Grundfos PS.W.04 Bedienungsanleitung

Pumping station systems

PS.W.04-20

Installation and operating instructions

GRUNDFOS INSTRUCTIONS

Table of contents

Pumping station systems

English (GB)

Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Čeština (CZ)

Montážní a provozní návod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Deutsch (DE)

Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Dansk (DK)

Monterings- og driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Español (ES)

Instrucciones de instalación y funcionamiento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Suomi (FI)

Asennus- ja käyttöohjeet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Français (FR)

Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Italiano (IT)

Istruzioni di installazione e funzionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Nederlands (NL)

Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Polski (PL)

Instrukcja montażu i eksploatacji . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Português (PT)

Instruções de instalação e funcionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Svenska (SE)

Monterings- och driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Slovensko (SI)

Navodila za montažo in obratovanje . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Slovenčina (SK)

Návod na montáž a prevádzku . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Türkçe (TR)

Montaj ve kullanım kılavuzu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Norsk (NO)

Installasjons- og driftsinstruksjoner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

Declaration of performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions

These installation and operating instructions describe Grundfos

pumping station system PS.W.04-20.

Sections 1-6 give the information necessary to be able to unpack,

install and start up the product in a safe way.

Sections 7-9 give important information about the product, as well

as information on service, fault finding and disposal of the

product.

CONTENTS

Page

1. General information

1.1 Hazard statements

The symbols and hazard statements below may appear in

Grundfos installation and operating instructions, safety

instructions and service instructions.

The hazard statements are structured in the following way:

1.2 Notes

The symbols and notes below may appear in Grundfos

installation and operating instructions, safety instructions and

service instructions.

1.3 Target group

These installation and operating instructions are intended for

professional installers.

1. General information 3

1.1 Hazard statements 3

1.2 Notes 3

1.3 Target group 3

2. Safety instructions 4

3. Receiving the product 5

3.1 Transporting the product 5

3.2 Inspecting the product 5

3.3 Storage 5

4. Installing the product 6

4.1 Preparing the foundation 6

4.2 Lifting the pit 6

4.3 Installing the pit 7

4.4 Backfill 7

4.5 Uplift prevention 8

4.6 Connecting the pipes 8

4.7 Location of inlet 9

4.8 Fitting the sleeve 9

4.9 Pipes with flange connections 10

4.10 Installing the pump(s) 10

4.11 Fitting the chain 10

4.12 Installing the cover 10

4.13 Installing the venting pipe 11

4.14 Installing the cable entry 11

5. Installing the level controllers 11

5.1 Start and stop levels 11

5.2 Installing the pump controller 11

5.3 Float switches 12

5.4 Air bells 12

5.5 Pressure transducer 12

5.6 Other types of level control equipment 12

6. Electrical connection 13

7. Product introduction 13

7.1 Product description 13

7.2 Applications 13

7.3 Pumped liquids 14

7.4 Pumping station system (PS.S) 14

7.5 Pumping station modular (PS.M) 14

7.6 CE approval of PS.W and PS.S 14

7.7 Identification 14

8. Maintaining and servicing the product 17

8.1 Repairing a non-return valve 18

8.2 Contaminated pumps 18

8.3 Service contract 18

9. Disposing of the product 18

Read this document before installing the product.

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.

Observe these instructions for explosion-proof

products.

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

Electrical connections

Maintaining and servicing the product

DANGER

Crushing hazard

Death or serious personal injury

- Place the pit on even ground to prevent the pit

from overturning.

WARNING

Crushing hazard

Death or serious personal injury

- The lifting equipment used for lifting the pit and the

pump must be rated for the weight of the pump,

approved and maintained according to local

regulations.

DANGER

Crushing hazard

Death or serious personal injury

- Do not stand under or close to a suspended load.

DANGER

Crushing hazard

Death or serious personal injury

- Before lifting the pit, make sure that the lifting

equipment is capable of lifting the load.

- Make sure that the lifting bracket is tightened

before attempting to lift the pit. Tighten if

necessary. Carelessness during lifting or

transportation of the pit may cause injury to

persons or damage to the pit.

CAUTION

Collapsing hazard

Minor or moderate personal injury

- Place the support for the crane at a suitable

distance from the pit to avoid collapse of the pit

hole.

Work according to local regulations.

WARNING

Electric shock

Death or serious personal injury

- Connect the pump or pump controller to an

external emergency stop.

If you use the main switch as emergency stop,

make sure that it fulfils EN 60204-1, 10.8.4.

