548011 2 Zoeller X292 Owners Manual

548010 2 Zoeller X292 Owners Manual 548010_2_Zoeller X292 Owners manual

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© Copyright 2014 Zoeller® Co. All rights reserved.
NOTICE TO INSTALLER: Instructions must remain with installation.
OWNER’S MANUAL
Safety Instructions
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA-
JOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE
PUMP.
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the pump or in the
manual, look for one of the following signal words
and be alert to the potential for personal injury or
property damage.
Warns of hazards that WILL cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause serious personal
injury, death or major property damage.
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.
CAUTION
Table of Contents
REFER TO WARRANTY ON PAGE 2.
EFFLUENT SEWAGE
X282, X284
X292, X293, X294, X295
X404, X405
X161, X163, X165
X185, X186, X188, X189
X191
ZOELLER HAZARDOUS ENVIRONMENT PUMPS
(For Class I, Division 1, Groups C & D Applications)
Explosion-Proof Motors
Model Number: ______________ Date Code: _______________
Simplex Duplex
Job Name: ____________________________________________
Distributor: ____________________________________________
Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____ Amps ______
Owner’s Information
Safety Instructions ....................................................................... 1
Limited Warranty .......................................................................... 2
Preinstallation Checklist .............................................................. 2
Electrical Data ............................................................................3-4
General Information ..................................................................5-6
Pump Dimensions ........................................................................ 7
Pump Wiring Instructions ......................................................... 8-9
General Maintenance ................................................................. 10
Operation ..................................................................................... 11
Service Checklist ........................................................................ 12
FM2298
Rev. A
1114
Supersedes
0810
Standard 3600 & 3615
Certied to CSA Standard
C22.2 No. 145
See page 3.
R
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
®
Register your
Zoeller Pump Company
Product on our website:
http://reg.zoellerpumps.com/
2
© Copyright 2014 Zoeller® Co. All rights reserved.
LIMITED WARRANTY
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, every new product to be free from defects in material and
workmanship under normal use and service, when properly used and maintained,
for a period of one year from date of purchase by the end user, or 18 months
from date of original manufacture of the product, whichever comes 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 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, 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.
PREINSTALLATION INFORMATION
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 oat switches must be connected to an intrinsically safe circuit in the
control panel. The installation of oat switches is the responsibility of the
installing party and care should be taken that the tethered oat 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 ttings
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.
6. 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 conned space requirements.
1.
Inspect your pump.
Occasionally, products are damaged during shipment. If the unit is damaged, contact your distributor 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 specic details regarding installation and use. These materials should be retained for future reference.
3. National Electrical Code (NEC) articles 500 through 503 explain in detail the requirements for the installation and wiring of electrical equipment in hazardous locations.
1. Not for use in acidic, methanol or ethyl acetate atmospheres.
2. Do not lift, carry, or hang pump by the electrical cables. Damage to the
electrical cables can cause shock, burns or death.
3. 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.
4. 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 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.
5. 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.
6. Risk of electric shock - These pumps have not been investigated for use in
swimming pool areas.
7. According to the state of California (Prop 65), this product contains chemicals
known to the state of California to cause cancer and birth defects or other
reproductive harm.
8. Electrical wiring and protection must be in accordance with the National
Electrical Code per NEC articles 500 through 503 for installation in Class I,
Division 1, Group C & D environments, and any other applicable state and
local electrical requirements.
9. Use pressure-rated pipe and ttings when connecting to the disharge of
the pump.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
3
© Copyright 2014 Zoeller® Co. All rights reserved.
