Ama r -Drainer-Box. Betriebsanleitung /2-90. ab Serie S-K from series S-K à partir de série S-K Vanaf serie S-K

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1 Betriebsanleitung /2-90 Ama r -Drainer-Box Automatische Schmutzwasser-Hebeanlage für Unter-/Überfluraufstellung Automatic Waste Water Lifting Unit for Underfloor/ Above-floor InstallationAutomatic Poste de relevage automatique pour eaux usées pour installation sur sol ou enterrée Automatische vuilwateropvoerinstallatie voor onder- en bovenvloeropstelling ab Serie S-K from series S-K à partir de série S-K Vanaf serie S-K Betriebsanleitung Diese Betriebsanleitung enthält wichtige Hinweise und Warnvermerke. Bitte vor Einbau, elektrischem Anschluß und Inbetriebnahme unbedingt lesen. Weitere Betriebsanleitungen, die Komponenten dieses Aggregates betreffen, sind zusätzlich zu berücksichtigen. Diese Betriebsanleitung soll in der Nähe der Anlage aufbewahrt werden. Notice de service Cette notice de service contient des informations et mises en garde importantes. Avant l installation, le branchement électrique et la mise en route, lire impérativement ce document et observer aussi les notices éventuelles fournies avec les composants du groupe. Conserver ce document à proximité du poste de relevage. Operating instructions These operating instructions contain fundamental information and precautionary notes. Please read the manual thoroughly prior to installation of unit, connection to the power supply and commissioning. It is imperative to comply with all other operating instructions referring to components of this unit. This manual shall always be kept close to the unit s location of operation. Bedrijfsvoorschrift Dit bedrijfsvoorschrift bevat belangrijke aanwijzingen en waarschuwingen. Wij vragen u dringend dit bedrijfsvoorschrift voor het inbouwen, de elektrische aansluiting en het in bedrijf nemen te lezen. Er dient bovendien rekening te worden gehouden met de overige bedrijfsvoorschriften, die betrekking hebben op de componenten van dit aggregaat.

2 Inhaltsverzeichnis Seite Sommaire Page 1 Allgemeines 3 2 Sicherheit 3 3 Transport, Zwischenlagerung 4 4 Beschreibung von Erzeugnis und Zubehör 4 5 Aufstellung/Einbau 4 6 Inbetriebnahme / Außerbetriebnahme 8 7 Wartung/Instandhaltung 9 8 Störungen/Ursachen und Beseitigung 10 9 Zugehörige Unterlagen 11 1 Généralités 33 2 Sécurité 33 3 Transport et stockage temporaire 34 4 Description du produit et des accessoires 34 5 Installation et montage 34 6 Mise en service / Mise hors service 38 7 Entretien 39 8 Incidents, causes et remèdes 40 9 Documentation annexe 41 Contents Page INHOUDSOPGAVE Pagina 1 General 18 2 Safety 18 3 Transport and Interim Storage 19 4 Description of the Product and Accessories 19 5 Installation at Site 19 6 Commissioning / Shutdown 23 7 Servicing / Maintenance 24 8 Trouble-shooting 25 9 Relevant Documentation 26 1 Algemeen 48 2 Veiligheid 48 3 Transport en tussentijdse opslag 49 4 Beschrijving van het aggregaat en toebehoren 49 5 Opstelling/Inbouw 49 6 In bedrijf nemen/uit bedrijf nemen 54 7 Service/onderhoud 54 8 Storingen/oorzaken en opheffen 55 9 Bijlagen 56 2

