Grundfos iGRID P-Zone User manual

iGRID P-Zone and T-Zone
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

2

Table of contents
3
iGRID P-Zone and T-Zone
English (GB)
Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Deutsch (DE)
Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dansk (DK)
Monterings- og driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Nederlands (NL)
Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Polski (PL)
Instrukcja montażu i eksploatacji . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

English (GB)
4
English (GB) Installation and operating instructions
Original installation and operating instructions
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
The product is designed for use as a pressure boosting unit (P-
Zone) or temperature mixing loop (T-Zone) in a district heating
transmission network. The product must be operated by trained
persons with knowledge of district heating systems.
The product must be connected to an existing district heating
network according to local technical regulations. The connection
is handled by the local district heating company or its business
partners.
1. General information 4
1.1 Hazard statements 4
1.2 Notes 4
1.3 Target group 4
2. Receiving the product 5
2.1 Transporting the product 5
2.2 Inspecting the product 5
2.3 Lifting precautions 5
3. Installing the product 6
3.1 Preparing the foundation 6
3.2 Installing the pit 7
3.3 Pump or pumps and pump control 9
3.4 Level control of the drain pit 9
3.5 Sensors 9
3.6 Electrical connection 10
3.7 Starting the pit 10
3.8 Complete work in the pit 11
4. Product introduction 11
4.1 P-Zone product description 11
4.2 P-Zone application 12
4.3 T-Zone product description 12
4.4 T-Zone application 12
4.5 Pumped liquids 12
4.6 Identification 13
5. Servicing the product 16
5.1 Accessing the products 16
5.2 Replacing a pump 17
5.3 Lifting a detached pump 17
5.4 Replacing a non-return valve, gasket, fixture tap or flow
sensor in the pipe system 17
5.5 Replacing a pressure sensor in the pipe system 18
5.6 Replacing a temperature sensor 18
5.7 Completing service 18
6. Taking the product out of operation 18
6.1 The pit is removed from the hole 18
6.2 The pit remains in the hole 18
7. 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)
5
2. Receiving the product
2.1 Transporting the product
• Transport the product in a vertical position and fasten it to the
vehicle. See fig. 1.
Provide adequate lifting equipment at the location of delivery.
The weight of the pit is shown on the nameplate and the product
label.
Follow the instructions below when transporting and
handling the product
• Secure the product properly during transport, see fig. 1.
• Do not tilt the product down from the vehicle. Lift the product
with lifting equipment in the lifting brackets of the product.
• Handle and lift the product according to local regulations. See
fig. 2.
• Use only approved straps made of textile or similar material
when lifting the product up or down from a vehicle or moving it
at the construction site.
• Do not expose the product to point load.
• Do not drag the product across the foundation.
• Do not expose the product to sharp edges.
• Place the product on a level surface.
Fig. 1 Fastening during transport
2.2 Inspecting the product
Check the product after transport and before installation.
The check must include the following:
• Check if the product has been damaged during transport. In
the event of damage, contact the transport company
immediately.
• Check that the delivered product is according to the order.
• Check the position and sizes of pipes.
• Tighten various joints as they may have loosened during
transport.
2.3 Lifting precautions
2.3.1 Lifting of pit with standard top cover
Use the lifting yoke as shown in fig. 2.
Fig. 2 Lifting of pit with standard top cover
2.3.2 Lifting of pit with heavy load top cover
Fig. 3 Maximum angle of inclination
Ensure that the product is correctly fastened. The
exterior pipe connections are not intended for
fastening during transport. See fig. 1.
When transporting and handling the product at low
temperatures, take into account that the impact
resistance of the product may be reduced.
TM07 4787 2019
The pit is fitted with lifting brackets. Always use the
lifting brackets when handling the product.
WARNING
Crushing hazard
Death or serious personal injury
- Do not stand under or close to hanging load.
- Follow local regulations when working in the pit.
WARNING
Crushing hazard
Death or serious personal injury
- Check that the lifting equipment can lift the load
before lifting the pit. See the weight on the
nameplate.
TM074891 2019
The units for pits with heavy load top covers are lifted
separately.
The maximum angle of inclination when lifting the
cover is 25 °.
TM06 3498 0615

