OWNER`S MANUAL 50/60Hz
NOTICE TO INSTALLER: Instructions must remain with installation.
Your Peace of Mind is Our Top Priority ®
50/60Hz
®
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
*
* NOTE: Applicable to 50 Hz units only.
OWNER’S MANUAL
ZM2607_Ec
0117
Supersedes
0916
visit our web site:
www.zoeller.com
**
** NOTE: Applicable to 60 Hz units only.
MODELS 7020 & 7021 PROGRESSING CAVITY GRINDER PUMPS
Congratulations on the purchase of a Zoeller submersible
progressing cavity grinder pump. Since 1939 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 progressing cavity 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 ZM2637 and ZM2638
for replacement parts on 7020 and 7021 Series Progressing Cavity
Grinder Pumps respectively. Should further assistance be necessary
please call our Product Support Department at 1-800-928-PUMP (7867)
or +1-502-778-2731.
Table of Contents
Safety Instructions
Safety Instructions........................................................................ 1
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.
Limited Warranty, Checklist and Application...........................2-3
General Information...................................................................... 4
Pump Wiring Instructions............................................................. 4
THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND
OPERATION OF THIS UNIT AND MUST BE KEPT WITH THE PUMP.
Typical Outdoor Prepackaged System.....................................5-6
Installation Instructions................................................................ 6
Operation Instructions...............................................................6-7
Maintenance................................................................................... 7
Service Checklist........................................................................... 8
Owner’s Information
Model Number: ______________ Date Code: _______________
 Simplex
 Duplex
 Packaged System
 Field Assembled System
Job Name: ____________________________________________
Distributor: ____________________________________________
Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____ Amps ______
CAUTION
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.
Warns of electrical shock hazards that can cause serious
personal injury, death or major property damage.
Identifies any terminal which is intended for connection
to and external conductor for protection against electrical
shock in case of a fault, or the terminal of a protective
earth (ground) electrode.
Read operator's manual.
INDICATES SPECIAL INSTRUCTIONS WHICH ARE
VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR
TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
REFER TO WARRANTY ON PAGE 2.
© Copyright 2017 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.
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 uncontrollable
act of nature; that has not been installed, operated or maintained in accordance
with Manufacturer's installation instructions; that has been exposed to outside
substances including but not limited to the following: sand, gravel, cement, mud,
tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline, solvents, etc.), or other
abrasive or corrosive substances, wash towels, feminine sanitary products, or
any other abusive entity, etc. in all 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 USA,
Attention: Customer Support Department to obtain any needed repair or replacement
of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF EXPRESSED
OR IMPLIED WARRANTY; AND ANY IMPLIED WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE AND OF MERCHANTABILITY SHALL BE
LIMITED TO THE DURATION OF THE EXPRESSED WARRANTY.
Some jurisdictions do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some jurisdictions 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 jurisdiction to jurisdiction.
Preinstallation Checklist
1. Inspect your pump. Occasionally, products are damaged during shipment. If the
unit is damaged, contact your dealer before using. DO NOT remove the test plugs
in the cover nor the motor housing.
SEE BELOW FOR
LIST OF WARNINGS
1.Make sure pump connection contains a ground terminal. The power cord
on all Zoeller Progressing Cavity 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.
Progressing cavity grinder pumps are designed for
pressure sewer applications. A UL listed and CSA certified pressure relief
valve must be installed in the system to prevent excessive pressure buildup.
2. Carefully read the literature provided to familiarize yourself with specific details
regarding installation and use. These materials should be retained for future reference.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
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 in the circuit bringing electrical
power to the pump.
3.The progressing cavity grinder pumps are operated by 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 at least 61 cm (24") in diameter for
simplex systems and 91.4 cm (36") or larger in diameter for duplex systems.
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 a Zoeller Authorized Service & Warranty Center or
Customer Care Center.
5.Maximum operating temperature must not exceed 54°C (130°F).
6.Do not operate an unsubmerged progressing cavity pump. Dry pump
operation may damage the hydraulic stator due to lack of lubrication. Do
not run dry.
7.To ensure proper pump operation, a swing or flapper style check valve
must be installed in the pump discharge line. A faulty or non-functional
check valve when combined with a pressure sewer may prevent the
pump from starting.
Do not attempt to turn the cutter blades
located on bottom of the unit with fingers. Use a wrench
when checking or removing the cutter.
NOTE: Pumps with the UL mark and the US mark are tested to UL standard UL778.
CSA-certified pumps are certified to CSA standard C22.2 No. 108.
© Copyright 2017 Zoeller® Co. All rights reserved.
