Pentair JUNG PUMPEN K2 plus User manual

B 47029-12-1607 www.jung-pumpen.de
EN Instruction manual
JUNG PUMPEN K2 plus

2
ENGLISH
You have purchased a product made by JUNG
PUMPEN and with it, therefore, also excellent
quality and service. Secure this service by
carrying out the installation works in accord-
ance with the instructions, so that our prod-
uct can perform its task to your complete
satisfaction. Please remember that damage
caused by incorrect installation or handling
will adversely affect the guarantee.
Therefore please adhere to the instructions in
this manual!
As with all electrical devices, this product
can also fail to operate due to an interruption
in the electricity supply or due to a techni-
cal defect. If this could result in damage, a
mains-independent alarm system must be
installed. Depending on the application, you
may also wish to install an emergency power
generator, or a second system as a back-up.
SAFETY
INSTRUCTIONS
This instruction manual contains essential
information that must be observed during
installation, operation and servicing. It is
therefore important that the installer and
the responsible technician/operator read this
instruction manual before the equipment is
installed and put into operation. The manu-
al must always be available at the location
where the pump or the plant is installed.
Failure to observe the safety instructions can
lead to the loss of all indemnity.
In this instruction manual, safety information
is distinctly labelled with particular symbols.
Disregarding this information can be danger-
ous.
General danger to people
Warning of electrical voltage
ATTENTION!
Danger to equipment and operation
Qualification and training of
personnel
All personnel involved with the operation,
servicing, inspection and installation of the
equipment must be suitably qualified for this
work and must have studied the instruction
manual in depth to ensure that they are suf-
ficiently conversant with its contents. The su-
pervision, competence and areas of respon-
sibility of the personnel must be precisely
regulated by the operator. If the personnel do
not have the necessary skills, they must be
instructed and trained accordingly.
Safety-conscious working
The safety instructions in this instruction
manual, the existing national regulations
regarding accident prevention, and any inter-
nal working, operating and safety regulations
must be adhered to.
Safety instructions for the
operator/user
All legal regulations, local directives and
safety regulations must be adhered to.
The possibility of danger due to electrical en-
ergy must be prevented.
Leakages of dangerous (e.g. explosive, toxic,
hot) substances must be discharged such
that no danger to people or the environment
occurs. Legal regulations must be observed.
Safety instructions for instal-
lation, inspection and main-
tenance works
As a basic principle, works may only be car-
ried out to the equipment when it is shut
down. Pumps or plant that convey harmful
substances must be decontaminated.
All safety and protection components must
be re-fitted and/or made operational imme-
diately after the works have been completed.
Their effectiveness must be checked before
restarting, taking into account the current
regulations and stipulations.
Unauthorised modifications,
manufacture of spare parts
The equipment may only be modified or al-
tered in agreement with the manufacturer.
The use of original spare parts and acces-
sories approved by the manufacturer is im-
portant for safety reasons. The use of other
parts can result in liability for consequential
damage being rescinded.
Unauthorised operating
methods
The operational safety of the supplied equip-
ment is only guaranteed if the equipment is
used for its intended purpose. The limiting
values given in the "Technical Data" section
may not be exceeded under any circumstanc-
es.
Instructions regarding acci-
dent prevention
Before commencing servicing or maintenance
works, cordon off the working area and check
that the lifting gear is in perfect condition.
Never work alone. Always wear a hard hat,
safety glasses and safety shoes and, if nec-
essary, a suitable safety belt.
Before carrying out welding works or using
electrical devices, check to ensure there is
no danger of explosion.
People working in wastewater systems must
be vaccinated against the pathogens that
may be found there. For the sake of your
health, be sure to pay meticulous attention to
cleanliness wherever you are working.
Make sure that there are no toxic gases in the
working area.
Observe the health and safety at work regu-
lations and make sure that a first-aid kit is
to hand.
In some cases, the pump and the pumping
medium may be hot and could cause burns.
For installations in areas subject to explosion
hazards, special regulations apply!
This appliance can be used by children aged
8 years or over and by persons with limited
physical, sensory or intellectual capabilities,
or with limited experience and knowledge,
provided that they are supervised or have
been instructed in the safe use of the appli-
ance and are aware of the dangers involved.
Children must not be allowed to play with the
appliance. Cleaning and user maintenance
must not be carried out by children unless
they are supervised.

