Zoeller QWIK JON ULTIMA 203 User manual

QWIK JON®ULTIMA 203 SYSTEMS
INSTALLATION INSTRUCTIONS
PREINSTALLATION CHECKLIST
NOTICE TO INSTALLER: Instructions must remain with installation. SECTION: 6.10.064
FM2408
1212
Supersedes
0310
P/N 018509
© Copyright 2012 Zoeller Co. All rights reserved.
1. Inspect all materials. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using. Do Not remove the test
plugs from the pump.
 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.
MODEL NO. ____________
DATE CODE: ___________
DATE INSTALLED: ______
SEE BELOW FOR LIST OF NOTES
NOTES
REFER TO WARRANTY ON PAGE 2.
SEE BELOW FOR LIST OF WARNINGS
SEE BELOW FOR LIST OF CAUTIONS
Patent No. 7,203,976
Other Patents Pending
Product information presented
here reects 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
®
Your Peace of Mind is Our Top Priority
®
1. Make sure there is a properly grounded receptacle available. All pumps
are furnished with provisions for proper grounding to protect you against the
possibility of electrical shock.
(SEE WARNING BELOW)
2. Make certain that the receptacle 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.
3. 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 local electrical code for the current shown
on the pump nameplate.
4. Testing for ground. As a safety measure, each electrical outlet should be
checked for ground using a circuit analyzer which will indicate if the power,
neutral and ground wires are correctly connected to your outlet. If they are
not,callaqualiedlicensedelectrician.
5. For Added Safety.Useofaresidualcurrentdevicewithanoperatingcurrent
not higher than 30 mA is recommended.
6. FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM
ITS POWER SOURCE BEFORE HANDLING. DO NOT UNDER ANY
CIRCUMSTANCES 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 local electrical code and all applicable
local codes and ordinances.
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qualiedlicensedelectrician.
9. Pumpinstallationandservicingshouldbeperformedbyaqualiedperson.
10. Riskofelectricshock-Thesepumpshavenotbeeninvestigatedforusein
swimming pool and marine areas.
11. If the supply cable is damaged, it must be replaced by the manufacturer or
itstechnicalserviceorsimilarlyqualiedpersonsinordertoavoidahazard.
12. 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 givensupervisionorinstruction concerning
use of the appliance by a person responsible for their safety.
13. Pump is not intended for potable water due to possible contamination by oil
contained in the pump.
 1. TheQwikJon® Ultima is ttedwithaspecially-designedgrinderpump
and is capable of pumping fecal matter, toilet paper and sanitary articles
which may be accidentally dropped into the toilet. It is not recommended
toushsuchforeignobjectsastheymightclogthesanitarysewer.
2. 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.
 3. Allplumbing(dischargeandventlines)mustbeinstalledtomeetlocal
codes. Unit must be vented. Do not use an automatic plumbing
vent device.
 4. Maximumoperatingtemperaturemustnotexceed130°F.
5. Do not use cleaning products containing bleach in the toilet tank, toilet or
attachedxturesastheywilldegradethepumpseals.
 1. RepairandserviceshouldbeperformedbyanAuthorizedServiceStation
only(consultfactory).
 2. Recommendedforinstallationsupto20'totaldynamichead.Consultfactory
ifinstallationisabove15'verticalheightin1"pipe.Mini-GrinderPumpis
designedforuseinQwikJon®Ultimaunitsonly.Itisnotdesignedforuse
in any other application.
 3. Pumpswiththe“UL”markand/orthe“US”markaretested to ULStandard
UL778.CSACertiedpumpsarecertied toCSA Standard C22.2No.
108.QwikJon®Ultimaunitsonly.Itisnotdesignedforuseinanyother
application.
 4. Allxturesconnectingtothesystemmustbeonthesameoorlevel.

