Grundfos PS.W.04-20 User manual

Pumping station systems
PS.W.04-20
Installation and operating instructions
GRUNDFOS INSTRUCTIONS

Pumping station systems
English (GB)
Installation and operating instructions ..........................................................4
Čeština (CZ)
Montážní a provozní návod .................................................................20
Deutsch (DE)
Montage- und Betriebsanleitung .............................................................37
Dansk (DK)
Monterings- og driftsinstruktion ..............................................................53
Español (ES)
Instrucciones de instalación y funcionamiento ...................................................69
Suomi (FI)
Asennus- ja käyttöohjeet ...................................................................86
Français (FR)
Notice d'installation et de fonctionnement .....................................................102
Italiano (IT)
Istruzioni di installazione e funzionamento .....................................................119
Nederlands (NL)
Installatie- en bedieningsinstructies ..........................................................135
Polski (PL)
Instrukcja montażu i eksploatacji ............................................................151
Português (PT)
Instruções de instalação e funcionamento .....................................................167
Srpski (RS)
Uputstvo za instalaciju i rad ................................................................183
Svenska (SE)
Monterings- och driftsinstruktion.............................................................199
Slovensko (SI)
Navodila za montažo in obratovanje .........................................................215
Slovenčina (SK)
Návod na montáž a prevádzku..............................................................231
Türkçe (TR)
Montaj ve kullanım kılavuzu ................................................................247
Українська (UA)
Інструкції з монтажу та експлуатації ........................................................263
Norsk (NO)
Installasjons- og driftsinstruksjoner ..........................................................280
EC declaration of conformity .............................................................296
UK declaration of conformity .............................................................298
Moroccan declaration of conformity........................................................299
UA declaration of conformity .............................................................301
EU declaration of performance ............................................................302
UK declaration of performance............................................................311
UA declaration of performance............................................................312
3
Table of contents

English (GB) Installation and operating instructions
Original installation and operating instructions
Table of contents
1. General information ........................4
1.1 Hazard statements..........................4
1.2 Notes ..................................4
1.3 Target group..............................4
2. Safety instructions .........................5
3. Product introduction........................6
3.1 Product description .........................6
3.2 Applications ..............................6
3.3 Pumped liquids ............................6
3.4 Pumping station system (PS.S) ..................6
3.5 Pumping station modular (PS.M) .................6
3.6 CE approval of PS.W and PS.S ..................6
3.7 Identification..............................7
4. Receiving the product.......................9
4.1 Transporting the product ......................9
4.2 Inspecting the product.......................10
4.3 Storage................................10
5. Installing the product ......................10
5.1 Preparing the foundation .....................10
5.2 Lifting the pit ............................11
5.3 Installing the pit ...........................11
5.4 Connecting the pipes .......................11
5.5 Location of inlet...........................11
5.6 Fitting the sleeve ..........................13
5.7 Backfill ................................13
5.8 Uplift prevention ..........................14
5.9 Pipes with flange connections ..................14
5.10 Installing the pump(s) .......................14
5.11 Fitting the chain...........................15
5.12 Installing the cover .........................15
5.13 Installing the venting pipe.....................15
5.14 Installing the cable entry .....................15
6. Installing the level controllers.................16
6.1 Start and stop levels ........................16
6.2 Installing the pump controller ..................16
6.3 Float switches............................16
6.4 Electrodes ..............................16
6.5 Pressure transducer ........................17
6.6 Air bells ...............................17
6.7 Other types of level control equipment .............17
7. Electrical connection ......................17
8. Maintaining and servicing the product ...........18
8.1 Accessing the products ......................18
8.2 Repairing a non-return valve ...................19
8.3 Contaminated pumps .......................19
8.4 Service contract ..........................19
9. Disposing of the product ....................19
10. Document quality feedback ..................19
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.
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.
The hazard statements are structured in the following way:
SIGNAL WORD
Description of the hazard
Consequence of ignoring the warning
• Action to avoid the hazard.
1.2 Notes
The symbols and notes below may appear in Grundfos installation
and operating instructions, safety instructions and service
instructions.
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.
1.3 Target group
These installation and operating instructions are intended for
professional installers.
4
English (GB)

