owner`s manual 61 hd series submersible non

owner`s manual 61 hd series submersible non
SECTION: Z2.10.200
Your Peace of Mind is Our Top Priority ®
ZM1759
0214
Supersedes
0510
®
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
(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624
visit our web site:
www.zoeller.com
OWNER’S MANUAL
61 HD SERIES SUBMERSIBLE NON-CLOG UNITS
Congratulations on the purchase of the Zoeller 61 HD Series
submersible pump. Since 1939 the name Zoeller has represented the
standard for submersible dewatering and sewage pumps. The same
high quality workmanship and easy maintenance design has been
incorporated into this line of heavy-duty solids-handling submersible
sewage pumps. This Zoeller 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 non-clog 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.
Many items contained within, when followed correctly, will not only
ensure a long and problem-free life for the pump, but also save time
and money during installation. Reference ZM1760 for repair manual
on 61 HD Series Pumps. Should further assistance be necessary
please call our Technical Service Department at 1-800-928-PUMP
(7867).
Table of Contents
Safety Instructions
Safety Instructions........................................................................ 1
to avoid serious or fatal personal injury or major property damage, read and follow all safety
instructions in THIS manual and on THE pump.
Limited Warranty........................................................................... 2
Preinstallation Information........................................................... 3
Electrical Data................................................................................ 3
Typical Dewatering Installation.................................................... 4
Typical Sewage Installation ......................................................... 4
This manual is intended to assist in the installation
and operation of this unit and must be kept with
the pump.
Pump Wiring Instructions..........................................................5-6
Operation........................................................................................ 7
Maintenance................................................................................... 7
Service Checklist........................................................................... 8
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: ____________________________________
CAUTION
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.
INDICATES SPECIAL INSTRUCTIONS WHICH ARE
VERY IMPORTANT AND MUST BE FOLLOWED.
thoroughly review all instructions and warnings
prior to performing any work on this pump.
maintain all safety decals.
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Operation: Voltage _____ Amps ______
Refer to Warranty on page 2.
© Copyright 2014 Zoeller Co. All rights reserved.
Limited Warranty
The Zoeller Engineered Products warrants its 61 HD 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 specified
*installations.
Conditions
1. Approval of installation and start up of the equipment by the companies authorized
on-site representative
2. 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 (nine months in Construction/Mining
and other portable installations) to end customer. Returns must have prior written
authorization from the company.
4. Hazardous Environment Series pumps have special repair procedures. Contact
Zoeller.
5. Controls and accessories warranty (See specific warranty below).
*MUNICIPAL SEWAGE PERMANENT INSTALLATION
Five Year (10,000 hr) Months After Shipment - Limited Warranty
MONTHS
HOURS
0-18
19-30
30-45
46-60
0-3,000 3,000-5,000 5,000-7,500 7,500-10,000
Rotor & Stator Mechanical Seal
Impeller
Wear Rings
Ball Bearings Pump Housing
0%
0%
0%
0%
0%
0%
30%
30%
30%
50%
50%
30%
50%
50%
50%
80%
80%
50%
80%
75%
80%
100%
100%
100%
*AGRICULTURAL/FOOD PROCESSING AND PERMANENT INDUSTRIAL
INSTALLATIONS CONTAINING LIMITED QUANTITIES (5% BY VOLUME) OF
WASTE OR ABRASIVES AND PERMANENT INDUSTRIAL INSTALLATIONS
15 Months After Shipment - Limited Warranty
MONTHS
Rotor & Stator Mechanical Seal
Impeller
Wear Rings
Ball Bearings Pump Housing
0-9
9-15
0%
25%
25%
25%
0%
25%
50%
50%
50%
50%
50%
50%
Controls and accessories included for nine months.
*CONSTRUCTION/MINING - OTHER PORTABLE INSTALLATIONS
Nine Months After Shipment - Limited Warranty
MONTHS
0-9
Rotor & Stator
Mechanical Seal Wear Rings
Ball Bearings
Pump Housing 0%
25%
25%
0%
25%
Controls and accessories included for nine months.
Limited Repair Warranty At An Authorized Service Station
Beginning on the date of repair, the term of the repair warranty shall be the longer of
the unexpired original warranty term or 30 days.
Controls and accessories included for 18 months.
