REFERENCE DOCUMENT- EXISTING PUMP SPECIFICATIONS.pdf

Submersible Grinder Pumps

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Text Box Kentucky Lock Existing Pump Specifications Reference Document

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FOR REFERENCE ONLY

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• Sewage lift stations.

• Housing developments.

• Low pressure sewer systems.

• High vertical lift or long force mains.

• 440 Stainless steel cutter and plate hardened to Rockwell C55-60.

• Discharge size - 2½" fl anged horizontal adaptable to 3" fl ange, 2" NPT optional.

• Seals - dual mechanical carbon/rotary ceramic/stationary, Buna-N elastomers.

• Moisture detection system.

• Construction - Cast iron ASTM A-48, Class 30, 30,000# tensile strength, protected with a corrosion resistant baked on epoxy powder coating.

• Balanced concentric pump housing and impeller.

• Attaching hardware - 304 stainless steel.

• O-ring seals - Buna-N.

• Impeller - Bronze vortex design.

• Optional: Trimmed Impeller. High Flow

Silicon carbide seal(s). Automatic Reversing Additional cord length ____ ft. (3-Phase Only) 2" NPT Vertical Discharge - Rail Systems

HH and HF Units Only

• 1 Phase - 230 Volt (3 & 5 BHP Only).

• 3 Phase - 200/230/460/575 Volt, 3450 RPM.

• Stator - Class F insulation and lead wires.

Nema B design.

• Thermal sensor with leads.

• Housing - Cast iron, oil-fi lled.

• Ball bearings - Upper and lower high carbon chromium steel.

• Power and sensor cable length - 25'.

1. 25' heavy duty power cable.

2. Protected cable entrance. The compression grommet allows for field replacement of the cable.

3. Each conductor is individually sealed to eliminate cord wicking of liquids.

4. Lifting lug integral part of housing.

5. Oil-fi lled motor housing assures uniform heat distribution, lubricates bearings, and conducts heat for cooler running.

6. Heavy duty motor features ball bearing construction. Class F motor insulation is double dipped and baked. End connections and lead wires are Class F. At maximum load, winding temperature will not exceed 250°F with motor housing not submerged.

7. Tandem seals. Carbon/rotating, ceramic/stationary, Buna-N elastomers.

8. Upper and lower high carbon chromium steel ball bearings.

9. Stainless steel shaft and hardware resists corrosion.

10. Patented moisture detection system with upper and lower probes, protecting the motor from liquid entry.

11. Thermal sensor protection.

12. 25' sensor cable.

ZM1766

Supersedes

13. High effi ciency impeller design made of cast bronze, fully balanced with integral pump out vane to clear debris.

14. “Star” type stainless steel cutter and plate hardened to Rockwell C55-60.

15. Concentric case reduces radial loading for longer bearing and seal life.

16. 2½" Flanged horizontal discharge adaptable to 3" fl ange. Optional 2" NPT vertical discharge available for HH and HF models.

17. Vent hole helps prevent air locking.

18. Screw on pipe legs for fi eld fl exibility.

19. Class 30 Cast Iron housing protected with corrosion resistant baked on epoxy powder coating.

20. Finned motor housing for quicker heat dissipation.

For additional information on 71 Series pumps, refer to catalogs on Performance Data

- ZM2013; Dimensional Data - ZM1787, ZM2186; Guide Specifi cations - ZM1767, ZM1771, ZM1769; Service Manual and Replacement Parts List - ZM1788; Owners Manual

- ZM1789.

For information on additional Zoeller products refer to catalog on Rail Systems - ZM1347;

Control Panels - ZM1342 and ZM1343; Float Switch Brackets -ZM1328; Pump Lifting Cables - ZM1328; Check Valves and Piping Accessories - ZM1348.

(Tested to UL778 and CSA22.2 108 Standards)

Product information presented here refl ects conditions at time of publication. Consult factory regarding discrepancies or inconsistencies. MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347

SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961

(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624

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Zoeller Engineered Products • 3649 Cane Run Road • Louisville, Kentucky 40211-1961 • (502) 778-2731

SWPA Data Categories Presented -- Data on this sheet supply design information as the minimum recommended by the Submersible Wastewater Pump Association and is de ned in accordance with SWPA’s Standardized De nitions for Pump and Motor Characteristics. The accuracy of the data is the responsibility of Zoeller Engineered Products.

