Installation and Maintenance

Micro 10 Polyethylene packaged pumping stationfor lifting waste water

3

FOREWORD

This manual must remain available close

to the machine/installation. All work carried

out must be undertaken by professional

personnel. Current national regulations and

local safety and hygiene requirements must

be complied with.

Disclaimer

Design modifications may have been carried

out on technical characteristics. In conse-

quence, the product as supplied may differ

from the illustrations and information con-

tained in this manual. Copying, transcription,

translation and any other form of reproduc-

tion of this manual are only authorised with

prior written agreement by the manufacturer.

This stipulation also applies to passages ex-

tracted from the text.

TABLE OF CONTENTS

Safety

Guarantee

Technical Characteristics

Transportation, unloading and storage

Installation

Cam locking mechanism option

Electrical connection

Maintenance

General Arrangement

List of spare parts

Declaration of conformity

467910131414151617

4

SAFETY

Security instructions to be followed bythe operator / user Current national regulations and local safety

and hygiene requirements must be complied

with. All danger of electrocution must be

avoided (for more detailed information,

please consult the regulations drawn up by

the local electricity supplier).

Modifications to the pumping station anduse of spare parts. No modifications to equipment and its instal-

lation may be carried out without prior con-

sultation with the ITT Lowara company. In

order to guarantee the performance of the

equipment it is essential to use original spare

parts or accessories authorised by the man-

ufacturer. Use of other spare parts may in-

validate any claims on the basis of the

guarantee or requests for compensation.

Disassembly and reassembly During maintenance of the pumping station

(for example, draining), it is crucial to avoid

endangering persons and/or the environ-

ment.

All refuse and waste (e.g. grey cooling liquid)

must be handled in an appropriate manner in

order to avoid harm to the environment.

The lifting equipment must be constantly

kept clean and in normal working order.

All applicable regulations must be adhered to.

Because of the nature and

level of performance

required for the equipment,

noise levels may reach

70 dB.

This manual contains essential information

on installation, operation and maintenance.

These instructions must be meticulously fol-

lowed. Installation and maintenance person-

nel must read these instructions carefully

before installation and commencing opera-

tion of the pumping station. This installation

and maintenance manual must be available

at the pumping station site at all times.

Safety and warning pictograms used inthis manual.

Danger of death

This pictogram is a reminder

that any failure to respect

the safety instructions set

out in this manual may have

fatal consequences.

High voltage

This pictogram indicates that

there is a risk of electrocution.

WARNING! Failure to heed this warning

may cause damage to

equipment or affect its

operation.

Personnel qualifications

Work must be carried out exclusively by

qualified personnel.

5

DANGER (Gas, dust, fumes, smoke)

Before any work on the

equipment, authorisation

must be obtained.

Gases may form within the

pumping station and

compliance with specific

rules for installation in an

explosive environment is

imperative.

Welding, cutting by means of a blowtorch,

or grinding present real risks of fire and/or

explosion.

For these operations, carefully remove in-

flammable dust or materials present in the

work area and the surrounding space. Be

careful to ensure sufficient ventilation (risk

of explosion).

SAFETY

Safety instructions The rules set out below must be scrupu-

lously adhered to in order to reduce accident

risks during servicing, installation and main-

tenance.

- Ensure that electrical equipment is discon

nected from the power supply and cannot

be reconnected inadvertently.

- Never work alone. During any work on the

interior of the pumping station, beware of

harmful gases and make systematic use

of a safety harness and rope as well as

breathing apparatus. Do not under-esti

mate the risks of drowning!

- Compy with local regulations for working

in confined spaces.

- Monitor the absence of toxic gases within

the work area.

- Do not under-estimate health risks.

Meticulously ensure that equipment is

clean.

- Beware of electrocution risks.

- Ensure that lifting equipment is in perfect

condition.

- Install appropriate barriers around the

work area, for example a security rail.

- Ensure that there is a safe exit route in

case of emergency.

- Wear a safety helmet, goggles and shoes.

- All persons working within sewage

facilities must be vaccinated against any

diseases which may develop there.

- A First Aid kit must be permanently

available near the facility.

- Comply with local safety instructions.

- Systematically re-close and lock the cover

before leaving the pumping station.