Limited Replacement Parts Warranty - 30 Days After Purchased
Each Zoeller 61 HD 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 kept on file at the Zoeller Engineered Products offices in Louisville,
KY. Failure to comply with the requirement will void the 5 year pro-rated warranty agreement.
Limitations
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 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 specific 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 modification of this warranty by any other party is their sole
responsibility. No other warranties expressed or implied, including implied warranties
of merchantability and fitness for a particular purpose will apply.
© Copyright 2014 Zoeller Co. All rights reserved.
2
Preinstallation Information
1. Inspect your pump. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using. DO NOT remove the test plugs in
the cover nor the motor housing.
2. Carefully read the literature provided to familiarize yourself with specific details regarding installation and use. These materials should be retained for future reference.
SEE BELOW FOR
LIST OF WARNINGS
1. Do not lift, carry, or hang pump by the electrical cables. Damage to the electrical
cables can cause shock, burns or death.
2.Make sure there is a properly grounded connection available. All pumps are
furnished with provisions for proper grounding to help protect you against the possibility of electrical shock.
3. Make certain that the control box is within the reach of the pump’s power
supply cord. DO NOT USE AN EXTENSION CORD. Extension cords that are too long
or too light do not deliver sufficient voltage to the pump motor. But, more important,
they could present a safety hazard if the insulation were to become damaged or the
connection end were to fall into the sump.
4. Make sure the pump electrical supply circuit is equipped with fuses and disconnect
or circuit breakers of proper capacity. A separate branch circuit is recommended,
sized according to the “National Electrical Code” for the current shown on the pump
nameplate.
5. 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 confined space requirements.
6. Risk of electric shock - These pumps have not been investigated for use in swimming
pool areas.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
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 installation of pumps using auxiliary variable level 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 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.
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.
Electrical Data
Service Amps Winding
ModelBHPFactor RPM Voltage Phase HertzKVA Code
Resistance
Full Load
In Air
Shut Off
Locked RotorLine-to-Line
E6111
5
1.2
3450 230
1
60
28.0
7.2
12.9
132.0
G
0.5/3.5
J6111
5
1.2 3450 200
3
60
17.5
5.7
9.2
66.0
J
0.8
F6111
5
1.2
3450 230
3
60
15.2
5.0
8.0
57.0
J
1.0
G6111
5
1.2
3450 460
3
60
7.6
2.5
4.0
28.5
J
4.0
BA6111
5
1.2
3450
575
3
60
6.1
2.3
3.2
25.2
J
6.5
J6112
7 1/2
1.2
3450
200
3
60
25.3
7.6
12.394.0D0.48
F61127 1/21.23450230 3 60 22.0 6.2 10.5
82.0
D
0.62
G61127 1/21.23450460 3 60 11.0 3.1 5.5
41.0
D
2.4
BA6112
7 1/21.23450575 3 60 9.0 2.9 4.5
36.0
E
3.4
J6113
10 1.0
3450
200
3
60
32.2
7.6
14.4
94.0
B
0.48
F6113
10 1.0
3450
230
3
60
28.0
6.6
12.3
82.0
B
0.62
G6113
10 1.0
3450
460
3
60
14.0
3.3
6.8
41.0
B
2.4
BA6113
10 1.0
3450
575
3
60
11.0
2.9
5.4
36.0
C
3.4
E6120
1
1.2
1750
230
1
60
6.9
4.1
4.7
48.0
M
2.5 / 4.8
J6120
1
1.2
1750 200
3
60
4.3
3.3
3.7
32.0
M
2.2
F6120
1
1.2
1750 230
3
60
3.7
2.2
2.6
28.0
M
3.0
G6120
1
1.2
1750
460
3
60
1.9
1.1
1.314.0M12.0
BA6120
1
1.2
1750
575
3
60
1.6
1.0
1.1
11.5
M
18.0
E6121
1 1/2
1.2
1750
230
1
60
8.9
4.3
5.3
48.0
J
2.5 / 4.8
J61211 1/21.21750200 3 60 5.9 3.3 3.7
