Zoeller 71 Series User manual

1
© Copyright 2011 Zoeller Co. All rights reserved.
ZM1789_Ec
0611
Supersedes
New
NOTICE TO INSTALLER: Instructions must remain with installation.
Congratulations on the purchase of the Zoeller 71 Series submersible
grinder pump. Zoeller Grinder Pumps are designed for grinding and pumping
sanitary sewage from submersible lift stations. The pump is intended to grind
and pump reasonable quantities of disposable diapers, sanitary napkins,
paper towels, rubber materials, plastics, cigarette butts and other items
normally found in sanitary sewage applications. For over seventy years the
name Zoeller has represented the standard for submersible dewatering and
sewage pumps. The same high quality workmanship and easy maintenance
design has been incorporated into this line of heavy-duty submersible grinder
pumps. This Zoeller pump will provide years of trouble-free service when
installed according to the manufacturers’ recommendations.
OWNER’S MANUAL
71 SERIES SUBMERSIBLE GRINDER UNITS
This manual incorporates the installation, operation, maintenance, and
service instructions into one document to aid in the ownership of a Zoeller
submersible wastewater product. Please read and review this manual before
installing the product. Follow the steps and procedures listed on ZM1074_Eb
for a proper start-up. Many items contained within, when followed correctly,
will not only ensure a long and problem-free life for the pump, but also
save time and money during installation. Reference ZM1788_Ec for repair
manualon71SeriesGrinderPumps.Shouldfurtherassistancebenecessary
please call our Technical Service Department at [phone] or email:
[e-mail].
Table of Contents
Safety Instructions ....................................................................... 1
Limited Warranty .......................................................................... 2
Preinstallation Information.......................................................... 3
Electrical Data............................................................................... 3
Typical Sewage Installation ........................................................ 4
Pump Wiring Instructions.........................................................5-6
Operation....................................................................................... 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 MANUAL AND ON THE PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH
THE PUMP.
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.
Warns of hazards that WILL cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
INDICATESSPECIALINSTRUCTIONS WHICHARE
VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
CAUTION
Owner’s Information
REFER TO WARRANTY ON PAGE 2.
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______
IF ANY INFORMATION CHANGES ON THIS SHEET, SEE ALSO ZM1789.
IF ANY INFORMATION CHANGES ON THIS SHEET, SEE ALSO ZM1789.
50/60 Hz
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:
zoellerengineered.com
Product information presented
here reects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.

2
© Copyright 2011 Zoeller Co. All rights reserved.
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
months from date of original manufacture of the product, whichever comes rst.
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 manufacture of the product,
whichever comes rst, 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,
subjected to misuse, misapplication, neglect, alteration, accident or act of
God; that has not been installed, operated or maintained in accordance with
Manufacturer's installation instructions; that has been exposed to outside sub-
stances including but not limited to the following: sand, gravel, cement, mud,
tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other
abrasiveorcorrosivesubstances,washtowelsorfeminine sanitary products, etc.
in all applications other than in raw sewage 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 connection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
USA, Attention: Customer Service Department to obtain any needed repair
or replacement of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLYDISCLAIMSLIABILITYFOR SPECIAL,CON-
SEQUENTIAL 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.
Limitations
Recommended Limits of Application
These recommended application limits are for pump stations pumping to a gravity main. Low-pressure pipe systems should be designed with a pump located at
each house. For applications where a lift station would handle more than 60 homes, a solids handling type pump should be considered.
*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service during unusual conditions.
Each Zoeller 71 Series Pump installation is required to have a completed Zoeller Engineered Products Start-up Report (ZM1074_Eb). The report is to be
completed by an approved Start-up Technician in the presence of the installing contractor. A copy of this report will be on le at the Zoeller Engineered Products
ofces in Louisville, KY USA. Failure to comply with the requirement will void the following warranty agreement.
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 USA, Attention:
Customer Service 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
IMPLIEDWARRANTYOFFITNESSFORAPARTICULAR PURPOSEANDOF 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.
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 maintained, for a period of one year from date of purchase by the end user, or 18
months from date of original manufacture of the product, whichever comes rst. 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 manufacture of the product, whichever comes rst, 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, subjected to misuse, misapplication,
neglect, alteration, accident or act of God; 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 applications other than in raw sewage pumping applications.
