ZM2608 Owner&#39
NOTICE TO INSTALLER: Instructions must remain with installation.
SECTION: Z4.10.300
ZM2608
0917
Supersedes
0117
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
Register your
Zoeller Engineered Product
on our website:
http://reg.zoellerengprod.com/
visit our web site:
zoellerengprod.com
OWNER’S MANUAL
®
U.S. Patent No.
8,562,287
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. For
replacement parts lists, please reference ZM2994 for 7008 series,
ZM2996 for 7009 series, and ZM2633 for 7010 series. Should further
assistance be necessary please call our Product Support 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.
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 2017 Zoeller® Co. All rights reserved.
1
P/N 151085
MODELS 7008, 7009, 7010 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 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 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 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
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 domestic sewage.
2. Zoeller Grinder Pumps can be installed in new applications or as
a direct replacement for other grinder application of like size and
capacity.
3. Refer to the Zoeller models 7020 and 7021 when retrofitting 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
Model
Duplex Station
HP
Homes
GPD
Homes
GPD
7020 Progressing Cavity Grinder
1
1
400
2
800
7021 Progressing Cavity Grinder
2
1
400
2
800
1-2
1
400
2
800
7011 w/o Reversing Control
7008, 7009, & 7010
2
2*
800
10
4,000
7011 w/ Reversing Control
2
2*
800
15
6,000
7012
2
2*
800
10
4,000
7013
2
2*
800
10
4,000
*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service during unusual
conditions.
© Copyright 2017 Zoeller® Co. All rights reserved.
2
Preinstallation Checklist
1.Inspect your grinder pump. If the unit has been damaged in shipment,
contact your dealer before installing. Do Not remove the test plug in the
cover nor the motor housing.
2.Carefully read all literature to familiarize yourself with details regarding
installation and use. Retain materials for future reference.
CAUTION
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.
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 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 conduit.
Failure to properly install this sealant material could void warranty.
Do not attempt to turn cutter located on
bottom of the unit with fingers. Use a wrench when checking
or removing cutter.
Electrical Data
Amps
Model
HP
Mode
RPM
Voltage
Phase
Hertz
Full Load
In Air
Shut Off
Locked
Rotor
WM7008
1
Auto
3450
115
1
60
13.6
8.0
10.2
46
F
Winding
Resistance
Line-to-Line
0.67 / 3.4
N7008
1
Non
3450
115
1
60
13.6
8.0
10.2
46
F
0.67 / 3.4
WH7008
1
Auto
3450
200-208
1
60
7.7
3.7
8.7
27.7
F
2.0 / 1.4
I7008
1
Non
3450
200-208
1
60
7.7
3.7
8.7
27.7
F
2.0 / 1.4
WD7008
1
Auto
3450
230
1
60
8.5
7.6
7.0
57
P
1.2 / 2.0
E7008
1
Non
3450
230
1
60
8.5
7.6
7.0
57
P
1.2 / 2.0
F7008
1
Non
3450
230
3
60
6.9
5.3
5.8
44.4
S
2.15
J7008
1
Non
3450
200
3
60
7.5
5.7
6.2
47.4
S
1.7
G7008
1
Non
3450
460
3
60
3.7
2.5
3.0
21.6
S
8.2
BA7008
1
Non
3450
575
3
60
2.7
2.1
2.3
17.5
S
13.6
WH7009
1.5
Auto
3450
200-208
1
60
12.0
8.8
8.7
61.6
K
0.87 / 2.0
I7009
1.5
Non
3450
200-208
1
60
12.0
8.8
8.7
61.6
K
0.87 / 2.0
WD7009
1.5
Auto
3450
230
1
60
10.8
7.6
8.3
57
K
1.2 / 2.0
E7009
1.5
Non
3450
230
1
60
10.8
7.6
8.3
57
K
1.2 / 2.0
F7009
1.5
Non
3450
230
3
60
8.2
5.3
6.5
44.4
N
2.15
J7009
1.5
Non
3450
200
3
60
9.2
5.7
7.1
47.4
M
1.7
G7009
1.5
Non
3450
460
3
60
4.2
2.5
3.3
21.6
N
8.2
BA7009
1.5
Non
3450
575
3
60
3.2
2.1
2.6
17.5
N
13.6
WH7010
2
Auto
3450
200-208
1
60
15.5
8.8
11.0
61.6
G
0.87 / 2.0
I7010
2
Non
3450
200-208
1
60
15.5
8.8
11.0
61.6
G
0.87 / 2.0
WD7010
2
Auto
3450
230
1
60
13.7
7.6
10.2
57
H
1.2 / 2.0
E7010
2
Non
3450
230
1
60
13.7
7.6
10.2
57
H
1.2 / 2.0
F7010
2
Non
3450
230
3
60
9.9
5.3
7.3
44.4
K
2.15
J7010
2
Non
3450
200
3
60
11.0
5.7
8.1
47.4
K
1.7
G7010
2
Non
3450
460
3
60
5.0
2.5
3.7
21.6
K
8.2
BA7010
2
Non
3450
575
3
60
3.9
2.1
2.9
17.5
K
13.6
© Copyright 2017 Zoeller® Co. All rights reserved.