32.0
J
2.2
F61211 1/21.21750230 3 60 5.1 2.3 2.9
28.0
J
3.0
G61211 1/21.21750460 3 60 2.6 1.2 1.5
14.0
J
12.0
BA6121
1 1/21.21750575 3 60 2.0 1.0 1.3
11.5
J
18.0
E6122
2
1.2
1750 230
1
60
14.5
6.3
10.5
86.0
L
.94/3.8
J6122
2
1.2
1750 200
3
60
7.8
4.5
5.0
46.0
J
1.5
F6122
2
1.2
1750 230
3
60
6.8
3.4
4.4
41.0
K
2.0
G6122
2
1.2
1750
460
3
60
3.4
1.2
2.2
20.5
K
8.0
BA6122
2
1.2
1750
575
3
60
2.7
1.4
1.816.2K12.0
E6123
3
1.2
1750 230
1
60
17.0
7.2
8.9
86.0
H
.94/3.8
J6123
3
1.2
1750 200
3
60
11.0
4.5
5.6
46.0
F
1.5
F6123
3
1.2
1750 230
3
60
9.6
3.4
4.7
41.0
F
2.0
G6123
3
1.2
1750
460
3
60
4.8
1.7
2.4
20.5
F
8.0
BA6123
3
1.2
1750
575
3
60
3.9
1.4
2.016.2F12.0
E6124
5
1.2
1750
230
1
60
28.0
16.1
19.7
139.0
H
.9 / 3.1
J6124
5
1.2
1750 200
3
60
17.5
6.2
7.6
64.0
D
1.0
F6124
5
1.2
1750 230
3
60
15.2
6.1
7.4
58.0
E
1.3
G6124
5
1.2
1750
460
3
60
7.6
3.1
3.7
29.0
E
5.2
BA6124
5
1.2
1750
575
3
60
6.1
1.5
3.4
23.0
E
8.0
J61257 1/21.01750200 3 60 25.3 17.9 18.3
83.0
C
0.5
F61257 1/21.01750230 3 60 22.0 15.0 15.7
72.0
C
0.7
G61257 1/21.01750460 3 60 11.0 7.5 7.9
36.0
C
2.8
BA6125
7 1/21.01750575 3 60 9.0 5.3 5.8
29.0
C
5.4
*Consult Factory.
© Copyright 2014 Zoeller Co. All rights reserved.
3
Typical Sewage/Waste Pumping System Installation
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) Electrical wiring and protection must be in accordance with
the National Electrical Code, and any other applicable state
TYPICAL INDOOR FIBERGLASS BASIN
and local electrical requirements.
(2) Install proper full flow check and shut-off valve.
3
5
(3) Install proper controls. (Outdoor panels require NEMA 3R
or 4X enclosure)
1
8
7
(4) All installations require a basin cover to prevent debris from
falling into the basin and to prevent accidental injury.
16
4
(5) Gas tight seals are required in all indoor sewage installations to contain gases and odors.
5
2
10
14
11
2
9
13
6
12
ZEPA0466
TYPICAL OUTDOOR CONCRETE BASIN WITH VALVE
BOX AND HINGED ACCESS COVERS
3
4
7
7
4
1
8
10
11
6
15
(8) Secure power cord to avoid entanglement with variable level
float switch mechanism.
(10) Basin must be in accordance with all applicable codes
and specifications. Basin must be sized to allow a minimum
3 minute lapse time between starts.
(11) Pump must be level and the tethered variable level float switch
must be free and not hang up on pump or pit peculiarities.
(12) If a rail system is used, discharge elbow must be firmly anchored to the bottom of basin. In fiberglass basin, the bottom
will need to be reinforced if the discharge elbow is used.
(13) If a rail system is used, the guide rails are ¾” schedule 40
pipe for threaded vertical discharge units and 2” schedule 40
pipe for flanged horizontal discharge units. Brass, stainless
steel or galvanized steel is recommended.
(14) Install ring and cable for lifting pump from pit.
10
14
(7) Vent gases and odors to the atmosphere through vent pipe
per Local and State codes.
(9) Do not reduce pump discharge pipe below 3” IPS size.
15
16
(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. Water stream will be visible
from this hole during pump run periods. Also a vent hole is
drilled in the pump housing. Be sure that this hole is cleared
during any servicing.
(15) Basin must be clean and free of debris after installation.
13
9
(16) Cords must be properly sealed to prevent moisture and gases
from entering the control panel.
2
6
12
ZEPA0071
© Copyright 2014 Zoeller Co. All rights reserved.
4
Pump Wiring Instructions
Installation and checking of electrical circuits and hardware should be performed by a qualified 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 float cords all must be sealed to prevent gases from the basin entering the control panel.
