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© Copyright 2017 Zoeller
®
Co. All rights reserved.
Outdoor Prepackaged System Installation Instructions
This set of instructions is for factory prepackaged outdoor progressing cavity grinder systems only. If this is a field assembled outdoor system you can
use these instructions as a guideline.
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 130°F
(54°C).
These units are not designed to handle liquids other than sanitary sewage. If pump is
used to dewater areas with contaminated liquids with heavy or abrasive materials, the
warranty will be voided.
NAMEPLATE DATA
The nameplate, located on the top of the pump, indicates specific 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
When not in use, the pump should be stored and the following is advised:
• Drain pump housing by laying pump horizontal with discharge down. Then stand pump
on legs.
• 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 seal 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.
• Electrical boxes dry and securely installed.
• Floats positioned properly.
• Discharge valves open.
• Adequate water level in basin for pump submersion.
Once the above has been verified proceed with the following checks:
• Pump power cables and control floats properly installed and voltage verified.
• Conduit connections to panel are properly sealed.
• After installing the pump into the basin, with adequate submergence, open the
discharge valve fully. Start the unit using manual controls. If flow 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 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 float switch setting. The off switch should deactivate the
pump before the water level drops to the mid-point of the pump.
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. Check for an anti-siphon valve when used
in a pressure sewer.
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. Do not run dry. 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.
1. Review the drawing in Fig. 4 on page 5 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 field assembly work. Float switches
are set and tethered for proper operation from the Factory. The alarm switch should
be located 2” above the pump “on” level.
3. Float switches are tied in place for shipping purposes on all model prepackaged
systems. Cut the cable tie around each float switch bulb or the unit will not operate
properly. Verify that where the float switches are set will work for your application.
Verifying that the float 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 backfill all around and deep enough to provide
either 12” of compacted backfill or 6” when a concrete pad is required. Ensure the
removable cover extends above the finished grade line and the grade slopes away
from the unit. Backfill and subbase should be 1/8” –3/4” pea gravel or 1/8” –1/2”
crushed stone. (Reference basin installation instructions included with unit)
5.
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 sufficiently locate the basin outside of the loading area of the
adjacent structures.
6. The location of the inlet fitting is determined by the depth of the inlet pipe. The inlet fitting
must be used with 4” pipe. It is best to install the inlet on the side of the basin opposite
the float switches. To install, use a 5” 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.
7. The bottom of the excavation can now be back filled and compacted. Set basin in
hole and connect the 4” inlet pipe to the inlet hub.
8. The discharge piping is connected to the 1-1/4” threaded fitting located in the
basin sidewall.
9. 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 fitting.
10. Pouring a concrete anchor around system can now be completed. Basin should be
filled with water when pouring concrete to minimize movement of the system. Back
fill around basin with specified media. Care should be used to avoid damaging
components or leaving voids when back filling. Refer to Basin installation reference
guide on more specific requirements.
11.
Note: The progressing cavity 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. Trench should be located at least 18” deep
and follow all applicable NEC codes. Connect electrical 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. Use the included sealant when
closing junction box.
13. If used, a control panel is installed within sight of the system. Connect float switches
and pump cords according to the “Pump Wiring Instructions” found 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. Add water to the basin and test the system for leaks and proper pump operation.
17. Record system start up data for future reference.
