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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SECTION: W2.40.020

Your Peace of Mind is Our Top Priority ®
®

Product information presented
here reflects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.

50/60Hz
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

FM2168_Ec
0815
Supersedes
1114

visit our web site:
www.zoeller.com

OWNER’S MANUAL

MODELS 840, 841 & 842 SUBMERSIBLE GRINDER UNITS
Congratulations on the purchase of a Zoeller submersible
grinder pump. Since 1939, the name Zoeller has represented
the standard for submersible dewatering and sewage pumps.
The same high-quality workmanship and easy maintenance
design has been incorporated into this line of heavy-duty
submersible grinder pumps. This Zoeller pump will provide
years of trouble-free service when installed according to the
manufacturer’s recommendations.
This manual incorporates the installation, operation,
maintenance, and service instructions into one document to

aid in the ownership of a Zoeller submersible wastewater
product. Please read and review this manual before installing
the product. Follow the steps in this manual for a proper startup. 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.

Table of Contents

Safety Instructions

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

TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR
PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN THIS MANUAL AND ON THE PUMP.

Owner’s Information
Model Number: ______________ Date Code: _______________
 Simplex



Duplex

 Packaged System



Field Assembled System

THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION
AND OPERATION OF THIS UNIT AND MUST BE KEPT WITH
THE PUMP.
This is a SAFETY ALERT SYMBOL.
When you see this symbol on the pump or in the
manual, look for one of the following signal words
and be alert to the potential for personal injury or
property damage.
Warns of hazards that WILL cause serious personal
injury, death or major property damage.
Warns of hazards that CAN cause serious personal
injury, death or major property damage.
CAUTION Warns of hazards that CAN cause personal injury
or property damage.
Indicates special instructions which are very important
and must be followed.

Job Name: ____________________________________________

THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY WORK ON THIS PUMP.

Distributor: ____________________________________________

MAINTAIN ALL SAFETY DECALS.

Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____ Amps _____

PUMPS WITH THE “UL” MARK AND PUMPS WITH THE “US”
MARK ARE TESTED TO UL STANDARD UL778. CSA CERTIFIED
PUMPS ARE CERTIFIED TO CSA STANDARD C22.2 NO. 108.
REFER TO WARRANTY ON PAGE 2.

LIMITED WARRANTY
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, every new product to be free from defects in material and
workmanship under normal use and service, when properly used and maintained,
for a period of one year from date of purchase by the end user, or 18 months
from date of original manufacture of the product, whichever comes first. Parts
that fail within the warranty period, one year from date of purchase by the
end user, or 18 months from the date of original manufacture of the product,
whichever comes first, that inspections determine to be defective in material or
workmanship, will be repaired, replaced or remanufactured at Manufacturer's
option, provided however, that by so doing we will not be obligated to replace
an entire assembly, the entire mechanism or the complete unit. No allowance
will be made for shipping charges, damages, labor or other charges that may
occur due to product failure, repair or replacement.
This warranty does not apply to and there shall be no warranty for any
material or product that has been disassembled without prior approval of
Manufacturer, subjected to misuse, misapplication, neglect, alteration, accident
or uncontrollable act of nature; that has not been installed, operated or maintained
in accordance with Manufacturer's installation instructions; that has been
exposed to outside substances including but not limited to the following: sand,
gravel, cement, mud, tar, hydrocarbons, hydrocarbon derivatives (oil, gasoline,
solvents, etc.), or other abrasive or corrosive substances, wash towels, feminine

sanitary products, or any other abusive entity, etc. in all pumping applications.
The warranty set out in the paragraph above is in lieu of all other warranties
expressed or implied; and we do not authorize any representative or other
person to assume for us any other liability in connection with our products.
Contact Manufacturer at, 3649 Cane Run Road, Louisville, Kentucky 40211
USA, Attention: Customer Support Department to obtain any needed repair
or replacement of part(s) or additional information pertaining to our warranty.
MANUFACTURER EXPRESSLY DISCLAIMS LIABILITY FOR SPECIAL,
CONSEQUENTIAL OR INCIDENTAL DAMAGES OR BREACH OF
EXPRESSED OR IMPLIED WARRANTY; AND ANY IMPLIED
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OF
MERCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THE
EXPRESSED WARRANTY.
Some jurisdictions do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some jurisdictions do not allow
the exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specific legal rights and you may also have other rights
which vary from jurisdiction to jurisdiction.

