Zoeller Pump Installation Instructions

Notice to Installing Contractor

Instructions must remain with installation.

Date Installed:

Model Number:

Manufacturer: ZOELLER PUMP COMPANY

Address: MAIL TO: P.O. BOX 16347 Louisville, KY 40256-0347 SHIP TO: 3649 Cane Run Road Louisville, KY 40211-1961

Contact: Tel: (502) 778-2731 / (800) 928-PUMP

Website: Visit our website: zoellerpumps.com

Product information presented here reflects conditions at time of publication. Consult factory regarding discrepancies or inconsistencies.

Register your Zoeller Pump Company Product on our website: http://reg.zoellerpumps.com/

[Zoeller Logo, ZMW Logo, Family Owned American Proud Emblem]

Installation Instructions Models 63 and 95

Pre-Installation Checklist - All Installations

NOTICE: VENT HOLE FOR CHECK VALVE SEE #1 IN CAUTION SECTION ON PAGE 2 AND #4 ON PAGE 4

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/oil fill plugs from the pump.
2. Carefully read the literature provided to familiarize yourself with specific details regarding installation and use. These materials should be retained for future reference.

Safety Instructions

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR 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.

[Information Symbol] 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.

• [Warning Symbol] WARNING: Warns of hazards that CAN cause serious personal injury, death or major property damage.
• [Caution Symbol] CAUTION: Warns of hazards that CAN cause personal injury or property damage.
• [Electrical Shock Symbol] Warns of electrical shock hazards that can cause serious personal injury, death or major property damage.
• [Grounding Symbol] Identifies any terminal which is intended for connection to an external conductor for protection against electrical shock in case of a fault, or the terminal of a protective earth (ground) electrode.

Read operator's manual.

THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS PUMP. MAINTAIN ALL SAFETY DECALS.

REFER TO CAUTIONS AND WARRANTY ON PAGE 2.

General Safety Precautions

1. 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 sufficient voltage to the pump motor and could present a safety hazard if the insulation were to become damaged or the connection end were to fall into a wet or damp area.
2. Check to be sure your power source is capable of handling the voltage requirements of the motor, as indicated on the pump name plate.
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 the "National 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 an Underwriters Laboratory Listed circuit analyzer which will indicate if the power, neutral and ground wires are correctly connected to your outlet. If they are not, call a qualified licensed electrician.
5. For Added Safety. Pumping and other equipment with a 3-prong grounded plug must be connected to a 3-prong grounded receptacle. For added safety the receptacle may be protected with a ground-fault circuit interrupter. When a pump needs to be connected in a watertight junction box, the plug can be removed and spliced to the supply cable with proper grounding. For added safety this circuit may be protected by a ground-fault circuit interrupter. The complete installation must comply with the National Electrical Code and all applicable local codes and ordinances.
6. FOR YOUR PROTECTION, ALWAYS DISCONNECT PUMP FROM ITS POWER SOURCE BEFORE HANDLING. Single phase pumps are supplied with a 3-prong grounded plug to help protect you against the possibility of electrical shock. 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 National Electrical Code and all applicable local codes and ordinances. Three phase pumps require motor starting devices with motor overload protection. See FM0486 for duplex installations.
7. Risk of electric 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 qualified licensed electrician.
9. Pump installation and servicing should be performed by a qualified person.
10. Risk of electric shock. These pumps have not been investigated for use in swimming pool and marine areas.

Do's and Don'ts for Installing a Sump Pump

Do's:

• Read thoroughly all installation material provided with the pump.
• Inspect pump for any visible damage caused by shipping. Contact dealer if pump appears to be damaged.
• Clean all debris from the sump. Be sure that the pump will have a hard, flat surface beneath it.
• Be sure that the sump is large enough to allow proper clearance for the level control switch(es) to operate properly.
• Always Disconnect Pump From Power Source Before Handling.
• Always connect to a separately protected and properly grounded circuit.
• Install a check valve and a union in the discharge line.
• Test pump immediately after installation to be sure that the system is working properly.
• Cover sump with an adequate sump cover.
• Review all applicable local and national codes and verify that the installation conforms to each of them.
• Consult manufacturer for clarifications or questions.
• Consider a two pump system with an alarm where an installation may become overloaded or primary pump failure would result in property damages.
• Consider a D.C. Backup System where a sump or dewatering pump is necessary for the prevention of property damages from flooding due to A.C. power disruptions, mechanical or electrical problems or system overloading.
• Inspect and test system for proper operations at least every three months.

