Zoeller 820 Series Owners Manual

Zoeller 820 Series Owners Manual
SECTION: 6.10.020
Your Peace of Mind is Our Top Priority™
FM2167
0611
Supersedes
1008
®
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
Congratulations on the purchase of the Zoeller 820 Series
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 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 FM1531
for replacement parts on 820 Series Grinder Pumps. 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........................................................................... 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: _______________
 Automatic

Nonautomatic
 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 019555
MODEL 820 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.
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
all applications other than 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.
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 820 Grinder Pumps are designed for grinding
and pumping sewage from single family residential
and commercial duty sewage pump stations. The
pump is intended to grind and pump reasonable
quantities of items normally found in residential
sewage.
2.Zoeller 820 Grinder Pumps can be installed in
new applications or as a direct replacement for
any grinder application of like size and capacity.
3.Refer to the Zoeller models 810 and 815 when
retrofitting existing positive displacement pump
installations.
© Copyright 2011 Zoeller Co. All rights reserved.
2
Preinstallation Checklist
2.Carefully read all literature to familiarize yourself with details
regarding installation and use. Retain materials for future
reference.
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.
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 receptacle 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.Automatic pumps have three prong plug caps and must
be connected to a three prong grounded receptacle with
ground fault circuit interrupter (GFCI).
5.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.
6.Installation of electrical hardware and checking of control panels and circuits should be performed by a qualified licensed
electrician.
7.Risk of electrical shock - These pumps have not been investigated
for use in swimming pool areas.
8.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.If Grinder pumps are operated by control panels with variable level float control switches, it is the responsibility of the
installing party 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
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 conduit. Failure to properly install
this sealant material could void warranty.
Electrical Data
Amps
Model
BHP
Mode
RPM
Voltage
Phase
Hertz
WD820
E820
WH820
I820
2
2
2
2
Auto
Nonauto
Auto
Nonauto
3450
3450
3450
3450
230
230
200
200
1
1
1
1
60
60
60
60
Locked KVA
Full Load In Air Shut Off Rotor Code
13.7
13.7
15.5
15.5
7.6
7.6
8.8
8.8
© Copyright 2011 Zoeller Co. All rights reserved.
3
10.2
10.2
11.0
11.0
57
57
61.6
61.6
H
H
H
H
Winding
Resistance
Line-to-Line
1.2 / 2.0
1.2 / 2.0
.8 / 2.0
.8 / 2.0
General Information
GRINDER PUMP DESCRIPTION
FIGURE 1.
4
7 5/8
6 1/2
4
4
METERS
1 1/4" N.P.T.
1. Installation and piping instructions are included with
the 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. Refer to the appropriate Indoor/Outdoor prepackaged
instructions on pages 6-9 for more information on
system installation.
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.
4. 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).
18 5/8
FEET
1. Pumps are constructed of class 30 cast iron 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 in the
clockwise (looking down on the unit) direction only, see
Fig. 6 on page 11.
2. Pump motors are single phase design. Single phase
motors require a starting relay, starting capacitor and
a run capacitor. These items are located in the switch
case on the pump.
3. The 820 Grinder Pump is a single seal design and does
not have sensor wires.
4. Automatic reset thermal overload protection is provided
in the pump motor.
FIELD ASSEMBLED INSTALLATION
PUMP PERFORMANCE CURVE
MODEL 820
110
32
100
28
5
90
MODEL
820
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
Shut-off Head:
Gal.
Liters
46
174
46
174
46
174
46
174
46
174
46
174
43
163
36
136
27
102
16.7
63
7
26
107 ft.(32.6m)
TOTAL DYNAMIC HEAD
SK1621
24
80
70
20
60
16
12
50
40
30
8
20
4
10
0
5
GALLONS
LITERS
0
10
40
010440
© Copyright 2011 Zoeller Co. All rights reserved.
4
15
20
25
80
FLOW PER MINUTE
35
30
120
40
45
50
160
010440
Pump Wiring Instructions
For your protection, always disconnect the pump from its power source before handling.
Single phase automatic pumps are supplied with a 3-prong grounded plug to help protect you against the possibility of electrical shock.
DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE GROUND PIN. The 3-prong plug must be inserted into a mating 3-prong
grounded receptacle. If the installation does not have such a receptacle, it 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 4.
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
5
Tether Length
min.
