PPS 1000 Series User manual

ConneCtion
•Easytoinstall
•Cableduct,ventduct,
inletsandoutlets
•Singleordualoutletscan
bepositionedtoyour
requirements(subjectto
chamberdiameter)
Lifting
Liftingeyesare
incorporatedwithin
thetopofthe
chambersforassisting
withoff-loadingand
positioning.
CLeAR oPening
750mm x 600mm
VALVe ACCess
Isolationvalveis
accessibleatcoverlevel
viathevalveextension
kit,preventingtheneed
toaccessthechamber
forvalveisolation(tobe
speciedattimeoforder).
CHAMBeR ConstRUCtion
•Singlepiecechamberconstruction
•Tank-gradepolyethylene
•Strengtheningribsthroughoutprovide
reinforcementandanchoring
•FEAtestedforhydrostaticpressure
andliftloadings
ContRoLs
•Singleordualcontrol
panelasstandard
•Highlevelalarm
•IntegrationwithBMS
•Telemetricoptionsfor
remotemonitoring
PUMPs
Awiderangeofpumps
andcongurationsto
suiteveryapplication.
Selectionbyimpellor
type,duty,powerand
numberofpumps.
BenCHing
•Accommodatesbenchingin
accordancewithcurrent
designstandards
•Directswastewatertowardsthe
pump/spreventingdeadzones
•Noatterthan60°
BAse
•Thepedestal/sisassembledontoa
baseplatebeforebeingsitedintothe
bottomofthechamber
•Uniquechamberbaseconstruction
providesstrengthandversatility
•Integralfeetprovidingstability
60º
•Bespokeproductselection
•Depthsfrom1000mmto4000mm
•Storagecapacityfrom510to2,675litres
•Availablefromstock
•Widerangeofaccessories
•Unrivaledquality
Installation and Operating Guidelines
1000 Series Pump Stations
Our all new 1000 Series range of packaged pump stations offers you a wide range of features
and benefits, for use in the residential, public sector, commercial, hospitality and retail
sectors. This range is suitable for ground, surface, storm and foul water applications.

Contents
1.0 Product Summary ................................................3
2.0 Installation Guidelines ..........................................3
3.0 Lifting Guide.........................................................6
4.0 Float Conguration...............................................7
5.0 Control Panel Operation.......................................8
6.0 Technical Specication.........................................9
7.0 Dimensions.........................................................10
8.0 Parts List ............................................................10
9.0 Accessories........................................................10
10.0 Wiring Diagrams.................................................10
11.0 Transport ............................................................10
12.0 Maintenance.......................................................11
13.0 Health and Safety...............................................11
14.0 Guarantee...........................................................13
15.0 Service Agreement .............................................13

Installation and Operating Guidelines
3
1.0 Product Summary
The 1000 series is a fully automatic pumping station specifically designed for pumping waste water
when gravity drainage is not possible or economical to install.
The system is suitable for installing either at the initial building stage or for retrotting to existing
buildings.
The system consists of a chamber, internal pipework / fittings, control panel, level controls, guide rails (if
applicable) and one or two submersible pumps.
The 1000 series is easy to install as inlets can be positioned to your requirements (inlet information to be
supplied at time of order).
2.0 Installation Guidelines
It is important to note that these instructions are for guidance only and it is the installer’s responsibility
to satisfy them self that the installation procedure is in accordance with the prevailing ground conditions
and good building practice, to eliminate any potential damage to the pumping station chamber either
during or after installation. The installer should also satisfy them self that the system can be installed in
conjunction with these guidelines, prior to work commencing.
The chamber is manufactured from polyethylene and as such is extremely robust. However, as with
any preformed chamber they are susceptible to oatation and hydrostatic pressures exerted in high
water table conditions therefore must always be fully supported by a concrete base and surround. The
chamber is only suitable for installations to a maximum of 500mm deeper than supplied from finished
ground level.
When installing a chamber deeper than above e.g. 500mm deeper than supplied from finished ground
level, a reinforced waterproof concrete sump must be formed for the chamber to be installed within.
This will ensure that any pressure present is not transferred onto the chamber itself. Furthermore, when
constructing the reinforced waterproof concrete sump it is important that adequate space is made for
connections to the chamber e.g. inlets, discharge, cable and vent ducts. Consideration must also be
made regarding the depth and orientation of all connections to ensure that they line up with the chamber.
It is imperative that you consult with a structural and waterproong engineer when designing the
reinforced waterproof concrete sump and backll ensuring that it allows for the anticipated pressures
and that they are not transferred onto the chamber.
Regardless of the use of a reinforced waterproof concrete sump the following installation method must
be followed.
Please read these instructions in full, prior to commencement of the installation. If you are unsure on any
point then ask for advice before proceeding. The PPS technical help desk is available on 01279 757400
from 9.00am – 5.30pm, Monday to Friday.

