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Zoeller ULTIMA 202 User Manual

Zoeller ULTIMA 202
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QWIK JON
®
ULTIMA 202 SYSTEM
INSTALLATION INSTRUCTIONS
PREINSTALLATION CHECKLIST
NOTICE TO INSTALLER: Instructions must remain with installation.
SECTION: W2.50.025
FM2369_Ec
0214
Supersedes
1213
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.Thesematerialsshouldberetainedfor
future reference.
SEE BELOW FOR LIST OF NOTES
NOTES
REFER TO WARRANTY ON PAGE 2.
SEE BELOW FOR LIST OF WARNINGS
CAUTION
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 USA
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 USA
+1 (502) 778-2731 • FAX +1 (502) 774-3624
®
Your Peace of Mind is Our Top Priority
®
visit our web site:
www.zoeller.com
50/60Hz
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 governing
codes. Unit must be vented. Do not use an automatic plumbing
vent device.
4. Maximum operating temperature must not exceed 54°C (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 with total dynamic head up to 6 m (20') for
60 Hz or 5 m (15') for 50 Hz. Consult factory if 50 Hz installation is above
5m(15')verticalheightinDN25(1")pipeorif60Hzinstallationisabove
4m(13')verticalheight.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.CSACertiedpumpsare certiedtoCSAStandardC22.2No.
108.QwikJon
®
Ultima units only. It is not designed for use in any other
application.
4. Model202toiletutilizes4.8or6.1liters(1.28or1.6gallons)perush.
5. Allxturesconnectingtothesystemmustbeonthesameoorlevel.
1. Toreducetheriskofelectricalshock,aproperlygroundedreceptacleor
controlboxmustbeinstalledinaccordancewiththegoverningcodes.Never
remove ground pin from plug.
2.Makecertainthatthegroundfaultinterrupterprotectedreceptacleor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,andtheycouldpresentasafety
hazard if the insulation were to become damaged or the connection end were
to fall into a damp or wet area.
3.Makesurethepump'selectricalsupplycircuitisequippedwithfusesorcircuit
breakersofpropercapacity.Aseparatebranchcircuitisrecommended,sized
according to the governing electrical codes for the current shown on the pump
name plate.
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qualiedlicensedelectrician.
5. FORYOUR PROTECTION,ALWAYS DISCONNECTPUMP FROMITS
POWERSOURCEBEFOREHANDLING.Ifpumpiswireddirect,de-energize
thecircuitatthecontrolbox.DONOT,UNDERANYCIRCUMSTANCES,
REMOVETHEGROUNDPIN.Wearinsulatedprotectiveshoesanddonot
standinwater.Certainplugtypesmayincludea3-pronggroundplugtohelp
protectagainstelectricalshock.Aproperlygrounded3-prongreceptacleor
control box must be installed in accordance with governing codes.
6. Installation and servicing of the pump's electrical circuits and hardware should
onlybeperformedbyaqualiedlicensedelectrician.
7. Installation andmaintenanceof thisapplianceisnot intendedforpersons
(including children) with reduced physical, sensory or mental capabilities, or
lackofexperienceorknowledge,unlesstheyhavebeengivensupervisionor
instruction concerning use of the appliance by a person responsible for their
safety.
8. Risk of electrical shock.Donotremovepowersupplycordandstrainrelief
or connect conduit directly to the pump. If the supply cable is damaged, it
must be replaced by an authorized Zoeller Representative.
9. Pumpcontainsoilwhichbecomespressurizedandhotwhenoperating.Allow
2½ hours after disconnecting before attempting service.
10. Pumpisnotintendedforpotablewaterduetopossiblecontaminationbyoil
contained in the pump.
11. Risk of electric shock.Thesepumpshavenotbeeninvestigatedforusein
swimming pools and marine areas.
DATE INSTALLED:
MODEL NUMBER:
© Copyright 2014 Zoeller Co. All rights reserved.