Amps
KVA
Code
Winding
Resistance
Line-to-Line
Model HP RPM Voltage Phase Hertz Full Load In Air Shut Off Locked Rotor
MX161 1/2 3450 115 1 60 15.5 7.7 52.2 N **
NX161 1/2 3450 115 1 60 15.5 7.7 52.2 N .53/.46*
DX161 1/2 3450 230 1 60 7.5 3.6 15.1 H **
EX161 1/2 3450 230 1 60 7.5 3.6 15.1 H 4.74/3.88*
HX161 1/2 3450 200 1 60 8.8 6.3 19.8 J **
IX161 1/2 3450 200 1 60 8.8 6.3 19.8 J 3.59/2.94*
JX161 1/2 3450 200 3 60 6.4 3.1 23.6 S6.25/5.12
FX161 1/2 3450 230 3 60 5.2 2.7 24.0 T 5.7/4.6
GX161 1/2 3450 460 3 60 2.9 1.4 12.0 T 22.8/18.5
BAX161 1/2 3450 575 3 60 2.4 1.3 11.3 U 38.0/33.0
MX163 1/2 3450 115 1 60 15.0 8.4 52.2 N **
NX163 1/2 3450 115 1 60 15.0 8.4 52.2 N .53/.46*
DX163 1/2 3450 230 1 60 7.5 4.0 15.1 H **
EX163 1/2 3450 230 1 60 7.5 4.0 15.1 H 4.74/3.88*
HX163 1/2 3450 200 1 60 8.5 4.3 19.8 J **
IX163 1/2 3450 200 1 60 8.5 4.3 19.8 J 3.59/2.94*
JX163 1/2 3450 200 3 60 6.0 3.4 23.6 S6.25/5.12
FX163 1/2 3450 230 3 60 4.8 3.0 24.0 T 5.7/4.6
GX163 1/2 3450 460 3 60 2.9 1.5 12.0 T 22.8/18.5
BAX163 1/2 3450 575 3 60 2.4 1.5 11.3 U 38.0/33.0
DX165 1 3450 230 1 60 10.2 5.5 20.1 E **
EX165 1 3450 230 1 60 10.2 5.5 20.1 E 3.06/2.51*
HX165 1 3450 200 1 60 12.6 6.1 26.8 F **
IX165 1 3450 200 1 60 12.6 6.1 26.8 F 2.11/1.72*
JX165 1 3450 200 3 60 7.5 4.8 31.1 M 3.74/3.06
FX165 1 3450 230 3 60 7.4 3.8 29.8 N 5.7/4.5
GX165 1 3450 460 3 60 3.7 2.1 14.9 N 22.6/18.2
BAX165 1 3450 575 3 60 3.0 1.7 10.0 L 38.8/34.5
DX185 1 3450 230 1 60 9.8 5.0 20.1 E **
EX185 1 3450 230 1 60 9.8 5.0 20.1 E 3.06/2.51*
HX185† 1 3450 200 1 60 11.5 5.1 26.8 F **
IX185† 1 3450 200 1 60 11.5 5.1 26.8 F 2.11/1.72*
JX185 1 3450 200 3 60 7.5 3.6 31.1 M 3.74/3.06
FX185 1 3450 230 3 60 7.4 3.8 29.8 N 5.7/4.5
GX185 1 3450 460 3 60 3.7 1.9 14.9 N 22.6/18.2
BAX185 1 3450 575 3 60 3.3 1.6 10.0 L 38.8/34.5
DX186 1-1/2 3450 230 1 60 13.7 9.3 45.7 H **
EX186 1-1/2 3450 230 1 60 13.7 9.3 45.7 H 1.29/1.05*
HX186 1-1/2 3450 200 1 60 17.2 11.8 54.5 J **
IX186 1-1/2 3450 200 1 60 17.2 11.8 54.5 J .86/.71*
JX186 1-1/2 3450 200 3 60 10.3 6.0 45.2 M 2.62/2.14
FX186 1-1/2 3450 230 3 60 9.2 5.5 39.4 M 3.52/2.8
GX186 1-1/2 3450 460 3 60 4.6 2.8 19.7 M 13.9/11.3
DX188 1-1/2 3450 230 1 60 14.0 7.4 45.7 H 1.29/1.05*
EX188 1-1/2 3450 230 1 60 14.0 7.4 45.7 H 1.29/1.05*
HX188 1-1/2 3450 200 1 60 16.8 9.8 54.5 J **
IX188 1-1/2 3450 200 1 60 16.8 9.8 54.5 J .86/.71*
JX188 1-1/2 3450 200 3 60 10.3 4.7 45.2 M 2.62/2.14
FX188 1-1/2 3450 230 3 60 8.9 4.1 39.4 M 3.52/2.8
GX188 1-1/2 3450 460 3 60 4.6 2.0 19.7 M 13.9/11.3
BAX188 1-1/2 3450 575 3 60 3.5 1.6 15.9 M 20.6/18.3
DX189 2 3450 230 1 60 17.1 9.4 45.7 F **
