CONDENSING GAS
FURNACE
OVERFLOW
MAIN CONDENSATE DISCHARGE
CONDENSATETRAP
GFCI
OUTLET
MOUNTING BRACKETS
Note: Insert, Tubing or Pipe,
Through the Inlet until the Tip
Contacts Bottom of Reservoir.
Drain Pipe
45°
CONDENSING GAS
FURNACE
A/C CONDENSER
MAIN DRAIN FROM COIL
OVERFLOW DRAIN FROM
COIL WHEN REQUIRED.
GFCI
OUTLET
MAIN DRAIN FROM FURNACE
CONDENSATE NEUTRILIZER
CARTRIDGE (IF REQUIRED)
OVERFLOW DRAIN
FROM FURNACE

5
© Copyright 2018 Zoeller®Co. All rights reserved.
Figure 4.1
Note: Do not use exible tubing larger than 3/8” ID. A hose clamp (not included) is recommended.
3.1) Extend the discharge pipe, from the barbed check valve, to the highest point possible. Refer to Figure 3.1
3.2) From this point, direct the discharge line to the location of the main drain, maintain a continuous downward slope.
Note: If a continuous downward slope is not possible, then make an inverted “U” at the highest point of the discharge line.
Note: Make sure the 3/8” ID tube is supported in a way it will not “Kink or Pinch off” blocking ow.
Figure 3.1 SK3179
STEP 3 Installation of Discharge Line
STEP 4 Installation of Safety Switch
GFCI Outlet
Pipe Supports
To Main Drain
Floor Joists
15 FT
Max.
(RECOMMENDED, NOT INCLUDED)
HOSE CLAMP
3/8" IDTubing
Inverted "U"
Note: Condensate Drain
Lines not Shown.
Refer to Step 2 for
Installation of Drain Lines.
POWER CORD
SAFETY SWITCH LEADS
INLETS (4)
MOUNTING BRACKET (2)
DISCHARGE FITTING
SK3173
4.1) The pump safety switch should be used on 24V Class II control circuits only. The pump safety switch connections
are available on the two wire leads extending from the pump. Wire into the 24 Volt thermostat circuit to shut off
A/C systems should an overow condition occur. The Safety Switch operates with or without power provided to
the pump.

6
© Copyright 2018 Zoeller®Co. All rights reserved.
5.1) Testing of Pump (Main Switch)
1) With the discharge line in place, plug in the pump.
2) Pour water into the pump reservoir, through one of the inlets, until the pump activates to verify that the unit works.
5.2) Testing of Safety Switch (If applicable)
Note: Unplug the pump for this test.
1) Energize the appliance so that it runs.
2) Pour water into the reservoir as described in Section 5.1 item 2.
3) As water rises in the reservoir, the overow Switch should activate, breaking the thermostat circuit to the appliance.
4) Plug the pump in and allow the pump to empty the tank. As the water level decreases, the appliance will reset.
STEP 5 Testing of Pump Operation
Maintenance Guidelines
Cleaning of Reservoir:
1) Remove entire pump from wall, if mounted.
2) Disassemble reservoir from the deck by inserting a screwdriver in either side of the deck.
3) Clean reservoir as needed.
.
4) Reassemble reservoir to the deck.
Cleaning of Check Valve:
1) Remove discharge line from valve.
2) Remove check valve with 9/16” wrench.
3) Visually check for obstructions or damage.
4) Replace valve by hand tightening, then tighten 1/2 turn with a 9/16” wrench.
CAUTION
Do not overtighten.

7
© Copyright 2018 Zoeller®Co. All rights reserved.
Trouble Shooting Guide
A. UNIT DOESN’T RUN.
B. PUMP MAKES LOUD NOISES WHEN
RUNNING.
C. PUMP RUNS BUT DOES NOT PUMP
LIQUID OUT.
D. LIQUID DRAINS BACK INTO PUMP
FROM DISCHARGE LINE.
E LIQUID LEAKS FROM AROUND
CHECK VALVE.
Pump not plugged in.
Low voltage; blown fuse, open circuit.
No condensate in reservoir.
Motor or wiring shorted.
Drain/Discharge line(s) blocked.
Debris in reservoir.
Float bound.
Maximum discharge height exceeded.
Discharge tube blocked.
Check Valve obstruction.
Check Valve damaged.
Check Valve damaged.
Check Valve obstruction.
Highest point of discharge line is less
than 5’.
Check Valve is too tight or too loose.
Plug in.
Have a qualied electrician check fuse circuit.
Be certain the appliance is generating
condensate. Check drain line(s) and/or
discharge line for blockage.
Contact Factory.
Check drain line(s) and/or discharge line for
blockage.
Refer to “Maintenance Guidelines” section for
cleaning instructions.
Refer to “Maintenance” section for cleaning
instructions.
Measure from bottom of pump to highest
point. Rework discharge if height is greater
that 18’. Refer to STEP 3 for guidelines.
Check discharge line for blockage, remove
debris.
Refer to “Maintenance” section for cleaning
instructions.
Contact Factory.
Contact Factory.
Refer to “Maintenance” section for cleaning
instructions.
Check valve may allow some condensate to
drain out of line into reservoir. This is normal.
Check valve should be hand tight, then tighten
an additional 1/2 turn with a 9/16” wrench.
Condition Possible Cause Remedy
Before servicing a pump, always shut off the main power
breaker and then unplug the pump - making sure you are not standing in
water and are wearing insulated, protective-sole shoes. Under flooded
conditions, contact your local electric company or a qualified licensed electrician
for disconnecting electrical service prior to pump removal.
If the above checklist does not solve the problem, consult Zoeller Technical
Service Department 1-(800) 928-PUMP - Do not attempt to service or otherwise
disassemble pump.

© Copyright 2018 Zoeller®Co. All rights reserved.
MAIL TO: P. O . BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
[phone] • 1 (800) 928-PUMP • FAX [phone] Visit our web site:
zoellerpumps.com
NOTES