Zoeller 810 & 815 Progressing Cavity Grinder Pumps

Introduction

Congratulations on the purchase of a Zoeller submersible progressing cavity grinder pump. Since 1939, Zoeller has been a standard for submersible dewatering and sewage pumps. This manual details the installation, operation, maintenance, and service for the Zoeller 810 and 815 Series Progressing Cavity Grinder Pumps. Please read and follow all instructions carefully for optimal performance and longevity.

For replacement parts, refer to FM2435 and FM2436. For assistance, contact Zoeller Technical Service at 1-800-928-PUMP (7867).

Table of Contents

• Safety Instructions
• Limited Warranty, Checklist and Application
• General Information
• Pump Wiring Instructions
• Typical Outdoor Prepackaged System
• Installation and Operation Instructions
• Maintenance
• Service Checklist

Owner's Information

Please record the following details:

• Model Number: ____________________
• Date Code: ____________________
• System Type: Simplex / Duplex
• Installation Type: 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 ______

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.

Safety Alert Symbol: When you see this symbol on the pump or in the manual, look for one of the following signal words:

• DANGER: Warns of hazards that WILL cause serious personal injury, death or major property damage.
• WARNING: 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.
• NOTICE: Warns of electrical shock hazards that can cause serious personal injury, death or major property damage.
• Ground Symbol: Identifies any terminal intended for connection to an external conductor for protection against electrical shock in case of a fault, or the terminal of a protective earth (ground) electrode.
• Read operator's manual.
• 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.

Limited Warranty

Zoeller Pump Company warrants its products against defects in material and workmanship for a period of two years from the date of purchase, provided they are properly used and maintained. Proof of purchase is required. Defective parts will be repaired, replaced, or remanufactured at Zoeller's option. This warranty does not cover damage from misuse, neglect, alteration, accident, or exposure to abrasive or corrosive substances, or parts that have been disassembled without prior approval.

Contact Zoeller Pump Company, 3649 Cane Run Road, Louisville, KY 40211, Attention: Customer Support Department for warranty service or information.

Zoeller expressly disclaims liability for special, consequential, or incidental damages. Implied warranties of fitness for a particular purpose and merchantability are limited to the duration of this express warranty.

Some states do not allow limitations on implied warranty duration or incidental/consequential damages.

In cases of alleged product failure causing property damage, the property owner must retain possession of the product for investigation.

Preinstallation Checklist

1. Inspect the grinder pump for shipping damage. Contact your dealer if damage is found. Do not remove test plugs.
2. Read all literature thoroughly for installation and use details. Retain for future reference.

WARNING:

• Ensure the pump connection has a ground terminal. The power cord includes a green conductor for grounding.
• Verify the electrical service is within reach of the power supply cord.
• Ensure panels and branch circuits have properly sized fuses and circuit breakers. An independent power circuit, sized per the National Electrical Code for the pump's nameplate current, is recommended.
• Always disconnect the power source before handling the pump. Ensure all pumps are properly grounded and wired per the National Electrical Code and local ordinances.
• Electrical hardware installation and circuit checks should be performed by a qualified licensed electrician.
• These pumps have not been investigated for use in swimming pool areas.
• California Proposition 65 Warning: Cancer and Reproductive Harm - visit www.P65Warning.ca.gov.
• Progressing cavity grinder pumps are designed for pressure sewer applications. A UL listed and CSA certified pressure relief valve must be installed to prevent excessive pressure buildup.

CAUTION:

• Ensure the power source can handle the pump's electrical requirements as indicated on the nameplate.
• Install a disconnect switch in the circuit supplying power to the pump.
• Float control switches must be installed to prevent them from hanging up and to ensure proper pump shut-off. Rigid pipe and fittings are recommended. The pit should be at least 24 inches in diameter for simplex systems and 36 inches or larger for duplex systems.
• Check grinder installations yearly for debris that may interfere with float switch operation. Repair and service, other than cutter assembly maintenance, should be performed by a Zoeller Authorized Service and Warranty Center or Customer Care Center.
• Maximum operating temperature of pump liquid must not exceed 130°F (54°C).
• Do not operate the pump unsubmerged; dry operation can damage the hydraulic stator. Do not run dry.
• Install a swing or flapper style check valve in the pump discharge line. A faulty check valve can prevent the pump from starting in a pressure sewer system.
• WARNING: Do not attempt to turn cutter blades with fingers. Use a wrench.

Applications

Zoeller Progressing Cavity Grinder Pumps are designed for grinding and pumping sanitary sewage from submersible lift stations. They are intended to handle reasonable quantities of items normally found in sanitary sewage. The 810 and 815 models can be installed in new applications, as replacements, in prepackaged systems, or field-assembled basin packages. They can also retrofit existing positive displacement pump installations.

