Zoeller840SingleDirectional

Zoeller840SingleDirectional
NOTICE TO INSTALLER: Instructions must remain with installation.
SECTION: 6.10.021
FM2168
0906
Supersedes
0206
Product information presented
here reflects 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
OWNER’S MANUAL
MODELS 840 & 841 SUBMERSIBLE GRINDER UNITS
Congratulations on the purchase of a Zoeller submersible grinder pump. For over sixty years 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 submersible grinder 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 Zoeller submersible wastewater
product. Please read and review this manual before installing the product. Follow the steps in this manual 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
FM1308 for replacement parts on 840 Series Grinder Pumps
or FM2180 for model 841 parts. Should further assistance be
necessary please call our Technical Service Department at
1-800-928-PUMP (7867).
Table of Contents
Safety Instructions
Safety Instructions ....................................................................... 1
Limited Warranty and Application .............................................. 2
Preinstallation Checklist .............................................................. 3
General Information ..................................................................... 4
Pump Wiring Instructions ............................................................ 5
Typical Indoor Prepackaged System .......................................... 6
Indoor Prepackaged Installation Instructions ........................... 7
Typical Outdoor Prepackaged System ....................................... 8
Outdoor Prepackaged Installation Instructions ........................ 9
Operation..................................................................................... 10
Cutter Maintenance .................................................................... 11
Service Checklist ........................................................................ 12
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.
Owner’s Information
Model Number: ______________ Date Code: _______________
Simplex
Duplex
Packaged System
Field Assembled System
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.
Job Name: ____________________________________________
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
Distributor: ____________________________________________
MAINTAIN ALL SAFETY DECALS.
Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____ Amps _____
PUMPS WITH THE “UL” MARK AND PUMPS WITH THE “US”
MARK ARE TESTED TO UL STANDARD UL778. CSA CERTIFIED
PUMPS ARE CERTIFIED TO CSA STANDARD C22.2 NO. 108.
REFER TO WARRANTY ON PAGE 2.
© Copyright 2006 Zoeller Co. All rights reserved.
1
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 first. 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 first, 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.
wash towels or feminine sanitary products, etc. in all applications other than in raw sewage 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.
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 God; 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,
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.
APPLICATIONS
1. Zoeller Grinder Pumps are designed for grinding and
pumping sanitary sewage from submersible lift stations.
The pump is intended to grind and pump reasonable
quantities of items normally found in sanitary sewage
applications.
2. Zoeller 840 and 841 Grinder Pumps can be installed
in new applications or as a direct replacement for any
grinder application of like size and capacity. Some rail
system retrofit kits are available.
3. The 840 and 841 can be installed in a Prepackaged Job
Ready System or may be used in a Field Assembled
basin package. Pages 6 and 8 show a couple of Prepackaged Systems. Field Assembled Systems are
discussed on pages 3 and 4.
4. Zoeller 840 and 841 Grinder Pumps can be retrofitted
to existing positive displacement pump installations.
Recommended Limits of Application 800 Series Grinder Pumps
These recommended application limits are for pump stations pumping to a gravity main. Low-pressure pipe systems should be designed with a
pump located at each house. For applications where a lift station would handle between 15 and 60 homes, consider the 71 Series grinder pump,
which is available through Zoeller Engineered Products. For applications where a lift station would handle more than 60 homes, a solids handling
type pump should be considered.
Simplex Station
Model
Duplex Station
HP
Homes
GPD
Homes
GPD
820
2
1
400
2
800
840 w/o Reversing Control
2
2*
800
10
4,000
840 w/ Reversing Control
2
2*
800
15
6,000
841
3
2*
800
10
4,000
*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service during unusual
conditions.
© Copyright 2006 Zoeller Co. All rights reserved.
2
Preinstallation Checklist
1. Inspect your grinder pump. If the unit has been damaged in
shipment, contact your dealer before installing. Do Not remove
the test plug in the cover nor the motor housing.
2. Carefully read all literature to familiarize yourself with details
regarding installation and use. Retain materials for future reference.
SEE BELOW FOR LIST OF WARNINGS
SEE BELOW FOR LIST OF CAUTIONS
1. Make sure pump connection contains a ground terminal.
The power cord on all Zoeller Grinder Pumps contains a green
conductor for grounding to help protect you against the possibility
of electric shock.
