Vacuum Sewer Systems Construction Manual

Transcription

1 Vacuum Sewer Systems Construction Manual Version: 2012 For Construction Companies and Consultants: Pipe laying and installation of RoeVac collection chambers and valves

2 0 Contact information Contact information Head Office Roediger Vacuum GmbH Kinzigheimer Weg Hanau Germany International Business Department Phone +49 (6181) Fax +49 (6181) Production & Development Centre Roediger Vacuum GmbH Betriebsstätte Tostedt Auf der Timmhorst Tostedt Germany Phone +49 (4182) Fax +49 (4182) 5009 Page 2 of 158

3 0 Table of contents Table of contents Contact information... 2 Table of contents Introduction General Further information and requirements: Definitions Health and safety Pipe-laying and profile design Pipes The Saw Tooth Profile Fittings - General RoeVac Lift fittings Service line fittings (House connection fittings) Inspection pipes Division valves (Gate valves) Branch line connections RoeVac PVC fittings: Details PVC service lines PVC inspection pipes PVC branch lines connections RoeVac HDPE fittings: Details HDPE- service lines HDPE inspection pipes HDPE branch line connections Test during construction Final Testing Leak testing Guidelines for the use of test-balls: Additional guidelines for the usage of large test balls How to isolate the collection chamber from the network Using test ball in an operating system Leak detection procedure with a test ball Pressure tables for the use of test ball according to sewer pipe Pressure table for PVC pipes and corresponding test ball diameters Pressure table for HDPE pipes and corresponding test ball diameters Air admittance station Functional Description Air admittance station sample drawing Page 3 of 158

4 0 Table of contents 5. RoeVac collection chambers Generalities What to be careful of when ordering collection chambers Gravity line connection to collection chamber Standard connections Connections at lower elevations RoeVac G-Type collection chamber Installation of the G-Type collection chambers Pedestrian load Flood proof and pedestrian load collection chamber Heavy traffic load RoeVac Z-Type collection chamber Installation of the Z-Type collection chambers Heavy traffic load RoeVac PE 50: Watervilla collection chambers Description Specific measures for noise reduction RoeVac Vacuum Valve Units Vacuum valve 65 mm 2, Description Drawing Vacuum valve 75 mm Description Drawing KPS Standard controller Description Adjustments Tube connections Drawing Assembling of the vacuum units (Vacuum valve and controller) RoeVac vacuum valve RoeVac Standard Controller (KPS) Schematic representation of the assembling Drawings Optional vacuum buffer for 3 vacuum valve unit Additional important information Preventative Maintenance Manual operation of vacuum valve Commissioning of RoeVac vacuum valve units in chamber Decommissioning of RoeVac vacuum valve units Page 4 of 158

5 0 Table of contents 7. Monitoring System for chamber (cable based) General In-ground cabling Cable Types to be applied Cable versions Cables placement Interference filter Cabling at the collection chamber Incoming Cable in the collection chamber Different collection chamber entries Cabling inside the collection chamber body Switch at the vacuum valve Allocation of the sensor module Installation of Monitoring Module Cabling at the control panel of the vacuum station Installation of Channel Generators Amplifier for long Cable lengths and/or large numbers of Collection Chambers Vacuum station Preconditions for the installation of a vacuum station Transport procedure and installation of vacuum vessels Bio-filter Important additional information Start-up of the system Cleaning of every collection chamber Cleaning of the pipe network before the first start-up Storage of the delivered equipment Delivery / Dispatch Mechanical and electrical equipment Vacuum Valves and controller Collection chambers As-built drawings Index Pictures and drawings Tables Confirmation of reception Confirmation of reception Page 5 of 158

6 1.1 General 1. Introduction 1.1 General The aim of this document is to provide a guideline for the construction of a RoeVac vacuum sewer system with all its specialised components. Vacuum sewer systems are typically used for transporting effluent from residential homes, commercial and industrial premises. When designing a vacuum sewer system local standards for pre-treatment of aggressive wastewater and the need for grease traps (from restaurants, etc.) have to be considered from the outset. Vacuum pumps, located in the vacuum station, generate negative pressure in the sewer network. Each collection chamber contains a vacuum valve which automatically discharges sewage in batches into the sewer network. After the vacuum valve closes, air enters the system which provides the necessary energy to drive the system. Air is required to transport the waste water through the vacuum sewer system. Vacuum sewer lines are designed in a saw tooth profile to maintain a relatively constant trench depth (typically m) and to prevent sedimentation of solid waste in the sewer network. The system is not designed to include storm and/or infiltrated ground water. Vacuum sewers must NOT be connected to residential yard drain systems. Measures should also be taken to avoid infiltration through the gravity system which connects premises to the collection chambers, particularly if there are manholes or inspection covers upstream of the vacuum system. Collection chambers should not be used as repositories for domestic or industrial solid waste. Guidelines for design and operation of vacuum sewer systems are given in the technical norms: EN 1091 (European Standard) DWA-A (German Standard) The vacuum sewer line must be air tight as per EN Pipe joints (PVC- solvent welded (SW) or HDPE- fusion welded connections) must be executed professionally by fully trained personnel in accordance with the standards and guidelines of the pipe manufacturers. If rubber ring joints are used for PVC pipes, the joints must be vacuum certified, to minus 80 kpa) 2.The direction of flow must be into the pipe sockets. If HDPE-pipes are used, only electro-fusion couplings or flanges may be used. Electrofusion sockets shall be in accordance with DIN 8074/75. 1 Also known as ATV-DVWK-A 116, Part kpa = 0.01 bar = Inch (Zoll) of Hg (32 F ) Page 6 of 158

7 1.2 Further information and requirements: Note: All pressure values in this document are given in kilopascal (kpa), relative to the atmospheric pressure. E.g. a negative pressure of -65 kpa is equal with bar or 35 kpa compared to the absolute pressure of approx. 100 kpa at sea level. 1.2 Further information and requirements: The patented RoeVac collection chamber should be installed according to the installation guidelines. The connection pipes at the vacuum service line and at the gravity drain should be installed with the correct slope as per design. Proper ventilation should be provided to the collection sump and gravity line to insure correct operation of the vacuum valve. The sanitary fixtures in the household do not need to be changed if an outdoor vacuum system is installed. Connected houses with sanitary fixtures below the gravity line have to be equipped with proper measures to prevent sewage back-up (i.e. non-return valve), according to local guidelines. Vacuum testing of the installed vacuum pipes should be carried out on sections no longer than 450 m before backfilling. In high temperature climates it is recommended that pipes are protected with a thin covering of backfill material to minimise expansion and sun scorch. For the pressure tests, a mobile vacuum pump unit should be used and connected to sections of vacuum line via vertical inspection pipes. Vacuum testing at minus 70 kpa is the only acceptable method. As-built drawings must be provided to the system supplier after the installation has been completed. 1.3 Definitions Consulting Engineer: Designer, supervising consultant or consulting firm representing the client and supervising the contractor. Contractor: Company which constructs the system (trenches, pipe laying, installation of the collection chambers, construction of the vacuum station building, etc.). System supplier: Roediger Vacuum or its local partner, whoever has received order to supply material from the contractor or from the end user. Operators: Persons/company operating the sewer system after construction, commissioning and hand over. 1.4 Health and safety The main contractor has to provide a Health and Safety manual according to the site requirements. Furthermore the main contractor is responsible for site inductions and all safety instructions to Roediger personnel. Page 7 of 158

8 2.1 Pipes 2. Pipe-laying and profile design 2.1 Pipes A precisely designed saw tooth profile pipeline must be precision laid to enable efficient sewage transportation. These profiles are designed by the consulting engineers and checked and approved by Roediger Vacuum GmbH. Construction should conform strictly to these drawings. The high and low points in the vacuum lines are critical for the system performance. All pipes and fittings must be laid exactly according to the profile plans. (Length, profile cross section and overview reference points) Tolerances of ± 12 mm are acceptable as per EN Although tolerances are acceptable, they should be avoided! Pipes should be laid at frost free depths and for ease of access located wherever possible in sidewalks. Local traffic needs may have to be considered. Pipe laying and jointing should be according to manufacturer s specifications and local standards. The pipe sections must have a minimum slope of 0.2 %. The pipe laying should be stable and installed by means of a laser level. Bedding is crucial to long term system performance. Important: fig. 1 Pipes lying in trench Always lay the pipe from the end of the line to the vacuum station. So that in case of unexpected obstacles it will be easier to change the profile. Any changes have to be done with the approval of the consulting engineer. Ensure the backfilling material is compacted layer by layer. Page 8 of 158

9 Construction Manual 2.1 Pipes Materials: System pipe materials consist either of Polyvinyl Chloride (PVC): min. PN3 10, SDR4 21 Polyethylene (HDPE): min. SDR 11 The contractor should be fully aware of the pipe manufacturer s warranties for applications involving vacuum sewer systems. PVC pipes stored outside MUST be protected from direct sunlight! Straight lengths of HDPE pipes must be used and NOT coiled HDPE pipes! (Compare fig. 2 and fig. 3) fig. 2 Correct pipe laying with a sand bed, and the trench free of waste! fig. 3 No sand bed, trench covered with waste and use of coiled HDPE pipes. 3 4 PN = Pressure Nominal SDR = Standard Dimension Ratio Page 9 of 158

10 2.1 Pipes In addition- the following points should be understood and adhered to: The drawings (construction plans) must be approved by the consulting engineer and Roediger vacuum GmbH. The pipe-laying instructions as determined by the pipe-manufacturer Local standards, and respective guidelines for pipe installation, load protection, stability protection, etc. The instructions of the manufacturer of the PVC- solvent cement (for PVC pipe only) The construction standards EN 1091, DWA-A State-of-the-art on pipe laying techniques Diameter translation: Nominal (DN), external diameter (d) The following table 1 shows diameters and parameters of common pipes. Nominal diameter External diameter PVC, PN10, SDR 21, wall thickness PVC, PN10, SDR 21, internal diameter HDPE, SDR 11, wall thickness HDPE, SDR 11, internal diameter DN d mm mm mm mm ,0 57,0 5,8 51, ,6 67,8 6,8 61, ,3 81,4 8,2 73, ,3 99,4 10,0 90, ,0 113,0 11,4 102, ,7 126,6 12,7 114, ,7 144,6 14,6 130, ,4 147, ,6 180,8 18,2 163, ,8 203,4 20,5 184, ,9 226,2 22,7 204, ,4 253,2 25,4 229,2 table 1 Pipe diameter translation Page 10 of 158

11 2.2 The Saw Tooth Profile 2.2 The Saw Tooth Profile For vacuum sewer networks a saw tooth pipe profile design is required: see fig. 4 to fig. 8. Only this profile type guarantees reliable transportation of the wastewater. Every profile for your project is shown in detail in the construction drawings. Approval of the constructional drawings by the consulting engineer and Roediger Vacuum GmbH is always necessary before starting construction! If unexpected obstacles occur during construction, please contact Roediger Vacuum GmbH and/or the construction supervisor immediately. Roediger Vacuum GmbH must be contacted if the pipe profile has to be changed. The pipe is laid with long down slope ending in a short lift section ranging from 200mm to 450mm of vertical height. Between the lifts, the pipe must slope at least 70% of a pipe diameter (internal pipe diameter) which is usually achieved with a downward slope of a min. 0.2%. The minimum distance between two lifts is 6 m. The minimum distance between a service line and a lift is 2 m Lift sections are formed by two elbow fittings (2x45 or 2x30 ). Roediger Vacuum GmbH can provide these special lift fittings based on the required pipe material, diameter and lift height. Please refer to the chapter and to fig. 7 and fig. 8. Inspection pipes should be installed on the high point of each lift in order to allow the insertion of test balls for leakage detection (see chapter 3.4). fig. 4 Schematic representation of the pocket of wastewater in a saw tooth profile Remark: Never change the profile. Lay the pipes exactly according to the design of the system supplier or the local consulting engineer. Please also consider the note given on page 8 Page 11 of 158

