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– Chain connected to the pressure pipe for pulling out the pump. Free
end of the chain is secured following the assembly of the pump
(Fig. 1, pos. 9).
The pipework supplied is for one or two-pump units (Fig. 2).
The synthetic shaft pumpstation, the selected Wilo-Drain pump and
the accessories for the units which have been ordered are delivered in
an unassembled state.
The shaft features either 2 (WS 900 E) or 4 (WS 1100 E/D) retracted
sleeves as DN 150 inlet openings. The unit also has two DN 100
connecting sleeves for the ventilation and cable outlets.
4.2 Products delivered
– Wilo-Synthetic pumpstation, with armatures and pressure piping,
– 2 Rolling rings for 2 KG-pipe DN 150 connections,
– Pump(s) and switchgear according to order placed,
– Synthetic shaft pumpstation drawings according to order placed,
– Installation and Operating Instructions
4.3 Accessories
Accessories must be ordered separately.
– Shaft cover l 830 mm, with non-slip profile,
– Shaft cover, flood proof, l 960 x 100 mm, with non-slip profile,
– Clamping screw for connection to PE or PVC pressure pipe,
1
1
/
" (AG) on 50 mm outer l
2
1
1
/
" (AG) on 63 mm outer l
2
1
2"
/
(AG) on 63 mm outer l
2
– Shaft extension l 730 x 800 mm inc. Assembly material (screws,
plates, flat seals and extension length for the stay bar of the level
controler)
Special extension lengths available on request.
5. Installation
5.1 Assembling the shaft
– The pit for the shaft must be deep enough for the inlets to have a
sufficient gradient once the shaft has been installed. Should the
inlets be positioned high enough, the height of the shaft must be
fixed so that the upper edge of the shaft is level with the floor.
Otherwise the shaft must be extended.
– The plastic shaft should be positioned vertically and in a holohedral
manner on filling sand (grain size 0 – 32 mm) in the pit and shaken
gently (Fig. 3).
When installing a shaft extension, the plastic shaft must be posi-
tioned in such a way that the upper edge of the shaft extension is
flush with the ground. Maximum distance from the upper edge of the
shaft to the ground: 700 mm or in accordance with the length of the
extension.
ATTENTION!
When using a shaft extension > 700 mm (special
extension length), the foundation pressure is liable
to increase as a result of the depth of the installa-
tion (> 2.5 m). Depending on the composition of
the ground, the form stability of the plastic-shaft
may be put at risk, this will not be covered by
guarantee.
– Connecting the inlets: Saw off the bottom of the inlet sleeve
intended for connection and push the KG inlet pipe (DN 150) into
the sleeve using the rolling ring supplied with the unit (Fig. 4 a).
– Connect the Compressed air piping (PE or PVC) to the pressure
supports using a clamp screw (accessories). The compressed air
piping must be kept safe from frost.
Once the assembly process has been completed, the compressed
air piping should undergo a compression test in accordance with
ATV A116 and DIN 4279, parts 1 – 9.
– Connecting the ventilation/cable pipe: Saw off the bottom of the
support intended for the connection (Fig. 4 b) and connect the
ventilation/cable pipe (DN 100) using a connecting sleeve. Connect
the conduit of pipes with the gradient to the shaft.
– Filling the pit. As long as the grain size of the earth removed from
the pit is no larger than 32 mm, this material ca be used to fill the pit.
Should the grain of the filling material be larger than this or sharper,
the shaft wall must be protected by a 50 cm thick layer of sand or
6
gravel (max. grain size: 32 mm). Filling material should be added and
then compressed evenly so that the shaft does not bulge or become
misshapen.
Under extreme ground or flooding conditions, the danger of shaft
lifting can be combated by placing suitable concrete weights on
both of the shaft's lifting preventers (fins) (Fig. 2). These concrete
weights should be placed securely over the earth, not directly over
the fins themselves. Place sand between the concrete and the fins.
This measure is not necessary under normal conditions.
– The user can choose from two different plastic covers (accessories)
for covering the shaft, one with a seal and one without. The shaft
cover with seal is suitable for areas regularly under flood alert. Both
covers are accessible.
– Should an extension of the shaft (Fig. 5) be necessary or desirable
as a result of low-lying inlets or for safety reasons (to protect against
frost, for example), an extension can be delivered as an accessory.
The maximum extension is 700 mm. Special extension lengths
available on request.
– Prior to the assembly of the shaft extension, the required connec-
tions should be made (inlet, ventilation and pressure pipe) and the
pit should then be filled to half the height of the shaft (beads which
run around the shaft).
– Push the shaft extension into the shaft opening until the upper
edge of the extension is flush with the ground (Fig. 5, pos. 1). For
an extension < 150 mm, the use of conventional concrete rings
and matching concrete covers is recommended, alternatively the
shaft extension must be shortened at the bottom end.
– The flat seal attached to the shaft extension should be pushed
down onto the upper edge of the shaft and the shaft extension
fixed in the desired position.
– Secure the shaft extension to the shaft at the uppermost
shaft beads using the six hexagon head screws (Fig. 5, pos. 2)
provided.
– Push the flat seal (pos. 3) into the upper slot of the shaft accord-
ing to Fig. 5 so that as much of its surface as possible and a small
flanging radius lies, without any creases, in the bottom of the slot.
Ensure that the area between the flat seal and the bottom of the
slot is clean!
– Fill the pit.
– Connect the stay bar for the level controler (Fig. 5, pos. 8) to the
supplied extension length (Flatsteel pos. 4) using the enclosed
bolts (If the shaft extensions is > 700 mm use 2 extension lengths).
– Instead of the shaft extension procedure described above, the
ground level can be adapted using suitable concrete rings and the
suitable concrete cover for this unit (max. 290 mm).
5.2 Assembling the pump:
– Clean shaft.
– Screw the pump and pressure pipe together outside the shaft using
the assembly material provided.
– The switch box should be positioned close enough to the pump to
ensure that there is sufficient wiring to allow for the pump to be
removed from the shaft for maintenance work at a later date.
– Lead the wires for the control gear (pump cable, control wire or
pneumatic tube) through the cable pipe to the control gear. Ensure
that sufficient wiring is available to reach the side of the shaft.
– Lower the pump and the pressure pipe into the shaft using the chain
and secure the coupling. Secure the chain to the chain hooks on the
shaft.
– Place the stay bar (Fig. 1 and 2, pos. 8) and level controller in the slit
which has been provided for this purpose in the crosshead.
– Adjust the level in accordance with the data sheet for installation and
connection dimensions (example for this unit Fig. 6 a, 6 b).
The minimum level (OFF) must not drop below the
ATTENTION!
bottom edge of the motor. The minimum level
(ON) required for certain units must ensure that
the pump only starts when it is covered by
sufficient water for cooling purposes, see exam-
ples in Fig. 6 a, 6 b and the drawing of the shaft
pumpstation enclosed.
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