Grundfos UNILIFT KP 150, UNILIFT KP 250, UNILIFT CC 5, UNILIFT KP 350, UNILIFT CC 7 Installation And Operating Instructions Manual
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GRUNDFOS INSTRUCTIONS
UNOLIFT, DUOLIFT
Installation and operating instructions
2
English (GB) Installation and operating instructions
Original installation and operating instructions
These installation and operating instructions
describe Grundfos Unolift and Duolift lifting stations.
They apply to the tank and installation kits. For
detailed information on installing and operating the
pumps and controller, see the installation and
operating instructions supplied with these products.
Sections 1-6 give the information necessary to be
able to unpack, install and start up the product in a
safe way.
Sections 7-16 give important information about the
product, as well as information on service, fault
finding and disposal of the product.
CONTENTS
Page
1. General information
1.1 Symbols used in this document
1.2 Symbols on the product
2. Receiving the product
2.1 Transporting the product
2.2 Inspecting the product
2.3 Scope of delivery
3. Installing the product
3.1 General guidelines
3.2 Choice of tank inlets
3.3 Location
3.4 Tools
3.5 Installation overview
3.6 Positioning the product
3.7 Installing the tank
3.8 Drilling holes in the tank
3.9 Fitting the cable glands
3.10 Fitting the air vent
3.11 Fitting the venting pipe
3.12 Connecting the inlet pipes
3.13 Installing the pump in the tank
3.14 Inner connecting pipes
3.15 Installing the level sensor tube
3.16 Installing an alarm float switch
3.17 Assembling the discharge pipes
3.18 Installing a diaphragm pump
3.19 Installing the controller
3.20 Electrical connection
3.21 Setting the controller before start-up
4. Starting up the product
5. Monitor the increasing liquid level in the
tank up to the start level and check that
the pumps start and stop at least twice.
4.3 Storing the product
4.4 Storing the product
5. Product introduction
5.1 Product overview
5.2 Applications
5.3 Pumped liquids
5.4 Automatic operation
5.5 Identification
5.6 Diaphragm pump
5.7 Level sensor tube
6. Operating the product
6.1 Setting the start levels
7. Starting up the product after standstill
8. Servicing the product
9. Taking the product out of operation
10. Technical data
10.1 Operating conditions
10.2 Material
10.3 Electrical data
10.4 Dimensions and weights
11. Fault finding the product
12. Disposing of the product
3
3
3
3
3
4
4
1. General information
6
6
1.1 Symbols used in this document
6
6
8
8
8
8
8
9
9
9
9
10
10
13
13
13
15
1.2 Symbols on the product
15
15
15
16
Prior to installation, read this document.
Installation and operation must comply
with local regulations and accepted codes
of good practice.
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or serious
personal injury.
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious personal injury.
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate personal injury.
European Conformity
2. Receiving the product
16
2.1 Transporting the product
16
16
17
17
17
17
17
WARNING
Falling objects
• Death or serious personal injury
• Secure the product during
transportation to prevent it from tilting
or falling down.
18
18
18
19
19
21
21
21
22
22
22
22
22
23
25
3
English (GB)
English (GB)
CAUTION
Back injury
• Minor or moderate personal injury
• Get assistance from another person or
use lifting equipment to carry the
product.
Inner connection pipes
Designation
KP/
CC
Quantity
SEG APB
CAUTION
Crushing of feet
• Minor or moderate personal injury
• Wear safety shoes when moving the
product.
2.2 Inspecting the product
1. Check that the product is as ordered.
2. Check that no visible parts have been damaged.
3. If parts are damaged or missing, contact your
local Grundfos sales company and refer to the
product numbers in section 2.3 Scope of delivery.
2.3 Scope of delivery
The scope of delivery depends on your order.
Pumps, tank and pipework are delivered separately
and are to be assembled.
