Zoeller X161 User manual

1
© Copyright 2010 Zoeller Co. All rights reserved.
NOTICE TO INSTALLER: Instructions must remain with installation.
OWNER’S MANUAL
Safety Instructions
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA-
JOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUALAND ON THE PUMP.
THISMANUALIS INTENDED TOASSISTIN THE INSTALLATION
ANDOPERATIONOFTHISUNITANDMUSTBEKEPTWITHTHE
PUMP. This is a SAFETYALERT SYMBOL.
When you see this symbol on the pump or in the
manual, look for one of the following signal words
and be alert to the potential for personal injury or
property damage.
WarnsofhazardsthatWILLcauseseriouspersonal
injury, death or major property damage.
Warnsof hazardsthatCAN causeserious personal
injury, death or major property damage.
Warns of hazards that CAN cause personal injury
or property damage.
INDICATESSPECIALINSTRUCTIONSWHICHARE
VERY IMPORTANTAND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMINGANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
Table of Contents
REFER TO WARRANTY ON PAGE 2.
EFFLUENT SEWAGE
X282, X284
X292, X293, X294, X295
X404, X405
X161, X163, X165
X185, X186, X188, X189
X191
ZOELLER HAZARDOUS ENVIRONMENT PUMPS
(For Class 1, Division 1, Groups C & D Applications)
Explosion Proof Motors
Model Number: ______________ Date Code: _______________
Simplex  Duplex
Job Name: ____________________________________________
Distributor: ____________________________________________
Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____Amps ______
Owner’s Information
Safety Instructions.......................................................................1
Limited Warranty..........................................................................2
Preinstallation Checklist..............................................................2
Electrical Data............................................................................3-4
General Information..................................................................5-6
Pump Dimensions........................................................................7
Pump Wiring Instructions.........................................................8-9
Operation.....................................................................................10
General Maintenance.................................................................11
Service Checklist........................................................................12
SECTION: 6.10.041
FM2298
0810
Supersedes
0610
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
Standard 3600 & 3615 Certified to CSA Standard
C22.2 No. 145
See page 3.
R

2
© Copyright 2010 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
monthsfromdateoforiginalmanufactureoftheproduct,whichevercomesfirst.
Partsthatfailwithinthewarrantyperiod,oneyearfromdateofpurchasebythe
end user, or 18 months from the date of original manufacture of the product,
whichevercomes first,thatinspectionsdetermine tobedefectivein materialor
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.
Thiswarrantydoesnotapplytoand thereshallbenowarranty foranymaterial
orproductthat has been disassembledwithoutpriorapprovalofManufacturer,
subjected to misuse, misapplication, neglect, alteration, accident or act of
God; that has not been installed, operated or maintained in accordance with
Manufacturer'sinstallationinstructions; that has been exposedtooutsidesub-
stances including but not limited to the following: sand, gravel, cement, mud,
tar,hydrocarbons,hydrocarbonderivatives(oil,gasoline,solvents,etc.),orother
abrasive or corrosive substances, wash towels or feminine sanitary products,
etc. in all pumping applications. The warranty set out in the paragraph above
is in lieu of all other warranties expressed or implied; and we do not authorize
any representative or other person to assume for us any other liability in con-
nection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211,
Attention: Customer Service Department to obtain any needed repair or re-
placement of part(s) or additional information pertaining to our warranty.
MANUFACTUREREXPRESSLYDISCLAIMSLIABILITYFORSPECIAL,CON-
SEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF EXPRESSED
OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS
FORAPARTICULAR PURPOSEAND OF MERCHANTABILITY SHALLBE
LIMITED TO THE DURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
Thiswarrantygivesyouspecificlegalrightsandyoumayalsohaveotherrights
which vary from state to state.
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 float switches must be connected to an intrinsically safe circuit in the
control panel. The installation of float switches is the responsibility of the
installing party and care should be taken that the tethered float switch will
not hang up on the pump apparatus or pit peculiarities and is secured so
that the pump will shut off. It is recommended that rigid piping and fittings
be used and the pit be 36" or larger in diameter.
3. INFORMATION - VENT HOLE PURPOSE. It is necessary that
all submersible pumps capable of handling various sizes of solid waste
be of the bottom intake design to reduce clogging and seal failures. If a
check valve is incorporated in the installation, a vent hole (approx. 3/16")
must be drilled in the discharge pipe 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
forclogging and cleanedas necessary.Trappedair is causedby agitation
and/or a dry basin.
