Grundfos PS.G Series Bedienungsanleitung

Pumping station systems

PS.G

Pumping station, glass-fibre-reinforced plastic (GRP)

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos

pumping station systems PS.G.

Sections 1-7 give the information necessary to be able to handle,

install and start using the product in a safe way.

Sections 8-10 give important information about the product, as

well as information on maintenance, service and disposal of the

product.

CONTENTS

Page

1. Symbols used in this document

The text accompanying the three hazard symbols DANGER,

WARNING and CAUTION is structured in the following way:

1. Symbols used in this document 2

2. Safety instructions 3

3. Receiving the product 4

3.1 Transporting the product 4

3.2 Inspecting the product 4

4. Installing the product 5

4.1 Preparing the foundation 5

4.2 Installing the pit 6

4.3 Installing the valve chamber 8

4.4 Connecting the pipes 8

4.5 Installing the cover 8

4.6 Connecting the vent pipe 10

5. Installing the pump(s) 10

6. Installing the level switches 10

6.1 Start and stop levels 10

6.2 Installing the pump controller 11

7. Electrical connection 11

7.1 Installing the cables 11

8. Product introduction 12

8.1 Product description 12

8.2 Service platform 13

8.3 Applications 13

8.4 Pumped liquids 13

8.5 Pumping station system (PS.S) 13

8.6 Pumping station modular (PS.M) 13

8.7 Identification 14

9. Maintaining and servicing the product 16

9.1 Repairing a non-return valve 17

9.2 Draining the main pipe 17

9.3 Contaminated pumps 17

9.4 Service contract 17

10. Disposal 17

Prior to installation, read this document. Installation

and operation must comply with local regulations and

accepted codes of good practice.

DANGER

Indicates a hazardous situation which, if not avoided,

will result in death or serious personal injury.

WARNING

Indicates a hazardous situation which, if not avoided,

could result in death or serious personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided,

could result in minor or moderate personal injury.

SIGNAL WORD

Description of hazard

Consequence of ignoring the warning.

- Action to avoid the hazard.

A blue or grey circle with a white graphical symbol

indicates that an action must be taken.

A red or grey circle with a diagonal bar, possibly with

a black graphical symbol, indicates that an action

must not be taken or must be stopped.

If these instructions are not observed, it may result in

malfunction or damage to the equipment.

Tips and advice that make the work easier.

English (GB)

2. Safety instructions

Receiving the product

Installing the product

Installing the pump(s)

Electrical connection

Maintaining and servicing the product

DANGER

Crushing hazard

Death or serious personal injury

- Place the pit on even ground to prevent the pit in

overturning.

- Make sure the lifting bracket or strap is tightened

before attempting to lift the pit. Tighten if

necessary. Carelessness during lifting or

transportation may cause injury to persons or

damage to the pit.

CAUTION

Collapsing hazard

Minor or moderate personal injury

- Support for the crane must be placed at a suitable

distance from the pit to avoid collapse of pit hole.

Work according to local regulations.

DANGER

Crushing hazard

Death or serious personal injury

- Make sure the lifting equipment is rated for the

weight of the pump and is approved and

maintained according to local regulations.

WARNING

Electric shock

Death or serious personal injury

- The pump or pump controller must be connected

to an external emergency stop.

If the main switch is used as emergency stop, it

must fulfil EN 60204-1, 10.8.4.

- Before starting any work on the product, make

sure that the power supply has been switched off

and that it cannot be accidentally switched on.

WARNING

Crushing and suffocation hazard

Death or serious personal injury

- Before entering the pit, make sure that the cover

and safety grid are locked in open position and

that the pit is ventilated according to local

regulations. If not, do not enter the pit.

DANGER

Falling hazard

Death or serious personal injury

- When entering the pit, wear a safety harness and

use approved equipment for lifting persons up from

the pit according to local regulation.

CAUTION

Pressurised system

Minor or moderate personal injury

- Relieve the pressure by draining the system before

dismantling the non-return valve.

CAUTION

Biological hazard

Minor or moderate personal injury

- Remove the fuses or switch off the main switch

before dismantling the non-return valve.

Make sure that the power supply cannot be

accidentally switched on.

- Use gloves and other suitable personal protection

equipment in accordance with local regulations.

Observe local regulations on exposure to

wastewater.

