KSB Ama-Drainer-Box Bedienungsanleitung
Automatic Waste Water Lifting Unit
Ama-Drainer-Box
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual Ama-Drainer-Box
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 SE & Co. KGaA, Frankenthal 08/01/2018
Contents
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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 this manual .........................................................8
2.5 Safety awareness ..............................................................................................................................................8
2.6 Safety instructions for the operator/user........................................................................................................8
2.7 Safety information for maintenance, inspection and installation ................................................................8
2.8 Unauthorised modes of operation..................................................................................................................8
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...........................................................................................................................13
4.6 Fluids handled.................................................................................................................................................14
4.7 Scope of supply...............................................................................................................................................14
4.8 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 Installing the lifting unit................................................................................................................................18
5.3.1 Installing the underfloor box ............................................................................................................18
5.3.2 Connect the underfloor box piping..................................................................................................19
5.3.3 Fitting the level-adjusting piece or the puddle flange with level-adjusting piece (not included in
the scope of supply)...........................................................................................................................24
5.3.4 Fitting MK400 and MK630 puddle flanges (not included in the scope of supply) ......................24
5.3.5 Backfilling around the tank ..............................................................................................................25
5.3.6 Fitting the sealing collar....................................................................................................................27
5.4 Installing the above-floor lifting unit ...........................................................................................................29
5.4.1 Installing the above-floor box...........................................................................................................29
5.4.2 Connecting the above-floor box piping ...........................................................................................30
5.5 Installing the submersible motor pump(s)....................................................................................................33
5.5.1 Single-pump units ..............................................................................................................................33
5.5.2 Dual-pump units ................................................................................................................................39
5.6 Fitting the cover plate/cover..........................................................................................................................43
5.7 Venting device with activated carbon filter (accessories)............................................................................45
6 Commissioning/Start-up/Shutdown................................................................................................... 47
6.1 Commissioning/Start-up.................................................................................................................................47
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6.1.1 Prerequisites for commissioning/start-up .........................................................................................47
6.1.2 Starting up/stopping the pump set...................................................................................................47
6.1.3 Operating limits .................................................................................................................................47
6.2 Shutdown/storage/preservation ....................................................................................................................47
6.2.1 Measures to be taken for shutdown ................................................................................................47
6.3 Returning to service .......................................................................................................................................48
7 Servicing/Maintenance........................................................................................................................ 49
7.1 Safety regulations...........................................................................................................................................49
7.2 Servicing/inspection........................................................................................................................................49
7.3 Drainage/cleaning ..........................................................................................................................................50
7.4 Recommended spare parts stock...................................................................................................................50
8 Trouble-shooting.................................................................................................................................. 51
9 Related Documents.............................................................................................................................. 52
9.1 General assembly drawing with list of components ....................................................................................52
9.1.1 Single-pump unit underfloor box1U / above-floor box1B...........................................................52
9.1.2 Dual-pump unit underfloor boxZ2U / above-floor boxZ2B .........................................................55
9.2 Dimensions......................................................................................................................................................58
9.2.1 Underfloor box of single-pump unit 1 U..........................................................................................58
9.2.2 Above-floor box of single-pump unit 1 B.........................................................................................59
9.2.3 Underfloor box of dual-pump unit Z2 U ..........................................................................................60
9.2.4 Above-floor box of dual-pump unit Z2 B .........................................................................................61
9.3 Installation example.......................................................................................................................................62
9.3.1 Underfloor box 1 U ............................................................................................................................62
9.3.2 Above-floor box 1 B...........................................................................................................................62
9.3.3 Underfloor box Z2 U ..........................................................................................................................63
9.3.4 Above-floor box Z2 B.........................................................................................................................63
10 EU Declaration of Conformity............................................................................................................. 65
11 Declaration of Performance as per Regulation (EU) No. 305/2011, Annex III.................................. 66
12 Certificate of Decontamination........................................................................................................... 67
Index ..................................................................................................................................................... 68
Glossary
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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.
Collecting tank
Component of a waste water lifting unit in which
the incoming waste water is stored in
unpressurised condition prior to automatic lifting.
Domestic waste water
Faecal-free waste water (grey water) from
washbasins, showers, washing machines, etc.
EN 12050-2
European Standard for waste water lifting units
which are used to dispose of faeces-free waste
water occurring below the flood level of buildings
and sites. It defines general requirements as well
as principles of construction and testing.
Grey water
Faecal-free waste water from washbasins,
showers, washing machines, etc.
Inlet line
Pipe used for draining waste water from sanitary
installations into the lifting unit
Noise characteristics
The noise characteristics are indicated as surface
sound pressure level in dB(A).
Nominal diameter DN
Identifier (inside diameter) used for characterising
mating components such as pipes, pipe
connections and fittings
Stormwater
Water from natural precipitation which has not
been contaminated by any form of use
Submersible motor pump
Submersible motor pumps are floodable, close-
coupled units which are not self-priming. The
pumps are usually operated completely
submerged. They may be operated outside the
fluid for short periods of time, until the minimum
fluid level has been reached.
Waste water
Water which has been changed by some type of
use, e.g. domestic waste water
Waste water lifting unit
Device for collecting and automatically lifting
faecal-free waste water above the flood level
1 General
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Observe the noise characteristics, indicated as surface sound pressure level.
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.
1.4 Other applicable documents
Table1: 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
Operating manual of control unit for dual-pump
units
1.5 Symbols
Table2: 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
2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table3: 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 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.
The safety information in all sections of this manual must be complied with.
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 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 in this operating 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.
2 Safety
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2.4 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with this operating manual 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, directives 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 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 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 has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning.
▪Make sure the lifting unit cannot be accessed by unauthorised persons (e.g.
children).
2.8 Unauthorised modes of operation
Always observe the limits stated in the product literature.
2 Safety
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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.
(ðSection2.9,Page9)
2.9 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 maximum flow rates 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 operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
3 Transport/Temporary Storage/Disposal
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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 and the insurer about the damage in writing
immediately.
3.2 Transport
DANGER
Waste water lifting unit falling off the pallet
Risk of injury by falling waste water lifting unit!
▷Always transport the waste water lifting unit in horizontal position.
▷Give due attention to the weight data and the centre of gravity.
▷Never suspend the pump by its power cable.
▷Prevent the waste water lifting unit 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 storage.
CAUTION
Damage during storage due to 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 of or damage to the lifting unit!
▷Only remove caps/covers from 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 lifting unit as described in the manual.
2. Always flush and clean the lifting unit, particularly if it has been used for
handling noxious, explosive, hot or other hazardous fluids.
3. If the unit has handled fluids whose residues could lead to corrosion damage in
the presence of atmospheric humidity or could ignite upon contact with oxygen,
the unit must also be neutralised and blown through with anhydrous inert gas
to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the lifting unit. (ðSection12,Page67)
Always indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
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