Zoeller X71 Series User manual

1
© Copyright 2015 Zoeller®Co. All rights reserved.
SECTION: Z4.30.150
ZM2209
Rev. A
0515
Supersedes
0714
NOTICE TO INSTALLER: Instructions must remain with installation.
Congratulations on the purchase of the Zoeller X71 Series submersible
grinder pump. This pump has been constructed in compliance with FM
and CSA testing. These requirements enable the unit to be listed as an
explosion proof pump rated for use in Class I, Division 1, Group C & D
environments. 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 sixty 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
incorporatedintothislineofheavy-dutysubmersiblegrinderpumps.ThisZoeller
pump will provide years of trouble-free service when installed according to the
manufacturers’ recommendations.
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 for
a proper start-up and warranty protection. 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. Should further assistance be
necessary please call our Technical Service Department at 1-800-928-PUMP
(7867).
REFER TO WARRANTY ON PAGE 2.
OWNER’S MANUAL
X71 HAZARDOUS ENVIRONMENT SERIES CLASS I ,
DIVISION 1, GROUP C & D SUBMERSIBLE GRINDER UNITS
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
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 _____
R
Certied to CSA Standard
C22.2 No. 145
Standard 3600 & 3615
Standard 3600
& 3615
Rev. 02/04
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
®
Register your
Zoeller Engineered Product
on our website:
http://reg.zoellerengprod.com/
CLICK ANYWHERE on THIS PAGE to RETURN TO SEPTIC PUMP INSPECTION & MAINTENANCE at InspectApedia.com

2
© Copyright 2015 Zoeller®Co. All rights reserved.
The Zoeller Engineered Products warrants its X71 Series of submersible pumps to
the original owner to be free from defects in workmanship and materials under the
following conditions and limitations by the owner paying the applicable percentage
of the list price of the following parts in effect at time of replacement in the specied
*installations.
Conditions
1. Approval of installation and start up of the equipment by the Zoeller Authorized
Factory Representative.
2. Removal, reinstallation and transportation charges shall be borne by the buyer.
3. Labor charges for warranty repair shall not be assumed by the company for repairs
made after one year from date of installation. Returns must have prior authorization
from the company.
4. Hazardous Environment Series pumps must be returned to Zoeller.
5. Controls and accessories warranty (See specic warranty below).
Each Zoeller X71 Series Pump installation is required to have a completed Zoeller Engineered Products Start-up Report (ZM1074). 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.
Failure to comply with the requirement will void the following warranty agreement.
Limited Warranty
*MUNICIPAL SEWAGE PERMANENT INSTALLATION
Five Year (10,000 hr) Months After Shipment - Limited Warranty
MONTHS 0-18 19-30 30-45 46-60
HOURS 0-3,000 3,000-5,000 5,000-7,500 7,500-10,000
Rotor & Stator 0% 30% 50% 80%
Mechanical Seal 0% 30% 50% 75%
Impeller 0% 30% 50% 80%
Cutter Assy. 0% 30% 50% 80%
Ball Bearings 0% 50% 80% 100%
Pump Housing 0% 30% 50% 100%
Controls and accessories included for 18 months.
Recommended Limits of a Grinder Pump Application
These recommended application limits are for pump stations pumping to a gravity main. 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.
Simplex Station Duplex Station
Model HP Homes GPD Homes GPD
X7110 High Head 3 2* 800 20 8,000
X7111 High Head 5 2* 800 25 10,000
X7112 High Head 7.5 2* 800 30 12,000
X7110 Reversing 3 2* 800 30 18,000
X7111 Reversing 5 2* 800 38 15,000
X7112 Reversing 7.5 2* 800 45 18,000
X7110 High Flow 3 2* 800 40 16,000
X7111 High Flow 5 2* 800 50 20,000
X7112 High Flow 7.5 2* 800 60 24,000
Limitations
corrosive substances, is in lieu of all other warranties expressed or implied.
Contact authorized service station to obtain any needed repair replacement parts. For
additional information pertaining to our warranty or if service cannot be obtained locally,
contact Zoeller Engineered Products, 3649 Cane Run Road, Louisville, Kentucky 40211-
1961, Attn: Customer Service.
ZOELLER ENGINEERED PRODUCTS EXPRESSLY DISCLAIMS LIABILITY FOR
SPECIAL, CONSEQUENTIAL, OR INCIDENTAL DAMAGES OR BREACH OR
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 limitation 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.
Zoeller Engineered Products neither assumes nor authorizes any person or company
to assume for it any other obligation in connection with the sale of its equipment. Any
enlargement or modication of this warranty by any other party is their sole responsibility.
No other warranties expressed or implied, including implied warranties of merchantability
and tness for a particular purpose will apply.
Zoeller Engineered Products’ sole obligation under all the above warranties shall be
to make repairs and to replace parts when necessary on products that have been
returned to Zoeller Engineered Products or an authorized service facility and found to
be defective by the company. Part(s) that fail and that inspection determines to be
defective in material or workmanship, will be repaired, replaced, or remanufactured
at Zoeller Engineered Product’s option provided, however, that by so doing we shall
not be obligated to replace an entire assembly, the entire mechanism, or the complete
unit. Major components and controls not manufactured by the company are covered
by the original manufacturer warranty in lieu of this warranty. This warranty shall not
apply to any product or part of a product, including pumps, controls, lifting devices,
basins, and power cables which are damaged or subject to misuse, accident, neglect,
operated outside the limits of the pump curves, used in a manner contrary to the printed
instruction, or damaged due to a defective power supply, improper electrical protection,
or faulty installation or repair.
The company will not be responsible for travel expenses, rented equipment, outside
contractor fees, or unauthorized repair shop expenses. 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 any material that has been disassembled without prior
approval of Zoeller Engineered Products, subjected to misuse, misapplication, neglect,
alternation, accident or act of God; that has not been installed in accordance with Zoeller
Engineered Products installation instructions; that has been exposed to but not limited to
hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.) or other abrasive or

