OWNER`S MANUAL
SECTION: Z2.30.150
Your Peace of Mind is Our Top Priority ®
ZM2669
0515
Supersedes
0811
®
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
Register your
Zoeller Engineered Product
on our website:
http://reg.zoellerengprod.com/
visit our web site:
www.zoeller.com
OWNER’S MANUAL
6680 SERIES SUBMERSIBLE NON-CLOG UNITS
Congratulations on the purchase of the Zoeller 6680 Series
submersible pump. For over seventy years the name Zoeller has
represented the standard for submersible dewatering and sewage
pumps. The same high quality workmanship and easy maintenance
design has been incorporated into this line of heavy-duty solidshandling 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 ZM1194 for repair manual on 6680
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 Sewage Installation ......................................................... 4
Pump Wiring Instructions..........................................................5-6
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH
THE PUMP.
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 2015 Zoeller® Co. All rights reserved.
Limited Warranty
The Zoeller Engineered Products warrants its 6680 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 6680 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 2015 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 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.
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
Model
BHP
Service
RPM
Voltage
Phase
Hertz
Full Load
Lock Rotor
Winding
Resistance
line to line
F6682
25
1.2
1750
230
3
60
68
314
0.12 - 0.14
G6682
25
1.2
1750
460
3
60
34
157
0.49 - 0.55
F6683
30
1.2
1750
230
3
60
80
360
0.09 - 0.10
G6683
30
1.2
1750
460
3
60
40
180
0.37 - 0.41
G6684
40
1.2
1750
460
3
60
52
240
0.31 - 0.35
G6685
50
1.2
1750
460
3
60
62
278
0.21 - 0.24
G6686
60
1.0
1750
460
3
60
75
278
0.21 - 0.24
© Copyright 2015 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.
TYPICAL OUTDOOR CONCRETE BASIN WITH VALVE BOX AND HINGED ACCESS COVERS
3
16
4
7
7
4
1
8
10
10
13
14
9
11
2
6
6
12
15
ZEPA0071_6680
(1) Electrical wiring and protection must be in accordance with the (9) Do not reduce pump discharge pipe below 4” IPS size.
National Electrical Code, and any other applicable state and local
electrical requirements.
(10) Basin must be in accordance with all applicable codes
and specifications. Basin must be sized to allow a minimum 3
(2) Install proper full flow check and shut-off valve.
minute lapse time between starts.
(3) Install proper controls. (Outdoor panels require NEMA 3R or 4X (11) Pump must be level and the tethered variable level float switch
enclosure)
must be free and not hang up on pump or pit peculiarities.
(4) All installations require a basin cover to prevent debris from falling (12) If a rail system is used, discharge elbow must be firmly anchored
into the basin and to prevent accidental injury.
to the bottom of basin. In fiberglass basin, the bottom will need
to be reinforced if the discharge elbow is used.
(5) Gas tight seals are required in all indoor sewage installations
to contain gases and odors.
(13) If a rail system is used, the guide rails are 2” schedule 40 pipe
for flanged horizontal discharge units. Brass, stainless steel or
(6) When check valve is installed, drill a 3/16” diameter hole in
galvanized steel is recommended.
the discharge pipe below the check valve even with the top of
the pump. NOTE: The hole must be below the basin cover and (14) Install ring and cable for lifting pump from pit.
cleaned periodically. Water stream will be visible from this hole
during pump run periods. Also a vent hole is drilled in the pump (15) Basin must be clean and free of debris after installation.
housing. Be sure that this hole is cleared during any servicing.
(16) Cords must be properly sealed to prevent moisture and gases
(7) Vent gases and odors to the atmosphere through vent pipe per
from entering the control panel.
Local and State codes.
(8) Secure power cord to avoid entanglement with variable level float
switch mechanism.
© Copyright 2015 Zoeller® Co. All rights reserved.
4
Pump Wiring Instructions
CAUTION
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.
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. If uncertain, the pump will draw the lowest
amps when rotating in the proper direction.
THERMAL SENSOR PROTECTION
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
(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 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.
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) A pump incorporating the seal failure sensor and thermal sensor protection require that interfacing terminals and functions be
incorporated into the panel.
(2) 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.
(3) 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.)
© Copyright 2015 Zoeller® Co. All rights reserved.
5
PHASE POWER AND SENSOR CORD, LEAD IDENTIFICATION
“6680 SERIES” FOUR CONDUCTOR
AWG. POWER CORD SIZE
RED & ORANGE
LEADS
TEMPERATURE
SENSOR
BLACK & WHITE
LEADS
SEAL FAILURE
SENSOR
BLACK
WHITE
RED
GREEN
GROUND
LEAD
MODEL
BHP
230/3PH
460/3PH
6682
25
2 AWG.
2 AWG.
6683
30
2 AWG.
2 AWG.
6684
40
2 AWG.
2 AWG.
6685
50
2 AWG.
2 AWG.
6686
60
2 AWG.
2 AWG.
GREEN GROUND
LEAD
POWER
CORD
APPROXIMATE CORD DIAMETER PER GAUGE
SENSOR CORD
18/5 AWG.
.50"
2/4 AWG.
1.38"
NOTE: SENSOR CORD 18/5 AWG. APPROXIMATELY
.50" DIAMETER.
ZEPA0039E
Three Phase Installation
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.
TYPICAL 3-PHASE WIRING DIAGRAM
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)
Refer to the wiring diagram supplied with specific
electrical control panel for correct cable termination
locations.
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: Sensor cable includes 5 leads; 2 leads for thermal sensor, 2 leads for moisture sensor, and a green ground lead. Sensor wire colors are as shown.
© Copyright 2015 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 2015 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 2015 Zoeller® Co. All rights reserved.
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