The warranty set out in the paragraph above is in lieu of all other warranties expressed or implied;
Simplex Station Duplex Station
Model Homes m3/day Homes m3/day
7110 High Head 2* 3 20 30
7111 High Head 2* 3 25 38
7112 High Head 2* 3 30 45
7110 Reversing 2* 3 30 45
7111 Reversing 2* 3 38 57
7112 Reversing 2* 3 45 68
7110 High Flow 2* 3 40 61
7111 High Flow 2* 3 50 76
7112 High Flow 2* 3 60 91

3
© Copyright 2011 Zoeller Co. All rights reserved.
PREINSTALLATION INFORMATION
1. Check to be sure your power source is capable of handling the voltage requirements
of the motor, as indicated on the pump nameplate.
2. The oat switches must be connected to an intrinsically safe circuit in the control
panel. The installation of pumps using auxiliary variable level oat switches is the
responsibility of the installing party and care should be taken that the tethered oat
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 ttings be used
and the pit be 36" (0.9 m) 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" (5 mm)) must be drilled in the discharge pipe below the
check valve and pit cover to purge the unit of trapped air. Water stream will be visible
from this hole during pump run periods. This vent hole should be checked periodically
for clogging and cleaned as necessary. Trapped air is caused by agitation and/or a
dry basin.
4. Water hammer creates momentary high pressure surges. These surges can cause
severe damage to check valves and the piping system. Consideration for water
hammer must be included in the piping system design. Reference ASPE 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 counterclockwise
looking into impeller inlet. See page 5 for instructions for checking 3 phase rotation.
6. Grinder installations should be checked frequently for debris and/or buildup which
may interfere with the “ON”/”OFF” cycles or the positions of variable level oat control
switches. For repair and service, other than cutter assembly maintenance, contact
factory.
7. 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 local guidelines on
conned space requirements.
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.
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 possibility of electrical
shock.
3. Make certain that the control box is within the 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 sufcient 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. Make sure the pump electrical supply circuit is equipped with fuses and disconnect
or circuit breakers of proper capacity. A separate branch circuit is recommended, sized
according to the governing electrical code for the current shown on the pump nameplate.
5. Risk of electric shock - These pumps have not been investigated for use in swimming
pool areas.
6. Do not attempt to turn cutter rotor located on bottom of the unit with
ngers. Use the appropriately sized wrench when checking or removing the
cutter.
7. The appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have
been given supervision or instruction to concerning use of the appliance by a person
responsible for their safety.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
DECLARATION OF CONFORMITY
We Zoeller declare under our sole responsibility that the models 7110/7111/7112 to which this declaration relates, are in conformity with the Council
Directives on the approximation of the laws of the EC Member States relating to:
-- Machinery Directive (2006/42/EC)
Standards used: EN 809: 1998
-- Electromagnetic Compatibility (2004/108/EC)
Standards used: EN 61000-3-2, EN 61000-3-3 and EN 55014-1
-- Electrical equipment designed for use within certain voltage limits (2006/95/EC)
Standards used: EN60335-1:2002 and EN60335-2-41:2003
Electrical Data
Amps Winding
Service Locked KVA Resistance
Model Factor RPM Voltage Phase Hertz Full Load In Air Shut Off Rotor Code Line-to-Line
AK7110 1.2 2800 380 3 50 6.2 3.0 4.0 41 K 4.0
E7110 1.2 3450 230 1 60 23.6 7.2 13.1 132 M 0.5/3.5
J7110 1.2 3450 200 3 60 17.3 5.7 10.7 66 J 0.8
F7110 1.2 3450 230 3 60 15.1 5.0 9.2 57 J 1.0
K7110 1.2 3450 380 3 60 9.3 2.6 6.2 70 K 2.5
G7110 1.2 3450 460 3 60 7.5 2.5 4.6 28.5 J 4.0
BA7110 1.2 3450 575 3 60 5.7 2.3 3.1 25.2 K 6.6
AK7111 1.2 2800 380 3 50 7.7 4 4.6 62 L 2.4
E7111 1.2 3450 230 1 60 28.0 7.2 17.1 132 G 0.5/3.5
J7111 1.2 3450 200 3 60 20.7 7.6 14.4 94 E 0.44
F7111 1.2 3450 230 3 60 18.0 6.2 13.0 82 E 0.62
K7111 1.2 3450 380 3 60 11.5 3.8 7.6 117 N 1.4
G7111 1.2 3450 460 3 60 9.0 3.1 6.5 41 E 2.4
BA7111 1.2 3450 575 3 60 7.2 2.9 5.2 36 J 3.4
AK7112 1.2 2800 380 3 50 9.5 4 5.5 62 J 2.4
J7112 1.2 3450 200 3 60 25.3 7.6 18.4 94 D 0.44
F7112 1.2 3450 230 3 60 22.0 6.2 16.0 82 D 0.62
K7112 1.2 3450 380 3 60 14.5 3.8 9.7 117 L 1.4
G7112 1.2 3450 460 3 60 11.0 3.1 8.0 41 D 2.4
BA7112 1.2 3450 575 3 60 9.0 2.9 6.5 36 E 3.4

4
© Copyright 2011 Zoeller Co. All rights reserved.