INSTRUCTIONS FOR CHECKING ROTATION OF THREE PHASE UNITS
It is very important that these units be connected for proper rotation. Since no rotating parts are visible without removing the pump from the pit,
the rotation on 3 phase units should be checked before installation into the pit as follows:
After the proper electrical connections are made, momentarily energize the pump observing the direction of kick back due to starting torque. The rotation is
correct if the kick back is in the opposite direction of the rotation arrow. If the rotation is not correct, disconnect power and switch any two power leads. Turn
power back on and retest for proper rotation.
THERMAL SENSOR PROTECTION (OPTIONAL FEATURE)
Two thermal sensors and leads are wired in series with each other and located adjacent to the motor windings. When the temperature exceeds the maximum
recommended limit, the pump will deactivate when the lead wires are connected to the magnetic starter circuit of a control panel with the thermal cutout feature.
Continual deactivation of this circuit requires attention from maintenance personnel.
MOISTURE SENSORS (OPTIONAL FEATURE)
(1) Pumps with moisture sensors have a separate sensor cord in addition to the power cord.
(2) Sensor cord conductors are connected to sensors probes in the lower seal cavity. The conductor wires are terminated in the control panel for activating
an indicator light when moisture is present in the lower seal cavity.
(3) When the moisture indicator light is activated, the lower seal has allowed leakage of water into the lower oil-filled seal cavity. The pump should be serviced
within 30 days to avoid damage to the motor and bearings.
(4) Oil in the motor housing and lower seal cavity must be checked when pump is serviced. If oil from the motor housing contains water or other contamination, both seals should be replaced during maintenance. Always replace with new factory recommended oil and service parts. All warranty repairs must
be made by Zoeller Authorized Service Stations.
(5) On existing applications where the control panel only has one moisture sensor hookup per pump, one moisture sensor lead from the pump should be
hooked to the moisture sensor lead in the panel, the other moisture sensor lead from the pump should be hooked to ground to complete the circuit.
(6) Moisture sensor circuit can be checked for continuity (complete circuit) with a (Volt-OHM-Meter). Set the VOM to read resistance and connect the VOM
leads to the sensor cord black and white wires. The VOM should read approximately 330k Ohms. Resistance readings significantly lower indicate a seal
leak with water in the seal chamber. If VOM reading is open then a problem exists with moisture sensor circuit.
Check resistance between the green ground conductor of the pump power cord and the sensor cord black and white wires. This resistance reading should
indicate an open circuit. If VOM reading returns a reading other than open, then a problem exists with the sensor circuit wiring or cordage. If resistance
readings show a problem with either test, then pump should be repaired by a Zoeller Authorized Service Station.
PUMPS WITHOUT MOISTURE SENSORS
(1) Double seal pumps offer extra protection from damage caused by seal failure. Pumps are installed without sensor probes.
(2) Pumps without sensor probes should be serviced on a periodic preventative maintenance schedule.
(3) Oil in the motor housing and lower seal cavity must be checked when pump is serviced. If oil from the motor housing contains water or other contaminations, both seals should be replaced during maintenance. Always replace with new factory recommended oil and service parts. All warranty repairs must
be made by Zoeller Authorized Service Stations.
CONTROL PANELS
These pumps are nonautomatic. They require a control panel. A motor starter circuit, control circuit, and alarm circuit within the panel are standard features.
Outdoor enclosures and alternating relays are often required. Variable level float switches are the most common level sensing device. The following should be
noted.
(1) Single phase units have externally mounted capacitors and starting relays. Your control panel should have provisions for mounting these starting components.
(2) A pump incorporating the seal failure sensor and thermal sensor protection require that interfacing terminals and functions be incorporated into the
panel.
(3) All pumps require overload protection in panel. Use with approved motor control that matches motor input in full load amperes with overload element(s)
selected or adjusted in accordance with control instructions.
(4) Hazardous Location pumps require panels that offer intrinsically safe relays and all other NEC requirements must be followed (See Article 500,501 & 502
plus any others that apply.)
