Xylem FLYGT Compit 901 Series User manual

Installation, Operation, and
Maintenance Manual
90011201_2.0
Flygt Compit 901

Table of Contents
1 Introduction and Safety..............................................................................................................3
1.1 Introduction.......................................................................................................................... 3
1.2 Safety terminology and symbols........................................................................................3
1.3 User safety.............................................................................................................................4
1.4 Special hazards.....................................................................................................................4
1.4.1 Confined spaces........................................................................................................... 4
1.4.2 Biological hazards.........................................................................................................4
1.4.3 Wash the skin and eyes................................................................................................5
1.5 Protecting the environment................................................................................................5
1.6 Spare parts............................................................................................................................5
1.7 Warranty................................................................................................................................5
2 Transportation and Storage...................................................................................................... 6
2.1 Precautions........................................................................................................................... 6
2.2 Position and fastening......................................................................................................... 6
2.3 Examine the delivery........................................................................................................... 6
2.3.1 Examine the package................................................................................................... 6
2.3.2 Examine the unit............................................................................................................6
2.4 Transportation guidelines...................................................................................................7
2.4.1 Lifting..............................................................................................................................7
2.5 Remove from the pallet: Unit delivered right-side up.....................................................7
2.6 Turn the unit to an upright position: Unit with anchoring ring (foot)............................ 8
2.7 Turn the unit to an upright position: Unit without anchoring ring (foot).................... 10
2.8 Long-term storage.............................................................................................................12
3 Product Description................................................................................................................. 13
3.1 Products included..............................................................................................................13
3.2 Design................................................................................................................................. 13
3.2.1 Anchoring ring (foot)..................................................................................................13
3.2.2 Parts..............................................................................................................................13
3.2.3 Intended use............................................................................................................... 14
3.2.4 Application limits........................................................................................................ 14
3.2.5 Dimensions..................................................................................................................15
3.2.6 Weight..........................................................................................................................16
3.2.7 Materials.......................................................................................................................16
3.2.8 External loads..............................................................................................................16
3.2.9 Pumping station identification.................................................................................. 16
3.3 Pump versions....................................................................................................................17
3.4 Monitoring equipment......................................................................................................17
3.5 The data plate.................................................................................................................... 17
4 Installation................................................................................................................................. 18
4.1 Precautions......................................................................................................................... 18
4.1.1 Underground utilities................................................................................................. 18
4.1.2 Excavations.................................................................................................................. 18
4.1.3 Inspect the work area before permit-required hot work....................................... 19
4.2 Installing the unit................................................................................................................19
4.2.1 Prepare the site........................................................................................................... 19
4.2.2 Prepare the pit base................................................................................................... 20
4.2.3 Attach the anchoring ring (foot)................................................................................20
4.2.4 Install the unit.............................................................................................................. 21
Table of Contents
Flygt Compit 901 Installation, Operation, and Maintenance Manual 1

4.2.5 Connect the external piping......................................................................................22
4.2.6 Install the extension: H-installation...........................................................................25
4.2.7 Install the extension: P-installation........................................................................... 25
4.2.8 Make the electrical connections............................................................................... 27
4.2.9 Installing the level sensors.........................................................................................27
4.2.10 Install the control panel........................................................................................... 28
4.2.11 Equipotential bonding.............................................................................................29
4.2.12 Insulate the unit........................................................................................................ 29
4.2.13 Backfill........................................................................................................................30
4.2.14 Installing the access cover.......................................................................................31
4.3 Installing the pump............................................................................................................33
4.3.1 Install with H-installation............................................................................................ 34
4.3.2 Install with P-installation.............................................................................................35
5 Operation.................................................................................................................................. 37
5.1 Precautions......................................................................................................................... 37
5.2 Before commissioning...................................................................................................... 37
5.3 Open and close the shutoff valve.................................................................................... 37
5.4 Start the pump....................................................................................................................38
6 Maintenance..............................................................................................................................39
6.1 Precautions......................................................................................................................... 39
6.1.1 Inspect the work area before permit-required hot work....................................... 40
6.2 Maintenance guidelines....................................................................................................40
6.3 Replace the check valve....................................................................................................40
7 Declaration of Conformity.......................................................................................................41
7.1 Declaration of Conformity................................................................................................ 41
Table of Contents
2 Flygt Compit 901 Installation, Operation, and Maintenance Manual

