Zoeller 6355 User manual

1
© Copyright 2009 Zoeller Co. All rights reserved.
INSTALLATION INSTRUCTIONS
RECOMMENDED MODELS
P/N 006355
Notice to installing contractor: Instructions must remain with installation. SECTION: 6.10.001
FM0447
Rev.A
1009
Supersedes
0809
PREINSTALLATION CHECKLIST -ALL INSTALLATIONS
*Effluentsystems shouldspecify thatpumps shouldnot handlesolids exceeding three fourths inch(¾") inorder toprevent largesolids fromentering leechingfields, moundsystems etc.
(Model 49 and 70 Series have 3/8" solids capability, 50, 90, 140, 145/4145, 151, 371 and 372 Series have ½", 130 Series has 5/8", 152,153, and 160/4160/180/4180, 373 Series have
¾".) Where codes permit, sewage pumps can be used for effluent systems. Nonautomatic pump(s) with external level control recommended for septic tank effluent applications.
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
DATE INSTALLED:
MODEL NUMBER:
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 reference.
NOTICE: VENT HOLE FOR
CHECK VALVE
SEE #3 IN CAUTION SECTION
BELOW AND #4 ON PAGE 3
EFFLUENT*/SUMP/DEWATERING SEWAGE
49, 50 Series, 70 Series, 98 Series 211 Series, 264 Series
130 Series, 140/4140, 145/4145 Series, 150 Series, 160/4160 Series 260 Series, 270/4270 Series
180/4180 Series, 191, 371, 372, 373 280/4280 Series, 290/4290 Series
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
1. Make certain that the receptacle is within the reach of the pump’s power supply cord. DO NOT
USEANEXTENSIONCORD.Extensioncords that are too long or too lightdonotdeliversufficient
voltagetothe pump motor. But, moreimportant,theycould present asafetyhazardif the insulation
were to become damaged or the connection end were to fall into the sump.
2. Make sure the pump electrical supply circuit is equipped with fuses or circuit breakers of
proper capacity. A separate branch circuit is recommended, sized according to the “National
Electrical Code” for the current shown on the pump nameplate.
3. 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.
4. ForAddedSafety. Pumpingandotherequipmentwitha3-pronggroundedplugmustbeconnected
toa3-pronggroundedreceptacle.Foraddedsafety thereceptaclemaybeprotectedwithaground-
fault circuit interrupter. When a pump needs to be connected in a watertight junction box, the plug
canbe removedandspliced tothe supplycablewith propergrounding.Foraddedsafety thiscircuit
may be protected by a ground-fault circuit interrupter. The complete installation must comply with
the National Electrical Code and all applicable local codes and ordinances.
5. FORYOURPROTECTION,ALWAYSDISCONNECTPUMPFROMITSPOWERSOURCEBEFORE
HANDLING. Single phase pumps are supplied with a 3-prong grounded plug to help protect you
against the possibility of electrical shock. DO NOT UNDER ANY CIRCUMSTANCES REMOVE
THEGROUNDPIN. The3-prongplugmustbeinsertedintoamating3-pronggroundedreceptacle.
If the installation does not have such a receptacle, it must be changed to the proper type, wired
and grounded in accordance with the National Electrical Code and all applicable local codes and
ordinances. Threephasepumpsrequiremotorstartingdeviceswithmotoroverloadprotection.See
FM0486 for duplex installations.
6. The tank is to be vented in accordance with local plumbing code. Pumps must be installed in ac-
cordance with the National Electrical Code and all applicable local codes and ordinances. Pumps
are not to be installed in locations classified as hazardous in accordance with National Electrical
Code,ANSI/NFPA 70.
7. “Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit
directly to the pump.
8. Installation and servicing of electrical circuits and hardware should be performed by a qualified
licensed electrician.
9. Pump installation and servicing should be performed by a qualified person.
10. Risk of electric shock - These pumps have not been investigated for use in swimming pool and
marine areas.
11. 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.
1. Check to be sure your power source is capable of handling the voltage requirements of the motor,
as indicated on the pump name plate.