3 1 General This KSB unit has been developed in accordance with state-ofthe-art technology; it is manufactured with utmost care and subject to continuous quality control. These operating instructions are intended to facilitate familiarisation with the unit and its designated use. The manual contains important information for reliable, proper and efficient operation. Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the unit and to avoid any risks. These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel called in for installation. This unit must not be operated beyond the limit values for the medium handled, capacity, speed, density, pressure, temperature and motor rating specified in the technical documentation. Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation. The name plate indicates the type series / size, main operating data and works / serial number; please quote this information in all queries, repeat orders and particularly when ordering spare parts. If you need any additional information or instructions exceeding the scope of this manual or in case of damage please contact KSB s nearest customer service centre. 2 Safety These operating instructions contain fundamental information which must be complied with during installation, operation and maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible trained personnel / operators prior to installation and commissioning, and it must always be kept close to the location of operation of the machine / unit for easy access. Not only must the general safety instructions laid down in this chapter on Safety be complied with, but also the safety instructions outlined under specific headings. 2.1 Marking of Instructions in the Manual The safety instructions contained in this manual whose non-observance might cause hazards to persons are specially marked with the general hazard sign, namely safety sign in accordance with ISO The electrical danger warning sign is safety sign in accordance with IEC besonders gekennzeichnet. The word Caution is used to introduce safety instructions whose non-observance may lead to damage to the machine and its functions. Instructions attached directly to the machine, e.g. -- arrow indicating the direction of rotation -- markings for fluid connections must always be complied with and be kept in a perfectly legible condition at all times. 2.2 Personnel Qualification and Training All personnel involved in the operation, maintenance, inspection and installation of the unit must be fully qualified to carry out the work involved. Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question is not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer / supplier to take care of such training. In addition, the operator is responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel. 2.3 Non-compliance with Safety Instructions Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine / unit itself. Non-compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages. In particular, non-compliance can, for example, result in: -- failure of important unit functions, -- failure of prescribed maintenance and servicing practices, -- hazard to persons by electrical, mechanical and chemical effects, -- hazard to the environment due to leakage of hazardous substances. 2.4 Safety Awareness It is imperative to comply with the safety instructions contained in this manual, the relevant national health and safety regulations and the operator s own internal work, operation and safety regulations. 2.5 Safety Instructions for the Operator / User -- Any hot or cold components that could pose a hazard must be equipped with a guard by the operator. -- Guards which are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed whilst the unit is operating. -- Leakages (e.g at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to avoid any danger to persons and the environment. Pertinent legal provisions must be adhered to. -- Electrical hazards must be eliminated. (In this respect refer to the relevant safety regulations applicable to different countries and / or the local energy supply companies.) 2.6 Safety Instructions for Maintenance, Inspection and Installation Work The operator is responsible for ensuring that all maintenance, inspection and installation work be performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual. Work on the machine / unit must be carried out only during standstill. The shutdown procedure described in the manual for taking the unit out of service must be adhered to without fail. Pumps or pump units handling media injurious to health must be decontaminated. 18