3
1
44
77
10
810
2
11
14
6
13
9
6
12
5
15
Typical Grinder Pumping System Installation
(8) Secure power cord to avoid entanglement with variable level
oat switch mechanism.
(9) Do not reduce pump discharge pipe below 2” (51mm) IPS size.
(10) Basin must be in accordance with all applicable codes
and specications. Basin must be sized to allow a minimum
3 minute off-time between starts.
(11) Pump must be level and the tethered variable level oat switches
must be free and not hang up on pump or pit peculiarities.
(12) If a rail system is used, discharge elbow must be rmly an-
chored to the bottom of basin. In berglass basin, the bottom
will need to be reinforced if the discharge elbow is used.
(13) If a rail system is used, the guide rails are 2” (51mm) schedule
40 pipe for all units. Brass, stainless steel or 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 and
before operation.
ZEPA0521
All installations must comply with all applicable
electrical and plumbing codes, including, but
not limited to, governing electrical code, local,
regional, and/or state plumbing codes, etc.
(1) Electrical wiring and protection must be in accordance with the
governing electrical code, and any other applicable state and
local electrical requirements.
(2) Install proper full ow check and shut-off valve.
(3) Install proper controls. (Outdoor panels require NEMA 3R or 4X
enclosure)
(4) All installations require a basin cover to prevent debris from
falling into the basin and to prevent accidental injury.
(5) Cords must be properly sealed to prevent moisture and gases
from entering the control panel.
(6) When check valve is installed, drill a 3/16" (5mm) 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
and cleaned periodically. Also a vent hole is drilled in the pump
housing. Be sure that this hole is cleared during any servicing.
(7) Vent gases and odors to the atmosphere through vent pipe per
Local and State codes.

5
© Copyright 2011 Zoeller Co. All rights reserved.
Installation and checking of electrical circuits and hardware should be performed by a qualied licensed electrician.
“Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit directly to the pump.
CAUTION
Power cords, sensor cords, and oat 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. The rotation is
correct if the kick back is in the opposite direction of the rotation arrow. If the rotation is not correct, disconnect power and switch any two power leads. Turn
power back on and retest for proper rotation.
THERMAL SENSOR PROTECTION
Two thermal sensors and leads are wired in series with each other and located adjacent to the motor windings. When the temperature exceeds the maximum
recommended limit, the pump will deactivate when the lead wires are connected to the magnetic starter circuit of a control panel with the thermal cutout feature.
Continual deactivation of this circuit requires attention from maintenance personnel.
MOISTURE SENSORS
(1) Pumps with moisture sensors have a separate sensor cord in addition to the power cord.
(2) Sensor cord conductors are connected to sensors probes in the lower seal cavity. The conductor wires are terminated in the control panel for activating
an indicator light when moisture is present in the lower seal cavity.
(3) When the moisture indicator light is activated, the lower seal has allowed leakage of water into the lower oil-lled seal cavity. The pump should be serviced
within 30 days to avoid damage to the motor and bearings.
(4) 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 contamination,
both seals should be replaced during maintenance. Always replace with new factory recommended oil and service parts. All warranty repairs must be
made by Zoeller Authorized Service Stations.
(5) On existing applications where the control panel only has one moisture sensor hookup per pump, one moisture sensor lead from the pump should be
hooked to the moisture sensor lead in the panel, the other moisture sensor lead from the pump should be hooked to ground to complete the circuit.
(6) Moisture sensor circuit can be checked for continuity (complete circuit) with a (Volt-OHM-Meter). Set the VOM to read resistance and connect the VOM
leads to the sensor cord black and white wires. The VOM should read approximately 330k Ohms. Resistance readings signicantly lower indicate a seal
leak with water in the seal chamber. If VOM reading is open then a problem exists with moisture sensor circuit.
(7) Check resistance between the green ground conductor of the pump power cord and the sensor cord black and white wires. This resistance reading should
indicate an open circuit. If VOM reading returns a reading other than open, then a problem exists with the sensor circuit wiring or cordage. If resistance
readings show a problem with either test, then pump should be repaired by a Zoeller Authorized Service Station.
