Grundfos PUST04 Bedienungsanleitung

English (GB)

English (GB) Installation and operating instructions

Original installation and operating instructions.

CONTENTS

Page

1. Symbols used in this document

2. General description

Grundfos pumping stations are pre-fabricated pumping stations

for collection and pumping of drainage water, rainwater or

wastewater.

The pump pit is made of PE-HD (polyethylene) and comes with

discharge pipes and valves fitted.

The pipework is made of PE or stainless steel depending on the

location of the pit and the pumped liquid, and thus the pump

selected.

Unless another solution is selected, the pits up to ∅1000 mm are

supplied with a PE-HD cover which is locked with a special M10 bolt.

Fig. 1 Example of version

3. Applications

Grundfos pumping stations are used for collection and pumping

of drainage water, rainwater and wastewater. Wastewater is led

into the pit. When the liquid in the pit reaches the starting level,

the pump will start and pump the liquid further in the system to a

sewage treatment plant or sewer.

The pits are prepared for various pumps depending on the

pumped liquid.

3.1 Pumped liquids

• Drainage water

• rainwater (surface water)

•wastewater.

3.1.1 Liquid temperature

Maximum 40 °C. For higher temperatures, contact Grundfos.

3.1.2 Acids and alkalis

The pump pit is resistant to strong acids and alkalis as well as

solvents.

The pumps are supplied with the pump pit and normally stand pH

values between 4 and 10. In case of doubt, contact Grundfos.

3.1.3 Viscosity

Very thick wastewater must not be led into the pit. See also the

installation and operating instructions of the pump.

3.1.4 Density

Maximum 1.1 tons/m3.

1. Symbols used in this document 6

2. General description 6

3. Applications 6

3.1 Pumped liquids 6

4. Identification 7

4.1 Type key, PUST04 - PUST10 7

4.2 Type key, PUST17 7

4.3 Nameplate 7

5. Pit versions 7

5.1 Cover 9

5.2 Vent pipe 9

5.3 Cables 9

6. Technical data 9

6.1 Weight 9

7. Sizing 9

8. Transportation 9

9. Installation 10

9.1 Pipe connection 11

9.2 Fitting the sleeve 12

9.3 Installation of pump 12

9.4 Pipework with flange connections 12

9.5 Fitting the chain 12

10. Pump control 12

10.1 Start and stop levels 12

10.2 Installation of level controller 12

10.3 Float switches 13

10.4 Rod electrodes 13

10.5 Air bells 13

10.6 Pressure transducer 13

10.7 Other types of level control equipment 13

11. Electrical connection and start-up 14

12. Maintenance 14

13. Service contract 14

14. Disposal 14

Warning

Prior to installation, read these installation and

operating instructions. Installation and operation

must comply with local regulations and accepted

codes of good practice.

Warning

If these safety instructions are not observed, it

may result in personal injury!

Caution

If these safety instructions are not observed, it

may result in malfunction or damage to the

equipment!

Note

Notes or instructions that make the job easier

and ensure safe operation.

TM02 9366 2404

Pos. Description

1Pump

2Chain

3 Guide rails

4 Float switch

5 Non-return valve

6Stopvalve

7 Flange/coupling

8 Connection, 1/2" internal thread

9 Cover

Caution

The liquid temperature depends on the pump

selected. See the installation and operating

instructions of the individual pumps.

English (GB)

4. Identification

4.1 Type key, PUST04 - PUST10

4.2 Type key, PUST17

4.3 Nameplate

Fig. 2 Nameplate

5. Pit versions

The pits come with pipes and valves, depending of the installation

selected. Some pumps are available with a float switch connected

directly to the pump and thus require no external or built-in

controller.

The following installation drawings show pits with a free-standing

pump, a pump on auto coupling, a pump on wall-mounted auto

coupling and a pit with two pumps.