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 retrofit
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 retrofitted
to existing positive displacement pump installations.

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

Homes

GPD / m /day

Homes

GPD / m3/day

840 w/o reversing control

800/3

4,000/15

840 w/ reversing control

800/3

6,000/22

841

800/3

4,000/15

842

800/3

4,000/15

Model

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

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 CAUTIONS

SEE BELOW FOR LIST OF WARNINGS

1. Make sure pump connection contains a ground terminal. The
power cord on all Zoeller Grinder Pumps contains a green conductor for
grounding to help protect you against the possibility of electric shock.
2. Make certain the electrical service is within reach of the power
supply cord.
3. Make sure any panels and branch circuits are equipped with
proper size fuses and circuit breakers. An independent power circuit
is recommended, sized according to the Governing Electrical Code,
for the current shown on the grinder pump nameplate.
4. For your protection, always disconnect the power source to the
grinder pump before handling. All grinder pumps must be properly
grounded and wired in accordance with the “National Electrical Codes”
and all local codes and ordinances.
5. Installation of electrical hardware and checking of control panels
and circuits should be performed by a qualified licensed electrician.
6. Risk of electrical shock - These pumps have not been investigated
for use in swimming pool areas.
7. The appliance is not intended for use by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of experience
and knowledge, unless they have been given supervision or instruction to
concerning use of the appliance by a person responsible for their safety.
Do not attempt to turn star cutter located
on bottom of the unit with fingers. Use a
wrench when checking or removing star cutter.

1. Make sure the power source is capable of handling the electrical
requirements of the grinder pump, as indicated on the nameplate.
2. A disconnect switch should be installed ahead of the pump.
3. The Grinder pumps are operated by control panels with variable level
float control switches. It is the responsibility of the installing party to
see that float control switches will not hang up on the grinder pump
or other pit peculiarities and are secured so that the grinder pump
will shut off. It is recommended to use rigid pipe and fittings and the
pit be 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 float 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.

Electrical Data
Amps
Model

RPM

Voltage

Phase

Hertz

Full Load

In Air

Shut Off

Locked Rotor

KVA Code

Winding Resistance
Line-to-Line
1.3 / 4.0

V840

2800

220

13.5

6.0

7.5

AK840

2800

380

4.4

1.6

2.8

9.7

I840

3450

200

20.0

6.6

12.1

1.0 / 1.5

E840

3450

230

17.2

4.0

10.9

1.3 / 4.0

J840

3450

200

12.3

3.7

7.7

1.9

F840

3450

230

10.8

3.3

6.9

2.4
4.8

K840

3450

380

6.8

3.2

4.2

G840

3450

460

5.5

1.6

3.5

9.7

BA840

3450

575

4.5

1.0

2.5

15.3
1.3 / 4.0

V841

2800

220

13.5

6.0

7.5

AK841

2800

380

4.4

1.6

2.8

9.7

I841

3450

200

20.0

6.6

12.1

1.0 / 1.5

E841

3450

230

17.2

4.0

10.9

1.3 / 4.0

J841

3450

200

12.3

3.7

7.7

1.9

F841

3450

230

10.8

3.3

6.9

2.4
4.8

K841

3450

380

6.8

3.2

4.2

G841

3450

460

5.5

1.6

3.5

9.7

BA841

3450

575

4.5

1.0

2.5

15.3

AK842

2800

380

4.4

1.6

2.8

9.7

I842

3450

200

20.0

6.6

12.1

1.0 / 1.5

E842

3450

230

17.2

4.0

10.9

1.3 / 4.0

J842

3450

200

12.3

3.7

7.7

1.9

F842

3450

230

10.8

3.3

6.9

2.4
4.8

K842

3450

380

6.8

3.2

4.2

G842

3450

460

5.5

1.6

3.5

9.7

BA842

3450

575

4.5

1.0

2.5

15.3

General Information
GRINDER PUMP DESCRIPTION
FIELD-ASSEMBLED INSTALLATION

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 flat 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.