CONTROL PANELS
These pumps are nonautomatic. They require a control panel. A motor starter circuit, control circuit, and alarm circuit within the panel are standard features.
Outdoor enclosures and alternating relays are often required. Variable level oat switches are the most common level sensing device. The following should be noted.
(1) Single phase units require externally mounted capacitors and starting relays. Your control panel should have provisions for mounting these starting components.
(2) The seal failure sensor and thermal sensor protection require that interfacing terminals and functions be incorporated into the panel.
(3) All pumps require overload protection in panel. Use with approved motor control that matches motor input in full load amperes with overload element(s)
selected or adjusted in accordance with control instructions.
Pump Wiring Instructions
“71 SERIES GRINDER” FOUR CONDUCTOR POWER CORD SIZE
60Hz 50Hz
MODEL 230/1PH 200/3PH 230/3PH 380/3PH 460/3PH 575/3PH 380/3PH-STD 380/3PH-CE
7110 8 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG H07RN-F4G4
7111 8 AWG 8 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG H07RN-F4G4
7112 N/A 8 AWG 8 AWG 12 AWG 12 AWG 12 AWG 12 AWG H07RN-F4G4
APPROXIMATE CORD DIAMETER
12 / 4 AWG apprx. = 0.64" 8 / 4 AWG apprx. = 0.93" H07RN apprx. = 0.58"
STANDARD SENSOR CORD 18/5 AWG. APPROXIMATELY 11mm (0.43") DIAMETER
CE VERSION SENSOR CORD H07RN-F5G1 APPROXIMATELY 11mm (0.43") DIAMETER
POWER AND SENSOR CORD, LEAD IDENTIFICATION, CE MODEL
ZEPA0640
SEAL FAILURE
BLACK & WHITE
LEAD
GROUND
POWER
CORD
LEAD
SENSOR CORD
GREEN GROUND
BLACK
GREEN
RED
WHITE
SENSOR
LEADS
TEMPERATURE
RED & ORANGE
SENSOR
LEADS
POWER AND SENSOR CORD, LEAD IDENTIFICATION
ZEPA0039E

6
© Copyright 2011 Zoeller Co. All rights reserved.
NOTE 1: Sensor cable includes 5 leads; 2 leads for thermal sensor , 2 leads for moisture sensor, and a green ground lead. Sensor wire colors are as shown.
Refer to Sensor and Control Panel sections on page 5.
T3
T2
T1
L3
L2
L1
POWER CABLE
3 PHASE MOTOR
3Ø VAC
SENSOR CABLE
BLUE
GRAY
BROWN
BLACK
GREEN/YELLOW
SEAL FAILURE MOISTURE SENSOR
LEADS MUST BE CONNECTED TO
INDUCTION CIRCUIT IN THE CONTROL
PANEL
RECOMMENDED THERMAL SENSOR
CONNECTED IN SERIES WITH
STARTER COIL
SEAL FAILURE PROBES
330K OHMS RESISTANCE
THERMAL
SENSOR
(N/C)
TYPICAL 3-PHASE WIRING DIAGRAM, CE MODEL
ZEPA0641
Three Phase Installation
(N/C)
SENSOR
330K OHMS RESISTANCE
SEAL FAILURE PROBES
PANEL.
INDUCTION CIRCUIT INTHE CONTROL
LEADS MUST BE CONNECTEDTO
SEAL FAILURE MOISTURE SENSOR
THERMAL
THETHERMAL SENSOR LEADS
ARETO BE CONNECTED IN
SERIES WITH STARTER COIL
NOTE 1
SENSOR CABLE WITHTHERMAL AND
MOISTURE PROTECTION IS STANDARD
ON ALL EXPLOSION PROOF MOTORS
(SEE NOTE 1)
SENSOR CABLE
P2
WHITE
P1
BLACK
W1
RED
W2
ORANGE
TYPICAL 3-PHASE WIRING DIAGRAM, STANDARD UNIT
ZEPA0038
21
5
WHITE
PUMP
START
MAIN
BLACK
L2
WHITE
BLACK
RUN CAPACITOR
RED
START CAPACITOR
L1
T2T1
3
2
1
GREEN
230 VAC 1ø
(SEE CHART) (SEE CHART)
7110/7111
MODELS
270-324UF 250V
START CAP. RUN CAP.
