Zoeller Models 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 line of heavy-duty pumps incorporates the same high quality workmanship and easy maintenance design, providing years of trouble-free service when installed according to manufacturer recommendations.

This manual provides comprehensive instructions for installation, operation, maintenance, and service. Please read and follow all steps for proper start-up and long-term performance.

For replacement parts, refer to FM2435 and FM2436 for the 810 and 815 Series. For assistance, contact Zoeller Technical Service at 1-800-928-PUMP (7867).

Safety Instructions

[Safety Alert Symbol] 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] Signal Words:

• [DANGER]: Hazards that WILL cause serious personal injury, death, or major property damage.
• [WARNING]: Hazards that CAN cause serious personal injury, death, or major property damage.
• [CAUTION]: 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.
• [Symbol for Grounded Terminal]: Identifies terminals for protection against electrical shock in case of a fault.
• [Read Operator's Manual Symbol]: Read operator's manual.
• [IMPORTANT INSTRUCTIONS SYMBOL]: Indicates special instructions that 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.

Owner's Information

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 ______

Limited Warranty

Zoeller warrants products to be free from defects in material and workmanship for two years from the date of purchase, under normal use and service. Proof of purchase is required. Defective parts will be repaired, replaced, or remanufactured at Zoeller's option. This warranty does not cover products that have been disassembled, misused, misapplied, neglected, altered, subjected to accidents, or exposed to abrasive or corrosive substances. It also excludes products not installed or maintained according to instructions.

This warranty is in lieu of all other warranties, expressed or implied. Zoeller expressly disclaims liability for special, consequential, or incidental damages. For warranty service, contact Zoeller Pump Company at 3649 Cane Run Road, Louisville, Kentucky 40211, Attention: Customer Support Department.

Some states may have limitations on implied warranties or consequential damages.

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

Preinstallation Checklist

1. Inspect the pump for damage during shipment. Contact your dealer if damage is found. Do not remove test plugs or motor housing.
2. Read all literature thoroughly for installation and use details. Retain for future reference.
3. Ensure the pump connection has a ground terminal. The power cord has a green conductor for grounding.
4. Verify the electrical service is within reach of the power supply cord.
5. Ensure panels and branch circuits have properly sized fuses and circuit breakers. An independent power circuit, sized according to the National Electrical Code (NEC) for the pump's nameplate current, is recommended.
6. Always disconnect the power source before handling the pump. Ensure all pumps are properly grounded and wired according to NEC and local codes.
7. Electrical hardware installation and circuit checking should be done by a qualified licensed electrician.
8. Risk of electrical shock: These pumps have not been investigated for use in swimming pool areas.
9. California Proposition 65 Warning: Cancer and Reproductive Harm - visit www.P65Warning.ca.gov.
10. 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.
11. Ensure the power source can handle the pump's electrical requirements as indicated on the nameplate.
12. Install a disconnect switch in the circuit supplying power to the pump.
13. Float control switches must be secured to prevent them from hanging up on the pump or basin components. Use rigid pipe and fittings. Minimum basin diameters: 24 inches for simplex, 36 inches for duplex.
14. Check grinder installations yearly for debris that may interfere with float switch operation. Repair and service (except cutter assembly) should be performed by a Zoeller Authorized Service and Warranty Center.
15. Maximum operating temperature must not exceed 130°F (54°C).
16. Do not operate the pump unsubmerged; dry operation can damage the hydraulic stator.
17. Install a swing or flapper style check valve in the pump discharge line. A faulty check valve can prevent the pump from starting in pressure sewer systems.
18. [WARNING]: Do not attempt to turn cutter blades with fingers. Use a wrench for checking or removal.

Applications

Zoeller Progressing Cavity Grinder Pumps are designed for grinding and pumping sanitary sewage from submersible lift stations. They are intended for reasonable quantities of items normally found in sanitary sewage. Models 810 and 815 can be installed in new applications or as replacements. They can be used in Prepackaged Job Ready Systems or Field Assembled basin packages. They can also retrofit existing positive displacement pump installations.

Recommended Limits of Application

These limits are for pump stations pumping to a gravity main. Low-pressure collection systems should have a pump at each house. For lift stations handling more than 2 homes, consider the 840 or 71 Series. For over 60 homes, a solids handling pump is recommended.