4 Immediately following completion of the work, all safety-relevant and protective devices must be re-installed and / or reactivated. Please observe all instructions set out in the chapter on Commissioning / Start-up before returning the unit to service. 2.7 Unauthorized Modification and Manufacture of Spare Parts Modifications or alterations of the equipment supplied are only permitted after consultation with the manufacturer. Original spare parts and accessories authorised by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer for consequential damage. 2.8 Unauthorized Modes of Operation The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance with its designated use. The limits stated in the data sheet must not be exceeded under any circumstances. 3 Transport and Interim Storage 3.1 Transport Single-lifting Unit Underfloor Box 32/40 The unit is supplied in 4 individual units. -- Tank with interstage casing, provisional cover, discharge pipe with return stop, floor drain and odour trap -- Pump with cable and shockproof plug or CEE plug -- Cover (flush or recess plate) -- Connection set Dual Lifting Unit - Underfloor Box Z 32 The dual unit is supplied ready for connection and comprises the following components: -- Tank with interstage casing, provisional cover, two submersible motor pumps starting and stopping automatically which feature an integrated swing check valve, a floor drain and an odour trap -- Cover (flush or recess plate) -- Switchgear for dual units Inspect the units for transport damage prior to assembly and installation. 3.2 Interim Storage The unit should be stored in a dry, dark, frost-proof room not exposed to sunlight. 4 Description of the Product and Accessories 4.1 Technical Specification KSB waste water lifting units are designed to collect and automatically lift waste water without faeces above the backwash level. Caution is not suitable for sewage from urinals and toilets. For these applications please use our Ama-Lift, Ama- Sani, mini-compacta/compacta sewage lifting units. Caution Substances / water which must not be discharged are, a.o.: F Solid matter, fibres, tar, sand, cement, ash, coarse paper, cardboard, debris, garbage, offal, grease or oil (DIN ). F Waste water from sanitary installations situated above the backwash level (EN ). F Waste water containing greasy substances (DIN ), e.g. greasy waste water from large-scale catering establishments. For drainage of greasy water, a grease separator to DIN must be fitted. 4.2 Designation Example of a complete. Ama-Drainer- Box Z 1 2 Type series Collecting tank Z = Dual unit Cover variant Code number for Ama-Drainer (here Ama-Drainer 301.1) 4.3 Underfloor Box 32 / 40 Impact-resistant plastic collecting tank of PE-LLD with submersible motor pump starting and stopping automatically and swing check valve, two suction nozzles arranged at an angle of 90 o, vent nozzle and discharge nozzle. Cover with vertically adjustable interstage casing for levelling purposes. Cover plate at customer s choice as flash plate or recess plate for tiled floors. Both designs include floor drains and odour traps. 4.4 Underfloor Box Z 32 Ready-to-connect dual unit with two submersible motor pumps starting and stopping automatically. Discharge line within the collecting tank, completely assembled with swing check valves and connection parts. Cover with vertically adjustable interstage casing for levelling purposes. Switchgear and float switch for automatic alternate, standby and peak load operation. Plastic plate as tank cover with screwed cable gland for power supply cables. 4.5 Above-floor Box 32 / 40 Single-piece, impact-resistant plastic collecting tank of PE-LLD with submersible motor pump starting and stopping automatically and swing check valve, two suction nozzles arranged at an angle of 90, vent nozzle and discharge nozzle. 4.6 Accessories Accessories can be ordered from our sales units. F Level-adjusting piece, 200 mm, to increase the installation depth F KSB alarm switchgears AS 0, AS 2, AS 4 and AS 5 F M 1 alarm contactor for KSB alarm switchgears 5 Assembly / Installation at Site 5.1 Safety Regulations F Your electrical installation must be in accordance with VDE 0100/IEC 364; i.e, the sockets must have earthing terminals for example. F Connection to the power supply must be effected by a trained electrician only. The applicable VDE regulations must be complied with. F The supply mains to which the unit is connected must be equipped with a highly sensitive earth leakage circuit breaker <30 ma. F Please observe the relevant DIN VDE 0100, Part 701, stipulations when installing the unit in bathrooms and shower facilities. F In the case of three-phase current the external protection equipment should always have three poles and an interlocking device. This will ensure complete separation from the mains and prevent the unit from running on two phases only. F All electrical equipment such as switch box, alarm transmitter and socket must be installed in a dry, floodproof location. 19