Description of kits
Tan k
Quantity
Designation
Tank 1 1
Cover with gasket 1 2
Screw, M8 x 30 12 24
Washer 12 24
Fastening brackets for
level sensor tube
Screws for fixing tank 4 4
Plugs for fixing tank 4 4
Socket seal, DN 40 1 1
Socket seal, DN 100 1 1
270 litres
tank
540 litres
tank
22
Double socket
R 2 - R 2
Nut, PVC, 2" 1 1 1
O-Ring Ø60,
EPDM
Nozzle adaptor,
F
Clamp,
stainless steel
Flexible
connecting
piece ∅50
Elbow 90° - 1 1
Flange ∅50 - 1 -
111
--1
222
222
111
Inner connection pipes
Designation
Adaptor Rp 2 R 1 1/2
4
Quantity
KP/
SEG APB
CC
11-
Screw,
for flange
Washer,
for flange
-4-
-8-
Inner connection pipes
Designation
Nut, M16,
for flange
O-ring ∅50,
for flange
Adaptor, KP
M1"1/2-M1"1/4
Quantity
KP/
SEG APB
CC
-4-
-1-
1--
Accessories
The following components are not part of the tank
delivery. They are recommended accessories which
must be ordered separately.
Discharge pipe
Quantity
Designation
Nonreturn
valve
Double
socket
Uno-lift Duolift
CC/KPAPB/
-* 1 -* 2
-135
SEG
CC/KPAPB/
SEG
English (GB)
Adaptor, CC
M1"1/2-F1"1/4
Thread tape,
PTFE
Venting port
Sleeve, PVC
75 x 63 x 2"
Flat gasket,
EPDM ∅63
Nut, PVC 2" 1 1 1
Other
Power plug
SCHUKO
Cable gland,
M20
Cable gland,
M25
1--
111
111
111
1-1
212
- 1 -
Isolating
valve
Fitting
union
T-part ,
PVC 90°
Elbow,
PVC 90°
Pipe,
∅50,
2 m
Thread
tape
Glue,
PVC-U
* The Unilift CC and KP pumps are delivered with
non-return clap valves.
1111
--22
--11
--22
--11
1111
--
125 g125
g
5
3. Installing the product
English (GB)
3.1 General guidelines
Guidelines for correct mechanical installation of
lifting station are according to EN 12056-4.
• If the lifting station is installed in a basement with
regular penetrating groundwater, we recommend
to install a drainage pump in a separate pump
sump below floor level (mandatory in certain
countries). If there is only a risk of penetrating
groundwater, we recommend to install a float
switch outside the lifting station and to connect it
a controller, which will indicate an high level
alarm in case of flooding.
• The collecting tank must be fixed to the floor.
• We recommend that you connect a diaphragm
pump to the collecting tank in order to be able to
empty the tank manually.
• All outlet pipes from the lifting station, diaphragm
pump and drainage pump must have a backwater
loop, i.e. a bend above the local backwater level.
Commonly, the highest point of the bend must be
above street level. See fig. 2.
• Surface water must not be discharged into the
lifting station inside the building. It must be
collected and discharged outside the building.
• A non-return valve must be installed at the
discharge of the lifting station to prevent back
flow from the sewer for example.
• Install isolating valves at the inlet and outlet of
the lifting station.
• The volume of the outlet pipe above the nonreturn valve up to the backwater loop (bend in the
pipe) must be smaller than the effective tank
volume.
• In general, a lifting station for black wastewater
must be vented above roof level. However, it is
permitted to lead the ventilation into the main
building ventilation system. Special two-way
venting valves must be placed outside the
building.
• If the wastewater is discharged into a collecting
line, the collecting line must have a filling ratio of
at least h/d = 0.7. The collecting line must be at
least one nominal diameter bigger after the outlet
pipe connection.
• 45 degrees bends must be used to avoid
sedimentation in pipework.
3.2 Choice of tank inlets
It is optimal to lead your pipework to the top inlets of
the tank, as it will prevent backflow and
sedimentation in the inlet pipe and give you the
possibility to use a high start level for the pump. A
high start level increases the effective tank volume
and decreases the numbers of start/stop of the
pumps.
