Zoeller Qwik Jon Ultima 204 User manual

QWIK JON®ULTIMA 204 SYSTEMS
INSTALLATION INSTRUCTIONS
PREINSTALLATION CHECKLIST
1. To help reduce the risk of electrical shock, a properly
grounded receptacle or control box of grounding type must
be installed and protected by a ground fault circuit interrupter
(GFCI) in accordance with the National Electrical Code and
applicablelocalcodes. Neverremovegroundpinfromplug.
If pump is wired direct, a GFCI must be installed in the control
box. (SEE WARNING BELOW)
2. Make certain that the ground fault interrupter protected
receptacle or control box is within reach of the pump’s power
supplycord.DONOTUSEANEXTENSIONCORD.Extension
cordsthataretoolongortoolightdonotdeliversufficientvoltage
to the pump motor. But more important, they could present a
safetyhazardiftheinsulationweretobecomedamagedorthe
connection end were to fall into a damp or wet area.
3. Makesurethepump'selectricalsupplycircuitisequipped
withfusesorcircuitbreakersofpropercapacity.Aseparate
branch circuit, sized according to the National Electrical Code
forthecurrentshownonthepumpnameplateisrecommended.
(See Note 3.)
4. TESTINGFORGROUND.Asasafetymeasure,eachelectrical
outlet should be checked for ground using an Underwriters
Laboratory Listed circuit analyzer which will indicate if the
power,neutralandgroundwiresarecorrectlyconnectedtoyour
outlet. If they are not, call a qualified licensed electrician.
5. FOR YOUR PROTECTION ALWAYS DISCONNECT PUMP
FROMITSPOWERSOURCEBEFOREHANDLING. Ifpump
is wired direct, de-energize the circuit at the control box.
Grounded 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 THE
GROUNDPIN.Toreducetheriskofelectricalshock,aproperly
grounded receptacle or control box of grounding type must be
installedandprotectedbyagroundfaultcircuitinterrupter(GFCI)
in accordance with National Electrical Code and applicable
local codes.
6. Installation and checking of electrical circuits and hardware
should only be performed by a qualified licensed electrician.
7. According to the state of California (Prop 65), this product
contains chemicals known to the state of California to cause
cancer and birth defects or other reproductive harm.
NOTICE TO INSTALLER: Instructions must remain with installation. SECTION: 6.10.065
FM2460
0909
Supersedes
1007
© Copyright 2009 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]
visit our web site:
www.zoeller.com
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 specific details regarding installation and use before
attempting the installation. These materials should be retained for future reference.
1. Check to be sure your power source is adequate to handle
the amperage requirements of the motor as indicated on the
pump or unit I.D. tag.
2. All plumbing (discharge and vent lines) must be installed
to meet local codes. Unit must be vented. Do not use an
automatic plumbing vent device.
3. Maximum operating temperature for model 204 must not
exceed 104°F (40°C). Duty cycle should not exceed 30
seconds on/30 seconds off.
4. Donotusecleaningproductscontainingbleachinthe attached
fixtures as they will degrade the pump seals.
1. Repair and service should be performed by an Authorized
Service Station only. (Consult Factory.)
2. NOTE:Recommendedforinstallationsupto20'totaldynamic
head. Consult Factory 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. Mini-grinder pump is rated for 115V, 60 Hz, 7 Amps, .5 HP.
4. NOTE: Pumps with the “UL” mark and pumps with the
“US” mark are tested to UL Standard UL778. CSA Certified
pumps are certified to CSA Standard C22.2 No. 108. Qwik
Jon®Ultima units only. It is not designed for use in any other
application.
5. All fixtures connecting to the system must be on the same
floor level.
Product information presented
here reflects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.
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 Pending