Don'ts:

• DO NOT install on sand, gravel or dirt.
• DO NOT ever cut, splice, or damage power cord (Only splice in a watertight junction box).
• DO NOT carry or lift pump by its power cord.
• DO NOT use an extension cord with a sump pump.
• DO NOT use a discharge pipe smaller than the pump discharge.
• DO NOT use a sump pump as a trench or excavation pump, or for pumping sewage, gasoline, or other hazardous liquids.

Installation Recommendations for All Applications

1. Electrical wiring and protection must be in accordance with National Electrical Code and any other applicable state and local electrical requirements.
2. Install proper Zoeller Unicheck (combination union and check valve) preferably just above the basin to allow easy removal of the pump for cleaning or repair. See (4) below.
3. All installations require a basin cover to prevent debris from falling into the basin and to prevent accidental injury.
4. When a Unicheck is installed, drill a 3/16" (5 mm) dia. hole in the discharge pipe even with the top of the pump. NOTICE: THE HOLE MUST ALSO BE BELOW THE BASIN COVER AND CLEANED PERIODICALLY. Water stream will be visible from this hole during pump run periods.
5. Securely tape or clamp power cord to discharge pipe, clear of the float mechanism(s).
6. Use full-size discharge pipe.
7. Basin must be in accordance with applicable codes and specifications.
8. Pump must be level and float mechanism(s) clear of sides of basin before starting pump.
9. Basin must be clean and free of debris after installation.
10. Gate valve or ball valve to be supplied by installer and installed according to any and all codes.
11. Gas tight seals required to contain gases and odors.
12. Vent gases and odors to the atmosphere through vent pipe (sewage and dewatering only).
13. Install a Zoeller pump stand (10-2421) under pump to provide a settling basin (dewatering only).

Typical Dewatering Installation Diagram Description

The diagram illustrates a typical dewatering sump pump installation within a basin. Key components include:

• 1. Pump: The submersible pump unit.
• 2. Discharge pipe: Carries water away from the pump.
• 3. Check valve (Zoeller Unicheck): Prevents backflow.
• 4. Vent hole: A small hole drilled in the discharge pipe below the check valve to release trapped air.
• 5. Power cord: Connects the pump to the electrical supply.
• 6. Discharge pipe (full size): Emphasizes using the correct pipe diameter.
• 7. Basin/Pit: The containment area for the pump. Minimum size shown is 457mm x 610mm (18" x 24").
• 8. Float mechanism: Controls the pump's on/off cycles based on water level.
• 9. Basin cover: Prevents debris from entering the basin and protects against injury.
• 10. Gate valve or ball valve: For controlling water flow.
• 11. Gas tight seals: To contain gases and odors.
• 12. Vent pipe: To vent gases and odors to the atmosphere.
• 13. Zoeller pump stand: Recommended for dewatering applications to provide a settling basin.
• Gravel: 10cm (4") of gravel is shown at the bottom of the basin.

Note: The diagram also references related documents (FM0531, FM0732, FM1420) for alarms, controls, and junction boxes.

All installations must comply with applicable electrical and plumbing codes, including National Electrical Code, local, regional, and state plumbing codes. Not intended for use in hazardous locations.

Service Checklist

[Warning Symbol] ELECTRICAL PRECAUTIONS: Before servicing a pump, always shut off the main power breaker and then unplug the pump. Ensure you are wearing insulated, protective sole-shoes and not standing in water. In flooded conditions, contact your local electric company or a qualified licensed electrician for disconnecting electrical service prior to pump removal.

[Warning Symbol] Submersible pumps contain oil that becomes pressurized and hot under operating conditions. Allow 2-1/2 hours after disconnecting before attempting service.

If the above checklist does not uncover the problem, consult the factory. Do not attempt to service or otherwise disassemble pump. Service must be performed by Zoeller Authorized Service Stations. Go to www.zoellerpumps.com/servicestations to find the Authorized Service Station in your area.

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 five years from the date of purchase. Proof of purchase is required.

Parts that fail within the warranty period, 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, wash towels or feminine sanitary products, 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 Service 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 specific legal rights and you may also have other rights which vary from state to state.

In those instances where damages are incurred as a result of an alleged pump failure, the Homeowner must retain possession of the pump for investigation purposes.

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