Wilo Wilo-Port 800 User manual

2543019 Ed.02-06/2015 WH
Pioneering for You
Wilo-Port 800
de Einbau- und Betriebsanleitung
en Installation and operating instructions
fr Notice de montage et de mise en service
es Instrucciones de instalación y funcionamiento
no Monterings- og driftsveiledning
sv Monterings- och skötselanvisning
 Asennus- ja käyttöohje
hr Upute za ugradnju i uporabu
sr Uputstvo za ugradnju i upotrebu
sl Navodila za vgradnjo in obratovanje
hu Beépítési és üzemeltetési utasítás
pl Instrukcjamontażuiobsługi
cs Návodkmontážiaobsluze
sk Návodnamontážaobsluhu
ro Instrucţiunidemontajşiexploatare

Installation and operating instructions Wilo-Port 800 31
English
1. Introduction 32
1.1. About this document 32
1.2. Personnelqualications 32
1.3. Copyright 32
1.4. Subjecttochange 32
1.5. Warranty 32
2. Safety 33
2.1. Instructions and safety instructions 33
2.2. Generalsafety 34
2.3. Electrical work 35
2.4. Safetyandmonitoringequipment 35
2.5. Explosiveatmosphere 35
2.6. Behaviour during operation 35
2.7. Sound pressure 36
2.8. Standards and guidelines used 36
2.9. CE marking 36
3. Product description 36
3.1. Intendeduseandeldsofapplication 36
3.2. Improperuseandeldsofapplication 36
3.3. Set-up 37
3.4. Functiondescription 37
3.5. Materials 38
3.6. Technical data 38
3.7. Type key 38
3.8. Dimensions 39
3.9. Scope of delivery 39
3.10. Accessories 39
4. Transportationandstorage 40
4.1. Delivery 40
4.2. Transport 40
4.3. Storage 40
5. Installation 40
5.1. Installationtypes 41
5.2. Installation 41
5.3. Electrical connection 52
6. Commissioning 52
6.1. Commissioning 53
6.2. Behaviour during operation 53
7. Decommissioning/disposal 53
7.1. Temporarydecommissioning 54
7.2. Complete decommissioning for maintenance
work 54
7.3. Disposal 55
8. Maintenance 55
9. Faults,causesandremedies 56
10. Appendix 56
10.1. Spare parts 56

32 WILOSE06-2015V05DINA4
English INTRODUCTION
1. Introduction
1.1. About this document
The language of the original operating instructions is German.
Allotherlanguagesoftheseinstructionsaretranslationsofthe
original operating instructions.
This manual is divided into individual sections, which are listed in the
tableofcontents.Eachsectionhasaheadingwhichclearlydescribes
its content.
AcopyoftheECdeclarationofconformityisacomponentofthese
operating instructions.
Ifatechnicalmodicationismadeonthedesignsnamedtherewith-
out our agreement, this declaration loses its validity.
1.2. Personnel qualications
All personnel who work on or with the pump chamber must be quali-
edtocarryoutthiswork,e.g.electricalworkmustbeperformedby
aqualiedelectrician.Allpersonnelmustbeoflegalage.
Operating and maintenance personnel must also observe national
accident prevention regulations.
It must be ensured that personnel have read and understood the in-
structionsinthisoperatingandmaintenancehandbook;ifnecessary,
this manual must be ordered from the manufacturer in the required
language.
This pump chamber is not designed to be used by persons (including
children) with restricted physical, sensory or mental capacities, or
thosewithalackofexperienceand/orknowledge,unlesstheyare
supervisedbyapersonresponsiblefortheirsafetyandhavereceived
instructions from that person on how the pump chamber is to be
used.
Children must be supervised to ensure that they do not play with or
in the pump chamber.
1.3. Copyright
This operating and maintenance manual has been copyrighted by
themanufacturer.Theoperatingandmaintenancemanualisintend-
ed for use by installation, operating and maintenance personnel. It
containsspecicationsanddrawingsofatechnicalnature,which
- either in whole or in part - may not be duplicated, disseminated,
utilised without authorisation for the purposes of competition or
distributedtothirdparties.Theillustrationsusedmaydifferfrom
theoriginalandareintendedmerelyasanexamplerepresentationof
the chamber.
1.4. Subject to change
Themanufacturerreservestherighttomaketechnicalmodications
to systems or components. This operating and maintenance manual
relatestothepumpchamberspeciedonthetitlepage.
1.5. Warranty
In terms of the warranty, the current version of the "General Terms
andConditionofBusiness"isapplicable.Youcanndthesehere:
www.wilo.com/legal
Any deviations must be contractually agreed and shall then be given
priority.
1.5.1. General
The manufacturer has an obligation to resolve any defects on cham-
berssoldifoneormoreofthefollowingapply:
• The defects are caused by the materials used or the way the product
was manufactured or designed.
• The defects were reported in writing to the manufacturer within the
agreed warranty period.