6

This guarantee does not therefore apply to

defects resulting from lack of maintenance,

inappropriate installation, repairs incorrectly

carried out or normal wear and tear.

Lowara moreover declines any responsibility

in the case of physical injuries, or material or

economic damages if the above mentioned

conditions have not been

respected.

Lowara guarantees supply of spare parts for

fifteen years following the termination of

manufacture of the product.

For any claims concerning a guarantee, con-

tact your nearest Lowara Representative

who will provide full information.

.

GUARANTEE

Lowara undertakes to remedy any defect

which may be presented by the products

sold by their intermediary subject to:

- The defect resulting from a design,

materials or manufacturing fault

- It being reported to Lowara or to the

local ITT Lowaraagency within the

guarantee period

- The product having been installed and

operated in compliance with the

instructions in this installation and

maintenance manual, and solely for the

applications for which it is intended

- The electrical surveillance equipment for

the pumping station has been correctly

installed and is in service

- All maintenance and repair works having

been entrusted to a service centre

approved by Lowara

- Only original Lowara spare parts are

used.

Location of series number

7

Weight Micro 10 1300 mm 130 Kg

Micro 10 2000 mm DN 50 150 Kg

Micro 10 2000 mm DN 65 210 Kg

Riser 350 mm 23 Kg

Total weight without pumps

Volume of tank (litres) Micro 10 1300 mm 1200 L

Micro 10 2,000 mm 1900 L

Pump DN50 DN 65

Refer to pump installation manual

Fuse boxRefer to instructions supplied with this equipment.

TECHNICAL CHARACTERISTICS

Applications The Micro 10 is delivered completely assem-

bled and ready to be put into service.

This pumping station is intended for pumping

raw sewage, black water with or without par-

ticles or fecal matter (bathroom and toilet fa-

cilities, WC, showers, kitchens), water

loaded with fabric, fibres or straw, slops,

rainwater or wastewater, discharged by:

Individual dwelling Collective dwelling

Housing development Campsite Hotel

Muncipal showers Restaurant kitchen

Sports complexes Milking parlour

Livestock pen Abattoir

Equipment The pumping station is delivered already

equipped with the following items:

1. Cover

2. Internal gates and tubing

3. Pump glands

4. Inlet gasket

Important Pumps, fuse box, levels controllers, chains

and shackles are delivered separately.

Temperature of pumped liquid: 35°C Max.

Depth of excavation: 2.7 m Max.

External constraints The pumping station is designed for a water

table which may reach ground level. The

pumping station must be installed in such a

way that loads caused by vehicular traffic are

not felt less than 1.0 metre from the edge of

the pumping station.

Tank and cover materials The Micro 10 tank is manufactured from ro-

tationally-molded polyethylene .

Guide bar materials A2 Stainless Steel

Pipework materials PVC DN 50 or DN 65 discharge pipes

Inlet to be drilled for pipe Ø 160(mm) ext.

The pumping station is not

intended for use in an

explosive environment or

for inflammable liquids

8

TECHNICAL CHARACTERISTICS

The pumping station is not

intended for use in an

explosive environment or

for inflammable liquids

PUMPS

DXGM 25-11

DXVM 50-11

DXVM 50-7

DXM 50-7

DP 3045 MT 234

DP 3057 MT 238

CP 3057 MT 264

DXG 25-11

DXV 50-7

DXV 50-15

DP 3057 MT 232

DXVM 50-11

DXVM 50-7

DXM 50-7

DP 3045 MT 234

DP 3057 MT 238

CP 3057 MT 264

DXV 50-7

DXV 50-15

DP 3057 MT 232

DP 8022 MT 215

DP 8022 MT 211

DP 8022 MT 208

ø DISCHARGE

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

65

65

65

REFERENCE

58 60 670

58 60 210

58 60 900

58 60 240

58 60 170

58 60 190

58 60 200

58 60 680

58 60 230

58 60 220

58 60 180

58 60 370

58 60 910

58 60,400

58 60 340

58 60 350

58 60 360

58 60 390

58 60 380

58 60 330

58 60 510

58 60 500

58 60 490

BOX

CPEM Z BOX

BOX CPEM Z

BOX

COMMANDER

MICRO

10 1300

MICRO

10 2000

9

TECHNICAL CHARACTERISTICS

Figure 1. Dimensions(Dimensions in mm)

Opening Ø 800

Opening Ø 800

460 <

F.E

.A <

75

0 D

rilli

ng

fo

r in

let Ø

16

0

460 <

F.E

.A <

14

50

Drilli

ng

fo

r in

let Ø

16

0

Checks:

Before installation or storage, check that the

Polyethylene tank and internal pipework are

in proper working order.

principle

Use both lifting handles to raise the pumping

station and place it in the pit.