2. Make certain the electrical service is within reach of the
power supply cord.
3. Make sure any panels and branch circuits are equipped with
proper size fuses and circuit breakers. An independent power
circuit is recommended, sized according to the National Electrical
Code, for the current shown on the grinder pump nameplate.
4. For your protection, always disconnect the power source to
the grinder pump before handling. All grinder pumps must be
properly grounded and wired in accordance with the “National
Electrical Codes” and all local codes and ordinances.
5. Installation of electrical hardware and checking of control panels
and circuits should be performed by a qualified licensed electrician.
6. Risk of electrical 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.
1. Make sure the power source is capable of handling the
electrical requirements of the grinder pump, as indicated on
the nameplate.
2. A disconnect switch should be installed ahead of the
pump.
3. The Grinder pumps are operated by control panels with variable level float control switches. It is the responsibility of the
installing party to see that float control switches will not hang up
on the grinder pump or other pit peculiarities and are secured
so that the grinder pump will shut off. It is recommended to
use rigid pipe and fittings and the pit be 24" in diameter for
simplex systems and 36" in diameter for duplex systems or
larger.
4. Grinder installations should be checked yearly for debris and/or
build up which may interfere with the “ON” or “OFF” positions of
variable level float control switches. Repair and service, other
than cutter assembly maintenance, should be performed by
Zoeller authorized service stations only.
5. Maximum operating temperature must not exceed 130°F,
(54°C).
6. Pump and float switch electrical connections must be
properly installed and protected from submergence.
7. Junction box conduit must be installed with watertight
Do not attempt to turn star cutter located
connection.
on bottom of the unit with fingers. Use
a wrench when checking or removing star cutter.
Electrical Data
Amps
KVA
Code
Winding
Resistance
Line-to-Line
Model
BHP
RPM
Voltage
Phase
Hertz
Full Load
In Air
Shut Off
Locked
Rotor
I840
2
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
E840
2
3450
230
1
60
17.2
4.0
10.9
56
F
1.3 / 4.0
J840
2
3450
200
3
60
12.3
3.7
7.7
54
L
1.9
F840
2
3450
230
3
60
10.8
3.3
6.9
42
K
2.4
G840
2
3450
460
3
60
5.5
1.6
3.5
21
K
9.7
BA840
2
3450
575
3
60
4.5
1.0
2.5
11
F
15.3
I841
3
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
E841
3
3450
230
1
60
17.2
4.0
10.9
56
F
1.3 / 4.0
J841
3
3450
200
3
60
12.3
3.7
7.7
54
L
1.9
F841
3
3450
230
3
60
10.8
3.3
6.9
42
K
2.4
G841
3
3450
460
3
60
5.5
1.6
3.5
21
K
9.7
BA841
3
3450
575
3
60
4.5
1.0
2.5
11
F
15.3
© Copyright 2006 Zoeller Co. All rights reserved.
3
General Information
GRINDER PUMP DESCRIPTION
FIELD ASSEMBLED INSTALLATION
1. Pumps are constructed of class 30 cast iron protected with powder
coated epoxy protection for long life when pumping sewage in submersible applications. The cutter assembly is comprised of stainless
steel components hardened to a value of 55-60 on the Rockwell C
scale; a star shaped cutter and a precision ground flat disk. Cutting
action takes place with the rotation of the star cutter at 3450 RPM
against the stationary cutter plate (see page 11).
1. Installation and piping instructions are included with the control panel,
rail system and basin instructions. If pump is being retrofitted to an
existing rail system, accessory parts may be required. Consult the
factory and advise make and model of rail system being used.
2. The cutter mechanism on the model 840 is bidirectional, enabling it
to cut in either direction. A control panel with the reversing feature
will alternate the pump’s rotational direction with each duty cycle.
The cutter mechanism on the model 841 is single directional.
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. Conduit and panel enclosure
openings must have a gas-tight seal. Installation of electrical panels
and connections should be made by a qualified licensed electrician.
3. Pump motors are available in single and three phase design. Single
phase motors require a starting relay, starting capacitor and a run
capacitor, which are mounted in a control panel (ref. page 8).
