536686 1 Zoeller Qwik Jon Ultima 203 System Install Manual User

User Manual: Pump 536686 1 Zoeller Qwik Jon Ultima 203 System Install Manual

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QWIK JON® ULTIMA 203 SYSTEMS

INSTALLATION INSTRUCTIONS

PREINSTALLATION CHECKLIST

NOTICE TO INSTALLER: Instructions must remain with installation. SECTION: 6.10.064

FM2408

1212

Supersedes

0310

P/N 018509

© Copyright 2012 Zoeller Co. All rights reserved.

1. Inspect all materials. Occasionally, products are damaged during shipment. If the unit is damaged, contact your dealer before using. Do Not remove the test

plugs from the pump.

 2. Carefullyreadalltheliteratureprovidedtofamiliarizeyourselfwithspecicdetailsregardinginstallationandusebeforeattemptingtheinstallation.These

materials should be retained for future reference.

MODEL NO. ____________

DATE CODE: ___________

DATE INSTALLED: ______

SEE BELOW FOR LIST OF NOTES

NOTES

REFER TO WARRANTY ON PAGE 2.

SEE BELOW FOR LIST OF WARNINGS

SEE BELOW FOR LIST OF CAUTIONS

Patent No. 7,203,976

Other Patents Pending

Product information presented

here re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

visit our web site:

www.zoeller.com

®

Your Peace of Mind is Our Top Priority

®

1. Make sure there is a properly grounded receptacle available. All pumps

are furnished with provisions for proper grounding to protect you against the

possibility of electrical shock.

(SEE WARNING BELOW)

2. 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sufcient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.

3. 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 local electrical code for the current shown

on the pump nameplate.

4. Testing for ground. As a safety measure, each electrical outlet should be

checked for ground using a circuit analyzer which will indicate if the power,

neutral and ground wires are correctly connected to your outlet. If they are

not,callaqualiedlicensedelectrician.

5. For Added Safety.Useofaresidualcurrentdevicewithanoperatingcurrent

not higher than 30 mA is recommended.

6. FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM

ITS POWER SOURCE BEFORE HANDLING. 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 local electrical code and all applicable

local codes and ordinances.

7. “Risk of electrical shock” Do not remove power supply cord and strain

relief or connect conduit directly to the pump.

8. Installation and servicing of electrical circuits and hardware should be

performedbyaqualiedlicensedelectrician.

9. Pumpinstallationandservicingshouldbeperformedbyaqualiedperson.

10. Riskofelectricshock-Thesepumpshavenotbeeninvestigatedforusein

swimming pool and marine areas.

11. If the supply cable is damaged, it must be replaced by the manufacturer or

itstechnicalserviceorsimilarlyqualiedpersonsinordertoavoidahazard.

12. Theapplianceisnotintendedforusebypersons(includingchildren)with

reducedphysical,sensoryormentalcapabilities,orlackofexperienceand

knowledge, unless they have been given supervision or instruction concerning

use of the appliance by a person responsible for their safety.

13. Pump is not intended for potable water due to possible contamination by oil

contained in the pump.

 1. TheQwikJon®Ultimaisttedwithaspecially-designedgrinderpump

and is capable of pumping fecal matter, toilet paper and sanitary articles

which may be accidentally dropped into the toilet. It is not recommended

toushsuchforeignobjectsastheymightclogthesanitarysewer.

2. Check to be sure your power source is adequate to handle the amperage

requirements of the motor as indicated on the pump or unit I.D. tag.

 3. Allplumbing(dischargeandventlines)mustbeinstalledtomeetlocal

codes. Unit must be vented. Do not use an automatic plumbing

vent device.

 4. Maximumoperatingtemperaturemustnotexceed130°F.

5. Do not use cleaning products containing bleach in the toilet tank, toilet or

attachedxturesastheywilldegradethepumpseals.

 1. RepairandserviceshouldbeperformedbyanAuthorizedServiceStation

only(consultfactory).

 2. Recommendedforinstallationsupto20'totaldynamichead.Consult factory

ifinstallationisabove15'verticalheightin1"pipe.Mini-GrinderPumpis

designedforuseinQwikJon®Ultimaunitsonly.Itisnotdesignedforuse

in any other application.

 3. Pumpswiththe“UL”markand/orthe“US”markaretested to ULStandard

UL778.CSA Certied pumps are certiedtoCSAStandardC22.2No.