Installation and operating instructions Wilo-Port 800 33
SAFETY English
• Thepumpchamberhasonlybeenusedunderthespeciedusage
conditions.
1.5.2. Warranty period
The length of the warranty period is set out in the "General Terms
and Conditions of Business".
Any deviations must be contractually agreed.
1.5.3. Spare parts, attachments and modications
Only genuine spare parts from the manufacturer may be used for
repairs,replacements,attachmentsandmodications.Independent
attachmentsandmodications,ortheuseofnon-genuineparts,
can lead to severe damage to the pump chamber and/or to injury to
personnel.
1.5.4. Maintenance
The prescribed maintenance and inspection work should be carried
outregularly.Thisworkmayonlybecarriedoutbyqualied,trained
and authorised personnel.
1.5.5. Damage to the product
Damage and malfunctions that endanger safety must be eliminated
immediatelybytrainedpersonnel.Thepumpchambermayonlybe
operatedinatechnicallysoundcondition.
In general, repairs should only be carried out by Wilo customer
service.
1.5.6. Disclaimer
No warranty is granted and no liability is accepted for damage to the
pumpchamberifoneormoreofthefollowingapply:
• Inadequatecongurationbythemanufacturerduetotheinfor-
mationprovidedbytheoperatororcustomerbeinginsufcientor
incorrect
• Non-compliance with safety instructions and working instructions
asspeciedinthisoperatingandmaintenancemanual
• Improper use
• Incorrect storage and transport
• Improper assembly/dismantling
• Insufcientmaintenance
• Incorrect repairs
• Inadequate construction site or construction work
• Chemical,electrochemicalandelectricalinuences
• Wear
Thismeansthemanufacturer’sliabilityexcludesallliabilityforper-
sonalinjury,materialdamageornanciallosses.
2. Safety
This section lists all the generally applicable safety instructions and
technicalinformation.Inaddition,alltheothersectionscontain
specicsafetyinstructionsandtechnicalinformation.Duringthe
various life cycle phases of the chamber (installation, operation,
maintenance, transportation etc.), all instructions must be followed
andcompliedwith.Theoperatorisresponsibleforensuringthatall
personnel comply with these instructions.
2.1. Instructions and safety instructions
This manual uses instructions and safety instructions for preventing
injuryanddamagetoproperty.Toclearlyidentifythemforperson-
nel, the instructions and safety instructions are distinguished as
follows:
• Instructionsappearinboldandreferdirectlytotheprecedingtextor
section.

34 WILOSE06-2015V05DINA4
English SAFETY
• Safety instructions are slightly indented and bold and always start
withasignalword.
• Danger
Serious or fatal injuries can occur!
• Warning
Serious injuries can occur!
• Caution
Injuries can occur!
• Caution (instruction without symbol)
Substantial property damage can occur. Irreparable damage is
possible!
• Safety instructions that refer to personal injury appear in black and
arealwaysaccompaniedbyasafetysymbol.Danger,prohibitionor
instruction symbols are used as safety symbols.
Example:
Dangersymbol:Generalhazard
Dangersymbol,forexample,electricalcurrent
Symbolforprohibitedaction,e.g.Noentry.
Instructionsymbol,forexample,wearprotectiveclothing
The safety symbols used conform to the generally applicable direc-
tivesandregulations,suchasDINandANSI.
• Safety instructions that only refer to material damage are printed in
grey, without safety symbols.
2.2. General safety
• Personnel may not work alone when installing and removing the
pumpchamber.Asecondpersonmustalwaysbepresent.
• Adequate ventilation must be ensured when working inside the
pump chamber.
• All work (assembly, dismantling, maintenance, installation) may only
becarriedoutwithoutapumpinstalled.
• The operator must report any faults or irregularities that occur to
alinemanagerimmediately.Theend-usermustshutdownthe
equipmentimmediatelyifdefectsoccurthatrepresentasafetyrisk.
Theseinclude:
• Material fatigue to pump chamber body
• Failureofthesafetyand/ormonitoringequipmentinstalled
• Damage to electrical equipment, cables and insulation
• Forweldingworkand/orworkonelectricalequipment,itisessential
toensurethatthereisnoriskofexplosion.
• Onlyuseliftinggearwhichislegallydenedassuchandofcially
approved.
• The lifting gear must be kept safely and must be suitable for the
conditions of use (weather, hooking unit, load, etc.).
• Mobileequipmentforliftingloadsshouldbeusedinsuchawaythat
it is guaranteed to remain stable during operation.
• When using mobile equipment for lifting non-guided loads, take
action to prevent tipping, shifting, sliding, etc.

Installation and operating instructions Wilo-Port 800 35
SAFETY English
• Measures should be taken to ensure that no person is ever directly
beneathasuspendedload.Furthermore,itisalsoprohibitedtomove
suspended loads over workplaces where people are present.
• Ifmobileequipmentisusedforliftingloads,asecondpersonshould
bepresenttocoordinatetheprocedureifrequired(forexample,if
theoperator’seldofvisionisblocked).
• The load to be lifted must be transported so that no-one will be
injuredifthereisapowerfailure.Furthermore,ifsuchworkisbeing
carried out outdoors, it must be cancelled if the weather conditions
worsen.
• Tools and other objects should only be kept in their designated plac-
es so that they can be found quickly.
These instructions must be strictly observed. Non-observance
can result in injury or substantial material damage.
2.3. Electrical work
ELECTRICAL hazard!
Incorrectly performed electrical work can result in fatal injury!
This work may only be carried out by aqualied electrician.
Apumpmustbettedtopumptheaccumulatedsewage.Itcanbe
operatedusinganalternatingorthree-phasecurrent.Theapplica-
blenationaldirectives,standardsandregulations(e.g.VDE0100)
andthespecicationsofthelocalenergysupplycompanymustbe
observed.
The operator must be instructed in the electrical power supply to the
pump and how to shut it off.
Fortheconnection,refertotheoperatingandmaintenancemanual
for the pump installed.
The pump installed must always be earthed.
2.4. Safety and monitoring equipment
The pump chamber is used to collect sewage containing faeces,
whichisthenpumpedoutusingasubmersiblepump.Ifthereis
amalfunctioninthesystem,theaccumulatedsewagecanbecome
backed up as far as the inlet.
To guarantee operational reliability, we recommend always using
ahighwateralarm.Thisreportsafaultifthewaterlevelinthepump
chamberistoohigh.Forincreasedreliability,thisalarmsignalshould
be issued using the GSM network. This ensures that service person-
nel can offer an appropriately rapid response time.
2.5. Explosive atmosphere
When pumping sewage containing faeces, gas can accumulate in the
collection reservoir. According to the local directives and standards,
itmaybenecessaryforthepumpchambertobedeclaredasanEx
zone.
RISK of explosive atmosphere!
This Ex zone denition is the responsibility of the operator in
line with the local directives. Ifan Ex zone is dened, all compo-
nents must have appropriate approval.
2.6. Behaviour during operation
During operation, no personnel may be present in the pump cham-
ber, and the pump chamber must be completely sealed.
The control and the level control for automatic operation must
function properly.
The laws and regulations applicable at the usage location for oper-
ationofsewagepumpingstationsmustbeobserved.Allpersonnel
are responsible for ensuring that regulations are observed.

