235 2 Zoeller E810 Product Instructions User Manual

235 2 Zoeller Product Instructions 235_2_Zoeller Product Instructions 235_2_Zoeller Product Instructions pdf pumpproducts

User Manual: Pump 235 2 Zoeller E810 Product Instructions

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Page Count: 8

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 ______

OWNER’S MANUAL

MODELS 810 & 815 SUBMERSIBLE GRINDER UNITS

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 FM2435 and FM2436

for replacement parts on 810 and 815 Series Progressing

Cavity Grinder Pumps respectively. Should further assistance

be necessary please call our Technical Service Department at

1-800-928-PUMP (7867).

Owner’s Information

Safety Instructions

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR

PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY

INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.

THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION

AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH

THE PUMP.

This is a SAFETY ALERT SYMBOL.

When you see this symbol on the pump or in the

manual, look for one of the following signal words

and be alert to the potential for personal injury or

property damage.

Warns of hazards that WILL cause serious personal

injury, death or major property damage.

Warns of hazards that CAN cause serious personal

injury, death or major property damage.

Warns of hazards that CAN cause personal injury

or property damage.

INDICATES SPECIAL INSTRUCTIONS WHICH ARE

VERY IMPORTANT AND MUST BE FOLLOWED.

THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS

PRIOR TO PERFORMING ANY WORK ON THIS PUMP.

MAINTAIN ALL SAFETY DECALS.

REFER TO WARRANTY ON PAGE 2.

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

heavy-duty submersible 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

Table of Contents

Safety Instructions ....................................................................... 1

Limited Warranty, Checklist and Application ..........................2-3

General Information ..................................................................... 3

Pump Wiring Instructions ............................................................4

Typical Outdoor Prepackaged System ....................................... 5

Installation and Operation Instructions ...................................... 6

Maintenance .................................................................................. 7

Service Checklist .......................................................................... 8

SECTION: 6.10.025

FM2458

0112

Supersedes

0610

NOTICE TO INSTALLER: Instructions must remain with installation.

Product information presented

here reects conditions at time

of publication. Consult factory

regarding discrepancies or

inconsistencies.

MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347

SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961

(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624

visit our web site:

www.zoeller.com

Your Peace of Mind is Our Top Priority

than in raw sewage pumping applications. The warranty set out in the

paragraph above is in lieu of all other warranties expressed or implied;

and we do not authorize any representative or other person to assume

for us any other liability in connection with our products.

Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky

40211, Attention: Customer Service Department to obtain any needed

repair or replacement of part(s) or additional information pertaining to

our warranty.

MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,

CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH

OF EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED

WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF

MERCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THE

EXPRESSED WARRANTY.

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.



rights which vary from state to state.

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,



from date of purchase by the end user, or 18 months from the date of



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

 

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.

          

installed in new applications or as a direct replacement for any grinder



available.

 





discussed on page 3.

           

positive displacement pump installations.

Applications

Preinstallation Checklist

1. Inspect your progressing cavity 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.

1. Make sure pump connection contains a ground terminal. The power



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

         

6. Risk of electrical shock - These pumps have not been investigated for

use in swimming pool areas.

          

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. The progressing cavity grinder pumps are operated by variable level





or other pit peculiarities and are secured so that the grinder pump will



at least 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





authorized service stations only.

5. Maximum operating temperature must not exceed 130°F,

(54°C).

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 apper 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 star cutter located on

bottom of the unit with ngers. Use a wrench when checking

or removing star cutter.

SEE BELOW FOR

LIST OF CAUTIONS

SEE BELOW FOR

LIST OF WARNINGS

      

-

sure relief valve must be installed in the system to prevent excessive

pressure buildup.

Recommended Limits of Application for Progressing Cavity Grinder Pumps

Simplex Station Duplex Station

Model HP Homes GPD Homes GPD

810 1 1 400 2 800

815 2 1 400 2 800

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 840 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.

General Information

FIGURE 1.

018330

PROGRESSING CAVITY

GRINDER PUMP DESCRIPTION

 

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;





the stationary cutter plate (see page 7).

2. The cutter mechanism on the model 810 & 815 is single directional.

 

capacitor, which is mounted in the the upper cap of the pump (ref.

page 4). The units have an internal thermal overload.

4. The 810 & 815 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.

FIELD ASSEMBLED INSTALLATION

1. Installation and piping instructions are included with the control panel,



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 “National Electrical

Code” and applicable local codes. Conduit and panel enclosure

openings must have a gas-tight seal. Installation of electrical panels and



4. A properly sized disconnect switch, supplied by others, shall be

installed on the service side of the pump and control panel.