4. The 840 and 841 Grinder Pumps are dual seal and have seal leak
probes. Single phase units have an internal thermal overload. Three
phase pumps have a thermal sensor.
5. Three phase pumps require overload protection in the control
panel.
FIGURE 1.
FEET
METERS
6. A Grinder Pump is an intermittent duty pump designed for pumping
sanitary sewage. It is not a dewatering or trash pump.
2. Refer to the appropriate Indoor/Outdoor prepackaged instructions
for more information on system installation.
4. A properly sized disconnect switch, supplied by others, shall be
installed on the service side of the pump and control panel.
5. When installing a pump with a check valve, or a rail system with
a check valve, you must give the pump case time to fill to help
prevent air lock when lowering the unit into the liquid. The 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 extra air vent hole (3/16") may 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 filled (Water should come out of 3/16" diameter hole).
PUMP PERFORMANCE CURVE
MODEL 840/841
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE SEWAGE
130
36
120
110
32
100
TOTAL DYNAMIC HEAD
28
24
90
80
70
20
60
16
12
50
40
016532
30
MODEL
840
841
Feet
Meters
5
1.5
10
3.0
20
6.1
30
9.1
40
12.2
50
15.2
60
18.3
70
21.3
80
24.4
90
27.4
100
30.5
110
33.5
120
36.6
Shut-off Head:
Gal.
Liters
45
170
45
170
45
170
44
167
42
159
36
136
30
114
23
87
16
61
10
38
3
11
----104 ft (31.7 m)
Gal.
Liters
61
231
61
231
61
231
61
231
61
231
61
231
60
227
55
208
47
178
38
144
28
106
18
68
7
26
125 ft (38.1 m)
8
20
4
10
840
841
0
10
20
30
40
50
60
70
GALLONS
LITERS
0
40
80
120
160
200
240
FLOW PER MINUTE
© Copyright 2006 Zoeller Co. All rights reserved.
4
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 and strain relief or connect conduit directly to pump.
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
SINGLE PHASE-2HP
MODEL 840
LEAD IDENTIFICATION
18-2
WIRING DIAGRAM
230V AC
OR
208V AC
PUMP
14-6
BLACK
WHITE
GREEN
RED
WHITE
BLACK
BLUE
ORANGE
MOISTURE
SENSOR
TERMINALS
START
MAIN
ORANGE
L2
T1
T2
5
START RELAY
2
WHITE
GROUND SCREW
START CAPACITOR
5
L1
CONTACTOR
RED
BLACK
BLACK
PROTECTOR
WHITE
FIGURE 2.
1
BLUE
2
RUN CAPACITOR
1
START RELAY
L1
L2
REVERSE MOTOR ROTATION BY INTERCHANGING
ORANGE WIRE WITH RED WIRE.
RUN CAPACITOR
START CAPACITOR
009048
SK1367
SINGLE PHASE
MODEL 841
LEAD IDENTIFICATION
3
4
5
1
2
3
4
5
RED
ORANGE
WHITE
BLUE
YELLOW
L1
L2
T1
T2
CONTACTOR
BLACK
GREEN
RED
WHITE
230V AC
OR
208V AC
5
GROUND SCREW
WHITE
RED
2
WHITE
BLACK
1
COVER
CHAMBER
BLACK
MOISTURE
SENSOR
TERMINALS
GREEN
14-4
WHITE
BLACK
18-2
WIRING DIAGRAM
BLACK
FIGURE 3.
2
START RELAY
1
START CAPACITOR
5
2
MOTOR
CHAMBER
RUN CAPACITOR
OVERLOAD
1
START RELAY
L1
L2
AUXILIARY WINDING
RUN CAPACITOR
START CAPACITOR
MAIN WINDING
SK2399
FIGURE 4.