Storage

Outdoor storage periods must not exceed

four months and the tank must be covered

(for example by a tarpaulin).

TRANSPORT, UNLOADING AND STORAGE

Transport:

1. Ensure the tank never comes into contact

with sharp edges.

2. Protect the tank from impacts.

Loading and unloading:

1. Carry out loading and unloading

operations with the greatest care.

2. Ensure that the pumpstation is unloaded

from the lorry by means of appropriate

lifting equipment.

3. Always use lifting slings with the correct

dimensions (reminder: maximum weight of

tank is 180 kg).

10

Filling: Important: during filling, ensure that the tank

is vertical.

Fill material must have a granulosity of be-

tween 2 and 36 mm. Filling must be carried

out before the water table surface reaches

the top of the fill material.

1) Spread a layer of fill material 300 mm

thick (B) Compact and level the surface, then

place the Micro 10 tank on top.

2) Add a layer of fill up to a minimum height

of 700 mm.

Compact in successive layers with a maxi-

mum thickness of 50 mm.

Fill of the upper part (C) must not contain

stones more than 50 mm. in calibre.

Water table: Figure 2B

In the case of difficult surfaces (impermeable

or clayey) or of ground water, the bottom of

the pit must consist of a concrete base 0.20

metres thick.

Concrete ballasting must be poured around

the pumping station

INSTALLATION

Installation of the pumping station is always

under the entire responsibility of the firm in

charge of the installation. General informa-

tion and instructions in accordance with EN

976-2:1997

Warning: Never install pumps before covering the tank

with earth.

Installation in the groundThe pumpstation is designed to resist

stresses linked to the presence of a water

table flush with ground level.

The pumping station must not be installed in

soil composed of peat. When the pumpsta-

tion is installed in soil which is argillaceous

(clayey) , granular, or silty, a geotextile fabric

must be laid over all excavation surfaces.

The geotextile fabric prevents the fill material

from becoming mixed with the soil (A).

Excavation dimensions: 1) Depth: 300 mm greater than the level in-

tended for installation.

2) Width: two metres greater than the pump-

station.

Fig 2 Fig 2B

CONCRETE BASE

Version Height (mm) Ø of concrete base Approximate volume of concrete (m3)

MICRO 10 Between

2000 and 2700 1,8 m 1,4

MICRO 10 Between

1300 and 1650 1,8 m 0.9

Note: Dimensions indicated In figures 2 and 2B are minimum dimensions

Remarks

Soil analysis MUST BE CARRIED OUT for all pumpstations and must comply

with DTU 64-1 and the Order of 6th May 1996.

11

INSTALLATION

Connection of inlet pipe (fig 2) • Fix the self-adhesive drill former on the drill

area (flat piece shown)

• Drill the tank with a jigsaw or similar

• Fit gasket Ø160

• Chamfer exterior of tube Ø160

• Pass the tube through the gasket

Connection of discharge pipe Connect the pump discharge pipe to the net-

work pipe with the PVC threaded/smooth fix-it

coupling (fig. 3)

Use of a flexible pipe fitting between the pump-

station and the network pipe is recommended in

order to avoid stresses or breakage of piping

due to any ground compaction.

Passing cabling through (fig. 4) In the upper part of the flat delivery input drilling

area is the assembly location for the two pump

glands.

Pass the cables through these pump glands.

Ensure that sufficient length of cable is left for

any subsequent work on the pump.

Note: Separate the earth cable from the live cable on

the pump.

Above the hooks for the regulators, in the flat

area, is the assembly area for the pump glands

for the level regulators.

Pass the cables through the pump glands.

Ensure that sufficient length of cable is avail-

able. Adjust the length and hook the cables

over their hook.

