Grundfos PUST04 User manual

English (GB)
6
English (GB) Installation and operating instructions
Original installation and operating instructions.
CONTENTS
Page
1. Symbols used in this document
2. General description
Grundfos pumping stations are pre-fabricated pumping stations
for collection and pumping of drainage water, rainwater or
wastewater.
The pump pit is made of PE-HD (polyethylene) and comes with
discharge pipes and valves fitted.
The pipework is made of PE or stainless steel depending on the
location of the pit and the pumped liquid, and thus the pump
selected.
Unless another solution is selected, the pits up to ∅1000 mm are
supplied with a PE-HD cover which is locked with a special M10 bolt.
Fig. 1 Example of version
3. Applications
Grundfos pumping stations are used for collection and pumping
of drainage water, rainwater and wastewater. Wastewater is led
into the pit. When the liquid in the pit reaches the starting level,
the pump will start and pump 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.
3.1 Pumped liquids
• Drainage water
• rainwater (surface water)
•wastewater.
3.1.1 Liquid temperature
Maximum 40 °C. For higher temperatures, contact Grundfos.
3.1.2 Acids and alkalis
The pump pit is resistant to strong acids and alkalis as well as
solvents.
The pumps are supplied with the pump pit and normally stand pH
values between 4 and 10. In case of doubt, contact Grundfos.
3.1.3 Viscosity
Very thick wastewater must not be led into the pit. See also the
installation and operating instructions of the pump.
3.1.4 Density
Maximum 1.1 tons/m3.
1. Symbols used in this document 6
2. General description 6
3. Applications 6
3.1 Pumped liquids 6
4. Identification 7
4.1 Type key, PUST04 - PUST10 7
4.2 Type key, PUST17 7
4.3 Nameplate 7
5. Pit versions 7
5.1 Cover 9
5.2 Vent pipe 9
5.3 Cables 9
6. Technical data 9
6.1 Weight 9
7. Sizing 9
8. Transportation 9
9. Installation 10
9.1 Pipe connection 11
9.2 Fitting the sleeve 12
9.3 Installation of pump 12
9.4 Pipework with flange connections 12
9.5 Fitting the chain 12
10. Pump control 12
10.1 Start and stop levels 12
10.2 Installation of level controller 12
10.3 Float switches 13
10.4 Rod electrodes 13
10.5 Air bells 13
10.6 Pressure transducer 13
10.7 Other types of level control equipment 13
11. Electrical connection and start-up 14
12. Maintenance 14
13. Service contract 14
14. Disposal 14
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!
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.
TM02 9366 2404
Pos. Description
1Pump
2Chain
3 Guide rails
4 Float switch
5 Non-return valve
6Stopvalve
7 Flange/coupling
8 Connection, 1/2" internal thread
9 Cover
Caution
The liquid temperature depends on the pump
selected. See the installation and operating
instructions of the individual pumps.
9
7
6
4
2
1
8
5
3

English (GB)
7
4. Identification
4.1 Type key, PUST04 - PUST10
4.2 Type key, PUST17
4.3 Nameplate
Fig. 2 Nameplate
5. Pit versions
The pits come with pipes and valves, depending of the installation
selected. Some pumps are available with a float switch connected
directly to the pump and thus require no external or built-in
controller.
The following installation drawings show pits with a free-standing
pump, a pump on auto coupling, a pump on wall-mounted auto
coupling and a pit with two pumps.
Example PUST 08.20. S. A. SS. SEG
Grundfos pumping station (standard)
Diameter [mm]
04: 400
06: 600
08: 800
10: 1000
Length [mm]
15: 1500
20: 2000
25: 500
30: 3000
S: One pump
D: Two pumps
Installation of pump
A: Auto coupling on tank bottom
W: Auto coupling on tank wall
S: Free-standing
Pipe material
PE: Polyethylene
SS: Stainless steel AISI 304
Prepared for pump type
KP: Unilift KP, Unilift CC
AP35: Unilift AP12.40, Unilift AP35
AP50: Unilift AP12.50, Unilift AP50
APB: Unilift AP35B, Unilift AP50B
DPEF: DP (0.6 - 1.5 kW), EF
DPSE:DP (2.6 kW), SL1.50.65 and SLV.65.65 (up to 3 kW)
SEG: SEG
Example PUST 17. 45. D. A. SS. DC. PE. 80
Grundfos pumping station
(standard)
Diameter [mm]
17: 1700
Length [mm]
20: 2000
25: 2500
30: 3000
35: 3500
40: 4000
45: 4500
50: 5000
55: 5500
60: 6000
S: One pump
D: Two pumps
T: Three pumps
Installation of pump
A: Auto coupling on tank bottom
S: Free-standing
Pipe material
PE: Polyethylene
SS: Stainless steel
Pipe design
DC: Direct outlet, common
DS: Direct outlet, separate
GC: Goose neck, common
NV: No valves
Pit material
GR: Glass-reinforced plastic
PE: Polyethylene
CO: Concrete
Internal pipe diameter
65: DN 65 (2 1/2")
80: DN 80 (3")
100: DN 100 (4")
150: DN 150 (5")
200: DN 200 (6")
TM03 4029 1406
Pos. Description
Type Type designation
Part No. Product number
P.c. Year-week code
Type:
96574128
Made in Denmark
DK-8850 Bjerringbro
Part No./
P. c .

