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Zoeller 61 HD Series User Manual

Zoeller 61 HD Series
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SECTION: W3.20.035
ZM1759_Ec
0912
Supersedes
New
NOTICE TO INSTALLER: Instructions must remain with installation.
Congratulations on the purchase of the Zoeller 61 HD Series
submersible pump. Since 1939, the name Zoeller has represented the
standard for submersible dewatering and sewage pumps. The same high
quality workmanship and easy maintenance design has been incorporated
into this line of heavy-duty solids-handling submersible sewage pumps.
This Zoeller pump will provide years of trouble-free service when installed
according to the manufacturer’s recommendations.
This manual incorporates the installation, operation, maintenance,
and service instructions into one document to aid in the ownership of a
Model Number: Date Code:
Serial Number: Pump 1 Pump 2
Simplex Panel P/N
Duplex Rail System P/N
Job Name:
Distributor:
Sales Order Number:
Contractor: Date of Installation:
System Readings During Operation: Voltage Amps
OWNER’S MANUAL
61 HD SERIES SUBMERSIBLE NON-CLOG UNITS
Zoeller submersible non-clog wastewater product. Please read and review
this manual before installing the product. Follow the steps and procedures
listed on ZM1074_Eb for a proper start-up. Many items contained within,
when followed correctly, will not only ensure a long and problem-free life
for the pump, but also save time and money during installation. Reference
ZM1760_Ec for repair manual on 61 HD Series pumps. Should further
assistance be necessary, please call our Product Support Department at
+1 (502) 778-2731 or email us at zeptechnical@zoeller.com.
Table of Contents
Safety Instructions ................................................................................... 1
Limited Warranty ...................................................................................... 2
Preinstallation Information ...................................................................... 2
Electrical Data ........................................................................................... 3
Typical Sewage Installation ....................................................................4
Pump Wiring Instructions .....................................................................5-6
Operation .................................................................................................. 7
Maintenance .............................................................................................. 7
Service Checklist ...................................................................................... 8
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.
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
Owners Information
REFER TO WARRANTY ON PAGE 2.
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 USA
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 USA
+1 (502) 778-2731 • FAX +1 (502) 774-3624
visit our web site:
zoellerengineered.com
50/60 Hz
© Copyright 2012 Zoeller Co. All rights reserved.

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Zoeller 61 HD Series Specifications

General IconGeneral
Model61 HD Series
Voltage115V
Maximum Head25 feet
Motor HousingCast Iron
Impeller MaterialThermoplastic
Thermal ProtectionYes
CategoryWater Pump
TypeSump
PhaseSingle
Discharge Size1-1/2" NPT
Switch TypeVertical Float
Cord Length10 feet

Summary

Safety Instructions

General Safety Alerts and Symbols

Explanation of safety alert symbols (DANGER, WARNING, CAUTION, NOTICE) and their usage.

Electrical Safety Precautions

Detailed warnings regarding electrical shock hazards, grounding, and circuit protection.

Pump Handling and Operation Safety

Guidelines for safe pump handling, power disconnection, and operational procedures.

Material Compatibility and Usage Restrictions

Restrictions on pumping materials and usage to prevent damage or voiding warranty.

System Specific Safety Guidelines

Safety advice for float switches, vent hole drilling, and three-phase pump rotation.

Limited Warranty

Warranty Coverage and Exclusions

Details on warranty period, coverage, exclusions, and limitations.

Start-up Report Requirement

Requirement for a completed Zoeller Engineered Products Start-up Report to validate warranty.

Electrical Data

Typical Sewage/Waste Pumping System Installation

Installation Requirements and Best Practices

Covers electrical codes, check valves, controls, basin covers, gas seals, vent holes, and pit sizing.

Pump Wiring Instructions

Wiring Safety Precautions

Safety warnings and precautions for electricians regarding pump wiring and electrical shock.

Three Phase Rotation Check

Procedure for checking and correcting three-phase pump motor rotation.

Sensor and Control Panel Wiring

Instructions for connecting thermal and moisture sensors to control panels.

Cord Specifications and Identification

Details on power and sensor cord identification, sizes, and diameters for different models.

Single Phase Installation

Single Phase Wiring Diagram and Component Layout

Diagrams and component layout for single-phase pump installation and hookup.

Three Phase Installation

Three Phase Wiring Diagram

Wiring diagrams for three-phase pump installation, including CE and Non-CE models.

Operation

General Operation and Pre-start-up

Covers pump lubrication, temperature limits, liquid compatibility, and pre-start checks.

Nameplate Data Interpretation

Guidance on understanding information provided on the pump's nameplate.

Storage Procedures

Recommendations for short-term storage of pumps and control panels.

Start-up Procedure

Step-by-step guide for initial pump start-up and functional testing.

Adjustment Procedures

Procedures for adjusting panel settings, pump rotation, and float switch locations.

Shutdown Procedures

Guidelines for system shutdown, including pump operation during storage and panel sealing.

Maintenance

Service and Repair Notice

Advisory that repair and service should be performed by authorized personnel.

General Safety for Maintenance

Critical safety warnings for maintenance, including power disconnection and basin entry.

Lubrication and Preventive Maintenance

Information on lubrication requirements and a suggested preventive maintenance schedule.

Monthly Maintenance Checks

Tasks to perform monthly, including float operation and check valve checks.

Annual Maintenance Checks

Tasks to perform annually, including basin inspection and component replacement.

Biennial Maintenance Checks

Tasks to perform every two years, including insulating oil checks and power cable inspection.

Double Seal Pump Maintenance

Specific maintenance advice for double seal pumps regarding seal cavity oil.

Service Checklist & Trouble Shooting

Electrical Precautions for Service

Essential electrical safety precautions before performing service or troubleshooting.

Pump Will Not Start or Run

Troubleshooting steps for pump failure to start or run, checking voltage and circuits.

Motor Overheats or Trips Overload

Common causes and checks for motor overheating and overload trips.

Pump Starts and Stops Too Often

Troubleshooting common issues causing frequent pump cycling.

Pump Will Not Shut Off

Checks for issues preventing the pump from shutting off, such as float switch problems.

Pump Delivers Little or No Water

Troubleshooting steps for reduced or no water delivery, including blockages and head issues.

Drop in Head or Capacity

Diagnosing decreased pump performance over time, such as pipe friction or impeller wear.

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