50UF 370V
R
RELAY
START
WIRING DIAGRAM COMPONENT LAYOUT
ZEPA0538 ZEPA0537C
Single Phase Installation 60 Hz (7110 & 7111 Only)
5
21
WHITE
RED
PUMP
MAIN
START
L1 L2
BLACK WHITE
230 VAC 1Ø
FROM CONTACTOR
START
BLACK
START
RELAY
CAPACITOR
RUN CAPACITOR
1 2 3
GREEN

7
© Copyright 2011 Zoeller Co. All rights reserved.
Operation
GENERAL
Zoeller pumps are lubricated and tested at the factory prior to shipment and require
minimum pre-start-up maintenance.
Maximum liquid temperature of a continuous operating pump liquid for this model
pump must not exceed 104°F (40°C). For longest service life, all pumps should be
totally submerged on long pumping cycles.
These units are not designed to handle liquids other than sewage. If pump is used
in water contaminated with heavy, viscous, or abrasive materials, the warranty will
be voided.
NAMEPLATE DATA
The nameplate, located on the top of pump, indicates specic information about the
constructionofthepump. Themodelnumber,datecode,and serial number information
shouldberecordedon thefrontpagein the“Owner’sInformation”sectionof this manual.
SHORT TERM STORAGE
If pump is to be stored, the following is advised:
• Store pump inside whenever possible or cover with some type of protective covering.
• Tape or seal in plastic bag the terminal ends of wire leads.
• Spray coat unpainted surfaces with rust inhibiting oil.
• Theimpellershouldberotated every six months inordertokeepthe seals lubricated
and not develop a permanent set.
If panel is to be stored, the following is advised:
• Store the panel inside whenever possible and leave in the shipping box.
• All openings shall be sealed.
• Store in an upright position.
• Do not stack anything on top of panel.
START-UP PROCEDURE
Before placing the equipment into operation the following should be checked:
• Correct pump rotation (3 Phase units only).
• Clean pit.
• Panel dry, securely installed and properly sealed.
• Floats positioned properly.
• Discharge valves open.
• 3/16” (5mm) vent hole drilled in pipe between check valve and pump.
Once the above has been veried proceed with the following checks:
• Pump power cables properly connected to panel.
• Float cables properly connected to panel.
• Conduit connections to panel are properly sealed.
• Thermal overload adjustments made in the panel.
• After installing the pump into the containment area, with adequate submergence,
open the discharge valve fully. Start the unit using manual controls. If ow is ap-
preciably less than rated performance, pump may be air locked. To expel trapped
air, jog the unit several times, using the manual controls.
• Have a qualied electrician take voltage and current measurements on the black
wire of single phase or all three power wires of three phase with the pump running.
Recordthesereadingsinthespace provided in the “Owner’sInformation”section
on page 1 of this manual for future reference.
After the preoperational functional test has been completed, system is ready for
operation. Zoeller requires completing a Start-up Report (ZM1074_Eb) whenever a
system is started for the rst time or after a system has had a signicant change take
place (i.e. pump replacement, overhaul, etc..). A copy of the Start-up Report should
remain with the system for future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required other than assuring correct rotation.
Panels: The thermal overloads in the panel must be set to the F.L.A. rating on the
pump nameplate (or refer to pump data sheet).
Floats: Refer to the system drawing for desired location of each oat function.
Valves: Discharge valves should be placed in the fully open position. Systems
should not be operated for extended periods of time with the discharge
valves partially closed due to damaging the valve.
SHUTDOWN PROCEDURES
If a system is shutdown for more than six months, the following is recommended:
Pumps: If pit is to remain dry, then the pump can remain in the pit. With the pump
in the pit, it should be operated for ve minutes once every three months.
If the pit is to remain wet, the pump should be removed and stored as
noted above.
Panels: The panel should have all openings sealed to prevent moisture and dust from
enteringtheenclosure.Priortorestartingsystem,thepanel shouldbe inspected
for presence of moisture and any loose connections.
Valves: Consultthevalve/actuator supplierforinformationconcerning thesesystems
components.
Maintenance
• Check for proper and unobstructed oat operation.
• Listen for proper check valve operation.
• Duplex Units - Check for even operating times. Uneven times indicate a
defective unit, oat switch or control.
• Inspect the panel for any presence of moisture in enclosure, loose connections, and
general component condition. Check out location and condition of oat switches.
Every year:
• In addition to the monthly checks, the basin should be inspected and cleaned. Any
defective components should be replaced. Inspect and remove any sand, debris,
or mud present in the pump basin assembly.
