Zoeller 508 Installation Guide

			FM3120
			0819
			Supersedes
Product information presented
here reflects conditions at time			0119
of publication. Consult factory
regarding discrepancies or
inconsistencies.
		MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347	Visit our website:
		SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
		TEL: [phone] • 1 (800) 928-PUMP • FAX: [phone]	zoellerpumps.com
Patent No.
D740329

Real Time Peace of Mind.™

12 VOLT DC BATTERY BACKUP PUMP

INSTALLATION INSTRUCTIONS

PREINSTALLATION CHECKLIST

1.Inspect your pump. Occasionally, products are damaged during shipment. If the unit or any of the parts are damaged, contact your dealer before using.

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

SEE BELOW FOR

LIST OF WARNINGS

1.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.

2.For your protection, always disconnect the power supply from its power source before handling the components of your DC backup pump or the primary pump.

3.Installation and servicing of electrical circuits and hardware should be performed by a qualified, licensed electrician.

4.All electrical and safety codes must be followed including the

National Electrical Code and all applicable local codes.

5.It is the owner’s responsibility to check the battery and

battery connection at least once a month. Batteries contain acid, and caution must be taken when handling.

6.Riskofelectricshock.Thesepumpshavenotbeeninvestigatedfor use in swimming pools and marine areas.

7.Prop65 Warning for California residents: Cancer and Reproductive Harmwww.P65Warning.ca.gov.

CAUTION	SEE BELOW FOR
	LIST OF CAUTIONS

1.Make sure there is a properly grounded 115 V receptacle available. Do not use primary pump circuit. The location must be within 6' (1.8 m) of the control box and battery. The power supply for your

DC control system plugs directly into the 115 V outlet. DONOTUSE AN EXTENSION CORD.

2.Make sure the 115 V electrical supply circuit is equipped with fuses or circuit breakers of proper capacity.

3.DC emergency pumps are designed for handling clear water. Do

not use in septic tanks to pump effluentor in sewage pits to pump sewage.

4.Repair and service of your DC backup system should be performed by an authorized service station.

5.TheinstallationofDCautomaticbackuppumpsrequirestheuseof avariablelevelfloatswitchforoperation.Itistheresponsibilityof the installing party to ensure that the floatswitch will not hang up on the pump apparatus or pit peculiarities and is secured so the pump will turn “on” and “off”. It is recommended that the pit be 18" (45.7 cm) in diameter or larger to accommodate both a primary and a DC backup pump.

6.For indoor use only.

CAUTION Turbulence caused by high-velocity incoming water can cause sump pumps to airlock. If this condition exists, theincomingwatermustbebaffledtoavoidexcessiveturbulence.

REFER TO WARRANTY ON PAGE 2.

© Copyright 2019 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 three years from date of purchase by the end user. Zoeller batteries have a 3 year warranty. Parts that fail within the warranty period, that inspections determinetobedefectiveinmaterialorworkmanship,willberepaired,replacedor remanufacturedatManufacturer'soption,providedhowever,thatbysodoingwe 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, subjectedtomisuse,misapplication,neglect,alteration,accidentoruncontrollable 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.inallpumpingapplications. Thewarrantysetoutintheparagraphaboveis

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.

ContactManufacturerat,3649CaneRunRoad,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 theabovelimitationmaynotapplytoyou.Somestatesdonotallowtheexclusion 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 instances where property damages are incurred as a result of an alleged product failure, the property owner must retain possession of the product for investigation purpose.

MAINTENANCE

1.	Inspect and test the system for proper operations at least every 3			(g)	Hold silence/ reset button for 3 seconds to reset the controller
	months.*				and clear any alarms or indicators.
	(a)	Green "system ready" indicator light should be on, indicating AC		2. Plug the controller and the primary pump into the wall outlet.
		power is on and there are no alarm conditions.		(a)	The primary pump will come on, lower the water to the normal
	(b)	Unplug the primary pump and the controller from the power supply.			operating level and shut off.
	(c)	Fill the sump with water to the “on” level for the DC pump. Allow		(b)	The battery light will be yellow when charging. The charger is
		the pump to run a few minutes.			replacing the energy consumed during the test. The green light
	(d)	Thealarmwillsoundapproximately1secondafterthepumpstarts			will come on after the charger has replaced the energy consumed
		to run.			during the test.
	(e)	Push the Silence/Reset button. The alarm will turn off.		*Wetcellbatterieswaterlevelshouldbecheckedeverymonth.AGMbatteries
				should not.
	(f)	Thepumpwillshutoffafterthewaterlevelisloweredandthefloat

drops to the "off" position.