36 WILOSE06-2015V05DINA4
English PRODUCT DESCRIPTION
2.7. Sound pressure
The pump chamber itself does not produce any noise. However, the
actual sound pressure of the system depends on several factors,
e.g.pumpinstalled,installationdepth,attachmentofaccessories
and piping, duty point etc.
We recommend that the operator carries out an additional meas-
urement when the system is running at its duty point an under all
operating conditions.
CAUTION: Wear ear defenders!
According to applicable laws and regulations, ear protection
must be worn if the sound-pressure level is 85dB(A) or more!
Theend-user must make sure that this is complied with!
2.8. Standards and guidelines used
The pump chamber is subject to various European directives and
harmonised standards. Refer to the EC declaration of conformity for
precise information about these.
There are also various additional regulations that are prerequisites
for use, installation and dismantling of the pump chamber.
2.9. CE marking
The CE marking is attached to the rating plate.
3. Product description
The pump chamber is manufactured with the utmost care and is
subjecttocontinuousqualityassurance.Fault-freeoperationis
guaranteed if it is installed and maintained correctly.
3.1. Intended use and elds of application
RISK of explosive atmosphere!
Sewage containing faeces can lead to gas accumulation in the
collection reservoir, which can ignite as aresult of improper
installation and operation.
When using the system for sewage containing faeces, the local
directives and regulations for Ex protection must be checked
and observed.
RISK due to explosive media!
Collection of explosive media (e.g.petrol, kerosene etc.) is
strictly prohibited. Thepump chamber is not designed for these
media.
Combinedwithasubmersiblepump,theWilo-Port800actsas
apumpingstationforsewagecontainingfaecesandfreeoffaeces
inadomesticsetting.Itseldofapplicationisindrainageofbuilding
dischargepointsandsitesbelowthebackowlevel,wherethesew-
age cannot drain into the public channel due to natural fall.
Intended use includes compliance with this manual. Any other use is
considered to be outside the intended use.
3.2. Improper use and elds of application
WARNING - Injuries hazardous to health!
Because of the materials used, the pump chamber is not suitable
for pumping of drinking water.
• If it comes into contact with sewage, there is arisk of damage to
health.
• Do not use the pump chamber inside buildings.

Installation and operating instructions Wilo-Port 800 37
PRODUCT DESCRIPTION English
CAUTION!
Introduction of prohibited media can cause damage to the pump
chamber.
• Never introduce solid materials, bres, tar, sand, cement, ash,
coarse paper, paper towels, cardboard, rubble, rubbish, slaughter-
ing waste, grease or oils.
• If greasy sewage occurs, agrease trap must be provided.
• Improper use and overloading leads to damage to the pump
chamber.
• The maximum possible inow must always be lower than the vol-
ume ow of the pump installed at the relevant duty point.
Thefollowingmediamaynotbeintroduced:
• Sewage from drainage objects that are located above the back-
owlevelandcanbedrainedbynaturalfall(inaccordancewithEN
12056-1)
• Explosiveandharmfulmediasuchassolidmaterials,rubble,ash,
rubbish,glass,sand/grit,plaster,cement,lime,mortar,bres,tex-
tiles, paper towels, nappies, cardboard, coarse paper, synthetic resin,
tar, kitchen waste, grease, oils, waste from slaughtering, carcass
disposal and keeping of animals (manure...)
• Toxic,aggressiveandcorrosivemediasuchasheavymetals,bioc-
ides, pesticides, acids, alkalis, salts, cleaning agents, disinfectant,
washing-upliquidanddetergentinexcessquantitiesandanymedia
thatformadisproportionateamountoffoam,swimmingpoolwater
(inGermanyinaccordancewithDIN1986-3).
3.3. Set-up
Fig. 1: Overview
1 Pump chamber 9 Inlet connection
2 Discharge pipe 10 Venting/cableducts
3 Non-return ball valve 11 Pump
4Surface coupling 12 Level control
5 Shut-off valve 13 Eyes for lifting equipment
6 Pressure connection 14 Hook for attachment of chain
7 Lifting equipment (chain) 15 Pump chamber cover
8 Cross member
TheWilo-Port800isapumpchamberwithstrongnningforverti-
calconcealedoorinstallationoutsidebuildings.
Thepumpchamberhasthreeinletconnectionsandaconnection
port for venting and cable ducts. As standard, the pump chamber
issuppliedwithinternalpipeworkincludinganon-returnvalvefor
connectionofamaceratorpump.
Foruseasapumpingstation,additionalaccessoriesarerequired.
3.4. Function description
The pump chamber works fully automatically in conjunction with
asubmersiblepumpandlevelcontrol.Theaccumulatedsewage
is fed to the pump chamber using the inlet connection (3), and is
initially collected. When the collected sewage reaches the switch-
onlevel,thesubmersiblepumpswitcheson.Thesubmersiblepump
pumps the sewage through the discharge pipe and the pressure con-
nectionintotheonsitepressuriseddischargepipe.Thewaterlevel
inthepumpchamberfalls.Thecontrolswitchesoffthesubmersible
pumpagainafterasettimeorwhentheswitch-offlevelisreached
(depending on the signal transmitter used).
1
2
3
4
5
6
7
8
9
9
10
11
12
13
14
15
Fig. 1