EX189 2 3450 230 1 60 17.1 9.4 45.7 F 1.29/1.05*
HX189 2 3450 200 1 60 20.5 11.5 54.5 F **
IX189 2 3450 200 1 60 20.5 11.5 54.5 F .86/.71*
JX189 2 3450 200 3 60 13.2 6.8 45.2 J 2.62/2.14
FX189 2 3450 230 3 60 11.2 5.1 39.4 J 3.5/2.8
GX189 2 3450 460 3 60 6.0 2.8 19.7 J 13.9/11.3
BAX189 2 3450 575 3 60 5.8 2.1 15.9 J 20.6/18.3
DX191 2 3450 230 1 60 14.5 8.5 45.7 F **
EX191 2 3450 230 1 60 14.5 8.5 45.7 F 1.29/1.05*
MX282 1/2 1750 115 1 60 10.3 7.3 30.2 H 1.46/1.20*
NX282 1/2 1750 115 1 60 10.3 7.3 30.2 H 1.46/1.20*
DX282 1/2 1750 230 1 60 5.0 4.0 15.1 H 5.84/4.80*
EX282 1/2 1750 230 1 60 5.0 4.0 15.1 H 5.84/4.80*
HX282† 1/2 1750 200 1 60 6.1 4.5 17.7 H 4.65/4.05*
IX282† 1/2 1750 200 1 60 6.1 4.5 17.7 H 4.65/4.05*
JX282 1/2 1750 200 3 60 3.6 2.5 12.8 K 8.13/6.62
FX282 1/2 1750 230 3 60 3.0 2.3 12.2 L 9.6/7.9
GX282 1/2 1750 460 3 60 1.7 1.1 6.1 L 38.4/31.5
BAX282 1/2 1750 575 3 60 1.4 1.1 5.11 M 63.6/55.3
ELECTRICAL DATA
* Line to line reading will only reect the run winding resistance.
** Line to line reading will only reect the relay coil resistance on automatic 160-290 series.
Start winding resistance can only be measured after removing the cover.
† Not CSA certied CONTINUED ON NEXT PAGE
4
© Copyright 2014 Zoeller® Co. All rights reserved.
ELECTRICAL DATA, continued
Amps
KVA
Code
Winding
Resistance
Line-to-Line
Model HP RPM Voltage Phase Hertz Full Load In Air Shut Off Locked Rotor
DX284 1 1750 230 1 60 8.9 6.7 24.9 G **
EX284 1 1750 230 1 60 8.9 6.7 24.9 G 2.62/2.14*
HX284† 1 1750 200 1 60 9.3 6.4 26.8 F **
IX284† 1 1750 200 1 60 9.3 6.4 26.8 F 2.01/1.82*
JX284 1 1750 200 3 60 5.5 4.0 26.3 L 2.99/2.70
FX284 1 1750 230 3 60 5.0 4.0 22.2 K 4.8/4.4
GX284 1 1750 460 3 60 2.6 1.9 11.1 K 19.2/17.4
BAX284 1 1750 575 3 60 2.2 1.7 12.1 N 20.4/17.7
MX292 1/2 3450 115 1 60 15.0 10.6 52.2 N **
NX292 1/2 3450 115 1 60 15.0 10.6 52.2 N .53/.46*
DX292 1/2 3450 230 1 60 7.5 7.5 15.1 H 4.74/3.88*
EX292 1/2 3450 230 1 60 7.5 7.5 15.1 H 4.74/3.88*
HX292 1/2 3450 200 1 60 8.8 8.8 19.8 J 3.55/2.94*
IX292 1/2 3450 200 1 60 8.8 8.8 19.8 J 3.55/2.94*
JX292 1/2 3450 200 3 60 6.4 6.4 23.6 S6.25/5.12
FX292 1/2 3450 200 3 60 5.2 5.2 24.0 T 5.7/4.6
GX292 1/2 3450 460 3 60 2.9 2.9 12.0 T 22.8/18.5
BAX292 1/2 3450 575 3 60 2.4 1.7 11.3 U 38.0/33.0
DX293 1 3450 230 1 60 10.2 5.5 20.1 E **
EX293 1 3450 230 1 60 10.2 5.5 20.1 E 3.06/2.51*
HX293 1 3450 200 1 60 12.0 6.4 26.8 F **
IX293 1 3450 200 1 60 12.0 6.4 26.8 F 2.11/1.72*
JX293 1 3450 200 3 60 8.2 4.4 31.1 M 3.74/3.06
FX293 1 3450 230 3 60 7.6 4.1 29.8 N 5.7/4.5
GX293 1 3450 460 3 60 4.0 2.2 14.9 N 22.6/18.2