Installation and Operating Guidelines
4
1. Select a suitable location for the pumping station. Where possible, installation of a pumping station
in a roadway should be avoided due to the need for periodic maintenance of the pumps contained
therein. If the location is adjacent to a roadway, the installation method should take account of the
imposed loads likely to be transmitted to the chamber by traffic etc.
2. Excavate the minimum opening in the ground to receive the chamber and external connections. It is
the installer’s responsibility to measure the chamber before sizing the excavation. If a machine is
used to remove the spoil, the sides of the excavation should be battened for stability. Where ground
water is present in the excavation you must make a provision for a sump in one corner for
dewatering purposes.
3. Where ground water is present in the excavation, de-watering must be undertaken throughout the
installation procedure and until the backfill has completely set.
4. Lift the chamber into the excavation (please refer to section 3, lifting guide) and position it such that
the inlet and outlet pipework connections are correctly aligned and temporarily pack the base to the
correct level. Mark all connections and remove the chamber before installing the rubber seals
(100mm pipe). Please note that all connections should be aligned square to the chamber enabling
the seals to remain watertight, connections: 100mm cable duct, 100mm vent duct, inlet pipework =
subject to inlet pipework size and pumping main (please use fittings supplied).
5. Simply lay clean hardcore to the base of the excavation ensuring that it is consolidated to a
minimum thickness of 150mm, then lay a WET mass concrete base to a thickness adequate for the
ground conditions (minimum 200mm), on top of the hardcore or to structural engineers
requirements.
6. Lift the chamber into the excavation (please refer to section 3, lifting guide) and carefully position it
onto the WET mass concrete base ensuring that no loose debris is inadvertently knocked onto the
base, under the chamber during this procedure. Position it such that the inlet and outlet pipework
are correctly aligned. The chamber is be imbedded 50mm into the WET mass concrete base,
provision should made to prevent the chamber from being lowered more than 50mm into the
concrete.
7. Once the chamber is positioned connect the 100mm cable duct, 100mm vent duct and inlet
pipework to the chamber (please use fittings supplied). The discharge pipework can then be
connected. We recommend that all discharge pipework be black MDPE or HDPE pipe.
8. The vent duct should be vented to atmosphere at high level. An air admittance valve/durgo/one way
valve must NOT be used.
9. The chamber MUST be ballasted with water at the same rate as backfilling such that the level
difference between the water and backfill does not exceed 300mm at any time.
10. Whilst the concrete base is still WET pour a WET mass concrete surround to a thickness adequate
for the ground conditions (minimum 250mm) upto the top of the chamber in a single pour. The
concrete must be evenly poured around the chamber ensuring that no voids are left within the
concrete. Care must be taken to ensure that any pipes (or other connections) made, are not
damaged. During the concrete pour, ensure that the chamber is vertical (by use of a spirit level
across the chamber’s opening). Additionally, ensure that the chamber is at the correct depth level.
DO NOT REMOVE THE WATER FROM THE CHAMBER.

Installation and Operating Guidelines
5
11. It is essential that the chamber remains level at all times, and the concrete must be evenly poured
around the chamber, and must not exceed 300mm between the water and backfill at any time.
THE BALLAST WATER INSIDE THE CHAMBER SHOULD NOT BE REMOVED UNTIL THE
BACKFILL HAS FULLY SET.
12. In a roadway application, the chamber should be installed with the top of the access shaft 300mm
below the finished cover level ensuring that the slab is supported by consolidated backfill. A suitable
rated cover and frame are to be bedded into the reinforced cover slab (to be specified at time of
order), such that it does not bear on undisturbed ground around the excavation and not directly onto
the chamber, to allow imposed loads to be deflected away from the chamber. Design of the cover
slab is the responsibility of the installer/structural engineer.
13. The control panel housing ‘KIOSK’ (if applicable) must be sited adjacent to the chamber on a
suitably sized concrete plinth complete with cable ducts for the cabling from the chamber and the
incoming power supply. If the control panel is not to be sited adjacent to the chamber we must be
advised at time of ordering so that we can make recommendation as to the cabling required.
14. It is extremely important that once the chamber has been installed and water drained that all
sand, silt, rubble and general debris is removed from the chamber. FAILURE TO DO THIS WILL
INVALIDATE THE WARRANTY ON THE PUMPS. Partly refill the chamber with clean water for testing
the system upon commissioning, and to facilitate a flush-through of the discharge pipe.
15. Install the pumps and float switches and draw these cables through the 110mm cable duct back to
the control panel location.
16. Mount the control panel within the desired location.
17. Provide a suitable electrical connection, this is to be isolated and adjacent to the now positioned
control panel.
18. Make the final electrical connections (as per the control panel wiring diagrams – found within control
panel).
A QUALIFIED ELECTRICIAN MUST CARRY OUT ALL ELECTRICAL CONNECTIONS.
19. Commission the pumping station. A commissioning service is available by PPS, simply contact us on
01279 757400 for further information.