Questions and Answers:

Zoeller ULTIMA 202 Specifications

General IconGeneral
BrandZoeller
ModelULTIMA 202
CategoryWater Pump
LanguageEnglish

Summary

Preinstallation Checklist

Inspect Materials

Inspect all materials for damage during shipment and do not remove test plugs.

Read Literature

Read all provided literature for installation and use details. Retain for future reference.

General Warnings

Electrical Grounding Requirements

Ensure proper grounding of receptacle/control box and never remove ground pin.

Receptacle Placement & Extension Cords

Ensure GFCI receptacle is within reach of power cord; never use extension cords.

Circuit Protection

Ensure the pump's electrical supply circuit has properly sized fuses or breakers.

Outlet Ground Testing

Test electrical outlets for proper ground connection using a circuit analyzer.

Disconnect Power Before Handling

Always disconnect the pump from its power source before any handling or service.

Qualified Electrician for Service

Electrical circuits and hardware installation/servicing must be done by a qualified electrician.

User Capabilities for Installation

Installation and maintenance not intended for persons with reduced capabilities or lack of experience.

Electrical Shock Precautions

Do not remove power cord/strain relief or connect conduit directly to pump.

Pump Oil Hazard & Cooling Time

Pump oil is pressurized and hot; allow 2.5 hours after disconnecting before service.

Non-Potable Water Use

Pump is not for potable water due to potential oil contamination.

Unsuitable Environments

Pumps not investigated for use in swimming pools or marine areas due to shock risk.

General Cautions

Foreign Object Flushing

Grinder pump handles specific waste; avoid flushing foreign objects to prevent clogs.

Power Source Adequacy

Ensure power source is adequate for motor's amperage requirements.

Plumbing and Venting Requirements

Install plumbing to codes, ensure unit is vented, and do not use automatic vent devices.

Maximum Operating Temperature

Do not exceed the maximum operating temperature of 54°C (130°F).

Avoid Bleach Cleaning Products

Do not use bleach products in toilet system as they degrade pump seals.

Important Notes

Authorized Service

Repair and service must be performed by an Authorized Service Station.

Recommended Head Limits

Recommended for total dynamic head up to 6m (60Hz) or 5m (50Hz).

Certifications and Standards

Pumps marked UL/US tested to UL778; CSA pumps certified to CSA C22.2 No. 108.

Flush Volume

Model 202 toilet uses 4.8 or 6.1 liters per flush.

Fixture Placement

All fixtures connecting to the system must be on the same floor level.

Limited Warranty Information

Warranty Coverage and Period

Warrants products free from defects for one year from purchase or 18 months from manufacture.

Warranty Exclusions

Excludes damage from disassembly, misuse, neglect, alteration, accident, or natural acts.

Liability Limitations

Disclaims liability for special, consequential, or incidental damages.

Helpful Installation Hints

Read Instructions First

Read all installation instructions thoroughly before starting.

Floor Leveling

Ensure the installation floor is level within 3 mm (1/8 inch).

Vent Pipe Seal Installation

Install vent pipe seal with the flange side facing outwards.

Lubricate Seals

Use soapy water to lubricate all seals for easier installation.

Vent Line Coupling

Install a rubber coupling/union in the vent line for disassembly aid.

Toilet Mounting Screws

Avoid over-torquing the toilet mounting screws.

Avoid Automatic Vent Devices

Do not use automatic plumbing vent devices; use proper venting.

Record Model and Date Code

Record model number and date code from the front of the manual.

Installation Dos and Don'ts

Read Installation Material

Read all provided installation material before proceeding.

Inspect for Shipping Damage

Inspect unit for shipping damage and contact dealer if found.

Clean Unit Debris

Ensure all visible debris is cleaned from the unit.

Power Connection and Safety

Disconnect power before handling; connect to protected, grounded GFCI circuit.

Discharge Line Valve and Union

Install a ball/gate valve and union downstream of the check valve.

