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 USA
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 USA
+1 (502) 778-2731 • FAX +1 (502) 774-3624
ZM2609_Ec
0715
Supersedes
0611
visit our web site:
www.zoeller.com
OWNER’S MANUAL
MODELS 7011, 7012 & 7013 SUBMERSIBLE GRINDER UNITS
Congratulations on the purchase of a Zoeller submersible
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 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. Should further
assistance be necessary please call our Product
Support Department at +1 (502) 778-2731 or email:
zeptechnical@zoeller.com.
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.
CAUTION 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 2015 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 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 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, USA 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 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 7011, 7012 and 7013 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 7011, 7012 and 7013 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 7011, 7012 and 7013 Grinder Pumps can be
retrofitted to existing positive displacement pump
installations.
Recommended Limits of Application 7000 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.
For applications where a lift station would handle more than 60 homes, a solids handling type pump should be considered.
Simplex Station
Duplex Station
Homes
m3/day
Homes
m3/day
7011 w/o Reversing Control
2*
3
10
15
7011 w/ Reversing Control
2*
3
15
23
7012
2*
3
10
15
7013
2*
3
10
15
Model
*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service during unusual conditions.
© Copyright 2015 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.
CAUTION
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 Governing 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 Governing 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.The appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of experience
and knowledge, unless they have been given supervision or instruction to
concerning use of the appliance by a person responsible for their safety.
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" (610 mm) in diameter for simplex systems and 36"
(91 cm) 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 Engineered
Products 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 the conduit. Failure to properly install this sealant
material could void warranty.
Electrical Data
Amps
Model
RPM
Voltage
Phase
Hertz
Full Load
In Air
Shut Off
Locked
Rotor
KVA
Code
Winding
Resistance
Line-to-Line
AK7011
2800
380
3
50
4.4
1.6
2.8
18
G
9.7
I7011
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
1.3 / 4.0
E7011
3450
230
1
60
17.2
4.0
10.9
56
F
J7011
3450
200
3
60
12.3
3.7
7.7
54
L
1.9
F7011
3450
230
3
60
10.8
3.3
6.9
42
K
2.4
K7011
3450
380
3
60
6.8
3.2
4.2
28
H
4.8
G7011
3450
460
3
60
5.5
1.6
3.5
21
K
9.7
15.3
BA7011
3450
575
3
60
4.5
1.0
2.5
11
F
AK7012
2800
380
3
50
4.4
1.6
2.8
18
G
9.7
I7012
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
1.3 / 4.0
E7012
3450
230
1
60
17.2
4.0
10.9
56
F
J7012
3450
200
3
60
12.3
3.7
7.7
54
L
1.9
F7012
3450
230
3
60
10.8
3.3
6.9
42
K
2.4
K7012
3450
380
3
60
6.8
3.2
4.2
28
H
4.8
G7012
3450
460
3
60
5.5
1.6
3.5
21
K
9.7
15.3
BA7012
3450
575
3
60
4.5
1.0
2.5
11
F
AK7013
2800
380
3
50
4.4
1.6
2.8
18
G
9.7
I7013
3450
200
1
60
20.0
6.6
12.1
60
H
1.0 / 1.5
1.3 / 4.0
E7013
3450
230
1
60
17.2
4.0
10.9
56
F
J7013
3450
200
2
60
12.3
3.7
7.7
54
L
1.9
F7013
3450
230
2
60
10.8
3.3
6.9
42
K
2.4
K7013
3450
380
3
60
6.8
3.2
4.2
28
H
4.8
G7013
3450
460
2
60
5.5
1.6
3.5
21
K
9.7
BA7013
3450
575
2
60
4.5
1.0
2.5
11
F
15.3
© Copyright 2015 Zoeller Co. All rights reserved.
3
®
General Information
GRINDER PUMP DESCRIPTION
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 at 3450 RPM against
the stationary cutter plate (see page 11).
2. The cutter mechanism on the model 7011 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 model 7012 and 7013 is single directional.
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 7011, 7012 and 7013 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.
METERS
FIGURE 1.
FEET
6. A Grinder Pump is an intermittent duty pump designed for pumping
sanitary sewage. It is not a dewatering or trash pump.
FIELD ASSEMBLED INSTALLATION
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
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. 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 5 mm (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 5 mm [3/16"] diameter hole).