3
ENGLISH
Only connect the pump to electri-
cal circuits that have been in-
stalled properly in accordance with
the regulations and are fitted with
at least a 10 A (delay) fuse and an
FI circuit breaker (≤30 mA).
Check the plug and the mains cable
for signs of mechanical and chemi-
cal damage. Damaged or kinked
hoses must be replaced.
Condensates from condensing boil-
ers contain acids! These can cause
irreparable damage if they come
into contact with skin or eyes.
USE
The K2 plus condensate pump was
specially developed for removing ag-
gressive condensate from condensing
boilers (up to 100 kW), refrigerated and
freezer display cases, air conditioning
systems and air dehumidifiers.
ATTENTION! The maximum admissible
temperature of the pumped media is
40°C. In the event of higher media inlet
temperatures, even for a short time, the
inlet hose must be laid in the form of
several cooling loops.
Provided that regular maintenance is
performed, the pump unit can convey
condensate with a pH value of ≥ 2.7. If
lower pH values are present, even if only
intermittently, then a neutralisation sys-
tem must be fitted upstream.
In addition, local conditions or par-
ticular technical or legal requirements
(such as local drainage bye-laws) may
require the use of a neutralisation sys-
tem.
ATTENTION! Admixtures of oils, par-
ticularly essential oils, are not permit-
ted.
The use of the K2 plus is not permissi-
ble for removing waste water, such as
from washbasins.
Condensate from condensing
boilers contains aggressive ac-
ids.
ATTENTION! The maximum influx is 14
l/h. The temporary peak influx, such as
when defrosting must not exceed 70 l/h.
ATTENTION! The maximum delivery
head of 3.5 metres must not be exceed-
ed in order to prevent deposits from
forming and keep the pump in good
working order.
ATTENTION! It is not permitted to use
the K2 plus outdoors.
When installed in bath and
shower rooms, the applicable
electrical regulations must be
observed (in Germany VDE 0100 part
701)!
You will find further information in the
DWA working paper "Condensates from
condensing boilers",(ATV-DVWL-A 251).
If installed in compliance with the reg-
ulations and used properly, then this
pump unit meets the protective require-
ments of the EMC Directive 2004/108/
EC and is suitable for domestic use and
connection to a power supply from the
grid.
Storage
The K2 plus is frost-free if stored in a
dry place at up to -20°C. The conden-
sate in the system must not freeze how-
ever in its built-in state.
ELECTRICAL
CONNECTION
Only qualified electricians may
carry out electrical work on the
pump, plug or the control unit.
Before carrying out any work,
unplug the pump unit from the
mains socket and ensure that
the power supply to the pump unit cannot
be switched on again by anyone else.
ATTENTION! Never put the mains plug in
water! If water gets into the plug, this can
cause malfunctions and damage.
Current applicable standards (such as
EN standards), national regulations
(such as VDE in Germany), and the reg-
ulations of the local power supply com-
panies must be complied with.
Observe the operating voltage (see type
plate)!
Only connect the pump to safety sock-
ets that have been installed properly
in accordance with the regulations. No
additional motor protection is required,
since the system has an integrated
winding thermostat.
Unacceptably high temperatures cause
the thermostat to shut down the motor.
After the thermostat has
switched the system off, un-
plug the mains cable before
remedying the fault, since the pump
unit can switch itself on again automat-
ically if the power is still connected!
Level control
The pump is switched on and off au-
tomatically depending on the level of
water in the collecting tank. A mul-
ti-coloured display in the lid indicates
the current operating status of the unit:
∙ Green - Standby
∙ Green flashing - Pump in operation
∙Green/orange - Alarm, pump is run-
ning
∙ Red - Alarm, pump switched off
Alarm
①The first alert level is for early
reporting of faults (such as kinked pip-
ing, inadequate pump performance) be-
fore more serious failure can occur.
If the condensate pump runs but does
not reach the switch-off point within ap-
proximately 60 seconds, then the alarm
will sound. A loud alarm tone sounds,
the display on the top flashes green/
orange, the potential-free contact is
switched, but the pumps carries on
running.
If the K2 plus reaches the switch-off
point within the 60 seconds that follow,
it will revert to "standby" mode and the
alarm will stop.
②If the switch-off level is not
reached within a total of 120 seconds,
then the condensate pump will shut
down for safety reasons to prevent
damage from occurring as a result.
The alarm continues to sound as a con-
tinuous tone, the display in the lid will
light up red, and the potential-free fault
indicator contact will remain activated.
To turn off the continuous alarm tone,
briefly interrupt the power supply (un-
plug it from the mains, remove the fuse,
...).
Remote alarm indication
The standard fault indicator contact
(change-over contact 0.5A/230V) is de-
signed for connecting an external alarm
device or for the fault indicator input of
the heating control system). When rest-
ing, contacts 40/42 are closed, and if the
alarm sounds in a continuous tone then
contacts 40/41 are closed.

