Zoeller 521 User manual

Product information presented here
reflects conditions at time of pub-
lication. 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
[phone] • 1 (800) 928-PUMP • FAX [phone]
SECTION: 6.10.086
FM2630
1210
Supersedes
New
INSTALLATION INSTRUCTIONS
MODEL 521 Condensate Pump
PREINSTALLATION CHECKLIST - ALL INSTALLATIONS
NOTICE TO INSTALLER: Instructions must remain with installation.
P/N 151386
© Copyright 2010 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
beinstalledandprotectedbyagroundfaultcircuitinterrupter
(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. Makecertainthatthegroundfaultinterrupterprotectedrecep-
tacleorcontrolboxiswithinreachofthepump’spowersupply
cord.DONOTUSEANEXTENSIONCORD.Extensioncords
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. Makesurethepump'selectricalsupplycircuitisequipped
with fuses or circuit breakers of proper capacity. A sep-
aratebranchcircuit,sizedaccordingtotheNationalElectrical
1. Inspect all materials. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before
using.
2. Carefullyreadall theliteratureprovidedtofamiliarizeyourselfwithspecificdetailsregardinginstallationandusebeforeattempting
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.
Codeforthecurrentshownonthepumpnameplateisrecom-
mended.
4. TESTINGFORGROUND.Asasafetymeasure,eachelectrical
outlet should be checked for ground using an Underwriters
Laboratory Listed circuit analyzer which will indicate if the
power,neutralandgroundwiresarecorrectlyconnectedtoyour
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 PROTECTION ALWAYS DISCONNECT PUMP
FROM ITS POWER SOURCE BEFORE HANDLING.
7. According to the state of California (Prop 65), this product
contains chemicals known to the state of California to cause
cancer and birth defects or other reproductive harm.
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 Certified pumps are
certified to CSAStandard C22.2 No. 108.
SEE BELOW FOR
LIST OF WARNINGS
visit our web site:
www.zoeller.com

2
© Copyright 2010 Zoeller Co. All rights reserved.
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,
whenproperlyinstalled,usedandmaintained,foraperiod
of two years from date of installation or 30 months from
dateofmanufacturer,whichevercomesfirst.Partsthatfail,
(within two years of installation or 30 months from date
of manufacturer, whichever comes first) 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.
Thiswarrantydoesnotapplytoanymaterialthathasbeen
disassembledwithoutpriorapprovalofZoellerPumpCom-
pany,subjectedtomisuse,misapplication,neglect,altera-
tion, accident or act of God; that has not been installed,
operated or maintained in accordance with Zoeller Pump
Company installation instructions; that has been ex
posed
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
otherpersonto assumefor usany otherliabilityin connec-
tion 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 re-
placement of part(s) or additional information pertaining
to our warranty.
ZOELLER PUMP COMPANY EXPRESSLY DISCLAIMS
LIABILITY FOR SPECIAL, CONSEQUENTIAL OR INCI-
DENTAL 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 DU-
RATION 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
ofincidentalor consequentialdamages,so theabove limi-
tation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may
also have other rights which vary from state to state.
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.
Do not overtighten.

3
© Copyright 2010 Zoeller Co. All rights reserved.
Performance Characteristics
151234
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 mainte-
nance guidelines.
5. Forbestresults,drainanddischargelinesshouldhave
a continuous downward slope.
1. DO read all installation material included with the
pump.
2. DOinspectunitforanyvisibledamagecausedbyship-
ping. Contact dealer if unit appears to be damaged.
3. DO clean all debris from the pump reservoir.
4. DOalwaysdisconnectpumpfrompowersourcebefore
handling.DOalwaysconnecttoaseparatelyprotected
and properly grounded ground fault protected circuit.
DO NOT ever cut, splice or damage power cord. DO
Ten Helpful Hints For Easy Installation
Do’s And Don't’s For Installing A Unit
NOT carry or lift pump by its power cord. DO NOTuse
an extension cord with this condensate pump.
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.
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 floor.

4
© Copyright 2010 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 brackets built into the deck so that it can be installed 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, flexible 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 flow.
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.
SK1762
SK1765 SK1763
STEP 1 Mounting Location
STEP 2 Installation of Condensate Drain Lines
Note: Insert, Tubing or Pipe,
Through the Inlet until the Tip
Contacts Bottom of Reservoir.
Drain Pipe
45°

5
© Copyright 2010 Zoeller Co. All rights reserved.
Figure 4.1
Note: Do not use flexible 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 flow.
Figure 3.1 SK1764
STEP 3 Installation of Discharge Line
STEP 4 Installation of Safety Switch
SK1767
4.1) Thepumpsafetyswitchshouldbeusedon24VClassIIcontrolcircuitsonly.Thepumpsafetyswitchconnections
are available on standard ¼" quick connect terminals located on the top cover. Two wires with pre-crimped
connectionsmay bepluggedontothe COMMONandRUNterminalsand wiredintothe24Volt thermostatcircuit
to shut offA/C systems should an overflow condition occur. The Safety Switch operates with or without power
provided to the pump. An optional alarm or remote trouble light may be connected.
Note: The third terminal of the safety switch closes when the water exceeds the high level limit. This terminal may be
connected to a light or buzzer to indicate system trouble.

6
© Copyright 2010 Zoeller Co. All rights reserved.
Trouble Shooting Guide
A. UNIT DOESN’T RUN.
B. PUMPMAKESLOUDNOISESWHEN
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 qualified electrician check fuse circuit.
Be certain the appliance is generating con-
densate. 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.
Measurefrombottomofpumptohighestpoint.
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.
Checkvalveshouldbehand tight,thentighten
an additional 1/2 turn with a 9/16” wrench.
Condition Possible Cause Remedy
Before servicing a pump, always shut off the main power
breakerandthenunplugthepump-makingsureyouarenotstandinginwater
andarewearinginsulated,protective-soleshoes.Underfloodedconditions,
contact your local electric company or a qualified licensed electrician for
disconnecting electrical service prior to pump removal.
Ifthe abovechecklist doesnotsolve theproblem, consultZoellerTechnical Service
Department 1-(800) 928-PUMP - Do not attempt to service or otherwise disas-
semble pump.
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 overflow Switch should activate, breaking the thermostat circuit to the appli-
ance and/or triggering the alarm.
4) Plug the pump in and allow the pump to empty the tank.As the water level decreases, the appliance and/or the
alarm will reset.
STEP 5 Testing of Pump Operation

7
NOTES:
© Copyright 2010 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]
www.zoeller.com
© Copyright 2010 Zoeller Co. All rights reserved.