Zehnder Rittling FPS-KE User manual

Pumping station
Operation Manual
FPS-KE /
D

2
Table of contents:
Page
Declaration of conformity............................................................................... 3
1. General.......................................................................................................... 4
1.1 Scope ..................................................................................................... 4
1.2 Enquiries and orders............................................................................... 4
1.3 Technical data ........................................................................................ 4
1.4 Range of application............................................................................... 5
1.5 Scope of supply...................................................................................... 5
2. Safety ............................................................................................................ 5
2.1 Marking of the notes contained in the operation manual......................... 5
2.2 Personnel development and training....................................................... 6
2.3 Dangers in case of non-observance of the safety notes.......................... 6
2.4 Safety-conscious way of working............................................................ 6
2.5 Safety notes for the operator/user........................................................... 6
2.6 Safety notes concerning maintenance, inspection, and
assembly works...................................................................................... 7
2.7 Unauthorised modification of the machine and fabrication of spare parts 7
2.8 Unauthorised modes of operation........................................................... 7
3. Transport and temporary storage................................................................... 7
3.1 Transport................................................................................................ 7
3.2 Temporary storage/conservation............................................................. 7
4. Description..................................................................................................... 7
4.1 General................................................................................................... 7
4.2 Assembly and mode of operation............................................................ 8
5. Installation...................................................................................................... 8
5.1 Excavation of the trench ......................................................................... 8
5.2 Insertion of the shaft ............................................................................... 8
5.3 Connection of the shaft........................................................................... 8
5.4 Filling of the trench.................................................................................. 9
6. Commissioning ............................................................................................ 10
7. Maintenance and repair ............................................................................... 10
8. Malfunctions; causes and elimination........................................................... 10
9. Guarantee.................................................................................................... 10
10. Technical modifications................................................................................ 10
Appendix:A main dimensions ........................................................................ 11
Appendix:B installation suggestion for manhole cover class D ...................... 12

3
Declaration of conformity
- for the purpose of the EC low voltage directive 73/23/EWG, Appendix III B
- for the purpose of the EMCdirective 92/31/EWG and 93/68/EWG
-------------------------------------------------------------------------------------------------------------------
We, the ZEHNDER Pumpen GmbH
Zwönitzer Straße 19
08344 Grünhain-Beierfeld,
herewith declare
that the prefabricated pump stations of the type FPS-K (A) conform to the following relevant
regulations:
- EC low voltage directive as amended 93/68/EWG, Appendix I
- EMC directive 92/31/EWG and 93/68/EWG
Applied harmonized standards, particularly:
- EN 292 part 1
- EN 292 part 2
- Draft EN 292 part 2 A1
- EN 60 335-1
- EN 60 335-2-41
- EN 55014/4.93
- EN 55104/95
Applied national technical standards and specifications, particularly:
- DIN EN 292 part 1
- DIN EN 292 part 2
- draft DIN EN 292 part 2 A1
- DIN VDE 0700 part 1
- DIN VDE 0700 part 41
- draft DIN EN 809
Grünhain, 12 January 2004
Matthias Kotte
Product Development
General technical approval Z-42.1.333

4
1. General
1.1 Scope
This operating manual is valid for the prefabricated pump station FPS-K (A).
If the instructions of the operation manual –especially the safety instructions - are not
observed, or in case of unauthorized modifications of the plant or the installation of non-
original spare parts, the guarantee expires automatically. The manufacturer assumes no
liability for damages resulting from such behaviour!
Manufacturer: ZEHNDER GmbH
Pumpen und Anlagenbau
Zwönitzer Straße 19
08344 Grünhain-Beierfeld
Manufactured sizes:
FPS-K (A) shaft fittings for individual or twin plants.
Pumps with a discharge coupling of 2’’ and an output of up to approx. 4 kW can be used.
State of the operation manual: July 2008
1.2 Enquiries and orders
In case of enquiries or orders, address yourself to your specialist retailer.
1.3 Technical data
Clear width: 1000 mm
External diameter approx.: 1100 mm
Shaft heights:
Base body height
Height with attachment
piece and BEGU-
manhole cover
class A
Height with attachment
piece and BEGU-
manhole cover
class B
Height with attachment
piece and BEGU-
manhole cover
class D
H2
1600
1730-1960
1775-2005
1810-2040
H3
2100
2230-2460
2275-2505
2310-2540
H5
3100
3230-3460
3275-3505
3310-3540
Opening of the manhole cover: 625 mm
Weight: 60 kg - 90 kg (without mounting parts)
Inlet: adapted for PVC-KG DN 150
Inlet depth: 675 mm (centre pipe) from bottom edge of shaft bottom
Pressure connection: PE HD DN 50 da= 63 mm
Depth of pressure connection: 675 mm (centre pipe) from bottom edge of shaft bottom
Operating volume: approx. 400 l
Ventilation/ductwork for cables: 2 x PVC-KG DN 100
Depth of connection: 1175 mm (centre pipe) from bottom edge of shaft bottom
Maximum media temperature: 60°C
The shaft is secured against uplift up to a groundwater level of 1.2m from the bottom edge of the shaft!
Materials
Shaft: Polyethylene
Coupling system: Cast iron GG 20
Gate valve: Brass
Pressure pipe: Polyethylene
Check valve: GG 25