10 15 20 22
max.
Pumping Range 9 13.5 18 22 24
5" MIN.
22" MAX.
Use only as a guide. Due to weight of
cable, pumping range above horizontal
is not equal to pumping range below
horizontal. Ranges are based on testing in
nonturbulent conditions. Range may vary
due to water temperature and cord shape.
As tether length increases, so does the
variance of the pumping range.
sk305D
20 AMP SWITCH (WD & WH MODELS)
Note: Failure to keep within proper tether limits may
prevent reliable switch operation.
MIN. "OFF" LEVEL
Note: Cable must be mounted in horizontal position.
SK2304
Models WD & WH are fully automatic. A float switch is included and factory wired in the pump circuit to provide automatic operation once the float switch is
secured properly to the outlet pipe. Use the diagram above to secure the float switch properly and obtain the proper tether to customize the on-off cycle to each
application. Note the minimum off level shown above. On Prepackaged Systems, the tether length is set at 5”.
FIGURE 5.
L2
L1
AUTOMATIC
WIRING DIAGRAM
WHITE
L1
L2
WHITE
START
CAPACITOR
GREEN
START
CAPACITOR
GREEN
BLACK
BLACK
WHITE
BLACK
BLACK
BLACK
2
5
BLACK
2
1
R
RELAY
WHITE
BLACK
WHITE
FLOAT
NONAUTOMATIC
WIRING DIAGRAM
1
R
RUN
CAPACITOR
5
RELAY
RUN
CAPACITOR
BLUE
(1)
RED
(2)
YELLOW
(3)
BLUE
(1)
RED
(2)
YELLOW
(3)
BLUE
(WHITE)
RED
(BROWN)
YELLOW
(BLACK)
BLUE
(WHITE)
RED
(BROWN)
YELLOW
(BLACK)
MOTOR
MOTOR
O.L.
O.L.
START
START
RUN
010415
MODELS WD820 and WH820
© Copyright 2011 Zoeller Co. All rights reserved.
5
RUN
MODELS E820 and I820
010443
Indoor Prepackaged System
FIGURE 2.
TO ALARM PANEL
PUMP POWER CORD
ALARM FLOAT
SWITCH CORD
16" X 1/4" STEEL
PUMP PLATE
CORD SEAL
24" X 1/4" STEEL
BASIN COVER
5/16" 304 STAINLESS STEEL
LIFTING BOLT
10" X 1/4" STEEL
INSPECTION PLATE
SK1691A
3" GROMMET SEAL
(VENT CONNECTION)
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.
HIGH WATER ALARM
(FIELD INSTALLED)
TO ALARM PANEL
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 GROMMET
(FIELD INSTALLED)
1 1/4" X 32"
GALVANIZED PIPE
36"
1 1/4" X 12"
GALVANIZED PIPE
ALARM
ON
SINGLE PHASE,2HP
AUTOMATIC
GRINDER PUMP
OFF
SK1691B
24" NOMINAL
© 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. 2 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 to the inlet hub using the rubber insert. If
using a cast iron hub, the 4” inlet pipe will need to
be caulked or gasketed to the hub. 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 alarm panel on the wall above the system. Connect the alarm float switch and pump
power cord.
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 2011 Zoeller Co. All rights reserved.
7
Typical Outdoor Grinder Pumping System Installation
FIGURE 3.
HIGH WATER ALARM
(FIELD INSTALLED)
ALARM FLOAT SWITCH MUST OPERATE OFF LOW VOLTAGE TO BE USED WITH QWIK BOX.
#10-2350 POTTING KIT
APPLIES TO INSIDE AND
OUTSIDE INSTALLATIONS
CONDUIT
1
1/4" TO 1/2"
SOLID FIBERGLASS COVER
WIRES OR
UL LISTED
PUMP CABLES
EPOXY SEALER
FOAM TAPE
SK1661
STAINLESS STEEL FLOAT HOOK
WATERTIGHT "QWIK BOX"
RECEPTACLE & ALARM
CONNECTIONS
1/8" 302 STAINLESS
STEEL LIFTING CABLE
COUPLING
3/8" X 1' 416 STAINLESS
STEEL PULL ROD
1 1/4" NPT BRASS
DISCONNECT FITTING
28" MIN. OR PER STATE
AND LOCAL CODES
1 1/4" PVC SLIP X SLIP
BALL VALVE
TO CONTROL PANEL
1 1/4" PVC SCH 40
PIPE AND FITTINGS
4" RUBBER INLET PIPE SEAL
(FIELD INSTALLED)
