FASTflo MINI Series User manual

®
1000
SERIES
MINI
SERIES
1500
SERIES
2000
SERIES
INSTALLATION MANUAL
Packaged Pump Station
Providing Pumping Solutions

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CONTENTS
GENERAL
Before You Begin 4
Health And Safety 5
PLUMBING
Plumbing Instructions And Installation Procedures 6
Typical Plumbing Installation 9
Tank Drawings ??
Uniseal Instructions 12
Important Notes For All Installations 13
Ventilation Requirements 14
Important Notice For Installer When Backfilling Holding Tank 15
ELECTRICAL
Electrical Wiring Instructions 16
Typical Electrical Installation Schematic 17
Std Control Box and Level Alarm Technical 18
Remote Alarm Plate Technical 19
Sealing of Control Panel Conduit 20
Float Switches – Technical 21
CHECKLIST
Pre Start Up Checklist 22

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yRead this manual completely before starting your installation.
yConsult local officials for any applicable codes and regulations.
yDetermine the best location for your tank and control panel.
yMinimize the use of elbows on the inlet line. If required only use 45° elbows.
yPlan your installation location carefully to insure a minimum 1:80 drop on the inlet line while staying within
the allowable inlet zone.
yDetermine where the incoming power will be supplied from and if it can handle the rated load for your pump
station.
yMount control panel in accordance with electrical codes and where alarm light can be easily seen.
(If applicable)
yObtain all necessary permits. Call your local relevant authorities before digging to locate all underground lines
and cables.
yMake sure you have the necessary equipment and supplies before starting your installation.
yDetermine the ballast requirements for your particular tank size.
yUse the electrical requirments specified.
BEFORE YOU BEGIN

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• Only qualified personal should, install, operate, and repair the pump and associated components.
• Safety and Protective clothing must be worn by service personal including overalls, protective footwear, and
rubber gloves, and safety glasses.
• Do not touch or allow any sewage to come in contact with hands or mouth as sewage contains a multitude
of germs, and infectious pathagens which could cause serious illnesses.
(We recommend all operators have a tetanus injection prior to working in these pump stations)
• Do not enter the tank under any circumstances as sewage contains toxic and explosive gases which could
cause suffocation. (If the tank is to be entered by the contractor then standard confined space procedures
must be followed).
• Do not smoke or light any matches in the vicinity of the pump station to avoid the risk of explosion.
• Always make sure that the power supply to the pump station is switched off and safely isolated, using
standard isolution procedures to reduce the risk of electrical shock or hazards
• Keep hands and fingers away from pump suction and discharge openings and do not insert fingers in pump
while power is connected as this could cause serious personal injury.
• Do not leave the pump cover/lid off the pump chamber except while servicing to prevent foreign materials
entering, or the danger of children falling into tank. (We recommend that a cone is put near the tank, and
the tank is fenced off with a safety netting around tank while being serviced).
NB: PUMP AND VALVE SPECIALTIES IS NOT RESPONSIBLE FOR LOSSES, INJURY OR DEATH RESULTING FROM A
FAILURE TO OBSERVE THESE SAFETY PRECAUTIONS, MISUSE OF PUMPS OR EQUIPMENT.
HEALTH & SAFETY