General Information

Progressing Cavity Grinder Pump Description

1. Pumps are constructed of cast iron with powder-coated epoxy for long life. The cutter assembly features hardened stainless steel components (55-60 Rockwell C), a star-shaped cutter, and a precision ground flat disk. Cutting action occurs at 1750 RPM between the cutter blades and a stationary plate.
2. The cutter mechanism on models 810 & 815 is single directional.
3. Motors are single-phase and require a run capacitor (mounted in the upper cap). Units have internal thermal overload protection.
4. Models 810 & 815 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 dewatering or trash.

Field Assembled Installation

1. Installation and piping instructions are included with the control panel, rail system, and basin. If retrofitting to an existing rail system, accessory parts may be needed. Consult the factory.
2. Refer to indoor/outdoor prepackaged instructions for system installation details.
3. All electrical connections must comply with the NEC 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 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 shows the pump performance curve for Models 810/815 in low-pressure sewer applications (design pressure 150 ft or less). The graph plots Total Dynamic Head (in feet and meters) against Flow Rate (in gallons per minute and liters per minute). The table provides specific data points for Total Dynamic Head/Flow per Minute for both 1 HP (Model 810) and 2 HP (Model 815) pumps.

Typical Operating Range: Indicated on the graph.

Pump Wiring Instructions

[WARNING] 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.

[WARNING] 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 illustrates pump control switch installation, including float tree, alarm float, and pump control float. Proper tether length is crucial for reliable switch operation. Minimum off level is shown. For Prepackaged Systems, tether length is set at 5 inches.

Determining Pumping Range:

• Tether Length (inches): 5 min. / 10 max.
• Pumping Range (GPM): 9 min. / 13.5 max.

Note: Ranges are a guide and may vary due to water temperature and cord shape. Increased tether length increases variance.

Electrical Data

* Line-to-line readings reflect run winding resistance. Start winding resistance requires cover removal.

** Start & run winding resistance requires cover removal and checking at through-wall terminals.

Wiring Diagrams

Figure 3A shows the wiring diagram for Models E810 and E815, illustrating connections for the motor, capacitor, and switches.

Figure 3B shows the wiring diagram for Models RWD810 and RWD815 (Replacement Grinder Assembly with Integral Pump and Alarm Float).

Typical Outdoor Grinder Pumping System Installations

Figures 4A and 4B illustrate typical outdoor packaged systems with flexible hose disconnect and Z-rail disconnect systems, respectively. These diagrams show the arrangement of the pump, basin, floats, piping, and control panel.

Figure 5 shows a typical basin setup with dimensions. Figure 5A details the piping connections for a pressure sewer system, including shut-off valve, check valve, and anti-siphon valve.

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

Outdoor Prepackaged System Installation Instructions

These instructions are for factory prepackaged systems; they can serve as a guideline for field-assembled systems.

1. Review Figure 4 (page 5) and the system components. Determine installation location for power feed, inlet, and discharge pipes.
2. Remove unit from packing. Prepackaged systems require minimal field assembly. Float switches are factory-set. Alarm switch should be 2 inches above pump "on" level.
3. Float switches are tied for shipping. Cut cable ties to ensure proper operation. Verify float switch settings are appropriate and will not hang up in the basin.
4. Dig a hole for the basin: at least 24 inches larger in diameter than the basin, providing 12 inches of backfill all around. Depth should allow for 12 inches compacted backfill or 6 inches with a concrete pad. Ensure cover extends above grade and grade slopes away from the unit. Use 1/8"-3/4" pea gravel or 1/8"-1/2" crushed stone for backfill.
5. [NOTICE] Be careful during excavation to avoid underground utilities and structures. Locate the hole at least ten feet from adjacent structures.
6. Inlet fitting location depends on inlet pipe depth. Use with 4 inch pipe. Install on the side opposite float switches. Drill a 5 inch hole at the correct elevation and attach the hub using provided sealant and hardware.
7. Backfill and compact the excavation bottom. Set basin in hole and connect the 4 inch inlet pipe to the hub.
8. Connect discharge piping to the 1-1/4 inch threaded fitting in the basin sidewall.
9. Connect pull rod to pump assembly and lift cable to the pump top. Lower pump into basin, ensuring the discharge pipe bracket slides into the disconnect fitting.
10. Pour a concrete anchor around the system. Fill basin with water during pouring to minimize movement. Backfill around basin, avoiding damage to components. Refer to basin installation guide for specifics.
11. [NOTICE] The grinder basin is a sewage holding tank. Vent connection must comply with all plumbing codes.
12. Dig an electrical conduit trench at least 18 inches deep, following NEC codes. Connect wiring to the junction box per instructions and wiring diagram. Use provided potting kit and sealant.
13. If a control panel is used, install it within sight of the system. Connect float switches and pump cords per "Pump Wiring Instructions" and the panel's wiring diagram.
14. Remove any debris from the basin. Check system operation with clean water.
15. Seal and secure the lid using proper bolts and sealant if it lacks a gasket.
16. Add water to the basin and test for leaks and proper pump operation.
17. Record system start-up data.