1 1/2" SQ. GUIDE RAIL
304 STAINLESS STEEL 16 GA.
1 1/4" BULK HEAD
DISCHARGE FITTING
*60"
*OTHER BASIN SIZES
ARE READILY AVAILABLE
CAST IRON MOUNT BRACKET
HIGH LEVEL
ALARM FLOAT
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
PUMP CONTROL
"ON - OFF" FLOAT
1 1/4" GALVANIZED
DISCHARGE PIPE
FIBERGLASS BASIN
CAST IRON RAIL BASE PLATE
FIBERGLASS
ANTI-FLOTATION FLANGE
24" MIN.
SK1670A
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 6-7 in this manual
that covers indoor systems.
(Reference basin installation instructions included with unit.)
1. Review the drawing in Fig. 3 on page 8 and the actual system
Connect the 4” inlet pipe to the inlet hub.
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 7.Pouring a concrete anchor around system can now be
completed. Basin should be filled with water when pouring
pipe will be located.
concrete to minimize movement of the system. Backfill
around basin with specified media. Care should be used
2. Remove the unit from packing. Prepackaged outdoor systems
to avoid damaging components or leaving voids when back
are preassembled at the Zoeller Company and require a
filling. Refer to Basin installation reference guide on more
minimum of field assembly work. Float switches are set and
specific requirements.
tethered for proper operation from the Factory. Systems using
an automatic unit, WD or WH series, have an integral “on/off”
float switch. See Fig. 4 on page 5 for adjustment instructions. 8.PVC or HDPE discharge piping is connected to the 1¼”
threaded fitting located in the basin sidewall. Support
The alarm switch should be located 3” above the pump “on”
discharge piping with sufficient backfill.
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”, 9. On basin depths of 72” and greater, the system’s disconnect
assembly is shipped loose and must be screwed into the
and 15” from the bottom of the basin. If the invert location is at
discharge piping. Apply pipe dope to threaded connection.
or below the level of the float switches, contact the factory.
3. Float switches are tied in place for shipping purposes on all 10. Connect pull rod to Pump assembly. Connect lift cable to top
of pump. Lower the pump into basin ensuring the discharge
model prepackaged systems. Cut the cable tie around each
pipe bracket slides into the disconnect fitting.
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 11. Note: The grinder basin is a sewage holding tank. Vent
connection should be installed in accordance with all
not hang up inside the basin is the responsibility of the
national, state and local plumbing codes.
installing contractor.
4.Dig a hole for the basin. The hole should be at least 24” 12. Dig a trench for the electrical conduit. The conduit should be
located below the frost line. Follow all applicable electrical
larger in diameter than the basin diameter to provide 12” of
codes.
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 13.Connect electrical conduit and wiring to junction box
according to wiring instructions included in this manual and
avoid underground utilities and disturbance of existing
wiring diagram in box. Use the potting kit provided with the
structure foundations. The hole should be located at least
junction box. Follow the instructions for sealing the conduit
ten feet from adjacent structures. Additional distance may
connection at the junction box.
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
5. The location of the inlet hub is determined by the depth of the
Instructions” found later in this manual and located inside the
inlet pipe. The inlet hub must be used with 4” pipe. It is best
panel enclosure.
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 15. Remove any debris from the basin. Using clean water, check
the system for proper operation.
with the hole in the basin. Attach the hub to the side of the
basin using the sealant and hardware provided.
16. Seal and secure the lid using the proper bolts and sealant
when using a lid without a formed gasket.
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 17. Test system for leaks and proper pump operation.
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. 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 top of 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 permanent 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.
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 Fig. 4 on page 5 or to the panel wiring schematic
for 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.
If panel is to be stored, the following is advised:
Shutdown procedures
If a system is shutdown for more than six months, the following
is recommended:
• 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.
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.
start-up Procedure
Before placing the equipment into operation the following should
be checked:
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.
• 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.
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.
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.
FIGURE 6.
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.
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.
®
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
Your Peace of Mind is Our Top Priority™
© Copyright 2011 Zoeller Co. All rights reserved.
12
visit our web site:
www.zoeller.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising