visit our web site - r-c
SECTION: 6.10.021
NOTICE TO INSTALLER: Instructions must remain with installation.
FM2168
0311
Supersedes
1009
Your Peace of Mind is Our Top Priority™
Product information presented
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of publication. Consult factory
regarding discrepancies or
inconsistencies.
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visit our web site:
www.zoeller.com
OWNER’S MANUAL
Congratulations on the purchase of a Zoeller submersible
grinder pump. For over seventy 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 startup. 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 model 840, FM2445 for model 842 and FM2180
for model 841 replacement 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 2011 Zoeller Co. All rights reserved.
1
P/N 019557
MODELS 840, 841 & 842 SUBMERSIBLE GRINDER UNITS
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.
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, wash towels or feminine sanitary products, etc. in
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, 841 and 842 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, 841 and 842 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, 841 and 842 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
Duplex Station
Model
HP
Homes
GPD
Homes
GPD
810 Progressing Cavity Grinder
1
1
400
2
800
815 Progressing Cavity Grinder
2
1
400
2
800
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
2
2*
800
10
4,000
842
2
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 2011 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 CAUTIONS
SEE BELOW FOR LIST OF WARNINGS
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.
Do not attempt to turn star cutter located
on bottom of the unit with fingers. Use a
wrench when checking or removing star cutter.
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 tem per a ture must not ex ceed 130°F,
(54°C).
6. Pump and float switch electrical connections must be
permanently installed, operational and protected from
submergence.
7. Junction box conduit must be installed with watertight
connection. Zoeller junction boxes include a UL Listed potting
kit for sealing the conduit. Failure to properly install this sealant
material could void warranty.
Electrical Data
Amps
KVA
Code
Winding
Resistance
Line-to-Line
Model
HP
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
2
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
E841
2
3450
230
1
60
17.2
4.0
10.9
56
F
1.3 / 4.0
J841
2
3450
200
3
60
12.3
3.7
7.7
54
L
1.9
F841
2
3450
230
3
60
10.8
3.3
6.9
42
K
2.4
G841
2
3450
460
3
60
5.5
1.6
3.5
21
K
9.7
BA841
2
3450
575
3
60
4.5
1.0
2.5
11
F
15.3
I842
2
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
E842
2
3450
230
1
60
17.2
4.0
10.9
56
F
1.3 / 4.0
J842
2
3450
200
3
60
12.3
3.7
7.7
54
L
1.9
F842
2
3450
230
3
60
10.8
3.3
6.9
42
K
2.4
G842
2
3450
460
3
60
5.5
1.6
3.5
21
K
9.7
BA842
2
3450
575
3
60
4.5
1.0
2.5
11
F
15.3
© Copyright 2011 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 and 842 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 and watertight
seal. Installation of electrical panels, conduit and connections
should be made by a qualified licensed electrician. A UL Listed
potting kit, P/N 10-2350, is available from Zoeller Company.
3. Pump motors are available in single and three phase design. Single
phase motors require a Zoeller approved starting relay, starting
capacitor and a run capacitor, which are mounted in a control panel
(ref. page 8).
4. The 840, 841 and 842 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
on pages 6-9 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).
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
PUMP PERFORMANCE CURVE
MODEL 840/841/842
130
36
110
32
100
TOTAL DYNAMIC HEAD
28
24
90
80
70
20
60
16
12
MODEL
840
841
842
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
27.4
90
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)
Gal.
Liters
34
129
34
129
34
129
34
129
34
129
34
129
34
129
32
121
29
110
25
95
20
76
13
49
4
15
125 ft (38.1 m)
120
50
40
016532
30
8
20
4
10
842
840
30
40
841
0
10
20
50
60
70
GALLONS
LITERS
0
40
80
120
160
200
240
FLOW PER MINUTE
© Copyright 2011 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.
FIGURE 2.
SINGLE PHASE-2HP
MODEL 840
LEAD IDENTIFICATION
18-2
WIRING DIAGRAM
230V AC
OR
208V AC
PUMP
14-6
BLACK
WHITE
L1
L2
T1
T2
CONTACTOR
START
MAIN
WHITE
GREEN
RED
WHITE
BLACK
MOISTURE
SENSOR
TERMINALS
BLUE
ORANGE
RED
BLACK
BLACK
PROTECTOR
ORANGE
5
START CAPACITOR
5
START RELAY
2
WHITE
GROUND SCREW
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
MODELS 841 & 842
FIGURE 3.
LEAD IDENTIFICATION
3
4
5
1
2
3
4
5
BLACK
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
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
THREE PHASE
MODELS 840, 841 & 842
FIGURE 4.