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IMPORTANT: Please read all instructions before commencing installation.
1. Excavate hole for tank. Excavation should be 100mm deeper than tank.
Approximate excavation hole size to allow:-
FASTFLO MINI 950mm deep x 1.0m diameter
FASTFLO 1000 1.8m deep x 1.5m diameter
FASTFLO 1500 2.2m deep x 1.5m diameter
FASTFLO 2000 2.7m deep x 1.5m diameter
2. Lay 100mm of sand, pea or drainage metal in base of excavation, in order for tank to be bedded on a at base,
and also shaped to suit tappered base of tank.
3. Lower pump station into excavated hole and check for level. Pump station lid should be flush with finished
ground level.
4. Tank should be backfilled as soon as possible, as follows:
For low water table areas:-
Partially backfill with a cohesive backfill and compact in 300mm layers around tank (up to sewer inlet level
only) using a mechanical plate compactor or vibrator. Ensure that tank is filled with water and kept same
level while backfilling tank.
For high water table areas:-
If bottom of tank is below maximum ground water level, then tank should be bedded down in concrete
whilst still fresh, and concrete continued up side of tank to just above second rib, or more for high water
table areas. Ensure that the tank is filled with water ahead of pouring concrete balanced and kept at the
same level while backfilling tank.
If the tank is in a trafficable area, then an additional concrete cover slab should be poured with heavy duty
lid option. (See Note 16)
Alternatively, continue concrete up sides of tank to the underside of the cover slab (inlet and electrical
outlet pipes to be done first – Refer No’s 5 – 11).
5. Cut sewer inlet hole with hole saw, in the desired position (usually between 1st and 2nd rib from top) and
insert large rubber inlet uniseal in hole from outside.
Hole sizes are as follows:- (Refer to seperate instruction page)
For 110mm uPVC = 127mm hole saw size
For 160mm uPVC = 170mm hole saw size
Lubricate inlet uniseal with o’ring lubricant or similar, and insert PVC inlet pipe (gravity drain) into tank.
PLUMBING INSTRUCTIONS
& INSTALLATION PROCEDURES

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6. Install 90º ramp/inspection bend (large inspection type) or 90º M&F inspection junction (supplied by others)
on inside of tank, so as to direct liquid flow downwards into the pump chamber. This also allows access for
plugging and water testing gravity drain.
Sewer drain is now ready to be laid from pump station inspection bend or junction back up to dwelling/
building.
7. Install vent from top of tank if required. Refer to separate page on Vent Requirements.
8. Cut discharge hole in tank wall with a hole saw, in desired position/direction (normally 75mm above top
rib). Insert the small rubber discharge uniseal into discharge hole on inside of tank, and lubricate with o’ring
lubricant or similar.
Hole sizes are as follows:-
For 50mm PVC pressure pipe = 76mm hole saw size
For 80mm PVC pressure pipe = 102mm hole saw size
For 100mm PVC pressure pipe = 127mm hole saw size
9. Screw vertical discharge pipe into pump outlet (if not already installed).
Note: If overall discharge height out of tank is lower than standard height, then shorten vertical discharge
pipe to suit.
Glue swept discharge bend (with valves attached) onto vertical pipe before installing pump(s), making sure
bend is facing over top of pump(s).
Note: The non-return ball valve(s) “Y” leg must always be facing upwards, as per the prefabricated
position. This must not be altered to any other position, as this will cause operational failure.
10. Install pump(s) in tank, as close to centre as possible. Pump(s) should sit on flat base of tank, so that when
valves are installed later, they are easily accessible when lid is open. Allow enough room for gravity drain
inlet bend/junction if directly opposite pump discharge position.
11. Install short PVC discharge pipe with coupling nut from inside tank. Push through the rubber uniseal
the required distance, so as to match up to pump pipework, and tighten quick connect coupling. Extend
discharge pipework beyond pump station to discharge point, in pipe material selected.
12. Hang rope(s) or chain(s) on hook(s) at top corner of tank. If hooks not mounted, position in corners adjacent
to pumps. KEEP CHAIN(S) WELL AWAY FROM PUMP FLOATS – ON OPPOSITE SIDE OF PUMP FLOATS, TO
AVOID MALFUNCTION.
13. Electrician to install 32mm/50mm PVC electrical conduit(s) and wiring between pump station and control
box/panel (mounted on building adjacent to pump station). Refer to electrical installation diagram and
instructions. Refer to Electrical Wiring Instructions for testing pump(s) and alarms.
14. Feed pump and alarm float cables through conduit(s) to control box/panel.