TROUBLESHOOTING INFORMATION

1.DC Pump won’t run.

(a)Check for proper connections.

(b)Check all wire terminal points. Clean if required.

(c)Check for low battery. Service battery if required.

(d)Check30ampfuseoncontroller(seefig.3).Iffuseisblown, replace with 30 amp automotive blade fuse.

2.Pump runs but pumps very little or no water without AC power.

(a)Check for low battery. Battery will recharge if green power “on” light indicates power has been restored and the float switch is in the off position.

(b)If immediate usage is required, remove and replace dead battery with a full recharged battery.

(c)Due to varying conditions the pump may continue to run on a low battery without sufficient power to remove water. Pump will not stop running until battery is below minimum voltage.

(d)		Weak batteries can be recharged but may not
	CAUTION

store sufficient energy for full service. A weak recharged battery can only be detected by reduced pumping time or by professional load testing equipment. If your emergency pump system is used frequently the battery should be checked by a qualified battery dealer.

3.Pump runs but pumps very little or no water.

(a)Verfiy pump is connected completely.

(b)Check to make sure pump weep hole is clear and unit is not airlocked.

(c)Make sure discharge piping is not blocked.

4.Pump cycles too frequently.

(a)Check positions of rubber stops on operational float rod.

(b)Adjust upper rubber float stop as required. Recommended for standard installation.

5.Float switch in “on” position for more than 3 seconds. Pump won’t run.

(a)Remove pump. Check for obstruction in pump preventing impeller from rotating.

6.Pump runs, but pumps water intermittently.

(a)Pumpisair locking.Checkflowofwater incoming tosump. Ifwater is entering the sump at a high velocity creating a turbulent condition, a mixture of air and water may cause a complete or partial air lock and reduce or stop the flow of water in the discharge pipe.

(b)Baffletheincomingstreamofwatertoreduceturbulence.Diverting water stream against wall of basin usually corrects an air lock problem.

7.Water level stays high. DC Pump continues to run.

(a)Battery is low.

(b)If power has been restored and water in sump remains high check primary pump. Service if required.

(c)After several hours the battery will be restored to full charge.

8.Alarm sounds during battery recharge cycle.

(a)To silence alarm if alarm will not reset, unplug the charger from

115 V wall outlet, then disconnect the black lead from charger on negative (-) battery post. Check battery. Replace if necessary. Reconnect and refer to Installation (step 12).

NOTE: The Z Control® Cloud may provide additional information.

© Copyright 2019 Zoeller® Co. All rights reserved.

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DESCRIPTION

This system is a backup to your primary sump pump. It is designed to provide flood prevention during power outages or primary pump failure. This system is unique in that it has self-testing and communication features (if using with Gateway and Z Control® Cloud).

		Construction	Non-corrodible plastic, premium seals
	<![if ! IE]> <![endif]>Pump	Performance	35 GPM at 10' (113 LPM at 3 m) at 12.7 volts
		Continuous Running Time	5.5 hours
		Duty Cycle of 10%	2 days
		Connection	9' (2.7 m) wire with 2 position connector
		Construction	ABS plastic
	<![if ! IE]> <![endif]>Controller	Power Requirement	115 V 15 amp circuit
		Consumption	Up to 3 amps at 115 V
		Charger output	7 amp multi-stage
		Connections	8' (2.4 m) AC power cord, 6' (1.8 m) DC charging cable, connections for pump, operation switch, high water switch
	<![if ! IE]> <![endif]>Z Control	WiFi	Built in
	<![if ! IE]> <![endif]>Battery Box	Construction	Non-corrodible plastic
		Safety	Snap tight lid, keeps battery safe and clean

* When AC power is available, DC Pump operation does not deplete battery.