- Rinse the non-return valve thoroughly with clean

water before carrying out maintenance and

service.

- Flush the pump thoroughly with clean water and

rinse the pump parts in water after dismantling.

English (GB)

3. Receiving the product

3.1 Transporting the product

The pit must be transported in a horizontal position and anchored

to the transport vehicle. Accessories, if any, must be secured

inside the pit.

The customer must provide appropriate lifting equipment at the

place of unloading. The weight of the pit is stated on the

nameplate.

Precautions during transport and handling

• Do not dump the pit from the lorry.

• Use approved straps of textile or similar materials when lifting

the pit on to or down from a lorry or moving it on the

construction site.

• Handle and lift the pit according to local regulations.

• Do not drag the pit over the ground.

• Point loads must not occur.

• The pit must not be exposed to sharp edges.

• Fix the pit securely during transport.

• When the pit is placed on the ground, make sure the ground is

even.

Fig. 1 Lifting the pit from a lorry

Fig. 2 Lifting straps

3.2 Inspecting the product

After transportation and before installation, the pumping station

must be inspected by the customer.

The inspection must include the following:

• Check the pumping station for transport damage. Contact the

transporter immediately if you detect any damage.

• Check that the products delivered correspond to the order.

• Check the positions and sizes of fittings.

• Retighten various connections, as they may have become

loose during the transport.

• Check that all valves, except the draining valve in the valve

chamber, are open.

• Check other equipment such as vent pipes.

When transporting and handling the pit at low

temperatures, take into consideration that the pit

impact resistance is reduced.

Before raising the pit into vertical position, remove

transport supports and accessories from the inside of

the pit.

DANGER

Crushing hazard

Death or serious personal injury

- Place the pit on even ground to prevent the pit in

overturning.

If the pit is equipped with a lifting point, use it during

handling.

TM06 1232 1914

TM06 1233 1914

DANGER

Crushing hazard

Death or serious personal injury

- Make sure the lifting bracket or strap is tightened

before attempting to lift the pit. Tighten if

necessary. Carelessness during lifting or

transportation may cause injury to persons or

damage to the pit.

English (GB)

4. Installing the product

4.1 Preparing the foundation

With reference to DS/EN 1997-1: Eurocode 7: Geotechnical

Category 2:

We recommend that you complete a geotechnical investigation of

the site conditions before you install the pit.

With reference to DS/EN 1997-1: Eurocode 7: Geotechnical

Category 1:

The geotechnical investigation can be judged to be unnecessary,

if the conditions below are fulfilled:

• There is a negligible risk of overall instability, ground

movements or adverse ground conditions.

• Comparable local experience shows that the ground

conditions are sufficiently uncomplicated.

• There is no excavation below the water table.

• Comparable local experience indicates that the proposed

excavation below the water table will be uncomplicated.

In case of doubt, consult a geotechnical specialist.

Fig. 3 Schematic installation drawing

4.1.1 Foundation layer

• The pit must be placed on a foundation layer if soil analyses

and information about the pit load indicate that the bottom is

not capable of bearing the weight.

• The foundation layer can be made after the excavation by

laying a stable layer of suitable gravel or similar material and

compacting it in layers of maximum 50 cm. Such a foundation

layer is also required if the excavation has become too deep

by mistake.

4.1.2 Foundation slab

The concrete for the foundation slab must meet these

requirements:

Fig. 4 Lowering the foundation slab

Fig. 5 Maximum angle of inclination

CAUTION

Collapsing hazard

Minor or moderate personal injury

- Support for the crane must be placed at a suitable

distance from the pit to avoid collapse of pit hole.

Work according to local regulations.

Installation of pits must be carried out by an

authorised person in accordance with local

regulations.

Work in or near wastewater pits must be carried out

according to local regulations.

TM06 1848 3214

Pos. Description

1 Foundation layer

2 Foundation slab

3 Backfill, compacted in layers of maximum 50 cm

4Distance of 50 cm from cover where heavy loads must

not occur

Select the location of the pit so that its installation

does not damage other equipment. And the other

equipment must not damage the buried pit.

Strength class C40/50-2

Exposure class XC4

Water-to-cement ratio ≤0.45

Maximum chloride content 0.4 %

Reinforcement B500B

Maximum angle of inclination 25 °

Maximum water absorption by mass 6 %

TM06 1237 2514TM06 3498 0615

Make sure that the foundation slab is level before

installing the pit.