4. Waterhammercreatesmomentaryhighpressuresurges.Thesesurgescan
causeseveredamagetocheckvalvesandthepipingsystem.Consideration
forwaterhammermustbeincludedinthepipingsystemdesign.Reference
ASPEDataBook,Chapter2.33.Somesystemsmayrequireexternalspring
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.
6. Careshouldbetakenduringtheinitialinstallationtobesurethatadequate
air supply is available whenever any person is in the basin.Always follow
OSHAguidelines on confined space requirements.
1. Inspect your pump. Occasionally, products are damaged during shipment. If the unit is damaged, contact your distributor 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.
3. NationalElectricalCode(NEC)articles500through503explainindetailtherequirementsfortheinstallationandwiringofelectricalequipmentinhazardouslocations.
1. Not for use in acidic, methanol or ethyl acetate atmo-
spheres.
2. Do not lift, carry, or hang pump by the electrical cables. Damage
to the electrical cables can cause shock, burns or death.
3. Make sure there is a properly grounded connection available.
Allpumpsarefurnishedwithprovisionsforpropergroundingtohelpprotect
you against the possibility of electrical shock.
4. 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
aretoo long ortoo light donot deliver sufficient voltage tothe pump motor.
But,moreimportant,theycouldpresentasafetyhazardiftheinsulationwere
to become damaged or the connection end were to fall into the sump.
5. Make sure the pump electrical supply circuit is equipped with
fusesanddisconnectorcircuitbreakersofpropercapacity.Aseparate
branch circuit is recommended, sized according to the “National Electrical
Code” for the current shown on the pump nameplate.
6. Risk of electric shock - These pumps have not been investigated
for use in swimming pool areas.
7. AccordingtothestateofCalifornia(Prop65),thisproductcontainschemicals
known to the state of California to cause cancer and birth defects or other
reproductive harm.
8. Electrical wiring and protection must be in accordance with the National
Electrical Code per NEC articles 500 through 503 for installation in Class
1, Division 1, Group C & D environments, and any other applicable state
and local electrical requirements.
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS

3
© Copyright 2010 Zoeller Co. All rights reserved.
Amps KVA
Code
Winding
Resistance
Line-to-Line
Model HP RPM Voltage Phase Hertz Full Load In Air Shut Off Locked Rotor
MX161 ½ 3450 115 1 60 15.5 7.7 52.2 N **
NX161 ½ 3450 115 1 60 15.5 7.7 52.2 N .53/.46*
DX161 ½ 3450 230 1 60 7.5 3.6 15.1 H **
EX161 ½ 3450 230 1 60 7.5 3.6 15.1 H 4.74/3.88*
HX161 ½ 3450 200 1 60 8.8 6.3 19.8 J **
IX161 ½ 3450 200 1 60 8.8 6.3 19.8 J 3.59/2.94*
JX161 ½ 3450 200 3 60 6.4 3.1 23.6 S 6.25/5.12
FX161 ½ 3450 230 3 60 5.2 2.7 24.0 T 5.7/4.6
GX161 ½ 3450 460 3 60 2.9 1.4 12.0 T 22.8/18.5
BAX161 ½ 3450 575 3 60 2.4 1.3 11.3 U 38.0/33.0
