Zoeller 600 Series User manual

SECTION: 6.10.029
FM1798
0810
Supersedes
0807
NOTICE TO INSTALLER: Instructions must remain with installation.
Congratulations on the purchase of the Zoeller 600 Series
submersiblepump.ForoversixtyyearsthenameZoellerhasrepre-
sentedthestandardforsubmersibledewateringandsewagepumps.
The same high quality workmanship and easy maintenance design
has been incorporated into this line of heavy-duty solids-handling
submersiblesewagepumps.ThisZoellerpumpwillprovideyearsof
trouble-free service when installed according to the manufacturers’
recommendations.
Model Number: _______________ Date Code: _______________
Serial Number: Pump 1_____________ Pump 2_____________
Simplex Panel P/N ______________________________
Duplex Rail System P/N ________________________
Job Name: ____________________________________________
Distributor: ____________________________________________
Sales Order Number: ____________________________________
Contractor: ____________________________________________
Date of Installation: _____________________________________
System Readings During Operation: Voltage _____Amps _____
OWNER’S MANUAL
600 SERIES SUBMERSIBLE NON-CLOG UNITS
This manual incorporates the installation, operation, mainte-
nance,andserviceinstructionsintoonedocumenttoaidintheowner-
ship of a Zoeller submersible non-clog wastewater product. Please
readandreviewthismanualbeforeinstallingtheproduct.Followthe
steps and procedures listed on FM0990 for a proper start-up. Many
itemscontainedwithin,whenfollowedcorrectly,willnotonly ensure
a long and problem-free life for the pump, but also save time and
money during installation. Reference FM1799 for repair manual on
600 Series Pumps. Should further assistance be necessary please
call our Technical Service Department at 1-800-928-PUMP(7867).
Table of Contents
Safety Instructions.......................................................................1
Limited Warranty..........................................................................2
Performance Data.........................................................................2
Preinstallation Information..........................................................3
Electrical Data...............................................................................3
Typical Dewatering Installation...................................................4
Typical Sewage Installation ........................................................4
Pump Wiring Instructions.........................................................5-6
Operation....................................................................................6-7
Maintenance..................................................................................7
Service Checklist..........................................................................8
Safety Instructions
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA-
JOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUALAND ON THE PUMP.
THISMANUALISINTENDEDTOASSIST IN THEINSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH
THE PUMP.
This is a SAFETYALERT 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.
WarnsofhazardsthatWILLcauseseriouspersonal
injury, death or major property damage.
Warnsof hazardsthat CAN cause seriouspersonal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
INDICATESSPECIALINSTRUCTIONSWHICHARE
VERY IMPORTANTAND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMINGANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
Owner’s Information
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
[phone] • 1 (800) 928-PUMP • FAX [phone]
visit our web site:
www.zoeller.com
© Copyright 2010 Zoeller Co. All rights reserved.
REFER TO WARRANTY ON PAGE 2.

2
© Copyright 2010 Zoeller Co. All rights reserved.
Performance Data
EachZoeller600SeriesPumpinstallationis required to have a completed Zoeller Pump Company Start-up Report (FM0990).The report is to be completed by
anapprovedStart-upTechnicianinthepresenceoftheinstallingcontractor.Acopyofthisreportwillbe onfileattheZoellerPumpCompanyofficesinLouisville,
KY. Failure to comply with the requirement will void the warranty agreement.
Limited Warranty
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, every new product to be free from defects in material and
workmanship under normal use and service, when properly used and main-
tained, for a period of one year from date of purchase by the end user, or 18
monthsfromdateoforiginalmanufactureoftheproduct,whichevercomesfirst.
Partsthatfailwithinthewarrantyperiod,oneyearfromdateofpurchasebythe
end user, or 18 months from the date of original manufacture of the product,
whichevercomesfirst, thatinspectionsdetermineto bedefectiveinmaterial 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.
Thiswarrantydoes notapplytoandthere shallbenowarranty foranymaterial
orproductthathasbeen disassembled withoutpriorapprovalofManufacturer,
subjected to misuse, misapplication, neglect, alteration, accident or act of
God; that has not been installed, operated or maintained in accordance with
Manufacturer'sinstallationinstructions; that has been exposed to outsidesub-
stances including but not limited to the following: sand, gravel, cement, mud,
tar,hydrocarbons,hydrocarbonderivatives(oil,gasoline,solvents,etc.),orother
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 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 con-
nection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
Attention: Customer Service Department to obtain any needed repair or re-
placement of part(s) or additional information pertaining to our warranty.