SENSOR
CORD
208V/230/460V
POWER
CORD
RED
WHITE
K
OR
AN
GE
BLAC
D
RE
GREEN
K
WH
ITE
AC
WIRING DIAGRAM
3ø POWER
14-4
N
EE
GR
BL
THREE PHASE
MODELS 840 & 841
LEAD IDENTIFICATION
18-4
OR
18-5
SK2400
CONTACTOR
L1
L2
L3
T1
T2
T3
SENSOR CABLE
(18-4 OR 18-5)
MAGNETIC
STARTER
T1
T2
T3
L1
L2
L3
GREEN
BLACK
WHITE
TEMPERATURE
SENSOR
TERMINALS
ORANGE
RED
POWER CABLE
MOISTURE
SENSOR
TERMINALS
THERMAL SENSOR
NORMALLY CLOSED
MOISTURE SENSOR
330K OHMS RESISTANCE
BEFORE 6/2000
NORMALLY OPEN
SK1368
© Copyright 2006 Zoeller Co. All rights reserved.
5
SK1370
Indoor Prepackaged System
FIGURE 5.
TO CONTROL PANEL
VARIABLE LEVEL
FLOAT SWITCHES
MOISTURE SENSOR CORD
PUMP POWER CORD
CORD SEAL
24" X 1/4" STEEL
BASIN COVER
10" X 1/4" STEEL
INSPECTION PLATE
16" X 1/4" STEEL
PUMP PLATE
3" GROMMET SEAL
(VENT CONNECTION)
5/16" 304 STAINLESS STEEL
LIFTING U-BOLT
SK1695A
All installations must comply with all applicable electrical and plumbing codes, including but not limited to
the National Electrical Code, local, regional and/or state plumbing codes, etc.
TO CONTROL PANEL
CONTROL PANEL
(FIELD INSTALLED)
1 1/4" PVC SLIP X SLIP
BALL VALVE
(FIELD INSTALLED)
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
(FIELD INSTALLED)
1 1/4" GROMMET SEAL
CAST IRON ADAPTERS
4" FIBERGLASS HUB
W/RUBBER INSERT
(FIELD INSTALLED)
1 1/4" X 32"
GALVANIZED PIPE
36"
1 1/2" X 8"
GALVANIZED PIPE
ALARM
ON
230V, 1PH
GRINDER PUMP
OFF
24" NOMINAL
© Copyright 2006 Zoeller Co. All rights reserved.
6
SK1695B
Indoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged indoor systems only. If your system is a
field assembled indoor system, use these instructions as a guideline. If your system is an outdoor system
then go to the next section in this manual that covers outdoor systems.
1. Indoor grinder pump systems are for installing at
grade in an indoor application only. If you will be
installing this system outside next to the residence
then you will need an outdoor system. DO NOT
INSTALL THE INDOOR SYSTEM OUTDOORS.
2. Review the drawing in Fig. 5 on page 6 and the
actual system to become familiar with the components in the grinder pump system. Review where
the unit will be installed. Determine where the
power feed, inlet pipe, discharge pipe and vent
will be located.
3. Remove the unit from the packing. Indoor prepackaged systems are preassembled at the Zoeller
Company and require a minimum of field assembly
work. All work inside the basin can be performed
via the inspection port. There should be no reason
to remove the cover from the basin. Pump and
float switches are already set inside the basin.
4. Remove the inspection plate from the cover. All
floats are set and tethered for proper operation from
the factory. Verify that where the float switches are
set will work for your application. Verifying that
the float switches are set properly and will not
hang up inside the basin is the responsibility
of the installing contractor. Float switches are
tied in place for shipping purposes. Cut the cable
tie around each float switch bulb or the unit will
not operate properly.
5. Dig a hole for the basin. The basin should be
located in a very low traffic area within 15' of the
power disconnect. The hole should be at least 8"
larger in diameter than the basin in order to leave
4" of backfill all the way around the perimeter.
A minimum of 4" of compacted subbase is also
required. Backfill and subbase should be 1/8" to
3/4" pea gravel or 1/8" to 1/2" crushed stone.
Also reference the basin installation instructions
included with the unit.
6. The 4" inlet hub should be located between the
top lip of the basin and the alarm float “on” level
with a minimum distance of 10 inches between
the floor of the basin and hub. Determine the
location of the inlet hub based upon your inlet
pipe arrangement. The inlet hub must be used
with 4" pipe. It is best to install the inlet on the
side of the basin opposite the float switches. To
install, use a 4" hole saw to drill into the side of
the basin at the correct elevation. Center the hub
inner diameter with the hole in the basin. Attach
the hub to the side of the basin using the sealant
and hardware provided.