12 2.2 The Saw Tooth Profile fig. 5 Example for a typical length profile cross section drawing (longitudinal section) Page 12 of 158

13 2.2 The Saw Tooth Profile fig. 6 Example for a lift fitting followed by an inspection pipe Page 13 of 158

14 2.2 The Saw Tooth Profile Flow direction fig. 7 Picture of a HDPE lift fitting with inspection pipe before backfilling Flow direction fig. 8 Picture of a PVC lift fitting with inspection pipe before backfilling Page 14 of 158

15 2.3 Fittings - General 2.3 Fittings - General RoeVac Lift fittings Lift fittings are required to build the saw tooth profile. The fittings are hydraulically optimized and made of HDPE or PVC. The lift fittings can be bought pre-manufactured from Roediger Vacuum GmbH, Germany. Typical sizes of RoeVac lift-fittings for saw tooth profiles (the length of the fittings is approx. 1 m): d in mm * Lift heights in mm Mod. 1 Mod. 2 Mod ** table 2 Lift heights * Other diameters and lift heights can be supplied on demand. ** Not available in PVC ATTENTION: The designed lift sizes (usually 20, 30 or 45 cm) are important for a reliable system performance. Please follow in detail the low and high points as per the length profile from the engineer s / Roediger design. In order to simplify matters in all Roediger Vacuum GmbH profiles, the ascent angle of all lifts is designed in a 45 -shape. In reality this a ngle value may vary between for HDPE material (due to the electro fusion sleeves) for some lift sizes. RoeVac lift HDPE RoeVac lift PVC fig. 9 Drawings of Roevac lift HDPE (left) and PVC (right) Page 15 of 158

16 2.3 Fittings - General When ordering from Roediger Vacuum GmbH, Germany, please indicate the following: Quantity, "Lift Fitting", material, external diameter d, SDR-class, lift height and use the Roediger Article number. Example of correct order: 1 pcs. Lift fitting, HDPE, d110, SDR 11, h = 300 mm. ( ) On request, Roediger Vacuum can provide the construction company with a parts list. Page 16 of 158

17 2.3 Fittings - General Service line fittings (House connection fittings) The pipe between the collection chamber and the connection to the main line is called the service line. The standard size is d90. A Vacuum service line shall slope downward from the vacuum valve in the collection chamber and shall connect via a fabricated top entry house tee to the main line at an angle not exceeding 60 (see fig. 10). The top entry configuration of the fitting prevents backflow towards the collection chamber. fig. 10 Service connection from above In order to connect the service line from-above to the vacuum main (without causing too many difficulties for the contractor staff), Roediger Vacuum provides special fittings, which are reinforced by a glass-fibre plastic-jacket. In order to prevent any back flow towards the collection chamber, the service line is connected by this special item from above in a 55 angle to the vacuum main (according to EN 1091). RoeVac service line fittings are available based in left-hand and right-hand fittings regarding the main flow direction. (See chapters and 2.5.1). Fittings, made to EN 1091 specification are only available from the Roediger. Definitions: Right-hand service line fitting means that when regarding the flow direction, the collection chamber is located on the right side Left-hand service line fitting means that when regarding the flow direction, the collection chamber is located on the left side It is essential to install the service line fittings according to flow direction (see fig. 20)! The service line must be installed with a minimum slope of 0.2% in the flow direction. The minimum distance between a service line fittings and a lift should be 2 m. Page 17 of 158

18 2.3 Fittings - General fig. 11 On-site picture of a right-hand service line fitting Inspection pipes Inspection pipes allow simple leakage detection during construction as well as during the operation of a vacuum sewer system. Inspection pipes enable the insertion of inflatable test balls for precise leak detection (see chapter 3.4 for more details). The vertical inspection pipes are sealed by a special PVC cap and are protected by a cast iron or concrete cover. Cast Iron covers are available in several sizes. The location of these inspection pipes are given in the construction drawings (length profiles) from Roediger Vacuum GmbH as approved by the local consulting engineer. The following rules apply: Inspections pipes are placed at the end of every line Inspection pipes have to be placed at least every 100 m On branch lines smaller than 100 m an inspection has to be placed on the branch line close to the main line The inspection pipe caps are installed underneath a traffic cover (see chapters and ) fig. 12 Picture of a division valve and inspection pipe of HDPE before backfilling Page 18 of 158

19 2.3 Fittings - General fig. 13 Picture of an end inspection pipe of HDPE NOTE: There should be 15 cm clearance between the rubber plug of the inspection cap and street cover. The sealing surface between the o-ringed cap and inspection pipe must be clean and free of grease (use only silicon grease and no gliding agent). Do not compact (especially if PVC) directly from above the pipe cap with heavy machinery. Debris and small stones may cause serious damage to the PVC pipes and the vertical PVC pipe, and may damage the T-fitting. Only use a hand-rammer. Ensure the backfilling material is compacted layer by layer fig. 14 Damaged T-fitting caused by careless compaction with heavy machinery Page 19 of 158

20 2.3 Fittings - General fig. 15 Inspection pipe cover Page 20 of 158

21 2.3 Fittings - General Street caps (size 1 and 2) for inspection pipes, main line sizes d90- d160 fig. 16 Street caps size 1 and 2 (Gr.1 / W1 and Gr.2 / W2) Page 21 of 158

22 2.3 Fittings - General Street caps for inspection pipes, main line sizes d fig. 17 Street caps subsurface (underground) hydrant Page 22 of 158

23 2.3 Fittings - General Division valves (Gate valves) According to the standards, vacuum tight division valves must be installed every 450 m at minimum. Branch connections longer than 200 m shall be isolated with a division valve. Generally the number of division valves is determined by the consulting engineer. Division valves must be certified for usage in a vacuum system. Roediger Vacuum offers special vacuum tested division valves. Street caps need to be provided locally. fig. 18 : Picture of a division valve Page 23 of 158

24 2.3 Fittings - General Branch line connections The branch line is connected to a main line with a standard 45 degree Y-fitting, which is installed according to flow direction (see fig. 20) in the main line. All branch connections of vacuum sewer shall be connected to the main line above the horizontal axis by a junctionfitting. The branch line must slope towards the main line (minimum slope 0.2%). The invert level of the branch line at its last high point should be equal or higher than the crown level of the pipe in the connection or subsequent low point. The distance between a branch connections and a lift shall not be less than 2 m. Attention To avoid backflow into a side-branch, preferred connections (between main lines and side-branches) in vacuum networks are made from above (see fig. 19): The min. level difference between the invert level of the main vacuum line and the invert level of the side branch should be one full internal diameter of the vacuum main line in a distance of 1,5 m (compare fig. 19). fig. 19 Branch line connection from above Page 24 of 158

25 2.3 Fittings - General fig. 20 Branch lines: Connection to main lines Page 25 of 158

26 2.4 RoeVac PVC fittings: Details 2.4 RoeVac PVC fittings: Details PVC service lines PVC: Dimensions of service line fittings for different pipe diameters Pipe Diameters Dimensions Main Line Service Connection d 1 DN d 2 DN a c e f [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] table 3 Dimensions of service line connection fittings for different pipe diameters Note: Other diameters are available on demand. Page 26 of 158

27 2.4 RoeVac PVC fittings: Details PVC Service line connection fitting, 55, r ight-hand fig. 21 PVC Service line connection fitting, 55, righ t-hand, for dimensions see table 3 Page 27 of 158

28 2.4 RoeVac PVC fittings: Details PVC Service line connection fitting, 55, l eft-hand fig. 22 PVC Service line connection fitting, 55, left -hand, for dimension see table 3 Page 28 of 158

29 2.4 RoeVac PVC fittings: Details PVC inspection pipes PVC: Dimensions of inspection pipes for different pipe diameters Pipe Diameters Dimensions Inspection Pipe Cap Street Cover d 1 d 2 a b Height Diameter acc. to DIN [mm] [mm] [mm] [mm] [mm] [mm] 1 and DIN 4055-U DIN size DIN size table 4 Dimensions of inspection pipes for different pipe diameters DIN 4055-U BEGU DN Street covers must allow the removal of the inspection pipe cap, therefore clearance of the street cap must be larger than inspection pipe cap diameter. For the drawings of the covers, please refer to chapter Note: Other diameters are available on demand. 5 Also known as W1 (Gr.1) and W2 (Gr.2) 6 BEGU DN 300 covers are not Roediger Vacuum standard parts and only available on demand Page 29 of 158

30 2.4 RoeVac PVC fittings: Details PVC inspection pipe fig. 23 PVC inspection pipe d 90 - d 250, for dimension see table 4 Page 30 of 158

31 2.4 RoeVac PVC fittings: Details PVC end inspection pipe fig. 24 PVC end inspection pipe d90 - d110 Page 31 of 158

32 2.4 RoeVac PVC fittings: Details PVC branch lines connections PVC branch lines connections are typically supplied from commercial sources, please follow the instruction given in the chapter PVC branch line fittings: Dimensions of for different pipe diameters Main line Branch line Parts D d A Wye 45 B Reducer short [mm] [mm] Type Type d d110 d110x d d125 d125x d125 d125x d d140 d140x d140 d140x d140 d140x d d160 d160x d160 d160x d160 d160x d160 d160x d d200 d200x160 / 160x d200 d200x160 / 160x d200 d200x160 / 160x d200 d200x x d200 d200x d d225 d225x160 / 160x d225 d225x160 / 160x d225 d225x160 / 160x d225 d225x160 / 160x d225 d225x d225 d225x d d250 d250x160 / 160x d250 d250x160 / 160x d250 d250x160 / 160x d250 d250x160 / 160x d250 d250x d250 d250x d250 d250x d table 5 Dimensions of branch line fittings for different pipe diameters see fig. 25 Page 32 of 158

33 2.4 RoeVac PVC fittings: Details PVC branch line connections fig. 25 PVC branch line fitting, for dimensions see table 5 Page 33 of 158

34 2.5 RoeVac HDPE fittings: Details 2.5 RoeVac HDPE fittings: Details HDPE- service lines HDPE- Dimensions of service line fittings for different pipe diameters The service line fittings in HDPE are universal fittings either left or right. This has mainly two advantages: It simplifies the order transaction and stock management on site Only one type of electro-fusion coupling needed on site They are delivered to site with a cap to plug the fitting during construction. The HDPE service line fittings are now composed of two parts (see fig. 26 and fig. 27) to be mounted according to site requirements. Please follow the instructions given in fig. 27. Pipe Diameters Dimensions Service Connection Main Line d 1 DN d 2 DN a b c d [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] table 6 Dimensions of service line connection fittings for different pipe diameters Note: Other diameters are available on demand. Page 34 of 158

35 2.5 RoeVac HDPE fittings: Details fig. 26 HDPE service line connection fitting,55, un iversal, dimensions see table 6 Page 35 of 158

36 2.5 RoeVac HDPE fittings: Details fig. 27 HDPE service line connection fitting, 55, l eft-hand, dimension see table 6 Page 36 of 158

37 2.5 RoeVac HDPE fittings: Details HDPE inspection pipes Dimensions of inspection pipes for different pipe diameters Pipes Dimension Inspection Pipe Cap d 1 d 2 a b c e Height Diameter [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] ca. 440 ca. 100 ca. 100 ca ca. 480 ca. 110 ca. 100 ca ca. 525 ca. 125 ca. 110 ca ca. 550 ca. 130 ca. 110 ca ca. 590 ca. 140 ca. 110 ca ca. 630 ca. 150 ca. 140 ca ca. 660 ca. 155 ca. 140 ca /160 ca. 705 ca. 165 ca. 150 ca ca. 740 ca. 170 ca. 150 ca ca. 770 ca. 185 ca. 180 ca Street Cap acc. to DIN 4056 and DIN 4055 DIN size 1 DIN size 2 DIN 4055-U BEGU DN 300 table 7 Dimensions of inspection pipes for different pipe diameters This table should be used to choose the street cap sizes. Street covers must allow removal of inspection pipe cap, therefore clearance of the street cap must be larger than inspection pipe cap diameter. For the drawings of the covers, please refer to chapter Note: Other diameters are available on demand. Attention For inspection pipes please use only silicon grease and no lubrication agents (i.e.soap). For inspection pipes size d225 a standard pipe d180 is used. The inspection pipe cap d160 is supplied with reducer d180 to d160. Page 37 of 158