38 WILOSE06-2015V05DINA4
English PRODUCT DESCRIPTION
The non-return ball valve in the discharge pipe prevents the sewage
fromowingbackoutoftheonsitepressuriseddischargepipe.
3.5. Materials
• Pumpchamber:PE
• Non-returnballvalve:Castiron
• Pipework:Stainlesssteel
• Surfacecoupling:Castiron
• Gatevalve:Redbrass
3.6. Technical data
Description Value Comments
Max.permittedpressure
inpressurepipe: 10bar
Discharge pipe connec-
tion: R1¼(DN32) Stainlesssteelpipe(VA) with thread
Inletconnection: 1xDN200,2xDN150
Ventilationconnection/
cablebushing: 1xDN100
Max.permittedambient
temperature: 20°C Ground, below depth of 0.5m
Max.permittedground-
waterlevel: Ground level
Impoundmentvolume: See data sheet/cata-
logue
Suitablepumptypes:
RexaCUT
DrainMTS40
DrainMTC40
Drain MTC 32
Suitablepumpcover: ClassA15,B125orD400
Observeeldofapplica-
tion in accordance with
EN124!
3.7. Type key
Example: Wilo-Port 800.1-2250-03B
Port Productfamily:Pumpchamber
800 Nominal chamber diameter in mm
11 = Single pump chamber
2 = Double pump chamber
2250 Monolithic chamber height without cover in mm
03 PressureconnectionDN32
B
Pipeworkforpumptype:
B=RexaCUT,DrainMTS40,DrainMTC40,DrainMTC32F39
C=DrainMTC32F49,DrainMTC32F55

Installation and operating instructions Wilo-Port 800 39
PRODUCT DESCRIPTION English
3.8. Dimensions
Fig. 2: Dimension drawing
ø880
ø900
ø820
ø110
ø200
500
755
R 1¼“
850
1140
1120
1750
ø160
ø160
110
100
120
120
120
ø880
ø900
ø820
ø110
ø200
R 1¼“
ø160
ø160
110
100
120
120
120
500
1350
1255
1620
1640
2250
The height dimensions increase by the upward protruding part of
the selected pump cover.
3.9. Scope of delivery
• Pump chamber with complete pipework, consisting of
• Dischargepipewithsurfacecoupling,90°non-returnballvalve
and pressure connection
• Shut-off device
• Cross member
• Chain (lifting equipment for pump installation)
• Installation materials for pumps
• Installation and operating instructions
NOTE:
Foruseasapumpingstation,accessoriesarerequiredthathaveto
be ordered separately.
3.10. Accessories
• ClampboltingforconnectiontoaPEdischargepipe
• Pumpchamberextension
• PumpcoverinclassesA15,B125orD400(inaccordancewith
EN124)
• Operating crank for shut-off device
• FlushconnectionwithStorzCconnection
• Flushconnectionextension
• Vacuumreliefvalve
• Levelcontrolusing:
• Dynamic pressure bell, optionally with bubbling-through system
• Level sensor
• Floatswitch
• Macerator pump
• Switchgear (depending on level control device)
• Excut-offrelayandZenerbarrierasseparateaccessoriesforcon-
nectionofoatswitchorlevelsensorinpotentiallyexplosiveareas
• Alarm switchgear
• Flashlight
Forfurtherinformation,seecatalogue.
Fig. 2

