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© 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 specific 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 float switches must be connected to an intrinsically safe 

circuit in the control panel. The installation of float switches is the 

responsibility of the installing party and care should be taken that 

the tethered float 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 fittings 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. 

Some systems may require external spring or lever 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 float 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 

adequate air supply is available whenever any person is in the basin. 

Always follow OSHA guidelines on confined space requirements.

NOTE: CSA Certified pumps are certified 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 sufficient 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. 

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.

 Electrical wiring and protection 

must 

be in accordance with the 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 fingers.

 Use the appropriately sized wrench 

when checking or removing the cutter.

Summary of Contents for X800 Series

Page 1: ...ructions 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 sta...

Page 2: ...efromdefectsinmaterial 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 pro...

Page 3: ...oper 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 float control switches For repair and service other than cutter assembly maintenance contact factory 7 Care should be...

Page 4: ...stem 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 AULListed potting kit P N 10 2350...

Page 5: ...rical 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 qualified 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...

Page 6: ...ation 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 INST...

Page 7: ... the side of the basin using the sealant and hardware provided 6 The bottom of the excavation can now be properly backfilled compacted and leveled Set basin in hole 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...

Page 8: ...specifications 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 float 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 firmly anchored to the bottom o...

Page 9: ...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 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 containment area with adequat...

Page 10: ...e 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 grindingbothdiscandstarcuttertoa32microfinish Donotattempt grinding in the field Send parts to a qualified machine shop or return to the facto...

Page 11: ...scontinuously atlowwaterlevel Low oil level in motor shell C Pump will not shut off Airlock debrisunderfloatassembly defectiveswitch incomingsewageexceeds capacity of pump D Pump operates but delivers little or no water Intakecloggedwithgreaseorsludge pumpairlocked clearventhole low orincorrectvoltage cloggeddischargeline operatingnearshut offhead E Pump starts and stops too often Check valve stuc...

Page 12: ...015 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 502 778 2731 1 800 928 PUMP FAX 502 774 3624 Visit our website zoellerpumps com ...

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