Zoeller 820 User manual

1
© Copyright 2008 Zoeller Co. All rights reserved.
Congratulations on the purchase of the Zoeller 820 Series
submersiblegrinderpump.ForoversixtyyearsthenameZoeller
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
Model Number: ______________ Date Code: _______________
Automatic  Nonautomatic
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
MODEL 820 SUBMERSIBLE GRINDER UNITS
in the ownership of a Zoeller submersible wastewater prod-
uct. Please read and review this manual before installing the
product. Follow the steps in this manual for a proper start-up.
Many items contained within, when followed correctly, will not
only ensure a long and problem-free life for the pump, but also
save time and money during installation. Reference FM1531
for replacement parts on 820 Series Grinder Pumps. Should
further assistance be necessary please call our Technical
Service Department at 1-800-928-PUMP (7867).
Owner’s Information
Table of Contents
Safety Instructions ....................................................................... 1
Limited Warranty .......................................................................... 2
Preinstallation Checklist.............................................................. 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
Safety Instructions
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MA-
JOR 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.
INDICATESSPECIALINSTRUCTIONSWHICHARE
VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS
PRIOR TO PERFORMING ANY WORK ON THIS PUMP.
MAINTAIN ALL SAFETY DECALS.
PUMPS WITH THE “UL” MARK AND PUMPS WITH THE “US”
MARK ARE TESTED TO UL STANDARD UL778. CSA CERTIFIED
PUMPS ARE CERTIFIED TO CSA STANDARD C22.2 NO. 108.
REFER TO WARRANTY ON PAGE 2.
SECTION: 6.10.020
FM2167
1008
Supersedes
0906
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
[phone] • 1 (800) 928-PUMP • FAX [phone]
visit our web site:
www.zoeller.com

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© Copyright 2008 Zoeller Co. All rights reserved.
LIMITED WARRANTY
1. Zoeller 820 Grinder Pumps are designed for grinding
and pumping sewage from single family residential
and commercial duty sewage pump stations. The
pump is intended to grind and pump reasonable
quantities of items normally found in residential
sewage.
2. Zoeller 820 Grinder Pumps can be installed in
new applications or as a direct replacement for
any grinder application of like size and capacity.
3. Refer to the Zoeller models 810 and 815 when
retrofitting existing positive displacement pump
installations.
Applications
all applications other than raw sewage 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 Service 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 APARTICULAR
PURPOSE AND OF MERCHANTABILITY SHALL BE LIMITED
TO THE DURATION 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 specific legal rights and you may also
have other rights which vary from state to state.
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
inspectionsdetermine 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 obli-
gated 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, misap-
plication, neglect, alteration, accident or act of God; 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 deriva-
tives (oil, gasoline, solvents, etc.), or other abrasive or corrosive
substances, wash towels or feminine sanitary products, etc. in

3
© Copyright 2008 Zoeller Co. All rights reserved.
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.
1. Make sure pump connection contains a ground terminal.
The power cord on all Zoeller Grinder Pumps contains a green
conductorfor grounding to help protect you againstthepossibility
of electric shock.
2. Make certain the receptacle 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
circuitis recommended, sized accordingtothe National Electrical
Code, for the current shown on the grinder pump nameplate.
4. Automatic pumps have three prong plug caps and must
be connected to a three prong grounded receptacle with
ground fault circuit interrupter (GFCI).
5. Foryour 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.
6. Installation of electrical hardware and checking of control pan-
els and circuits should be performed by a qualified licensed
electrician.
7. Riskofelectrical shock-Thesepumps havenotbeen investigated
for use in swimming pool areas.
8. According to the state of California (Prop 65), this product
contains chemicals known to the state of California to cause
cancer and birth defects or other reproductive harm.
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. If Grinder pumps are operated by control panels with vari-
able level float control switches, it is the responsibility of the
installing party 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 24" in diameter for simplex
systems and 36" in diameter for duplex systems or larger.
4. Grinderinstallations shouldbe checkedyearly fordebris 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 130°F,
(54°C).
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 conduit. Failure to properly install
this sealant material could void warranty.
SEE BELOW FOR LIST OF WARNINGS SEE BELOW FOR LIST OF CAUTIONS
Electrical Data
Amps Winding
Locked KVA Resistance
Model BHP Mode RPM Voltage Phase Hertz Full Load In Air Shut Off Rotor Code Line-to-Line
WD820 2 Auto 3450 230 1 60 13.7 7.6 10.2 57 H 1.2 / 2.0
E820 2 Nonauto 3450 230 1 60 13.7 7.6 10.2 57 H 1.2 / 2.0
WH820 2 Auto 3450 200 1 60 15.5 8.8 11.0 61.6 H .8 / 2.0
I820 2 Nonauto 3450 200 1 60 15.5 8.8 11.0 61.6 H .8 / 2.0
Do not attempt to turn star cutter
located on bottom of the unit with fingers. Use a
wrench when checking or removing star cutter.

