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Installation, Care & Maintenance

Retrofit TOP bottom sump

Table of Contents

Table of Contents
SAFETY.................................................................................................................................................... 2 Safety.....................................................................................................................................................2 GUARANTEE........................................................................................................................................... 3 Guarantee.............................................................................................................................................3 PRODUCT DESCRIPTION......................................................................................................................4 General................................................................................................................................................. 4 Application........................................................................................................................................... 4 Pump versions......................................................................................................................................4 Material................................................................................................................................................. 4 Matrix materials................................................................................................................................... 4 Reinforcing materials.......................................................................................................................... 4 INSTALLATION....................................................................................................................................... 6 Safety precautions............................................................................................................................... 6 Preparation of concrete bottom........................................................................................................ 7 DIMENSIONS........................................................................................................................................10 Dimensions........................................................................................................................................ 10

Retrofit TOP bottom sump Installation, Care & Maintenance

SAFETY

SAFETY
Safety
This manual contains basic information on the Installation, Operating and Maintenance and should be followed carefully. It is essential that these instructions are carefully read before installation or commissioning by both the installation crew as well as those responsible for operation or maintenance. The operating instructions should always be readily available at the location of the unit. Identification of safety and warning symbols WARNING: General Danger: Non-observance given to safety instructions in this manual, which could cause danger to life have been specifically highlighted with this general danger symbol. Electrical Hazard: High Voltage: The presence of a dangerous voltage is identified with this safety symbol.

NOTICE: Non-observance to this warning could damage the unit or affect its function. Qualifications of personnel An authorized (certified) electrician and mechanic shall carry out all work. Safety regulations for the owner/operator All government regulations, local health and safety codes shall be complied with. All dangers due to electricity must be avoided (for details consult the regulations of your local electricity supply company). Unilateral modification and spare parts manufacturing. Modifications or changes to the unit/installation should only be carried out after consulting with Xylem. Original spare parts and accessories authorized by the manufacturer are essential for compliance. The use of other parts can invalidate any claims for warranty or compensation.

Retrofit TOP bottom sump Installation, Care & Maintenance

GUARANTEE

GUARANTEE
Guarantee
Xylem undertakes to remedy faults in products sold by Xylem provided that: the fault is due to defects in design, materials or workmanship; the faults are reported to Xylem or Xylems represenatative during the guarantee period; the product is used only under condition described in the Installation, Care and Maintenance manual and in applications for which it is intended; the monitoring equipment incorporated in the product is correctly connected and in use; all service and repair work is done by a work shop authorized by Xylem; genuine Xylem parts are used. Hence, the guarantee does not cover faults caused by deficient maintenance, improper installation, incorrectly executed repair work or normal wear and tear. Xylem assumes no liability for either bodily injuries, material damages or economic losses beyond what is stated above. Xylem guarantees that spare parts will be kept for 15 years after that the manufacture of this product has been discontinued. The pictures in this manual may differ somewhat from the delivered pump station depending on size and configuration.

Retrofit TOP bottom sump Installation, Care & Maintenance

PRODUCT DESCRIPTION

PRODUCT DESCRIPTION
General
Thank you for buying a Retrofit TOP bottom sump from Xylem. This design is patented by Xylem. In this Installation manual you will find information on how to handle, assemble and install the TOP bottom to give it a long and reliable life. The TOP Retrofit bottom is primarily designed to up-grade old concrete pump stations. The unique design of the TOP sump together with Xylems pump discharge connections, designed especially for TOP, has been hydraulically optimized to improve the flow over the sump floor during pumping. This increases turbulence and causes re-suspension of settled solids and entrainment of floating debris. The result: more solids are removed from the sump, leaving minimum residue beneath the pumps which is ready to be removed during the next pump cycle.

Application
This retrofit bottom is intended to be used for; pumping of wastewater pumping of raw or clean water For further information on applications, contact your nearest Xylem representative.

Pump versions
Depending on the size of the retrofit bottom, the following pumps can be used: CP/DP 3045, 3057 CP/DP/MP 3068 CP/DP/NP/MP 3085, 3102 HT, MT, LT and 3127 HT, SH, MT CP/DP/NP 3140 HT, MT and 3152 HT, MT NP 3153 HT, SH, MT and 3171 HT, MT Liquid temperature Max. 40C (104F) Index of pH of the pumped liquid 5.5 - 8

Material
The retrofit bottom is fabricated of Glass-fibre Reinforced Polymer (GRP), i.e. thermosetting resins incorporating reinforcement materials and processing agents and possibly fillers and/or additives.

Matrix materials
The thermosetting resin used is unsaturated polyester and phenylacrylate (vinyl ester) resins of suitable commercial grade and complies with the technical requirement of the application.

Reinforcing materials
The reinforcing material is a suitable grade of glass fibre as chopped or continues roving strands, chopped strand mat or woven roving.