General Information

PROGRESSING CAVITY GRINDER PUMP DESCRIPTION

1. Pumps are constructed of cast iron with powder-coated epoxy for durability in submersible applications. The cutter assembly features hardened stainless steel components (55-60 Rockwell C) with a star-shaped cutter and a precision ground flat disk. Cutting action occurs at 1750 RPM between the cutter blades and the stationary cutter plate.
2. The cutter mechanism is single directional.
3. Motors are single-phase and require a run capacitor (located in the upper cap) and have an internal thermal overload.
4. The 810 & 815 pumps have a single seal.
5. A pressure relief valve provides motor protection against inadvertent shut-off head conditions.
6. These are intermittent duty pumps designed for sanitary sewage, not for dewatering or trash pumping.

FIELD ASSEMBLED INSTALLATION

1. Refer to control panel, rail system, and basin instructions for installation and piping. Accessory parts may be required for retrofitting to existing rail systems; consult the factory.
2. Refer to appropriate Indoor/Outdoor prepackaged instructions for system installation details.
3. All electrical connections must comply with the National Electrical Code and applicable local codes. Conduit and panel enclosure openings must have a gas-tight seal. Electrical panel installation should be done by a qualified licensed electrician.
4. A properly sized disconnect switch, supplied by others, must be installed on the service side of the pump and control panel.
5. When used in a pressure sewer, install an anti-siphon valve (see Figure 5A).

Pump Performance Curve (Figure 1)

This section displays the pump performance curve for Models 810/815, illustrating Total Dynamic Head versus Flow Rate. The graph shows two performance curves, one for the 1 HP (Model 810) and one for the 2 HP (Model 815) pump. The axes are labeled as Total Dynamic Head in feet and meters, and Flow Rate in Gallons per Minute (GPM) and Liters per Minute. A 'Typical Operating Range' is indicated on the graph. The graph also includes a table showing Total Dynamic Head and Flow Rate in Feet, Meters, Gallons, and Liters for various operating points for both Model 810 and Model 815.

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 the pump. Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.

Pump Control Switch Installation (Figure 2)

This diagram illustrates the installation of a pump control switch, including the float tree assembly with pump control and alarm floats. It details determining the pumping range based on tether length (in inches) and corresponding GPM. Notes emphasize keeping within proper tether limits for reliable switch operation and mounting the cable horizontally. The diagram shows minimum tether lengths and recommended pit dimensions.

Electrical Data

The following table provides electrical specifications for Zoeller 810 and 815 series pumps:

* Line-to-line reading reflects run winding resistance. Start winding resistance requires cover removal.

** Start & run winding resistance can only be measured after removing the cover and checking at the through-wall terminals.

Wiring Diagrams

• Figure 3A: Models E810 and E815 Wiring Diagram: This diagram illustrates the wiring connections for the E810 and E815 models, showing connections to the motor, capacitor, and relay, with color-coded wires and terminal designations.
• Figure 3B: Models RE810 and RE815 Wiring Diagram: This diagram shows the wiring for the RE810 and RE815 models, which include a replacement grinder assembly with a manual run feature. It details connections to the motor, capacitor, relay, and pump switch.
• Figure 3C: Models RWD810 and RWD815 Wiring Diagram: This diagram illustrates the wiring for the RWD810 and RWD815 models, featuring a replacement grinder assembly with an integral pump and alarm float, and a manual run function. It shows connections to the motor, capacitor, relay, and alarm switch.

Typical Outdoor Grinder Pumping System Installations

• Figure 4A - Packaged System with Flexible Hose Disconnect: This diagram shows a typical packaged system installation in a fiberglass basin. Key components include the basin, cover, lifting cable, discharge fitting, inlet, float tree assembly (pump control and alarm floats), and a flexible discharge hose.
• Figure 4B - Packaged System with Z-Rail Disconnect System: This diagram illustrates another packaged system installation in a fiberglass basin, using a Z-rail disconnect system. Components shown include the basin, cover, lifting cable, discharge fitting, inlet, float tree assembly, and a Z-rail disconnect system. A simplex control panel is also depicted.
• Figure 5: This figure shows dimensional details of the pump and basin, including diameter and height measurements.
• Figure 5A: This diagram depicts a typical system layout for a pressure sewer application. It shows the main line, curb/valve box, shut-off valve, check valve, anti-siphon valve, and the discharge line connecting to the positive displacement grinder pump.

All installations must comply with applicable electrical and plumbing codes, including the National Electrical Code and local, regional, and state plumbing codes.