2. Theinstallation ofautomatic pumpswithvariablelevelfloatswitchesor nonautomaticpumps using
auxiliary variable level float switches is the responsibility of the installing party and care should be
taken that the tethered float switchwillnothangup on the pump apparatus or pit peculiarities and
is secured so that the pump will shut off. It isrecommended to use rigid piping and fittingsandthe
pit be 18" or larger in diameter.
3. Information- vent holepurpose. Itisnecessary thatallsubmersiblesump,effluent, andsewage
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 below the check valve and pit cover to purge the unit
of trapped air. Trapped air is caused by agitation and/or a dry basin. Vent hole should be checked
periodically for clogging. The 50 or 90 Series pumps have a vent located in the pump housing
opposite the float, adjacent to a housing lug, but an additional vent hole is recommended. The
vent hole on a High Head application may cause too much turbulence. You may not want to drill
one.If youchoose nottodrillaventhole,be surethe pumpcaseandimpelleriscoveredwith liquid
before connecting the pipe to the check valve and no inlet carries air to the pump intake. NOTE:
THEHOLEMUSTALSOBEBELOWTHEBASINCOVERANDCLEANEDPERIODICALLY.Water
stream will be visible from this hole during pump run periods.
4. Pumpshouldbecheckedfrequentlyfordebrisand/orbuildupwhichmayinterferewiththefloat“on”
or “off” position. Repair and service should be performed by Zoeller Pump Company Authorized
Service Station only.
5. Dewatering and effluent sump pumps are not designed for use in pits handling raw sewage.
6. Maximumoperatingtemperatureforstandardmodelpumpsmustnotexceed130°F(54°C). Model
49max.temperaturemustnotexceed104ºF(40ºC).The70and211Seriesmax.temperaturemust
not exceed 110ºF (43ºC).
7. Pumpmodels 188/4188, 189/4189,and295/4295 nonautomatic pumpmustrun totallysubmerged
and CSAcertified pumps must be operated submerged with “off - on” level controls.
8. Pumpmodels266,267,268,137 and 139 must be operated in an upright position. Do not attempt
to start pump when tilted or laying on its side.
9. Do not operate a pump in an application where the Total Dynamic Head is less than the minimum
Total Dynamic Head listed on the Pump Performance Curves.
10. Model 49 is for indoor use only.
REFER TO WARRANTY ON PAGE 2.
NOTE: Pumps with the “UL” mark and pumps with the “US” mark are tested to UL Standard UL778.
CSACertified pumps are certified to CSA Standard C22.2 No. 108.

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© Copyright 2009 Zoeller Co. All rights reserved.
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 connection with our products.
ContactManufacturerat,3649CaneRunRoad,Louisville,Kentucky 40211,Attention:
CustomerServiceDepartmenttoobtainanyneededrepairorreplacementofpart(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; ANDANY IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSEAND 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
limitationofincidentalorconsequentialdamages,sotheabovelimitationorexclusion
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.
Limited Warranty
Manufacturerwarrants,tothe purchaserand subsequentowner duringthe warranty
period,everynewproducttobefreefromdefectsinmaterialandworkmanshipunder
normaluseandservice,whenproperlyusedandmaintained,foraperiodofoneyear
fromdateofpurchasebytheenduser,or18monthsfromdateoforiginalmanufacture
of the product, whichever comes first. Parts that fail within the warranty period, one
year from date of purchase by the end user, or 18 months from the date of original
manufactureoftheproduct,whichever comes first, that inspections determine to be
defectiveinmaterialorworkmanship,willberepaired,replacedorremanufacturedat
Manufacturer'soption,providedhowever,thatbysodoingwewillnotbeobligatedto
replaceanentireassembly,theentiremechanismorthecompleteunit. Noallowance
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
productthathasbeendisassembledwithoutpriorapprovalofManufacturer,subjected
to misuse, misapplication, neglect, alteration, accident or act of God; that has not
beeninstalled,operatedormaintainedinaccordancewithManufacturer'sinstallation
instructions;thathasbeenexposedtooutsidesubstancesincludingbutnotlimitedto
thefollowing: sand,gravel,cement,mud,tar,hydrocarbons,hydrocarbonderivatives
(oil,gasoline,solvents,etc.),orotherabrasiveorcorrosivesubstances,washtowels
orfemininesanitary products, etc. in all pumpingapplications. Thewarrantyset out
ELECTRICALPRECAUTIONS- Beforeservicingapump,alwaysshutoffthemainpowerbreakerandthenunplugthepump-making
sure you are wearing insulated protective sole shoes and not standing in water. Under flooded conditions, contact your local electric company or a
qualified licensed electrician for disconnecting electrical service prior to pump removal.
