550289 3 Zoeller 840 Series Owners Manual

: Pump 550289 3 Zoeller 840 Series Owners Manual 550289_3_Zoeller 840 Series Owners Manual pdf

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Page Count: 12

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 840, 841 & 842 SUBMERSIBLE GRINDER UNITS

aid in the ownership of a Zoeller submersible wastewater

product. Please read and review this manual before installing

the product. Follow the steps in this manual for a proper start-

up. Many items contained within, when followed correctly,

will not only ensure a long and problem-free life for the pump,

but also save time and money during installation. Reference

FM1308 for model 840, FM2445 for model 842 and FM2180

for model 841 replacement parts. Should further assistance

be necessary, please call our Product Support Department at

+1-502-778-2731.

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.

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.

CAUTION

Table of Contents

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

Limited Warranty and Application ..............................................2

Preinstallation Checklist ........................................................... 2-3

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

REFER TO WARRANTY ON PAGE 2.

SECTION: W2.40.020

FM2168_Ec

0815

Supersedes

1114

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

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 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

visit our web site:

www.zoeller.com

50/60Hz

Zoeller Pump Company

Product on our website:

http://reg.zoellerpumps.com/

LIMITED WARRANTY

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.

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 840, 841 and 842 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 retrot

kits are available.

3. The 840, 841 and 842 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

page 4.

4. Zoeller 840, 841 and 842 Grinder Pumps can be retrotted

to existing positive displacement pump installations.

*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service

during unusual conditions.

Recommended Limits of Application 800 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, which is available through Zoeller Engineered Products. For

applications where a lift station would handle more than 60 homes, a solids handling type pump should be considered.

Simplex Station Duplex Station

Model Homes GPD / m3/day Homes GPD / m3/day

840 w/o reversing control 2* 800/3 10 4,000/15

840 w/ reversing control 2* 800/3 15 6,000/22

841 2* 800/3 10 4,000/15

842 2* 800/3 10 4,000/15

sanitary products, or any other abusive entity, etc. in all pumping applications.

The warranty set out in the paragraph above is in lieu of all other warranties

expressed or implied; and we do not authorize any representative or other

person to assume for us any other liability in connection with our products.

Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211

USA, Attention: Customer Support Department to obtain any needed repair

or replacement of part(s) or additional information pertaining to our warranty.

MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,

CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF

EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED

WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF

MERCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THE

EXPRESSED WARRANTY.

Some jurisdictions do not allow limitations on the duration of an implied warranty,

so the above limitation may not apply to you. Some jurisdictions do not allow

the exclusion or limitation of incidental or consequential damages, so the above

limitation or exclusion may not apply to you.

This warranty gives you specic legal rights and you may also have other rights

which vary from jurisdiction to jurisdiction.

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 rst. 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 rst, that inspections determine to be defective in material or

workmanship, will be repaired, replaced or remanufactured at Manufacturer's

option, provided however, that by so doing we will not be obligated to replace

an entire assembly, the entire mechanism or the complete unit. No allowance

will be made for shipping charges, damages, labor or other charges that may

occur due to product failure, repair or replacement.

This warranty does not apply to and there shall be no warranty for any

material or product that has been disassembled without prior approval of

Manufacturer, subjected to misuse, misapplication, neglect, alteration, accident

or uncontrollable act of nature; that has not been installed, operated or maintained

in accordance with Manufacturer's installation instructions; that has been

exposed to outside substances including but not limited to the following: sand,

gravel, cement, mud, tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline,

solvents, etc.), or other abrasive or corrosive substances, wash towels, feminine

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 “National Electrical Codes”

and all local codes and ordinances.

5. Installation of electrical hardware and checking of control panels

and circuits should be performed by a qualied 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.

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

oat control switches. It is the responsibility of the installing party to

see that oat 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 ttings and the

pit be 61 cm (24") in diameter for simplex systems and 91 cm (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 oat control switches. Repair and service, other than cutter

assembly maintenance, should be performed by Zoeller authorized

service stations only.

5. Maximum operating temperature must not exceed 54°C (130°F).

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.

