KSB Compacta UZ10.450D Instructions d'installation

Floodable Sewage Lifting Unit

Compacta - Amarex N/KRT

from series S-V/1

Installation/Operating

Manual

Legal information/Copyright

Installation/Operating Manual Compacta - Amarex N/KRT

Original operating manual

KSB Aktiengesellschaft Frankenthal

or processed for any other purpose, nor otherwise transmitted, published or made available to a third

party without KSB´s express written consent.

Subject to technical modification without prior notice.

Contents

Glossary ................................................................................................ 5

1 General ................................................................................................ 7

1.1 Principles .......................................................................................................... 7

1.2 Installation of partly completed machinery .................................................. 7

1.3 Target group ................................................................................................... 7

1.4 Other applicable documents .......................................................................... 7

1.5 Symbols ............................................................................................................ 7

2 Safety ................................................................................................... 8

2.1 Key to safety symbols/markings ..................................................................... 8

2.2 General ............................................................................................................ 8

2.3 Intended use .................................................................................................... 8

2.4 Personnel qualification and training ............................................................. 9

2.5 Consequences and risks caused by non-compliance with these operating

instructions ...................................................................................................... 9

2.6 Safety awareness ............................................................................................. 9

2.7 Safety instructions for the operator/user .................................................... 10

2.8 Safety instructions for maintenance, inspection and installation work .... 10

2.9 Unauthorised modes of operation ............................................................... 10

2.10 Note on explosion protection ...................................................................... 10

3 Transport/Temporary Storage/Disposal ........................................... 11

3.1 Checking the condition upon delivery ......................................................... 11

3.2 Transport ....................................................................................................... 11

3.3 Storage/Preservation ..................................................................................... 12

3.4 Return to supplier ......................................................................................... 12

3.5 Disposal .......................................................................................................... 13

4 Description ........................................................................................ 14

4.1 General description ....................................................................................... 14

4.2 Designation ................................................................................................... 14

4.3 Name plates ................................................................................................... 15

4.4 Design details ................................................................................................ 15

4.5 Configuration and function ......................................................................... 17

4.6 Technical specifications ................................................................................. 17

4.7 Fluids handled ............................................................................................... 18

4.8 Collecting tank .............................................................................................. 19

4.9 Noise characteristics ...................................................................................... 19

4.10 Scope of supply ............................................................................................. 19

4.11 Dimensions and weights ............................................................................... 19

Contents

Compacta - Amarex N/KRT 3 of 56

5 Installation at Site ............................................................................. 21

5.1 Safety regulations ......................................................................................... 21

5.2 Checking the site before installation .......................................................... 21

5.3 Installing the lifting unit ............................................................................... 21

5.4 Connecting the piping .................................................................................. 22

5.5 Cellar drainage .............................................................................................. 24

5.6 Connection to power supply ........................................................................ 24

5.7 Checking the direction of rotation .............................................................. 24

6 Commissioning/Start-up/Shutdown ................................................. 26

6.1 Commissioning/start-up ................................................................................ 26

6.2 Operating limits ............................................................................................ 26

6.3 Commissioning/start-up of control unit ....................................................... 27

6.4 Shutdown ...................................................................................................... 29

7 Operation .......................................................................................... 31

7.1 Control panel ................................................................................................. 31

7.2 Manual-0-automatic selector switch ............................................................ 33

7.3 Control panel ................................................................................................. 33

8 Servicing/Maintenance ...................................................................... 38

8.1 General information/Safety regulations ...................................................... 38

8.2 Servicing/inspection ...................................................................................... 38

8.3 Dismantling the pump .................................................................................. 40

8.4 Reassembly .................................................................................................... 40

8.5 Tightening torques ....................................................................................... 41

8.6 Disposal/recycling of the lifting unit ............................................................ 41

8.7 Check list for commissioning/inspection ➀ and maintenance ➁ ................ 41

9 Trouble-shooting ............................................................................... 43

10 Related Documents ........................................................................... 45

10.1 General assembly drawing/exploded view and list of components ........... 45

10.2 Connection examples .................................................................................... 48

10.3 Dimensions .................................................................................................... 49

10.4 Wiring diagrams ............................................................................................ 50

11 Certificate of Decontamination ....................................................... 53

12 Draft EC Declaration of Conformity ................................................. 54

Index .................................................................................................. 55

Contents

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Glossary

Backflow

Waste water flowing back from the sewer into

the connected drainage piping

Backflow loop

The section of the discharge pipe of a waste

water lifting unit that is located above the

flood level

Certificate of decontamination

A certificate of decontamination certifies that

the unit has been properly cleaned and

decontaminated to eliminate any

environmental and health hazards arising from

components in contact with the fluid handled.