108.QwikJon®Ultimaunitsonly.Itisnotdesignedforuseinanyother

application.

 4. Allxturesconnectingtothesystemmustbeonthesameoorlevel.

2

© Copyright 2012 Zoeller Co. All rights reserved.

LIMITED WARRANTY

HELPFUL HINTS FOR EASY INSTALLATION

1. Readallinstructionsbeforebeginninginstallation.

 2. Besuretheoorislevelwithin1/8".

 3. Installventpipesealswithangesideofsealonoutsideoflid.

 4.Usesoapywatertolubricateallsealstoaidinstallation.

 5. Installrubbercoupling/unioninventlinetoaiddisassembly.

 6. Donotover-torquetoiletmountingscrews.

7. Do not use an automatic plumbing vent device.

8. Obtain model number and date code, and record information in the

spaceprovidedonthefrontofthismanual.Refertothisinformation

when calling the factory.

DO’S AND DON'T’S FOR INSTALLING UNIT

1. DO read all installation material with the unit.

2. DO inspect unit for any visible damage caused by shipping. Contact

dealer if unit appears to be damaged.

3. DO clean all visible debris from the unit.

4. DO always disconnect pump from power source before handling. DO

always connect to a separately protected and properly grounded ground

faultprotectedcircuit.DONOTevercut,spliceordamagepowercord.DO

NOTcarryorliftpumpbyitspowercord.DONOTuseanextensioncord.

5. DO install a ball or gate valve and a union in the discharge line

downstream of the check valve.

6. DO test pump immediately after installation to be sure that the system

is working properly.

7. DO review all applicable local codes and verify that the installation

conforms to each of them.

 8. WeDONOTrecommendthisproductbeconnectedtoutilitiesother than

those found in a normal bathroom application. Washing machines and

dishwashersareexamplesofequipmentthatweDONOTrecommend.

9. DO inspect and test system for proper operations at least every 3 months.

DO’S AND DON'T’S, CONTINUED

TYPICAL PIPING CONFIGURATIONS

SK2932

* Ceiling heights shown for reference only.

NOTE: All installations must

comply with all applicable

local codes.

8’ CEILING

*

7’ CEILING

*

8"

MIN

2” x 8”

FLOOR JOISTS

SUBFLOOR 3/4"

THICK MINIMUM

CHECK VALVE

P/N 30-0181

Installation may not

be exactly as shown.

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

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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 uncontrollable act of nature; 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, or any other abusive entity, 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 Support 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speciclegalrightsandyoumayalsohaveother

rights which vary from state to state.

3

© Copyright 2012 Zoeller Co. All rights reserved.

1

7

8

3

4

65

2

SERVICE PARTS

QWIK JON® ULTIMA 203

203-A 203-A

(PREMIUM)

9/06

thru

Current

5/12

thru

Current

Item Description Part No.

1QwikJon®UltimaModel203SewageRemovalSystem 203-0005 203-1006

2 203 replacement pump with discharge pipe 017374 152165

3Tankcoverwithdischargettings 017373 017373

4Tank 018513 018513

5 Seal 017350 017350

6 Float switch assembly 018501 018501

7Flangeextensionkit 018510 018510

8 Closet seal 017347 017347 SK2613

If the above checklist does not solve the problem, consult the Zoeller Product SupportDepartment(502)778-2731.Do not attempt to service or otherwise disassemble pump.

Careofnish:Soapandwaterisallthatisrecommendedforcleaningtheoutsideofthetank.Othercleaningproductsmaycausediscolorationandscratching.

CONDITION POSSIBLE CAUSE REMEDY

A. PUMP WILL NOT START OR RUN.

Lowvoltage,blownfuse,opencircuit. Haveaqualiedelectriciancheckfuseandcircuit.

Impeller bound. Contact a Zoeller Service Station.

Motor or wiring shorted.

Debrisonoatswitch. Removedebris.

B. PUMP STARTS TOO SOON. Float“ON”pointisadjustedtoolow. Raisetheoatstops,makesuretheoatisbetweenthetwostops.

C. WATER LEVEL EXCESSIVE BEFORE PUMP

TURNS ON. Float“ON”pointadjustedtoohigh. Lowertheupperoatstop.

D. PUMP WILL NOT SHUT OFF OR RUNS TOO LONG

BEFORE WATER IS PUMPED.

