Zoeller X800 Series User manual

© Copyright 2015 Zoeller®Co. All rights reserved.
FM2615
Rev. A
0615
Supersedes
0512
Part 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 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.
INDICATES SPECIALINSTRUCTIONSWHICHARE
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.
CAUTION
Table of Contents
Safety Instructions ....................................................................... 1
Limited Warranty and Application .............................................. 2
Preinstallation Checklist.............................................................. 3
General Information ..................................................................... 4
Pump Wiring Instructions............................................................ 5
Typical Outdoor Prepackaged System ....................................... 6
Outdoor Prepackaged Installation Instructions ........................7
Electrical Data............................................................................... 8
Operation....................................................................................... 9
Cutter Maintenance .................................................................... 10
Service Checklist........................................................................ 11
REFER TO WARRANTY ON PAGE 2.
This manual incorporates the installation, operation, maintenance, and
service instructions into one document to 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. Consult factory for replacement parts. Should further assistance
be necessary please call our Product Support Department at 1-800-928-7867.
Congratulations on the purchase of a Zoeller submersible grinder pump.
This pump has been constructed in compliance with FM and CSA testing.
These requirements enable the unit to be listed as an explosion proof
pump rated for use in Class
I , Division 1, Group C & D environments.
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.
FAMILY OWNED
PROUD
AMERICAN
X800 SERIES HAZARDOUS ENVIRONMENT SERIES
CLASS
I , DIVISION 1, GROUP C & D SUBMERSIBLE GRINDER UNITS
R
Certied to CSA Standard
C22.2 No. 145
Standard 3600 & 3615
NOTICE TO INSTALLER: Instructions must remain with installation.
Product information presented
here reects 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 website:
zoellerpumps.com
Patent No. 6,364,620
Register your
Zoeller Pump Company
Product on our website:
http://reg.zoellerpumps.com/
OWNER’S MANUAL

2
© Copyright 2015 Zoeller®Co. All rights reserved.
*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 X800 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 more than 60 homes, a solids handling type pump should be
considered.
Simplex Station Duplex Station
Model HP Homes GPD Homes GPD
X840 w/o Reversing Control 2 2* 800 10 4,000
X840 w/ Reversing Control 2 2* 800 15 6,000
X841 2 2* 800 10 4,000
X842 2 2* 800 10 4,000
than in 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 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
ANDOFMERCHANTABILITYSHALLBELIMITEDTOTHEDURATION
OF THE EXPRESSED WARRANTY.
Somestates donot allowlimitationson theduration ofan impliedwarranty,
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
thewarrantyperiod, every new producttobe free from defectsinmaterial
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 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,replacedor remanufactured at Manufacturer'soption,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
ofManufacturer,subjected to misuse,misapplication,neglect, alteration,
accidentor act ofGod;that has notbeen installed, operatedormaintained
inaccordancewith Manufacturer's installationinstructions;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 other abrasive or corrosive substances,
wash towels or feminine sanitary products, etc. in all applications other
Model X840, X841 and X842 Applications
1. Zoeller Grinder Pumps are designed for grinding and pumping
sanitarysewagefrom submersible lift stations. The pumpisintended
to grind and pump reasonable quantities of items normally found in
sanitary sewage applications.
2. Zoeller 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 can be installed in a Prepackaged Job Ready System or may
be used in a FieldAssembled basin package. Pages 6 and 8 show
a couple of Prepackaged Systems. Field Assembled Systems are
discussed on pages 3 and 4.
4. Zoeller Grinder Pumps can be retrotted to existing positive
displacement pump installations.