Max. 25 °

English (GB)

The anchor bolts for the foundation slab can be delivered on site

before the pit arrives. It is thus possible to install the anchor bolts

and perform a tensile test before the pumping station arrives at

the installation site.

4.2 Installing the pit

1. Clean the surface of the foundation slab, making sure there is

no material or any objects between the foundation slab and

the mounting flange of the pit.

2. Lift the pit by the lifting lugs and place it in the middle of the

circle of anchoring bolts on the foundation slab.

Fig. 6 Lowering the pit

3. Position the pit correctly so that the flanges are in the right

direction in relation to the inlet and outlet pipes.

Fig. 7 How to fill the hollow space with concrete

If the pumping station is installed in corrosive soil

condition/environment, this may cause the

galvanized anchor bolts to corrode. In that case,

choose other bolt material.

For further clarifications, please contact your local

Grundfos sales office.

Each anchor bolt must be able to withstand 20 kN

(2000 kg) in a tensile test.

If the foundation slab is cast on site, rub down the

surface of the slab to a smooth surface.

If the foundation slab is to be cast on site, see the

data booklet 98697625 for casting dimensions. The

document is available in Grundfos Product Center.

TM06 3859 1015

Check the pit for external damage before lowering it

into position. When the pit has been installed,

Grundfos cannot be held responsible for possible

damage.

CAUTION

Collapsing hazard

Minor or moderate personal injury

- Support for the crane must be placed at a suitable

distance from the pit to avoid collapse of pit hole.

Work according to local regulations.

Before lowering the pit into position, retighten various

connections, as they may have become loose during

the transport.

net.grundfos.com/qr/i/98697625

Use either the QR code or the web address below to

access the data booklet.

TM06 1238 1914

In pits with diameters of 2.0, 2.2 or 3.0 m, with outlet

pipes above DN 150 and with two holes in the bottom

of the pit, fill the hollow space below the bottom of

the pit with concrete to avoid vibrations. See fig. 7.

TM06 4359 2115

English (GB)

Fig. 8 Securing the mounting brackets

4. Fit the mounting brackets, washers and M20 F8.8 nuts, and

tighten the nuts to 430 ± 10 Nm.

4.2.1 Backfill

• The backfill must provide sufficient support of the pit on all

sides and ensure that the load can be transferred without

detrimental point impacts or similar impacts.

• The backfill material must be compactable gravel or sand with

an even particle size. The maximum particle size is 32 mm.

The backfill material must not contain any stones larger than

the maximum particle size.

• The backfilling must be carried out so that the pit is not

damaged or deformed.

• The backfill must be compacted in layers of maximum 50 cm.

Fig. 9 Compacted layers of maximum 50 cm

Fig. 10 Insufficient compaction under pipes

TM06 1239 1914

Do not lower the pit onto the anchoring bolts as they

may damage the surface of the pit.

Make sure that no residual stresses remain in the

reinforced plastic structures of the pit bottom.

Do not use plate compactors at a distance of less

than 30 cm from the pit wall.

430 ± 10 Nm

TM06 3352 5214

Compact the backfill under the inlet and outlet pipes

properly so that they are not exposed to downward

loads when the backfill settles. See fig. 10.

TM06 1879 3314

During backfilling, the cover must be fitted on the pit

to ensure that the pit is not deformed (becomes

oval).

Max. 50 cm

English (GB)

Fig. 11 Even pressure on all sides of the pit

Fig. 12 Compactors

4.3 Installing the valve chamber

When installing the valve chamber, follow the same instructions

as for the installation of the pit. See section 4. Installing the

product.

Fig. 13 Valve chamber

4.4 Connecting the pipes

Compact the backfill around the pit up to the lower part of a pipe

connection, before connecting the pipe. See fig. 13.

Before connecting the pipes, check the following:

• The pipes and the gaskets must be clean.

• The inlet pipe must be properly aligned with the pipe

connection.

4.5 Installing the cover

Fig. 14 Not approved for pedestrians and vehicles

As standard, covers are made of fibre glass and hatches of

aluminium. Standard covers are pre-installed.

From PS.G.30 and up, the pumping station has both a

maintenance hatch and a service hatch.

