KSB Mini-Compacta S-Y/1 Series Montageanleitung

Floodable Sewage Lifting Unit

mini-Compacta

From Series S-Y/1

From Series 2013w01

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual mini-Compacta

Original operating manual

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.

Contents

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Contents

Glossary .................................................................................................................................................. 6

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

1.6 Key to safety symbols/markings.......................................................................................................................7

2 Safety...................................................................................................................................................... 9

2.1 General..............................................................................................................................................................9

2.2 Intended use .....................................................................................................................................................9

2.3 Personnel qualification and training...............................................................................................................9

2.4 Consequences and risks caused by non-compliance with this manual .......................................................10

2.5 Safety awareness ............................................................................................................................................10

2.6 Safety instructions for the operator/user......................................................................................................10

2.7 Safety information for maintenance, inspection and installation ..............................................................10

2.8 Unauthorised modes of operation................................................................................................................11

3 Transport/Storage/Disposal ................................................................................................................ 12

3.1 Checking the condition upon delivery..........................................................................................................12

3.2 Transport.........................................................................................................................................................12

3.3 Storage/preservation......................................................................................................................................13

3.4 Return to supplier...........................................................................................................................................13

3.5 Disposal ...........................................................................................................................................................14

4 Description............................................................................................................................................ 15

4.1 General description ........................................................................................................................................15

4.2 Designation.....................................................................................................................................................15

4.3 Name plates ....................................................................................................................................................17

4.4 Design details..................................................................................................................................................18

4.5 Configuration and function...........................................................................................................................19

4.6 Technical data.................................................................................................................................................21

4.6.1 Electrical data (LevelControl Basic 1) ................................................................................................21

4.6.2 Electrical data (LevelControl Basic 2) ................................................................................................22

4.7 Fluids handled.................................................................................................................................................23

4.8 Collecting tank................................................................................................................................................23

4.9 Noise characteristics .......................................................................................................................................23

4.10 Scope of supply...............................................................................................................................................24

4.11 Dimensions and weights ................................................................................................................................24

5 Installation at Site................................................................................................................................ 25

5.1 Safety regulations...........................................................................................................................................25

5.2 Checks to be carried out prior to installation...............................................................................................25

5.3 Installing the sewage lifting unit ..................................................................................................................26

5.4 Connecting the piping ...................................................................................................................................27

5.5 Cellar drainage ...............................................................................................................................................29

5.6 Electrical connection ......................................................................................................................................30

5.7 Checking the direction of rotation................................................................................................................31

6 Commissioning/Start-up/Shutdown................................................................................................... 32

6.1 Commissioning/Start-up.................................................................................................................................32

6.1.1 Prerequisites for commissioning/start-up .........................................................................................32

6.2 Operating limits..............................................................................................................................................32

6.2.1 Frequency of starts.............................................................................................................................32

6.2.2 Supply voltage....................................................................................................................................33

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6.3 Prerequisites for commissioning/start-up......................................................................................................33

6.3.1 Lifting unit with LevelControl Basic 1...............................................................................................33

6.3.2 Commissioning with LevelControl Basic2 ........................................................................................37

6.4 Shutdown........................................................................................................................................................39

7 Operation.............................................................................................................................................. 40

7.1 Control panel (LevelControl Basic2) .............................................................................................................40

7.1.1 LED display .........................................................................................................................................40

7.1.2 Display ................................................................................................................................................41

7.1.3 Navigation keys..................................................................................................................................42

7.2 Manual-0-automatic selector switch .............................................................................................................42

7.3 Control panel..................................................................................................................................................42

7.3.1 Displaying measured values ..............................................................................................................42

7.3.2 Displaying and changing parameters ...............................................................................................43

7.3.3 Displaying and acknowledging alerts and warnings.......................................................................45

7.3.4 Displaying the alerts list ....................................................................................................................46

7.3.5 Replacing the rechargeable battery .................................................................................................47

8 Servicing/Maintenance........................................................................................................................ 48

8.1 General information/safety regulations........................................................................................................48

8.2 Maintenance schedule ...................................................................................................................................49

8.2.1 Inspection contract ............................................................................................................................49

8.2.2 Measuring the insulation resistance .................................................................................................49

8.2.3 Unblocking the cutter........................................................................................................................49

8.2.4 Oil check/Oil change ..........................................................................................................................49

8.2.5 Emergency operation with one pump..............................................................................................51

8.3 Dismantling the hydraulic system..................................................................................................................51

8.3.1 Removing the rotating assembly ......................................................................................................51

8.3.2 Dismantling the motor section .........................................................................................................52

8.3.3 Removing the rotating assembly and pump/plate assembly ..........................................................52

8.3.4 Removing the rotating assembly ......................................................................................................53

8.3.5 Dismantling the motor section .........................................................................................................53

8.4 Reassembly......................................................................................................................................................54

8.4.1 General instructions...........................................................................................................................54

8.4.2 Installing the bearing assembly/ shaft seal......................................................................................54

8.4.3 Fitting the bearing assembly/shaft seal............................................................................................56

8.4.4 Fitting the rotating assembly............................................................................................................56

8.5 Installing the float switch ..............................................................................................................................58

8.6 Fitting the repair kit and check valve............................................................................................................58

8.7 Tightening torques.........................................................................................................................................59

8.8 Disposal/recycling of the lifting unit .............................................................................................................60