3
© Copyright 2015 Zoeller®Co. All rights reserved.
Preinstallation Information
1. Inspect your pump. Occasionally, products are damaged during shipment. If the unit is damaged, contact your distributor before using. DO
NOT remove the test plugs in the cover nor the motor housing.
2. Carefully read the literature provided to familiarize yourself with specic details regarding installation and use. These materials should be
retained for future reference.
3. National Electrical Code (NEC) articles 500 through 503 explain in detail the requirements for the installation and wiring of electrical
equipment in hazardous locations.
1. Check to be sure your power source is capable of handling the
voltage requirements of the motor, as indicated on the pump
nameplate.
2. The oat switches must be connected to an intrinsically safe
circuit in the control panel. The installation of oat switches is the
responsibility of the installing party and care should be taken that
the tethered oat switch will not hang up on the pump apparatus
or pit peculiarities and is secured so that the pump will shut off. It
is recommended that rigid piping and ttings be used and the pit
be 36" or larger in diameter.
3. INFORMATION - VENT HOLE PURPOSE. It is necessary that
all submersible pumps capable of handling various sizes of solid
waste be of the bottom intake design to reduce clogging and seal
failures. If a check valve is incorporated in the installation, a vent
hole (approx. 3/16") must be drilled in the discharge pipe below
the check valve and pit cover to purge the unit of trapped air.Water
stream will be visible from this hole during pump run periods. This
vent hole should be checked periodically for clogging and cleaned
as necessary. Trapped air is caused by agitation and/or a dry basin.
4. Water hammer creates momentary high pressure surges. These
surges can cause severe damage to check valves and the piping
system. Consideration for water hammer must be included in the
piping system design. Reference ASPE Data Book, Chapter 2.33.
Somesystemsmay require external springorlever weighted check
valves or other engineered solutions.
5. Three phase pumps must be connected for proper rotation, which
is counterclockwise looking into impeller inlet. See page 4 for
instructions for checking 3 phase rotation.
6. Grinder installations should be checked frequently for debris and/
or buildup which may interfere with the “ON”/”OFF” cycles or the
positions of variable level oat control switches. For repair and
service, other than cutter assembly maintenance, contact factory.
7. Care should be taken during the initial installation to be sure that
adequateair supply isavailablewhenever anypersonis inthebasin.
Always follow OSHA guidelines on conned space requirements.
NOTE: CSA Certied pumps are certied to CSA Standard C22.2 No. 145.
CAUTION
SEE BELOW FOR
LIST OF CAUTIONS
SEE BELOW FOR
LIST OF WARNINGS
1. Not for use in acidic atmospheres.
2. Do not lift, carry, or hang pump by the electrical cables. Damage to
the electrical cables can cause shock, burns or death.
3. Make sure there is a properly grounded connection available.
All pumps are furnished with provisions for proper grounding to help
protect you against the possibility of electrical shock.
4. Make certain that the control box is within the reach of the pump’s
power supply cord. DO NOT USE AN EXTENSION CORD. Extension
cords that are too long or too light do not deliver sufcient voltage
to the pump motor. But, more important, they could present a safety
hazard if the insulation were to become damaged or the connection
end were to fall into the sump.
5. Make sure the pump electrical supply circuit is equipped with
fuses and disconnect or circuit breakers of proper capacity. A
separate branch circuit is recommended, sized according to the “Na-
tional Electrical Code” for the current shown on the pump nameplate.
6. Risk of electric shock - These pumps have not been investigated for
use in swimming pool areas.
7. 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.
8. Electricalwiring and protectionmustbein accordancewiththe National
Electrical Code per NEC articles 500 through 503 for installation in
Class I, Division 1, Group C & D environments, and any other ap-
plicable state and local electrical requirements.
9. Do not attempt to turn cutter rotor located on bottom of
the unit with ngers. Use the appropriately sized wrench
when checking or removing the cutter.