Collecting tank

Unpressurised component of a sewage lifting

unit in which the incoming waste water is

stored prior to automatic lifting

DIN 1986-3 and -30

German standard which stipulates technical

rules for the operation, maintenance and

servicing of drainage systems in buildings and

on premises

Discharge line

Pipe for transporting waste water to a level

above the flood level into the sewer system

DOL starting

For low power ratings (usually up to 4 kW), the

three-phase motor is connected directly to the

mains voltage with an electromechanical

protection device.

Domestic waste water

Faeces-free waste water from washbasins,

showers, washing machines, etc.

Dual-pump unit

Sewage lifting unit containing a duplicate

pumping device which starts up automatically

as necessary

Effective volume

Volume in the collection tank between start

and stop level that can be lifted

EN 12 050-1

European standard governing sewage lifting

units used for the disposal of domestic waste

water produced below the flood level. It

defines general requirements as well as

principles of construction and testing.

EN 12 056-4

European standard governing the selection,

operation and maintenance of sewage lifting

units within buildings and sites.

Flood level

Maximum backflow level of waste water in a

drainage system

Inlet line

Pipe used for draining waste water from

sanitary installations into the lifting unit

Noise characteristics

The noise emission to be expected, indicated as

sound pressure level LpA in dB(A)

Nominal diameter DN

Identifier (inside diameter) used for

characterising mating components such as

pipes, pipe connections and fittings

Separator

Device which uses gravity to prevent any

ingress of harmful substances into the drainage

system by separating these substances from the

waste water, e.g. grease separator

Sewage lifting unit

Device for collecting and automatically lifting

waste water with or without faeces above the

flood level

Stormwater

Water from natural precipitation which has not

been contaminated by any form of use

Vent line

Pipe provided to limit pressure fluctuations

within the sewage lifting unit. The vent line is

led through the roof.

Waste water

Water which has been changed by some type

of use, e.g. domestic waste water

Glossary

Compacta - Amarex N/KRT 5 of 56

Working space

The space required for performing work on the

unit

Glossary

6 of 56 Compacta - Amarex N/KRT

1 General

1.1 Principles

This operating manual is supplied as an integral part of the type series and variants

indicated on the front cover. The manual describes the proper and safe use of this

equipment in all phases of operation.

The name plate indicates the type series/size, the main operating data and the order

number. The series/serial number uniquely identifies the lifting unit and serves as

identification for all further business processes.

In the event of damage, immediately contact your nearest KSB service centre to

maintain the right to claim under warranty.

Noise characteristics (⇨ Section 4.9 Page 19)

1.2 Installation of partly completed machinery

To install partly completed machinery supplied by KSB, please refer to the sub-

sections under Servicing/Maintenance.

1.3 Target group

This manual is aimed at the target group of trained and qualified specialist technical

personnel.

1.4 Other applicable documents

Table 1: Overview of other applicable documents

Document Contents

Sub-supplier product literature Operating manuals and other product literature

of accessories and integrated machinery

components,

operating manual of submersible motor pump

1.5 Symbols

Table 2: Symbols used in this manual

Symbol Description

✓Conditions which need to be fulfilled before proceeding with the

step-by-step instructions

⊳Safety instructions

⇨Result of an action

⇨Cross-references

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

1 General

Compacta - Amarex N/KRT 7 of 56

2 Safety

All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

!DANGER

DANGER

indicates a high-risk situation which, if not avoided, will result in

death or serious injury.

!WARNING

WARNING

indicates a medium-risk situation which, if not avoided, could result

in death or serious injury.

CAUTION

indicates a hazardous situation which, if not avoided, could

damage the machine and its functions.

Explosion protection symbol

provides information about avoiding explosions in potentially

explosive atmospheres in accordance with EU Directive 94/9/EC

(ATEX).

General hazard

In conjunction with one of the signal words this symbol indicates a

hazard which will or could result in death or serious injury.

Electrical hazard

provides information about protection against electrical voltages.

In conjunction with the signal word CAUTION, this symbol indicates

a hazardous situation for the machine and its functions.

2.2 General

This manual contains general installation, operating and maintenance instructions

that must be observed to ensure safe operation of the lifting unit and prevent injury

and damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/

operators responsible prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the site

at all times.

