Grundfos PS.W.04 User manual

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

Table of contents
2
Pumping station systems
English (GB)
Installation and operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Čeština (CZ)
Montážní a provozní návod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Deutsch (DE)
Montage- und Betriebsanleitung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dansk (DK)
Monterings- og driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Español (ES)
Instrucciones de instalación y funcionamiento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Suomi (FI)
Asennus- ja käyttöohjeet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Français (FR)
Notice d'installation et de fonctionnement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Italiano (IT)
Istruzioni di installazione e funzionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Nederlands (NL)
Installatie- en bedieningsinstructies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Polski (PL)
Instrukcja montażu i eksploatacji . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Português (PT)
Instruções de instalação e funcionamento. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Svenska (SE)
Monterings- och driftsinstruktion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Slovensko (SI)
Navodila za montažo in obratovanje . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Slovenčina (SK)
Návod na montáž a prevádzku . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Türkçe (TR)
Montaj ve kullanım kılavuzu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Norsk (NO)
Installasjons- og driftsinstruksjoner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Declaration of performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

English (GB)
3
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions describe Grundfos
pumping station system PS.W.04-20.
Sections 1-6 give the information necessary to be able to unpack,
install and start up the product in a safe way.
Sections 7-9 give important information about the product, as well
as information on service, fault finding and disposal of the
product.
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
These installation and operating instructions are intended for
professional installers.
1. General information 3
1.1 Hazard statements 3
1.2 Notes 3
1.3 Target group 3
2. Safety instructions 4
3. Receiving the product 5
3.1 Transporting the product 5
3.2 Inspecting the product 5
3.3 Storage 5
4. Installing the product 6
4.1 Preparing the foundation 6
4.2 Lifting the pit 6
4.3 Installing the pit 7
4.4 Backfill 7
4.5 Uplift prevention 8
4.6 Connecting the pipes 8
4.7 Location of inlet 9
4.8 Fitting the sleeve 9
4.9 Pipes with flange connections 10
4.10 Installing the pump(s) 10
4.11 Fitting the chain 10
4.12 Installing the cover 10
4.13 Installing the venting pipe 11
4.14 Installing the cable entry 11
5. Installing the level controllers 11
5.1 Start and stop levels 11
5.2 Installing the pump controller 11
5.3 Float switches 12
5.4 Air bells 12
5.5 Pressure transducer 12
5.6 Other types of level control equipment 12
6. Electrical connection 13
7. Product introduction 13
7.1 Product description 13
7.2 Applications 13
7.3 Pumped liquids 14
7.4 Pumping station system (PS.S) 14
7.5 Pumping station modular (PS.M) 14
7.6 CE approval of PS.W and PS.S 14
7.7 Identification 14
8. Maintaining and servicing the product 17
8.1 Repairing a non-return valve 18
8.2 Contaminated pumps 18
8.3 Service contract 18
9. 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)
4
2. Safety instructions
Receiving the product
Installing the product
Electrical connections
Maintaining and servicing the product
DANGER
Crushing hazard
Death or serious personal injury
- Place the pit on even ground to prevent the pit
from overturning.
WARNING
Crushing hazard
Death or serious personal injury
- The lifting equipment used for lifting the pit and the
pump must be rated for the weight of the pump,
approved and maintained 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 attempting to lift the pit. Tighten if
necessary. Carelessness during lifting or
transportation of the pit may cause injury to
persons or damage to the pit.
CAUTION
Collapsing hazard
Minor or moderate personal injury
- Place the support for the crane at a suitable
distance from the pit to avoid collapse of the pit
hole.
Work according to local regulations.
WARNING
Electric shock
Death or serious personal injury
- Connect the pump or pump controller to an
external emergency stop.
If you use the main switch as emergency stop,
make sure that it fulfils EN 60204-1, 10.8.4.
DANGER
Electric shock
Death or serious personal injury
- Before starting work on the pump or valves,
remove the fuses or switch off the main switch.
Make sure that the power supply cannot be
accidentally switched on.
DANGER
Electric shock
Death or serious personal injury
- The control cabinet and internal pipes must be
earthed.
DANGER
Crushing and suffocation hazard
Death or serious personal injury
- Before entering PS.W.20, 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
Fall 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 regulations.
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 of the main switch
before dismantling the non-return valve.
Make sure 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)
5
3. Receiving the product
3.1 Transporting the product
For correct lifting methods, see section 4.2 Lifting the pit.
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.
• When lifting the pumping station with a strap, use the ribs on
the pumping station.
• 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 that the
ground is even.
Fig. 1 Lifting the pit from a lorry
Fig. 2 Placing the pit in upright position by means of 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, etc.
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.
• Check and retighten all bolted connections as they may have
become loose during the transport.
• Check that the valves are open.
• Check other equipment such as venting pipes.
3.3 Storage
In case the pit is not installed immediately or the ambient
temperature exceeds 30 °C, store the pit in upright position to
avoid deformation.
When transporting and handling the pit at low
temperatures, take into consideration that the pit
impact resistance is reduced.
DANGER
Crushing hazard
Death or serious personal injury
- Place the pit on even ground to prevent the pit
from overturning.
The weight of a PS.W pit can vary from 50 to
maximum 2500 kg.
If the pit is equipped with a lifting point, use it during
handling.
TM06 1232 1914
TM06 1233 1914

English (GB)
6
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 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.
Fig. 3 Schematic installation drawing
4.1.1 Foundation layer
• Place the pit on a foundation layer if soil analyses and
information about pit load show 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
approx. 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 Lifting the pit
Fig. 4 Lifting the pit
CAUTION
Collapsing hazard
Minor or moderate personal injury
- Place the support for the crane at a suitable
distance from the pit to avoid collapse of the pit
hole.
Work according the 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 3629 0715
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. The other
equipment must not damage the buried pit.
4
3
2
1
4
TM06 9855 3517
Place the support for the crane at a suitable distance
from the pit to avoid collapse of the pit hole.
Observe 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 attempting to lift the pit. Tighten if
necessary. Carelessness during lifting or
transportation of the pit may cause injury to
persons or damage to the pit.