MANUFACTUREREXPRESSLYDISCLAIMSLIABILITYFORSPECIAL,CON-
SEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF EXPRESSED
OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS
FORAPARTICULAR 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.
Thiswarrantygivesyouspecificlegalrightsandyoumayalsohaveotherrights
which vary from state to state.
013859

3
© Copyright 2010 Zoeller Co. All rights reserved.
*Consult Factory.
Preinstallation Information
Electrical Data
Service Amps Winding
Model HP Factor RPM Voltage Phase Hertz KVA Code Resistance
Full Load InAir Shut Off Locked Rotor Line-to-Line
E611 1 1.2 1750 230 1 60 6.3 4.1 4.7 48.0 M 2.5 / 4.8
J611 1 1.2 1750 200 3 60 4.1 3.3 3.7 32.0 M 2.2
F611 1 1.2 1750 230 3 60 3.6 2.2 2.6 28.0 M 3
G611 1 1.2 1750 460 3 60 1.8 1.1 1.3 14.0 M 12
BA611 1 1.2 1750 575 3 60 1.4 1.0 1.1 11.5 M 18
E621 1 1/2 1.2 1750 230 1 60 8.7 4.3 5.3 48.0 J 2.5 / 4.8
J621 1 1/2 1.2 1750 200 3 60 5.8 3.3 3.7 32.0 J 2.2
F621 1 1/2 1.2 1750 230 3 60 5.1 2.3 2.9 28.0 J 3
G621 1 1/2 1.2 1750 460 3 60 2.6 1.2 1.5 14.0 J 12
BA621 1 1/2 1.2 1750 575 3 60 2.0 1.0 1.3 11.5 J 18
E631 2 1.2 1750 230 1 60 14.5 7.2 8.0 86.0 L .94/3.8
J631 2 1.2 1750 200 3 60 7.8 4.5 5.0 46.0 J 1.5
F631 2 1.2 1750 230 3 60 6.8 2.3 4.4 41.0 K 2
G631 2 1.2 1750 460 3 60 3.4 1.2 2.2 20.5 K 8
BA631 2 1.2 1750 575 3 60 2.7 1.4 1.8 16.2 K 12
E641 3 1.2 1750 230 1 60 17.0 7.2 8.9 86.0 H .94/3.8
J641 3 1.2 1750 200 3 60 11.0 4.5 5.6 46.0 F 1.5
F641 3 1.2 1750 230 3 60 9.6 2.3 4.7 41.0 F 2
G641 3 1.2 1750 460 3 60 4.8 1.7 2.4 20.5 F 8
BA641 3 1.2 1750 575 3 60 3.9 1.4 2.0 16.2 F 12
E651 5 1.2 1750 230 1 60 28.0 16.1 19.7 139.0 H .9 / 3.1
J651 5 1.2 1750 200 3 60 17.5 6.1 7.6 64.0 D 1
F651 5 1.2 1750 230 3 60 15.2 6.1 7.4 58.0 E 1.3
G651 5 1.2 1750 460 3 60 7.6 3.1 3.7 29.0 E 5.2
BA651 5 1.2 1750 575 3 60 6.1 1.5 3.4 23.0 E 8.0
J661 7 1/2 1.0 1750 200 3 60 28.0 17.9 18.3 83.0 C 0.5
F661 7 1/2 1.0 1750 230 3 60 23.0 15.0 15.7 72.0 C 0.7
G661 7 1/2 1.0 1750 460 3 60 12.5 7.5 7.9 36.0 C 2.8
BA661 7 1/2 1.0 1750 575 3 60 9.4 5.3 5.8 29.0 C 5.4
1. Check to be sure your power source is capable of handling the voltage require-
ments of the motor, as indicated on the pump nameplate.
2. The installation of pumps using auxiliary variable level float switches is the
responsibility of the installing party and care should be taken that the tethered
float switch will not hang up on the pump apparatus or pit peculiarities and is
secured so that the pump will shut off. It is recommended that rigid piping and
fittings be used and the pit be 36” or larger in diameter.
3. INFORMATION - VENT HOLE PURPOSE. It is necessary that all submersible
pumps capable of handling various sizes of solid waste be of the bottom intake
design to reduce clogging and seal failures. If a check valve is incorporated in
the installation, a vent hole (approx. 3/16”) must be drilled in the discharge pipe
belowthecheckvalveandpitcovertopurgetheunitoftrappedair.Waterstream
will be visible from this hole during pump run periods. This vent hole should be
checkedperiodicallyforcloggingandcleanedasnecessary.Trappedairiscaused
by agitation and/or a dry basin.