3
© Copyright 2015 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 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" or larger in diameter.
3. INFORMATION - VENT HOLE PURPOSE. It is necessary that all sub-
mersible 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 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 4 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
OSHA guidelines on conned 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 specic details regarding installation and use. These materials should be retained for future
reference.
3. National Electrical Code (NEC) articles 500 through 503 explain in detail the requirements for the installation and wiring of electrical equipment
in hazardous locations.
1. Not for use in acidic atmospheres.
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. All pumps
are furnished with provisions for proper grounding to help protect you against
the possibility of electrical shock.
4. Make certain that the control box is within the reach of the pump’s power sup-
ply 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.
5. Make sure the pump electrical supply circuit is equipped with fuses and
disconnect or circuit breakers of proper capacity. 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. 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.
8. Electricalwiringandprotectionmustbeinaccordancewiththe National Electrical
Code per NEC articles 500 through 503 for installation in Class I, Division 1,
Group C & D environments, and any other applicable state and local electrical
requirements.
9. 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.
NOTE: CSA Certied pumps are certied to CSA Standard C22.2 No. 145.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
Electrical Data
Amps Winding
Service
Locked KVA Resistance
Model HP Factor RPM Voltage Phase Hertz Full Load In Air Shut Off Rotor Code
Line-to-Line
EX7110 3 1.2 3450 230 1 60 23.6 7.2 13.1 132 M 0.5/3.5
JX7110 3 1.2 3450 200 3 60 17.3 5.7 10.7 66 J 0.8
FX7110 3 1.2 3450 230 3 60 15.1 5.0 9.2 57 J 1.0
GX7110 3 1.2 3450 460 3 60 7.5 2.5 4.6 28.5 J 4.0
BAX7110 3 1.2 3450 575 3 60 5.7 2.3 3.1 25.2 K 6.6
EX7111 5 1.2 3450 230 1 60 28.0 7.2 17.1 132 G 0.5/3.5
JX7111 5 1.2 3450 200 3 60 20.7 7.6 14.4 94 E 0.44
FX7111 5 1.2 3450 230 3 60 18.0 6.2 13.0 82 E 0.62
GX7111 5 1.2 3450 460 3 60 9.0 3.1 6.5 41 E 2.4
BAX7111 5 1.2 3450 575 3 60 7.2 2.9 5.2 36 J 3.4
JX7112 7 1/2 1.2 3450 200 3 60 25.3 7.6 18.4 94 D 0.44
FX7112 7 1/2 1.2 3450 230 3 60 22.0 6.2 16.0 82 D 0.62
GX7112 7 1/2 1.2 3450 460 3 60 11.0 3.1 8.0 41 D 2.4
BAX7112 7 1/2 1.2 3450 575 3 60 9.0 2.9 6.5 36 E 3.4