English (GB)
8
TM02 9364 2404 TM02 9363 2404
Fig. 3 Pit with free-standing pump Fig. 4 Pit with pump on auto coupling
TM02 9366 2404 TM02 9365 2404
Fig. 5 Pit with pump on wall-mounted auto coupling Fig. 6 Pit with two pumps

English (GB)
9
5.1 Cover
5.1.1 PUST04 - PUST10
Unless another solution is selected, ∅400 to 1000 mm pits are
supplied with a PE-HD cover locked with a special M10 bolt.
Fig. 7 Cover
Fig. 8 Locked cover
5.1.2 PUST17
Covers for ∅1700 mm pits come with various lock systems.
5.2 Vent pipe
We recommend to provide the pit with a vent pipe.
Fig. 9 Pit with vent pipe
5.3 Cables
The cables to the level switches and the pump can be led into the
pit in different ways. Often the cables are led into the pit through a
cable entry in the side of the pit. If the pit is equipped with a vent
pipe, the pipe can be used as cable entry.
6. Technical data
6.1 Weight
6.1.1 PUST04 - PUST10
PUST.10.25.D.A.SS.DPSE is the heaviest standard pit, weighing
312 kg.
6.1.2 PUST17
PUST.17.60.D.A.SS.SW.PE.100 is the heaviest standard pit,
weighing approximately 1000 kg.
7. Sizing
The pit volume depends on the wastewater flow rate and the
pump performance.
If the liquid in the pit is static during long periods, sediments may
build up in the pit. The pump should therefore be started at least
twice per 24 hours.
8. Transportation
When handling and transporting the pit at low temperatures, take
into consideration that the pit impact resistance is reduced.
Precautions in order to avoid damage to the pit during handling/
transport:
• Do not tip the pit from the lorry.
• Use straps of textile or similar materials when lifting the pit on
or from a lorry or moving it.
• Do not drag the pit over the ground.
• Always use a suitable means of transport.
• Point loads must not occur.
• The pit must not be exposed to sharp edges.
• Fix the pit securely during transport.
Fig. 10 Lifting the pit (PUST04 - PUST10)
TM02 9499 0805TM02 9498 0805
Warning
The pit must be locked to prevent unwanted
access.
TM02 9496 2704
TM02 9340 2404

English (GB)
10
Fig. 11 Lifting the pit (PUST17)
9. Installation
Fig. 12 Schematic installation drawing
Foundation layer
• The bottom of the pit must have a foundation layer if soil
analyses and information about pit load show that the bottom
is not capable of bearing. 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.
Bedding layer
• The material for the bedding layer must be compactable and
composed so that neither its properties nor 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 usually have a thickness of 10 cm.
If the bottom of the excavation meets these requirements, a
bedding layer is not required.
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 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).
Place the pit on the bedding layer.
Check that the pit is vertical.
Groundwater must not rise above the bedding layer until the
backfilling has been completed.
Fig. 13 Insufficient compaction under pipes
Fig. 14 Oval pit after compaction
TM04 9511 4410
Warning
Observe 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 traffic
loads must not occur
Caution
The location of the pit must be selected so that
its establishment does not damage other
constructions. Conversely, these must not
damage the buried pit.
44
3
2
1
Warning
Before the pit is lowered into position, various
connections must be retightened, as they may
have become loose during the transport.
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.
Note
Compact the bedding layer under the inlet and
discharge pipes properly so that they are not
exposed to downward loads when the backfill is
compacted. See fig. 13.
TM02 9360 2404
Note
During backfilling, the cover must be on the pit to
ensure that the pit is not deformed (becomes
oval).
TM02 9361 2404

