Zehnder Pumpen MICROBOY User manual

Wastewater
lifting unit
MICROBOY
Operating instructions

Contents:
page
Declaration of Conformity....................................................................... 3
1. General............................................................................................... 4
1.1 Application........................................................................................ 4
1.2 Technical data................................................................................... 4
1.3 Areas of application........................................................................... 4
1.4 Accessory.......................................................................................... 5
2. Safety................................................................................................ 5
2.1 Marking of information in the instruction for use.............................. 5
2.2 Danger arising due to non-compliance with safety advice............. 5
2.3 Safety conscious working .................................................................. 5
2.4 Safety information for owner / operator.............................................. 5
2.5 Safety information for maintenance, inspection and fitting................ 5
2.6 Non-manufacturer modification and spare part production................ 6
2.7 Unauthorised usage........................................................................... 6
3. Description........................................................................................ 6
4. Installation and commencement of operation..................................... 6
5. Operation.......................................................................................... 7
6. Maintenance/Servicing...................................................................... 7
7.Disturbance,cause and elimination..................................................... 7
8. Spare parts......................................................................................... 9
9. Warranty............................................................................................ 10
10.Technical modification..................................................................... 10

3
Declaration of Conformity
- In accordance with EG- low voltage specifiactions i.d.F. 93/68/EWG, appendix I
- In accordance with EMV 92/31/EWG und 93/68/EWG
- In accordance with 2006/42/EG
----------------------------------------------------------------------------------------------------
We the following ZEHNDER Pumpen GmbH
Zwönitzer Straße 19
08344 Grünhain-Beierfeld,
declare that the wastewater lifting-unit Microboy
conforms to the following specifications:
- EMV 92/31/EWG und 93/68/EWG
- EG- low voltage specifiactions i.d.F. 93/68/EWG, appendix I
- 2006/42/EG
Applied harmonized norms, particularly
- EN 809
- EN 60 335-1
- EN 60 335-2-41
- EN 50 081-1
- EN 50082-1
Grünhain, 22.12.2009
Matthias Kotte
Product development manager

4
1.General
1.1. Application
This operating instruction is valid for the wastewater lifting-unit type MICROBOY.
Non-compliance with the operating instructions - in particular with the safety instructions - as well as non-
manufacturer modification or use of non-original spare parts will result in loss of guarantee coverage. The
manufacturer accepts no liability for damage or injury resulting from incorrect use of the equipment.
This compact unit can be used for waste disposals from one toilet and additionally other sanitary applications
such as hand-basins, showers and bidets which are located beneath the canalization (f.e. in cellar rooms).
This unit is designed only to pump household sewage water and not any harmful material according DIN 1986
T3.Sanitary towels, food, long-fibres, sanitary articles and similar subjects are prohibited.
Also it is not allowed to connect washing machines.
Manufacturer: Zehnder Pumpen GmbH
Zwönitzer Straße 19
08344 Grünhain-Beierfeld
Instruction last modified: January 2009
1.2Technical data:
Power P1......................................0,65 kW
Voltage U....................................230 V-50 Hz
Nominal current ..........................2,5 A
Speed...........................................2800 U/min
Max. capacity Qmax......................10 m3/h
Max. head Hmax ...........................10 m
Max. temperature tmax..................40°C
Outlet connection........................11/4 inch
Weight.........................................11 Kg
Overall dimensions......................454x254x299 mm
Materials:
container......................................ABS
cover............................................ABS
pump-body..................................PP
impeller .......................................PA 6
shaft.............................................Stainless steel
outlet hose...................................EPDM
seals.............................................NBR
1.3 Areas of application
This compact unit is designed for direct connection to a toilet basin equipped with a horizontal discharge pipe.
The sewage water of this toilet and additionally of a hand-basin, shower or bidet can be pumped to the
canalization at a higher level or to a sewarage far away.
This unit is constructed to handle waste water of households. All sanitary objects must be installed in the same
room as this lifting unit.
Connection of washing-machines is not allowed !
Also waste-water with sanitary towels, food, long-fibres,solvents,acids and similar cannot be
pumped
Attention !