MX163 ½ 3450 115 1 60 15.0 8.4 52.2 N **
NX163 ½ 3450 115 1 60 15.0 8.4 52.2 N .53/.46*
DX163 ½ 3450 230 1 60 7.5 4.0 15.1 H **
EX163 ½ 3450 230 1 60 7.5 4.0 15.1 H 4.74/3.88*
HX163 ½ 3450 200 1 60 8.5 4.3 19.8 J **
IX163 ½ 3450 200 1 60 8.5 4.3 19.8 J 3.59/2.94*
JX163 ½ 3450 200 3 60 6.0 3.4 23.6 S 6.25/5.12
FX163 ½ 3450 230 3 60 4.8 3.0 24.0 T 5.7/4.6
GX163 ½ 3450 460 3 60 2.9 1.5 12.0 T 22.8/18.5
BAX163 ½ 3450 575 3 60 2.4 1.5 11.3 U 38.0/33.0
DX165 1 3450 230 1 60 10.2 5.5 20.1 E **
EX165 1 3450 230 1 60 10.2 5.5 20.1 E 3.06/2.51*
HX165 1 3450 200 1 60 12.6 6.1 26.8 F **
IX165 1 3450 200 1 60 12.6 6.1 26.8 F 2.11/1.72*
JX165 1 3450 200 3 60 7.5 4.1 31.1 M 3.74/3.06
FX165 1 3450 230 3 60 7.4 3.8 29.8 N 5.7/4.5
GX165 1 3450 460 3 60 3.7 2.1 14.9 N 22.6/18.2
BAX165 1 3450 575 3 60 3.0 1.7 10.0 L 38.8/34.5
DX185 1 3450 230 1 60 9.8 5.0 20.1 E **
EX185 1 3450 230 1 60 9.8 5.0 20.1 E 3.06/2.51*
HX185† 1 3450 200 1 60 11.5 5.1 26.8 F **
IX185† 1 3450 200 1 60 11.5 5.1 26.8 F 2.11/1.72*
JX185 1 3450 200 3 60 7.5 3.6 31.1 M 3.74/3.06
FX185 1 3450 230 3 60 7.4 3.8 29.8 N 5.7/4.5
GX185 1 3450 460 3 60 3.7 1.9 14.9 N 22.6/18.2
BAX185 1 3450 575 3 60 3.3 1.3 10.0 L 38.8/34.5
DX186 1½ 3450 230 1 60 13.7 9.3 45.7 H **
EX186 1½ 3450 230 1 60 13.7 9.3 45.7 H 1.29/1.05*
HX186 1½ 3450 200 1 60 17.2 11.8 54.5 J **
IX186 1½ 3450 200 1 60 17.2 11.8 54.5 J .86/.71*
JX186 1½ 3450 200 3 60 10.3 6.0 45.2 M 2.62/2.14
FX186 1½ 3450 230 3 60 9.2 5.5 39.4 M 3.52/2.8
GX186 1½ 3450 460 3 60 4.6 2.8 19.7 M 13.9/11.3
DX188 1½ 3450 230 1 60 14.0 7.4 45.7 H 1.29/1.05*
EX188 1½ 3450 230 1 60 14.0 7.4 45.7 H 1.29/1.05*
HX188 1½ 3450 200 1 60 16.8 9.8 54.5 J **
IX188 1½ 3450 200 1 60 16.8 9.8 54.5 J .86/.71*
JX188 1½ 3450 200 3 60 10.3 4.7 45.2 M 2.62/2.14
FX188 1½ 3450 230 3 60 8.9 4.1 39.4 M 3.52/2.8
GX188 1½ 3450 460 3 60 4.6 2.0 19.7 M 13.9/11.3
BAX188 1½ 3450 575 3 60 3.5 1.6 15.9 M 20.6/18.3
DX189 2 3450 230 1 60 17.1 9.4 45.7 F **
EX189 2 3450 230 1 60 17.1 9.4 45.7 F 1.29/1.05*
HX189 2 3450 200 1 60 20.5 11.5 54.5 F **
IX189 2 3450 200 1 60 20.5 11.5 54.5 F .86/.71*
JX189 2 3450 200 3 60 13.2 5.9 45.2 J 2.62/2.14
FX189 2 3450 230 3 60 11.2 5.1 39.4 J 3.5/2.8
GX189 2 3450 460 3 60 6.0 2.8 19.7 J 13.9/11.3
BAX189 2 3450 575 3 60 5.8 2.1 15.9 J 20.6/18.3
DX191 2 3450 230 1 60 14.5 8.5 45.7 F **
EX191 2 3450 230 1 60 14.5 8.5 45.7 F 1.29/1.05*
MX282 ½ 1750 115 1 60 10.3 7.3 30.2 H 1.46/1.20*
NX282 ½ 1750 115 1 60 10.3 7.3 30.2 H 1.46/1.20*
DX282 ½ 1750 230 1 60 5.0 4.0 15.1 H 5.84/4.80*
EX282 ½ 1750 230 1 60 5.0 4.0 15.1 H 5.84/4.80*
HX282† ½ 1750 200 1 60 6.1 4.5 17.7 H 4.65/4.05*
IX282† ½ 1750 200 1 60 6.1 4.5 17.7 H 4.65/4.05*
JX282 ½ 1750 200 3 60 3.6 2.5 12.8 K 8.13/6.62
FX282 ½ 1750 230 3 60 3.0 2.3 12.2 L 9.6/7.9
GX282 ½ 1750 460 3 60 1.7 1.1 6.1 L 38.4/31.5
BAX282 ½ 1750 575 3 60 1.4 1.1 5.11 M 63.6/55.3
Electrical Data
* Line to line reading will only reflect the run winding resistance.