Retrofit TOP bottom sump Installation, Care & Maintenance

PRODUCT DESCRIPTION

Glass fibre material complies with the following standards: Roving of glass fibre ISO 2797 Chopped strand mat ISO 2559 Woven roving ISO 2113
Table 1: Weight in Kgs (Excluding discharge connections)

TOP size TOP 50 TOP 65 TOP 65 TOP 80 TOP 100S TOP 150S TOP 150L

Part No 654 29 00 654 29 01 654 29 02 654 29 03 654 29 04 654 29 05 654 29 06

Weight 11,5 17,0 17,0 30,0 34,0 50,5 58,5

Retrofit TOP bottom sump Installation, Care & Maintenance

INSTALLATION

INSTALLATION
Safety precautions
In order to minimize the risk of accidents in connection with transporting and installation work the following rules should be followed: WARNING: Always pay extra attention to safety aspects when working with lifting equipment. Never work alone. Use safety helmet and protective shoes. Make sure that the lifting equipment is approved and in good condition. Stay clear of suspended loads. Read the installation, care and maintenance manuals for pumps and other equipment. Follow all other health and safety rules and local codes and ordinances. The installation of the retrofit bottom is always borne by the contractor. Retrofit bottom is delivered with pre-bored holes intended for mounting of discharge connections and anchor plates. Bore hole diameter = 22 mm. Appy a lute of Sikaflex 221 type, as illustrated below, before mounting the discharge connections and its anchor plates, in order to tighten the holes.

Figure 1

Evenly apply the anchoring bars on the bottom as illustrated below.

Retrofit TOP bottom sump Installation, Care & Maintenance

INSTALLATION

Figure 2

Preparation of concrete bottom


Make the bottom of the shaft clean and even.If necessary, apply a layer of concrete. For TOP 80-150 a 50 mm support is needed to balance the bottom. Use a spirit level and a wooden block as illustrated in Figure 3: (page 7).

Figure 3

Anchoring Lower down the retrofit bottom into the concrete station and align it. The concrete will affect the Retrofit bottom with the following lifting force:
Table 2

Retrofit TOP 50 TOP 65 TOP 80 TOP 100S TOP 150S TOP 150L

Lifting force 0,5 ton 0,7 ton 1,2 ton 1,7 ton 2,7 ton 3,6 ton

Retrofit bottom volume 0,18 m3 0,28 m3 0,49 m3 0,70 m3 1,10 m3 1,50 m3

The Retrofit bottom needs to be anchored against above lifting forces during the casting of the concrete and remain anchored until the concrete is solid. It is the contractor's responsibility to secure that the anchoring can manage the lifting forces. The anchoring can be made in many different ways depending on the appplication. One method could be to bolt the supports to the concrete wall (Figure 4: (page 8)).

Retrofit TOP bottom sump Installation, Care & Maintenance

INSTALLATION

Figure 4

Figure 5

If the Retrofit bottom is anchored on the bottom (see Figure 5: (page 8)) the pressure has to be equalized on a minimum surface of:
Table 3

Retrofit TOP 50 TOP 65 TOP 80 TOP 100S TOP 150S TOP 150L 1,4 dm2 2,2 dm2 3,9 dm2 5,5 dm2 8,6 dm2 11,5 dm2

Minimum surface (~1,2x1,2 dm) (~1,5x1,5 dm) (~2,0x2,0 dm) (~2,4x2,4 dm) (~3,0x3,0 dm) (~3,4x3,4 dm)

Another method could be to manufacture a special tool (see Figure 6: (page 9)).

Retrofit TOP bottom sump Installation, Care & Maintenance

INSTALLATION

Figure 6

If the discharge connections are not mounted before the embedment, the anchor bolts holding the connections, have to be secured with lock nuts until the concrete is solid. Fill the space between the pump station and the TOP Retrofit bottom with self compacting concrete. Fill up to the edge of the Retrofit bottom. WARNING: Do not vibrate the concrete as it can damage the Retrofit bottom.

Finally, cast a concrete slope towards the station wall and paint the surface with twocomponent epoxy. Fit the guide bars, discharge pipes, valves and other equipment. Lower the pumps and the station is ready!

Figure 7

Retrofit TOP bottom sump Installation, Care & Maintenance

DIMENSIONS

DIMENSIONS
Dimensions

Figure 8

10

Retrofit TOP bottom sump Installation, Care & Maintenance

Xylem |zlm|
1) The tissue in plants that brings water upward from the roots 2) A leading global water technology company We're 12,000 people unified in a common purpose: creating innovative solutions to meet our world's water needs. Developing new technologies that will improve the way water is used, conserved, and re-used in the future is central to our work. We move, treat, analyze, and return water to the environment, and we help people use water efficiently, in their homes, buildings, factories and farms. In more than 150 countries, we have strong, long-standing relationships with customers who know us for our powerful combination of leading product brands and applications expertise, backed by a legacy of innovation. For more information on how Xylem can help you, go to xyleminc.com

Xylem Water Solutions AB Gesllvgen 33 174 87 Sundbyberg Sweden Tel. +46-8-475 60 00 Fax +46-8-475 69 00 http://tpi.xyleminc.com

Visit our Web site for the latest version of this document and more information The original instruction is in English. All non-English instructions are translations of the original instruction.

2011 Xylem Inc

895575_1.1_en.US_2012-01_IOM_Retrofit_TOP_CM