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15. Check that pump control and alarm floats are free and clear of any obstructions.
Check that high level alarm float is not below sewer inlet drain. If so, it must be shifted to one side, as this
could cause malfunction of alarm.
Correct high level float operating position should be approx. 200mm below the invert level.
Some special electrical instructions may apply to 3-phase single or dual pump stations.
16. Complete backfilling as follows:-
OPTION 1: STANDARD PE PEDESTRIAN-RATED LID
Original Back-fill can be brought up to & flush with tank lid. Aim to slope ground away from lid (if possible)
to stop any water ponding around lid area.
OPTION 2: CAST IRON TRAFFICABLE-RATED LID
Cast Iron lid / frame needs to be set in a concrete apron (i.e. 100mm – 150mm cover slab x 300mm wide),
which is poured above the top of the P.E tank opening.
Allow for a 20 – 25mm gap to separate the cast-iron lid from the PE pump station neck, to avoid direct
traffic load bearing onto P.E tank. (Refer to drawing FFP40A).
17. Pump Station may now be commissioned as follows:-
(a) Fill tank with water up to normal pump working float level and check pump operation.
(b) Lift high level float and check audio-visual alarm operation.
(c) Check that ball isolation valve in tank is turned on.
(d) Bolt down lid with stainless steel bolts provided or padlock lids if provision available.

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TYPICAL PLUMBING INSTALLATION
Installation Notes:
yGround level should be sloping away from tank to avoid ponding and oatation of pump station
yPosition tank at the lowest part of drainage system or in a position appropriate to drainage system.
yDrill gravity inlet and discharge pipe between ribs of pump chamber at a height to suit the on-site conditions.
yControl Panel to be mounted on wall in a position within close proximity to pump station
yTank to be backlled with compatable material in 300mm layers.
yMust have a concrete plug in high water table areas.
Road
Council Drain or
Manhole
Discharge pipe
(PE or PVC)
PE acess lid
Gravity Drain
PE Holding Tank
Sub Pump
Allow for concrete plug in high
water table areas
Cohesive Backll
(compacted in 300mm layers)
100mm Sub Base
(compacted - ne grade scoria or similar)
VENT (Option 1)
80mm vent pipe vented
to atmosphere.
(If 80mm TV not available)
VENT (Option 2)
80mm TV
OR

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DRAIN INLET
BY OTHERS
ISOLATING
VALVE
HIGH LEVEL
ALARM
POLYETHYLENE 330
LITRE TANK
TANK RIB
QUICK
COUPLING
DISCHARGE
PIPE
CONCRETE BALLAST (0.3m3)
REQUIRED IF INSTALLED IN HIGH
WATER TABLE AREA (BY OTHERS)
PUMP FLOAT
SWITCH
SUBMERSIBLE PUMP
SELECTION TO SUIT SITE
CONDITIONS
NON RETURN
VALVE
650mm sq POLYETHYLENE LID
850
820 dia. TANK
SEPT 2010
NTS
FFP 30/A
FASTFLO " MINI" PUMP STATION
(ROUND 330 TANK LITRE TANK)
TYPICAL ARRANGEMENT
FASTFLO PUMP SYSTEMS
41 Raiha St, Elsdon, Porirua
P O Box 56-008, Wellington 5249
Tel [phone] Fax [phone]
NB: Tank must be vented
(refer seperate page)
MINI 330 LTR TANK