5
1.4 Range of application
The pump stations of the type series FPS-K (A) are used for the disposal (collection and conveyance)
of domestic and industrial wastewater which accumulates below the backwater level of the canal.
They are used outside of buildings.
1.5 Scope of supply
The prefabricated pump station FPS-K (A) is delivered completely with:
-Screwless coupling system
-Gate valve DN 50
-Check valve DN 50
-Complete pressure pipe with fittings
-Rinsing connection prepared, sealed by means of a plug
-Submersible motor pump DN 50 (see separate operation manual)
-Pneumatic level control system (see separate operation manual)
-Variable attachment piece with lip seal
-BEGU –manhole cover class A (walkable) (class B or D optionally available)
2. Safety:
(from: “VDMA sheet 24 292“)
The operation manual at hand provides basic notes which have to be taken into account during
assembly, operation and maintenance works. Therefore, before assembly and commissioning, this
operation manual has to be read by the assembler as well as by the responsible personnel/operator
at all costs. It always has to be available on site of operation of the machine/plant.
The general safety notes listed under the main point safety are not the only notes to be taken into
account. Please also observe the specific safety instructions, such as those for private use, listed
under other main points.
2.1 Marking of the notes contained in the operation manual
The safety notes contained in this operation manual which can cause danger to persons are
specifically marked by the following general danger symbol:
Safety sign according to DIN 4844 - W 9,
The following symbol warns against dangers caused by voltage:
Safety sign according to DIN 4844 - W 8

6
In case of safety notes the non-observance of which can cause danger to the machine and its
functioning, the word ATTENTION! is inserted.
Notes that are directly attached to the machine, such as - arrow indicating the direction of rotation
- marking of fluid connections
have to be observed and kept in completely readable condition at all costs.
2.2 Personnel development and training
The personnel responsible for operation, maintenance, inspection and assembly must have the
corresponding qualifications for those types of work. Area of responsibility, competence and the
surveillance of the personnel have to be regulated precisely by the operator. If the personnel do not
possess the necessary knowledge, they are to be trained and instructed. By order of the operator, the
instruction and training, if necessary, can be carried out by the manufacturer/supplier. Furthermore
the operator has to make sure that the personnel have completely understood the content of the
operation manual.
2.3 Dangers in case of non-observance of the safety notes
The non-observance of the safety notes can cause dangers to persons as well as to the environment
and the machine. If the safety notes are not observed, this can result in the loss of all compensation
claims.
In detail, non-observance can for instance result in the following damages:
- Failure of important functions of the machine/plant
- Failure of the prescribed methods for maintenance and repair
- Endangerment of persons through electrical, mechanical and chemical influences
- Endangerment of the environment through leakage of hazardous substances
2.4 Safety-conscious way of working
The safety notes listed in this operation manual, the existent national regulations on accident
prevention as well as possible internal working, operating, and safety instructions of the operator are
to be observed.
2.5 Safety notes for the operator/user
- Hot or cold machine components which could cause danger have to be secured against contact
by the customer.
- Protection against contact with moving parts (e.g. coupling) must not be removed while the
machine is operating.
- Leakages (e.g. of the shaft sealing) of hazardous materials to be conveyed (e.g. explosive, toxic,
hot) have to be discharged in such a way that no danger arises for persons or the environment.
The legal requirements are to be observed.
- Endangerments through electric power are to be eliminated (details concerning this, see e.g. the
regulations of the VDE (German Association for Electrical, Electronic and Information Technology)
and the local energy suppliers).

