Zoeller 810 Series User manual

1
© Copyright 2017 Zoeller®Co. All rights reserved.
Model Number: ______________ Date Code: _______________
Simplex  Duplex
Packaged System Field Assembled System
Job Name: ____________________________________________
Distributor: ____________________________________________
Date of Purchase: _________ Zoeller S/O No.: ______________
Contractor: ____________________________________________
Date of Installation: ____________________________________
System Readings During Start-up: Voltage _____ Amps ______
OWNER’S MANUAL
MODELS 810 & 815 PROGRESSING CAVITY GRINDER PUMPS
in the ownership of a Zoeller submersible wastewater product.
Pleasereadandreviewthismanualbeforeinstallingtheproduct.
Follow the steps in this manual for a proper start-up. Many items
contained within, when followed correctly, will not only ensure
a long and problem-free life for the pump, but also save time
and money during installation. Reference FM2435 and FM2436
for replacement parts on 810 and 815 Series Progressing
Cavity Grinder Pumps respectively. Should further assistance
be necessary please call our Technical Service Department at
1-800-928-PUMP (7867).
Owner’s Information
Congratulations on the purchase of a Zoeller submersible
progressing cavity grinder pump. Since 1939 the name Zoeller
has represented the standard for submersible dewatering and
sewage pumps. The same high quality workmanship and easy
maintenance design has been incorporated into this line of
heavy-duty submersible progressing cavity grinder pumps. This
Zoeller pump will provide years of trouble-free service when
installed according to the manufacturer’s recommendations.
This manual incorporates the installation, operation,
maintenance, and service instructions into one document to aid
Table of Contents
Safety Instructions ....................................................................... 1
Limited Warranty, Checklist and Application..........................2-3
General Information ..................................................................... 3
Pump Wiring Instructions............................................................ 4
Typical Outdoor Prepackaged System ....................................... 5
Installation and Operation Instructions...................................... 6
Maintenance.................................................................................. 7
Service Checklist.......................................................................... 8
FM2458
0117
Supersedes
1215
NOTICE TO INSTALLER: Instructions must remain with installation.
Product information presented
here reflects conditions at time
of publication. Consult factory
regarding discrepancies or
inconsistencies.
MAIL TO: P.O. BOX 16347 • Louisville, KY 40256-0347
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961
TEL: [phone] • 1 (800) 928-PUMP • FAX: [phone]
Visit our web site:
zoellerpumps.com
Safety Instructions
REFER TO WARRANTY ON PAGE 2.
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.
Warns of electrical shock hazards that can cause serious
personal injury, death or major property damage.
Identies any terminal which is intended for connection
to and 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 REVIEWALLINSTRUCTIONSAND WARNINGS PRIOR
TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
CAUTION
Register your
Zoeller Pump Company
Product on our website:
http://reg.zoellerpumps.com/

2
© Copyright 2017 Zoeller®Co. All rights reserved.
or other abrasive or corrosive substances, wash towels or feminine sanitary
products, 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,
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 FORAPARTICULAR PURPOSE AND OF MERCHANTABILITY
SHALLBELIMITEDTOTHEDURATION OF THE EXPRESSED WARRANTY.
Some states do not allow limitations on the duration of an implied warranty,
so the above limitation may not apply to you. Some states do not allow the
exclusion or limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
This warranty gives you specic legal rights and you may also have other rights
which vary from state to state.
Limited Warranty
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, every new product to be free from defects in material and
workmanshipundernormaluseandservice,whenproperlyused 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,
subjectedtomisuse,misapplication,neglect,alteration,accidentor 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.),
Applications
Preinstallation Checklist
1. Inspect your progressing cavity grinder pump. If the unit has been
damaged in shipment, contact your dealer before installing. Do Not
remove the test plugs in the cover nor the motor housing.
2. Carefully read all literature to familiarize yourself with details regarding
installation and use. Retain materials for future reference.
1. Make sure pump connection contains a ground terminal. The power
cord on all Zoeller Progressing Cavity 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 National Electrical Code, for the
current shown on the grinder pump nameplate.