For unusual conditions a reserve safety factor is engineered into the design of every Zoeller pump.

7110 3.0 1.2 23.6 132.0 17.3 66.0 15.1 57.0 7.5 28.5 6.0 25.2 7111 5.0 1.2 28.0 132.0 20.7 94.0 18.0 82.0 9.0 41.0 7.2 36.0

7112 7.5 1.2 NA NA 25.3 94.0 22.0 82.0 11.0 41.0 9.0 36.0

* Units with FLA greater than 20 amps use a #8-4 gauge power cord.

** Requires a circuit in control panel to function.

CARBON/CERAMIC

CARBON /SILICON CARBIDE SILICON CARBIDE/SILICON CARBIDE

CARBON /SILICON CARBIDE SILICON CARBIDE/SILICON CARBIDE

THERMAL SENSORS WITH AUTOMATIC RESET

MOISTURE SENSING PROBES

DESIGN POINT: ____ GPM @ ____' TDH, IMPELLER DIA. ____"

104°F (40°C)

Bronze Vortex Standard

ANSI B16.1 NEMA B (3 Ph) NEMA L (1 Ph)

245 lbs. (111 kg) 25' (7.6 m) _______'

416 SS #12-4 SO*

3450 Class F

Submersible 311°F (155°C)

(Tested to UL778 and CSA22.2 108 Standards)

3.0 5.0 7.5

1.2 1.2 1.2

M (1 Ph) G (3 Ph) G (1 Ph) H (3 Ph) D

5.3 6.4 8.0

REFER TO PUMP PERFORMANCE DATA

2 1/2" Flanged, adaptable to 3" 2" NPT

Ph)

h) H (3 P

2 NPT

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ZM1786

Supersedes

Zoeller Engineered Products • 3649 Cane Run Road • Louisville, Kentucky 40211-1961 • (502) 778-2731

SWPA Data Categories Presented -- Data on this sheet supply design information as the minimum recommended by the Submersible Wastewater Pump Association and is de ned in accordance with SWPA’s Standardized De nitions for Pump and Motor Characteristics. The accuracy of the data is the responsibility of Zoeller Engineered Products.

FLANGED DISCHARGE HIGH HEAD MODELS

Model Horsepower Diameter

7110 - 3.0 BHP - 5-1/4"

7111 (1 Phase) - 5.0 BHP - 6" 7111 (3 Phase) - 5.0 BHP - 6-1/4" 7112 (3 Phase) - 7.5 BHP - 7-1/8"

Motor overloading can occur if an oversized impeller is used in an application without enough head. Always verify the actual TDH of an application before using a nonstandard impeller size. Single phase pumps are not sold with oversized impellers.

Impeller Trim

Product information presented here refl ects conditions at time of publication. Consult factory regarding discrepancies or inconsistencies. MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347

SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961

(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624

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ZM1787

Supersedes

*All dimensions in inches unless otherwise noted.

Product information presented here reflects conditions at time of publication. Consult fac-tory 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

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ZM1789

Supersedes

Congratulations on the purchase of the Zoeller 71 Series sub mers ible grinder pump. Zoeller Grinder Pumps are designed for grind ing and pump-ing sanitary sewage from sub mers ible lift stations. The pump is in tend ed to grind and pump reasonable quan ti ties of dis pos able diapers, san i tary napkins, paper tow els, rub ber ma te ri als, plas tics, cig a rette butts and other items nor mal ly found in sanitary sewage applications. For over sixty years the name Zoeller has rep re sent ed the standard for sub mers ible dewatering and sew age pumps. The same high quality work man ship and easy main te nance design has been in cor po rat ed into this line of heavy-duty submersible grinder pumps. This Zoeller pump will pro vide years of trou ble-free service when installed ac cord ing to the man u fac tur ers’ rec om men da tions.

OWNER’S MANUAL

71 SERIES SUBMERSIBLE GRINDER UNITS

This manual in cor po rates the in stal la tion, op er a tion, main te nance, and service instructions into one doc u ment to aid in the own er ship of a Zoeller submersible wastewater product. Please read and re view this manual before installing the product. Follow the steps and procedures listed on ZM1074 for a proper start-up. Many items con tained with in, when fol lowed cor rect ly, will not only ensure a long and prob lem-free life for the pump, but also save time and money during installation. Reference ZM1788 for repair manual on 71 Series Grinder Pumps. Should further as sis tance be nec es sary please call our Tech ni cal Service De part ment at 1-800-928-PUMP (7867).