Pumpnotpluggedintopiggybackoatswitchreceptacle. Ensurepumpisnotpluggeddirectlyintotheoutlet.Plugpump

intopiggybackoatswitchreceptacle.

Debrisunderoat. Removedebrisfromaroundoat.

Faultyoatswitch. Contact a Zoeller Service Station.

Float“Off”pointadjustedtoolow. Raisetheloweroatstop.

Pump is air locked. Make sure vent hole in discharge pipe is clear.

Water level too low. Raisetheloweroatstop.

Waste material has accumulated, blocking flow of

material to pump intake.

Holdushhandledownonthetoiletfor15seconds.Ifunitwill

not clear, unplug and wait 30 minutes. Plug unit back in and

repeat. If unit still will not turn off, it will need to be opened and

the debris relocated.

E. PUMP OPERATES BUT DELIVERS LITTLE OR NO

WATER.

Debris around intake. Clean area around intake.

Blockage in discharge pipe. Removepipeandushoutdebris.

Loworincorrectvoltage. Haveaqualiedelectriciancheckhousewiring.

Damaged Impeller. Contact a Zoeller Service Station.

Incorrectoatadjustment. Contact Product Support Dept.

Pump is air locked. Make sure vent hole in discharge pipe is clear.

Vertical lift too high. Change discharge piping or contact Product Support Dept.

TROUBLE SHOOTING

4

© Copyright 2012 Zoeller Co. All rights reserved.

QWIK JON

®

ULTIMA QWIK REFERENCE GUIDE

STEP 1 LOCATION SELECTION

GFCI

OUTLET

WATER

SUPPLY

DISCHARGE

PIPE

VENT

PIPE

LEVEL FLOOR

BALL OR GATE VALVE

SOLD SEPARATELY.

SK2588

STEP 2 LEVELING OF PUMP UNIT

SK2614

SK2615

STEP 3-1 STEP 3-3, 3-4

STEP 3-2

1/8"

Plan your new installation carefully.

Floor:Theoorshouldbestructurallysoundandlevelwithin1/8".Iftheoorisnot level, use hydraulic

cementorsimilarmaterialtoleveltheoor.

Water: A water supply will be needed to operate the shower and lav.

Electrical:A115voltGFCIreceptaclewillbeneededtosupplyelectricalpowerto the pump.

Sewage:Accesstoasewagelineisrequired.TheQwikJon®Ultimarequiresa1"(or3/4"ifcodes

permit)sewagedischargelinetoconnecttoanexistingsewageline.Aballorgatevalveshouldbe

installed in the discharge line.

Vent:Accesstoaventpipeisrequired.TheuseofamechanicalventsystemisNOTrecommended.,

asthetoiletwillnotush.

NOTE:Ifabuilt-ininstallationistobeused,locatethepumpunitinanareathatwill allow access

to the pump and switch.

Do not use wooden shims to level the pump unit!

Ensurethatnails,screwsorothersharpobjectsdonotpuncturethepumpunit!

Levelthepumpunitwithin1/8"usinghydrauliccementorsimilarmaterial.

STEP 3 ROUGH-IN

1) Positionthepumpunitaminimumof1/8"fromthewallwiththe

inlet facing forward. Attach the bellows to the inlet using the

worm drive clamp provided.

 2) Placethetoiletinfrontofpumpunitaligningthedischargeofthe

toilet with the inlet of the pump unit. Make sure that the bellows

willbridge thegapadequatelyfornalinstallation.Thetoilet

tankshouldbeaminimumof1/2"fromthewall.

 3) Lightlymarkthelocationsofthepumpunit,toiletandcloset

boltlocationsontheoor.Lightlymarkthewallwiththeheight

of the pump unit and the bottom and sides of the toilet tank to

ensure against interference from pipe runs later.

 4) Removethetoiletfromthepumpunitandsetitaside.

(STAND-ALONE INSTALLATION) (BEHIND THE WALL INSTALLATION)

1) Installing the grinder unit behind a wall will require an

extensionkit(P/N10-2123)soldseparately.

 2) Placethetoiletassemblyaminimumof1/2" from the wall

andmarktheclosetboltlocationsontheoor.

 3) Measuretheappropriatelengthof3½"Schedule 40 PVC

pipeprovidedwiththeextensionkitandcutittolength.

See sketch at right.

 4) Settoiletaside.

 Toilet assembly is top heavy. Take special

precautions to ensure that toilet does not tip over and break.