BAX293 1 3450 575 3 60 3.3 1.8 10.0 L 38.8/34.5
DX294 1-1/2 3450 230 1 60 13.7 9.7 45.7 H **
EX294 1-1/2 3450 230 1 60 13.7 8.1 45.7 H 1.29/1.05*
HX294 1-1/2 3450 200 1 60 17.8 10.1 54.5 J **
IX294 1-1/2 3450 200 1 60 17.8 10.1 54.5 J .86/.71*
JX294 1-1/2 3450 200 3 60 10.8 5.3 45.2 M 2.62/2.14
FX294 1-1/2 3450 230 3 60 9.5 5.6 39.4 M 3.5/2.8
GX294 1-1/2 3450 460 3 60 4.8 2.3 19.7 M 13.9/11.3
BAX294 1-1/2 3450 575 3 60 3.8 2.2 15.9 M 20.6/18.3
DX295 2 3450 230 1 60 17.1 9.1 45.7 F **
EX295 2 3450 230 1 60 17.1 9.1 45.7 F 1.29/1.05*
HX295 2 3450 200 1 60 20.5 11.5 54.5 F **
IX295 2 3450 200 1 60 20.5 11.5 54.5 F .86/.71*
JX295 2 3450 200 3 60 14.3 6.3 45.2 J 2.62/2.14
FX295 2 3450 230 3 60 12.2 5.3 39.4 J 3.5/2.8
GX295 2 3450 460 3 60 6.1 2.7 19.7 J 13.9/11.3
BAX295 2 3450 575 3 60 4.9 2.2 15.9 J 20.6/18.3
EX404 2 1750 230 1 60 12.9 9.9 44.8 B 1.80/1.60*
IX404 2 1750 200 1 60 14.4 11.5 49.6 B 1.42/1.28*
JX404 2 1750 200 3 60 13.8 13.1 56.8 H 1.6/1.3
FX404 2 1750 230 3 60 10.5 9.7 44.6 G 2.3/2.0
GX404 2 1750 460 3 60 5.2 4.8 22.3 G 9.1/8.0
BAX404 2 1750 575 3 60 4.1 3.8 17.6 G 14.6/12.7
EX405 3 1750 230 1 60 19.0 9.3 44.8 B 1.80/1.60
IX405 3 1750 200 1 60 20.2 8.8 49.6 B 1.42/1.28*
JX405 3 1750 200 3 60 14.8 12.5 56.8 H 1.6/1.3
FX405 3 1750 230 3 60 12.2 9.7 44.6 G 2.3/2.0
GX405 3 1750 460 3 60 6.1 4.8 22.3 G 9.1/8.0
BAX405 3 1750 575 3 60 4.8 3.8 17.6 G 14.6/12.7
* Line to line reading will only reect the run winding resistance.
** Line to line reading will only reect the relay coil resistance on automatic 160-290 series.
Start winding resistance can only be measured after removing the cover.
† Not CSA certied
5
© Copyright 2014 Zoeller® Co. All rights reserved.
HAZARDOUS ENVIRONMENTAL PUMP DESCRIPTION
1. Pumps are constructed of class 30 cast iron with powder coated
epoxy protection for long life when pumping sewage in submersible
applications.
2. Pump motors are available in single and three phase design.
3. The Hazardous Environmental Pump is a single seal design and
has seal leak probes. Single phase units have an internal thermal
overload. Three phase pumps have a thermal sensor. A moisture
sensor seal fail circuit is incorporated into the control panel required
for nonautomatic pumps. Moisture sensor indicator panel, 10-1031,
is recommended but not required for automatic pump models.
4. Three phase pumps require overload protection in the control panel.
5. These pumps are to be repaired by rms approved
by Zoeller Company and in accordance to Policy # FM0212-3d.
Otherwise, they are to be returned to the factory for repair.
