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© Copyright 2015 Zoeller
®
Co. All rights reserved.
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 submer-
gence, 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.
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 Au-
thorized 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.
Maintenance