40 WILOSE06-2015V05DINA4
English TRANSPORTATION AND STORAGE
4. Transportation and storage
4.1. Delivery
On delivery, check immediately that the shipment is complete and
undamaged.Ifanypartsaredamagedormissing,thetransportcom-
panyorthemanufacturermustbenotiedonthedayofdelivery.
Claims made after this date cannot be recognised. Damage to parts
must be noted on the freight documentation.
4.2. Transport
Only the designated and approved sling gear, transport and lifting
equipment are to be used for transportation. They must have suf-
cientloadbearingcapacityandliftingforcetoenablethepump
chamber to be transported safely. When using chains, they must be
secured against slipping.
Thepersonnelmustbequaliedforthetasksandmustfollowall
applicable national safety regulations during the work.
The pump chamber is supplied in suitable packaging by the man-
ufacturer or supplier. This normally precludes the possibility of
damage occurring during transportation and storage.
4.3. Storage
Whendelivered,newpumpchambersarepreparedinsuchaway
thattheycanbestoredforatleast1year.Forintermediatestorage,
the pump chamber must be cleaned thoroughly before storage.
Thefollowingshouldbetakenintoconsiderationforstorage:
• Placethepumpchambersecurelyonasolidbearingsurfaceand
secure it against falling over or sliding away. Pump chambers are
stored vertically.
DANGER due to falling over!
Never set down the pump chamber without it being secured.
There is arisk of injury if the pump chamber falls over.
• Thepumpchambermustbestoredinadry,frost-proofroom.We
recommendaroomtemperatureofbetween5°Cand25°C.
• The pump chamber may not be stored in rooms where welding work
is carried out, as the resulting gases and radiation can attack the
elastomer parts.
• All connection ports and the pump chamber inlet must be securely
sealed to prevent contaminants.
• Accessories such as the pump and level sensors must be dismantled.
• The pump chamber must be protected from direct sunlight, heat,
dust and frost. Heat or frost can result in damage to the elastomer
parts.
• Afteralongperiodofstorage,thepumpchambermustbecleaned
of impurities before commissioning.
Notethatelastomerpartsaresubjecttoanaturalprocessofem-
brittlement. We recommend checking them if stored for more than 6
months. Consult the manufacturer for further details.
5. Installation
RISK of death due to improper handling!
Incorrect installation and improper electrical connections can be
life-threatening.
• Installation and electrical connection may only be carried out
by specialist personnel and in accordance with the applicable
regulations.
• Adhere to regulations for accident prevention!

Installation and operating instructions Wilo-Port 800 41
INSTALLATION English
DANGER of suffocation!
Toxic or harmful substances in sewage pump chambers can lead
to infections or suffocation.
• During any work in pump chambers, asecond person must be
present for safety reasons.
• Ensure that the pump chamber and the surrounding area are ade-
quately ventilated.
NOTE:
During dimensioning and installation, the applicable national and
regional standards and regulations for installation of sewage tech-
nologysystemsmustbeobserved,e.g.EN1610.
Likewise, the installation and operating instructions for the acces-
sories must be observed.
In order to prevent damage to the product or serious injury during
installation,thefollowingpointsmustbeobserved:
• The installation work – assembly and installation of the pump
chamber–mayonlybeperformedbyqualiedpersonnelincompli-
ance with the safety instructions.
• Before starting the installation work, the pump chamber must be
checked for transport damage.
Failuretocomplywithinstructionsforassemblyandinstallation
jeopardises the safety of the pump chamber/personnel and voids the
safety declarations issued.
5.1. Installation types
• Concealedoorinstallationoutsidebuildings
5.2. Installation
DANGER due to falling!
Personnel can fall into the open pump chamber during installa-
tion and suffer serious injuries.
• During installation, the installation location must be appropriately
marked and secured.
• Always close the installed pump chamber with an appropriate
pump cover.
Notethefollowingforinstallationofthepumpchamber:
• This work must be performed by specialist personnel and electrical
workmustbeperformedbyaqualiedelectrician.
• The installation location must be frost-free.
• A second person must be present for safety reasons. Take the
necessarycountermeasuresifthereisariskoftoxicorsuffocating
gases collecting.
• If lifting equipment is to be used for installation of the pump
chamber, problem-free installation of the lifting equipment must
beensured.Thelocationwherethepumpchamberisusedandset
downmustbesafelyaccessiblewiththeliftingequipment.Theset-
downlocationmusthaveasolidbearingsurface.Totransportthe
pumpchamber,theliftinggearmustbeattachedtothespecied
lifting eyes. When using chains, these must be connected to the
liftingeyesusingashackle.Onlystructurallyapprovedliftinggear
may be used.
• The power supply cables for the pump used and for the signal trans-
mittersmustbelaidinsuchawaythatsafeoperationandprob-
lem-free installation/dismantling are possible at any time. Check the
cable cross-section used and the selected routing to make sure the
availablecablelengthissufcient.
• Check the dimensioning documents (installation plans, inlet and
outlet conditions) for completeness and accuracy.

42 WILOSE06-2015V05DINA4
English INSTALLATION
• Also refer to all regulations, rules and laws for working with heavy
and suspended loads. Wear appropriate protective clothing/equip-
ment.
• Please also observe the applicable national accident prevention
regulations and trade association safety provisions.
5.2.1. Work steps
1. Preparatory tasks
2. Pump chamber installation
3. Setting up pipe connections
4. Installingthepumpchamberextension
• With pump chamber cover class A15 and B125
• WithpumpchambercoverclassD400
5. Fillingthepit
6. Installing the pump
7. Installing the level control device
8. Laying the pipes and connection cables
9. Installing the pump cover
10. Finaltasks
5.2.2. Preparatory tasks
• Selectinstallationlocation:
• Outside buildings
• Not in the immediate vicinity of living and sleeping areas
• Max.heightadjustmentwithconcreterings:200mm
• Max.heightadjustmentwithplasticpumpchamberextension:
500mm
CAUTION!
The pump chamber may not be installed in peaty ground. This
can lead to destruction of the pump chamber.
• Pump cover
• Must be ordered separately.
• ClassesinaccordancewithEN124:A15,B125orD400
ForclassD400aloaddistributionplatemust be provided onsite.
• Loaddistributionplate:
Dimensions:ExternalØ:1700mm;InternalØ:700mm;Thickness:
300mm;Concretegrade:C35/45;Reinforcement:Concretesteel
B500A10mm,spacing150mmlongitudinal+lateral,up+down
5.2.3. Pump chamber installation
• Take into account the direction of the inlet, pressure and ventilation
connection.
• Take into account the cable length for the pump and level control
device, so that the pump and level control device can be lifted out of
the pump chamber.
• Have the pump cover ready.
Fig. 3: Pump chamber installation
1 Pump cover X Required pit depth
2Pumpchamberextension Y Pump cover height
3 Pump chamber Z Max.pumpchamberdiameter
4 ConnectionportDN150
5ConnectionportDN200
6 Levelling layer
7 Underlay