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 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 star cutter at 3450 RPM against
the stationary cutter plate (see page 11).
2. The cutter mechanism on the model X840 is bidirectional, enabling
it to cut in either direction. A control panel with the reversing feature
willalternatethepump’srotational direction with eachdutycycle.The
cutter mechanism on the model X842 & X841 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
(ref. page 5).
4. The X800 Series 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. Installationandpiping instructionsare includedwith thecontrolpanel,
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 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 (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 3/16" diameter hole).
FIGURE 1.
016532
HEAD CAPACITY CURVE
MODEL X840/X841/X842
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
10 0
110
120
32
36
X840 X841X842
TOTAL DYNAMIC HEAD/FLOW
PER MINUTE
SEWAGE
MODEL
Feet
Shut-off Head:
X840
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)
X841
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
X842
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.
MOISTURE SENSOR
L1 L2 L3
POWER CABLE
CONTACTOR T1 T2 T3
208V/230/460V
3ø POWER
SENSOR CABLE
THERMAL SENSORS (2)
ORANGE BLACK RED WHITE GREEN
(18-4 OR 18-5)
BEFORE 6/2000
NORMALLY OPEN
330K OHMS RESISTANCE
NORMALLY CLOSED
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
14-4
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
18-5
GREEN
Pump Wiring Instructions
FORYOUR PROTECTION,ALWAYS DISCONNECTTHEPUMP FROMITSPOWER SOURCE BEFOREHANDLING.
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 2. LEAD IDENTIFICATION WIRING DIAGRAM
SINGLE PHASE-2 BHP
MODEL X840
SK1367 009048
THREE PHASE
MODELS X840, X841 & X842
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
SINGLE PHASE
MODELS X841 & X842
LEAD IDENTIFICATION WIRING DIAGRAM
WIRING DIAGRAMLEAD IDENTIFICATION
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
SK1368 SK1370
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

6
© Copyright 2015 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 Packaged Duplex Grinder Pump Station
FIGURE 5.
SK2843
(36" MINIMUM)
SHUT-OFF VALVE
2" DISCHARGE PIPE
3/4" GUIDE RAILS
CHECK VALVE
WEEP HOLE
NON-SPARKING
RAIL SYSTEM 1 1/4" X 2"
ANTI-FLOATATION RING
WEIGHTED FLOAT SWITCHES
LEAD PUMP "OFF" FLOAT
LEAD PUMP "ON" FLOAT
ALARM FLOAT
LAG PUMP "ON" FLOAT
INLET FITTING
(SHIPPED LOOSE)
TO CONTROL PANEL
28" MIN. OR PER STATE
AND LOCAL CODES
HATCH COVER
HATCH COVER
STEEL
ALUMINUM
GAS TIGHT
CONTROL PANEL - INSTRINSICALLY SAFE
(FIELD INSTALLED)
LIFTING CABLE
ELECTRICAL CONDUIT COUPLING

7
© Copyright 2015 Zoeller®Co. All rights reserved.
Duplex Prepackaged System Installation Instructions
1. Review the drawing in Fig. 5 on page 6 and the actual system to
becomefamiliarwith the componentsinthe packagedgrinderpump
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
3” above the pump “on” level. Three oat systems used with a
control panel are placed at 27”, 24”, and 15” from the bottom of
the basin. Four oat systems used with a control panel are placed
at 30”, 27”, 24”, and 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 24” larger in
diameter than the basin diameter to provide 12” of backll all around
and deep enough to provide either 12” of compacted backll or
6” when a concrete pad is required. Note: Care must be taken
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 4” pipe. It is best to install
the inlet on the side of the basin opposite the oat switches. To
install, use a 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 1/8” –3/4” pea
gravel or 1/8” –1/2” crushed stone. (Reference basin installation
instructions included with unit.) Most systems are supplied with a
eld installed 4” pipe seal inlet tting. This inlet tting is installed
in the basin's side-wall in a 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 2” threaded
tting located in the basin sidewall. Support discharge piping with
sufcient backll.
9. Connect lift cable to top of pump. Lower the pump into basin
ensuring the discharge pipe bracket slides into the disconnect
tting.
10. Note: The grinder basin is a sewage holding tank. Vent
connectionshouldbe installed in accordance withallnational,
state and local plumbing codes.
11. Dig a trench for the electrical conduit. The conduit should be
located below the frost line. Follow all applicable electrical codes.
12. Connectelectrical conduitand wiringaccordingto wiringinstructions
included in this manual.
13. Mount the control panel within sight of the system. Connect
oat switches and pump cords according to the “Pump Wiring
Instructions” found later in this manual and located inside the panel
enclosure.
14. Remove any debris from the basin. Using clean water, check the
system for proper operation.
15. Seal and secure the lid using the proper bolts and sealant when
using a lid without a formed gasket.
16. Test system for leaks and proper pump operation.
17. Record system start up data for future reference.
This set of instructions is for factory prepackaged outdoor grinder systems only. If this is a eld assembled
outdoor system you can use these instructions as a guideline. The pump should not be installed in the basin until permanent
electrical power is available.