Table of Contents Safety Instructions

This is a When you see this symbol on the pump or in the man u al, look for one of the following signal words and be alert to the potential for personal injury or property damage.

Warns of hazards that cause serious personal injury, death or major property damage.

Warns of hazards that cause serious personal injury, death or major property damage.

Warns of hazards that cause personal injury or prop er ty damage.

INDICATES SPECIAL INSTRUCTIONS WHICH ARE

VERY IMPORTANT AND MUST BE FOLLOWED.

Owner’s Information

Product information presented here re fl ects con di tions at time of publication. Consult fac-tory re gard ing dis crep an cies or in con sis ten cies.

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Limited Warranty

6. Controls and accessories warranty (See specifi c warranty below).

Five Year (10,000 hr) Months After Shipment - Limited Warranty

MONTHS 0-18 19-30 30-45 46-60

HOURS 0-3,000 3,000-5,000 5,000-7,500 7,500-10,000

Rotor & Stator 0% 30% 50% 80% Mechanical Seal 0% 30% 50% 75% Impeller 0% 30% 50% 80% Cutter Assy. 0% 30% 50% 80% Ball Bearings 0% 50% 80% 100% Pump Housing 0% 30% 50% 100%

Controls and accessories included for 18 months.

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 main-tained, 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 fi rst.

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 fi rst, 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 sub-stances 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 applications other than in raw sewage 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, Lou is ville, Ken tucky 40211, At-tention: Cus tom er Ser vice De part ment to obtain any need ed repair or re place ment of part(s) or additional in for ma tion pertaining to our 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 con se quen tial dam ag es, so the above lim i ta tion or exclusion may not apply to you.

This warranty gives you specifi c legal rights and you may also have other rights which vary from state to state.

Limitations

Recommended Limits of Application

These recommended application limits are for pump stations pumping to a gravity main. Low-pressure pipe systems should be designed with a pump located at each house. For applications where a lift station would handle more than 60 homes, a solids handling type pump should be considered.

*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service during unusual conditions.

Simplex Station Duplex Station

Model HP Homes GPD Homes GPD

Each Zoeller 71 Series Pump installation is re quired to have a completed Zoeller Engineered Products Start-up Report (ZM1074). The report is to be completed by an approved Start-up Technician in the presence of the installing contractor. A copy of this report will be on fi le at the Zoeller Engineered Products offi ces in Louisville, KY.

The Zoeller Engineered Products warrants its 71 Series of submersible pumps to the original owner to be free from defects in workmanship and materials under the fol low ing conditions and limitations. The owner will pay the ap pli ca ble per cent age of the list price of the fol low ing parts in effect at time of replacement.

Conditions

1. Approval of the installation and start up of the equipment by the authorized

Zoeller representative.

2. Pump removal, reinstallation and transportation charges shall be borne by the owner.

3. Warranty repairs shall be conducted by an authorized service station only.

4. Labor charges for warranty repair shall not be assumed by Zoeller for repairs made after one year from date of installation. Returns to Factory must have prior au tho ri za tion from the company.

5. Hazardous Environment Series pumps must be serviced at an approved service station or returned to the factory.

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Preinstallation Information

. Check to be sure your power source is ca pa ble of han dling the voltage re quire ments of the motor, as in di cat ed on the pump nameplate.

The float switches must be connected to an intrinsically safe circuit in the control panel. The installation of pumps using aux il ia ry vari able level fl oat switch es is the re spon si bil i ty of the in stall ing party and care should be taken that the teth ered fl oat switch will not hang up on the pump apparatus or pit pe cu liar i ties and is secured so that the pump will shut off. It is rec om mend ed that rigid piping and fi ttings be used and the pit be 36" or larger in diameter.

It is nec es sary that all sub-mers ible pumps ca pa ble of handling var i ous sizes of solid waste be of the bottom intake design to reduce clog ging and seal failures. If a check valve is in cor po rat ed in the in stal la tion, a vent hole (approx. 3/16") must be drilled in the dis charge 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 pe ri od i cal ly for clogging and cleaned as necessary. Trapped air is caused by agitation and/or a dry basin.