4. Water hammer creates momentary high pressure surges. These surges can
causeseveredamageto check valves and thepipingsystem. Consideration for
water hammer must be included in the piping system design. ReferenceASPE
Data Book, Chapter 2.33. Some systems may require external spring or lever
weighted check valves or other engineered solutions.
5. Three phase pumps must be connected for proper rotation, which is counter-
clockwise looking into impeller inlet. See page 4 for instructions for checking 3
phase rotation.
1. Inspect your pump. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using. DO NOT remove the test plugs in
the cover nor the motor housing.
2. Carefully read the literature provided to familiarize yourself with specific details regarding installation and use. These materials should be retained for future refer ence.
1. Do not lift, carry, or hang pump by the electrical cables. Damage to the electrical
cables can cause shock, burns or death.
2. Make sure there is a properly grounded connection available. All pumps are
furnished with provisions for proper grounding to help protect you against the pos-
sibility of electrical shock.
3. Make certain that the control box is within the reach of the pump’s power
supplycord.DONOTUSEANEXTENSIONCORD.Extensioncordsthataretoolong
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 the sump.
4. Makesurethepumpelectricalsupplycircuitisequippedwithfusesanddisconnect
or circuit breakers of proper capacity. Aseparatebranchcircuit is recommended,
sized according to the “National Electrical Code” for the current shown on the pump
nameplate.
5. Care should be taken during the initial installation to be sure that adequate
air supply is available whenever any person is in the basin. Always follow OSHA
guidelines on confined space requirements.
6. Riskofelectricshock-Thesepumpshavenotbeeninvestigatedforuseinswimming
pool areas.
NOTE: Pumps with the “UL” mark and pumps with the “US” mark are tested to ULStandard
UL778. CSACertified pumps are certified to CSAStandard C22.2 No. 108.
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS

4
© Copyright 2010 Zoeller Co. All rights reserved.
Allinstallations mustcomply with all applicable electrical and plumbing codes, including, but not limited to, National Electrical Code,
local, regional, and/or state plumbing codes, etc.
TYPICAL OUTDOOR CONCRETE BASIN WITH VALVE
BOXAND HINGEDACCESS COVERS
TYPICAL INDOOR FIBERGLASS BASIN
Typical Sewage/Waste Pumping System Installation
(1) Electricalwiringandprotectionmustbeinaccordancewiththe
National Electrical Code, and any other applicable state and
local electrical requirements.
(2) Install proper full flow check and shut-off valve.
(3) Install proper controls. (Outdoor panels require NEMA3R or
4X enclosure)
(4) All installations require a basin cover to prevent debris from
falling into the basin and to prevent accidental injury.
(5) Gastightsealsarerequiredinallindoorsewageinstallations
to contain gases and odors.
(6) When check valve is installed, drill a 3/16” diameter hole in
the discharge pipe below the check valve even with the top
of the pump. NOTE: The hole must be below the basin cover
andcleanedperiodically. Waterstreamwillbevisiblefromthis
holeduringpump run periods.Alsoa vent hole is drilled in the
pump housing. Be sure that this hole is cleared during any
servicing.
(7) Ventgasesandodorstotheatmospherethroughventpipeper
Local and State codes.
(8) Secure power cord to avoid entanglement with variable level
float switch mechanism.
(9) Do not reduce pump discharge pipe below 3” IPS size.
(10) Basin must be in accordance with all applicable codes
and specifications. Basin must be sized to allow a minimum 3
minute lapse time between starts.
(11) Pumpmustbelevelandthetetheredvariablelevelfloatswitch
must be free and not hang up on pump or pit peculiarities.
(12) Ifarailsystemisused,dischargeelbowmustbefirmlyanchored
tothebottomofbasin.Infiberglassbasin,thebottomwillneed
to be reinforced if the discharge elbow is used.
(13) If arailsystemisused,theguiderailsare¾”schedule40pipe
for threaded vertical discharge units and 2” schedule 40 pipe
forflangedhorizontaldischargeunits.Brass,stainlesssteelor
galvanized steel is recommended.
(14) Install ring and cable for lifting pump from pit.
(15) Basin must be clean and free of debris after installation.
(16) Cords mustbeproperly sealedto prevent moistureand gases
from entering the control panel.