FEET

FIGURE 1.

METERS

6. A Grinder Pump is an intermittent duty pump designed for pumping sanitary
sewage. It is not a dewatering or trash pump.

1. Installation and piping instructions are included with the control panel, rail
system and basin instructions. If pump is being retrofitted to an existing
rail system, accessory parts may be required. Consult the factory and
advise make and model of rail system being used.
2. Refer to the appropriate Indoor/Outdoor prepackaged instructions 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 qualified, licensed electrician. A
UL Listed potting kit, P/N 10-2350, is available from Zoeller Company.
4. A properly sized disconnect switch, supplied by others, shall be installed
on the service side of the pump and control panel.
5. When installing a pump with a check valve, or a rail system with a check
valve, you must give the pump case time to fill to help prevent air lock
when lowering the unit into the liquid. The pump case has an air vent
located behind the discharge. This air vent is across the pump housing
mounting surface and must be cleaned before each reinstall. An extra
air vent hole 5 mm (3/16") may be drilled in discharge pipe below the
check valve to help prevent air lock. This drilled hole must be cleaned
before each reinstall. After the pump is installed, run the unit submerged
to assure the pump case is filled (Water should come out of 5 mm (3/16")
diameter hole).

60Hz

HEAD CAPACITY CURVE
MODEL 840/841/842

130

TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE

120
110

32
100

TOTAL DYNAMIC HEAD

90
80
70

20
60
16

50
40
30
20

842

840

MODEL

840

Feet
Meters
5
1.5
10
3.0
20
6.1
30
9.1
40
12.2
50
15.2
60
18.3
70
21.3
80
24.4
90
27.4
100
30.5
110
33.5
120
36.6
Shut-off Head:

Gal.
Liters
45
170
45
170
45
170
44
167
42
159
36
136
30
114
23
87
16
61
10
38
3
11
----104 ft (31.7 m)

841
Gal.
Liters
59
223
59
223
59
223
59
223
59
223
59
223
57
216
48
182
39.5
150
31
117
22
83
13
49
4.5
17
125 ft (38.1 m)

842
Gal.
Liters
34
129
34
129
34
129
34
129
34
129
34
129
34
129
32
121
29
110
25
95
20
76
13
49
4
15
125 ft (38.1 m)

016532

841

0
GALLONS
LITERS
0

10
40

20
80

120

160

200

240

FLOW PER MINUTE

Pump Wiring Instructions
FOR YOUR PROTECTION, ALWAYS DISCONNECT THE PUMP FROM ITS POWER SOURCE BEFORE HANDLING.
All electrical connections must be wired and grounded in accordance with the National Electrical Code and all applicable
local codes and ordinances.
Risk of electrical shock. Do not remove the power supply cord and strain relief or connect conduit directly to pump.
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
© Copyright 2015 Zoeller® Co. All rights reserved.
4

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

FIGURE 2.

SINGLE PHASE-2HP
MODEL 840

LEAD IDENTIFICATION

50/60Hz

WIRING DIAGRAM
COMPONENT LAYOUT

18-2

230V AC

14-6

PUMP

208V AC

PROTECTOR

WHITE

CONTACTOR

GREEN

START

MAIN

ORANGE

GROUND SCREW

START CAPACITOR
5

WHITE

RED

WHITE

BLACK

BLUE

ORANGE

MOISTURE
SENSOR
TERMINALS

RED

BLACK

START RELAY

WHITE

BLUE

RUN CAPACITOR
1
START RELAY

REVERSE MOTOR ROTATION BY INTERCHANGING
ORANGE WIRE WITH RED WIRE.