Every two years:
• Check insulating oil in motor and seal chambers. Inspect oil for contaminations
as follows:
• Clear oil, no burnt odor - Oil, motor and seals are in satisfactory condition.
• Dark oil, burnt odor - Pump motor has overheated. Check the motor winding
resistance to ground. Ohm readings of 1 megohm or higher is required. If lower
readings are present, return the unit to an Zoeller Authorized Service Station for
service.
• Milky, emulsied oil - Seals have failed. Unit must be returned to an authorized
service facility for service.
• Dispose of the motor insulating oil properly if replacement is required.
• Inspect power cables for damage or wear. Replace immediately if damage or wear
is detected.
• Inspect impeller for damage or wear. Replace as required by a Zoeller Authorized
Service Station.
DOUBLE SEAL PUMPS
•
Double seal pumps offer extra protection from damage caused by seal failure.
• Oil in a motor housing and lower seal cavity must be checked when pump is
serviced. If oil from the motor housing contains water or other contamination,
both seals should be replaced during maintenance. Always replace with new
factory recommended oil and service parts. All repairs must be made by Zoeller
Authorized Service Stations.
Repairandserviceshould be performed byZoellerPumpCompany
Authorized Service Station only.
SAFETY PROCEDURES
For your protection, always disconnect pump and panel from its
power source before handling.
Never enter the basin until it has been properly vented and tested.
Any person entering a basin should be wearing a harness with safety rope extending
to the surface so that they can be pulled out in case of asphyxiation. Sewage water
gives off methane and hydrogen sulde gases, both of which can be highly poisonous.
Installation and checking of electrical circuits and hardware should be performed by
a qualied electrician.
Pump is never to be lifted by power cord.
Unit must be ushed and disinfected, inside and out, prior to servicing.
GENERAL SYSTEM INSPECTION
Before the system is placed into operation, a system Start-up Report should be
conducted by a qualied technician.
Wiring and grounding must be in accordance with the governing
electrical code and all applicable local codes and ordinances.
LUBRICATION PROCEDURES
No lubrication is required.
If pumps are to be stored for more than six months, refer to short term storage
procedure in the Operation section.
PREVENTIVE MAINTENANCE
Preventivemaintenanceisrecommended to ensurealongservice life fromtheproduct.
Provided is a suggested maintenance schedule.
Every month:

8
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ELECTRICAL PRECAUTIONS Before servicing a pump, always shut off the main power breaker to the panel and then disconnect the pump - making
sure you are wearing insulated protective sole shoes and are not standing in water. Under ooded conditions, contact your local electric company or a qualied licensed
electrician for disconnecting electrical service prior to pump removal.
Submersible pumps contain oils which become pressurized and hot under operating conditions - allow 2½ hours after dis-
connecting before attempting service.
CONDITION
A. Pump will not start or run.
COMMON CAUSES
B. Motor overheats and trips overload or blows fuse. - Incorrect Voltage
- Unbalanced power source
- Incorrect motor rotation
- Negative or low head
- Excessive water temperature
- Impeller, cutter, or seal mechanically bound
- Defective capacitor or relay
- Motor shorted
- Lost a leg in a Three Phase unit
C. Pumps starts and stops too often. - Check valve stuck open
- Level controls out of adjustment
- Temperature sensor tripping
- Thermal overload switch out of
adjustment or defective
- Pit too small
D. Pump will not shut off. - Debris clogging cutter mechanism.
- Debris under oat switch
- Float travel obstructed
- Defective or damaged oat switch
- Magnetic starter contacts shorted
- Air lock - check vent hole
E. Pump operates but delivers little or no water. - Check for plugged cutter, pump housing,
pipe or sticking check valve
- Vent hole clogged or not drilled
- Discharge head exceeds pumps capacity
- Low or incorrect voltage
- Incorrect motor rotation
- Defective capacitor
F. Drop in head and/or capacity after a period or use. - Increase Pipe Friction
- Clogged line or check valve
- Abrasive material & chemical,
deteriorated impeller and pump housing
If the above check list does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump.
Service Checklist & Trouble Shooting
Steps Check Voltage At If No Voltage If Voltage
No. 1 Line terminals in pump's Check Disconnect switch, line Proceed to No. 2
control panel fuse, and/or circuit breakers
L1- L2- L3(3 Phase) in power supply circuit.
No. 2 Pump motor terminals in Check for control circuit Check starting relay
pump’s control panel voltage. Check out magnetic and capacitor (1
T1- T2- T3starter contacts, thermal phase units). Check
overloads, and oat switches pump for ground,
and binding impeller