**Line to line reading will only reflect the relay coil resistance on automatic 160-290 series.
Start winding resistance can only be measured after removing the cover.
† Not CSA certified. CONTINUED ON NEXT PAGE

4
© Copyright 2010 Zoeller Co. All rights reserved.
Electrical Data (continued)
Amps KVA
Code
Winding
Resistance
Line-to-Line
Model HP RPM Voltage Phase Hertz Full Load In Air Shut Off Locked Rotor
DX284 1 1750 230 1 60 8.9 6.7 24.9 G **
EX284 1 1750 230 1 60 8.9 6.7 24.9 G 2.62/2.14*
HX284† 1 1750 200 1 60 9.3 6.4 26.8 F **
IX284† 1 1750 200 1 60 9.3 6.4 26.8 F 2.01/1.82*
JX284 1 1750 200 3 60 5.5 4.0 26.3 L 2.99/2.70
FX284 1 1750 230 3 60 5.0 3.5 22.2 K 4.8/4.4
GX284 1 1750 460 3 60 2.6 1.9 11.1 K 19.2/17.4
BAX284 1 1750 575 3 60 2.2 1.7 12.1 N 20.4/17.7
MX292 ½ 3450 115 1 60 15.0 10.6 52.2 N **
NX292 ½ 3450 115 1 60 15.0 10.6 52.2 N .53/.46*
BAX292 ½ 3450 575 3 60 2.4 1.7 11.3 U 38.0/33.0
DX293 1 3450 230 1 60 10.2 5.5 20.1 E **
EX293 1 3450 230 1 60 10.2 5.5 20.1 E 3.06/2.51*
HX293 1 3450 200 1 60 12.0 6.4 26.8 F **
IX293 1 3450 200 1 60 12.0 6.4 26.8 F 2.11/1.72*
JX293 1 3450 200 3 60 8.2 4.4 31.1 M 3.74/3.06
FX293 1 3450 230 3 60 7.6 4.1 29.8 N 5.7/4.5
GX293 1 3450 460 3 60 4.0 2.2 14.9 N 22.6/18.2
BAX293 1 3450 575 3 60 3.3 1.8 10.0 L 38.8/34.5
DX294 1½ 3450 230 1 60 13.7 8.1 45.7 H **
EX294 1½ 3450 230 1 60 13.7 8.1 45.7 H 1.29/1.05*
HX294 1½ 3450 200 1 60 17.8 10.1 54.5 J **
IX294 1½ 3450 200 1 60 17.8 10.1 54.5 J .86/.71*
JX294 1½ 3450 200 3 60 10.8 5.3 45.2 M 2.62/2.14
FX294 1½ 3450 230 3 60 9.5 4.5 39.4 M 3.5/2.8
GX294 1½ 3450 460 3 60 4.8 2.3 19.7 M 13.9/11.3
BAX294 1½ 3450 575 3 60 3.8 1.8 15.9 M 20.6/18.3
DX295 2 3450 230 1 60 17.1 9.1 45.7 F **
EX295 2 3450 230 1 60 17.1 9.1 45.7 F 1.29/1.05*
HX295 2 3450 200 1 60 20.5 11.5 54.5 F **
IX295 2 3450 200 1 60 20.5 11.5 54.5 F .86/.71*
JX295 2 3450 200 3 60 14.3 6.3 45.2 J 2.62/2.14
FX295 2 3450 230 3 60 12.2 5.3 39.4 J 3.5/2.8
GX295 2 3450 460 3 60 6.1 2.7 19.7 J 13.9/11.3
BAX295 2 3450 575 3 60 4.9 2.2 15.9 J 20.6/18.3
EX404 2 1750 230 1 60 12.9 9.9 44.8 B 1.80/1.60*
IX404 2 1750 200 1 60 14.4 11.5 49.6 B 1.42/1.28*
JX404 2 1750 200 3 60 13.8 13.1 56.8 H 1.6/1.3
FX404 2 1750 230 3 60 10.5 9.7 44.6 G 2.3/2.0
GX404 2 1750 460 3 60 5.2 4.8 22.3 G 9.1/8.0
BAX404 2 1750 575 3 60 4.1 3.8 17.6 G 14.6/12.7
EX405 3 1750 230 1 60 19.0 9.3 44.8 B 1.80/1.60
IX405 3 1750 200 1 60 20.2 8.8 49.6 B 1.42/1.28*
JX405 3 1750 200 3 60 14.8 12.5 56.8 H 1.6/1.3
FX405 3 1750 230 3 60 12.2 9.7 44.6 G 2.3/2.0
GX405 3 1750 460 3 60 6.1 4.8 22.3 G 9.1/8.0
BAX405 3 1750 575 3 60 4.8 3.8 17.6 G 14.6/12.7
* Line to line reading will only reflect the run winding resistance.