Outdoor Prepackaged System Installation Instructions

These instructions are for factory prepackaged outdoor progressing cavity grinder systems. They can also serve as a guideline for field-assembled systems.

1. Review Figure 4 on page 5 and the system components to familiarize yourself with the packaged grinder pump system and determine installation locations for power feed, inlet pipe, and discharge pipe.
2. Remove the unit from packing. Prepackaged systems are preassembled; minimal field assembly is required. Float switches are factory set; the alarm switch should be 2 inches above the pump 'on' level.
3. Float switches are tied for shipping. Cut cable ties to ensure proper operation. Verify float switch settings are appropriate for your application and will not hang up inside the basin. This is the responsibility of the installing contractor.
4. Dig a hole for the basin, ensuring it is at least 24 inches larger in diameter than the basin for 12 inches of backfill all around. The depth should allow for 12 inches of compacted backfill or 6 inches if a concrete pad is used. Ensure the cover extends above finished grade and the grade slopes away from the unit. Use 1/8"-3/4" pea gravel or 1/8"-1/2" crushed stone for backfill and subbase. Refer to basin installation instructions for specifics.
5. Exercise caution during excavation to avoid underground utilities and existing structures. Locate the hole at least ten feet from adjacent structures, with additional distance potentially needed away from loading areas.
6. The inlet fitting location is determined by the inlet pipe depth and requires 4" pipe. Install the inlet on the side of the basin opposite the float switches. Drill a 5" hole at the correct elevation, center the hub, and attach it using provided sealant and hardware.
7. Backfill and compact the excavation bottom. Set the basin in the hole and connect the 4" inlet pipe to the inlet hub.
8. Connect the discharge piping to the 1-1/4" threaded fitting in the basin sidewall.
9. Connect the pull rod to the pump assembly and the lift cable to the pump's top. Lower the pump into the basin, ensuring the discharge pipe bracket slides into the disconnect fitting.
10. Pour a concrete anchor around the system. Fill the basin with water during pouring to minimize movement. Backfill around the basin with specified media, avoiding damage to components. Refer to the Basin installation reference guide for details.
11. The grinder basin is a sewage holding tank. Vent connections must comply with all national, state, and local plumbing codes.
12. Dig an electrical conduit trench at least 18 inches deep, following all applicable NEC codes. Connect wiring to the junction box per the manual's instructions and diagram. Use the provided potting kit and sealant for the junction box.
13. If a control panel is used, install it within sight of the system. Connect float switches and pump cords according to the "Pump Wiring Instructions" and the panel's wiring diagram.
14. Remove any debris from the basin. Test the system for proper operation using clean water.
15. Seal and secure the lid using proper bolts and sealant if the lid lacks a gasket.
16. Add water to the basin and test for leaks and proper pump operation.
17. Record system start-up data for future reference.

Operation

GENERAL

Zoeller pumps are factory lubricated and tested, requiring minimal pre-start-up maintenance. Maximum operating temperature for pump liquid is 130°F (54°C). These units are designed only for sanitary sewage and are not intended for dewatering contaminated liquids with heavy or abrasive materials, as this will void the warranty.

NAMEPLATE DATA

The pump's nameplate provides construction details. Record the model number and date code on page 1 in the "Owner's Information" section.

SHORT TERM STORAGE

If the pump is not in use:

• Drain the pump housing by laying it horizontally with the discharge down, then stand it on its legs.
• Store the pump indoors or cover it with protective covering.
• Seal the terminal ends of wire leads in a plastic bag.
• Spray unpainted surfaces with rust-inhibiting oil.
• Rotate the impeller every six months to keep the seal lubricated and prevent a permanent set.

If the panel is to be stored:

• Store the panel indoors in its shipping box.
• Seal all openings.
• Store upright.
• Do not stack items on the panel.

START-UP PROCEDURE

Before operation, check the following:

• Pit is clean.
• Electrical boxes are dry and securely installed.
• Floats are positioned properly.
• Discharge valves are open.
• Adequate water level in the basin for pump submersion.

After verifying the above:

• Ensure pump power cables and control floats are properly installed and voltage is verified.
• Confirm conduit connections to the panel are properly sealed.
• With the pump submerged and discharge valve open, start the unit manually. If flow is low, the pump may be air-locked. Jog the unit several times to expel trapped air.
• Have a qualified electrician measure voltage and current while the pump is running. Record these readings in the "Owner's Information" section.

ADJUSTMENT PROCEDURE

• Pumps: No adjustments are required.
• Floats: Refer to system drawings or panel wiring schematics for float switch settings. The 'off' switch should deactivate the pump before the water level drops to the pump's midpoint.
• Valves: Discharge valves should be fully open. Operating with partially closed discharge valves can damage the valve. Check for an anti-siphon valve in pressure sewer systems.