4. For your protection, always disconnect the power source to the
grinder pump before handling. All grinder pumps must be properly
grounded and wired in accordance with the “National Electrical Codes”
and all local codes and ordinances.
5. Installation of electrical hardware and checking of control panels
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. Prop65 Warning for California residents: Cancer and Reproductive
Harm- www.P65Warnings.ca.gov.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
Progressing cavity grinder pumps are designed
for pressure sewer applications. A UL listed and CSA certied pres-
sure relief valve must be installed in the system to prevent excessive
pressure buildup.
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 in the circuit bringing
electrical power to the pump.
3. The progressing cavity grinder pumps are operated by 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 at least 24" in diameter for simplex systems and 36" or larger in
diameter for duplex systems.
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 a Zoeller Authorized Service
and Warranty Center or Customer Care Center only.
5. Maximum operating temperature must not exceed 130°F,
(54°C).
6. Do not operate an unsubmerged progressing cavity pump. Dry pump
operation may damage the hydraulic stator due to lack of lubrication.
Do not run dry.
7. To ensure proper pump operation, a swing or apper style check
valve must be installed in the pump discharge line. A faulty or
non-functional check valve when combined with a pressure sewer
may prevent the pump from starting.
Do not attempt to turn the cutter blades
located on bottom of the unit with ngers. Use a wrench
when checking or removing the cutter.
1. Zoeller Progressing Cavity 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 810 and 815 Progressing Cavity Grinder Pumps can be
installed in new applications or as a replacement for another grinder
of like size and capacity.
3. The 810 and 815 can be installed in a Prepackaged Job Ready System
or may be used in a Field Assembled basin package. Page 5 shows
a couple of the Prepackaged Systems. Field Assembled Systems are
discussed on page 3.
4. Zoeller 810 and 815 Grinder Pumps can be retrotted to existing
positive displacement pump installations.

3
© Copyright 2017 Zoeller®Co. All rights reserved.
Recommended Limits of Application for Progressing Cavity Grinder Pumps
Simplex Station Duplex Station
Model HP Homes GPD Homes GPD
810 1 1 400 2 800
815 2 1 400 2 800
These recommended application limits are for pump stations pumping to a gravity main. Low-pressure collection systems should be designed with
a pump located at each house. For applications where a lift station would handle more than 2 homes, consider the 840 or 71 Series grinder pump.
For applications where a lift station would handle more than 60 homes, a solids handling type pump should be considered.
General Information
FIGURE 1.
PROGRESSING CAVITY
GRINDER PUMP DESCRIPTION
1. Pumps are constructed of class 30 cast iron protected with powder
coated epoxy for long life when pumping sewage in submersible
applications. The cutter assembly is comprised of stainless steel
components hardened to a value of 55-60 on the Rockwell C scale;
a star shaped cutter and a precision ground at disk. Cutting action
takes place with the rotation of the cutter blades at 1750 RPM against
the stationary cutter plate (see page 7).
2. The cutter mechanism on the model 810 & 815 is single directional.
3. Pump motors are single phase. Single phase motors require a run
capacitor, which is mounted in the the upper cap of the pump (ref.
page 4). The units have an internal thermal overload.
4. The 810 & 815 progressing cavity grinder pumps are single seal.
5. The pressure relief valve provides motor protection under inadvertent
shut-off head condition.
6. A progressing cavity grinder pump is an intermittent duty pump designed
for pumping sanitary sewage. It is not a dewatering or trash pump.
FIELD ASSEMBLED INSTALLATION
1. Installation and piping instructions are included with the control panel, 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 for more
information on system installation.
3. All electrical connections including pump to control box and power supply
to control panels must comply with the “National Electrical Code” and
applicable local codes. Conduit and panel enclosure openings must have
a gas-tight seal. Installation of electrical panels and connections should
be made by a qualied licensed electrician.
4. A properly sized disconnect switch, supplied by others, shall 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 Fig. 5A).