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 WARNINGS

CAUTION

SEE BELOW FOR LIST OF CAUTIONS

Electrical Data

Amps KVA Code Winding Resistance

Line-to-Line

Model RPM Voltage Phase Hertz Full Load In Air Shut Off Locked Rotor

V840 2800 220 1 50 13.5 6.0 7.5 24 A 1.3 / 4.0

AK840 2800 380 3 50 4.4 1.6 2.8 18 G 9.7

I840 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5

E840 3450 230 1 60 17.2 4.0 10.9 56 F 1.3 / 4.0

J840 3450 200 3 60 12.3 3.7 7.7 54 L 1.9

F840 3450 230 3 60 10.8 3.3 6.9 42 K 2.4

K840 3450 380 3 60 6.8 3.2 4.2 28 H 4.8

G840 3450 460 3 60 5.5 1.6 3.5 21 K 9.7

BA840 3450 575 3 60 4.5 1.0 2.5 11 F 15.3

V841 2800 220 1 50 13.5 6.0 7.5 24 A 1.3 / 4.0

AK841 2800 380 3 50 4.4 1.6 2.8 18 G 9.7

I841 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5

E841 3450 230 1 60 17.2 4.0 10.9 56 F 1.3 / 4.0

J841 3450 200 2 60 12.3 3.7 7.7 54 L 1.9

F841 3450 230 2 60 10.8 3.3 6.9 42 K 2.4

K841 3450 380 3 60 6.8 3.2 4.2 28 H 4.8

G841 3450 460 2 60 5.5 1.6 3.5 21 K 9.7

BA841 3450 575 2 60 4.5 1.0 2.5 11 F 15.3

AK842 2800 380 3 50 4.4 1.6 2.8 18 G 9.7

I842 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5

E842 3450 230 1 60 17.2 4.0 10.9 56 F 1.3 / 4.0

J842 3450 200 3 60 12.3 3.7 7.7 54 L 1.9

F842 3450 230 3 60 10.8 3.3 6.9 42 K 2.4

K842 3450 380 3 60 6.8 3.2 4.2 28 H 4.8

G842 3450 460 3 60 5.5 1.6 3.5 21 K 9.7

BA842 3450 575 3 60 4.5 1.0 2.5 11 F 15.3

General Information

GRINDER PUMP DESCRIPTION

1. Pumps are constructed of class 30 cast iron protected with powder coated

epoxy protection for long life when pumping sewage in submersible

applications. The cutter assembly is comprised of stainless steel components,

hardened to a value of 55-60 on the Rockwell C scale, a star shaped cutter

and a precision-ground at disk. Cutting action takes place with the rotation

of the star cutter at 3450 RPM (60 Hz) or 2800 RPM (50 Hz) against the

stationary cutter plate (see page 11).

2. The cutter mechanism on the model 840 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 models 841 and 842 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 (see page 8).

4. The 840, 841 and 842 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.

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 retrotted 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-tight and watertight seal. Installation of electrical panels, conduit

and connections should be made by a qualied, 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 ll 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 lled (Water should come out of 5 mm (3/16")

diameter hole).

FIGURE 1.

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 qualied licensed electrician.

60Hz

Pump Wiring Instructions

016532

HEAD CAPACITY CURVE

MODEL 840/841/842

0 40 80 120 160 200 240

70605040302010

130

FLOW PER MINUTE

GALLONS

LITERS

TOTAL DYNAMIC HEAD

METERS

FEET

100

110

120

840 841842

TOTAL DYNAMIC HEAD/FLOW

PER MINUTE

SEWAGE

MODEL

Feet

Shut-off Head:

840

Meters Gal. Liters

30 9.1

6.1

3.0

1.5

167

170

104 ft (31.7 m)

110

100

120

12.2

15.2

18.3

21.3

24.4

27.4

30.5

33.5

36.6

30 114

136

159

10 38

-- --

125 ft (38.1 m)

841

Gal. Liters

45 170

125 ft (38.1 m)

9525

20 76

129

121

110

129

842

Gal.

129

Liters

57 216

223

39.5

31 117

150

182

4.5 17

59 223

FIGURE 2.

LEAD IDENTIFICATION WIRING DIAGRAM

SINGLE PHASE-2HP

MODEL 840

SK1367 009048

FIGURE 4.

FIGURE 3.