3
8
7
5
16
1
14
6
13
12
11
10
2
2
9
54
15
ZEPA0466
ZEPA0071
744 7
3
16
1
10
6
12
9
6
13
2
10
14
15
8
11

5
© Copyright 2010 Zoeller Co. All rights reserved.
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
“Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit directly to the pump.
Power cords, sensor cords, and float cords all must be sealed to prevent gases from the basin entering the control panel.
INSTRUCTIONS FOR CHECKING ROTATION OF THREE PHASE UNITS
It is very important that these units be connected for proper rotation. Since no rotating parts are visible without removing the pump
from the pit, the rotation on 3 phase units should be checked before installation into the pit as follows:
After the proper electrical connections are made, momentarily energize the pump observing the direction of kick back due to starting torque.
Therotation is correct if the kick back is in the oppositedirectionofthe rotation arrow.Iftherotation is not correct, disconnect power and switch
any two power leads. Turn power back on and retest for proper rotation.
DOUBLE SEAL PUMPS
(1) Double seal pumps offer extra motion protection from damage caused by seal failure.
(2) Pumps should be serviced on a periodic preventative maintenance schedule.
(3) Oil in the motor housing and lower seal cavity must be checked when pump is serviced. If oil from the motor housing contains water or
other contaminations, both seals should be replaced during maintenance.Always replace with new factory recommended oil and service
parts.All warranty repairs must be made by ZoellerAuthorized Service Stations.
CONTROL PANELS
These pumps are nonautomatic. They require a control panel.Amotor starter circuit, control circuit, and alarm circuit within the panel are stan-
dard features. Outdoor enclosures and alternating relays are often required. Variable level float switches are the most common level sensing
device. The following should be noted.
(1) Single phase units have externally mounted capacitors and starting relays. Your control panel should have provisions for mounting these
starting components.
(2) Allpumpsrequireoverloadprotectioninpanel.Usewithapprovedmotorcontrolthatmatchesmotorinputinfullloadampereswithoverload
element(s) selected or adjusted in accordance with control instructions.
(3) HazardousLocation pumps require panels that offerintrinsically safe relays and all other NEC requirements must be followed (SeeArticle
500,501 & 502 plus any others that apply.)
Pump Wiring Instructions
Threephasepumpsarenonautomatic.Tooperateautomatically,acontrolpanel
is required. Follow the instructions provided with the panel to wire the system.
Beforeinstallingapump,checkthepumprotationtoinsurethatwiringhasbeen
connected properly to power source, and that the green lead of power cord
(Seewiringdiagram),isconnectedtoavalidground,Momentarilyenergizethe
pump,observingthe directionsofkick backduetostartingtorque. Rotationis
correct if kick back is in the opposite direction of rotation arrow on the pump
casing. If rotation is not correct, switching of any two power leads other than
ground, should provide the proper rotation.
Theabovewiringdiagramshowsatypicalhookupfora230volt,3phasepump,
twovariablelevelfloatswitches,andamagneticstarter. Itisnotintendedthat
thisdiagramcoverallapplications. Seewiringdiagramsuppliedwithspecific
electrical controllers and panels.
ZEPA0036
OL
OLOL
STARTER
MAGNETIC
IS REQUIRED
CIRCUIT TRANSFORMER
3 PHASE A CONTROL
NOTE - FOR 460 VOLT
FLOAT SWITCH
"OFF"
FLOAT SWITCH
"ON"
L3L2
L1
2
3
MOTOR
PUMP
T3
T2
T1
OL
M
230 VOLTS, 60 HZ., 3 PH.
TYPICAL WIRING DIAGRAM
Three Phase Installation
TYPICAL 3-PHASE WIRING DIAGRAM
T3
T2
T1
L3
L2
L1
POWER CABLE
3 PHASE MOTOR
3ø VAC
ZEPA0038F
“600 SERIES” FOUR CONDUCTORAWG. POWER CORD SIZE
MODEL BHP 230/1PH 200/3PH 230/3PH 460/3PH 575/3PH
611 1 12AWG. 12AWG. 12AWG. 12AWG. 12AWG.
621 1.5 12 AWG. 12AWG. 12AWG. 12AWG. 12AWG.
631 2 12AWG. 12AWG. 12AWG. 12AWG. 12AWG.
641 3 12AWG. 12AWG. 12AWG. 12AWG. 12AWG.
651 5 8AWG. 12AWG. 12AWG. 12AWG. 12AWG.
661 7.5 N/A 8AWG. 8AWG. 12AWG. 12AWG.
Approximate cord diameter per gauge
12/4AWG. .64"
8/4AWG. .93"