Installation and operating instructions Wilo-Port 800 43
INSTALLATION English
300
400
Z + 2000
Z
X
Y
1
2
3
4
4
5
6
7
1. Excavatethepittakingintoaccountthefollowingpoints:
• Pump chamber height
• Inlet pipe depth
• ConnectionportDN150orDN200height
• Underlayapprox.300mm
• Levellinglayerapprox.100mm
• Pump cover height
• Pumpchamberextensionheight,max.500mm
• The pit diameter on the ground must be 2 m larger than the pump
chamber diameter.
• Observe the applicable regulations for earthworks in underground
engineering and road building (slope angle, installation).
• If required due to the groundwater level, the pit must be protected
usingagroundwaterdrawdown.
NOTE:
IfaclassD400pumpcoveristobeused,aloaddistributionplate
mustalsobeinstalled.Todothis,theadditionalheightof300mm
and the corresponding substructure must be taken into account.
2. Checktheoorofthepitforbearingcapacity.
3. Installtheload-bearingmineralmixtureunderlayproperlyandsealit
(Dpr97%).
4. Addalevellinglayerofsandapprox.100mmthickandleveloff.
5. Prepare the onsite inlet, venting and pressure pipes.
6. Install the pump chamber in the pit, align the connections with the
onsite piping and drive in evenly.
Fig. 3

44 WILOSE06-2015V05DINA4
English INSTALLATION
The ground ns must sink completely into the levelling layer.
7. Check the plumb-vertical alignment and position of the pump
chamber, including the height of the pump cover and any pump
chamberextension,againstthesurroundingsurfacelevelandadjust
if necessary.
5.2.4. Setting up pipe connections
Fig. 4: Preparing pipe connections
Install and lay all pipes so that they are stress-free.
1. Cut out the selected connection ports for the inlet and venting pipe
and remove burrs.
2. Laythepipingwithadownwardslopetothepumpchamberand
connecttotheopenedconnectionportswithaKGsleeveusing
lubricants.
NOTE:
Foreasierlayingoftheelectricalconnectioncables(pump/level
controldevice)max.30°pipebendsaretobeusedintheonsite
ventilationlineandatierodshouldbetted.
3. Connect the onsite pressure pipe to the pressure connection using
clamp bolting and ensure frost-proof routing.
4. Performaleaktestinaccordancewiththeapplicableregulations.
5.2.5. Installing the pump chamber extension – When using A15 and
B125 pump cover
CAUTION!
The max. installation depth of 2750 mm including extension,
concrete adjusting rings and pump cover may not be exceed-
ed. Otherwise, deformation or cracks in the body of the pump
chamber could occur.
To compensate for the height difference between the top edge of
thepumpchamberandthesurfacelevel,aplasticpumpchamber
extensioncanbeinstalledorconcreteadjustingringscanbeused.
Plastic pump chamber extension
Fig. 5: Installing the pump chamber extension
1 Pump chamber 4Groove for O-ring
2Pumpchamberextension 5 O-ring
3 Surface level 6 Pump cover
Theplasticpumpchamberextensioncanbeusedtoextendthe
pumpchamberby200to500mm.Thepumpchamberextensionis
made of PE material and must be ordered as an accessory.
1. Determinetherequiredextensionforthesurfacelevel.
Take into account the height of the pump cover.
2. Therequireddimensionisdenedbytheselectedgrooveatthe
taperoftheextension.
1
2
4
5
36
1
10
200...500
Fig. 5
15...26
Fig. 4

Installation and operating instructions Wilo-Port 800 45
INSTALLATION English
Selecttheappropriategrooveusingthefollowingtable:
Groove Extension in mm
(from top edge of pump chamber to top edge of extension)
3 200
4250
5 300
6 350
7400
8450
9 500
Grooves 1, 2 and 10 may not be used.
3. InserttheO-ringsuppliedintheselectedgrooveintheextension.
4. Coat the O-ring and the inside of the taper on the pump chamber
with lubricant (washing-up liquid or even water in an emergency).
5. Slidethepumpchamberextensionintothepumpchamberuntilthe
O-ring wedges securely in the cone in the taper.
Do not push the O-ring beyond the cone. Make sure that the
O-ring slides cleanly into the taper, does not twist and is not
pushed out of the groove. Ifnecessary, push the O-ring further by
hand when tting the extension.
Concrete adjusting rings
Fig. 6: Installing concrete rings
1Coverange 4 Pump cover with frame
2Filling(sandormortar) 5Filling/compactinglayer
3 Concrete adjusting rings 6 Surface level substructure
Standard concrete adjusting rings can be used for height compen-
sationtothesurfacelevel,uptoamaximumof200mmabovethe
top edge of the pump chamber including the pump cover height.
Theconcreteringsshouldbeprovidedbythecustomer.
1. 1.Placetheconcreteringcentrallyonthecoverange
2. Fillthegapbetweentheconcreteringandthecoverangewith
sand or mortar.
3. Place further concrete rings centrally.
Toensureasolidandfull-facedcontactbetweentheconcreterings
and the cover frame and to minimise additional water ingress by
groundwaterorsurfacewater,athinlayerofmortarmustbeapplied
to the mating surfaces on the concrete rings and the cover frame.
5.2.6. Installing the pump chamber extension – When using D400 pump
cover
CAUTION!
The max. installation depth of 2750 mm including load distribu-
tion plate, concrete adjusting rings and pump cover may not be
exceeded. Otherwise, deformation or cracks in the body of the
pump chamber could occur.
CAUTION!
When using the load distribution plate, absolute impermeability
to the interior of the pump chamber is not achieved. This can
lead to increased ingress of water into the pump chamber at
ahigh ground water level. Inturn, this can overload the pump
and cause consequential damage to the pumping station.
1
4
6
5
max.
200
3
2
Fig. 6