2. Safety instructions
Transporting the product
DANGER
Crushing hazard
Death or serious personal injury
‐Place the pit on even ground to prevent it from
overturning.
DANGER
Crushing hazard
Death or serious personal injury
‐Make sure that the lifting bracket or strap is tightened
before lifting the pit. Tighten if necessary.
‐Carelessness during lifting or transport may cause
injury to persons or damage to the pit.
Preparing the foundation
CAUTION
Crushing hazard
Minor or moderate personal injury
‐Place the support for the crane at a suitable distance
from the pit to prevent the pit hole from collapsing.
Work must be carried out according the local
regulations.
Lifting the pit
CAUTION
Crushing hazard
Minor or moderate personal injury
‐Place the support for the crane at a suitable distance
from the pit to prevent the pit hole from collapsing.
Work must be carried out according to local
regulations.
DANGER
Crushing hazard
Death or serious personal injury
‐Do not stand under or close to a suspended load.
DANGER
Crushing hazard
Death or serious personal injury
‐Before lifting the pit, make sure that the lifting
equipment is capable of lifting the load.
‐Make sure that the lifting bracket is tightened before
lifting the pit. Tighten if necessary.
‐Carelessness during lifting or transport of the pit may
cause injury to persons or damage to the pit.
Backfill
WARNING
Collapsing hazard
Death or serious personal injury
‐Make sure that the specified size of gravel is used for
the backfill.
Installing the pump(s)
WARNING
Crushing hazard
Death or serious personal injury
‐The lifting equipment must be rated for the weight of
the pump, approved and maintained according to local
regulations.
Fitting the chain
WARNING
Crushing hazard
Death or serious personal injury
‐The lifting equipment must be rated for the weight of
the pump, approved and maintained according to local
regulations.
Electrical connections
WARNING
Electric shock
Death or serious personal injury
‐Connect the pump or pump controller to an external
emergency stop.
‐If the main switch is used as emergency stop, it must
fulfil EN 60204-1, 10.8.3.
DANGER
Electric shock
Death or serious personal injury
‐Before working on the pump or valves, remove the
fuses or switch off the main switch.
‐Make sure that the power supply cannot be switched
on unintentionally.
DANGER
Electric shock
Death or serious personal injury
‐The control cabinet and internal pipes must be
earthed.
Maintaining and servicing the product
DANGER
Crushing of hands
Death or serious personal injury
‐Before entering PS.W.20, make sure that the cover
and safety grid are locked in open position.
DANGER
Toxic material
Death or serious personal injury
‐Before entering it, ventilate the pit according to local
regulations.
DANGER
Crushing hazard
Death or serious personal injury
‐When entering the pit, wear a safety harness and use
approved equipment according to local regulations.
CAUTION
Biological hazard
Minor or moderate personal injury
‐Use gloves and other suitable personal protective
equipment. Observe local regulations on exposure to
wastewater.
Repairing a non-return valve
CAUTION
Pressurised system
Minor or moderate personal injury
‐Drain the system before dismantling the non-return
valve to relieve pressure.
DANGER
Electric shock
Death or serious 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 switched
on unintentionally.
CAUTION
Biological hazard
Minor or moderate personal injury
‐Rinse the non-return valve thoroughly with clean water
before carrying out maintenance and service.
Contaminated pumps
CAUTION
Biological hazard
Minor or moderate personal injury
‐Flush the pump thoroughly with clean water, and rinse
the pump parts after dismantling.
5
English (GB)