2
Applications
1. Zoeller Progressing Cavity 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 7020 and 7021 Progressing Cavity Grinder Pumps can be installed
in new applications or as a replacement for another grinder pump of
like size and capacity. Some rail system retrofit kits are available.
3. The 7020 and 7021 can be installed in a Prepackaged Job Ready System
or may be used in a Field Assembled basin package. Page 5 shows
a couple of the Prepackaged Systems. Field Assembled Systems are
discussed on page 4.
4. Zoeller 7020 and 7021 Grinder Pumps can be retrofitted to existing
positive displacement pump installations.
Recommended Limits of Application for Progressing Cavity Grinder Pumps
These recommended application limits are for pump stations pumping to a gravity main. Low-pressure collection systems should be designed with
a pump located at each house. For applications where a lift station would handle more than 2 homes, consider the 7011 or 71 Series grinder pump.
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/LPD
Homes
GPD/LPD
7020
1
1
400 / 1,514
2
800 / 3,028
7021
2
1
400 / 1,514
2
800 / 3,028
Meters
1.5
3.0
6.1
12.2
18.3
24.4
30.5
36.6
42.7
48.8
54.9
61.0
67.1
73.2
METERS
FEET
Gal
10.8
10.7
10.4
10.0
9.6
9.1
8.7
8.2
7.8
7.3
6.9
6.4
6.0
5.6
60 Hz
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
Liters
40.9
40.5
39.4
37.9
36.3
34.4
32.9
31.0
29.5
27.6
26.1
24.2
22.7
21.2
MODEL
7020
MODEL
7021
PUMP PERFORMANCE
CURVE
MODEL 7021 50 Hz
METERS
Feet
5
10
20
40
60
80
100
120
140
160
180
200
220
240
50 Hz
7021
FEET
MODEL
FIG. 1.2
Feet
5
10
20
40
60
80
100
120
140
150
160
180
200
220
240
Meters
1.5
3.0
6.1
12.2
18.3
24.4
30.5
36.6
42.7
45.7
48.8
54.9
61.0
67.1
73.2
Gal.
14.6
14.4
14.0
13.2
12.5
11.7
10.9
10.1
9.4
9.0
8.6
7.8
7.0
6.3
5.5
Liters
55
55
53
50
47
44
41
38
36
34
33
30
27
24
21
PSIG
FIG. 1.1
PUMP PERFORMANCE CURVE
MODEL 7020/7021
260
260
110
240
70
72
240
100
220
220
64
200
56
TOTAL DYNAMIC HEAD
TOTAL DYNAMIC HEAD
180
50
160
140
40
120
30
100
10
160
70
LOW PRESSURE SEWER
DESIGN PRESSURE (150 FT OR LESS)
60
120
50
100
80
60
0
2
0
4
10
6
8
20
30
FLOW PER MINUTE
10
12
40
10
20
0
GALLONS
LITERS
0
TYPICAL
OPERATING
RANGE
20
40
8
1 HP
40
30
16
40
GALLONS
LITERS
180
140
24
2 HP
80
40
60
20
153091
48
32
80
20
90
200
TOTAL DYNAMIC HEAD
60
2
4
© Copyright 2017 Zoeller® Co. All rights reserved.
3
6
8
10
20
40
FLOW PER MINUTE
12
14
16
0
60
018330
General Information
PROGRESSING CAVITY
GRINDER PUMP DESCRIPTION
FIELD-ASSEMBLED INSTALLATION
1. Pumps are constructed of class 30 cast iron protected with powder
coated epoxy 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 against the stationary
cutter plate (see page 7).
2. The cutter mechanism on the model 7020 & 7021 is single directional.
3. Pump motors are single phase. Single phase motors require a run
capacitor, which is mounted in the the upper cap of the pump. The
units have an internal thermal overload.
4. The 7020 & 7021 progressing cavity grinder pumps are single seal.
5. The pressure relief valve provides motor protection under inadvertent
shut-off head condition.
6. A progressing cavity grinder pump is an intermittent duty pump designed
for pumping sanitary sewage. It is not a dewatering or trash pump.
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. Refer to the appropriate Indoor/Outdoor prepackaged instructions
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 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.
4. A properly sized disconnect switch, supplied by others, shall be
installed on the service side of the pump and control panel.
5. When used in a pressure sewer, install an anti-siphone valve (see
Figure 5A).
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.
FIG. 2. Pump Control Switch Installation
FLOAT TREE
Determining Pumping Range
(1' - 25 mm)
Tether Length
127 mm
(5")
254 mm
(10")
Pumping Range
22.9 cm
(9")
34.3 cm
(13.5")
ALARM FLOAT
127 mm (5") MIN.