38 2.5 RoeVac HDPE fittings: Details HDPE inspection pipe fig. 28 HDPE inspection pipe, for dimensions see table 7 Page 38 of 158

39 2.5 RoeVac HDPE fittings: Details HDPE end inspection pipe fig. 29 HDPE end inspection pipe, d90 d110 Page 39 of 158

40 2.5 RoeVac HDPE fittings: Details HDPE branch line connections HDPE branch line fittings: Dimensions for different pipe diameters Pipe Diameter Dimensions d a b c [mm] [mm] [mm] [mm] table 8 Dimensions of branch line fittings for different pipe diameters Note: Other diameters are available on demand. Reducer elements for incoming lines are available from Roediger Vacuum Page 40 of 158

41 2.5 RoeVac HDPE fittings: Details HDPE branch line fitting fig. 30 HDPE branch line fitting, for dimensions see table 8 Page 41 of 158

42 2.6 Test during construction 2.6 Test during construction According to the norm EN 1091: After not more than 450m of vacuum pipeline has been laid, the vacuum sewer and service connections have to be tested at a vacuum of 70 ± 5 kpa below atmospheric. This vacuum has to be allowed to stabilize for a minimum time period of 30 min. The tested pipe shall not lose more than 1% of vacuum in a test period of two hours in the case of lines without inspection pipes or 5% in the same test period for a system installed with inspection pipes. NOTE: Only vacuum shall be used for tightness test, not high pressure! fig. 31 Picture of the mobile vacuum test pump 2.7 Final Testing When the complete network is built, every section needs to be recorded and a final test has to be performed, according to the norm EN Documents attesting this test have to be signed by the consultant / the client representative. Page 42 of 158

43 3.1 Guidelines for the use of test-balls: 3. Leak testing 3.1 Guidelines for the use of test-balls: The vacuum strength (see table 9 and table 10) must not be exceeded. (-30 kpa relative) Check the inner diameter of the pipeline to be tested and use the test ball size conforming to the pipe diameter shown in the tables. Do not clean the test-ball with solvents and with cleaning agents containing mineraloil. This could damage the ball. Before inflating the test-ball, it must be fully inserted into the pipe. The test-ball must be inflated to the recommended operational pressure (see table 9 and table 10). If the pressure is too high, the test-ball can burst. If the pressure is too low, the testball might slip in the pipeline to be tested causing damage to pipe or test-ball. Careless handling of the test equipment can cause damage to the equipment and injure the operator. Care must be taken when inflating and deflating the test balls. The hose must be properly anchored and held by hand. The high suction forces during vacuum testing can cause injury if operators do not exercise due care. Note: Control the fixation of the test ball before each uses. fig. 32 Small test ball Page 43 of 158

44 3.1 Guidelines for the use of test-balls: Additional guidelines for the usage of large test balls The test ball 8 is supplied with a nylon-rope (approx. 100 m). Connect test ball to the end of the rope. Tie a metal bar (anchor) to the rope at the test length (as determined during leak test) see chapter Make sure that the connection is very secure and that the anchor cannot enter the pipe. Transfer vacuum to the pipe section to be tested. Let the test ball be pulled by the vacuum to the predetermined test length. When the test length is reached the metal bar (anchor) will secure the test ball position. Now, if the anchor is safe, inflate the test ball to the recommended pressure by using the foot pump. The pipe line must be fully aerated to atmosphere before the test ball is deflated and removed. Attention! fig. 33 Large test Ball utilisation guidelines To avoid injury - Never ever hold the rope with your hands. Big test ball diameters may create very strong forces and can hurt people seriously. Page 44 of 158

45 3.2 How to isolate the collection chamber from the network 3.2 How to isolate the collection chamber from the network Vacuum isolation plugs (for chamber with a 65 mm 2,5 vacuum valve) or vacuum isolation balls (for chamber with a 75 mm 3 vacuum valve ) are provided with each chamber in order to allow to isolate this chamber from the vacuum network. For the isolation plugs, (see fig. 34) in order to ensure the tightness of this plug, care has to be taken that the screw is properly set before using it. fig. 34 chamber isolated from vacuum line with isolation plug (G 65 chamber) fig. 35 Isolation ball for 3 valve respectively isolation caps 3.3 Page 45 of 158

46 3.4 Using test ball in an operating system 3.4 Using test ball in an operating system Leak detection procedure with a test ball Leak detection should follow the procedure outlined below: Start the leak detection by breaking down the entire sewer network into smaller parts. This can be done using the division valves. Vacuum division valves should be installed every 450m in main lines as well as in side branches which are longer than 250m. 1. Isolate with vacuum isolation plugs the collection chambers which are connected to the 450m section to be tested. 2. Connect the vacuum test gauge to one of the existing inspection pipes within a line section between two vacuum division valves or end inspection, as shown on fig Close the downstream vacuum division valve (i.e. valve towards the vacuum station). 4. If the vacuum gauge on the inspection shows loss in vacuum, the leakage is in this separated section. 5. Open vacuum division valve and increase the vacuum in this line again. 6. Put in a vacuum test gauge with a 5 m hose and test-ball ( inspection pipe in the middle of 450 m section upstream of a vacuum division valve) and inflate test-ball with foot pump (see fig. 37) 7. If the vacuum test gauge shows loss in vacuum, the leakage is located upstream of the test-ball (see fig. 37). 8. Remove the test gauge and the test-ball and repeat the procedure using the next upstream inspection pipe until no vacuum loss can be detected. Then the leakage is located between the last two tested inspection pipes (see fig. 38). 9. Remove vacuum test gauge (with test-ball) and insert them in the previous downstream inspection pipe (do not inflate the test-ball yet), see fig Insert approx. 50 m of the 100 m long vacuum test hose (with test-ball) into the inspection pipe last tested (see step 8). 11. Inflate the test-ball. 12. Inflate the test-ball of the vacuum test gauge (with 5 m hose and test-ball, item 10), to test the line section (length approx. 50 m) between the two test balls (see fig. 39). 13. If the vacuum test gauge shows loss of vacuum, the leakage is located between both test-balls. If not, the leakage is upstream of the vacuum hose test ball. 14. By varying the length of the test hose and repeating steps 10 to 13, the leak can be located to within 1m. 15. Allow atmospheric pressure into the leaking line and repair the leak. Note: Do not exceed pressures indicated in the table 9 and table 10 Caution: You have to decrease the vacuum at the VS to -30 kpa (-0,3 bar). Page 46 of 158

47 3.4 Using test ball in an operating system fig m section of vacuum line with vacuum division valve Page 47 of 158

48 3.4 Using test ball in an operating system fig. 37 Pressure gauge with 5 m hose connected to inspection pipe in the middle of 450 m section (upstream) Page 48 of 158

49 3.4 Using test ball in an operating system fig. 38 Test with pressure gauge with on the upstream inspection pipes Page 49 of 158

50 3.4 Using test ball in an operating system fig. 39 leak detection in untight 100 m section between 2 inspections Page 50 of 158

51 3.5 Pressure tables for the use of test ball according to sewer pipe 3.5 Pressure tables for the use of test ball according to sewer pipe Pressure table for PVC pipes and corresponding test ball diameters Dimensions Street covers Test balls Main line Outer Wall Inner Insp. pipe (DIN and Nominal Max. allowed Allowed pressure Nom. width diameter thickness diameter diameter DIN 4055-U) width pressure main line mm mm mm mm mm inch kpa (relative) kpa (relative) DN DIN Gr. 1 2" DN DIN Gr. 1 2" DN DIN Gr. 1 3" DN DIN Gr. 1 3" DN DIN Gr. 2 4" DN DIN 4055-U* 5" DN DIN 4055-U* 6" DN BEGU DN 300 8" DN BEGU DN 300 8" * Street cap underground hydrant table 9 Pressure table for PVC pipes and corresponding test ball diameter Page 51 of 158

52 3.5 Pressure tables for the use of test ball according to sewer pipe Pressure table for HDPE pipes and corresponding test ball diameters Dimensions Street covers Test balls Main line Outer Wall Inner Insp. pipe (DIN and Nominal Max. allowed Allowed pressure Nom. width diameter thickness diameter diameter DIN 4055-U) width pressure main line mm mm mm mm mm inch kpa (relative) kpa (relative) d DIN Gr. 1 2" d DIN Gr. 1 3" d DIN Gr. 2 3" d DIN Gr. 2 3" d DIN Gr. 2 4" d DIN 4055-U* 5" d DIN 4055-U* 5" d / 160 DIN 4055-U* 6" d BEGU DN 300 8" d BEGU DN 300 8" * Street cap underground hydrant table 10 Pressure table for HDPE pipes and corresponding test ball diameter Page 52 of 158

53 4.1 Functional Description 4. Air admittance station 4.1 Functional Description Due to hydraulic reasons, an air admittance station may be needed for some projects. During peak-flow periods water locks can occur which could isolate upstream vacuum sewer line sections. This can cause the vacuum strength to drop (e.g. -30 kpa) which would prevent proper sewage transportation. For such situations, the RoeVac air admittance station has been developed The air admittance station consists of an electrical controller and a RoeVac vacuum valve. The unit is placed in an outdoor cabinet and is connected to the vacuum sewer network. The exact location for an air admittance station needs to be approved by Roediger vacuum and/or local consulting engineer. If the vacuum has dropped under a minimum level, the electrical controller opens a RoeVac vacuum valve inside the air admittance station which admits air into the pipe for a pre-determined interval. The air transports the excessive water in the pipeline towards the vacuum station (air flushing) and the vacuum will increase to its correct level. The pipe is air flushed only for a short time. The cycle will be repeated until the vacuum strength has returned to normal. If the vacuum strength in this pipe has not recovered in a given period, other reasons (e.g. leakage in the pipe network) have to be assumed. In such circumstances the air admittance station shuts down automatically. The air admittance station can be operated with the following power sources: 230/240V main power 24V solar powered 12V battery powered fig. 40 Picture of an air admittance station Page 53 of 158

54 4.2 Air admittance station sample drawing 4.2 Air admittance station sample drawing fig. 41 Air admittance station, sample drawing Page 54 of 158

55 5.1 Generalities 5. RoeVac collection chambers 5.1 Generalities There are several types of collection chambers that have been designed for varying site conditions. As a standard, consultants should not design a project in which the design peak-flow per vacuum valve exceeds 0.2 lit/sec (40 PE 7 ) for the 75 mm valve and 0.13 lit/sec (25 PE 7 ) for the 65 mm valve. This limitation is necessary to provide an efficient air-to-liquid-ratio for the transport of wastewater, and to minimize the saturation risk in the vacuum network. There are three types of collection chamber designs: Two for in ground installations. Standard collection chamber (RoeVac G-Type) (see chapter 5.4) Cylindrical collection chamber (RoeVac Z-Type) (see chapter 5.5), if the chamber can only be installed under roads. One specific for water villas: Watervilla chamber (PE 50) (see chapter 5.6) There are two different valves which are available for the both ground collection chambers (G-Type and Z-Type): 65mm 2,5 (see chapter 6.1) 75mm 3 (see chapter 6.2) In addition, there are different types of load conditions for the collection chambers: pedestrian load (use G-Type) flood proof and pedestrian load (use G-Type) flood proof and traffic load (up to 40 tons) (use Z-Type) With the collection chambers that are designed to be placed in the ground, the use of G- type chambers is recommended for pedestrian loads if possible, because this chamber allows easy access for maintenance and does not need extra caps for the ventilation pipes of the valve chamber and sumps. 7 Waste water discharge per person is here considered with 150 litres per day and a peak factor of 3 Page 55 of 158