3. Product introduction
3.1 Product description
Grundfos pumping stations are prefabricated for wastewater
collection and pumping.
The pit is made of polyethylene (PE-HD) or polypropylene (PP) and
comes with pipes and valves fitted.
The pipes are made of PE or stainless steel depending on the
location of the pit, the pumped liquid, and the selected pump.
Wastewater is led into the pit. When the liquid in the pit reaches the
maximum level, the pump starts and pumps the liquid further into
the sewer system.
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3
4
5
10
8
1
9
6
3
7
TM069860
Example of a pumping station
Pos. Description
1 Pit
2 Cover
3 Pipes
4 Non-return valve
5 Isolating valve
6 Pipe coupling
7 Auto coupling
8 Guide rails
9 Guide-rail holders
10 Level-control system
3.2 Applications
Grundfos pumping stations are used for collection and pumping of
drainage water, rainwater (surface water) and wastewater.
Wastewater is led into the pumping station. When the liquid in the
pumping station reaches the starting level, the pump starts and
pumps the liquid further in the system to a sewage treatment plant
or sewer.
The pits are prepared for various pumps depending on the pumped
liquid.
3.3 Pumped liquids
3.3.1 Liquid temperature
The maximum liquid temperature in the pit is 40°C. For higher
temperatures, contact Grundfos.
Select the pump based on the liquid temperature. See the
installation and operating instructions of the individual
pumps.
3.3.2 Acids and alkalis
The pit is resistant to strong acids and alkalis as well as solvents.
The pumping station is capable of withstanding pH values between
4 and 10. For further information, contact Grundfos.
3.3.3 Viscosity
Thick wastewater must not be led into the pit. See also the
installation and operating instructions of the pump.
3.3.4 Density
Maximum 1100 kg/m3.
3.4 Pumping station system (PS.S)
This section applies only to pumping station systems consisting of
Grundfos-approved components indicated on the nameplate.
The PS.S contains all the elements that make it function as one
unit. It can contain the following five elements:
• pit
• pump
• pump controller
• level controller
• accessories.
The PS.S may not always have all five elements. However, it
always has a pit and a pump. The pump controller or the level
controller may be incorporated in the pump, while accessories may
be omitted.
3.4.1 CE approval of PS.S
PS.S is CE approved in accordance with the following directives
and standards:
• 2006/42/EC, EU Machinery Directive
• EN/ISO 12100
- Safety of machinery
- General principles for design
- Risk assessment and risk reduction.
To ensure safe transport and to fulfil customer requests, the PS.S
elements can be assembled on site. However, the CE approval of
PS.S is only valid if the following conditions have been fulfilled:
• The PS.S has been assembled correctly according to the
installation and operating instructions of the PS.S, the pit, the
pump and the control systems.
• The PS.S contains the Grundfos specified elements stated on
the nameplate. The PS.S nameplate is fitted inside the pit.
If one or more of the components, for example the controllers, in the
pumping station system are not supplied by Grundfos, it is not
possible to obtain a CE approval.
3.5 Pumping station modular (PS.M)
The PS.M is used when the CE approval for the complete system is
not needed or some of the components in the pumping station, for
example the controllers, are not supplied by Grundfos.
A risk assessment for the complete system must be performed by
the customer.
3.6 CE approval of PS.W and PS.S
The PS.W and PS.S are CE-approved according to the following
standards:
• EN 12050-1
• EN 12050-2.
6
English (GB)

