OWNER`S MANUAL
NOTICE TO INSTALLER: Instructions must remain with installation.
SECTION: 6.10.027
Your Peace of Mind is Our Top Priority ®
FM0937
1104
Supersedes
0903
®
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
MODEL 404/4404 AND 405/4405
Congratulations on the purchase of the Zoeller 400/4400 series
submersible pump. For over fifty years the name Zoeller has represented the standard for submersible sump 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 sewage product. Please read
and review this manual before installing the product. 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.
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 MANUAL AND ON PUMP.
Limited Warranty............................................................................. 2
Service Checklist............................................................................. 2
Preinstallation Information............................................................... 3
Pump Performance Data................................................................. 4
Typical Dewatering Installation........................................................ 4
Typical Sewage Installation ............................................................ 4
Pump Wiring Instructions................................................................. 5
Operation......................................................................................... 6
Maintenance.................................................................................... 6
Replacement Parts.......................................................................... 7
Owner’s Information
Model Number: _______________ Date Code: _______________
Simplex Panel P/N ______________________________
Duplex  Rail System P/N ________________________
Job Name: ____________________________________________
Dealer: _______________________________________________
Date of Purchase: ______________________________________
Contractor: ____________________________________________
Date of Installation: _____________________________________
System Readings During Operation: Voltage _____ Amps _____
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.
CAUTION
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.
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.
REFER TO WARRANTY ON PAGE 2.
Limited Warranty
Manufacturer warrants, to the purchaser and subsequent owner during the warranty period, every new product to be free from defects
in material and workmanship under normal use and service, when
properly used and maintained, for a period of one year from date of
purchase by the end user, or 18 months from date of original manufacture of the product, whichever comes first. Parts that fail within
the warranty period, one year from date of purchase by the end user,
or 18 months from the date of original manufacture of the product,
whichever comes first, that inspections determine to be defective in
material or workmanship, will be repaired, replaced or remanufactured
at Manufacturer's option, provided however, that by so doing we will
not be obligated to replace an entire assembly, the entire mechanism
or the complete unit. No allowance will be made for shipping charges,
damages, labor or other charges that may occur due to product failure,
repair or replacement.
This warranty does not apply to and there shall be no warranty for
any material or product that has been disassembled without prior approval of Manufacturer, subjected to misuse, misapplication, neglect,
alteration, accident or act of God; that has not been installed, operated
or maintained in accordance with Manufacturer's installation instructions; that has been exposed to outside substances including but not
limited to the following: sand, gravel, cement, mud, tar, hydrocarbons,
hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other abrasive
or corrosive substances, wash towels or feminine sanitary products,
etc. in all pumping applications. The warranty set out in the paragraph
above is in lieu of all other warranties expressed or implied; and we
do not authorize any representative or other person to assume for us
any other liability in connection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky
40211, Attention: Customer Service Department to obtain any needed
repair or replacement of part(s) or additional information pertaining
to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH
OF EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND
OF MERCHANTABILITY SHALL BE LIMITED TO THE DURATION
OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied
warranty, so the above limitation may not apply to you. Some states
do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may also have
other rights which vary from state to state.
Service Checklist
ELECTRICAL PRECAUTIONS- Before servicing a pump, always shut off the main power breaker and then unplug the
pump - making sure you are not standing in water and wearing insulated protective sole shoes. 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 becomes pressurized and hot under operating conditions - allow 2½ hours after disconnecting before attempting service.
CONDITION
COMMON CAUSES
A. Pump will not start or run.
Check fuse, low voltage, overload open, open or incorrect wiring, open switch, impeller or
seal bound mechanically, defective capacitor or relay when used, motor or wiring shorted.
Float assembly held down. Switch defective, damaged, or out of adjustment.
B. Motor overheats and trips overload or
blows fuse.
Incorrect voltage, negative head (discharge open lower than normal) impeller or seal
bound mechanically, defective capacitor or relay, motor shorted.
