Zoeller 840 User manual

1
© Copyright 2015 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 840, 841 & 842 SUBMERSIBLE GRINDER UNITS
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 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
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
[phone].
Owner’s Information
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.
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.
Indicatesspecialinstructionswhich arevery 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.
CAUTION
Table of Contents
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
REFER TO WARRANTY ON PAGE 2.
SECTION: W2.40.020
FM2168_Ec
0815
Supersedes
1114
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
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 USA
SHIP TO: 3649 Cane Run Road • Louisville, KY 40211-1961 USA
[phone] • 1-800-928-7867 • FAX [phone]
visit our web site:
zoellerpumps.com
50/60Hz
Register your
Zoeller Pump Company
Product on our website:
http://reg.zoellerpumps.com/

2
© Copyright 2015 Zoeller®Co. All rights reserved.
LIMITED WARRANTY
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.
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 retrot
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 retrotted
to existing positive displacement pump installations.
*Zoeller Company does not recommend a simplex station on anything over two homes in order to maintain continuous service
during unusual conditions.
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
Model Homes GPD / m3/day Homes GPD / m3/day
840 w/o reversing control 2* 800/3 10 4,000/15
840 w/ reversing control 2* 800/3 15 6,000/22
841 2* 800/3 10 4,000/15
842 2* 800/3 10 4,000/15
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.
Somejurisdictions do notallow limitations onthe duration ofan 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 specic legal rights and you may also have other rights
which vary from jurisdiction to jurisdiction.
Manufacturer warrants, to the purchaser and subsequent owner during the
warranty period, every new product to be free from defects in material and
workmanshipundernormaluseandservice, 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 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, subjectedto misuse, misapplication, neglect, alteration,accident
oruncontrollableactofnature; that has not been installed,operatedormaintained
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 otherabrasive or corrosivesubstances, wash towels,feminine

3
© Copyright 2015 Zoeller®Co. All rights reserved.
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
groundedand wired in accordance with the “NationalElectrical 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. The appliance is not intended for use by persons (including children)
with reducedphysical,sensoryormental capabilities,or lackof experience
and knowledge, unless they have been given supervision or instruction to
concerning use of the appliance by a person responsible for their safety.
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
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 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 oat 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.
Do not attempt to turn star cutter located
on bottom of the unit with ngers. Use a
wrench when checking or removing star cutter.
SEE BELOW FOR LIST OF WARNINGS
CAUTION
SEE BELOW FOR LIST OF CAUTIONS
Electrical Data
Amps KVA Code Winding Resistance
Line-to-Line
Model RPM Voltage Phase Hertz Full Load In Air Shut Off Locked Rotor
V840 2800 220 1 50 13.5 6.0 7.5 24 A 1.3 / 4.0
AK840 2800 380 3 50 4.4 1.6 2.8 18 G 9.7
I840 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5
E840 3450 230 1 60 17.2 4.0 10.9 56 F 1.3 / 4.0
J840 3450 200 3 60 12.3 3.7 7.7 54 L 1.9
F840 3450 230 3 60 10.8 3.3 6.9 42 K 2.4
K840 3450 380 3 60 6.8 3.2 4.2 28 H 4.8
G840 3450 460 3 60 5.5 1.6 3.5 21 K 9.7
BA840 3450 575 3 60 4.5 1.0 2.5 11 F 15.3
V841 2800 220 1 50 13.5 6.0 7.5 24 A 1.3 / 4.0
AK841 2800 380 3 50 4.4 1.6 2.8 18 G 9.7
I841 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5
E841 3450 230 1 60 17.2 4.0 10.9 56 F 1.3 / 4.0
J841 3450 200 2 60 12.3 3.7 7.7 54 L 1.9
F841 3450 230 2 60 10.8 3.3 6.9 42 K 2.4
K841 3450 380 3 60 6.8 3.2 4.2 28 H 4.8
G841 3450 460 2 60 5.5 1.6 3.5 21 K 9.7
BA841 3450 575 2 60 4.5 1.0 2.5 11 F 15.3
AK842 2800 380 3 50 4.4 1.6 2.8 18 G 9.7
I842 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5
E842 3450 230 1 60 17.2 4.0 10.9 56 F 1.3 / 4.0
J842 3450 200 3 60 12.3 3.7 7.7 54 L 1.9
F842 3450 230 3 60 10.8 3.3 6.9 42 K 2.4
K842 3450 380 3 60 6.8 3.2 4.2 28 H 4.8
G842 3450 460 3 60 5.5 1.6 3.5 21 K 9.7
BA842 3450 575 3 60 4.5 1.0 2.5 11 F 15.3