TOTAL DYNAMIC HEAD/FLOW

PER MINUTE

PUMP PERFORMANCE CURVE

MODEL 810/815

Pump Wiring Instructions

.

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.

  

FIGURE 3A. Models 810

and 815 Wiring Diagram

002397

RUN

O.L.

MOTOR

(3)

BLUE RED

WHITE

BLACK

GREEN

L1 L2

START

(1) (2)

YELLOW

BLUE RED

CAPACITOR

(WHITE) (BLACK)

(BROWN)

10" MAX.

5" MIN.

FIGURE 2. Pump Control Switch Installation





Note: Failure to keep within proper tether limits

may prevent reliable switch operation.

Note: Cable must be mounted in horizontal

position.

Determining Pumping Range

in Inches (1 inch - 2.5 cm)

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.

Tether Length (inches) 5 10

 9 13.5

min. max.

SK305D

SK2651

ALARM FLOAT

PUMP CONTROL

FLOAT TREE

FLOAT

16"

MIN. OFF

Electrical Data

Amps KVA

Code

Winding

Resistance

Line-to-Line

Model BHP RPM Voltage Phase Hertz Full Load Shut Off Locked

Rotor

E810 1 1750 230 1 60 7.0 7.0 24.5 G 2.3 / 2.0*

E815 2 1750 230 1 60 10.5 10.5 44.0 1.80 / 1.60*



removing the cover.

FIGURE 3B. Models 810

and 815 Wiring Diagram

(932 Replacement Grinder System)

018929

RUN

O.L.

MOTOR

(3)

BLUE RED

GREEN

START

(1) (2)

YELLOW

BLUE RED

CAPACITOR

(WHITE) (BLACK)

(BROWN)

RED

BLACK

WHITE

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.

Typical Outdoor Grinder Pumping System Installations

FIGURE 4A - PACKAGED SYSTEM WITH

FLEXIBLE HOSE DISCONNECT

24"

MINIMUM

ANTI FLOATATION RING

1 1/4" BRASS CHECK VALVE

SHUT-OFF BALL VALVE

ALARM FLOAT

PUMP CONTROL FLOAT

12" MIN. OFF LEVEL

FIBERGLASS BASIN

1/8" 302 STAINLESS

STEEL LIFTING CABLE

1 1/4" FLEXIBLE

DISCONNECT FITTING

1 1/4" BULK HEAD

DISCHARGE FITTING

SOLID FIBERGLASS

COVER

GROMMET SEAL

2" ELECTRICAL PVC PIPE

4" INLET W-SEAL

(FIELD INSTALLED)

24"

MINIMUM

60"

DISCHARGE HOSE

HIGH WATER ALARM

(NOT INCLUDED)

WATERTIGHT "QWIK BOX"

(NOT INCLUDED)

FLOAT TREE

48"

72"

1 1/4"SCH 80 PVC PIPE

BRASS ANTI-SIPHON VALVE

1 1/4" MALE THREAD X SLIP FITTING

1 1/4" MALE THREAD X

SLIP FITTING

SK2540 SK2569

FIGURE 4B - PACKAGED SYSTEM WITH

SQUARE GUIDE RAIL SYSTEM

SK2533

6 5/8

8 3/8

5 1/4

4 3/8

10 1/2 DIA.

22 3/8

FIGURE 5 FIGURE 5A

SK2810

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 eld assembly work. Float switches

are set and tethered for proper operation from the Factory. The alarm switch should

be located 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 oat switch bulb or the unit will not operate

properly. Verify that where the oat switches are set will work for your application.

Verifying that the oat 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 backll all around and deep enough to provide

either 12” of compacted backll or 6” when a concrete pad is required. Ensure the

removable cover extends above the nished grade line and the grade slopes away

from the unit. Backll and subbase should be 1/8” –3/4” pea gravel or 1/8” –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 sufciently locate the basin outside of the loading area of the

adjacent structures.

6. The location of the inlet tting is determined by the depth of the inlet pipe. The

inlet tting must be used with 4” pipe. It is best to install the inlet on the side of the

basin opposite the oat switches. To install, use a 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 lled and compacted. Set basin in

hole and connect the 4” inlet pipe to the inlet hub.

8. The discharge piping is connected to the 1¼” threaded tting located in the basin

sidewall.