46 WILOSE06-2015V05DINA4
English INSTALLATION
NOTE:
WhenusingtheclassD400pumpcover,aloaddistributionplate
mustalsobeinstalled.Todothis,thecoverangeonthepump
chamberoronthepumpchamberextensionhastobecutoff.
The load distribution plate must be provided by the customer.
WhenusingtheD400pumpcover,amaximumpumpchamberex-
tension of 570 mm is possible. However, the required load distribu-
tionplatenecessarilyresultsinanextensionofatleast300mm.This
must be taken into account during the installation work.
The load distribution plate must be provided by the customer.
Ifanadditionalextensionofmorethanthisminimum300mmisre-
quired, we recommend that this is achieved using standard concrete
adjusting rings.
In addition, to ensure that the load distribution plate can be properly
installed,thecoverangeonthepumpchambermustbecutoff.
Fig. 7: Removing the cover ange
Forproperoperationwhensubjecttoroadtrafcrequirements,
acorrespondingsubstructuremustalsobeinstalled.Thisisincorpo-
ratedwhenllingthepit.
The load distribution plate may rest on the pump chamber, but
must rest completely on the corresponding substructure.
Allfurtherdetailscanbefoundinthe"Fillingthepit"section.
5.2.7. Filling the pit
Duringlling,thepumpchambermustbecontinuouslycheckedfor
aplumb-verticalandconstantposition,andforanydeformationor
other indications of installation errors.
The areas directly adjacent to the pump chamber wall and the cover
angeofthepumpchamberandthepumpchamberextensionmust
belledmanuallyandcompacted(shovel,handrammer).
Inaddition,thepumpchamberandanypumpchamberextension
installedmustbeheldinpositionandmaynotriseup.Ifnecessary,
thiscanbeensuredbyllingthepumpchamberwithwaterbefore
llingandcompacting.
Using the A15 and B125 pump cover
Fig. 8: Filling the pit (with A15 and B125 pump cover)
1 Underlay
2 Levelling layer
3Sand/gravel layer with no sharp-edged content,
grainsize0...32mm,max.layerthickness300mm
4 Concreteadjustingringsforpumpchamberextension
5 Surface level substructure
6 Pump cover class A15 or B125
TheclassA15andB125pumpcoverscanbedirectlyttedinthe
coverangeonthepumpchamberorthepumpchamberextension
usingthecoverframesupplied(maximumouterdiameter825mm).
1. Fillthepitalayeratatime(layerthicknessmax.300mm)with
coarse-grained soil all the way around to an even height (sand/gravel
with no sharp-edged content, grain size 0-32 mm) and compact
properly(Dpr.97%).Compactbyhandatthepumpchamberwall
andatthecoverangeonthepumpchamberandpumpchamber
extension,ensuringthatthepumpchamberisinaplumb-vertical
position and avoiding deformation.
Fig. 8
2
45
6
1
3
max.
200
Ø660
1
Fig. 7

Installation and operating instructions Wilo-Port 800 47
INSTALLATION English
The top sand/gravel layer (compacting layer) must reach as far as
the cover ange.
Piping must be properly embedded, lled and sealed in accord-
ance with the applicable national standards.
2. Align the surface level including substructure with the pump cover.
NOTE:
If the surrounding ground is made up of cohesive material
(e.g.topsoil),forbetterassimilationtothesurroundingscanbe
achievedbyllingancompactingthe"substructuretosurface
level"withthismaterial(max.grainsize20mm).
Using the D400 pump cover
Fig. 9: Filling the pit (with D400 pump cover)
1 Underlay
2 Levelling layer
3Sand/gravel layer with no sharp-edged content,
grainsize0...32mm,max.layerthickness300mm
4Substructureasfortrafcsurface,butatleastgravelorrubblelayer,min.
layerthickness400mmandafrictionangleof>37.5°
5Sandlayer,max.grainsize16mm,minimumlayerthickness100mm
6 Load distribution plate
7Concreteadjustingringsforpumpchamberextension
8Trafcsurfacesubstructure
9ClassD400pumpcover
1. Fillthepitalayeratatime(layerthicknessmax.300mm)with
coarse-grained soil all the way around to an even height (sand/gravel
with no sharp-edged content, grain size 0-32 mm) as far as the base
ofthesubstructureandcompactproperly(Dpr.97%).Compactby
hand at the pump chamber wall, ensuring that the pump chamber is
inaplumb-verticalpositionandavoidingdeformation.
Piping must be properly embedded, lled and sealed in accord-
ance with the applicable national standards.
2. Install the substructure for the load distribution plate in the same
wayasthesubstructurefortrafcsurfacesinaccordancewiththe
validdirectives.Minimumrequirement:
• Gravelorrubblelayerwithamin.layerthicknessof400mmand
africtionangleof>37.5°
• The substructure (if not planar) should have an outer diameter of
at least 2.90 m at the base.
There must be aprotective sand layer (max. grain size 16 mm) of
at least 100 mm between the substructure for the load distri-
bution plate and the body of the pump chamber or the pump
chamber extension.
3. Place the load distribution plate centrally.
Make sure that the load distribution plate has afull-faced contact
with the substructure.
4. Ifanadditionalpumpchamberextensionwithconcreteringsis
required, they can now be placed centrally on the load distribution
plate.Toensureasolidandfull-facedcontactbetweentheconcrete
rings and to minimise additional water ingress by ground water or
surfacewater,athinlayerofmortarmustbeappliedtothemating
surfaces on the concrete rings.
2
4
6
78
9
1
3
max. 570
min.
2900
min.
100
min. 400
5
Fig. 9