SK1367

009048

FIGURE 3.

START CAPACITOR

50/60Hz

WIRING DIAGRAM

BLACK

RED

ORANGE

WHITE

BLUE

YELLOW

CONTACTOR

GROUND SCREW

START CAPACITOR

BLACK

GREEN

RED

WHITE

BLACK

230V AC
OR
208V AC

WHITE

RED
2

WHITE

BLACK
1

COVER
CHAMBER

MOISTURE
SENSOR
TERMINALS

GREEN

14-4

WHITE

BLACK

SINGLE PHASE
MODELS 841 & 842

LEAD IDENTIFICATION

18-2

RUN CAPACITOR

START RELAY

MOTOR
CHAMBER

RUN CAPACITOR

OVERLOAD

1
START RELAY

AUXILIARY WINDING
RUN CAPACITOR

START CAPACITOR

MAIN WINDING

SK2399

FEET

FIGURE 4.

METERS

SK2400

TOTAL DYNAMIC HEAD

27
80

0
M3/HR
L/SEC

50Hz

PUMP PERFORMANCE CURVE
MODELS 840/841/842
50 Hz

TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE

841

MODEL

842

Meters
Feet
1.5
5.0
2
6.6
4
13.1
6
19.7
8
26.2
12
39.4
16
52.5
20
65.6
24
78.7
Shut-off Head:

840

2
0

4
1

6
2
FLOW

840
m /hr
L/sec
10.0
2.8
9.8
2.7
9.2
2.6
8.6
2.4
7.8
2.1
5.8
1.6
3.8
1.1
1.6
0.4
--22.6m (74.1 ft.)

841
3

m /hr
L/sec
7.7
2.1
7.7
2.1
7.7
2.1
7.7
2.1
7.7
2.1
7.7
2.1
7.0
1.9
4.9
1.4
2.4
0.7
26.8m (88 ft.)

842
3

m /hr
L/sec
12.7
3.6
12.7
3.5
12.7
3.5
12.7
3.5
12.5
3.4
11.6
3.2
8.9
2.5
5.8
1.6
2.5
0.7
26.8m (88 ft.)

A00648B

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

FIGURE 5.

50/60Hz

THREE PHASE
MODELS 840, 841 & 842
LEAD IDENTIFICATION

SENSOR
CORD

RED

BLAC
K

WHITE

14-4

3ø POWER

CONTACTOR

T3
SENSOR CABLE
(18-4 OR 18-5)

MAGNETIC
STARTER

GREEN
BLACK
WHITE

POWER CABLE
TEMPERATURE
SENSOR
TERMINALS

MOISTURE
SENSOR
TERMINALS

ORANGE
RED

GREEN

208V/230/460V

POWER
CORD

N
EE
GR

ITE

18-4
OR
18-5

WIRING DIAGRAM

THERMAL SENSOR
NORMALLY CLOSED

MOISTURE SENSOR
330K OHMS RESISTANCE
BEFORE 6/2000
NORMALLY OPEN

THREE PHASE
MODELS 840, 841, 842
CE MODEL

LEAD IDENTIFICATION

WIRING DIAGRAM

POWER
CORD

3Ø POWER

50 Hz

GRAY

BLACK

LLO

BROW

CONTACTOR

/YE

AC
K

EEN

MAGNETIC
STARTER

POWER CABLE

TEMPERATURE
SENSOR
TERMINALS

BLACK
BROWN

GRA
Y

HO7RNF4G1.5

MOISTURE
SENSOR
TERMINALS

SENSOR
CORD

BRO

UE
BL

GREEN/YELLOW

HO7RNF5G1.0

SK1370

GREEN/YELLOW
BLUE
GRAY

SK1368

SENSOR CABLE
HO7RN-F5G1.0

THERMAL SENSOR
NORMALLY CLOSED

MOISTURE SENSOR
330K OHMS RESISTANCE
BEFORE 6/2000
NORMALLY OPEN

CONTROL PANEL - 3Ø

3 PHASE MOTOR

SK2859

SK2860

INDOOR PREPACKAGED SYSTEM

FIGURE 6.

