Grundfos PS.G Series User manual

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

2

Table of contents
3
Pumping station systems
English (GB)
Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Čeština (CZ)
Montážní a provozní návod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dansk (DK)
Monterings- og driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Deutsch (DE)
Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Español (ES)
Instrucciones de instalación y funcionamiento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Français (FR)
Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Italiano (IT)
Istruzioni di installazione e funzionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Nederlands (NL)
Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Polski (PL)
Instrukcja montażu i eksploatacji . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Português (PT)
Instruções de instalação e funcionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Русский (RU)
Паспорт, Руководство по монтажу иэксплуатации . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Slovenčina (SK)
Návod na montáž a prevádzku . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Suomi (FI)
Asennus- ja käyttöohjeet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Svenska (SE)
Monterings- och driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Declaration of conformity 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Declaration of conformity RU 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Declaration of performance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

English (GB)
4
English (GB) Installation and operating instructions
Original installation and operating instructions.
CONTENTS
Page
1. Symbols used in this document
2. Safety instructions
Receiving the product
Installing the product
Installing the product
Servicing the product
1. Symbols used in this document 4
2. Safety instructions 4
3. Receiving the product 5
3.1 Transporting the product 5
3.2 Inspecting the product 6
4. Installing the product 6
4.1 Preparing the foundation 6
4.2 Installing the pit 7
5. Installing the valve chamber 8
5.1 Connecting the pipes 8
5.2 Installing the cover 9
5.3 Venting pipe 10
5.4 Service platform 10
5.5 Cables 10
6. Sizing 11
6.1 Installing the pump 11
7. Pump control 11
7.1 Start and stop levels 11
7.2 Installing the control system 11
7.3 Installing the level control system 11
8. Electrical connection and starting up the product 11
9. Product introduction 12
10. Applications 13
10.1 Liquid temperature 13
10.2 Acids and alkalis 13
10.3 Liquid density 13
11. Pumping station system (PS.S) 13
11.1 CE approval of PS.S 13
11.2 Identification 13
11.3 Nameplate, PS.G 14
11.4 Type key, PS.G 15
12. Servicing the product 15
12.1 Repairing a non-return valve 16
12.2 Draining the main pipe 17
12.3 Contaminated pumps 17
13. Service contract 17
14. Disposal 17
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.
Warning
If these instructions are not observed, it may lead
to electric shock with consequent risk of serious
personal injury or death.
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.
Warning
Make sure that the lifting bracket is tightened
before attempting to lift the pit.
Carelessness during lifting or transportation may
cause injury to persons or damage to the pit.
Warning
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.
Warning
Before lowering the pit into position, retighten
various connections, as they may have become
loose during the transport.
Warning
The pit must be locked to prevent unwanted
access.
Warning
The lifting equipment used for lifting the pump
must be rated for the weight of the pump,
approved and maintained according to local
regulations.
Warning
Chains supplied by Grundfos are marked with
maximum load and production date. The
maximum load must not be exceeded.
Maintenance must be carried out according to
local regulations.
We recommend that you check chains and
shackles supplied by Grundfos at least once per
year for cracks, corrosion or other irregularities.
If any defects are found, replace the chain or
shackles.
Warning
The electrical connection must be carried out by
an authorised person in accordance with local
regulations.
Warning
The pump or pump controller must be connected
to an external emergency stop.
If a power supply circuit breaker is used as
emergency stop, it must fulfil EN 60204-1, 10.8.4.
Warning
Before starting work on the pump or valves,
make sure that the fuses have been removed or
the main switch has been switched off.
Make sure that the power supply cannot be
accidentally switched on.
Warning
Check the ladder supplied by Grundfos, the
service platform and fastening of these at least
once per year for cracks, corrosion or other
irregularities. Observe local regulations.

English (GB)
5
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.
• 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 Lifting straps
Warning
When entering the pit, wear safety harness and
use proper ladder and equipment for lifting
persons up from the pit.
All work in pits must be carried out according to
local regulations and supervised by at least one
person outside the pumping station.
Warning
When work is going on in an open, or in the
proximity of an open pumping station or valve
chamber, place proper warning signs and correct
safety barriers around the pit in order to avoid
that persons fall into the pit. The warning signs
must be visible from all directions.
Warning
If the top opening is up to
∅ 1000, normal
precautions are sufficient. Openings larger than
∅ 1000 must be equipped with safety barriers or
other safety measures.
Warning
Pumps can be lifted by means of a crane, using
lifting points.
Proper slings or chains, approved for lifting must
be used.
Warning
Gloves and other suitable personal protection
equipment must be used in accordance with local
regulations.
Observe local regulations on exposure to
wastewater.
Warning
Make sure that the escaping water does not
cause injury to persons or damage to the
equipment.
Warning
Before starting work on the non-return valves,
make sure that the fuses have been removed or
the main switch has been switched off.
Make sure that the power supply cannot be
accidentally switched on.
Warning
Make sure that the isolating valves cannot be
accidentally opened.
Warning
If a pump has been used for a liquid which is
injurious to health or toxic, the pump will be
classified as contaminated.
Note
When transporting and handling the pit at low
temperatures, take into consideration that the pit
impact resistance is reduced.
Caution
Before raising the pit into vertical position,
remove transport supports and accessories from
the inside of the pit.
Caution
If the pit is equipped with a lifting point, use it
during handling.
TM06 1232 1914TM06 1233 1914
Caution
Support for the crane must be placed in a
suitable distance from the pit to avoid collapse of
pit hole.
Observe local regulations.
Warning
Make sure that the lifting bracket is tightened
before attempting to lift the pit.
Carelessness during lifting or transportation may
cause injury to persons or damage to the pit.