7. Set the basin in the hole and connect the 4" inlet
pipe. Caulk or gasket the inlet hub to pipe. Backfill around the basin with specified media. Care
should be taken not to damage components or
leave voids when backfilling. Finish grade of floor
should be poured in place around the top 6" of
the basin assembly.
8. Connect the discharge pipe, valves and vent according to all applicable National, State and Local
plumbing codes.
9. Mount the control panel on the wall within 15' of
the system. Connect the float switch and pump
cords.
10. Clean any debris out of the basin. Fill the basin with
water and check the system for proper operation.
11. Record system start-up data for future reference.
12. Seal and secure the inspection plate to the lid using
the proper bolts and sealant. Pouring concrete
around the system can now be completed.
© Copyright 2006 Zoeller Co. All rights reserved.
7
Typical Outdoor Grinder Pumping System Installation
FIGURE 6.
CONTROL PANEL
(FIELD INSTALLED)
SOLID
FIBERGLASS
COVER
STAINLESS STEEL FLOAT HOOK
WATERTIGHT
NEMA 4X J-BOX
1/8" 302 STAINLESS
STEEL LIFTING CABLE
3/8" X 1' 416 STAINLESS
STEEL PULL ROD
18" MIN. OR PER STATE
AND LOCAL CODES
1 1/4" NPT BRASS
DISCONNECT FITTING
TO CONTROL PANEL
1 1/4" PVC SCH 40
1 1/4"
PIPE AND FITTINGS
DISCHARGE FITTING
1 1/4" PVC SLIP X SLIP
BALL VALVE
4" RUBBER INLET PIPE SEAL
(FIELD INSTALLED)
1 1/2" SQ. GUIDE RAIL
* 60"
304 STAINLESS STEEL 16 GA.
HIGH LEVEL
ALARM FLOAT
FIBERGLASS BASIN
1 1/4" FEMALE NPT
PUMP CONTROL
"ON" FLOAT
CAST IRON CHECK VALVE
1 1/4" GALVANIZED
DISCHARGE PIPE
PUMP CONTROL
"OFF" FLOAT
FIBERGLASS
ANTI-FLOTATION FLANGE
24" MIN.
* OTHER BASIN SIZES
ARE READILY AVAILABLE.
SK1665
All installations must comply with all applicable electrical and plumbing codes, including but not limited
to the National Electrical Code, local, regional and/or state plumbing codes, etc.
© Copyright 2006 Zoeller Co. All rights reserved.
8
Outdoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged outdoor grinder systems only. If this is a field assembled
outdoor system you can use these instructions as a guideline. If this is an indoor system then go to the previous section in this
manual that covers indoor systems.
1. Review the drawing in Fig. 6 on page 8 and the actual
system to become familiar with the components in the packaged grinder pump system. Review where the unit will be
installed. Determine where the power feed, inlet pipe, and
discharge pipe will be located.
hub to the side of the basin using the sealant and hardware
provided.
7. The bottom of the excavation can now be back filled and
compacted. Set basin in hole and connect the 4" inlet pipe
to the inlet hub.
2. Remove the unit from packing. Prepackaged outdoor
systems are preassembled at the Zoeller Company and
require a minimum of field assembly work. Float switches
are set and tethered for proper operation from the Factory.
The alarm switch should be located 2" above the pump “on”
level. Three float systems used with a control panel are
placed at 27", 24", and 15" from the bottom of the basin.
Four float systems used with a control panel are placed at
30", 27", 24", and 15" from the bottom of the basin. If the
invert location is at or below the level of the float switches,
contact the factory.
10. Connect pull rod to Pump assembly. Connect lift cable to top
of pump. Lower the pump into basin ensuring the discharge
pipe bracket slides into the disconnect fitting.
3. Float switches are tied in place for shipping purposes
on all model prepackaged systems. Cut the cable tie around
each float switch bulb or the unit will not operate properly.
Verify that where the float switches are set will work for
your application. Verifying that the float switches are
set properly and will not hang up inside the basin is
the responsibility of the installing contractor.