START RELAY

START CAPACITOR

GREEN

RED

WHITE

BLACK

BLUE

ORANGE

MOISTURE

SENSOR

TERMINALS

WHITE

BLACK

14-618-2

REVERSE MOTOR ROTATION BY INTERCHANGING

ORANGE WIRE WITH RED WIRE.

RUN CAPACITOR

GROUND SCREW

COMPONENT LAYOUT

PUMP

START RELAY

START CAPACITOR

RUN CAPACITOR

RED

WHITE

ORANGE

BLACK

MAIN START

PROTECTOR

BLACK

WHITE

L1 L2

230V AC

208V AC

CONTACTOR

BLUE

SINGLE PHASE

MODELS 841 & 842

LEAD IDENTIFICATION WIRING DIAGRAM

START RELAY

START CAPACITOR

MOISTURE

SENSOR

TERMINALS

BLACK

WHITE

L1 L2

RUN CAPACITOR

GROUND SCREW

BLACK

WHITE

RED

GREEN

18-2 14-4

SK2399

RUN CAPACITOR START CAPACITOR

BLACK

WHITE

START RELAY

L1 L2

208V AC

230V AC

CONTACTOR

YELLOW

MAIN WINDING

AUXILIARY WINDING

OVERLOAD

BLUE

ORANGE

WHITE

RED

BLACK

GREEN

WHITE

BLACK

RED

MOTOR

CHAMBER

COVER

CHAMBER

SK2400

50/60Hz

50Hz

A00648B

Locate section with appropriate phase and model number, then match lead wire color.

841

842

840

PUMP PERFORMANCE CURVE

MODELS 840/841/842

50 Hz

1412108642

L/SEC

M /HR

TOTAL DYNAMIC HEAD

METERS

FEET

FLOW

1 2 3

MODEL

Meters Feet

1.5 5.0

2 6.6

4 13.1

6 19.7

8 26.2

12 39.4

16 52.5

842

L/secm /hr

3.6

3.5

3.512.7

12.7

841

L/secm /hr

2.1

2.17.7

7.7

Shut-off Head: 26.8m (88 ft.)26.8m (88 ft.)

20 65.6

24 78.7

7.7

7.0

4.9

2.4

2.1

1.9

1.4

0.7

12.7

12.5

11.6

8.9

5.8

2.5

3.5

3.4

3.2

2.5

1.6

0.7

TOTAL DYNAMIC HEAD/FLOW

PER MINUTE

SEWAGE

L/secm /hr

2.810.0

840

2.79.8

2.69.2

2.48.6

2.17.8

1.65.8

1.13.8

0.41.6

----

22.6m (74.1 ft.)

DECLARATION OF CONFORMITY

We Zoeller declare under our sole responsibility that the models 840

/ 841 / 842 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:

-- Machinery Directive (2006/42/EC)

Standards used: EN 809: 1998

-- 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

HO7RN-

L1 L2 L3

T1 T2 T3

BROWN

GR AY

POWER

CORD

MAGNETIC

STARTER

CORD

SENSOR

BLACK

BLUE

BLACK

BROWN

GRAY

MOISTURE

SENSOR

TERMINALS

CONTROL PANEL - 3Ø

SENSOR

TERMINALS

TEMPERATURE

F4G1.5

GREEN/YELLOW

HO7RN-

F5G1.0

GREEN/YELLOW

3 PHASE MOTOR

MOISTURE SENSOR

L1 L2 L3

POWER CABLE

CONTACTOR

T1 T2 T3

3Ø POWER

50 Hz

SENSOR CABLE

THERMAL SENSOR

BLACK

BLUE

BROWN

GR AY

GREEN/YELLOW

HO7RN-F5G1.0

BEFORE 6/2000

NORMALLY OPEN

330K OHMS RESISTANCE

NORMALLY CLOSED

SK2859 SK2860

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.