5 F Caution! Switch off the pump prior to each assembly and dismantling of the pipelines or any other work on the unit. F If you use an extension cord, please see to it that it is of the same quality as the power supply cable supplied. F Keep unauthorized persons (e.g. children) away from the unit. Caution Please observe the stipulations of EN Gravity drainage systems in buildings when installing the unit at site. Caution It is imperative to comply with all other operating instructions referring to components of this unit. Remove transport locks, if applicable. Discharge line for 40 (see section 9.6) Interstage casing 113 can be removed to facilitate installation. Pipes 1 and 2 to be found in tank 591 shall be used for the discharge line. Loosen sheet metal screw and introduce special pipe part 720 into elbow as far as it will go. Firmly screw pipe 2 with joint ring from outside through the Ø 49 hole (after removing the plug from the tank) into the elbow of pipe 1 (see Illustration 1). Connect the DN 40 discharge line (outside pipe diam. 50) using flexible tube 719 and hose clip 733 and lay it with a slightly rising slope. Fastening of leveladjusting piece Suction line 5.2 Checks to Be Carried out Prior to Installation Caution A closed concrete pan must be provided in areas with pressing ground water. All structural work required must have been prepared as illustrated in section 9.1 Installation Instructions. Make sure the installation is frost-proof. Caution No driving on the! 5.3 Tank Above-floor Box 32 / 40 (with Plastic Plate) Place the tank on the delivered rubber buffers and secure it to the floor by means of steel hoops to prevent it from lifting. After determining the inlet, remove the corresponding connection nozzle cover by means of a saw or right-angle grinder and connect the inlet opening to the suction line using commercial connection elements (see section 9.1.2). Refer to section 5.4 for further instructions on installing the discharge pipe. Remove the tank cover (plastic plate) and install the submersible motor pump in acc. with 5.5 or 5.7. The submersible motor pumps with a.c. motors are equipped with shock-proof plugs; the variants with three-phase motors feature CEE plugs. Prior to introducing the cable into the cable duct, the relevant plug must be removed. In the case of three-phase motors, the cable of the float switch must also be inserted into the cable duct. Connection of a new shock-proof plug or CEE plug must be effected by an electrician only (see section 5.9). 5.4 Tank Underfloor Box 32, Z 32, 40 (with Provisional Cover) Place the complete tank 591 with interstage casing 113 on an underlayer of gravel and backfill as illustrated in section Unfinished State. After determining the inlet, remove the corresponding connection nozzle cover by means of a saw or right-angle grinder and connect the inlet opening to the suction line using commercial connection elements, e.g. parts without sockets (see section 9.1.2) Discharge line for 32, Z 32 (see sections 9.4 and 9.5) Connect the DN 32 discharge line (outside pipe diam. 40) using flexible tube 719 and hose clip 733 and lay it with a slightly rising slope. Pipe 1 Vent pipe Pipe 2 Discharge line Cable duct Illustration 1 Note: With its water column above the integrated check valve, the unit itself constitutes an odour trap towards the sewer. Therefore the tank inlets connected do not require any odour traps, nor must the Ama-Drainer Underfloor Box be equipped with a vent pipe. The odour trap will only be used if the discharged liquid itself is malodorous. If not, the 180 o bend will be separated at 90 o to serve as inlet. If all inlets are equipped with odour traps, a vent pipe has to be connected to the otherwise closed vent nozzle in order to avoid that the odour traps are completely drained. Cut off the vent nozzle cover and connect the vent pipe by means of commercial connection elements, laying it with a slightly rising slope. If the pump power supply cable is not run through the vent pipe, lay the cable duct with a slightly rising slope towards the socket. Sharp bends of the cable duct must be avoided. After connecting all lines and before backfilling with concrete the necessary precautions must be taken to avoid warping of tank 591. It is particularly important to make sure that the tank bottom is level. To this effect, fill the tank with water and introduce interstage casing 113 into the tank in the required position. The interstage casing at the collecting tank can be continuously turned by 360 o (adjustment to the tile structure) and permits to compensate for level differences of up to 100 mm. Check and verify fit of O-ring between tank and interstage casing. To benefit from this feature the site operator must provide for a shuttering of 550 mm diam. for the interstage casing before any further backfilling takes place. See also section Lay the screed / tile the floor up to the upper edge of the interstage casing. Make sure that no filler penetrates into the space between frame /.2 and pump foot pad 892 (cover plate 68-3). After completion of the carcass work, remove the provisional cover of the tank and screw the cover plate supplied onto the interstage casing (see section 5.8). 20