English (GB)
6
Pits with heavy top load covers are delivered separately from the
metal cover, concrete slab and concrete ring.
1. Lift the pit as shown in fig. 2.
2. Lift the concrete ring as shown in fig. 4.
3. Lift the concrete slab as shown in på fig. 5.
4. Lift the metal cover as shown in fig. 5.
Fig. 4 Lifting the concrete ring
Fig. 5 Lifting the concrete slab and metal cover
3. Installing the product
3.1 Preparing the foundation
With reference to DS/EN 1997-1: Eurocode 7: Geotechnical
Category 2:
• We recommend that you conduct a geotechnical survey of the
conditions on site before installing the pit.
With reference to DS/EN 1997-1: Eurocode 7: Geotechnical
Category 1:
The geotechnical survey may be deemed unnecessary if the
following conditions are met:
• There is an insignificant risk of general instability, soil
movement or adverse conditions.
• Comparable local experience shows that the ground
conditions are sufficiently uncomplicated.
• There is no excavation under the water level.
• Comparable local experience shows that the proposed
excavation under the water level will be without complications.
In case of doubt, contact a geotechnical specialist.
Fig. 6 Principle sketch of the installation
3.1.1 Foundation layer
• If soil analyses and information concerning the strain of the pit
indicate that the soil cannot support the weight of the pit, a
foundation layer must be prepared.
• The bedding layer on which the pit is placed is not regarded as
a foundation layer.
• The foundation layer can be constructed by adding a stable
layer of suitable gravel after excavation which is compacted in
layers of no more than 30 cm corresponding to approximately
20 cm after compaction. A foundation layer is also necessary if
the hole was mistakenly dug too deep.
3.1.2 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.
• Particle size over 16 mm must not occur.
• The content of particles between 8 and 16 mm must not
exceed 10 %.
• The material must not be frozen.
• Sharp flint and similar must not occur.
• The bedding layer must have a thickness of 10 cm.
TM07 5343 3519TM07 5248 3519 - TM07 5264 3519
The installation of the pit must be carried out by
trained persons and according to local technical
regulations.
When placing the pumping station, be careful not to
damage any other equipment and vice versa.
TM07 5066 3019
Pos. Description
1 Foundation layer
2 Bedding layer
3 Backfill compacted in layers of maximum 30 cm
4Distance of 50 cm from the cover where heavy traffic
must not occur
1
2
3
44

English (GB)
7
3.2 Installing the pit
Before installing the pit, ensure that the foundation and bedding
layer have been carried out according to the guidlines in
3.1 Preparing the foundation.
Check for external damage to the pit before lowering it into place.
Once the pit is installed, no claims can be made against Grundfos
for any damage.
The following instructions will guide you through the installation of
the pit.
1. Place the pit on the bedding layer.
– Check that the pit is level or leaning slightly towards the
drain pump.
2. Perform the backfill. Ensure that the backfill is carried out
according to the guidelines in section 3.2.3 Backfill.
– Groundwater must not rise above the bedding layer until the
backfill is completed.
– Compact the backfill around the pit up to the lower part of a
pipe connection before connecting the pipes.
3.2.1 Connection of district heating pipes
Install a sensor to register water on the floor or
similar for an alarm to sound in case of flooding and
malfunctions in the pit.
Do not alter the design of the product.
Position the support for the lifting equipment at a
safe distance away from the hole to prevent it from
collapsing.
Carry out work according to local regulations.
DANGER
Falling hazard
Death or serious personal injury
- Ensure to mark off the area around the pit.
- Follow local regulations when working at the pit.
- Use the ladder and handles when descending into
the pit.
WARNING
Risk of being hit by a vehicle
Death or serious personal injury
- Ensure to mark off the area around the pit when
working in the pit.
- Follow local regulations when working in the pit.
WARNING
Crushing hazard
Death or serious personal injury
- Do not stand under or close to hanging load.
- Follow local regulations when working in the pit.
WARNING
Crushing hazard
Death or serious personal injury
- Check that the lifting equipment can lift the load
before lifting the pit. See the weight on the
nameplate.
WARNING
Crushing hazard
Death or serious personal injury
- Position the support for the lifting equipment at a
safe distance away from the hole to prevent it from
collapsing.
- Follow local regulations when working in and in
proximity to the pit.
WARNING
Steam
Death or serious personal injury
- Avoid tension in the pipe connections to the pit and
minimise thermal stress. See fig. 7.
WARNING
Steam
Death or serious personal injury
- Ensure that the welding is carried out without
tension.
- Ensure that the welded connections are carried out
according to the pipe manufacturer's instructions.