Example PUST 08.20. S. A. SS. SEG

Grundfos pumping station (standard)

Diameter [mm]

04: 400

06: 600

08: 800

10: 1000

Length [mm]

15: 1500

20: 2000

25: 500

30: 3000

S: One pump

D: Two pumps

Installation of pump

A: Auto coupling on tank bottom

W: Auto coupling on tank wall

S: Free-standing

Pipe material

PE: Polyethylene

SS: Stainless steel AISI 304

Prepared for pump type

KP: Unilift KP, Unilift CC

AP35: Unilift AP12.40, Unilift AP35

AP50: Unilift AP12.50, Unilift AP50

APB: Unilift AP35B, Unilift AP50B

DPEF: DP (0.6 - 1.5 kW), EF

DPSE:DP (2.6 kW), SL1.50.65 and SLV.65.65 (up to 3 kW)

SEG: SEG

Example PUST 17. 45. D. A. SS. DC. PE. 80

Grundfos pumping station

(standard)

Diameter [mm]

17: 1700

Length [mm]

20: 2000

25: 2500

30: 3000

35: 3500

40: 4000

45: 4500

50: 5000

55: 5500

60: 6000

S: One pump

D: Two pumps

T: Three pumps

Installation of pump

A: Auto coupling on tank bottom

S: Free-standing

Pipe material

PE: Polyethylene

SS: Stainless steel

Pipe design

DC: Direct outlet, common

DS: Direct outlet, separate

GC: Goose neck, common

NV: No valves

Pit material

GR: Glass-reinforced plastic

PE: Polyethylene

CO: Concrete

Internal pipe diameter

65: DN 65 (2 1/2")

80: DN 80 (3")

100: DN 100 (4")

150: DN 150 (5")

200: DN 200 (6")

TM03 4029 1406

Pos. Description

Type Type designation

Part No. Product number

P.c. Year-week code

Type:

96574128

Made in Denmark

DK-8850 Bjerringbro

Part No./

P. c .

English (GB)

TM02 9364 2404

TM02 9363 2404

Fig. 3 Pit with free-standing pump Fig. 4 Pit with pump on auto coupling

TM02 9366 2404

TM02 9365 2404

Fig. 5 Pit with pump on wall-mounted auto coupling Fig. 6 Pit with two pumps

English (GB)

5.1 Cover

5.1.1 PUST04 - PUST10

Unless another solution is selected, ∅400 to 1000 mm pits are

supplied with a PE-HD cover locked with a special M10 bolt.

Fig. 7 Cover

Fig. 8 Locked cover

5.1.2 PUST17

Covers for ∅1700 mm pits come with various lock systems.

5.2 Vent pipe

We recommend to provide the pit with a vent pipe.

Fig. 9 Pit with vent pipe

5.3 Cables

The cables to the level switches and the pump can be led into the

pit in different ways. Often the cables are led into the pit through a

cable entry in the side of the pit. If the pit is equipped with a vent

pipe, the pipe can be used as cable entry.

6. Technical data

6.1 Weight

6.1.1 PUST04 - PUST10

PUST.10.25.D.A.SS.DPSE is the heaviest standard pit, weighing

312 kg.

6.1.2 PUST17

PUST.17.60.D.A.SS.SW.PE.100 is the heaviest standard pit,

weighing approximately 1000 kg.

7. Sizing

The pit volume depends on the wastewater flow rate and the

pump performance.

If the liquid in the pit is static during long periods, sediments may

build up in the pit. The pump should therefore be started at least

twice per 24 hours.

8. Transportation

When handling and transporting the pit at low temperatures, take

into consideration that the pit impact resistance is reduced.

Precautions in order to avoid damage to the pit during handling/

transport:

• Do not tip the pit from the lorry.

• Use straps of textile or similar materials when lifting the pit on

or from a lorry or moving it.

• Do not drag the pit over the ground.

• Always use a suitable means of transport.

• Point loads must not occur.

• The pit must not be exposed to sharp edges.

• Fix the pit securely during transport.

Fig. 10 Lifting the pit (PUST04 - PUST10)

TM02 9499 0805TM02 9498 0805

Warning

The pit must be locked to prevent unwanted

access.