DANGER

Electric shock

Death or serious personal injury

- Before starting work on the pump or valves,

remove the fuses or switch off the main switch.

Make sure that the power supply cannot be

accidentally switched on.

DANGER

Electric shock

Death or serious personal injury

- The control cabinet and internal pipes must be

earthed.

DANGER

Crushing and suffocation hazard

Death or serious personal injury

- Before entering PS.W.20, 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

Fall 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 regulations.

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 of the main switch

before dismantling the non-return valve.

Make sure 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

For correct lifting methods, see section 4.2 Lifting the pit.

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.

• When lifting the pumping station with a strap, use the ribs on

the pumping station.

• 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 that the

ground is even.

Fig. 1 Lifting the pit from a lorry

Fig. 2 Placing the pit in upright position by means of 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, etc.

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.

• Check and retighten all bolted connections as they may have

become loose during the transport.

• Check that the valves are open.

• Check other equipment such as venting pipes.

3.3 Storage

In case the pit is not installed immediately or the ambient

temperature exceeds 30 °C, store the pit in upright position to

avoid deformation.

When transporting and handling the pit at low

temperatures, take into consideration that the pit

impact resistance is reduced.

DANGER

Crushing hazard

Death or serious personal injury

- Place the pit on even ground to prevent the pit

from overturning.

The weight of a PS.W pit can vary from 50 to

maximum 2500 kg.

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

handling.

TM06 1232 1914

TM06 1233 1914

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 below conditions 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

• Place the pit on a foundation layer if soil analyses and

information about pit load show that the soil is not capable of

bearing the weight. The bedding layer on which the pit is

placed is not regarded as a foundation layer.

• 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 30 cm (corresponding to

approx. 20 cm after compaction). Such a foundation layer is

also required if the excavation has become too deep by

mistake.

4.1.2 Bedding layer

• The material for the bedding layer must be compactable and

composed so that neither its properties nor the compaction will

cause damage to the pit.

• Grains larger than 16 mm must not be present.

• The content of grains between 8 and 16 mm must not exceed

10 %.

• The material must not be frozen.

• Sharp flint etc. must not be present.

• The bedding layer must have a thickness of 10 cm.

4.2 Lifting the pit

Fig. 4 Lifting the pit

CAUTION

Collapsing hazard

Minor or moderate personal injury

- Place the support for the crane at a suitable

distance from the pit to avoid collapse of the pit

hole.

Work according the 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 3629 0715

Pos. Description

1 Foundation layer

2 Bedding layer

3 Backfill compacted in layers of maximum 30 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. The other

equipment must not damage the buried pit.

TM06 9855 3517

Place the support for the crane at a suitable distance

from the pit to avoid collapse of the pit hole.

Observe local regulations.

DANGER

Crushing hazard

Death or serious personal injury

- Do not stand under or close to a suspended load.

DANGER

Crushing hazard

Death or serious personal injury

- Before lifting the pit, make sure that the lifting

equipment is capable of lifting the load.

- Make sure that the lifting bracket is tightened

before attempting to lift the pit. Tighten if

necessary. Carelessness during lifting or

transportation of the pit may cause injury to

persons or damage to the pit.

English (GB)

4.3 Installing the pit

Before lowering the pit into position, retighten various

connections, as they may have become loose during the

transport.

Place the pit on the bedding layer.

Check that the pit is vertical.

Groundwater must not rise above the bedding layer until

backfilling has been completed.

4.4 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. See fig. 5.

• The backfill must meet the same requirements as those for the

bedding layer.

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

damaged or deformed.

• The backfill must be compacted in layers of maximum 30 cm,

corresponding to approx. 20 cm after compaction.

Fig. 5 Insufficient compaction under pipes

Fig. 6 Oval pit after compaction

Fig. 7 Even pressure on all sides of the pit

Fig. 8 Compactors

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. See fig. 7.

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

- Place the support for the crane at a suitable

distance from the pit to avoid collapse of the pit

hole.

Work according to the local regulations.

Before lowering the pit into position, retighten various

connections, as they may have become loose during

the transport.

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. 5.

TM06 3628 0715

During backfilling, fit the cover on the pit to prevent

the pit from becoming deformed or oval-shaped.

TM02 9361 2404TM06 3603 0615

Do not use plate compactors at a distance of less

than 30 cm from the pit wall.

If the hole for the pit is drilled, pay special attention to

the compaction of the backfill to prevent uplift.