Installation and Operating Guidelines
6
3.0 Lifting Guide
When lifting the chamber it is critical that the below lifting procedure is followed:
• Asuitableliftplanshouldbedevisedbytheinstallernotingthebelowspecicstoensurethatthereis
no damage to the chamber during this process.
• Pleaserefertotheindividualpallet/chamberweightstickerandselecttheappropriatelifting
equipment for this individual chamber.
• Inspectallchamberliftingeyes.
• Provideandinspectallliftingequipment,suitableforthechamberweight.
• Ensurethatthechamberisliftedusingthecorrectlengthandbreadth4hookliftingspreaderbeamfor
the widths of the chamber lifting eyes.
• Pleasenotethatundernocircumstancesshouldtheliftingequipmentencroachontheclearopening
anges, which in turn would apply pressure to this area and will result in the chamber being damaged.
• Adheretoallcurrentlegislativeandtrainingrequirements.

Installation and Operating Guidelines
7
4.0 Float Configuration
The control panel is designed to operate from 4 float switches, which are as follows: Stop, Start
Assist and High Level.
STOP FLOAT
The Stop oat controls the level at which the pumps turn off. It also needs to be in the On position for the
pumps to start.
START FLOAT
The Start oat controls the level at which the duty pump will activate. The Start oat and Stop oat both
need to be in the On position for the duty pump to start.
ASSIST FLOAT
The Assist float will activate the standby pump should the duty pump fail.
HIGH LEVEL FLOAT
The High Level float will activate the HLA lamp and audio sounder on the control panel should the level
inside the chamber continue to rise due to pump failure or the volume of waste water received exceeds
the discharge capability of the pump.
STOP
NON-RETURN VALVE
START
ASSIST LEVEL
HIGH LEVEL
GATE VALVE

Installation and Operating Guidelines
8
IMPORTANT INFORMATION
• TheStopoatshouldbepositionedapproximately100mmabovetheintakeofthepumps.
• TheStartoatshouldbepositionedtoactivateapproximately150mmbelowtheDutyAssistoat.
• TheDutyAssistoatshouldbepositionedapproximately150mmbelowtheHighLeveloat.
• TheHighLeveloatshouldbepositionedtoactivatejustabovetheinletleveloftheincoming
pipework.
5.0 Typical Control Panel Operation
A. Pump 1 Running Indicator. When lit this signies that pump 1 is in operation.
B. Pump 1 Tripped Indicator. When lit this signies that there is a problem with pump 1 causing the
overload relay within the panel to trip.
C. High Level Indicator. When lit this signies that there is a high level condition within the chamber.
D. Pump 2 Running Indicator. When lit this signies that pump 2 is in operation.
E. Pump 2 Tripped Indicator. When lit this signies that there is a problem with pump 2 causing the
overload relay within the panel to trip.
F. Pump 1 Control Switch. This switch controls the operation of Pump 1. It has 3 settings:
HAND This will run the pump without the use of the oat switches.
OFF This will remove all power to the pump for maintenance and break downs to prevent any
further damage to the pump.
AUTO This will run the pump according to the oat switches within the chamber. This is the
setting for normal operation.
A B C D E
F G H
I
J

Installation and Operating Guidelines
9
G. Alarm Mute Button. This button will silence the audio sounder should there be a high level condition
within the chamber.
H. Pump 2 Control Switch. This switch controls the operation of Pump 2. It has 3 settings:
HAND This will run the pump without the use of the oat switches.
OFF This will remove all power to the pump for maintenance and break downs to prevent any
further damage to the pump.
AUTO This will run the pump according to the oat switches within the chamber. This is the
setting for normal operation.
I. High Level Alarm. This is the audio sounder that will activate if there is a high level condition within
the chamber.
J. Mains Isolator Switch. This switch controls the main electrical supply to the unit.
IMPORTANT INFORMATION
• Neverleaveapumprunningonmanualunattended,thiscanleadtothepumptakinginair,whichwill
cause an air lock within the pipework or may lead to permanent damage to the pump/s.
• ShouldaPumpTrippedIndicatorbecomelititisadvisedthatthePumpControlSwitchbeputinto
the OFF position to prevent any potential damage to the pump/s and contact the PPs technical help
desk on 01279 757400 for further advice.
6.0 Technical Specifications
Power Supply
Rated Current
Motor Rating
Frequency
Revolutions per Minute
Max. Vertical Output
Max. Horizontal Output
Max. Flow Rate
Max. Liquid Temperature
Discharge Size
Cable Length
Weight
Colour