48 WILOSE06-2015V05DINA4
English INSTALLATION
5. Placethecoverangecentrallyontheloaddistributionplateoron
the last concrete ring.
6. Alignthetrafcsurfaceincludingsubstructurewiththepumpcover.
5.2.8. Installing the pump
Observe the installation and operating instructions for the pump.
CAUTION!
Stud bolts not removed from the hydraulics (Drain MTS, Rexa
CUT)can lead to malfunctions and damage to the pump chamber
wall.
Some parts of the uid can accumulate on the stud bolts,
impairing free access to the intake area and macerator in the
pump.
The intake area and macerator in the pump must be kept free of
deposits.
Fig. 10: Preparing the pump
1 Pump 3 Attachment for chain
2 Discharge pipe 4Cable tie
• Remove coarse contaminants in the pump chamber.
• Screw together the pump and discharge pipe outside the pump
chamber using the assembly materials supplied.
• Attach the connection cable to the horizontal section of the dis-
chargepipeusingthecabletiesupplied.Thecableshouldrunfrom
the pump to the cable tie with slight tension and with no slack.
• Close the shut-off device
• Suspend the chain from the discharge pipe (observing the separate
installation and operating instructions for the chain) and lower the
pump and discharge pipe into the pump chamber until the two cou-
plings have completely engaged with one another.
When lowering the pump, guide it in such away that it does not
remain suspended on the pump chamber ttings.
NOTE:
Forproblem-freeinstallationofthepump,itmustbetwistedlater-
allybyaround90°sothatitcanbeguidedpastthecrossmember.
• After suspending the pump, check that it is suspended freely and
withsufcientclearancefromthepumpchamberwallandthatit
cannot touch the pump chamber wall.
• Detach the chain from the lifting equipment and suspend it from the
chain hooks in the pump chamber.
CAUTION!
Improper handling of the pump can lead to damage. Only sus-
pend the pump from the installed discharge pipe with achain,
never from the connection cable.
5.2.9. Installing the level control device
Observe the installation and operating instructions for the level
control device.
RISK of explosive atmosphere!
If the operator has declared the operating space as an Ex zone,
the signal transmitters must be connected using an intrinsically
safe electric circuit.
Consult your electrician for further details.
1
2
43
Fig. 10

Installation and operating instructions Wilo-Port 800 49
INSTALLATION English
CAUTION!
To prevent damage to the pumping station, the following points
must be observed:
• The switching points must be set so that no backing up occurs in
the inlet pipe.
• To ensure that correct level measurement is possible, the signal
transmitters may not be located directly in the inlet ow.
• Check the operating mode for which the pump is approved for
non-immersed operation. ForS2 or S3 operation, the specied
operating and idle times must be observed when setting the level
control device.
Levelmeasurementcanbecarriedoutindifferentways:
• Dynamic pressure bell
• Level sensor
• Floatswitch
The signal transmitters used depend on the switchgear used.
Fig. 11: Attaching the signal transmitters
1 Cross member 3 Dynamic pressure bell
2 Mount for dynamic pressure bell and level sensor
Dynamic pressure bell
Whenusingadynamicpressurebell,levelmeasurementiscarried
out by measuring the static pressure in the pump chamber. Note
that the dynamic pressure bell must emerge after each pumping
proceduresothatitcanbevented.Alternatively,abubbling-through
systemcanbeused.Inthiscase,asmallcompressorcontinuously
pumps air into the dynamic pressure bell.
In addition, we recommend installation of an additional second
dynamic pressure bell for autarkic measurement and signalling of the
high water alarm.
Level sensor
Whenusingalevelsensor,levelmeasurementiscarriedoutusing
adiaphragm.Makesurethatthediaphragm(thelowersectionofthe
levelsensor)remainconstantlyimmersed.Thelevelsensormaynot
rest on the base of the pump chamber.
Float switch
Whenusingoatswitches,levelmeasurementiscarriedoutusing
oats.Makesurethattheoatswitcheshavesufcientfreedomof
movement and do not bump into the pump chamber.
Installation
Thedynamicpressurebellandthelevelsensoraretteddirectlyin
the mount on the cross member from above using the accessories
supplied.
Theoatswitchisattachedtotheverticaldischargepipeusing
cableties.Forfault-freelevelmeasurement,afreecablelengthof
approx.250mmisrequired.
Topreventdepositsaseffectivelyaspossible,theuidmustbe
replaced regularly. Therefore, we recommend using the switching
pointsforthelowerinlet.Thecorrespondingswitchingpointsare
shown in the following tables.
1
2
3
Fig. 11