6 5.5 Submersible Motor Pump for 32 with Installation Kit For variants, see sections to (see illustration in section 9.4). Separate the discharge line installed in tank 591 between delivery suspension pipes and by loosening screw Screw delivery suspension pipe including return stop 854 into joining pipe of pump Loosen union nut Place pump with discharge line into the tank. Slide delivery suspension pipe into and secure them both using screw Level up, if required, by turning pipe union 731. Now turn pump to the left until it almost touches the tank wall (thus permitting free movement of the float arm) and firmly tighten union nut Once the union nut has been firmly tightened it must be impossible to move the pump any further. If the pump can still be moved, the pump discharge nozzle and pipe union 731 have to be sealed by means of suitable sealing material (e.g. teflon tape). The submersible motor pumps are equipped with a shock-proof plug. Prior to introducing the cable into the cable duct, the relevant plug must be removed. Connection of a new shockproof plug must be effected by a trained electrician only (see also section 5.8). A free cable length of approx. 1 m should always remain in the tank to permit lifting the pump out of the tank for servicing. Please make sure that the cable will not get caught at the float arm with Ama-Drainer 324 SE (see illustration in section 9.4) On Underfloor Box with Ama-Drainer 324 SE, remove socket 73-1 with swing check valve. The float fitted must be replaced with float 74-4 from the installation kit. For further details regarding assembly, see section 5.4. Tank 591 without interstage casing 113 Float 74-4 Vent pipe Illustration 4 Cable duct Suction line Ama-Drainer F 324, 301, 303 Discharge line with Ama-Drainer 301 SE (see illustration in section 9.4) On Underfloor Box with Ama-Drainer 301 SE, remove socket 73-1 with swing check valve. Take joining pipe (120 mm long) from the installation kit and screw it onto the pump discharge nozzle as far as it will go. For further details regarding assembly, see section 5.4 (for installation, see Illustration 4). Illustration 2 Ama-Drainer 324 SE Take joining pipe (70 mm long) from the installation kit and screw it onto the pump discharge nozzle as far as it will go. Separate the lower threaded part of the discharge line, which has been dismantled as described in section 5.4, at pipe union 731 (above the octagon, see Illustration 3). Screw union nut and pipe union into joining pipe. Illustration separate here with Ama-Drainer 303 SE (see illustration in section 9.4) On with Ama-Drainer 303 SE, remove socket 73-1 with swing check valve. Take joining pipe (120 mm long) from the installation kit and screw it onto the pump discharge nozzle as far as it will go. Separate the lower threaded part of the discharge line, which has been dismantled as described in section 5.4, at pipe union 731 (above the octagon, see Illustration 3). Screw union nut and pipe union into joining pipe. For further details regarding assembly, see section 5.4 (for installation, see Illustration 4). 5.6 Submersible Motor Pump for Z 32 (completely assembled) (see illustration in section 9.5) The mechanical components of Underfloor Box Z 32 are completely assembled. Pull pump power supply cables together with float switch plugs and cables through the vent pipe. Have a trained electrician effect connection to power supply in accordance with the circuit diagram. A free cable length of approx. 1 m should always remain in tank 591 to permit lifting pump out of tank for servicing. Please make sure that the cable will not get caught at float switch

7 5.7 Submersible Motor Pump for 40 with Installation Kit tion 1). Tighten union nut and sheet metal screw (see Illustration 7). (see illustration in section 9.6) For preliminary work, see sections to Remove handle 576 on pump by loosening cap nut 920 and disc 550. If required, pull the float switch (81-45) cable out of the handle eyelet (see Illustration 5) prior to removing the handle. 2331:9002 Illustration 7 Turn the float switch cable in clamp so that the flat side of the float floats on the water surface. Check whether the float switch can move freely and compress the clamp to lock the cable in its final position. To correct the float switch position, loosen the fixing of the cable in the clamp. To do so, lift off one half of the clamp using a flat screwdriver (see Illlustration 8). Illustration 5 Fix holder 732 from installation kit 99-7 as well as handle by means of the stay bolts, so as to ensure that the float switch cable runs behind the holder (see Illustration 6). Position the handle and retighten both cap nuts. 2331:9003 Illustration :9001 Illustration 6 Place pump with pipe 710 into the tank. Place joint ring between pipe and special pipe part 720. Effect level adjustment in elbow through sliding fit of special pipe part 720. Slightly screw on union nut Turn the pump anticlockwise until it almost touches the tank wall (see Illustra- 22 The submersible motor pumps with a.c. motors are equipped with shockproof plugs; the variants with three-phase motors feature CEE plugs. Prior to introducing the cable into the cable duct, the relevant plug must be removed. Connection of a new shockproof plug (not included in the scope of supply) or new CEE plug must be effected by a trained electrician only (see also section 5.8). A free cable length of approx. 1 m should always remain in the tank to permit lifting the pump out of the tank for servicing. Fasten the extra cable length at the handle / pipe using cable tie Please make sure that the cable will not get caught at the float switch (see Illustration 9).