English (GB)
8
3.2.2 Avoiding tension in pipe connections
The pipe sections between the isolating valves must not be
removed due to tension in the pipes. See pos. 2 in fig. 7.
Fig. 7 Avoiding tension in pipe connections to the pit
Compact the backfill around the pit up to the lower part of a pipe
connection before connecting the pipes.
Before connecting the pipes, check the following:
• The pipes must be clean and protected with plastic plugs.
• The inlet pipes must be properly aligned in relation to the pipe
connections.
3.2.3 Backfill
Fig. 8 Even pressure on all sides of the pit
Observe the following conditions when you carry out the backfill:
• The backfill must meet the same requirements as those for the
bedding layer. See section 3.1.2 Bedding layer.
• 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.
Fig. 9 Even pressure on all sides of the pit
• The backfilling must be carried out so that the pit is not
damaged or deformed.
TM07 5212 3519
Pos. Description
1 Existing return pipe
2 Existing supply pipe without flow
3 New supply pipe, low temperature
4 New supply pipe, high temperature
5 T-Zone
The connection of district heating pipes must be
carried out by trained persons. The connection must
be done according to local technical regulations from
the local utility company and according to regulations
from the supplier of the district heating pipes.
45
321
WARNING
Risk of collaps
Death or serious personal injury
- Ensure the specified size of gravel is used for the
backfill.
The plate compactor must not have mechanical
contact with the pit and the connected pipes.
Use either a plate compactor or earth rammer when
working in proximity to the pit.
TM06 3602 0615
TM06 3603 0615
Use mechanical compacting equipment and compact
the backfill to minimum proctor density = 97 %.
1
Max.
25 kN
Max.
150 kg
1a
2