7
2.6 Safety notes concerning maintenance, inspection, and assembly works
The operator has to make sure that all maintenance, inspection, and assembly works are carried out
by authorised, skilled, and qualified personnel which are adequately informed by having thoroughly
studied the operation manual.
Generally, works on the machine are only to be carried out when the machine is turned off. The
procedure of switching off the machine, which is described in the operation manual, has to be
observed at all costs.
Pumps or pump units which convey media that are hazardous to health have to be decontaminated.
Immediately after completion of the works, all safety and protection devices have to be reattached or
reactivated.
Before restart, the points listed in the chapter commissioning have to be taken into consideration.
2.7 Unauthorised modification of the machine and fabrication of spare parts
Modifications of the machine are permitted only after having consulted the manufacturer. Original
spare parts and accessories authorised by the manufacturer ensure the safety. The use of other parts
can lead to the removal of liability for the resulting damages.
2.8 Unauthorised modes of operation
The operational reliability is only guaranteed, if the machine is used as intended according to chapter
1 –General. The limit values stated in the data sheet must not be exceeded!
3. Transport and temporary storage
3.1 Transport
The prefabricated pump stations of the type series FPS-K (A) are not to be thrown or dropped.
Furthermore, they should be transported in upright position.
3.2 Temporary storage/conservation
For temporary storage and conservation, it suffices if the plant is stored in a cool, dark, dry, and frost-
protected place. The plant should be stored in upright position.
4. Description
4.1 General
The pump station is completely assembled, so that only the pump has to be put into place and the
connections (inlet, pressure pipe, ventilation line, level control system and power supply) have to be
established.

8
4.2 Assembly and mode of operation
On the shaft bottom, a coupling system is mounted on which the pump is hung up without screws. In
order to guide the pump during hanging it up, a guide tube exists which is fixed on a traverse inside
the taper shaft ring. By means of an attached chain, the pump can completely be lifted out of the shaft
without loosening the screw fittings inside the shaft beforehand. In order to lift the pump out of the
shaft, according to the size of the pump, a lifting tool could become necessary. After a longer period
of operation, the pump could adhere to the coupling pedestal. In order to detach the pump, sightly pull
the chain and shake it until the pump detaches from the coupling pedestal. After this, the pump can
be pulled out easily. In order to avoid damages on the plastic shaft, excessive tractive forces on the
chain are to be avoided. This way, maintenance and repair work on the pump can be carried out
outside of the shaft. In order to avoid a flow back of the water column inside the pressure pipe during
maintenance and repair work, a gate valve is mounted in front of the check valve inside the pressure
pipe.
5. Installation
5.1 Excavation of the trench
Concerning the excavation of the trench, please observe the regulations of the Employer's Liability
Insurance Association (angle of repose, possible sheeting etc.).
5.2 Insertion of the shaft
Before inserting the shaft, the trench has to be filled up with 30 cm of gravel and 5 cm of chippings.
Those materials have to be compressed in such a way that a horizontal supporting surface is formed.
Afterwards the polyethylene-shaft has to be inserted into the trench. Subsequently, the shaft has to be
levelled. Now fill up approx. 30 cm of backing sand and compress it.
Please check if the shaft is still in horizontal position.
5.3 Connection of the shaft
Inlet
The shaft is equipped with an inlet sleeve DN 150 with lip seal. The inlet pipe (sewer pipe DN 150)
has to be inserted into this inlet sleeve. Further inlets are optionally possible.
Pressure pipe
The pressure pipe line terminates in a pipe socket PE HD 63x5.8 approx. 180 mm outside the shaft.
As pressure pipe line, PE HD-pipes 63x5.8 should be laid. The connection to the pipe socket, which is
existent on the shaft, can be established by means of standard clamp fittings.