						Model 508 Fit
								508-C
					Item	Description	Qty	8/18
								thru Current
					1	Pump 12 V DC / Backup	1	155652
				8		(service part)
	7
						Flapper asm, (service
6					2		1	152970
						part)
					3	Fitting, asm & clamp	1	152969
						"508" (service part)
1				9		Fitting, PVC 1-1/2"
					4	(DN40) tee/SCH 40	1	153766
						(pressure fitting)
					5	Valve, check / 1.5"	1	153772
						(DN40) Inline / vertical
					6	Operational float	1	155654
2		3		10	7	Clamp, #28 Worm-SS	2	004287
			11			(float switch)
				12 VOLT BATTERY	8	Fit controller	1	155368
4				SUPPLIED BY USER	9	Fuse, 30 amp automo-	1	016918
						tive
					10	High water float, NC	1	155653
5					11	Battery box asm (box	1	10-0764
				12		and cover)
					12	Hardware pak, charger	2	152864
						/switch mode
				SK3183

PERFORMANCE

The DC pump performance at 12.7 Vdc

Discharge	5	10	15	28
Feet of Head	(1.5 m)	(3 m)	(4.6 m)	(85 m)
Flow	43	35	27	Shut-off
GPM (LPM)12.7 volts	(163)	(132)	(102)	Head

The DC controller is equipped with a charger for maintaining the battery in a ready state and recharging the battery after use when AC power is restored. Time for recharge depends upon the amount of power consumed by the pumping cycle during the AC power interruption. The pump may go back to the ready run position in a very short period of time. A completely drained battery may require up to 24 hours for full recharge. If battery does not charge properly, the LED battery will flash red.

BATTERY SELECTION

The DC emergency pump system requires a good quality, 12 volt battery to obtain maximum pumping time during a power outage. A deep-cycle,

12 volt, 105 amp-hour marine battery or larger is recommended and will provide approximately 5.5 hours of continuous pumping time in a sump pump installation with 8' (2.4 m) of head pressure. In most installations, the pump runs intermittently and the battery life is extended accordingly. Batteries with top terminals are recommended for ease of installation. "Wet" cell batteries contain acid, and proper precaution must be taken when handling. Battery box will accommodate a maximum battery size of 13-1/2" (34.3 cm) Length x 7" (17.8 cm) Width x 9-1/2" (24.1 cm) Height. AGMbatteriesalsorecommended.Donotusegelbatteriesorautomotive batteries.

© Copyright 2019 Zoeller® Co. All rights reserved.

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INSTALLATION

1.ThepreferredmethodofinstallationforbackuppumpsisshowninFigure1. The installation kit includes the necessary fittings. Includes the parts needed to install as in Figure 1. A check valve is incorporated in the discharge of the backup pump.

NOTE: Do not install in small spaces where the controller will not be properly cooled.

2.Remove all parts from the shipping carton, and make sure all parts are included. Refer to the parts list on page 3.

3.Select a location for the battery and the controller. The controller must be within 8' (2.4 m) of a 115 V wall outlet and within 6' (1.8 m) of pump and basin. Connect to a separate circuit from the primary pump.

4.If the primary pump is installed, disconnect power.

NOTE: Discharge piping must be 1-1/2" SCH 40 PVC

5.Remove the discharge pipe from the pump and place it aside.

6.Solvent weld the DC Pump discharge reducer fitting to the tee as shown in Figure 1. Ensure the O-ring is properly located on the pump discharge.

Slide the DC pump into the fitting, and tighten the hose clamp.

NOTE: The pump must be pushed all the way into the fitting to prevent the fitting from leaking.

7.Determine the position of the DC pump and measure for discharge piping. Use that measurement to cut the discharge pipe. Solvent weld that piece to the tee. Measure, cut and solvent weld any remaining discharge piping above the tee.

NOTE: Check float operations to ensure the hose clamp screws will not interfere with the float operation of the primary pump.