4
© Copyright 2015 Zoeller®Co. All rights reserved.
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” IPS size.
(10) Basin must be in accordance with all applicable codes
and specications regarding Class I, Division 1, Group C &
D environments. Basin must be sized to allow a minimum
3 minute off-time between starts.
(11) The tethered variable level oat switches must be free and not
hang up on pump or pit peculiarities. Float switch circuits shall
be intrinsically safe.
(12) If a rail system is used, it should be non-sparking. Discharge
elbow must be rmly anchored 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, it should be non-sparking. The guide
rails are 2” 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.
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.
ZEPA0560
(1) 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.
(2) Install proper full ow check and shut-off valve.
(3) Installpropercontrols.(Outdoorpanelsin ventillated areas require
NEMA 3R or 4X enclosure) Float switch connections shall be
intrinsically safe.
(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 per NEC articles 500 through 503
for installation in Class I, Division 1, Group C & D environments,
to prevent moisture and gases from entering the control panel.
(6) When check valve is installed, drill a 3/16" 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 hous-
ing. 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.
9
10
5
1
8
4
3
4
7
10
7
15
6
14
11
12
13
2
6

5
© Copyright 2015 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.
SENSOR CABLE
The sensor cable is the smaller cable, which contains 5 wires. The red and orange wires connect to the thermal cut-out circuit and the black and white wires
connect to the seal leak probes. The green wire is a ground connection. All 5 wires must terminate in the control panel.
The following should be noted:
(1) The thermal sensors are normally closed and mounted adjacent to the motor windings. If internal temperatures exceed a maximum limit, the pump will
deactivate when the red and orange wires are connected in series to the control coil of the motor starter circuit. The pump is able to restart once the motor
cools down. Continued deactivation of this circuit requires the attention from maintenance personnel.
(2) The black and white seal leak wires are connected to a 330K ohm circuit in the seal cavity, where 2 seal leak probes are housed. An indicator light will
activate whenever water is present in the cavity. Whenever the seal leak light is activated, indicating that the lower seal has failed, the pump should be
removed and serviced in order to avoid damage to the motor.
(3) The green wire shall be connected to a ground lug in the panel.
CONTROL PANELS
These pumps require a control panel. The control panel rarely requires an explosion proof rating since it is usually located outside the hazardous area. A motor
starter circuit, control circuit, and alarm circuit within the panel are standard features. Outdoor enclosure ratings and alternating relays are often required. Vari-
able level oat switches are the most common level sensing device.
The following should be noted:
(1) Float switch connections must be intrinsically safe.
(2) Single phase units have externally mounted capacitors and starting relays. Your control panel should have provisions for mounting these starting compo-
nents.
(3) The seal failure sensor and thermal sensor protection shall be incorporated into the panel.
(4) 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.
(5) Hazardous Location pumps require panels that offer intrinsically safe relays and all other NEC requirements must be followed (See Article 500,501, 502
& 503 plus any others that apply.)
Pump Wiring Instructions
ZEPA0039E
POWER AND SENSOR CORD, LEAD IDENTIFICATION
SEAL FAILURE
BLACK & WHITE
LEAD
GROUND
POWER
CORD
LEAD
SENSOR CORD
GREEN GROUND
BLACK
GREEN
RED
WHITE
SENSOR
LEADS
TEMPERATURE
RED & ORANGE
SENSOR
LEADS
“X71 SERIES GRINDER” FOUR CONDUCTOR AWG. POWER CORD SIZE
MODEL HP 230/1PH 200/3PH 230/3PH 460/3PH 575/3PH
X7110 3 8 AWG. 12 AWG. 12 AWG. 12 AWG. 12 AWG.
X7111 58 AWG. 8 AWG. 12 AWG. 12 AWG. 12 AWG.
X7112 7.5 N/A 8 AWG. 8 AWG. 12 AWG. 12 AWG.
APPROXIMATE CORD DIAMETER PER GAUGE
12/4 AWG. .64"
8/4 AWG. .93"
NOTE: SENSOR CORD 18/5 AWG. APPROXIMATELY .44" DIAMETER.