11. Pouring a concrete anchor around system can now be
completed. Basin should be filled with water when pouring concrete to minimize movement of the system. Back fill
around basin with specified media. Care should be used
to avoid damaging components or leaving voids when back
filling. Refer to Basin installation reference guide on more
specific requirements.
4. Dig a hole for the basin. The hole should be at least 24"
larger in diameter than the basin diameter to provide 12" of
backfill all around and deep enough to provide either 12" of
compacted backfill or 6" when a concrete pad is required.
Ensure the removable cover extends above the finished
grade line and the grade slopes away from the unit. Backfill
and subbase should be 1/8"–3/4" pea gravel or 1/8"–1/2"
crushed stone. (Reference basin installation instructions
included with unit)
12. Note: The grinder basin is a sewage holding tank. Vent
connection should be installed in accordance with all
national, state and local plumbing codes.
8. The discharge piping is connected to the 1¼" threaded fitting
located in the basin sidewall.
9. On basin depths of 72" and greater, the system’s disconnect
assembly is shipped loose and must be screwed into the
discharge piping. Apply pipe dope to threaded connection.
13. Dig a trench for the electrical conduit. Trench should be
located at least 18" deep and follow all applicable NEC codes.
Connect electrical wiring to Junction box according to wiring
instructions included in this manual and wiring diagram in
box. Use the included sealant when closing Junction box.
5. Note: Care must be taken when excavating in
order to avoid underground utilities and disturbance
of existing structure foundations. The hole should be
located at least ten feet from adjacent structures. Additional distance may be required to sufficiently locate
the basin outside of the loading area of the adjacent
structures.
14. Mount the control panel within sight of the system. Connect
float switches and pump cords according to the “Pump Wiring
Instructions” found later in this manual and located inside
the panel enclosure.
6. The location of the inlet hub is determined by the depth of
the inlet pipe. The inlet hub must be used with 4" pipe. It
is best to install the inlet on the side of the basin opposite
the float switches. To install, use a 4" hole saw to drill into
the side of the basin at the correct elevation. Center the
hub inner diameter with the hole in the basin. Attach the
16. Seal and secure the lid using the proper bolts and sealant
when using a lid without a formed gasket.
15. Remove any debris from the basin. Using clean water, check
the system for proper operation.
17. Test system for leaks and proper pump operation.
18. Record system start up data for future reference.
© Copyright 2006 Zoeller Co. All rights reserved.
9
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 for grinder pumps
must not exceed 130°F (54°C).
These units are not designed to handle liquids other than sanitary
sewage. 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 specific
information 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.
• Pump, float switches and electrical cables are dry and properly
installed.
• 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 verified proceed with the following
checks:
• Pump power cables and control floats properly installed and
voltage verified.
• Conduit connections to panel are properly sealed.
• After installing the pump into the containment area, with adequate submergence, open the discharge valve fully. Start the
unit using manual controls. If flow 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 qualified 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: Refer to the system drawing or to the panel wiring
schematic for the desired location of each float switch
setting.
Valves: Discharge valves should be placed in the fully open
position. Systems 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
five 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 2006 Zoeller Co. All rights reserved.
10
Cutter Maintenance
1. All power circuits must be disconnected and locked out
before any attempts are made at servicing. The star cutter
and disc can be removed and sharpened by grinding the cutting faces. Both star cutter and disc must be removed from
the pump. Removal of these parts can be accomplished in
the field by removing pump from the sump and positioning
horizontally to access the intake of the pump. If seals or other
repairs are required, the pump must be totally removed and
serviced in a shop by a qualified pump technician or authorized
service center.
2. Remove the three countersunk screws on the plastic guard
ring and remove the ring.
3. Thoroughly clean the star cutter and disc assembly. Tilt pump
back to the vertical position to make certain the end play has
been removed. Check and record the clearance between the
star cutter and disc with a feeler gage. The correct running
clearance is between 0.004" and 0.008".
4. With pump in horizontal position, heat the hex head bolt in
the center of the star cutter with a propane torch. The bolt
must be heated to 350°F to soften the thread lock sealer on
the bolt for ease of removal. Remove the bolt by turning in a
counterclockwise rotation. It will be necessary to use a wood
block to prevent the star cutter from turning while removing
the bolt. Pull star cutter from the shaft and remove the spacer
shims located behind the star cutter.