English (GB)
11
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/construction contractor and are outside
Grundfos’ area of responsibility.
9.1 Pipe connection
Holes for inlet pipe, electrical connection and venting are to be
drilled at 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 table.
9.1.1 PUST04 - PUST10
Fig. 15 Drilling the inlet, ∅400-1000 mm
9.1.2 PUST17
Drilling from the outside
If the hole diameter is greater than 150 mm or the hole is to be
drilled into a rib, drill in the centre of a rib. See fig 16.
Fig. 16 Drillilng 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 17.
Fig. 17 Drillilng from the inside
Caution
If the hole for the pit is drilled, pay special
attention to the compaction of the backfill to
prevent uplift.
Caution
Use mechanical compacting equipment and
compact the backfill to 98-100 % proctor density.
Caution
The above requirements are minimum
requirements. Observe 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 to
drill the inlet in the
cylindrical,smooth
part.
Note
The hole saw must have a cup depth of minimum
90 mm.
Caution
The inlet 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)
12
9.2 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. 20.
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. 18.
Fig. 18 Pipe with LM50/100 sleeve, seen from side
L965 sleeves: Push the inlet pipe into the sleeve and against the
stop. See fig. 19.
Fig. 19 Pipe with L965 sleeve, seen from side
Fig. 20 Pipe with L965 sleeve, seen from top
9.3 Installation of pump
Some versions come without the pump installed. For installation
and start-up of the pump, see the installation and operating
instructions of the pump.
9.4 Pipework with flange connections
9.5 Fitting the chain
In the case of pumps on auto coupling, we recommend to fit the
chain in the foremost lifting eye of the lifting bracket. The number
of lifting eyes depends on the pump.
Fig. 21 Chain fitted to pump
10. Pump control
When installing the level switches, the following points should be
observed:
• 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 1-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 2-pump operation, the start level switches
should be installed in such a way that pump 2 is started before
the liquid level reaches the lower edge of the bottom inlet pipe
to the pit, and so that pump 1 is started correspondingly
earlier.
• The high-level alarm switch should always be installed about
10 cm 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 pump controller selected.
10.1 Start and stop levels
The effective volume of the pump pit must be so large that the
number of starts does not exceed the maximum permissible
number. See the installation and operating instructions of the
pump.
10.2 Installation of level controller
See the installation and operating instructions of the controller.
Note
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 5 cm.
TM03 3709 0806TM03 3708 0806TM03 3768 1006
Caution
Lower the pump carefully into the pit in order to
avoid damage to pump and pit.
Pit side
Max. 5 cm
Pit side
Pit side
Note
If the pit is to be installed at a temperature below
0 °C, slacken all bolts of the flange and retighten
them when the pit has been installed.
This prevents stress in the pipes.
TM02 9341 2404
Warning
The lifting equipment used for lifting the pump
must be rated for the weight of the pump and
approved according to local regulations.

English (GB)
13
10.3 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
float switches.
Fig. 22 Adjustment of float switches
The pit inlet must not be located within the area shown in fig. 23,
as it will disturb the function of float switches.
Fig. 23 Location of inlet
10.4 Rod electrodes
If rod electrodes are used for level measurement, note that the
rods come in standard length (1 m). When they are installed, their
length must therefore be adjusted so that they are activated at
the correct levels.
If possible, bend the rods away from each other so that paper and
similar items cannot get stuck between the rods and disturb the
signal.
When they have been shortened, 10 to 15 mm of the lower end of
the rods must be stripped.
The rods come with 10 metres of cable.
Fig. 24 Rod electrodes in a pit with one pump
Fig. 25 Rod electrodes in a pit with two pumps
10.5 Air bells
Air bells are pulse generators for the pressure switches of the
controller and function by means of pneumatic pressure changes.
The pressure changes when the liquid level in a pickup changes.
The air bells are connected to the pressure switches of the
controller by means of hoses.
Fig. 26 Air bells in a pit with one pump
10.6 Pressure transducer
If a pressure transducer is used, it should be installed in a riser
pipe in order to prevent contamination and deposits.
10.7 Other types of level control equipment
See the installation and operating instructions of the equipment.
Note
Note that the bottom float switch (stop) must stop
the pump before the level in the pit falls below
the minimum level of the pump. See the
installation and operating instructions of the
pump.
TM02 8960 1204
A Min. 300 mm
B 50 to 100 mm
C Deactivation range 110 mm
Caution
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
TM02 8962 1204TM02 8963 1204TM01 9345 2404
Alarm: 32
Start: 22
The stop level
depends on the
pump type.
Common: 11
Alarm: 42
Start2: 32
The stop level
depends on the
pump type.
Common: 11
Start1: 22
CU211
CU 211

English (GB)
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11. Electrical connection and start-up
See the installation and operating instructions of the pump and
the controller.
12. Maintenance
See the installation and operating instructions of the pump and
the controller.
13. Service contract
It is possible to make a service contract with Grundfos.
14. Disposal
This product or parts of it must be disposed of in an
environmentally sound way:
1. Use the public or private waste collection service.
2. If this is not possible, contact the nearest Grundfos company
or service workshop.
3. If it is not possible to dispose of the product as a complete
unit, the pump installation can be removed from the pit, and
the pit can be filled and covered.
Note
The controller must not be installed in the pit.
Warning
Secure the pit cover against overload and
unwanted opening and removal.
Subject to alterations.