8 5.7.3 with Ama-Drainer A 5.. S./10 K (with Cooling Jacket, Particle Size 10) Take pipe 710 (90 mm long) from installation kit Use a suitable sealing material (e.g. teflon tape) to seal the thread. Screw the pipe into the pump discharge nozzle by turning it approx. 8 times (see Illustration 6). Take holder assembly 732 from the installation kit. Slightly fix float switch (81-45) cable in clamp at a distance of 200 mm from the float switch end (see Illustration 10). Illustration : with Ama-Drainer A 4.. S./10 (without Cooling Jacket, Particle Size 10) Take pipe 710 (290 mm long) from installation kit Use a suitable sealing material (e.g. teflon tape) to seal the thread. Screw the pipe into the pump discharge nozzle by turning it approx. 8 times (see Illustration 6). Take holder assembly 732 from the installation kit. Slightly fix float switch (81-45) cable in clamp at a distance of 200 mm from the float switch end (see Illustration 10). 5.8 Tank Cover Tank Cover Underfloor Box 32 / 40 If the tank (inlet) is not vented, it must be connected to a vent pipe (see note in section 5.4) Tank Cover Underfloor Box 32, Z 32, 40 (see illustration in section 9.4) The tank cover is availalbe as either flush plate or recess plate, each provided with a floor drain. A 180 o bend to serve as odour trap is supplied with the tank cover. It will only be installed in vented tanks since otherwise the pump would not operate properly or the drain traps would be completely drained. When placing cover plates 68-3/.1/.2 on the tank do not forget to fit gaskets 400.2/.3! No driving on the! Illustration with Ama-Drainer A 4.. S./35 (without Cooling Jacket, Particle Size 35) Take pipe 710 (230 mm long) from installation kit Use a suitable sealing material (e.g. teflon tape) to seal the thread. Screw the pipe into the pump discharge nozzle by turning it approx. 8 times (see Illustration 6). Take holder assembly 732 from the installation kit. Slightly fix float switch (81-45) cable in clamp at a distance of 180 mm from the float switch end (see Illustration 10). 5.9 Connection to Power Supply Connection to the power supply must be effected by a trained electrician only (see 5.1)! Voltage and frequency must correspond to the data on the pump name plate. Protect the power supply cable (see also annexed pump operating instructions). The pumps are supplied with power supply cable and shockproof plug (1~230 V) or CEE plug (3~400 V) and are ready for connection. A shockproof socket or CEE threephase current socket must be provided for connectingthe pump. Plug/socket or switchgear are not floodable. They must be installed in a dry location! Effect connection to the power supply in accordance with the pump operating instructions. Check the direction of rotation of pumps with three-phase motor. Functional test After the pump has been installed in the tank, qualified specialist personnel must carry out a functional test on the Ama-Drainer Underfloor Box. 6 Commissioning, Start-up / Shutdown For commissioning, start-up / shutdown, the operating instructions Ama-Drainer submersible waste water pumps and if required the switchgear operating instructions must be complied with. They are supplied with the individual components. 23

9 Note: Leakage of the medium handled at vent hole 5B is a normal event. The operating instructions of submersible motor pumps Ama-Drainer 4../5.. describe where the vent holes are located. On 40 with Ama-Drainer A 4.. S./10 and A 4.. S./35, pipe 710 features an additional vent hole (see Illustration 11). Illustration 11 Do not close vent hole 5B 7 Servicing / Maintenance 7.1 General Instructions The operator is responsible for ensuring that all maintenance, inspection and installation work be performed by authorized, qualified specialist personnel who are thoroughly familiar with the manual. A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the unit with a minimum of maintenance expenditure and work. Work on the unit must only be carried out with the electrical connections disconnected. Make sure that the unit cannot be switched on accidentally. Pumps handling liquids posing health hazards must be decontaminated. 7.2 Servicing / Inspection DIN stipulates that drainage systems must be serviced and maintained so as to ensure that waste water can be properly discharged and changes be detected and remedied at an early stage. Operating reliability will be improved by regularly checking the pump s proper functioning. From time to time the tank interior should be checked for deposits mainly in the float switch area and cleaned, if required. EN and -4 stipulate that the unit shall be serviced by suitably trained personnel only. The servicing intervals should not exceed: 1. 1 / 4 year for units installed in industrial businesses 2. 1 / 2 year for units installed in multiple dwelling buildings 3. 1 year for units installed in single-family houses Maintenance Contract For all inspection and servicing work to be carried out at regular intervals we recommend to take out the maintenance contract offered by KSB. Get in touch with your Service Partner for details. 7.3 Dismantling / Reassembly Dismantling and reassembly must always be carried out in accordance with the relevant drawings. The drawings and other relevant documents are found in the annex. The dismantling / reassembling sequence can be derived from the drawings. For dismantling / reassembly of the submersible motor pumps the pump operating instructions must be complied with. In case of damage you can always contact our service departments. 7.4 Spare Parts It is not necessary to keep spare parts on stock. In the case of damage please refer to the service centre directory attached. 24