Submersiblepumpscontainoilswhichbecomespressurizedandhotunderoperatingconditions-allow2½hoursafterdisconnectingbefore
attempting service.
If the above checklist does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump. Service must
be performed by ZoellerAuthorized Service Stations. Go to www.zoeller.com/zcopump/TechSupport/authsslisting.htm to find the Authorized Service
Station in your area.
SERVICE CHECKLIST
EASY DO’S & DON'T’S FOR INSTALLING A SUMP PUMP
1. DO read thoroughly all installation material provided with the pump.
2. DO inspect pump for any visible damage caused by shipping. Contact
dealer if pump appears to be damaged.
3. DOcleanalldebrisfromthesump. Besurethatthepumpwillhaveahard,
flat surface beneath it. DO NOT install on sand, gravel or dirt.
4. DObe surethatthesumpislargeenoughtoallowproperclearanceforthe
level control switch(es) to operate properly.
5. DOAlways Disconnect Pump From Power Source Before Handling.
DO always connect to a separately protected and properly grounded
circuit.
DONOTevercut,splice,ordamagepowercord(Onlyspliceinawatertight
junction box).
DO NOT carry or lift pump by its power cord.
DO NOT use an extension cord with a sump pump.
6. DO install a check valve and a union in the discharge line.
DO NOT use a discharge pipe smaller than the pump discharge.
7. DONOT useasumppumpasatrenchorexcavationpump,orforpumping
sewage, gasoline, or other hazardous liquids.
8. DO test pump immediately after installation to be sure that the system is
working properly.
9. DO cover sump with an adequate sump cover.
10. DOreviewallapplicablelocalandnationalcodesandverifythattheinstallation
conforms to each of them.
11. DO consult manufacturer for clarifications or questions.
12. DO
consideratwopumpsystemwithanalarmwhereaninstallationmaybecome
overloaded or primary pump failure would result in property damages.
13. DO consider a D.C. Backup System where a sump or dewatering pump
is necessary for the prevention of property damages from flooding due
to A.C. power disruptions, mechanical or electrical problems or system
overloading.
14. DO inspect and test system for proper operations at least every three
months.
CONDITION COMMON CAUSES
A. Pump will not start or run. Checkfuse,lowvoltage,overloadopen,openorincorrectwiring,openswitch,impellerorsealboundmechanically,
defective capacitor or relay when used, motor or wiring shorted. Float assembly held down. Switch defective,
damaged, or out of adjustment.
B. Motoroverheatsandtripsoverload
or blows fuse. Incorrectvoltage,negativehead (discharge open lowerthannormal)impellerorsealboundmechanically, defec-
tive capacitor or relay, motor shorted.
C. Pump starts and stops too often. Float tight on rod, check valve stuck or none installed in long distance line, overload open, level switch(s) defec-
tive, sump pit too small.
D. Pump will not shut off. Debris under float assembly, float or float rod bound by pit sides or other, switch defective, damaged or out of
adjustment.
E. Pumpoperatesbutdeliverslittleor
no water. Check strainer housing, discharge pipe, or if check valve is used vent hole must be clear. Discharge head
exceeds pump capacity. Low or incorrect voltage. Incorrect motor rotation. Capacitor defective. Incoming water
containing air or causing air to enter pumping chamber.
F. Drop in head and/or capacity after
a period of use. Increased pipe friction, clogged line or check valve. Abrasive material and adverse chemicals could possibly
deteriorate impeller and pump housing. Check line. Remove base and inspect.
In those instances where damages are incurred as a result of an alleged pump failure,
the Homeowner must retain possession of the pump for investigation purposes.