C. Pump starts and stops too often.
Float tight on rod, check valve stuck or none installed in long distance line, overload open,
level switch(s) defective, sump pit too small.
D. Pump will not shut off.
Debris under float assembly, float or float rod bound by pit sides or other, switch defective,
damaged or out of adjustment.
E. Pump operates but delivers little or no
water.
Check strainer housing, discharge pipe, or if check valve is used vent hole must be
clear. Discharge head exceeds pump capacity. Low or incorrect voltage. Incorrect
motor rotation. Capacitor defective. Incoming water containing air or causing air to
enter pumping chamber.
F. Drop in head and/or capacity after a
period of use. Increased pipe friction, clogged line or check valve. Abrasive material and adverse
chemicals could possibly deteriorate impeller and pump housing. Check line. Remove
base and inspect.
If the above checklist does not uncover the problem, consult the factory - Do not attempt to service or otherwise disassemble pump.
Service must be by Zoeller Authorized Service Stations.
© Copyright 2012 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.
CAUTION
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 receptacle 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 receptacle 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 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. FOR ADDED SAFETY. Pumping and other electrical equipment
must be connected to a 3-prong grounded receptacle with integral
ground-fault circuit interrupter (GFCI).
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.
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 sump, effluent, and sewage 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. Trapped air is caused by agitation and/or a dry
basin. This vent hole should be checked periodically for clogging
and cleaned as necessary. Water stream will be visible from this
hole during pump run periods.
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.
REFER TO WARRANTY ON PAGE 2.
FEET
METERS
Pump Performance Data
MODELS 404/4404/405/4405
12
40
35
10
TOTAL DYNAMIC HEAD
30
8
6
MODEL
404/4404
405/4405
Feet
Meters
5
1.5
10
3.0
15
4.6
20
6.1
25
7.6
30
9.1
35
10.7
Shut-off Head:
Gal.
Liters
300
1136
265
1003
224
848
184
698
134
503
60
227
--33 ft.(10.1m)
Gal.
Liters
361
1367
326
1234
284
1075
241
912
197
746
134
507
50
189
38 ft.(11.6m)
PUMP PERFORMANCE CURVE
405/4405
25
20
15
012116
4
10
404/4404
2
5
0
50
GALLONS
LITERS
0
200
100
400
150
600
200
800
250
1000
300
1200
350
400
1400
FLOW PER MINUTE
© Copyright 2012 Zoeller Co. All rights reserved.
3
Electrical Data
Model
HP
RPM
Voltage
Ph
HZ
Amps
Full Load
(@ 5’)
Amps
Locked
Rotor
KVA
Code
Fuse/Circuit
Breaker Amps
(Delay)
Winding
Resistance
Line-to-Line
1.7
E404
2
1725
230
1
60
12.9
44.0
F
20
WD404
2
1725
230
1
60
12.9
44.0
F
20
1.7
I404
2
1725
200/208
1
60
14.4
49.5
E
20
1.2
1.5
J404
2
1725
200/208
3
60
13.8
46.0
J
20
F404
2
1725
230
3
60
13.1
42.0
K
15
2.2
G404
2
1725
460
3
60
5.2
21.0
K
10
8.8
BA404
2
1725
575
3
60
4.1
17.9
K
10
13.6
E405
3
1725
230
1
60
19.0
44.0
C
25
1.7
WD405
3
1725
230
1
60
19.0
44.0
C
25
1.7
I405
3
1725
200/208
1
60
20.2
49.5
B
30
1.2
J405
3
1725
200/208
3
60
14.8
46.0
F
20
1.5
F405
3
1725
230
3
60
12.2
42.0
G
20
2.2
G405
3
1725
460
3
60
6.1
21.0
G
10
8.8
BA405
3
1725
575
3
60
4.8
17.9
G
10
13.6
Typical Dewatering 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 and local electrical requirements.
2. Install proper full flow check valve, equal to Zoeller Pump Company P/N 30-0160 (3”) or P/N 30-0170 (4”)
preferably just above the basin.