56 5.2 What to be careful of when ordering collection chambers 5.2 What to be careful of when ordering collection chambers As every project is different and specific, please note on your order the following points: Is it a HDPE or a PVC Network? For chambers G 75, Z 65 and Z 75: - Do you need a core driller (if yes which diameter DN 150 or DN 200)? - Which Gaskets size do you need (DN 150 or DN 200)? - How many gaskets do you need altogether (standard delivery is one per chamber Extra gaskets have to be ordered separately)? For G 75 and Z 75: - Do you need an extra isolation ball (standard delivery is one isolation ball for 10 chambers)? For Z 65 and Z 75: - Do you need a tool for the sump service cover? - As a standard the vacuum valve unit arrives mounted in the collection chamber on the building site. Page 56 of 158

57 5.3 Gravity line connection to collection chamber 5.3 Gravity line connection to collection chamber Standard connections fig. 42 Standard house connection (here with G-Type collection chamber) Page 57 of 158

58 5.3 Gravity line connection to collection chamber Connections at lower elevations fig. 43 House connections at lower elevations(here with G-type collection chamber) Page 58 of 158

59 5.4 RoeVac G-Type collection chamber 5.4 RoeVac G-Type collection chamber The collection chamber is divided into two separate main parts; the valve chamber and the sump (see fig. 44 and fig. 45): Valve chamber: Sump : - Vacuum valve with controller - Service elbow - Connecting and mounting parts for the vacuum valve unit - Closed sump (waste water collecting area) Suction pipe and sensor pipe Connection area for house s gravity connection lines Connection to vacuum service line Page 59 of 158

60 5.4 RoeVac G-Type collection chamber Valve Chamber Suction Pipe d63 Sensor House connection (gravity line) DN 200 Sump 30l Service line connection Pipe d50 fig. 44 Picture of a G-type collection chamber G-65 2,5 pedestrian load Valve Chamber Suction Pipe d90 Sensor Sump 60litres House connection (gravity line) DN 200 Service line connection Pipe d50 fig. 45 Picture of a G-type collection chamber G-75 3 pedestrian load Page 60 of 158

61 5.4 RoeVac G-Type collection chamber Regarding the valve (and so the capacity to evacuate waste water), there are two types of RoeVac G-type collection chamber: G 65-2,5 : with a small sump (30litres) G 75-3 : with a big sump (60litres) Care has to be taken with the gravity line connections to these two sumps as they are different. Please refer to the chapter and drawing which correspond to the chambers that will be installed! (Chapters and 5.4.3) Regarding the load capacity, there are two types of G-type collection chamber: pedestrian load: supplied with an adequate splash-water proof RoeVac cover and able to withstand the weight of an adult. flood proof and pedestrian load: supplied with the following additional parts, compared with the standard chamber: - RoeVac cover of MDPE (pedestrian load and flood proof version) with integrated thermal insulation, replacing the cover and thermal insulation layer of a standard pedestrian load chamber. - Sealing Gasket for flood proof cover - Lockable cover for sump pipe, MDPE plug (green) DN Vent cap for the gravity line, PVC-black DN 100 or 150 (often supplied locally) - Vent cap for breather line to the valve chamber of HDPE black DN 20 (often also supplied locally) - There are also four different G-type collection chambers, which are shown in detail on the following pages. Page 61 of 158

62 5.4 RoeVac G-Type collection chamber Installation of the G-Type collection chambers Assembly of RoeVac G-Type collection chambers fig. 46 Assembly of G-type collection chambers Page 62 of 158

63 5.4 RoeVac G-Type collection chamber fig. 47 Measuring the pipe length of a G-Type collection chamber on site In situ installation Backfilling material Ensure that cohesion less soil is used for backfilling. Grain size for round granular material is 32 mm max., for edged granular material 16 mm max. The backfill must be filled in carefully and compressed layer by layer by a hand rammer. Page 63 of 158

64 5.4 RoeVac G-Type collection chamber fig. 48 Installation of collection chambers into excavation pit fig. 49 How to keep the G-Type collection chamber level during installation & backfill Page 64 of 158

65 5.4 RoeVac G-Type collection chamber fig. 50 Collection chamber: pipes inside the valve chamber (vacuum, sensor and evacuation) Page 65 of 158

66 5.4 RoeVac G-Type collection chamber Connection to the vacuum service line The invert level of the vacuum service line can be adjusted vertically. The direction of the vacuum service line can also be adjusted by rotating the 90 degree bend. The connection to vacuum service line of G-chambers is made of PVC, if you are building a HDPE sewer network, you will have to install an adaptor PVC- HDPE (provided free of charge by Roediger vacuum). This adaptor has to be solvent welded on the PVC side and connected by the means of an electro-fusion coupling on HDPE side.( see picture below) fig. 51 Connection of the adaptor PVC-HDPE Page 66 of 158

67 5.4 RoeVac G-Type collection chamber Connection to the house gravity line The gravity line (PVC DN 200) is used as storage volume (emergency storage) in case the system is out of service. The required storage volume must be determined by the local engineer. If sanitary fixtures are connected lower than the sewage back-up level, please install safety devices against back-flow, pursuant to DIN Should local conditions determine the need, lift pumps may be necessary for a house connection. The following loads shall not be exceeded (see chapter 5.3): G 65 (2,5 ): l sewage at a rate of 1-3 l/s per evacuation cycle (max 30 sec). G 75 ( 3 ) : l sewage at a rate of 1-3 l/s per evacuation cycle (max 30 sec). Care has to be taken that enough recovery time between pump cycles is guaranteed (max pump starts per hour). According to DIN 1986, the house owner is responsible for the proper installation of the vents for the gravity lines inside the building. The sumps of the collection chambers differ (volume and shape) according to the chosen valve; consequently the way to connect the gravity line is also. (See the following chapters and ) For installation of gravity lines into the sump of the G 75 collection chamber, a core drill of the correct size is required from Roediger Vacuum. The hole for the gravity line is not drilled, it has to be done on site. The holes (to be done locally) have to have the following diameters to fit the gaskets supplied: NOTE: DN 200: 215 mm DN 150: 175 mm The core drill is not included with the collection chamber and has to be ordered separately. The core drill can be purchased from Roediger Vacuum and requires a hexagonal bit. As standard with each collection chamber G75 a gasket DN200 is provided for the incoming gravity line, as an option, this gasket can be replace by a DN 150 (please specify with your order). If you need more gaskets, they have to be ordered separately. Page 67 of 158

68 5.4 RoeVac G-Type collection chamber Connection to the house gravity line for the G 65 mm 2,5 fig. 52 Top view of the connection to gravity line for G 65 2,5 Page 68 of 158

69 5.4 RoeVac G-Type collection chamber Connection to the house gravity line for the G 75 mm 3 fig. 53 Top view of the connections to gravity line for the G75 3 Page 69 of 158

70 5.4 RoeVac G-Type collection chamber Installation possibilities of the G-Type collection chamber Please take care that the pedestrian load cover of the G-Type collection chamber is protected against surface water. That means that the complete lid and upper body of the valve chamber needs to be 10 cm above ground (compare the collection chamber drawings) to avoid surface water entering the valve chamber. In addition, the collection chambers must not be installed at low points and/or flood zones. Please find the following (fig. 54 to fig. 56) examples of the G-type collection chamber (Pedestrian load) installations from different countries. fig. 54 Pedestrian load collection chamber G-type on private property fig. 55 Pedestrian load collection chamber G-type in public green fig. 56 Pedestrian load collection chamber G-type with protection brickwork Page 70 of 158

71 5.4 RoeVac G-Type collection chamber Pedestrian load Description The collection chamber designed by Roediger Vacuum is made of MDPE and supplied with water proof RoeVac cover, but is not sealed against flooding. The standard valve chamber is splash-proof (not flood proof) and separated from the sump to ensure hygienic access to the vacuum valve. A Service-Wye is provided in the valve chamber which allows for connection of the vacuum intake plug, isolation plug and clean-out lance. The collection chamber consists of the following four main components: Valve chamber with thermal insulation layer, valve unit with controller, service Wye (isolation plug) and rubber elbow with sump stack hose Chamber piping, consisting of service elbow pipe, PVC-suction pipe assembly, sensor pipe and vacuum service line Gravity line connection consisting of sump (see chapter for specifications and connection of the gravity line) RoeVac cover, passenger load and lockable, made of MDPE. Collection chambers are supplied in component form and require assembly on site. This allows the contractor to adjust the chamber height to local requirements. The vertical pipes are supplied by the contractor and are cut to length. Page 71 of 158

72 5.4 RoeVac G-Type collection chamber Installation instructions for the pedestrian load collection chamber The standard collection chamber must be installed in such a way that the upper edge of the valve chamber rim is 10 cm above finished grade. Flooding the valve chamber must not be allowed, the chamber must not be installed in any surface depressions. Make sure locally that no surface water infiltration into the valve chamber is possible. The chamber must be backfilled properly and per local conditions (ground quality, loads, etc.). It is also recommended to prepare as built drawings for installation depths, valve unit numbers, etc. Roediger Vacuum can provide forms on request. In case of high ground-water table, anti-floatation (buoyancy collar protection) might be required. Concrete can be poured around the valve chamber ring to secure the chamber. The vacuum service line from the chamber to the main line (under the road) must be laid out with a slope of 0.2 % (see page 17) in the direction of flow. If the service lines require lifts, contact Roediger Vacuum or the consulting engineer. The gravity line from the building to the collection chamber must be officially tested and approved by the responsible authority. DIN 1986 is a guideline for all pipe installations inside buildings. Particularly the sewage back-up level has to be considered during design (see e.g. DIN 1986). The sewage back-up level (see DIN 4045) is defined by the local authorities. However the maximum back-up level is at the sump pipe rim of the collection chamber. Page 72 of 158

73 5.4 RoeVac G-Type collection chamber G65 2,5, pedestrian load collection chamber fig. 57 RoeVac Chamber type G 65 2,5 pedestrian load: Installation Page 73 of 158

74 5.4 RoeVac G-Type collection chamber fig. 58 RoeVac Chamber type G 65 2,5 pedestrian load: Parts list Page 74 of 158

75 5.4 RoeVac G-Type collection chamber G75 3, pedestrian load fig. 59 RoeVac Chamber type G 75 3 pedestrian load: Installation Page 75 of 158

76 5.4 RoeVac G-Type collection chamber fig. 60 RoeVac Chamber type G 75 3 pedestrian load: Parts list Page 76 of 158

77 5.4 RoeVac G-Type collection chamber Flood proof and pedestrian load collection chamber Description The flood proof and pedestrian load collection chamber is supplied with the following additional parts, compared to the standard chamber: RoeVac cover of MDPE (pedestrian load and flood proof version) with integrated thermal insulation, replacing the cover and thermal insulation layer of standard passenger-load chamber) Gasket for the flood proof cover Lockable cover for the sump pipe, MDPE plug (green) DN 200 Vent cap for the gravity line, PVC-black DN 100 or DN 150 (according to the size of the vacuum valve) (supplied locally) Vent cap for breather line to the chamber of HDPE black DN 20 (often also supplied locally) The flood proof chamber is installed in the same way as the standard chamber (see installation instruction drawings, chapter ). The ventilation pipe for the gravity incoming pipe must not be installed at a distance of more than10m from the vertical axis of the valve chamber. The valve chamber ventilation pipe must not be installed at a distance greater than 6 m from the vertical axis of the valve chamber. Compare the installation drawings Additional instructions for the flood proof and pedestrian load When closing the valve chamber cover (HDPE), it is important to keep the cover and its gasket free of dirt. The collection chamber must be installed in such a way that the ring nuts of the chamber cover have a distance of 5-6 cm to the lower edge of the surface. The seal lips of the gasket must point towards the inner part of the chamber. The distance between the ring nut of the sump cap and the street cover should be 5 to 6 cm. The chamber should not be installed in a low point. It should be backfilled with permeable gravel. This gravel layer may not be destroyed in order to ensure the drainage of condensation- and surface-water into the lower soil. It is recommended to prepare as-built drawings for each collection chamber indicating installation depths, valve unit numbers, etc. The ventilation pipe to the valve chamber and the gravity vent line must be installed with constant slope and out of the traffic-area. Vent caps must be properly installed. For optimized air-flow, the breather line to the house drain gravity pipe can be connected using a Y-fitting instead of a T-fitting. The height of the ventilation above the surface is dependent on the potential flood or snow circumstances on site. Page 77 of 158