1 Introduction and Safety
1.1 Introduction
Purpose of the manual
The purpose of this manual is to provide the necessary information for working with the
unit. Read this manual carefully before starting work.
Read and keep the manual
Save this manual for future reference, and keep it readily available at the location of the
unit.
Intended use
WARNING:
Operating, installing, or maintaining the unit in any way that is not covered in this manual
could cause death, serious personal injury, or damage to the equipment and the
surroundings. This includes any modification to the equipment or use of parts not
provided by Xylem. If there is a question regarding the intended use of the equipment,
please contact a Xylem representative before proceeding.
Other manuals
See also the safety requirements and information in the original manufacturer's manuals
for any other equipment furnished separately for use in this system.
1.2 Safety terminology and symbols
About safety messages
It is extremely important that you read, understand, and follow the safety messages and
regulations carefully before handling the product. They are published to help prevent
these hazards:
•Personal accidents and health problems
• Damage to the product and its surroundings
• Product malfunction
Hazard levels
Hazard level Indication
DANGER:
A hazardous situation which, if not avoided, will result in
death or serious injury
WARNING:
A hazardous situation which, if not avoided, could result
in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could result
in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
1 Introduction and Safety
Flygt Compit 901 Installation, Operation, and Maintenance Manual 3

Special symbols
Some hazard categories have specific symbols, as shown in the following table.
Electrical hazard Magnetic fields hazard
Electrical Hazard: CAUTION:
1.3 User safety
All regulations, codes, and health and safety directives must be observed.
The site
•Observe lockout/tagout procedures before starting work on the product, such as
transportation, installation, maintenance, or service.
• Pay attention to the risks presented by gas and vapors in the work area.
• Always be aware of the area surrounding the equipment, and any hazards posed by
the site or nearby equipment.
Qualified personnel
This product must be installed, operated, and maintained by qualified personnel only.
Protective equipment and safety devices
• Use personal protective equipment as needed. Examples of personal protective
equipment include, but are not limited to, hard hats, safety goggles, protective gloves
and shoes, and breathing equipment.
• Make sure that all safety features on the product are functioning and in use at all times
when the unit is being operated.
1.4 Special hazards
1.4.1 Confined spaces
DANGER: Inhalation Hazard
The chamber or tank where the equipment is installed should be treated as a confined
space. Always follow the applicable safety laws, regulations and guidelines for confined
spaces.
Never work alone in a confined space. Before entering the space, check that the following
requirements are complied with:
•The atmosphere contains sufficient oxygen
• The atmosphere contains no explosive or toxic gases
• If there is a risk of insufficient oxygen or toxic or hazardous gases, then use an airline
respirator or self-contained breathing apparatus.
• All energy sources are locked out and tagged out
• Adequate ventilation is in place
• There is a clear path of retreat
• Monitoring is in place for hazards which can develop after entering the confined space
• The applicable safety laws, regulations, and guidelines for confined spaces are
understood and followed.
1.4.2 Biological hazards
The product is designed for use in liquids that can be hazardous to your health. Observe
these rules when you work with the product:
1 Introduction and Safety
4 Flygt Compit 901 Installation, Operation, and Maintenance Manual

• Make sure that all personnel who may come into contact with biological hazards are
vaccinated against diseases to which they may be exposed.
• Observe strict personal cleanliness.
WARNING: Biological Hazard
Infection risk. Rinse the unit thoroughly with clean water before working on it.
1.4.3 Wash the skin and eyes
Follow these procedures for chemicals or hazardous fluids that have come into contact
with your eyes or your skin:
Condition Action
Chemicals or hazardous fluids in
eyes
1. Hold your eyelids apart forcibly with your fingers.
2. Rinse the eyes with eyewash or running water for at least 15 minutes.
3. Seek medical attention.
Chemicals or hazardous fluids on
skin
1. Remove contaminated clothing.
2. Wash the skin with soap and water for at least 1 minute.
3. Seek medical attention, if necessary.
1.5 Protecting the environment
Emissions and waste disposal
Observe the local regulations and codes regarding:
•Reporting of emissions to the appropriate authorities
• Sorting, recycling and disposal of solid or liquid waste
• Clean-up of spills
Exceptional sites
CAUTION: Radiation Hazard
Do NOT send the product to Xylem if it has been exposed to nuclear radiation, unless
Xylem has been informed and appropriate actions have been agreed upon.
1.6 Spare parts
CAUTION:
Only use the manufacturer’s original spare parts to replace any worn or faulty
components. The use of unsuitable spare parts may cause malfunctions, damage, and
injuries as well as void the warranty.
1.7 Warranty
For information about warranty, see the sales contract.
1 Introduction and Safety
Flygt Compit 901 Installation, Operation, and Maintenance Manual 5