5
1.4 Accessory
This unit is ready for plug-in,complete with pressure connection,check-valve and all necessary seals.
2. Safety
These instructions for use contain general information, which should be noted when setting up, using and serving
the equipment.
2.1 Marking of information in the instruction for use
danger symbol in accordance with DIN 4844 - W9,
for warnings regarding electrical current the following symbol is used
danger symbol in accordance with DIN 4844 - W8
Instructions which must be complied with if damage to the equipment and malfunctioning is to be avoided are
indicated by the presence of the words
- Attention! or Important! -
2.2 Dangerous arising due to non-compliance with safety advice
Ignoring of security instructions can lead to danger of personnel and to the environment as well as causing
possible damage to the equipment. Non-compliance with security instructions can lead to the loss of right to
claim damages.
Non-compliance with security instructions can lead for example to:
- Breakdown in important functions of the equipment
- Breakdown in prescript methods for maintenance and upkeep
- Danger of injury from electrical, mechanical or chemical sources
- Environmental damage resulting from leaks of environmentally dangerous substances
2.3 Safety concious work
These safety instructions, as well as all national safety requirements and extra internal company precautions or
such laid down by the owner of the euipment must be observed.
2.4 Safety information for the owner / operator
- Any parts of the machine which could de a possible source of hot or cold burns should be covered.
Covering for moving parts (e.g. couplings) should not be removed while the machine is in use.
Leak out of dangerous substances (e.g. explosives, poisons, hot liquids) have to be handled in such a way
that no danger to persons or the environment may occur. Legal requirements must be observed.
- Danger resulting from electrical current must be prevented (For more information consult the
specifications of the VDE or your local electricity board).
2.5 Safety information for maintenance, inspection and fitting
The owner must ensure that all maintenance, inspection and fitting work is carried out by qualified and authorised
personel who are familiar with the operating instructions for equipment. In general all maintenance work must be
carried out while the equipment is not in operation. The instructions for turning off the equipment contained in
these operating instructions must be observed.
Pumps and units which carry hazardous materials must be decontaminated.

6
Immediately after completion of the work all safety and protection coverings should be reinstalled and / or
switched on.
Before switching the equipment on again the points covered in the section concerning first use of the equipment
should be consulted.
2.6 Non-manufacturer modifications and spare part production
Modifications or changes to the pump are only allowed after consulting the manufacturer. Original spare parts
and accessories authorised by the manufacturer should be used to ensure safety. The use of other parts may lead
to loss of liability.
2.7 Unauthorised usage
The safety of the delivered pump is only guaranteed by usage according to the section 1 - General of the
instructions. The listed maximum ratings as per specification should under no circumstances be exceeded.
3. Description
This unit is a waste water lifting plant according DIN 19762.
The standard voltage is 230 V-50 Hz.
The unit works automatically by a built-in pressure switch.The sewage water flows into the tank by gravity.
At a definated level this pressure switch starts the pump and the liquid will be delivered to the canalization.
At a minimmum water level the pressure switch disconnects from mains and a time-relay inside the control-box
keeps the pump working for another 10 seconds.During this time the cutting device will be cleaned.
After this the pump stops.
In case of a mal-function the water level inside the tank will not decrease.Another 30 seconds later the alarm
buzzer will be activated.
For manual tests the pump can be started by pressing the switch at the units top.
4. Installation and commencement of operation
Before installing and starting please check the pump at possible demages (f.e. during trans
port) to prevent personal injury by electrical shock.
Prior to working (installing,servicing,repairs etc.) the main plug must be disconnected from
power supply.
Attention! The pump unit has a cutting device (rotating knife!) at the suction side.
Danger of injury !
Before installing the transport securing (carton) between pump unit and cover must be removed.
Loosen the screws of this cover,remove , take out this carton and fasten the cover.
Connection of lavatory:
The lifting unit has to be connected to the lavatory by using the main seal. The distance between toilet and unit
must be min. 1 cm.
Installing of pressure outlet:
The construction allows installation of the outlet pipe to the right or left side.Therefore turn the bend into
preferred direction.Use the clip to fix the pressure hose to this bend and shorten it to the appropriate length.
The pressure pipe has to be connected at the thread of the check-valve.
The minimum diameter of the pressure pipe must be 25 mm and has to be connected to the next sewage pipe
frost-resistant and in uptaking position.
Please take care for the right position of the check-valve to pretend return flow from canalization.It is
recommendable to install a gate valve.