“61 HD SERIES” FOUR CONDUCTOR AWG. POWER CORD SIZE
PHASE POWER AND SENSOR CORD, LEAD IDENTIFICATION
BLACK
WHITE
RED
GREEN
GROUND
LEAD
POWER
CORD
MODEL
RED & ORANGE
LEADS
TEMPERATURE
SENSOR
BLACK & WHITE
LEADS
SEAL FAILURE
SENSOR
GREEN GROUND
LEAD
BHP
230/1PH
200/3PH
230/3PH
460/3PH
575/3PH
6120
1
12 AWG.
12 AWG.
12 AWG.
12 AWG.
12 AWG.
6121
1.5
12 AWG.
12 AWG.
12 AWG.
12 AWG.
12 AWG.
6122
2
12 AWG.
12 AWG.
12 AWG.
12 AWG.
12 AWG.
6123
3
12 AWG.
12 AWG.
12 AWG.
12 AWG.
12 AWG.
6124
5
8 AWG.
12 AWG.
12 AWG.
12 AWG.
12 AWG.
6125
7.5
N/A
8 AWG.
8 AWG.
12 AWG.
12 AWG.
6111
5
8 AWG.
12 AWG.
12 AWG.
12 AWG.
12 AWG.
6112
7.5
N/A
8 AWG.
8 AWG.
12 AWG.
12 AWG.
6113
10
N/A
8 AWG.
8 AWG.
12 AWG.
12 AWG.
SENSOR CORD
Approximate cord diameter per gauge
zepa0039e
12/4 AWG.
.64"
8/4 AWG.
.93"
NOTE: SENSOR CORD 18/5 AWG. APPROXIMATELY .44" DIAMETER.
© Copyright 2014 Zoeller Co. All rights reserved.
5
Single Phase Installation
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 Zoeller control panel. For components purchased separately used 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
RED
BLACK
3
T2
START
START
RELAY
2
1
6
4
3
1
5
2
6
4
1
2
MODELS
6111 / 6122 / 6123 / 6124
AND 6120 / 6121 USING GE
RELAY AFTER 10/1/07
COMPONENT LAYOUT
3
WHITE
RED
BLACK
2
A
L1
L2
T1
T2
2
R
5
RUN CAPACITOR
MAIN
GREEN
PUMP
START
1
2
3
WHITE
START
1
zepa0477
230 VAC 1Ø
RED
MAIN
GREEN
RUN CAP.
40UF 370V
BLACK
PUMP
START CAP.
324-389UF 125V
WHITE
WIRING DIAGRAM
WHITE
MODELS
6120/6121
zepa0478
230 VAC 1Ø
FROM CONTACTOR
L1
L2
1
START
RELAY
1
2
5
START CAPACITOR
(SEE CHART)
RUN CAPACITOR
(SEE CHART)
START
CAPACITOR
BLACK
5
BLACK
MAIN
GREEN
RED
T1
START
2
RUN
CAPACITOR
START
RELAY
L2
BLACK
WHITE
BLACK
1
PUMP
L1
WHITE
MAIN
GREEN
BLACK
L2
COMPONENT LAYOUT
230 VAC 1ø
WHITE
L1
MODELS 6120 / 6121
USING SUPCO PR90
RELAY BEFORE 10/1/07
PUMP
WHITE
230 VAC 1ø
FROM CONTACTOR
START
RELAY
START
CAPACITOR
RUN CAPACITOR
(SEE CHART)
MODELS
6120/6121
6111/6122/6123/6124
zepa0538
START CAPACITOR
(SEE CHART)
START CAP.
216-259UF 250V
270-324UF 250V
RUN CAP.
40UF 370V
50UF 370V
zepa0537A
Three Phase Installation
TYPICAL 3-PHASE WIRING DIAGRAM
Three phase pumps are nonautomatic. To operate
automatically, a control panel 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 specific
electrical control panel for correct cable termination
locations.
Refer to Sensor and Control Panel sections on
page 4.
3Ø VAC
L1
L2
L3
T1
T2
T3
RECOMMENDED THERMAL SENSOR
CONNECTED IN SERIES WITH
STARTER COIL
SENSOR CABLE
POWER CABLE
ORANGE
RED
BLACK
WHITE
GREEN
THERMAL
SENSOR
(N/C)
SEAL FAILURE PROBES
330K OHMS RESISTANCE
3 PHASE MOTOR
SEAL FAILURE MOISTURE SENSOR
LEADS MUST BE CONNECTED TO
INDUCTION CIRCUIT IN THE CONTROL
PANEL.
ZEPA0038E
NOTE 1: Optional sensor cable includes 5 leads; 2 leads for thermal sensor, 2 leads for moisture sensor, and a green ground lead. If one sensor only is specified,
both sensors are provided and must be hooked up to validate warranty. The sensors must be specified at time of initial pump order and are not available for field
installation. Sensor wire colors are as shown.