Test Pump After Installation

Test the pump immediately after installation to ensure proper operation.

Code Compliance

Review and verify compliance with all applicable local and national codes.

Application Restrictions

Do not connect to utilities outside of normal bathroom applications.

Regular System Testing

Inspect and test the system for proper operation at least every 3 months.

Typical Piping Configurations

Service Parts

Troubleshooting

Pump Will Not Start or Run

Addresses issues where the pump fails to start or operate.

Pump Starts Too Soon

Troubleshooting for premature pump activation.

Water Level Excessive Before Pump Turns On

Diagnoses high water levels before pump activation.

Pump Will Not Shut Off or Runs Too Long

Resolves issues with the pump not shutting off or running excessively.

Pump Operates But Delivers Little or No Water

Troubleshooting for low or no water delivery.

Dimensions

Location Selection

Floor Requirements

Ensure the installation floor is structurally sound and level within 3 mm (1/8").

Water Supply

A DN15 (1/2") water supply line with a shut-off valve is needed.

Electrical Requirements

An appropriate voltage receptacle is needed for electrical power.

Sewage Line Connection

Requires access to a sewage line with a DN25 (1") discharge line and valve.

Vent Pipe Requirement

Access to a vent pipe is required; mechanical vent systems are not recommended.

Leveling of Pump Unit

Avoid Wooden Shims

Do not use wooden shims to level the pump unit.

Prevent Punctures

Ensure nails, screws or sharp objects do not puncture the pump unit.

Rough-In Installation

Stand-Alone Installation

Position unit 3mm from wall, attach bellows, place toilet, mark locations.

Behind-the-Wall Installation

Requires extension kit; place toilet assembly, mark closet bolts, measure pipe.

Piping

Discharge Pipe Fitting

Cut and dry-fit DN25 (1") discharge pipe, position and mark fitting location.

Vent Pipe Fitting

Cut and dry-fit DN40 (1½") vent pipe, connect with street elbow.

Proper Venting Required

Proper venting is required; do not use a mechanical type vent.

Solvent Weld Piping

Clean, prime, and solvent weld discharge/vent piping; avoid glue in check valve.

Additional Bathroom Fixtures

Inlets can accept fixtures; drill 44mm hole. Use check valve on incoming line.

Toilet Installation

Install Closet Bolts

Install closet bolts at the marked points.

Place Toilet Assembly

Place toilet assembly over bolts, install hardware, tighten, and shim as needed.

Install Rubber Bellows

Install rubber bellows onto discharge and tank hub, secure with clamps.

Install Water Supply Line

Connect water supply line from shut-off valve to toilet connection.

Check Water Supply and Leaks

Open water supply valve, check for leaks, and adjust tank fill level.

Connect Power and Test Flush

Plug in pump, flush toilet, listen for pump, check for leaks and proper venting.

Pump Performance Charts

50 Hz Performance

Shows maximum pipe lengths for 50 Hz operation at various head levels.

60 Hz Performance

Shows maximum pipe lengths for 60 Hz operation at various head levels.

Pump Performance Data

50 Hz Performance Curve

Graph showing Total Dynamic Head vs. Flow Rate for 50 Hz operation.

60 Hz Performance Curve

Graph showing Total Dynamic Head vs. Flow Rate for 60 Hz operation.

Performance Data Tables

Tables detailing Total Dynamic Head/Flow Rate for sewage applications.

Declaration of Conformity

EC Machinery Directive Compliance

Declares conformity with EC Machinery Directive (2006/42/EC).

EC EMC Directive Compliance

Declares conformity with EC Electromagnetic Compatibility Directive (2004/108/EC).

EC Low Voltage Directive Compliance

Declares conformity with EC Electrical Equipment Directive (2006/95/EC).

EC Construction Products Directive Compliance

Declares conformity with EC Construction Products Directive (89/106/EEC).

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