Hooks for supporting chains (pumps) (fig. 5)

The hooks are located on the stainless steel

cross-beam.

There are 2 small folded lugs on the cross

beam which enable the chains to be hookedup

(fig. 5).

Tank

Tube

Gasket

Fig 2

Fig 3

Fig 4

Fig 5

Glands for level regulators

Pump glands

Hooks

12

INSTALLATION

Ventilation Ventilation

This can be mounted on the upper part of one

of the two flat pieces

1. Drill a hole of the same dimensions as your

ventilation pipe.

2. Connect the ventilation duct using a gasket

(equipment not provided) (fig 6)

Note:

Ventilation duct and electrical connections

must be installed inside separate sheaths

The gasket The access point cover gasket is made of foam,

with a self-adhesive rectangular section.

This gasket is mounted fixed to the lower part of

the access point cover.

Tightness is achieved when the access point

cover is clamped over the tank.

Ensure a minimum of two full turns in order to

achieve perfect tightness.

Riser The riser is screwed on the upper part of the

tank in the place normally occupied by the

cover. The cover is then screwed to the upper

part of the riser

Up to two may be fitted (Fig. 8)

Figure 5. Angular position of hook on riser.

Ground rod and earth strap (optional)

Hook the earth strap between the guide bar support

and the cross beam

Pump Installation

Refer to instructions supplied with the pump.

Check the direction of the pump’s rotation

before the pump is installed in the pumpstation.

WARNING! Before installing the pump

or pumps, remove any

earth or gravel which may

have fallen into the tank.

Tank

Gasket

Fig. 6

Fig. 7 Gasket position

Access point cover

Fig. 8

13

CAM LOCKING MECHANISM OPTION• Take the cover and drill a Ø 21 mm hole in

the centre of the hollow cylindrical shape

provided for the locking mechanism

• Insert the upper part of the barrel (1) in the

hole which has been drilled (the triangular

shape of the barrel should be outside the

cover) as indicated in the diagram below.

• Next thread the nut (2) over the barrel

(inside of the cover)

• Then place the locking lug (3) over the

square form of the barrel and insert the

screw (4) to keep the lug in place.

• Using the spanner (5) release the locking

device so that the lug (3) does not project

outside the cover. Screw the cover over

your lift station, then lock the cover with the

spanner. Remove the spanner and position

the cap supplied over the cover in order to

prevent clogging with dirt.

14

ELECTRICAL CONNECTIONS

Information for the electrician connecting the

Micro 10 pumpstation.

When making connections inside the station,

do not forget that this is a humid environ-

ment and that appropriate electrical protec-

tion devices are indispensible.

Condensation forms inside the pumpstation

and the connection casings.

Do not use terminal boards as these can

easily cause short-circuiting. Use isolated

connectors filled with silicon. For even

greater safety and to avoid condensation

forming, fill the casings with Vaseline

(or petroleum jelly).

Fix the motor cable giving it a wide curve.

If the cable is too long, it may be sucked into

the pump. Shorten the cable to an appropri-

ate length.

Be careful to ensure that the cable ends are

not immersed; water can be sucked into the

cable by capillarity.

Hang the level regulators on the hooks or to

a support which can be easily removed when

the pump needs to be lifted up. Adjust the

cable to the desired length.

Note: Monitor the direction of wheel rotation.

If the direction of rotation is inverted, the

pump will still work but with reduced perform-

ance.

Monitoring operation

1. Open the stop cock with the valve key

supplied.

2. Start the pump from the control panel.

All electrical work is to be carried out under the supervision of an authorised electrician. Strictly comply with local codes and regulations. Before beginning work, check that the electrical supply cable is disconnected from mains power.

Check the supply voltage on the pump’s data

plate.

Check that the specifications on the motor’s

dataplate match the mains voltage and

frequency.

Carefully read the installation and mainte-

nance manual supplied with the pump to-

gether with that on the electrical control box.

Pass the cables (motor cable, level regulator

cable and equipotential bonding) through the

cable entrance to the electrical control box.

Connect the wires in accordance with the

wiring diagram.

Use the appropriate ITT Lowara clamps to

retain cables inside the pumping station.

Installation of level regulator

Two Flygt ENM-10 level regulators are

provided for startup and for alarms.