60Hz
HEAD CAPACITY CURVE
MODEL 7011/7012/7013
130
36
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
120
110
32
100
TOTAL DYNAMIC HEAD
28
24
90
80
70
20
60
16
12
8
50
40
30
20
4
MODEL
7011
7013
7012
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
30.5
100
33.5
110
36.6
120
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
59
223
59
223
59
223
59
223
59
223
59
223
57
216
48
182
39.5
150
31
117
22
83
13
49
4.5
17
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
49
13
15
4
125 ft (38.1 m)
016532
10
7012
7011
30
40
7013
0
GALLONS
LITERS
0
10
40
20
80
120
160
50
200
60
70
240
FLOW PER MINUTE
© Copyright 2015 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-2 BHP
MODEL 7011
LEAD IDENTIFICATION
WIRING DIAGRAM
COMPONENT LAYOUT
230V AC
18-2
14-6
OR
PUMP
208V AC
BLACK
WHITE
L1
L2
T1
T2
CONTACTOR
START
MAIN
ORANGE
GROUND SCREW
START CAPACITOR
5
5
WHITE
GREEN
RED
WHITE
BLACK
MOISTURE
SENSOR
TERMINALS
BLUE
ORANGE
RED
BLACK
BLACK
PROTECTOR
START RELAY
2
WHITE
2
1
BLUE
RUN CAPACITOR
1
START RELAY
L1
L2
REVERSE MOTOR ROTATION BY INTERCHANGING
ORANGE WIRE WITH RED WIRE.
SK1367
SINGLE PHASE
MODELS 7012 & 7013
LEAD IDENTIFICATION
GREEN
WHITE
3
4
5
1
2
3
4
5
RED
ORANGE
WHITE
BLUE
L2
T1
T2
CONTACTOR
5
2
GROUND SCREW
START CAPACITOR
5
WHITE
2
L1
BLACK
1
BLACK
RED
WHITE
GREEN
COVER
CHAMBER
BLACK
230V AC
OR
208V AC
YELLOW
WHITE
BLACK
MOISTURE
SENSOR
TERMINALS
009048
14-4
BLACK
18-2
START CAPACITOR
WIRING DIAGRAM
RED
FIGURE 3.
RUN CAPACITOR
START RELAY
1
2
MOTOR
CHAMBER
RUN CAPACITOR
OVERLOAD
1
START RELAY
L1
L2
AUXILIARY WINDING
RUN CAPACITOR
START CAPACITOR
MAIN WINDING
SK2399
WHITE
K
GE
BLAC
POWER
CORD
3ø POWER
CONTACTOR
L1
L2
L3
T1
T2
T3
SENSOR CABLE
(18-4 OR 18-5)
MAGNETIC
STARTER
T1
T2
T3
L1
L2
L3
GREEN
BLACK
WHITE
POWER CABLE
TEMPERATURE
SENSOR
TERMINALS
ORANGE
RED
D
RE
ITE
WH
GREEN
AN
WIRING DIAGRAM
208V/230/460V
N
MOISTURE
SENSOR
TERMINALS
OR
14-4
EE
GR
K
AC
LEAD IDENTIFICATION
SENSOR
CORD
18-4
OR
18-5
BL
THREE PHASE
MODELS 7011, 7012 & 7013
RED
FIGURE 4.
SK2400
THERMAL SENSOR
NORMALLY CLOSED
MOISTURE SENSOR
330K OHMS RESISTANCE
BEFORE 6/2000
NORMALLY OPEN
SK1368
© Copyright 2015 Zoeller® Co. All rights reserved.
5
SK1370
IMPELLER
DIAMETER
Meters
Feet
1.5
5.0
2
6.6
4
13.1
6
19.7
8
26.2
12
39.4
16
52.5
20
65.6
Shut-off Head:
STANDARD SIZE (5.52")
60
5.00"
18
4.81"
50
16
4.60"
14
40
10
4.81"
5.00"
m /hr
L/sec
10.0
2.8
9.8
2.7
9.0
2.5
7.9
2.2
6.9
1.9
4.5
1.3
2.1
0.6
--19.2m (63 ft.)
m /hr
L/sec
10.0
2.8
9.8
2.7
9.1
2.5
8.2
2.3
7.2
2.0
5.1
1.4
2.9
0.8
--20.4m (67 ft.)