2
© Copyright 2012 Zoeller Co. All rights reserved.
LIMITED WARRANTY
HELPFUL HINTS FOR EASY INSTALLATION
1. Readallinstructionsbeforebeginninginstallation.
 2. Besuretheoorislevelwithin1/8".
 3. Installventpipesealswithangesideofsealonoutsideoflid.
 4.Usesoapywatertolubricateallsealstoaidinstallation.
 5. Installrubbercoupling/unioninventlinetoaiddisassembly.
 6. Donotover-torquetoiletmountingscrews.
7. Do not use an automatic plumbing vent device.
8. Obtain model number and date code, and record information in the
spaceprovidedonthefrontofthismanual.Refertothisinformation
when calling the factory.
DO’S AND DON'T’S FOR INSTALLING UNIT
1. DO read all installation material with the unit.
2. DO inspect unit for any visible damage caused by shipping. Contact
dealer if unit appears to be damaged.
3. DO clean all visible debris from the unit.
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.
5. DO install a ball or gate valve and a union in the discharge line
downstream of the check valve.
6. DO test pump immediately after installation to be sure that the system
is working properly.
7. DO review all applicable local codes and verify that the installation
conforms to each of them.
 8. WeDONOTrecommendthisproductbeconnectedtoutilitiesotherthan
those found in a normal bathroom application. Washing machines and
dishwashersareexamplesofequipmentthatweDONOTrecommend.
9. DO inspect and test system for proper operations at least every 3 months.
DO’S AND DON'T’S, CONTINUED
TYPICAL PIPING CONFIGURATIONS
SK2932
* Ceiling heights shown for reference only.
NOTE: All installations must
comply with all applicable
local codes.
8’ CEILING *
7’ CEILING *
8"
MIN
2” x 8”
FLOOR JOISTS
SUBFLOOR 3/4"
THICK MINIMUM
CHECK VALVE
P/N 30-0181
Installation may not
be exactly as shown.
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 uncontrollable act of nature; 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, or any other abusive entity, 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
otherperson to assume forusanyother liability in connectionwithourproducts.
ContactManufacturerat,3649CaneRunRoad,Louisville,Kentucky40211,
Attention: Customer Support 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 IMPLIED WARRANTY
OFFITNESSFORAPARTICULAR PURPOSEAND OFMERCHANTABILITY
SHALLBE LIMITED TO THE DURATIONOFTHEEXPRESSEDWARRANTY.
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.

3
© Copyright 2012 Zoeller Co. All rights reserved.
1
7
8
3
4
65
2
SERVICE PARTS
QWIK JON®ULTIMA 203
203-A 203-A
(PREMIUM)
9/06
thru
Current
5/12
thru
Current
Item Description Part No.
1QwikJon®UltimaModel203SewageRemovalSystem 203-0005 203-1006
2 203 replacement pump with discharge pipe 017374 152165
3Tankcoverwithdischargettings 017373 017373
4Tank 018513 018513
5 Seal 017350 017350
6 Float switch assembly 018501 018501
7Flangeextensionkit 018510 018510
8 Closet seal 017347 017347 SK2613
If the above checklist does not solve the problem, consult the Zoeller Product SupportDepartment(502)778-2731.Do not attempt to service or otherwise disassemble pump.
Careofnish:Soapandwaterisallthatisrecommendedforcleaningtheoutsideofthetank.Othercleaningproductsmaycausediscolorationandscratching.
CONDITION POSSIBLE CAUSE REMEDY
A. PUMP WILL NOT START OR RUN.
Lowvoltage,blownfuse,opencircuit. Haveaqualiedelectriciancheckfuseandcircuit.
Impeller bound. Contact a Zoeller Service Station.
Motor or wiring shorted.
Debrisonoatswitch. Removedebris.
B. PUMP STARTS TOO SOON. Float“ON”pointisadjustedtoolow. Raisetheoatstops,makesuretheoatisbetweenthetwostops.
C. WATER LEVEL EXCESSIVE BEFORE PUMP
TURNS ON. Float“ON”pointadjustedtoohigh. Lowertheupperoatstop.
D. PUMP WILL NOT SHUT OFF OR RUNS TOO LONG
BEFORE WATER IS PUMPED.
Pumpnotpluggedintopiggybackoatswitchreceptacle. Ensurepumpisnotpluggeddirectlyintotheoutlet.Plugpump
intopiggybackoatswitchreceptacle.
Debrisunderoat. Removedebrisfromaroundoat.
Faultyoatswitch. Contact a Zoeller Service Station.
Float“Off”pointadjustedtoolow. Raisetheloweroatstop.
Pump is air locked. Make sure vent hole in discharge pipe is clear.
Water level too low. Raisetheloweroatstop.
Waste material has accumulated, blocking flow of
material to pump intake.
Holdushhandledownonthetoiletfor15seconds.Ifunitwill
not clear, unplug and wait 30 minutes. Plug unit back in and
repeat. If unit still will not turn off, it will need to be opened and
the debris relocated.
E. PUMP OPERATES BUT DELIVERS LITTLE OR NO
WATER.
Debris around intake. Clean area around intake.
Blockage in discharge pipe. Removepipeandushoutdebris.
Loworincorrectvoltage. Haveaqualiedelectriciancheckhousewiring.
Damaged Impeller. Contact a Zoeller Service Station.
Incorrectoatadjustment. Contact Product Support Dept.
Pump is air locked. Make sure vent hole in discharge pipe is clear.
Vertical lift too high. Change discharge piping or contact Product Support Dept.
TROUBLE SHOOTING