English (GB)
7
4.3 Installing the pit
Before lowering the pit into position, retighten various
connections, as they may have become loose during the
transport.
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.
4.4 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. See fig. 5.
• 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.
• The backfill must be compacted in layers of maximum 30 cm,
corresponding to approx. 20 cm after compaction.
Fig. 5 Insufficient compaction under pipes
Fig. 6 Oval pit after compaction
Fig. 7 Even pressure on all sides of the pit
Fig. 8 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. 7.
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
- Place the support for the crane at a suitable
distance from the pit to avoid collapse of the pit
hole.
Work according to the local regulations.
Before lowering the pit into position, retighten various
connections, as they may have become loose during
the transport.
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. 5.
TM06 3628 0715
During backfilling, fit the cover on the pit to prevent
the pit from becoming deformed or oval-shaped.
TM02 9361 2404TM06 3603 0615
Do not use plate compactors at a distance of less
than 30 cm from the pit wall.
If the hole for the pit is drilled, pay special attention to
the compaction of the backfill to prevent uplift.
TM06 3602 0615
Use mechanical compacting equipment and compact
the backfill to 98-100 % proctor density.
2
1
Max.
25 kN
Max.
150 kg
1a

English (GB)
8
4.5 Uplift prevention
The pit design ensures that the pit is protected against uplift if
installed correctly. Requirements for uplift prevention depend on
the geotechnical conditions. They should 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 shoulder of the pit is a stabilising
force. The sand volume is determined as a cone with hollow core
as illustrated in fig. 9.
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. 9 Stabilising sand volume
4.6 Connecting the pipes
Holes for inlet pipe, electrical connection and venting are to be
drilled on site.
1. Mark the pit where the inlet is to be.
2. Drill the marked spot with a hole saw.
3. Remove all burrs from the hole.
4.6.1 Drilling the inlets
Figures 10 and 11 show which hole saw to use for the various
pumping station diameters, depending on the difference in the
wall thickness.
Fig. 10 Wall profile PS.W.04-10
Fig. 11 Wall profile PS.W.20
The requirements below are minimum requirements.
Observe local regulations.
TM06 7269 2316
We recommend that you provide the pit with a vent
pipe, supplied as an accessory.
Place inlet and outlet pipe connections in accordance
with local regulations.
PS.W.04 - PS.W.10
Diameter
[mm]
Wall thickness - A
[mm]
400 30
600 44
800 57
1000 72
TM06 3605 1317
PS.W.20
Wall thickness varies for SN2 and SN4
Diameter [mm] SN2 [mm] SN4 [mm]
2000 Minimum 84 Minimum 114.5
TM06 3610 0615
X

English (GB)
9
4.7 Location of inlet
The pit inlet must not be located within the area shown in fig. 12,
as it will disturb the function of the float switches.
Fig. 12 Location of inlet relative to level control
Fig. 13 Location of inlet relative to pipes with one pump
Fig. 14 Location of inlet relative to pipes with two pumps
Fig. 15 Location of inlet relative to inclined bottom plates
4.8 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. LM50/100/150 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.
18.
4. Lubricate the inside of the sleeve with a water-based
lubricant.
5. Chamfer the pipe and press it home.
LM50/100/150 sleeves
Push the inlet pipe through the sleeve. See fig. 16.
Fig. 16 Pipe with LM50/100/150 sleeve, seen from the side
TM06 9859 3517
The pit inlet must not be located within the areas
shown in figs 13 and 14 as it will interfere with piping
and valves.
TM06 9856 3517TM06 9857 3517
The pit inlet must not be located within the area
shown in fig. 15 as it will destroy the function of the
inclined bottom plates.
200 200
220°
190°
TM06 9858 3517
As it must be possible to pull the pump up through
the pit, the inlet pipe must not project more than 5 cm
beyond the sleeve.
TM03 3709 0806
Pit side
Max. 50 mm

English (GB)
10
L965 sleeves
Push the inlet pipe into the sleeve and against the stop. See figs
17 and 18.
Fig. 17 Pipe with L965 sleeve, seen from the side
Fig. 18 Pipe with L965 sleeve, seen from the top
4.9 Pipes with flange connections
4.10 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.
4.11 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. 19 Chain fitted to the pump
4.12 Installing the cover
PS.W is delivered with factory-fitted cover. The cover is not
approved for traffic unless stated otherwise.
For traffic-approved cover, contact Grundfos.
Fig. 20 Not approved for pedestrians and vehicles
TM03 3708 0806TM03 3768 1006
Loosen all bolts of the flange and retighten them
when the pit has been installed.
This will prevent stress in the pipes.
Lower the pump carefully into the pit to avoid
damage to pump and pit.
WARNING
Crushing hazard
Death or serious personal injury
- The lifting equipment used for lifting the pit and the
pump must be rated for the weight of the pump,
approved and maintained according to local
regulations.
Pit side
Pit side
TM02 9341 2404
WARNING
Crushing hazard
Death or serious personal injury
- The lifting equipment used for lifting the pit and 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.
Make sure that covers are closed and locked to
prevent unwanted access.
Never leave an open pit unattended.
TM06 0113 4913 - TM06 0114 4913