018330
0
2 4 6 8 10 12 14 16
0
20
40
60
80
100
120
140
160
180
200
260
PUMP PERFORMANCE CURVE
MODEL 810/815
8
16
24
32
40
48
56
64
GALLONS
LITERS
METERS
FEET
TOTAL DYNAMIC HEAD
FLOW PER MINUTE
220
240
72
20 40 60
10
20
30
40
50
60
70
80
90
100
110
0
PSIG
TOTAL DYNAMIC HEAD
2 HP
1 HP
LOW PRESSURE SEWER
TYPICAL
OPERATING
RANGE
DESIGN PRESSURE (150 FT OR LESS)
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
MODEL
Feet
810
Meters Gal. Liters
MODEL
815
5
10
20 6.1
3.0
1.5 14.6 55
40
60 18.3
12.2
80
100 30.5
24.4
120 36.6
140
150 45.7
42.7
55
53
50
47
44
41
38
36
34
14.4
14.0
13.2
12.5
11.7
10.9
10.1
9.4
9.0
160 48.8
180 54.9
200 61.0
220 67.1
240 73.2 5.5
33
30
27
24
21
8.6
7.8
7.0
6.3

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© Copyright 2017 Zoeller®Co. All rights reserved.
Pump Wiring Instructions
FOR YOUR PROTECTION,ALWAYS DISCONNECT THE PUMPFROM 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.
FIGURE 3A. Models E810
and E815 Wiring Diagram
002397
254 mm (10") MAX.
127 mm (5") MIN.
FIGURE 2. Pump Control Switch Installation
Use the diagram above to secure the oat switch properly and obtain the proper tether to customize the on-off cycle to each application. Note the
minimum off level shown above. On Prepackaged Systems, the tether length is set at 5”.
Note: Failure to keep within proper tether
limits may prevent reliable switch operation.
Note: Cable must be mounted in horizontal
position.
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
Use only as a guide. Due to weight
of cable, pumping range above
horizontal is not equal to pumping
range below horizontal. Ranges are
based on testing in nonturbulent
conditions. Range may vary due to
water temperature and cord shape.As
tether length increases, so does the
variance of the pumping range.
Tether Length (inches) 5 10
Pumping Range (GPM) 9 13.5
min. max.
SK305D
SK2651
ALARM FLOAT
PUMP CONTROL
FLOAT TREE
FLOAT
406 mm (16")
MIN. OFF
Electrical Data
Amps KVA
Code
Winding
Resistance
Line-to-Line
Model BHP RPM Voltage Phase Hertz Full Load Shut Off Locked
Rotor
E810 1 1750 230 1 60 7.0 7.0 24.5 G 2.3 / 2.0*
E815 2 1750 230 1 60 10.5 10.5 44.0 B 1.80 / 1.60*
RE810 1 1750 230 1 60 7.0 7.0 24.5 G **
RE815 2 1750 230 1 60 10.5 10.5 44.0 B **
* Line to line reading from the electrical load will only reect the run winding resistance. Start winding resistance can only be measured after
removing the cover.
** Start & run winding resistance can only be measured after removing the cover and checking at the through wall terminals.
152554
RUN
O.L.
MOTOR
(3)
BLUE RED
WHITE
BLACK
GREEN
L1 L2
START
(1) (2)
YELLOW
BLUE RED
CAPACITOR
(WHITE) (BLACK)
(BROWN)
FIGURE 3B. Models RE810
and RE815 Wiring Diagram
(932 Replacement Grinder
Assembly w/ Manual Run)
RUN
O.L.
MOTOR
(3)
BLUE RED
GREEN
START
(1) (2)
YELLOW
BLUE RED
CAPACITOR
(WHITE) (BLACK)
WHITE
BLACK
RED
YELLOW
BLUE
ORANGE
R
RELAY
4
60
1
R
2
64
5
GE RELAY
(BROWN)
1)
NOTES:
INSULATORS REQUIRED ON GE RELAY TERMINALS 2 & 5;
OMRON RELAY TERMINALS 1 & 4.