Water ham mer creates mo men tary high pres sure surg es. These surges can cause severe damage to check valves and the piping system. Con sid er ation for water hammer must be included in the piping sys tem design. Reference ASPE Data Book, Chapter 2.33. Some systems may re quire external spring or lever weight ed check valves or other en gi neered so lu tions.

Three phase pumps must be connected for proper ro ta tion, which is coun ter clock wise looking into impeller inlet. See page 5 for in struc tions for check ing 3 phase rotation.

Grinder installations should be checked frequently for debris and/or buildup which may interfere with the “ON”/”OFF” cycles or the po si tions of variable level fl oat control switches. For repair and ser vice, other than cutter as sem bly main te nance, con tact factory.

Care should be tak en during the initial installation to be sure that ad e quate air supply is available whenever any person is in the basin. Always follow OSHA guidelines on confi ned space requirements.

Occasionally, products are damaged during ship ment. If the unit is damaged, contact your dealer before using. remove the test plugs in the cover nor the motor housing.

provided to familiarize your self with spe cifi c details re gard ing installation and use. These ma te ri als should be retained for fu ture reference.

Do not lift, carry, or hang pump by the elec tri cal ca bles. Damage to the electrical cables can cause shock, burns or death.

All pumps are fur nished with pro vi sions for prop er ground ing to help pro tect you against the pos si bil i ty of elec tri cal shock.

Make cer tain that the control box is with in the reach of the pump’s power supply cord. Ex ten sion cords that are too long or too light do not deliver suffi cient voltage to the pump motor. But, more im por tant, they could present a safety hazard if the in su la tion were to become dam aged or the con nec tion end were to fall into the sump.

A sep a rate branch cir cuit is rec om mend ed, sized ac cord ing to the “Na tion al Elec tri cal Code” for the cur rent shown on the pump nameplate.

Risk of electric shock - These pumps have not been in ves ti gat ed for use in swimming pool areas.

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 re pro duc tive harm.

Use the appropriately sized wrench when checking or re mov ing the cutter.

NOTE: Pumps with the "UL" mark and pumps with the "US" mark are tested to UL Standard UL778.

CSA Certifi ed pumps are certifi ed to CSA Standard C22.2 No. 108.

SEE BELOW FOR

LIST OF CAUTIONS

SEE BELOW FOR

LIST OF WARNINGS

Electrical Data Amps Winding Service Locked KVA Resistance Model BHp Factor RPM Voltage Phase Hertz Full Load In Air Shut Off Rotor Code Line-to-Line

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Typical Grinder Pumping Sys tem Installation

(8) Secure power cord to avoid entanglement with variable lev el fl oat switch mecha nism.

(9) reduce pump discharge pipe below 2” IPS size.

(10) Basin be in accordance with all applicable codes and specifi cations. Basin must be sized to allow a min i mum

3 minute off-time between starts.

(11) Pump must be level and the tethered variable level fl oat switch es must be free and not hang up on pump or pit pe cu liar i ties.

(12) a rail system is used, discharge elbow be fi rm ly an-chored to the bottom of basin. In fi ber glass basin, the bottom will need to be re in forced if the discharge elbow is used.

(13) a rail system is used, the guide rails are 2” schedule 40 pipe for all units. Brass, stainless steel or gal va nized steel is rec om mend ed.

(14) Install ring and cable for lifting pump from pit.

(15) Basin must be clean and free of debris after installation and before operation.

(1) Electrical wiring and protection be in ac cor dance with the National Electrical Code, and any other ap pli ca ble state and local elec tri cal re quire ments.

(2) Install proper full fl ow check and shut-off valve.

(3) Install proper controls. (Outdoor panels NEMA 3R or 4X enclosure)

(4) All installations a basin cover to prevent de bris from fall ing into the basin and to prevent ac ci den tal injury.

(5) Cords must be properly sealed to prevent moisture and gases from entering the control panel.

(6) , drill a 3/16" diameter hole in the discharge pipe below the check valve even with the top of the pump. NOTE: The hole must be below the basin cover and cleaned periodically. Also a vent hole is drilled in the pump hous-ing. Be sure that this hole is cleared during any servicing.