4
© Copyright 2012 Zoeller Co. All rights reserved.
QWIK JON
®
ULTIMA QWIK REFERENCE GUIDE
STEP 1 LOCATION SELECTION
GFCI
OUTLET
WATER
SUPPLY
DISCHARGE
PIPE
VENT
PIPE
LEVEL FLOOR
BALL OR GATE VALVE
SOLD SEPARATELY.
SK2588
STEP 2 LEVELING OF PUMP UNIT
SK2614
SK2615
STEP 3-1 STEP 3-3, 3-4
STEP 3-2
1/8"
Plan your new installation carefully.
Floor:Theoorshouldbestructurallysoundandlevelwithin1/8".Iftheoorisnot level, use hydraulic
cementorsimilarmaterialtoleveltheoor.
Water: A water supply will be needed to operate the shower and lav.
Electrical:A115voltGFCIreceptaclewillbeneededtosupplyelectricalpowerto the pump.
Sewage:Accesstoasewagelineisrequired.TheQwikJon®Ultimarequiresa1"(or3/4"ifcodes
permit)sewagedischargelinetoconnecttoanexistingsewageline.Aballorgatevalveshouldbe
installed in the discharge line.
Vent:Accesstoaventpipeisrequired.TheuseofamechanicalventsystemisNOTrecommended.,
asthetoiletwillnotush.
NOTE:Ifabuilt-ininstallationistobeused,locatethepumpunitinanareathatwill allow access
to the pump and switch.
Do not use wooden shims to level the pump unit!
Ensurethatnails,screwsorothersharpobjectsdonotpuncturethepumpunit!
Levelthepumpunitwithin1/8"usinghydrauliccementorsimilarmaterial.
STEP 3 ROUGH-IN
1) Positionthepumpunitaminimumof1/8"fromthewallwiththe
inlet facing forward. Attach the bellows to the inlet using the
worm drive clamp provided.
 2) Placethetoiletinfrontofpumpunitaligningthedischargeofthe
toilet with the inlet of the pump unit. Make sure that the bellows
willbridgethe gapadequatelyfornalinstallation.Thetoilet
tankshouldbeaminimumof1/2"fromthewall.
 3) Lightlymarkthelocationsofthepumpunit,toiletandcloset
boltlocationsontheoor.Lightlymarkthewallwiththeheight
of the pump unit and the bottom and sides of the toilet tank to
ensure against interference from pipe runs later.
 4) Removethetoiletfromthepumpunitandsetitaside.
(STAND-ALONE INSTALLATION) (BEHIND THE WALL INSTALLATION)
1) Installing the grinder unit behind a wall will require an
extensionkit(P/N10-2123)soldseparately.
 2) Placethetoiletassemblyaminimumof1/2" from the wall
andmarktheclosetboltlocationsontheoor.
 3) Measuretheappropriatelengthof3½"Schedule 40 PVC
pipeprovidedwiththeextensionkitandcutittolength.
See sketch at right.
 4) Settoiletaside.
 Toilet assembly is top heavy. Take special
precautions to ensure that toilet does not tip over and break.
STEP 4-4
STEP 4-3 STEP 4-2
STEP 4-1
SK2616