If you use the bottom inlet, you have to select the
lowest start level. If the start level is above the inlet
height, there will be backflow in the inlet pipe. thus
increasing the risk of sedimentation in the pipework.
3.3 Location
The lifting station must be installed in a properly lit
and vented room with 60 cm free space around all
parts to be serviced and operated.
The tank must not be exposed to direct sunlight. UV
can affect the properties of its composite material,
resulting in a shorter life.
The product is designed for indoor operation. If
installed outside, it must be placed in a closed pit.
The tank can be flooded and may be installed in a
basement with risk of penetrating groundwater.
6
Pos. Description
6
2
3
4
5
1
16
3
4
5
1 Isolating valve, inlet
2 Controller
3 Drainage pump
Non-return valve,
4
discharge
Isolating valve,
5
discharge
6 Venting pipe
TM065789 0216
Fig. 1 Installation example with tank in a pit and with a controller. The diaphragm pump is not shown.
Pos. Description
1 Isolating valve, inlet
3 Drainage pump
Non-return valve,
4
discharge
Isolating valve,
5
discharge
6 Venting pipe
TM065790 0216
Fig. 2 Installation example with tank directly mounted on basement floor (the diaphragm pump is not
shown)
English (GB)
7
3.4 Tools
English (GB)
• Thread tape
•Glue
Not delivered with the product:
• Drilling machine
• Drilling bits: Ø6, Ø16, Ø25
• Cup saw: Ø40, Ø100
• Deburring tool for polyethylene
3.5 Installation overview
Depending on your product type, you must go
through different steps in order to install and setup
your system. The steps below are necessary steps in
order to start your system. You may need to go
through extra steps if you have additional
accessories.
Unolift/Duolift with pumps with float switches
1. Fix tank to the floor
2. Drill holes for inlet pipes
3. Connect inlets to tank
4. Fit venting port and cable glands
5. Adjust length of float switch cable to set start
levels
6. Install pumps inside tank
7. Fit inner connecting pipe
8. Fit venting pipe
9. Fit discharge pipes
Unolift/Duolift with controller and level sensor
tube
1. Fix tank to the floor
2. Drill holes for inlet pipes
3. Connect inlets to tank
4. Fit venting port and cable glands
5. Install pumps inside tank
6. Install sensor tube inside tank
7. Fit inner connecting pipes
8. Fit venting pipe
9. Fit discharge pipes
3.6 Positioning the product
CAUTION
Back injury
• Minor or moderate personal injury
• Get assistance from another person or
use lifting equipment to carry the
product.
3.7 Installing the tank
Fix the tank to the floor to prevent uplift and twist.
Use the mounting brackets to fix the tank with
screws.
3.8 Drilling holes in the tank
CAUTION
Sharp element
• Minor or moderate personal injury
• Wear protective gloves.
Depending on the size, the the tank has three to four
pre-moulded holes ∅ 100 for the inlet pipes. The
tank also has a pre-mouled hole ∅ 40 for the
diaphragm pump. See section 5.1 Product overview.
These holes must be cut opened in order to be used.
Holes for discharge pipes, venting pipe and minimum
required cable glands are already opened.
The minimum required cable glands depend on the
model:
• Unolift, APB, CC, KP: one hole opened for pump
cable
• Unolift SEG: two holes opened for pump cable
and sensor hose
• All Duolifts: three holes opened for pump cables
(2) and sensor hose (1)
3.8.1 Drilling holes for pipes
1. Determine which inlets you want to use.
See “Choice of tank inlets” on page 6.
2. Drill holes with a cup saw.
The diameter of the cup saw must be the same
as the diameter of the pipe.
Inlet: Ø100
Outlet, pipe for diaphragm pump: Ø40
3. Deburr the holes.
TM065780 0116
CAUTION
Crushing of feet
• Minor or moderate personal injury
• Wear safety shoes when moving the
product.