2 Transportation and Storage
2.1 Precautions
DANGER: Electrical Hazard
Before starting work on the unit, make sure that the unit and the control panel are isolated
from the power supply and cannot be energized. This applies to the control circuit as well.
CAUTION:
The operator must be aware of safety precautions to prevent physical injury.
Tip risk if pallet straps are removed
If the straps securing the unit to its pallet have been removed, then the unit must be
secured from tipping or falling.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or damage property.
2.2 Position and fastening
Units with a concrete access cover are delivered in a vertical position, standing upside
down on the delivery pallet. Regardless of the type of access cover, the unit must be
stored in an upright position.
2.3 Examine the delivery
2.3.1 Examine the package
1. Examine the package for damaged or missing items upon delivery.
2. Record any damaged or missing items on the receipt and freight bill.
3. If anything is out of order, then file a claim with the shipping company.
If the product has been picked up at a distributor, make a claim directly to the
distributor.
2.3.2 Examine the unit
1. Remove packing materials from the product.
Dispose of all packing materials in accordance with local regulations.
2. To determine whether any parts have been damaged or are missing, examine the
product.
3. If applicable, unfasten the product by removing any screws, bolts, or straps.
Use care around nails and straps.
4. If there is any issue, then contact a sales representative.
2 Transportation and Storage
6 Flygt Compit 901 Installation, Operation, and Maintenance Manual

2.4 Transportation guidelines
2.4.1 Lifting
Always inspect the lifting equipment and tackle before starting any work.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
NOTICE:
Never lift the unit by its cables or hose.
Lifting equipment
Lifting equipment is always required when handling the unit. It must fulfill the following
requirements:
• The minimum height (contact your local sales and service representative for
information) between the lifting hook and the floor must be sufficient to lift the unit.
• The lifting equipment must be able to hoist the unit straight up and down, preferably
without the need for resetting the lifting hook.
• The lifting equipment must be securely anchored and in good condition.
• The lifting equipment must support weight of the entire assembly and must only be
used by authorized personnel.
• Two sets of lifting equipment must be used to lift the unit for repair work.
• The lifting equipment must not be oversized.
CAUTION: Crush Hazard
Over-dimensioned lifting equipment can lead to injury. A site-specific
risk analysis must be done.
Separate handling of pump and unit
The unit and the pump are delivered separately. Never install a pump prior to lifting the
unit.
Empty the unit before lifting
The unit must be emptied of liquid before lifting.
2.5 Remove from the pallet: Unit delivered right-side up
This section is applicable for units that are delivered with a plastic access cover. Units with
a plastic access cover are delivered in a vertical position, standing right-side up on the
delivery pallet.
1. Unload the unit from the truck and put it carefully on a rigid, horizontal surface.
2. Attach a sling to the lifting eye.
2 Transportation and Storage
Flygt Compit 901 Installation, Operation, and Maintenance Manual 7

WS011555A
Figure 1: Lifting eyes
3. Connect the other end of the lifting strap to the lifting equipment.
4. Raise the lifting hook until the lifting sling is taut.
5. Cut the straps which secure the pump station to the pallet.
6. Lift the unit straight up.
The unit may jolt or sway near the end of the lifting operation.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is
properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
7. Lower the unit into position.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or
damage property.
2.6 Turn the unit to an upright position: Unit with anchoring ring
(foot)
This section is applicable for pump units that are delivered with a concrete access cover.
The unit is delivered with the foot attached.
Units with a concrete access cover are delivered in a vertical position, standing upside
down on the delivery pallet.
1. Unload the unit from the truck and put it carefully on a rigid, horizontal surface.
2. Attach a sling around the foot.
2 Transportation and Storage
8 Flygt Compit 901 Installation, Operation, and Maintenance Manual

WS011669B
3. Raise the lifting hook until the lifting sling is taut.
4. Cut the straps which secure the pump station to the pallet.
WS011670A
5. Lift the unit straight up.
The unit may jolt or sway near the end of the lifting operation.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is
properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
Make sure that the concrete cover stays on the pallet.
2 Transportation and Storage
Flygt Compit 901 Installation, Operation, and Maintenance Manual 9

WS012520A
6. Put the unit on the ground in a horizontal position.
7. Attach a sling to the lifting eye.
WS011554C
8. Lift the unit.
9. Put the unit on the pallet in an upright position.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or
damage property.
2.7 Turn the unit to an upright position: Unit without anchoring ring
(foot)
This section is applicable for pump units that are delivered with a concrete access cover.
The unit is delivered without the foot.
Units with a concrete access cover are delivered in a vertical position, standing upside
down on the delivery pallet.
WARNING: Crush Hazard
Always lift the unit by its designated lifting points.
Use suitable lifting equipment and ensure that the product is properly harnessed.
Wear personal protective equipment.
Stay clear of cables and suspended loads.
1. Unload the unit from the truck and put it carefully on a rigid, horizontal surface.
2. Fit a lifting sling around the pump station as shown in the following figure.
Arrange the lifting sling so that the pump station outlet will face upwards when the
pump station is lifted.
2 Transportation and Storage
10 Flygt Compit 901 Installation, Operation, and Maintenance Manual