TM02 9496 2704

TM02 9340 2404

English (GB)

Fig. 11 Lifting the pit (PUST17)

9. Installation

Fig. 12 Schematic installation drawing

Foundation layer

• The bottom of the pit must have a foundation layer if soil

analyses and information about pit load show that the bottom

is not capable of bearing. 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.

Bedding layer

• The material for the bedding layer must be compactable and

composed so that neither its properties nor 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 usually have a thickness of 10 cm.

If the bottom of the excavation meets these requirements, a

bedding layer is not required.

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 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).

Place the pit on the bedding layer.

Check that the pit is vertical.

Groundwater must not rise above the bedding layer until the

backfilling has been completed.

Fig. 13 Insufficient compaction under pipes

Fig. 14 Oval pit after compaction

TM04 9511 4410

Warning

Observe local regulations.

TM02 9362 2404

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 traffic

loads must not occur

Caution

The location of the pit must be selected so that

its establishment does not damage other

constructions. Conversely, these must not

damage the buried pit.

Warning

Before the pit is lowered into position, various

connections must be retightened, as they may

have become loose during the transport.

Note

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.

Note

Compact the bedding layer under the inlet and

discharge pipes properly so that they are not

exposed to downward loads when the backfill is

compacted. See fig. 13.

TM02 9360 2404

Note

During backfilling, the cover must be on the pit to

ensure that the pit is not deformed (becomes

oval).

TM02 9361 2404

English (GB)

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/construction contractor and are outside

Grundfos’ area of responsibility.

9.1 Pipe connection

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

drilled at site.

Mark the pit where the inlet is to be. Drill the marked spot with a

hole saw. Remove all burrs from the hole. The hole saw is

available as an accessory. See table.

9.1.1 PUST04 - PUST10

Fig. 15 Drilling the inlet, ∅400-1000 mm

9.1.2 PUST17

Drilling from the outside

If the hole diameter is greater than 150 mm or the hole is to be

drilled into a rib, drill in the centre of a rib. See fig 16.

Fig. 16 Drillilng from the outside

Drilling from the inside

Due to the circular pit shape, the pilot drill must extend beyond

the cutting edge of the hole saw by at least 23 mm. The position

of the hole is not an issue. See fig 17.

Fig. 17 Drillilng from the inside

Caution

If the hole for the pit is drilled, pay special

attention to the compaction of the backfill to

prevent uplift.

Caution

Use mechanical compacting equipment and

compact the backfill to 98-100 % proctor density.

Caution

The above requirements are minimum

requirements. Observe local regulations.

Sleeve

Pipe diameter

Product number

Hole saw [mm]

Borehole tolerance

[mm]

Product number

LM50/40 40 96230763 51 - 2/+ 1 96571532

LM50/50 50 96230753 60 - 2/+ 1 96571533

LM50/63 63 96571523 75 - 2/+ 1 96571534

LM50/75 75 96571527 86 - 2/+ 1 96571535

LM50/90 90 96571528 102 - 2/+ 1 96571536

L965/110 110 91716040 127 - 0/+ 2 91713756

L965/160 160 91713754 177 - 0/+ 2 91713755

LM100/200 200 91712032 212 - 2/+ 1 91712025

Pilot drill 91712026

TM02 9342 2404

We recommend to

drill the inlet in the

cylindrical,smooth

part.

Note

The hole saw must have a cup depth of minimum

90 mm.

Caution

The inlet must not be drilled in the pit close to

pipes, float switches or other parts of the pit

installation.

TM04 9441 4210TM04 9573 4610

English (GB)

9.2 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 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. 20.

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

5. Chamfer the pipe and press it home.

LM50/100 sleeves: Push the inlet pipe through the sleeve.

See fig. 18.

Fig. 18 Pipe with LM50/100 sleeve, seen from side

L965 sleeves: Push the inlet pipe into the sleeve and against the

stop. See fig. 19.

Fig. 19 Pipe with L965 sleeve, seen from side

Fig. 20 Pipe with L965 sleeve, seen from top

9.3 Installation of pump

Some versions come without the pump installed. For installation

and start-up of the pump, see the installation and operating

instructions of the pump.