**Line to line reading will only reflect the relay coil resistance on automatic 160-290 series.
Start winding resistance can only be measured after removing the cover.
† Not CSA certified.

5
© Copyright 2010 Zoeller Co. All rights reserved.
HAZARDOUS ENVIRONMENTAL PUMP DESCRIPTION
1. Pumps are constructed of class 30 cast iron with powder coated
epoxyprotectionforlonglifewhenpumpingsewageinsubmersible
applications.
2. Pump motors are available in single and three phase design.
3. The Hazardous Environmental Pump is a single seal design and
has seal leak probes. Single phase units have an internal thermal
overload. Three phase pumps have a thermal sensor. A moisture
sensorsealfailcircuitisincorporatedintothecontrolpanelrequired
fornonautomaticpumps.Moisturesensorindicatorpanel,10-1031,
is recommended but not required for automatic pump models.
4. Three phase pumps require overload protection in the control
panel.
FIELDASSEMBLED INSTALLATION
1. Contractor shall furnish all labor, material, equipment and
incidentals required for installation of hazardous environmental
pump.
2. Installationandpipinginstructionsareincludedwiththerailsystem
and basin instructions. If pump is being retrofitted to an existing
railsystem,accessorypartsmayberequired. Consultthefactory
and advise make and model of rail system being used.
3. All electrical connections including pump to control box and
power supply to control panels must comply with the “National
ElectricalCode”andapplicablelocalcodes.Installationofelectrical
panels and connections should be made by a qualified licensed
electrician.
4. When installing a pump with a check valve, or a rail system with
a check valve, you must give the pump case time to fill to help
preventairlockwhenloweringtheunitintotheliquid.The6404/6405
pumpcase hasanair ventlocatedbehind thedischarge.Thisair
vent is across the pump housing mounting surface and must be
cleaned before each reinstall. An air vent hole (3/16") must be
drilledindischargepipebelowthecheckvalvetohelppreventair
lock.Thisdrilledholemustbecleanedbeforeeachreinstall.After
thepumpisinstalled,runtheunitsubmergedtoassurethepump
case is filled (Water should come out of 3/16" diameter hole).
General Information
010740

6
© Copyright 2010 Zoeller Co. All rights reserved.
X404
FLOW PER MINUTE
PUMP PERFORMANCE CURVE
MODELS X404/X405
3" SOLIDS CAPACITY
250
FEET
METERS
LITERS 2000 600400 800
50
TOTAL DYNAMIC HEAD
20
6
GALLONS
2
0
4
5
10
15
10
8
12
25
30
35
40
150100 200
X405
1000 1200 1400
350300 400
012116
General Information (continued)
PUMP PERFORMANCE CURVE
MODEL X282/X284/X292/X293/X294/X295
2" SOLIDS CAPACITY
720
190
GALLONS
LITERS 080
6
4
2
0
10
5
10 20
15
20
FLOW PER MINUTE
110
160 240 320 400
30 40 50 60 70 80 10090
X282
560480 640
150130120 140
X292
170160 180
X284
80
14
12
10
8
TOTAL DYNAMIC HEAD
25
30
35
40
45
22
20
18
16
50
55
60
65
70
METERS
FEET
X293
800
X295
210200
X294
220
75
24
010739
R
T
O
N
I
A
T
O
9 7/8
6 1/4
25 3/8
25 15/16
6 3/16
12 11/16
4" CHECK VALVE
STD. 4" 90° ELBOW
SK1915

7
© Copyright 2010 Zoeller Co. All rights reserved.
