Grundfos PS.R Series User manual

Pumping station systems
PS.R.05 - 17
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.R.05-17.
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 5
4.3 Installing the valve chamber 7
4.4 Connecting the pipes 8
4.5 Fitting the sleeve 9
4.6 Pipes with flange connection 9
5. Installing the pump(s) 9
5.1 Fitting the chain 9
6. Installing the level switches 10
6.1 Start and stop levels 10
6.2 Installing the pump controller 10
6.3 Float switches 10
6.4 Electrodes 11
6.5 Air bells 11
6.6 Pressure transducer 11
6.7 Other types of level control equipment 11
7. Electrical connection 11
7.1 Installing the cables 11
8. Product introduction 12
8.1 Product description 12
8.2 Applications 12
8.3 Pumped liquids 12
8.4 Pumping station system (PS.S) 12
8.5 Pumping station modular (PS.M) 12
8.6 Identification 13
9. Maintaining and servicing the product 15
9.1 Repairing a non-return valve 16
9.2 Contaminated pumps 16
9.3 Service contract 16
10. Disposal 16
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
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.
WARNING
Crushing hazard
Death or serious personal injury
- 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
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.
DANGER
Electric shock
Death or serious personal injury
- 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.
DANGER
Crushing and suffocation hazard
Death or serious personal injury
- Before entering PS.R.17, 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)
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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
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 0063 4713
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)
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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. 2 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 soil is not
capable of bearing the weight. 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
approximately 20 cm after compaction). Such a foundation
layer is also required if the excavation has become too deep
by mistake.
4.1.2 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.
• 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 have a thickness of 10 cm.
4.2 Installing the pit
Place the pit on the bedding layer.
Check that the pit is vertical.
Groundwater must not rise above the bedding layer until
backfilling has been completed.
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.
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 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
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.

English (GB)
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4.2.1 Backfill
Fig. 3 Compactors
• 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. See fig. 4.
Fig. 4 Even pressure on all sides of the pit
• 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.
Fig. 5 Oval pit after compaction
• The backfill must be compacted in layers of maximum 30 cm
(corresponding to approx. 20 cm after compaction).
Fig. 6 Insufficient compaction under pipes
Do not use plate compactors at a distance of less
than 30 cm from the pit wall.
TM06 3602 0615TM06 3603 0615
During backfilling, the cover must be fitted on the pit
to ensure that the pit is not deformed (becomes
oval).
TM02 9361 2404
1
Max.
25 kN
Max.
150 kg
1a
2
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. 6.
TM02 9360 2404
If the hole for the pit is drilled, pay special attention to
the compaction of the backfill to prevent uplift.
Use mechanical compacting equipment and compact
the backfill to minimum 97 % proctor density.

English (GB)
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4.2.2 Uplift prevention
• The pit design ensures that the pit is protected against uplift if
installed correctly (excluded D 800 x 1000 and D 1200 x
1500). Requirements for uplift prevention depend on the
geotechnical conditions. They must be determined by the
engineer or contractor and are outside Grundfos' area of
responsibility.
The safety against uplift is determined according to Eurocode EN
1997-1 including national annex, DS/EN 1997-1 DK NA:2015.
The most unfavourable ground water conditions for the pit is
when the ground water table is located at terrain level. This
situation creates the highest hydrostatic water pressure at the
bottom of the pit, and causes the highest reduction in soil weight
for the stabilising soil volume.
The sand volume resting on the pit’s shoulder is a stabilising
force. The sand volume is determined as a cone with hollow core
as illustrated in fig. 7.
The inclination of the cone is illustrated 1:n. The inclination n can
be determined based on the friction angle for the design. The
characteristic friction angle for sand with a unit weight of 19 kN/
m3, compacted to 97 % standard proctor, is estimated to 37
degrees. The design friction angle is 32 degrees which
corresponds to an inclination of n = 1.6.
Fig. 7 Stabilising sand volume
4.3 Installing the valve chamber
When installing the valve chamber, follow the same instructions
as for installation of the pit. See section 4. Installing the product.
Fig. 8 Valve chamber
The requirements below are the minimum
requirements. Observe local regulations.
TM06 7269 2316
The valve chamber is only to be installed for PS.R.17
pits.
TM06 1754 2614
Isolating valves
Non-return valves

English (GB)
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4.4 Connecting the pipes
Compact the backfill around the pit up to the lower part of a pipe
connection, before connecting the pipe.
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.
Holes for inlet pipe, electrical connection and venting are to be
drilled on 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 the table below.
4.4.1 PS.R.05 - PS.R.10
Fig. 9 Drilling the inlet hole, ∅500-1200
4.4.2 PS.R.17
Drilling from the outside
If the hole diameter is bigger than 150 mm or the hole is to be
drilled into a rib, drill in the centre of a rib. See fig. 10.
Fig. 10 Drilling 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. 11.
Fig. 11 Drilling from the inside
We recommend that you provide the pit with a vent
pipe (accessory).
Place inlet and outlet pipe connections in accordance
with 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 that
you drill the inlet
hole in the
cylindrical, smooth
part.
The hole saw must have a cup depth of minimum 90
mm.
The inlet hole 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)
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4.5 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. 14.
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. 12.
Fig. 12 Pipe with LM50/100 sleeve, seen from side
L965 sleeves: Push the inlet pipe into the sleeve and against the
stop. See fig. 13.
Fig. 13 Pipe with L965 sleeve, seen from side
Fig. 14 Pipe with L965 sleeve, seen from top
4.6 Pipes with flange connection
5. Installing the pump(s)
Some versions come without the pump(s) installed. For
installation and startup of the pump, see the installation and
operating instructions for the pump.
5.1 Fitting the chain
For pumps on auto coupling, we recommend that you fit the chain
in the foremost lifting eye of the lifting bracket. The number of
lifting eyes depends on the pump.
Fig. 15 Chain fitted to the pump
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 50 mm.
TM03 3709 0806TM03 3708 0806TM03 3768 1006
Pit side
Max. 50 mm
Pit side
Pit side
If the pit is to be installed at a temperature below 0
°C, loosen all bolts of the flanges and retighten them
when the pit has been installed.
This will prevent stress in the pipes.
Lower the pump(s) carefully into the pit in order to
avoid damage to pump(s) and pit.
TM02 9341 2404
WARNING
Crushing hazard
Death or serious personal injury
- The lifting equipment used for lifting the pump
must be rated for the weight of the pump,
approved and maintained according to local
regulations.
Chains supplied by Grundfos are marked with
maximum load and production date.
Do not exceed the maximum load.
Maintain the chain 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.

English (GB)
10
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
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 two-pump operation, the start level switches
should be installed in such a way that pump two is started
before the liquid level reaches the lower edge of the bottom
inlet pipe, and so that pump one is started correspondingly
earlier.
• 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.
6.2 Installing the pump controller
See the installation and operating instructions for the pump
controller.
6.3 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
the float switches.
Fig. 16 Adjustment of float switches
The pit inlet must not be located within the area shown in fig. 17,
as it will disturb the function of float switches.
Fig. 17 Location of inlet
If the pit is equipped with an AutoADAPT-controlled
pump, an external level controller is not needed.
Note that the bottom float switch (the stop switch)
must stop the pump before the liquid level in the pit
falls below the minimum level of the pump. See the
installation and operating instructions for the pump.
TM02 8960 1204
A Minimum 300 mm
B 50 to 100 mm
C Operating range 110 mm
Distance B must not be too big as otherwise the float
switch may get stuck in other parts of the installation.
TM02 8961 1204
A
BC
200 200