5
© Copyright 2012 Zoeller Co. All rights reserved.
STEP 4 PIPING
1) Addingbathroomxtures-TheQwikJon®Ultimaisdesignedtoaccept
bathroomxturesutilizingthetwosideinlets.Theseinletscanbeattachedvia
the2"MPT(outsidediameter)orthe1½"slip(insidediameter).Theseinlets
musthavetheinnerportiondrilledoutusinga44mm(1¾")holesaw(see
Figure3.2).Thisistoensuretherearenoleakageproblemsfrominletsnotin
use. When utilizing side inlets, install a check valve on the incoming line.
 2) Cutanddry-tthepipeandttingsasrequiredfor1"diameter discharge
pipe(maybereducedto¾"diameterifcodespermit).
 3) Whiledry-ttingthedischargepipe,positionandmarkthelocation of
thepumpunitdischargetting.
 4) Cut and dry-t 1½" vent pipe as required to ensure that the vent
pipe does not interfere with other components. Make the connection to the
pumpunitwiththeprovidedstreetelbow.A2"x1"90°dischargettinghas
been provided, however, it may be easier to pipe straight up depending on
the installation. Proper venting is required. Do not use a
mechanical type vent.
 5) Clean, prime and solvent weld the inlet and discharge piping and
pumpunitdischargetting. When applying solvent weld to
dischargetting,ensurethatnonegetsintothecheckvalveassembly(see
Figure3.3).Paycloseattentiontotheproperalignmentofthedischargetting
previously marked above.
 6) Cleanandsolventweldventpipingasrequiredforproper venting.
SK2673 SK2591
DRILL POINT
1-1/2" SLIP INSIDE
2" MPT OUTSIDE
SK2586
Figure 3.1 Figure 3.2 Figure 3.3
Discharge Vent
Do not put glue in this area.
 1) Installtheclosetboltsatthepointsmarkedearlier.
 2) Placethetoiletassemblyovertheclosetbolts.Installtheanchoring
hardware and tighten in an alternating pattern. Check for level and shim
as required. Be careful when tightening bolts or nuts against china to
avoid cracking the china.
 3) Installrubberbellowsontothetoiletdischargeandgrindertankhub
and secure with the worm clamps provided for installation. See sketch
inStep3.Forbuilt-ininstallation,installtherubbercouplingstoboth
thegrindertankandthetoiletdischargeandsecuretoextensionpipe
with worm clamps provided. See sketch in Step 4.
 4) Installthewatersupplylinefromtheexistingwatershut-offvalvetothe
toilet water supply connection.
 5) Openthewatersupplyvalveandcheckforleaks.Thetoilettankshould
lltotheproperlevel.Adjustifrequired.
 6) Plugthepump'spowercordintotheoutlet.
 7) Flushthetoiletandwatchforproperoperation.Listenforthepumpto
start.Thepumpunitrequiresproperventinginorderfortoilettoush.
Check for leaks.
 8) Repeatushcyclestoassureproperoperation.
FLOOR LEVEL TO WITHIN 1/8"
PUMP UNIT
AUX. INLET
WATER
SUPPLY
GFCI
OUTLET
DISCHARGE
PIPE VENT PIPE
(PER ALL CODES.
DO NOT USE
MECHANICAL VENT.)
SK2595
STEP 5 TOILET INSTALLATION (TOILET SUPPLIED BY OTHERS)
NOTE:Maynotbepicturedexactlyasshown.

6
© Copyright 2012 Zoeller Co. All rights reserved.
TOTAL DYNAMIC HEAD
FLOW PER MINUTE
15
LITERS 0
GALLONS
20 40
5 10
0
2
5
25
100
8060
20 50
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
PUMP PERFORMANCE CURVE
MODEL 202
FEET
METERS
4
10
15
620
Shut-off Head:
15 4.6
Feet Meters
5
10
1.5
3.0
MODEL
30 ft. (9.1m)
35 132
Gal. Liters
45
40
170
151
202
45403530
25
30
35
120 140 160 180
8
10
20 6.1 27 102
25 7.6 16 61
018512

7
© Copyright 2012 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]
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®
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© Copyright 2012 Zoeller Co. All rights reserved.