78 5.4 RoeVac G-Type collection chamber G65 2,5, flood proof and pedestrian load fig. 61 RoeVac Chamber type G 65 2,5 flood-proof and pedestrian load: Installation Page 78 of 158

79 5.4 RoeVac G-Type collection chamber fig. 62 RoeVac Chamber type G 65 2,5 flood-proof and pedestrian load: Parts list Page 79 of 158

80 5.4 RoeVac G-Type collection chamber G75 3, flood proof and pedestrian load fig. 63 RoeVac Chamber type G 75 3 flood-proof and pedestrian load: Installation Page 80 of 158

81 5.4 RoeVac G-Type collection chamber fig. 64 RoeVac Chamber type G 75 3 flood-proof and pedestrian load: Parts list Page 81 of 158

82 5.4 RoeVac G-Type collection chamber Heavy traffic load The Z-Type collection chamber replaces the formerly used G-Type collection chambers for G-type traffic load. If you need information about installation of traffic load G-Type collection chambers, please refer to a previous version of the basic instruction manual or contact Roediger Vacuum. Page 82 of 158

83 5.5 RoeVac Z-Type collection chamber 5.5 RoeVac Z-Type collection chamber The collection chamber consists of a chamber body with a cover. The chamber body has external ribbing. The rib segments help to counteract floatation. The chamber body can be shortened at the segments (see ). The chamber is divided into two separate areas arranged one above the other (see fig. 65). Valve chamber (at the top): Vacuum valve with controller Service elbow Connecting and mounting parts for the vacuum valve unit Sump (at the bottom): Closed sump (waste water collecting area) Suction pipe and sensor pipe Connection area for house connection lines fig. 65 Picture of a shortened Z-type collection chamber 2,5 Page 83 of 158

84 5.5 RoeVac Z-Type collection chamber Installation of the Z-Type collection chambers Procedure 1. Prepare the place of installation for the chamber; see If necessary, shorten the chamber body, see chapter Install the chamber body, see chapter Connect the vacuum line, see chapter Connect the house sewage system to the chamber, see chapter Attach the lateral connections to chamber, see chapter Fill in in-situ concrete, see chapter Connect chamber monitoring device (option), see chapter Mount the cover, see chapter Pre-requisites and preparatory work required. The gravity pipeline from the building to the chamber must be accepted, unless the executing company is authorised to make changes. DIN 1986 applies to all installations inside the building, in particular the backup level must be observed, in accordance with DIN The backup level (see DIN 4045) is determined by the local authority. The top edge of the collection chamber is always the minimum backup level. If connections below the backup level within a building cannot be avoided, backup safety devices must be installed. DIN 1997 must be observed in case of such installations. Dependent on the local conditions sewage lifting units may be required. These units may deliver depending on the size of the vacuum valve see chapter 5.3 and : - Z : litres of sewage at a rate of 1-3 l/s per pumping cycle (max 30 sec). - Z 75 3 : litres of sewage at a rate of 1-3 l/s per pumping cycle (max 30 sec). According to DIN 1986 the owner himself is responsible for the correct installation of the aeration lines within the house. Ground excavation for the collection chamber observing the permissible installation depth. Page 84 of 158

85 5.5 RoeVac Z-Type collection chamber Shortening the chamber body Shortening of the chamber body can be executed on site. For major projects the chamber body can shortened in the factory prior to despatch 1. Detach chamber top part (fig. 66) from chamber bottom part by loosening the tightening clamp. 2. Remove 1 to 3 segments, as required, see fig. 67. Removal of 1 segment shortens the chamber by 20.3 cm. 3. Shorten the two pipes (sensor pipe and suction pipe) at the corresponding mark (M) (when the chamber is shortened by 1 segment, saw off the two pipes at mark M1), see fig. 66. Use a saw for shortening. 4. Chamfer the pipes from inside. 5. Re-connect the chamber top part and chamber bottom part using the tightening clamp. Please tighten both screws with a fastening torque of 26 Nm. 1 2 Isolation m3 m2 m1 fig. 66 RoeVac Chamber type Z: body fig. 67 RoeVac Chamber type Z: body, shortened of 2 segments Page 85 of 158

86 5.5 RoeVac Z-Type collection chamber The marks "A" on the edges of the two parts must be aligned. A Note: fig. 68 RoeVac Chamber type Z body assembly Care has to be taken of the following advice (also written on collection chamber see fig. 69)! fig. 69 Adhesive label on Z-Chamber with advice Page 86 of 158

87 5.5 RoeVac Z-Type collection chamber Installing the chamber body Install the collection chamber so that the distance between the ring nuts on the cover and the bottom edge of the cover is 5-6 cm. The bead of the gasket must point to the inside of the chamber. ATTENTION: The collection chamber must be surrounded by a layer of permeable gravel. Ensure that this layer of gravel is preserved to permit seepage into the ground. Backfilling material Ensure that cohesion less soils are used for backfilling. Grain size for round granular material is 32mm max; for edged granular material 16mm max. The backfilling must be compressed layer by layer with a hand compactor. The area around the chamber covers must be paved or asphalted. Page 87 of 158

88 5.5 RoeVac Z-Type collection chamber Connection to vacuum service line The vacuum service line from the chamber to the main line must be laid with a slope of minimum 0.2 % in the direction of flow. Special solutions are necessary for: House connection lines longer than 20 m Problematic cases Collection chambers installed very deep requiring a lift on the service line In these cases, please contact Roediger Vacuum GmbH or the local consultant. The connection to the vacuum service line of Z-chambers is made of HDPE, in case you are building a PVC sewer network, you will have to install an adaptor HDPE- PVC (provided free of charge by Roediger). This adaptor has to be solvent welded on the PVC side and connected by the mean of an electro-fusion coupling on HDPE side. fig. 70 Connection of the adaptor PVC-HDPE Page 88 of 158

89 5.5 RoeVac Z-Type collection chamber Connection to the house gravity lines Attention! Please do not drill in this area. M fig. 71 : Z-type chamber body connection to the house gravity line with warning Non-observance may cause collection chamber malfunction. Drilling is not permitted within the marked area. A circumferential mark (M), see fig. 71, for the center of the inlet drill hole is applied to the outside of the chamber body. A maximum of five gravity lines can be connected to the Z-type collection chamber. For arrangement see the top view on fig. 72. For installation of gravity lines into the sump of the Z-type collection chamber, a core driller of the correct size is required from Roediger Vacuum. The hole for the gravity line are not drilled, it has to be done on site. The holes (to be done locally) have to present the following diameters to fit the gaskets: NOTE: DN 200: 215 mm DN 150: 175 mm The core drill is not included with the collection chamber and has to be ordered separately. The core drill that can be purchased by Roediger Vacuum requires a hexagonal bit. As standard with each collection chamber Z-type a gasket DN200 is provided for the incoming gravity line, as option, this gasket can be replace by a DN 150 (please specify with your order). If you need more gaskets, they have to be ordered separately. Page 89 of 158

90 5.5 RoeVac Z-Type collection chamber fig. 72 Top view of the connection to gravity line for the Z-type collection chamber Page 90 of 158

91 5.5 RoeVac Z-Type collection chamber Keep to the angles of 33 and 60 as specified for the vacuum connection. Proceed as follows: 1. Drill the hole in the permissible position using a RoeVac drilling tool. Position the square bit so that a pipeline offset is excluded. 2. Debur and clean the hole. 3. Insert the RoeVac inlet pipe gasket without using anti seize agent. Check the seating of the gasket. 4. Thoroughly clean the RoeVac inlet gasket before mounting the pipe. 5. Coat the spigot end of the inlet pipe with a sufficient amount of anti seize agent and push the pipe into the inlet hole provided with the RoeVac inlet gasket by about mm. No articulating links are required between the RoeVac Z-type chamber and the inlet pipe. Page 91 of 158

92 5.5 RoeVac Z-Type collection chamber Securing the chamber body by means of in situ concrete To secure the chamber against floatation in-situ concrete must be placed around the outside of the chamber. Installation steps: 1. Insert the chamber body into the pit and partially backfill with non-binding building material. Grain size for round grain material 32 mm max., for edged grain material 16 mm max. fig. 73 RoeVac Chamber type Z: body, partially backfilled 2. Fit installation aid; insert drainage pipes and backfill with gravel up to the mark on the installation aid. fig. 74 RoeVac Chamber type Z: body with installation aid Page 92 of 158

93 5.5 RoeVac Z-Type collection chamber 3. Fill in in-situ concrete up to the desired height. fig. 75 RoeVac Chamber type Z: body with in-situ concrete filled in 4. Remove the installation aid after adequate setting time of the in-situ concrete. fig. 76 RoeVac Chamber type Z: Chamber body, secured fig. 77 Installation aid stocked on construction site Page 93 of 158

94 5.5 RoeVac Z-Type collection chamber Verification in the valve chamber Before closing the chamber please always verify that: The sensor plug is tightly connected The inspection connection valve is closed (see picture below) All yellow caps have been removed from the controller Mounting the cover fig. 78 Inspection connection valve (to be closed) Clean all sealing faces and the cover seal prior to assembly. 1. The cover and brim of the chamber top have tolerances. Insert the cover seal in the correct position. 2. Fix the cover on the collection chamber by closing the two locks. fig. 79 Locks on cover (open left / closed -right) fig. 80 Warning (arrow) on the bottom side of the Z-type chamber cover Page 94 of 158

95 5.5 RoeVac Z-Type collection chamber Tools The following tools are required for fault removal: Suction lance Suction hose with taper plug Tool for opening the service cover fig. 81 Suction lance and, suction hose with taper plug fig. 82 Tool (arrow) for opening the sump service cover Page 95 of 158

96 5.5 RoeVac Z-Type collection chamber Heavy traffic load Description Two types of collection chambers are available. Although identical in their outward appearance they differ in the installation devices, valves and controllers: Type Z 65: with the 65 mm (2.5 ) valve. Type Z 75: with the 75 mm (3 ) valve. The length of the chamber bottom part can be adjusted to the local conditions. The standard chamber has 3 ribs (3 segments) which corresponds to a standard height of 2,20 m. The chamber can be shortened at the ribs. One segment corresponds to a length of 20.3 cm. (see chapter ) The permissible traffic load of the cover is 40 t. Make sure adequate surface water drainage is provided between the chamber plastic cover and the heavy-duty street cover. Please consider the 4 drain pipes, see fig. 83 to fig Lateral ventilation pipe connections to the chamber There are two connections on the side of the chamber: Top connection The top connection is intended for ventilating the top chamber area. Bottom connection The bottom connection is intended to make the valve unit in the top chamber area flood proof, i.e. when the upper chamber area is flooded, the air reaches the controller through this connection directly from outside. The ventilation lines must be laid to the chamber with a constant slope to the valve chamber and lead away from the traffic load area, fastened properly and provided with ventilation caps. The height of the ventilation above the surface is dependent on the potential flood or snow circumstances on site. The ventilation pipe for the gravity incoming pipe must not be installed at a distance of more than10 m around the vertical axis of the valve chamber. The valve chamber ventilation pipe must not be installed at a distance greater than 6 m around the vertical axis of the valve chamber. Compare the installation drawings. Page 96 of 158

