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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