10 8 Trouble-shooting A B C D E Key Key Pump is running, but does not deliver Pump delivers insufficient flow rate Excessive current/power input Insufficient discharge head Vibrations and noise during pump operation Cause Remedy The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. Disconnect the pump from the power supply and let it cool down before working on it. 1 D D Pump is running in the off-design range (low flow/overload). Check the pump s operating data. 2 D D Pump intake clogged by deposits. Clean the intake, pump components and non-return valve. 3 D D D Supply line or impeller clogged. Remove deposits in the pump and/or piping. 4 D D Dirt / fibres in the clearance between the casing wall and impeller, sluggish rotor. Check whether the impeller can be easily rotated; clean the hydraulic system, if required. 5 D D D D Wear of internal pump parts. Replace worn components by new ones. 6 D D D Defective riser pipe (pipe and seal elements). Fit new riser pipes. Fit new sealing elements. 7 D D D Wrong direction of rotation (in case of 3 ~) Interchange two of the phases of the power supply cable. 8 D D Pump clogged by sand, dirt in the tank, insufficient inflow. Clean the intake, strainer, pump components and swing check valve; drain and clean the tank. 9 D The temperature switch monitoring the winding has tripped the pump because of excessive temperature rise in the winding. The motor will restart automatically once the unit has cooled down. After repeated tripping, the unit must be checked. 10 D D Deposits in the collecting tank. Clean the collecting tank; in case of greasy deposits, fit a grease separator. 11 D Swing check valve does not close. Clean swing check valve. 12 D Defective CEE plug / switchgear. Check CEE plug / switchgear; see pump or switchgear operating instructions. 13 D Defective float switch; dirt or fluff block the float. Check the float switch, clean the float. Caution: Before opening the pump unit within the warranty period please always consult the manufacturer. Disregard of this warning will lead to forfeiture of any and all rights to claims for damages. 25

11 9 Relevant Documentation 9.1 Installation Instructions Underfloor Unfinished State Finished State Cablewithplug Cable duct Vent pipe DN 70 Vent pipe DN 70 Flush plate cover variant with floor drain Recess plate cover variant with floor drain Discharge line DN 32 / DN 40 Provisional cover Discharge line DN 32 / DN 40 Screed Tiles Screed Concrete Concrete Shuttering Concrete Concrete Concrete Suction nozzles arranged at an angle of 90 to each other Concrete Suction nozzles arranged at an angle of 90 to each other Underlayer of gravel Underlayer of gravel Soil Soil 9.2 Installation Schematic of Single Underfloor Unit Vent pipe Backwash level Discharge line In case of water levels above the backwash level, a gate valve should be installed on the discharge side. 26

12 9.3 Outline Drawing Above -floor Box 32 / 40 Discharge nozzle Inlet Inlet Discharge nozzle Venting Inlet A 2x DN 100/70, graded, arranged at an angle of 90 (outsideø 110/78 mm, e.g. for parts without sockets) Discharge side C Box 32, Box Z 32 (with hose piece insideø 40) Box 40 (with hose piece insideø 50) Venting D DN 70 (outsideø 75 mm) Cover plate H 11 mm for flush plate 26 mm for recess plate 27