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CONCRETE BALLAST
REQUIRED IF INSTALLED IN
HIGH WATER TABLE AREA
(BY OTHERS)
400
150
1680mm (1000 model) OR 2200mm (1500 model) OR 2600mm (2000 model)
1140mm Diameter
610x610 SEALED ACCESS COVER
FIXED WITH TAMPER PROOF SCREWS
HOLES FOR REO
RODS (IF
REQUIRED)
WATERPROOF CABLE
CONNECTORS
DOUBLE UNION
ISOLATING VALVE
UNISEAL
S.S. CHAIN
1800
CONDUIT TO
CONTROL BOX
(by others)
FIXED HOOK
100mm INLET
DRAIN AND
INSPECTION BEND
(BY OTHERS)
HIGH LEVEL FLOAT
SWITCH
SUBMERSIBLE PUMP
SELECTION TO SUIT SITE
CONDITIONS
NON RETURN
VALVE
PUMP FLOAT
SWITCH (32dia OR 50 dia)
DISCHARGE PIPE
JULY 12
FASTFLO "1000/1500/2000" SINGLE PUMP
PACKAGED PUMP STATION
TYPICAL ARRANGEMENT
1:10
FFP1-A
FASTFLO PUMP SYSTEMS
41 Raiha St, Elsdon, Porirua
P O Box 56-008, Wellington 5249
Tel [phone] Fax [phone]
NB: Tank must be vented
(refer seperate page)
1000/1500/2000 LTR TANK

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1. Cut hole to the Holesaw size indicated for the UNISEAL® you are using (see below).
Example: 3” UNISEAL® =4” Hole (Holesaw).
2. Ensure that the hole is clean cut with sharp edges. Irregularities could cause poor seating and ultimate leakage.
3. Insert the UNISEAL® into the hole with the wide side facing the pipe to be inserted.
4. Make certain that the pipe end to be inserted is clean cut. File the edges so that there are no sharp points
to cut UNISEAL®.
5. Using detergent, lubricate the outside of the pipe end to be inserted, then push the pipe through the
UNISEAL® from the large flange side. The detergent will be squeezed off as the pipe passes through the
UNISEAL®. The co-efficient of friction of the rubber holds the pipe tightly in place.
SIDE VIEW
Wall
UNISEAL
Pipe
SPECIFICATIONS
Wall Thickness – 1/8” X ½” 3mm – 12mm
Part # DN# Pipe ID Pipe OD Holesaw
U018 3/16” 0.25” 6mm 0.375” 10mm
U025 ¼” 0.375” 10mm 0.5” 12.7mm
U038 10 3/8” 0.675” 17mm 1” 25.4mm
U050 15 ½” 0.840” 21mm 1.25” 31.7mm
U075 20 ¾” 1.050” 27mm 1.25” 31.7mm
U100 25 1” 1.315” 33mm 1.75” 44.4mm
U125 32 1” 1.660” 42mm 2” 50.8mm
U150 40 1 ½” 1.900” 48mm 2.50” 63.5mm
U200 50 2” 2.375” 60mm 3” 76.2mm
U300 80 3” 3.500” 89mm 4” 101.6mm
U400 100 4” 4.500” 114mm 5” 127mm
U600 6” 6.625” 168mm 7” 178mm
U400-35 4” 110mm 5” 127mm
U600-35 6” 160mm 7” 178mm
Metric Hole Tolerance +2mm.
UNISEAL INSTRUCTIONS

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PLEASE READ CAREFULLY
ALL WORK MUST BE CARRIED OUT BY A REGISTERED DRAINLAYER AND MUST
COMPLY WITH THE PLUMBING REGULATIONS AND CODES OF PRACTICE
1. Each FASTFLO Pump Station installation should be done in accordance with local Territorial Authority
requirements.
2. All discharge pipework bends should be large radius type (formed swept bends).
3. Keep pipe runs to discharge as direct as possible and keep number of bends to a minimum for smooth
liquid flow.
4. Minimum discharge pipe diameters as follows:
Vortex & Cutter pumps: 50mm I.D.
Grinder pumps: 40mm I.D.
For longer pipe runs, consult with Fastflo Pump Systems.
5. Check that all pump leads, chains, high level floats, etc, are free of obstructions, and that high level floats
are not below sewer inlet drains.
6. PUMP STATION VENTING: Refer separate vent requirement details.
7. Once installed, tank must be left with enough water in it to avoid any risk of flotation caused by heavy
rainfall or unpredicted water entry. This also applies if tank installation is left uncompleted temporarily, as
well as when unit is fully installed.
8. Make sure there is no chance of any stormwater entry, e.g. entry from unfinished downpipes or any
rainwater/drainway runoff.
9. Once unit is installed, never leave lid(s) unbolted or unpadlocked at any time, to avoid serious or fatal injury.
IMPORTANT NOTES FOR ALL INSTALLATIONS