SK2865

24" [610mm] *

OFF

ALARM

TO CONTROL PANEL

VARIABLE LEVEL

FLOAT SWITCHES MOISTURE SENSOR CORD

3" [76mm] GROMMET SEAL

10" X 1/4" [254mm X 6mm] STEEL 16" X 1/4" [406mm X 6mm] STEEL

5/16" [8mm] 304 STAINLESS STEEL

24" X 1/4" [610mm X 6mm] STEEL

TO CONTROL PANEL

CORD SEAL

INSPECTION PLATE

BASIN COVER

PUMP PLATE

LIFTING U-BOLT

1 1/4" [32mm] PVC SLIP X SLIP

BALL VALVE

1 1/4" FEMALE NPT

CAST IRON CHECK VALVE

1 1/4" X 32" [32mm X 813mm]

GALVANIZED PIPE

1 1/2" X 8" [38mm X 203mm]

GALVANIZED PIPE

1 1/4" [32mm] GROMMET SEAL

4" [102mm] PIPE SEAL

CAST IRON ADAPTERS

PUMP POWER CORD

(FIELD INSTALLED)

GRINDER PUMP

(FIELD INSTALLED)

(VENT CONNECTION)

CONTROL PANEL

(FIELD INSTALLED)

36" [914mm] *

* = OPTIONAL SIZES AVAILABLE

INDOOR PREPACKAGED SYSTEM

LEAD IDENTIFICATION WIRING DIAGRAM

THREE PHASE

MODELS 840, 841, 842

CE MODEL

FIGURE 5.

FIGURE 6.

MOISTURE SENSOR

L1 L2 L3

POWER CABLE

CONTACTOR T1 T2 T3

208V/230/460V

3ø POWER

SENSOR CABLE

THERMAL SENSOR

ORANGE

BLACK

RED

WHITE

GREEN

(18-4 OR 18-5)

BEFORE 6/2000

NORMALLY OPEN

330K OHMS RESISTANCE

NORMALLY CLOSED

THREE PHASE

MODELS 840, 841 & 842

WIRING DIAGRAMLEAD IDENTIFICATION

14-4

18-4

L1 L2 L3

T1 T2 T3

BLACK

RED

GREEN

POWER

CORD

MAGNETIC

STARTER

CORD

SENSOR

WHITE

BLACK

ORANGE

RED

WHITE

MOISTURE

SENSOR

TERMINALS

SENSOR

TERMINALS

TEMPERATURE

18-5

GREEN

50/60Hz

SK1368 SK1370

Locate section with appropriate phase and model number, then match lead wire color.

Indoor Prepackaged System Installation Instructions

This set of instructions is for factory prepackaged indoor systems only. If your system

is a eld-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, you will

need an outdoor system. DO NOT INSTALL THE

INDOOR SYSTEM OUTDOORS.

2. Review the drawing in Figure 7 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 eld 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 oat switches are already

set inside the basin.

4. Remove the inspection plate from the cover. All

oats are set and tethered for proper operation from

the factory. 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. Float switches are tied in place

for shipping purposes. Cut the cable tie around each

oat 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 trafc area within 5 m (15')

of the power disconnect. The hole should be

at least 203 mm (8") larger in diameter than the

basin in order to leave 102 mm (4") of backll all

the way around the perimeter. A minimum of 102

mm (4”) of compacted subbase is also required.

Backll and subbase should be 3.2 mm (1/8") to

3/4” (19 mm) pea gravel or 3.2 mm (1/8”) to 12.7

mm (1/2") crushed stone. Also reference the basin

installation instructions included with the unit.

6. The 102 mm (4") inlet hub should be located between

the top lip of the basin and the alarm oat “on” level

with a minimum distance of 254 mm (10") between the

oor of the basin and hub. Determine the location of

the inlet hub based upon your inlet pipe arrangement.

The inlet hub must be used with102 mm (4") pipe. It is

best to install the inlet on the side of the basin opposite

the oat switches. Most systems are supplied with a

eld installed 102 mm (4") pipe seal inlet tting. This

inlet tting is installed in the basin's side-wall in a 127

mm (5") hole drilled with a hole saw at a location lining

up with the inlet pipe.

7. Set the basin in the hole and connect the 102 mm

(4") inlet pipe to the inlet hub using the rubber insert.

Backll around the basin with specied media. Care

should be taken not to damage components or leave

voids when backlling. Finish grade of oor should

be poured in place around the top 152 mm (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 control panel on the wall within 5 m (15')

of the system. Connect the oat 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.

Typical Outdoor Grinder Pumping System Installation

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.

FIGURE 7.