Position the tank so that all components are easily
accessible during operation and maintenance.
8
TM065851 0216
Fig. 3 Drilling holes for pipes
3.8.2 Drilling holes for cable glands
Note
1. Determine where to lead the pressure hose from
the level sensor tube and cable from the alarm
float switch, if any.
2. Drill holes.
Pressure hose: Ø20
Alarm float switch cable: Ø25
3. Deburr the holes.
3.9 Fitting the cable glands
Choose the appropriate cable gland for the
application:
Cable gland for Unilift cable: M20
Cable gland for level sensor hose: M20
Cable gland for SEG cable: M25
Cable gland for alarm switch: M20
3.11 Fitting the venting pipe
The venting pipe is not delivered with the
product
You can connect your venting pipes to the air vent in
three different ways.
• By means of a PVC venting pipe with an outer
diameter of 63 mm and the glue delivered with
the product.
• By means of a flexible pipe connection with an
inner diameter of 75 mm and with clamps.
A flexible pipe connection with clamps is
available as an accessory.
• By means of a PP double socket with an inner
diameter of 75 mm. The socket must comply with
EN 1451.
3.12 Connecting the inlet pipes
You can connect up to three or four inlet pipes to the
tank, depending on the size of the tank. First you
must cut the holes open. See section 3.8 Drilling
holes in the tank.
1. Fit the socket seal in the inlet.
2. Connect the isolating valve to the inlet pipe.
The isolating valve is an accessory and is not
part of the tank delivery.
3. Insert the inlet pipe into the socket seal.
English (GB)
Fig. 4 Fixing the cable glands
3.10 Fitting the air vent
1. Fit the seal on the sleeve.
2. Fit the sleeve in the hole for the air vent. The air
vent is located on top of the tank.
3. Fit the nut from inside the tank and tighten it.
Fig. 5 Fitting the air vent
TM065779 0116TM065924 0316
Fig. 6 Fitting an inlet pipe with an isolating
The isolating gate valve can be ordered as
accessory. Use product number 96615831.
valve (type gate)
TM065859 0216
9
3.13 Installing the pump in the tank
1
English (GB)
Pumps with float switches: before installing the
pump, make sure that you have set the length of the
float switch. See “Installing the pump in the tank” on
page 10.
1. Remove the plug from the power cable of the
pump. You may need to cut the cable.
2. Position the pump in the tank.
If the pump has a float switch, make sure it can
move freely.
Unilift CC, KP, APB: Position the pump between
the three positioning dots at the bottom of the
tank so that it stays in place during operation.
See figures 7 and 8.
SEG: The pump weight ensures that the pump
stays in place.
3. Lead the supply cable through the cable gland of
the tank.
4. Tighten the cable gland.
3.14 Inner connecting pipes
3.14.1 Cutting the flexible connecting piece
The inner connecting pipe is delivered with a flexible
connection piece Ø50. You need to cut it to a specific
size, which depends on the pump type. Use the
dimensions in the table below:
Pump type
Unilift CC
Unilift KP
Unilift APB
SEG 375
3.14.2 Assembling the inner pipes
Use the thread tape delivered with the assembly kit
to seal the threads.
1. Assemble all the parts of the connecting pipe
outside the tank, except for the outlet connecting
piece. See pos. 1 in fig. 9.
2. Fit the connecting pipe to the pump in the tank.
3. Fit the outlet connecting piece to the discharge
port of the tank. Make sure that the pump is in
position and that the float switch, if any, can
move freely, before you tighten the outlet
connecting piece.
Delivered
size
[mm]
350
500
Cut to size
[mm]
240
350
(no cut)
423
TM065965 0316TM065966 0316
Fig. 7 Correct position of Unilift CC and KP
Fig. 8 Correct position of Unilift APB pumps
10
pumps
TM04 9563 2014
Fig. 9 Example with Unilift KP pumps
English (GB)
Fig. 10 Unilift CC, KP
TM0 59630 3913
11
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