© Copyright 2014 Zoeller Co. All rights reserved.
6
Operation
General
Zoeller pumps are lubricated and tested at the factory prior to shipment and
require minimum pre-start-up maintenance.
Maximum continuous operating temperature of pump liquid for standard model
pumps must not exceed 140° F (40° C). For longest service life all pumps should be totally
submerged on long pumping cycles and a maximum of ½ hour run time per hour.
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 warranty will be voided.
Nameplate data
The nameplate, located on the top of pump, indicates specific 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.
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 checked:
• Correct pump rotation (3 Phase units only).
• Clean pit.
• Panel 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:
• Pump power cables properly connected to panel.
•
•
•
•
Float cables properly connected to panel.
Conduit connections to panel are properly sealed.
Thermal overload adjustments made in the panel.
After installing the pump into the containment area, with adequate submergence, open the discharge valve fully. Start the unit using manual controls.
If flow 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 qualified electrician take voltage and current measurements on the
black wire of single phase or all three power wires of three phase with the
pump running. 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 first time or after a system has had a significant 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 float 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 five 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 should be performed by a Zoeller Pump
Company Authorized Service Station only.
Safety procedures
For your protection, always disconnect pump and panel from
its power source before handling.
Never enter the basin until it has been properly vented and
tested. Any person entering a basin should be wearing a harness with safety rope
extending to the surface so that they can be pulled out in case of asphyxiation.
Sewage water gives off methane and hydrogen sulfide gases, both of which
can be highly poisonous.
Installation and checking of electrical circuits and hardware should be performed
by a qualified electrician.
Pump is never to be lifted by power cord.
Unit must be flushed 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 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.
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 float operation.
• Listen for proper check valve operation.
• Duplex Units - Check for even operating times. Uneven times indicate a
defective unit, float 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 float switches.
every year:
• In addition to the monthly checks, the basin should be inspected and cleaned.
Any defective components should be replaced. Inspect and remove any sand,
debris, or mud present in the pump basin assembly.
every two years:
• Check insulating oil in motor and seal chambers. Inspect oil for contaminations
as follows:
• Clear oil, no burnt odor - Oil, motor and seals are in satisfactory condition.
• Dark oil, burnt odor - Pump motor has overheated. Check the motor winding resistance
to ground. Ohm readings of 1 megohm or higher is required. If lower readings are
present, return the unit to an Zoeller Authorized Service Station for service.
• Milky, emulsified oil - Seals have failed. Unit must be returned to an authorized
service facility for service.
• Dispose of the motor insulating oil properly if replacement is required.
• Inspect power cables for damage or wear. Replace immediately if damage
or wear is detected.
• Inspect impeller for damage or wear. Replace as required by a Zoeller Authorized Service Station.
DOUBLE SEAL PUMPS
• Double seal pumps offer extra protection from damage caused by seal failure.
• Oil in a motor housing and lower seal cavity must be checked when pump
is serviced. If oil from the motor housing contains water or other contamination, both seals should be replaced during maintenance. Always replace with
new factory recommended oil and service parts. All repairs must be made by
Zoeller Authorized Service Stations.
© Copyright 2014 Zoeller Co. All rights reserved.
7
Service Checklist & Trouble Shooting
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 flooded conditions, contact your local electric company or a qualified licensed
electrician for disconnecting electrical service prior to pump removal.
Submersible pumps contain oils which become pressurized and hot under operating conditions - allow 2½ hours after disconnecting before attempting service.
CONDITION
A. Pump will not start or run.
Steps
No. 1
Check Voltage At
If No Voltage
If Voltage
Line terminals in pump’s
control panel
L1 - L2 - L3 (3 Phase)
Check Disconnect switch, line
fuse, and/or circuit breakers
in power supply circuit.
Proceed to No. 2
No. 2
Pump motor terminals in
Check for control circuit
pump’s control panel voltage. Check out magnetic
starter contacts, thermal
T1 - T2 - T3
overloads, and float switches
Check starting relay
and capacitor (1
phase units). Check
pump for ground,
and binding impeller
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 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 under float switch
- Float travel obstructed
- Defective or damaged float switch
- Magnetic starter contacts shorted
- Air lock - check vent hole
E. Pump operates but delivers little or no water.
- Check for plugged Pump housing, discharge 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.
© Copyright 2014 Zoeller Co. All rights reserved.
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