3
4
10
2
1
2
3
4
1
0
5
FLOW
6
8
7
9
10
11
2
3
7012
3
m /hr
L/sec
7.7
2.1
7.7
2.1
7.7
2.1
7.7
2.1
7.7
2.1
7.7
2.1
7.0
1.9
4.9
1.4
2.4
0.7
26.8m (88 ft.)
7013
3
m /hr
L/sec
12.7
3.6
12.7
3.5
12.7
3.5
12.7
3.5
12.5
3.4
11.6
3.2
8.9
2.5
5.8
1.6
2.5
0.7
26.8m (88 ft.)
SENSOR
CORD
HO7RNF4G1.5
METERS
70
21
60
18
50
15
40
12
30
9
20
6
10
3
7013
7012
2
0
GRAY
N
BLACK
BROW
T1
T2
T3
L1
L2
L3
8
10
2
L1
L2
L3
T1
T2
T3
POWER CABLE
SENSOR CABLE
HO7RN-F5G1.0
THERMAL SENSOR
NORMALLY CLOSED
MOISTURE SENSOR
330K OHMS RESISTANCE
BEFORE 6/2000
NORMALLY OPEN
CONTROL PANEL - 3Ø
SK2859
INDOOR PREPACKAGED SYSTEM
DECLARATION OF CONFORMITY
We Zoeller declare under our sole responsibility that the models 7011 /
7012 / 7013 to which this declaration relates, are in conformity with the
Governing Electrical Code on the approximation of the laws of the EC
Member States relating to:
SK2860
3 PHASE MOTOR
TO CONTROL PANEL
FIGURE 5.
VARIABLE LEVEL
FLOAT SWITCHES
MOISTURE SENSOR CORD
PUMP POWER CORD
CORD SEAL
24" X 1/4" [610mm X 6mm] STEEL
BASIN COVER
16" X 1/4" [406mm X 6mm] STEEL
PUMP PLATE
10" X 1/4" [254mm X 6mm] STEEL
INSPECTION PLATE
-- Machinery Directive (2006/42/EC)
Standards used: EN 809: 1998
3" [76mm] GROMMET SEAL
(VENT CONNECTION)
-- Electromagnetic Compatibility (2004/108/EC)
Standards used: EN 61000-3-2, EN 61000-3-3 and EN 55014-1
-- Electrical equipment designed for use within certain voltage
limits (2006/95/EC)
Standards used: EN60335-1:2002 and EN60335-2-41:2003
TO CONTROL PANEL
1 1/4" [32mm] PVC SLIP X SLIP
BALL VALVE
(FIELD INSTALLED)
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
(FIELD INSTALLED)
1 1/4" [32mm] GROMMET SEAL
CAST IRON ADAPTERS
4" [102mm] PIPE SEAL
(FIELD INSTALLED)
1 1/4" X 32" [32mm X 813mm]
GALVANIZED PIPE
36" [914mm] *
ALARM
All installations must comply with all applicable electrical and
plumbing codes, including but not limited to the Governing
Electrical Code, local, regional and/or state plumbing codes, etc.
5/16" [8mm] 304 STAINLESS STEEL
LIFTING U-BOLT
CONTROL PANEL
(FIELD INSTALLED)
1 1/2" X 8" [38mm X 203mm]
GALVANIZED PIPE
ON
GRINDER PUMP
OFF
* = OPTIONAL SIZES AVAILABLE
24" [610mm] *
SK2865
© Copyright 2015 Zoeller® Co. All rights reserved.
6
12
3
50 Hz
BLACK
BROWN
MAGNETIC
STARTER
6
3Ø POWER
W
LLO
/YE
AC
K
TEMPERATURE
SENSOR
TERMINALS
4
1
FLOW
POWER
CORD
EEN
GRA
Y
24
WIRING DIAGRAM
GR
BL
WN
BRO
MOISTURE
SENSOR
TERMINALS
27
80
0
M 3/HR
L/SEC
THREE PHASE
MODELS 7011, 7012 & 7013
CE MODEL
CONTACTOR
UE
BL
3
m /hr
L/sec
10.0
2.8
9.8
2.7
9.2
2.6
8.6
2.4
7.8
2.1
5.8
1.6
3.8
1.1
1.6
0.4
22.6m (74.1 ft.)