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PLEASE READ CAREFULLY
ALL VENTING MUST COMPLY WITH THE PLUMBING REGULATIONS, CODES OF
PRACTICE AND THE PLUMBING AND DRAINAGE STANDARD AS/NZS3500.2 : 2003.
FASTFLO Undersink Sullage Chamber
Must be vented at all times to atmosphere.
Minimum vent size should be 32mm
FASTFLO MINI / 1000 / 1500 / 2000 Models
Refer to Drg No’s FFP.1 and FFP.2.
For Domestic Applications
Vent size required: 80mm either indirectly or directly.
If the pump station is within 40 mtrs of the 80/100mm house drain TV(Terminal Vent) and the dwelling has less
than 3 WC pans - then no extra vent pipe is required.
If the 80mm house drain vent has been reduced in size then a seperate 80mm pump chamber vent should be
provided. All vents to atmosphere shall terminate in accordance with AS/NZS3500.2 and vent shall be taken
from the top of the pump chamber.
For Industrial / Commercial Applications
Vent size required: 80mm Above ground level
100mm From tank / below ground level
All vents to atmosphere shall terminate in accordance with AS/NZS3500.2 and vent shall be taken from the
top of the pump chamber.
FASTFLO 3000 / 4000 / XL / FRP Models
Refer to Drg No’s FFP.10 and FFP.11 (3000 & 4000)
Minimum vent size required: 80mm Above ground level
100mm From tank / below ground level
All vents shall terminate in accordance with AS/NZS3500.2 and the vent shall be taken from the top of the
pump chamber.
IMPORTANT NOTE
AIR ADMITTANCE VALVES MUST NOT BE USED ON A FASTFLO PUMP STATION AT ANY TIME.
ALL VENTS MUST BE OPEN TO ATMOSPHERE.
VENTILATION REQUIREMENTS

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WARNING: Tank otation may occur if not installed correctly.
Installation in LOW WATER TABLE AREAS
1. To avoid flotation, the tank must be backfilled with cohesive compactable backfill - AP40 Crush metal or
similar and compacted in 300mm layers, keeping compactor approx. 150mm from side of tank.
DO NOT backfill with shingle or pea metal.
2. The tank must be gradually filled with water at the same time as the backfilling level, to ¾ of the way up
the tank.
Installation in HIGH WATER TABLE AREAS:
1. The tank must be approximately half filled with water ahead of concrete being poured around tank.
2. The tank requires concrete to be placed around tank ribs, around sides of tank.
Minimum amount of concrete:
250 litre Valve Box 0.2m³ concrete
330 litre Mini Tank 0.3m³ concrete
500 litre Double Valve Box 0.3m³ concrete
1000 litre Tank 0.5m³ concrete
1500 litre Tank 0.75m³ concrete
2000 litre Tank 1.0m3concrete
3. If further backfill is required, this should be compacted in 300mm layers (as above), BUT ONLY ONCE
CONCRETE HAS SET.
4. Tank should continue to be filled with water as the backfilling is done.
IMPORTANT NOTICE FOR INSTALLER WHEN
BACKFILLING HOLDING TANK