DECLARATION OF CONFORMITY

TO CONTROL PANEL
VARIABLE LEVEL
FLOAT SWITCHES

MOISTURE SENSOR CORD
PUMP POWER CORD

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:

CORD SEAL
24" X 1/4" [610mm X 6mm] STEEL
BASIN COVER

16" X 1/4" [406mm X 6mm] STEEL
PUMP PLATE

10" X 1/4" [254mm X 6mm] STEEL
INSPECTION PLATE
3" [76mm] GROMMET SEAL
(VENT CONNECTION)

5/16" [8mm] 304 STAINLESS STEEL
LIFTING U-BOLT
TO CONTROL PANEL

CONTROL PANEL
(FIELD INSTALLED)

1 1/4" [32mm] PVC SLIP X SLIP
BALL VALVE
(FIELD INSTALLED)
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
(FIELD INSTALLED)
1 1/4" [32mm] GROMMET SEAL

CAST IRON ADAPTERS

4" [102mm] PIPE SEAL
(FIELD INSTALLED)

-- 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

1 1/4" X 32" [32mm X 813mm]
GALVANIZED PIPE
36" [914mm] *

ALARM

1 1/2" X 8" [38mm X 203mm]
GALVANIZED PIPE
ON

GRINDER PUMP

OFF
* = OPTIONAL SIZES AVAILABLE
24" [610mm] *

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

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, 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 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 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 backfill all
the way around the perimeter. A minimum of 102
mm (4”) of compacted subbase is also required.
Backfill 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 float “on” level
with a minimum distance of 254 mm (10") 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 with102 mm (4") pipe. It is
best to install the inlet on the side of the basin opposite
the float switches. Most systems are supplied with a
field installed 102 mm (4") pipe seal inlet fitting. This
inlet fitting 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.
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 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 float switch and pump
cords.
10. Clean any debris out of the basin. Fill the basin with
water and check the system for proper operation.
11. Record system start-up data for future reference.
12. Seal and secure the inspection plate to the lid using
the proper bolts and sealant. Pouring concrete
around the system can now be completed.

Typical Outdoor Grinder Pumping System Installation
FIGURE 7.
CONTROL PANEL
(FIELD INSTALLED)

#10-2350 POTTING KIT
APPLIES TO INSIDE AND
OUTSIDE INSTALLATIONS
CONDUIT

1
(25 mm)

SOLID
FIBERGLASS
COVER

1/4" TO 1/2"
(6.4 mm TO 12.7 mm)

WIRES OR
UL LISTED
PUMP CABLES
EPOXY SEALER
FOAM TAPE
SK1661

WATERTIGHT
NEMA 4X J-BOX

STAINLESS STEEL FLOAT HOOK

SK1601

1/8" [3mm] 302 STAINLESS
STEEL LIFTING CABLE

COUPLING

3/8" X 1' [10mm X 305mm]
416 STAINLESS
STEEL PULL ROD

28" [711mm] MIN. OR PER STATE
AND LOCAL CODES

1 1/4" NPT BRASS
DISCONNECT FITTING

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

TO CONTROL PANEL

PIPE AND FITTINGS
1 1/4" [32mm]
DISCHARGE FITTING

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

4" [102mm] RUBBER INLET PIPE SEAL
(FIELD INSTALLED)

1 1/2" [38mm] SQ. GUIDE RAIL
304 STAINLESS STEEL 16 GA.