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© Copyright 2009 Zoeller Co. All rights reserved.
Onsomeinstallationsitmaybedesirable
to install an independent hanger for the
level control switches to avoid possible
hang ups on the pumps, piping, valves,
etc. Float hangers are available from
Zoeller Company on Catalog Sheet
FM0526 or can be fabricated from stan-
dard pipe and fittings.
SUGGESTED METHODS OF FLOAT INSTALLATION
TYPICAL FLOAT HANGER ON CONCRETE PITS
OR SEPTIC TANK RISERS
TYPICAL FLOAT HANGER ON STEEL COVER PITS
ACCESS COVER
STANDARD PIPE
FLANGE
PVC OR LIGHT WEIGHT
STAINLESS STEEL PIPE
PEAGRAVEL
TYPICAL FLOAT HANGER ON CONCRETE PITS
OR SEPTIC TANK RISERS
10-1457 FLOAT TREE
WITH 3 FLOATS SHOWN
SK1217 SK1218
RECOMMENDED INSTALLATION FOR ALL APPLICATIONS
All installations must comply with all applicable electrical and plumbing codes, including, but not limited to, National Electrical Code, local, regional, and/or state plumbing
codes, etc. Not intended for use in hazardous locations.
(1) Electrical wiring and protection must be in accordance with National
Electrical Code and any other applicable state and local electrical
requirements.
(2) Install proper Zoeller unicheck (combination union and check valve),
preferably just above the basin to allow easy removal of the pump for
cleaning or repair. On sewage, effluent or dewatering, if high head or
below cover installation is required use 30-0164 on 1½" pipe, 30-0152
on 2" pipe and 30-0160 on 3" pipe. See (4) below.
(3) All installations require a basin cover to prevent debris from falling into
the basin and to prevent accidental injury.
(4) When a Unicheck is installed, drill a 3/16" dia. hole in the discharge
pipe even with the top of the pump. NOTE: THE HOLE MUSTALSO
BE BELOW THE BASIN COVERAND CLEANED PERIODICALLY.
(High Head unit see #3 under “Caution” on front page). Water stream
will be visible from this hole during pump run periods.
(5) Securely tape or clamp power cord to discharge pipe, clear of the float
mechanism(s).
(6) Use full-size discharge pipe.
(7) Basin must be in accordance with applicable codes and
specifications.
(8) Pump must be level and float mechanism(s) clear of sides of basin
before starting pump.
(9) Basin must be clean and free of debris after installation.
(10) Gate Valve or Ball Valve to be supplied by installer and installed
according to any and all codes.
(11) Locate float switches as shown in sketches.The best place for the
“off” point is above the motor housing and positioned 180° from the
inlet. Never put “off” point below discharge on pump (Sewage &
Effluent only). NOTE: FORAUTOMATIC PUMPS, USE
DEWATERING INSTALLATION SKETCH.
(12) Gas tight seals required to contain gases and odors.
(13) Vent gases and odors to the atmosphere through vent pipe (Sewage
& Dewatering only).
(14) Install Zoeller Pump Stand (Model 10-2421) under pump to provide a
settling basin. (Effluent & Dewatering only.)
For Effluent Only:
(15) Wire pump to power through a Zoeller watertight junction box or
watertight splice. NOTE: Watertight enclosure is a must in damp
areas. See No. 8 on front page of FM0732.
(16) Refer to SSPMA Effluent Sizing Manual for determining “on” - “off”
switches.
(17) Septic tank risers must be used for easy pump and filter access.
NOTE: Double seal pumps offer extra protection from damage caused by
seal failure.
TYPICAL SEWAGE INSTALLATION
SK290
Always refer to
FM0551 and/or
SSPMArecom-
mended sewage
pump installation
and maintenance.
TYPICAL EFFLUENT INSTALLATION
SK291
See FM0531,
FM0732 & FM1420
for alarms, controls
& junction boxes
TYPICAL DEWATERING INSTALLATION
SK292
See FM0531, FM0732 & FM1420 for alarms,
controls & junction boxes

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© Copyright 2009 Zoeller Co. All rights reserved.
