KSB AmaDrainer Box Box Z2 B Installation instructions

Automatic Grey Water Lifting Unit
AmaDrainer Box
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual AmaDrainer Box
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 2023-10-17

Contents
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Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ...........................................................................................................................................................6
1.2 Installation of partly completed machinery....................................................................................................6
1.3 Target group.....................................................................................................................................................6
1.4 Other applicable documents............................................................................................................................6
1.5 Symbols .............................................................................................................................................................6
1.6 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.3 Personnel qualification and training...............................................................................................................9
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety instructions for the operator/user........................................................................................................9
2.7 Safety information for maintenance, inspection and installation ..............................................................10
2.8 Unauthorised modes of operation................................................................................................................10
3 Transport/Storage/Disposal ................................................................................................................ 11
3.1 Checking the condition upon delivery..........................................................................................................11
3.2 Transport.........................................................................................................................................................11
3.3 Storage/preservation......................................................................................................................................11
3.4 Return to supplier...........................................................................................................................................12
3.5 Disposal ...........................................................................................................................................................12
4 Description............................................................................................................................................ 13
4.1 General description ........................................................................................................................................13
4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................13
4.3 Designation.....................................................................................................................................................14
4.4 Name plate......................................................................................................................................................14
4.5 Design details..................................................................................................................................................15
4.6 Configuration and function...........................................................................................................................16
4.7 Noise characteristics .......................................................................................................................................17
4.8 Scope of supply...............................................................................................................................................17
4.9 Dimensions and weights ................................................................................................................................18
4.10 Accessories ......................................................................................................................................................18
5 Installation at Site................................................................................................................................ 19
5.1 Safety regulations...........................................................................................................................................19
5.2 Checks to be carried out prior to installation...............................................................................................20
5.3 Mounting/installing the underfloor box.......................................................................................................21
5.3.1 Installing the underfloor box ........................................................................................................... 21
5.3.2 Underfloor box: Connecting the piping .......................................................................................... 23
5.3.3 Underfloor box: Fitting the level-adjusting piece/ puddle flange with level-adjusting piece (not
included in the scope of supply) ...................................................................................................... 28
5.3.4 Underfloor box: Backfilling around the collecting tank and pouring concrete around the top. 30
5.3.5 Underfloor box: Fitting the sealing collar ....................................................................................... 32
5.4 Installing the above-floor box .......................................................................................................................35
5.4.1 Installing the above-floor box.......................................................................................................... 35
5.4.2 Above-floor box: Connecting the piping......................................................................................... 36
5.5 Installing the pump set ..................................................................................................................................39
5.5.1 Single-pump lifting units: Installing the pump set ......................................................................... 39
5.5.2 Dual-pump lifting units: Installing the pump set............................................................................ 43
5.6 Electrical connection ......................................................................................................................................49
5.6.1 Underfloor box: Electrical connection ............................................................................................. 49

Contents
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5.6.2 Above-floor box: Electrical connection............................................................................................ 50
5.7 Fitting the cover plate/ cover........................................................................................................................53
5.7.1 Underfloor box: Fitting the cover plate........................................................................................... 53
5.7.2 Above-floor box: Fitting the cover................................................................................................... 54
5.8 Venting device with activated carbon filter (accessory) ..............................................................................55
6 Commissioning/Start-up/Shutdown................................................................................................... 56
6.1 Commissioning/Start-up.................................................................................................................................56
6.1.1 Prerequisites for commissioning/start-up ........................................................................................ 56
6.1.2 Start-up.............................................................................................................................................. 56
6.2 Operating limits..............................................................................................................................................57
6.2.1 Free passage ...................................................................................................................................... 57
6.2.2 Fluid handled .................................................................................................................................... 58
6.3 Shutdown/storage/preservation ....................................................................................................................59
6.3.1 Measures to be taken for shutdown................................................................................................ 59
6.3.2 Stopping ............................................................................................................................................ 59
6.4 Returning to service .......................................................................................................................................59
7 Servicing/Maintenance........................................................................................................................ 60
7.1 Safety regulations...........................................................................................................................................60
7.2 Servicing/inspection........................................................................................................................................60
7.3 Drainage/cleaning ..........................................................................................................................................61
7.4 Recommended spare parts stock...................................................................................................................61
8 Trouble-shooting.................................................................................................................................. 62
9 Related Documents.............................................................................................................................. 63
9.1 Exploded view and list of components .........................................................................................................63
9.1.1 Single-pump lifting units: underfloor box/ above-floor box......................................................... 63
9.1.2 Dual-pump lifting units: underfloor box / above-floor box ........................................................... 68
9.2 Dimensions and connections .........................................................................................................................72
9.2.1 Underfloor box: Dimensions and connections ................................................................................ 72
9.2.2 Above-floor box: Dimensions and connections............................................................................... 74
9.3 Installation example.......................................................................................................................................76
9.3.1 Underfloor box: installation example.............................................................................................. 76
9.3.2 Above-floor box: Installation example ............................................................................................ 77
10 EU Declaration of Conformity............................................................................................................. 78
11 Declaration of Performance as per Regulation (EU) No. 305/2011, Annex III.................................. 79
12 Certificate of Decontamination........................................................................................................... 80
Index ..................................................................................................................................................... 81

Glossary
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Glossary
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 is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Collecting tank
Component of a grey water lifting unit in which
the incoming grey water is stored in unpressurised
condition prior to automatic lifting.
Domestic grey water
Faecal-free waste water (grey water) from
washbasins, showers, washing machines, etc.
Grey water lifting unit
Device for collecting and automatically lifting
faecal-free waste water above the flood level
Nominal size DN
Identifier (inside diameter) used for characterising
mating components such as pipes, pipe
connections and fittings
Stormwater
Water from natural precipitation which has not
been contaminated by any form of use
Submersible motor pump
Submersible motor pumps are floodable, close-
coupled units which are not self-priming. The
pumps are usually operated completely
submerged. They may be operated outside the
fluid for short periods of time, until the minimum
fluid level has been reached.
Swing check valve
Element of a waste water lifting unit which
prevents waste water from flowing back from the
discharge line into the waste water lifting unit.

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service facility to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.3,Page9)
1.4 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals and other product literature
describing accessories and integrated machine
parts,
submersible motor pump operating manual,
switchgear operating manual for dual-pump lift-
ing units
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
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product

1 General
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1.6 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
WARNING
!
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could res-
ult in damage to the machine and its functions.
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
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and 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.
2.2 Intended use
▪The lifting unit must not be used in potentially explosive atmospheres.
▪The lifting unit must only be operated within the operating limits described in
the other applicable documents.
▪Only operate lifting units which are in perfect technical condition.
▪Do not operate partially assembled lifting units.
▪Only use the lifting unit to 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 minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪Observe the minimum flow rate and maximum flow rate indicated in the data
sheet or product literature (to prevent overheating, mechanical seal damage,
cavitation damage, bearing damage, etc).
▪Do not throttle the flow rate on the inlet side of the lifting unit (to prevent
cavitation damage)
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
▪Never exceed the permissible application and operating limits specified in the
data sheet or product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.

2 Safety
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2.3 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.
2.4 Consequences and risks caused by non-compliance with this manual
▪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
2.5 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety instructions for the operator/user
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪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 Safety
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2.7 Safety information for maintenance, inspection and installation
▪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 maintenance, inspection and installation are
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.
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
▪Make sure the lifting unit cannot be accessed by unauthorised persons (e.g.
children).
2.8 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.
(ðSection2.2,Page8)