Installation and Operating Guidelines
10
7.0 Dimensions
Diameter
Height
Add 100mm for external diameter.
8.0 Parts List
Qty Product Name Part Number
9.0 Accessories
Product Product Code
10.0 Wiring Diagrams
The wiring diagram can be found within the control panel.
11.0 Transport
Carefully unpack the product from its packaging and inspect for any signs of damage. Should there be
any damage or parts missing this must be reported immediately (no claim will be considered after 24
hours from time of delivery).

Installation and Operating Guidelines
11
12.0 Maintenance
IMPORTANT – All maintenance works (inspections and services) MUST be undertaken by a technically
qualied/competent company/engineer. Before carrying out any maintenance work the system MUST
be completely disconnected from the mains power supply, and measures should be taken to prevent
the system from being inadvertently switched back on. When undertaking works within the chamber
suitable measures MUST to taken to ensure safe access in accordance with current regulations.
The product should be inspected every three months. The inside of the chamber should be inspected
to ensure that all oats are clean and free of any build-up of materials that may inhibit the products
operation. The internal chamber should be hosed down, where necessary, remove any build-up of solid
materials. Furthermore the bottom of the chamber should be checked to make sure there is no debris or
materials that could enter the pumps and cause damage.
All moving parts should be checked to ensure that they are moving freely. Also the control panel
operations should be tested in accordance with the operating guidelines.
A full visual inspection should be undertaken to the product and its overall condition, this must include
the chamber, oats, oat brackets, pumps, lifting chains, shackles, pedestals, top brackets, guide rails,
all internal pipework / ttings and valves, access cover, control panel etc.
In addition to the above it is important that the product undergoes a full service at a minimum frequency
of once yearly (increased servicing frequency is subject to site and product specic details. Where a
product is serving more than a single residential dwelling and/or there is a risk of flooding as a result of
product failure the servicing frequency should be increased accordingly). Please make contact with
PPS.
Please refer to section 14.0 for further information on service agreements offered by PPS.
IMPORTANT – The following items must not be disposed of via the pumping station:
• Anyhardobjectsi.e.wood,metal,plasticetc.
• Anybrousmaterialssuchascloths,babywipes,rags,sanitarytowels,nappiesetc.
• Orsimilar.
13.0 Health and Safety
Please pay attention to the following regulations when installing the pumps or ask your qualied
electrician/distributor.
Safety Precautions
In order to minimise the risk of accidents in connection with the service and installation work the
following guidelines should be followed:
• Neverworkalone.Usealiftingharness,safetylineandrespiratorasrequired.Donotignoretherisk
of drowning.
• Makesuretherearenopoisonousgaseswithintheworkarea.
• Checktheexplosionriskbeforeweldingorusingelectrichandtools.