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ELECTRICAL WIRING INSTRUCTIONS
1-PHASE OR 3-PHASE PUMPS
ALL WORK MUST BE DONE BY A REGISTERED ELECTRICIAN AND MUST COMPLY WITH THE
ELECTRICITY REGULATIONS AND CODES OF PRACTICE.
1. The pump station requires a dedicated 20 amp power supply from the nearest switchboard.
2. Supply and install the following rigid conduits between the control panel (or cubicle) and the pump
chamber:-
1 x 32mm for single pump
2 x 32mm for dual pumps
Plus 1 x 32mm for float/sensor cables
• Conduits are to be lock nutted into chamber wall and into the control panel.
• Large radius or swept bends only to be used.
• Ends of conduit to be sealed to prevent the transfer of sewer gas which is extremely corrosive to
electrical components.
3. Run pump and float flexible cables directly into the control panel, via the conduits detailed above.
If the control panel distance exceeds the available cable length, an approved accessible joint must be made
to extend the cables.
4. Some floats have 3 conductors for change-over switching, it is important to seal off the spare core, as
under certain circumstances it could be alive.
5. Before lowering the pumps into the tank, check that the pump is operating. For 3-phase pumps, check
directions of rotation, by observing the direction of the starting kick when power is momentarily appliedl.
The starting kick should be anti-clockwise when looking down the pumps.
Check correct setting of overload to match the pump running current.
6. Check starting and stopping of each pump, and the auto-alternating feature of the dual pumps.
7. Check operation of the alarm by lifting up the alarm float.
8. Float operating levels may be adjusted by changing the length of the cable drop.
PUMP TECHNICAL DATA
MODEL PUMP kW Rating Amps Phase Type
VX F-21U(F) 0.75 kW 5.3 Amps 1-phase Vortex
CR F-21P(F) 0.75 kW 5.3 Amps 1-phase Cutter
GR 32GF21.0(F) 1.0kW 6.4 Amps 1-phase Grinder
GR PLUS 32GF21.5(F) 1.5 kW 10.2 Amps 1-phase Grinder

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TYPICAL ELECTRICAL INSTALLATION SCHEMATIC
Notes:
y32mm conduit (to be sealed at both ends to prevent gas entry)
y1x2 core + E pump cable 2.5mm2circular
y1x3 core alarm cable 0.75mm2circular
y1x 4 core security cable from Controller to Alarm Plate inside
yMax length of pump cable = 8m
yMax length of alarm cable = 8m
yIf pump station is to be further than 6m from house, pump and control cables will need to be extended -
ensure joint is waterproof.
yNo cable joints are permitted in conduit.
32mm conduit
Pump Float (on/off)
Pump Cable
Control
Box
Sub Pump
PE Pump Chamber
HL Alarm Float
230V in • 2-Core + Earth
• Minimuim 2.5mm2
• 20 AMP
4 Core
security
cable
Alarm plate (ts into
standard electrical
ush box)

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STD CONTROL BOX & LEVEL ALARM TECHNICAL
POWER ON LED
Indicated mains
power is on
HIGH LEVEL
LED
Indicates a
high wetwell
level
MUTE BUTTON
Mutes alarm/test function if pressed for 3 secs
ALARM PCB
Provides
alarm
fuctionality
CONTROL MCB
Isolates alarm PCB
TERMINALS
Connection
to external
wiring
OVERLOAD
RESET
BUTTON
Shuts off
if pump is
blocked

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REMOTE ALARM PLATE TECHNICAL
POWER ON LED
Indicated mains
power is on
HIGH LEVEL LED
Indicates a high
wetwell level
MUTE BUTTON
Mutes alarm/test function if pressed for 3secs
POWER IN
TERMINALS
Power from
alarm PCB
NC/NO SELECTOR
SWITCH
Changes from a
high to low level
(N/O) always)
LEVEL INPUT
TERMINALS
From alarm PCB

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STEPS & TIPS:
yConduit entering controller should be sealed to prevent water/fumes inltration.
yOr cable/s should be glanded correctly in open conduit installs
yBefore installing the cover make certain that all cords are cable-tied up and clear of the pump level control.
SEALING WHERE CONDUIT ENTERS
ELECTRICAL ENCLOSURE
(IF SEALED SEPARATE VENT MUST BE USED)
SEALING WITH CABLE GLAND
(WHEN SEALED CABLE GLAND OPTION
SHOULD BE USED)
SEALING OF CONTROL PANEL CONDUIT