8
© Copyright 2015 Zoeller®Co. All rights reserved.
Additional Installation Notes
Electrical Data
Amps
KVA
Code
Winding
Resistance
Line-to-Line
Model BHP RPM Voltage Phase Hertz Full Load In Air Shut O󰀨 Locked
Rotor
IX840 2 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5
EX840 2 3450 230 160 17.2 4.0 10.9 56 F1.3 / 4.0
JX840 2 3450 200 3 60 12.3 3.7 7.7 54 L 1.9
FX840 2 3450 230 3 60 10.8 3.3 6.9 42 K2.4
GX840 2 3450 460 3 60 5.5 1.6 3.5 21 K 9.7
BAX840 2 3450 575 3 60 4.5 1.0 2.5 11 F15.3
IX842 2 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5
EX842 2 3450 230 160 17.2 4.0 10.9 56 F1.3 / 4.0
JX842 2 3450 200 3 60 12.3 3.7 7.7 54 L 1.9
FX842 2 3450 230 3 60 10.8 3.3 6.9 42 K2.4
GX842 2 3450 460 3 60 5.5 1.6 3.5 21 K 9.7
BAX842 2 3450 575 3 60 4.5 1.0 2.5 11 F15.3
IX841 2 3450 200 1 60 20.0 6.6 12.1 60 H 1.0 / 1.5
EX841 2 3450 230 160 17.2 4.0 10.9 56 F1.3 / 4.0
JX841 2 3450 200 3 60 12.3 3.7 7.7 54 L 1.9
FX841 2 3450 230 3 60 10.8 3.3 6.9 42 K2.4
GX841 2 3450 460 3 60 5.5 1.6 3.5 21 K 9.7
BAX841 2 3450 575 3 60 4.5 1.0 2.5 11 F15.3
(5) Vent gases and odors to the atmosphere through vent pipe
per local and state codes.
(6) Basin must be in accordance with all applicable codes
and specications regarding Class I, Division 1, Group C &
D environments. Basin must be sized to allow a minimum
3 minute off-time between starts.
(7) The tethered variable level oat switches must be free and not
hang up on pump or pit peculiarities. Float switch circuits shall
be intrinsically safe.
(8) If a rail system is used, it should be non-sparking. Discharge
elbow must be rmly anchored to the bottom of basin. In
berglass basin, the bottom will need to be reinforced if the
discharge elbow is used.
(1) Electrical wiring and protection must be in accordance with the
National Electrical Code per NEC articles 500 through 503 for
installation in Class 1, Division 1, Group C & D environments,
and any other applicable state and local electrical requirements.
(2) Install propercontrols. (Outdoor panelsin ventillated areasrequire
NEMA 3R or 4X enclosure) Float switch connections shall be
intrinsically safe.
(3) Cords must be properly sealed per NEC articles 500 through 503
for installation in Class I, Division 1, Group C & D environments,
to prevent moisture and gases from entering the control panel.
(4) When check valve is installed, drill a 3/16" diameter hole in
the discharge pipe below the check valve even with the top of
the pump. NOTE: The hole must be below the basin cover and
cleaned periodically. Also a vent hole is drilled in the pump hous-
ing. Be sure that this hole is cleared during any servicing.