English (GB)
9
3.2.4 Protection against buoyancy
When correctly installed, the design of the pit provides protection
against buoyancy. The requirements for buoyancy protection
depend on the geotechnical conditions. They must be determined
by the engineer or the contractor and are outside Grundfos' area
of responsibility.
The buoyancy protection is determined according to Eurocode
EN 1997-1, including national supplementary provision DS/EN
1997-1 DK NA: 2015.
The most unfavorable groundwater conditions for the pit are
when the water level is at ground level. This creates the highest
hydrostatic water pressure at the bottom of the pit and results in
the highest reduction in soil weight for the stabilising soil volume.
The sand volume resting on the base plate of the pit has a
stabilising effect.
3.2.5 Installation of heavy load top cover
The covers are available for all pit sizes as accessories. The
heavy load top cover consists of a concrete ring, a concrete slab
and a metal cover. The parts are delivered separately.
Do the following:
1. Lower the concrete ring onto the compacted backfill. The
particle size beneath the concrete ring must be between 2 to
20 cm.
2. The concrete slab is placed on top of the concrete ring.
Ensure that there is at minimum 5 cm between the concrete
slab and the pit.
3. The concrete slab must be covered with asphalt, soil or
another type of cover. See fig. 10.
Fig. 10 Installation of heavy load top cover
3.2.6 Installation of standard top cover
The cover is fitted from the factory on top of the iGRID P-Zone
and the T-Zone pit with bolts, washers and nuts.
3.2.7 Installation of insulating pads
Attach the subsequently purchased insulating pads. When
installing the insulating pads after startup, see section
5. Servicing the product.
3.3 Pump or pumps and pump control
iGRID P-Zone and T-Zone is delivered with the pump or pumps
installed. See the pump installation and operating instructions for
pump startup.
3.4 Level control of the drain pit
Sensor for level control of the water level in the drain pit is set by
Grundfos at delivery.
3.5 Sensors
3.5.1 Sensors for temperature measurement in district
heating pipes
If the iGRID P-Zone and T-Zone have pre-installed temperature
sensors, check that the working range of the sensors
corresponds to the expected working pressure. Temperature
sensors are mounted in thermowells.
3.5.2 Sensors for pressure measurement in pipe connections
If the iGRID P-Zone and T-Zone have pre-installed pressure
sensors, check that the working range of the sensors
corresponds to the expected working temperature.
3.5.3 Sensors for flow measurement in pipe connections
If the pit has a pre-installed flow sensor, check that the working
range of the sensor correponds to the expected flow.
The requirements below are minimum requirements.
Observe local regulations.
WARNING
Falling hazard
Death or serious personal injury
- Ensure to mark off the area around the pit.
- Follow local regulations when working at the pit.
TM07 5257 3519
Pos. Description
1 Asphalt
2 Heavy load top cover
3 Concrete slab
4 Concrete ring
5 P-Zone/T-Zone
The cover must be locked with special tools to
prevent unwanted access.
The foundation layer for the cover must be able to
carry the load which the cover is intended for. Carry
out work according to local regulations.
12 3 45
Place the cover at least 20 cm above the terrain.
The cover must be locked with a pad lock to prevent
unwanted access.
Temperature sensors in district heating pipes are not
standard with iGRID P-Zone.

English (GB)
10
3.6 Electrical connection
3.6.1 Installing the cables
The cables for the pump or pumps are lead through a cable
bushing in the side of the pit. Ensure that the cable connections
are waterproof.
Flexible cables must always be used inside the pit between the
pump and the junction box for vibration in the cables.
3.6.2 Routing of cables
The cables between the power box and the pump or pumps must
be routed in the pre-assembled cable trays or channels.
3.7 Starting the pit
WARNING
Electric shock
Death or serious personal injury
- All electrical connections must be carried out by an
authorised electrician according to local
regulations.
DANGER
Electric shock
Death or serious personal injury
- The system must be fitted with an external
disconnecting device. Ensure that the
disconnecting device can be locked in the
disconnected position [OFF].
- If not supplied by Grundfos, the pumps must be
individually fitted with an external disconnecting
device.
DANGER
Electric shock
Death or serious personal injury
- If the regulations require a residual-current device
(RCD) or similar, see the pump and motor
installation and operating instructions.
- All electrical installations must comply with EN
60204-1 and local regulations.
- No constructive changes must be made to the
product.
WARNING
Electric shock
Death or serious personal injury
- Follow the installation and operating instructions
for the pump or pumps and other electrical
equipment.
WARNING
Electric shock
Death or serious personal injury
- Ensure that any control panels and internal pipe
installations are connected to earth.
WARNING
Electric shock
Death or serious personal injury
- Ensure that the cables do not touch hot surfaces.
When installing or removing the pump, do not pinch
or damage the cables.
– When working in or near an open pit, always
place warning signs and safety guards around
the pit to ensure that persons and vehicles do
not fall into the pit. The warning signs must be
clearly marked and visible from all sides.
– The cover and locking device must be operated
by the same person.
– The cover and locking device must only be used
when no persons are in the pit.
WARNING
Falling hazard
Death or serious personal injury
- Ensure that the cover has been properly opened
and secured against closing while work is
performed in the pit.
- Use personal protective equipment when working
in the pit.
WARNING
Steam
Death or serious personal injury
- Ensure that the pipe connections are carried out
according to the pipe manufacturer's instructions
before startup.
WARNING
Falling hazard
Death or serious personal injury
- Use personal protective equipment when working
in the pit.
WARNING
Falling hazard
Death or serious personal injury
- Stand in the pit when you carry out work in the pit.