8.9 Checklist for commissioning/inspection ➀ and maintenance ➁..................................................................60

9 Trouble-shooting.................................................................................................................................. 62

10 Related Documents.............................................................................................................................. 64

10.1 General assembly drawings/exploded views with list of components........................................................64

10.1.1 mini-Compacta U60, U100, UZ150 - Rotating assembly ..................................................................64

10.1.2 mini-Compacta U60 C, U100 C, UZ150 C - Rotating assembly.........................................................66

10.1.3 mini-Compacta U60, U100 - Collecting tank ...................................................................................68

10.1.4 mini-Compacta UZ150 - Collecting tank...........................................................................................70

10.1.5 mini-Compacta US40 – Rotating assembly .......................................................................................72

10.1.6 mini-Compacta US100, UZS150 - Rotating assembly .......................................................................75

10.1.7 mini-Compacta US40 – Collecting tank ............................................................................................78

10.1.8 mini-Compacta US100 - Collecting tank ...........................................................................................79

10.1.9 mini-Compacta UZS150 - Collecting tank .........................................................................................80

10.2 Connection examples .....................................................................................................................................81

10.2.1 mini-Compacta US40, U60, U100, US100 ..........................................................................................81

10.2.2 mini-Compacta UZ150, UZS150.........................................................................................................82

10.2.3 mini-Compacta US40 – concealed in a pre-wall system...................................................................83

10.3 Dimensions......................................................................................................................................................84

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10.3.1 mini-Compacta US40 and U60...........................................................................................................84

10.3.2 mini-Compacta U100 and US100.......................................................................................................85

10.3.3 mini-Compacta UZ150 and UZS150...................................................................................................86

10.3.4 Dimensions of shut-off elements ......................................................................................................87

10.4 Connections ....................................................................................................................................................89

10.4.1 mini-Compacta US40 / U60................................................................................................................89

10.4.2 mini-Compacta U100 / US100............................................................................................................90

10.4.3 mini-Compacta UZ150 / UZS150........................................................................................................91

10.5 Types of connection .......................................................................................................................................92

10.6 Wiring diagrams .............................................................................................................................................93

10.6.1 LevelControl Basic 1 - single-phase (1~) ...........................................................................................93

10.6.2 LevelControl Basic 1 - three-phase (3~) ............................................................................................94

10.6.3 LevelControl Basic 2 Type BC - dual-pump unit - up to 1.5 kW, 1~ ................................................95

10.6.4 LevelControl Basic 2 Type BC - single-pump unit with cutter - up to 1.5 kW, single-phase 1~ ....96

10.6.5 LevelControl Basic 2 Type BS - dual-pump unit with cutter - up to 1.5 kW, 1~ .............................97

10.6.6 LevelControl Basic 2 Type BC - dual-pump unit - DOL - up to 4 kW ...............................................98

11 EU Declaration of Conformity............................................................................................................. 99

12 Declaration of Performance as per Regulation (EU) No. 305/2011, Annex III................................ 100

13 Declaration of Performance as per Regulation (EU) No. 305/2011, Annex III................................ 101

14 Certificate of Decontamination......................................................................................................... 102

Index ................................................................................................................................................... 103

Glossary

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Glossary

ATEX

The acronym ATEX is the French abbreviation for

"Atmosphère explosible" and refers to the two

European Union (EU) directives covering the area

of explosion protection: ATEX Equipment Directive

2014/34/EU (also referred to as ATEX95) and ATEX

Workplace Directive 1999/92/EC (also referred to

as ATEX137).

Bubbler control with compressor

The air compressor is integrated in the measuring

system in addition to the pneumatic level

measurement. Condensation can be discharged.

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.

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.

Effective volume

Volume in the collection tank between start and

stop level that can be lifted

EN 12 056-4

European standard governing the selection,

operation and maintenance of sewage lifting units

within buildings and sites.

EN 12050-1

European Standard for sewage lifting units which

are used to dispose of sewage with faeces

occurring below the flood level of buildings and

land. It defines general requirements as well as

principles of construction and testing.

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

Nominal diameter DN

Identifier (inside diameter) used for characterising

mating components such as pipes, pipe

connections and fittings

Pneumatic level measurement

Determining the liquid level in the tank by means

of a pressure sensor integrated in the control unit.

Separator

Device for physically separating the two phases of

a two-phase flow, e.g. for separating solid

particles or liquid drops from flowing gases.

Sewage lifting unit

Device for collecting and automatically lifting

waste water with or without faeces above the

flood level

Soft starting

Measures taken to limit the output of a power

supply unit or electric motor, to limit the starting

current, and avoid excessive acceleration and

torques.

Star/delta starting

For starting large three-phase squirrel-cage motors

(5.5 kW and above). Prevents voltage dips and

fuses from tripping. Used if direct starting would

result in a high starting current.

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

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 and size as well as the main operating data.

They uniquely identify the pump (set) and serve as identification for 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 machinery

components

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

Step-by-step instructions

Note

Recommendations and important information on how to handle

the product

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.

1 General

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Symbol Description

CAUTION

This signal word indicates a hazard which, if not avoided, could

result in damage to the machine and its functions.

Explosion protection

This symbol identifies information about avoiding explosions in

potentially explosive atmospheres in accordance with EU Directive

2014/34/EU (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

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.

2.3 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.

2 Safety

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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.)

2.7 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. (ðSection6.4,Page39)

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