FIELD ASSEMBLED INSTALLATION
1. Contractor shall furnish all labor, material, equipment and
incidentals required for installation of hazardous environmental
pump.
2. Installation and piping instructions are included with the rail system
and basin instructions. If pump is being retrotted to an existing
rail system, accessory parts may be required. Consult the factory
and advise make and model of rail system being used.
3. All electrical connections including pump to control box and power
supply to control panels must comply with the “National Electrical
Code” and applicable local codes. Installation of electrical panels
and connections should be made by a qualied licensed electrician.
4. When installing a pump with a check valve, or a rail system with
a check valve, you must give the pump case time to ll to help
prevent air lock when lowering the unit into the liquid. The 6404/6405
pump case has an air vent located behind the discharge. This air
vent is across the pump housing mounting surface and must be
cleaned before each reinstall. An air vent hole (3/16") must be
drilled in discharge pipe below the check valve to help prevent air
lock. This drilled hole must be cleaned before each reinstall. After
the pump is installed, run the unit submerged to assure the pump
case is lled (Water should come out of 3/16" diameter hole).
GENERAL INFORMATION
010740
6
© Copyright 2014 Zoeller® Co. All rights reserved.
FLOW PER MINUTE
250
FEET
METERS
LITERS 2000 600400 800
50
TOTAL DYNAMIC HEAD
20
6
GALLONS
2
0
4
5
10
15
10
8
12
25
30
35
40
150100 200
1000 1200 1400
350300 400
X404
PUMP PERFORMANCE CURVE
MODELS X404/X405
3" SOLIDS CAPACITY
X405
012116
GENERAL INFORMATION, continued
720
190
GALLONS
LITERS 0 80
6
4
2
0
10
5
10 20
15
20
FLOW PER MINUTE
110
160 240 320 400
30 40 50 60 70 80 10090
X282
560480 640
150130120 140
X292
170160 180
X284
80
14
12
10
8
TOTAL DYNAMIC HEAD
25
30
35
40
45
22
20
18
16
50
55
60
65
70
METERS
FEET
X293
800
X295
210200
X294
220
75
24
PUMP PERFORMANCE CURVE
MODEL X282/X284/X292/X293/X294/X295
2" SOLIDS CAPACITY
010739
R
T
O
N
I
A
T
O
9 7/8”
(251 mm)
6 1/4” (159 mm)
26 27/32”
(682 mm)
27 7/32”
(691 mm)
6 3/16” (157 mm)
12 11/16” (322 mm)
4" CHECK
VALVE
STD. 4" 90° ELBOW
SK1915
7
© Copyright 2014 Zoeller® Co. All rights reserved.
PUMP DIMENSIONS
6 1/2”
(165 mm)
8 3/4”
(222 mm)
1 1/2" NPT STANDARD
2" NPT
OR
3" NPT
AVAILABLE
22 29/32”
(566 mm)
4 9/16” (116 mm)
4 9/16” (116 mm)
23 9/32”
(591 mm)
1 1/2" NPT
CONDUIT CONNECTION
CHECK VALVE
6 1/16” (154 mm)
SK1912
X160 - X190 Series
6 5/16”
(160 mm)
8 9/16”
(217 mm)
5”
(127 mm)
5” (127 mm)
23 5/32”
(588 mm)
23 17/32”
(598 mm)
6 5/16” (160 mm)
1 1/2” NPT
CONDUIT CONNECTION
2” NPT
OR
3” NPT
AVAILABLE
CHECK
VALVE
SK1913
4 9/16” 8 3/4”
6 1/2”
1 1/2” NPT STANDARD
2” NPT
OR
3” NPT
FLANGE AVAILABLE
4 9/16”
8 9/16”
1 1/2” NPT
CONDUIT
CONNECTION
24 15/16”
21 1/2”
4 29/32” (125 mm)
6 1/16” (154 mm)
(116 mm) (222 mm)
(165 mm)
(116 mm)
(217 mm)
(633 mm)
(546 mm)
SK2506
5”
(127 mm)
8 9/16”
(217 mm)
6 5/16”
(160 mm)
2” NPT
OR
3” NPT
FLANGE AVAILABLE
5” (127mm)
8 9/16” (217 mm)
1 1/2” NPT
CONDUIT
CONNECTION
25 3/16”
(640 mm)
21 3/4”
(552 mm)
6 5/16” (160 mm)
SK2507
X280 Series
SK1914
6 1/2”
(165 mm)
8 3/4”
(222 mm)
22 31/32”
(566 mm)
4 9/16”
(116 mm)
4 9/16” (116 mm)
23 9/32”
(591 mm)
CHECK VALVE
2" NPT
OR
3" NPT
AVAILABLE
1 1/2" NPT
CONDUIT CONNECTION
6 1/16” (154 mm)
8 3/4”
(222 mm)
6 1/2”
(165 mm)
2" NPT
OR
3" NPT
FLANGE AVAILABLE
1 1/2" NPT
CONDUIT CONNECTION
6 1/16” (154 mm)
21 1/2”
(546 mm)
24 15/16”
(633 mm)
4 9/16” (116 mm)
8 9/16”
(217 mm)
4 9/16”
(116 mm)
SK2508
X290 Series
AUTOMATIC AUTOMATIC
NONAUTOMATIC
NONAUTOMATIC
AUTOMATIC
NONAUTOMATIC
8
© Copyright 2014 Zoeller® Co. All rights reserved.