FIGURE 7.
5. Remove the three cap screws holding the disc and remove
disc from the pump.
6. The disc and star cutter can be replaced with new service
parts or resurfaced by grinding. Resurfacing is accomplished
by surface grinding both disc and star cutter to a 32 micro
finish. Do not attempt grinding in the field. Send parts to a
qualified machine shop or return to the factory for repair.
The disc, star cutter and shims are a matched set. Keep
parts together. Measure disc before and after resurfacing
with micrometer and record measurements.
7. After resurfacing, the disc and star cutter must be flat within
0.001". If the disc has been surface ground, it will be necessary to remove shims to compensate for the material removed
from the disc. As a starting point, remove shims of the same
thickness as the amount machined from the cutter disc (step
6 above). Final running clearance must be between 0.004"
and 0.008". Be sure pump is in vertical position and all end
play has been removed before measuring.
8. Clean bottom of pump where disc is located and replace
disc and retainer screws. Torque to 63-67 in-lbs. Replace
star cutter with the correct shims. Install washer and torque
hex head bolt to 71-75 in-lbs. apply Loctite 262 thread-lock
sealant or equal to bolt threads prior to insertion. Check
running clearance with pump in vertical position to remove
end play. Clearance must be between 0.004" and 0.008" to
obtain efficient grinding when pump is put back in service.
9. Replace plastic guard ring and its three screws.
To remove star cutter: Remove guard ring then heat the
center bolt to 350°F to loosen Loctite® thread sealant.
10. Check the oil in the motor housing before reinstalling. Contact
the factory if the oil has a milky appearance or burnt smell.
The level should be even with the fill plug when pump is in
the upright position. Add oil if required. Use insulating oil
supplied by the factory.
(Model 840 components shown)
Grind the Star Cutter and Disc seen here to a 32 microfinish.
Surfaces must be flat to within 0.001" T.I.R. Gap must be between
0.004" and 0.008" on these parts.
© Copyright 2006 Zoeller Co. All rights reserved.
11
General Maintenance
Repair and service should be performed by a Zoeller
Pump Company Authorized Service Station only.
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 sulfide gases, both of which can be highly
poisonous.
Installation and checking of electrical circuits and hardware should be
performed by a qualified electrician.
Pump is never to be lifted by power cord.
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 qualified 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 month:
• Check for proper and unobstructed float operation.
• Listen for proper check valve operation.
Every 3 months:
• Inspect and test system for proper operations.
Service Checklist
Electrical precautions. Before servicing a grinder pump, always shut off the main power circuit. Make sure you are wearing insulated protective sole shoes and not standing in water. Under flooded conditions, contact your local electric company or a qualified
licensed electrician for disconnecting electrical service to the pump prior to removal.
Grinder pumps contain oil which becomes pressurized and hot under operating conditions. Allow 2½ hours after shut
down before servicing pump.
Condition
Common Causes
A. Pump will not start or run.
Blown panel or circuit breaker fuse, low voltage, thermal overload open, defective capacitor circuit, cutter or impeller clogged, float switch held down or defective, incorrect
wiring in control panel, water in cap assembly.
B. Motor overheats and trips on overload.
Incorrect voltage, impeller or cutter blocked, negative head (discharge lower than
intake of pump). Defective “off” float. Pump runs continuously at low water level. Low
oil level in motor shell.
C. Pump will not shut off.
Air lock, debris under float assembly, defective switch, incoming sewage exceeds
capacity of pump.
D. Pump operates but delivers little or no water.
Intake clogged with grease or sludge, pump air locked (clear vent hole), low or
incorrect voltage, clogged discharge line, operating near shut-off head.
E. Pump starts and stops too often.
Check valve stuck open or defective. Sump pit too small to handle incoming sewage.
Level control out of adjustment. Thermal overload tripping.
F. Large red flashing light comes on at control box.
High water in pit. Check pump for clogging, or overload trip. On single phase pumps,
check the start capacitor in the control panel. See “A” and “D” above.
G. Grease and solids accumulate in pit around pump.
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.
www.zoeller.com
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
© Copyright 2006 Zoeller Co. All rights reserved.
12
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