Operation

General

Zoeller pumps are factory lubricated and tested, requiring minimal pre-start-up maintenance. Maximum operating temperature of pump liquid must not exceed 130°F (54°C). These units are for sanitary sewage only; using them for dewatering contaminated liquids will void the warranty.

Nameplate Data

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

Short Term Storage

If the pump is not in use:

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

If the panel is stored:

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

Start-Up Procedure

Before operation, check:

• 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 verification:

• Ensure pump power cables and control floats are properly installed and voltage is verified.
• Conduit connections to the panel are properly sealed.
• With adequate submergence, open the discharge valve fully. Start the unit using manual controls. 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.

Adjustment Procedure

• Pumps: No adjustments are required.
• Floats: Refer to system drawing or panel wiring schematic for desired 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. Avoid operating with partially closed valves. 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 noted in "Short Term Storage."
• Panels: Seal all openings to prevent moisture and dust. Inspect for moisture and loose connections before restarting.
• Valves: Consult the valve/actuator supplier for specific instructions.

Cutter Maintenance

[WARNING] All power circuits must be disconnected and locked out before servicing.

1. Cutter and disc can be removed and sharpened by grinding. Removal may be done in the field by positioning the pump horizontally to access the intake. For seal or other repairs, the pump must be serviced by a qualified technician or authorized service center.
2. Thoroughly clean the cutter and disc assembly. Tilt pump vertically to remove end play. Check and record cutter-disc clearance with a feeler gauge; correct clearance is 0.007" - 0.012".
3. With the pump horizontal, heat the center hex head bolt to 350°F (177°C) to soften thread lock sealer. Remove the bolt counterclockwise, using a wood block to prevent cutter rotation. Pull cutter from the shaft and remove spacer shims.
4. Remove the six cap screws holding the disc and remove the disc.
5. 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 disc before and after resurfacing.
6. After resurfacing, disc and cutter must be flat within 0.001". If the disc is ground, remove shims to compensate for material removed. Final running clearance must be 0.007" - 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 disc and retainer screws (torque to 63-67 in-lbs). Replace cutter with correct shims. Install washer and torque hex head bolt to 71-75 in.-lbs. Apply Loctite 262 or equivalent to bolt threads. Check running clearance (0.007" - 0.012") with pump vertical and end play removed.
8. Check motor housing oil before reinstalling. Contact the factory if oil is milky or smells burnt. Oil level should be even with the fill plug when the pump is upright. Use factory-supplied insulating oil if needed.

To remove cutter: Heat the center bolt to 350°F to loosen Loctite® thread sealant.

Grind the Cutter and Disc to a 32 microfinish. Surfaces must be flat within 0.001" T.I.R. Gap must be between 0.007" and 0.012".

General Maintenance

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

Safety Procedures

• [WARNING] Always disconnect pump and panel from 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 poisonous.
• Installation and checking of electrical circuits and hardware should be performed by a qualified electrician.
• [WARNING] Pump is never to be lifted by power cord.
• [WARNING] Unit must be cleaned and disinfected before servicing.

General System Inspection

Before operation, have the system inspected by a qualified technician.

[WARNING] Wiring and grounding must comply with NEC and local codes.

Lubrication Procedures

No lubrication is required. Refer to short-term storage procedures for pumps stored for over six months.

Preventive Maintenance

Recommended for long service life:

• 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 with a Zoeller rebuild kit. Flush and clean basin.