KSB Compacta UZ10.450D Installation instructions

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
All rights reserved. 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 KSB´s express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 01.11.2011

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
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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
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Working space
The space required for performing work on the
unit
Glossary
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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
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1 General
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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
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
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▪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
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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
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