Installation and Operating Guidelines
12
• Donotignorehealthhazards.Observestrictcleanliness.
• Bearinmindtheriskofelectricalaccidents.
• Makesurethattheliftingequipmentisingoodcondition.
• Provideasuitablebarrieraroundyourworkarea,e.g.guardrail.
• Makesureyouhaveaclearpathofretreat
• Useasafetyhelmet,safetygogglesandprotectiveshoes.
• Allpersonnelwhoworkwithsewagesystemsmustbevaccinatedagainstdiseasestowhichthey
may be exposed.
• Arstaidkitmustbeclosetohand.
• Notethatspecialrulesapplytoinstallationsinanexplosiveatmosphere.
Electrical Connections
• Thefollowingworksshouldonlybeundertakenqualifiedandauthorisedelectricians.
•PPS disclaimsallresponsibilityforworkdonebyuntrainedor/andunauthorisedpersonnel.
• Heedoperatingvoltage(seenameplateandadditionallabels).
•Takeoutthemainfusestoisolatethemainssupplyfromthecontrolunitbeforerepairsoranyother
works and ensure it cannot be energized again.
• Ifthepumpsareequippedwithanautomaticlevelcontrol,thereisariskofasuddenrestart.
• Beforestartingchecktheefficiencyoftheprotectivearrangementsofthepumpandthemonitoring
equipment. Failure to heed this warning may cause a lethal accident.
• Donotputtheleadendsintowater!Irruptionofwatermaycausemalfunctions.
• Ifpersonsarelikelytocomeintophysicalcontactwiththepumporpumpedmedia,theearthed
(grounded) socket must have an additional connection to an earth (ground) fault protection device
(GFI).
• Usethepumpsonlyinaccordancetothedatastatedonthepumpsplaterespectively.
Special rules apply to installations in explosive atmosphere. Intrinsically safe circuits (Exi) are normally
required for the automatic level control system by level regulators.
• Connectiononlytoamainssupplyinstalledinaccordancetothelocalregulations.Forfusingof
d.o.l. starting pumps use only slow fuses or automatic circuit breakers with C characteristics. This is
because the motor’s nominal voltage is measured at the terminal board of the pump; please consider
the voltage drop of long supply cables.
• Themotorsofthethree-phaseACpumpsmustbeprotectedbyasuitableovercurrentrelease.
Adjustment as follows;
Direct start +10% of normal current
Star-delta start (nominal current x 0.58) + 10%
If the protective arrangement has triggered, eliminate the trouble.
• Replacethecableifthecablejacketisdamaged.Donotpinchthecableorpullitaroundsharp
bends.
• Alwaysinstallthecontrolunitinadryandwell-ventilatedroomabovethebackpressurelevel.Never
install the control unit within the chamber / sump.
Earthing
For safety reasons, the earth conductor should be approximately 50mm (2”) longer than the phase
conductors. If the motor cable is jerked loose by mistake, the earth conductor should be the last
conductor to come loose from the rst terminal. This applies to both ends of the cable. Ensure the
correct earthing of the pump and control unit.

Installation and Operating Guidelines
13
14.0 Guarantee
24 month component Guarantee.
If within the guarantee period of the product any defect is discovered in respect of workmanship,
construction or material, we will make good the defect or replace the defective part at our expense
inside normal working hours at the company’s premises providing, written notice is given immediately
the defect is discovered and that, if required by us, the part or complete unit is returned to the
company’s premises carriage paid. Spares or repaired parts are delivered ex works exclusive of tting.
The guarantee does not apply to defects caused by incorrect installation, abnormal conditions of
working, accidents, misuse or neglects. Our responsibility is in all cases limited to the cost of making
good the defect or replacing the defective part at the company’s premises inside normal working hours.
We exclude all liability for any consequential or other damage or losses which may occur.
15.0 Service Agreement
All PPS products are manufactured to the highest possible standards and we have every confidence
that the equipment will serve you well. However, as with all systems of this nature, regular
maintenance is essential (in accordance with BS EN 12056-4) to ensure your system operates at its
optimum level and fulfills the expected lifespan.
Frequency of visits (according to BS EN 12056):
Once annually – Single residential dwelling
Bi-annually – Multiple residential dwellings
Quarterly – Commercial premises
For site and product specific service frequency details, please make contact with our aftersales
department on 01279 757400.
Service Agreements are available nationwide at competitive prices. Servicing of your equipment will
be undertaken at regular intervals, subject to contract. Our fully trained and experienced engineers will
complete a full report on the works undertaken and any recommendations required.
You can see significant benefits through:
• Reducedrunningcostsincludingenergyandmaintenance
• Increasedlifeexpectancyofequipment
• Reducedriskofbreakdownwithitsassociatedcostsandinconveniences
• Betterplantutilisation
• Improvedenvironmentalconditions
Our Service Agreements consist of the following:
• Scheduledservicevisitsperyear
• Reducedhourlychargesforun-scheduledcallouts
• Fullytrainedserviceengineers
• Freetechnicaladvicefromourhelpline
• Preferentialschedulingforun-scheduledcallouts
•Warranty for life via Direct Debit Standard Plan

Installation and Operating Guidelines
14
Please nd attached the service documentation, comprising of a Service Agreement, Equipment
Schedule and Work Schedule. Simply complete the attached documentation and return to:
Packaged Pump Systems
Unit 12 Haslemere Industrial Estate
Pig Lane
Bishop's Stortford
Herts.
CM23 3HG
or contact us by email/telephone for further information (01279 757400 /
[email protected]).

Installation and Operating Guidelines

Packaged Pump Systems
Unit 12 Haslemere Ind. Est
Pig Lane
Herts, CM23 3HG
Tel: [phone]
Email: [email protected]
Web: www.ppsgroupuk.com