254 mm (10") 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.
PUMP CONTROL
FLOAT
406 mm (16")
MIN. OFF
SK305D
Note: Failure to keep within proper tether
limits may prevent reliable switch operation.
Note: Cable must be mounted in horizontal
position.
SK2651
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”.
Electrical Data
Amps
Winding
Resistance
Line-to-Line
Model
KW
RPM
Voltage
Phase
Hertz
Full Load
Shut Off
Locked
Rotor
E7020
1.5
1750
230
1
60
7.0
7.0
24.5
2.3 / 2.0*
E7021
2.1
1750
230
1
60
10.5
10.5
44.0
1.80 / 1.60*
RE7020
1.5
1750
230
1
60
7.0
7.0
24.5
**
RE7021
2.1
1750
230
1
60
10.5
10.5
44.0
**
Z7021
2.0
1400
230
1
50
8.5
8.5
24.0
2.6 / 2.2
* Line to line reading from the electrical load will only reflect the run winding resistance. Start winding resistance can only be measured after
removing the cover.
** Start and run winding resistance can only be measured after removing the cover and checking at the through wall terminals.
© Copyright 2017 Zoeller® Co. All rights reserved.
4
Electrical Data, continued
FIG. 3B. Models E7020 &
E7021 Wiring Diagram
GR
WHITE
ORANGE
EE
N
L2
L1
L2
L1
FIG. 3C. Models RE7020 & RE7021
Wiring Diagram (932 Replacement
Grinder Assembly w/ Manual Run)
BLACK
FIG. 3A. Model Z7021 CE
Wiring Diagram
GE RELAY
RED
WHITE
BLUE
1
4
2
5
R
GREEN/YELLOW
GREEN
CAPACITOR
RELAY
CAPACITOR
BLACK
BROWN
6
0
R
6
4
BLUE
CAPACITOR
BLUE
RED
(2)
(1)
BLUE
(WHITE)
BLUE
(3)
BLUE
(WHITE)
RED
YELLOW
(BROWN) (BLACK)
(1)
RED
(2)
BLUE
RED
YELLOW
(BROWN) (BLACK)
(1)
BLUE
(WHITE)
MOTOR
MOTOR
RED
(2)
YELLOW
(3)
RED
(BROWN)
YELLOW
(BLACK)
MOTOR
O.L.
O.L.
O.L.
START
START
START
RUN
NOTES:
RUN
RUN
002397
(3)
002397
152554
1)
INSULATORS REQUIRED ON GE RELAY TERMINALS 2 & 5;
OMRON RELAY TERMINALS 1 & 4.
Typical Outdoor Grinder Pumping System Installations
FIG. 4B - PACKAGED SYSTEM WITH
Z-RAIL® DISCONNECT SYSTEM
FIG. 4A - PACKAGED SYSTEM WITH
FLEXIBLE HOSE DISCONNECT
HIGH WATER ALARM
(NOT INCLUDED)
HIGH WATER ALARM (NOT INCLUDED)
DISCONNECT FITTING
SOLID FIBERGLASS
COVER
BRASS ANTI-SIPHON VALVE
1 1/4" MALE NPT THREAD X DN32 (1 1/4") SLIP FITTING
SOLID FIBERGLASS COVER
DN32 (1 1/4") SCH 80 PVC PIPE
SHUT-OFF BALL VALVE
3 mm (1/8") 302 STAINLESS
STEEL LIFTING CABLE
WATERTIGHT "QWIK BOX"
GROMMET SEAL
DN32 (1 1/4") PVC SCH 80
PIPE AND FITTINGS
3 mm (1/8") 302 STAINLESS
STEEL LIFTING CABLE
60.9 cm (24")
1 1/4" BULK HEAD
DISCHARGE FITTING
DN50 (2") PVC ELECTRICAL PIPE
DN50 (2") PVC ELECTRICAL PIPE
WATERTIGHT "QWIK BOX"
(NOT INCLUDED)
1 1/4" BULK HEAD
DISCHARGE FITTING
DN100 (4") INLET W-SEAL
(FIELD INSTALLED)
FLOAT TREE
1 1/4" MALE NPT THREAD X
DN32 (1 1/4") SLIP FITTING
FLOAT TREE ASSEMBLY
DN32 (1 1/4") PVC PIPE
122 cm (48")
152 cm (60")
183 cm (72")
DN32 (1 1/4") PVC SLIP X SLIP
BALL VALVE
1 1/4" MALE NPT THREAD
X DN32 (1 1/4") SLIP FITTING
DN100 (4") RUBBER INLET
PIPE SEAL (FIELD INSTALLED)
1 1/4" FEMALE NPT
CHECK VALVE
1 1/4" GALVANIZED
DISCHARGE PIPE
HIGH LEVEL ALARM FLOAT
1 1/4" NPT BRASS CHECK VALVE
152 cm (60")
183 cm (72")
213 cm (84")
244 cm (96")
PUMP CONTROL "ON - OFF" FLOAT
BRASS ANTI-SIPHON VALVE
DN32 (1 1/4") FLEXIBLE
DISCHARGE HOSE
ALARM FLOAT
2" TO 1 1/4" REDUCER
3/4" SS GUIDE RAIL PIPES
FIBERGLASS BASIN
FIBERGLASS BASIN
30.4 cm (12") MIN. OFF LEVEL
FIBERGLASS ANTI-FLOTATION FLANGE
PUMP CONTROL FLOAT
60.9 cm (24")
MINIMUM
ANTI FLOATATION RING
SK2540
60.9 cm (24") MIN.