TM06 3602 0615

Use mechanical compacting equipment and compact

the backfill to 98-100 % proctor density.

Max.

25 kN

Max.

150 kg

English (GB)

4.5 Uplift prevention

The pit design ensures that the pit is protected against uplift if

installed correctly. Requirements for uplift prevention depend on

the geotechnical conditions. They should be determined by the

engineer or contractor and are outside Grundfos' area of

responsibility.

The safety against uplift is determined according to Eurocode EN

1997-1 including national annex, DS/EN 1997-1 DK NA:2015.

The most unfavourable ground water conditions for the pit is

when the ground water table is located at terrain level. This

situation creates the highest hydrostatic water pressure at the

bottom of the pit, and causes the highest reduction in soil weight

for the stabilising soil volume.

The sand volume resting on the shoulder of the pit is a stabilising

force. The sand volume is determined as a cone with hollow core

as illustrated in fig. 9.

The inclination of the cone is illustrated 1:n. The inclination n can

be determined based on the friction angle for the design. The

characteristic friction angle for sand with a unit weight of 19 kN/

m3, compacted to 97 % standard proctor, is estimated to 37

degrees. The design friction angle is 32 degrees which

corresponds to an inclination of n = 1.6.

Fig. 9 Stabilising sand volume

4.6 Connecting the pipes

Holes for inlet pipe, electrical connection and venting are to be

drilled on site.

1. Mark the pit where the inlet is to be.

2. Drill the marked spot with a hole saw.

3. Remove all burrs from the hole.

4.6.1 Drilling the inlets

Figures 10 and 11 show which hole saw to use for the various

pumping station diameters, depending on the difference in the

wall thickness.

Fig. 10 Wall profile PS.W.04-10

Fig. 11 Wall profile PS.W.20

The requirements below are minimum requirements.

Observe local regulations.

TM06 7269 2316

We recommend that you provide the pit with a vent

pipe, supplied as an accessory.

Place inlet and outlet pipe connections in accordance

with local regulations.

PS.W.04 - PS.W.10

Diameter

[mm]

Wall thickness - A

[mm]

400 30

600 44

800 57

1000 72

TM06 3605 1317

PS.W.20

Wall thickness varies for SN2 and SN4

Diameter [mm] SN2 [mm] SN4 [mm]

2000 Minimum 84 Minimum 114.5

TM06 3610 0615

English (GB)

4.7 Location of inlet

The pit inlet must not be located within the area shown in fig. 12,

as it will disturb the function of the float switches.

Fig. 12 Location of inlet relative to level control

Fig. 13 Location of inlet relative to pipes with one pump

Fig. 14 Location of inlet relative to pipes with two pumps

Fig. 15 Location of inlet relative to inclined bottom plates

4.8 Fitting the sleeve

1. Fold the sleeve and insert it into the hole from the outside of

the pit.

2. Unfold the sleeve so that it lies evenly in the hole.

3. LM50/100/150 sleeves: Pull the sleeve outwards until its

collar touches the inside of the pit all around the hole.

L965 sleeves: Pull the sleeve outwards until its collar touches

the inside of the pit at the positions 3 and 9 o'clock. See fig.

18.

4. Lubricate the inside of the sleeve with a water-based

lubricant.

5. Chamfer the pipe and press it home.

LM50/100/150 sleeves

Push the inlet pipe through the sleeve. See fig. 16.

Fig. 16 Pipe with LM50/100/150 sleeve, seen from the side

TM06 9859 3517

The pit inlet must not be located within the areas

shown in figs 13 and 14 as it will interfere with piping

and valves.

TM06 9856 3517TM06 9857 3517

The pit inlet must not be located within the area

shown in fig. 15 as it will destroy the function of the

inclined bottom plates.

200 200

220°

190°

TM06 9858 3517

As it must be possible to pull the pump up through

the pit, the inlet pipe must not project more than 5 cm

beyond the sleeve.

TM03 3709 0806

Pit side

Max. 50 mm

English (GB)

L965 sleeves

Push the inlet pipe into the sleeve and against the stop. See figs

17 and 18.

Fig. 17 Pipe with L965 sleeve, seen from the side

Fig. 18 Pipe with L965 sleeve, seen from the top

4.9 Pipes with flange connections

4.10 Installing the pump(s)

Some versions come without the pump(s) installed. For

installation and startup of the pump, see the installation and

operating instructions for the pump.

4.11 Fitting the chain

For pumps on auto coupling, we recommend that you fit the chain

in the foremost lifting eye of the lifting bracket. The number of

lifting eyes depends on the pump.