3
KVA
Code
General Information
GRINDER PUMP DESCRIPTION
FIELD ASSEMBLED INSTALLATION
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 440C stainless
steel components hardened to a value of 55-60 on the Rockwell C
scale; a two-bladed cutter and a precision ground flat disk. Cutting
action takes place with the rotation of the cutter in the clockwise
(looking down on the unit) direction only, see Fig. 6 on page 11.
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.
2. Single phase motors' starting relay, starting capacitor and a run
capacitor are located in the pump.
3. These grinder pumps have a single seal design and do not have
sensor wires.
4. Automatic reset thermal overload protection is integral on single
phase motors. For three phase models, overload protection is to
be provided in the control panel.
4"
[102 mm]
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).
7-5/8"
[194 mm]
6-1/2"
[165 mm]
4" [102 mm]
4" [102 mm]
1-1/4" N.P.T.
METERS
FEET
PUMP PERFORMANCE CURVE
MODELS 7008/7009/7010
18-5/8" [473 mm]
110
32
7010
100
5" [127 mm]
28
SK1621
24
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE AND DEWATERING
90
80
7009
70
MODEL
7008
7009
7010
Feet
Meters
5
1.5
10
3.0
15
4.6
20
6.1
25
7.6
30
9.1
35
10.7
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
163
43
42
159
40
151
37
140
33
125
28
106
22
83
16.5
62
53 ft. (16.2m)
Liters
Gal.
163
43
163
43
43
163
163
43
43
163
42
159
41
155
39
148
32
121
22
83
12
45
81 ft. (24.7m)
Liters
Gal.
46
174
46
174
46
174
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
20
60
16
12
8
50
7008
40
30
20
4
10
0
U.S. GALLONS
LITERS
5
0
20
10
40
15
60
154108
© Copyright 2017 Zoeller® Co. All rights reserved.
4
20
80
25
100
30
120
40
35
140
45
160
55
50
180
200
FLOW PER MINUTE
154108
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
10 15 20 22
min.
max.
5" MIN.
22" MAX.
Pumping Range 9 13.5 18 22 24
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.
NONAUTOMATIC
WIRING DIAGRAM
1 PH
AUTOMATIC
WIRING DIAGRAM
L2
L1
L1
WHITE
L2
WHITE
START
CAPACITOR
GREEN
NONAUTOMATIC
WIRING DIAGRAM
3 60
PHHZ
L1
START
CAPACITOR
L2
L3
GREEN
BLACK
WHITE
BLACK
WHITE
BLACK
BLACK
BLACK
WHITE
2
5
FLOAT
RELAY
GREEN
BLACK
BLACK
2
1
R
1
R
RUN
CAPACITOR
5
RED
WHITE
BLACK
RELAY
RUN
CAPACITOR
(1)
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
RUN
010415
BLUE
MOTOR
010443
© Copyright 2017 Zoeller® Co. All rights reserved.
5
006848
(2)
RED
(3)
YELLOW
Indoor Prepackaged System
FIGURE 2.
TO ALARM PANEL
ALARM FLOAT
SWITCH CORD
PUMP POWER 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)
SILENCE
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
(FIELD INSTALLED)
POWER
INPUT 1
1 1/4" GROMMET SEAL
CAST IRON ADAPTERS
4" RUBBER INLET
PIPE SEAL
(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
24" NOMINAL
© Copyright 2017 Zoeller® Co. All rights reserved.
6
SK1691B
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 2017 Zoeller® Co. All rights reserved.
7
Typical Outdoor Grinder Pumping System Installation
FIGURE 3.
#10-2350 POTTING KIT
APPLIES TO INSIDE AND
OUTSIDE INSTALLATIONS
CONDUIT
1
(25 mm)
ALARM FLOAT SWITCH MUST OPERATE OFF LOW
VOLTAGE TO BE USED WITH QWIK BOX.
1/4" TO 1/2"
(6.4 mm TO 12.7 mm)
LOCATION VARIES WITH BASIN DEPTH
WIRES OR
UL LISTED
PUMP CABLES
EPOXY SEALER
FOAM TAPE
SK1661
SILENCE
LOUISVILLE, KY
HIGH WATER ALARM
OR SIMPLEX
CONTROL PANEL
(FIELD INSTALLED)
R
POWER
INPUT 1
SOLID FIBERGLASS COVER
1/8" 302 STAINLESS STEEL
LIFTING CABLE
FLOAT TREE ASSEMBLY
2" PIPE SEAL
(FIELD INSTALLED)
2" FLEX BOOT FITTING
(LOCATION VARIES
WITH BASIN DEPTH)
4" PIPE SEAL
(FIELD INSTALLED)
2" SCH. 80 BALL VALVE
2" PVC SCH. 80 PLBG.
ALARM
ON
3/4" GALV. GUIDE RAILS
OFF
2" CAST IRON CHECK VALVE
1.25-2" Z-RAIL
2HP GRINDER PUMP
FIBERGLASS AFD
SK3110
24" MIN.