English (GB)
6
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 venting pipes.
4. Installing the product
4.1 Preparing the foundation
Fig. 3 Schematic installation drawing
4.1.1 Foundation layer
The bottom of the hole must have a foundation layer if soil
analyses and information about pit load show 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 must meet these requirements:
Fig. 4 Lowering the foundation slab
Fig. 5 Maximum angle of inclination
The anchor bolts for the foundation slab can be delivered on
before the pit. It is thus possible to install the anchor bolts and
perform a tensile test before the pumping station arrives at the
installation site.
Warning
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
Caution
The location of the pit must be selected 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
Note
Make sure that the foundation slab is level before
installing the pit.
Note
Each anchor bolt must be able to withstand 20 kN
(2000 kg) in a tensile test.
Note
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.
Note
If the foundation slab is cast on site, the surface
of the slab must be rubbed down to a smooth
surface.
Max. 25 °

English (GB)
7
4.2 Installing the pit
1. Clean the surface of the foundation slab, making sure nothing
can to get 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 for inlet and outlet pipes.
Fig. 7 How to fill the hollow space with concrete
Fig. 8 Securing the mounting brackets
4. Fit the brackets, washers and M20 F8.8 nuts, and tighten the
nuts to 430 ± 10 Nm.
TM06 3859 1015
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.
Warning
Before lowering the pit into position, retighten
various connections, as they may have become
loose during the transport.
TM06 1238 1914
Note
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.
net.grundfos.com/qr/i/98697625
Use either the QR code or the web address below to
access the data booklet.
TM06 4359 2115TM06 1239 1914
Caution
Do not lower the pit onto the anchoring bolts as
they may damage the surface of the pit.
Note
Make sure that no residual stresses remain in the
reinforced plastic structures of the pit bottom.
430 ± 10 Nm

English (GB)
8
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 fraction size. The maximum fraction size is 32 mm.
The backfill material must not contain any stones larger than
the maximum fraction 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
5. Installing the valve chamber
Follow the same instructions as for the installation of the pit. See
section 4. Installing the product.
Fig. 11 Valve chamber
5.1 Connecting the pipes
Compact the backfill around the pit up to the lower part of a pipe
connection, before connecting the pipe. See fig. 10.
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.
Caution
Plate compactors must not be used at a distance
of less than 30 cm from the pit wall.
TM06 3352 5214
Note
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
Caution
During backfilling, the cover must be fitted on the
pit to ensure that the pit is not deformed
(becomes oval).
Maximum. 50 cm
TM06 3603 0615
Caution
Use mechanical compacting equipment and
compact the backfill to 98-100 % proctor density.
TM06 3288 1015
2
Isolating
valves
Non-return
valves

English (GB)
9
5.2 Installing the cover
Fig. 12 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 Grundfos Product Center.
5.2.1 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. 13 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 fraction size under the cover and close to the
pit top must be 2 to 20 mm.
Lower the concrete ring onto the compacted backfill. A blacktop
can be made on the ring.
Fig. 14 Installing a cover with 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
figures 15 and 16.
After installation, there must be an air space of 150 mm between
the cover and pit. See figures 15 and 16.
Fig. 15 Cover approved for traffic, sectional view
Fig. 16 Cover approved for traffic
Caution
Covers are not approved for pedestrians and
vehicles unless stated otherwise.
TM06 0113 4913 - TM06 0114 4913
Note
The safety grid is split when the pit diameter is
greater than 2 m.
Warning
The pit must be locked to prevent unwanted
access.
Caution
The maximum angle of inclination when lifting
the cover is 25 °.
TM06 3498 0615
Caution
The foundation and bedding layer for the cover
must be of such nature so the surface can carry
the load that the concrete cover is rated for.
Observe local regulations.
Note
The pit comes with a 500 mm collar that must be
cut to the right length on the installation site.
Caution
The pit must not support the ring.
25 °
TM06 3921 1215
TM06 3575 0615
TM06 1847 3214
Note
If the concrete ring is to be cast on site, see the
data booklet 98697625 for casting dimensions.
The document is available in Grundfos Product
Center.
350-250 mm
Fraction size:
2-20 mm
Compacted layers
Blacktop (optional)
500 mm
Thickness of ring:
150-250 mm
Ground level Concrete ring Cover
Air space: 150 mm
Pit
Compacted
ground layers
Top level of the pit

English (GB)
10
5.3 Venting pipe
We recommend that you provide the pit with a venting pipe
(accessory). See section 5.1 Connecting the pipes.
Fig. 17 Pit with top-mounted venting pipe
Fig. 18 Pit with side-mounted venting pipe
5.4 Service platform
The service platform is for one person only and is to be used
when operating the isolating valves inside the pit.
Fig. 19 Fixed service platform
Fig. 20 Liftable service platform
5.5 Cables
The cables to the level switches and the pump can be led into the
pit through a cable entry placed on the side of the pit.
Fig. 21 Cable entry
TM06 3859 1015TM06 1683 2614TM06 1684 2614
Caution
Do not place pumps temporarily on the service
platform.
net.grundfos.com/qr/i/98697625
Use either the QR code or the web address below to
access the data booklet.
TM06 1687 2614TM06 1737 2714
Caution
When dismantling or assembling the pump, make
sure not to pinch or damage the cables.
When the pump and cables have been installed,
the cables must be suspended in such a way that
any stress is relieved from the cables.
TM03 3709 5014
Caution
If corrosion gasses are present, we recommend
that you use a gas-tight cable entry.