LEAD IDENTIFICATION
SENSOR
CORD
3ø POWER
RED
GE
WHITE
BLAC
K
AN
CONTACTOR
L1
L2
L3
T1
T2
T3
N
D
RE
OR
GREEN
208V/230/460V
POWER
CORD
EE
WH
WIRING DIAGRAM
14-4
GR
K
AC
BL
ITE
18-4
OR
18-5
SK2400
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 2011 Zoeller Co. All rights reserved.
5
SK1370
Indoor Prepackaged System
FIGURE 5.
36”
48”
60”
24” NOMINAL
SK1695
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 2011 Zoeller Co. All rights reserved.
6
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.
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. Most systems
are supplied with a field installed 4" pipe seal inlet
fitting. This inlet fitting is installed in the basin's
side-wall in a 5" hole drilled with a hole saw at a
location lining up with the inlet pipe.
7. Set the basin in the hole and connect the 4"
inlet pipe to the inlet hub using the rubber insert.
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.
4. Remove the inspection plate from the cover. All 8. Connect the discharge pipe, valves and vent
according to all applicable National, State and
floats are set and tethered for proper operation from
Local plumbing codes.
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 9. Mount the control panel on the wall within 15' of
the system. Connect the float switch and pump
hang up inside the basin is the responsibility
cords.
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 10. Clean any debris out of the basin. Fill the basin with
water and check the system for proper operation.
operate properly.
5. Dig a hole for the basin. The basin should be 11. Record system start-up data for future reference.
located in a very low traffic area within 15' of the
power disconnect. The hole should be at least 8" 12. Seal and secure the inspection plate to the lid using
the proper bolts and sealant. Pouring concrete
larger in diameter than the basin in order to leave
around the system can now be completed.
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.
© Copyright 2011 Zoeller Co. All rights reserved.
7
Typical Outdoor Grinder Pumping System Installation
FIGURE 6.
CONTROL PANEL
(FIELD INSTALLED)
#10-2350 POTTING KIT
APPLIES TO INSIDE AND
OUTSIDE INSTALLATIONS
CONDUIT
1
SOLID
FIBERGLASS
COVER
1/4" TO 1/2"
WIRES OR
UL LISTED
PUMP CABLES
EPOXY SEALER
FOAM TAPE
SK1661
STAINLESS STEEL FLOAT HOOK
WA
WATERTIGHT
NEMA 4X J-BOX
NE
1/8" 302 STAINLESS
STEEL LIFTING CABLE
COUPLING
3/8" X 1' 416 STAINLESS
STEEL PULL ROD
28" 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 2011 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 back to pages 6 and 7 in this
manual that covers indoor systems. The pump should not be installed in the basin until permanent electrical power is available.
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.
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 3” 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.
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.
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.
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.
5. 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
hub to the side of the basin using the sealant and hardware
provided.
6. The bottom of the excavation can now be properly backfilled,
compacted and leveled. Set basin in hole. 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.)
Most systems are supplied with a field installed 4” pipe seal
inlet fitting. This inlet fitting is installed in the basin's side-wall
in a 5” hole drilled with a hole saw at a location lining up with
the inlet pipe. Other type fittings and sizes are occasionally
provided.
7. 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. Backfill around
basin with specified media. Care should be used to avoid
damaging components or leaving voids when backfilling.
Refer to Basin installation reference guide on more specific
requirements.
8. PVC or HDPE discharge piping is connected to the 1¼”
threaded fitting located in the basin sidewall. Support
discharge piping with sufficient backfill.
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.
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.
11. Note: The grinder basin is a sewage holding tank. Vent
connection should be installed in accordance with all
national, state and local plumbing codes.
12. Dig a trench for the electrical conduit. The conduit should be
located below the frost line. Follow all applicable electrical
codes.
13. Con nect elec tri cal conduit and wiring to junction box
according to wiring instructions included in this manual and
wiring diagram in box. Use the potting kit provided with the
junction box. Follow the instructions for sealing the conduit
connection at the junction box.
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.
15. Remove any debris from the basin. Using clean water, check
the system for proper operation.
16. Seal and secure the lid using the proper bolts and sealant
when using a lid without a formed gasket.
17. Test system for leaks and proper pump operation.
18. Record system start up data for future reference.
© Copyright 2011 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 designed for intermittent duty sanitary sewage
applications. If pump is used to dewater areas or pump 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
Do not install pump until electrical power is available and
system is operational. 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, electrical cables and junction box are
dry and properly installed.
• Electrical boxes dry, sealed 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 and junction box 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 2011 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 2011 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.
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Your Peace of Mind is Our Top Priority™
© Copyright 2011 Zoeller Co. All rights reserved.
12
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