2
© Copyright 2009 Zoeller Co. All rights reserved.
Manufacturerwarrants,tothepurchaserandsubsequentownerduring
thewarrantyperiod,everynewproducttobefreefromdefectsinmaterial
andworkmanshipundernormaluseandservice,whenproperlyused
andmaintained,foraperiodofoneyearfromdateofpurchasebythe
enduser,or18monthsfromdateoforiginalmanufactureoftheproduct,
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
dateoforiginalmanufactureoftheproduct,whichevercomesfirst,that
inspectionsdeterminetobedefectiveinmaterialorworkmanship,willbe
repaired,replacedorremanufacturedatManufacturer'soption,provided
however,thatbysodoingwewillnotbeobligatedtoreplaceanentire
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
approvalofManufacturer,subjectedtomisuse,misapplication,neglect,
alteration,accidentoractofGod;thathasnotbeeninstalled,operatedor
maintainedinaccordancewithManufacturer'sinstallationinstructions;
thathasbeenexposedtooutsidesubstancesincludingbutnotlimited
to the following: sand, gravel, cement, mud, tar, hydrocarbons,
hydrocarbonderivatives(oil,gasoline,solvents,etc.),orotherabrasive
or corrosive substances, wash towels or feminine sanitary products,
etc.inallpumpingapplications. Thewarrantysetoutintheparagraph
above is in lieu of all other warranties expressed or implied; and we
donot authorize any representativeorotherperson to assume forus
any other liability in connection with our products.
ContactManufacturerat, 3649 Cane Run Road, Louisville, Kentucky
40211,Attention:CustomerServiceDepartmenttoobtainanyneeded
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 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 specific legal rights and you may also have
other rights which vary from state to state.
Limited Warranty
Helpful Hints For Easy Installation
1. Read all instructions before beginning installation.
2. Be sure the floor is level within 1/8".
3. Use soapy water to lubricate all seals to aid
installation.
4. Install rubber coupling/union in vent line to aid
disassembly.
5. Do not use an automatic plumbing vent device.
6. 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
Factory.
Do’s And Don't’s For Installing A 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. DOalwaysdisconnectpumpfrompowersourcebefore
handling.DOalwaysconnecttoaseparatelyprotected
andproperlygroundedground 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. DOtestpumpimmediatelyafterinstallationtobesure
that the system is working properly.
7. DO review all applicable local and national codes
and verify that the installation conforms to each of
them.
8. We DO NOT recommend this product be connected
to utilities other than 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.

3
© Copyright 2009 Zoeller Co. All rights reserved.
Typical Piping Configurations
NOTE: 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.
1
3
4
6
5
2
Service Parts
Item Description Part No.
1 Qwik Jon®Ultima Model 204 System 204-1000
2 N202 replacement pump with discharge pipe 017374
3 Tank cover with discharge fitting 018533
4 Tank 018534
5 Seal 017350
6 Float switch assembly 018532
SK2671
SK2587
Installation may not
be exactly as shown.