1 1/4" H X 1 1/4" Z-RAIL
DISCONNECT SYSTEM, EPOXY
COATED DUCTILE IRON
SK3019
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 2017 Zoeller® Co. All rights reserved.
5
FIG. 5
FIG. 5A
5 1/4”
(133mm)
4” (103 mm)
MAIN
(JWA)
4 3/8”
(111 mm)
8 3/8”
(213 mm)
10 1/2”
(267 mm)
DIA.
(HOME OWNER)
SHUT OFF
VALVE
CHECK VALVE
OPTIONAL LOCATION 1 1/4"
NPT ANTI-SIPHON VALVE
DISCONNECT
CURB/VALVE
BOX
22 3/8” (568 mm)
DN32 (1 1/4") SHUT OFF VALVE
1 1/4" NPT CHECK VALVE
1 1/4" NPT
ANTI-SIPHON VALVE
DN32 (1 1/4")
DISCHARGE LINE
6 5/8” (143 mm)
POSITIVE DISPLACEMENT
GRINDER PUMP
SK2810
SK2533
Outdoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged outdoor progressing cavity grinder systems only. If this is a field assembled outdoor system you can
use these instructions as a guideline.
1. Review the drawing in Fig. 4 on page 5 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 5 cm (2”) above the pump “on” level.
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 61 cm (24”) larger in diameter
than the basin diameter to provide 30 cm (12”) of backfill all around and deep enough
to provide either 30 cm (12”) of compacted backfill or 16 cm (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 3 mm (1/8”) –
19 mm (3/4”) pea gravel or 3 mm (1/8”) – 13 mm (1/2”) crushed stone. (Reference
basin installation instructions included with unit)
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.
6. The location of the inlet fitting is determined by the depth of the inlet pipe. The inlet
fitting must be used with 10 cm (4”) pipe. It is best to install the inlet on the side of
the basin opposite the float switches. To install, use a 13 cm (5”) 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. The bottom of the excavation can now be back filled and compacted. Set basin in
hole and connect the 10 cm (4”) inlet pipe to the inlet hub.
8. The discharge piping is connected to the 3 cm (1-1/4”) threaded fitting located in
the basin sidewall.
9. 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.
10. 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.
11. Note: The progressing cavity 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. Trench should be located at least 45 cm (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 potting kit provided with the junction box. Use the included sealant
when closing junction box.
13. If used, a control panel is installed within sight of the system. Connect float switches
and pump cords according to the “Pump Wiring Instructions” found in this manual
and located inside the panel enclosure.
14. Remove any debris from the basin. Using clean water, check the system for proper
operation.
15. Seal and secure the lid using the proper bolts and sealant when using a lid without
a formed gasket.
16. Add water to the basin and test the system for leaks and proper pump operation.
17. Record system start up data for future reference.
Operation
GENERAL
Zoeller pumps are lubricated and tested at the factory prior to shipment and require
minimum pre-start-up maintenance.
Maximum operating temperature for E and RE model pumps must not exceed
54 °C (130 °F). Maximum operating temperature for Z model pumps must not exceed
40 °C (104 °F).
NAMEPLATE DATA
The nameplate, located on the top 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:
These units are not designed to handle liquids other than sanitary sewage. If pump is
• Drain pump housing by laying pump horizontal with discharge down. Then stand pump
used to dewater areas with contaminated liquids with heavy or abrasive materials, the
on legs.
warranty will be voided.
• 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.
© Copyright 2017 Zoeller® Co. All rights reserved.
6
Operation, continued
• Spray coat unpainted surfaces with rust inhibiting oil.