3. Install proper pump starting controls. Refer to Zoeller FM1596 or FM0486.
4. Install proper full flow shut off valve. One per pump.
5. All installations require a basin cover to prevent debris from failing into the basin and to prevent accidental
injury.
6. To prevent air locking, 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.
7. Secure power cord to avoid entanglement with variable level float switch mechanism.
8. Do not reduce pump discharge pipe below 3” IPS size.
9. Basin must be in accordance with all applicable codes and specifications.
10. Pump must be level and the tethered variable float switch must be free and not hang up on pump or pit
peculiarities.
11. Install ring and chain for lifting pump from pit.
12. If rail system is used (not shown in sketch), discharge elbow must be firmly anchored to the bottom of
SK1026
basin. No part of the pump can rest on the floor. The cantilevered weight of the pump is required to seal
the discharge connection. Refer to Zoeller FM0793 for rail system installation Instructions.
13. Basin must be clean and free of debris after installation.
3
4
2
5
11
1
6
7
10
8
9
PEAGRAVEL
Typical Sewage 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.
2
1. Electrical wiring and protection must be in accordance with the National Electrical Code, and any other
applicable state and local electrical requirements.
2. All installations require a basin cover to prevent debris from failing into the basin and to prevent accidental
1
TO AC
SOURCE
injury.
6
3. Do not reduce pump discharge pipe below 3” IPS size.
4. Install proper full flow unicheck valve, equal to Zoeller Pump Company P/N 30-0160 (3”) or P/N 30-0170
7
(4”).
5. When a 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.
4
6. Install proper full flow shut off valve. One per pump.
9
7. Secure power cord to avoid entanglement with variable level float switch mechanism.
5
8. Pump must be level and the tethered variable float switch must be free and not hang up on pump or pit
8
peculiarities.
3
9. Install ring and chain for lifting pump from pit.
10. Vent gases and odors to the atmosphere through vent pipe per Local and State codes.
11. If rail system is used, discharge elbow must be firmly anchored to the bottom of basin. No part of the pump
can rest on the floor. The cantilevered weight of the pump is required to seal the discharge connection.
Refer to Zoeller FM0793 for rail system installation Instructions.
SK1025
12. Basin must be clean and free of debris after installation.
10
2" IPS
GUIDE RAILS
4" CHECK
VALVE SHOWN
3/16"
VENT HOLE
11
4" DISCHARGE
ELBOW
© Copyright 2012 Zoeller Co. All rights reserved.
4
Pump Wiring Instructions
FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM ITS POWER SOURCE BEFORE HANDLING. Single phase
pumps are supplied with a 3-prong grounded plug to help protect you against the possibility of electrical shock. DO NOT UNDER ANY CIRCUMSTANCES
REMOVE THE GROUND PIN. The 3-prong plug must be inserted into a mating 3-prong grounded receptacle. If the installation does not have such
a receptacle, it must be changed to the proper type, wired and grounded in accordance with the National Electrical Code and all applicable local codes and
ordinances.
All three phase pumps require motor starting devices with motor overload protection. See FM0514 for simplex installations or FM0486 for duplex
installations. Three phase pumps must be installed in accordance with the National Electrical Code and all applicable local codes and ordinances. Pumps are
not to be installed in locations classified as hazardous in accordance with National Electrical Code, ANSI/NFPA 70.
“Risk of electrical shock” Do not remove power supply cord and strain relief or connect conduit directly to the pump.
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
Single Phase Installation
Three Phase Installation
Models E404/E405 and I404/I405 are nonautomatic. To operate automatically a control panel or 20 amp control switch (P/N 10-0748) must be added
to the power circuit. Follow the instructions provided with the panel or float
switch to wire the system.
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.
L2
L1
WHITE
GREEN
CAPACITOR
BLACK
L1
BLUE
RED
(2)
(1)
L2
L3
GREY
(3)
BROWN
GREEN/YELLOW
BLUE
(WHITE)
RED
(BROWN)
YELLOW
(BLACK)
BLACK
MOTOR
O.L.