SHUTDOWN PROCEDURES

If a system is shut down for more than six months:

• Pumps: If the pit remains dry, the pump can stay in the pit (do not run dry). If the pit remains wet, remove and store the pump as described in Short Term Storage.
• Panels: Seal all panel openings to prevent moisture and dust ingress. Inspect for moisture and loose connections before restarting.
• Valves: Consult the valve/actuator supplier for specific instructions.

Cutter Maintenance

1. Disconnect and lock out all power circuits before servicing. The cutter and disc can be removed and sharpened by grinding. Removal can be done in the field by positioning the pump horizontally to access the intake. For seal or other repairs, the pump must be removed and serviced by a qualified technician or authorized service center.
2. Clean the cutter and disc assembly thoroughly. Tilt the pump vertically to ensure end play is removed. Check and record the clearance between the cutter and disc using a feeler gauge; the correct running clearance is 0.007" to 0.012".
3. With the pump horizontal, heat the hex head bolt in the center of the cutter with a propane torch to 350°F to soften the thread lock sealer. Remove the bolt counterclockwise, using a wood block to prevent the cutter from turning. Pull the cutter from the shaft and remove spacer shims.
4. Remove the six cap screws holding the disc and remove the disc from the pump.
5. The disc and cutter can be replaced or resurfaced by grinding to a 32 micro finish. Do not attempt field grinding; send parts to a qualified machine shop. The disc, cutter, and shims are a matched set. Measure the disc before and after resurfacing.
6. After resurfacing, the disc and cutter must be flat within 0.001". If the disc was surface ground, remove shims to compensate for material removed. The final running clearance must be between 0.007" and 0.012". Ensure pump is vertical and end play is removed before measuring.
7. Clean the pump bottom where the disc is located and replace the disc and retainer screws. Torque screws to 63-67 in-lbs. Replace the cutter with correct shims. Install the washer and torque the hex head bolt to 71-75 in-lbs, applying Loctite 262 or equivalent thread-lock sealant to the bolt threads. Check running clearance with the pump vertical and end play removed; it must be between 0.007" and 0.012" for efficient grinding.
8. Check the oil in the motor housing before reinstalling. If the oil appears milky or burnt, contact the factory. The oil level should be even with the fill plug when the pump is upright. Add insulating oil supplied by the factory if needed.

Figure 7: Illustrates the cutter and disc assembly. To remove the cutter, heat the center bolt to 350°F to loosen the thread sealant. The cutter and disc should be ground to a 32 micro finish, be flat within 0.001" T.I.R., and have a gap between 0.007" and 0.012".

General Maintenance

Repair and service should be performed by a Zoeller Authorized Service & Warranty Center or Customer Care Center only.

SAFETY PROCEDURES

• WARNING: Always disconnect the pump and panel from the power source before handling.
• WARNING: Never enter a basin until it has been properly vented and tested. Use a harness with a safety rope. Sewage gases (methane, hydrogen sulfide) can be highly poisonous.
• Installation and checking of electrical circuits and hardware should be performed by a qualified electrician.
• WARNING: The pump must never be lifted by its power cord.
• NOTICE: The unit must be cleaned and disinfected, inside the pumping chamber and all exterior surfaces, prior to servicing.

GENERAL SYSTEM INSPECTION

Before system operation, a qualified technician should perform an inspection. Wiring and grounding must comply with the National Electrical Code and applicable local codes.

LUBRICATION PROCEDURES

No lubrication is required. For pumps stored over six months, refer to the short-term storage procedure in the Operation section.

PREVENTIVE MAINTENANCE

Preventive maintenance ensures a long service life. Suggested schedule:

• Every Year: Inspect basin for grease accumulation. Check float operation. Listen for proper check valve operation.
• Every 8 Years or 2,000 Hours: Remove pump, inspect, and service using a Zoeller rebuild kit. Flush and clean the basin.

Service Checklist

WARNING: Before servicing, always shut off the main power circuit. Wear insulated protective shoes and do not stand in water. For flooded conditions, contact your local electric company or a qualified electrician to disconnect electrical service.

WARNING: Grinder pumps contain pressurized, hot oil. Allow 2-1/2 hours after shut down before servicing.

If the checklist does not resolve the problem, consult the Product Support Department. Do not attempt to service or disassemble the pump yourself. Service must be performed by a Zoeller Authorized Service Station. Find a service locator at https://www.zoellerpumps.com/en-us/where-to-buy/service-locator.