HIGH LEVEL
ALARM FLOAT

* 60" [1524mm]

FIBERGLASS BASIN
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE

PUMP CONTROL
"ON" FLOAT

1 1/4" [32mm] GALVANIZED
DISCHARGE PIPE

PUMP CONTROL
"OFF" FLOAT

FIBERGLASS
ANTI-FLOTATION FLANGE
24" MIN. [610mm]

* OTHER BASIN SIZES
ARE READILY AVAILABLE.

SK2864

All installations must comply with all applicable electrical and plumbing codes, including but not limited
to the National Electrical Code, local, regional and/or state plumbing codes, etc.
© Copyright 2015 Zoeller® Co. All rights reserved.
8

Outdoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged outdoor grinder systems with Square Guide Rail system. If
installing a Z-Rail® Package or a field-assembled outdoor system you can use these instructions as a guideline. If this is an indoor
system then go back to pages 6 and 7 in this manual that covers indoor systems. The pump should not be installed in the basin
until permanent electrical power is available.
1. Review the drawing in 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 field 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-float 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 float 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
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 610 mm
(24") larger in diameter than the basin diameter to provide 305
mm (12") of backfill all around and deep enough to provide
either 305 mm (12") of compacted backfill 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
sufficiently locate the basin outside of the loading area
of the adjacent structures.

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 field installed 102 mm (4") pipe seal inlet fitting. This
inlet fitting 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 fittings and sizes are occasionally provided.
7. Pouring a concrete anchor around system can now be
completed. Basin should be filled with water when pouring
concrete to minimize movement of the system. Backfill
around basin with specified media. Care should be used
to avoid damaging components or leaving voids when back
filling. Refer to Basin installation reference guide on more
specific requirements.
8. PVC or HDPE discharge piping is connected to the 132 mm
(1¼”) threaded fitting located in the basin sidewall. Support
discharge piping with sufficient backfill.
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 fitting.
11. Note: The grinder basin is a sewage holding tank. Vent
connection should be installed in accordance with all
national, state and local plumbing codes.
12. Dig a trench for the electrical conduit. The conduit should be
located below the frost line. Follow all applicable electrical
codes.
13. Connect electrical conduit and wiring to junction box
according to wiring instructions included in this manual and
wiring diagram in box. Use the potting kit provided with the
junction box. Follow the instructions for sealing the conduit
connection at the junction box.

5. The location of the inlet hub is determined by the depth of
the inlet pipe. The inlet hub must be used with 102 mm (4")
pipe. It is best to install the inlet on the side of the basin
opposite the float 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.

14. Mount the control panel within sight of the system. Connect
float switches and pump cords according to the “Pump Wiring
Instructions” found in this manual and located inside the
panel enclosure.

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

17. Test system for leaks and proper pump operation.

15. Remove any debris from the basin. Using clean water, check
the system for proper operation.
16. Seal and secure the lid using the proper bolts and sealant
when using a lid without a formed gasket.
18. Record system start-up data for future reference.

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 specific
information about the construction of the pump. The model number
and date code information should be recorded on the front page
in the “Owner’s Information” section of this manual.
SHORT-TERM STORAGE
Do not install pump until electrical power is available and
system is operational. When not in use, the pump should be
stored, and the following is advised:
• Store pump inside whenever possible, or cover with some type of
protective covering.
• Tape or seal in plastic bag the terminal ends of wire leads.
• Spray-coat unpainted surfaces with rust inhibiting oil.
• The impeller should be rotated every six months in order to
keep the seals lubricated and not develop a permanent set.

• Pump power cables and control floats properly installed and
voltage verified.
• 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 flow is appreciably less than
rated performance, pump may be air locked. To expel trapped
air, jog the unit several times, using the manual controls.
• Have a qualified electrician take voltage and current
measurements with the pump running. Record these readings
in the space provided in the “Owner’s Information” section
on page 1 of this manual for future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Refer to the system drawing or to the panel wiring
schematic for the desired location of each float switch
setting.
Valves: Discharge valves should be placed in the fully open
position. Systems should not be operated for extended
periods of time with the discharge valves partially closed
due to damaging the valve.