Instructions attached directly to the lifting unit must always be complied with and be

kept in a perfectly legible condition at all times. This applies to, for example:

▪Arrow indicating the direction of rotation

▪Markings for connections

▪Name plate

The operator is responsible for ensuring compliance with all local regulations not

taken into account in this manual.

2.3 Intended use

The lifting unit must only be operated within the operating limits described in the

other applicable documents.

▪The lifting unit must only be operated when in perfect technical condition.

▪Do not operate partially assembled lifting units.

!DANGER

2 Safety

8 of 56 Compacta - Amarex N/KRT

▪The lifting unit must only handle the fluids described in the product literature of

the respective design variant.

▪Never operate the lifting unit without the fluid to be handled.

▪Observe the information on minimum flow rates specified in the product

literature (to prevent overheating, bearing damage, etc).

▪Observe the information on maximum flow rates specified in the product

literature (to prevent overheating, mechanical seal damage, cavitation damage,

bearing damage, etc).

▪Do not throttle the flow rate on the suction side of the lifting unit (to prevent

cavitation damage).

▪Consult the manufacturer about any other modes of operation not described in

the product literature.

Prevention of foreseeable misuse

▪Never exceed the permissible operating limits (pressure, temperature, etc.)

specified in the product literature.

▪Observe all safety information and instructions in this manual.

2.4 Personnel qualification and training

All personnel involved must be fully qualified to install, operate, maintain and

inspect the equipment this manual refers to.

The responsibilities, competence and supervision of all personnel involved in

installation, operation, maintenance and inspection must be clearly defined by the

operator.

Deficits in knowledge must be rectified by means of training and instruction

provided by sufficiently trained specialist personnel. If required, the operator can

commission the manufacturer/supplier to train the personnel.

Training on the lifting unit must always be supervised by technical specialist

personnel.

2.5 Consequences and risks caused by non-compliance with these operating

instructions

▪Non-compliance with these operating instructions will lead to forfeiture of

warranty cover and of any and all rights to claims for damages.

▪Non-compliance can, for example, have the following consequences:

–Hazards to persons due to electrical, thermal, mechanical and chemical

effects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2.6 Safety awareness

In addition to the safety information contained in this manual and the intended use,

the following safety regulations shall be complied with:

▪Accident prevention, health and safety regulations

▪Explosion protection regulations

▪Safety regulations for handling hazardous substances

▪Applicable standards and laws

2 Safety

Compacta - Amarex N/KRT 9 of 56

2.7 Safety instructions for the operator/user

▪The operator shall fit contact guards for hot, cold and moving parts and check

that the guards function properly.

▪Do not remove any contact guards while the pump is running.

▪Provide the personnel with protective equipment and make sure it is used.

▪Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.

explosive, toxic, hot) so as to avoid any danger to persons and the environment.

Adhere to all relevant laws.

▪Eliminate all electrical hazards. (In this respect refer to the applicable national

safety regulations and/or regulations issued by the local energy supply

companies.)

2.8 Safety instructions for maintenance, inspection and installation work

▪Modifications or alterations of the lifting unit require the manufacturer's prior

consent.

▪Use only original spare parts or parts authorised by the manufacturer. The use of

other parts can invalidate any liability of the manufacturer for resulting damage.

▪The operator ensures that all maintenance, inspection and installation work is

performed by authorised, qualified specialist personnel who are thoroughly

familiar with the manual.

▪Carry out work on the lifting unit during standstill only.

▪The pump casing must have cooled down to ambient temperature.

▪Pump pressure must have been released and the pump must have been drained.

▪When taking the lifting unit out of service always adhere to the procedure

described in the manual.

▪Decontaminate lifting units which handle fluids posing a health hazard. (⇨

Section 8.1 Page 38)

▪As soon as the work is complete, re-install and/or re-activate any safety-relevant

and protective devices. Before returning the product to service, observe all

instructions on commissioning. (⇨ Section 6.1 Page 26)

▪Make sure the lifting unit cannot be accessed by unauthorised persons (e.g.

children).

2.9 Unauthorised modes of operation

Always observe the limits stated in the product literature.

The warranty relating to the operating reliability and safety of the lifting unit

supplied is only valid if the equipment is used in accordance with its intended use.

2.10 Note on explosion protection

DANGER

Never use sewage lifting units in potentially explosive atmospheres.

2 Safety

10 of 56 Compacta - Amarex N/KRT

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