KSB Evamatic-Box N 200 l Installation instructions

Automatic Waste Water Pump Station
Evamatic-Box N
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual Evamatic-Box N
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 S.A.S, Gennevilliers (Paris) 17.09.2013

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
2 Safety .....................................................................................................7
2.1 Key to safety symbols/markings ....................................................................... 7
2.2 General .............................................................................................................. 7
2.3 Personnel qualification and training ............................................................... 7
2.4 Consequences and risks caused by non-compliance with these operating
instructions ........................................................................................................ 8
2.5 Safety awareness ..............................................................................................8
2.6 Safety instructions for the operator/user ........................................................ 8
2.7 Safety instructions for maintenance, inspection and installation work ....... 8
2.8 Unauthorised modes of operation .................................................................. 9
2.9 Intended use .....................................................................................................9
3 Transport/Temporary Storage/Disposal .............................................10
3.1 Checking the condition upon delivery .......................................................... 10
3.2 Transport ......................................................................................................... 10
3.3 Storage/Preservation ...................................................................................... 10
3.4 Return to supplier ........................................................................................... 10
3.5 Disposal ...........................................................................................................11
4 Description ..........................................................................................12
4.1 General description ........................................................................................ 12
4.2 Designation ..................................................................................................... 12
4.3 Name plate ...................................................................................................... 12
4.4 Design details .................................................................................................. 12
4.5 Configuration and function ........................................................................... 14
4.6 Scope of supply ............................................................................................... 15
4.7 Dimensions and weights ................................................................................16
5 Installation at Site ...............................................................................17
5.1 Safety regulations ........................................................................................... 17
5.2 Checks to be carried out prior to installation ............................................... 17
5.3 Preparing the collecting tank ........................................................................18
5.4 Connecting the piping ...................................................................................21
5.5 Installing the pump(s) and pipe(s) in the collecting tank ............................ 31
5.6 Fitting the cover ............................................................................................. 38
Contents
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5.7 Installing the pump station ............................................................................ 38
5.8 Electrical system .............................................................................................. 40
6 Commissioning/Start-up/Shutdown ...................................................41
6.1 Commissioning/start-up ................................................................................. 41
6.2 Shutdown/storage/preservation .................................................................... 42
6.3 Returning to service .......................................................................................42
7 Servicing/Maintenance .......................................................................43
7.1 Safety regulations ........................................................................................... 43
7.2 Servicing/inspection ........................................................................................ 43
7.3 Drainage/disposal ........................................................................................... 44
7.4 Recommended spare parts stock ................................................................... 44
8 Trouble-shooting ................................................................................45
9 Related Documents ............................................................................46
9.1 Exploded view and list of components .........................................................46
9.2 Outline drawing ............................................................................................. 51
9.3 Accessories ...................................................................................................... 53
9.4 Installation drawing .......................................................................................54
10 EC Declaration of Conformity ............................................................56
11 Certificate of Decontamination .........................................................57
Index ....................................................................................................58
Contents
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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.
Check valve
Element of a waste water lifting unit which
prevents waste water from flowing back from
the discharge line into the lifting unit.
Domestic waste water
Faecal-free waste water (grey water) from
washbasins, showers, washing machines, etc.
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)
Stormwater
Water from natural precipitation which has not
been contaminated by any form of use
Waste water
Water which has been changed by some type
of use, e.g. domestic waste water
Glossary
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1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. This manual describes the proper and safe use of this equipment
in all phases of operation.
The name plate indicates the type series/size and main operating data. The works
number/serial number uniquely describes the system and is used as identification in
all further business processes.
In case of damage, immediately contact your nearest KSB service centre to maintain
the right to claim under warranty.
Noise characteristics see operating manual of the pump.
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 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
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
result 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.
2.2 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 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.
!DANGER
2 Safety
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2.4 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
2.5 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
2.6 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.)
2.7 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.
▪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 41)
▪Make sure the lifting unit cannot be accessed by unauthorised persons (e.g.
children).
2 Safety
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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.
(⇨ Section 2.9 Page 9)
2.9 Intended use
The unit must only be operated within the application limits described in the other
applicable documents.
▪Only operate units which are in perfect technical condition.
▪Do not operate partly assembled units.
▪The unit may only handle the fluids described in the technical product literature
of the respective design variant.
▪Never operate the unit without the fluid to be handled.
▪Observe the information on minimum flow rates specified in the technical
product literature (to prevent overheating, bearing damage, etc.).
▪Observe the information on maximum flow rates specified in the technical
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 unit (to prevent
cavitation damage).
▪Consult the manufacturer about any other modes of operation not described in
the technical product literature.
Prevention of foreseeable misuse
▪Never exceed the permissible application limits (pressure, temperature, etc.)
specified in the technical product literature.
▪Observe all safety notes and instructions in this manual.
2 Safety
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
DANGER
System falling off the pallet
Risk of injury by falling system!
▷Always transport the system in vertical position (with the cover on top).
▷Never suspend the system by its power cable.
▷Prevent the system from getting knocked or dropped.
3.3 Storage/Preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for storing the lifting unit:
CAUTION
Damage during storage by frost, humidity, dirt, UV radiation or vermin
Corrosion/contamination of the lifting unit!
▷Store the lifting unit in a frost-proof, roofed area.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage of the lifting unit!
▷Only open the openings of the lifting unit at the time of installation.
Store the lifting unit in a dry, protected room where the atmospheric humidity is as
constant as possible.
3.4 Return to supplier
1. Drain the system as per operating instructions.
2. Always flush and clean the system, particularly if it has been used for handling
noxious, hot or other hazardous fluids.
3. If the pump set has handled fluids whose residues could lead to corrosion in the
presence of atmospheric humidity or could ignite upon contact with oxygen,
the pump set must also be neutralised, and anhydrous inert gas must be blown
through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the system. (⇨ Section 11 Page 57)
It is imperative to indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
KSB web site at: www.ksb.com/certificate_of_decontamination
3 Transport/Temporary Storage/Disposal
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