1
2
3
4
WS011556C
1. Lifting sling
2. Pump station outlet
3. Pump station lifting eye
4. Strap securing pump station to pallet
3. Raise the lifting hook until the lifting sling is taut.
4. Cut the straps which secure the pump station to the pallet.
5. Lift the unit straight up.
The unit may jolt or sway near the end of the lifting operation.
Make sure that the concrete cover stays on the pallet.
WS012520A
6. Put the unit on the ground in a horizontal position.
7. Attach a sling to the lifting eye.
WS011554C
Figure 2: Lifting eye. Generic Compit 901 is shown.
8. Lift the unit.
9. Put the unit on the pallet in an upright position.
2 Transportation and Storage
Flygt Compit 901 Installation, Operation, and Maintenance Manual 11

CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or
damage property.
2.8 Long-term storage
Long-term storage outdoors must not exceed four months. Make sure that the unit is
covered with a tarpaulin or similar.
2 Transportation and Storage
12 Flygt Compit 901 Installation, Operation, and Maintenance Manual

3 Product Description
3.1 Products included
This document includes the following products:
Product denomination Installation type Installation type description
Compit 901H H Stationary wet installation suspended from the discharge pipe.
The quick connection joint has an integrated non-return valve.
Compit 901P P Semipermanent wet well installation. The pump is installed
between guide-bars on a discharge connection.
3.2 Design
The pump station unit is delivered pre-assembled for the installation of pipes, from the
house and to the force main, and for the connection of the power supply. It can function,
for example, as a wastewater collection tank for a single house with a connection to
natural infiltration, or in a branched pressure sewer system.
Pump station with anchoring ring (foot)
The unit is designed to prevent it from being forced up in normal types of ground.
Depending on the subsoil water table, an anchoring ring can be needed.
3.2.1 Anchoring ring (foot)
(31.5 in)
WS011553E
2
1
>800 mm
(31.5 in)
<800 mm
1. A foot is needed when the ground water table is high.
2. If the ground water table is lower than 800 mm (31.5 in) below the surface, then the
foot is not needed.
3.2.2 Parts
Items included in the pumping station Items that are ordered separately, or provided locally
• Tank
• Access cover
PE, Class A, Class B
• Internal pipes and valves
• Anchoring ring (foot)
• Operating handle with chain for shutoff valve
• Access cover Class D
This cover is constructed on site
• Pump
• Elbow pipe, if needed for the pump
• Discharge connection
• Level sensor
• Control panel
The following figures show examples of H- and P-installations.
3 Product Description
Flygt Compit 901 Installation, Operation, and Maintenance Manual 13

H-installation P-installation
1
2
3
4
5
6
7
8
9
WS011673B
1. Access cover
2. Tank
3. Outlet
4. Shutoff valve
5. Discharge connection unit with check valve
6. Pump
7. Anchoring ring (foot)
8. Level sensor
9. Inlet
9
10
1
2
3
4
5
6
7
11
8
WS11679B
1. Access cover
2. Tank
3. Shutoff valve
4. Outlet pipe
5. Check valve unit
6. Discharge connection unit
7. Pump
8. Anchoring ring (foot)
9. Level sensor
10. Inlet
11. Guide bar system
3.2.3 Intended use
The product is intended for use in sewer applications.
3.2.4 Application limits
For pump limitations, read the Installation, Operation, and Maintenance manual for the
pump.
The unit must be installed underground, outside of the building.
Data Description
Media temperature Maximum 60°C (140°F)
pH of the pumped media 5.5 - 8
Other For other applications, contact the local sales and service
representative for information.
3 Product Description
14 Flygt Compit 901 Installation, Operation, and Maintenance Manual

3.2.5 Dimensions
Drawings
A
(825)
Maximum 3000 mm
1202
1286
1855
755
1030
WS011552C
1410
Figure 3: Dimensional drawing. Unit: mm
Access Cover Dimension A, mm
Plastic 72
Class A 33
Class B 78
135°
(45 )
135°
25°
(45 )
5
4
2
3
1
WS011557E
43
1
2
3
6
Figure 4: Location of outlet and inlets
1. Inlet: DN 150
2. Inlet: DN 100
3. Inlet: DN 150
4. Inlet: DN 100
5. Outlet: DN 32 or DN 50
6. Cable duct or venting:
DN 100
3 Product Description
Flygt Compit 901 Installation, Operation, and Maintenance Manual 15