9. On basin depths of 72” and greater, the system’s disconnect assembly is shipped

loose and must be screwed into the discharge piping. Apply pipe dope to threaded

connection.

10. Connect pull rod to Pump assembly. Connect lift cable to top of pump. Lower the

pump into basin ensuring the discharge pipe bracket slides into the disconnect

tting.

11. Pouring a concrete anchor around system can now be completed. Basin should

be lled with water when pouring concrete to minimize movement of the system.

Back ll around basin with specied media. Care should be used to avoid damaging

components or leaving voids when back lling. Refer to Basin installation reference

guide on more specic requirements.

12. 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.

13. Dig a trench for the electrical conduit. Trench should be located at least 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 included sealant when closing Junction box.

14. If used, a control panel is installed within sight of the system. Connect oat switches

and pump cords according to the “Pump Wiring Instructions” found in this manual

and located inside the panel enclosure.

15. Remove any debris from the basin. Using clean water, check the system for proper

operation.

16. Seal and secure the lid using the proper bolts and sealant when using a lid without

a formed gasket.

17. Add water to the basin and test the system for leaks and proper pump operation.

18. Record system start up data for future reference.

Outdoor Prepackaged System Installation Instructions

This set of instructions is for factory prepackaged outdoor progressing cavity grinder systems only. If this is a eld assembled outdoor system you can

use these instructions as a guideline.

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 not designed to handle liquids other than sanitary sewage. If pump is

used to dewater areas with contaminated liquids with heavy or abrasive materials, the

warranty will be voided.

NAMEPLATE DATA

The nameplate, located on the top of the pump, indicates specic 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:

• Drain pump housing by laying pump horizontal with discharge down. Then stand pump

on legs.

• 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 seal 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.

• 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 veried proceed with the following checks:

• Pump power cables and control oats properly installed and voltage veried.

• 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 ow 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 qualied 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 oat 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. 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.

Operation

Cutter Maintenance



to 350°F to loosen Loctite® thread sealant.



       

0.012" on these parts.

1. All power circuits must be disconnected and locked out before

any attempts are made at servicing. The star cutter and disc can



cutter and disc must be removed from the pump. Removal of these



sump and positioning horizontally to access the intake of the pump. If

seals or other repairs are required, the pump must be totally removed



service center.

2. 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 0.007" and

0.012".

 

of the star cutter with a propane torch. The bolt must be heated to

350° F to soften the thread lock sealer on the bolt for ease of removal.

Remove the bolt by turning in a counterclockwise rotation. It will be

necessary to use a wood block to prevent the star cutter from turning



the spacer shims located behind the star cutter.

4. Remove the six cap screws holding the disc and remove disc from

the pump.

5. The disc and star cutter can be replaced with new service parts or

resurfaced by grinding. Resurfacing is accomplished by surface grinding





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.

 

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



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 star cutter with the

correct shims. Install washer and torque hex head bolt to 71-75 in.-lbs.

apply Loctite 262 thread-lock sealant or equal to bolt threads prior to

insertion. Check running clearance with pump in vertical position to

remove end play. Clearance must be between 0.007" and 0.012" to



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



Add oil if required. Use insulating oil supplied by the factory.

FIGURE 7.

General Maintenance

Repair and service should be performed by a Zoeller



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



Installation and checking of electrical circuits and hardware should be





Unit must be cleaned and disinfected, inside the

pumping chamber and all exterior surfaces, prior to servicing.

GENERAL SYSTEM INSPECTION





       

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

reventive maintenance is recommended to ensure a long service life



Every month:

 

 

Service Checklist

 



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

 

 

 







G. Grease and solids accumulate in pit around pump.

Common Causes





control panel, water in cap assembly, check valve not installed or malfunctioning.

Incorrect voltage, impeller or cutter blocked, negative head (discharge lower than intake





          

pump.

Intake clogged with grease or sludge, low or incorrect voltage, clogged discharge

line, operating near shut-off head.

Check valve stuck open or defective. Sump pit too small to handle incoming sewage.

Level control out of adjustment. Thermal overload tripping.





pump intake. Continue until solids are cleared from the pit.

Do not drain kitchen grease down the sink.

MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347

SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961

(502) 778-2731 • 1 (800) 928-PUMP • FAX (502) 774-3624

Your Peace of Mind is Our Top Priority

®visit our web site:

www.zoeller.com

235 2 Zoeller E810 Product Instructions User Manual

235 2 Zoeller Product Instructions 235_2_Zoeller Product Instructions 235_2_Zoeller Product Instructions pdf pumpproducts

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