WIRING DIAGRAM FOR MODELS
F404/F405 - 230V, 3 PH, 60 HZ
G404/G405 - 460V, 3 PH, 60 HZ
J404/J405 - 200/208V, 3 PH, 60 HZ
BA404/BA405 - 575V, 3 PH, 60 HZ
F4404/F4405 - 230V, 3 PH, 60 HZ
G4404/G4405 - 460V, 3 PH, 60 HZ
J4404/J4405 - 200/208V, 3 PH, 60 HZ
BA4404/BA4405 - 575V, 3 PH, 60 HZ
START
RUN
002397
WIRING DIAGRAM FOR MODELS
E404/E405 - 230V, 1 PH, 60 HZ
I404/I405 - 200/208V, 1 PH, 60 HZ
E4404/E4405 - 230V, 1 PH, 60 HZ
I4404/I4405 - 200/208V, 1 PH, 60 HZ
(1)
BLUE
(3)
(2)
RED
YELLOW
MOTOR
006848
WD Model Installation
L2
L1
SK305D
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
WHITE
GREEN
Tether Length 5 10152022
BLACK
min.
BLACK
RUN
CAPACITOR
FLOAT
SWITCH
BLUE
(1)
RED
(2)
(3)
BLUE
(WHITE)
RED
(BROWN)
YELLOW
(BLACK)
MOTOR
O.L.
START
011835
max.
Pumping Range 9 13.5 18 22 24
WHITE
Use only as a guide. Due to weight of
cable, pumping range above horizontal
is not equal to pumping range below
horizontal. Ranges are based on testing in
nonturbulent conditions. Range may vary
due to water temperature and cord shape.
As tether length increases, so does the
variance of the pumping range.
5" MIN.
22" MAX.
20 AMP SWITCH (WD & WH MODELS)
RUN
WIRING DIAGRAM FOR MODELS
WD405 - 230V, 1 PH, 60 HZ
WH4405 - 200/208V, 1 PH, 60 HZ
Models WD404/WD405 are fully automatic. A float switch is included and factory wired in the pump circuit to
provide automatic operation once the float switch is secured properly to the outlet pipe. Use the diagram above to
secure the float switch properly and obtain the proper tether to customize the on-off cycle to each application.
© Copyright 2012 Zoeller Co. All rights reserved.
5
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 130° F (54° C). WD models pump liquid should not
exceed 120° F (49° C). Nonautomatic pumps and pumps with adjustable
level controls must be totally submerged on long pumping cycles. 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 and date code 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 for more than six months, 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 for more than six months, 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.
STARTUP 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 of this manual for future reference.
After the preoperational functional test has been completed, system is ready
for operation. Zoeller recommends completing a Start-up Report (FM0990)
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, ect.). 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 (3 Ph systems) 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 below.
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 (used on dewatering pump stations only).
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.
to servicing.
Unit must be flushed and disinfected, inside and out, prior
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.
© Copyright 2012 Zoeller Co. All rights reserved.
6
Maintenance (continued)
• The pumps should be removed, cleaned, and inspected. Any defective
components should be replaced. Inspect and remove any sand, debris, or
mud present in the pump basin assembly. Inspect the panel for any presence of moisture in enclosure, loose connections, and general component
condition. check out location and condition of float switches.
• Dispose of the motor insulating oil properly.
• 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 an Zoeller
Authorized Service Station.
Every two years:
• Remove and replace insulating oil for 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.
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 changed 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.
Replacement Parts
The following parts lists are provided for ordering service parts. Consult factory for specific part numbers. Please have pump model number and date code for
immediate service. All repair and service should be preformed by a Zoeller Pump Company authorized service station.
REF.
NO.
DESCRIPTION
1
Cover & Cord Asm
*QTY
NOTES
REF.
NO.
1
3
24
Housing, Pump-Mach.
1
25
Cord Term & Seal Power
1
3
Seal, Cord-Asm & Str Rlf
1
3
DESCRIPTION
*QTY
2
Bolt, Eye
1
3
Cover-Mach.