97 5.5 RoeVac Z-Type collection chamber Installation instructions traffic load D400 and flood proof Z 65 2,5 traffic load D400 and flood proof fig. 83 Type Z 65 2½, traffic load classification D400 and flood proof. Installation Page 97 of 158

98 5.5 RoeVac Z-Type collection chamber fig. 84 Type Z 65 2½, traffic load classification D400 and flood proof. Parts list Page 98 of 158

99 5.5 RoeVac Z-Type collection chamber Z 75 3 traffic load D400 and flood proof: fig. 85 Type Z 75 3, traffic load classification D400 and flood proof installation Page 99 of 158

100 5.5 RoeVac Z-Type collection chamber fig. 86 Type Z 75 3, traffic load classification D400 and flood proof. Parts list Page 100 of 158

101 5.6 RoeVac PE 50: Watervilla collection chambers 5.6 RoeVac PE 50: Watervilla collection chambers Description The RoeVac chamber PE 50 is specially designed for the collection of waste water from watervillas (holiday resort villas that are built above water). The installation of these chambers is below the walkways and can easily be done with three fixation devices (sleeves). It has a vacuum valve of 75mm 3. The specific design allows for ease of installation and maintenance from above. fig. 87 Picture of the collection chamber PE50 (watervilla) Page 101 of 158

102 5.6 RoeVac PE 50: Watervilla collection chambers fig. 88 Drawing of the collection chamber PE 50 (watervilla) Page 102 of 158

103 5.7 Specific measures for noise reduction 5.7 Specific measures for noise reduction In most applications, the standard Roediger Vacuum sewer equipment requires no additional noise reduction equipment. However, noise depends on many factors such as soil condition, installation depth, and distance to structural elements reflecting noise. As a rule of thumb the collection chamber should be at least 7m from a room where quiet is required. To reduce the noise from a collection chamber a special vent should be connected to the house drain line. (See the drawing below of measures for noise reduction). The special vent pipe DN 100 shall not exceed 3 to 4 m. The vent cap must be 30 cm above finished grade and as far as possible away from noise sensitive locations. For further details please contact your representative or Roediger Vacuum. A special plug for noise reduction in the collection sump can be supplied by Roediger Vacuum. fig. 89 Measures for Noise Reduction Page 103 of 158

104 5.7 Specific measures for noise reduction fig. 90 Picture of a noise reduction equipment Page 104 of 158

105 5.7 Specific measures for noise reduction 6. RoeVac Vacuum Valve Units The RoeVac valve unit, works solely on pneumatic (no electrical connection required) and consists of the RoeVac vacuum valve and the RoeVac controller. Both units are interconnected with small diameter tubing. The RoeVac valve units can operate in flooded conditions if they are connected to a breather pipe, which provides ventilation to atmosphere. Valve units can be installed in the both types of collection chambers (G and Z). Sumps are sized according to design volume. Vacuum isolation plugs (for chamber with a 65 mm 2,5 vacuum valve) or vacuum isolation balls (for chamber with a 75 mm 3 vacuum valve ) are provided to isolate chambers from the vacuum network. Page 105 of 158

106 6.1 Vacuum valve 65 mm 2,5 6.1 Vacuum valve 65 mm 2, Description The RoeVac vacuum valve model 65 mm is a diaphragm valves made of ABS. fig. 91 Picture of the vacuum valve 65 mm / 2,5 Page 106 of 158

107 6.1 Vacuum valve 65 mm 2, Drawing fig. 92 Drawing of the vacuum valve 65mm / 2,5 Page 107 of 158

108 6.2 Vacuum valve 75 mm Vacuum valve 75 mm Description The RoeVac vacuum valve model 75 mm is a pinch valve made of ABS. fig. 93 Picture of the vacuum valve 75 mm / 3 Page 108 of 158

109 6.2 Vacuum valve 75 mm Drawing fig. 94 Drawing of the vacuum valve 75 mm / 3 Page 109 of 158

110 6.3 KPS Standard controller 6.3 KPS Standard controller Description The RoeVac controller is made of fibre glass reinforced polyamide and mounted on the vacuum valve body by an attachment slide. Vacuum tubes connect the controller to the valve. The purpose of the RoeVac standard controller (38 mm) is to open the vacuum valve when the sump is filled and to evacuate it in one cycle, plus admit air into the system when the sump is empty. The functioning principle is that air pressure in the sensor tube increases as the sump fills and activates the controller when the air pressure is sufficient to trigger the controller. When the pressure in the sensor pipe falls, a timer in the controller keeps the valve open to admit air. When the time has elapsed, the controller interrupts the vacuum supply and transfers air to the vacuum valve. The vacuum valve closes and completes the evacuation cycle. The controller activates only when the vacuum strength exceeds -22 kpa. This limitation is factory set to avoid valve flutter, ensuring proper sewerage transport and air admittance into the vacuum lines. Which controller to use depends on the type of collection chamber Adjustments The opening time of the RoeVac valve unit is factory set to 5 seconds which is typical for a standard RoeVac collection chamber providing the correct air to liquid ratio in most operating conditions. It is possible to adjust the controller in order to optimise performance. This adjustment must only be done by Roediger trained technicians! Page 110 of 158

111 6.3 KPS Standard controller Tube connections The RoeVac standard controller has 4 tube connections (see the fig. 95 and fig. 96). From the bottom of the controller to the top, they are: U Connection for vacuum (Tube connection to vacuum intake plug) AV Connection for vacuum valve (Tube connection to the valve) A Connection to atmosphere (A tube is connected only if the valve unit has to operate in a submerged condition. In a normal application no tube is connected. Top-connection Connection to the sensor cap. fig. 95 Picture of the standard controller KPS Page 111 of 158

112 6.3 KPS Standard controller Drawing fig. 96 Drawing of the standard controller KPS Page 112 of 158

113 6.4 Assembling of the vacuum units (Vacuum valve and controller) 6.4 Assembling of the vacuum units (Vacuum valve and controller) The RoeVac valve unit consists of the vacuum valve and the standard controller (KPS). The installation in a collection chamber is done as follows. fig. 97 Vacuum valve unit (with a 65 mm valve) mounted in a G type collection chamber fig. 98 Vacuum valve unit (with a 75 mm valve) mounted in a G type collection chamber Page 113 of 158

114 6.4 Assembling of the vacuum units (Vacuum valve and controller) RoeVac vacuum valve The vacuum valve is connected to the chamber pipework via rubber couplings. Two standard hose clamps and two quick release clamps are supplied with the rubber couplings. Leave the quick release couplings open when attaching the valve to the rubber couplings. Attention: Please install the vacuum valve in the correct direction of flow! The arrows on the valve body have to point to the vacuum side (downstream). First connect the RoeVac vacuum valve with the straight rubber coupling to the service wye and then the rubber elbow to the suction pipe. Make sure the valve and couplings fit firmly. Then close the quick release clamps. Remove the vacuum isolation plug from the service wye and insert the vacuum intake plug. Attention: Check if there is vacuum in the supply tubing from the intake plug! RoeVac Standard Controller (KPS) Attention: Before installing the controller please remove all yellow protective caps! Mount the standard controller on the attachment slide of the vacuum valve body. If water has collected in the sump, it must be drained before connecting the sensor pipe. To manually drain the sump, bypass the controller and apply vacuum directly to the vacuum valve via the tubing from the vacuum intake plug. Stop manual draining when the sump is empty. Remove all debris (stones, dirt, etc.) from the sump. Connect all tubing to the valve unit and sensor pipe. Insert the condensate trap into the sensor pipe Connect the sensor cap on the sensor pipe as shown on the fig. 101 and fig. 102 Attention: Check all the tube connections for a tight seal. Leaking connections can lead to the valve unit malfunctioning Page 114 of 158

115 6.4 Assembling of the vacuum units (Vacuum valve and controller) Schematic representation of the assembling fig. 99 Schema of the 65 mm 2,5 valve unit: Tubing fig. 100 Schema of the 75 mm 3 valve unit with its vacuum buffer: Tubing Page 115 of 158

116 6.4 Assembling of the vacuum units (Vacuum valve and controller) Drawings fig. 101 Drawing of the RoeVac Valve unit (65mm / 2,5 ) Page 116 of 158

117 6.4 Assembling of the vacuum units (Vacuum valve and controller) fig. 102 Drawing of the RoeVac Valve unit (75mm / 3 ) Page 117 of 158

118 6.4 Assembling of the vacuum units (Vacuum valve and controller) Optional vacuum buffer for 3 vacuum valve unit Optionally for the vacuum valve unit 3 a vacuum buffer can be used. This vacuum buffer has to be used in particular cases. The engineers of Roediger Vacuum GmbH will indicate you the cases where you have to install them. For the installation instructions, please follow the two figures below. Also respect the indications on the buffer, the TOP side (indicated) has to be placed upwards in the valve chamber. fig. 103 Schema of the 75 mm 3 valve unit with its vacuum buffer: Tubing Page 118 of 158

119 6.4 Assembling of the vacuum units (Vacuum valve and controller) fig. 104 Drawing of the RoeVac Valve unit (75mm / 3 ) Page 119 of 158

120 6.4 Assembling of the vacuum units (Vacuum valve and controller) Additional important information Preventative Maintenance Every 4 to 5 years the membrane of the RoeVac vacuum valve 65 mm 2.5 should be changed,. Every 8 to 10 years the complete valve unit (vacuum valve and controller) should be overhauled. This is done at Roediger Vacuum GmbH in Germany. All rubber parts (diaphragms and seals) are replaced and the units are re-set and tested. Roediger offer an exchange program for RoeVac units. Page 120 of 158

121 6.4 Assembling of the vacuum units (Vacuum valve and controller) Manual operation of vacuum valve It is possible to manually operate the controller. The following procedure can be used, In the event this procedure does not work (e.g. if the tubing is too stiff), an inspection ball could be used as an air pump to create an overpressure in the sensor (top) connection of the KPS controller. fig Vacuum valve (Normal) The vacuum valve can be manually actuated by simulating the sensor pressure in two easy steps: Step 1: Pinch the tubing between sensor pipe and controller. fig Vacuum valve (sensor tubing manually bent) Step 2: Apply pressure on tubing between pinched section and controller. Because the controller is activated by the small increase in pressure, the valve will open. fig Vacuum valve (sensor tubing manually bent and pressed) Page 121 of 158

122 6.4 Assembling of the vacuum units (Vacuum valve and controller) Commissioning of RoeVac vacuum valve units in chamber When all collection chambers are placed in the ground and connected to the network, the vacuum valves should be placed in the chamber. The collection chambers are isolated by using the isolation plug, ball or caps, depending on the size of the vacuum valve units installed (compare the following pictures). fig. 108 A chamber G65 with its isolation plug fig. 109 Isolation plug (left), Isolation ball (centre) and isolation cap (right) For chambers G65 and Z65, use the isolation plug For chambers G75 and Z75, use either the ball or the caps fig. 110 Isolation of chamber G75 or Z75 Before installation every collection chamber must be cleaned. Make sure that all building debris brick fragments, tiles, forgotten tools, leaves, etc., have been removed as well as any debris that could block or damage the system. The chamber should be clean and dry with no standing water Page 122 of 158

123 6.4 Assembling of the vacuum units (Vacuum valve and controller) To connect RoeVac vacuum valve units in the valve chamber: Place the vacuum valve unit inside the collection chamber. fig. 111 Placing the vacuum valve unit in the valve chamber Connect all tubes and use hose clamps. Close 1 st release clamp. fig. 112 Connecting the vacuum valve unit to the tubes Close 2 nd release clamp fig. 113 Closing the 1 st clamp fig. 114 Closing the 2 nd clamp Remove the isolation plug, ball or caps and test the chamber with clean water by filling up the sump, either through the house drain line or direct into the sump. Depending on the vacuum strength, a liquid level between 20 and 40 cm in the sump causes activation of the RoeVac controller and opens the RoeVac valve. Page 123 of 158