9
© 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 explosion proof
grinder pumps must not exceed 104°F (40°C).
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
information about the construction of the pump. The model number
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 and electrical cables are dry and properly
installed.
• Electrical boxes dry, sealed and securely installed.
• Floats positioned properly.
• Discharge valves open.
• 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 are properly sealed.
• After installing the pump into the containment area, with adequate
submergence, open the discharge 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 qualied electrician take voltage and current measurements
with the 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.
SHUTDOWN PROCEDURES
If a system is shutdown for more than six months, the following is
recommended:
Pumps: If pit is to remain dry, then 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: Consultthevalve/actuatorsupplier for information concerning
these systems components.

10
© Copyright 2015 Zoeller®Co. All rights reserved.
Cutter Maintenance
To remove star cutter: Remove guard ring then heat the center
bolt to 350°F to loosen Loctite®thread sealant.
Grind the Star Cutter and Disc seen here to a 32 micronish.
Surfaces must be at to within 0.001” T.I.R. Gap must be between
0.004” and 0.008” on these parts.
1. All power circuits must be disconnected and locked out before
any attempts are made at servicing. The star cutter and disc
can be removed and sharpened by grinding the cutting faces. Both
star cutter and disc must be removed from the pump. Removal of
these parts can be accomplished in the eld by removing pump
from the sump and positioning horizontally to access the intake of
the pump. If seals or other repairs are required, the pump must
be totally removed and serviced in a shop by a qualied pump
technician or authorized service center.
2. Remove the three countersunk screws on the plastic guard ring
and remove the ring.
3. Thoroughly clean the star cutter and disc assembly. Tilt pump
back to the vertical position to make certain the end play has
been removed. Check and record the clearance between the star
cutter and disc with a feeler gage. The correct running clearance
is between 0.004" and 0.008".
4. With pump in horizontal position, heat the hex head bolt in the
center of the star cutter with a propane torch. The bolt must be
heated to 350°F to soften the thread lock sealer on the bolt for
ease of removal. Remove the bolt by turning in a counterclockwise
rotation. It will be necessary to use a wood block to prevent the
star cutter from turning while removing the bolt. Pull star cutter
from the shaft and remove the spacer shims located behind the
star cutter.
5. Remove the three cap screws holding the disc and remove disc
from the pump.
6. The disc and star cutter can be replaced with new service parts or
resurfaced by grinding. Resurfacing is accomplished by surface
grinding both disc and star cutter to a 32 micro nish. Do not attempt
grinding in the eld. Send parts to a qualied machine shop or
return to the factory for repair. The disc, star cutter and shims are
a matched set. Keep parts together. Measure disc before and
after resurfacing with micrometer and record measurements.
7. After resurfacing, the disc and star cutter must be at within
0.001". If the disc has been surface ground, it will be necessary
to remove shims to compensate for the material removed from the
disc. As a starting point, remove shims of the same thickness as
the amount machined from the cutter disc (step 6 above). Final
running clearance must be between 0.004” and 0.008”. Be sure
pump is in vertical position and all end play has been removed
before measuring.
8. Clean bottom of pump where disc is located and replace disc and
retainer screws. Torque to 63-67 in-lbs. Replace star cutter with
the correct shims. Install washer and torque hex head bolt to 71-
75 in.-lbs. apply Loctite 262 thread-lock sealant or equal to bolt
threads prior to insertion. Check running clearance with pump in
vertical position to remove end play. Clearance must be between
0.004" and 0.008" to obtain efcient grinding when pump is put
back in service.
9. Replace plastic guard ring and its three screws.
10. Check the oil in the motor housing before reinstalling. Contact the
factory if the oil has a milky appearance or burnt smell. The level
should be even with the ll plug when pump is in the upright position.
Add oil if required. Use insulating oil supplied by the factory.
FIGURE 7.
(Model X840 components shown)