STEP 4-4

STEP 4-3 STEP 4-2

STEP 4-1

SK2616

5

© Copyright 2012 Zoeller Co. All rights reserved.

STEP 4 PIPING

1) Addingbathroomxtures-TheQwikJon®Ultimaisdesignedtoaccept

bathroomxturesutilizingthetwosideinlets.Theseinletscanbeattachedvia

the2"MPT(outsidediameter)orthe1½"slip(insidediameter).Theseinlets

musthavetheinnerportiondrilledoutusinga44mm(1¾")holesaw(see

Figure3.2).Thisistoensuretherearenoleakageproblemsfrominletsnotin

use. When utilizing side inlets, install a check valve on the incoming line.

 2) Cutanddry-tthepipeandttingsasrequiredfor1"diameter discharge

pipe(maybereducedto¾"diameterifcodespermit).

 3) Whiledry-ttingthedischargepipe,positionandmarkthelocation of

thepumpunitdischargetting.

 4) Cut and dry-t 1½" vent pipe as required to ensure that the vent

pipe does not interfere with other components. Make the connection to the

pumpunitwiththeprovidedstreetelbow.A2"x1"90°dischargettinghas

been provided, however, it may be easier to pipe straight up depending on

the installation. Proper venting is required. Do not use a

mechanical type vent.

 5) Clean, prime and solvent weld the inlet and discharge piping and

pumpunitdischargetting. When applying solvent weld to

dischargetting,ensurethatnonegetsintothecheckvalveassembly(see

Figure3.3).Paycloseattentiontotheproperalignmentofthedischargetting

previously marked above.

 6) Cleanandsolventweldventpipingasrequiredforproper venting.

SK2673 SK2591

DRILL POINT

1-1/2" SLIP INSIDE

2" MPT OUTSIDE

SK2586

Figure 3.1 Figure 3.2 Figure 3.3

Discharge Vent

Do not put glue in this area.

 1) Installtheclosetboltsatthepointsmarkedearlier.

 2) Placethetoiletassemblyovertheclosetbolts.Installtheanchoring

hardware and tighten in an alternating pattern. Check for level and shim

as required. Be careful when tightening bolts or nuts against china to

avoid cracking the china.

 3) Installrubberbellowsontothetoiletdischargeandgrindertankhub

and secure with the worm clamps provided for installation. See sketch

inStep3.Forbuilt-ininstallation,installtherubbercouplingstoboth

thegrindertankandthetoiletdischargeandsecuretoextensionpipe

with worm clamps provided. See sketch in Step 4.

 4) Installthewatersupplylinefromtheexistingwatershut-offvalvetothe

toilet water supply connection.

 5) Openthewatersupplyvalveandcheckforleaks.Thetoilettankshould

lltotheproperlevel.Adjustifrequired.

 6) Plugthepump'spowercordintotheoutlet.

 7) Flushthetoiletandwatchforproperoperation.Listenforthepumpto

start.Thepumpunitrequiresproperventinginorderfortoilettoush.

Check for leaks.

 8) Repeatushcyclestoassureproperoperation.

FLOOR LEVEL TO WITHIN 1/8"

PUMP UNIT

AUX. INLET

WATER

SUPPLY

GFCI

OUTLET

DISCHARGE

PIPE VENT PIPE

(PER ALL CODES.

DO NOT USE

MECHANICAL VENT.)

SK2595

STEP 5 TOILET INSTALLATION (TOILET SUPPLIED BY OTHERS)

NOTE:Maynotbepicturedexactlyasshown.

6

© Copyright 2012 Zoeller Co. All rights reserved.

TOTAL DYNAMIC HEAD

FLOW PER MINUTE

15

LITERS 0

GALLONS

20 40

5 10

0

2

5

25

100

8060

20 50

TOTAL DYNAMIC HEAD/FLOW

PER MINUTE

SEWAGE

PUMP PERFORMANCE CURVE

MODEL 202

FEET

METERS

4

10

15

620

Shut-off Head:

15 4.6

Feet Meters

5

10

1.5

3.0

MODEL

30 ft. (9.1m)

35 132

Gal. Liters

45

40

170

151

202

45403530

25

30

35

120 140 160 180

8

10

20 6.1 27 102

25 7.6 16 61

018512

7

© Copyright 2012 Zoeller Co. All rights reserved.

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

Your Peace of Mind is Our Top Priority

®

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© Copyright 2012 Zoeller Co. All rights reserved.