Fig. 19 Chain fitted to the pump

4.12 Installing the cover

PS.W is delivered with factory-fitted cover. The cover is not

approved for traffic unless stated otherwise.

For traffic-approved cover, contact Grundfos.

Fig. 20 Not approved for pedestrians and vehicles

TM03 3708 0806TM03 3768 1006

Loosen all bolts of the flange and retighten them

when the pit has been installed.

This will prevent stress in the pipes.

Lower the pump carefully into the pit to avoid

damage to pump and pit.

WARNING

Crushing hazard

Death or serious personal injury

- The lifting equipment used for lifting the pit and the

pump must be rated for the weight of the pump,

approved and maintained according to local

regulations.

Pit side

TM02 9341 2404

WARNING

Crushing hazard

Death or serious personal injury

- The lifting equipment used for lifting the pit and the

pump must be rated for the weight of the pump,

approved and maintained according to local

regulations.

Chains supplied by Grundfos are marked with

maximum load and production date.

Do not exceed the maximum load.

Maintain the chain 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.

Make sure that covers are closed and locked to

prevent unwanted access.

Never leave an open pit unattended.

TM06 0113 4913 - TM06 0114 4913

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Grundfos Wasserpumpe Handbücher

Grundfos

Grundfos TPE 2 Series Betriebsanleitung

Grundfos

Grundfos Unilift KP 150 Bedienungsanleitung

Grundfos

Grundfos MixiMizer Betriebsanleitung

Grundfos

Grundfos LC 232 Bedienungsanleitung

Grundfos

Grundfos MAGNA1 D Betriebsanleitung

Grundfos

Grundfos MTB Series Bedienungsanleitung

Grundfos

Grundfos UNILIFT AP35B Bedienungsanleitung

Grundfos

Grundfos Sololift2 WC-1 Bedienungsanleitung

Grundfos

Grundfos TPE Bedienungsanleitung

Grundfos

Grundfos Unilift AP12 Bedienungsanleitung

Grundfos

Grundfos ALPHA2 Series Bedienungsanleitung

Grundfos

Grundfos NK Bedienungsanleitung

Grundfos

Grundfos Unilift AP12 Bedienungsanleitung

Grundfos

Grundfos UNILIFT KP 150 A Bedienungsanleitung

Grundfos

Grundfos MAGNA3 25-100 (N) Bedienungsanleitung

Grundfos

Grundfos MSS Series Bedienungsanleitung

Grundfos

Grundfos DME AR Series Bedienungsanleitung

Grundfos

Grundfos DPK Bedienungsanleitung

Grundfos

Grundfos MTA Series Bedienungsanleitung

Grundfos

Grundfos ALPHA Bedienungsanleitung

Grundfos

Grundfos LC Bedienungsanleitung

Grundfos

Grundfos UNILIFT AP35B Bedienungsanleitung

Grundfos

Grundfos CR Series Bedienungsanleitung

Grundfos

Grundfos CREC Bedienungsanleitung

Beliebte Wasserpumpe Handbücher anderer Marken

Neptun

Neptun NPHW 5500 Bedienungsanleitung

Sensidyne

Sensidyne Gilian BDX-II Montage- und Bedienungsanleitung

Draper

Draper 47808 Bedienungsanleitung

Trolla

Trolla 12820 Bedienungsanleitung

Sunfab

Sunfab SVH Series Bedienungsanleitung

WilTec

WilTec 50740 Bedienungsanleitung

Fieldmann

Fieldmann FVC 5015 EK Bedienungsanleitung

Everbilt

Everbilt EFSUB5-122HD Bedienungsanleitung

Graco

Graco Husky 3300e Bedienungsanleitung

esotec

esotec 101018 Bedienungsanleitung

Becker

Becker BASIC VASF 2.80/1-0.AC230 Bedienungsanleitung

Sykes AmeriPumps

Sykes AmeriPumps GP100M Fehlerbehebungshandbuch

DUROMAX

DUROMAX XP WX Series Bedienungsanleitung

BRINKMANN PUMPS

BRINKMANN PUMPS SBF550 Bedienungsanleitung

Franklin Electric

Franklin Electric IPS Bedienungsanleitung

Xylem

Xylem e-1532 Series Bedienungsanleitung

Milton Roy

Milton Roy PRIMEROYAL Bedienungsanleitung

STA-RITE

STA-RITE ST33APP Bedienungsanleitung