Pump Dimensions
6 1/2
8 3/4
1 1/2" NPT STANDARD
2" NPT
OR
3" NPT
AVAILABLE
21 7/16
4 9/16
4 9/16
22
1 1/4" - 11 1/2 NPT
CHECK VALVE
6 1/16
SK1912
X160 - X190 Series
1 1/4" - 11 1/2 NPT
CHECK VALVE
22 1/4
2" NPT
OR
3" NPT
AVAILABLE
6 5/16
21 11/16
5
5 8 9/16
6 5/16
SK1913
SK2506 SK2507
X280 Series
SK1914
6 1/2
8 3/4
21 1/2
6 1/16
4 9/16
4 9/16
22
CHECK VALVE
2" NPT
OR
3" NPT
AVAILABLE
1 1/4" - 11 1/2 NPT
SK2508
X290 Series
AUTOMATIC AUTOMATIC
NONAUTOMATIC
NONAUTOMATIC
AUTOMATIC
NONAUTOMATIC

8
© Copyright 2010 Zoeller Co. All rights reserved.
Pump Wiring Instructions
FORYOURPROTECTION,ALWAYS DISCONNECTTHE PUMPFROM ITSPOWERSOURCE BEFOREHANDLING.
AllelectricalconnectionsmustbewiredandgroundedinaccordancewiththeNationalElectricalCodeandallapplicable
local codes and ordinances.
“Risk of electrical shock” Do not remove the power supply cord or strain relief.
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
EXPLOSION PROOF WIRING DIAGRAMS
X160, X180, X190, X280, X290, X400 SERIES
Allinstallation of controls,protectiondevices and wiringshouldbe done byaqualifiedlicensed electrician. All electricalandsafetycodes should
be followed including the most recent National Electrical Code (NEC) and the Occupational Safety and HealthAct (OSHA).
Not for use in acidic, methanol or ethyl acetate atmospheres.
012941 012943
SINGLE PHASE NONAUTOMATIC THREE PHASE

9
© Copyright 2010 Zoeller Co. All rights reserved.
Pump Wiring Instructions (continued)
016889 016890
SINGLE PHASE AUTOMATIC
MODEL X282 SINGLE PHASE AUTOMATIC
MODELS X160 - X290

10
© Copyright 2010 Zoeller Co. All rights reserved.
Operation
GENERAL
Zoellerpumpsarelubricatedandtestedatthefactorypriortoshipment
and require minimum pre-start-up maintenance.
Maximumoperatingtemperatureofpump liquidmustnotexceed104°F
(40°C).
Theseunitsare not designedtohandle liquids otherthaneffluent:160
and 180 or sanitary sewage: 280, 290 and 400. If pump is used to de-
waterareaswithcontaminatedliquidswithheavyorabrasivematerials,
the warranty will be voided.
NAMEPLATE DATA
The nameplate, located on the side of the pump, indicates specific
information about the construction of the pump. The model number
anddatecode information should berecordedonthe front page inthe
“Owner’s Information” section of this manual.
SHORT TERM STORAGE
When not in use, the pump should be stored and the following is
advised:
• Storepumpinsidewheneverpossibleorcoverwithsometypeofprotective
covering.
• Tape or seal in plastic bag the terminal ends of wire leads.
• Spray coat unpainted surfaces with rust inhibiting oil.
• Theimpellershouldberotatedeverysixmonthsinordertokeepthe
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:
• Clean pit.
• Electrical boxes dry and securely installed.
• Floats positioned properly.
• Discharge valves open.
• 3/16” vent hole drilled in pipe between check valve and pump.
Once the above has been verified proceed with the following checks:
• Pumppowercables andcontrolfloatsproperlyinstalledandvoltage
verified.
• Conduit connections to panel are properly sealed.
• After installing the pump into the containment area, with adequate
submergence, open the discharge valve fully. Start the unit using
manualcontrols. Ifflow isappreciablylessthanrated performance,
pump may be air locked. To expel trapped air, jog the unit several
times, using the manual controls.