4
ENGLISH
For the alarm relay system, a mul-
ti-conductor sheathed cable with a rat-
ed voltage of at least 300/500 V must
be used, such as H05... or equivalent;
permissible wire size 0.5 - 1.5 mm². To
ensure that the strain relief and seal
function properly, the cable must have a
diameter between 5 and 8 mm.
The length of the free conductors (un-
sheathed length) should be kept as
short as possible (not longer than 15
mm).
Insert the alarm connection cable into
the condensate pump housing parallel
to the mains cable. To do so, the second
opening in the cable grommet must be
opened up.
Feed the cable through the two strain
relief clamps to terminals 40-41-42.
When connecting the conductors, make
sure that they are securely fixed to the
terminals. Then tighten both clamps.
INSTALLATION
ATTENTION! It is not permitted to use
the appliance outdoors.
The following points must be observed
when choosing a suitable location for
installing the pump:
∙The condensate must flow into the
condensate pump from the siphon
trap using gravity.
∙The louvres on the K2 plus for ven-
tilating the pump must not be ob-
structed.
∙The connecting hoses must be laid in
such a way that there are no kinks in
the piping.
∙The K2 plus must be easy to access
to allow maintenance to be carried
out.
Pump
The condensate pump can be either
floor-standing or wall-mounted.
If wall-mounted, the distance between
drill-holes must be 19.5 cm. Please use
the fastening hardware supplied. It is
easy to level off the pump using the grid
pattern on the back of the pump.
ATTENTION! The pump must be in-
stalled in an absolutely horizontal posi-
tion as shown in the example.
Inlet
The K2 plus has three inlets from above
(2x ø28 and 1x ø33). Unused openings
must be closed off with plugs. The inlet
hose from the boiler or refrigerator/air
conditioning must be laid in such a way
that the condensate can flow into the
pump from the siphon trap using grav-
ity. To avoid obstructions, the inlet hose
must be cut off obliquely. A siphon must
be fitted in all inlets, unless this is al-
ready available in the heater, to prevent
exhaust from entering.
The connection of safety modules is not
permissible.
Pressure line
ATTENTION! Do not use grease or hose
clamps to attach the hose to the dis-
charge branch.
The hose must be laid from the conden-
sate pump to the wastewater collect-
ing sewer. The DN 50 connection piece
supplied facilitates the connection. The
smallest admissible radius when laying
the hose is 60 mm.
It would be advantageous if the hose
outlet was located at approximately the
same height as the pump. This would
considerably enhance the pumping per-
formance, avoid deposits in the hose
and extend the life of the pump as a re-
sult.
Take the pressure line up vertically
to the highest possible point and then
route it to the discharge point with a
slight downward gradient.
ATTENTION! The pressure line, from
its highest point, must be able to com-
pletely discharge its contents. Pockets
of air in the pressure line increase the
pumping resistance.
Alternatively to using the hose supplied
(ø10mm), it is also possible to use your
own 12 mm hose for this purpose. This
will reduce the resistance and increase
the pump performance if necessary.
ATTENTION! If the condensate pump is
installed below the back-flow level and
the discharge point is located on a sew-
er which is below the back-flow level
and is not protected against back-flow,
then the pressure line must be laid with
a loop located above the back-flow lev-
el. The connection to the sewer must be
pressure-tight.
Emergency overflow
To prevent damage to property, the
emergency overflow can be used in con-
junction with the alarm contact.
The emergency overflow is used for sys-
tematically draining off condensates in
the event of a pump breakdown.
ATTENTION! It must be ensured that
the condensate can drain off into an
emergency tank by gravity and the hose
is completely emptied.
At the same time, the alarm contact in
the pump can be used to turn off the
heater or air-conditioner to prevent fur-
ther condensate from occurring in the
event of a fault.

