KGN pillinger OM0008 Manual

Dry Well Submersible Pump Set
Operating & Maintenance
Original Instructions
Dated: 10.02.2022 –Revision: 1
Ref: OM0008

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Operating & Maintenance
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Table of Content:
1) Introduction ………………………………………….……………
3
2) Warnings for the Safety of People & Property ………………...
3
3) Overview……….….…………………….…………………………
4
4) Main Components. ……………………………….……………...
5
5) Handling ……………………………….…….………
6
6) Operating Limits ……………………………………….….………
6
7) Product Identification Code……………….……………………...
7
8) Health & Safety
9) Block Prevention ………………………………………………….
8
9
10)Installation…………………………………………………......…...
9 –12
11)Commissioning…….……………………………….………………
13
12) Operation……………………………………………………………
13 –14
13) Maintenance……………….….……………………………………
14 –15
14) General Fault-Finding Guidance ………………………….….….
15
15) UKCA Declaration of Conformity….……………………………...
16

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1). Introduction:
The information contained within this manual is intended for the installer/user of this equipment to
safely install & operate the products mentioned.
The products are to be installed by a competent person who is familiar with all the required and
relevant regulations.
Failure to install/operate or maintain the equipment in accordance with these instructions could
cause harm, injury to persons or damage to property.
Failure to install/operate/maintain the equipment according to the Operating & Maintenance
instructions could invalidate the warranty as provided by KGN Pillinger.
No liability can be accepted for damage or operation disorders due to neglect, misuse, modification
or use of equipment other than for its intended application.
This information should be read in conjunction with the manufacturers O&M.
2). Warnings for the Safety of People & Equipment:
DANGER:
Failure to observe this caution may result in injury
and/or damage to equipment.
ELECTRIC SHOCK:
Failure to observe this warning may result electric
shock.
WARNING:
Failure to observe this warning may cause
damage/injury to property, environment or person(s).
QR Code:
The codes are scannable via a smart phone or tablets
camera to retrieve specific product details in support of
these instructions.

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3). Overview:
KGN Pillinger’s range of dry well pump sets consists of a skid mounted stainless steel holding tank
with all the necessary ports for the connection of inlet, outlet and air vents, horizontally mounted
electric submersible pumps, values, pipework and controls.
These units are supplied complete with an electrical control panel, which should be mounted within
relative proximity to the pump set. When the level in the tank reaches start level 1, One pump will
operate. If the level rises to level 2 the second pump will operate until the level drops.
The pump sets are designed and manufactured to automatically collect the product and transfer it,
via the pumps, under the dictates of float switches or level electrodes fitted within the Stainless steel
holding tank.
The installer/operator is responsible for following the instructions and complying with the safety
requirements given in this operation manual.
Failures to install, operate, or maintain the equipment according to the ‘Operating & Maintenance
Instructions’ could invalidate the warranty as provided by KGN Pillinger.
No liability can be accepted for damage or operation disorders that are the result of non-compliance
with the operating instructions.

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4). Main Component Listing –Dry Well Submersible Pump Set.

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5). Handling:
➢The Pump Set should be transported in a vertical position.
➢Ensure it cannot roll or fall over.
➢Delivery vehicles should be guided and supervised on site at all times by a competent
banksman.
➢If a crane is used, ensure that it is adequately sized, correctly stabilised, and supervised by a
suitably qualified experienced banksman.
➢Only qualified personnel should be involved in lifting or transporting this equipment.
➢If unloading is to be carried out in a public area, the appropriate Personal Protective
Equipment must be worn and local safety rules must be observed and obeyed.
6). Operating Limits:
See product/pump specific operation & maintenance manual for further details.
Noise emissions:
Assembled units are heavy. Failure to properly lift & support these sets can
result in serious personal injury and/or equipment damage. The appropriate
rated lifting devices and methods must be used for & during lifting
operations.
Exposure to excessive noise can cause permanent hearing damage.
It is the end users’ responsibility to identify the required legal
requirements, ensuring the appropriate safety equipment (PPE) is
applied and noise control is in place.

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7). Product Identification Code(s).
All KGN Pillinger’s Dry Well Submersible Pump Sets are identified by either of the below coding
options:
•‘P’ Number.
•Serial Number
•Site/job Reference.
Which are located on the set name plate.