7
Installing of ventilation pipe:
The ventilation of the unit is possible either by the integrated carbon filter into the room directly or by an external
pipe over the roof.The diameter of this pipe must be 40 mm. In case of external ventilation the integrated carbon
filter and ball must be removed.
Additional connections:
On both sides of the unit are two optional inlets 40 mm to connect a hand basin, shower etc.
The plastic caps must be removed to connect this additional waste pipes.
5. Operation
Because of the rotating cutting edge at the pumps shaft the screw lid is secured by a screw. During
operation this lid must be closed For repairs or servicing the unit must be disconnected from electrical
net.
All connections must be checked up if fitted correctly and tightly.
To check the function of the unit toilet must be flushed.(may be two times to fill the tank to the starting level.
The pump starts automatically and is in operation for about 6-12 seconds which depends on the lifting head.
During this time the tank will be emptied but the pump will work for another 15 seconds additionally to clean the
cutting device. This time can be changed by adjusting the time relay inside the control-box.
6. Maintenance/Servicing
- Disconnect the plug before working
Cleaning:
- All outside surfaces (tank,cover and screw lid cover) with usual domestic cleansing agent.
- In case of using WC cleansing agent it is necessary to flush several times to be sure that there are no remains
inside the container.
-Permanent cleaners inside the toilet basin must fixed carefully !
Dismantling of pump unit and control box must be done by authorized personal !
May not be initiated among other things:
·Firm materials, fibrous materials, tar, sand, cement, cinder, coarse paper, paper towels, cardboard,
rubble, garbage, battle rubbish, fat, oils.
·All drainage objects lying about the back up level (EN 12 056-1).
·Sewage with injurious materials (German Institute for Standardization 1986-100), e.g., adipose
sewage of canteen kitchens. The introduction may occur only over a fat separator to German Institute
for Standardization 4040-1.

8
7. Disturbance,cause and elimination
-Disconnect from mains before working!
Disturbance
Cause
Elimination
1. Motor doesn`t turn
- no voltage
- connect plug
- check wall socket and fuse
- cutting edge is blocked
- remove cover,turn shaft clockwise
with screwdriver
-inform service at recurrence
- motor overloaded
- thermical overload stops motor,reset
-inform service at recurrence
- level-switch damaged
- use push botton to empty tank
and inform service
- control system damaged
- inform service
- motor defective
- inform service
2. motor turns,but no pumping
- outlet hose clogged or buckled
- clean or repair,testrun
- air vent of pump housing clogged
- remove hose and clean hose and
nipple
- check-valve installed in wrong
direction
- turn and test run
- ventilation of tank insufficient
- replace carbon filter
3. motor starts and stops
- ventilation clogged
- cleaning
- check-valve leak
- cleaning/exchange
- toilet flush defected
- check/repair
4. motor turns very noisy
- solid inside
- inform service.
5. alarm buzzer is activated
- max. level of liquid (reasons see
above)
- use push botton /inform service

8. Spare parts
With spare part order give please always the investment type with standard number!
assembly
drawing
no.
Qty
nomination
Article
number
assembly
lifting unit
1.0
1
Assembly unit complete
11017E2
1.10/1.20
1
Container MICROBOY; complete without pump and
switching device
117620
1.120
1
O-ring 30x3
117703
1.140
1
Valve insert PE
117186
1.150
1
Lip seal
117188
1.160
1
Covering cap MICROBOY
117602
1.170
1
Check lid
117012.1
1.180
1
Cover for Check lid
117603
1.190
1
O-ring 125x8
117013
1.200
5
Sleeve
117015
1.210
1
Activated carbon filter
117016.0
1.220
1
Blind cover
117017
1.230
1
Valve ball
117189
1.270
2
Gasket ring Pg 9
117025
1.290
1
Sleeve gasket grey
117029
1.300
0,15m
Venting hose 12x2x150 long
117030
1.310
1
Angle nozzle G3/8
117031
1.320
1
Pressure hose MICROBOY
117604
1.330
2
Hose clip 20-32
117033
1.340
2
O-ring 34,52x3,53
117034
1.350
4
Rubber foot
117035
1.360
2
Countersunk 3,5x9,5
117605
1.370
1
Non return valve valve
117056
1.410
1
Lense head screw 4,8x22
117045
1.460
1
Reducing fitting G 1 ¼
117055
1.470
1
Threaded sleeve G 1 ¼-IG-IG
117195
1.570
1
Locking device for check lid cover
117149
1.580
1
Lense head screw 3,5x13
117614
1.590
1
Rubber disc
117150
1.720
2
Hose sewer small
129011
1.730
2
Cap nut
129910
1.770
3
Lens head screw 3,9x13
207022
1.800
1
Protection cap from silicone
117406
1.810
1
Clamping piece
117044
1.820
1
O-ring 15x2
117206
1.830
1
Counternut G 3/8
117205
assembly: pump
2.0
1
Pump MICROBOY-E2; complete
117502
2.10
1
End shield
200.040
2.20
1
Cablel failead
117040
2.30
1
Supply cable pump
117009
2.50
3
Shoulder bolt M5x130
800.078
2.60
3
Hex-nut M5
800.077
2.70
1
Stator MICROBOY
117132.1
2.80
1
Rotor MICROBOY
117052.1
2.90
2
Compansating disk
270029