5
ENGLISH
MAINTENANCE
In view of the different uses, various
types of contamination can occur: Li-
mescale, algae growth and dust from
air conditioning/refrigeration or crusts
due to acids from condensing boilers.
This contamination must be removed
regularly to ensure proper operation
and maximum pump efficiency.
1. The upper section of the pump does
not need to be opened for cleaning
or maintenance purposes. Disen-
gage the condensate collector by
rotating the two side fasteners by a
1/4 turn (->open). Put your forefin-
gers under the two side fasteners,
and your thumbs in the side pockets
and then lift the upper section off
with your forefingers. In wall-mount-
ed appliances, press the conden-
sate collector downwards while the
upper section remains on the wall.
2. Clean the float switch and the con-
densate collector.
3. Before assembling these parts
again, please grease the sealing ring
with a sanitary fitting lubricant, e.g.
high-temperature grease.
4. Check the back-flow prevention valve
to ensure it does not leak, and clean
it if necessary. To do so, open the bay-
onet joint on the discharge branch
and take the valve out. If condensate
now leaks, empty the hose, clean the
rubber seal and ball and replace if
necessary. Assemble the parts again
and connect the pressure line with
the bayonet joint.
5. After completing these steps, con-
duct a performance test with the test
run button (rear left). The alarm can
also be tested by pressing the test
run button for more than 60 seconds
and for more than 120 seconds.
Quick tips for remedying
faults
Pump does not work
∙Press the test run button. If the
pump is now running, check the float
switch and clean it if necessary.
∙Check the mains voltage, the fuse
and the FI circuit breaker. Replace
defective fuses only with fuses with
the same nominal value. If the fuse
triggers again, call our service engi-
neers.
∙If the mains cable is damaged, it must
be replaced by the manufacturer only.
Decreased pumping performance
∙Pressure line, pump or back-flow
prevention valve obstructed = clean.
ATTENTION! If possible, reduce the
length of the hose or install the end
of the pressure line at a lower level.
This will increase the rate of flow in
the hose and avoid deposits.
∙Provide and use a hose with a larger
internal diameter (12 mm)
∙The pressure line is kinked or flat-
tened = observe minimum installa-
tion radius of 60 mm when laying it.
∙Rotor worn out = have it replaced by
the manufacturer since special tools
are required for this
Black-flow prevention valve is leak-
ing
∙Valve is contaminated = clean it or
replace it
Short alarm tone during pumping op-
eration
∙Please refer to "Decreased pumping
performance"
∙ Influx too large
Continuous alarm tone if tank is full
∙Please refer to "Decreased pumping
performance"
∙ Motor obstructed or faulty
Note
To turn off the continuous alarm tone,
briefly interrupt the power supply (un-
plug it from the mains, remove the fuse,
...).

6
3,1 [kg]
P1 65 [W]
U 1/N/PE ~230 [V]
f 50 [Hz]
IP 44
Technische Daten - Technical Data - Caractéristiques techniques - Techni-
sche Gegevens - Dati Tecnici - Dane techniczne - Műszaki adatok - 技术数 据
Max. Pumpenlaufzeit: siehe Abschnitt "Alarm".
The maximum running time of the pump is described in the
section entitled "Alarm".
Durée de fonctionnement max. de la pompe : voir para-
graphe « Alarme ».
Max. pomplooptijd: zie hoofdstuk "Alarm".
Per il tempo massimo di funzionamento della pompa vedere
il paragrafo "Allarme".
Maksymalny czas biegu pompy: patrz rozdział „Alarm”.
A szivattyú maximális menetidejéről lásd a „Riasztás“ c.
részt.
关于泵的最大运行时间，请参考“警报”章节。
Leistung - Performance - Capaciteit - Prestazioni -
Wydajności i moce - Teljesítmény - 性能
H [m] 1,5 2,0 2,5 3,0 3,5
Q[l/h] 520 440 365 290 200

