Grundfos PS.G Series User manual

Pumping station systems
PS.G
Pumping station, glass-fibre-reinforced plastic (GRP)
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

English (GB)
2
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)
3
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)
4
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)
5
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.
44
3
2
1
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)
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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)
7
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)
8
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
2
1
Max.
25 kN
Max.
150 kg
1a
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)
9
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)
10
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.