3.7 Identification
3.7.1 Nameplate, PS.S and PS.M
Model
Type
Made in
P.c.
Well cpl.
Control System
Pump cpl.
Level System
Accessories
Weight
EC declaration of conformity
Standard used: EN ISO 12100
Pumping Station System
98579229
911 13 14
3
10
12
5
8
6
4
7
1 2
DK-8850 Bjerringbro, Denmark
U.K. Importer: Grundfos Pumps ltd., Grovebury Road
Leighton Buzzard, Bedfordshire LU74TL
TM061743
Nameplate, PS.S
99153401
DK-8850 Bjerringbro, Denmark
Well cpl.
Model Pumping Station Modular
Type
Made in
Control System
Accessories
Weight
Pump cpl.
Level System
PS.M.R.17.25.SEG.LCD.10.FS2
P.c.
1 2
3
5
7
9
11
13
4
6
8
10
12
TM067590
Nameplate, PS.M
Pos. Description
1 Product number
2 Production site
3 Type designation
4 Country of origin
5 Weight
6 Production code (YYWW)
7 Installation and operating instructions, publication number
8 Product number, pit
9 Product number, pump
10 Product number, pump controller
11 Product number, level controller
12 Product number(s), accessories
13 Not filled in
3.7.2 Type key, PS.S and PS.M
Example: PS.S.W.20.25.SEG.LCD110.FS2
Code Explanation Designation
PS Grundfos pumping station
S CE-marked system
System type
MModular system1)
R Rotation-moulded PE
W Welded PE or PP
04 400 mm
XX × 100 = Pit sump
diameter [mm]
Example:
08 × 100 = 800 mm
05 500 mm
06 600 mm
08 800 mm
10 1000 mm
12 1200 mm
12 1250 mm
16 1600 mm
17 1700 mm
20 2000 mm
25 2500 mm
XX × 100 = Pit depth
[mm]
Example: 25 × 100 =
2500 mm
CC Unilift CC
Pump type
KP Unilift KP
AP12 Unilift AP12.50
AP35 Unilift AP35, Unilift AP12.40
AP50 Unilift AP50
APB Unilift AP35B, Unilift AP50B
APG Unilift APG
SEG SEG
DP/EF DP (0.6 - 1.5 kW), EF
DP/SL DP (2.6 kW), SL1.50.65 and
SLV.65.65
DPK DPK, DPK.V
SE/SL SE/SL
X No Grundfos controller
Pump controller
BIP Built into the pump
CU Control unit
LC107
Level controller
LC108
LC110
LC115
LC231S
LC241S
LC231D
Level controller - two pumps
LC241D
LCD107
LCD108
LCD110
LCD115
DC318 Dedicated controls
DC319
DCD318 Dedicated controls - two
pumps
DCD319
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English (GB)

Code Explanation Designation
BIP Built into the pump
Level controller
AB2 Two air bells
AB3 Three air bells
FS2 Two float switches
FS3 Three float switches
FS4 Four float switches
FS5 Five float switches
EL3 Three electrodes
EL4 Four electrodes
EL5 Five electrodes
PT Pressure transducer
PF1 Pressure transducer and one
float switch
PF2 Pressure transducer and two
float switches
1) Without CE approval.
3.7.3 Nameplate, PS.W
Type
Standards used: EN 12050-1 or EN 12050-2
Model
Weight kg
P.c.
Made in Denmark
EU declaration of performance
P10
98646710
1325
22 0197 22 0197
22 0197 DK-8850 Bjerringbro, Denmark
U.K. Importer: Grundfos Pumps ltd., Grovebury Road
Leighton Buzzard, Bedfordshire LU74TL
98495490
1 3 2 6
8
495
7
TM061249
Nameplate, PS.W
Pos. Description
1 Product number
2 Production site
3 Product name
4 Country of origin
5 Net weight
6 Weight unit
7 Production code (YYWW)
8Installation and operating instructions, publication
number
9 Not filled in
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English (GB)