9
Ventilation/cable duct
For ventilation/cable entry, 2 sleeves with lip seal DN 100 are existent. The vent pipe (sewer pipe DN
100) has to be inserted into the sleeve. In order to avoid unpleasant odours, we recommend laying
the vent pipes over the roof. The ductwork for cables (sewer pipe DN 100) has to be inserted into the
other sleeve and lead on to the switching device. The pipe has to be closed on the outlet inside the
switch cabinet or the building (e.g. by means of a blind cover with clamp fitting).
Electrical connection
The pump cable and the pneumatic hose have to be lead to the switching device via the ductwork for
cables.
For the electric connection of the pump, the operation manual and the connection diagram are valid.
ATTENTION The switch-off point and the follow-up time have to be set in such a way that the
pumping process is completed before the pump case resurfaces; at this point, though, the pilot tube
has to have completely resurfaced already. The pneumatic hose has to be lead to the switching
device in a constantly ascending manner and without loops. The maximum length should not exceed
20 m.
5.4 Filling of the trench
Before the trench is filled, the lip seal for the attachment piece has to be positioned inside the shaft,
and the attachment piece has to be inserted and adjusted to the ground level with the BEGU-manhole
cover.
ATTENTION Please note that the pressure test of the pressure pipe according to ATV A116 or
DIN 4279 Part 1-9 must not be carried out against the closed gate valve in the pump shaft. If all pipes
are connected and checked for tightness, the trench can be filled.
According to the regulations, backing sand or gravel sand has to be used to fill the trench.
Only use gravel sand of a grit size of up to 32 mm, as far as the excavated ground
does not correspond to the grit size group of 0- max 32 mm. Compact soil, debris,
rock or sharp-edged granulates are not to be used!
The filling material has to be filled in in layers of a thickness of max. 30 cm. Compress the filling
material evenly. In case of a lowering of the groundwater of the trench, the compression of the filling
material can be carried out by adding water while simultaneously operating the lowering system.
Use non-cohesive filling material!
In order to guarantee that the shaft is secured against uplift in clay soil as well, the shaft has to be
backfilled externally with sand, clay or concrete. In order to eliminate any possibility of a deformation
of the polyethylene shaft, the filling material must not be filled in unevenly!
Only after final completion of the shaft, including filling and compression of the trench, may the
possibly used groundwater lowering system be turned off.
The overlapping attachment of the attachment piece has to be backfilled and compressed properly.
In order to guarantee safe plant operation, the shaft has to be brought in horizontal position after the
filling.
If a manhole cover class D is used, please observe the notes found in the appendix at all
costs.

10
6. Commissioning
Before commissioning the plant, all connections have to be checked for correct assembly and
tightness; the check valve has to be open.
In order to commission the pump, please read the separate operation manual for the pump and the
switching device.
7. Maintenance and repair
Disconnect the power supply before carrying out any kind of work on the plant!
Maintenance work includes visual inspections of the entire plant at regular intervals. In oder to carry
out those visual checks, several operating cycles of the pump are to be monitored, and all pipeline
components and valves have to be checked for tightness and function. For maintenance instructions
for the pump, please see the respective operation manual. After accomplished maintenance, the
maintenance interval indicator of the control system can be reset. Maintenance is to be carried out by
authorised specialist companies only. You will find an up-to-date list of our after-sales service points
on the internet: www.zehnder-pumpen.de.
8. Malfunctions; causes and elimination
Disconnect the power supply before carrying out any kind of work on the plant!
In case of malfunctions of the pump(s), please read the respective operation manual. In case of
leakages of the pipelines or in case of malfunctions of the valves, the respective parts can be
replaced (substitution).
9. Warranty
As manufacturer, for this product we provide a warranty of 24 months from date of purchase.
Your sales receipt passes for verification. During that warranty period, we gratuitously remedy all
deficiencies which are attributed to material or fabrication defects by either repairing the plant, or by
replacing the defective parts (to our choice).
Defects which are attributed to misuse or wear are excluded from warranty. We will assume no
responsibility for consequential damages that are caused by a breakdown of the plant. In case of
warranty, adress yourself to your specialist retailer.
10. Technical modifications
We reserve the possibility of technical modifications for the purpose of further development.
© 2008 by Zehnder GmbH

11
Appendix A main dimensions

12
Appendix B installation suggestion for manhole cover class D
Installation suggestion according to standard road structures according to RstO (directive for the
standardisation of the superstructure of traffic areas) in connection with the ZTVE-StB (Additional
conditions of contract and directives for excavacations with regard to road construction) and DIN
18196
1 Customary BEGU –manhole cover class D
2 Customary concrete rings for height compensation
3 Attachment piece made of plastic, adjustable in height from 40 –max. 300 mm
Safety notes!
Installation, assembly, operation and maintenance are to be carried out by a professional
company only! Please observe the respective directives and safety instructions (e.g. VBG
(Employers' Liability Insurance Association) 37 and DIN 4124).

13
Translation graphics Appendix A:
Deutsch
Englisch
Abdeckung
Cover
Klasse
Class
Lüftung
Ventilation
Kabelleerohr
Ductwork for cables
Stck.
Pcs.
Diametral
Diametrical
Lippendichtung
Lip seal
Zulauf
Inlet
Höhenverstellbar
Ajustable in height
Druckabgang
Discharge coupling
Schachthöhe
Height of shaft
handelsüblich
customary
Übersetzung Grafik Appendix B:
Ca.
Approx.
Verschleißschicht
wearing surface
bituminös
bituminous
Sauberkeitsschicht
Granular sub-grade course
Schotter
Gravel
Frostschutzkies
Frost blanket gravel
Erdreich
Ground
Splitt
Chippings