PUMP WIRING INSTRUCTIONS
FOR YOUR PROTECTION, ALWAYS DISCONNECT THE PUMP FROM ITS POWER SOURCE BEFORE HANDLING.
All electrical connections must be wired and grounded in accordance with the National Electrical Code and all applicable
local codes and ordinances.
RISK OF ELECTRICAL SHOCK Do not remove the power supply cord or strain relief.
Installation and checking of electrical circuits and hardware should be performed by a qualied licensed electrician.
EXPLOSION PROOF WIRING DIAGRAMS
X160, X180, X190, X280, X290, X400 SERIES
All installation of controls, protection devices and wiring should be done by a qualied licensed electrician. All electrical and safety codes should
be followed including the most recent National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA).
Not for use in acidic, methanol or ethyl acetate atmospheres.
012941 012943
SINGLE PHASE NONAUTOMATIC THREE PHASE
9
© Copyright 2014 Zoeller® Co. All rights reserved.
PUMP WIRING INSTRUCTIONS, continued
016889 016890
SINGLE PHASE AUTOMATIC
MODEL X282
SINGLE PHASE AUTOMATIC
MODELS X160 - X290
10
© Copyright 2014 Zoeller® Co. All rights reserved.
Repair and service must be performed by a rm approved by
Zoeller Company to repair a pump with an explosion-proof motor in accordance
to the guidelines listed in Policy # FM0212-3d. Contact the Zoeller Product
Support Department for additional information.
If the motor housing or cord cap is disassembled or
repaired by a rm NOT approved to work on explosion-proof motors,
the explosion proof rating is void, and the FM and CSA tags MUST BE
REMOVED FROM THE PUMP.
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
sulde gases, both of which can be highly poisonous.
Installation and checking of electrical circuits and hardware should be performed
by a qualied electrician.
Pump is never to be lifted by power cord.
GENERAL MAINTENANCE
Unit must be cleaned and disinfected, inside the
pumping chamber and all exterior surfaces, prior to servicing.
GENERAL SYSTEM INSPECTION
Before the system is placed into operation, it should be inspected by
a qualied 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 six months:
• Inspect and test system for proper operation.
• Check for proper and unobstructed oat operation.
• Listen for proper check valve operation.
Every 5 years or 10,000 hours of operation:
• Remove pump, inspect and service using a Zoeller rebuild kit.
• Flush and clean basin.
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.
SENSOR WIRES (See pages 8 and 9)
The power and sensor wires are contained in the same cord. The green wire is a ground connection. All wires must terminate in the control panel.
The following should be noted:
(1) The thermal sensors are normally closed and mounted adjacent to the motor windings. If internal temperatures exceed a maximum limit, the pump will
deactivate. On 3 phase models connect the white and red wires with the black tracer to the control panel's thermal cut-out terminals. The pump is able to
restart once the motor cools down. Continued deactivation of this circuit requires the attention from maintenance personnel.