11
© Copyright 2015 Zoeller®Co. All rights reserved.
Service Checklist
Electrical precautions. Before servicing a grinder pump, always shut off the main power circuit. Make sure you are wearing
insulated protective sole shoes and not standing in water. Under ooded conditions, contact your local electric company or a qualied
licensed electrician for disconnecting electrical service to the pump prior to removal.
Grinder pumps contain oil which becomes pressurized and hot under operating conditions. Allow 2½ hours after shut
down before servicing pump.
General Maintenance
Repair and service must be performed by a rm approved
by Zoeller Company. To repair a pump with an explosion-proof motor in ac-
cordance to the guidelines listed in Policy FM0212-3d, contact the Zoeller
Product Support Department for additional information.
If the motor housing, seal cavity or cord cap is disassembled
or repaired by a rm not approved to work on explosion proof motors, the
explosion proof rating is void and the FM CSA approval tags MUST BE
REMOVED FROM THE PUMP.
SAFETY PROCEDURES
For your protection, always disconnect pump and
panel from its power source before handling.
Never enter the basin until it has been properly
vented and tested. Any person entering a basin should be wearing
a harness with safety rope extending to the surface so that they can
be pulled out in case of asphyxiation. Sewage water gives off methane and
hydrogen sulfide gases, both of which can be highly poisonous.
Installationand checkingof electricalcircuits and hardwareshould beperformed
by a qualied electrician.
Pump is never to be lifted by power cord.
Unit must be cleaned and disinfected, inside the
pumping chamber and all exterior surfaces, prior to servicing.
Condition Common Causes
A. Pump will not start or run.
Blown panel or circuit breaker fuse, low voltage, thermal overload open, defective
capacitor circuit, cutter or impeller clogged, oat switch held down or defective,
incorrect wiring in control panel, water in cap assembly.
B. Motor overheats and trips on overload.
Incorrect voltage, impeller or cutter blocked, negative head (discharge lower than
intake of pump). Defective “off” oat. Pump runs continuously at low water level.
Low oil level in motor shell.
C. Pump will not shut off.
Air lock, debris under oat assembly, defective switch, incoming sewage exceeds
capacity of pump.
D. Pump operates but delivers little or no water. Intakeclogged with greaseorsludge, pump airlocked (clear venthole),low
or incorrect voltage, clogged discharge line, operating near shut-off head.
E. Pump starts and stops too often.
Check valve stuck open or defective. Sump pit too small to handle incoming
sewage. Level control out of adjustment. Thermal overload tripping.
F. Large red ashing light comes on at control box.
High water in pit. Check pump for clogging, or overload trip. On single phase
pumps, check the start capacitor in the control panel. See “A” and “D” above.
G. Grease and solids accumulate in pit around pump.
Break up solids and run pump with water running into the pit. Allow level to lower
to the pump intake. Continue until solids are cleared from the pit. Do not drain
kitchen grease down the sink.
GENERAL SYSTEM INSPECTION
Before the system is placed into operation, it should be inspected by a qualied
technician.
Wiring and grounding must be in accordance with the
National Electrical Code and all applicable local codes and ordinances.
LUBRICATION PROCEDURES
No lubrication is required.
If pumps are to be stored for more than six months, refer to short term storage
procedure in the Operation section.
PREVENTIVE MAINTENANCE
preventive maintenance is recommended to ensure a long service life from the
product. Provided is a suggested maintenance schedule.
Every month:
• Check for proper and unobstructed oat operation.
• Listen for proper check valve operation.
• Duplex Units - Check for even operating times. Uneven times indicate a
defective unit, oat switch or control.
• Inspect thepanelforany presenceofmoisture in enclosure,looseconnections,
and general component condition. check out location and condition of oat
switches.
Every year:
• In additionto themonthly checks,the basinshould beinspected andcleaned.
Any defective components should be replaced. Inspect and remove any
sand, debris, or mud present in the pump basin assembly.
Every two years:
• Inspect power cables and cap assembly for damage or wear. Replace
immediately if damage or wear is detected by an approved Service Station.
Replace if damage or wear has signicantly altered the impeller’s geometry.
• Inspect impeller for damage or wear.

© Copyright 2015 Zoeller®Co. All rights reserved.
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 website:
zoellerpumps.com