• The hydraulic rotor should be rotated every six months in order to keep the seal
lubricated and not develop a permanent set.
• 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.
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.
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. The off switch should deactivate the
pump before the water level drops to the mid-point of the pump.
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. Check for an anti-siphon valve
when used in a pressure sewer.
START-UP PROCEDURE
Before placing the equipment into operation the following should be checked:
• Clean pit.
• Electrical boxes dry and securely installed.
• Floats positioned properly.
• Discharge valves open.
• Adequate water level in basin for pump submersion.
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.
SHUT-DOWN PROCEDURES
If a system is shut down for more than six months, the following is recommended:
Pumps: If pit is to remain dry, then the pump can remain in the pit. Do not run dry. 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.
Cutter Maintenance
1. All power circuits must be disconnected and locked out before any attempts are
made at servicing. The cutter and disc can be removed and sharpened by grinding
the cutting faces. Both 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. Thoroughly clean the 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 cutter and disc with a feeler gage. The correct running clearance is
between 0.178 mm (0.007") and 0.305 mm (0.012").
3. With pump in horizontal position, heat the hex head bolt in the center of the cutter
with a propane torch. The bolt must be heated to 177° C (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
cutter from turning while removing the bolt. Pull cutter from the shaft and remove the
spacer shims located behind the cutter.
4. Remove the six cap screws holding the disc and remove disc from the pump.
5. The disc and cutter can be replaced with new service parts or resurfaced by grinding.
Resurfacing is accomplished by surface grinding both disc and 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, cutter and shims are a matched set. Keep
parts together. Measure disc before and after resurfacing with micrometer and record
measurements.
6. After resurfacing, the disc and cutter must be flat within 0.025 mm (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. Final running clearance
must be between 0.178 mm (0.007") and 0.305 mm (0.012"). Be sure pump is in
vertical position and all end play has been removed before measuring.
7. Clean bottom of pump where disc is located and replace disc and retainer screws.
Torque to 28 kg (63 in-lbs) - 30 kg (67 in-lbs). Replace cutter with the correct shims.
Install washer and torque hex head bolt to 23 kg (71 in-lbs) - 34 kg (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 0.178 mm (0.007") and 0.305 mm (0.012") to obtain efficient grinding
when pump is put back in service.
8. 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.
FIG. 6.
To remove cutter: Heat the center bolt to 177 °C
(350 °F) to loosen Loctite® thread sealant.
Grind the Cutter and Disc seen here to a 32 microfinish. Surfaces must be flat to within
0.025 mm (0.001") T.I.R. Gap must be between 0.178 mm (0.007") and 0.305 mm
(0.012") on these parts.
© Copyright 2017 Zoeller® Co. All rights reserved.
7
General Maintenance
Repair and service should be performed by a Zoeller
Authorized Service & Warranty Center or Customer Care Center 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 year:
• Inspect basin, report any sighting of grease accumulation.
• Check for proper and unobstructed float operation.
• Listen for proper check valve operation.
Every 8 years or 2,000 hours of operation:
• Remove pump, inspect and service using a Zoeller rebuild kit.
• Flush and clean basin.
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 2-1/2 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 clogged, damaged hydraulic stator or rotor, float switch held down or defective,
incorrect wiring in control panel, water in cap assembly, check valve not installed or
malfunctioning.
B. Motor overheats and trips on overload.
Incorrect voltage, hydraulic rotor 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. Pump running at shut-off head, check valve not installed or malfunctioning.
C. Pump will not shut off.
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, damaged hydraulic stator or rotor, 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.
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.
If the above checklist does not reveal the problem, consult the Product Support Department. Do not attempt to service or otherwise disassemble
pump. Service must be peformed by a Zoeller Authorized Service Station. Go to www.zoellerpumps.com/servicestations to find the Zoeller Authorized
Service & Warranty Center or Customer Care Center in your area.
DECLARATION OF CONFORMITY
NOTE: for CE-rated pumps only.
We, Zoeller, declare under our sole responsibility that the model 7021 to which this declaration relates, are in conformity with the Council Directives on the
approximation of the laws of the EC Member States relating to:
-- Machinery Directive (2006/42/EC)
Standards used: EN 809: 1998
-- Electrical equipment designed for use within certain voltage limits (2006/95/EC)
Standards used: IEC 60335-1:2010 and IEC 60335-2:2012
-- Electromagnetic Compatibility (2004/108/EC)
Standards used: EN 61000-3-2, EN 61000-3-3 and EN 55014-1
These are the original installation instructions.
© Copyright 2017 Zoeller® Co. All rights reserved.
8
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