WD & WH MODEL INSTALLATION
WIRING DIAGRAM FOR MODELS
WD - 230V, 1 Ph, 60 Hz.
WH - 200/208V, 1 Ph, 60 Hz.
ModelsWD&WHarefullyautomatic.Afloatswitchisincludedand
factory wired in the pump circuit to provide automatic operation
oncethefloatswitchissecuredproperlytotheoutletpipe.Usethe
diagramabove to securethefloat switch properlyandobtain the
proper tether to customize the on-off cycle to each application.
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
Tether Length 5 10 15 20 22
Pumping Range 9 13.5 18 22 24
max.
Use only as a guide. Due to weight of
cable, pumping range above horizontal
is not equal to pumping range below
horizontal.Rangesarebasedontestingin
nonturbulentconditions.Rangemayvary
duetowatertemperatureandcordshape.
As tether length increases, so does the
variance of the pumping range.
min.
START
RUN
BLUE
MOTOR
(WHITE) RED
(BROWN)
O.L.
YELLOW
(BLACK)
SWITCH
FLOAT
BLACK
BLACK
WHITE
CAPACITOR
BLUE
(1) (2)
RED
RUN
WHITE
GREEN
L1 L2
(3)
011835 Note:Failuretokeepwithinpropertetherlimits
may prevent reliable switch operation.
Note: Cable must be mounted in horizontal
position.
22" MAX.
5" MIN.
20 AMP SWITCH (WD & WH MODELS)
SK305
THREE PHASE WIRING INSTRUCTIONS
FOR YOUR PROTECTION, ALWAYS
DISCONNECT PUMP FROM ITS POWER SOURCE
BEFORE HANDLING.
To automatically operate a nonautomatic three phase pump, a
controlpanelisrequired. Followtheinstructionsprovidedwiththe
panel to wire the system. For automatic three phase pumps see
automatic 3 phase wiring diagram located to the far right.
Before installing a pump, check the pump rotation to ensure that
wiring has been connected properly to power source, and that
the green lead of power cord (See wiring diagram), is connected
to a valid ground. Momentarily energize the pump, observing the
directionsofkick back duetostartingtorque.Rotationis correctif
kickbackisintheoppositedirectionofrotationarrowonthepump
casing.Ifrotationisnot correct, switching of any two powerleads
other than ground, should provide the proper rotation.
Allthree phase pumps requiremotorstartingdevices with motor
overloadprotection.SeeFM0486forduplexinstallations. Pumps
mustbeinstalledinaccordancewiththeNationalElectricalCode
andall applicable localcodesand ordinances. Pumps arenot to
be installed in locations classified as hazardous in accordance
with National Electrical Code,ANSI/NFPA70.
NONAUTOMATIC
3 PHASE AUTOMATIC
3 PHASE
MOTOR
(3)
BLUE RED
BLACK
GREEN
L1 L2
(1) (2)
YELLOW
L3
WHITE
RED
013071
SINGLE PHASE WIRING INSTRUCTIONS
FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM ITS POWER SOURCE BEFORE HANDLING. Single phase
pumpsaresuppliedwitha3-pronggroundedplugtohelpprotectyouagainstthepossibilityofelectricalshock.DONOTUNDERANYCIRCUMSTANCES
REMOVE THE GROUND PIN. The 3-prong plug must be inserted into a mating 3-prong grounded receptacle. If the installation does not have such
a receptacle, it must be changed to the proper type, wired and grounded in accordance with the National Electrical Code and all applicable local codes
and ordinances. “Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit directly to the pump.
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
Units supplied without a plug (single and three phase) and single phase nonautomatic units with a 20 amp plug must have a motor
control and liquid level control provided at time of installation. The control device should have suitable voltage, ampere, frequency, grounding and
horsepower rating for the pump to which it is connected.
IMPORTANT NOTICE: Some insurance policies, both commercial and residential, extend coverage for damages incurred by product failure. You will need to
havepossessionoftheproducttosupportyourclaiminmostcases.ZoellerPumpCo.willexchangetheunitorrefundtheoriginalpurchasepriceoncetheclaim
is settled with the insurer in the case where you need to retain possession of the product to support a damage claim you submit to your insurance company.
006848