The regulators are suspended from hooks in-

side the pumping station. It is recommended

that you install the startup level regulator at

the height of the pump lifting handle and the

alarm regulator 50 cm, higher.

MAINTENANCE

- Refer to the SAFETY section of this

manual for safety measures.

- (Visually) check that the system is tight.

- Lift the pump and check that the dis

charge outlet gasket on the Hook up

system is in a proper state of repair.

- Systematically re-close and lock the

cover before leaving the pumping station.

Pump

Comply with instructions regarding the

frequency of inspection. See Pump Installation

Manual.

Equipotential bonding

Ensure that all connections are tight and show

no signs of corrosion.

Carry out any necessary replacements.

If the pump within the station runs dry or hums,

the surface of the pump and surrounding liquid may be hot.

Be careful of the risk of burning.

15

GENERAL ARRANGEMENT

40 3

2 5 3 4

2728

1 8

14

16

15

26

23 24

25

22 24

2119

13

20

119

7

Discharge 2 pvc

Inlet drilling for

pvc tube Ø 150

with gasket

16

GENERAL ARRANGEMENT

Figure Qty DESIGNATION REMARKS

1 1 Tank polyethylene

2 1 Cover polyethylene

3 1 Cover gasket epdm

4 1 Cover locking system cam type

5 1 Plug polyethylene

7 1 Keyed joint Ø 160 ext. epdm

8 2 Dn50 pump (material according to type)

9 2 Dn50 mounting base cast iron

10 1 Reinforcing plate for mounting base galvanised steel (tbc)

11 2 Fixing insert for mounting base stainless steel

13 4 Guide bar Ø026.9 2.65 th 4x850 length galvanised steel

14 2 Guide bar support stainless steel

15 1 Cross-beam (guide bar-pipework) galvanised steel

16 3 Clip for dn50 return tube pvc

17 1 Support for regulator 4 pts Stainless steel

18 1 Pump gland (to be advised)

19 1 Pipework dn50 total length Pvc

20 2 Male 2” female 63 endpiece Pvc

21 4 Female 45° elbow joint dn63 Pvc

22 2 Loose flange dn50 Pvc

23 2 Fixed flange dn50 pvc

24 4 Flange joint dn50 epdm

25 2 Ball valve dn50 with drilled flange cast iron

26 2 Dn50 gate – female 63 Pvc

27 3 90° elbow joint female dn50 Pvc

28 1 Female tee dn50 Pvc

29 1 Female pipe fitting 63 Pvc

30 1 Feedthrough male 63 –male 2” Pvc

40 * Spacer Polyethylene (option+cover gasket)

LIST OF PARTS

17

DECLARATION OF CONFORMITY

About XylemXylem (XYL) is a leading global water technology provider, enabling customers to transport, treat, test and efficiently use water in public utility, residential and commercial building services, industrial and agricultural settings. The company does business in more than 150 countries through a number of market-leading product brands, and its peo-ple bring broad applications expertise with a strong focus on finding local solutions to the world’s most challengingwater and wastewater problems. Launched in 2011 from the spinoff of the water-related businesses of ITT Corpora-tion, Xylem is headquartered in White Plains, N.Y., with 2011 revenues of $3.8 billion and 12,500 employees worldwide.

The name Xylem is derived from classical Greek and is the tissue that transports water in plants, highlighting the engineering efficiency of our water-centric business by linking it with the best water transportation of all -- that which occurs in nature. For more information, please visit us at www.xyleminc.com

Lowara UK LimitedMillwey Rise Industrial Estate Axminster, Devon EX13 5HU - UK Tel: 01297 630230 Fax: 01297 630270e-mail: lowaraukenquiries@xyleminc.com http://www.lowara.co.ukhttp://completewatersystems.com

Xylem Water Solutions Ireland Limited50 Broomhill CloseAirton RoadTallaght - Dublin 24Tel. (+353) 01 4524444Fax (+353) 01 4524795e-mail: lowara.ireland@xyleminc.comhttp://www.lowara.ie

Lowara is a trademark of Xylem Inc. or one of its subsidiaries.

© 2011 Xylem, Inc.

Lowara reserve the right to make modifications without prior notice.

Order code UKLIT0036 P 09/12