(7) Vent gases and odors to the atmosphere through vent pipe per Local and State codes.

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Installation and checking of electrical circuits and hardware should be performed by a qualifi ed licensed electrician.

Do not remove power supply cord and strain relief or connect conduit directly to the pump.

Power cords, sen sor cords, and fl oat cords all must be sealed to prevent gases from the basin entering the control panel.

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.

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.

(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-fi lled 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 300k Ohms. Resistance readings signifi cantly lower indicate a seal leak with water in the seal chamber. If VOM reading is open then a problem exists with moisture sensor circuit.

(7) 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.

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 fl oat switches are the most common level sensing device. The following should be noted.

(1) Single phase units require externally mounted capacitors and starting relays. Your control panel should have provisions for mounting these starting components.

(2) 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.

Pump Wiring Instructions

7110 3 8 AWG. 12 AWG. 12 AWG. 12 AWG. 12 AWG.

7111 5 8 AWG. 8 AWG. 12 AWG. 12 AWG. 12 AWG.

7112 7.5 N/A 8 AWG. 8 AWG. 12 AWG. 12 AWG.

APPROXIMATE CORD DIAMETER PER GAUGE

12/4 AWG. .64"

8/4 AWG. .93"

NOTE: SENSOR CORD 18/5 AWG. APPROXIMATELY .44" DIAMETER.

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Three Phase Installation

Three phase pumps are nonautomatic. To op er ate au to mat i cal ly, a con trol pan el is required. Follow the in struc tions pro vid ed with the panel to wire the system.

Before installing a pump, check the pump rotation to in sure that wiring has been connected prop er ly to power source, and that the green lead of pow er cord (See wiring di a gram), is con nect ed to a valid ground, Mo men tari ly en er gize the pump, observing the directions of kick back due to start ing torque. Ro ta tion is correct if kick back is in the op po site direction of rotation arrow on the pump cas ing. If rotation is not correct, switching of any two power leads other than ground, should provide the proper ro ta tion.

Refer to wiring diagram sup plied with specifi c electrical control panel for correct electrical cable termination locations.

Sensor cable includes 5 leads; 2 leads for ther mal sensor , 2 leads for moisture sensor, and a green ground lead. Sensor wire colors are as shown.

Refer to Sensor and Control Panel sections on page 5.

Single Phase Installation (7110 & 7111 Only) All single phase models require start capacitor, run capacitor and relay in the circuit to start and operate properly. These components can be purchased separately or prewired in a Zoeller control panel. For components purchased separately use the diagram for installation and hookup.

Single phase models are nonautomatic. To operate au to mat i cal ly a control panel must be added to the pow er cir cuit. Follow the instructions pro vid ed with the panel.

ased s nstruc phase a Zoe are no

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Operation

Zoeller pumps are lubricated and tested at the factory prior to shipment and require minimum pre-start-up maintenance.

Maximum liquid temperature of a continuous operating pump liquid for this model pump must not exceed 104°F (40°C). For longest service life, all pumps should be totally sub merged on long pump ing cycles.

These units are not designed to handle liquids other than sewage. If pump is used in water contaminated with heavy, viscous, or abrasive materials, the warranty will be voided.

The nameplate, located on the top of pump, indicates specifi c information about the construction of the pump. The model number, date code, and serial number infor-mation should be recorded on the front page in the “Owner’s Information” section of this manual.

If pump is to be stored, the following is advised:

• Store pump inside whenever possible or cover with some type of protective cov er ing.

• 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 ship ping box.

• All openings shall be sealed.

• Store in an upright position.

• Do not stack anything on top of panel.

Before placing the equipment into operation the following should be checked:

• Correct pump rotation (3 Phase units only).

• Clean pit.

• Panel dry, securely installed and properly sealed.

• Floats positioned properly.

• Discharge valves open.

• 3/16” vent hole drilled in pipe between check valve and pump.

Once the above has been verifi ed 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 ad e quate sub mer gence, open the discharge valve fully. Start the unit using manual controls. If fl ow is ap-preciably less than rated performance, pump may be air locked. To expel trapped air, jog the unit several times, using the manual controls.

• Have a qualifi ed 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 section on page 1 of this manual for future reference.