A00648
LEAD IDENTIFICATION
HO7RNF5G1.0
STANDARD
3
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
Meters
Feet
1.5
5.0
2
6.6
4
13.1
6
19.7
8
26.2
12
39.4
16
52.5
20
65.6
24
78.7
Shut-off Head:
6
0
M 3/HR
L/SEC
3
MODEL
3.60"
8
FEET
4.60"
m /hr
L/sec
9.1
2.5
8.9
2.5
7.9
2.2
6.9
1.9
5.8
1.6
3.7
1.0
0.9
0.3
--17.1m (56 ft.)
3
4.00"
30
20
4.00"
m /hr
L/sec
7.5
2.1
7.2
2.0
6.0
1.7
4.8
1.3
3.4
0.9
------12.3m (40.5 ft.)
3
12
GREEN/YELLOW
TOTAL DYNAMIC HEAD
20
3.60"
m /hr
L/sec
6.6
1.8
6.3
1.7
5.0
1.4
1.0
3.6
0.6
2.1
------10.4m (34 ft.)
PUMP PERFORMANCE CURVE
MODELS 7012/7013
50 CYCLE
GREEN/YELLOW
BLUE
GRAY
22
TOTAL DYNAMIC HEAD
FEET
METERS
24
70
50Hz
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
HEAD CAPACITY CURVE
MODEL 7011 TRIMMED IMPELLERS
50 CYCLE
14
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.
6.The 4” (102 mm) inlet hub should be located
between the top lip of the basin and the alarm
float “on” level with a minimum distance of 10”
(254 mm) 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” (102 mm) 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" (102 mm) pipe seal inlet fitting. This
inlet fitting is installed in the basin's side-wall in
a 5" (127 mm) hole drilled with a hole saw at a
location lining up with the inlet pipe.
1.Indoor grinder pump systems are for installing at
grade in an indoor application only. If you will be
installing this system outside next to the residence
then you will need an outdoor system. DO NOT
INSTALL THE INDOOR SYSTEM OUTDOORS.
2.Review the drawing in Fig. 5 on page 6 and
the actual system to become familiar with the
components in the grinder pump system. Review
where the unit will be installed. Determine where
the power feed, inlet pipe, discharge pipe and vent
will be located.
3.Remove the unit from the packing. Indoor
prepackaged systems are preassembled at the
Zoeller Company and require a minimum of field
assembly work. All work inside the basin can be
performed via the inspection port. There should
be no reason to remove the cover from the basin.
Pump and float switches are already set inside the
basin.
4.Remove the inspection plate from the cover. All
floats are set and tethered for proper operation from
the factory. Verify that where the float switches are
set will work for your application. Verifying that
the float switches are set properly and will not
hang up inside the basin is the responsibility
of the installing contractor. Float switches are
tied in place for shipping purposes. Cut the cable
tie around each float switch bulb or the unit will
not operate properly.
5.Dig a hole for the basin. The basin should be
located in a very low traffic area within 15’
(4.6 m) of the power disconnect. The hole should
be at least 8” (203 mm) larger in diameter than the
basin in order to leave 4” (102 mm) of backfill all
the way around the perimeter. A minimum of 4”
(102 mm) of compacted subbase is also required.
Backfill and subbase should be 1/8” (3.2 mm) to
3/4” (19 mm) pea gravel or 1/8” (3.2 mm) to 1/2”
(12.7 mm) crushed stone. Also reference the basin
installation instructions included with the unit.
7.Set the basin in the hole and connect the 4"
(102 mm) 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” (152 mm) of the basin assembly.
8.Connect the discharge pipe, valves and vent
according to all applicable National, State and
Local plumbing codes.
9.Mount the control panel on the wall within 15’
(4.6 m) of the system. Connect the float switch
and pump cords.
10.Clean any debris out of the basin. Fill the basin with
water and check the system for proper operation.
11.Record system start-up data for future reference.
12. Seal and secure the inspection plate to the lid using
the proper bolts and sealant. Pouring concrete
around the system can now be completed.
© Copyright 2015 Zoeller® Co. All rights reserved.
7
Typical Outdoor Grinder Pumping System Installation
FIGURE 6.