8.AssembletheoperationfloatassemblyperFigure3.Installfloatswitches as seen in Figure 1.

9.Install the operational float switch bracket above the "on" level of the primary pump using the clamp provided. Make certain the clamp is tight on the pipe to avoid slippage. Ensure that the "off" level of the float is 1"

(2.5 cm) minimum above the outlet of the DC backup pump. Position the pumpsinthesumpandmovefloatupanddown,ensuringfreemovement without interference from any obstructions inside the sump or lid. The floatswitchcanbemovedonthedischargepipe,ortherubberstopscan be adjusted as necessary. Cut extra float rod length below lower float stop to prevent debris from interfering with float operation. Install the high water switch with the "on" level set at least 1" (2.5 cm) above the "on" level of the operational float using the supplied clamp. Move the switch

up and down, ensuring free movement without interference from any obstructions inside the sump or lid.

10.Install the Fit Controller (see Figure 3) by using the anchors provided.

For best cooling, install wall mount configuration. The controller should be located at least 3' (1 m) above the sump.

11.Connect the leads from the controller to the battery terminals. Positive (+) lead to positive terminal and black neg. (-) lead to negative battery terminal.

CAUTION

Correct battery hook-up is essential for operation

of the system. Use wing nuts supplied with battery and eyelet connectors on battery wire leads. The positive terminal is the larger stud, 3/8" (10 mm) diameter. The smaller stud, 5/16" (8 mm) diameter is the negative terminal. The stud sizes on the AGM battery are identical. Apply grease to the terminals to help prevent corrosion.

12.Connect the pump's plug into the controller terminal.

13.Plug the controller into the 115 V wall outlet. The primary sump pump and the controller should be on separate circuits.

14.Reconnect power to the primary sump pump.

15.The Aquanot® FIt Controller is designed for use with Z Control®.

INITIAL START-UP AND OPERATION

1.Testtheinstallationforleaksbyrunningwaterintothesump,allowing for normal operation of the primary pump.

2.Check the controller. The System ready light will be green when the unit is plugged into the 115 V wall outlet. The battery will indicate its condition when the controller has DC power. When the unit is first plugged in, all lights will flash and alarm will sound to verify all lights and the alarm work. Note that the charger may not begin charging for several minutes.

3.Disconnect the primary pump from its power source before touching any component in the sump pit.

4.Lift theoperationalfloatswitch.AfteracouplesecondstheDCbackup pump will run, and the alarm will sound after about 1 second. Lower the operational float switch after the alarm sounds. Take care that the intake of the DC pump is set above the inlet of the primary pump. Press silence for 3 seconds to clear out the alarm and reset the unit.

	Continuous dry running may cause overheating and
CAUTION

damage the pump seals. Upon release of the float switch, the pump will shut off. Be sure there are no obstructions around the float.

5.Check installation of the high water switch. Lift the high water float. The alarm will sound, and the light will alert of high water. If the operational float is down, the pump will run until the float lowers and the pump is no longer pumping water, or the run timer expires a foat

fault LED will be lit. If the operational float is up during high water, unitwillalarmandhighwaterfloatlightwillilluminate.Thepumpwill turn off once water is pumped lower than the operational float.

6.Completethefinaltestingofyourinstallationbyensuringtheprimary pumpisstilldisconnectedfrompower. Then,unplugthefitcontroller from the 115 V wall outlet. Run water into the sump until the DC backup pump is activated by the operational float switch. Check all connections for leaks.

7.Push the Silence button when the pump is running. This will silence the alarm. The pump will continue to run until the operational float is deactivated.

8.ReconnectthecontrollerandtheprimarypumptotheACwalloutlets. The primary pump may come on, lower the water level in the sump back to its normal operating level, and shut off. Both primary and backup systems are now ready for use. Hold silence button for several seconds to reset the unit.

9.The battery hold silence button for several seconds to reset the unit. LED will be yellow during normal charging operation. See page 6 for a description of controller functions.

NOTE: When running the pumps, it is normal for a stream of water to spray out of the 1/8" (3 mm) air relief hole.

© Copyright 2019 Zoeller® Co. All rights reserved.

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