7
DE · Konformitätserklärung
CS · Prohlášeni o shodě
DA · Overensstemmelseserklæring
EN · Declaration of Conformity
FI · Vaatimustenmukaisuusvakuutus
FR · Déclaration de Conformité
HU · Megfelelöségi nyilatkozat
IT · Dichiarazione di conformità
NL · Conformiteitsverklaring
PL · Deklaracja zgodności
RO · Declaraţie de conformitate
SK · Vyhlásenie o zhode
SV · Försäkran om överensstämmelse
JUNG PUMPEN GmbH - Industriestr. 4-6 - 33803 Steinhagen - Germany - www.jung-pumpen.de
DE · Wir erklären in alleiniger Verantwortung, dass das Produkt den aufgeführten Richtlinien entspricht.
CS · Prohlašujeme na svou výlučnou odpovědnost, že výrobek odpovídá jmenovaným směrnicím.
DA · Vi erklærer under ansvar at produktet i overensstemmelse med de retningslinjer
EN · We hereby declare, under our sole responsibility, that the product is in accordance with the specified Directives.
FI · Me vakuutamme omalla vastuullamme, että tuote täyttää ohjeita.
FR · Nous déclarons sous notre propre responsabilité que le produit répond aux directives.
HU · Kizárólagos felelősségünk tudatában kijelentjük, hogy ez a termék megfelel az Európai Unió fentnevezett irányelveinek.
IT · Noi dichiariamo sotto la nostra esclusiva responsabilità che il prodotto è conforme alle direttive citate
NL · Wij verklaren geheel onder eigen verantwoordelijkheid dat het product voldoet aan de gestelde richtlijnen.
PL · Z pełną odpowiedzialnością oświadczamy, że produkt odpowiada postanowieniom wymienionych dyrektyw.
RO · Declarăm pe proprie răspundere că produsul corespunde normelor prevăzute de directivele mai sus menţionate.
SV · Vi försäkrar att produkten på vårt ansvar är utförd enligt gällande riktlinjer.
SK · Na výlučnú zodpovednosť vyhlasujeme, že výrobok spíňa požiadavky uvedených smerníc.
CE 355-12-1604
Steinhagen, 20-04-2016
______________________ i.V. ____________________
Stefan Sirges, General Manager Rüdiger Rokohl, Sales Manager
DE · Weitere normative Dokumente CS · Jinými normativními dokumenty DA · Andre normative doku-
menter EN · Other normative documents FI · Muiden normien FR · Autres documents normatifs HU
· Egyéb szabályozó dokumentumokban leírtaknak IT · Altri documenti normativi NL · Verdere normatieve
documenten PL · Innymi dokumentami normatywnymi RO · Alte acte normative SV · Vidare normerande
dokument SK · Iným záväzným dokumentom:
• 2006/42/EG (MD) EN 60335-1:2012/AC:2014
• 2011/65/EU (RoHS)
• 2014/30/EU (EMC) EN 55014-1:2006/A2:2011, EN 55014-2:1997/A2:2008, EN 61000-3-2:2014, EN 61000-3-3:2013
DE · Richtlinien - Harmonisierte Normen
CS · Směrnice - Harmonizované normy
DA · Direktiv - Harmoniseret standard
EN · Directives - Harmonised standards
FI · Direktiivi - Yhdenmukaistettu standardi
FR · Directives - Normes harmonisées
HU · Irányelve - Harmonizá szabványok
IT · Direttive - Norme armonizzate
NL · Richtlijnen - Geharmoniseerde normen
PL · Dyrektywy - Normy zharmonizowane
RO · Directivă - Norme coroborate
SK · Smernice - Harmonizované normy
SV · Direktiv - Harmoniserade normer
K2 plus (JP46589)
DE · Bevollmächtigter für technische Dokumentation CS · Oprávněná osoba pro technickou dokumentaci
DA · Autoriseret person for teknisk dokumentation EN · Authorized person for technical documentation
FI · Valtuutettu henkilö tekninen dokumentaatio FR · Personne autorisée à la documentation technique
HU · Hivatalos személy műszaki dokumentáció IT · Persona abilitata per la documentazione tecnica
NL · Bevoegd persoon voor technische documentatie PL · Pełnomocnik ds. dokumentacji technicznej
RO · Persoană autorizată pentru documentatiei tehnice SV · Auktoriserad person för teknisk dokumenta-
tion SK · Oprávnená osoba pre technickú dokumentáciu:
JUNG PUMPEN - Stefan Sirges - Industriestr. 4-6 - 33803 Steinhagen

Ersatzteile - Spare parts - Pièces de rechange - Reserveonderdelen - Parti di ricambio - Reservedele - Reserv-
delar Varaosat - Części zamienne - Náhradní díly - Alkatrészek - Piese de schimb - Запасные части - 备件
B 47594 -11-1602 www.jung-pumpen.de
JUNG PUMPEN K2 PLUS (JP46589)
①Haube Hood JP47008
②Probelauftaster Push button trial run JP47000
③Netzleitung Cable JP47006
④Steuerung Control panel JP47002
⑤Schalter Switch JP47001
⑥Schwimmer Float JP46999
⑦Lippendichtung Lip seal ring JP47004
⑧Komponenten-
träger Component receiver JP47009
⑨Laufrad Impeller JP47005
⑩Verschlüsse Locking device JP47010
⑪Kondensatwanne Condensate tank JP47007
⑫Rückschlagventil Non-return valve JP47003
⑬Anschluss-Set
DN50
Connection-Set
DN 50 JP41200
8

9

Pump Technical Services Limited - Pump House - Unit 12 -
Bilton Road Industrial Estate - Erith - Kent - DA8 2AN
Tel: [phone] - Fax: [phone] - Email: [email protected]