4
© Copyright 2015 Zoeller®Co. All rights reserved.
General Information
GRINDER PUMP DESCRIPTION
1. Pumps are constructed of class 30 cast iron protected with powder coated
epoxy protection for long life when pumping sewage in submersible
applications. Thecutterassemblyis comprised of stainless steelcomponents,
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 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.
6. A 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 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 qualied, 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 ll 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 lled (Water should come out of 5 mm (3/16")
diameter hole).
FIGURE 1.
FORYOURPROTECTION,ALWAYSDISCONNECTTHEPUMP FROMITS POWER SOURCEBEFORE 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.
60Hz
Pump Wiring Instructions
016532
HEAD CAPACITY CURVE
MODEL 840/841/842
0 40 80 120 160 200 240
70605040302010
0
10
4
8
12
16
20
130
70
60
50
40
30
20
FLOW PER MINUTE
GALLONS
LITERS
TOTAL DYNAMIC HEAD
80
90
28
24
METERS
FEET
100
110
120
32
36
840 841842
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
MODEL
Feet
Shut-off Head:
840
Meters Gal. Liters
5
10
20
30 9.1
6.1
3.0
1.5
44
45
167
170
104 ft (31.7 m)
60
50
40
90
80
70
110
100
120
12.2
15.2
18.3
21.3
24.4
27.4
30.5
33.5
36.6
42
36
30 114
136
159
23
16
10 38
61
87
3
--
-- --
--
11
125 ft (38.1 m)
841
Gal. Liters
45 170
45 170
125 ft (38.1 m)
9525
13
4
20 76
49
15
34
32
29
34
34
34
34
129
121
110
129
129
129
129
842
Gal.
34
34
129
129
Liters
52
49 185
197
43
36
28 106
136
163
19
11
415
42
72
54 204
54 204
54 204
54 204
54 204

5
© Copyright 2015 Zoeller®Co. All rights reserved.
FIGURE 2.
LEAD IDENTIFICATION WIRING DIAGRAM
SINGLE PHASE-2HP
MODEL 840
SK1367 009048
FIGURE 4.
FIGURE 3.
L1
START RELAY
START CAPACITOR
GREEN RED WHITE BLACK BLUE ORANGE
MOISTURE
SENSOR
TERMINALS
WHITE BLACK
14-618-2
REVERSE MOTOR ROTATION BY INTERCHANGING
ORANGE WIRE WITH RED WIRE.
L2
RUN CAPACITOR
GROUND SCREW
2
1
5
COMPONENT LAYOUT
PUMP
START RELAY
START CAPACITOR
RUN CAPACITOR
RED
WHITE
ORANGE
BLACK
MAIN START
PROTECTOR
BLACK
WHITE
L1 L2
T2
T1
230V AC
OR
208V AC
CONTACTOR
BLUE
2
1
5
SINGLE PHASE
MODELS 841 & 842
LEAD IDENTIFICATION WIRING DIAGRAM
START RELAY
START CAPACITOR
MOISTURE
SENSOR
TERMINALS
BLACK WHITE
L1 L2
RUN CAPACITOR
GROUND SCREW
BLACK WHITE RED GREEN
18-2 14-4
2
1
5
SK2399
RUN CAPACITOR START CAPACITOR
T1
BLACK
WHITE
T2
START RELAY
L1 L2
208V AC
OR
230V AC
CONTACTOR
YELLOW
MAIN WINDING
AUXILIARY WINDING
OVERLOAD
BLUE
5
5
ORANGE WHITE RED BLACK
43
43
21
21
GREEN
WHITE BLACK RED
MOTOR
CHAMBER
COVER
CHAMBER
2
1
5
SK2400
50/60Hz
50/60Hz
50Hz
A00648B
Locate section with appropriate phase and model number, then match lead wire color.
841
842
840
PUMP PERFORMANCE CURVE
MODELS 840/841/842
50 Hz
0
1412108642
3
21
18
15
12
9
6
TOTAL DYNAMIC HEAD
27
METERS
FEET
FLOW
10
20
30
40
50
60
70
24
80
1 2 3
L/sec
m /hr
3
MODEL
Meters Feet
1.5 5.0
2 6.6
4 13.1
6 19.7
8 26.2
12 39.4
16 52.5
842
L/secm /hr
3
3.6
3.5
3.512.7
12.7
12.7
841
L/secm /hr
3
2.1
2.1
2.17.7
7.7
7.7
Shut-off Head: 26.8m (88 ft.)26.8m (88 ft.)
20 65.6
24 78.7
7.7
7.7
7.7
7.0
4.9
2.4
2.1
2.1
2.1
1.9
1.4
0.7
12.7
12.5
11.6
8.9
5.8
2.5
3.5
3.4
3.2
2.5
1.6
0.7
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
L/secm /hr
2.810.0
840
2.79.8
2.69.2
2.48.6
2.17.8
1.65.8
1.13.8
0.41.6
----
22.6m (74.1 ft.)