3.7.4 Type key, PS.W
Example: PS.W.20.25.D.GC.304.100.A100.SEG
Code Explanation Designation
PS Grundfos pumping station
W Welded PE or PP Pit type and material
04 400 mm
XX × 100 = Pit sump
diameter [mm]
Example:
08 × 100 = 800 mm
06 600 mm
08 800 mm
10 1000 mm
12 1250 mm
16 1600 mm
20 2000 mm
25 2500 mm
XX × 100 = Pit depth
[mm]
Example: 25 × 100 =
2500 mm
N No pump
Number of pumps
S One pump
D Two pumps
DC Direct outlet, common
Pipe design
DS Direct outlet, separated
GC Goose neck, common
NV No valves, separated
CL Launcher for cleaning pig
304.32 DN 32 (1")
Pipe material and
diameter
Stainless steel EN
1.4301 / AISI 304
304.40 DN 40 (1 1/2")
304.50 DN 50 (2")
304.65 DN 65 (2 1/2")
304.80 DN 80 (3")
304.100 DN 100 (4")
304.125 DN 125 (5")
304.150 DN 150 (6")
316.32 DN 32 (1")
Pipe material and
diameter
Stainless steel EN
1.4401 / AISI 316
316.40 DN 40 (1 1/2")
316.50 DN 50 (2")
316.65 DN 65 (2 1/2")
316.80 DN 80 (3")
316.100 DN 100 (4")
316.125 DN 125 (5")
316.150 DN 150 (6")
PE.63 D63 mm (2")
Pipe material and
diameter
Polyethylene
PE.75 D75 mm (2 1/2")
PE.90 D90 mm (3")
PE.110 D110 mm (4")
PE.160 D160 mm (6")
A40 DN 40 pump connection
Installation type
Auto coupling
A50 DN 50 pump connection
A65 DN 65 pump connection
A80 DN 80 pump connection
A100 DN 100 pump connection
A150 DN 150 pump connection
S Free-standing pump Installation type
Free-standing
Code Explanation Designation
CC Unilift CC
Pump type
KP Unilift KP
AP12 Unilift AP12.50
AP35 Unilift AP35, Unilift AP12.40
AP50 Unilift AP50
APB Unilift AP35B, Unilift AP50B
APG Unilift APG
SEG SEG
DP/EF DP (0.6 - 1.5 kW), EF
DP/SL DP (2.6 kW), SL1.50.65 and
SLV.65.65
SE/SL SE/SL
4. Receiving the product
4.1 Transporting the product
When transporting and handling the pit at low
temperatures, take into consideration that the pit impact
resistance is reduced.
Precautions during transport
• Transport the pit in horizontal position and anchor it securely to
the lorry.
• Secure the accessories, if any, inside the pit.
• Do not dump the pit from the lorry.
Precautions during handling
The customer must provide appropriate lifting equipment at the
place of unloading. The weight of the pit is stated on the nameplate.
Before lifting the pit into vertical position, remove transport
supports and accessories from the inside of the pit.
• Handle and lift the pit according to local regulations.
• 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.
• When lifting the pumping station with a strap, use the ribs on the
pumping station.
• Point loads must not occur.
• Do not drag the pit over the ground.
• Do not expose the pit to sharp edges.
DANGER
Crushing hazard
Death or serious personal injury
‐Place the pit on even ground to prevent it from
overturning.
If the pit is equipped with a lifting point, use it during
handling.
9
English (GB)

TM061232
Lifting the pit from a lorry
TM061233
Lifting straps
DANGER
Crushing hazard
Death or serious personal injury
‐Make sure that the lifting bracket or strap is tightened
before lifting the pit. Tighten if necessary.
‐Carelessness during lifting or transport may cause
injury to persons or damage to the pit.
For more information on correct lifting methods, see section Lifting
the pit.
Related information
5.2 Lifting the pit
4.2 Inspecting the product
After transport and before installation, inspect the pumping station:
• Check the pumping station for transport damage. In case of any
damage, contact the transporter immediately.
• Check that the delivered products correspond to the order.
• Check the positions and sizes of fittings.
• Check and retighten all bolted connections as they may become
loose during transport.
• Check that the valves are open.
• Check other equipments, such as vent pipes.
4.3 Storage
In case the pit is not installed immediately or the ambient
temperature exceeds 30 °C, store the pit in vertical position to avoid
deformation.
5. Installing the product
5.1 Preparing the foundation
CAUTION
Crushing hazard
Minor or moderate personal injury
‐Place the support for the crane at a suitable distance
from the pit to prevent the pit hole from collapsing.
Work must be carried out according the local
regulations.
Installation of pits must be carried out by an authorised
person.
Work in or near wastewater pits must be carried out
according to local regulations.
With reference to DS/EN 1997-1: Eurocode 7: Geotechnical
Category 2:
Complete a geotechnical investigation of the site conditions before
installing the pit.
With reference to DS/EN 1997-1: Eurocode 7: Geotechnical
Category 1:
The geotechnical investigation can be judged to be unnecessary, if
below conditions 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.
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3
2
1
TM063629
Schematic installation drawing
10
English (GB)