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© 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 SPECIAL INSTRUCTIONS WHICH ARE 

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.

FA M I LY   O W N E D

PROUD

AMERICAN

X800 SERIES HAZARDOUS ENVIRONMENT SERIES 

CLASS 

I

, DIVISION 1, GROUP C & D SUBMERSIBLE GRINDER UNITS

Certified to CSA Standard

C22.2 No. 145

Standard 3600 & 3615

NOTICE TO INSTALLER:  Instructions must remain with installation.

Product information presented 

here reflects conditions at time 

of  publication. Consult factory 

regarding discrepancies or 

inconsistencies.

MAIL TO

:  P.O. BOX 16347 • Louisville, KY  40256-0347

SHIP TO

:  3649 Cane Run Road  • Louisville, KY  40211-1961

TEL

: (502) 778-2731 • 1 (800) 928-PUMP • 

FAX

: (502) 774-3624

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

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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