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© Copyright 2008 Zoeller Co. All rights reserved.
1 1/4" - 11 1/2 N.P.T.
18 5/8
5
6 1/2
4
4
7 5/8
4
General Information
GRINDER PUMP DESCRIPTION
1. Pumps are constructed of class 30 cast iron with powder
coated epoxy protection for long life when pumping sew-
age 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 in the
clockwise (looking down on the unit) direction only, see
Fig. 6 on page 11.
2. Pump motors are single phase design. Single phase
motors require a starting relay, starting capacitor and
a run capacitor. These items are located in the switch
case on the pump.
3. The 820 Grinder Pump is a single seal design and does
not have sensor wires.
4. Automatic reset thermal overload protection is provided
in the pump motor.
FIELD ASSEMBLED INSTALLATION
1. Installation and piping instructions are included with
the 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 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. 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 (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 3/16" diameter hole).
SK1621
FIGURE 1.
PUMP PERFORMANCE CURVE
MODEL 820
GALLONS
LITERS 0
0
10
4
8
20
30
32
TOTAL DYNAMIC HEAD
70
16
12 40
50
20
60
24 80
28 90
100
METERS
FEET
110
20
40
5 10 15
80
25
120
30 35
160
40 45 50
FLOW PER MINUTE
Feet Meters Gal. Liters
20
30
50
40
15.2
9.1
12.2
6.1
107 ft.(32.6m)Shut-off Head:
3.010
18.360 16343
21.370 13636
24.480 10227
30.5100 267
51.5
MODEL
90 27.4 16.763
46174
46174
46174
46174
46174
46174
820
010440 010440

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© Copyright 2008 Zoeller Co. All rights reserved.
MIN. "OFF" LEVEL
RUN
O.L.
MOTOR
(3)
BLUE RED
BLACK
GREEN
L1 L2
START
(1) (2)
YELLOW
RED
R
RELAY
(WHITE) (BLACK)
YELLOW
(BROWN)
BLUE
1
5
2
WHITE
CAPACITOR
START
WHITE
BLACK
BLACK
CAPACITOR
RUN
RUN
O.L.
MOTOR
(3)
BLUE RED
FLOAT
BLACK
GREEN
L1 L2
START
(1) (2)
YELLOW
RED
R
RELAY
(WHITE) (BLACK)
YELLOW
CAPACITOR
(BROWN)
BLUE
WHITE
1
5
2
BLACK
WHITE
CAPACITOR
START
RUN
BLACK
WHITE
BLACK
22" MAX.
5" MIN.
20 AMP SWITCH (WD & WH MODELS)
FOR YOUR PROTECTION, ALWAYS DISCONNECT THE PUMP FROM ITS POWER SOURCE BEFORE HANDLING.
Single phase automatic pumps are supplied with a 3-prong grounded plug to help protect you against the possibility of electrical shock.
DO NOT UNDER ANY CIRCUMSTANCES REMOVE THE GROUND PIN. The 3-prong plug must be inserted into a mating 3-prong
grounded receptacle. If the installation does not have such a receptacle, it must be wired and grounded in accordance with the National Electri-
cal 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.
Pump Wiring Instructions
Installation and checking of electrical circuits and hardware should be performed by a qualified licensed electrician.
010415
AUTOMATIC
WIRING DIAGRAM
MODELS WD820 and WH820
010443
NONAUTOMATIC
WIRING DIAGRAM
MODELS E820 and I820
FIGURE 4.
FIGURE 5.
Models WD & WH are fully automatic. A float switch is included and factory wired in the pump circuit to provide automatic operation once the float switch is
secured properly to the outlet pipe. Use the diagram above to secure the float 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”.
Determining Pumping Range
in Inches (1 inch - 2.5 cm)
Tether Length 5 10 15 20 22
Pumping Range 9 13.5 18 22 24
Use only as a guide. Due to weight of
cable, pumping range above horizontal
is not equal to pumping range below
horizontal.Rangesarebasedon testing in
nonturbulentconditions.Rangemayvary
duetowatertemperatureandcordshape.
As tether length increases, so does the
variance of the pumping range.
Note: Failure to keep within proper tether limits may
prevent reliable switch operation.
Note: Cable must be mounted in horizontal position. SK2304
min. max.
SK305D