6
© Copyright 2015 Zoeller®Co. All rights reserved.
X71 Series Three Phase Installation
Single Phase Installation (X7110 & X7111 Only)
All single phase models require start capacitor, run capacitor and relay in the circuit to start and operate properly. These components can be purchased separately
or prewired in a Zoeller control panel. For components purchased separately use the diagram for installation and hookup.
Single phase models are nonautomatic. To operate automatically a control panel must be added to the power circuit. Follow the instructions provided with the
panel.
WIRING DIAGRAM COMPONENT LAYOUT
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)
R
RELAY
START
MODELS
7110 / 7111
START CAP.
270-324UF 250V
RUN CAP.
50UF 370V
ZEPA0537C
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
Three phase pumps are nonautomatic. To operate automatically, a
control panel with level control is required. Follow the instructions
provided with the panel to wire the system.
Before installing a pump, check the pump rotation to insure that
wiring has been connected properly to power source, and that
the green lead of power cord (See wiring diagram), is connected
to a valid ground, Momentarily energize the pump, observing the
directions of kick back due to starting torque. Rotation is correct if
kick back is in the opposite direction of rotation arrow on the pump
casing. If rotation is not correct, switching of any two power leads
other than ground, should provide the proper rotation.
Refer to the wiring diagram supplied with specic electrical control
panel for correct electrical cable termination locations.
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.
330K OHMS RESISTANCE
SEAL FAILURE PROBES
3 PHASE MOTOR
SEAL FAILURE MOISTURE SENSOR
LEADS MUST BE CONNECTED TO
INDUCTION CIRCUIT IN THE CONTROL
PANEL.
THERMAL SENSOR
T1 T2
L1 L2
T3
L3
3Ø VAC
BLACK
GREEN
WHITE
SENSOR CABLE
RED
(N/C)
STARTER COIL
POWER CABLE
ORANGE
RECOMMENDED THERMAL SENSOR
CONNECTED IN SERIES WITH
ZEPA0038G
ZEPA0538

7
© Copyright 2015 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 standard
model pumps must not exceed 104°F (40°C). For longest service life all pumps should be
totally submerged on long pumping cycles. Maximum submerged depth is 50'.
These units are not designed to handle liquids other than water or sewage. If pump
is used in water contaminated with heavy, viscous, or abrasive materials, the war-
ranty will be voided.
NAMEPLATE DATA
The nameplate, located on the top of pump, indicates specic information about
the construction of the pump. The model number, date code, and serial number
information should be recorded on the front page in the “Owner’s Information”
section of this manual.
If the pump is repaired in th eld, its explosion
proof rating may be voided.
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.
• The impeller should be rotated every six months in order to keep the 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” 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 in an intrinsically safe 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
appreciably 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
wireofsingle phase orall three powerwiresof threephasewith the pumprunning.
Record these readings in the space provided in the “Owner’s Information”
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) 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 entering the enclosure. Prior to restarting system, the panel should be
inspected for presence of moisture and any loose connections.
Valves: Consult the valve/actuator supplier for information concerning these
systems components.
Maintenance
Repair and service must be performed by a rm approved by
Zoeller Company. The rm must be certied to work on explosion proof motors if
motor housing, adapter or cord cap is repaired. Contact Zoeller Technical Service
Department regarding warranty issues.
Ifrepair tothemotorhousing, adapterorcordcap isdisassembled
or repaired by a rm not certied to work on explosion proof motors, the explosion
proof rating is void and the FM approval tag MUST BE REMOVED FROM THE
PUMP.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 national
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
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 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:
• Inspect power cables for damage or wear. Replace immediately if damage
or wear is detected. Replace as required by an approved Service Station.
• Inspect impeller for damage or wear.
DOUBLE SEAL PUMPS
• Double seal pumps offer extra protection. During every inspection of the unit,
check the control panel seal failure for a warning. Whenever the seal leak is
activated, indicating that the lower seal has failed, the pump should be removed
and serviced in order to avoid damage to the motor.

8
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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 one line 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
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.
CONDITION
A. Pump will not start or run.