For more information, see the data booklet 98697625. The

document is available in www.grundfos.com, Grundfos Product

Center.

TM06 3603 0615TM06 3602 0615

Use mechanical compacting equipment and compact

the backfill to > 95 % proctor density.

TM06 3288 1015

Max.

25 kN

Max.

150 kg

Isolating

valves

Non-return

valves

Place inlet and outlet pipe connections in accordance

with local regulations.

Covers are not approved for pedestrians and

vehicles unless this is specifically stated.

TM06 0113 4913 - TM06 0114 4913

The safety grid is split when the pit diameter is

greater than 2 m.

The pit must be locked to prevent unwanted access.

English (GB)

4.5.1 Installing a cover approved for traffic

The covers are available for all pit sizes as an optional cover. The

cover is a concrete slab with a steel hatch.

Fig. 15 Maximum angle of inclination

Installing a cover with concrete ring

Be careful when compacting the backfill to prevent damage to the

top of the pit. The particle size under the cover and close to the

pit top must be 2 to 20 mm.

Lower the concrete ring onto the compacted backfill. The ring

may be covered with asphalt.

Fig. 16 Installing a cover with a concrete ring

Installing a cover with air space

Lower the cover onto the pumping station when the backfill has

been compacted to the top level of the pumping station. See figs

17 and 18.

After installation, there must be an air space of 150 mm between

the cover and the pit. See figs 17 and 18.

Fig. 17 Cover approved for traffic, sectional view

Fig. 18 Cover approved for traffic

The maximum angle of inclination when lifting the

cover is 25 °.

TM06 3498 0615

The foundation and bedding layer for the cover must

be able to carry the load that the concrete cover is

rated for. Observe local regulations.

The pit comes with a 500 mm collar that must be cut

to the right length on the installation site.

The pit must not support the ring.

TM06 3921 1215

25 °

350-250 mm

Particle size:

2-20 mm

Compacted backfill

Asphalt (optional)

500 mm

Thickness of ring:

150-250 mm

TM06 3575 0615

TM06 1847 3214

If the concrete ring is to be cast on site, see the data

booklet 98697625 for casting dimensions. The

document is available in www.grundfos.com,

Grundfos Product Center.

TM06 3859 1015

Ground level Concrete ring Cover

Air space: 150 mm

Pit

Compacted

backfill

Top level of the pit

net.grundfos.com/qr/i/98697625

Use either the QR code or the web address below to

access the data booklet.

English (GB)

4.6 Connecting the vent pipe

We recommend that you provide the pit with a vent pipe

(accessory). See section 4.4 Connecting the pipes.

Fig. 19 Pit with top-mounted vent pipe

Fig. 20 Pit with side-mounted vent pipe

5. Installing the pump(s)

For installation and startup of the pump(s), see the installation

and operating instructions for the pump.

6. Installing the level switches

See the installation and operating instructions for the level control

system.

When installing the level switches, observe the following points:

• To prevent air intake and vibrations in the pump, the stop level

switch must be fitted in such a way that the pump is stopped

before air is sucked into the pump.

• In the case of one-pump operation, the start level switch must

be installed in such a way that the pump is started at the

required level; however, the pump must always be started

before the liquid level reaches the lower edge of the bottom

inlet pipe.

• In the case of multipump operation, the start level switches

must be installed in such a way that pumps are started before

the liquid level reaches the lower edge of the bottom inlet pipe.

• The high-level alarm switch must always be installed about

100 mm above the start level switch; however, the alarm must

always be given before the liquid level reaches the inlet pipe.

For further settings, see the installation and operating instructions

for the level switch selected.

6.1 Start and stop levels

The effective volume of the pit must be so large that the number

of starts does not exceed the maximum permissible number. See

the installation and operating instructions for the pump.

TM06 1683 2614TM06 1684 2614

Lower the pump carefully into the pit in order to avoid

damage to the pump and the pit.

DANGER

Crushing hazard

Death or serious personal injury

- Make sure the lifting equipment is rated for the

weight of the pump and is approved and

maintained according to local regulations.

We recommend that you check chains and shackles

supplied by Grundfos at least once a year for cracks,

corrosion or other irregularities. If you find any

defects, replace the chain or shackles.

If the pit is equipped with an AUTOADAPT -controlled

pump, an external level controller is not needed.

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