Xylem FLYGT Compit 901 Series User manual

Installation, Operation, and
Maintenance Manual
EN SV
DE
888322_3.0
Compit 901

en Installation, Operation and Maintenance
Manual.........................................................4
de Installations-, Betriebs- und
Wartungshandbuch....................................82
sv Installations-, drift- och underhållsmanual
...................................................................43
3

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 re-
garding the intended use of the equipment, please contact a Xylem repre-
sentative before proceeding.
Other manuals
See also the safety requirements and information in the original manufacturer's manuals for any other equip-
ment 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 re-
sult in death or serious injury
CAUTION:
A hazardous situation which, if not avoided, could re-
sult in minor or moderate injury
NOTICE:
Notices are used when there is a risk of equipment
damage or decreased performance, but not personal
injury.
Special symbols
Some hazard categories have specific symbols, as shown in the following table.
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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 equip-
ment.
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-con-
tained 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:
• Make sure that all personnel who may come into contact with biological hazards are vaccinated against dis-
eases 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:
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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 radia-
tion, 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 malfunc-
tions, damage, and injuries as well as void the warranty.
1.7 Warranty
For information about warranty, see the sales contract.
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 ap-
plies to the control circuit as well.
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CAUTION:
The operator must be aware of safety precautions to prevent physical in-
jury.
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.
2.4 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:
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• 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 per-
sonnel.
• 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 cov-
er 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.
Figure 1: Lifting eyes
WS011555A
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.
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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.
WS011669B
3. Raise the lifting hook until the lifting sling is taut.
4. Cut the straps which secure the pump station to the pallet.
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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.
WS012520A
6. Put the unit on the ground in a horizontal position.
7. Attach a sling to the lifting eye.
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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.
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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.
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Figure 2: Lifting eye. Generic Compit 901 is shown.
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.
2.8 Long-term storage
Long-term storage outdoors must not exceed four months. Make sure that the unit is covered with a tarpaulin or
similar.
3 Product Description
3.1 Products included
This document includes the following products:
Product denomina-
tion
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 be-
tween 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)
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(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 lo-
cally
• Tank
• Access cover
PE, Class A, Class B
• Internal pipes and valves
• Anchoring ring (foot)
Depending on version
• 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.
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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.
3.2.5 Dimensions
Drawings
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Figure 3: Dimensional drawing. Unit: mm
A
(825)
Maximum 3000 mm
1202
1286
1855
755
1030
WS011552C
1410
Access Cover Dimension A, mm
Plastic 72
Class A 33
Class B 78
Figure 4: Location of outlet and inlets
135°
(45 )
135°
25°
(45 )
5
4
2
3
1
WS011557E
43
1
2
3
6
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 vent-
ing: DN 100
3.2.6 Weight
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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 lon-
gest 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 includ-
ed
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/cm2 but 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 pe-
destrians 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
Gray P One pump DN50
3.3 Pump versions
Depending on the type of unit, different pumps can be used.
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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 equip-
ment. For more information, please contact your local sales and service representative.
3.5 The data plate
1
WS012463A
2
3 54 6
1. Country of origin
2. Manufacturer
3. Product
4. Product number
5. Production week and year
6. Serial number
4 Installation
4.1 Precautions
Before starting work, make sure that the safety instructions in the chapter Introduction and Safety on page 4
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.
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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, elec-
tric, or water lines, may be encountered. Utility companies and owners must be contacted to locate utility instal-
lations.
When the excavation operations approach the estimated location of the underground installation, the exact loca-
tion must be determined by safe and acceptable means.
While the excavation is open, any underground installation must be protected, supported or removed as neces-
sary 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.
• Do not work in an excavation or trench unless it is properly protected against collapse. Examples of protec-
tion systems are shown in the following figures.
Figure 5: Bracing and shoring
WS007564A
Figure 6: Shield box
WS004325A
• Regularly check the walls of an excavation or trench for cracks, bulges and spalling. Check the shoring for
signs of distress, especially after a rainstorm.
• Do not work in an excavation that is filled or partially filled with water. Remove personnel from the excavation
during a rainstorm, and inspect the excavation carefully before re-entry.
• Do not store excavated material and equipment along the edge of the trench or excavation. Do not drive or
park vehicles along the edge of an excavation.
4.1.3 Inspect the work area before permit-required hot work
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WARNING: Explosion/Fire Hazard
Before starting any permit-required hot work such as welding, gas cutting,
grinding, or using electrical handtools, do the following: 1. Check the explo-
sion risk. 2. Provide sufficient ventilation.
4.2 Installing the unit
• The contractor is responsible for ensuring that the installation follows the local regulations and EN
976-2:1997.
• The unit must be installed underground, outside of the building.
• Dimensions in installation figures must be regarded as minimum dimensions.
4.2.1 Prepare the site
• Check that the following requirements are complied with:
– The excavation method of the pit must be adapted to the current soil conditions. Considerations include
slope stability and possible water drainage.
– Complicated soil conditions must be investigated by a geotechnical engineer.
– The unit must not be installed in mud or peat.
– Drains and sewers that are connected to the unit must be constructed and tested according to EN 1610.
• If the unit is installed in filled material of stony material, silt and clay, or in organic soil, attach a separating
layer of geotextile to the pit walls and bottom before backfilling and compaction.
The geotextile prevents any material transportation from the backfill material into the soil.
• Refer to EN 976-2:1987 for demands on the quality of geotextile and installation method.
• Excavate to 300 mm (1 ft) below the planned installation level. Make the pit at least 2 m (6.6 ft) wider than
the tank.
4.2.2 Prepare the pit base
• Check that the pit bottom is even before preparing the base.
• Check that the base is flat, evenly compacted, and horizontally leveled before installing the unit.
• Prepare a pit base with crushed material.
Pit base thickness 0.3 m
Grain size 2 – 36 mm
4.2.3 Attach the anchoring ring (foot)
Follow these instructions when the pump station and the foot have been delivered separately. The foot must be
fitted on the pump station before the pump station is lowered into position.
The foot is needed when the ground water table is high. For more information, see Anchoring ring (foot) on page
13.
1. Set the foot on a flat and level surface.
2. Align the arrow on the foot with the arrow at the bottom of the pump station.
WS011666A
3. Lower the pump station onto the foot.
4. Insert the U-shaped bolt through the two holes and fit the washer.
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