6
© Copyright 2015 Zoeller®Co. All rights reserved.
DECLARATION OF CONFORMITY
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:
-- 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
HO7RN-
L1 L2 L3
T1 T2 T3
BROWN
GR AY
POWER
CORD
MAGNETIC
STARTER
CORD
SENSOR
BLACK
BLUE
BLACK
BROWN
GRAY
MOISTURE
SENSOR
TERMINALS
CONTROL PANEL - 3Ø
SENSOR
TERMINALS
TEMPERATURE
F4G1.5
GREEN/YELLOW
HO7RN-
F5G1.0
GREEN/YELLOW
3 PHASE MOTOR
MOISTURE SENSOR
L1 L2 L3
POWER CABLE
CONTACTOR
T1 T2 T3
3Ø POWER
50 Hz
SENSOR CABLE
THERMAL SENSOR
BLACK BLUE BROWN GR AY GREEN/YELLOW
HO7RN-F5G1.0
BEFORE 6/2000
NORMALLY OPEN
330K OHMS RESISTANCE
NORMALLY CLOSED
SK2859 SK2860
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
24" [610mm] *
OFF
ON
ALARM
TO CONTROL PANEL
VARIABLE LEVEL
FLOAT SWITCHES MOISTURE SENSOR CORD
3" [76mm] GROMMET SEAL
10" X 1/4" [254mm X 6mm] STEEL 16" X 1/4" [406mm X 6mm] STEEL
5/16" [8mm] 304 STAINLESS STEEL
24" X 1/4" [610mm X 6mm] STEEL
TO CONTROL PANEL
CORD SEAL
INSPECTION PLATE
BASIN COVER
PUMP PLATE
LIFTING U-BOLT
1 1/4" [32mm] PVC SLIP X SLIP
BALL VALVE
1 1/4" FEMALE NPT
CAST IRON CHECK VALVE
1 1/4" X 32" [32mm X 813mm]
GALVANIZED PIPE
1 1/2" X 8" [38mm X 203mm]
GALVANIZED PIPE
1 1/4" [32mm] GROMMET SEAL
4" [102mm] PIPE SEAL
CAST IRON ADAPTERS
PUMP POWER CORD
(FIELD INSTALLED)
(FIELD INSTALLED)
GRINDER PUMP
(FIELD INSTALLED)
(VENT CONNECTION)
CONTROL PANEL
(FIELD INSTALLED)
36" [914mm] *
* = OPTIONAL SIZES AVAILABLE
INDOOR PREPACKAGED SYSTEM
LEAD IDENTIFICATION WIRING DIAGRAM
THREE PHASE
MODELS 840, 841, 842
CE MODEL
FIGURE 5.
FIGURE 6.
MOISTURE SENSOR
L1 L2 L3
POWER CABLE
CONTACTOR T1 T2 T3
208V/230/460V
3ø POWER
SENSOR CABLE
THERMAL SENSOR
ORANGE BLACK RED WHITE GREEN
(18-4 OR 18-5)
BEFORE 6/2000
NORMALLY OPEN
330K OHMS RESISTANCE
NORMALLY CLOSED
THREE PHASE
MODELS 840, 841 & 842
WIRING DIAGRAMLEAD IDENTIFICATION
14-4
18-4
L1 L2 L3
T1 T2 T3
BLACK
RED
GREEN
POWER
CORD
MAGNETIC
STARTER
CORD
SENSOR
WHITE
BLACK
ORANGE
RED
WHITE
MOISTURE
SENSOR
TERMINALS
SENSOR
TERMINALS
TEMPERATURE
OR
18-5
GREEN
50/60Hz
SK1368 SK1370
Locate section with appropriate phase and model number, then match lead wire color.

7
© Copyright 2015 Zoeller®Co. All rights reserved.
Indoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged indoor systems only. If your system
is a eld-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 eld 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 oat switches are already
set inside the basin.
4. Remove the inspection plate from the cover. All
oats are set and tethered for proper operation from
the factory. Verify that where the oat switches are
set will work for your application. Verifying that the
oat 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
oat 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 trafc 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 backll all
the way around the perimeter. A minimum of 102
mm (4”) of compacted subbase is also required.
Backll 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 oat “on” level
with a minimum distance of 254 mm (10") between the
oor 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 oat switches. Most systems are supplied with a
eld installed 102 mm (4") pipe seal inlet tting. This
inlet tting 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.
Backll around the basin with specied media. Care
should be taken not to damage components or leave
voids when backlling. Finish grade of oor 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 oat 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.