5
© Copyright 2017 Zoeller®Co. All rights reserved.
All installations must comply with all applicable electrical and plumbing codes, including but not limited to the National Electrical Code, local,
regional and/or state plumbing codes, etc.
Typical Outdoor Grinder Pumping System Installations
FIGURE 4A - PACKAGED SYSTEM WITH
FLEXIBLE HOSE DISCONNECT
24" (60.9 cm)
MINIMUM
ANTI FLOATATION RING
1-1/4" NPT BRASS CHECK VALVE
SHUT-OFF BALL VALVE
ALARM FLOAT
PUMP CONTROL FLOAT
12" (30.4 cm) MIN. OFF LEVEL
FIBERGLASS BASIN
1/8" (3 mm) 302 STAINLESS
STEEL LIFTING CABLE
1-1/4" FLEXIBLE
DISCONNECT FITTING
1-1/4" BULK HEAD
DISCHARGE FITTING
24" (60.9 cm)
SOLID FIBERGLASS
COVER
GROMMET SEAL
4" INLET W-SEAL
(FIELD INSTALLED)
MINIMUM
60" (152 cm)
DISCHARGE HOSE
HIGH WATER ALARM
(NOT INCLUDED)
WATERTIGHT "QWIK BOX"
(NOT INCLUDED)
FLOAT TREE
48" (122 cm)
72" (183 cm)
1-1/4" SCH 80 PVC PIPE
BRASS ANTI-SIPHON VALVE
1-1/4" MALE NPT THREAD X SLIP FITTING
1-1/4" MALE NPT THREAD X
SLIP FITTING
2" PVC ELECTRICAL PIPE
SK2540
SK2533
6-5/8” (143 mm)
8-3/8”
(213 mm)
5-1/4”
(133 mm)
4-3/8”
(111 mm)
10-1/2”
(267 mm)
DIA.
22-3/8” (568 mm)
4” (103 mm)
FIGURE 5
1 1/4" NPT
ANTI-SIPHON
VALVE
1 1/4" NPT CHECK VALVE
DISCONNECT
1 1/4" SHUT OFF VALVE
(HOME OWNER)(JWA)
CURB/VALVE
BOX
CHECK VALVE
SHUT OFF
VALVE
MAIN
OPTIONAL LOCATION
1 1/4" NPT ANTI-SIPHON
VALVE
POSITIVE DISPLACEMENT
GRINDER PUMP
1 1/4" DISCHARGE LINE
FIGURE 5A
SK2810
1.25 BALL VALVE
SILENCE
INPUT1
POWER
PIPE SEAL
24" MIN.
4" RUBBER INLET
84" 33-1594-36"D
(FIELD INSTALLED)
72" 33-1597-24"D
60" 33-1598-24"D
ANTI-FLOTATION
FIBERGLASS
DISCHARGE FITTING
1-1/4" BULK HEAD
ALARM FLOAT
VALVE
1-1/4" BRASS CHECK
DISCHARGE PIPE
1-1/4" GALVANIZED
HIGH LEVEL
1-1/4" BRASS BALL VALVE
FIBERGLASS BASIN
"ON - OFF" FLOAT
PUMP CONTROL
PIPE AND FITTINGS
1-1/4" PVC SCH 80
FLOATTREE ASSEMBLY
STEEL LIFTING CABLE
1/8" 302 STAINLESS
1-1/4" PVC PIPE
FLANGE
3/4" GALV GUIDE RAIL
BRASS ANTI-SIPHON VALVE
96" 33-1596-36"D
1-1/4" H X 1-1/4" Z-RAIL
DISCONNECT SYSTEM, EPOXY
COATED DUCTILE IRON
2"TO 1-1/4" REDUCER
HIGH WATER ALARM
OR SIMPLEX CONTROL PANEL
(FIELD INSTALLED)
R
LOUISVILLE,KY
SOLID FIBERGLASS COVER
SK3091
FIGURE 4B - PACKAGED SYSTEM WITH
Z-RAIL®DISCONNECT SYSTEM