(2) The seal failure wires are connected to a 330K ohm moisture detection circuit. An indicator light will activate whenever water is present in the shaft seal
cavity or cord cap assembly. Whenever the seal leak light is activated, indicating the entry of moisture into the pump, it should be removed and serviced
in order to avoid damage to the motor. 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 moisture sensor wires. The VOM should read approximately 330k Ohms. Resistance readings
signicantly lower indicates an entry of moisture into the pump. If VOM reading is open then a problem exists with moisture detection circuit.
(3) The green wire shall be connected to a ground lug in the panel. Check resistance between the green ground conductor and all other 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
and the pump should be taken to an approved repair station.
CONTROL PANELS
These pumps are nonautomatic and they require a control panel with intrinsically safe oat and moisture sensor circuits. A motor starter circuit, control circuit,
and high-water alarm circuit within the panel are standard features. Enclosures rated for outdoor use and alternating relays are often required. The following
should be noted.
(1) The seal failure sensor and thermal sensor (3 phase only) protection require that interfacing terminals and functions be incorporated into the panel.
(2) All 3 phase 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) Lightning arrestors, condensation heaters and elapsed-time meters are optional features that provide added protection.
INSTRUCTIONS FOR CHECKING ROTATION OF THREE PHASE UNITS
11
© Copyright 2014 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 operating temperature of pump liquid must not exceed 104°F (40°C).
These units are not designed to handle liquids other than efuent: 160 and 180
or sanitary sewage: 280, 290 and 400. If pump is used to dewater areas with
contaminated liquids with heavy or abrasive materials, the warranty will be voided.
NAMEPLATE DATA
The nameplate, located on the side of the pump, indicates specic informa-
tion about the construction of the pump. The model number and date code
information should be recorded on the front page in the “Owner’s Information”
section of this manual.
SHORT TERM STORAGE
When not in use, the pump should be stored and 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 should be checked:
• Clean pit.
• Electrical boxes 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 veried proceed with the following checks:
• Pump power cables and control oats properly installed and voltage veried.
• Conduit connections to panel are properly sealed.
• After installing the pump into the containment area, with adequate submer-
gence, open the discharge valve fully. Start the unit using manual controls.
If ow 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 qualied electrician take voltage and current measurements 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.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Nonautomatic - Refer to the system drawing or to the panel wiring
schematic for the desired location of each oat switch setting.
Automatic - Float is factory set to provide approximate on/off levels
as follows:
SERIES ON OFF
X160/X190 19-1/2" 9-3/4"
X280 19-3/4" 10"
X290 19-1/2" 9-3/4"
A tighter pumping range can be set by moving the oat stop closer
to the oat thereby lowering the "on" point.
Valves: Discharge valves should be placed in the fully open position. Sys-
tems 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 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 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.
© Copyright 2014 Zoeller® Co. All rights reserved.
SERVICE CHECKLIST
Electrical precautions. Before servicing the pump, always shut off the main power circuit. Make sure you are wearing
insulated protective sole shoes and not standing in water. Under ooded conditions, contact your local electric company or a qualied
licensed electrician for disconnecting electrical service to the pump prior to removal.
Pumps contain oil which becomes pressurized and hot under operating conditions. Allow 2-1/2 hours after shut down
before servicing pump.
Condition
A. Pump will not start or run.
B. Motor overheats and trips on overload.
C. Pump will not shut off.
D. Pump operates but delivers little or no water.
E. Pump starts and stops too often.
F. Large red ashing light comes on at control box.
G. Grease and solids accumulate in pit around pump.
Common Causes
Blown panel or circuit breaker fuse, low voltage, thermal overload open, impeller
clogged, oat switch held down or defective, incorrect wiring in control panel, water
in cap assembly.
Incorrect voltage, impeller blocked, negative head (discharge lower than intake of pump).
Pump runs continuously at low water level. Low oil level in motor shell.
Air lock, debris under oat assembly, incoming sewage exceeds capacity of pump.
Intake clogged with grease or sludge, pump air locked (clear vent hole), low or
incorrect voltage, clogged discharge line, operating near shut-off head.
Check valve stuck open. Sump pit too small to handle incoming sewage. Level control
out of adjustment. Thermal overload tripping.
High water in pit. Check pump for clogging, or overload trip. See “A” and
“D” above.
Break up solids and run pump with water running into the pit. Allow level to lower
to the pump intake. Continue until solids are cleared from the pit. Do not drain
kitchen grease down the sink.
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
®
®visit our web site:
www.zoeller.com
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