After the preoperational functional test has been completed, system is ready for op-eration. Zoeller requires completing a Start-up Report (ZM1074) when ev er a sys tem is started for the fi rst time or after a system has had a signifi cant change take place (i.e. pump replacement, overhaul, etc..). A copy of the Start-up Report should remain with the system for future reference.

Pumps: No adjustments are required other than as sur ing correct ro ta tion.

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 lo ca tion of each fl oat func tion.

Valves: Discharge valves should be placed in the fully open po si tion. Sys tems should not be operated for extended periods of time with the dis charge valves partially closed due to damaging the valve.

If a system is shutdown for more than six months, the following is rec om mend ed:

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 fi ve minutes once every three months.

If the pit is to remain wet, the pump should be removed and stored as noted above.

Panels: The panel should have all openings sealed to prevent mois ture and dust from entering the enclosure. Prior to restarting sys tem, the panel should be inspected for presence of mois ture and any loose con nec tions.

Valves: Consult the valve/actuator supplier for information con cern ing these systems components.

Maintenance

• Check for proper and unobstructed fl oat operation.

• Listen for proper check valve operation.

• Duplex Units - Check for even operating times. Uneven times in di cate a defective unit, fl oat switch or control.

• Inspect the panel for any presence of moisture in enclosure, loose connections, and general com po nent condition. Check out location and con di tion of fl oat switches.

• In addition to the monthly checks, the basin should be inspected and cleaned. Any de fec tive com po nents should be replaced. Inspect and remove any sand, debris, or mud present in the pump basin assembly.

• 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, emulsifi ed 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 Au tho rized

Service Station.

• Double seal pumps offer extra protection from damage caused by seal fail ure.

• 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.

Repair and service should be performed by Zoeller Pump Company Authorized Service Station only.

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 as phyx i a tion. Sewage water gives off methane and hydrogen sulfi de gases, both of which can be highly poisonous.

Installation and checking of electrical circuits and hardware should be per formed by a qualifi ed electrician.

Pump is never to be lifted by power cord.

Unit must be fl ushed and disinfected, inside and out, prior to ser vic ing.

Before the system is placed into operation, a system Start-up Report should be conducted by a qualifi ed technician.

Wiring and grounding must be in accordance with the na tion al electrical code and all applicable local codes and ordinances.

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 is recommended to ensure a long service life from the product.

Provided is a suggested main te nance schedule.

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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 fl ooded conditions, contact your local electric company or a qualifi ed licensed electrician for disconnecting electrical service prior to pump removal.

Submersible allow 2½ hours after dis-connecting before attempting service.

- Incorrect Voltage

- Unbalanced power source

- Incorrect motor rotation

- Negative or low head

- Excessive water temperature

- Impeller, cutter, or seal mechanically bound

- Defective capacitor or relay

- Motor shorted

- Lost a leg in a Three Phase unit

- Check valve stuck open

- Level controls out of adjustment

- Tem per a ture sensor tripping

- Thermal overload switch out of adjustment or defective

- Pit too small

- Debris clogging cutter mechanism.

- Debris under fl oat switch

- Float travel obstructed

- Defective or damaged fl oat switch

- Magnetic starter contacts shorted

- Air lock - check vent hole

- Check for plugged cutter, pump housing, pipe or sticking check valve

- Vent hole clogged or not drilled

- Discharge head exceeds pumps capacity

- Low or incorrect voltage

- Incorrect motor rotation

- Defective capacitor

- Increase Pipe Friction

- Clogged line or check valve

- Abrasive material & chemical, deteriorated im pel ler and pump housing

Service Checklist & Trouble Shooting

Steps Check Voltage At If No Voltage If Voltage

No. 1 Line terminals in pump's Check Dis con nect switch, line Pro ceed to No. 2 control panel fuse, and/or circuit breakers L1 - L2 - L3 (3 Phase) in power supply circuit.

No. 2 Pump motor terminals in Check for control circuit Check start ing re lay pump’s control panel voltage. Check out magnetic and ca pac i tor (1 T1 - T2 - T3 starter con tacts, thermal phase units). Check overloads, and fl oat switches pump for ground, and bind ing im pel ler

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Text Box Kentucky Lock Existing Pump Specifications Reference Document

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