• Haveaqualifiedelectriciantakevoltageandcurrentmeasurements
withthepumprunning.Recordthesereadingsinthespaceprovided
inthe“Owner’s Information” section onpage1of this manual for
future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Nonautomatic - Refer to the system drawing or to the panel
wiringschematic forthedesired locationofeach float switch
setting.
Automatic-Floatisfactorysettoprovideapproximateon/off
levels as follows:
SERIES ON OFF
X160/X180 19½" 9¾"
X280 19¾" 10"
X290 19½" 9¾"
Atighter pumping range can be set by moving the float stop
closer to the float thereby lowering the "on" point.
Valves: Dischargevalvesshouldbeplacedinthefullyopenposition.
Systemsshouldnotbeoperatedforextendedperiodsoftime
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.
Withthepumpinthepit,itshouldbeoperatedforfiveminutes
onceeverythreemonths.Ifthepitistoremainwet,thepump
should be removed and stored as noted above.
Panels: The panelshould haveall openingssealed toprevent moisture
anddustfromenteringtheenclosure.Priortorestartingsystem,
thepanelshouldbeinspectedforpresenceofmoistureandany
looseconnections.
Valves: Consultthevalve/actuatorsupplierforinformationconcerning
these systems components.

11
© Copyright 2010 Zoeller Co. All rights reserved.
Repair and service must be performed by a firm ap-
proved by Zoeller Company. The firm must be approved to work on
explosionproofmotorsifmotorhousing,adapterorcordcapisrepaired.
ContactZoellerTechnicalServiceDepartmentregardingwarrantyissues.
SAFETY PROCEDURES
For your protection, always disconnect pump
and panel from its power source before handling.
Never enterthe basinuntil ithasbeenproperly
ventedandtested.Anypersonenteringabasinshouldbewear-
ing 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 sulfide gases, both of which can be highly
poisonous.
Installationandchecking of electrical circuitsandhardware should be
performed by a qualified electrician.
Pump is never to be lifted by power cord.
Unitmustbecleanedanddisinfected,insidethe
pumping chamber and all exterior surfaces, prior to servicing.
General Maintenance
GENERAL SYSTEM INSPECTION
Before the system is placed into operation, it should be inspected by
a qualified technician.
Wiring and grounding must be in accordance
with the National Electrical Code and all applicable local codes
and ordinances.
LUBRICATION PROCEDURES
No lubrication is required.
Ifpumpsaretobestored for more than six months, refer to short term
storage procedure in the Operation section.
PREVENTIVE MAINTENANCE
Preventive maintenance is recommended to ensure a long service
life from the product. Provided is a suggested maintenance schedule.
Every month:
• Check for proper and unobstructed float operation.
• Listen for proper check valve operation.

12
© Copyright 2010 Zoeller Co. All rights reserved.
Service Checklist
Electrical precautions. Before servicing the pump, always shut off the main power circuit. Make 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 to the pump prior to removal.
Pumpscontainoilwhichbecomespressurizedandhotunderoperatingconditions.Allow2½hoursaftershutdownbefore
servicing pump.
Condition
A. Pump will not start or run.
B. Motor overheats and trips on overload.
C. Pump will not shut off.
D. Pump operates but delivers little or no water.
E. Pump starts and stops too often.
F. Large red flashing light comes on at control box.
G. Grease and solids accumulate in pit around pump.
Common Causes
Blown panel or circuit breaker fuse, low voltage, thermal overload open, defective
capacitor circuit, impeller clogged, float switch held down or defective, incorrect wiring
in control panel, water in cap assembly.
Incorrect voltage, impeller blocked, negative head (discharge lower than intake of
pump). Defective “off” float. Pump runs continuously at low water level. Low oil level
in motor shell.
Air lock, debris under float assembly, defective switch, incoming sewage exceeds
capacity of pump.
Intakecloggedwithgreaseorsludge,pumpairlocked(clearventhole),lowor
incorrect voltage, clogged discharge line, operating near shut-off head.
Check valve stuck open or defective. Sump pit too small to handle incoming sewage.
Level control out of adjustment. Thermal overload tripping.
High water in pit. Check pump for clogging, or overload trip. See “A” and “D”
above.
Breakup solidsand runpump withwater runninginto thepit.Allowleveltolowertothe
pump intake. Continue until solids are cleared from the pit.
Do not drain kitchen grease down the sink.
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