Zoeller 7011 - User Manual

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ZM2609_Ec

0715

Supersedes

0611

NOTICE TO INSTALLER: Instructions must remain with installation.

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 7011, 7012 & 7013 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. Should further

assistance be necessary please call our Product

Support Department at +1 (502) 778-2731 or email:

zeptechnical@zoeller.com.

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 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.

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

50/60Hz

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 USA

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

+1 (502) 778-2731 • FAX +1 (502) 774-3624

visit our web site:

zoellerengineered.com

Main Page

Need help?

Do you have a question about the Zoeller 7011 and is the answer not in the manual?

Summary

Product Specifications and Applications

Limited Warranty

Outlines the terms, conditions, exclusions, and limitations of the product warranty.

Application Guidelines

Describes the intended uses and recommended limits for Zoeller Grinder Pumps.

Grinder Pump Description

Explains the construction, cutter mechanism, motor types, seals, and duty cycle of the pumps.

Safety and Pre-Installation

Safety Instructions

Provides crucial warnings about electrical shock, handling, grounding, and qualified personnel.

Preinstallation Checklist

A list of essential checks and requirements before installing the grinder pump.

Installation and Wiring

Pump Wiring Instructions

Details wiring diagrams and lead identification for single-phase and three-phase grinder pumps.

Indoor Prepackaged System Installation

Step-by-step guide for installing factory prepackaged indoor grinder pump systems.

Outdoor Prepackaged System Installation

Step-by-step guide for installing factory prepackaged outdoor grinder pump systems.

Operation and Maintenance

Operation Procedures

Covers start-up, storage, adjustment, and shutdown procedures for the pump system.

Cutter Maintenance

Instructions on how to maintain and service the grinder pump's cutter and disc assembly.

General Maintenance and Service

Routine maintenance schedule, service checklist, and common troubleshooting for grinder pumps.

Summary

Product Specifications and Applications

Limited Warranty

Outlines the terms, conditions, exclusions, and limitations of the product warranty.

Application Guidelines

Describes the intended uses and recommended limits for Zoeller Grinder Pumps.

Grinder Pump Description

Explains the construction, cutter mechanism, motor types, seals, and duty cycle of the pumps.

Safety and Pre-Installation

Safety Instructions

Provides crucial warnings about electrical shock, handling, grounding, and qualified personnel.

Preinstallation Checklist

A list of essential checks and requirements before installing the grinder pump.

Installation and Wiring

Pump Wiring Instructions

Details wiring diagrams and lead identification for single-phase and three-phase grinder pumps.

Indoor Prepackaged System Installation

Step-by-step guide for installing factory prepackaged indoor grinder pump systems.

Outdoor Prepackaged System Installation

Step-by-step guide for installing factory prepackaged outdoor grinder pump systems.

Operation and Maintenance

Operation Procedures

Covers start-up, storage, adjustment, and shutdown procedures for the pump system.

Cutter Maintenance

Instructions on how to maintain and service the grinder pump's cutter and disc assembly.

General Maintenance and Service

Routine maintenance schedule, service checklist, and common troubleshooting for grinder pumps.

The document describes the Zoeller Models 7011, 7012, and 7013 Submersible Grinder Units, providing installation, operation, maintenance, and service instructions. These pumps are designed for grinding and pumping sanitary sewage from submersible lift stations, handling reasonable quantities of items normally found in sanitary sewage applications. They are suitable for new installations, direct replacements for similar grinder applications, and retrofitting existing positive displacement pump installations.

Function Description:

The Zoeller grinder pumps are heavy-duty submersible units designed for intermittent duty sanitary sewage applications. They effectively grind and pump sewage, preventing clogs in low-pressure pipe systems. The cutter assembly, made of stainless steel components hardened to 55-60 on the Rockwell C scale, consists of a star-shaped cutter and a precision ground flat disk. Cutting action occurs as the star cutter rotates at 3450 RPM against the stationary cutter plate. Model 7011 features a bidirectional cutter mechanism, allowing it to cut in either direction, with control panels offering a reversing feature to alternate rotational direction with each duty cycle. Models 7012 and 7013 have a single-directional cutter mechanism. The pumps are equipped with dual seals and seal leak probes. Single-phase units include an internal thermal overload, while three-phase pumps have a thermal sensor and require overload protection in the control panel.

Important Technical Specifications:

Construction: Class 30 cast iron, protected with powder-coated epoxy for long life.
Cutter Assembly: Stainless steel, hardened to 55-60 Rockwell C scale.
Motor Speed: 3450 RPM (for 60Hz models), 2800 RPM (for 50Hz models).
Maximum Operating Temperature: 130°F (54°C).
Electrical Data (60Hz models):
- 7011 (1 Phase): 200V (20.0A Full Load), 230V (17.2A Full Load).
- 7011 (3 Phase): 200V (12.3A Full Load), 230V (10.8A Full Load), 380V (6.8A Full Load), 460V (5.5A Full Load), 575V (4.5A Full Load).
- 7012 (1 Phase): 200V (20.0A Full Load), 230V (17.2A Full Load).
- 7012 (3 Phase): 200V (12.3A Full Load), 230V (10.8A Full Load), 380V (6.8A Full Load), 460V (5.5A Full Load), 575V (4.5A Full Load).
- 7013 (1 Phase): 200V (20.0A Full Load), 230V (17.2A Full Load).
- 7013 (2 Phase): 200V (12.3A Full Load), 230V (10.8A Full Load), 460V (5.5A Full Load), 575V (4.5A Full Load).
- 7013 (3 Phase): 380V (6.8A Full Load).
Electrical Data (50Hz models):
- AK7011 (3 Phase): 380V (4.4A Full Load).
- AK7012 (3 Phase): 380V (4.4A Full Load).
- AK7013 (3 Phase): 380V (4.4A Full Load).
Shut-off Head (60Hz): 7011 (104 ft / 31.7 m), 7012 (125 ft / 38.1 m), 7013 (125 ft / 38.1 m).
Recommended Application Limits (60Hz):
- Simplex Station: 7011 (w/o reversing control) for 2 homes (3 m³/day), 7011 (w/ reversing control) for 2 homes (3 m³/day), 7012 for 2 homes (3 m³/day), 7013 for 2 homes (3 m³/day).
- Duplex Station: 7011 (w/o reversing control) for 10 homes (15 m³/day), 7011 (w/ reversing control) for 15 homes (23 m³/day), 7012 for 10 homes (15 m³/day), 7013 for 10 homes (15 m³/day).
Basin Diameter: Recommended 24" (610 mm) for simplex systems, 36" (91 cm) or larger for duplex systems.

Usage Features:

Installation Flexibility: Can be installed as a prepackaged "Job Ready System" (indoor or outdoor) or as a field-assembled basin package.
Control Panels: Pumps are operated by control panels with variable level float control switches. Single-phase motors require a Zoeller-approved starting relay, starting capacitor, and run capacitor, all mounted in a control panel.
Air Lock Prevention: The pump case has an air vent located behind the discharge, which must be cleaned before each reinstall. An extra air vent hole (5 mm / 3/16") can be drilled in the discharge pipe below the check valve to further prevent air lock.
Electrical Safety: All electrical connections must comply with the National Electrical Code and local codes. A disconnect switch should be installed ahead of the pump. Junction box conduit must be watertight, and a UL Listed potting kit (P/N 10-2350) is available for sealing.
Float Switch Management: Float switches are factory-set and tethered for proper operation. Installers are responsible for verifying correct float switch placement to prevent hanging up and ensuring the pump shuts off. Cable ties used for shipping must be cut for proper operation.
System Start-up: After installation, the pump should be run using manual controls with adequate submergence. If flow is low, the pump may be air-locked and should be "jogged" several times using manual controls to expel trapped air. Voltage and current measurements should be taken by a qualified electrician during operation.

Maintenance Features:

Pre-start-up: Zoeller pumps are lubricated and tested at the factory, requiring minimum pre-start-up maintenance.
Short-term Storage: If not in use, the pump should be stored indoors or covered, wire leads taped/sealed, unpainted surfaces spray-coated with rust-inhibiting oil, and the impeller rotated every six months to keep seals lubricated. Control panels should be stored indoors in their shipping box, sealed, upright, and not stacked.
Shutdown Procedures: For systems shut down for more than six months, if the pit remains dry, the pump can stay in the pit but should be operated for five minutes every three months. If the pit remains wet, the pump should be removed and stored as noted above. Panels should be sealed to prevent moisture/dust and inspected for moisture/loose connections before restarting.
Preventive Maintenance (Every six months): Check for proper and unobstructed float operation, and listen for proper check valve operation.
Preventive Maintenance (Every 5 years or 10,000 hours): Remove pump, inspect, and service using a Zoeller rebuild kit. Flush and clean the basin.
Cutter Maintenance:
- Disassembly: Disconnect power, remove the plastic guard ring, heat the hex head bolt (to 350°F / 176°C) to soften thread lock sealant, remove the bolt, pull the star cutter from the shaft, and remove spacer shims. Remove the three cap screws holding the disc and remove the disc.
- Resurfacing: The disc and star cutter can be replaced or resurfaced by grinding to a 32 micro finish. Resurfacing should be done by a qualified machine shop or returned to the factory. After resurfacing, parts must be flat within 0.001" (.025 mm). Shims may need to be removed to compensate for material loss.
- Reassembly: Clean the pump bottom, replace the disc and retainer screws (torque to 63-67 in-lbs / 7.1-7.6 N.m). Replace the star cutter with correct shims, install washer, and torque the hex head bolt (71-75 in.-lbs. / 8-8.5 N.m) with Loctite 262 thread-lock sealant.
- Clearance: The correct running clearance between the star cutter and disc must be between 0.004" (0.1 mm) and 0.008" (0.2 mm).
- Oil Check: Check the oil in the motor housing before reinstalling. Contact the factory if the oil is milky or burnt. The oil level should be even with the fill plug when the pump is upright. Use insulating oil supplied by the factory if refilling is needed.
Troubleshooting: A service checklist provides common causes and solutions for issues like the pump not starting, motor overheating, pump not shutting off, low water delivery, frequent starting/stopping, alarm light activation, and grease/solids accumulation.