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8). Health & Safety
➢Foul water pumps will be handling raw sewage, which can lead to Leptospirosis (or Weils
Disease), which can potentially be a life-threatening disease if it comes into contact with
broken skin.
➢Due to the nature of the surface water the pump sets could contain unknown substances
creating potential hazards ranging from chemicals within the water to harmful gasses within
any pump chamber.
➢Only those engineers trained and qualified to work with such hazards and in confined spaces
should attempt any level of service or maintenance on these pumps.
➢NO SMOKING.
➢No naked flames or sparks.
➢Only qualified people may carry out maintenance / service work.
It is the responsibility of the customer, and/or contractor to ensure:
anyone working on the equipment is wearing all necessary
PPE, aware of the appropriate health warnings and has
read & understood the information in this manual.
Sewage gases are explosive and toxic.
The equipment and the area immediately surrounding it should be
subject to the following safety precautions:

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9). Blockage Prevention
➢Disposable nappies - These are not designed to be flushed down the toilet, and will certainly
block the pump if disposed of in this way.
➢Sanitary towels - Due to changes in design and material used, these are no longer flushable
and ought to be disposed of in a bin.
➢Items made of cloth or plastic - These should not be flushed down the toilet, as again they
do not break up in order to be pumped away. The more common items found in cases of
blockages along these lines are cleaning cloths, condoms and cotton buds.
➢Toilet cleaning wipes - These are becoming more commonly used and they cause problems
for all pumps as they do not break up causing blockages.
➢Cooking Fat - The build-up of fat in the sump is a common problem. If fat comes into contact
with cold water it solidifies causing the start/stop float to jam, in which case the pump will
either burn out or stop working.
These items will cause pump failure due to blockages, and any site attendance by our
engineers will be fully chargeable and could prove very costly:
10). Installation
➢Use the appropriate lifting equipment to handle the pump set, DO NOT lift the set using the
pipework.
➢Prior to installation the set should be thoroughly checked for any damage during
transportation and reported immediately to KGN Pillinger and not installed.
➢The pressure booster set requires install in a ventilated, dry frost-free position, allowing 0.5m
clearance on all sides and front to enable general maintenance.
➢The pump set should be installed on level structurally sound surface.
➢Partly fill the tank with clean water for testing the system upon commissioning and to
facilitate a flush through of the discharge pipe prior to sewage/drainage pumping.
➢Install float-switches and interconnecting cables. If extensions are required, draw these
electrical cables through the cable duct to the proposed position of the control panel.
➢Position the control panel (and kiosk if applicable).
➢Provide a suitable electrical supply, to be isolated and adjacent to the positioned control
panel.
➢Make the final electrical connections according to the ‘Field Connections’ instruction
provided with the control panel.
➢Always check the rotation direction of the pumps to ensure they have been correctly wired.
Do not dispose of the following items through the drainage or
pump system.:

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Electrical Connections
➢The incoming supply must be sized to carry the motor full load current of all pumps
(as all can be in operation at any one time).
➢All electrical connections are to be made against the relevant product wiring diagrams.
➢All electrical connections should be sized, installed and protected in accordance with the
requirements of the latest safety standards and any other current local rules and regulations.
➢It is the responsibility of the installer to ensure that the cable and fuse/MCB protection is
suitably rated to accommodate the pump set, and that the integrity of the main incoming
supply is tested and certified prior to applying power to the set.
➢It’s essential that this equipment is earth bonded to the building earth system.
Pre-start up
➢The pump(s) must not be allowed to run dry under any circumstances as overheating will
rapidly damage the internal components of the pump.
➢Pipework attached to the pump set must be suitably supported so that there are no forces
acting upon the discharge pipes of the set.
Please also refer to the specific pump manufactures manual.
These instructions are in general and not specific to a particular
pump set –refer to your quote/order details to confirm specific
model.

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11). Commissioning
If the pumping equipment is not installed, operated and maintained correctly it can lead to failure,
void warranty and cost time and money.
The commissioning of the set assures all systems and components of the equipment supplied are
installed, tested, operated and maintained according to the operational requirements of the system.
The commissioning process comprises of a set of engineering philosophies and procedures that
inspect and test every operational component of the equipment, from individual functions such as
instrumentation and control logic, through to the full operation of the system.
The main objective of commissioning is to provide the safe and orderly handover of the unit to the
customer, guaranteeing its operability in terms of performance, reliability and safety.
12). Operation
Duty/Standby
These units are designed to operate on a Duty/Standby basis under the dictates of either:
1). Float Switches - ‘Stop’, ‘Start’ & ‘High Level’.
2). Electrodes - ‘Stop’, ‘Start’, ‘High Level’ and ’Common’.
➢The starters are interlocked so that only one pump may run at any time whether manual or
auto control has been selected.
➢In manual control each pump may be run on its own by operating the respective ‘manual’
switch mounted on the door.
➢In auto control the pumps will run under level control by operating both ‘auto’ switches. As
the fluid level rises the duty pump will become enabled via the relative float/electrode.
➢This pump will continue to run until the level falls below the stop position of the
float/electrode.
➢The pump duty is now alternated so that the other pump becomes the duty unit next time
they are called to run.
We recommend the unit is commissioned and subsequently
serviced biannually by a fully trained KGN Pillinger engineer.