4
© Copyright 2009 Zoeller Co. All rights reserved.
CONDITION POSSIBLE CAUSE REMEDY
A. PUMP WILL NOT START OR
RUN.
Low voltage, blown fuse, open
circuit. Have a qualified electrician check fuse and circuit.
Impeller bound. Contact a Zoeller Service Station.
Motor or wiring shorted.
Debris on float switch. Remove debris
B. PUMP STARTS TOO SOON. Float “ON” point is adjusted too
low. Raise the float stops, make sure the float is between the two stops.
C. WATER LEVEL EXCESSIVE
BEFORE PUMP TURNS ON. Float “ON” point adjusted to high. Lower the upper float stop.
D. PUMP WILL NOT SHUT OFF
OR RUNS TOO LONG BEFORE
WATER IS PUMPED.
Pump not plugged into piggyback
float switch receptacle.
Ensure pump is not plugged directly
into the outlet. Plug pump into
piggyback float switch receptacle.
Debris under float. Remove debris from around float.
Faulty float switch. Contact a Zoeller Service Station.
Float “Off” point adjusted too low. Raise the lower float stop.
Pump is air locked. Make sure vent hole in discharge
pipe is clear.
Water level too low. Raise the lower float stop.
E. PUMP OPERATES BUT
DELIVERS LITTLE OR NO
WATER.
Debris around intake. Clean area around intake.
Blockage in discharge pipe. Remove pipe and flush out debris.
Low or incorrect voltage. Have a qualified electrician check
house wiring.
Damaged Impeller. Contact a Zoeller Service Station.
Incorrect float adjustment. Contact Technical Service
Department.
Pump is air locked. Make sure vent hole in discharge
pipe is clear.
Vertical lift too high. Change discharge piping or contact
Technical Service Department.
Beforeservicingapump,alwaysshutoff
the main power breaker and then unplug the pump -
makingsureyouare wearinginsulatedprotectivesole
shoes and not standing in water. Under flooded conditions,
contact your local electric company or a qualified licensed
electricianfordisconnectingelectricalservicepriortopump
removal.
Submersible pumps contain oil which become
pressured and hot under operating conditions - allow 2½
hours after disconnecting before attempting service.
If the above checklist does not solve the problem, consult
Zoeller Technical Service Department 1-(800) 928-PUMP
- Do not attempt to service or otherwise disassemble
pump.
CAREOFFINISH:Soapandwaterisallthatisrecommended
forcleaningtheoutsideofthetank.Othercleaningproducts
may cause discoloration and scratching.

5
© Copyright 2009 Zoeller Co. All rights reserved.
Qwik Jon®Ultima Qwik Reference Guide
STEP 1 Location Selection
Plan your new installation carefully.
Floor: The floor should be structurally sound
and level within 1/8". If the floor is not level,
use hydraulic cement or similar material to
level the floor.
Water:Awatersupplywillbeneededtooperate
the shower and lav.
Electrical: A 115 volt GFCI receptacle will
be needed to supply electrical power to the
pump.
Sewage:Accessto asewageline is required.
The Qwik Jon®Ultima requires a 1" (or 3/4" if
your codes permit) sewage discharge line to
connect to an existing sewage line. A ball or
gatevalveshouldbeinstalledinthedischarge
line.
Vent: Access to a vent pipe is required. The
use of a mechanical vent system is NOT
recommended.
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.
GFCI
OUTLET
DISCHARGE
PIPE VENT
PIPE
LEVEL FLOOR
BALL OR GATE VALVE
SOLD SEPARATELY.
SK2672
STEP 2 Leveling of Pump Unit
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 to within 1/8" using hydraulic cement or
similar material.
SK2673

6
© Copyright 2009 Zoeller Co. All rights reserved.
STEP 3 Piping
1) Adding bathroom fixtures - The Qwik Jon®Ultima
is designed to accept bathroom fixtures 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 1¾" hole saw(see Figure 3.2).
This is to ensure there is no leakage problems from
inlets not in use. When utilizing side inlets, install a
check valve on the incoming line.
2) Cut and dry-fit the pipe and fittings as required for
1" diameter discharge pipe (may be reduced to 3/4"
diameter if codes permit).
3) Whiledry-fittingthedischargepipe,positionandmark
the location of the pump unit discharge fitting.
4) Cut and dry-fit 1-1/2" vent pipe as required to ensure
that the vent pipe does not interfere with other
components. Make the connection to the pump unit
withtheprovidedstreetelbow. A2"x1"90°discharge
fitting 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,primeandsolventweldtheinletanddischarge
piping and pump unit discharge fitting.
When applying solvent weld to discharge
fitting,ensurethatnonegetsintothecheckvalveassembly
(seeFigure5.3).Paycloseattentiontotheproperalignment
of the discharge fitting previously marked above.
6) Clean and solvent weld vent piping as required for
proper venting.
SK2673 SKxxxx
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.

7
© Copyright 2009 Zoeller Co. All rights reserved.
STEP 3 NOTES

8
© Copyright 2009 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]
Manufacturers of..
www.zoeller.com