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.
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.
1. Review the drawing in Fig. 3 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. 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. The alarm
switch should be located 3” above the pump “on” level. Three
float systems used with a control panel are placed at 27”, 24”,
and 15” from the bottom of the basin. Four float systems used
with a control panel are placed at 33”, 27”, 24”, and 15” from the
bottom of the basin. If the invert location is at or below the level
of the float switches, contact the factory.
3. Float switches are tied in place for shipping purposes on all model
prepackaged systems. Cut the cable tie around each float switch
bulb or the unit will not operate properly. Verify that where the float
switches are set will work for your application. Verifying that the
float switches are set properly and will not hang up inside
the basin is the responsibility of the installing contractor.
4. Dig a hole for the basin. The hole should be at least 24” larger
in diameter than the basin diameter to provide 12” of backfill all
around and deep enough to provide either 12” of compacted
backfill or 6” when a concrete pad is required. Note: Care must
be taken when excavating in order to avoid underground
utilities and disturbance of existing structure foundations.
The hole should be located at least ten feet from adjacent
structures. Additional distance may be required to sufficiently
locate the basin outside of the loading area of the adjacent
structures.
5. The location of the inlet hub is determined by the depth of the inlet
pipe. The inlet hub must be used with 4” pipe. It is best to install
the inlet on the side of the basin opposite the float switches. To
install, use a 4” hole saw to drill into the side of the basin at the
correct elevation. Center the hub inner diameter with the hole
in the basin. Attach the hub to the side of the basin using the
sealant and hardware provided.
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 2” threaded
fitting located in the basin sidewall. Support discharge piping with
sufficient backfill.
9. Connect lift cable to top of pump. Lower the pump into basin
ensuring the discharge pipe bracket slides into the disconnect
fitting.
10. Note: The grinder basin is a sewage holding tank. Vent
connection should be installed in accordance with all national,
state and local plumbing codes.
11. Dig a trench for the electrical conduit. The conduit should be located
below the frost line. Follow all applicable electrical codes.
12. If using a junction box, connect the electrical conduit and wiring
according to instructions included in this manual and wiring diagram
in box. If a potting kit is provided with the junction box, follow the
instructions for sealing the conduit connection to the junction box.
If a potting kit is not provided, the conduit connection to the junction
box must be sealed.
13. 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.
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. Test system for leaks and proper pump operation.
17. Record system start up data for future reference.
6. The bottom of the excavation can now be properly backfilled,
compacted and leveled. Set basin in hole. Ensure the removable
cover extends above the finished grade line and the grade slopes
away from the unit. Backfill and subbase should be 1/8” –3/4” pea
gravel or 1/8” –1/2” crushed stone. (Reference basin installation
instructions included with unit.) Connect the 4” inlet pipe to the
inlet hub.
© Copyright 2017 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.
If panel is to be stored, the following is advised:
• Store the panel inside whenever possible and leave in the shipping
box.
• All openings shall be sealed.
• Store in an upright position.
• Do not stack anything on top of panel.
START-UP PROCEDURE
Before placing the equipment into operation the following should be
checked:
• Clean pit.
• Pump, float switches, electrical cables and junction box are dry and
properly installed.
• Electrical boxes dry, sealed and securely installed.
• Floats positioned properly.
• Discharge valves open.
• 3/16” vent hole drilled in pipe between check valve and pump.
Once the above has been verified proceed with the following checks:
• Pump power cables and control floats properly installed and voltage
verified.
• Conduit connections to panel and junction box are properly sealed.
• After installing the pump into the containment area, with adequate
submergence, open the discharge valve fully. Start the unit using
manual controls. If flow is appreciably less than rated performance,
pump may be air locked. To expel trapped air, jog the unit several
times, using the manual controls.
• Have a qualified electrician take voltage and current measurements
with the pump running. Record these readings in the space provided
in the “Owner’s Information” section on page 1 of this manual for
future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Refer to 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.
SHUTDOWN PROCEDURES
If a system is shutdown for more than six months, the following is
recommended:
Pumps: If pit is to remain dry, then the pump can remain in the pit.
With the pump in the pit, it should be operated for five minutes
once every three months. If the pit is to remain wet, the pump
should be removed and stored as noted above.
Panels: The panel should have all openings sealed to prevent moisture
and dust from entering the enclosure. Prior to restarting system,
the panel should be inspected for presence of moisture and any
loose connections.
Valves: Consult the valve/actuator supplier for information concerning
these systems components.
© Copyright 2017 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 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 0.004"
and 0.008".
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 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 0.001". 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.
7. Clean bottom of pump where disc is located and replace disc and
retainer screws. Torque to 63-67 in-lbs. Replace 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.
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.
FIGURE 6.
To remove cutter: Heat the center bolt to 350°F to
loosen Loctite® thread sealant.
Grind the Cutter and Disc seen here to a 32 microfinish.
Surfaces must be flat to within 0.001" T.I.R. Gap must
be between 0.004" and 0.008" on these parts.
© Copyright 2017 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 6 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
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624
© Copyright 2017 Zoeller® Co. All rights reserved.
12
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