1
Gasket, Case/Cover
1
27
Seal, Cord-Asm & STRRLF
0 to 1
Relay 200-230V, 1 Ph
0 to 1
28
Clamp, #6 Auto-SS
0 to1
Wire Pkg (5) Wires
0 to 1
29
0 to 1
30
4
•
5
6
•
7
Capacitor & Clamp Asm.
8
Housing, Mtr-Str
9
1
1
2 to 3
33
Plug,T est White
11
•
Seal, Thru Wall Term
3
Rotor & Brg
1
13
•
Bearing,Radial
1
14
•
Seal, Mtr Hsg
1 to 2
15
•
Oil, Dielectric-(44 Oz.Can)
1
Adapter-Mach.
1
17
•
Washer, Seal Locating & Snap Ring
0 to 1
18
•
Seal, Shaft
1 to 2
19
Adapter-Mach. Lower
0 to1
20
Impeller Asm
1
21
Key, Woodruff #404
1
22
Washer, 7/16 Std Flat SS
1
23
Nut, 7/16-20 SS Hex
1
34
2
•
•
31
Bearing, Sleeve
•
16
1&2
26
32
10
12
3
•
•
35
Cord Term & Seal Control
0 to1
Seal, Cord-Asm & Str Rlf Control Cord
0 to 1
Clamp Str Rlf
0 to 1
Screw, #6-32 x .25 RHM Sl Tc Stlgr
1 to 4
Float Switch Term & Seal
0 to 1
Seal, Float Switch Cord-Asm & Strain Relief
0 to 1
Connector, Wirenut
0 to 1
36
•
Screw, .25-20 x .75 HHm-SS
4
37
•
Screw, .25-20 x 1” HHm-SS
4
38
•
Screw, .313-18 x 1 HH Cap-SS
4 to 8
39
•
Screw, .313-18 x 1 HH Cap-SS
2
40
•
Washer, Flat - SS
2
41
Bracket, Lifting - SS
1
42
Resistor, Moisture Sensor Asm.
0
43
Wire Asm. Sensor
0
44
Cord Term & Seal Sensor
0
Seal, Cord-Asm & Strain Relief Sensor
0
Washer, Lock - SS
2
Rebuild Kit
1
45
46
•
•Indicates items included in rebuild kit. *Quantities vary depending upon model, voltage, and phase.
NOTES
NOTES:
1) Mtr. Hsg., Brg., Stator & Term. (Item 8) are preassembled at the factory and must be replaced as a unit. Stator is permanently attached to Mtr. Hsg. Plug
(Item 10); Seal, Thru Wall Term. (Item 11) and Bearing (Item 9) are replaceable.
2) When ordering Motor Housing, Bearing, Stator, and Term (Item 8); or Rotor and Bearing (Item 12) specify either GE or Emerson motor.
3) If an “X” follows Model No., or Date Mfg. on brass I.D. tag, consult factory for ordering of this part.
4) See FM1641 (404/4404) and FM0948 (405/4405) replacement parts list for listing of part numbers.
5) See FM0160 Parts Price Sheet for listing of parts prices.
© Copyright 2012 Zoeller Co. All rights reserved.
7
Replacement Parts (continued)
APPLICABLE CORD,
SEAL, & GROUND SCREW
38
39
45
40
"E" MODEL
1
25
27
2
36
"WD" MODEL
27
25
26
26
28
32
33
31
35
32
34
14
3
4
5
SENSOR
CORDAGE
15
38
32
7
10
32
11
17
38
DOUBLE SEAL ONLY
11
41
14
18
19
37
12
9 22
23
12
13
13
25
26
32
15
42
10
8
9
27
43
44
16
6
"I" MODEL
18
"J", "F", "G"
& "BA" MODELS
12 & 14 GA.
"J", "F", "G"
& "BA" MODELS
16 & 18 GA.
25
26
27
32
25
26
27
32
20
21
27
24
"XE" MODEL
25
26 29
30
28
31
32
SK1814
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