3.2.6 Weight
For pump weights, see the dimensional drawing of the pump.
A complete preassembled pumping station for two pump including anchoring ring, Class
B cover, and the longest extension, can weigh up to 277 kg (611 lb). This weight does not
include the pumps.
Table 1: Main unit
Type Discharge connection
Material
Number of pumps
The pump is not included
Discharge connection Weight, kg (lb)
901 H PPA 1 DN32 105 (231)
901 H Cast iron 1 DN50 115 (254)
901 H Cast iron 2 DN50 129 (284)
901 P Cast iron 1 DN32 108 (238)
901 P Cast iron 1 DN50 109 (240)
Table 2: Other items
Item Description Material Weight, kg (lb)
Anchoring ring (foot) – PE 16 (35)
Cover Class A Concrete and steel 78 (172)
Cover Class B Concrete and steel 107 (236)
Cover Plastic PE 5 (11)
Extension 750 mm (29.5 in) PE 14 (31)
Extension 1400 mm (55.1 in) PE 25 (55)
Maximum allowed pump weight
55 kg
3.2.7 Materials
The unit is rotomoulded polyethylene, PE.
3.2.8 External loads
• The maximum load rating for the plastic access cover is 1 kg/cm2but no heavier than
120 kg (264.6 lb).
• A concrete access cover Class A is applicable for any location where it is subjected
only to loads from pedestrians or pedal cyclists.
• A concrete access cover Class B is applicable for pedestrian areas, car parks, or car
parking decks.
• A concrete access cover Class D is applicable for carriage ways of roads, hard
shoulders, and parking areas for all types of road vehicles.
NOTICE:
Only pump stations which are designed for Class D can be used in Class D environments.
3.2.9 Pumping station identification
At delivery, the color of the outlet end cap shows what type of station it is.
End cap color Installation Number of pumps Discharge connection characteristics
Yellow H One pump Cast iron parts
Transparent H Two pumps Cast iron parts
Red H One pump High performance polyamide (HPPA) parts
Green P One pump DN32
3 Product Description
16 Flygt Compit 901 Installation, Operation, and Maintenance Manual

End cap color Installation Number of pumps Discharge connection characteristics
Gray P One pump DN50
3.3 Pump versions
Depending on the type of unit, different pumps can be used.
For more information, please contact your local sales and service representative.
3.4 Monitoring equipment
Several pump protection and monitoring functions are available as options depending on
the version of equipment. For more information, please contact your local sales and
service representative.
3.5 The data plate
1
WS012463A
2
354 6
1. Country of origin
2. Manufacturer
3. Product
4. Product number
5. Production week and year
6. Serial number
3 Product Description
Flygt Compit 901 Installation, Operation, and Maintenance Manual 17

4 Installation
4.1 Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and
Safety on page 3 have been read and understood.
DANGER: Inhalation Hazard
The chamber or tank where the equipment is installed should be treated as a confined
space. Always follow the applicable safety laws, regulations and guidelines for confined
spaces.
WARNING: Electrical Hazard
Risk of electrical shock or burn. A certified electrician must supervise all electrical work.
Comply with all local codes and regulations.
WARNING: Fall Hazard
Check that suitable barriers for the work area are in place.
Tip risk if pallet straps are removed
If the straps securing the unit to its pallet have been removed, then the unit must be
secured from tipping or falling.
CAUTION: Crush Hazard
Make sure that the unit cannot roll or fall over and injure people or damage property.
Sewage station tank ventilation
Vent the tank of a sewage station in accordance with local plumbing codes.
Class D environments
NOTICE:
Only pump stations which are designed for Class D can be used in Class D environments.
4.1.1 Underground utilities
Before starting excavation work, determine whether any utility installations such as sewer,
telephone, fuel, electric, or water lines, may be encountered. Utility companies and
owners must be contacted to locate utility installations.
When the excavation operations approach the estimated location of the underground
installation, the exact location must be determined by safe and acceptable means.
While the excavation is open, any underground installation must be protected, supported
or removed as necessary to safeguard employees.
4.1.2 Excavations
Before entering trenches, pits or other excavations, the following conditions must be met:
•The applicable safety laws, regulations, and guidelines for excavations are understood
and followed.
• Be aware that site conditions can change rapidly, for example due to heavy rain, rapid
thaw, vibrations or other factors.
4 Installation
18 Flygt Compit 901 Installation, Operation, and Maintenance Manual