FOAM TAPE

UL LISTED

EPOXY SEALER

#10-2350 POTTING KIT

APPLIES TO INSIDE AND

OUTSIDE INSTALLATIONS

CONDUIT 1

WIRES OR

PUMP CABLES

1/4" TO 1/2"

(25 mm) (6.4 mm TO 12.7 mm)

SK1661

24" MIN. [610mm]

WATERTIGHT

HIGH LEVEL

1 1/4" FEMALE NPT

1 1/4" [32mm] GALVANIZED

DISCHARGE PIPE

FIBERGLASS

4" [102mm] RUBBER INLET PIPE SEAL

FIBERGLASS

1 1/4" NPT BRASS

DISCONNECT FITTING

1 1/2" [38mm] SQ. GUIDE RAIL

304 STAINLESS STEEL 16 GA.

PUMP CONTROL

"ON" FLOAT

"OFF" FLOAT

PUMP CONTROL

3/8" X 1' [10mm X 305mm]

1/8" [3mm] 302 STAINLESS

NEMA 4X J-BOX

ANTI-FLOTATION FLANGE

ALARM FLOAT

SOLID

STAINLESS STEEL FLOAT HOOK

STEEL LIFTING CABLE

416 STAINLESS

1 1/4" [32mm] PVC SCH 40

PIPE AND FITTINGS

1 1/4" [32mm] PVC SLIP X SLIP

BALL VALVE

1 1/4" [32mm]

DISCHARGE FITTING

CAST IRON CHECK VALVE

COVER

(FIELD INSTALLED)

CONTROL PANEL

FIBERGLASS BASIN

TO CONTROL PANEL

COUPLING

28" [711mm] MIN. OR PER STATE

AND LOCAL CODES

STEEL PULL ROD

60" [1524mm]

OTHER BASIN SIZES

ARE READILY AVAILABLE.

SK2864

SK1601

Outdoor Prepackaged System Installation Instructions

1. Review the drawing in Figure 8 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 eld assembly work. Float switches

are set and tethered for proper operation from the Factory.

The alarm switch should be located 76 mm (3") above the

pump “on” level. Three-oat systems used with a control

panel are placed at 686 mm (27"), 610 mm (24"), and 381mm

(15") from the bottom of the basin. Four oat systems used

with a control panel are placed at 762 mm (30"), 686 mm

(27"), 610 mm (24"), and 381mm (15") from the bottom of

the basin. If the invert location is at or below the level of the

oat 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 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 610 mm

(24") larger in diameter than the basin diameter to provide 305

mm (12") of backll all around and deep enough to provide

either 305 mm (12") of compacted backll or 152 mm (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

sufciently 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 102 mm (4")

pipe. It is best to install the inlet on the side of the basin

opposite the oat switches. To install, use a 102 mm (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.

6. The bottom of the excavation can now be properly backlled,

compacted and leveled. Set basin in hole. Ensure the

removable cover extends above the nished grade line and

the grade slopes away from the unit. Backll and subbase

should be 3.2 - 19 mm (1/8” –3/4”) pea gravel or 3.2 - 12.7 m

(1/8” –1/2”) crushed stone. (Reference basin installation

instructions included with unit.) Most systems are supplied

with a eld installed 102 mm (4") pipe seal inlet tting. This

inlet tting is installed in the basin's side-wall in a 127 mm (5")

hole drilled with a hole saw at a location lining up with the inlet

pipe. Other type ttings and sizes are occasionally provided.

7. 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.

8. PVC or HDPE discharge piping is connected to the 132 mm

(1¼”) threaded tting located in the basin sidewall. Support

discharge piping with sufcient backll.

9. On basin depths of 1.8 m (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. 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.

14. Mount the control panel 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. Test system for leaks and proper pump operation.

18. Record system start-up data for future reference.

This set of instructions is for factory prepackaged outdoor grinder systems with Square Guide Rail system. If

installing a Z-Rail® Package or a eld-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.

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 54°C (130°F).

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 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

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.

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, oat switches, electrical cables and junction box are

dry and properly installed.

• Electrical boxes dry, sealed and securely installed.

• Floats positioned properly.

• Discharge valves open.

• 5 mm (3/16") vent hole drilled in pipe between check valve and

pump.

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 and junction box are properly

sealed.

• For three-phase units, check for proper pump rotation and

connect overload protection sitting in the panel.

• After installing the pump into the containment area, with

adequate submergence, open the shut-off 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 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 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.