8
© Copyright 2015 Zoeller®Co. All rights reserved.
Typical Outdoor Grinder Pumping System Installation
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.
FIGURE 7.
FOAM TAPE
UL LISTED
EPOXY SEALER
#10-2350 POTTING KIT
APPLIES TO INSIDE AND
OUTSIDE INSTALLATIONS
CONDUIT 1
WIRES OR
PUMP CABLES
1/4" TO 1/2"
(25 mm) (6 mm TO 12 mm)
SK1661
24" MIN. [610mm]
WATERTIGHT
HIGH LEVEL
1 1/4" FEMALE NPT
1 1/4" [32mm] GALVANIZED
DISCHARGE PIPE
FIBERGLASS
4" [102mm] RUBBER INLET PIPE SEAL
FIBERGLASS
1 1/4" NPT BRASS
DISCONNECT FITTING
1 1/2" [38mm] SQ. GUIDE RAIL
304 STAINLESS STEEL 16 GA.
PUMP CONTROL
"ON" FLOAT
"OFF" FLOAT
PUMP CONTROL
3/8" X 1' [10mm X 305mm]
1/8" [3mm] 302 STAINLESS
NEMA 4X J-BOX
ANTI-FLOTATION FLANGE
ALARM FLOAT
SOLID
STAINLESS STEEL FLOAT HOOK
STEEL LIFTING CABLE
416 STAINLESS
1 1/4" [32mm] PVC SCH 40
PIPE AND FITTINGS
1 1/4" [32mm] PVC SLIP X SLIP
BALL VALVE
1 1/4" [32mm]
DISCHARGE FITTING
CAST IRON CHECK VALVE
COVER
(FIELD INSTALLED)
(FIELD INSTALLED)
CONTROL PANEL
FIBERGLASS BASIN
TO CONTROL PANEL
COUPLING
28" [711mm] MIN. OR PER STATE
AND LOCAL CODES
STEEL PULL ROD
60" [1524mm]
OTHER BASIN SIZES
ARE READILY AVAILABLE.
*
*
SK2864
SK1601

9
© Copyright 2015 Zoeller®Co. All rights reserved.
Outdoor Prepackaged System Installation Instructions
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 eld 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-oat 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 oat 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
oat 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 oat switch bulb or the unit will not operate properly.
Verify that where the oat switches are set will work for
your application. Verifying that the oat 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") largerindiameter than the basin diameter to provide 305
mm (12") of backll all around and deep enough to provide
either 305 mm (12") of compacted backll or 152 mm (6")
whena concrete padis required. Note: Care must betaken
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
sufciently locate the basin outside of the loading area
of the adjacent structures.
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 oat 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.
6. The bottom of the excavation can now be properly backlled,
compacted and leveled. Set basin in hole. Ensure the
removable cover extends above the nished grade line and
the grade slopes away from the unit. Backll and subbase
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 eld installed 102 mm (4") pipe seal inlet tting. This
inlet tting 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 ttings and sizes are occasionally provided.
7. Pouring a concrete anchor around system can now be
completed. Basin should be lled with water when pouring
concrete to minimize movement of the system. Backll
around basin with specied media. Care should be used
to avoid damaging components or leaving voids when back
lling. Refer to Basin installation reference guide on more
specic requirements.
8. PVC or HDPE discharge piping is connected to the 132 mm
(1¼”) threaded tting located in the basin sidewall. Support
discharge piping with sufcient backll.
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 tting.
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.
14. Mount the control panel within sight of the system. Connect
oat switches and pump cords according to the “Pump Wiring
Instructions” found in this manual and located inside the
panel enclosure.
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.
17. Test system for leaks and proper pump operation.
18. Record system start-up data for future reference.
This set of instructions is for factory prepackaged outdoor grinder systems with Square Guide Rail system. If
installing a Z-Rail® Package or a eld-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.

10
© Copyright 2015 Zoeller®Co. All rights reserved.
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 specic
informationabout the construction ofthepump. Themodelnumber
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.
If panel is to be stored, the following is advised:
• 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.
START-UP PROCEDURE
Before placing the equipment into operation, the following should
be checked:
• Clean pit.
• Pump, oat 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 veried, proceed with the following
checks:
• Pump power cables and control oats properly installed and
voltage veried.
• 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 ow 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 withthe 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 oat 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.
SHUT-DOWN PROCEDURES
If a system is shut down for more than six months, the following
is recommended:
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 ve
minutes once every three months. If the pit is to remain
wet, the pump should be removed and stored as noted
above.
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.
Valves: Consult the valve/actuator supplier for information
concerning these systems components.