If panel is to be stored, the following is advised:

SHUT-DOWN PROCEDURES
If a system is shut down for more than six months, the following
is recommended:

• Store the panel inside whenever possible and leave in the
shipping box.
• All openings shall be sealed.
• Store in an upright position.
• Do not stack anything on top of panel.

Pumps: If pit is to remain dry, the pump can remain in the pit.
With the pump in the pit, it should be operated for five
minutes once every three months. If the pit is to remain
wet, the pump should be removed and stored as noted
above.

START-UP PROCEDURE
Before placing the equipment into operation, the following should
be checked:

Panels: The panel should have all openings sealed to prevent
moisture and dust from entering the enclosure. Prior
to restarting system, the panel should be inspected for
presence of moisture and any loose connections.

• Clean pit.
• Pump, float switches, electrical cables and junction box are
dry and properly installed.
• Electrical boxes dry, sealed and securely installed.
• Floats positioned properly.
• Discharge valves open.
• 5 mm (3/16") vent hole drilled in pipe between check valve and
pump.
Once the above has been verified, proceed with the following
checks:

Valves: Consult the valve/actuator supplier for information
concerning these systems components.

Cutter Maintenance
1. All power circuits must be disconnected and locked
out before any attempts are made at servicing. The star
cutter and disc can be removed and sharpened by grinding
the cutting faces. Both star cutter and disc must be removed
from the pump. Removal of these parts can be accomplished
in the field by removing pump from the sump and positioning
horizontally to access the intake of the pump. If seals or
other repairs are required, the pump must be totally removed
and serviced in a shop by a qualified pump technician or
authorized service center.
2. Remove the three countersunk screws on the plastic guard
ring and remove the ring.
3. Thoroughly clean the star cutter and disc assembly. Tilt pump
back to the vertical position to make certain the end play has
been removed. Check and record the clearance between the
star cutter and disc with a feeler gage. The correct running
clearance is between 0.1 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.

FIGURE 8.
To remove star cutter: Remove guard ring then heat the center
bolt to176°C (350°F) to loosen Loctite® thread sealant.

5. Remove the three cap screws holding the disc and remove
disc from the pump.
6. The disc and star cutter can be replaced with new service
parts or resurfaced by grinding. Resurfacing is accomplished
by surface-grinding both disc and star cutter to a 32 micro
finish. Do not attempt grinding in the field. Send parts to
a qualified machine shop or return to the factory for repair.
The disc, star cutter and shims are a matched set. Keep
parts together. Measure disc before and after resurfacing
with micrometer and record measurements.
7. After resurfacing, the disc and star cutter must be flat within
0.025 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 efficient grinding
when pump is put back in service.
9. Replace plastic guard ring and its three screws.
10. Check the oil in the motor housing before reinstalling. Contact
the factory if the oil has a milky appearance or burnt smell.
The level should be even with the fill plug when pump is in
the upright position. Add oil if required. Use insulating oil
supplied by the factory.

(Model 840 components shown)

Grind the Star Cutter and Disc seen here to a 32 microfinish.
Surfaces must be flat to within 0.025 mm (0.001") T.I.R. Gap must
be between 0.1 mm (0.004") and 0.2 mm (0.008") on these parts.
© Copyright 2015 Zoeller® Co. All rights reserved.
11

General Maintenance
Repair and service should be performed by a Zoeller Pump
Company Authorized Service Station only.

LUBRICATION PROCEDURES
No lubrication is required.

SAFETY PROCEDURES
For your protection, always disconnect pump and
panel from its power source before handling.

If pumps are to be stored for more than six months, refer to short-term storage
procedure in the Operation section.

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.

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 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.
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 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 fuse, open circuit breaker, low voltage, no control voltage, thermal overload
open, defective capacitor circuit, impeller clogged, float switch held down or defective, 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" float. 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 float assembly, defective switch, incoming flow 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 flow
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 find the Authorized Service Station in your area.

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