9.4 Pipework with flange connections

9.5 Fitting the chain

In the case of pumps on auto coupling, we recommend to fit the

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

of lifting eyes depends on the pump.

Fig. 21 Chain fitted to pump

10. Pump control

When installing the level switches, the following points should be

observed:

• 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 1-pump operation, the start level switch should

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 2-pump operation, the start level switches

should be installed in such a way that pump 2 is started before

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

to the pit, and so that pump 1 is started correspondingly

earlier.

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

10 cm 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 pump controller selected.

10.1 Start and stop levels

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

number of starts does not exceed the maximum permissible

number. See the installation and operating instructions of the

pump.

10.2 Installation of level controller

See the installation and operating instructions of the controller.

Note

As it must be possible to pull the pump up

through the pit, the inlet pipe must not project

beyond the sleeve by more than 5 cm.

TM03 3709 0806TM03 3708 0806TM03 3768 1006

Caution

Lower the pump carefully into the pit in order to

avoid damage to pump and pit.

Pit side

Max. 5 cm

Pit side

Note

If the pit is to be installed at a temperature below

0 °C, slacken all bolts of the flange and retighten

them when the pit has been installed.

This prevents stress in the pipes.

TM02 9341 2404

Warning

The lifting equipment used for lifting the pump

must be rated for the weight of the pump and

approved according to local regulations.

English (GB)

10.3 Float switches

If float switches have been selected, they can be fitted on a tube

which can be lifted out of the pit. This ensures easy adjustment of

float switches.

Fig. 22 Adjustment of float switches

The pit inlet must not be located within the area shown in fig. 23,

as it will disturb the function of float switches.

Fig. 23 Location of inlet

10.4 Rod electrodes

If rod electrodes are used for level measurement, note that the

rods come in standard length (1 m). When they are installed, their

length must therefore be adjusted so that they are activated at

the correct levels.

If possible, bend the rods away from each other so that paper and

similar items cannot get stuck between the rods and disturb the

signal.

When they have been shortened, 10 to 15 mm of the lower end of

the rods must be stripped.

The rods come with 10 metres of cable.

Fig. 24 Rod electrodes in a pit with one pump

Fig. 25 Rod electrodes in a pit with two pumps

10.5 Air bells

Air bells are pulse generators for the pressure switches of the

controller and function by means of pneumatic pressure changes.

The pressure changes when the liquid level in a pickup changes.

The air bells are connected to the pressure switches of the

controller by means of hoses.

Fig. 26 Air bells in a pit with one pump

10.6 Pressure transducer

If a pressure transducer is used, it should be installed in a riser

pipe in order to prevent contamination and deposits.

10.7 Other types of level control equipment

See the installation and operating instructions of the equipment.

Note

Note that the bottom float switch (stop) must stop

the pump before the level in the pit falls below

the minimum level of the pump. See the

installation and operating instructions of the

pump.

TM02 8960 1204

A Min. 300 mm

B 50 to 100 mm

C Deactivation range 110 mm

Caution

Distance B must not be too big as otherwise the

float switch may get stuck in other parts of the

installation.

TM02 8961 1204

200 200

TM02 8962 1204TM02 8963 1204TM01 9345 2404

Alarm: 32

Start: 22

The stop level

depends on the

pump type.

Common: 11

Alarm: 42

Start2: 32

The stop level

depends on the

pump type.

Common: 11

Start1: 22

CU211

CU 211

English (GB)

11. Electrical connection and start-up

See the installation and operating instructions of the pump and

the controller.

12. Maintenance

See the installation and operating instructions of the pump and

the controller.

13. Service contract

It is possible to make a service contract with Grundfos.

14. Disposal

This product or parts of it must be disposed of in an

environmentally sound way:

1. Use the public or private waste collection service.

2. If this is not possible, contact the nearest Grundfos company

or service workshop.

3. If it is not possible to dispose of the product as a complete

unit, the pump installation can be removed from the pit, and

the pit can be filled and covered.

Note

The controller must not be installed in the pit.

Warning

Secure the pit cover against overload and

unwanted opening and removal.

Subject to alterations.

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