Baugruppen
Pos.-Nr.:
Stückza
hl
Bezeichnung
Artikelnummer
assembly: pump
2.100
2
Ball bearing 6202
270017
(continuation)
2.110
1
Compensating disk 24x35x0,5
270018
2.120
1
Shaft seal 12x26x7
117125
2.130
1
Mechanical seal bonnet
270921
2.140
1
Mechanical seal bottom section
270021
2.160
1
Impeller
272905
2.170
1
Locking ring A12x1
270028
2.180
1
Shim ring 6/1x12
117200
2.190
2
Shim ring 6/0,5x12
117201
2.200
4
Shim ring 6/0,1x12
117202
2.210
1
Cutter
117197
2.220
1
Retaining ring S6
117006
2.230
1
Socket head srew M6x12
117005
2.240
1
Pump housing MICROBOY-E2
100.400
2.250
1
Bottom flange MICROBOY-E2
117002.1
2.280
1
O-ring 120x2,5
117007
2.290
4
Lens head screw 4,2x19
270024
2.300
1
O-ring 72x3,5
117700
2.310
1
Cutting plate
117198
2.320
3
Countersunk M4x8
117199
2.330
1
Hose nozzle, in-line G 3/8
117191
2.340
3
Clamping piece
117182
2.350
3
Socket head screwM6x8
117026
assembly:
Switch device
3.0
1
Switching deviceMICROBOY-E2; complete
117410.1
3.10
1
Switching box bonnet
117606
3.20
1
Switching box bottom section
117607
3.25
1
Circuit board MICROBOY-E2
600.250
3.30
1
Cable H05-VV-F-3G1-1,5m with male connector
117047
3.40
1
Control cable H03-VV-F-2x0,75-0,5m
117048
3.50
1
Pushbutton
117042
3.60
2
Cable fairlead d=8
117040
3.70
1
Cable fairlead d=5
117041
3.80
1
Manostat type 901.10
117024
3.90
1
Protection cap for manostat
117024.2
3.200
2
Lens head screw 2,9x6,5
117347
3.220
4
Lens head screw 3,5x13
117614
3.260
1
Capacitor
297226
9. Warranty
This unit carries a 24 month manufacturer warranty on material and workmanship. The warranty period begins
with the date of purchase by the end user. Proof of purchase should be retained. This warranty does not cover
frost damage, dry running, thermal overloading or pumping abrasive parts in the liquid.
Warranty claims are recognized only if the unit is returned fully assembled to your dealer. Consequential
damages are not covered by the manufacturer.
10. Technical modification
.................. without prior notice

Appendix 1: Installation example
Appendix 2: pump unit

Appendix 3 and 4: overview complete lifting unit

Appendix 5: Switch device
Delay time and overdrive time depending on DIP-switch setting
delay time 5 s
overdrive time 5 s
delay time 5 s
overdrive time 15 s
delay time 5 s
overdrive time 10 s
delay time 0 s
overdrive time 5 s
delay time 5 s
overdrive time 20 s
delay time 5 s
overdrive time 10 s
delay time 0 s standard adjustment
overdrive time 15 s standard adjustment
delay time 0 s
overdrive time 20 s