124 6.4 Assembling of the vacuum units (Vacuum valve and controller) Decommissioning of RoeVac vacuum valve units Decommissioning of collection chambers should be considered if a chamber will not be used for a longer time or when a house connection needs to be isolated. For example: Collection chambers might have been already installed but the vacuum system is not operational. According to the schedule all the chambers have been placed in the ground but vacuum station will be built later When the collection chamber was delivered with pre-assembled vacuum valves (Z- type chamber). Following steps should be followed: Empty the sump by manually activating the valve 2 or 3 times Isolate the chamber from the network by the means of the isolation plug, ball or caps. Open 1 st release clamp Open the 2 nd release clamp. fig. 115 Opening the 1 st clamp fig. 116 Opening the 2 nd clamp Page 124 of 158

125 6.4 Assembling of the vacuum units (Vacuum valve and controller) Disconnect all tubes. fig. 117 Disconnecting the vacuum valve unit from the tubes Remove the vacuum valve unit out of the collection chamber. fig. 118 Removing the vacuum valve unit out of the valve chamber Replace the protection cover over the chamber. Page 125 of 158

126 7.1 General 7. Monitoring System for chamber (cable based) 7.1 General A monitoring system consists of the following: At the central vacuum station - Channel generator and Signal management mounted inside the electrical control panel. At the collection chamber: - Transfer cable to and from module (in the valve chamber) - Signal transfer module with enclosure (in the valve chamber) - Float switch with weight (in the sump of the collection chamber) - Vacuum valve with reed contact (in the valve chamber) fig. 119 Chamber monitoring system: overview Page 126 of 158

127 7.2 In-ground cabling 7.2 In-ground cabling Cable Types to be applied fig. 120 Cables to be applied for the monitoring system Each collection chamber is connected to the vacuum station via buried cables type NYY-J sizes 5 x 1.5 mm and/or 7 x 1.5 mm² for a network length of up to 6 km, depending on the number of chambers. In case of longer networks, a cross section of 2.5 mm² per each core shall be chosen due to the resistance of the cable. Furthermore, it is sometimes necessary to use signal boosters for long lines. The cable external diameter has to be between 9 and 17 mm to fit the standard threaded plastic connections. If a trenchless installation process is used, the cable can be cut with a length of approximately 50 cm inside each collection chamber. The cable should be installed continuously between the collection chambers with a minimum chamber to chamber installation length. Attention! The distance from the monitoring line to high voltage and heavy current lines must be a minimum of 30 cm! The use of buried cable sleeves is not allowed! Cable versions fig. 121 Cable version 5 x 1.5mm² and channel generator A cable of 5 x 1.5 mm² is suitable for connecting 2 lines including each max. 128 collection chambers (total 256) and one signal per collection chamber. fig. 122 Cable version 7 x 1.5mm² and channel generator A cable of 7 x 1.5 mm² is suitable for connecting 3 lines including each max. 128 collection chambers (total 384) at one signal per collection chamber. Page 127 of 158

128 7.2 In-ground cabling Cables placement Classical routing fig. 123 Placement along the vacuum line, from chamber to chamber Chambers with 2 cable entries The green dots in the figure on the left-hand side show the continuous connection of the chambers in one line. fig. 124 Example for cable placement to a chamber with 2 cable entries Chambers with 3 cable entries The dot in the figure on the left shows a distribution with one incoming (green) and 2 outgoing (blue) lines. fig. 125 Example for cable placement to a chamber with 3 cable entries Chambers with 3 cables entries on crossing Branching must be applied at the interfaces, according to the various branching on the vacuum lines. (See fig. 126) In this case a chamber including 3 cable entries is installed at two points causing a branching in several directions. fig. 126 Example for cable placement with branching Page 128 of 158

129 7.3 Cabling at the collection chamber Interference filter At the end of a long line, an interference filter (see picture below) has to be installed. This is to help prevent interference due to electrical fields which can also affect buried cabling, causing malfunctions and false signals. These malfunctions can be filtered out by means of the interference filter by up to 90 %. fig. 127 Picture of an interference filter The interference filter has to be connected to the BUS-Line in the last chamber of the line. 7.3 Cabling at the collection chamber Incoming Cable in the collection chamber Incoming Outgoing Incoming Outgoing Outgoing Page 129 of 158

130 7.3 Cabling at the collection chamber 2 cables into a collection chamber 3 cables into a collection chamber fig. 128 Cables in the collection chamber Different collection chamber entries Note: There are two different types of collection chambers for of either 2 or 3 cables. When ordering collection chambers including the monitoring system please indicate which type you require. Insert the incoming line cable into the collection chamber before inserting it into the terminal box through the upper threaded plastic connection. The cable shall be terminated after the Threaded Plastic Connection (M25) inside the terminal box. Tighten the Threaded Plastic Connection first inside the terminal box (M25) and next at the Threaded Plastic Connection (M25) at the collection chamber body. Insert the outgoing line(s) into the second (and third) Threaded Plastic Connection (M25) and follow the same procedure. Note: The outside diameter of the cable may vary. The contractor is requested to communicate the diameter to Roediger Vacuum, to ensure that the correct threaded plastic connections are supplied with each collection chamber. Standard Threaded connection is suitable for a cable of circular section only, with an external diameter between 9 and 17 mm. fig. 129 Threaded Plastic Connection Page 130 of 158

131 7.3 Cabling at the collection chamber Cabling inside the collection chamber body Installation of float switch Float switch cable Valve cable Balancing Weight fig. 130 Cabling inside the collection chamber and floating switch Push the cable for the float switch through the balancing weight (the PVC Threaded Plastic Connection shows upwards), until the vertical distance between the float switch and the weight is 5 cm. Then tighten the weight. Insert the float switch cable (2 wires) from the sump through the Threaded Plastic Connection (M16) into the collection chamber and then through the Threaded Plastic Connection (M16) to inside the terminal box. The float switch must be fixed at a height of 10 cm above the gravity inlet to the chamber. Please make sure that the cable ends are inside the terminal box. Afterwards, tighten the Threaded Plastic Connection inside the terminal box (M25) and then the Threaded Plastic Connection at the collection chamber sump lid. Attention: The monitoring Terminal Box is splash water proof only and should not be submerged (i.p. 67). Please pay attention to the rubber seal inside the threaded plastic connections and the enclosure. If the seals are lost, water can infiltrate into the box! Do not leave any of the thread connections open (i.e. end of line) and ensure all are securely tightened. Page 131 of 158

132 7.3 Cabling at the collection chamber Switch at the vacuum valve Installation of the RoeVac vacuum valve Insert the 2 wire cable connected to the RoeVac Vacuum Valve through the threaded plastic connection (M12) into the terminal box. Make sure that the cable ends are inside the terminal box. Tighten the threaded plastic connection at the terminal box (M12). Install the RoeVac vacuum valve in the collection chamber. fig. 131 General view of the vacuum valve 2.5, controller and monitoring system in the chamber Mounting the REED-switch on the RoeVac Vacuum Valve fig. 132 REED switch Installation of the RoeVac Vacuum Valve 3 The REED-switch is normally installed in the RoeVac vacuum valve before delivery, or will be installed on site, by screwing the reed switch into the valve housing. Attention: this is not possible for the 75 mm 3 valve. The mounting has to be done at Roediger. Install the RoeVac vacuum valve in the collection chamber. Insert the 2 wire cable which is connected to the RoeVac vacuum valve through the threaded plastic connection (M12) into the terminal box. Make sure that the cable ends are inside the terminal box. Afterwards, tighten the Threaded Plastic Connection at the terminal box (M12). fig. 133 Vacuum valve 3 installation into the collection chamber Page 132 of 158

133 7.3 Cabling at the collection chamber Mounting the REED-switch on the RoeVac Vacuum Valve 3 The REED-switch has to be installed on the RoeVac vacuum valve before delivery, with correct ordering article number. fig. 134 REED switch mounted on a vacuum valve Allocation of the sensor module fig. 135 Programmer for the sensor modules The sensor module is able to transmit 4 messages. The standard will be a centralised 3 messages to one signal, and it will be transmitted to the channel generator. The following failure signals activate the alarm: 1. Vacuum valve open (via reedswitch in vacuum valve) 2. High level in the collection sump (via float switch) 3. self-test- failure Every module will be assigned via a programming device one address, which will be scanned by the channel generator. A maximum of 128 signals can be converted per channel generator. Therefore a maximum of 128 collection chambers can be connected to one channel generator. Every 128 messages (= collection chambers) need two leads for one line. Every line has an address range for the modules from A1 to P8. The address sequence refers to 8 numbers per character, resulting in the cycle A1 to A8, and then B1 to B8 and so on. An accordant address is pre-assigned at the module, and is labelled on the topside of the module. Page 133 of 158

134 7.3 Cabling at the collection chamber It s important to make the addressing of the modules sequential! E.g.: If you have to install 20 modules they will correspond to the addresses A1 to A8, B1 to B8 and C1 to C4. Between the module addresses there shall be no spaces, which means no addresses (e.g. A4) missing. The predefined module numbers are given in the lists which are delivered with each system. Enter the street and the house number per line according to the module address. The allocation of the module within the vacuum network is not relevant. If a signal is missing longer than 60 sec. (time variable), the operator field will show a message on the control panel (Touchpanel), e.g. chamber monitoring failure 1016 On the basis of the message,,chamber monitoring failure 1016 the operator has to check the list, find which street and which collection chamber the failure belongs to, and then clear the failure at the collection chamber. Page 134 of 158

135 7.3 Cabling at the collection chamber Installation of Monitoring Module Module Clamp Dupline 8118 Brown Blue Grey White Green Yellow Pink fig. 136 Installation instruction of the monitoring module The monitoring module (Dupline 8118) is normally pre-programmed with an address and the module is pre-installed inside the terminal box.. The incoming and outgoing cables (incoming = from direction control panel or from the previous chamber, outgoing = towards next collection chamber) and the float switch as well as the reed switch inside the valve are installed inside the terminal box. Refer to the following terminal connecting plan. (fig. 137 for the 65 mm valve and fig. 138 for the 75 mm valve). After connecting the cables inside the terminal box and before closing it, use the PU-spray provided in order to protect the connections. Page 135 of 158

136 7.3 Cabling at the collection chamber fig. 137 Connection of the sensor module in the chamber for valve 65 mm (2,5 ) fig. 138 Connection of the sensor module in the chamber for valve 75 mm (3 ) IMPORTANT! The installation and the connection shall be only be done by an authorized person! Unused wire pairs have to be connected - at one spot in the chamber monitoring network they have to be connected to earth potential! Page 136 of 158

137 7.4 Cabling at the control panel of the vacuum station 7.4 Cabling at the control panel of the vacuum station Installation of Channel Generators fig. 139 Channel generator Profibus cable at PLC, right connection (axial Connector) fig. 140 Setup of the channel generator Channel generator setup: as shown in fig. 140 from left to right First switch (1 on fig. 140) into position P DIP-Switch (2 on fig. 140) at 1 = off; 2 = on; 3 = off; 4 = off Second switch (3 on fig. 140) into position 0 if you have less than 10 channel generators Third switch (4 on fig. 140) begins at address 3, and increased for each next channel generator Signals at the Channel Generator: fig. 141 Signals at the channel generator Green LED / Ready for service Voltage ok, Channel Generator operating Yellow LED / On line Dupline Bus Status - LED flashes if the Dupline- Module is wrongly connected or if there is a BUS- Failure (e.g. short circuit). Red LED / Fault Profibus-Status - LED illuminated if the Profibus connection has failed. Page 137 of 158