13 Above -floor Box 32, Z 32, 40 Standard with level-adjusting piece Single Unit Box 32 Inlet PG 21 cable gland for cable duct BC DIN for single units only Venting Discharge nozzle Dual Unit Box Z 32 Single Unit Box 40 Inlet Inlet Venting and cable duct Discharge nozzle Venting Discharge nozzle Inlet A 2x DN 100/70, graded, arranged at an angle of 90 (outsideø 110/78 mm, e.g. for parts without sockets) Discharge side C Box 32, Box Z 32 (with hose piece insideø 40) Box 40 (with hose piece insideø 50) Venting D DN 70 (outsideø 75 mm) and cable duct for Box Z 32 Cover plate H 11 mm for flush plate 26 mm for recess plate 28

14 9.4 Exploded View and List of Components [411.4] 99-6 Part No. Description 113 Interstage casing 139 Suction elbow 13-4 Inlet screen 400.2/.3 Gasket Joint ring O-ring Disc 591 Tank, complete 68-3/.1/.2 Cover plate Delivery suspension pipe 719 Flexible tube Joining pipe 731 Pipe union 73-1 Socket 733.1/.2 Hose clip Pump ) Plate 826 Cable gland stuffing box 854 Return stop 892 Pump foot pad Frame Countersunk head screw ) Sheet metal screw 903 Screwed plug 914 Socket head cap screw Hex. nut Nut Union nut 1 ) Not illustrated in the sectional drawing [ ] Supplied in packaging units only ( ) Not available as individual spare part 29

15 9.5 Sectional Drawing and List of Components Z 32 1 ) Not illustrated in the sectional drawing; refer to 32 (illustration in section 9.4). [ ] For spare parts, refer to the relevant pump ( ) Not available as individual spare part Part No. Description O-ring Joint ring 550.3/.5/.6/.7 Disc 591 Tank Pipeline 411.2/.4 Joint ring O-ring Disc 713 Delivery suspension pipe Hose connection Nipple joint Tee 900 Sheet metal screw Socket head cap screw Hex. nut Hose pipe Flexible tube Pipe clamp Hose pipe Flexible tube Pipe clamp 30 Part No. Description Hose pipe O-ring Flexible tube Pipe clamp 73-1 Socket Nipple Hose connection 732.1/.2/.3 Holder Float switch Float switch Shim Clamp Cable tie Socket head cap screw Hex. nut Shim Clamp Cable tie Socket head cap screw Hex. nut Part No. Description Pump 914.3/.5/.6/.7 Socket head cap screw 920.3/.5/.6/.7 Hex. nut 113 1) Interstage casing 139 1) Suction elbow /.2 1 ) Cover plate ) Plate ) Sheet metal screw

16 9.6 Sectional Drawing and List of Components 40 Part No. Description 591 Tank, complete Pipeline Elbow 747 Swing check valve Sheet metal screw O-ring 720 Special pipe part Union nut Joint ring Nipple 731.1/.2 Elbow Pipeline 719 Flexible tube 733 Pipe clamp 73-3 Hose nozzle Joint ring 746 Butterfly valve Shim Clamp Hex. nut 914 Socket head cap screw Part No. Description Pump 550 Disc 576 Handle Float switch 920 Cap nut 826 Cable gland stuffing box, complete Nut 826 Cable gland stuffing box Joint ring O-ring 99-7 Installation kit 732 Holder Clamp Hex. nut 914 Socket head cap screw Cable tie 710 Pipe ) Interstage casing ) Suction elbow /.2 1 ) Cover plate ) Plate ) Sheet metal screw 1 ) Not illustrated in the sectional drawing; refer to 32 (illustration in section 9.4). [ ] For spare parts, refer to the relevant pump ( ) Not available as individual spare part 31

17 9.7 Name Plate Typical name plate 9.8 Recycling The lifting unit consists of materials that can be separately recycled. Plastic components are marked in accordance with ISO Safety Standards The waste water pumps are in accordance with the following European standards: Name plate location Serial no. Name plate location Underfloor-Box 32, Z 32, 40 Above-floor-Box 32/ (name plate) 32

18 / Technische Änderungen bleiben vorbehalten