SHUT-DOWN PROCEDURES

If a system is shut down for more than six months, the following

is recommended:

Pumps: If pit is to remain dry, the pump can remain in the pit.

With the pump in the pit, it should be operated for ve

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.

Cutter Maintenance

To remove star cutter: Remove guard ring then heat the center

bolt to176°C (350°F) to loosen Loctite® thread sealant.

Grind the Star Cutter and Disc seen here to a 32 micronish.

Surfaces must be at to within 0.025 mm (0.001") T.I.R. Gap must

be between 0.1 mm (0.004") and 0.2 mm (0.008") 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 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 eld 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 qualied 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 0.1 mm (0.004") and 0.2 mm (0.008").

4. With pump in horizontal position, heat the hex head bolt in

the center of the star cutter with a propane torch. The bolt

must be heated to 176°C (350°F) to soften the thread lock

sealer on the bolt for ease of removal. Remove the bolt by

turning in a counterclockwise rotation. It will be necessary

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

while removing the bolt. Pull star cutter from the shaft and

remove the spacer shims located behind the star cutter.

5. Remove the three cap screws holding the disc and remove

disc from the pump.

6. The disc and star cutter can be replaced with new service

parts or resurfaced by grinding. Resurfacing is accomplished

by surface-grinding both disc and star cutter to a 32 micro

nish. Do not attempt grinding in the eld. Send parts to

a qualied 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 at within

0.025 mm (0.001"). If the disc has been surface ground, it

will be necessary to remove shims to compensate for the

material removed from the disc. As a starting point, remove

shims of the same thickness as the amount machined from

the cutter disc (step 6 above). Final running clearance must

be between 0.1 mm (0.004") and 0.2 mm (0.008"). Be sure

pump is in vertical position and all end play has been removed

before measuring.

8. Clean bottom of pump where disc is located and replace disc

and retainer screws. Torque to 7.1-7.6 Nm (63-67 in-lbs).

Replace star cutter with the correct shims. Install washer

and torque hex head bolt to 8-8.5 Nm (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 0.1

mm (0.004") and 0.2 mm (0.008") to obtain efcient 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 ll plug when pump is in

the upright position. Add oil if required. Use insulating oil

supplied by the factory.

FIGURE 8.

(Model 840 components shown)

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

sulde gases, both of which can be highly poisonous.

Installation and checking of electrical circuits and hardware should be performed

by a qualied 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 qualied

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 six months:

• Inspect and test system for proper operation.

• Check for proper and unobstructed oat 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.

DOUBLE SEAL PUMPS

Double seal pumps offer extra protection when these pumps are supplied with

optional moisture sensors, check the control panel's seal failure light for a

warning. Whenever the seal leak light is activated, it's indicating that moisture

is present, and the pump should be removed and serviced in order to avoid

damage to the motor.

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 ooded conditions, contact your local electric company or a qualied

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 fuse, open circuit breaker, low voltage, no control voltage, thermal overload

open, defective capacitor circuit, impeller clogged, oat switch held down or defec-

tive, incorrect wiring in control panel, water in cap assembly.

B. Motor overheats and trips overload.

Incorrect voltage, impeller restricted, negative head discharge lower than intake

of pump). Defective "off" oat. Pump runs continuously at low water level. Low oil

level in motor shell. Reverse rotation of a 3-phase pump.

C. Pump will not shut off. Air lock, debris under oat assembly, defective switch, incoming ow rate exceeds

capacity of pump.

D. Pump operates, but delivers little or no water. Intake clogged with grease or sludge, pump air locked (clear vent hold), 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 ow

rate. Level control out of adjustment. Thermal overload tripping.

F. Red beacon comes on at control panel. High water in pit. Check pump for clogging, or overload trip. See "A", "B", 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 intakes. Heavy accumulations of grease may require a dish soap

additive. Continue until solids are cleared from the pit. Do not drain kitchen grease

down the sink.

If the above checklist does not uncover the problem, consult the factory. Do not attempt to service or otherwise disassemble pump. Service must be

performed by Zoeller Authorized Service Stations. Go to www.zoellerpumps.com/servicestations to nd the Authorized Service Station in your area.

550289 3 Zoeller 840 Series Owners Manual

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