138 7.5 Amplifier for long Cable lengths and/or large numbers of Collection Chambers 7.5 Amplifier for long Cable lengths and/or large numbers of Collection Chambers fig. 142 Amplifier for long cable and typical street enclosures Amplifiers are used if the chamber monitoring system is loaded due to long cable lengths and/or large numbers of collection chambers. These amplifier units require on operational voltage of 24 VDC or 115 or 230 VAC (Please specify in your purchase order).the amplifier needs to be housed in a column with an individual power supply. Alternatively, it can be installed inside a building with an appropriate wall enclosure. The required quantities of amplifiers and their positions are provided specifically for your project by Roediger Vacuum. NOTE: The amplifiers need a local source of electric supply. The number of amplifiers and their positions are calculated by Roediger. A layout diagram showing all chamber and vacuum lines together with the amplifier positions is provided. Each signal amplifier is supplied with the adequate set of overvoltage protection modules. fig Overvoltage protection for signal amplifiers Page 138 of 158

139 7.5 Amplifier for long Cable lengths and/or large numbers of Collection Chambers Installation has to be carried out using the following guidelines. fig. 144 Installation concept for overvoltage protection Page 139 of 158

140 8.1 Preconditions for the installation of a vacuum station 8. Vacuum station 8.1 Preconditions for the installation of a vacuum station In order to ensure the correct electro-mechanical installation of the equipment in the Vacuum Station, the following conditions have to be met for both the inside and outside areas of the Vacuum Station: 1. Full access to the Vacuum Station and the collection tanks, i.e. the area is refilled up to the necessary levels. 2. Incoming three phase electricity supply terminated inside the building. 3. Electrical supply to Roediger control panel terminated and tested (Local regulations apply) all building services such as light, sockets etc. connected 4. Water supply (if required) connected (water-outlets, sinks etc.) 5. All floor/wall tiling works finished (including foundation works for the pumps). 6. Access to the basement with fixed stairs or fixed installed entrances (no ladders etc.). 7. Openings for assembly must be locked with security covers. 8. Mounting rails and hoists or cargo-hooks for lifting installed and tested. 9. Windows and doors installed and lockable. Vent stacks of 30 cm or more in size must be locked or equipped with the adequate grills. 10. The vacuum station must be clean and free of all building debris. 11. If the inside temperature can fall to below 5 C the station must be heatable (should be heated for at least 2 days previous). 12. During the time when our technicians are working on the premises it must be guaranteed that no other technicians from competitive firms are allowed inside the Vacuum Station. 13. The Vacuum Tank must be emptied and clean. 14. Painting works must be finished. 15. Access to the Vacuum Station in form of a hard-surface road. 16. Please provide us with digital photos of the Vacuum Station and surrounding areas prior to the arrival of the Roediger Technicians. We kindly ask you to thoroughly check the afore-mentioned preconditions. Only if all the conditions are fulfilled will our technicians arrive on site and start with the installation. In the event of the preconditions not being met, due to wrong statements and/or nonobservance of the conditions which prevent the installation from being started, we will unfortunately be forced to charge you any costs occurring, due to the time, manpower and expense involved. Page 140 of 158

141 8.2 Transport procedure and installation of vacuum vessels 8.2 Transport procedure and installation of vacuum vessels These instructions will help prevent damage to the external and internal vessel coating Unloading During transportation the tanks are to be kept on frames or racks with a sufficient large and soft footprint. Generally, the tank unloading from the forwarder s truck is, according to the contract, to be coordinated by the main contractor. In order to avoid damage to the external coating of the tank, unloading and uploading has to be done using tie rods or via lifting lugs (see photos below) and NOT with metal chains wrapped around the tanks. The entire unloading procedure has to be done with the utmost care and attention to detail Positioning and storage On site, before positioning into the pre-excavated pit, the tank (in case of a tank which has to be installed vertically) has to be brought from the horizontal into the vertical position. This procedure stresses the lower dished head. In order to protect the coating in this area, we recommend unloading onto soft subsoil (e.g. sand). In case the tank has to be stored for a long period prior to installation, the tank coating should be protected from direct UV radiation. (e.g. a cover sheet securely fixed over the tank). fig. 145 Arrival of the trucks with tank at a construction site Page 141 of 158

142 8.2 Transport procedure and installation of vacuum vessels fig. 146 Correct unloading from the truck by means of the 2 lifting lugs fig. 147 Correct unloading/positioning of the vessel via the lifting lugs fig. 148 Damage of external coating caused by use of chains Page 142 of 158

143 8.2 Transport procedure and installation of vacuum vessels Checks to the tank Visual check: In order to conform to warranty obligations, the tank must be visually inspected for any surface damage to the external coating by the site manager prior to positioning the tank in the ground Flanges: The sealing surfaces have to be checked at all welded flanges. It is imperative that all sealing surfaces have a constant coating thickness. In case of irregularities, these have to be removed by means of a scraper Flange rings of the dished ends: There are rotary flange rings on the top and bottom dished ends of the vertical vessels. In order to guarantee a rim-pull and watertight connection between the upper flange ring and the in-situ concrete (for buoyancy protection), the upper flange ring is not covered by an external coating Repair works: In case there is damage to the external coating, this need to be repaired. Before repairing the coating remove the loose bitumen layers with a scraper. Then apply a coating with a scraper or a thick brush (coating thickness µm). This layer should be left to harden for at least 24 hours. Usually one can of approximately 1 kg of external coating material will be sent with the vessel in order to allow small repairs to be carried out on site. Larger and more extensive damage should be only repaired by the supplier s staff. Page 143 of 158

144 8.2 Transport procedure and installation of vacuum vessels Tank installation In order to avoid buoyancy problems due to groundwater all buried tanks need to be encased by an upper concrete structure. For the design and the required concrete volumes please contact the consultant. During the installation of the vessel into the pit attention has be paid to ensure that damage does not occur to the vessel. The embedding of the entire tank casing is done by a 20 cm thick homogeneous sand layer. The depth of the pit needs to be prepared according to the invert level of the incoming vacuum main. The tank has to be positioned according to the correct layout position (see nozzle position in the Roediger layout drawings) and backfilled. Temporary protection against buoyancy during the construction period is possible by filling the tank with water. The tank should only be emptied after finishing the permanent buoyancy protection. Transportation lugs or any other additional welded parts have to be protected against corrosion prior to backfilling. Backfilling of the tank should only be done when all pipe connections are complete. During the pouring of the concrete precautions should be taken to ensure that the concrete does not come into contact with the outer coating of the tank. In order to avoid damage a protective foil must be placed between the tank wall and the backfilled concrete Mounting of the manhole pit onto the buoyancy protection concrete The consultant needs to verify if a swell seal is required between the concrete buoyancy protection and the manhole pit. This should be checked for all sealing surfaces beneath the existing ground water level. Page 144 of 158

145 8.2 Transport procedure and installation of vacuum vessels Works inside the tank Damage to the inner tank coating should be avoided. Therefore, during work inside the tank, work shoes/boots should be cleaned before entering the tank and the relevant areas on the tank bottom should be covered e.g. by cardboard. Penetrating, sharp-edged objects such as stones, construction gravel etc. should be removed prior to any work inside the tank being started. While positioning the discharge pumps in the vessel a soft, protective cover should be used. Minor damages at the inner coating should be repaired by means of a special 2 component-varnish (available throughout Roediger Vacuum GmbH). In case of major damages, proceed as described for the external coating and inform the manufacturer. In order to correspond to warranty obligations, it is necessary that the internal coating of the tank is visually checked by the site manager before commissioning. The entire tank surface has to be checked for surface damage or poor coating Norms DIN 6608 Parts 1 and 2 DIN 6607 DIN Part 3 TRbF 121/221 GW 9 (DVGW) Page 145 of 158

146 8.3 Bio-filter 8.3 Bio-filter Description of a bio-filter A bio-filter is usually composed of the following components: 1. Concrete structure 2. Gravel layer 3. Plastic pipes for air distribution 4. Air permeable fabric mat 5. Mulch layer As a result of airborne H 2 S within the vacuum pump exhaust, odour may be a concern at the site of the vacuum station. In these cases various methods for controlling odour (e.g.: activated carbon filter etc.) can be used. The type of odour control unit is decided by the client/consultant, this unit is usually not part of the Roediger Vacuum GmbH scope of supply. Roediger Vacuum GmbH normally recommends a bio-mass compost bed (= bio-filter), which is simply a bed of organic material (medium), typically a mixture of compost and wood chips or shreds, placed at different depths in a concrete structure. Air passes through the bio-filter and the microbes, adhering to the organic material, convert malodorous gases to carbon dioxide and water (leachate). Leachate from a bio-filter is not allowed to percolate into the ground. It must be collected and drained to the vacuum sewer system. In case direct draining through dedicated collection chamber is not feasible, the leachate can be evacuated using a collection tank. fig. 149 Picture of a bio-filter fig. 150 Picture of a bio-filter with protective cover Page 146 of 158

147 Sizing of bio-filters The effectiveness of the bio-filter is primarily a function of the amount of time the odorous air spends in the bio-filter (contact time) and the moisture of the filter material. Contact time is part of the bio-filter design while moisture content is a function of good management. The size (footprint) of the bio-filter depends primarily on the amount of air needing treatment. Usually RoeVac does not consider the Standby-pump in any calculation, that means e.g.: In case of a Vacuum Station with 3x Vacuum pumps with 250 m³/h each, the Suction capacity would be 2x250m³/h = 500m³/h. Only two pumps are taken into account because one is considered a standby. The design of the bio-filter should be done by the local consultant; however Roediger Vacuum GmbH can recommend examples of from existing projects. Suction capacity vacuum pumps 220 m³/h 220 to 440 m³/h 440 to 660 m³/h 660 to 880 m³/h 880 to 1100 m³/h Min. volume of biomass material 2.2 m³ 4.4 m³ 6.6 m³ 8.8 m³ 11.0 m³ Air pipeline DN 100 DN 100 DN 125 DN 150 DN 150 table 11 Typical bio-filter sizes depending on the total suction capacity Page 147 of 158

148 9.1 Start-up of the system 9. Important additional information 9.1 Start-up of the system In the setting-up phase (the phase direct after the end of the building time and before the first use of a system), it is a priority to clean the whole installation with sufficient quantities of water. The cleaning water should not be pumped out of the vacuum tank by the mean of discharge pump but by the mean of a suction truck in order not to damage the discharges pumps. The discharge pumps can only be started when the tank has been emptied Cleaning of every collection chamber Concrete fragments, forgotten tools, little metal pieces, etc., debris that could block or damage the system, must be removed from every collection chamber prior to testing Cleaning of the pipe network before the first start-up The vacuum sewer network must be completely flushed before commissioning to ensure that no construction debris or tools are in the vacuum pipe network. 30 litres of clean water per collection chamber is required Emptying of the vacuum tank After flushing, the vacuum tanks at the vacuum station should be cleaned manually to remove debris and avoid damage to the discharge pumps. Page 148 of 158

149 9.2 Storage of the delivered equipment 9.2 Storage of the delivered equipment Roediger Vacuum GmbH ensures delivery of the equipment to site. Often, the products such as pumps, tanks, etc. are on site for a period of time before installation. Particular care must be taken Delivery / Dispatch Please check that all deliveries are complete directly after arrival (see general conditions of sale and delivery - Roediger Vacuum ). In case of missing parts please contact forwarder responsible at Roediger Vacuum GmbH or local representative Mechanical and electrical equipment All equipment should be placed in a clean and dry area and covered at all times. Spares should also be kept inside and in a dry area. Pumps, tools and parts will rust if they are not properly stored. It is also recommended that spare parts be kept wrapped. fig. 151 Good storage of the control panel Page 149 of 158

150 9.3 As-built drawings Vacuum Valves and controller Keep valves and controllers in their boxes in a clean and dry area during storage. In order to minimize storage costs the delivery should be scheduled according to progress on site. Long storage periods should be avoided if possible Collection chambers fig. 152 Good storage of the vacuum valve and controllers Keep the collection chambers in its transport packing on stable ground in a clean and fenced area, fig. 153 Good storage of the collection chambers 9.3 As-built drawings All as-built drawings (layout plan and length profiles with pipe invert levels) must be sent to Roediger Vacuum GmbH, Hanau (Germany) and/or its local representative. Page 150 of 158