CONTROL PANEL
(FIELD INSTALLED)
APPLIES TO INSIDE AND OUTSIDE INSTALLATIONS
1/4" TO 1/2" [6mm TO 13mm]
CONDUIT
1 [25mm]
UL LISTED
EPOXY SEALER
SOLID
FIBERGLASS
COVER
WIRES OR PUMP CABLES
FOAM TAPE
SK2863
WATERTIGHT
NEMA 4X J-BOX
STAINLESS STEEL FLOAT HOOK
1/8" [3mm] 302 STAINLESS
STEEL LIFTING CABLE
COUPLING
3/8" X 1' [10mm X 305mm]
416 STAINLESS
STEEL PULL ROD
28" [711mm] MIN. OR PER STATE
AND LOCAL CODES
1 1/4" NPT BRASS
DISCONNECT FITTING
1 1/4" [32mm] PVC SCH 40
TO CONTROL PANEL
PIPE AND FITTINGS
1 1/4" [32mm]
DISCHARGE FITTING
1 1/4" [32mm] PVC SLIP X SLIP
BALL VALVE
4" [102mm] RUBBER INLET PIPE SEAL
(FIELD INSTALLED)
1 1/2" [38mm] SQ. GUIDE RAIL
304 STAINLESS STEEL 16 GA.
HIGH LEVEL
ALARM FLOAT
* 60" [1524mm]
FIBERGLASS BASIN
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
PUMP CONTROL
"ON" FLOAT
1 1/4" [32mm] GALVANIZED
DISCHARGE PIPE
PUMP CONTROL
"OFF" FLOAT
FIBERGLASS
ANTI-FLOTATION FLANGE
24" MIN. [610mm]
* OTHER BASIN SIZES
ARE READILY AVAILABLE.
SK2864
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 2015 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” (76 mm) above the
pump “on” level. Three float systems used with a control
panel are placed at 27” (686 mm), 24” (610 mm), and 15”
(381mm) from the bottom of the basin. Four float systems
used with a control panel are placed at 30” (762 mm), 27”
(686 mm), 24” (610 mm), and 15” (381mm) 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”
(610 mm) larger in diameter than the basin diameter to provide
12” (305 mm) of backfill all around and deep enough to provide
either 12” (305 mm) of compacted backfill or 6” (152 mm)
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.
(3.2 - 12.7 m)crushed stone. (Reference basin installation
instructions in cluded with unit.) Most systems are supplied
with a field installed 4” (102 mm) pipe seal inlet fitting. This
inlet fitting is installed in the basin's side-wall in a 5” (127 mm)
hole drilled with a hole saw at a location lining up with the inlet
pipe. Other 271 mm 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 back
filling. Refer to Basin installation reference guide on more
specific requirements.
8. PVC or HDPE discharge piping is connected to the 1¼”
(132 mm) threaded fitting located in the basin sidewall.
Support discharge piping with sufficient backfill.
9.On basin depths of 72” (1.8 m) 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.Connect electrical 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.
5. The location of the inlet hub is determined by the depth of
the inlet pipe. The inlet hub must be used with 4” (102 mm)
pipe. It is best to install the inlet on the side of the basin
opposite the float switches. To install, use a 4” (102 mm)
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.
14. Mount the control panel within sight of the system. Connect
float switches and pump cords according to the “Pump Wiring
Instructions” found later in this manual and located inside the
panel enclosure.
6. The 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” (3.2 - 19 mm) pea gravel or 1/8” –1/2”
17. Test system for leaks and proper pump operation.
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.
18. Record system start up data for future reference.
© Copyright 2015 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.
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.
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” (5 mm) vent hole drilled in pipe between check valve
and pump.
Valves:Consult the valve/actuator supplier for information
concerning these systems components.
© Copyright 2015 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" (0.1 mm) and 0.008" (0.2 mm).
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 (176°C ) 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.
To remove star cutter: Remove guard ring then heat the center
bolt to 350°F (176°C ) to loosen Loctite® thread sealant.
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" (.025 mm). 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” (0.1 mm) and 0.008”(0.2mm). 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 (7.1-7.6 N.m).
Replace star cutter with the correct shims. Install washer
and torque hex head bolt to 71-75 in.-lbs. (8-8.5 N.m) 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" (0.1 mm) and 0.008" (0.2 mm) to obtain efficient
grinding when pump is put back in service.
9. Replace plastic guard ring and its three screws.
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 7011 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. (.025 mm) Gap must
be between 0.004” (0.1 mm) and 0.008” (0.2 mm) on these parts.
© Copyright 2015 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 Governing 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 six months:
• Check for proper and unobstructed float operation.
• Listen for proper check valve operation.
Every 5 years or 10,000 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 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 USA
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 USA
+1 (502) 778-2731 • FAX +1 (502) 774-3624
Your Peace of Mind is Our Top Priority ®
© Copyright 2015 Zoeller® Co. All rights reserved.
12
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