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Operation –Continued:
➢Should the duty pump be running and the level continues to rise to the high level
float/electrode, the high level light will illuminate and the buzzer will sound. This may be
muted by pressing ‘cancel alarm’. This alarm may be reset once the level is below the high
level float switch.
Duty/Assist
These units are designed to operate from either:
1). Float switches - ‘Stop’, ‘Duty Start’, ‘Assist. Start’ and ‘High Level’.
2). Electrodes - ‘Stop’, ‘Duty Start’, ‘Assist. Start’, ‘High Level’ and ‘Common’.
➢In manual control each pump may be run on its own by operating the respective ‘manual’
switch mounted on the door.
➢In auto control the pump/s will run under level control by operating both ‘auto’ switches. As
the fluid level rises the duty pump will become enabled via the relative float/electrode.
➢If the level continues to rise the Assist Pump will become enabled via the second
float/electrode. The pump/s will continue to run until the level falls below the stop position of
the float/electrode.
➢The pump duty is now alternated so that another pump becomes the duty unit next time they
are called to run.
➢Should the duty pump be running and the level continues to rise to the high level
float/electrode, the high level light will illuminate and the buzzer will sound. This may be
muted by pressing ‘cancel alarm’. This alarm may be reset once the level is below the high
level float switch.
➢Should the duty pump have stopped or failed to clear the sump water and the level has
reached the high level float/electrode, the assist pump will start and run until the level falls
below the stop float. Visual and audible indication of high level will also occur again at this
point.
➢The remote beacon will be illuminated until the level falls below the high level float at which
point pressing ‘cancel alarm’ will extinguish the beacon.

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13). Maintenance
On each service we would carry out the following:
➢Visual Inspection of the pumps.
➢Top up the oil levels where necessary.
➢Test the pump motors.
➢Clean and check the operation of the electrodes, non-return and gate valves and all
associated electrical connections.
➢Test all electrical controls.
➢Following each visit, we would send a separate report of our findings, together with an
invoice for the service.
➢Any minor faults found during the service visit would be rectified at the time following verbal
instruction, although should we pick up on any more major faults, you would be notified in
writing and the work would be carried out and invoiced separately on receipt of an order from
yourselves.
The unit is constructed using low maintenance components throughout and should not require
any day to day maintenance.
The following is the recommended frequency for various maintenance tasks.
➢Other items, such as security of fixings, terminations, plant room mechanisms and
accessories are not specified, but should be carried out as a matter of course, as on any
other piece of equipment.
We suggest that routine maintenance visits are carried out on a
twice yearly basis by a KGN engineer.

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Monthly checks:
➢Make a thorough visual check of the equipment, watching the operation through a complete
cycle.
➢If dirt or debris appears to be clinging to the high level float switch - or to the other float
switches when fitted, clean them off by spraying with a water hose.
➢Check that the high level float switch - and the other float switches when fitted - have not
moved from their pre-set positions and that the pumps are operating correctly.
15). General Fault-Finding Guidance:
FAULT
POSSIBLE CAUSE
RECOMMENDED ACTION
Pumps will not run:
1). Power failure.
Check main isolator.
Check that a power supply is
available prior to the control
panel –(e.g Distribution board)..
Pump(s) start frequently:
1). Start switching point set to
low.
Reset the switching point higher
Pump(s) run longer than
normal operation:
1). NRV not sealing properly.
2). Discharge pipe blockage.
Check.
Check and remove any
blockages.
Pumping set ‘flooded’:
Isolate electrical supply.
Use a separate portable pump to
pump out chamber as low as
possible.
Check for cause of flooding and
repair.

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Disposal:
This product and its associated parts must be disposed of in accordance with local regulations,
including all packaging.
K.G. Norman Ltd –t/a KGN Pillinger
Unit 12 Wells Pl, Merstham, Redhill
RH1 3AS

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16). UKCA Declaration of Conformity
UK DECLARATION OF CONFORMITY
In accordance with UK Government Guidance
We hereby declare that the following KGN Pillinger (KG Norman Ltd )
manufactured products:
Type A, AV, EV, SE, FSA, CAT5 & UPOD
are produced in accordance with the below provisions laid down by the:
MACHINERY Directive (2006/42/EC)
LOW VOLTAGE Directive (2014/30/EU)
EMC Directive (2014/65/EU)
& conforms to the below technical standards:
EN ISO 12100:2010 - EN 809+A1:2009 –EN 61000-6-1:2007 –EN 61000-6-2:2005
EN 61000-6-3:2007+A1:2011 - EN 60204-1:2006+A1:2009
Christopher Norman
Director
For & on behalf of
KGN Pillinger
Unit 12 Wells Pl, Merstham, Redhill
RH1 3AS
01/01/2022